New York Air Brake CCB Brake System EMD CONTRACT CCB BRAKE EQUIPMENT MAINTENANCE MANUAL IP-148-C For the SD 70MAC LOCOMOTIVE DECEMBER 2001 CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text effected by the changes is indicated by a vertical line in the outer margin of the page. The total number of pages in this Maintenance and Instruction Manual, is 560, consisting of: PAGE NO. CHANGE NO. ISSUE Title 3 December/01 A 3 December/01 B 3 December/01 i through viii 2 December/01 1-1 through 1-82 2 December/01 2-1 2 December/01 2-2 2 December/01 includes: C.W. 135 3 May/99 C.W. 217 6 November/01 C.W. 218 2 May/98 C.W. 219 2 October/95 C.W. 220 2 October/95 C.W. 221 5 April/00 C.W. 222 2 October/95 C.W. 223 3 May/98 C.W. 224 3 May/98 C.W. 225 2 June/96 C.W. 226 4 May/97 C.W. 227 3 August/98 C.W. 228 3 May/98 C.W. 229 3 May/98 C.W. 230 2 June/96 C.W. 231 3 June/96 C.W. 232 1 April/94 C.W. 233 5 August/97 C.W. 235 1 April/94 C.W. 236 2 October/95 C.W. 237 3 September/96 C.W. 239 3 November/97 C.W. 240 1 April/94 C.W. 243 3 June/96 C.W. 245 4 December/01 C.W. 250 1 June/95 C.W. 253 1 August/95 C.W. 266 1 June/97 ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM: NEW YORK AIR BRAKE CORPORATION A KNORR BRAKE COMPANY The Change No. "0" indicate the Original Issue for Manual 748 STARBUCK AVENUE The Change No. "1" indicates the Original Issue for NYR,NYT & C.W. WATERTOWN, NY 13601 The Change Letter "A" indicates the Original Issue for P/L,W/D,P/D IP-148-C - A - DECEMBER/01 CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: The portion of the text effected by the changes is indicated by a vertical line in the outer margin of the page. The total number of pages in this Maintenance and Instruction Manual, is 560, consisting of: PAGE NO. CHANGE NO. ISSUE C.W. 279 1 November/01 C.W. 280 1 December/01 3-1 through 3-4 2 December/01 4-1 through 4-8 2 December/01 5-1 through 5-43 2 December/01 6-1 through 6-10 2 December/01 Includes: NYR-345 4 November/01 NYR-350 4 August/00 7-1 2 December/01 7-2 (Blank) 2 December/01 Includes: P/L: 1441 L February/93 P/L: 1482 G May/95 P/L: 1484 G May/95 P/L: 1505 C October/96 P/L: 1544 C March/98 P/L: 1567 A December/98 P/L: 1586 A August/99 P/D - 1441 K February/93 P/D - 1482 D May/94 P/D - 1484 D May/95 P/D - 1544 A March/98 P/D - 1567 A April/99 P/D - 1586 F October/99 W/D - 1441 F February/93 W/D - 1482 H July/95 W/D - 1484 J August/95 W/D - 1505 F September/96 W/D - 1544 B March/98 W/D - 1567 C April/99 W/D - 1586 F October/99 8-1 through 8-14 3 December/01 ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM: NEW YORK AIR BRAKE CORPORATION A KNORR BRAKE COMPANY The Change No. "0" indicate the Original Issue for Manual 748 STARBUCK AVENUE The Change No. "1" indicates the Original Issue for NYR,NYT & C.W. WATERTOWN, NY 13601 The Change Letter "A" indicates the Original Issue for P/L,W/D,P/D DECEMBER/01 - B - IP-148-C CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL TABLE OF CONTENTS CHAPT/SECT TITLE PAGE 1.0 OPERATING PROCEDURES 1-1 1.1 AIR BRAKE EQUIPMENT 1-1 1.1.1 AIR BRAKE EQUIPMENT IN AIR BRAKE COMPARTMENT 1-1 1.1.2 BRAKE VALVE 1-16 1.1.3 AIR BRAKE SET-UP 1-17 1.1.4 LOSS OF POWER MODE 1-19 1.1.5 POWER UP PENALTY 1-19 1.2 GENERAL INFORMATION 1-20 1.2.1 CCB INTRODUCTION 1-20 1.2.2 SYSTEM DESCRIPTION 1-22 1.2.3 OPERATION 1-24 A. RELEASE POSITION 1-24 B. BRAKE CYLINDER PRESSURE CONTROL 1-29 C. SERVICE APPLICATION-AUTOMATIC 1-32 D. BRAKE CYLINDER-AUTOMATIC 1-38 E. SUPPRESSION POSITION 1-38 F. CONTINUOUS SERVICE POSITION 1-43 G. EMERGENCY APPLICATION-EMERGENCY 1-45 H. EMERGENCY APPLICATION-FIREMAN’S VALVE 1-53 I. EMERGENCY APPLICATION-TRAIN SEPARATION 1-53 J. AUTOMATIC APPLICATION-BAIL OFF 1-55 K. TRAIL POSITION-AUTOMATIC BRAKE 1-61 L. TRAIL POSITION-ANY EMERGENCY APPLICATION AND RELEASE 1-61 M. TRAIL OPERATION-BAIL OFF 1-61 N. INDEPENDENT APPLICATION AND RELEASE 1-66 O. TRAILING INDEPENDENT BRAKING 1-74 P. LOSS OF POWER OR DEFAULT MODE 1-74 Q. SERVICE PENALTY DEFAULT 1-74 R. INDEPENDENT - BACK UP TRAIL OPERATION 1-79 S. AUTOMATIC SERVICE APPLICATION 1-79 BAIL OFF-BACK UP TRAIL OPERATION T. EMERGENCY APPLICATION BAIL-OFF 1-80 BACK UP TRAIL OPERATION 2.0 EQUIPMENT DESCRIPTION 2-1 2.1 COMPONENT DESCRIPTIONS 2-1 3.0 PREPARATION FOR MAINTENANCE 3-1 3.1 GENERAL INFORMATION 3-1 3.2 SAFETY PRECAUTIONS 3-1 3.3 COMPONENT ASSEMBLY PRECAUTIONS 3-3 IP-148-C i DECEMBER/01 CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL TABLE OF CONTENTS (Contd.) CHAPT/SECT TITLE PAGE 4.0 SCHEDULED INSPECTION 4-1 4.1 GENERAL INFORMATION 4-1 4.2 INSPECTIONS 4-1 4.3 92 DAY INSPECTION 4-1 4.4 AIR PRESSURE TEST 4-1 4.5 EQUIPMENT REPLACEMENT, REPAIR, AND OVERHAUL 4-5 5.0 ON-LOCOMOTIVE CHECKOUT AND ANALYSIS 5-1 5.1 GENERAL INFORMATION 5-1 5.2 FUNCTION TESTING 5-1 5.2.1 Locomotive Air Brake Test 5-1 5.2.2 CCB Tests 5-2 5.3 REMOTE SESSIONS 5-8 5.3.1 Overview 5-8 5.3.2 Description Of Operation 5-8 5.3.3 Screen Layout 5-9 5.4 SUBSYSTEM ANALYSIS PROCEDURE FOR TROUBLESHOOTING 5-34 LOCOMOTIVE COMPUTER CONTROLLED BRAKE EQUIPMENT FOR EMD/BN (Ref. NYT-1272-C) 6.0 EQUIPMENT REPLACEMENT 6-1 6.1 General Information 6-1 6.2 Replacement Procedures 6-1 6.2.1 General Procedures 6-1 6.2.2 DIT Valve Replacement 6-2 6.2.3 Brake Valve Controller 6-7 6.2.4 Computer Relay Unit 6-9 6.2.5 Pneumatic Control Unit Replacement 6-10 NYR-332 NYR-345 NYR-350 DECEMBER/01 ii IP-148-C CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL TABLE OF CONTENTS (Contd.) CHAPT/SECT TITLE PAGE 7.0 SYSTEM EQUIPMENT 7-1 Parts Lists Piping Diagrams Wiring Diagrams 8.0 NYAB/KNORR CCB - EMD - FAULT CODES 8-1 8.1 General Information 8-1 8.2 NYAB/KNORR CCB – FAULT CODES 8-2 8.3 Diag Sum Messages 8-4 8.4 AIR BRAKE FAIL INDICATIONS 8-5 8.5 AIR BRAKE FAIL CREW MESSAGES 8-5 8.6 AIR BRAKE FAIL DETECTION AND CLEAR 8-6 8.7 FAULT SET-UP OR CLEAR 8-8 8.8 MU OF CCB BRAKING SYSTEM 8-14 8.9 CLEARING FAULTS ON MU 8-14 IP-148-C iii DECEMBER/01 CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL LIST OF ABBREVIATIONS ABCB ...........................................Air Brake Circuit Breaker AD ................................................Analog to Digital AE1 ..............................................Automatic Emergency Switch NO. 1, N.C. AE2 ..............................................Automatic Emergency Switch NO. 2, N.O. AP ................................................Automatic Variable Handle Potentiometer AR ................................................Automatic Release Switch, N.O. AW4-ER .......................................Analog Converter Equalizing Reservoir AW4-16 ........................................Analog Converter 16 Pipe (control Pipe) BAN..............................................Battery Negative BAP..............................................Battery Positive BC ................................................Brake Cylinder BCCO...........................................Brake Cylinder Cut-Out Pressure Switch BCT..............................................Brake Cylinder Transducer BEA..............................................Binary Input Output BO1..............................................Bail Off Switch, Automatic BO2..............................................Bail Off Switch, Independent BP ................................................Brake Pipe BPCO...........................................Brake Pipe Cut-Off Valve BPT ..............................................Brake Pipe Transducer BVJ1-BVJ2...................................Brake Valve External Connectors C1 ................................................Communicator Connector CCB .............................................Computer Controlled Brake ° C................................................Degree Centigrade COMM..........................................Communications Cont .............................................Controller COR .............................................Cut-Out Relay CP ................................................Central Processor CRU .............................................Computer Relay Unit CS ................................................Continuous Service DB1 ..............................................Magnet Valve Driver Board PCB DB2 ..............................................Relay Driver PCB dc .................................................Direct Current DCV .............................................Double Check Valve DI ................................................Diagnostic PCB ELV ..............................................Emergency Limiting Valve DECEMBER/01 iv IP-148-C CCB EMD CONTRACT LOCOMOTIVE MAINTENANCE MANUAL LIST OF ABBREVIATIONS (Cont.) EMER...........................................Emergency EPA1............................................Automatic Application Analog Converter Driver PCB (AW4-ER) EPA2............................................Control Pipe Analog Converter Driver PCB (AW4-16) ER ................................................Equalizing Reservoir ERT..............................................Equalizing Reservoir Transducer EXH..............................................Exhaust Magnet Valve ES ................................................Emergency Sand Fig ................................................Figure FLT...............................................Flow Transducer FOJ1 ............................................Automatic Fiber Optic External Connector FOJ2 ............................................Independent