OPERATION & MAINTENANCE MANUAL

MICROPROCESSOR CONTROLLED BRAKE SYSTEM (EMCBS)

FOR 3 PHASE ELECTRIC LOCOMOTIVE
Doc. No. RED-RD-BS-028-OM-01
RDSO Spec. RDSO/EL/SPEC/2017/0126 Rev. 0

Document Revision History

Rev. Date Changes and reasons for change Prepared by Reviewed by Approved by
00 22/06/2021 Initial Release Biswajit Bose Devesh Kaushik Satish Kumar I
01 11/01/2022 Drawing and Information Added Biswajit Bose Devesh Kaushik Satish Kumar I
02 13/10/2022 Fault code list updated Nagababu Krovi Manoj Kumar Devesh Kaushik
03 16/06/2024 Image and Information Updated Rajat Yadav Prateek Lawaniya Gulab Chand

Escorts Kubota Limited

(Formerly Escorts Limited)
Railway Equipment Division
 Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

TABLE OF CONTENTS

1 ABBREVIATIONS..............................................................................................................................................................10
2 INTRODUCTION ................................................................................................................................................................11
2.1 PRINCIPLE OF OPERATION.................................................................................................................................................... 11
2.2 ADVANTAGES OF EMCBS ...................................................................................................................................................... 11
3 EMCBS SYSTEM OVERVIEW ..........................................................................................................................................12
3.1 MAJOR PARTS OF EMCBS...................................................................................................................................................... 12
3.1.1 PNEUMATIC PANEL consists of following....................................................................................................................... 12
4 BRAKE CONTROL UNIT (BCU) .......................................................................................................................................13
4.1 BP MODULE ............................................................................................................................................................................. 13
4.1.1 BP CHARGING (NORMAL) .............................................................................................................................................. 13
4.1.2 BP CHARGING (QUICK).................................................................................................................................................. 13
4.1.3 AIR FLOW INDICATOR ................................................................................................................................................... 13
4.1.4 BP LEAKAGE TEST (SELF TEST) .................................................................................................................................. 14
4.2 INDEPENDENT MODULE ........................................................................................................................................................ 14
4.2.1 BC GENERATION ............................................................................................................................................................ 14
4.2.2 DBP GENERATION ......................................................................................................................................................... 14
4.2.3 BC GENERATION IN LEAD LOCO (NO POWER) .......................................................................................................... 14
4.2.4 BC GENERATION BY DBP IN TRAIL LOCO (WITH POWER) ....................................................................................... 14
4.2.5 BC GENERATION BY DBP IN TRAIL LOCO (NO POWER) ........................................................................................... 14
4.2.6 BAIL OFF.......................................................................................................................................................................... 14
4.3 LEAD & TRAIL MODULE........................................................................................................................................................... 14
4.4 AUTOMATIC & EMERGENCY MODULE .................................................................................................................................. 14
4.4.1 EMERGENCY BRAKING ................................................................................................................................................. 14
4.4.2 DEAD ENGINE FEATURE ............................................................................................................................................... 14
4.4.3 BP GENERATION (REDUNDANCY MODE) ................................................................................................................... 15
4.5 MR1 FILTER.............................................................................................................................................................................. 15
4.6 DISTRIBUTOR VALVE (DV) ..................................................................................................................................................... 15
4.7 BKP-BPC ISOLATING COCK ................................................................................................................................................... 15
4.8 BP FILTER ................................................................................................................................................................................ 15
4.9 MR2 FILTER.............................................................................................................................................................................. 15
4.10 MREP FILTER ........................................................................................................................................................................... 15
4.11 BCEP FILTER ........................................................................................................................................................................... 15
5 AUXILIARY CONTROL UNIT (ACU) .................................................................................................................................16
5.1 PANTOGRAPH MODULE ......................................................................................................................................................... 16
5.2 SANDING MODULE .................................................................................................................................................................. 16
5.3 PARKING BRAKE MODULE ..................................................................................................................................................... 16
5.4 UNLOADER MODULE .............................................................................................................................................................. 16
5.5 EMERGENCY MODULE ........................................................................................................................................................... 16
5.6 FEED PIPE MODULE................................................................................................................................................................ 17
5.7 DUPLEX CHECK VALVE .......................................................................................................................................................... 17
5.8 TC-FC MODULE ....................................................................................................................................................................... 17
5.9 PRESSURE SWITCHES ........................................................................................................................................................... 17
5.9.1 PRESSURE SWITCHES PROVIDED IN AUX PANEL .................................................................................................... 17
5.10 REGENERATIVE BRAKE ......................................................................................................................................................... 17
5.11 BRAKE BLENDING ................................................................................................................................................................... 17

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

6 DRIVER’S BRAKE CONTROLLER ...................................................................................................................................18

6.1 DRIVER’S BRAKE CONTROLLER MAJOR PARTS ................................................................................................................. 18
6.2 INDEPENDENT BRAKE HANDLE ............................................................................................................................................ 19
6.2.1 FULL SERVICE ................................................................................................................................................................ 19
6.2.2 RELEASE ......................................................................................................................................................................... 19
6.3 AUTOMATIC BRAKE HANDLE ................................................................................................................................................. 19
6.3.1 REL................................................................................................................................................................................... 19
6.3.2 RUN .................................................................................................................................................................................. 20
6.3.3 MIN ................................................................................................................................................................................... 20
6.3.4 FULL SERVICE ................................................................................................................................................................ 20
6.3.5 EMERGENCY .................................................................................................................................................................. 20
6.4 MODE SELECTOR SWITCH .................................................................................................................................................... 20
6.5 DISPLAY ................................................................................................................................................................................... 20
7 DRIVER’S BACK-UP VALVE ............................................................................................................................................21
8 CONTROL ELECTRONICS ...............................................................................................................................................22
8.1 ELECTRONICS CONTROL UNIT (ECU) .................................................................................................................................. 22
8.1.1 POWER FILTER BCE ...................................................................................................................................................... 23
8.1.2 INPUT BCE ...................................................................................................................................................................... 24
8.1.3 CPU BCE.......................................................................................................................................................................... 24
8.1.4 OUTPUT BCE .................................................................................................................................................................. 24
8.2 VCD DESCRIPTION ................................................................................................................................................................. 25
8.2.1 VCD FEATURES .............................................................................................................................................................. 25
8.2.2 POWER FILTER VCD ...................................................................................................................................................... 25
8.2.3 INPUT VCD ...................................................................................................................................................................... 25
8.2.4 CPU VCD ......................................................................................................................................................................... 26
8.2.5 OUTPUT VCD .................................................................................................................................................................. 26
8.3 COMMUNICATION NETWORK TOPOLOGY ........................................................................................................................... 26
9 DRIVER INFORMATION SHEET.......................................................................................................................................27
10 EMCBS DRIVER INSTRUCTIONS FOR 1ST TIME BRAKE RELEASE ............................................................................32
11 EMCBS LRU’S DETAILS ..................................................................................................................................................33
12 PNEUMATIC CIRCUIT FOR 3 PHASE ELECTRIC LOCO WAP-7 & WAP-9 ...................................................................36
13 SCHEMATIC DIAGRAM OF BRAKE PANEL ...................................................................................................................37
14 FUNCTIONAL DESCRIPTION OF EMCBS.......................................................................................................................38
14.1 BP MODULE ............................................................................................................................................................................. 38
14.1.1 BP CONTROL ............................................................................................................................................................ 38
14.2 INDEPENDENT MODULE ........................................................................................................................................................ 39
14.2.1 BC GENERATION ...................................................................................................................................................... 39
14.2.2 BC GENERATION BY DBP IN TRAIL LOCOMOTIVE (WITH POWER) .................................................................... 39
14.2.3 DIRECT BRAKE PIPE– (DBP) GENERATION .......................................................................................................... 40
14.2.4 BC GENERATION BY DBP IN TRAIL LOCO (NO POWER) ..................................................................................... 40
14.2.5 BAIL OFF .................................................................................................................................................................... 40
14.3 AUTOMATIC & EMERGENCY MODULE .................................................................................................................................. 41
14.3.1 EMERGENCY BRAKING ........................................................................................................................................... 41
14.3.2 BP GENERATION (REDUNDANT MODE) ................................................................................................................ 41
14.3.3 BP QUICK CHARGING IN REDUNDANT MODE ...................................................................................................... 41
14.4 LEAD & TRAIL MODULE........................................................................................................................................................... 42
14.4.1 BC CHARGING IN REDUNDANT MODE .................................................................................................................. 42

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(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

14.4.2 DBP CHARGING IN REDUNDANT MODE ................................................................................................................ 42

14.5 BP CHARGING FROM BACKUP VALVE .................................................................................................................................. 43
14.6 BC CHARGING FROM DV ........................................................................................................................................................ 43
14.7 DEAD ENGINE CONDITION ..................................................................................................................................................... 44
14.8 SPECIAL FEATURES OF EMCBS ............................................................................................................................................ 44
14.8.1 BANKING OPERATION ............................................................................................................................................. 44
14.8.2 DEAD ENGINE FEATURE ......................................................................................................................................... 44
14.8.3 LOSS OF POWER FEATURE .................................................................................................................................... 44
14.8.4 BAIL OFF FUNCTION ................................................................................................................................................ 44
15 EMCBS FAILURE MODES ................................................................................................................................................45
16 TROUBLESHOOTING GUIDELINE FOR EMCBS ELECTRONIC DEVICE .....................................................................50
17 EMCBS SYSTEM OPERATIONAL PENALTIES ..............................................................................................................54
17.1 POWER ON SAFE PENALTY ................................................................................................................................................... 54
17.2 WRONG CONFIGURATION PENALTY .................................................................................................................................... 54
17.3 MODE CHANGE PENALTY ...................................................................................................................................................... 54
17.4 SYSTEM SAFETY PENALTY.................................................................................................................................................... 54
17.5 SYSTEM FAULT PENALTY ...................................................................................................................................................... 54
17.6 EMERGENCY PENALTY .......................................................................................................................................................... 54
18 INFORMATIVE AND DIAGNOSTIC LCD MESSAGES:....................................................................................................55
18.1 HOME SCREEN MESSAGE:MESSAGE01 .............................................................................................................................. 55
18.1.1 FIRST ROW DESCRIPTION ...................................................................................................................................... 55
18.1.2 SECOND ROW DESCRIPTION ................................................................................................................................. 55
18.2 INACTIVE DBC MESSAGE: MESSAGE02 ............................................................................................................................... 55
18.3 POWER ON SCREEN: MESSAGE03 ....................................................................................................................................... 55
18.4 SELF TEST OK: MESSAGE04 .................................................................................................................................................. 56
18.5 POWER ON SAFE PENALTY: MESSAGE05 ............................................................................................................................ 56
18.6 WRONG CONFIGURATION PENALTY: MESSAGE06 ............................................................................................................ 56
18.7 MODE CHANGE PENALITY: MESSAGE07 .............................................................................................................................. 56
18.8 SYSTEM SAFE PENALITY: MESSAGE08 ................................................................................................................................ 56
18.9 PVEF SIGNAL ON: MESSAGE09 ............................................................................................................................................. 56
18.10 EMERGENCY SIGNAL ON BY EMERGENCY PARTING/ALP/VCD: MESSAGE10 ................................................................. 56
18.11 EMERGENCY BY AUTO HANDLE DBC A: MESSAGE12 ........................................................................................................ 57
18.12 EMERGENCY BY AUTO HANDLE DBC B: MESSAGE13 ........................................................................................................ 57
18.13 VCD EMERGENCY PENALITY RESET: MESSAGE14 ............................................................................................................ 57
18.14 ONE BC LRU FAIL: MESSAGE15 .............................................................................................................................................. 57
18.15 BOTH BC LRU FAIL: MESSAGE16........................................................................................................................................... 57
18.16 ONE BP LRU FAIL: MESSAGE17 ............................................................................................................................................. 57
18.17 BOTH BP LRU FAIL: MESSAGE18 ........................................................................................................................................... 58
18.18 BOTH BP AND BC LRU FAIL: MESSAGE19 ............................................................................................................................. 58
BANKING OPERATION: MESSAGE20 ................................................................................................................................................. 58
18.19 BP LEAKAGE TEST: MESSAGE21 .......................................................................................................................................... 58
18.20 TRAILING MODE OPERATION: MESSAGE23 ......................................................................................................................... 58
19 FAULT DOWNLOADING SOFTWARE .............................................................................................................................60
19.1 PROCEDURE FOR DATA DOWNLOAD ................................................................................................................................... 60
20 EMCBS ELECTRIC WIRING DIAGRAM ...........................................................................................................................65

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21 PARTS LIST FOR PNEUMATIC VALVES ........................................................................................................................66

21.1 DUPLEX CHECK VALVE .......................................................................................................................................................... 66
21.2 PART LIST FOR DUPLEX CHECK VALVE- 1J106010287 (REF. FIG. NO. 42) ........................................................................... 67
21.3 REPAIR KIT FOR DUPLEX CHECK VALVE (1J106010734) .................................................................................................... 68
21.4 RELAY VALVE .......................................................................................................................................................................... 69
21.5 PART LIST FOR RELAY VALVE - 3EB10816 (REF. FIG. NO. 43) ............................................................................................... 70
21.6 REPAIR KIT FOR RELAY VALVE (1J106010735) .................................................................................................................... 71
21.7 BKP BPC ISOLATING COCK .................................................................................................................................................... 72
21.8 PART LIST FOR BKP BPC ISOLATING COCK- 3EB9001 (REF. FIG. NO. 44) ........................................................................... 73
21.9 REPAIR KIT FOR BKP BPC ISOLATING COCK (1J106010736) .............................................................................................. 74
21.10 EMERGENCY ISOLATING COCK ............................................................................................................................................ 75
21.11 PART LIST FOR EMERGENCY ISOLATING COCK - 1J106010309 (REF. FIG. NO. 45) ............................................................ 76
21.12 REPAIR KIT FOR EMERGENCY ISOLATING COCK (1J106010737) ...................................................................................... 77
21.13 CHECK VALVE ......................................................................................................................................................................... 78
21.14 PART LIST FOR CHECK VALVE- 4EB10843 (REF. FIG. NO. 46) ............................................................................................... 78
21.15 REPAIR KIT FOR CHECK VALVE (1J106010738) ................................................................................................................... 79
21.16 SANDING MAGNET VALVE ..................................................................................................................................................... 80
21.17 PART LIST FOR SANDING MAGNET VALVE - 1J106010421 (REF. FIG. NO. 47) ..................................................................... 81
21.18 REPAIR KIT FOR SANDING MAGNET VALVE (1J106010739) ............................................................................................... 82
21.19 FILTER 3/4”( DBP,MREP, MR2 ON BRAKE PANEL) ..................................................................................................................... 83
21.20 PART LIST FOR FILTER 3/4”- 3EB10967 (REF. FIG. NO. 48)..................................................................................................... 83
21.21 REPAIR KIT FOR FILTER ¾” (1J106010740) ........................................................................................................................... 84
21.22 FILTER 1” (AUX COMP., MREP ON AUXILIARY PANEL, BP, MR1 ON BRAKE PANEL) ...................................................................... 85
21.23 PART LIST FOR FILTER 1”- 3EB10965 (REF. FIG. NO. 49)........................................................................................................ 85
21.24 REPAIR KIT FOR FILTER 1” (1J106010741) ............................................................................................................................ 86
21.25 MAIN RESERVOIR FILTER ...................................................................................................................................................... 87
21.26 PART LIST FOR MAIN RESERVOIR FILTER ASSEMBLY- 1J106010422 (REF. FIG. NO. 50)................................................... 87
21.27 REPAIR KIT FOR MAIN RESERVOIR FILTER ASSEMBLY (1J106010742) ............................................................................ 88
21.28 AIR FLOW MEASURING VALVE .............................................................................................................................................. 89
21.29 PART LIST FOR AIR FLOW MEASURING VALVE –(1J106010363) (REF. FIG. NO. 51)............................................................ 90
21.30 REPAIR KIT FOR AIR FLOW MEASURING VALVE (1J106010743) ........................................................................................ 91
21.31 PRESSURE REDUCING VALVE (PRV) .................................................................................................................................... 92
21.32 PART LIST FOR PRESSURE REDUCING VALVE (PRV)- 2EB9826 (REF. FIG. NO. 52) ........................................................... 93
21.33 REPAIR KIT FOR PRESSURE REDUCING VALVE (REFER DRAWING NO. - 1B116030057) ...................................................... 93
21.34 DISTRIBUTOR VALVE.............................................................................................................................................................. 93
21.35 ANTI COMPOUND VALVE, 3/8”................................................................................................................................................ 94
21.36 PART LIST FOR ANTI COMPOUND VALVE, 3/8” - 1J106010105 (REF. FIG. NO. 53) ............................................................... 94
21.37 REPAIR KIT FOR ANTI COMPOUND VALVE, 3/8” (1J106010745) .......................................................................................... 94
21.38 AUTO DRAIN VALVE ................................................................................................................................................................ 95
21.39 PART LIST FOR AUTO DRAIN VALVE, 1J106010081 (REF. FIG. NO. 54) ................................................................................. 96
21.40 REPAIR KIT FOR AUTO DRAIN VALVE (1J106010746) .......................................................................................................... 96
21.41 OIL SEPARATOR WITH AUTO DRAIN VALVE ........................................................................................................................ 97
21.42 PART LIST FOR OIL SEPARATOR WITH AUTO DRAIN VALVE- 1J106010080 (REF. FIG. NO. 55) ......................................... 98
21.43 REPAIR KIT FOR OIL SEPARATOR WITH AUTO DRAIN VALVE (1J106010747) .................................................................. 98
21.44 COMPRESSOR CHECK VALVE 1-1/4" .................................................................................................................................... 99
21.45 PART LIST FOR COMPRESSORE CHECK VALVE 1-1/4”- 1J106010473 (REF. FIG. NO. 56)................................................... 99

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.46 REPAIR KIT FOR COMPRESSOR CHECK VALVE 1-1/4” (1J106010748) ............................................................................ 100
21.47 UNLOADER EXHAUST VALVE 1" .......................................................................................................................................... 101
21.48 PART LIST FOR UNLOADER EXHAUST VALVE 1"- 1J102060014 (REF. FIG. NO. 57) ........................................................... 102
21.49 REPAIR KIT FOR UNLOADER EXHAUST VALVE 1” (1J106010749) .................................................................................... 103
21.50 DOUBLE CHECK VALVE, ¾” .................................................................................................................................................. 103
21.51 PART LIST FOR DOUBLE CHECK VALVE, ¾”- 4EB11496 (REF. FIG. NO. 58) ....................................................................... 103
21.52 REPAIR KIT FOR DOUBLE CHECK VALVE, ¾” (1J106010750) ............................................................................................ 104
21.53 CHECK VALVE, 1-1/4” (WITH REDUCER ¾”) ........................................................................................................................ 104
21.54 CHECK VALVE, 1-1/4” (WITH REDUCER ¾”)- 1J106010639 (REF. FIG. NO. 59) .................................................................... 105
21.55 REPAIR KIT FOR CHECK VALVE, 1-1/4” (WITH REDUCER ¾”) (1J106010751) .................................................................. 105
21.56 EMERGENCY EXHAUST VALVE 1-1/4" ................................................................................................................................. 106
21.57 PART LIST FOR EMERGENCY EXHAUST VALVE 1-1/4"-- 1J106010472 (REF. FIG. NO. 60) ................................................ 107
21.58 REPAIR KIT FOR EMERGENCY EXHAUST VALVE 1-1/4” (1J106010752) ........................................................................... 107
21.59 2 WAY HORN VALVE.............................................................................................................................................................. 108
21.60 PART LIST FOR 2 WAY HORN VALVE- 1J102060012 (REF. FIG. NO. 61) .............................................................................. 109
21.61 REPAIR KIT FOR 2 WAY HORN VALVE (1J106010753) ........................................................................................................ 109
21.62 DRIVER’S BACK UP VALVE ................................................................................................................................................... 110
21.63 PART LIST FOR DRIVER’S BACK UP VALVE- 2EB 9038 (REF. FIG. NO. 62).......................................................................... 111
21.64 REPAIR KIT FOR DRIVER’S BACK UP VALVE (1J106010754) ............................................................................................. 112
21.65 BP MODULE ASSEMBLY ....................................................................................................................................................... 113
21.66 PART LIST FOR BP MODULE ASSEMBLY- 2EB9768 ( REF. FIG NO. 63) ............................................................................... 114
21.67 REPAIR KIT FOR BP MODULE ASSEMBLY (1J106010762) ................................................................................................. 115
21.68 BP MODULE SOLENOID VALVE NAME PLATE ORIENTATION ........................................................................................... 115
21.69 IND MODULE ASSEMBLY ...................................................................................................................................................... 116
21.70 PART LIST FOR IND MODULE ASSEMBLY- 2EB9667 ( REF. FIG NO. 64).............................................................................. 117
21.71 REPAIR KIT FOR IND MODULE ASSEMBLY (1J106010763) ................................................................................................ 118
21.72 IND MODULE SOLENOID VALVE NAME PLATE ORIENTATION ......................................................................................... 118
21.73 L&T MODULE ASSEMBLY ..................................................................................................................................................... 119
21.74 PART LIST FOR L&T MODULE ASSEMBLY- 2EB9683 ( REF. FIG NO. 65) ............................................................................. 120
21.75 REPAIR KIT FOR L&T MODULE ASSEMBLY (1J106010764) ............................................................................................... 121
21.76 L&T MODULE SOLENOID VALVE NAME PLATE ORIENTATION ........................................................................................ 121
21.77 A&E MODULE ASSEMBLY ..................................................................................................................................................... 122
21.78 PART LIST FOR A&E MODULE ASSEMBLY- 2EB9703 ( REF. FIG NO. 66)............................................................................. 123
21.79 REPAIR KIT FOR A&E MODULE ASSEMBLY (1J106010765) ............................................................................................... 124
21.80 A&E MODULE SOLENOID VALVE NAME PLATE ORIENTATION ........................................................................................ 124
21.81 NC VALVE ASSEMBLY........................................................................................................................................................... 125
21.82 PART LIST FOR NC VALVE ASSEMBLY- 1J106010410 (REFER FIG. NO. 67)........................................................................ 125
21.83 REPAIR KIT FOR NC VALVE ASSEMBLY (1J106010769) ..................................................................................................... 126
21.84 NO VALVE ASSEMBLY .......................................................................................................................................................... 127
21.85 PART LIST FOR NO VALVE ASSEMBLY- 3EB10975 (REFER FIG. NO. 68) ............................................................................ 127
21.86 REPAIR KIT FOR NO VALVE ASSEMBLY (1J106010768) .................................................................................................... 128
21.87 3/2 VALVE ASSEMBLY ........................................................................................................................................................... 129
21.88 PART LIST FOR 3/2 VALVE ASSEMBLY - 1J106010320 (REFER FIG. NO. 69) ....................................................................... 130
21.89 REPAIR KIT FOR 3/2 VALVE ASSEMBLY (1J106010780) ..................................................................................................... 130
21.90 DEAD ENGINE COCK ASSEMBLY ........................................................................................................................................ 131
21.91 PART LIST FOR DEAD ENGINE COCK ASSEMBLY - 3EB9729 (REFER FIG. NO. 70)............................................................ 132

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(Formerly Escorts Limited)
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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.92 REPAIR KIT FOR DEAD ENGINE COCK ASSEMBLY (1J106010779) .................................................................................. 133
21.93 TEST INSTANCE .................................................................................................................................................................... 134
21.94 ON-LOCOMOTIVE SYSTEM TEST ........................................................................................................................................ 134
21.94.1 GENERAL INFORMATION .................................................................................................................................... 134
21.94.2 TEST FORMAT FOR 3-PHASE ELECTRIC LOCOMOTIVE (WAG9/WAP7/WAP5) ............................................. 134
MAINTENANCE AND OVERHAULING SCHEDULE FOR M/S. ESCORTS MAKE EMCBS .................................................142

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

TABLE OF FIGURES

Figure 1 : Block Diagram of EMCBS ...................................................................................................................................... 11

Figure 2 : Microprocessor Controlled Brake System (EMCBS) .......................................................................................... 12
Figure 3 : Brake Control Unit (BCU) ...................................................................................................................................... 13
Figure 4 : Driver’s Brake Controller ....................................................................................................................................... 18
Figure 5 : Driver’s Brake Controller Parts ............................................................................................................................. 19
Figure 6 : Driver’s Back-up valve ........................................................................................................................................... 21
Figure 7 : Electronics Control Unit (ECU) ............................................................................................................................. 22
Figure 8 : Electronics Control Unit Block Diagram .............................................................................................................. 23
Figure 9 : Power Filter BCE .................................................................................................................................................... 23
Figure 10 : Input BCE .............................................................................................................................................................. 24
Figure 11 : CPU BCE ............................................................................................................................................................... 24
Figure 12 : Output BCE ........................................................................................................................................................... 24
Figure 13 : Power Filter VCD .................................................................................................................................................. 25
Figure 14 : Input VCD .............................................................................................................................................................. 25
Figure 15: CPU VCD ................................................................................................................................................................ 26
Figure 16 : Output VCD ........................................................................................................................................................... 26
Figure 17 : Network topology for brake electronics............................................................................................................. 26
Figure 18 : Escorts EMCBS Brake System on 3 Phase Loco .............................................................................................. 27
Figure 19 : Driver Brake Controller (DBC)............................................................................................................................. 28
Figure 20 : EMCBS DRIVER INSTRUCTIONS FOR 1ST TIME BRAKE RELEASE............................................................... 32
Figure 21 : BP MODULE.......................................................................................................................................................... 33
Figure 22 : IND MODULE ........................................................................................................................................................ 34
Figure 23 : L&T MODULE........................................................................................................................................................ 34
Figure 24 : A&E MODULE ....................................................................................................................................................... 35
Figure 25 : Pneumatic circuit for 3 phase electric loco WAP-7 & WAG-9 .......................................................................... 36
Figure 26 : Schematic diagram of Brake Panel .................................................................................................................... 37
Figure 27 : BP Module............................................................................................................................................................. 38
Figure 28 : Independent Module ............................................................................................................................................ 39
Figure 29 : Automatic & Emergency Module ........................................................................................................................ 41
Figure 30 : Lead & Trail Module ............................................................................................................................................. 42
Figure 31 : BP Charging from Backup Valve ........................................................................................................................ 43
Figure 32 : BC Charging From DV ......................................................................................................................................... 43
Figure 33 : Dead Engine Condition ........................................................................................................................................ 44
Figure 34 : Login Window....................................................................................................................................................... 60
Figure 35 : Communication Port Settings ............................................................................................................................. 60
Figure 36 : Main Screen .......................................................................................................................................................... 61
Figure 37 : delete the ............................................................................................................................................................. 61
Figure 38 : Settings Window .................................................................................................................................................. 63
Figure 39: Fault Data View Window ....................................................................................................................................... 63
Figure 40: Report Generation Window .................................................................................................................................. 64
Figure 41 : EMCBS Wiring Diagram ....................................................................................................................................... 65
Figure 42 : Duplex Check Valve ............................................................................................................................................. 66
Figure 43 : Relay Valve .......................................................................................................................................................... 69
Figure 44 : BKP BPC Isolating Cock..................................................................................................................................... 72
Figure 45 : Emergency Isolating Cock ................................................................................................................................. 75
Figure 46 : Check Valve ......................................................................................................................................................... 78
Figure 47 : Sanding Magnet Valve ........................................................................................................................................ 80
Figure 48 : Filter ¾”................................................................................................................................................................ 83
Figure 49 : Filter 1”................................................................................................................................................................. 85
Figure 50 : Main Reservoir Filter ........................................................................................................................................... 87

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Escorts Kubota Limited
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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Figure 51 : Air Flow Measuring Valve ................................................................................................................................... 89

Figure 52 : Pressure Reducing Valve ................................................................................................................................... 92
Figure 53 : Anti Compound Valve, 3/8” ................................................................................................................................ 94
Figure 54 : Auto Drain Valve ................................................................................................................................................. 95
Figure 55 : Oil Separator With Auto Drain Valve ................................................................................................................. 97
Figure 56 : Compressor Check Valve 1-1/4” ........................................................................................................................ 99
Figure 57 : Unloader Exhaust Valve 1"............................................................................................................................... 101
Figure 58 : Double Check Valve ¾” .................................................................................................................................... 103
Figure 59 : Check Valve, 1-1/4” (With Reducer ¾”) ........................................................................................................... 104
Figure 60 : Emergency Exhaust Valve 1-1/4"..................................................................................................................... 106
Figure 61 : 2 WAY HORN VALVE ........................................................................................................................................ 108
Figure 62 : DRIVER’S BACK UP VALVE ............................................................................................................................. 110
Figure 63 : BP MODULE ASSEMBLY .................................................................................................................................. 113
Figure 64 : IND MODULE ASSEMBLY................................................................................................................................. 116
Figure 65 : L & T MODULE ASSEMBLY .............................................................................................................................. 119
Figure 66 : A & E MODULE ASSEMBLY ............................................................................................................................. 122
Figure 67 : NC VALVE ASSEMBLY ..................................................................................................................................... 125
Figure 68 : NO VALVE ASSEMBLY ..................................................................................................................................... 127
Figure 69 : 3/2 VALVE ASSEMBLY ..................................................................................................................................... 129
Figure 70 : DEAD ENGINE COCK ASSEMBLY ................................................................................................................... 131

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

1 ABBREVIATIONS
S. No. ABBREVIATION NAME
1 BC BRAKE CYLINDER
2 BCC BRAKE CYLINDER CONTROL
3 DBP DIRECT BRAKE PIPE
4 BCEPS BRAKE CYLINDER EQUALIZING PRESSURE SENSOR
5 BCS BRAKE CYLINDER SENSOR
6 BKP_BPC BACK UP BRAKE PIPE CONTROL
7 BL BAIL OFF
8 BOS BAIL OFF SENSOR
9 BP BRAKE PIPE
10 BPC BRAKE PIPE CONTROL
11 BPS BRAKE PIPE SENSOR
12 CV CONTROL VALVE
13 DCV DOUBLE CHECK VALVE
14 DE DEAD ENGINE
15 DV DISTRIBUTOR VALVE
16 EM EMERGENCY
17 FL FLOW CONTROL
18 FLS FLOW SENSOR
19 FLTR FILTER
20 FP FEED PIPE
21 MR MAIN RESERVOIR
22 MREPS MAIN RESERVOIR EQUALIZING PIPE SENSOR
23 MRS MAIN RESERVOIR SENSOR
24 NRV NON-RETURN VALVE
25 PS PARKING BRAKE
26 PRV PRESSURE REDUCING VALVE
27 PV PNEUMATIC VALVE
28 QC QUICK CHARGING
29 SV SOLENOID VALVE
30 TP TEST POINT
31 A AUTO BRAKE RELAY VALVE (TO BC)
32 H BRAKE CYLINDER CUT OUT COCK
33 J AUXILIARY RESERVOIR
34 K BPVV
35 L DIRECT BRAKE PIPE
36 M FLOWMETER GAUGE
37 U MR2 (MAIN RESEVOIR SUPPLY)
38 W MR1 (MAIN RESEVOIR SUPPLY)
39 X MREP (MAIN RESEVOIR EQUALISING PIPE)
40 Z PER (PNEUMATIC EQUALIZING PRESSURE)
41 AA BP (BRAKE PIPE)
42 AFMV AIR FLOW MEASURING VALVE

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

2 INTRODUCTION
The Electronics based Microprocessor Controlled Brake System (EMCBS) for 3-Phase Electric locomotives is
a Modular Braking System developed for Graduated application & release of Train Brake and Locomotive
Brake in accordance with Twin Pipe Graduated Release Air Brake System. Its Electro-Pneumatic line
Replaceable Intelligent Modules connected in local network, function together in conjunction with the Loco
Computer to achieve the desired Brake functionality.

Figure 1 : Block Diagram of EMCBS

2.1 PRINCIPLE OF OPERATION

When the Driver operates the Driver’s Brake Controller, based on the position of the handle the Controller
sends signal to the ECU of EMCBS Panel. The ECU, in turn, sends signals to the respective Controller of the
Brake Panel and the respective Controllers develops the required pressure.

2.2 ADVANTAGES OF EMCBS

Compact, modular & reliable design
Distributed control through 8 nos. of high-performance Micro Controllers
Intelligent Electro Pneumatic modules with redundancy
Penalty Brake in case Driver becomes incapacitated.
Back-up in case of Electronic Brake failure
Seamless interface with Loco propulsion system
User-friendly Operation & Easy Maintenance
User-friendly GUI based Software with advanced features for diagnostics.
Check and configure the programmable variables, Fault Data viewing and status display.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

3 EMCBS SYSTEM OVERVIEW

Figure 2 : Microprocessor Controlled Brake System (EMCBS)

3.1 MAJOR PARTS OF EMCBS

 Pneumatic Panel
Electronic Control Unit
Driver’s Brake Controller
Driver’s Back-Up Valve
Various Communication Channels
Data/Fault Logging, Diagnostics and Display
Integrated Vigilance Control Device

3.1.1 PNEUMATIC PANEL consists of following

1. Brake Control Unit (BCU)
2. Auxiliary Control Unit (ACU)
3. Standardized Header

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

4 BRAKE CONTROL UNIT (BCU)

The BCU Comprises of the following Parts
1. Brake Pipe (BP) Module
2. Independent (IND) Module
3. Automatic & Emergency (A&E) Module
4. Lead & Trail (L&T) Module
5. Distributor Valve (DV)
6. BKP BPC Isolating Cock
7. Filters
8. Header Assy.

Figure 3 : Brake Control Unit (BCU)

4.1 BP MODULE

4.1.1 BP CHARGING (NORMAL)

When Auto handle is moved to RUN position, BP Relay Valve produces BP equal to 5kg/cm2 using
Pilot pressure from Proportionate Valve and MR1 which reaches BP Relay Input Port after passing
through 5.5 mm Choke.

4.1.2 BP CHARGING (QUICK)

When Auto Handle is moved to REL position for 3 seconds, BP is overcharged up to 5.5 kg/cm2
through a 8 mm port.

4.1.3 AIR FLOW INDICATOR

MR air flows through a series of Chokes in series and builds up the pressure in AFMV line. Whenever
train separation occurs, excessive flow of air passes through Chokes, causing a pressure drop, which
is reflected in Air Flow Indicator.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

4.1.4 BP LEAKAGE TEST (SELF TEST)

BP line is charged at 5 kg/cm2 and further charging is stopped for a specific time period, BP is monitored to
complete the test.

4.2 INDEPENDENT MODULE

4.2.1 BC GENERATION
Whenever Driver applies the Brake from Auto Handle/IND Handle, ECU commands the Proportionate
Valve to generate the BC pilot pressure according to Handle position and further BC pressure is generated
by Relay Valve in accordance with BC pilot pressure.

4.2.2 DBP GENERATION

Whenever Driver applies the Brake from IND Handle, computer commands the Proportionate Valve to
generate the DBP pilot pressure according to Handle position. Then the BC-Relay produces pressure
which is sent to DBP line. Thus DBP is generated.

4.2.3 BC GENERATION IN LEAD LOCO (NO POWER)

In case of Electronics failure, BC pilot is generated from DV as per BP pressure drop. BC Pilot goes to the
BC Relay and Relay generates the BC pressure as per the pilot pressure.

4.2.4 BC GENERATION BY DBP IN TRAIL LOCO (WITH POWER)

The DBP generated from the LEAD Loco enters the EMCBS Panel of the TRAIL Loco. DBP pressure is
sensed by the Pressure Transducer and accordingly BC is generated for Trail Loco.

4.2.5 BC GENERATION BY DBP IN TRAIL LOCO (NO POWER)

The DBP generated from the LEAD Loco enters the EMCBS Panel of the TRAIL Loco. DBP pressure
reaches BC Relay as pilot and BC is generated accordingly.

4.2.6 BAIL OFF

When the Bail Off command is activated, the Bail off Solenoid Valve is energized. This cuts off and vents
the supply of the Control Port of the BC RELAY Valve. Thus the control pressure of the BC RELAY Valve is
vented resulting in the reduction of the BC pressure.

4.3 LEAD & TRAIL MODULE

Major function of the Lead & Trail Module is to generate BC and BCEP during Redundancy mode

4.4 AUTOMATIC & EMERGENCY MODULE

4.4.1 EMERGENCY BRAKING

When the Emergency Brake is applied by Auto Handle, the Emergency Solenoid Valve gets energized
which in turn vents the Pilot of Emergency Valve. As a result, it starts to vent BP through a larger port. Thus
Emergency Brakes are applied.

4.4.2 DEAD ENGINE FEATURE

When the EMCBS system is in Dead condition, the Dead Engine Cock is turned ON to charge the AR
pressure. BP air enters the AR line via the Check Valve, Dead Engine Cock and Pressure Regulating Valve
to fill the AR Reservoir. The AR Pressure is further used to generate BC pressure.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

4.4.3 BP GENERATION (REDUNDANCY MODE)

When the BP Module fails, A&E Module takes over and starts generating BP pressure.

4.5 MR1 FILTER

This Filter is placed on the Panel at the entry point of the MR1 Pressure line to filter out the contamination.

4.6 DISTRIBUTOR VALVE (DV)

The Distributor Valve is a third stage (primary IND Module & secondary L&T Module) Mechanical Redundant
Valve. When the Electronic System fails, DV starts to produce pilot to the BC Relay, which produces BC for
the Locomotive.

4.7 BKP-BPC ISOLATING COCK

The BKP-BPC Isolating Cock is Backup Brake Pipe Control Isolating Cock which enables building of BP
pressure in the line through Driver’s Back-up Valve when the Electronic system is not working. The Driver
needs to keep it in ‘ON’ position.

4.8 BP FILTER
This Filter is placed on the panel at the exit point of the BP Pressure line to filter out the contamination.

4.9 MR2 FILTER

This Filter is placed on the panel at the entry point of the MR2 Pressure line to filter out the contamination.

4.10 MREP FILTER

This Filter is placed on the panel at the exit point of the MREP Pressure line to filter out the contamination.

4.11 BCEP FILTER

This Filter is placed on the panel at the entry/exit point of the BCEP Pressure line to filter out the
contamination.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

5 AUXILIARY CONTROL UNIT (ACU)

The Auxiliary Control Unit consist of the following Modules.
1. Pantograph Module
2. Sanding Module
3. Parking Brake Module
4. Unloader Module
5. Emergency Module
6. Pressure Switches
7. TC-FC Module

5.1 PANTOGRAPH MODULE

Pantograph Module is provided for raising and lowering of Pantograph through the Panto Isolating Cock
which is kept open and when Panto Magnet Valve is driven by VCU command. Pantograph would be raised
by air pressure from Auxiliary Compressor through Pantograph Isolating Cock and Panto Magnet Valve.
Pantograph of Cab-1 or Cab-2 is raised according to the position of Panto Selection Switch.

5.2 SANDING MODULE

Pneumatic sanding provision is provided for the leading axles of each Locomotive in either direction of travel.
When Driver pushes the Sanding Foot Pedal, Sanding Magnet Valve in Auxiliary Panel gets energized which
initiates sanding according to Locomotive’s moving direction.

5.3 PARKING BRAKE MODULE

Parking Brake is used for parking the Train when the train is stand still.
To apply Parking Brake, Mode Selector is turned to Standby position and “Parking Brake Push Button (BPPB)
to be pushed ‘ON’. When Parking Brake is applied, the Push-Button Switch gets illuminated (Red). Parking
Brakes are also automatically applied in the event of loss of the Main Reservoir pipe pressure. It is possible to
release individual Parking Brake manually by pulling out the manual release device installed at the Parking
Brake Cylinder near the wheel.

5.4 UNLOADER MODULE

To avoid the Main Compressor to start against air pressure, an Unloader Magnet Valve is provided in
Auxiliary Panel. An Unloader Valves is also provided for both the Main Compressors. During Compressor
start, the Unloader Magnet Valve is energized resulting in Unloader Valve operation so that the Compressors
can start without any back pressure.

5.5 EMERGENCY MODULE

Emergency Module is used to apply Emergency Braking in case of any fault/penalty generated from VCD. BP
line is connected at the inlet port of Emergency Valve and BP air via a Choke is also built up as the Pilot of
the Emergency Valve.
Emergency Magnet Valve is always energized to hold the pilot pressure of Emergency Valve. Whenever
there is fault/ penalty generation, Emergency Magnet Valve is De-energized which vents out the pilot
pressure, resulting in BP venting through a larger orifice to apply Emergency braking.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

5.6 FEED PIPE MODULE

Feed Pipe Module generates the Feed Pipe pressure. The PRV in the FP Module generates pressure
equivalent to 6 kg/cm2 and sends it as a pilot to FP_RELAY. Further FP_RELAY Valve produces FP
equivalent to pilot pressure received using MR1 as Input.

5.7 DUPLEX CHECK VALVE

Duplex Check Valve is used to charge the Loco Main Reservoir when the Locomotive Compressor is unable
to meet the air supply requirement. Duplex Check Valve generates MREP Pressure Using MR1 as input.
When MR1 reaches at 5 kg/cm2 it starts feeding the MREP Pressure.

5.8 TC-FC MODULE

This Module provides air to the Filter Cubicle of Locomotive.

5.9 PRESSURE SWITCHES

Pressure Switches are used for sending Signals at a set pressure. These Pressure Switches are of
differential pressure, which facilitates the Cut-in and Cut-out pressures of that particular function.

5.9.1 PRESSURE SWITCHES PROVIDED IN AUX PANEL

1. BC Pressure Switch
2. BP Pressure Switch
3. FP Pressure Switch
4. Auxiliary compressor Pressure Switch
5. Parking Brake Pressure Switch
6. Panto 1 Pressure Switch
7. Panto 2 Pressure Switch

5.10 REGENERATIVE BRAKE

When Regenerative Brakes are applied, the Locomotive Brakes will be cut off if the Brakes are applied
through Automatic Brake Valve. However, in case of Emergency Brake Application by Driver's Brake Valve or
by Assistant Driver's Emergency Brake Valve, the Regenerative Brakes will be Cut-Off and Locomotive
Brakes will be applied.

5.11 BRAKE BLENDING

In case train is being controlled by Regenerative Brake on Locomotive and Regenerative Brakes are not
sufficient to slow down the Locomotive/Train then Friction Brakes also applied as per the Friction Brake force
demand received from Locomotive Computer through Brake blending feature.
In case, if the Regenerative Brake fails, purely Air Brakes on Locomotive will be automatically applied in
proportion to the position of Automatic Brake Handle.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

6 DRIVER’S BRAKE CONTROLLER

Cab Controller is the “Human Machine” interface to the EMCBS Brake System. The Brake Controller
communicates (Handle movements by the driver) to the Air Brake System via the local network. The Brake
Controller is designed for installation as a Driver Desk Mount. It is used by the Operator to control the
Independent Brake, Automatic Brake and Mode Selection Switch. The Brake Controller includes a “Display”
where the Operator can view instantly the status of Brakes inclusive of any faults. Faults are viewable to the
Operator on the LCD Display.

Figure 4 : Driver’s Brake Controller

6.1 DRIVER’S BRAKE CONTROLLER MAJOR PARTS

 Independent Brake Handle
 Automatic Brake Handle
 Mode Selector Switch which has the following positions:
 Test Mode
 Lead Mode
 Trail Mode
 Helper Mode
 Display

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Figure 5 : Driver’s Brake Controller Parts

6.2 INDEPENDENT BRAKE HANDLE

Independent Brake Handle is used to apply Brakes for Lead and Trail Locomotive (MU operation).
Independent handle has two Handle positions.
 Release (REL)
 Full Service (FULL)

6.2.1 FULL SERVICE

For Applying the Locomotive Direct Brake, the IND Handle needs to be moved away from the Driver (Full
Direct application is the extreme forward position) to the ‘FULL’ position.

6.2.2 RELEASE
For Releasing the Locomotive Direct Brake, the IND Handle needs to be moved towards the Driver. The
Brake Valve will Self-Lap at any point in the application zone where Handle movement has been stopped.
Brake Cylinder pressure will be accordingly maintained. The 2nd Brake Handle should always be in
RELEASE position (closest to Driver) when the locomotive is a Trailing Unit in a Multiple-Unit consists or is
being towed DEAD.

6.3 AUTOMATIC BRAKE HANDLE

The Brake Valve Controller Automatic Handle operates through five positions:
 Release (REL)
Running (RUN)
Minimum (MIN)
Full Service (FS)
Emergency (EMER)

6.3.1 REL
When the Driver to senses BP pressure to be very low, to over charge the BP, Auto Handle is placed at
REL position for 3 sec. As a result, BP will be charged at a faster rate up to a pressure of 5.5 kg/cm2.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

6.3.2 RUN
When the Auto Handle is placed in RUN position, BP is charged to a pressure of 5 kg/cm2. This also
Releases the Service Brakes completely.

6.3.3 MIN
When a Service Brake application is to be made, the Automatic Brake Handle is moved away from the
Driver to MIN position. This will reduce the BP pressure by 0.3-0.5 kg/cm2. As a result, BC pressure is
generated. When the Auto Handle is moved further, BP is reduced in proportion to the Handle Movement
and BC is generated accordingly.

6.3.4 FULL SERVICE

When the Auto Handle is placed in FS position, BP is reduced and BC is generated as per the requirement.

6.3.5 EMERGENCY
When the Auto Handle is placed in Emergency position BP is exhausted at a faster rate. Simultaneously,
BC is also generated at a faster rate. Thus Emergency Brakes are applied.
Handle Positions and Pressure Values
Auto Handle BP Pressure BC (WAG-9 & BC (WAP-5)
S. No.
Position (kg/cm2) WAP-7 (kg/cm2) (kg/cm2)
1 Release 5.5±0.1 0.00 0.00
2 Run 5.0±0.1 0.00 0.00
3 Minimum Reduction 4.6±0.1 0.40±0.1 0.75±0.15
4 Full Service 3.35±0.2 2.5±0.1 5.15±0.30
5 Emergency Less than 0.3 2.5±0.1 5.15±0.30

6.4 MODE SELECTOR SWITCH

 TEST Mode: In this mode BP leakage test can be done by system.
 LEAD Mode: In this mode both Auto and IND Handle on Driver’s Brake Controller are fully
functional.
 TRAIL Mode: In this mode, only EMER can be applied from Auto Handle.
 BANK Mode: In this mode, IND Handle will be fully functional and only EMER can be applied from
Auto Handle.

6.5 DISPLAY
Display is used to guide the Driver for initial Settting up of Locomotive Brake System. Setup of locomotive
Brake, pressure value and fault indication massages are displayed.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

7 DRIVER’S BACK-UP VALVE

It is a Pneumatic Back-Up Valve which pneumatically controls Train Brake in case of EMCBS non-functional. It is
used to run the train at slow speed. There is also a provision of Emergency Braking in this valve.
DBV Handle has 3 positions:
 APPLY
 LAP
 RELEASE

PRV

Figure 6 : Driver’s Back-up valve

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

8 CONTROL ELECTRONICS
It collects the Input from the Driver’s Brake Controller and these Inputs are processed by the software within
the ECU and sends Output signal to Auxiliary functions of the Locomotive.
The Electronic Control Unit is divided in to two sub categories-
1. Brake Control Electronics (BCE)
2. Vigilance Control Device (VCD)

8.1 ELECTRONICS CONTROL UNIT (ECU)

Brake Control Electronics take Input from the DCB, Brake Panel, Customer Interface and VCD Interface. It
stores the data for event recording of the system.
It has features like data logging, diagnostics and fault recording. Fault table is stored in form of fault code with
date and time which can be downloaded through USB port. For the system faults analysis a data pack of 8
snapshots (five prior to faults and 3 post faults) are stored in the memory. This data can be retrieved via USB
port and analysised in a PC with a MMI Software.

Figure 7 : Electronics Control Unit (ECU)

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 OPERATION AND MAINTENANCE MANUAL
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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Figure 8 : Electronics Control Unit Block Diagram

8.1.1 POWER FILTER BCE

Power Filter Card 110V DC ±30% Battery Voltage is provided to the card using a
3 Pin Connector. Main function of the Card is to filter out the noise and transients
from the input supply. Filtered 110V DC is fed to Power Card.
Power Filter Card also provides the status of various powers as given in below
table.
S. No. LED LED Colour Description
1 BAT Green Input Battery Supply is available
2 BAT ALM Red Input Battery Voltage is out of range
3 PSF1 OK Green 110V Supply to Pressure switch is OK
4 PSF2 OK Green 110V Supply to Pressure switch is OK
5 +24V Green +24V available
Figure 9 : Power Filter 6 +24V ALM Red +24V is out of range
BCE 7 +5V Green +5V available

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

8.1.2 INPUT BCE

Input Card has 12 nos. of Digital Input and 1 number of Analog Input.

Converts these Input Voltage Signal to required Voltage level and forward it to CPU
Card through BUS Interface.

Figure 10 : Input BCE

8.1.3 CPU BCE

CPU Card is the heart of the Electronic Control Unit. It takes the input from the
Input Card and gives output via Output Card to Interface Card. Controller mounted
in the PCB, processes the inputs and based on the Algorithm/ Software gives the
output.

Following ports/ LEDs are provided on the Facia of the CPU Card.

LED
S. No. LED Description
Colour
1 Active Green Indicate that system is active.
2 Fault Red Indicate that there is Fault / Error in the system.
3 Healthy Green Indicate that there is no Fault / Error in the system.

Figure 11 : CPU BCE

.

8.1.4 OUTPUT BCE

Output Card provides the Relay outputs and controls the various Solenoid
Valves. LEDs on the Facia indicates as below:

Following ports/ LEDs are provided on the Facia of the Output Card.

S. No. LED LED Colour Description

1 OP1 Green Relay Output 1 is ON
2 OP2 Green Relay Output 2 is ON
3 OP3 Green Relay Output 3 is ON
4 OP4 Green Relay Output 4 is ON
5 OP5 Green Relay Output 5 is ON
Figure 12 : Output BCE

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

8.2 VCD DESCRIPTION

Vigilance Control Software works on Microprocessor Based System which monitors alertness of the crew
through Multi-Resetting System such as Foot Pedal or Push Button. In absence of normal driving
acknowledgement in a specified period, Vigilance Control System gets activated to Flash Indication &
Audio Warning. If warnings are not acknowledged, Emergency Brake Application comes into operation.
Software is intended for Indian Railways 3-Phase Locomotive Brake System to provide Fail-Safe Feature.

8.2.1 VCD FEATURES

Vigilance Control Device is a Microprocessor Based Fail-Safe System. It can be reset by operation of
frequently operated functions by the driver. VCD mainly performs following function as follows
 Activating the system  Penalty Brake Cycle
 Vigilance/delay cycle  Penalty Brake Release
 Action/warning cycle  Vigilance Reset
 Audio-Visual Warning  Vigilance Suppression
 Data Storage

8.2.2 POWER FILTER VCD

Power Filter Card 110V DC ±30% Battery Voltage is provided to the card using a
3 Pin Connector. Main function of the Card is to filter out the noise and transients
from the input supply. Filtered 110V DC is fed to Power Card.
Power Filter Card also provides the status of various powers as given in below
table.

S. No. LED LED Colour Description

1 BAT Green Input Battery Supply is available
2 BAT ALM Red Input Battery Voltage is out of range
3 +5V Green +5V available
Figure 13 : Power Filter
VCD

8.2.3 INPUT VCD

Input Card has 12 nos. of Digital Input and 1 number of Analog Input.

Converts these Input Voltage Signal to required Voltage level and forward it to
CPU Card through BUS Interface.

Figure 14 : Input VCD

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

8.2.4 CPU VCD

CPU Card is the heart of the Electronic Control Unit. It takes the input from the
Input Card and gives output via Output Card to Interface Card. Controller mounted
in the PCB, processes the inputs and based on the Algorithm/ Software gives the
output.
Following ports/ LEDs are provided on the Facia of the CPU Card.

LED
S. No. LED Description
Colour
1 Active Green Indicate that system is active.
2 Fault Red Indicate that there is Fault / Error in the system.
Indicate that there is no Fault / Error in the
3 Healthy Green
system.
Figure 15: CPU VCD

8.2.5 OUTPUT VCD

Output Card provides the Relay outputs and controls the various Solenoid Valves.
LEDs on the Facia indicates as below:
Following ports/ LEDs are provided on the Facia of the Output Card.

S. No. LED LED Colour Description

1 OP1 Green Relay Output 1 is ON
2 OP2 Green Relay Output 2 is ON
3 OP3 Green Relay Output 3 is ON
4 OP4 Green Relay Output 4 is ON
5 OP5 Green Relay Output 5 is ON
Figure 16 : Output VCD

8.3 COMMUNICATION NETWORK TOPOLOGY

Figure 17 : Network topology for brake electronics

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9 DRIVER INFORMATION SHEET

Figure 18 : Escorts EMCBS Brake System on 3 Phase Loco

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Figure 19 : Driver Brake Controller (DBC)

9.1 LOCO CAB SET-UP

• LEAD Loco: Operative cab, DBC Mode-switch in LEAD and AUTO/A9 handle unlocked.
Inoperative cab, DBC Mode-switch in TRAIL and AUTO/A9 handle locked at FS using FS Stopper.

• TRAIL Loco: For Loco in TRAIL mode, mode switches of both DBCs should be in TRAIL Position.

• BANKER Loco: for Loco in Banking, ‘ZBAN’ switch on driver desk in ‘ON’ position and DBC mode
switch in BANK Position before node information reaches at ‘550’.

• TEST: To check BP leakage of train, move DBC Mode Switch to TEST. This would stop the BP
charging for train-line leakage test (For safety this would apply 3.5 kg/cm2 BC pressure on
Locomotive till mode switch is in TEST position). After test is over, move Mode switch back to
LEAD to come out from test mode. BC will reduce to 0 kg/cm2

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9.2 AUTO/A9 OPERATION

To charge the BP on first power up (i.e. Loco charging):

• Keep AUTO/A9 handle in FS to energize the Loco, wait to see the message on LCD display of
Controller as “Target BP 3.35 kg/cm2”. Move the AUTO handle to RUN from FS position, BP
would charge to 5 kg/cm2 and BC would reduce to zero.

• To overcharge the BP to 5.50 kg/cm2, hold AUTO/A9 in REL (Release) position for 3 seconds.
Once BP starts overcharging, leave AUTO/A9 handle. BP will charge to 5.50 kg/cm2.

• Quick release of auto brakes in Loco, can be performed by pressing PVEF Foot switch.

9.3 RECOVERY OF PENALTY SERVICE BRAKE

• Penalty service brake would result into dropping below 3.35 Kg/cm2 & LCD message will appear
as “PUT AUTO IN FS 10 Sec.”, To recover this penalty brake, move AUTO/A9 handle to FS and
then bring AUTO/A9 handle back to RUN BP would charge to 5.0 kg/cm2.

9.4 RECOVERY OF PENALTY EMERGENCY BRAKE

• Emergency penalty brake can also get applied by over speed relay, Emergency stop button and
train parting. When Emergency penalty applied, LCD message will appear as “PUT AUTO (A9)
HANDLE IN EMER.”

• To recover Emergency penalty, AUTO/A9 handle should be moved to EMER then LCD message
will appear as “PUT AUTO IN RUN” and then move AUTO/A9 handle to RUN, BP would charge
to 5.0 kg/cm2.

9.5 RECOVERY OF VIGILANCE PENALTY BRAKE

Vigilance penalty would result into dropping BP to ‘0’ kg/cm2, application of full BC pressure & LCD
message will appear as “EMR VCD/DRIVE”

• To Recover Vigilance penalty, Put Throttle Handle (TE/BE) at ideal 0 and Wait for 32 seconds.

• Press BPVR on driver’s Desk. After that move AUTO/A9 handle to EMER position then LCD
message will appear as “PUT AUTO IN RUN”.

• To charge “BP” move AUTO/A9 handle to RUN. BP would charge to 5.0 kg/cm2.

• Press BPFA button to acknowledge and Resume normal operation. Follow the DBC LCD display
instructions.

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9.6 DRIVER’S BACKUP VALVE (PTDC) SET UP & OPERATION

(This feature has been provided to use in case there is any problem with EMCBS system. By keeping
brake system in this mode, Locomotive can be operated with 10 kmph to clear the block section).

• Switch off Pneumatic Panel MCB (127.7) in SB2 panel, one time message of “BRAKE
ELECTRONICS FAILED” message will appear on Loco DDS.

• Turn off IC_EE cock and then Turn “ON” BKP_BPC IC (Backup Brake Pipe Control IC) cock on
Brake Panel and press the BPFA to acknowledge message, the message of “BRAKE
ELECTRONICS FAILED” will not appear again.

• Verify AUTO/A9 handle of DBC UNLOCKED in operative cab and LOCKED in other cab.

• In active Driver’s cab, move and hold the PTDC handle in the RELEASE position. BP would
charge to normal level of 5 kg/cm2 and BC should reduce to Zero. If BC is not reducing to zero
then give brief pulls to quick release lever provided at bottom of Distributor Valve. Ensure BC
reduces to zero. (Note: If Loco Brake remains applied, press TP_ BCC,TP_BCEP (Test Point) of
IND Module on Brake Panel to Release BC to Zero.

• Apply and Release Auto brake through PTDC by moving the handle slightly towards APPLY
position and RELEASE position observing the BP pressure gauge.

• Now release Parking Brake by pressing BPPB and operate the Loco (take traction).

9.7 DEAD LOCOMOTIVE OPERATION

• Switching off control electronics by switching off MCB (127.7)

• Drain MR Pressure (MR1, MR2 and 240 Liter Aux. Reservoirs)

• Close Vigilance IC_EE cock (74) on Auxiliary panel, Connect BP & FP Hose to another Loco or
train, Turn ‘ON’ Dead Engine cock (47) provided on A&E Module and allow to charge BP & 240
Liter Aux. Reservoir.

• Close FP cock (136) on the auxiliary manifold.

• AUTO/A9 handle in both the cabs should be kept locked in FS position (Move FS stopper to lock
the AUTO/A9 Handle) and Put IND/SA9 Brake Handle in both cabs should be in REL position.
Ensure that BP is charged to normal level.

• Verify (after charging of BP pressure to normal level) Brakes are fully released and BC pressure
is zero in the gauge. If BC is not reducing to zero then give brief pulls to quick release lever at
the bottom of Distributor Valve (DV) and ensure BC reduces to zero.

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• Release Parking Brake by pressing plunger (solenoid “30”) on Aux panel or by pulling Manual
Release Pins of Parking Brake Unit.

• (Note: If Loco brake remains applied, press TP_BCC (Test point) of IND Module on Brake Panel
to release BC to Zero.

9.8 CAB CHANGING PROCEDURE

• In currently operating cab:

• Put AUTO/A9 handle in FS position & Lock it using FS Stopper. Changes the position of Mode selection
switch from LEAD to TRAIL & Place the BL key to Self Hold Mode as usually done with E-70 Brake
system.

• Non-operating Cab (Which is to make Active):

• wait for 5 sec. then change the position of Mode selector switch from TRAIL to LEAD & unlock the
AUTO/A9 handle, then Mode change penalty is applied and LCD will display message as “MODE
CHANGE PENALTY PUT AUTO IN FS 10sec” Keep AUTO/A9 handle in FS position then LCD message
will appear as “SYSTEM SAFETY PENLTY KEEP AUTO IN FS” Keep AUTO/A9 handle in FS for 10 sec.
When LCD message will appear as “TARGET BP 3.35” then bring AUTO/A9 handle from FS position to
RUN position to charge the BP, Resume Operation.

• NOTE: When both selector switch will be in (LEAD/TRAIL Switch) LEAD-LEAD/LEAD-TEST/LEAD-HLPR

then a fault “WRONG CONFIG PENALTY”, PUT AUTO IN FS 10 SEC. will be displayed on Driver’s brake
controller LCD.

• When Inactive cab’s Auto/A9 handle will be at EMER then a fault “EMERGENCY AUTO A” will come, By
Taking A9 Handle at FS position, this fault code will be removed.

• While changing position of LEAD & TRAIL switch, ensure loco speed at ‘0’ and A9/Auto Handle position
should be at FS.

• If Auto/A99 handle is not at FS and Operator changes LEAD/TRAIL switch position then penalty will come
and to recover it, please follow the DBC LCD displayed message.

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10 EMCBS DRIVER INSTRUCTIONS FOR 1ST TIME BRAKE RELEASE

Figure 20 : EMCBS DRIVER INSTRUCTIONS FOR 1ST TIME BRAKE RELEASE

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PROCEDURE FOR 1ST TIME BRAKE RELEASE TO USE IN:-

1. DRIVER BACK-UP VALVE (PTDC)

2. DEAD ENGINE

3. MULTIPLE UNIT (MU)

STEP-1:

IND MODULE – REMOVE PRESSURE TEST POINT LOCK COVER BY PRESSING BUTTON PROVIDED AT TEST POINT
(TPBPC, TPBCC AND TPBCEP) AND USED A INSERT PIN/ALLEN SCREW DRIVER TO RELEASE THE PRESSURE AS
SHOWN IN PICTURES.

STEP-2:

DV – AFTER REMOVING THE BC PRESSURE, PUL “QRV HANDLE” OF DV UP SIDE TO ELEASE THE CR PRESSURE AS
SHOWN IN PICTURES.

11 EMCBS LRU’s DETAILS

Figure 21 : BP MODULE

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Figure 22 : IND MODULE

Figure 23 : L&T MODULE

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Figure 24 : A&E MODULE

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12 PNEUMATIC CIRCUIT FOR 3 PHASE ELECTRIC LOCO WAP-7 & WAP-9

Figure 25 : Pneumatic circuit for 3 phase electric loco WAP-7 & WAG-9

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13 SCHEMATIC DIAGRAM OF BRAKE PANEL

Figure 26 : Schematic diagram of Brake Panel

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14 FUNCTIONAL DESCRIPTION OF EMCBS

14.1 BP MODULE

Figure 27 : BP Module

14.1.1 BP CONTROL

14.1.1.1 BP CHARGING (NORMAL)

When Auto handle is placed in RUN position BP_RELAY produces BP equal to pilot pressure from
CV_BP which is 5 kg/cm2 using MR as input.
1. CV_BP1 receives Voltage Signal based on the handle position in DBC.
2. CV_BP1 generates pneumatic output proportional to the Voltage received which goes to PV_BPC1.
3. PV_BPC1 receives pilot signal from SV_BPC as it gets energized.
4. PV_BPC1 allows pneumatic signal received from CV_BP1 to BP_RELAY 1 as pilot pressure.
5. Simultaneously MR1 after passing through Chokes, reaches BP_RELAY1 as input.
6. BP_RELAY 1 generates output pressure (BP) equivalent to the pilot pressure.
7. BP Pressure reaches to PV_BP1 valve and same time BP pressure also pilots the PV_BP1 valve
through the SV_BP1 valve, through PV_BP1 valve, BP pressure is fed into the BP line.

14.1.1.2 BP CHARGING (QUICK)

When Auto Handle is placed in REL position for 3 seconds, BP is overcharged up to 5.5 kg/cm2 with
MR1 as input received by BP_RELAY1, bypassing chokes through a 8 mm port.
1. When the Auto handle of the DBC is moved to Release position, SV_QC1 is energized which allows
pressure to reach PV_QC1 as pilot.
2. MR1 passes through PV_QC1 to reach BP_RELAY1 directly as input.

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3. CV_BP1 produces pneumatic signal equal to 5.5 kg/cm2 which goes to BP_RELAY1 as pilot.
4. As a result, BP_RELAY1 starts to produce BP equivalent to 5.5 kg/cm2.
5. BP Pressure reaches to PV_BP1 valve and same time BP pressure also pilots the PV_BP1 valve
through the SV_BP1 valve, through PV_BP1 valve, BP pressure is fed into the BP line.
6. This condition is also known as Quick Charging which comes to normal state of 5 kg/cm2 within 180
seconds automatically.

14.2 INDEPENDENT MODULE

Figure 28 : Independent Module

14.2.1 BC GENERATION
Whenever Driver applies the Brake from Auto Handle / IND Handle, computer commands the
Proportionate Valve to generate the BC pilot pressure according to Handle position and further BC
pressure is generated by Relay Valve in accordance with BC pilot pressure.
1. AR comes as input to CV_BC.
2. CV_BC receives Voltage Signal based on the handle positions in DBC.
3. CV_BC generates Proportionate Pneumatic signal which goes to SV_BCC.
4. SV_BCC when energized allows input pressure to pass through, which goes to SV_BL1 after
passing through DCV_DV.
5. The pressure passes SV_BL1 which reaches BC_RELAY as pilot after passing through DCV1.
6. AR also reaches BC_RELAY as input pressure.
7. This input pressure is used by BC_RELAY to produce output pressure (BC) which is equivalent to
pilot pressure received.
8. This pressure passes through PV_BC1, after receiving pilot pressure from SV_BC1 when energized
and enters BC line.
9. Thus BC is generated in Locomotive.

14.2.2 BC GENERATION BY DBP IN TRAIL LOCOMOTIVE (WITH POWER)

The DBP generated from the LEAD Locomotive, enters the EMCBS panel of the TRAIL Locomotive. BC
pressure is sensed by the Pressure Transducer and accordingly BC is generated for Trail Loco.

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1. DBP pressure coming from LEAD Locomotive is sensed by BCEPS1.

2. Based on the DBP pressure value sensed BCEPS1, DBP pressure is generated by BC_RELAY.
3. Output generated by BC_RELAY passes through PV_BCEP1, after receiving pilot from SV_BCEP2,
enters DBP line.
4. Thus, DBP is generated.

14.2.3 DIRECT BRAKE PIPE– (DBP) GENERATION

Whenever Driver applies the Brake from IND Handle, computer commands the proportionate valve to
generate the DBP pilot pressure according to handle position and further DBP pressure is generated by
Relay valve in accordance with pilot pressure.
1. AR comes as input to CV_BC.
2. CV_BC receives voltage signal based on the handle positions in DBC.
3. CV_BC generates proportionate pneumatic signal which goes to SV_BCC.
4. SV_BCC when energized allows input pressure to pass through, which goes to SV_BL1 after
passing through DCV_DV.
5. The pressure passes SV_BL1 which reaches BC_RELAY as pilot after passing through DCV1.
6. AR also reaches BC_RELAY as input pressure.
7. This input pressure is used by BC_RELAY to produce output pressure (DBP) which is equivalent to
pilot pressure received.
8. This pressure passes through PV_BCEP1, after receiving pilot pressure from SV_BCEP2 when
energized and enters DBP line.
9. Thus, DBP is generated in Locomotive.

14.2.4 BC GENERATION BY DBP IN TRAIL LOCO (NO POWER)

The DBP generated from the LEAD Locomotive enters the EMCBS panel of the TRAIL Locomotive.
DBP pressure directly goes to the BC Relay and BC is generated equivalent to the DBP pressure.

14.2.5 BAIL OFF

When the Bail Off command is activated, the Bail off Solenoid Valve is energized. This cuts off and
vents the supply of pneumatic signal to the Control port of the BC_RELAY Valve. Thus the control
pressure of the BC_ RELAY Valve is reduced to zero resulting in complete release of Locomotive
Brake.
1. When Driver presses the PVEF (Foot Pedal), the SV_BL1 Valve is energized, which cuts off and
vents the supply to the control port of the BC_RELAY Valve. Since the Pilot Pressure is cut-off, the
BC_RELAY drains out the BC Pressure.

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14.3 AUTOMATIC & EMERGENCY MODULE

Figure 29 : Automatic & Emergency Module

14.3.1 EMERGENCY BRAKING

When the Emergency Brake is applied by Auto Handle, the Emergency Solenoid Valve gets energized
which in turn vents BP. Thus, Emergency Brakes are applied.
1. PV_EM is designed in such a way that it generates pilot pressure by itself from the input BP
pressure, which helps to keep input disconnected from output.
2. The output of PV_EM is connected to exhaust.
3. When driver applies emergency, SV_EM Exhaust the internal pilot of PV_EM which in-turn connects
input of PV_EM to its output resulting in BP exhaust, Emergency Brakes are applied.

14.3.2 BP GENERATION (REDUNDANT MODE)

When the BP Module fails, A&E Module takes over and starts generating BP pressure.
1. CV_BP2 receives MR1 pressure at input port.
2. Based on the Auto handle position in DBC, CV_BP2 receives voltage signal accordingly.
3. CV_BP2 generates output pressure proportionate to voltage signal received, which goes to
BP_RELAY2 as pilot. MR1 pressure reaches BP_RELAY2 as input, after passing through Chokes.
4. BP_RELAY2 generates output pressure equivalent to the pilot pressure received.
5. This output pressure goes to PV_BP2
6. When SV_BP2 is energized PV_BP2 receives MR1 as pilot.
7. After.PV_BP2 valve, BP pressure is fed into the BP line.

14.3.3 BP QUICK CHARGING IN REDUNDANT MODE

1. When the BP Module fails and Auto handle is moved to release position, SV_QC2 is energized
2. Thus PV_QC2 receives pilot pressure from SV_QC2 Valve.
3. MR2 reaches input of BP_RELAY2 directly through PV_QC2 with bigger port.
4. CV_BP2 produces pneumatic signal equal to 5.5 kg/cm2 which goes to BP_RELAY2 as pilot.
5. As a result, BP_RELAY2 starts to produce BP equivalent to 5.5 kg/cm2.

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14.4 LEAD & TRAIL MODULE

Figure 30 : Lead & Trail Module

14.4.1 BC CHARGING IN REDUNDANT MODE

1. When the Independent Module fails, BC Charging is done through Lead & Trail Module in
Redundant Mode.
2. MR2 pressure reaches input port of CV_BCEP.
3. Based on the handle position in DBC, CV_BCEP receives voltage signal.
4. CV_BCEP generates output pressure proportionate to the Voltage signal received.
5. This pressure reaches BCEP_RELAY as pilot after passing through SV_BL2.
6. BCEP_RELAY generates output pressure equivalent to pilot pressure from input pressure (MR2).
7. The output of BCEP_RELAY reaches PV_BC3.
8. When SV_BC2 is energized, PV_BC3 receives pilot pressure which connects input with output.
9. Thus, BC is generated.

14.4.2 DBP CHARGING IN REDUNDANT MODE

1. The output generated by BCEP_RELAY also reaches the input of PV_BCEP2.
2. When SV_BCEP2 is energized, PV_BCEP2 receives MREP as pilot.
3. As a result, input port of PV_BCEP2 is connected to its output which is directly connected to DBP
line.
4. Thus, DBP is generated.

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14.5 BP CHARGING FROM BACKUP VALVE

Figure 31 : BP Charging from Backup Valve

1. In the event of complete electronic failure, BP charging happens through Driver’s Backup Valve.
2. After electronic failure, driver turns ON the BKP_BPC Valve which is mounted on the Brake Panel.
3. Backup Valve receives MR2 at its input with which it generates Brake Pipe Control pressure, which
goes further to the pilot port of BP_RELAY1.
4. As a result, BP_RELAY1 starts to generate BP pressure equivalent to the pilot pressure received,
using MR1 at its input.
5. BP Pressure reaches to PV_BP1 valve and same time BP pressure also pilots the PV_BP1 valve
through the SV_BP1 valve. After.PV_BP1 valve, BP pressure is fed into the BP line.

14.6 BC CHARGING FROM DV

Figure 32 : BC Charging From DV

1. When both Independent Module and Lead & Trail Module fail, BC generated from DV is used in
generating BC for the Locomotive.
2. BC generated from DV passes through SV_DV1, PRV_DV, DCV_DV, SV_BL1, DCV1 and reaches
the pilot port of BC_RELAY in IND Module.
3. BC_RELAY using the AR pressure at input, generates output pressure equivalent to pilot.
4. The output pressure after passing through PV_BC2 fills BC line of the Locomotive.
5. Thus, BC is generated.
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Page 43
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

14.7 DEAD ENGINE CONDITION

Figure 33 : Dead Engine Condition

1. When the Locomotive is being used as a Dead Locomotive, Driver turns ON IC_DE which is
mounted on A&E module.
2. BP can now pass through NRV_DE, IC_DE, PRV_DE and reach DV as AR and charges AR of the
Dead Locomotive.
3. BC generated by the DV goes to BC_RELAY as pilot and AR pressure reaches as input.
4. BC_RELAY generates BC equivalent to the pilot received using AR.
5. Thus, BC is generated in the Dead Locomotive.

14.8 SPECIAL FEATURES OF EMCBS

14.8.1 BANKING OPERATION

The Brake System has necessary provision for using the Locomotive as Banking Locomotive. When
Locomotive is used for Banking operation, it should not be possible to Apply/Release the Train Brakes
from Banking Locomotive. But it is possible to apply Independent and Emergency Brake from Banking
Locomotive.

14.8.2 DEAD ENGINE FEATURE

While hauling a Dead Locomotive as a Trailing Locomotive, Application and Release of Brakes on this
Locomotive from the Leading Locomotive would be enabled. While hauling a Dead Locomotive as a
piped vehicle, Application and Release of Brakes with the help of Distributor Valve on this Locomotive
would be possible.

14.8.3 LOSS OF POWER FEATURE

When voltage supply feed to Microprocessor Controlled Brake System (EMCBS) is disrupted or in the
case of Over Head Equipment Power Failure, Brakes can be applied on Rolling Stock through Driver’s
Back Up Valve working directly via Distributor Valve.

14.8.4 BAIL OFF FUNCTION

Release of an Automatic Locomotive Brake while retaining the Train’s Brake Cylinder pressure shall be
possible by Operating Foot Pedal (PVEF). Bail Off will remain inactive during Emergency Application.

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Page 44
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

15 EMCBS FAILURE MODES

S. No. POTENTIAL FIELD FAILURE POTENTIAL CAUSES DIAGNOSTIC PROCEDURE

SANDING MODULE
Check for voltage near connector using multimeter.
Magnet Valve not receiving signal If there is no voltage, this means valve is not getting
1 Sanding is not happening signal
If the voltage is there, replace the Valve and check for
Magnet Valve is faulty
sanding function
Unable to Isolate Sanding
2 IC is faulty Replace the IC and check for function
Magnet Valve
EMERGENCY MODULE
Check for voltage signal with a multimeter.
Magnet Valve not receiving signal
If there is no voltage, check wiring connections
VCB unable to apply Magnet Valve is faulty If the voltage is there, replace and check
1
Emergency Limit Switch is faulty Replace IC-EE with a working limit switch and check
Limit Switch is not getting Check if the pin is able to deactivate the IC-EE or not
deactivated by pin in IC-EE Check EEV if problem exists further
VCB able to apply Emergency IC-EE is faulty Replace the IC-EE and check for function
2
even when the IC EE is closed Limit switch is faulty Replace Limit Switch and check
PARKING MODULE
PRV Setting changed Check if the PRV setting is not zero
Parking Brake Cylinder Solenoid Valve not receiving
1 Check with multi-meter for voltage
pressure not building signal
Solenoid Valve faulty If there is voltage, replace Solenoid Valve
Parking Brake system isolation
2 IC-PB is faulty Replace the IC-PB and check for function
failure
Solenoid not receiving signal Check with multi-meter for voltage
3 Parking Brake not released
Solenoid is faulty If there is voltage, replace solenoid valve
PANTO MODULE
Magnet Valve not receiving signal Check for voltage using multimeter.
1 Pantograph are not raising Magnet Valve is faulty If the voltage is there, replace the Magnet Valve
Isolating Cock faulty Check Isolating Cock
Panto pressure Leaking
2 IC assembled reverse Reverse the IC
continuously
3 Panto Isolation failure IC is leaking Replace the IC
FP MODULE
PRV wrongly set/faulty Check PRV setting
IC-FP is faulty Check if there is a leakage in IC-FP
1 FP not equal to 6 kg/cm2 Check for leakage in Relay Valve,
Faulty relay valve Try adjusting Valve Head of Relay Valve and If problem
still persists replace the Valve

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

S. No. POTENTIAL FIELD FAILURE POTENTIAL CAUSES DIAGNOSTIC PROCEDURE

DUPLEX CHECK VALVE

Duplex Check Valve wrongly set Try changing the setting of pressure
1 MREP generation failure
Duplex Check Valve is faulty Replace the Valve

UNLOADER MODULE

Unloader Valve not receiving Magnet Valve not receiving signal Check for voltage near connector using multimeter.
1
Signal Magnet Valve is faulty If the voltage is there, replace the Magnet Valve
2 Unable to isolate Unloader IC is faulty Replace the IC and check for function

BP MODULE
Check pressure in TP-BPC. If the pressure is not as
PV_BPC1 is leaking
required, then replace PV-BPC1.
If pressure at TP-BPC is as required, check pressure at
TP_BP.
BP-Relay is faulty
If the pressure at TP-BP is not as required then relay as
BP generation failure while BP faulty
1
Module active PV_BP1 is faulty If TP-BP pressure is as required, replace PV-BP1
Look if there is any pressure leak from BP-Relay 2(A&E)
PV_BP2 is faulty(A&E)
exhaust. If yes then replace PV-BP2
EEV leakage(Emergency Module) If the problem still persists, check for leakage in EEV
Filter is blocked(BP) Look if Filters is blocked inside with dust

A&E MODULE
Check pressure in TP-BPC. If the pressure is not
BP-Relay 2 faulty
matching with BP output pressure, replace BP-relay 2
A&E module active- BP PV-BP2 faulty If BP-Relay 2 is ok, replace PV-BP2
1
generation failure If the problem still persists, check for leakage from BP-
PV_BP1 leakage(BP) relay 1 (BP) exhaust.
If there is leakage, replace PV-BP1(BP)
IND MODULE
Check Pressure at TP-BCC.
DCV-DV is stuck
If the pressure is less or zero, replace DCV-DV
IND Module in active mode-BC DCV 1 is stuck If pressure at TP-BCC is ok, Replace DCV 1.
1
charging failure- Lead condition BC relay faulty If the problem still exists, adjust/replace BC-relay
Check for leakage near BCEP Relay exhaust (L&T)
PV_BC3 is leaking(L&T)
If leakage, exits replace PV-BC3(L&T)
Check Pressure at TP-BCEP, If pressure is less, replace
PV-BCEP 1 faulty
IND module active -BCEP PV-BCEP1
2
charging failure Check for leakage at exhaust of BCEP-relay, If yes
PV-BCEP 2 faulty(L&T)
replace PV-BCEP 2(L&T).
IND module active-BC release Pressure getting trapped at
3 Replace DCV_DV
failure DCV_DV

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Page 46
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

S. No. POTENTIAL FIELD FAILURE POTENTIAL CAUSES DIAGNOSTIC PROCEDURE

L&T MODULE

BCEP Relay faulty Adjust Valve Head of BCEP relay/ replace it

If there is no leakage from BC-Relay exhaust(IND),
PV-BC3 faulty
replace PV-BC3
L&T module active-BC If the problem persists, look if there is air leakage at the
1 PV-BC1 faulty(IND)
generation failure BC-Relay. If yes, replace PV-BC1(IND)
PV-BC2 faulty(IND) If there is leakage still, replace PV-BC2(IND)
DCV 2 stuck(IND) If there is leakage still, replace DCV 2

MISCELLANEOUS
If the emergency application is not happening with cab
PV-EM failure(A&E) controller, replace PV-EM

If the emergency application is not happening via VCB,

1 Emergency application failure
EEV failure replace EEV

If there is unwanted Emergency Application, replace IC-

IC-EE failure(Emergency Module)
EE
Look if there is air leakage from BKP-BPC exhaust. If
BKP-BPC faulty yes, replace the BKP_BPC

BP Generation failure by If there is no leakage from BKP-BPC, check for pressure

2 reading at TP-BPC.
Backup Valve
Backup valve PRV faulty If there is pressure difference, try adjusting Backup
Valve PRV.
If the problem still persists replace Backup Valve
Check for pressure at TP-MR.
MR Generation Failure, i.e., If Filter 2 blocked
3 BP module & A&E module are If there is not enough pressure, replace Filter 2
not receiving MR Pressure If still the problem persists, open Filter-MR and look for
Filter-MR blocked
blockage
4 MR2 generation failure Filter 4 is blocked Replace Filter 4 and look for blockage
Filter 5 blocked causing BP
Replace Filter 5
buildup failure
BP,BCEP & MREP are being
Filter 1 blocked causing BCEP
5 produced but not appearing in Replace Filter 1
buildup failure
respective lines
Filter 3 blocked causing MREP
Replace Filter 3
not reaching L&T module
AUTOMATIC HANDLE RELEASE POSITION FAILURE
This means the REL position limit
Automatic handle Release switch is not closed
position Failure Out-dent on the cam has not yet
*After pulling the handle reached the position to Actuate the Check the Spring inside the REL limit switch housing for
1
towards the REL position- Limit Switch designated free length, Nos of coils, Coil Dia
Intended fast charging of BP This will be due to the Return
does not take place Spring in the Limit Switch housing
has reached solid height before

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

S. No. POTENTIAL FIELD FAILURE POTENTIAL CAUSES DIAGNOSTIC PROCEDURE

Limit Switch actuated
NG Dimensions of the Spring Check Limit Switch housing for dimensions related to
seating inside Limit Switch housing Spring seating
Faulty Limit Switch Check the REL limit switch for correct functioning
Improper connection of wires or Check for the wires connecting REL limit switch to the
electronics failure PCB-Check for any electronics failure
NG Dimension of the REL Limit
Check the Automatic housing for the REL Limit Switch
Switch mounting holes on Auto
housing mounting holes
housing
AUTOMATIC HANDLE STUCK IN REL POSITION
This means the spring is not able
to push back the handle to RUN Check the spring inside the REL Limit Switch housing
position for designated spring force in fitted length and functional
Spring force can be less than the length
After placing the handle in REL designed Value
position, Once the required BP Spring missing in the Limit Switch Check for the presence of spring in the Limit Switch
is reached, Driver releases the housing housing
1
handle to go back to normal
RUN position. But Handle is Remove the AUTO handle from the DBC-Check for the
Auto Rotating Shaft jammed with
stuck in REL Position free rotation of the Auto Rotating Shaft-Ensure the Auto
the bush
Rotating Shaft rotates freely and not jammed with bush
Rotating cams fouling with the Remove the side cover from the DBC-Rotate the AUTO
surrounding parts leaving the handle and check if the cams foul with the surrounding
handle stuck parts
AUTOMATIC HANDLE RUN POSITION FAILURE
This means the limit switch is not
actuated.
After placing the handle in the
Outdent on the cam has not Check for the designated angular positioning of
1 RUN position- Required BP is
reached the limit switch position. Outdents on the cam against drawing
not reached
Outdent angular position on the
Cam can be wrong
AUTOMATIC HANDLE MIN POSITION FAILURE
Check for the designated positioning, width of slots on
NG Dimensioning of spring
After placing the handle in the the cam which if NG leads to improper seating of spring
plunger slots on the cam
1 MIN position- Required BP is plunger
not achieved Position of limit switch mounting Check the auto housing for limit switch housing
holes can be wrong mounting holes
AUTOMATIC HANDLE FS POSITION FAILURE

After placing the handle in the Faulty limit switch Check for the functioning of respective limit switches
1 FS position- Required BP is not Improper connection of wires or Check for the wires connecting limit switch to the PCB-
achieved electronics failure Check for any electronics failure
AUTOMATIC HANDLE STUCK IN A POSITION
Remove the AUTO handle from the DBC-Check for the
Auto rotating shaft jam with the
Driver is not able to rotate the free rotation of the AUTO rotating shaft-Ensure the Auto
1 bush
handle rotating shaft rotates freely and not jammed with bush
Auto handle fouling with FS Rotate the handle and check if the handle is fouling with

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

S. No. POTENTIAL FIELD FAILURE POTENTIAL CAUSES DIAGNOSTIC PROCEDURE

Stopper on upper housing FS stopper
Rotating cams fouling with the Remove the side cover from the DBC-Rotate the Auto
surrounding parts leaving the handle and check if the cams foul with the surrounding
handle stuck parts
LEAD AND TRAIL SWITCH FAILURE
Driver is not able to rotate the Remove the Display Assy and check for the rotary
1 Rotary switch jammed
switch on the Display Assy switch
DISPLAY SCREEN FAILURE
Details in the Display Screen Remove the Display Assy and check for electronics
1 Electrical malfunction
not visible to the driver failure
IND HANDLE STUCK IN A POSITION
Remove the IND handle from the DBC-Check for the
IND rotating shaft jam with the
free rotation of the IND rotating shaft-Ensure the IND
bush
Driver is not able to rotate the rotating shaft rotates freely and not jammed with bush
1
handle Rotating cams fouling with the Remove the side cover from the DBC-Rotate the IND
surrounding parts in the handle handle and check if the cams foul with the surrounding
stuck parts
IND HANDLE BRAKES RELEASED POSITION FAILURE
This means the Limit Switch is not
actuated
Outdent on the cam has not Check for the designated angular positioning of
After placing the handle in the reached the Limit Switch Outdents on the cam against drawing
1 REL position- Required BP is position*Outdent angular position
not reached on the Cam can be wrong
Check for the designated positioning, width of slots on
Dimensioning of spring plunger
the cam which if NG leads to improper seating of spring
slots on the cam
plunger
IND HANDLE BRAKES APPLIED POSITION FAILURE
Position of limit switch mounting Check the IND housing for Limit Switch housing
After placing the handle in the holes can be wrong mounting holes
1 Brakes applied position- Faulty Limit Switch Check for the functioning of respective Limit Switches
Required BP is not achieved Improper connection of wires or Check for the wires connecting Limit Switch to the PCB-
electronics failure Check for any electronics failure
ELECTRONICS FAILURE DUE TO MOISTURE ENTRY INSIDE
Ingress protection failure due to
opening in the interface of upper Check for potential fluid entry points in DBC Assy.
Electronics failure due to fluids housing and side cover
1
leaking into the DBC
Ingress protection failure through
Check for potential fluid entry points in side covers.
side cover

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Page 49
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

16 TROUBLESHOOTING GUIDELINE FOR EMCBS ELECTRONIC DEVICE

All Electronics cards are sensitive, hence, if any problem is observed in any Electronic cards. It should be
informed to OE manufacturer, Escorts Ltd. and should not be handled without the presence of OE authorised
personal.
Fault
Fault Code Description Troubleshooting Method
Code
Make sure that all connectors of A&E Module outside and inside are properly fitted.
1101 A&E Module FLS2 Sensor Open
Open the FLS2 sensor connector, check the voltage between ground and supply of
sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
FLS2 sensor and connector with FLS2 sensor. Now check again, sensor fault
1102 A&E Module FLS2 Sensor Short status of FLS2 through PC diagnostic application. This fault code should not exist,
if not replace electronic board of A&E module.
Make sure that all connectors of A&E Module outside and inside are properly fitted.
1103 A&E Module MRS2 Sensor Open
Open the MRS2 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
MRS2 sensor and connect the connector with MRS2 sensor. Now check again,
1104 A&E Module MRS2 Sensor Short sensor fault status of MRS2 through PC diagnostic application. This fault code
should not exist, if not replace electronic board of A&E module.
Make sure that all connectors of A&E Module outside and inside are properly fitted.
1105 A&E Module BPS2 Sensor Open
Open the BPS2 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BPS2 sensor and connect the connector with BPS2 sensor. Now check again,
1106 A&E Module BPS2 Sensor Short sensor fault status of BPS2 through PC diagnostic application. This fault code
should not exist, if not replace electronic board of A&E module.
Make sure that all connectors of A&E Module outside and inside are properly fitted.
1107 A&E Control BP Sensor Open
Open the BPCS2 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BPCS2 sensor and connect the connector with BPCS2 sensor. Now check again,
1108 A&E Control BP Sensor Short sensor fault status of BPCS2 through PC diagnostic application. This fault code
should not exist, if not replace electronic board of A&E module.
Make sure that all connectors of A&E Module outside and inside are properly fitted.
Check the communication fault status of A&E module through PC diagnostic
A&E Module CAN Communication application if fault code is persisting, then check the CAN electrical wiring
1301
Fault continuity. If wire found open, then corrects it as per electrical wiring connection.
Now check communication fault status again through PC diagnostic application. If
the problem is not solved, then change the electronic card of A&E module.
Make sure that all connectors of BP Module outside and inside are properly fitted.
2101 BP Module MRS Sensor Open
Open the MRS1 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
MRS1 sensor and connector with MRS1 sensor. Now check again, sensor fault
2101 BP Module MRS Sensor Short status of FLS1 through PC diagnostic application. This fault code should not exist,
if not replace electronic board of BP module.
Make sure that all connectors of BP Module outside and inside are properly fitted.
2103 BP Module FLS Sensor Open
Open the FLS1 sensor connector, check the voltage between ground and supply of
sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
FLS1 sensor and connector with FLS1 sensor. Now check again, sensor fault
2104 BP Module FLS Sensor Short status of FLS1 through PC diagnostic application. This fault code should not exist,
if not replace electronic board of BP module.

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Page 50
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Fault
Fault Code Description Troubleshooting Method
Code
Make sure that all connectors of BP Module outside and inside are properly fitted.
2105 BP Module BPS Sensor Open
Open the BPS1 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BPS1 sensor and connector with BPS1 sensor. Now check again, sensor fault
2106 BP Module BPS Sensor Short status of BPS1 through PC diagnostic application. This fault code should not exist,
if not replace electronic board of BP module.
Make sure that all connectors of BP Module outside and inside are properly fitted.
2107 BP Control BP Sensor Open
Open the BPCS1 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BPCS1 sensor and connect the connector with BPCS1 sensor. Now check again,
2108 BP Control BP Sensor Short sensor fault status of BPCS1 through PC diagnostic application. This fault code
should not exist, if not replace electronic board of BP module.
Make sure that all connectors of BP Module outside and inside are properly fitted.
Check the communication fault status of BP module through PC diagnostic
BP Module CAN Communication application if fault code is persisting, then check the CAN electrical wiring
2301
Fault continuity. If wire found open, then corrects it as per electrical wiring connection.
Now check communication fault status of again through PC diagnostic application.
If the problem is not solved, then change the electronic card of BP module.
Make sure that all connectors of IND Module outside and inside are properly fitted.
3101 IND Module BCS Sensor Open
Open the BCS sensor connector, check the voltage between ground and supply of
sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the BCS
sensor and connector with BCS sensor. Now check again, sensor fault status of
3102 IND Module BCS Sensor Short BCS through PC diagnostic application. This fault code should not exist, if not
replace electronic board of IND module.
Make sure that all connectors of IND Module outside and inside are properly fitted.
IND Module BCEPS2 Sensor
3103
Open Open the BCEPS2 sensor connector, check the voltage between ground and
supply of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK.
Replace the BCEPS2 sensor and connector with BCEPS2 sensor. Now check
IND Module BCEPS2 Sensor
3104 again, sensor fault status of BCEPS2 through PC diagnostic application. This fault
Short
code should not exist, if not replace electronic board of IND module.
Make sure that all connectors of IND Module outside and inside are properly fitted.
3105 IND Module BOS Sensor Open
Open the BOS sensor connector, check the voltage between ground and supply of
sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the BOS
sensor and connector with BOS sensor. Now check again, sensor fault status of
3106 IND Module BOS Sensor Short BOS through PC diagnostic application. This fault code should not exist, if not
replace electronic board of IND module.
Make sure that all connectors of IND Module outside and inside are properly fitted.
3107 IND Control BC Sensor Open
Open the BCC sensor connector, check the voltage between ground and supply of
sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the BCC
sensor and connector with BCC sensor. Now check again, sensor fault status of
3108 IND Control BC Sensor Short BCC through PC diagnostic application. This fault code should not exist, if not
replace electronic board of IND module.
Make sure that all connectors of IND Module outside and inside are properly fitted.
Check the communication fault status of IND module through PC diagnostic
IND Module CAN Communication application if fault code is persisting, then check the CAN electrical wiring
3301
Fault continuity. If wire found open, then corrects it as per electrical wiring connection.
Now check communication fault status again through PC diagnostic application. If
the problem is not solved, then change the electronic card of IND module.

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Page 51
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Fault
Fault Code Description Troubleshooting Method
Code
Make sure that all connectors of L&T Module outside and inside properly fitted.
4101 L&T Module BCCS2 Sensor Open
Open the BCCS2 sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BCCS2 sensor and connector with BCCS2 sensor. Now check again, sensor fault
4102 L&T Module BCCS2 Sensor Short status of BCCS2 through PC diagnostic application. This fault code should not
exist, if not replace electronic board of L&T module.
Make sure that all connectors of L&T Module outside and inside are properly fitted.
L&T Module MREPS Sensor
4103
Open Open the MREPS sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
MREPS sensor and connector with MREPS sensor. Now check again, sensor fault
4104 L&T Module MREPS Sensor Short status of MREPS through PC diagnostic application. This fault code should not
exist, if not replace electronic board of L&T module.
Make sure that all connectors of L&T Module outside and inside are properly fitted.
4105 L&T Module BCEPS Sensor Open
Open the BCEPS sensor connector, check the voltage between ground and supply
of sensor. If the supply voltage is 5V±0.1 then sensor supply is OK. Replace the
BCEPS sensor and connector with BCEPS sensor. Now check again, sensor fault
4106 L&T Module BCEPS Sensor Short status of BCEPS through PC diagnostic application. This fault code should not
exist, if not replace electronic board of L&T module.
Make sure that all connectors of L&T Module outside and inside are properly fitted.
Check the communication fault status of L&T module through PC diagnostic
L&T Module CAN Communication application if fault code is persisting, then check the CAN electrical wiring
4301
Fault continuity. If wire found open, then corrects it as per electrical wiring connection.
Now check communication fault status again through PC diagnostic application. If
the problem is not solved, then change the electronic card of L&T module.
Make sure that all connectors of BCE outside and inside are properly fitted.
Check the communication fault status of BCE card through PC diagnostic
5301 BCE_CAN_COM_FAIL application if fault code is persisting, then check the CAN electrical wiring
continuity. If wire found open, then corrects it as per electrical wiring connection.
Now check communication fault status of BCE card through PC diagnostic
application. If problem, persist then change CPU card of BCE.
DBC_CAB1_AUTO_POT_LOW_E
6101 No Action Needed.
VENT
DBC_CAB2_AUTO_POT_PRO_Z
6102 No Action Needed.
ONE_EVENT
DBC_CAB1_IND_POT_LOW_EV
6103 No Action Needed.
ENT
DBC_CAB1_IND_POT_PRO_ZO
6104 No Action Needed.
NE_EVENT
Make sure that all connectors of DBCA, outside and inside are properly fitted.
Check the communication fault status of DBCA through PC diagnostic application if
6301 DBC CAB1 NODE CAN ERROR fault code is persisting, then check the CAN electrical wiring continuity. If wire
found open, then corrects it as per electrical wiring connection. Now check
communication fault status of DBCA through PC diagnostic application. If problem,
persist then change electronic card of DBCA.
DBC_CAB2_AUTO_POT_LOW_E
7101 No Action Needed.
VENT

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Page 52
Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Fault
Fault Code Description Troubleshooting Method
Code
DBC_CAB2_AUTO_POT_PRO_Z
7102 No Action Needed.
ONE_EVENT

7103 DBC_CAB2_IND_POT_LOW No Action Needed.

DBC_CAB2_IND_POT_PRO_ZO
7104 No Action Needed.
NE_EVENT
Make sure that all connectors of DBCB, outside and inside are properly fitted.
Check the communication fault status of DBCB through PC diagnostic application if
7301 DBC CAB2 NODE CAN ERROR fault code is persisting, then check the CAN electrical wiring continuity. If wire
found open, then corrects it as per electrical wiring connection. Now check
communication fault status of DBCB through PC diagnostic application. If problem,
persist then change electronic card of DBCB.
This fault causes due to any fault (1101, 1102, 1103, 1104, 1105, 1106 or 1301)
8501 A&E MODULE FAIL
and automatically resolved when said fault.is rectified.
This fault causes due to any fault (4101, 4102, 4103, 4104, 4105, 4106 or 4301)
8502 L&T MODULE FAIL
and automatically resolved when said fault.is rectified.
This fault causes due to any fault (2101, 2102, 2103, 2104, 2105, 2106 or 2301)
8503 BP MODULE FAIL
and automatically resolved when said fault.is rectified.
This fault causes due to any fault (3101, 3102, 3103, 3104, 3105, 3106 or 3301)
8504 IND MODULE FAIL
and automatically resolved when said fault.is rectified.
DBC LT SW WRONG
9501 No Action Needed.
CONFIGURATION

9502 MR2_LOW_FLT No Action Needed.

VCD_EMER_PENALTY_SPEED>
9503 No Action Needed.
1.5 kmph

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

17 EMCBS SYSTEM OPERATIONAL PENALTIES

1. Power ON safe penalty
2. Wrong configuration penalty
3. Mode change penalty
4. System safety penalty
5. System fault penalty
6. Emergency penalty
Description and reset procedure of each penalties

17.1 POWER ON SAFE PENALTY

Power on safe penalty is applied when EMCBS system start-up from power on cycle. When this penalty
come up across then POWER ON SAFETY PENALTY as per MESSAGE05
PENALTY RESET: Move AUTO handle in FS of active cab if it is already in FS then ignore. Keep AUTO in
FS position up to 10 sec and follow LCD instructions.

17.2 WRONG CONFIGURATION PENALTY

Wrong configuration penalty is applied when EMCBS system is in wrong mode selection i.e. No cab DBC is
in TRAIL mode. When this penalty come up across then WRONG CONFIGURATION MODE as per
MESSAGE06.
PENALTY RESET: Move AUTO handle in FS of active cab if it is already in FS then ignore. Keep auto in
FS position up to 10 sec and follow LCD instructions.

17.3 MODE CHANGE PENALTY

Mode change penalty is applied when EMCBS system mode is changed i.e. Select DBC mode change
LEAD to Bank. When this penalty come up across then MODE CHANGE PENALTY as per MESSAGE07.
PENALTY RESET: Move AUTO handle in FS of active cab if it is already in FS then ignore. Keep AUTO in
FS position up to 10 sec and follow LCD instructions.

17.4 SYSTEM SAFETY PENALTY

System safety penalty is applied When Auto handle move to FS position of active cab 10-second system
safety penalty comes and LCD display shows as per MESSAGE08.
PENALTY RESET: Keep Auto in FS position of active cab of active cab up to 10 sec and follow LCD
instructions. After 10-second if there is no fault, then home screen

17.5 SYSTEM FAULT PENALTY

System Fault penalty is automatically applied when EMCBS system sense any faults in the system and
when this penalty come up across then SYSTEM FAULT PENALTY then LCD display shows any message
among MESSAGE15 to MESSAGE19 as per the fault condition.
PENALTY RESET: Keep auto in FS position of active cab of active cab up to 10 sec and follow LCD
instructions.

17.6 EMERGENCY PENALTY

System Fault penalty is automatically applied when EMCBS system sense train parting, VCD emergency
signal and ALP signal. When EMCBS System is come across emergency then LCD display shows screen
as per MESSAGE10.
PENALTY RESET: Move AUTO handle of DBC in emergency position of active cab. After 2-3 second
emergency penalty resets if any emergency signal is not sensed further.

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

18 INFORMATIVE AND DIAGNOSTIC LCD MESSAGES:

LCD messages are very useful for system operation instruction and diagnostic of the system.

18.1 HOME SCREEN MESSAGE:MESSAGE01

XXX XXXXX XXX

TARGET BP=X.XX

18.1.1 FIRST ROW DESCRIPTION

LEFT SIDE: XXX -> Indicates AUTO HANDLE position.
RIGHT SIDE: XXX -> Indicates IND HANDLE position.
MIDDLE SIDE: XXXXX -> Indicates LEAD/TRAIL SWITCH position.
AUTO HANDLE POSITION LCD DISPLAY
RELEASE REL
RUN RUN
MINIMUM MIN
FULL SERVICE FSA
EMERGENCY EMR

IND HANDLE POSITION LCD DISPLAY

IND RELEASE REL
IND FULL FSA
IND SER SERVICE SER

L/T Switch POSITION LCD DISPLAY

LEAD LEAD
TRAIL TRAIL
BANKER BANKER
TEST TEST

18.1.2 SECOND ROW DESCRIPTION

TARGET BP=X.XX (Where X.XX value of BP pressure in kg/cm2)

18.2 INACTIVE DBC MESSAGE: MESSAGE02

When EMCBS System DBC mode switch in trail mode then then LCD display shows below screen

DBC CURRENTLY
INACTIVE

18.3 POWER ON SCREEN: MESSAGE03

When EMCBS System starts system, self-test on power ON cycle then LCD display shows below screen

FSA LEAD FULL

SELF TEST STARTED
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 OPERATION AND MAINTENANCE MANUAL
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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

18.4 SELF TEST OK: MESSAGE04

When EMCBS System have no fault and system found OK then LCD display shows below screen
FSA LEAD FULL
SELF TEST PASS

18.5 POWER ON SAFE PENALTY: MESSAGE05

When EMCBS System power on then system come across POWER ON SAFE PENALTY then LCD
Display shows below screen

POWER ON SAFE PENALTY

PUT AUTO IN FS 10sec

18.6 WRONG CONFIGURATION PENALTY: MESSAGE06

When EMCBS System is wrongly mode configured then then LCD display shows below screen

WRONG CONFIG PENALTY

PUT AUTO IN FS 10sec

18.7 MODE CHANGE PENALITY: MESSAGE07

When EMCBS System is mode changed by mode change selection switch then LCD display shows below
screen
MODE CHANGE PENALTY
PUT AUTO IN FS 10sec

18.8 SYSTEM SAFE PENALITY: MESSAGE08

When system in power ON, wrongly configuration, mode change and system fault penalty then handle, we
need to auto handle move to FS position then LCD display shows below screen

SYSTEM SAFETY PENALTY

PUT AUTO IN FS

18.9 PVEF SIGNAL ON: MESSAGE09

When PVEF signal is ON by using foot then LCD display shows below screen

XXX XXXXX XXX

PVEF SIGNAL ON

18.10 EMERGENCY SIGNAL ON BY EMERGENCY PARTING/ALP/VCD: MESSAGE10

When System is come across emergency penalty by emergency parting, ALP and VCD emergency then
LCD display shows below screen.
XXX XXXXX XXX
EMR PARTING/ALP/VCD
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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

After 2 SEC MESSAGE11

XXX XXXXX XXX
PUT AUTO IN EMR

18.11 EMERGENCY BY AUTO HANDLE DBC A: MESSAGE12

When auto handle of DBC 1 move to emergency position then LCD display shows below screen
XXX XXXXX XXX
EMERGENCY AUTO A

18.12 EMERGENCY BY AUTO HANDLE DBC B: MESSAGE13

When auto handle of DBC 2 move to emergency position then LCD display shows below screen

XXX XXXXX XXX

EMERGENCY AUTO B

18.13 VCD EMERGENCY PENALITY RESET: MESSAGE14

When VCD emergency penalty reset signal comes then LCD display shows below screen

WAIT FOR 32 SEC

PRESS BPVR&TE/BE-'0'

18.14 One BC LRU FAIL: MESSAGE15

When BC LRU fail then LCD display shows below screen

FAULT: BC LRU FAIL

PUT AUTO IN FS 10sec

18.15 BOTH BC LRU FAIL: MESSAGE16

When both BC LRU failed then LCD, display shows below screen

EMCBS FAULT PENALTY

BOTH BC MODULES FAIL

18.16 ONE BP LRU FAIL: MESSAGE17

When BP LRU failed then LCD, display shows below screen

FAULT: BP LRU FAIL

PUT AUTO IN FS 10sec

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

18.17 BOTH BP LRU FAIL: MESSAGE18

When both BP LRU failed then LCD, display shows below screen

EMCBS FAULT PENALTY

BOTH BP MODULES FAIL

18.18 BOTH BP AND BC LRU FAIL: MESSAGE19

When both BP and BC LRU failed then LCD, display shows below screen

EMCBS FAULT PENALTY

BP & BC MODULES FAIL

BANKING OPERATION: MESSAGE20

When EMCBS system in banking mode of operation then LCD, display shows below screen

XXX BANKER XXX

BANKING OPERATION

18.19 BP LEAKAGE TEST: MESSAGE21

When EMCBS system in test mode of operation then LCD, display shows below screen

XXX TEST XXX

BP LEAKAGE TEST
After BP pressure, build-up 5 bar then following screen come MESSAGE22.

XXX TEST XXX

LEAKAGE TEST STARTED

18.20 TRAILING MODE OPERATION: MESSAGE23

When EMCBS system in trailing mode of operation then LCD, display shows below screen

XXX TRAIL XXX

MU-TRAIL OPERATION

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

EMCBS FAULT CODE

Sr. No. Fault Description Fault code

1 A&E Module FLS2 Sensor Open 1101
2 A&E Module FLS2 Sensor Short 1102
3 A&E Module MRS2 Sensor Open 1103
4 A&E Module MRS2 Sensor Short 1104
5 A&E Module BPS2 Sensor Open 1105
6 A&E Module BPS2 Sensor Short 1106
7 A&E Module CAN Communication Fault 1301
8 BP Module MRS Sensor Open 2101
9 BP Module MRS Sensor Short 2102
10 BP Module FLS Sensor Open 2103
11 BP Module FLS Sensor Short 2104
12 BP Module BPS Sensor Open 2105
13 BP Module BPS Sensor Short 2106
14 BPM Module CAN Communication Fault 2301
15 IND Module BCS Sensor Open 3101
16 IND Module BCS Sensor Short 3102
17 IND Module BCEPS2 Sensor Open 3103
18 IND Module BCEPS2 Sensor Short 3104
19 IND Module BOS Sensor Open 3105
20 IND Module BOS Sensor Short 3106
21 IND Module CAN Communication Fault 3301
22 L&T Module BCCS2 Sensor Open 4101
23 L&T Module BCCS2 Sensor Short 4102
24 L&T Module MREPS Sensor Open 4103
25 L&T Module MREPS Sensor Short 4104
26 L&T Module BCEPS Sensor Open 4105
27 L&T Module BCEPS Sensor Short 4106
28 L&T Module CAN Communication Fault 4301
29 BCE_CAN_COM_FAIL 5302
30 BCA_CAN_COM_ERROR 6301
31 BCB_CAN_COM_ERROR 7301

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

19 FAULT DOWNLOADING SOFTWARE

19.1 PROCEDURE FOR DATA DOWNLOAD

Connect USB cable one end to USB port of BCE CPU card and other end to a laptop. Open diagnostic
application on the laptop. Click Fault Data View button.
Now check how many faults existing in the system. Click No. of faults. For each faults we can download pre
and post data.
First Screen of GUI-LOGIN WINDOW

Figure 34 : Login Window

Access to next window will only happen by putting the correct Username & Password and Loco Number.
Online option is selected if brake system is connected to laptop. Select offline mode in case analysis need
to be done without brake system.
2nd Screen Communication Port Settings

Figure 35 : Communication Port Settings

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Here user will configure the COM Port to establish the communication with EMCBS. Baud Rate is hard
coded to 57600

3rd Screen Main Screen

Figure 36 : Main Screen
In this window, User has the option to check and control the following parameters:
• Fault Data View – On clicking this button, application software will take you to Fault Data window
• Date & Time – On clicking this button, application software will take you to Date & Time Window
• Settings - On clicking this button, application software will take you to Settings Window
• Exit - On clicking this button, application software will get exited
• Event Data View: On clicking this button, application software will take you to Event Data View
Window
• Configure User: On clicking this button, application software will take you to Configure User Window
• Report: On clicking this button, application software will take you to Report Window
• ODL: On clicking this button, application software will take you to ODL Window

Figure 37 : delete the

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Major functions:
I. View – clicking this button will show the RTC time of the EMCBS Electronics
II. Update – clicking this button will update the RTC with the Date & Time we put in the above fields.
III. EXIT – Clicking this button will traverse the control back to Main Window

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Next Screen Settings Window

Figure 38 : Settings Window

Major functions:
I. Get Config – clicking this button will show the current parameter setting configuration of EMCBS
II. Set Config – clicking this button will update the desired parameter setting configuration of EMCBS
by selecting the desired loco type in LOCO TYPE field.
III. EXIT – Clicking this button will traverse the control back to Main Window
Next Screen Fault Data View Window

Figure 39: Fault Data View Window

Major functions:
I. NO. OF FAULTS – clicking this button will show the number of stored faults in EMCBS
II. FAULT TABLE – clicking this button will show the Fault code table with date & time
III. SAVE TABLE - clicking this button will save the Fault code table in the location shown in the window
IV. CLEAR FAULTS - clicking this button will clear the Fault codes from memory of EMCBS
V. REPORT - clicking this button will jump to next window where it will show report window
VI. EXIT – Clicking this button will traverse the control back to Main Window
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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Figure 40: Report Generation Window

I. All Data – clicking this button will show all events and faults between start date and end date.
II. Event Data – clicking this button will show all the events between selected start date and end date.
III. Fault Data - clicking this button will show all the faults between selected start date and end date.
IV. Event & Fault Data- clicking this button will show all events and faults between selected start date
and end date.
IV. Generate Report - clicking this button will generate the PDF reports.
V. EXIT – Clicking this button will traverse the control back to Main Window
VI. Start Date: User can select start date from here. Enabled only if All data is unchecked.
VII. End Date: User can select end date from here. Enabled only if All data is unchecked.

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

20 EMCBS ELECTRIC WIRING DIAGRAM

Electrical connectivity between different sub-systems and interfacing with Locomotive is as shown in the
diagram below.

Figure 41 : EMCBS Wiring Diagram

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21 PARTS LIST FOR PNEUMATIC VALVES

21.1 DUPLEX CHECK VALVE

Figure 42 : Duplex Check Valve

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.2 PART LIST FOR DUPLEX CHECK VALVE- 1J106010287 (Ref. Fig. no. 42)
S. No. DESCRIPTION QTY DRG. No. CLASS
1 HOUSING 1 1J106010289 C
2 BUSH 1 1J106010290 C
3 PIN (FOR CUP SLEEVE LOWER) 1 1J106010291 C
4 VALVE HEAD 1 1J106010292 C
5 O-RING 1 1J106010293 A
6 GUIDE PISTON 1 1J106010295 C
7 O-RING (6x1.5) 1 4EB9654 A
8 O-RING(43x3.5) 1 1J106010064 A
9 PLAIN WASHER B6 1 DIN 125 B
10 NYLOCK NUT ( M6) 1 DIN:982 A
11 COMPRESSION SPRING 1 1J106010297 B
12 COMPRESSION SPRING 1 1J106010298 B
13 SPRING PLATE 1 1J106010299 C
14 COVER 1 1J106010300 C
15 SPRING WASHER B10 ZN PLATED 1 DIN 127 A
16 HEX NUT M10 1 DIN 934 C
SOCKET HD. CAP SCREW M6x35 C
17 4 IS:2269
(S.S)
18 LOCKING PLUG M30X1.5 1 DIN906 C
19 O-RING 28X3.5 2 4A40125/23 A
20 ADJUSTING SCREW 1 1J106010301 C
HEX SOCKET HEAD - CAP SCREW - C
21 4 1S102140027
DIN 912- M8 X 1.25 X 65- SS
22 COMPRESSION SPRING 1 1J106010294 B

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.3 REPAIR KIT FOR DUPLEX CHECK VALVE (1J106010734)

S. No. DESCRIPTION QTY DRG. No. CLASS

1 O-RING 1 1J106010293 A
2 O-RING (6x1.5) 1 4EB9654 A
3 O-RING(43x3.5) 1 1J106010064 A
4 PLAIN WASHER B6 1 DIN 125 B
5 NYLOCK NUT ( M6) 1 DIN:982 A
6 COMPRESSION SPRING 1 1J106010297 B
7 COMPRESSION SPRING 1 1J106010298 B
8 SPRING WASHER B10 ZN PLATED 1 DIN 127 A
9 O-RING 28X3.5 2 4A40125/23 A
10 COMPRESSION SPRING 1 1J106010294 B

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21.4 RELAY VALVE

Figure 43 : Relay Valve

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.5 PART LIST FOR RELAY VALVE - 3EB10816 (Ref. Fig. no. 43)
S. No. DESCRIPTION DRAWING No. QTY CLASS
.
1 RELAY VALVE HOUSING 3EB10800 1 C
2 VALVE BUSH 4A38277 1 C
3 RELAY GUIDE TUBE 4EB8634 1 C
4 VALVE SEALING RING 3B58852/12 1 A
5 SNAP RING 4KB1223 1 B
6 RELAY VALVE HEAD 4EB8635 1 C
7 COMPRESSION SPRING 4A37656/12 1 B
8 WASHER 4A38280 1 B
9 GROOVED RING 4A18294/37 1 A
10 FLAT SEALING RING 4A31340/15 1 A
11 K RING 4KB1224 1 A
12 VALVE HOLDER 4A38279 1 C
13 O RING 28X3.5 4A40125/23 2 A
14 O RING 10 x 2.5 4A40125/7 1 A
15 GUIDE BUSH 4A58818 1 C
16 VALVE SEALING RING 3B58852/7 1 A
17 VALVE GUIDE HARD ANODISED 4B64673 1 C
18 COUNTER DISC 4A38268 1 C
19 DIAPHRAGM 4A38266 1 C
20 DIAPHRAGM PLATE 4A38267 1 C
21 EXTERNAL CIRCLIP 15x1 IS:3075 1 B
22 CYLINDER PIN 5M6*28 4KB1161 1 C
23 COVER 3EB8636 1 C
24 O-RING (7.5x2.3) 4EB 9314/13 1 A
25 HEX SOCKET HEAD - CAP 1S102140031 4 C
SCREW -DIN 912- M12 X 1.75 X
35- SS

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.6 REPAIR KIT FOR RELAY VALVE (1J106010735)

S. No. DESCRIPTION DRAWING No. QTY. CLASS

1 VALVE SEALING RING 3B58852/12 1 A
2 SNAP RING 4KB1223 1 B
3 COMPRESSION SPRING 4A37656/12 1 B
4 WASHER 4A38280 1 B
5 GROOVED RING 4A18294/37 1 A
6 FLAT SEALING RING 4A31340/15 1 A
7 K RING 4KB1224 1 A
8 O RING 28X3.5 4A40125/23 2 A
9 O RING 10 x 2.5 4A40125/7 1 A
10 VALVE SEALING RING 3B58852/7 1 A
11 EXTERNAL CIRCLIP 15x1 IS:3075 1 B
12 O-RING (7.5x2.3) 4EB 9314/13 1 A

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.7 BKP BPC ISOLATING COCK

Figure 44 : BKP BPC Isolating Cock

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21.8 PART LIST FOR BKP BPC ISOLATING COCK- 3EB9001 (Ref. Fig. no. 44)
S. NO DESCRIPTION QTY DRG NO. CLASS
1 HOUSING 1 3EB 8995 C
2 CAM SHAFT 1 4EB 8996 C
3 EXTERNAL CIRCLIP A10 x1MM 1 1S102040022 B
4 WING NUT 1 4EB 5625 C
5 STOPPER PLATE 1 4EB 5626 C
6 TOP PLATE 1 4EB 5629 C
7 O-RING 1 4EB 5632 A
8 CAP 1 4EB 5627 C
9 SEAL SUPPORT 1 1J112010032 C
10 BALL SEAL 2 4EB 5623 B
11 BALL 1 4EB 8998 C
12 O-RING 23X1.5 1 1J112010033 A
13 COMPRESSION SPRING 1 4EB 5628 B
14 INTERNAL CIRCLIP B35 1 IS:3075-2/DIN 472 B
15 INTERNAL CIRCLIP 26X1.2 1 IS:3075-2 B
16 O-RING 2 4EB 5631 A
17 O RING (11X2) 3 4EB 9002 A
18 CSK SCREW M5*12(SS) 2 IS:6761 C
19 CYLINDERICAL PIN 4M6X10 1 DIN 7 C
20 O-RING 32X1.5 1 4EB5662 A
21 PIN 1 4EB 8997 C
22 COMPRESSION SPRING 1 4EB 8999 B
23 Bush 1 1J106010305 C
24 SLOTTED PAN HEAD SCREW M3X16 2 DIN 85 C
SNAP ACTION SWITCH TYPE- 1 1J106010655
25 C
S870W1D1a
SS HEX SOCKET HEAD CAP SCREW 2
26 1S102140030 C
M6X60 (SS)

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.9 REPAIR KIT FOR BKP BPC ISOLATING COCK (1J106010736)

S. NO DESCRIPTION QTY DRG NO. CLASS

1 EXTERNAL CIRCLIP A10 x1MM 1 1S102040022 B
2 O-RING 1 4EB 5632 A
3 BALL SEAL 2 4EB 5623 B
4 O-RING 23X1.5 1 1J112010033 A
5 COMPRESSION SPRING 1 4EB 5628 B
6 INTERNAL CIRCLIP B35 1 IS:3075-2/DIN 472 B
7 INTERNAL CIRCLIP 26X1.2 1 IS:3075-2 B
8 O-RING 2 4EB 5631 A
9 O RING (11X2) 3 4EB 9002 A
10 O-RING 32X1.5 1 4EB5662 A
11 COMPRESSION SPRING 1 4EB 8999 B

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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.10 EMERGENCY ISOLATING COCK

Figure 45 : Emergency Isolating Cock

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 OPERATION AND MAINTENANCE MANUAL
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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.11 PART LIST FOR EMERGENCY ISOLATING COCK - 1J106010309 (Ref. Fig. no. 45)
S. NO. DESCRIPTION QTY DRG. NO. CLASS
1 HOUSING 1 3EB 8995 C
2 CAM SHAFT 1 4EB 8996 C
3 EXTERNAL CIRCLIP A10 x1MM 1 1S102040022 B
4 WING NUT 1 4EB 5625 C
5 STOPPER PLATE 1 4EB 5626 C
6 TOP PLATE 1 4EB 5629 C
7 O-RING 1 4EB 5632 A
8 CAP 1 4EB 5627 C
9 SEAL SUPPORT WITH GROOVE 1 1J112010032 C
10 BALL SEAL 2 4EB 5623 B
11 BALL WITH VENT FOR IC EE 1 1J106010306 C
12 O-RING 23 X 1.5 1 1J112010033 A
13 COMPRESSION SPRING 1 4EB 5628 B
IS:3075-2/DIN B
14 INTERNAL CIRCLIP B35 1
472
INTERNAL CIRCLIP 26X1.2 (SS- B
15 1 IS:3075-2
420)
16 O-RING 2 4EB 5631 A
17 O RING (11X2) 3 4EB 9002 A
18 CSK SCREW M5*10 2 DIN 87 C
19 CYLINDERICAL PIN 4M6X6 1 DIN 7 C
20 O-RING 32X1.5 1 4EB5662 A
21 PIN 1 4EB 8997 C
22 COMPRESSION SPRING 1 4EB 8999 B
23 BUSH 1 1J106010305 C
SLOTTED PAN HEAD SCREW C
24 2 DIN 85
M3X16
SNAP ACTION SWITCH TYPE- C
25 1 1J106010655
S870W1D1a
HEX SOCKET HEAD - CAP SCREW 2 1S102140030 C
26
-DIN 912- M6 X 1 X 60- SS

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.12 REPAIR KIT FOR EMERGENCY ISOLATING COCK (1J106010737)

S. NO. DESCRIPTION QTY DRG. NO. CLASS

1 EXTERNAL CIRCLIP A10 x1MM 1 1S102040022 B
2 O-RING 1 4EB 5632 A
3 BALL SEAL 2 4EB 5623 B
4 O-RING 23 X 1.5 1 1J112010033 A
5 COMPRESSION SPRING 1 4EB 5628 B
IS:3075-2/DIN
6 INTERNAL CIRCLIP B35 1 B
472
7 INTERNAL CIRCLIP 26X1.2 (SS-420) 1 IS:3075-2 B
8 O-RING 2 4EB 5631 A
9 O RING (11X2) 3 4EB 9002 A
10 O-RING 32X1.5 1 4EB5662 A
11 COMPRESSION SPRING 1 4EB 8999 B

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.13 CHECK VALVE

Figure 46 : Check Valve

21.14 PART LIST FOR CHECK VALVE- 4EB10843 (Ref. Fig. no. 46)
S.NO. DESCRIPTION QTY DRG. NO. CLASS
1 CHECK VALVE BODY 1 3EB10828 C
2 BUSH 1 4EB5658 C
3 VALVE HEAD 1 1J106010342 C
4 COMPRESSON SPRING 1 4EB5660 B
5 O-RING 32X1.5 1 4EB5662 A
6 VALVE GUIDE 1 1J106010343 C
7 INTERNAL CIRCLIP B35 1 IS:3075-2/DIN 472 B
8 O-RING 10 x 2.5 2 4A40125/7 A
9 HEX. SOCKET HD. CAP SCREW 2 IS:2269
C
(6x40)
Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.15 REPAIR KIT FOR CHECK VALVE (1J106010738)

S.NO. DESCRIPTION QTY DRG. NO. CLASS

1 COMPRESSON SPRING 1 4EB5660 B
2 O-RING 32X1.5 1 4EB5662 A
3 INTERNAL CIRCLIP B35 1 IS:3075-2/DIN 472 B
4 O-RING 10 x 2.5 2 4A40125/7 A

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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.16 SANDING MAGNET VALVE

Figure 47 : Sanding Magnet Valve

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.17 PART LIST FOR SANDING MAGNET VALVE - 1J106010421 (Ref. Fig. no. 47)
S. No. DESCRIPTION QTY DRG No. CLASS
1 HOUSING (SANDING 1 3EB10606 C
MAGNET VALVE)
2 CIRCLIP B52 (INTERNAL) 1 IS:3075 B
3 BOTTOM DISC 1 4EP 6461 A
4 O-RING (49x1.5) 1 4EP 6466 A
5 K-RING 1 N896/48 A
6 PISTON 1 4EP 6457 C
7 O-RING (18.5x3) 1 4EP 6465 A
8 CIRCLIP B42 (INTERNAL) 1 IS:3075 B
9 GUIDE SCREW 1 4EP 6460 C
10 GUIDE BUSH 1 4EP 6456 C
11 O-RING (DIA 31-OR 30003100) 3 4EB9336 A
12 O-RING (38.5x1.8) 1 4EP 6464 A
13 SEAT WASHER 1 4EP 6459 C
14 COMPRESSION SPRING 1 4A28000 B
15 AL.PLUG ø5 p6x5 4 4EP6216/4 C
16 O-RING (18x2.5) 3 4EP 6467 A
17 SOLENOID VALVE 3/2 NC, 1 1J106010643 C
110V. DC (MAKE-JANATICS)
18 HEX. SOCKET HD. CAP 2 IS:2269 C
SCREW (M8x70)
19 BALL 1/8" 2 DIN 5401 C
20 ALLEN SCREW M8X70 2 IS:2269 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.18 REPAIR KIT FOR SANDING MAGNET VALVE (1J106010739)

S. No. DESCRIPTION QTY DRG No. CLASS

1 CIRCLIP B52 (INTERNAL) 1 IS:3075 B
2 BOTTOM DISC 1 4EP 6461 A
3 O-RING (49x1.5) 1 4EP 6466 A
4 K-RING 1 N896/48 A
5 O-RING (18.5x3) 1 4EP 6465 A
6 CIRCLIP B42 (INTERNAL) 1 IS:3075 B
7 O-RING (DIA 31-OR 30003100) 3 4EB9336 A
8 O-RING (38.5x1.8) 1 4EP 6464 A
9 COMPRESSION SPRING 1 4A28000 B
10 O-RING (18x2.5) 3 4EP 6467 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.19 FILTER 3/4”( DBP,MREP, MR2 on Brake Panel)

Figure 48 : Filter ¾”

21.20 PART LIST FOR FILTER 3/4”- 3EB10967 (Ref. Fig. no. 48)
S.NO DESCRIPTION QTY DWG.NO CLASS
1 FILTER BODY 1 3EB10525 C
2 FILTER COVER 1 4EB10526 C
3 FILTER CAP 1 4EB10527 C
4 FILTER TUBE 1 4EB10528 C
5 FRONT RUBBER DISC 1 4EB10529 A
6 REAR RUBBER DISC 1 4EB10530 A
7 FILTER HOLDING SPRING 1 4EB10531 B
8 O-RING 40 X 1.5 1 4EB10532 A
9 O-RING 25 X 4 2 4EB9701 A
10 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
11 O-RING 1 4EB9774 A
12 CSK SCREW M6 X 16 4 1S102140018 C
13 SOCKET HEAD CAP SCREW M6X70 2 IS-2269 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.21 REPAIR KIT FOR FILTER ¾” (1J106010740)

S.NO DESCRIPTION QTY DWG.NO CLASS

1 FRONT RUBBER DISC 1 4EB10529 A
2 REAR RUBBER DISC 1 4EB10530 A
3 FILTER HOLDING SPRING 1 4EB10531 B
4 O-RING 40 X 1.5 1 4EB10532 A
5 O-RING 25 X 4 2 4EB9701 A
6 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
7 O-RING 1 4EB9774 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.22 FILTER 1” (Aux Comp., MREP on Auxiliary Panel, BP, MR1 on Brake Panel)

Figure 49 : Filter 1”

21.23 PART LIST FOR FILTER 1”- 3EB10965 (Ref. Fig. no. 49)

S.NO DESCRIPTION QTY DWG.NO CLASS

1 1” FILTER BODY 1 3EB10756 C
2 FILTER COVER 1 4EB10526 C
3 FILTER CAP 1 4EB10527 C
4 FILTER TUBE 1 4EB10757 C
5 FRONT RUBBER DISC 1 4EB10529 A
6 REAR RUBBER DISC 1 4EB10530 A
7 FILTER HOLDING SPRING 1 4EB10531 B
8 O-RING 40 X 1.5 1 4EB10532 A
9 O-RING 25 X 4 2 4EB9701 A
10 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
11 O-RING 1 4EB9774 A
12 CSK SCREW M6 X 16 4 1S102140018 C
13 SOCKET HEAD CAP 4 IS:2269
C
SCREW M6X70

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.24 REPAIR KIT FOR FILTER 1” (1J106010741)

S.NO DESCRIPTION QTY DWG.NO CLASS

1 FRONT RUBBER DISC 1 4EB10529 A
2 REAR RUBBER DISC 1 4EB10530 A

3 FILTER HOLDING SPRING 1 4EB10531 B

4 O-RING 40 X 1.5 1 4EB10532 A

5 O-RING 25 X 4 2 4EB9701 A

6 CIRCLIP B48 (INTERNAL) 1 IS:3075 B

7 O-RING 1 4EB9774 A

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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.25 MAIN RESERVOIR FILTER

Figure 50 : Main Reservoir Filter

21.26 PART LIST FOR MAIN RESERVOIR FILTER ASSEMBLY- 1J106010422 (Ref. Fig. no. 50)
S. CLASS
No. DESCRIPTION QTY. DRG. No.
1 MR FILTER HEAD 1 3EB10533 C
MR FILTER BODY WITH B
2 1 1J106010722
FILTER ELEMENT
3 O-RING DIA30X3 2 4A40125/12 A
4 TAPER PLUG 1/4 BSP 2 DIN 906 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.27 REPAIR KIT FOR MAIN RESERVOIR FILTER ASSEMBLY (1J106010742)

S. No. DESCRIPTION QTY. DRG. No. CLASS

MR FILTER BODY WITH B
1 1 1J106010722
FILTER ELEMENT
2 O-RING DIA30X3 2 4A40125/12 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.28 AIR FLOW MEASURING VALVE

Figure 51 : Air Flow Measuring Valve

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.29 PART LIST FOR AIR FLOW MEASURING VALVE –(1J106010363) (Ref. Fig. no. 51)

S. NO. DESCRIPTION QTY. DRG. NO. CLASS

1 HOUSING SUB-ASSEMBLY 1 1J106010364 ---
2 VALVE STEM 1 1J106010368 C
3 COMPRESSION SPRING 1 1J106010373 B
4 VALVE HEAD 1 1J106010374 C
SNAP RING-DIN 7993- B
5 1 1S102120003
B12X1-A2
6 DIAPHRAGM FOLLOWER 1 1J106010369 C
7 LARGE DIAPHRAGM 1 1J106010370 A
8 DIAPHRAGM HOLDER 1 1J106010371 C
9 SMALL DIAPHRAGM 1 1J106010372 A
10 COMPRESSION SPRING 1 1J106010376 B
11 O-RING 5X2 2 DIN3770 A
12 COVER SUB-ASSEMBLY 1 1J106010377 ---
13 ALLEN SCREW M8X30 4 DIN EN IS0 21269 C
14 APPLICATION CHOKE - φ1 1 1J106010466 C
15 LOCKING PLUG M20*1.5 1 DIN906 C
16 APPLICATION CHOKE - φ3 1 1J106010467 C
17 O-RING (18X2.5) 1 4EP6467 A
SINGLE FERRULE FITTING C
18 1 STD.
1/4''X10MM
HEX SOCKET HEAD - CAP C
19 SCREW -DIN 912- M10 X 4 1S102140023
1.25 X 60- SS

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.30 REPAIR KIT FOR AIR FLOW MEASURING VALVE (1J106010743)

S. NO. DESCRIPTION QTY. DRG. NO. CLASS

1 COMPRESSION SPRING 1 1J106010373 B
2 SNAP RING-DIN 7993-B12X1-A2 1 1S102120003 B
3 LARGE DIAPHRAGM 1 1J106010370 A
4 SMALL DIAPHRAGM 1 1J106010372 A
5 COMPRESSION SPRING 1 1J106010376 B
6 O-RING 5X2 2 DIN3770 A
7 O-RING (18X2.5) 1 4EP6467 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.31 PRESSURE REDUCING VALVE (PRV)

Figure 52 : Pressure Reducing Valve

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 OPERATION AND MAINTENANCE MANUAL
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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.32 PART LIST FOR PRESSURE REDUCING VALVE (PRV)- 2EB9826 (Ref. Fig. no. 52)
S. NO. DESCRIPTION QTY DRG. NO. CLASS
1 HOUSING S/A 1 2KB4221 --
2 FILTER 1 4KB1285 C
3 VALVE PLATE S/A 1 4KB3270 --
4 COMPRESSION SPRING 1 4A35388 B
5 K-RING 1 N897/28.2 A
6 ROUND CORD RING 1 4A27763/33 A
7 LOCKING SCREW 1 4A74552 C
8 K-RING 1 N896/80.2 A
9 PISTON S/A 1 4A58315 --
10 COMPRESSION SPRING 1 4A62245 B
11 COMPRESSION SPRING 1 4A62246 B
12 ADJUSTING SCREW 1 4KB759 C
13 SPRING PLATE 1 4A78374 C
14 SPRING HOUSING 1 3KB761 C
15 HEX. HEAD BOLT M8X45 4 IS:1363 C
16 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C
17 SEALING RING 2 4A27763/32 A
18 SPRING WASHER B12 1 IS:3063 A
19 HEX NUT M12X1.5 1 IS:1363 C
20 NAME PLATE 1 4KB745 C
21 SPRING WASHER B8 4 IS:3063 A
22 HEX. NUT M8 4 IS:1363 C
23 CAP R1-1/2" 1 4KB1220 C
24 RD. HD. SC 1/8 BSW 1/4 STD 2 STD. C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.33 REPAIR KIT FOR PRESSURE REDUCING VALVE (Refer drawing no. - 1B116030057)

21.34 DISTRIBUTOR VALVE

For DV refer Operation and Maintenance Manual for Escorts KE Series Distributor Valve
Doc. No RED-RD-BS-011-OM-01-20

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.35 ANTI COMPOUND VALVE, 3/8”

Figure 53 : Anti Compound Valve, 3/8”

21.36 PART LIST FOR ANTI COMPOUND VALVE, 3/8” - 1J106010105 (Ref. Fig. no. 53)

S.NO DESCRIPTION QTY DRG. NO. CLASS

HOUSING (ANTI COMPOUND VALVE 3/8") 1 1J106010113 C
1
END CONNECTOR (ANTI COMPOUND VALVE 3/8") 2 1J106010114 C
2
3 PISTON (DOUBLE CHECK VALVE) 1 4KB5243 C
4 SEAL (DOUBLE CHECK VALVE) 2 4KB5242 B
NAME PLATE (ANTI COMPOUND VALVE) 1 1J106010115 C
5
6 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.37 REPAIR KIT FOR ANTI COMPOUND VALVE, 3/8” (1J106010745)

S.NO DESCRIPTION QTY DRG. NO. CLASS
1 SEAL (DOUBLE CHECK VALVE) 2 4KB5242 B

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.38 AUTO DRAIN VALVE

Figure 54 : Auto Drain Valve

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.39 PART LIST FOR AUTO DRAIN VALVE, 1J106010081 (Ref. Fig. no. 54)

S.NO DESCRIPTION QTY DRG NO CLASS

1 RESERVOIR (AUTO DRAIN VALVE) 1 1J106010121 C
2 VALVE SEAT (AUTO DRAIN VALVE) 1 1J106010122 C
3 COMPRESSION SPRING (AUTO DRAIN VALVE) 1 1J106010123 B
4 O RING 1 4EP5064 A
5 VALVE SPINDLE (AUTO DRAIN VALVE) 1 1J106010124 C
6 FLAT SEALING RING (AUTO DRAIN VALVE) 1 1J106010125 A
7 VALVE BODY (AUTO DRAIN VALVE) 1 1J106010126 C
8 BALL DIN 5401 - 1/8"(3.175mm) G3 1.4034" 2 DIN 5401 C
9 O-RING (6.8x1.9) 1 1J106010127 A
10 DIAPHRAGM HOLDER (AUTO DRAIN VALVE) 1 1J106010128 C
11 DIAPHRAGM (AUTO DRAIN VALVE) 1 1J106010129 C
12 O-RING 3X1.6 1 4EB8611 A
13 COVER (AUTO DRAIN VALVE) 1 1J106010130 C
14 HEX SOCKET HEAD CAP SCREW M5x16 4 IS:2269 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.40 REPAIR KIT FOR AUTO DRAIN VALVE (1J106010746)

S.NO DESCRIPTION QTY DRG NO CLASS

1 COMPRESSION SPRING (AUTO DRAIN VALVE) 1 1J106010123 B
2 O RING 1 4EP5064 A
3 FLAT SEALING RING (AUTO DRAIN VALVE) 1 1J106010125 A
4 O-RING (6.8x1.9) 1 1J106010127 A
5 O-RING 3X1.6 1 4EB8611 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.41 OIL SEPARATOR WITH AUTO DRAIN VALVE

Figure 55 : Oil Separator With Auto Drain Valve

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 OPERATION AND MAINTENANCE MANUAL
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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.42 PART LIST FOR OIL SEPARATOR WITH AUTO DRAIN VALVE- 1J106010080 (Ref. Fig. no. 55)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 UPPER HOUSING 1 1J106010136 C
2 HEXAGON SOCKET HEAD CAP SCREW M10X90 - S.S. 1 IS:2269 C
3 HEX NYLOCK NUT M10x1 1 DIN:982 A
4 PLAIN WASHER A10 8 4EB5897/2 B
5 FILTER SUB ASSEMBLY (OIL SEPERATOR) 1 1J106010310 C
6 GASKET 1 1J106010143 A
7 LOWER HOUSING 1 1J106010138 C
8 CYLINDERICAL DOWEL PIN 5h6x12 1 DIN7 C
9 FLAT SEALING RING 1 1J106010144 B
10 DRAIN PLUG 1 1J106010145 C
11 HEX HEAD SCREW M10 X30(S.S) 7 DIN933 C
12 AUTO DRAIN VALVE 1 1J106010081 C
13 DUPL NIPP3/4X3/4DIN156 1 1B43120007300 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.43 REPAIR KIT FOR OIL SEPARATOR WITH AUTO DRAIN VALVE (1J106010747)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 PLAIN WASHER A10 8 4EB5897/2 B
2 GASKET 1 1J106010143 A
3 FLAT SEALING RING 1 1J106010144 B
4 HEX NYLOCK NUT M10x1 1 DIN:982 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.44 COMPRESSOR CHECK VALVE 1-1/4"

Figure 56 : Compressor Check Valve 1-1/4”

21.45 PART LIST FOR COMPRESSORE CHECK VALVE 1-1/4”- 1J106010473 (Ref. Fig. no. 56)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 TOP COVER-CCV 1 1J106010609 C
2 HOUSING MACHINING-EEV 1 1J106010390 C
3 PISTON-CCV 1 1J106010610 C
4 SPRING-CCV 1 1J106010395 B
5 BUSH-CCV 1 1J106010392 C
6 O RING 65x3.5 1 4EP6420/8 A
7 NAME PLATE 1 1J106010471 C
8 RIVET DIA. 2X5 2 IS:2155 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.46 REPAIR KIT FOR COMPRESSOR CHECK VALVE 1-1/4” (1J106010748)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 SPRING-CCV 1 1J106010395 B
2 O RING 65x3.5 1 4EP6420/8 A

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.47 UNLOADER EXHAUST VALVE 1"

Figure 57 : Unloader Exhaust Valve 1"

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.48 PART LIST FOR UNLOADER EXHAUST VALVE 1"- 1J102060014 (Ref. Fig. no. 57)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 TOP COVER 1 1J102060035 C
2 PISTON 1 1J102060034 C
3 GROOVED RING 1 4EP5477 A
4 UPPER BUSH 1 1J102060031 C
5 O-RING (19.5x3) 1 1J102060037 A
6 SHAFT 1 1J102060033 C
7 BUSH 1 1J102060028 C
8 UNLOADER PISTON 1 1J106010611 C
9 HOUSING 1 1J102060027 C
10 BOTTOM COVER 1 1J102060029 C
11 BOTTOM BUSH 1 1J102060030 C
12 O-RING 1 4EB5642 A
13 UNLOADER SPRING (SS) 1 1J106010612 B
14 O-RING (54.22x3.5) 1 4EP6403/3 A
15 O-RING 1 4A40125/13 A
16 O-RING (60x3) 1 1J102060024 A
17 PLANE WASHER M8X1.6(S.S) 1 ISO:7092 B
18 HEX HEAD NUT M8 (S.S) 1 IS:1364(A2-70) C
FLAT HEAD COUNTER SUNK SOCKET CAP C
19 SCREW-ISO 10642-M6X1X16-A270 8 1S102140018
20 NAME PLATE 1 1J102060036 C
21 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.49 REPAIR KIT FOR UNLOADER EXHAUST VALVE 1” (1J106010749)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 GROOVED RING 1 4EP5477 A
2 O-RING (19.5x3) 1 1J102060037 A
3 O-RING 1 4EB5642 A
4 UNLOADER SPRING (SS) 1 1J106010612 B
5 O-RING (54.22x3.5) 1 4EP6403/3 A
6 O-RING 1 4A40125/13 A
7 O-RING (60x3) 1 1J102060024 A
8 PLANE WASHER M8X1.6(S.S) 1 ISO:7092 B

21.50 DOUBLE CHECK VALVE, ¾”

Figure 58 : Double Check Valve ¾”

21.51 PART LIST FOR DOUBLE CHECK VALVE, ¾”- 4EB11496 (Ref. Fig. no. 58)

S.NO DESCRIPTION QTY DRG. NO. CLASS

1 HOUSING 1 1J102020002 C
2 SIDE COVER 2 1J102020003 C
3 PISTON 1 1J102020004 C
4 PISTON SEAL 2 1J102020005 B
5 NAME PLATE 1 1J102020007 C
6 O RING (68.1X3.5) 2 4EP 6309/1 A
7 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.52 REPAIR KIT FOR DOUBLE CHECK VALVE, ¾” (1J106010750)

S.NO DESCRIPTION QTY DRG. NO. CLASS

1 PISTON SEAL 2 1J102020005 B
2 O RING (68.1X3.5) 2 4EP 6309/1 A

21.53 CHECK VALVE, 1-1/4” (WITH REDUCER ¾”)

Figure 59 : Check Valve, 1-1/4” (With Reducer ¾”)

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EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.54 CHECK VALVE, 1-1/4” (WITH REDUCER ¾”)- 1J106010639 (Ref. Fig. no. 59)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 TOP COVER-CCV 1 1J106010609 C
2 HOUSING MACHINING-EEV 1 1J106010390 C
3 PISTON-CCV 1 1J106010610 C
4 SPRING-CCV 1 1J106010395 B
5 BUSH-CCV 1 1J106010392 C
6 O RING 65x3.5 1 4EP6420/8 A
7 NAME PLATE 1 1J106010471 C
8 RIVET DIA. 2X5 2 IS:2155 C
9 REDUCING BUSH (1-1/4" x 3/4") 2 1S102030001 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.55 REPAIR KIT FOR CHECK VALVE, 1-1/4” (WITH REDUCER ¾”) (1J106010751)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 SPRING-CCV 1 1J106010395 B
2 O RING 65x3.5 1 4EP6420/8 A

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.56 EMERGENCY EXHAUST VALVE 1-1/4"

Figure 60 : Emergency Exhaust Valve 1-1/4"

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.57 PART LIST FOR EMERGENCY EXHAUST VALVE 1-1/4"-- 1J106010472 (Ref. Fig. no. 60)

S.NO DESCRIPTION QTY DRG NO CLASS

1 TOP COVER-EEV 1 1J106010385 C
2 HOUSING MACHINING-EEV 1 1J106010390 C
3 EEV BUSH-SS 1 1J106010605 C
4 PISTON-EEV 1 1J106010386 C
5 SPRING-EEV 1 1J106010388 B
6 O-RING (28X2) 1 4EP 6157/8 A
7 O-RING DIA 64.77X3.5 1 4EP6420/8 A
8 LARGE SPRING-EEV 1 1J106010474 B
9 NAME PLATE 1 1J106010471 C
10 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.58 REPAIR KIT FOR EMERGENCY EXHAUST VALVE 1-1/4” (1J106010752)

S.NO DESCRIPTION QTY DRG NO CLASS

1 SPRING-EEV 1 1J106010388 B
2 O-RING (28X2) 1 4EP 6157/8 A
3 O-RING DIA 64.77X3.5 1 4EP6420/8 A
4 LARGE SPRING-EEV 1 1J106010474 B

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.59 2 WAY HORN VALVE

Figure 61 : 2 WAY HORN VALVE

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.60 PART LIST FOR 2 WAY HORN VALVE- 1J102060012 (Ref. Fig. no. 61)

S.NO DESCRIPTION QTY DRG NO CLASS

1 CIRCLIP INTERNAL 24X1.2 2 IS:3075 PART-2 (86) B
2 BOTTOM PLATE 2 4EB 9423 C
3 O-RING (21.6x1.2) 2 4EB 9429/2 A
4 COMPRESSION SPRING 2 4A60934A B
5 SPINDLE COMPLETE 2 1J102060002 C
6 O-RING (3.5x1.5) 2 4EB 9429/1 A
7 HOLDING BRACKET 1 1J102060004 C
8 PIN 1 1J102060009 C
9 UPPER PIECE 1 1J102060005 C
10 BELLOW RING PLATE 1 1J106010553 C
11 BELLOW 1 1J106010552 B
12 ARM 1 1J102060010 C
13 BALL GRIP 1 4EB 9431 C
14 SLOTTED PAN HD. SCREW M6x20 6 DIN 85 C
15 BRACKET 1 1J106010554 C
16 NYLOCK NUT ( M6) 6 DIN:982 A
17 HOUSING 1 1J102060001 C
18 SLOTTED CHEESE HEAD SCREW M5*10 6 IS:1366 C
19 CHEESE HEAD SCREW M4x10 4 DIN 84 C
20 SPLIT PIN DIA 1.5x15 1 IS:549 C
21 NAME PLATE 1 1J102060013 C
22 HAMMER DRIVE SCREW 2*5/32 2 IS:7519 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.61 REPAIR KIT FOR 2 WAY HORN VALVE (1J106010753)

S.NO DESCRIPTION QTY DRG NO CLASS

1 CIRCLIP INTERNAL 24X1.2 2 IS:3075 PART-2 (86) B
2 O-RING (21.6x1.2) 2 4EB 9429/2 A
3 COMPRESSION SPRING 2 4A60934A B
4 O-RING (3.5x1.5) 2 4EB 9429/1 A
5 BELLOW 1 1J106010552 B
6 NYLOCK NUT ( M6) 6 DIN:982 A

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EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.62 DRIVER’S BACK UP VALVE

Figure 62 : DRIVER’S BACK UP VALVE

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.63 PART LIST FOR DRIVER’S BACK UP VALVE- 2EB 9038 (Ref. Fig. no. 62)

S.NO DESCRIPTION QTY DRG NO CLASS

1 HOUSING (DBV) 1 2EB9040 C
2 BUSH 2 4EP6004 C
3 SPINDLE CAM 1 3EB 9042 C
4 SIDE COVER 1 3EB 9043 C
5 BUSH 2 4EB9045 C
6 BALL SPRING PLUNGER M12 2 4EP6422/1 C
7 VALVE PLATE 2 4EB 8399 C
8 O-RING (29X3.5) 2 4A40125/26 A
9 END PIECE 2 4EB8448 C
10 VALVE BUSH 2 4A34387 C
11 COMPRESSION SPRING SMALL 2 N1615 / 1002 B
MINIATURE CARTRIDGE REGULATOR- 11-990- C
12 NORGREN MAKE 1 196/GW188943
13 COMPRESSION SPRING 1 4B63010 B
14 DBV CHOKE 1 4EB10310 C
15 ALLEN PLUG 1/2 4 STD. C
16 PLUG (DIA.18) 1 4EP 6216/8 C
17 PLUG 10.5 S6X8 1 4EP6216/3 C
18 SHAFT FOR BALL 1 4EB 9046 C
19 HEX. SOCKET HD. CAP SCREW M6X20 (MAT: SS) 6 IS:2269 C
20 VALVE SHAFT S/A 2 4EB 8400 C
21 LOCK NUT M12 2 IS:2389 C
22 DBV MOUNTING PLATE 1 1J106010551 C
23 SOCKET HD. C'SK SCREW M6x12 (S.S) 4 IS:1365 C
24 FLANGE 2 4EB 8398 C
25 TAPER PLUG 1/4 BSP 2 DIN 906 C
26 SPRING HOLDER 1 4EB10308 C
27 EMERGENCY PISTON 1 4EB10304 C
28 EMERGENCY BUSH 1 4EB10306 C
29 DBV HANDLE 1 4EB10307 C
30 RETAINING RING YELLOW PASSIVATED 2 4A37485 C
31 GROOVED RING 2 4A18294/9 A
32 O-RING 4.5 X 2 1 4EB10309 A

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.64 REPAIR KIT FOR DRIVER’S BACK UP VALVE (1J106010754)

S.NO DESCRIPTION QTY DRG NO CLASS

1 O-RING (29X3.5) 2 4A40125/26 A
2 COMPRESSION SPRING SMALL 2 N1615 / 1002 B
3 COMPRESSION SPRING 1 4B63010 B
4 GROOVED RING 2 4A18294/9 A
5 O-RING 4.5 X 2 1 4EB10309 A

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.65 BP MODULE ASSEMBLY

Figure 63 : BP MODULE ASSEMBLY

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.66 PART LIST FOR BP MODULE ASSEMBLY- 2EB9768 ( Ref. Fig no. 63)
S.NO DESCRIPTION QTY DRG NO. CLASS
1 BP MODULE HOUSING S/A 1 3EB10274 ---
2 BP MODULE COVER S/A 1 3EB10275 ---
3 COVER 1 3EB 8636 C
4 ALLEN SCREW-M12X35 - SS 4 1S102140031 C
VALVE - PROPORTIONAL, 24V, 0-10 BAR,
5 1 1J106010650 C
LVP5010BX111HSR
6 ALLEN SCREW -M4X55 - SS 2 1S102140032 C
7 SENSOR - PRESSURE, 0-15 BAR, PX3AG1BS015BSAAX 4 1J106010537 C
8 VALVE - SOLENOID, 24V, 0-9 BAR, V0317E-5D2-Q, 3 1J106010651 C
9 RELAY VALVE SUB ASSEMBLY 1 1J106010412 C
10 FLAT SEALING RING 1 4A31340/15 A
11 DIAPHRAGM ASSEMBLY 1 1J106010414 ---
12 O-RING (7.5x2.3) 1 4EB 9314/13 A
13 O-RING (12X3) 1 4EP 6267/7 A
14 FILTER ELEMENT 1 1J106010362 C
15 O-RING (7x2) 2 1J106010061 A
16 NC VALVE ASSY 1 1J106010410 ---
17 BP NC VALVE ASSY 1 1J106010715 ---
PNEUMATIC PRESSURE TEST POINT,MAX. WORKING
18 4 P.No.- N01234617 C
PRESSURE:- 10 BAR
19 O-RING 10X2.5 6 4A40125/7 A
20 O-RING 28X3.5 3 4A40125/23 A
21 O-RING 21X3.5 1 4A40125/25 A
22 HEX HEAD SCREW M8 X 12 - SS 6 DIN 933 C
23 3/2 VALVE ASSEMBLY 1 1J106010320 ---

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.67 REPAIR KIT FOR BP MODULE ASSEMBLY (1J106010762)

S.NO DESCRIPTION QTY DRG NO. CLASS

1 FLAT SEALING RING
1 4A31340/15 A
2 O-RING (7.5x2.3)
1 4EB 9314/13 A
3 O-RING (12X3)
1 4EP 6267/7 A
4 O-RING (7x2)
2 1J106010061 A
5 O-RING 10X2.5
6 4A40125/7 A
6 O-RING 28X3.5
3 4A40125/23 A
7 O-RING 21X3.5
1 4A40125/25 A

21.68 BP MODULE SOLENOID VALVE NAME PLATE ORIENTATION

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.69 IND MODULE ASSEMBLY

Figure 64 : IND MODULE ASSEMBLY

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.70 PART LIST FOR IND MODULE ASSEMBLY- 2EB9667 ( Ref. Fig no. 64)
S.NO DESCRIPTION QTY DRG NO. CLASS
1 IND MODULE HOUSING S/A 1 2EB9668 ---
2 IND MODULE COVER S/A 1 3EB10280 ---
3 N.O. VALVE ASSY 1 3EB10975 ---
4 COVER 1 3EB 8636 C
5 ALLEN SCREW-M12X35 - SS 4 1S102140031 C
6 VALVE - PROPORTIONAL, 24V, 0-10 BAR, LVP5010BX111HSR 1 1J106010650 C
7 ALLEN SCREW M4X55 - SS 2 1S102140032 C
8 SENSOR - PRESSURE, 0-15 BAR, PX3AG1BS015BSAAX 4 1J106010537 C
9 HEX HEAD SCREW M8X12 - SS 6 DIN 933 C
10 DOUBLE CHECK VALVE ASSY 3 1J106010463 ---
11 VALVE - SOLENOID, 24V, 0-9 BAR, V0317E-5D2-Q, 5 1J106010651 C
12 RELAY VALVE SUB ASSY 1 1J106010412 ---
13 FLAT SEALING RING 1 4A31340/15 A
14 DIAPHRAGM ASSEMBLY 1 1J106010414 ---
15 O-RING (7.5x2.3) 1 4EB9314/13 A
16 O-RING (12X3) 1 4EP6267/7 A
17 FILTER ELEMENT 1 1J106010362 C
18 O-RING (7x2) 2 1J106010061 A
19 NC VALVE ASSY 2 1J106010410 ---
20 O-RING (10 x 2.5) 5 4A40125/7 A
21 O-RING (28X3.5) 4 4A40125/23 A
PNEUMATIC PRESSURE TEST POINT, MAX. WORKING PRESSURE:- 10
C
22 BAR MAKE- STAUBLI 3 P.No.- N01234617

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.71 REPAIR KIT FOR IND MODULE ASSEMBLY (1J106010763)

S.NO DESCRIPTION QTY DRG NO. CLASS

1
A
FLAT SEALING RING 1 4A31340/15
2
A
O-RING (7.5x2.3) 1 4EB9314/13
3
A
O-RING (12X3) 1 4EP6267/7
4
A
O-RING (7x2) 2 1J106010061
5
A
O-RING (7x2) 2 1J106010061
6
A
O-RING (10 x 2.5) 5 4A40125/7
7
A
O-RING (28X3.5) 4 4A40125/23

21.72 IND MODULE SOLENOID VALVE NAME PLATE ORIENTATION

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.73 L&T MODULE ASSEMBLY

Figure 65 : L & T MODULE ASSEMBLY

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.74 PART LIST FOR L&T MODULE ASSEMBLY- 2EB9683 ( Ref. Fig no. 65)

S.NO. DESCRIPTION QTY DRG NO. CLASS

1 L&T MODULE SUB-ASSY 1 2EB9684 ---
2 L&T MODULE COVER S/A 1 3EB10276 ---
3 NC VALVE ASSY 2 1J106010410 ---
4 COVER 1 3EB8636 C
5 HEX SOCKET HEAD - CAP SCREW -DIN 912- M12 X 1.75 X 35- SS 4 1S102140031 C
6 VALVE - PROPORTIONAL, 24V, 0-10 BAR, LVP5010BX111HSR 1 1J106010650 C
7 HEX SOCKET HEAD - CAP SCREW -DIN 912- M4 X 0.7 X 55-SS 2 1S102140032 C
8 SENSOR - PRESSURE, 0-15 BAR, PX3AG1BS015BSAAX 4 1J106010537 C
9 VALVE - SOLENOID, 24V, 0-9 BAR, V0317E-5D2-Q, 3 1J106010651 C
10 HEX HEAD SCREW M8X12(S.S) 6 DIN933 C
11 RELAY VALVE SUB ASSEMBLY 1 1J106010412 ---
12 DIAPHRAGM ASSEMBLY 1 1J106010414 ---
13 FLAT SEALING RING 1 4A31340/15 A
14 O-RING DIA25X4 4 4EB9701 A
15 O-RING (7.5x2.3) 1 4EB 9314/13 A
16 O-RING(7x2) 2 1J106010061 A
17 O-RING (12x3) 1 4EP 6267/7 A
18 FILTER ELEMENT 1 1J106010362 C
19 O-RING DIA 9X3 3 4EB9682 A

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.75 REPAIR KIT FOR L&T MODULE ASSEMBLY (1J106010764)

S.NO. DESCRIPTION QTY DRG NO. CLASS

1 FLAT SEALING RING
1 4A31340/15 A
2 O-RING DIA25X4
4 4EB9701 A
3 O-RING (7.5x2.3)
1 4EB 9314/13 A
4 O-RING(7x2)
2 1J106010061 A
5 O-RING (12x3)
1 4EP 6267/7 A
6 O-RING DIA 9X3
3 4EB9682 A

21.76 L&T MODULE SOLENOID VALVE NAME PLATE ORIENTATION

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.77 A&E MODULE ASSEMBLY

Figure 66 : A & E MODULE ASSEMBLY

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.78 PART LIST FOR A&E MODULE ASSEMBLY- 2EB9703 ( Ref. Fig no. 66)

S.NO DESCRIPTION QTY DRG NO. CLASS

1 A&E MODULE HOUSING S/A 1 3EB10277 ---
2 A&E MODULE COVER S/A 1 3EB10279 ---
3 COVER 1 3EB8636 C
4 HEX SOCKET HEAD - CAP SCREW-DIN 912- M12 X 1.75 X 35- SS 4 1S102140031 C
5 VALVE - PROPORTIONAL, 24V,0-10 BAR, LVP5010BX111HSR 1 1J106010650 C
6 HEX SOCKET HEAD - CAP SCREW-DIN 912- M4 X 0.7 X 55- SS 2 1S102140032 C
7 SENSOR - PRESSURE, 0-15 BAR,PX3AG1BS015BSAAX 4 1J106010537 C
8 DEAD ENGINE COCK ASSY 1 3EB9729 ---
9 COMPACT INTERFACE MOUNT REGULATOR- NORGREN MAKE 1 SLA/15542 C
10 VALVE - SOLENOID, 24V, 0-9 BAR, V0317E-5D2-Q, 3 1J106010651 C
11 EMERGENCY EXHAUST VALVE ASSEMBLY 1 3EB10977 ---
12 HEX HEAD SCREW M8X12(S.S) 6 DIN933 C
13 RELAY VALVE SUB ASSEMBLY 1 1J106010412 ---
14 FLAT SEALING RING 1 4A31340/15 A
15 DIAPHRAGM ASSEMBLY 1 1J106010414 ---
16 O-RING (7.5x2.3) 1 4EB9314/13 A
17 O-RING (12x3) 1 4EP6267/7 A
18 FILTER ELEMENT 1 1J106010362 C
19 O-RING(7x2) 2 1J106010061 A
20 NC VALVE ASSY 2 1J106010410 ---
PNEUMATIC PRESSURE TEST POINT, MAX. WORKING PRESSURE:-
21 1 P.No.- N01234617 C
10 BAR MAKE- STAUBLI
22 O-RING (25X4) 4 4EB9701 A
23 O-RING DIA 9X3 4 4EB9682 A

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.79 REPAIR KIT FOR A&E MODULE ASSEMBLY (1J106010765)

S.NO DESCRIPTION QTY DRG NO. CLASS

1
FLAT SEALING RING 1 4A31340/15 A
2
O-RING (7.5x2.3) 1 4EB9314/13 A
3
O-RING (12x3) 1 4EP6267/7 A
4
O-RING(7x2) 2 1J106010061 A
5
O-RING (25X4) 4 4EB9701 A
6
O-RING DIA 9X3 4 4EB9682 A

21.80 A&E MODULE SOLENOID VALVE NAME PLATE ORIENTATION

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.81 NC VALVE ASSEMBLY

Figure 67 : NC VALVE ASSEMBLY

21.82 PART LIST FOR NC VALVE ASSEMBLY- 1J106010410 (Refer Fig. No. 67)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 N.C. VALVE BODY 1 3EB10332 C
2 N.C. VALVE END CAP 1 4EB10333 C
3 N.C. VALVE FRONT COVER 1 4EB10334 C
4 N.C. VALVE GUIDE BUSH 1 4EB10335 C
5 N.C. COMPRESSION SPRING 1 4EB10336 B
6 N.C. VALVE MOVEMENT PISTON 1 4EB10337 C
7 O RING DIA. 6 X1 1 1J106010380 A
8 O-RING DIA25X4 2 4EB9701 A
9 O-RING (8x3) 1 4EB 9314/10 A
10 O-RING (48x2.5) 2 4EB9774 A
11 O-RING 23.5 X 2 1 4EB10361 A
12 O-RING 40 X 1 1 4EB10338 A
13 TOP VALVE SEAT 1 1J106010303 C
14 COVER-SEALING RING 1 1J106010304 C
15 K-RING 1 N896/48 A
16 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
17 NYLOCK NUT ( M6) 1 DIN:982 A

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

18 VALVE SEALING RING 1 3B58852/7 A

19 HEX. SOCKET HD. CAP SCREW M6X70 (MAT: SS) 2 IS:2269 C
20 PLUG (DIA.5) 2 4EP 6216/4 C
FLAT HEAD COUNTER SUNK SOCKET CAP
21 8
SCREW-ISO 10642-M6X1X16-A270 1S102140018 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.83 REPAIR KIT FOR NC VALVE ASSEMBLY (1J106010769)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 O RING DIA. 6 X1 1 1J106010380 A
2 O-RING DIA25X4 2 4EB9701 A
3 O-RING (8x3) 1 4EB 9314/10 A
4 O-RING (48x2.5) 2 4EB9774 A
5 O-RING 23.5 X 2 1 4EB10361 A
6 O-RING 40 X 1 1 4EB10338 A
7 K-RING 1 N896/48 A
8 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
9 NYLOCK NUT ( M6) 1 DIN:982 A
10 VALVE SEALING RING 1 3B58852/7 A
11 N.C. COMPRESSION SPRING 1 4EB10336 B

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.84 NO VALVE ASSEMBLY

Figure 68 : NO VALVE ASSEMBLY

21.85 PART LIST FOR NO VALVE ASSEMBLY- 3EB10975 (Refer Fig. No. 68)
S.NO DESCRIPTION QTY. DRG. NO. CLASS
1 N.O. VALVE BODY 1 3EB10340 C
2 N.O. VALVE END CAP 1 4EB10341 C
3 N.C. VALVE FRONT COVER 1 4EB10334 C
4 N.O. VALVE GUIDE BUSH 1 4EB10342 C
5 N.O. VALVE APPLICATION SPRING 1 4EB10344 B
6 N.O. VALVE MOVEMENT PISTON 1 4EB10343 C
7 O-RING 40 X 1 1 4EB10338 A
8 TOP VALVE SEAT 1 1J106010303 C
9 COVER-SEALING RING 1 1J106010304 B
10 O RING 48 X 2 2 4EB10347 A
11 K-RING 1 N896/48 A
12 O RING DIA. 6 X1 1 1J106010380 A
13 NYLOCK NUT ( M6) 1 DIN:982 A
14 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
FLAT HEAD COUNTER SUNK SOCKET CAP SCREW-ISO 10642-
15 8
M6X1X16-A270 1S102140018 C
16 O-RING (25X4) 2 4EB9701 A
17 O-RING (8x3) 1 4EB 9314/10 A
18 O-RING 9.5 X 2 1 4EB10369 A
19 VALVE SEALING RING 1 3B58852/7 B

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

20 PLUG (DIA.5) 2 4EP 6216/4 C

21 HEX. SOCKET HD. CAP SCREW M6X70 (MAT: SS) 2 IS:2269 C

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.86 REPAIR KIT FOR NO VALVE ASSEMBLY (1J106010768)

S.NO DESCRIPTION QTY. DRG. NO. CLASS

1 N.O. VALVE APPLICATION SPRING 1 4EB10344 B
2 O-RING 40 X 1 1 4EB10338 A
3 COVER-SEALING RING 1 1J106010304 B
4 O RING 48 X 2 2 4EB10347 A
5 K-RING 1 N896/48 A
6 O RING DIA. 6 X1 1 1J106010380 A
7 NYLOCK NUT ( M6) 1 DIN:982 A
8 CIRCLIP B48 (INTERNAL) 1 IS:3075 B
9 O-RING (25X4) 2 4EB9701 A
10 O-RING (8x3) 1 4EB 9314/10 A
11 O-RING 9.5 X 2 1 4EB10369 A
12 VALVE SEALING RING 1 3B58852/7 B

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.87 3/2 VALVE ASSEMBLY

Figure 69 : 3/2 VALVE ASSEMBLY

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.88 PART LIST FOR 3/2 VALVE ASSEMBLY - 1J106010320 (Refer Fig. No. 69)
DESCRIPTION QTY. DRG. NO. CLASS
S.NO
1 HOUSING 1 1J106010322 C
2 O-RING(ID17.4X1.8) 1 1J106010336 A
3 BUSH 1 1J106010323 C
4 PISTON 1 1J106010326 C
5 O-RING(ID17.9X2.8) 1 1J106010327 A
6 COMPRESSION SPRING 1 1J106010328 B
7 O-RING(ID5.8X1.8) 1 1J106010329 A
8 VALVE HEAD 1 1J106010330 C
9 PISTON ROD 1 1J106010331 C
10 COMPRESSION SPRING 1 1J106010333 B
11 O-RING (ID 23X1) 1 1J106010334 A
12 O-RING (ID 29X1.25) 1 1J106010335 A
13 COVER 1 1J106010337 C
14 COVER 1 1J106010338 C
15 CSK HEAD SCREW M4X12 DIN:7991 4 1S102140010 C
16 O-RING 4.5 X 2 1 4EB10309 A
17 O-RING (7.5x2.3) 3 4EB 9314/13 A
18 HEX SOCKET HEAD - CAP SCREW -DIN 912- M5 X 0.7 X 50- SS 2 1S102140033 C
19 VALVE HEAD 1 1J106010332 C
20 COMPRESSION SPRING 1 4A30485/9 B

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

21.89 REPAIR KIT FOR 3/2 VALVE ASSEMBLY (1J106010780)

S.NO DESCRIPTION QTY. DRG. NO. CLASS
1 O-RING(ID17.4X1.8) 1 1J106010336 A
2 O-RING(ID17.9X2.8) 1 1J106010327 A
3 COMPRESSION SPRING 1 1J106010328 B
4 O-RING(ID5.8X1.8) 1 1J106010329 A
5 COMPRESSION SPRING 1 1J106010333 B
6 O-RING (ID 23X1) 1 1J106010334 A
7 O-RING (ID 29X1.25) 1 1J106010335 A
8 O-RING 4.5 X 2 1 4EB10309 A
9 O-RING (7.5x2.3) 3 4EB 9314/13 A
10 COMPRESSION SPRING 1 4A30485/9 B

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.90 DEAD ENGINE COCK ASSEMBLY

Figure 70 : DEAD ENGINE COCK ASSEMBLY

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.91 PART LIST FOR DEAD ENGINE COCK ASSEMBLY - 3EB9729 (Refer Fig. No. 70)
S.NO DESCRIPTION QTY. DRG. NO. CLASS
1 DEAD ENGINE COCK HOUSING 1 3EB9730 C
2 BUSH 1 4EB 5658 C
3 VALVE HEAD 1 1J106010342 C
4 COMPRESSON SPRING 1 4EB5660 B
5 VALVE GUIDE 1 4EB 5663 C
IS:3075-2/DIN
6 INTERNAL CIRCLIP B35 2 B
472
7 PIN 1 4EB 5624 C
EXTERNAL CIRCLIP A10 X 1 MM (C-60/C-80/EN42)
8 ZINC FLAKE /IMMERSION COATING 8-12 MICRON 1 1S102040022 B
THICK
9 WING NUT 1 4EB 5625 C
10 STOPPER PLATE 1 4EB 5626 C
11 TOP PLATE 1 4EB 5629 C
12 O-RING 1 4EB 5632 A
13 CAP 1 4EB 5627 C
14 BALL SEAL 2 4EB 5623 B
15 SEAL SUPPORT 1 4EB 5630 C
16 COMPRESSION SPRING 1 4EB 5628 B
17 INTERNAL CIRCLIP 26X1.2 (SS-420) 1 IS:3075-2 B
18 BALL 1 4EB 5622 C
19 O-RING 2 4EB5631 A
20 CSK SOCKET HEAD SCREW M5x10 2 IS:6761 C
21 PLUG DIA10 3 4EB9670 C
22 CYLINDERICAL PIN 4M6X6 1 DIN 7 C
HEX SOCKET HEAD - CAP SCREW -DIN 912- M8 X 1.25
23 2 1S102140027 C
X 65- SS
24 O-RING DIA 9X3 2 4EB9682 A
25 O-RING 32X1.5 2 4EB5662 A

Class Definition
A Replace during every dis-assembly/Overhaul
B Replace during Overhaul
C Replace if damaged

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.92 REPAIR KIT FOR DEAD ENGINE COCK ASSEMBLY (1J106010779)

S.NO DESCRIPTION QTY. DRG. NO. CLASS
1 COMPRESSON SPRING 1 4EB5660 B
2 INTERNAL CIRCLIP B35 2 IS:3075-2/DIN 472 B
EXTERNAL CIRCLIP A10 X 1 MM (C-60/C-80/EN42) ZINC
3 1 1S102040022 B
FLAKE /IMMERSION COATING 8-12 MICRON THICK
4 O-RING 1 4EB 5632 A
5 BALL SEAL 2 4EB 5623 B
6 COMPRESSION SPRING 1 4EB 5628 B
7 INTERNAL CIRCLIP 26X1.2 (SS-420) 1 IS:3075-2 B
8 O-RING 2 4EB5631 A
9 O-RING DIA 9X3 2 4EB9682 A
10 O-RING 32X1.5 2 4EB5662 A

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Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

21.93 TEST INSTANCE

21.94 ON-LOCOMOTIVE SYSTEM TEST

21.94.1 GENERAL INFORMATION

The following test instruction is to be used at Locomotives Works for the purpose of commissioning the
3 Phase Electric Locomotive. This test instruction contains the on-Locomotive test requirements for the
EMCBS or test per IR test code.

Notification!
 This instruction is provided uncontrolled within the contents of this manual. It
shall be the responsibility of the user to maintain the latest revision of this
instruction from Locomotives Works. This instruction appears reformatted
without technical changes for insertion within this manual

21.94.2 TEST FORMAT FOR 3-PHASE ELECTRIC LOCOMOTIVE

(WAG9/WAP7/WAP5)

21.94.2.1 TEST PREPARATION

6. Check all the Cocks are properly closed & all the Multiple Hose Couplings are properly secured on
Dummy Couplings.
7. Open all the Drain Cocks of Reservoirs, drain Condensed air and close them properly.
8. In Driving Cab.
 Keep Direct Brake Controller handle ( Independent Brake Handle) in RELEASE position.
 Keep Automatic Brake Controller Handle in RUN position.
 Parking Brake in Applied condition (& when started to RELEASE).
9. Air Dryer By-Pass Handle is in Close Position
10. Vigilance Isolating Cock is in open condition.
11. Brake Pipe Isolating Cock Handle is in Open condition.
12. Horn and Wiper Isolating Cock Handle is in Open condition.
13. Dead Engine Cock in close condition.
14. In Non-Driving Cab:
 Keep Direct Brake Controller Handle (Independent Brake Handle) in RELEASE position.
 Keep Automatic Brake Controller Handle Locked in Full Service Position.
15. During the Leakage Test, no attempt should be made to stop the BP leakage.
This Specification has been combined with a test Record Sheet which appears at Right Hand
side of the page (Result Column).
When the test has been performed correctly and result are as per requirement, a tick (✓)
mark along with value obtained should be placed in front of relevant test result column.
Whenever required, Achieved Values should be recorded with dates.

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Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
1. AUXILIARY COMPRESSOR (PENTOGRAPH & VCB)
1.1 Ensure air is completely vented from Locomotive Pantograph Reservoir
OK
1.2 Panto Pressure Gauge reading must be Zero before starting the test
1.3 Turn On BL Key, Now MCPA Starts, Record Pressure Built Up Time Open - 8±0.15 kg/cm2
1.4 Check Panto Pressure Switch. Close - 7±0.15 kg/cm2
1.5 Unearth VCB HOM Switch. Open Blue Key (KABA Key) and fit in Panto
OK
Isolating Cock (KABA Cock) in Pneumatic Panel
1.6 Check Panto Safety Valve operates between 8.3-8.7 kg/cm2 8.5±0.20 kg/cm2
1.7 Pressure should not exceed 9.5±0.2 kg/cm2 above opening Pressure. < 9.5±0.20 kg/cm2
1.8 Set Pantograph Selection Switch in Auto position.
1.9 Open Pan-2 Isolating Cock and KABA Cock by Blue Key (KABA Key). OK
1.10 Set Cab-1 Pan UP in Panel A. see Panto-2 Rises. Close VCB then open.
1.11 Check Pan-2 Pressure Switch setting.
Open - 4.5±0.2 kg/cm2
Check signal config File: 05A MPrSWPan-2 P/S-09/2
Close - 5.5±0.2 kg/cm2
(Repeat this test from Cab2 & also check signal)
1.12 Close Pan-2 Isolating Cock. Panto 2 falls.
1.13 Open Pan-2 Isolating Cock, Panto 2 Rises. OK
1.14 Close KABA Cock, Panto-2 falls.
1.15 Set Pantograph Selection Switch in Pan-1, Cab Pan ON in panel A, See
OK
Panto-1 Rises.
1.16 Check Pan-1 Pressure Switch setting. Open - 4.5±0.2 kg/cm2
Check signal config File: 05A MPrSWPan-1 P/S-09/1 Close - 5.5±0.2 kg/cm2
1.17 Close Pan-1 Isolating Cock, Panto 1 falls.
1.18 Open Pan-1 Isolating Cock, Panto-1 Rises. OK
1.19 Close KABA Cock, Panto-1 Down.
1.20 Set Pantograph Selection Switch in Pan-2, Cab Pan ON in panel A, see
Panto-2 Rises. OK
Check signal config file: 05A MPrSWPan-2
1.21 Record Pantograph Rise Time 6 to 10 Sec
1.22 Record Pantograph Lowering Time 6 to 10 Sec
1.23 Pantograph line pressure drop is Less than 0.7 kg/cm2 in one 01 minute 0.70/01 Mts
2. AIR SUPPLY (Compressor System)
a. Fit Test Gauge at Test Point 40 in the Machine Room OK
b. Isolate Compressor No. 2, Run Comp. No. 1, Record Pr. Build Up Time. 12 Minute Max.
c. Check Low MR Pressure Switch 37, Close at 6.40±0.15 kg/cm2.
6.25-6.55 kg/cm2
Check Signal Config File: 06E-MPr Sw Low MR
d. Check Compressor Pressure Switch 35, Close at 10±0.2 kg/cm2.
9.80-10.20 kg/cm2
Check Signal Config File: 06E-MPr Sw8 bar
e. Check Compressor Pressure Switch 35, Open at 8±0.2 kg/cm2.
7.8-8.2 kg/cm2
Check Signal Config File: 06E-MPr Sw8 bar
f. Check Low MR Pressure Switch 37, Open at 5.6±0.15 kg/cm2.
5.45-5.75 kg/cm2
Check Signal Config File: 06E-MPr Sw Low MR
g. Isolate Compressor No. 1. Run Comp. No. 2, Record Pr. Build Up Time 12 Minute Max.
h. Check Compressor Pressure Switch 36, Close at 10±0.2 kg/cm2
9.80-10.20 kg/cm2
Check Signal Config File: 06E-MPr Sw7.5 bar

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
i. Check Compressor Pressure Switch 36 Open at 8±0.2
7.8-8.2 kg/cm2
j. Check Signal Config File: 06E-MPr Sw7.5 bar
k. Run Both Compressor, Record Pr. Build Up Time 06 Min Max
l. At the time of Comp start up for CP-1, Unloader-1 operates for 3 sec Min.
03 sec Min.
Check Signal Config File: 06D-BEPCPUnlode
m. At the time of Comp start up for CP-2 Unloader-2 operates for 3 sec Min.
03 sec Min.
Check Signal Config File: 06D-BEPCPUnlode
n. Check both Auto Drain Valve Operates When Compressor starts Slight drain
o. Drain MR Air below 8 kg/cm2 to start Both Compressors Check Start-up of both
Check Signal Config File:06E-BcontComp-1&2 Comp.
p. Check Operation of Comp-1 Safety Valve 10/1, Range 11.50±0.35 kg/cm2 11.15 - 11.85 kg/cm2
q. Pr. Does not exceed 1.2 kg/cm2 above safety Valve opening pressure 12.3±0.35 kg/cm2
r. Safety Valve 10 resets by 1.2 kg/cm2 below safety valve opening pressure 10.3±0.35 kg/cm2
s. Check Operation of Comp -2 safety Valve 10/2, Range 11.50±0.35 kg/cm2 11.15 - 11.85 kg/cm2
t. Pr. Does not exceed 1.2 kg/cm2 above safety Valve opening pressure 12.3±0.35 kg/cm2
u. Safety Valve 10 resets by 1.2 kg/cm2 below safety valve opening pressure 10.3±0.35 kg/cm2
v. Run Compressor Direct through BLCP Switch in Panel A Comp starts
w. Check Operation of Safety Valve 39, 10.35 to 11.05 kg/cm2 10.7±0.35 kg/cm2
x. Safety Valve 39 resets by 1.1 kg/cm2 below safety valve opening Pressure 9.6±0.35 kg/cm2
3. MAIN RESERVOIR EQUALIZING PIPE EQUIPMENT
a. Isolate Compressor, Drain MR Pr. Below 3 kg/cm2 by MREP End Cock
b. Start Compressor, Check Setting of Duplex Check valve 4.80 to 5.20 5.0±0.20 kg/cm2
kg/cm2
c. Open Isolating Cock FP, FP Pr. 5.80 to 6.20 kg/cm2 6.0±0.20 kg/cm2
d. Fit end hose in dummy holder
Max. 29 Sec
e. Open End Cock FP, Ensure Both Compressor Start In 29 Sec.
f. Open Pressure Switch FP. Open - 5.0±0.10 kg/cm2
Check Signal Config File: 06E-MPr Sw BkFP Close - 5.6±0.10 kg/cm2
4. AIR DRYER OPERATION
Make:
a. Record Make & S. No. of Air Dryer
S. No.
b. Open Drain Cock of MR2 to start Compressor.
c. Air Dryer towers to change in every 2 Min±10 Sec. Min 4 changes of CP-1 110sec to 130sec
Check Signal Config File:06D BAirDryer
d. Air Dryer towers to change in every 2 Min±10 Sec. Min 4 changes of CP-2
110sec to 130sec
Check Signal Config File:06D BAirDryer
e. Check Purge Air Stops from Air Dryer at just Compressor stop CP-2.
OK
Check Signal Config File: 06D BAirDryer
f. Close Isolating Cock of Air Dryer & Open Bypass Cock to ON position.
OK
Pressure Builds up when MCP starts. Close & seal Air Dryer \
5. MAIN RESERVOIR SYSTEM
a. Set up Loco in Normal from any Cab for activation in Driving mode Charge
OK
BP at 5.0 kg/cm2

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
b. Pr. Drop at MR-TP is 0.35 kg/cm2 in 5 Mts. 2 Min settling time to be given 0.35/5 Mts
c. Put Auto Brake in FS Direct in ON in 5 Mts. 2 min settling time Given Cab1 0.35/5 Mts
d. Put Auto Brake in FS Direct in ON in 5 Mts. 2 min settling time Given Cab2 0.35/5 Mts
e. BP Drop in 5 Mts. At BP-TP, 2 Min settling time to be given 0.35/5 Mts
f. Close MR Isolating Cock, Open Drain Cock of MR2, Fit Gauge at Aux. MR
0.15/5 Mts.
Drain Cock and Check Pr. Drop
6. BRAKE TEST- (Automatic Brake Operation)
a. Put Auto Handle to REL position.
BP 5.4 to 5.6 kg/cm2
b. BP Pr. Steady at 5.5±0.1 kg/cm2 in 60 Sec. to 80 Sec.
c. When BP comes to 5.10 kg/cm2 Make Initial Application. Check BP Falls to
4.7±0.1 kg/cm2, Return Auto handle to RUN. BP Goes to 5.5±0.1 kg/cm2 OK
before Bleed Down Starts.
d. Record BP Reduction time from 5.5±0.1 kg/cm2 to 5.0±0.01 kg/cm2 180±20 sec
e. Check Proportionality of Auto Brake, record BP & BC Pressure (in kg/cm2)
at each step
BC Pressure BC Pressure
Auto Brake BP Pressure
WAG-9/ WAP-7 WAP 5
Handle Position (kg/cm2)
(kg/cm2) (kg/cm2)
RUN 5.00± 0.10 0.00 0.00 OK

INITIAL (MIN) 4.60± 0.10 0.4± 0.1 0.75± 0.15

FULL
3.35± 0.2 2.50± 0.1 5.15± 0.30
SERVICE
EMERGENCY <0.3 2.50± 0.1 5.15± 0.30

f. Check Signal for actual Brake Pipe Pressure

5 kg/cm2 = %
Check Signal Config File: 06H FLG2: 01 01X Pr.Auto.Bk.Ln
g. Record Time to BP Fall to 3.50 kg/cm2 in 06 to 10 sec.
h. BC rise to 2.50± 0.1 kg/cm2 (WAP 5 -5.15± 0.30 kg/cm2) 8±2 Sec
(Ensure Auto Brake Handle moved directly to FS from RUN)
i. Operate Asst. Driver Cock. BP Pr. Drops below 2.50 Kg/cm2
j. Check BP PS operates. Close Asst. Driver Cock. BP-PS Reset Close - 4.05- 4.35 kg/cm2
k. Record BP PS setting Open - 2.85-3.15 kg/cm2
Check Signal Config File: 06A MPr Sw EmgBk
l. BC Apply Time for WAG-9 (BC 2.50±0.1 kg/cm2) 18-24 sec
m. BC Apply Time for WAP-7 (BC 2.50±0.1 kg/cm2) 6-9 sec
n. BC Apply Time for WAP-5 (BC 5.15±0.30 kg/cm2) 3-5 sec
o. BC Release Time up to 0.4 kg/cm2 for WAG-9 45-60 sec
p. BC Release Time up to 0.4 kg/cm2 for WAP-7 & WAP-5 15-20 sec
q. Close BP Isolating Cock (Keep DBC Mode Switch in Test Position)
OK
r. Check Signal Config File: O6A Lcock BkCon & also in DDS
s. Close IC_EE Cock
OK
t. Check Signal Config File: 06A LemgBkut & also in DDS (In Horizontal)
u. Fit 7 mm Leak Hole Dummy Coupler at Non Operative End in BP End
BP > 4.0 kg/cm2
Hose. Then open eEnd Cock BP.

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
v. Move Auto Handle to release BP > 4.25 kg/cm2 BP > 4.25 kg/cm2
w. Isolate BC Isolating Cock CoC-BC1 (Gauge for BC2). Check BC Pressure
Close - 0.60-0.70 kg/ cm2
Switch 64/1 setting,
Open - 0.25-0.35kg/ cm2
Check Signal Config File: 06AMpr Sw BkCyl-1
x. Isolate BC Isolating Cock CoC-BC2. Gauge for BC1, Check BC Pressure
Close - 0.60-0.70kg/ cm2
Switch 64/2 setting,
Open - 0.25-0.35kg/ cm2
Check Signal Config File: 06AMpr Sw BkCyl-2
7. DYNAMIC BRAKE – (Blending Brake)
a. This test to be done by Signal from Laptop 06H Actual BE E1 = 100% BC = 2.5/5.15 ± 0.15kg/ cm2
b. This test to be done by Signal from Laptop 06H Actual BE E1 = 50% BC = 1.25/2.55 ± 0.15 kg/cm2

8. DIRECT BRAKE
a. Direct (Independent) Brake Handle, apply Direct Brake in Full 3.3-3.7 kg/cm2
b. BC is 3.50±0.2 kg/cm2 (WAG9/WAP7), BC is 5.15±0.3 kg/cm2 (WAP5) 4.85-5.45 kg/cm2
c. Check DBP (Yellow End Hose) is 3.50±0.2 kg/cm2 3.3-3.7 kg/cm2
d. Check P/S 59F, Close at 0.65±0.05 kg/cm2, Open at 0.3±0.05 Kg/cm2 Close - 0.6-0.70 kg/cm2
Check Signal Config File: 06AMpr SwLocoBk Open - 0.25-0.35 kg/cm2
e. Apply DB Full Record BC filling time upto 95% of Max BC pressure Max 8 Sec.
f. Close CP & Isolate Cocks 13, 14, & 70F, Drain MREP by End Cock below
BC 3.5/5.15 kg/cm2
1 kg/cm2, Apply Full DB & Check: Full BC comes in Cab Gauges In DBP
DBP 0.0 kg/cm2
(Yellow End Hose) No Pressure
g. Open 13,14,70F, Check in 601Mode. Apply 3.5 kg/cm2
BC 3.5/5.15 kg/cm2
h. External Pressure in DBP, BCP comes 3.5/5.15 kg/cm2
9. PARKING BRAKE (FOR WAP5 ONLY)
a. PB Applied, Auto & DB Release, Drain MR below 4.5 kg/cm2, Open Isolating Cock 47F
Change Aux Reservoir through Main Compressor (Dead engine COC)
b. Press BP- PB, released in each axle, Lamp Off in Panel A, PB Pressure in PB Gauge
Check Signal Config File: 06B BEP RelPBk 6 kg/ cm2
c. Press BP- PB, PB applied in each axle, Lamp Off in Panel A, PB Pressure in PB Gauge
Check Signal Config File: 06B BEP ApplyPBk 0 kg/ cm2
d. Manually Press Parking Brake Impulse Magnet Valve Release button, PB PB Pressure in PB Gauge
released in each axle. Lamp Off in Panel A. 6 kg/cm2
e. Check Pressure Switch on PB Module, Close 5.00±0.1 kg/cm2 4.90-5.10 kg/cm2
f. Manually Press Parking Brake Solenoid Valve Apply BUTTON, PB applied PB Pressure in PB Gauge
in each axle. Lamp Glow in Panel A. 0 kg/cm2
g. Check Pressure Switch on PB Module, Close 4.00±0.1 kg/cm2 3.90-4.10 kg/cm2
h. Pull Manual Release lever of each Parking Brake Cylinder provided on
PB Releases
wheels 2.6,7 & 11, PB Releases
i. Reset Manually Parking Brake Solenoid Valve in Release Condition, wait
OK
for 30 Sec.
j. Apply PB by PB Solenoid Valve Apply Button. PB Applied in each axle,
Lamp Glow in Panel A OK
Check Signal Config File: 06B BEPApplyPBk
k. Fit Test Gauge in Aux. Reservoir, Close 47F (Dead engine COC). Remove
Gauges in D/C 90
Hose 104 from Body side.

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
l. Release PB, Pressure in Aux. Reservoir Test Gauge is More than 6.00
kg/cm2 (maintained by MR prevention Choke), Ensure Parking Brake is > 6.00 kg/cm2
Indicated as Applied (Lamp in Panel A Glow)
m. Apply PB, Connect bogie hose 104, Open isolating Cock 70 F.
5.85- 6.15 kg/cm2
n. Check pressure in PB gauge with MR 10 kg/cm2, 6± 0.15 kg/cm2
10. ANTI SLIP BRAKE
a. For Signal by laptop.: 06B ASV. Bogie -1 0.60 kg/cm2 in Freight
b. For Signal by laptop.: 06B ASV Bogie -2 0.80 kg/cm2 in Passenger

11. FRICTIONAL BRAKE COMPONENT

a. Check Brake Block Clearance is 5+5=10 mm in freight, 1.0-1.5 mm each
OK
side i.e. 3 mm in passenger (WAP 5)
12. TRAILING LOCOMOTIVES OPERATION (Set Brake Controller Mode Switch in Trail Mode)
a. Connect Ext. Supply in BP Line. Wait 2 min. to fill MR. No Leakage
No Leakage observed
observed in Brake Panel
b. Drop BP to 4 kg/cm2, BC comes above 1 kg/cm2 (2.00 kg/cm2 in WAP5) BC - 1.00/2.00 kg/cm2
c. Drop BP to 0 kg/cm2, BC comes 2.5 kg/cm2, (5-5.15 kg/cm2 WAP5) BC - 2.50/5.15 kg/cm2
d. Rise BP to 4 kg/cm2. BC comes below 2 kg/cm2 (2.00 kg/cm2 in WAP5) BC - 2.00/4.00 kg/cm2
e. Increase BP to 5 kg/cm2, BC Comes to Zero. 0.0 kg/cm2
13. DEAD ENGINE WORKING
a. Drain MR & Aux Res. Air< 2 kg/cm2. Close 74 F {Emergency module Cock
(IC-EE)}, 136 F {Feed pipe Cock (IC-FP)}, Open 47 F (Dead engine COC), OK
Switch OFF pneumatic MCB in SB2 Panel.
b. Connect ext. supply in BP Line wait 2 min. to fill Aux. Res to 5 Kg/cm2 OK
c. Drop BP to 4 kg/cm2, BC comes 1 kg/cm2 (2.00 kg/cm2 in WAP5) BC - 1.00/2.00 kg/cm2
d. Drop BP to 0 kg/cm2, BC comes 2.5 kg/cm2 (5-5.15 kg/cm2 WAP5) BC - 2.50/5.15 kg/cm2
e. Rise BP to 4 kg/cm2, BC comes 1 kg/cm2 (2.00 kg/cm2 in WAP5) BC - 1.00/2.00 kg/cm2
f. Increase BP to 5 kg/cm2 BC Comes to Zero. 0 kg/cm2
g. Re-Install Loco in correct position, Close 47F (Dead engine Cock). OK
14. SANDING EQUIPMENT
a. Check Sand-1 Isolating Cock in open position, press Sander Foot Switch
with reverser in Forward direction. Sand on Rail Front
Check Signal Config File: BEPSand- 1&3
b. Check sand-2 Isolating Cock in open position, press Sander Foot Switch
with Reverser in Reverse direction. Sand on Rail Rear
Check Signal Config File: BEPSand- 2&4
15. CAB EQUIPMENTS (CAB Gauge Check)
a. Check Cab Gauge with test Gauge Against the Volume shown OK
b. MR Gauge in Both Cabs (Permitted Error± 0.15 kg/cm2) OK
c. FP Gauge in Both Cabs (Permitted Error± 0.15 kg/cm2) OK
d. BP Gauge in Both Cabs (Permitted Error± 0.15 kg/cm2) OK
e. BC Gauge in Both Cabs (Permitted Error± 0.15 kg/cm2), BC1, BC2 OK

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
f. PB Gauge in Both Cabs (Permitted Error± 0.15 kg/cm2) OK
g. Panto Gauge at Pn. Panel (Permitted Error± 0.15 kg/cm2) OK
16. AIR HORN (Warning) & FRONT LOOK OUT GLASS CLEANING
a. Open Horn Isolating Cock 120/1&2, Operate Dr. & Asst. Dr. Horn Valve in
HT Horn Sounds
Front Direction
b. Open Horn Isolating Cock 120/1&2, Operate Dr. & Asst. Dr. Horn Valve in
LT Horn Sounds
Back Direction
17. WIPER/ WASHER
a. Record Make of WIPER Make:
b. Adjust Wiper Blade Vertical in all 4 Glasses in both Cabs as Per Drawing. Vertical 900
c. Turn On Wiper Operating Valve Check Wiper’s Stroke /min 35 to 55 min
d. Check Manual Operating Handle is as per requirement (tightened) Check tightness
e. Carry on Washer Test Water Spray
18. VIGILANCE SYSTEM TESTING
a. Check Vigilance Control Unit by Test & Monitor Unit EU-148 of D&M. VCU-ok / Not ok
b. In vigilance unit Green LED is On. Active Loco in “Driving Mode” From any Set Up for Check Loco
CAB. Check No Air Leakage from Exhaust Valve-71F Normal
c. Turn Off VCD Elect Supply BP Fall through Valve 71 No Supply in 14 No.
d. Turn Switch 237.1 to (0-pos) vigilance isolate. BP now recharge VCD. In Service
e. Turn Off VCD switch 237.1. Check Indication in CAB.
f. In Pixy/ Memotel ABB give false speed Exceeding 10 kmph
See DDS NO Message
g. Check indication after 60+8 Sec in Pixy. Switch VCD switch 237.1 to
Normal
normal.
h. Check indication in DDS (ABB Memotel), Vigilance is in Service
i. Close Iso Cock 74F {Emergency module Cock (IC-EE)}. Check Indication
74 Isolated
in DDS Pixy
j. Keep Speed Above 10kmph. Check after 60 sec, LAMP start flashing.
OK
k. Check after next 6-10 sec, Alarm sound along with LAMP flashing.
l. Check after next 6-10 sec Penalty Brake Applied,
OK
m. BP Falls to zero and BC rise to 2.5 kg/cm2 (WAP5-5.15 kg/cm2)
n. Penalty Brake reset possible only after next 32 sec OK
o. Reduce speed to zero power control OFF, Press BPVR, Operate Foot SW
OK
Ensure VCD Reset.
p. Keep Speed Above 10kmph. After 30 sec press Depressed Paddle switch.
OK
q. Vigilance Cycle Reset.
r. Keep Speed Above 10kmph. After 20 sec press Sander.
OK
s. Vigilance Cycle Reset.
t. Keep Speed Above 10kmph. After 20 sec press BPVG ASSL on Panel-D.
OK
u. Vigilance Cycle Reset.
v. Keep Speed Above 10kmph. Wait until LAMP starts flashing Press Driver
Vigilance Paddle, Warning Cycle Reset. OK
w. On the next Alarm, Press BPVG, Warning Cycle Reset.
x. Keep Speed above 10kmph. Apply Auto Brake above 2.2 Kg.
OK
y. After 90 Sec. No Vigilance alarm. Release brake, after 60 sec Alarm starts.

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Result
TEST TO BE CONDUCTED Standard
Cab1 Cab2
z. Keep Speed at 1kmph, No Vigilance warning OK
19. ALARM CHAIN PULLING System in Passenger Locomotives
a. Check Alarm Chain Pulling System works Properly in Passenger
OK
Locomotives
20. TRACK TEST (Do not Carry out the following tests unless you are sure that the Mechanical brakes are fully Operational.)
a. Set up the loco in cooling mode and try to drive. It should not be possible OK
b. Test emergency stop push button and functionality of mechanical brake. OK
c. This test must be carried out on both cabs. Set up loco in driving Mode
Raise Pantograph and close VCB.
d. Brake Loco by means of the Auto Air Brake in Initial. Brake cylinder
OK
pressure must increase (Check gauge in Panel B)
e. Set Reverser 140 in forward position. Set throttle 150 and move Loco with
Low Speed (10 km/Hr) Push Emergency Stop in operating Cab VCB mush OK
Open. Pantograph must lower.
f. Emergency brake should Apply & Loco Must Stop. OK
g. Set up loco in driving mode, Raise pantograph and close VCB. Move Loco
with Low Speed (10 km/Hr). Brake Loco by using the direct brake and Loco OK
must stop.
h. Move Loco with Low Speed (10 km/Hr). Brake Loco by using the Auto
OK
brake in full service. Loco must brake and stop.
i. Test Emergency Brake. Loco must brake and stop. OK
j. In this the following Cab Controls, which activate the Emergency Brake
OK
must be tested of their functionality on both cabs.
k. Assistant Drivers Emergency Brake cock. OK
l. Driver’s Brake controller Emergency Position. OK
m. Test Equivalent Pneumatic Loco Brake. OK
n. Set up loco in driving mode. Move Loco with Speed around 20kmph, start a
slightly regenerative braking by setting a braking effort demand through
throttle 150 more than 10KN. Apply brake by Drivers Auto brake handle to Full OK
service. Brake Pipe Pressure drops to 3.35 but brake cylinder pressure does
not develop (Auto BC Bail Off Function)
21. RE-INSTALLING OF LOCOMOTIVE AFTER TEST
a. Remove all test Gauge’s Plug with fitted for test.
b. Ensure Electrical items of Pn panel.
c. Terminal are tight and covers secured.
OK
d. Wire/seal electronic Enclosure of Pneumatic Panel in closed position.
e. Ensure all isolating Cocks and other items of equipment are in normal &
safe working position
22. REMARKS IF ANY

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(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

MAINTENANCE AND OVERHAULING SCHEDULE FOR M/S. ESCORTS MAKE EMCBS

Maintenance Schedule
S No. Equipment Activities
IA IB IC MOH IOH POH
Electrical items
1 Electrical wiring Check tightness of all connectors and cards to
2 ECU ensure proper locking.
3 LRU’s Function test with complete system and √ √ √ √ √ √
4 DBC’s repair/replace if any problem found in any
5 VCD individual unit.
Auxiliary Panel Items
Isolating Cocks (IC-FC, IC-UL, Check for correct orientation of Isolating Cocks
√ √ √ √ √ √
IC-VCB, IC-PAN1, IC-PAN2, handles
6
IC-SAN1, IC-SAN2, IC-EE, IC- Overhaul of Isolating Cocks & Functional / leakage
x x x x √ √
FP, Kaba Key, PB) test as per OEM guidelines
Ensure that PRV seals are not tempered √ √ √ √ √ √
7 Pressure Reducing Valve Overhaul of Valve & functional test as per OEM
x x x x √ √
guidelines
Ensure that connectors of Magnet Valve are fixed
Solenoid Valves (UL, PAN1, √ √ √ √ √ √
properly.
8 PAN2, SAND1, SAND2, EE1
Overhaul of Magnet Valves & functional test as per
& EE2) x x x x √ √
OEM guidelines.
Check the working and condition of Valve.
√ √ √ √ √ √
Relay Valve Repair/Replace if any problem is found.
9
Overhaul of Valve & functional test as per OEM
x x x x √ √
guidelines
Check the working and condition of Valve.
√ √ √ √ √ √
Duplex Check Valve Repair/Replace if any problem is found.
10
Overhaul of Valve & functional test as per OEM
x x x x √ √
guidelines
Check the working and condition of valve.
√ √ √ √ √ √
Check Valve Repair/Replace, any problem found.
11
Overhaul of valve & functional test as per OEM
x x x x √ √
guidelines
Check connector for proper tightness and
√ √ √ √ √ √
Parking Brake Solenoid functional test
12
Valves Overhaul of valve
x x x x √ √
Functional test as per OEM guidelines
Check the working and condition of Governors.
√ √ √ √ √ √
13 Pressure switch Calibrate/Replace if any problem is found.
Functional test and calibration x x x x √ √
Safety Valves Check the working and condition of valve.
√ √ √ √ √ √
14 AC-SV and Replace, if any problem found.
Panto pressure gauge Functional test as per OEM guidelines x x x x √ √
Check the working and condition of gauge.
Panto pressure gauge Filter Calibrate/Replace if any problem found
15 √ √ √ √ √ √
(Aux Comp. and MREP)
Functional test as per OEM guidelines
BRAKE PANEL Items
Ensure DV Isolation handle in working position. √ √ √ √ √ √
16 Distributor Valve Functional / leakage test as per OEM guidelines
× × × × √ √
Overhaul of Valves

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 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Check the functioning of valve √ √ √ √ √ √

BKP-BPC Isolating Cock, Limit Overhaul of valve & Functional / leakage test × × × × √ √
17
Switch
Ensure that connector of Magnet valve is fixed
√ √ √ √ √ √
properly.
Drain the main Reservoir Filter assembly by
opening manual drain valve located at the bottom √ √ √ √ √ √
MR Filter Assembly
18 of MR filter housing.
Replacement of all Filter Elements & rubber parts
× × × √ √ √
of filters. Check leakage after replacement
Filter Element DBP, BP, MR1, Replacement of all Filter Elements & rubber of
19 × × × √ √ √
MREP, AUX Comp filters. Check leakage after replacement
Check the working and condition of Valve.
√ √ √ √ √ √
Repair/Replace if any problem is found.
20 Air Flow Measuring Valve
Overhaul of Valve & functional test as per OEM
x x x x √ √
guidelines
Emergency Valve, Check the working and condition of Valve. Repair/
√ √ √ √ √ √
PTDC(DBV), PRV, Check Replace if any problem is found.
Valves, Unloader Valve, Oil
21 Separator, Auto Drain Valves,
Air Horns, Horn Operating Overhaul of Valves & functional test × × × x √ √
Valves, Sanding Valve, 2 Way
Horn Valve
Accessories Items
Emergency Valve, Check the working and condition of Valve. Repair/
√ √ √ √ √ √
PTDC(DBV), PRV, Check Replace if any problem is found.
Valves, Unloader Valve, Oil
21 Separator, Auto Drain Valves,
Air Horns, Horn Operating Overhaul of Valves & functional test × × × x √ √
Valves, Sanding Valve, 2 Way
Horn Valve
Safety Valves Check the working and condition of Valve.
22 √ √ √ √ √ √
(MR-SV and CP-SV) Replace, if any problem is found.
Check the working and condition of Valve.
√ √ √ √ √ √
Check Valve (CP-NRV) & Repair/Replace if any problem is found.
23
Double Check Valve Overhaul of Valve & functional test as per OEM
× × × × √ √
guidelines
Check the working and condition of Governors.
√ √ √ √ √ √
24 Pressure Switch Calibrate/Replace if any problem is found.
Functional test and calibration × × × × √ √
Check for correct orientation of Cocks Handle,
Isolating Cock w/vent 3/4" (for
25 leakage, functioning. Replace it if found damaged √ √ √ √ √ √
MREP & DBP and BC)
during inspection/shed visit.
Check for functioning, leakage. Replace it if found
26 Drain Cocks Reservoirs 1/2" √ √ √ √ √ √
damaged during inspection/shed visit.
Check for correct orientation of Cocks Handle,
Isolating Cock 3/8" Horns &
27 leakage, functioning Replace if found damaged √ √ √ √ √ √
Wipers
during inspection/shed visit.
Check for correct orientation of Cocks Handle,
28 Angle Cocks leakage, functioning. Replace it if found damaged √ √ √ √ √ √
during inspection/shed visit.
Flexible Hose-Sanding,
Check the working and condition of Hose. Replace
29 Flexible Hose-Parking, √ √ √ √ √ √
it if found damaged during inspection/shed visit.
Flexible Hose-Brake Cylinders
Functional test
30 Pressure Gauges √ √ √ √ √ √
Replace, if any problem found.

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Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Reservoir
Visually examine of Fasteners, leaks or other
31 Reservoir √ √ √ √ √ √
damages and replace if required.

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Escorts Kubota Limited
(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

NOTES

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(Formerly Escorts Limited)
Railway Equipment Division
 OPERATION AND MAINTENANCE MANUAL
EMCBS Rev.03
Doc. No. RED-RD-BS-028-OM-01 Date-16/06/2024
Customer Spec no. RDSO/EL/SPEC/2017/0126, Rev. 0

Escorts Kubota Limited

(Formerly Escorts Limited)

Railway Equipment Division

Plot No. 114 & 115, Sector 24, Faridabad-121005 (India)

Head Office & works Mumbai Branch Chennai Branch Kolkata Branch
Plot no.114 & 115, Sector 24, Times Square, Unit no.2, M-3, “M” Block, South West Wing,
Faridabad-121 005 A-Wing, 3rd floor, Andheri 3rd Avenue, 9th floor, “AC Market”
Haryana, (India) Kurla Road, Sakinaka, Anna Nagar East, 1, Shakespeare Sarani,
Email: [email protected] Mumbai- 400 059 Chennai-600 102 Kolkata- 700 071
Web. Maharashtra, India Tamil Nadu, India E-mail:
escortsrailwayproducts.com E-mail: E-mail: [email protected]
Tel: 91-129-2516382, 6608 [email protected] [email protected] Tel: 91-33-22825191
Fax: 91-129-2232148 Tel: 91-22-24218159 Tel: 91-44-26287729 Fax: 91-33-22814518
Fax: 91-44-26287341

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Railway Equipment Division