Rail Vehicle Systems ... IP-234. Rev. 10 (3/17/17) -en ... Maintenance and Repair. EP-60 Freight Car Integrated Brake Control System

Transcription

1 Rail Vehicle Systems IP-234 Rev. 10 (3/17/17) -en EP-60 Freight Car Integrated Brake Control System

2 Contact address New York Air Brake 748 Starbuck Avenue Watertown, NY USA Phone: Fax: This document was originally written in English. Knorr-Bremse Group Page 2 / 107

3 Revision History Rev. Date Name Para Description of Change 01 Oct/07 Original Release ALL 02 Dec/07 ALL 03 May/08 5.9, 5.10 Added Sections 5.9 and July/08 28,29,32, 33,40,41, 44,45,54, 62,63,68 Added Clarification of Connecting Nut O-Ring Installation 05 10/13/09 M. Parisian Add CCD Battery Charging Requirements Per NYAB PCD-379 Add / Illustrate Inter-Car P/N for JB Assy's 06 10/15/09 M. Parisian ALL Clarification To T/L Pin To Pin Termination Other Misc. Clarifications 07 5/7/10 M. Parisian thru /13/12 M. Parisian All Length of armor sheathing removed 14-1/2" was 8" Added shrink tubing in illustrations and text Added Section EP Overlay CCD Added reference to NYAB IP-224 Added reference to NYAB IP-224 Inserted Plug and Play JB to Section 6 Inserted Plug and Play JB to Section 7 Updated 8.1 Updated 8.2 Added Plug and Play IDM JB Installation Procedure Renumbered illustrations to add section number 09 5/22/14 T. Ware ALL Updated text and illustrations throughout document 10 3/17/17 L. LaLone 7.1 Added Apply anti-corrosive was Fig. 7.1: Added two Notes. Added Mount IDM prior to car frame painting. Knorr-Bremse Group Page 3 / 107

4 Table of contents 1 General information Technical changes Target group for this document Notes and warning messages 7 2 Introduction Related documents 8 3 General Introduction to EP-60 Freight Car Components General Safety Awareness Tools Required EP-60 Freight Car - Old Style End of Car Junction Box EP-60 Freight Car - New Style End of Car Junction Box 14 4 General Description of EP-60 Freight Car Components EP-60 Stand Alone Valve Assembly on a Single Sided Pipe Bracket EP-60 Control Valves EP-60 CCD Diagnostics LEDs EP-60 Vent Valve (EP-60 VV) Junction Box Assemblies and Identification Module (IDM) Trainline Cable and Accessories 23 5 EP-60 Valve Assemblies EP-60 Valve Assemblies CCD Battery Installation Masking of EP-60 Stand Alone CCD for Painting Masking of EP-60 Overlay for Painting CCD Software Control 47 6 Junction Box Assemblies Junction Box Assemblies with IDM End of Car Junction Box Assemblies with Armored Cable End of Car Junction Box Assemblies with 1" Liquidtight Conduit 56 Knorr-Bremse Group Page 4 / 107

5 7 Installation Procedures Plug and Play Junction Box Assembly with IDM Plug and Play End Of Car Junction Box Assembly 59 8 EP-60 Freight Car Trainline Component Accessories EP-60 Freigh Car Trainline Component Accessories Cable Connections to Junction Box CCD to IDM Cable Connection Trainline Cable Connection to Junction Box Repair Procedure: Armored Cable/Non-Armored Cable with Ring Termination Repair Procedure: Armored Cable/Non-Armored Cable with Pin Termination Repair Procedure: Removing Debris from Inter-Car Connector Contacts Repair Procedure: Inter-Car Connector Pull-Out Repair Replacement Procedure: Inter-Car Connector Lanyard Replacement Procedure: EOC Junction Box Appendix Project Parts List Project Piping Diagram Commissioning Verification Instruction: CVI Abbreviations 107 Knorr-Bremse Group Page 5 / 107

6 1 General information DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment. 1.1 Technical changes NYAB reserves the right to change the equipment or this document at any time without giving special notice. 1.2 Target group for this document This document is intended for use by NYAB trained service technicians who have the skill, experience, safety awareness and professional ability: to remove and install the equipment, to inspect, maintain and debug the equipment, have read and understood this document from start to finish, and are familiar with the safety codes and accident prevention regulations for these activities. NOTE This document will be useful to other target groups as well, e.g. project engineers. However, it does not claim to provide complete information for such target groups. Knorr-Bremse Group Page 6 / 107

7 1.3 Notes and warning messages Warning messages are subdivided into the following hazard levels in this document: DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment. WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment. Safety notes have a specific structure which is explained here for DANGER: DANGER Source of the danger Consequences of the danger Remedial measures Notes do not contain any messages relevant to safety and are included only for the sake of completeness. NOTE Notes contain useful hints and additional information about the unit. Warning messages in other parts of this Description draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications. Knorr-Bremse Group Page 7 / 107

8 2 Introduction This Description contains particulars specific to the EP-60 Freight Car Integrated Brake Control System and discusses maintenance and repair of the EP-60 components. 2.1 Related documents The related installation drawings specific to each component must be consulted. Knorr-Bremse Group Page 8 / 107

9 3 General Introduction to EP-60 Freight Car Components 3.1 General Safety Awareness Observe all rules and regulations of the railroad where the equipment is being used. Whenever there is a conflict between the instructions in this manual and the instructions of the user railroad, the rules and regulations of the user railroad will govern When performing any test work on devices or equipment while they are on the vehicle (on vehicle test, etc.) special precautions must be taken to ensure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment. Make sure the handbrake is applied and that the wheels are chocked to prevent vehicle from moving. WARNING High Voltages (AC and/or DC) are present. Always exercise extreme care when working in close proximity to electrically energized apparatus or when making current measurments. To prevent receiving electrical shock when performing electrical tests, hands must be clear of electrical components, contacts, and housing. There must be no bodily contact with the work area. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. WARNING Ensure that power and/or switches are turned off prior to making any electrical connections/disconnections. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences Shut off power and open airbrake breaker whenever continuity is to be checked or when handling equipment connections. When shutting off power by means of knife or switch Attach an approved WARNING tag to the open breaker De-pressurize air system before loosening connections or components. Before removing any component from its mountings, the train must be safely parked. To prevent personal injury, all main reservoir, brake supply reservoir, and brake cylinder on the affected vehicle must be vented. Knorr-Bremse Group Page 9 / 107

10 3.1.5 "Bottled" up air under pressure (even though air supply is cut off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when any component part is removed from the equipment arrangement. Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on these component parts The use of an air jet, which must be less than 30 PSIG, to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. These particles and droplets may cause skin and /or eye irritation. Personal eye protection must be worn to protect the eyes from possible injury. When using an air jet do not direct it toward another person. WARNING Cleaning using compressed air can cause particles to become airborne, be sure to: Wear eye protection Do not exceed 30 PSI Failure to observe these safety precautions can lead to injury If degreasing fluids are used for cleaning purposes, the current local safety regulations plus the safety precautionary statements of the manufacturer of the cleaning agent must be adhered to. Otherwise, physical harm could result from the inhalation of toxic fumes. Make sure the area is well ventilated when working with materials that produce harmful fumes. WARNING Solvents and solvent fumes can be harmful to health, when using solvents, be sure to: Wear eye, skin, and respiratory protection Work in a well-ventilated area Avoid repeated or prolonged contact Keep solvent container closed Keep solvent away from sparks, flames, and heat Failure to observe these safety precauitons can lead to injury or intoxication Personal eye protection must be worn when doing any work to protect eyes from possible injury Where fasteners removed from the equipment are not satisfactory for reuse, care must be taken to select replacements that match the originals. Mismatched or incorrect fasteners can result in equipment damage or malfunction, or possible personal injury. Knorr-Bremse Group Page 10 / 107

11 To ensure the correct functioning of each component, use only the manufacturers genuine spare parts as replacements Appropriate tool selection is required when performing all maintenance operations to avoid personal injury Person(s) having the appropriate job skill level, as governed by the user railroad, are required when performing maintenance and/or operational tasks with the brake system and system components Whenever a valve or system component is removed from a vehicle for any reason, and it is reinstalled or replaced with a new or repaired and tested component, a stationary vehicle air brake test and an equipment test must be performed to ensure that the component functions properly within the system (reference NYAB EPSCTD Test Document IP-224) When air pressure measurements are to be made for the purpose of pressure level verification and/or adjustment, an air brake test gauge having an accuracy of ± 1 PSI is required. Knorr-Bremse Group Page 11 / 107

12 3.2 Tools Required 1) ½" Drive Deep Well Socket Set W/Extensions 2) ½" Drive Stud Remover 3) ¼" Drive Torque Wrench 0-50 in-lb 4) ½" Drive Torque Wrench ft-lb 5) ¼" Socket Set 6) ¼" Metric Deep Well w/extensions Socket Set 7) ¼" Torque Nut Driver 0-50 in-lb 8) Complete Set Of English & Metric Open End Box Wrenches 9) Heat Gun 10) Crimp Tools 11) 9" Lineman Pliers 12) Wire Strippers 13) Side Cutting Pliers 14) Scratch Awl 15) (2) Tape Measure (25' & 100') 16) Hack Saw W/Spare blade 17) Utility Knife 18) Screw Driver Set 19) Needle Nose Pliers 20) Pipe Wrenches (Small, Medium, Large) 21) Vice Grips 22) Loctite PST567 23) Extension cord (100' ft) 24) Headlamp Flashlight 25) Magnifying Lens 26) Channel Locks (Small, Large) 27) Crescent Wrench 28) 2 ¼" Open End Box Wrench 29) Multi-Tester 30) "Greenlee" Cable Cutter 31) Wire Puller 32) Electrical Tape 33) Allen Wrenches 34) SCTD Pump & Dump Kit 35) Pressure Gauge psi 36) Flat Blade Screwdriver Knorr-Bremse Group Page 12 / 107

13 3.3 EP-60 Freight Car - Old Style Junction Box End of Car Junction Box (old style) Trainline Cable CCD with Vent Valve Junction Box with Car ID Module Figure 3-1 EP-60 Freight Car - Old Style End Of Car Junction Box Knorr-Bremse Group Page 13 / 107

14 3.4 EP-60 Freight Car - New Style End Of Car Junction Box End of Car Junction Box (new style) Trainline Cable Car ID Module Junction Box with IDM End of Car Junction Box (new style) CCD with Vent Valve Figure 3-2 EP-60 Freight Car - New Style End Of Car Junction Box Knorr-Bremse Group Page 14 / 107

15 4 General Description of EP-60 Freight Car Components Figure 4-1 EP-60 Stand Alone Assembly Mounted on a Single Sided Pipe Bracket 4.1 EP-60 Stand Alone Valve Assembly on a Single Sided Pipe Bracket The EP-60 Stand Alone Valve Assembly consists of a Car Control Device (CCD) and an EP-60 Vent Valve mounted on a single sided pipe bracket using standard studs and gaskets. Because the EP-60 braking system does not require an exhaust retaining valve, the assembly is also supplied with a blanking pad for the exhaust port of the pipe bracket. The CCD and The EP-60 Vent Valve fit in the installation envelope of both the DB60 and the ABDX valve assemblies mounting to both a conventional and single side type DB30 brake pipe bracket. Knorr-Bremse Group Page 15 / 107

16 4.2 EP-60 Car Control Valves EP-60 Stand Alone Car Control Device (CCD) Figure 4-2 EP-60 Stand Alone Car Control Device (CCD) The Car Control Device (CCD) is an integrated electronic and pneumatic control package that interfaces with the head end unit through a two-conductor trainline cable. The CCD uses trainline power to charge its battery and to supply power to its electronics. The CCD derives its power from its battery when trainline power is not available. The CCD is also capable of operating using trainline power in the event that its battery becomes non-functional. The Brake Pipe is used to provide a supply of air to the reservoirs. The CCD provides almost instantaneous response to locomotive braking commands, including graduated brake release and re-applications. The CCD responds appropriately to undesired separation or malfunction of hoses, cabling, or brake pipe. The stand-alone CCD includes a pneumatic backup function that is always active. This provides a means of propagating a pneumatic brake pipe emergency and of pneumatically applying emergency brake cylinder pressure (i.e., requiring no electrical power) if brake pipe vents below a set pressure. Normally, electronic CCD operation takes precedence over the pneumatic back up in the control of brake cylinder pressure. The pneumatic emergency backup brake cylinder pressure is not load weight sensitive. Knorr-Bremse Group Page 16 / 107

17 The pneumatic backup remains active when the CCD is electrically cut-out or shutdown (including due to a failure / fault condition, etc.). A pneumatic emergency brake cylinder applicaiton will be released when the brake pipe pressure is increased above a set pressure or when electronic CCD operation has taken precedence. The CCD brake control for both service and emergency brake cylinder pressure is provided by electro-pneumatic and all pneumatic hardware. Normally, the CCD software and electronics determines and controls the brake cylinder pressure using the electro-pneumatic and pneumatic hardware. The CCD provides fault detection and response in accordance with AAR S4200 specification. When a fault condition results in the CCD to electrically cut-out or shutdown or if ECP is ended (ECP is not active), emergency pneumatic backup brake pressure control is provided thru the CCD all pneumatic hardware - if brake pipe pressure vents below a set pressure emergency brake cylinder pressure is applied - and if brake pipe pressure is charged above a set pressure emergency brake cylinder pressure is released. Knorr-Bremse Group Page 17 / 107

18 4.2.2 EP-60 Overlay Car Control Device (Overlay CCD) Figure 4-3 EP-60 Overlay Car Control Device (Overlay CCD) Similar to the Stand Alone Car Control Device outlined in Section 4.2.1, the Overlay Car Control Device provides an integrated electronic and pneumatic control package that interfaces with the head end unit through a two conductor trainline cable, but with added capability to work in parallel with a conventional AAR control system to provide both conventional and ECP modes of operation. The Overlay CCD design incorporates a solenoid (Magnet Valve - OMV) along with a larger capacity Pilot Operated Valve (POV) that, when energized or de-energized, directs the mode of operation. ECP Operation: During normal ECP Operation the EP-60 Overlay CCD energizes, the OMV is energized from train-line power as commanded from the head end unit, directing reservoir pressure to pilot the POV, positioning it so that: - the CCD Relay Valve output connects to the brake cylinder connection of the AB pipe bracket, allowing the Overlay CCD to control BC pressure. - the Conventional Control Valve output is blanked off from the brake cylinder control Conventional Operation: During conventional pneumatic operation the EP-60 Overlay OMV de-energizes causes the POV Pilot to be exhausted positioning it to allow: - the EP-60 Overlay CCD Relay Valve Output is blanked off from the brake cylinder - the Conventional Control Valve output is connected to the brake cylinder, allowing the conventional control valve to control brake cylinder Unlike the EP-60 Stand Alone CCD, the pneumatic back up functionality is within the conventional control valve assembly. Knorr-Bremse Group Page 18 / 107

19 Figure 4-4 EP-60 Overlay Car Control Device (Overlay CCD) The CCD is connected to the conventional brake control valve by using a CCD Manifold Interface Plate, a DB60/ABDX Manifold Interface Plate and four (4) hoses. Four (4) hoses are connected to each of the Manifold Interface Plates. The CCD is mountedd to its Manifold Interface Plate that will be mounted to the car body as close to the conventional brake control valve as possible. The EP60 Overlay Car Control Device (CCD) can be interfaced with the Knorr-Bremse DB60 Control Valve or the Wabtec/Westinghouse ABDX Control Valve. A manifold Interface Plate is installed between the emergency portion and its pipe bracket. Plates are available for use on both the Single Sided type pipe bracket and the Conventional (DB30 type) pipe bracket. Depending on the car application, there are available (3) different configurations of the CCD Manifold Interface Plates as well as three different configurations of the DB60 type plates (reference Section 5.1). Knorr-Bremse Group Page 19 / 107

20 4.3 EP-60 CCD Diagnostics LEDs PWR LED (Red or Green): OFF = CCD shut down Green = CCD under battery power Red = CCD receiving 230 VDC trainline power Flashing = Battery voltage is low BRK LED (Green): OFF = Brakes Released Green = Brakes applied Flashing = CCD is Cut-Out (ECP) COM LED (Green): OFF = No communication signal received from the HEU Flashing = Communications signal is received from the HEU Solid = Emulation Mode FLT LED (Red): OFF = OK Red = Active Fault(s) Two circular connectors (J1) and (J2) are provided on the front of the CCD. The connector on the left side of the front face (J1) is for connecting to the trainline cable / car identification module (IDM). The circular connector on the right side of the front face (J2) is for a local power and communications network interface for the add-on capability of any potential future "Smart Car" technologies. The CCD is designed for an operating temperature range of -36C to 66C (-50F to 150F). The CCD includes a rugged aluminum casting providing a total weight of approximately 43 lbs. NOTE CCDs can be upgraded using the EPSCTD to the the latest revision software, which is supplied by NYAB. Knorr-Bremse Group Page 20 / 107

21 4.4 EP-60 Vent Valve (EP-60 VV) Figure 4-5 EP-60 Vent Valve (EP-60 VV) The EP-60 vent valve is used on stand-alone wagon configurations for propagation of brake pipe pressure during a pneumatic initiated emergency brake. The EP-60 Vent Valve rapidly vents the brake pipe air to atmosphere during a pneumatic emergency application. The performance of the vent valve meets the applicable sections of the AAR Manual of Standards & Recommended Practices. The design of the EP-60 Vent Valve incorporates the components of the service proven DB20 emergency portion. It also eliminates the DB20's unnecessary undesired high-pressure spool, accelerated emergency release and accelerated application venting. It provides sensitivity, transmission-time and resistance to UDEs equal to the best-in-class DB20. The result is low in-train forces in the unlikely event that the pneumatic backup is used to stop the train during ECP operation. It is mounted to a conventional or single-sided DB-30 or AB pipe bracket using existing studs and gaskets. Knorr-Bremse Group Page 21 / 107

22 4.5 Junction Box Assemblies and Identification Module (IDM) Figure 4-6 Junction Box Assembly and IDM EP-60 equipped freight cars are supplied with two styles of plug and play junction boxes: the End Of Car junction boxes are used as termination points for trainline power and the IDM junction box houses the Identification Module to communicate to the Car Control Device (CCD). The End of Car junction box, mounted at each end of a freight car, enables car switch out anywhere in a train. Using the AAR approved Freight Mate intercar connector, cars can easily be disconnected from one another and changed out. The Freight Mate intercar connector is easily replaced using the same wrench that is typically used to replace the car s brake pipe hose. The identification module (IDM) connects to the CCD on the car. The ID module provides vehicle specific information including road number, type of vehicle, orientation and other vehicle parameters through the latest NYAB revision software. In addition, the ID module contains circuitry, which is used for determining the order (sequence) of the cars and locomotives in the train. Knorr-Bremse Group Page 22 / 107

23 4.6 Junction Box Assemblies and Identification Module (IDM) Trainline Cable Assembly with Ring to Ring Contacts Trainline Cable Assembly with Ring to Pin Contacts Trainline Cable Assembly with Pin to Pin Contacts Inter-Car Cable Assembly w/lanyard CCD to IDM Cable Assembly Figure 4-7 Cable Assemblies In order to provide communications and power throughout a train, Trainline cable is required to run the entire length of a train. Trainline cable must be secured along the car using various hardware and accessories available from NYAB. The car's AAR approved trainline cable is routed between the junction boxes. The car's trainline cable is available in liquid tight, armored, and rigid pipe configurations. The rigid conduit is connected to a junction box at each end of the car using a Sealtite or Liquidtight style connector. The trainline cable has two (2) #8 AWG conductors that are used to form the trainline communication and power network that continues the length of the train. The length of a Knorr-Bremse Group Page 23 / 107

24 freight car's trainline cable is typically defined by the application in which it will be used. Based on installation location, cable routing, etc., cable lengths will vary from application to application. The trainline cable runs the length of each car and terminates at each end. The Freight Mate inter-car cables are connected to each End of Car junction box so all cars and locomotives of a train can be connected together. These AAR approved inter-car cables are designed to have only one way in which they can be connected. Knorr-Bremse Group Page 24 / 107

25 5 EP-60 Valve Assemblies 5.1 EP-60 Valve Assemblies EP-60 Valve Assembly - Single Sided Pipe Bracket, P/N Tools Required 1/2" Drive Torque Wrench ft-lbs. (0-203 N-M) 1/2" Drive Stud Remover 1/2" Deep Well Socket w/extension Large Flat Blade Screw Driver Figure 5-1 EP-60 Valve Assembly - Single Sided Pipe Bracket Knorr-Bremse Group Page 25 / 107

26 EP-60 Valve Assembly - Single Sided Pipe Bracket, P/N Item No. Part Number Description Reference Nut, Hex 5/8-11 UNC Tighten to ft-lbs ( N-M) CCD Stand Alone w/shipping Cover Gasket, Service Portion EP60 Vent Valve w/shipping Cover Gasket, Emergency Portion Nut, Strainer Filter Element Single Sided Pipe Bracket Strainer Screw, Self-Locking Hex Head Torque to ft-lbs (27-33 N-M) Blanking Pad Gasket, Blanking Pad Knorr-Bremse Group Page 26 / 107

27 5.1.2 EP-60 Overlay Valve Configuration - Single Sided Pipe Bracket (back access) Figure 5-2 EP60 Overlay Valve Configuration - Single Sided Pipe Bracket (back access) Knorr-Bremse Group Page 27 / 107

28 EP-60 Overlay Valve Configuration - Single Sided Pipe Bracket (back access) Item No. Part Number Description Reference Pipe Bracket Assembly, EP30S Mounting Kit Filter Element Nut, Strainer Stud Stud 7 B69271/4 Stud Stud, Special Gasket Manifold Interface Plate Assy Hex Nut Torque to ft-lbs ( N-M). Torque in even steps to prevent gasket leakage. Do not overtighten Gasket, Service Portion DB10 Service Portion Gasket, Emergency Portion DB20 Emergency Portion Strainer Screw, Self Locking Hex Head xxxx Hose Assy, 3/8 x 3/8 Flange Ring Gasket 20A Overlay Car Control Device OR 20B Overlay Car Control Device OR 20C Overlay Car Control Device Knorr-Bremse Group Page 28 / 107

29 5.1.3 EP-60 Overlay Valve Configuration - Single Sided Pipe Bracket (side access) Figure 5-3 EP60 Overlay Valve Configuration - Single Sided Pipe Bracket (side access) Knorr-Bremse Group Page 29 / 107

30 EP-60 Overlay Valve Configuration - Single Sided Pipe Bracket (side access) Item No. Part Number Description Reference Pipe Bracket Assembly, EP30S Mounting Kit Filter Element Nut, Strainer Stud Stud 7 B69271/4 Stud Stud, Special Gasket Manifold Interface Plate Assy Hex Nut Torque to ft-lbs ( N-M). Torque in even steps to prevent gasket leakage. Do not overtighten Gasket, Service Portion DB10 Service Portion Gasket, Emergency Portion DB20 Emergency Portion Strainer Screw, Self Locking Hex Head xxxx Hose Assy, 3/8 x 3/8 Flange Ring Gasket 20A Overlay Car Control Device OR 20B Overlay Car Control Device OR 20C Overlay Car Control Device Knorr-Bremse Group Page 30 / 107

31 5.1.4 EP-60 Valve Assembly - Conventinal Pipe Bracket, P/N Tools Required 1/2" Drive Torque Wrench ft-lbs (0-203 N-M) 1/2" Drive Stud Remover 1/2" Deep Wall Socket w/extension Large Flat Blade Screw Driver Figure 5-4 EP-60 Valve Assembly - Conventinal Pipe Bracket (P/N ) Knorr-Bremse Group Page 31 / 107

32 EP-60 Valve Assembly - Conventional Pipe Bracket, P/N Item No. Part Number Description Reference Nut, Hex 5/8-11 UNC Tighten to ft-lbs ( N-M) CCD Stand Alone w/shipping Cover Gasket, Service Portion Nut, Strainer Filter Element Strainer Strainer Screw, Self-Locking Hex Head Torque to ft-lbs (27-33 N-M) Blanking Pad Gasket, Blanking Pad DB30 Bracket Assembly EP60VV Valve Portion w/shipping Cover Gasket, Emergency Portion Knorr-Bremse Group Page 32 / 107

33 5.1.5 EP-60 Overlay Valve Configuration - Conventional Pipe Bracket (front access) Figure 5-5 EP60 Overlay Valve Configuration - Conventional Pipe Bracket (front access) Knorr-Bremse Group Page 33 / 107

34 EP-60 Overlay Valve Configuration - Conventional Pipe Bracket (front access) Item No. Part Number Description Reference Bracket Assembly, EP30 Pipe 2A Strainer 2B Strainer Stud, Special Gasket Manifold Interface Plate Assy Stud Stud 8 B69271/4 Stud Filter Element Nut, Strainer Gasket, Service Portion DB10 Service Portion Hex Nut Torque to ft-lbs ( N-M). Torque in even steps to prevent gasket leakage. Do not overtighten Gasket, Emergency Portion DB20 Emergency Portion Screw, Self Locking Hex Head xxxx Hose Assy, 3/8 x 3/8 Flange Ring Gasket 19A Overlay Car Control Device OR 19B Overlay Car Control Device OR 19C Overlay Car Control Device Knorr-Bremse Group Page 34 / 107

35 5.1.6 EP-60 Overlay Valve Configuration - Conventional Pipe Bracket (rear access) Figure 5-6 EP60 Overlay Valve Configuration - Conventional Pipe Bracket (rear access) Knorr-Bremse Group Page 35 / 107

36 EP-60 Overlay Valve Configuration - Conventional Pipe Bracket (rear access) Item No. Part Number Description Reference Bracket Assembly, EP30 Pipe 2A Strainer 2B Strainer Stud, Special Gasket Manifold Interface Plate Assy Stud Stud 8 B69271/4 Stud Filter Element Nut, Strainer Gasket, Service Portion DB10 Service Portion Hex Nut Torque to ft-lbs ( N-M). Torque in even steps to prevent gasket leakage. Do not overtighten Gasket, Emergency Portion DB20 Emergency Portion Screw, Self Locking Hex Head xxxx Hose Assy, 3/8 x 3/8 Flange Ring Gasket 19A Overlay Car Control Device OR 19B Overlay Car Control Device OR 19C Overlay Car Control Device Knorr-Bremse Group Page 36 / 107

37 5.2 CCD Battery Installation Power Sonic Battery P/N Tools Required 1/2" Socket Set 1/2" Drive Torque Wrench in-lbs (0-203 N-M) Small Flat Blade Screw Driver Step 1: Loosen two screws (1) to remove battery cover (2) and gasket (3). Screws will stay with cover. Step 2: Slowly slide the Battery Carriage Assembly (6) out until it comes to a stop, approximately 2 inches. Step 3: Unlatch the Battery Carriage Assembly (5) and disconnect the two battery leads from the battery (4). Step 4: Remove the battery (4). WARNING Before changing battery ensure trainline power is off. Failure to do so could result in electrical shock or permanent injury. NOTE Use caution when removing captive cover screws to avoid cross threading within cover. Use of impact wrench not recommended. Step 5: Reverse steps 1 through 3 to install new battery. Use caution to avoid pinching battery wires between carriage and CCD body. When connecting the battery wires ensure that the black negative terminal is connected to the black negative post and the red positive terminal is connected to the red positive post on the battery. NOTE Reversing polarities from the battery to the CCD will cause the CCD to short and malfunction under battery operation Figure 5-7 CCD Power Sonic Battery Replacement Knorr-Bremse Group Page 37 / 107

38 CCD Battery Removal - Power Sonic Battery P/N Item No. Part Number Description Reference Screw Assembly, Captive 5/16-18 Tighten to 11 +/-1 ft-lbs (15 +/-1 N-M) Cover, Battery Gasket Battery, 12V Carriage Assembly, Battery Knorr-Bremse Group Page 38 / 107

39 5.2.2 Enersys Cyclone Battery P/N WARNING Before changing battery ensure trainline power is off. Failure to do so could result in electrical shock or permanent injury. Tools Required 1/2" Socket Set 1/2" Drive Torque Wrench in-lbs (0-203 N-M) Small Flat Blade Screw Driver Step 1: Loosen two screws (1) to remove battery cover (2) and gasket (3). Screws will stay with cover. NOTE Use caution when removing captive cover screws to avoid cross threading within cover. Use of impact wrench not recommended. Step 2: Disconnect the Mate-N-Lock connector from the PMM connector. Step 3: Remove the battery pack assembly (4). Step 4: To install battery reverse order of Steps 1 through 3 ensuring that battery wires run between the battery and top right side of the battery compartment. Use caution to avoid pinching battery wires. Figure 5-8 CCD Enersys Cyclone Battery Replacement Knorr-Bremse Group Page 39 / 107

40 CCD Battery Removal - Enersys Cyclone Battery P/N Item No. Part Number Description Reference Screw Assembly, Captive 5/16-18 Tighten to 11 +/-1 ft-lbs (15 +/-1 N-M) Cover, Battery Gasket Battery Pack Assemby, 12V Knorr-Bremse Group Page 40 / 107

41 5.2.3 CCD Battery Charging Requirements Charging Algorithm Initial current into the battery shall never exceed 1250mA. The battery shall be charged until the terminal voltage reaches to volts at ambient temperature. This terminal voltage shall be held until the current into the battery falls below 50mA. The point when the charging current falls below 50mA with a terminal voltage of to the battery can be considered fully charged and ready to be placed in service. If at this time the battery is not placed in service, the charging should either be stopped or the terminal voltage of the charger shall be reduced to to volts. This is a safe voltage to be used to maintain or "FLOAT" charge the battery. When held at this voltage the battery will seek its own current level and maintain a fully charged condition Battery Identification after Charging At the completion of a charge the battery is to be clearly marked on the top of the battery with permanent marker. This marking should include the month, day, and year (i.e. 6/20/06 for a battery removed from charge on June 20th, 2006) when the battery is removed from the charger. A battery should be placed in a new or repaired end assembly within 10 days of the date marked when removed from charging Preferred Battery Charger Shelf Life The battery manufacturer, Power Sonic, produces a battery charger to satisfy the above charging algorithm. The charger is specifically designed for the charging of a 5.0 Amp Hour SLA battery. This charger also has a charge indicator to determine the charge state of the battery. Power Sonic Model PSC-12500A is the preferred charger to charge the battery P/N It is recommended that the SLA Battery, P/N / (Enersys) be stored at temperatures between 10 0 C (50 0 F) and 30 0 C (86 0 F). The maximum storage time at different temperatures is provided in the following Table: MAXIMUM STORAGE TEMPERATURE MAXIMUM STORAGE TIME 30 0 C (86 0 F) 15 months 40 0 C (104 0 F) 7 months 50 0 C (122 0 F) 3 months 60 0 C (140 0 F) 1 month After the SLA battery is in storage for its maximum storage time, it shall then be connected to a battery charger and allowed to fully re-charge. Failure to re-charge after the maximum storage time will result in permanent damage to the battery s ability to hold a charge (Reference PCD-379 Storage and Maintenance Instructions for EP-60 Batteries). Knorr-Bremse Group Page 41 / 107

42 5.3 Masking of EP-60 Stand Alone CCD for Painting Masking the front of the CCD Stand Alone Figure 5-9 Masking Front of EP-60 Stand Alone CCD The front of the EP-60 Stand Alone CCD requires masking in three places before painting: 1) Nameplate 2) Patent Label 3) Operating Status LED Display Knorr-Bremse Group Page 42 / 107

43 5.3.2 Masking the bottom of the CCD Stand Alone Figure 5-10 Masking Bottom of EP-60 Stand Alone CCD The bottom of the EP-60 Stand Alone CCD requires masking in six places before painting: 1) Release Valve Exhaust 2) Stack Exhaust 3) Exhaust 2 Port 4) PSM Reference Port 5) Relief Exhaust 6) POV Exhaust Knorr-Bremse Group Page 43 / 107

44 5.3.3 Masking the back of the CCD Stand Alone Figure 5-11 Masking Back of EP-60 Stand Alone CCD The back of the EP-60 Stand Alone CCD requires masking in two places before painting: 1) Relief Valve Vent 2) POV Vent Knorr-Bremse Group Page 44 / 107

45 5.4 Masking of EP-60 Overlay CCD for Painting Masking the front of the CCD Overlay Figure 5-12 Masking Front of EP-60 Overlay CCD The front of the EP-60 Overlay CCD requires masking in three places before painting: 1) Nameplate 2) Patent Label 3) Operating Status LED Display Knorr-Bremse Group Page 45 / 107

46 5.4.2 Masking the bottom of the CCD Overlay Figure 5-13 Masking Bottom of EP-60 Overlay CCD The bottom of the EP-60 Overlay CCD requires masking in four places before painting: 1) Stack Exhaust 2) Exhaust 2 Port 3) PSM Reference Port 4) Relief Exhaust Knorr-Bremse Group Page 46 / 107

47 5.5 CCD Software Control NOTE Single Car Test must be the last process performed to verify freight car integrity CCDs are supplied with the latest production release software CCDs can be upgraded with the latest software using the EPSCTD and the latest EPSCTD revision software supplied by NYAB as outlined in NYAB IP-224. Figure 5-14 NYAB EPSCTD Software CD, PN NYAB EPSCTD licensed software is a windows based program that is installed on a laptop or desktop computer using the NYAB EPSCTD software CD, NYAB P/N Software is downloaded at Single Car Test (Reference NYAB IP-224). Knorr-Bremse Group Page 47 / 107

48 6 Junction Box Assemblies 6.1 Junction Box Assemblies with IDM Plug and Play IDM Junction Box Assembly Figure 6-1 Plug and Play IDM Junction Box Assembly (P/N ) Knorr-Bremse Group Page 48 / 107

49 IDM JUNCTION BOX ASSEMBLY KIT P/N (Figure 6-1) Item No. Qty. Description P/N 2 Flange Assembly, Trainline (includes items 1 thru 4) Flange Connector, Strain Relief Screw, Washer Faced Hex Head O-Ring Spacer, Wire Sleeve, Wire Spacer Tubing, Cold Shrink Junction Box Assembly, IDM (includes items 9 and 10) O-Ring Shipping Cover Knorr-Bremse Group Page 49 / 107

50 6.1.2 Junction Box Assembly with IDM, P/N Tools Required 1/4" Deep Well Socket Set 1/2" Deep Well Socket Set w/extension 1/4" Drive Torque Wrench or 1/4" Torque Nut Driver 0-50 in-lbs (0-5.6 N-M) 1/2" Drive Torque Wrench ft-lbs (0-203 N-M) 2-1/4" Open End Wrench Large Channel Locks Small Flat Blade Screw Driver Large Flat Balde Screw Driver Small Pipe Wrench Figure 6-2 Center Junction Box Assembly with IDM (P/N ) Knorr-Bremse Group Page 50 / 107

51 Center Junction Box Assembly with IDM, P/N (Figure 6-2) Item No. Part Number Description Reference Screw, Retained Hex Head, 1/4-20 UNC Tighten to 65 +/- 5 in-lbs (7.3 +/-1 N-M) Washer, Split Lock, 1/4" Washer, Flat Lanyard Cover, Junction Box Gasket Junction Box Cable Assembly, CCD to IDM Connector, 1/2" Strain Relief Tighten to 25 ft-lbs (34 N-M) 10A Connector, 3/4" Strain Relief Tighten Strain Relief Connector to 500 inlbs. or allowing 1/32"-1/16" of the Stop Washer to protrude from the Connector 10B 10C Stop Washer, Strain Relief Grommet, Strain Relief Connector Cable Assembly, Trainline Screw, Hex Head Cap, 3/8" Torque to 22 +/-1 ft-lbs (30 +/-1 N-M) Washer, Flat Nut, Self-Locking ID Module Assembly (Reference Figure 6-7) Knorr-Bremse Group Page 51 / 107

52 Center Junction Box Assembly with IDM P/N (cont d.) Tools Required ¼" Deep Well Socket Set ¼" Drive Torque Wrench or ¼" Torque Nut Driver 0-50 in-lbs (0-5.6 N-M) ½" Drive Torque Wrench ft-lbs. (0-203 N-M) Small Flat Blade Screw Driver Large Flat Blade Screw Driver Figure 6-3 Center Junction Box Assembly with IDM (P/N ) Knorr-Bremse Group Page 52 / 107

53 Center Junction Box Assembly with IDM, P/N (Cont d.) (Figure 6-3) Item No. Part Number Description Reference ID Module with Hardware (Includes items 16 thru 22) Nut, Special Torque to 14 in-lbs (dry) (1.6 N-M) Washer, Split Lock, # Washer, Flat, # Standoff DO NOT REMOVE Nut, Electrical Hex Torque to 20 in-lbs (dry) (2.3 N-M) Washer, Split Lock, # Washer, Flat, # Screw, Socket Head Torque to 6 +/-1 ft-lbs (8.1 +/-1 N-M) Washer, Lock, M Decal, IDM Junction Box Knorr-Bremse Group Page 53 / 107

54 6.2 End of Car Junction Box Assemblies End of Car Junction Box Assembly with Armored Cable, P/N Tools Required 1/2" Socket Set 1/2" Drive Torque Wrench ft-lbs (0-203 N-M) Medium Channel Locks Figure 6-4 End of Car Junction Box Assembly, P/N Knorr-Bremse Group Page 54 / 107

55 End of Car Junction Box Assembly with Armored Cable, P/N (Figure 6-4) Item No. Part Number Description Reference Screw, Hex Head, Washer Faced Torque to ft-lbs (34-41 N-M) Cover, EOC Junction Box O-Ring Insert Assembly, EOC JB O-Ring O-Ring Sleeve, Wire Spacer Spacer, Wire Body, EOC JB Trainline Cable Assembly, Armored 11A /4" Strain Relief Tighten Strain Relief Connector to 500 in-lbs. or allowing 1/32"-1/16" of the Stop Washer to protrude from the Connector 11B 11C Stop Washer, Strain Relief Grommet, Strain Relief Connector Knorr-Bremse Group Page 55 / 107

56 6.3 End of Car Junction Box Assembly with Liquidtight Conduit, P/N Tools Required 1/2" Socket Set 1/2" Drive Torque Wrench ft-lbs (0-203 N-M) Medium Channel Locks Figure 6-5 End of Car Junction Box Assembly, P/N Knorr-Bremse Group Page 56 / 107

57 End of Car Junction Box Assembly with 1" Liquidtight Conduit, P/N (Figure 6-5) Item No. Part Number Description Reference Screw, Hex Head, Washer Faced Torque to ft-lbs (34-41 N-M) Cover, EOC Junction Box O-Ring Insert Assembly, EOC JB O-Ring O-Ring Sleeve, Wire Spacer Spacer, Wire Body, EOC JB Trainline Cable Assembly, Non Armored Connector, 1" Liquidtight Strain Relief Tighten Strain Relief Connector to 500 in-lbs. or allowing 1/32"-1/16" of the Stop Washer to protrude from the Connector Conduit, Sealtite, 1" Knorr-Bremse Group Page 57 / 107

58 7 Installation Procedures 7.1 Plug and Play Junction Box Assembly with IDM Figure 7-1 Plug and Play Junction Box Assembly with IDM Mount IDM Junction Box Assembly using a mounting bracket (reference Fig. 7-1), three standard hex head bolts (3/8" x 4-1/4" long), six 3/8" washers, and three 3/8" locking nuts. Evenly torque nuts to 20 +/-2 ft-lbs (27 +/-3 NM) Apply Anti-corrosive grease between unpainted mounting plate and IDM Mount IDM Junction Box Assembly such that cover marked "A END" cable runs to A end and cover marked "B END" cable runs to B end Mount IDM prior to car frame painting. Knorr-Bremse Group Page 58 / 107

59 7.2 Plug and Play End of Car Junction Box Figure 7-2 Installation of Plug and Play End of Car Junction Box Mount the EOC Junction Box Assembly using an AAR Standard Angle Cock U-Bolt (p/n ), washer (p/n ) and nut (p/n ). Torque nut, p/n , to 90 ft-lbs (10 +/-1 N-M) The front of the ECP connector must be clear of obstacles for wrench installation of coupling nut. Knorr-Bremse Group Page 59 / 107

60 8 EP-60 Freight Car Trainline Component Accessories 8.1 EP-60 Freight Car Trainline Component Accessories Figure 8-1 EP-60 Freight Car Component Accessories EP-60 Freight Car Component Accessories Item Part No. Description Reference Armored Cable Clamp Torque to 13 +/- 2 ft.-lbs (17.6 N-M). Recommended distance between clamps approximately 18-24" Knorr-Bremse Group Page 60 / 107

61 8.2 Installation Procedure: Cable Connections to Junction Box Bend Radiuses The recommended bend radiuses for trainline cable configurations are: Armored Cable 11-1/4" Non Armored Cable 8-3/4" Liquidtight Conduit 12" CCD Drop Cabel 4-3/4" Figure 8-2 Bend Radius Drip Loop Ensure all cables have a drip loop at their entry point to junction box as shown in Figure 8-3. For a proper drip loop, the cable should have a loop angled toward the ground approximately equal to the thickness of the cable. Figure 8-3 Cable Connections to Junction Box NOTE Care should be taken to ensure that all cable is positioned in locations where it will not be damaged by normal operation of the cars, or damaged by friction between the cable and another surface. Knorr-Bremse Group Page 61 / 107

62 8.3 Installation Procedure: CCD to IDM Cable Assembly Figure 8-4 Connecting the CCD to IDM Cable Assembly The IDM Junction Box is required to be mounted within approximately 88 cable routing inches of the J1 connector on the CCD The CCD to IDM cable assembly should be secured firmly to the car body every inches using cable support hardware: Cable Support Hardware Item Part No. Description Reference Hose Clamp, Drop Cable #4 Hose Recommended distance between clamps approximately 12" Screw, Spot Weld, 3/8" x 1" Torque to 13+/-2 ft-lbs (17.6 N-M) Washer, 3/8" Locknut, 3/8" Torque to 20 +/-2 ft-lbs (27 +/-2 N-M) Knorr-Bremse Group Page 62 / 107

63 Figure 8-5 Connecting CCD to IDM Cable Assembly to the J1 Connector Plug the CCD to IDM cable assembly plug into the CCD J1 Connector. Hand tighten the connecting collar of the plug onto the J1 connector aligning the collar aligning keys in the slots on the J1 Connector. Rotate connector clockwise until an audible click indicates the connector is locked in place. A strap wrench may be required. Knorr-Bremse Group Page 63 / 107

64 8.4 Installation Procedure: Trainline Cable Connection to Junction Box Trainline Cable to IDM Plug and Play Junction Box Figure 8-6 Trainline Cable Connection to IDM Junction Box Assembly NOTE Avoid contacting cable pins with abrasive materials / files Slide the shrink tubing, connector, stop washer, and rubber grommet onto the trainline cable. Wire Ideal Yellow 77 wire pulling lubricant, NYAB P/N789745, may be used to help slide the rubber grommet over the trainline cable Insert the trainline cable through the male fitting and junction box until it protrudes approximately 5" on the opposite end of the junction box. Knorr-Bremse Group Page 64 / 107

65 Figure 8-7 Wire Spacer and Spacer Sleeve With the F on wire spacer facing the IDM Junction Box Assembly, snap trainline cable contact pins, trainline ground contact pin, and car body ground pin into wire spacer at positions identified in Figure 8-7, Step Trainline cable contact pins and trainline ground contact pin should extend 3/4" from wire spacer. The car body ground contact pin should be snapped into molded groove of wire spacer Slide the wire spacer sleeve over the wire spacer (reference Figure 8-7, Step 2). Knorr-Bremse Group Page 65 / 107

66 Figure 8-8 Trainline Flange Assembly and Cable Connection Aligning wire spacer and wire spacer sleeve assembly with opening in trainline flange assembly, slowly push/pull trainline cable back through trainline flange assembly until wire spacer and wire spacer sleeve assembly bottoms out within flange assembly (reference Figure 8-8, Step 1). The following instructions apply to both A-End and B-End covers of the IDM Junction Box Assembly Aligning contact pins with contact socket of trainline insert assembly, install trainline flange onto end cover (reference Figure 8-8, Step 2). Torque screws to 25 to 30 ft-lbs (34-41 N-M). Knorr-Bremse Group Page 66 / 107

67 Figure 8-9 Trainline Cable Connection to IDM Junction Box Assembly Position rubber grommet so it has entered male fitting and slide stop washer against grommet. Carefully thread connector onto male fitting and hand tighten. Use caution when tightening connector onto male fitting to avoid cross threading. Ensure trainline flange assembly is in place and tightened to specifications before installing connector Using channel locks, continue tightening connector onto strain relief fitting until 1/16" of the stop washer protrudes through connector. Before applying shrink tubing, ensure that it is correctly positioned over strain relief connector and flush against strain relief nut Slide shrink tubing over the armored or non-armored cable until it covers strain relief connector and is flush with strain relief connecting nut (reference Figure 8-9). Knorr-Bremse Group Page 67 / 107

68 8.4.2 Trainline Cable Connection to Junction Box with IDM - Armored Cable Figure 8-10 Trainline Cable Connection to Junction Box - Armored Cable Slide the shrink tubing, connector, stop washer, and rubber grommet onto the trainline cable. Wire Ideal Yellow 77 wire pulling lubricant, NYAB P/N789745, may be used to help slide the rubber grommet over the trainline cable Position the rubber grommet and trainline cable into the junction box ensuring that the rubber grommet has entered the male fitting and there is approximately 1/2" of exposed cable inside the junction box Slide the stop washer against the grommet Slide the connector over the stop washer and grommet. Carefully thread the connector onto the male fitting and hand tighten. NOTE Use caution when tightening the connector onto the male fitting to avoid cross threading Using channel locks, continue tightening the connector onto the strain relief fitting until the stop washer is protruding 1/16" from the top of the connector Slide the shrink tubing over the armored cable until the shrink tubing is covering the armored cable and connector and butts up agains the hex fitting. Apply shrink tubing. Knorr-Bremse Group Page 68 / 107

69 8.4.3 Trainline Cable Connection to Junction Box with IDM - 1" Liquidtight Conduit Figure 8-11 Trainline Cable Connection to Junction Box - 1" Liquidtight Conduit Slide the connector, seal ring, and metal grommet onto the trainline cable. Insert the metal grommet into the 1" Liquidtight. Wire Ideal Yellow 77 wire pulling lubricant, NYAB P/ N789745, may be used to help slide the rubber grommet over the 1" Liquidtight Conduit Position the trainline cable into the junction box ensuring that there is approximately 1/2" of exposed non-armored cable inside the junction box Slide the seal ring against the metal grommet Slide the connector over the seal ring and metal grommet. Carefully thread the connector onto the male fitting and hand tighten. NOTE Use caution when tightening the connector onto the male fitting to avoid cross threading Using channel locks, continue tightening the connector onto the strain relief fitting until the stop washer is protruding 1/16" from the top of the connector. Knorr-Bremse Group Page 69 / 107

70 8.4.4 Trainline Cable Wiring to Junction Box with IDM Figure 8-12 Trainline Cable Wiring to Junction Box with IDM Connect Trainline Cable wires to postions 1, 2, and 4 on the ID Module Assembly. NOTE Ensure that the IDM Cable connectors remain on the terminal studs before connecting trainline wire connectors Using a torque wrench, torque nuts to 20 +/-2 in/lbs. Knorr-Bremse Group Page 70 / 107

71 8.4.5 Trainline Cable Connection to EOC Junction Box (new style) - Armored Cable Figure 8-13 Trainline Cable Connection to End of Car Junction Box (Armored Cable) NOTE Avoid contacting cable pins with abrasive materials / files Slide the shrink tubing, connector, stop washer, and rubber grommet onto the trainline cable. Wire Ideal Yellow 77 wire pulling lubricant, NYAB P/N789745, may be used to help slide the rubber grommet over the trainline cable Insert the trainline cable through the male fitting and junction box until it protrudes approximately 5" on the opposite end of the junction box. Figure 8-14 Trainline Cable Connection in Wire Spacer Knorr-Bremse Group Page 71 / 107

72 With the F on the wire spacer in front, snap the trainline cable pins and trainline ground into the wire spacer at the positions identified in Figure 8-14 (Reference Figure 8-15 for car body ground positioning). Pins should extend 3/4" from wire spacer. Figure 8-15 Wire Spacer Sleeve Slide the wire spacer sleeve over the wire spacer and snap the car body ground pin into the bottom of the spacer sleeve. Figure 8-16 EOC Insert Assembly Slide the EOC Junction Box Insert Assembly onto the trainline cable pins and spacer sleeve. Knorr-Bremse Group Page 72 / 107

73 NOTE It is recommended that the flat of the EOC Insert Assembly runs parallel to the ground (reference Figure 8-17). Figure 8-17 Flat of EOC Insert Assembly Figure 8-18 Trainline Cable Connection NOTE Use caution when inserting the Insert Assembly into the junction box to avoid rolling the Insert Assembly O-Ring Slowly pull the trainline cable back through the junction box until the spacer sleeve with EOC insert assembly bottoms out within the junction box body. Use caution to avoid rolling the insert assembly o-rings. (Reference Figure 8-18) Install the Junction Box Cover with O-Ring onto the junction box body using cover screws. Torque screws to 25 to 30 ft.lbs (34-41 N-M). (Use of cover screws may aid in drawing down the spacer sleeve and insert assembly.) (Reference Figure 8-18). Knorr-Bremse Group Page 73 / 107

74 Position the rubber grommet so it has entered the male fitting and slide the stop washer against the grommet. Figure 8-19 Trainline Cable Connection to EOC Junction Box Carefully thread the connector onto the male fitting and hand tighten. NOTE Use caution when tightening the connector onto the male fitting to avoid cross threading Using channel locks, continue tightening the connector onto the strain relief fitting until 1/16" of the stop washer protrudes through the connector. NOTE Before applying shrink tubing, ensure that it is correctly positioned over the strain relief connector and flush against the strain relief nut Slide the shrink tubing over the armored and non-armored cable until it covers the strain relief connector and is flush with the strain relief connecting nut (Reference Figure 8-19). Knorr-Bremse Group Page 74 / 107

75 8.4.6 Trainline Cable Connection to EOC Junction Box (new style) - 1" Liquidtight Conduit Figure 8-20 Trainline Cable Connection to End of Car Junction Box (1" Liquidtight Conduit) NOTE Avoid contacting cable pins with abrasive materials / files Slide the connector and stop washer onto the 1" Liquidtight Conduit. Slide the metal grommet into the end of the 1" Liquidtight Conduit. Wire Ideal Yellow 77 wire pulling lubricant, NYAB P/N789745, may be used to help slide the rubber grommet over the 1" Liquidtight Conduit Insert the trainline cable through the male fitting and junction box until it protrudes approximately 5" on the opposite end of the junction box. Figure 8-21 Trainline Cable Connection in Wire Spacer Knorr-Bremse Group Page 75 / 107

76 With the F on the wire spacer in front, snap the trainline cable pins and trainline ground into the wire spacer at the positions identified in Figure 8-21 (Reference Figure 8-22 for car body ground positioning). Pins should extend 3/4" from wire spacer. Figure 8-22 Wire Spacer Sleeve Slide the wire spacer sleeve over the wire spacer and snap the car body ground pin into the bottom of the spacer sleeve. Figure 8-23 EOC Insert Assembly Knorr-Bremse Group Page 76 / 107

77 Slide the EOC Junction Box Insert Assembly onto the trainline cable pins and spacer sleeve. NOTE It is recommended that the flat of the EOC Insert Assembly runs parallel to the ground (reference Figure 8-24). Figure 8-24 Flat of EOC Insert Assembly Figure 8-25 Trainline Cable Connection NOTE Use caution when inserting the Insert Assembly into the junction box to avoid rolling the Insert Assembly O-Ring Slowly push/pull the trainline cable back through the junction box until the spacer sleeve with EOC insert assembly bottoms out within the junction box body. Use caution to avoid rolling the insert assembly o-rings. (Reference Figure 8-25). Knorr-Bremse Group Page 77 / 107

78 Install the Junction Box Cover with O-Ring onto the junction box body using cover screws. Torque screws to 25 to 30 ft.lbs (34-41 N-M). (Use of cover screws may aid in drawing down the spacer sleeve and insert assembly.) (Reference Figure 8-25) Insert the 1" Liquidtight Conduit with installed metal grommet into the female socket of the 1" Liquidtight Connector Slide the stop washer against the installed metal grommet Carefully thread the connector onto the male fitting and hand tighten. NOTE Use caution when tightening the connector onto the male fitting to avoid cross threading. Figure 8-26 Trainline Cable Connection to EOC Junction Box Using channel locks, continue tightening the connector onto the strain relief fitting to 500 in-lbs (56.5 N-M) torque. Knorr-Bremse Group Page 78 / 107

79 8.4.7 Inter-Car Cable Assembly Connection to EOC Junction Box and EOC Termination Figure 8-27 O-Ring Installation Ensure the o-ring is installed in the machined groove on the face of the gland nut (reference Figure 8-27). Figure 8-28 Inter-Car Cable Assembly Connection Slide the connecting gland nut of the inter-car cable assembly back away from plug. Align contact pins with socket and push the plug into socket until plug bottoms out (reference Figure 8-28). Knorr-Bremse Group Page 79 / 107

80 Carefully thread the gland nut of the inter-car cable assembly into the female threads of the EOC assembly. CAUTION Use caution when threading the connecting gland nut into the EOC to ensure only the gland nut is turned and not the complete inter-car cable assembly which can result in damage to contact pins. NOTE Use caution when threading the cable assembly gland nut into the EOC to avoid cross threading. Figure 8-29 Inter-Car Cable Connection to EOC Junction Box The gland nut should be hand tightened to junction box until tight. Then, using a 2-1/4" open end or adjustable wrench, tighten an additional 1/3 turn. Ensure that the o-ring is not exposed outside of the gland nut after tightening the gland nut. NOTE Over tightening of the inter-car cable assembly gland nut may result in O-Ring damage. Knorr-Bremse Group Page 80 / 107

81 8.5 Repair Procedure: Armored Cable/Non-Armored Cable with Ring Termination Figure 8-30 Armored Cable Trainline Armored Cable consisting of: Armor sheathing Braided shield Outer jacket Binder and fillers Textile covering Wires Armored Cable Ring Termination Armor Sheathing Figure 8-31 Armored Sheathing Remove 14-1/2" of armor sheathing from end of cable. Knorr-Bremse Group Page 81 / 107

82 8.5.3 Braided Shield Figure 8-32 Braided Shield Cut and strip outer jacket back exposing 6" of braided shield, leaving a 8-1/2" length of outer jacket protruding from the cable armor. NOTE Use caution when cutting outer jacket to avoid cutting through the braided shield underneath. Figure 8-33 Braided Shield Create an opening in the braided shield at the edge of the outer jacket and opposite the drain wire. Knorr-Bremse Group Page 82 / 107

83 Carefully pull inner conductor wires and filler through opening in braided shield ensuring that strands of braided shield are not broken or damaged. Do not comb braided shield (reference Figure 8-34). Figure 8-34 Conductor Wires Pull braid tight to twist and form one conductor (reference Figure 8-35). Figure 8-35 Braided Shield Conductor Wire Verify that length of each exposed conductor wire is 6". Knorr-Bremse Group Page 83 / 107

84 Apply a 5-1/2" long x ¼ dia. shrink tube over the conductor wire formed from the twisted shield and apply heat Cable Shrink Tubing Figure 8-36 Braided Shield Shrink Tubing Figure 8-37 Cable Shrink Tubing Slide the 2-1/2" long x 1-1/2" dia. shrink tube over conductor wires and position so one half of its length is over the armored jacket and the other half over the insulated cable. Apply heat to shrink tube. Knorr-Bremse Group Page 84 / 107

85 8.5.5 Ring Terminals Figure 8-38 Ring Terminals Strip insulation on individual wires back 1/2" +/-1/32". Slide ring terminals over wire ends and crimp into place (STA-KON ERG2001 Ergonomical Crimping Tool recommended). NOTE Crimp connections on conductors must be capable of withstanding 150 lb. Pull Test for 8 AWG and 110 lbs. for shield wire Completed Cable Termination Figure 8-39 Completed Cable Termination with Ring Terminals Knorr-Bremse Group Page 85 / 107

86 8.6 Repair Procedure: Armored Cable/Non-Armored Cable with Pin Termination Figure 8-40 Armored Cable Trainline Armored Cable consisting of: Armor sheathing Outer jacket Textile covering Braided shield Binder and fillers Wires Armored Cable Pin Termination Armor Sheathing Figure 8-41 Armored Sheathing Remove 9-7/8" of armor sheathing from end of cable. Knorr-Bremse Group Page 86 / 107

87 8.6.3 Braided Shield Figure 8-42 Braided Shield Cut and strip outer jacket back exposing 2-1/2" of braided shield, leaving a 7-3/8" length of outer jacket protruding from the cable armor. NOTE Use caution when cutting outer jacket to avoid cutting through the braided shield underneath Push braid down slightly to loosen it. At edge of outer jacket and adjacent to drain wire pick 9 bundles of braid strands out of braided shield, centered around the drain wire. Figure 8-43 Drain Wire Knorr-Bremse Group Page 87 / 107

88 Pick drain wire out through the hole that was created being careful not to damage the remaining braided shield Twist the 9 bundles of braided strands that were previously picked out with drain wire into trainline ground conductor. Trim conductor to 2-1/2" from the outer jacket. Figure 8-44 Conductor Drain Wire Carefully comb out remaining braided shield and twist into car body ground conductor on the opposite side of the cable from the previously created drain wire conductor. Trim conductor to 2-1/2" from outer jacket Trim the fillers and binders as close to the outer jacket as possible. Figure 8-45 Trim Binder and Fillers Knorr-Bremse Group Page 88 / 107

89 Apply a 2-1/4" long x 1/4" diameter shrink tube over twisted shield conductor. Figure 8-46 Shrink Tube over Twisted Shield Conductor Slide male contact pin, P/N , over drain wire conducter and ground pin, P/N , over twisted shield conductor. Ensure both conductors are fully inserted into their respective pins. Crimp into place (Pico Corporation Pneumatic Power Crimping Tool 414DA-12N with die set DTM-1098 recommended). Figure 8-47 Pin Terminals NOTE Crimped connections on conductors must be capable of withstanding 150 lb. Pull Test for 8 AWG and 110 lbs. for Shield wire. Knorr-Bremse Group Page 89 / 107

90 Strip insulation on black and white conductors back 1/2" +/-1/32". Slide pin terminal P/N onto each black and white conductor wire. Verify shoulders on both pin terminals align and crimp into place (Pico Corporation Pneumatic Power Crimping Tool 414DA-8HEX with die set DTM-1098 recommended). Reference Figure 8-48 for Locator and Die listing. Figure 8-48 Pin Terminals Apply a 2-1/4" long x ¼ dia. shrink tube over the drain wire conductor with contact pin. Shrink tubing must overlap the crimped area of terminals on each conductor. Apply heat to shrink into place on each conductor. Figure 8-49 Conductor Shrink Tubing Knorr-Bremse Group Page 90 / 107

91 8.6.4 Cable Shrink Tubing Slide the 2-1/2" long x 1-1/2" dia. shrink tube over the four wires and position so one half of its length is over the armored jacket and the other half over the insulated cable. Apply heat to shrink tube Completed Cable Termination Figure 8-50 Cable Shrink Tubing Figure 8-51 Completed Cable Termination with Ring and Pin Terminals Knorr-Bremse Group Page 91 / 107

92 8.7 Repair Procedure: Removing Debris from Inter-Car Connector Contacts Figure 8-52 Inter-Car Connector Electrical Connectors NOTE Use caution when cleaning the conductive contacts of the Inter-Car Connector. The use of hard abrasive materials for the purpose of removing debris, ice, or snow from the conductive contacts will result in excessive corrosion to the contacts The use of plastic tools is recommended to clean out the electrical connectors of the Inter- Car Connector when necessary. Avoid using hard abrasive materials such as metal files Snow and ice should be removed by the use of a non-corrosive deicer. Knorr-Bremse Group Page 92 / 107

93 8.8 Repair Procedure: Inter-Car Connector Pull-Out Repair Figure 8-53 Inter-Car Connector Cable Pullout Repair Unscrew gland nut from the junction box and separate the plastic skid washer from the gland nut. Figure 8-54 Plastic Skid Washer Knorr-Bremse Group Page 93 / 107

94 Figure 8-55 Machined O-Ring Groove Ensure the o-ring is installed in the machined groove on the face of the gland nut (reference Figure 8-55). Figure 8-56 Inter-Car Connector Cable Pullout Repair Slide the gland nut onto the inter-car cable assembly Spread the plastic skid washer just enough to slip it onto the cable assembly between the gland nut and the connector plug. Position the plastic skid washer so the lip of the washer is against the lip of the connector plug. Knorr-Bremse Group Page 94 / 107

95 Figure 8-57 Inter-Car Connector Cable Pullout Repair Slide the gland nut of the inter-car cable assembly back away from plug. Align contact pins with socket and push the plug into socket until plug bottoms out (reference Figure 8-57) Carefully thread the gland nut of the inter-car cable assembly into the female threads of the EOC assembly. CAUTION Use caution when threading the connecting gland nut into the EOC to ensure only the gland nut is turned and not the complete inter-car cable assembly which can result in damage to contact pins. NOTE Use caution when threading the cable assembly gland nut onto the EOC to avoid cross threading. Knorr-Bremse Group Page 95 / 107

96 Figure 8-58 Inter-Car Cable Connection to EOC Junction Box The gland nut should be hand tightened to junction box until tight. Then, using a 2-1/4" open end or adjustable wrench, tighten an additional 1/3 turn. Ensure that the o-ring is not exposed outside of the gland nut after tightening the gland nut. NOTE Over tightening of the inter-car cable assembly gland nut may result in O-Ring damage. Knorr-Bremse Group Page 96 / 107

97 8.9 Replacement Procedure: Inter-Car Connector Lanyard Figure 8-59 Inter-Car Connector Lanyard Replacement Procedure Remove the Inter-Car Connector Cable Assembly by unscrewing the gland nut from the junction box and separating the plastic skid washer from the gland nut. Figure 8-60 Plastic Skid Washer Remove the skid washer from the Inter-Car Connector and pull the gland nut off the Inter-Car Connector plug. Knorr-Bremse Group Page 97 / 107

98 Figure 8-61 Removing the Lanyard Eyebolt Using a special thin walled deep well 3/8" hex socket, remove the eyebolt nut located in the recessed hole within the Inter-Car Connector boot. Figure 8-62 Inter-Car Connector Cable Pullout Repair Slide the damaged lanyard off the Inter-Car Connector Cable Assembly as shown in Figure Knorr-Bremse Group Page 98 / 107

99 8.9.5 NYAB Lanyard Strap Assembly Replacement Kits (Refer to Figures 8-63 and 8-64) Figure 8-63 AAR Lanyard Strap Assembly Replacement Kit, P/N Figure 8-64 Non AAR Lanyard Strap Assembly Replacement Kit, P/N Knorr-Bremse Group Page 99 / 107

100 Figure 8-65 Installing the New Lanyard Onto the Inter-Car Connector Assembly Slide the new freight car replacement lanyard onto the Inter-Car Connector Assembly (reference Figure 8-65). Figure 8-66 Installing the Replacement Lanyard Eyebolt Assembly Using the lock nut and washer supplied with the lanyard replacement kit, reconnect the lanyard eyebolt to the Inter-Car Connector boot using a torque value of 150 in-lbs (17 N-M) (Figure 8-66). NOTE The use of Loctite is recommended when fastening the nut onto the lanyard eyebolt. Knorr-Bremse Group Page 100 / 107