Download Amtrak Heritage Fleet Mechanical Schematics
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AMTRAK MAINTENANCE MANUAL SUPPLEMENT Section Section Section Section A B C D G-79-6 1203-72 1350-79 2900-97 10400-10403 February Baggage Car Baggage Car Sleeper Car Wheel Car 15, 1982 A-O-1 DRAWING HEP Conversion by RSI: Circuits Single Line and Heat 64 Volt Power System Trainline Circuits KC -312 KC-108 KC-122 Kc-g28 KC-956 KC-lO3 KC -305 KC-304 KC-318 KC-123 Selector Switch Wiring Nelco Heater Wiring AC Wiring 64V DC Single Line Schematic _7 Point Trainline Schematic Electric Locker Ceiling Lighting Wiring Reconversion By Beech Grove: Temperature Control Schematic Single-line Schematic 480V Junction Box 480V Trainline Schematic 27 Point Trainline Schematic Electric 480 Volt Locker Wiring Switchboard Lighting Switchboard Loop Relay Panel Marker Light Resistor Heat Contactor Panel Panel C-04-456 C-04-457 D-04-458 KC-301 KC-313 Baggage Car Arrangement Undercar Arrangement Receptacle Arrangement and 27 Point Cable Routing 480V Trainline Arrangement Heat Controls HEP LIST D-01-565 D-01-716 R-00-519 D-01-910 E-01-911 R-01-722 D-00-431 D-00-536 D-00-684 D-00-686 D-OO-7O4 sht. -I sht. -I B-O-I DRAWING Beech Grove Converted: Temperature Control Schematic Single-Line Schematic 480V Junction Box 480V Trainline Schematic 27 Point Trainline Schematic Electric Locker 480V Switchboard LIST Wiring Lighting Switchboard Loop Relay Panel _larker Light Resistor Heat Contactor Panel Panel D-01-915 D-o1-g12 R-00-519 D-01-910 E-Ol-911 E-04-913 D-00-431 D-00-536 D-00-684 D-00-686 D-00-914 Sht.-I Sht.-I C-0-1 AMTRAK MAINTENANCE MANUAL SUPPLEMENT 2900-97 This book is Manual #G-79-6. Most manual; things unique supplement. SECTION C SLEEPING G-79-6 CAR meant as a supplement to the Amtrak details of these cars are described to these cars are described here in Maintenance in the main the x_ C-0-3 Figure 0.1 Maintenance Manual Revisions DATE CHAPTER PAGES CHANGES C-0-5 TABLE OF CONTENTS Preface Title Table Page C-O-I C-O-5 Page of Contents CHAPTER i 1.0 1.1 List of Illustrations General Car Numbers 1.2 Floor Plans and Equipment CHAPTER Refer to Main 3 HEATING Page C-1-1 C-1-1 C-1-2 C-1-3 Weights 2 CAR VENTILATION BODY AND - List of General Illustrations Lamp Schedules Interior Fixtures Marker Lights Interior Consist Signs Exterior Consist Signs Switches Convenience Outlets Drawing List AIR CONDITIONING Page C-3-2 C-3-3 C-3-7 C-3-17 C-3-43 C-3-43 List of Illustrations General Air Conditioning Temperature Controls Shunt Trip Pilot Light Air Vaporizer Fans Refer to Main Manual Heating Air Distribution Dampers Drawing List CHAPTER i 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 GENERAL Manual CHAPTER i 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 I C-3-54 C-3-55 4 LIGHTING Page C-4-1 C-4-3 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-8 C-0-6 CHAPTER 5 COMMUNICATIONS AND PUBLIC ADDRESS Page C-5-3 General Tape Player Public Telephone Operating Instructions Audio Instruction Manual, Safetran Annunciator Drawing List CHAPTER i 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6 7 7 7 7 7 7 7 7 7 System System ELECTRICAL List of General 7 AIR BRAKE Page C-6-2 C-6-3 C-6-3 C-6-3 C-6-3 C-6-4 C-6-8 C-6-15 C-6-28 C-6-28 C-6-29 SYSTEM Page C-7-1 Illustrations Brake System Operation - Refer to Main Manual Carbody Components - Refer to Main Manual Truck Mounted Components Decelostat Wheel Slide Protection System Brake Condition Indication System Maintenance and Overhaul Procedures Brazing Pipe Procedures Refer to Main Manual Drawing List CHAPTER Refer CHAPTER C-5-3 C-5-4 C-5-4 C-5-4 C-5-4 C-5-4 SYSTEM List of Illustrations General 480 Volt Main Power Distribution and Cable System - Refer to Main Manual 27 Point Trainline Circuits Battery and Battery Charging System Transformers Switch Locker Electric Locker Food Service Electric Locker Panels N/A Service Procedures - Refer to Main Manual Drawing List CHAPTER i N/A N/A N/A N/A 9 8 to FOOD HANDBRAKE Main Manual SERVICE N/A EQUIPMENT C-7-3 C-7-3 C-7-3 C-7-3 C-7-13 C-7-23 C-7-23 C-7-23 C-7-23 C-0-7 CHAPTER Refer CHAPTER 11 10 to Main COUPLER Refer to CHAPTER Manual AND Main 12 List of Illustrations General Undercar and Interior Water Cooler Water Heater Insulation Water System - Food Service Water Draining, Filling and Refer to Main Manual 12.7 Drawing DRAFT GEAR Manual WATER i 12.0 12.1 12.2 12.3 12.4 12.5 12.6 SYSTEM Refer Refer Refer to to to Main Main Main Manual Manual Manual Refer to Main Manual Area N/A Flushing Instructions 13 TOILET Refer CHAPTER 14 to PERIODIC Main APPOINTMENTS Manual MISCELLANEOUS Refer 15 Page C-12-1 C-12-3 C-12-3 C-12-3 C-12-3 C-12-8 C-12-8 C-12-8 C-12-8 List CHAPTER CHAPTER TRUCKS to Main INSPECTION Refer to CHAPTER Refer Main 16 to Main EQUIPMENT Manual AND MAINTENANCE Manual RETROFITS Manual SCHEDULES C-I-1 CHAPTER i 1.0 1.1 1.2 1 List of Illustrations General Car Numbers Floor Plans and Equipment List 1.1 1.2 Floor Floor 1.0 Plan Plan and and of Equipment Equipment GENERAL Page C-1-1 C-I-1 C-I-2 C-1-3 Weights Illustrations Arrangement Arrangement Page C-1-I C-1-2 2900-41 2980-97 GENERAL This manual is prepared for converted to head end power beginning accomplished by the Amtrak facilities engineering was provided by Equipment DC. The systems were volt 3 phase The direct current electrical removed and the cars were head end power operation. maximum minimize Standard inventory Standard HEP I. 2. 3. 4. 5. 6. 7. 8. 9. I0. 11. 12. 13. the 31 conventional sleeping cars in June, 1977. Work was at Beech Grove, Indiana; Engineering, Amtrak, Washington, operating HEP equipment and facilitate Equipment speed equipment rewired is 105 was utilized maintenance. mph as and steam heating for all electric 480 for much the as cars. possible to Used: Power trainlines, receptacles and jumpers. 480 volt power junction box. Communication trainline receptacles and jumpers. Batteries and battery charger. Conductors signal pushbuttons. Marker lamps. Loop relays. Cars are equipped with 4 emergency sash units. Rooms equipped with new type rugged design industrial thermostat. All relays and contactors are stock General Electric most parts are interchangeable. Some transformers and circuit breakers. Air vane switch and klixon. Water antifreeze system. type and C-1-2 Features Floor ii To These Cars heaters. 2. Overhead 3. A/C heater _Do not interchange with Std. a. Freon b. c. d. A/C starter Compressor Condenser e. f. Evaporator No reheat out together, panel and blower Controls Switchboards 6. CF 7. P-3 8. No Fresh 9. No PA 10. Floor Heat Transformers HEP parts can be used). II. No 12. Water i.I Car - Lighting and 480 V (If all 3 are brakes Pneumatic Air Decelostat Damper Unit Brake Applied Heater (Some and Released parts Pressure common to changed Switches standard HEP cars). Numbers QTY New HEP Number Original Number Year Built 13 18 2900-41 2980-97 2600-41 2710-33 1949 1949 cars unit). 12 5. All HEP System: Temperature . Unique are 10-6 sleepers with similar appearance. Builder Budd Budd std. C-1-3 CHAPTER1.2 FLOOR PLANS, ARRANGEMENT OF EQUIPMENT AND CAR WEIGHTS LEGEND WC LK ELE SWB OHV HB WH Water Cooler Locker Electric Locker Switch Locker Overhead Unit (A/C) Handbrake Water Heater THERMOSTATS: RAT FAT FHT Return Fresh Floor LHT HHT OHT Layover Heat Thermostat Hall Heat Thermostat Overhead Heat Thermostat Air Thermostat Air Thermostat Heat The_rmostat _1_, 'A" END AMTRAK EQUIPMENT PLAN AND _.1_ SPECIFICATION DATA FOR CARS "B' END [LECTR!CAL SYSTEN BATTERY MODEL SYANDB¥ RCPT._ COMM EOUI_ . HEJ.D END POWER _l, NO TYPE" N/A ED/$ON ED-O0 4 r'-(G. i.t ..... ___, ...... I , I I 14.ovl [_ i ,(_ I_.ovl _._.o_._, ___.... r._ _.o_ T ..... a ..... ( "---_ '_-.' ..... 7 T ...... , ........ -I L- ........ j_f-gA-;1 _ _ _ UNDERBODY FORMER L- ..... f_--ll_._6._l<i=_lll 12.1I'l AMTRAK CARS' VIEW 2600,. (FORMER _--_J I i/ II-R _.sLJ II _ THROUGH - ,_..... ) ) , ,, "-..... _-_--i ....... l_-'r ..... _ ..... ; FLOOR 41 CARS_ UP 1401- 1449) EQUIPMENT ENGINEERING - FEBRUARY,1978 r.- I AMTRAK EQUIPMENT PLAN AND 'A' END" SPECIFICATION TOTAL DATA FOR WT." 'B' 17" BATTERY MOOEL VOLTAGE 64 LIGHT_NG WHEEL OiA.: 36" CLASS: JOURNAL _ BrU_RING TYPE: BOtSTER EPRn_GS, RE P{0ESTAL EOUALIZER ROLLER ADAPTER COMM SPRING SHOCKS" VERT, WEtG:_T FREEZE TYRE: _NTI FREEZE NO.: BRAKES TYPE:D8 CONTROL RELAY NO LAT. ¸ 'A" END, (CFM! VALVE _¢4_VE ANTt-SLIDE 'B' TYPE TYPE TrPE" F-6 AP-Jr OU_CK H_O NO' ENO_ -SGHEOULE O22 BRAKE C_I_INOER EOUIP ANTI TYPE: ¸ SERVM3E TyPE:PK SJZE ¸ • RO0 L B NO EDISON EO-80 NOM CAPY AC:F'LUOR SJZE: No: CARS TYPE" OE 80_4H /NC N/.4 ('_AFING [ I._E,41"//v_ TAPE T,4PE _4TER ° UNDER C.4R TANKS ,o/pING {2] END: _I c), I ,"L_ I I J---I. ¢_ I r :_'_ I I I_.t I ( j_ ' t I %w _l_ .( A,,,}r--3 BATTERY ._--:" !( A,R )I I .J_ ' .... b i I I I I .ATERTANK ' I . WATER _'_' TANK t_........ j' I r ......_-_ " I "F _- ( I "_'P--_" .... __ .... l J ........ _ I I-- BATTERY UNDERBODY FORMER (FORMER VIEW AMTRAK THROUGH CARS" CARS:SFE FLOOR ;>710-2753 1617-1632) ! I C-2-I CHAPTER Refer to 2 Main CAR BODY Manual C-3-I i 3.0 3.1 3.1.1 CHAPTER 3 HEATING, List of General Illustrations Air Conditioning Safety Co. A/C VENTILATION AND AIR CONDITIONING Page C-3-2 C-3-3 C-3-7 C-3-9 Manual 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 Temperature Controls Panel Description Thermostats 3.3 3.4 3.5 3.6 3.6.1 3.6.2 3.6.3 3.7 3.7.1 3.7.2 3.8 Shunt Trip Pilot Light Air Vaporizer N/A Fans - Refer to Main Manual C-3-43 C-3-43 Heating Overhead Heat Floor Heat Antifreeze Protection C-3-44 C-3-45 C-3-49 C-3-54 C-3-54 C-3-54 C-3-54 C-3-55 Blower Logic Cooling Logic Overhead Heat Logic Floor Heat Logic Damper Logic N/A Temperature Control C-3-17 C-3-17 C-3-23 C-3-30 C-3-30 C-3-33 C-3-37 wa_. Panel Manual Air Distribution Dampers Fresh Air Intake Damper N/A Annemostats Refer to Main Manual Drawing List C-3-41 C-3-2 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 CHAPTER 3 LIST ILLUSTRATIONS OF HEATING, VENTILATION AND AIR CONDITIONING Page# Fresh Air - Return Air Balance Air Filter Systems Safety Co. Evaporator Part List Safety Co. Condenser Part List Safety Co. Compressor Part List Temperature Control Panel Cover Temperature Control Panel Cover Instructions Pilot Lamp Assignment Temperature Control Panel Relay Functions Thermostat Types Thermostat Assignment and Function Heating and A/C Thermostat Thermostat Location Part List Cooling Control Points Air Vane Switch Overhead Heat Control Points Floor Heat Control Points Layover Heat Control Points Temperature Control Panel Manual Temperature Control Panel Part List Car Heating Capacity Overhead Heater Element Replacement & Part List Room Heat Local Circuit Breakers and Control Teleweld - Built Heaters C-3-4 C-3-5 C-3-10 C-3-11 C-3-12 C-3-19 C-3-20 C-3-21 C-3-22 C-3-25 C-3-27 C-3-28 C-3-29 C-3-31 C-3-35 C-3-36 C-3-38 C-3-39 C-3-41 C-3-42 C-3-44 C-3-46 C-3-51 C-3-52 C-3-3 CHAPTER 3.0 3 HEATING, VENTILATION & AIR CONDITIONING General NOTE: All HeatinB and A/C circuit breakers should remain on _ear round. While it may seem a good idea to turn off the A/C breaker in the winter or heating breakers in the summer, this is not the case. The temperature controls will turn on the heat or A/C as needed and have logic interlocks to prevent incorrect operation. Also, while it might be cool in one part of the country, it may be hot in another region. Many of the heating or cooling failures reported on HEP cars have been caused by breakers being off when they should not have been. of car Climate 4 operations: from control 1. Ventilation 2. Circulation 3. Filtration 4. Temperature for passenger comfort on these cars consists Control Ventilation is accomplished outside, replacing the stale by introducing fresh air being exhausted. air into the A one horsepower blower fan (unique to the 2900 cars) is located above the vestibule ceiling, and is responsible for car air circulation. It takes fresh air, normally 600 cfm, and mixes it with recirculated air, delivering 2,400 cfm to the car's main air duct. (See Fig. 3-1) The blower is also responsible for car pressurization. To keep dust and dirt out of the car, the car is kept slightly pressurlzed. Thus, all the tiny openings in the carbody will have a small draft flowing out through them, keeping dust and dirt Out. The car air is filtered to remove dirt and lint by the air filters. These cars use two sets of filters, one for fresh air, and one for recirculating air (See Fig. 3-2). It is very important to keep these filters clean (as well as the thermostats). Otherwise, the car air conditioning and heating system will not function properly. through side of Air Note that the air filters them in only one direction, the frame. Filter, 16" x 20" x 2" are as AMT meant to indicated #24A9001385 have air flowing by the arrows on AMMS # the EVAPORATOR COIL -- / FRESH AIR 600 CFM / -- HEATING COIL 4 2400 Z BLOWE R '#MAIN CFM '====¢> DISTRIBUTION DUCT RETURN AIR 1800 CFM FIGURE FRESH 5.1 AIR / RE TURN AIR BALANCE ('b I OJ I eu _- FRESH AIR c-3-5 i F,LT fi _/_ / L , FI LTER BLOWER GRILL DUAL FILTER AIR The direction, car filter however it FIGURE FILTER frame is 1. Fresh Air opening. 2. Return air should SYSTEM 5.2 SYSTEM indicate correct air flow always: Filter - air flows into grill air flows up the through car from this this opening. Temperature control is accomplished through the use of refrigeration or electric heat. Each car has one 8-ton cooling located in the ceiling. Heating is accomplished by a combination overhead and floor heat, independently controlled. heating, A single cooling temperature control and ventilation. panel controls all aspects unit of of C-3-7 3.1 Air Conditionin 9 Each car is conditioning system. interchangeable with equipped with a single Safety Co. 8-Ton The system uses R-12 and parts are not the freon-22 system of later converteTHEP air cars. Evaporator The push-through evaporator is located almost above the vestibule of the car, along with the direct drive blower fan. The evaporator is split into two stages for 1/2 and full cooling. Included with the overhead assembly are the modulation valve, a moisture/flow indicator and strainer. The unit is also equipped with a two stage overhead heater. Condenser the (on The air coil itself, the back). cooled condenser is located the fan and motor, and the undercar, modulation and consists of pressure switch Compressor The open-frame compressor and near the condenser. Included undercar, controls. Startin 9 drive with motor it are are located the pressure Panel The includes the contactors. The I. . A/C starter panel is located in the electric locker A/C logic relays, blower fan, compressor, overhead Refer to Figure 6-14 for parts. A/C logic Lockout Overload compressor reset is includes below the following 50 .° outside air safety features: temperature. relays for blower fan, condenser fan motors to protect against overload. required on each. 3. Air Vane evaporator Switch & Blower Fan freeze-up, should 4. Low pressure resetting. 5. High pressure resetting. shutdown shutdown (but (but interlock the blower not not and lockout) lockout) and Manual to prevent fail to operate. self - self C-3-8 Freon Charge The weight of a full 40 Compressor both charge of with For a complete description list and maintenance instructions, Section 3.1.1. For 3.6. A/C system tests, DESCRIPTION Freon Freon 11 Brazing Alloy Silicon Compound refer to be Amtrak utilized # test MANU. Terminal oz tube Handy Harmon & # spec. as well as parts Co. Manual, P0-79-I AMT 47L9001790 ........ ("Silver Solder") AMMS in can be safely intermixed, (except WFI 32) oils should when being replaced with pumped) CF CL Kit 2 may - ....... (Water 220 Test oils of the A/C system refer to the Safety MANU. 12 Nitrogen Acid approximately: Texaco Although Sunisco 3GS and Capella B other grades of Sunisco and Texaco not be mixed, but should be drained the standard oil. and is Oil Until further notice, the following Amtrak air conditioning systems: Sunisco 3GS Note: 12 pounds Texaco, Type Capella B* * Capella B may be replaced 3.3 freon 47BgOO34gg SILFOS Safety T15583 Dow- #3 25A4000275 tests # 3.2, AMMS# C-3-g Section Operating 3.1.1 Instructions Safety 8-Ton Co. Air Conditioning Weight of Compressor Condenser Evaporator 40 Sunlsic Texaco Texaco Valve Coil Manual Type System 12 Full Approx. Solenoid Service Component Freon Oil: & Charge pounds 3GS Capella WFI32 Resistance Motor Resistance Fan Motor Resistance Fan Motor Resistance ohms ohms ohms ohms Figure 3.3 A/C EVAPORATO_ - SAFETY CO. PART LIST ITEH QTY 1 1 1 I 4 2 DESCRIPT[ON Refer to Safety Nanual for Further Part Lists Evaporator Blower Fan & Motor Unit Cemplete (Not same as ether HEP cars) Air Flow Switch Blower Wheel Left Blower Wheel Right Hotor 1HP 480V 3_, 1.5A, 1725 RPH, 182T Resilient le_untSat (Frame to Car) Shaft Extension Assembly HFG HF6 # M4T | Safety B-1434-15 23X9012879 09ontz Safety Safety Baldor Safety Safety 8373-214 T-1793-4 T-1793-3 38N73-287 T-13706-5 T-14037-3 25H9012249 25H9011513 1 Evaporator Unit Complete Electric Heater Unit (Not same as other BEP cars) Safety Safety B-1444-17 8-4319-1 25T9011509 25P9011518 1 2 2 2 Overheat Thermostat "Kltxon" 200° Expansion Valve (ALCO) Expansion Valve Power Element Expansion Valve Cage Texas Inst. Safety Safety Safety C439157442-0_ T-3695-1 T-7339-1 T-11S_ 231)9006951 251.9011519 14 15 Modulation Solenoid Valve Solenoid Valve Coll Safety Safety T-3330-1 T-7820-4 25K9011514 25E9011515 16 17 18 Strainer, Hotsture Flexible Safety Alco Safety T-15531 MI-1SSS B-4409 23A4000306 23A4000305 Reeves Bros. Aerotube 2209 -- 23X9007382 46N9001208 10 I1 12 13 "19 20 1 AR ..mmmk Liquid Indicator Duct - Blower to Evaporator Flexible Duct - Evaporator to Car Duct, Insulation, 2 1/8" ID Fom, l/Z ° Wall "Flextduct _ AJeIS # ! _o I A/C ITErl QTY DESCRIPTION Refer to Safety Co. Manual for further Figure 3.4 COI_DENSER PART LIST MFG MFG # Safety Safety B-2442-14 B-1566 Safety Baldor Safety M-1890-2 T-12967-2 T-13706 163748 8 Ton Dry Condenser Condenser Coil Unit 3 4 5 Fan Motor - Condenser Liquid Receiver 6 7 8 Sight Glass, Receiver Resilient Mount Set Pressure Switch, Modulation Safety Safety Safety 9 10 11 Filter Drier Ass(_nbly, Complete Gasket, Outlet Core Retaining Plate Gasket, End Plate Safety Safety Safety 12 13 14 Core, Filter Drier Shut Off Valve, Liquid Line at Drier Vibration Eliminator, Liquid Line Safety Safety Safety 15 16 Vibration Eliminator, Hot Gas Line Sight Glass/Moisture Indicator Safety Safety 2HP, 1725 RPM # AMMS # Details I 2 Fan, AMT 3.1A 25K9010511 25T9011512 M-1782 25A9001569 I {# 4 Figure3.5 A/CCOMPRESSOR AND COMPRESSOR UNITPART LIST ITEM QTY DESCRIPTION For Further MFG MFG # B-3988-4 161705 AMT # 1 2 I I Details, Refer to Safety Manual Direct Driven Compressor Unit, 8 Ton Compressor (Form 5295) 5F40 ............ Safety Safety 3 4 5 I I I Coupling, Thomas Motor, 15 HP, 1760 RPM, Resilient Mount Set Safety Baldor Safety 161685 6 7 8 1 (I) (1) Refrigeration Controls High Pressure Gauge Low Pressure Gauge Safety Safety Safety B-289g-2 T-16284-I T-16283 25A4000064 25A4000065 9 10 11 (I) (I) (I) Manual Selector Switch High Pressure Switch 30-270 PSI Low Pressure Switch 20" Vacuum - 120 PSI Safety Allen Bradley Alien Bradley S-8816-2 836 HI1 XHCS 836 ALl1NKCS 25X9011517 25A8000451 25D9006178 12 13 14 (I) (I) (2) Box Cover Box Seal Service Valve Safety Safety Safety T-2964 T-1816g 114 115 I I 2 REF Vibration Vibration Compressor, Eliminator, Eliminator, 19-7A, 480/3/60 Assembly, Complete Suction Line Discharge Line 5F40 New Built Rebuilt 15A 15B 16A 16B I I 4 4 Suction Shut Off Valve, Suction Shut Off Valve, Cap Screw for Item 15A, Cap Screw for Item 15B, 1 5/8" 1 5/8" 20A 20B 17 18 19 1 2 2 Gasket, Cap Screw (Item 15) Valve Cap (Item 15 and 20) Valve Cap Gasket (Mueller) (Henry) AMMS # 25N9010510 25X9011511 T-13623-2 Safety Safety Safety Safety 161705 T-11902-I Safety Safety Safety Safety 162481 T-4945 162482 54825 Safety Safety Safety 151303 T2467 T2466 C_ I A/C 20A 20B 21 Shut Off Valve, Shut Off Valve, Gasket, Suction COMPRESSOR Figure 3.5 AND COMPRESSOR Page 2 Discharge (Mueller) Discharge (Henry) or Discharge Valve to Crankcase UNIT PART LIST Safety Safety Safety 162480 T4924 162497 Replacement Gasket Set Main Bearing, Seal End Dowel Pin, Valve Plate Oil Return Check Valve Package Safety Safety Safety Safety 162510 161978 T-2464 162126 22 23 24 25 -(I) (4) 2 26 27 28 2 1 1 Cylinder Head Gasket Suction Strainer _ssembly Oil Filter Screen Package Safety Safety Safety 162487 162032 T2455 Z9 30 31 1 1 6 Manifold Cover Gasket Oil Regulating Valve Package Cap Screw 3/8 - 16 x i" (Manifold Safety Safety Safety 162486 T2465 157557 32 33 34 28 34 I Cap Screw 3/8 - 16 x 3" (Cylinder Cap Screw Gasket (3/8) Shaft Seal Package Safety Safety Safety 162424 151286 T1401 35 36 37 38 8 I (I) (i) Cap Screw 3/8 - 16 x I - I/4 (Shaft Seal Cover) Bearing Head and Oil Pump Assembly Includes: Bearing Head Gasket Main Bearing, Pump End Safety Safety Safety Safety 151375 T2462 162493 162429 39 40 41 (3) (12) (6) Cap Screw Gasket (518") Cap Screw Gasket (3/8") (Bearing Head) Hex Head Cap Screw I/4 - 28 x 3/4 (Oil Pump Cover) Safety Safety Safety T2466 151286 164363 42 43 44 45 46 (6) (1) (1) (I) (1) Cap Screw Gasket (1/4") Dowel Pin (Bearing Washer) Oil Pump Package (Matched Parts) Oil Pb_np Cover Gasket Bearing Head Gasket Safety Safety Safety Safety Safety 163534 T2463 T13006 T12652 162493 Cover) Head Suction Manifold) I L_ A/C 47 48 49 5O 51 52 53 54 55 56 57 58 59 60 61 62 12 I I Hex Head Cap Screw (318 - 16 x 1-314") Cover) Woodruff Key #21 Retaining Washer (3/8") COMPRESSOR (Bearing Head Figure 3.5 AND COMPRESSOR Page 3 UNIT PART LIST Safety T245g Safety Safety 162505 162450 1 1 4 Lockwasher (318") Cap Screw (3/8 - 24 x 7/8") Connecting Rod and Bearing Package Safety Safety Safety 4411 162502 T2451 1 1 1 Bearing Washer, Pump end Seal End Thrust Washer (steel) Seal End Bearing Washer (bronze) Safety Safety Safety 162461 162460 162459 4 1 Piston and Pin Package (UnassembledJ Piston Ring Package Includes: Compression Ring Oil Ring Safety Safety Safety Safety 162462 T7690 ----- 2 Valve Valve Valve Safety Safety Safety T2453 --162488 Safety Safety Safety 162487 162468 162469 (l) (1) Plate Package Plate Plate Gasket Includes: 63 64 65 (I) (2) (12) 66 67 68 69 {6_ (4) (6) (2) Guide Lockwasher Suction Valve Clip Cap Screw I/4 - 28 x 1 (Guide to Valve Plate) Discharge Valve Guide Assembly Includes: Safety Safety Safety Safety 162476 161984 162426 T13007 70 71 72 (1) (1) (6) Discharge Discharge Discharge Safety Safety Safety 162471 162472 162474 Cylinder Head Suction Valve Suction Valve Gasket Disc Spring Valve Guide Valve Valve Spring I A/C UNIT PART LIST 162475 162425 162478 Dowel Pin - 1/4 x I/2" (Guide) Cap Screw 3/8 - 16 x I (Valve Plate to Crankcase) Cap Screw Gasket (3/8") Handhole Cover and Sight Glass Assy. Includes: Safe ty Safety Safety Safety 163519 157557 161286 162426 Sight Glass Sight Sight Glass Glass Assembly Gasket Safety Safety Safety T13004 T12670 T12671 Safety Safety Safety 163527 163532 Socket Head Cap Screw {5/16 - 24 x 1 - 7/B") Cap Screw Gasket (5/16") Control Valve Assy. Package Includes: Valve Gasket, Inner Safety Safety Safety Safety 164368 164359 164360 163533 (I) (3) (I) Seal Lock Plate Cap Screw (1/4 - 28 x I") (Lock Plate Dowel Pin - 3/16 x 3/4 (Guide) 76 77 78 79 (i) (4) (4) I 80 81 82 {1) 83 84 85 1 (I) (I) Handhole Cover and Control Handhole Cover Gasket Hydraulic Relay (1) 86 87 88 89 Figure 3.5 AND COMPRESSOR Page 4 Safety Safety Safety 73 74 75 1) I) COMPRESSOR Package to Guide) Includes: Valve Assem. Includes: 90 91 92 (1) Valve Gasket, Outer Control Valve Assembly Includes: Spring (7# - for R-12 and R-500) Safety Safety Safety 163531 164361 163529 93 94 95 {i) (i) External Valve Assembly Valve Body wlth Bellows Cap Screw 3/8 - 16 x 2 - I/4" (Handhole Safe ty Safety Safety 163528 164362 162423 96 97 98 99 24 1 3 18 Safety Safety Safety Safety 151286 162490 163535 163536 24 Cap Screw Gasket 3/8" Handhole Cover Gasket Unloader Sleeve Valve Lifter Spring (Handhole Cover Cover) with Sight Glass) c) I C_ i A/C COMPRESSOR Figure 3.5 AND COMPRESSOR Page 5 UNIT PART LIST 100 101 102 18 3 (3) Valve Lifter Pin Unloader Power Element Lockwasher (I/4") Safety Safety Safety 103 104 105 (3) (1) (I) Socket Head Cap Screw 1/4 - 28 x I - 3/4" Cotter Pin (II16 x 318") Plate Washer Safety 5a fety Safety 106 107 108 (I) (I) 3 Clevis Pin Unloader Fork Unloader Bracket Safety Safety Safety 163526 T2457 163530 109 6 Safety 163521 110 111 6 1 Socket Head Cap Screw 1/4 - 28 x i" (Unloader Assby to Crankcase) Cap Screw Lock_asher (I/4") Dust Seal Package Safety Safety T9400 T2661 Insulation, Oil Aerotube Sunisco Texaco Texaco --3GS Capella-B WFI32 112 113 Gasket Foam 2 I/8" ID Foam, I/2" Wall OR 163537 163524 T9400 46N9001208 F) I _O I 0_ FORM 5774 OPERATING INSTRUCTIONS AND SERVICE MANUAL "SAFETY" COMPONENTTYPE 8 TON - REFRIGERANT 12 AIR CONDITIONING SYSTEM AMTRAK REFURBISHED CARS ARRANGED FOR OPERATION AT 460/3/60 AND 120/I/60 POWER SUPPLY CONTROL VOLTAGE (4/78) General Safety the Electrical conditions the and Equipment warranty provided Terms Corp. made following Conditions will at the procedures of Warranty only time and be of responsible sale of conditions this are under equipment, met by the buyer: (1} All equipment specified the (Z) i"n the items accepted All items the serviced Service and properly, Instruction not specifically maintenance having practice a normal electrical warranty covered must wear contacts, in as Manual factor, etc. for do not come be responsible for any loss Safety will not be responsible for any defective used Safety writing by will by as to. motor brushes, under the terms conditior_s. not approved manual, adhered such will parts this be Safety the (6) and "Safety" are good bearings, (4) maintained equipment. Where of is for maintenance or repair of are refrigerant. equipment furnished unless or Safety. accept the no Company return or of its equipment agent. unless authorized in I In order to maintain "SAFETY" ELECTRO-MECHANICAL AIR CONDITIONING EQUIPMENT in proper condition, a schedule for servicing and inspection should be established and followed. Operating conditions will vary on different railroads, so a suitable schedule will have to be based on experience. It is hoped that this manual will serve as a guide to setting up a good maintenance program... Information such as maintenance procedures, wiring diagrams and tools to facilitate disassembly and reassembly, has been included to assist the maintenance forces in proper care of this equip_lent. When supplemental information concerning "SAFETY" ELECTRO-MECHANICAL AIR CONDITIONING EQUIPMENT is required, it can be obtained from any of our District Offices... "SAFETY"COMPONENT TYPE INDEX OF AIR CONDITIONING SYSTEM SECTIONS PAGE TITLE SECTION I THE REFRIGERATION SECTION II DESCRIPTION I. 2. 3. A. B. II-I OF EQUIPMENT General Description Description Motor I. 2. 3. 4. 5. 6. I-l CYCLE of Operation of Components II-l II-l II-l MAIN COMPONENTS II-l Compressor Unit - Cat. No. B-3988-4 Adapter Frame - Cat. No. M-5999-3 Compressor - Cat. No. 161705 Compressor Motor - Cat. No. T-18554 Flexible Coupling - Cat. No. 161685 Refrigeration Controls - Cat. No.B-2899-2 Support Bracket - Cat. No. B-I023 Air Cooled Condenser - Cat. No. B-2247-I0 I. Condenser 2. 3. Liquid Receiver - Cat. No. M-1782 Condenser Fan and Motor C. Evaporator I. 2. O. & Blower Assembly-Cat.No. II-2 II-2 II-2 II-2 II-2 II-3 II-3 II-3 II-3 II-3 B-1444-17 II-4 Electric Heat Assembly - Cat. No. B-4319-I Evaporator Coil Assembly - Cat. No. M-4142-I II-4 II-4 (a) (b) (c) 3. 4. 5. Coil - Cat. No. B-1566 II-l Evaporator Coil - Cat. No. B-2488-I Expansion Valve - Cat. No. T-3695-I Modulation Control Solenoid Valve T3330-II Drain Pan - Cat. No. M-1485-I Flexible Plenum - Cat. No. B-4409 Blower and Motor Assembly - Cat. No. B-1434-15 Motor Start and Control SYSTEM Panel Assembly II-4 II-5 II-6 11-6 11-6 II-6 II-7 AUXILIARIES a. b. c. d. Moisture and Liquid Indicator Liquid Line Solenoid Valve Liquid Line Strainer Assembly Check Valve II-7 II-8 II-8 II-9 e. f. Liquid Line Filter-Drier Flexible Tube Line Connectors II-9 II-9 o INDEX OF SECTIONS TITLE SECTION Ill III-l OPERATION Operating III-2 Instructions III-2 III-2 III-3 Initial Starting Check Starting Instructions Nominal Operating Data SECTION IV ROUTINE SERVICE IV-l INSTRUCTIONS IV-l IV-l IV-l IV-l Weekly Servicing Monthly Servicing Annual Inspection Preparations for Winter SECTION V TROUBLE DIAGNOSIS V-I CHART High Head Pressure Low Head Pressure High Suction Pressure Low Suction Pressure Frequent Noises Cycling Compressor is Noisy Compressor Will Not Start Cylinders and Crankcase Sweating Failure to Cool Air Circulating SECTION Vl MAINTENANCE I. Fans Not Operating AND SERVICE INSTRUCTIONS V-I V-I V-I V-2 V-2 V-2 V-3 V-3 V-3 V-4 V-4 VI-l VI-l General al PAGE Safety (I) Importance of Dehydration (2.)Use of Alcohol (3) Grease Solvents (4) Soldered Connections (B) Opening the System (6) Evacuating Air From The System (7) Testing for Leaks (B) To Add Refrigerant to the System VI-l VI-l VI-I Vl-2 VI-2 VI-2 VI-2 VI-3 VI-3 (a) Low Side Charging (Vapor) (b) High Side Charging (Liquid) (g) Removal of Non-Condensable Gases (lO) Adding or Removing Oil Vl-4 VI-4 VI-5 VI-S (a) Compressor ii Lubrication VI-5 INDEX OF SECTIONS TITLE SECTION Vl MAINTENANCE AND SERVICE Servicing the Motor Assembly 2, a. b. c. d. e. f. g. h. Components Servicing Condenser the CompressorVl-6 Modulation b. (I) (2) (3) Coil 5. Repairing 6. Safety the Air VI-15 Cooled Vl-17 Vl-17 From The Unit VI-19 VI-20 VI-20 the Motor the Motor VI-21 Pump Down To Remove Refrigerant To Remove Receiver To Replace Receiver Coil of the Vl-21 VI-22 VI-23 VI-24 Evaporator and VI-25 Assembly Evaporator Coil (a) To Remove Expansion Valves Evaporator Coil Blower Motor (a) Maintenance (b) To Remove (c_ To Remove the VI-25 Coil Assembly Modulating the the Motor Blower Solenoid Valve Wheels Leaks Precautions VI-17 Vl-17 VI-18 VI-19 Receiver Evaporator (2) (3) (4) Switch Maintenance Servicing Components Blower Assembly (I) of Vl-12 VI-12 VI-13 VI-14 VI-15 Fan Motor Maintenance To Remove To Replace Liquid (I) (2) (3) (4) Vl-6 VI-6 VI-7 VI-7 VI-7 Vl-8 VI-12 To Clean the Condenser Coil To Remove the Condenser Coil To Replace the Condener Coil Condenser c, Control the Components Assembly Condenser (I) (2) (3) a. of (continued) Description (a) Selector Switch (b) Gauge and Valve Assembly (c) Dual Pressure Control Adjustments (d) Repairs Pressure a. 4. INSTRUCTIONS To Remove the Motor To Remove the Compressor To Replace the Compressor Compressor Compressor Service Valves Flexible Coupling Alignment Refrigeration Controls Assembly (I) , PAGE VI-25 VI-25 VI-26 VI-29 VI-29 VI-29 VI-29 VI-30 VI-30 in iii Handling Refrigerant 12 VI-33 INDEX OF SECTIONS PAGE TITLE SECTION Vll VII-l AIR CONDITIONING STARTER PANEL Air Conditioning Starter Panel Operation VII-l Air Conditioning Starter Panel Troubleshooting VII-2 iv LIST OF ILLUSTRATIONS TITLE SECTION I THE REFRIGERATION Table I-I Physical Figure l-I Diagram SECTION II CYCLE Properties of Refrigerant of the Refrigeration DESCRIPTION II-I Motor Figure 11-2 Air Cooled Condenser Figure 11-3 Evaporator & Blower Compressor III OPERATION Table III-I Pressure Control Table 111-2 Operating Data SECTION VI I-2 12 I-3 Cycle OF EQUIPMENT Figure SECTION PAGE MAINTENANCE Unit (Type Unit II-ll (Type B-2447) Assembly Switch II-lO B-3988) (Type B-1444) III-2 Settings (Nominal) AND SERVICE II-12 III-3 INSTRUCTIONS Figure VI-] Compressor Figure Vl-2 Flexible Coupling VI-8 Figure Flexible (Caliper Coupling Alignment and Straight Edge) Vl-lO Coupling VI-3 Service VI-8 Valve Figure VI-4 Flexible Figure VI-5 Refrigeration Figure VI-6 Range and Differential Adjustment Pressure Control Switch Figure VI-7 Wiring Figure VI-8 Pressure Alignment Control Diagram (Alignment Modulation Control Vl-ll _I-12 Assembly - Refrigeration Gauge) - Controls Switch VI-13 VI-15 VI-16 F_gure VI-9 Condenser Fan Motor VI-19 Figure Vl-IO Expansion Valve VI-28 V APPENDIX FIGURE DIAGRAMS Schematic - Refrigerant Schematic - Wiring l Flow - MSK-2396 Diagram 2 - B-4302 FORM NO. PARTS LISTS Air Cooled Condenser Direct Condenser Fan Motor Driven Motor Evaporator & Blower - Fan Motor Flexible - Cat, Cat. Assembly - Coupling Cat. - No. B-2447 type Unit - Cat. No. B-3988 Cat, No. Cat. No. 5775 B-1444-17 5784 Motor and Control 5310-A 161685 Assembly Panel 5776 5782 T-18554 - 5777 5783 No. T-16807-I Controls Starter Cat. No. T-16822 No. Refrigeration SERVICE - Motor-Compressor Compressor Blower Assembly - Cat. No. B-2899 type - Cat. No. B-4290-1 5310-A 5779 INSTRUCTIONS AND PARTS LIST Compressor I. 2. 3. - Cat. 5297 161705 Servicing the Compressor Capacity Control for Unloading Parts List Service Manifold Solenoid Valve Filter-Drier Instructions in Blast Rubber No. Gauge Assembly - Cat. No, Assembly - for Field Coil Heaters Bladed Fan - Cat. - Compressor Cat, No. 5285 T-12497 5453-A T-3330-II Cat. No. 5287-A 163088 Replacement of Resistance Coils 5634 No. M-3897-4 vi 5778 SECTION 1. THE REFRIGERATION CYCLE SECTION THE REFRIGERATION 1 CYCLE The refrigeration cycle is based on the principle that a volatile liquid, in evaporating or changing from a liquid to a vapor, absorbs heat. For example, wetting the hand and blowing upon it will produce a sensation of coolness. The evaporation of the water requires heat which is taken from the hand, causing a lowering of the temperature. There are many liquids which can be used to produce cooling ing them to change from a liquid to a vapor, but some are better by caussuited for use in a refrigerating system than others because of their physical and chemical properties. A refrigerant suitable for use in an air conditioning equipment should have the following characteristics: I. 2. 3. 4. 5. 6. 7. Non-flammable. Non-explosive. tlon-toxic Stable. l,_ustnot combine with material used in the equipment. Require low or moderate operating pressures. Be readily available. Refrigerant 12 possesses these qualities and is, therefore, commonly used in air conditioning systems. The temperature pressure relation for this refrigerant is shown in Table on Page I-2. The flow of refrigerant through the cycle may be traced by reference to Figure 1, Page I-3. Liquid refrigerant flows from the receiver through the expansion valve to the evaporator. The pressure in the receiver is higher than the pressure in the evaporator and the expansion valve automatically regulates the flow as called for by the conditions of pressure and temperature in the evaporator. In the evaporator the cooling effect takes place upon change of state of the refrigerant from a liquid to a vapor during the heat transfer process between the air to be cooled and the refrigerant. The expansion valve admits sufficient refrigerant such that all liquid has evaporated prior to leaving the coil. The air circulating evaporator surface. through the car is cooled by passing it over the The refrigerant vapor formed in the evaporator is removed by the action of the compressor. On the down or suction stroke of the compressor I-I Pressure Tcm_. I;>SqlitT *F. I0 12 |4 16 18 29.35 30.56 31.80 33.08 34.40 14.65 15.86 17.10 18.38 19.70 0.0112 ,0112 .0112 .0112 .0113 1.351 1.301 1.253 1.207 1.163 89.45 89.24 89.03 88.81 88.58 0,7402 .7687 .7981 .8288 ,8598 20 22 24 26 28 35.75 37.15 38.58 40.07 41.59 21.05 22.45 23.88 2_,.37 26.89 0.0113 .0113 .0113 .0114 ,0114 1.121 1.081 1.043 1.007 0,973 88.37 88.13 87.91 87.68 87.47 0.8921 .9281 .9588 .9930 1.028 3O 32 34 36 38 43.16 44.77 46.42 48.13 49.88 28,46 30,07 31.72 33.43 35.18 0.0115 .0115 .0115 ,0116 .0116 0.939 .908 .877 .848 .819 87.24 87.02 86.78 86.55 86,33 1.065 1.102 1.140 1.180 1.221 40 42 44 46 48 51.68 53.51 55.40 57.35 59.35 36.98 38.81 40.70 42.65 44.65 0,0116 .0116 .0117 .0117 .0117 0.792 .767 .742 .718 .695 86.10 85.88 85.66 85.43 85.19 1.263 1.304 1.349 1.393 1.438 50 52 54 56 58 61.39 63.49 65.63 67.84 70,10 46.69 48.79 50.93 53.14 55.40 0.0118 .Ol 18 .0118 .0119 .0119 0.673 .652 .632 .612 .593 84.94 84.71 84.50 84.28 84.04 1.485 1.534 1.583 1.633 1.686 60 82 64 66 68 72.41 74.77 77.20 79.67 82.24 57.71 60.07 62.50 64.97 67.54 0.0119 .0120 .0120 .0120 .0121 0.575 .557 .540 .524 .508 83.78 83.57 83.34 83.10 82.86 1.740 1.795 1.851 1.909 1.968 70 72 74 76 76 54.82 87.50 90.20 93,00 95.85 70.12 72.80 75.50 78.30 81.15 0.0121 .0121 .0122 .0122 .0123 0.493 .479 .464 .451 ,438 82.60 82.37 82.12 81.87 81.62 2.028 2,090 2.158 2.218 2.284 60 82 84 88 65 98.76 101.7 104.6 107.9 I 1 I_ 1 84.06 87.00 90.1 93.2 96,4 0.0123 ,0123 .0124 .0124 .0124 0.425 .413 ,401 .389 .378 81.39 81.12 80.87 80.63 80.37 2.353 2.423 2.495 2.569 2,645 90 92 94 96 98 114.3 117.7 121.0 124.5 128,0 99.6 103.0 106,3 109.8 113.3 0.0125 .0125 .0126 .0126 ,012(_ 0.368 .357 .347 .338 ,328 80.11 79.86 79.60 79.32 79.06 2.721 2,799 2.880 2.963 3.048 I00 102 104 106 108 131.6 135.3 139.0 142.8 146.8 116.9 120.6 124.3 128.1 132.1 0.0127 ,0127 .0128 0.319 ,310 .302 t0128 .0129 .293 .285 78.80 78.54 78.27 78.00 77.73 3.135 3.224 3.316 3.411 3.509 I10 112 114 116 118 150,7 154.0 158.9 163.1 167.4 136,0 140.1 144.2 148.4 152.7 8.0129 .0130 .0130 .0131 .0131 0.277 .269 .262 .254 .247 77.46 77.18 76,89 76.60 76.32 3.610 3.714 3,823 3.934 4.049 120 122 124 126 128 171.8 176.2 180.8 185.4 190:1 157.1 161,5 166.1 170,7 175,4 0.0132 .0132 .0133 .0133 .0134 0.240 .233 .227 .220 .214 76.02 75.72 75.40 75.10 74.78 4.167 4.288 4.413 4.541 4.673 130 132 134 136 138 194.9 199.8 204,8 209.9 215.0 180,2 185.1 190.1 195.2 200.3 0,0134 .0135 .0135 .0136 .0137 0.208 .202 .196 .191 .185 74.46 74.13 73.81 73.46 73.10 4.808 4.948 5,094 5.247 8.409 140 220.2 205.5' 0.0138 0.180 72.73 8.$71 TABLE I-2 Voluml Abs. ib./in.Z I-1 Ca|e Ib./inJ Liquid f t.I/Ib, Vapor ft. J/lb. Liquid Ib./11.) PHYSICAL PROPERTIES OF Vapor lb./ft. REFRIGERANT I 12 piston, the cylinder is filled with vapor and on the up or discharge stroke, this vapor is compressed and discharged into the condenser. As the pressure is increased, the temperature likewise is raised due to the work done on vapor by the compressor. The process which takes place in the condenser is the reverse of that in the evaporator. In the latter, heat is ADDED to the liquid, causing it to vaporize. In the condenser, heat is ABSTRACTED from the vapor causing it to condense to the liquid state. This heat is removed by passing outside air over the condenser surface. COLD LIQUID REFRIOERANT ¢OOL EX_NeJON_LVE (HOT GAS) ;0MPRESSOR HOT LIQUID 3[RANT (HOT FIGURE LIQUID) I-I RECEIVER DIAGRAM OF REFRIGERATION CYCLE I-3 SECTION 2 DESCRIPTION SECTION DESCRIPTION . OF EQUIPMENT 2 OF EQUIPMENT GENERAL The "Safety" component type 8-ton (Refrigerant 12) electromechanical system consists of a separately mounted Motor-Compressor Unit, and a Condenser Unit applied underframe, together with an Evaporator and Blower Assembly which is mounted above the ceiling area at one end of the car. The motors are arranged for operation on 460/3/60 power supply and a control voltage of 120/I/60 hz. MAIN COMPONENTS 2. CAT. NO. I. Motor Compressor 2. Air Cooled Condenser 3. Evaporator and Blower 4. Motor Control DESCRIPTION B-3988-4 Unit Panel Unit Assembly B-2247-I0 B-1444-17 B-4290-I OF OPERATION To deliver conditioned air to the interior of the car body, a mixture of recirculated air, (returned from the car body) and outside air is filtered, passed through the evaporator and electric heat surfaces by the blower fans and discharged into the overhead centerline air distribution duct. By absorbing heat taken from the air, the liquid refrigerant from the receiver is vaporized in the evaporator. This cools and conditions the leaving air which is then ducted into the car body. The refrigerant vapor leaving the evaporator is returned sor where it is forced to higher temperature and pressure discharged into the condenser. This compressed vapor is in thecondenser by drawing outside air through the coil liquid refrigerant returns to the receiver and the cycle 3. DESCRIPTION to the compreslevels and then liquified surface. The is repeated. OF COMPONENTS MAIN COMPONENTS A. Motor-Compressor Unit - Cat. No. B-3988-4 Included in this unit are an adapter frame, compressor, motor, flexible coupling, refrigeration controls, and supporting bracket. The motor is flanged mounted to the bracket which holds the compressor to form a rigid unit as shown in Figure II-l. The assembly is isolated from the underframe support members by resilient mounts. II-I I. Adapter Frame - Cat. No. M-5999-3 The adapter frame is a rugged steel weldment which is secured to the undercar support membersto provide the mounting structure for the resiliently mounted motor and compressor assend)ly. 2. Compressor - Cat. No. 161705 The compressor is a Carrier manufactured four cylinder, air cooled, open, "Vee-type", with forced feed lubrication and is powered by an external driving motor. To match the requirements of the system, variations in capacity are obtained by the operation of a built-in cylinder control mechanism. Power for this control unit to load or unload three cylinders in sequence is obtained hydraulically from the forced feed lubrication system in response to changes in the suction pressure. The principles of operation and maintenance procedures for the compressor equipped with capacity control mechanism are included in the Appendix, Form 5297. 3. Compressor Motor - Cat. No. T-18554 The compressor motor operates on 460/3/60 hz power, is a NEMA D-flange type, totally enclosed fan cooled, frame size 254T, and is rated 15 horsepower at 1760 RPM. Class "B" insulation is used and the design full load power is approximately 13 HP. 4. Flexible Coupling - Cat. No. 161685 Torque is transmitted to the compressor through a flexible coupling designed for high speed operation and heavy duty service. The stainless steel laminated disc assembly is torsionally rigid to prevent damage due to backlash and also provides for free end float of both connecting shafts. 5. Refrigeration Controls - Cat. No. B-2899-2 The refrigeration controls are installed in a weatherproof box attached to the support frame. These controls include a dual pressurestat having high and low pressure control switches, discharge and suction pressure gauges,.and a three position selector switch for MANUAL-OFF-AUTOMATIC operation of the equipment. Gauge lines are equipped with shut off valves which should be opened only to determine operating pressure in the system. In the MANUAL position, the temperature control circuit is by-passed. This permits the operation of the equipment for test purposes at intervals when the thermostatic controls are satisfied. For normal operation, the AUTOMATIC setting should be used. When the cover of the control box is closed, the selector switch is positioned to the AUTOMATIC position. 11-2 6. Support Bracket - Cat. No. B-I023 The compressor bracket support is designed for the severe impact and shock loads experienced in railroad service. Thils unit is of all welded steel construction with a removable strut member to provide greater accessibility to service the compressor. B. Air Cooled Condenser - Cat. No. B-2247-I0 The air cooled condenser shown in Figure II-2 consists of a condenser coil mounted in an all welded support frame, liquid receiver, integrally mounted motor with direct connected axial flow fan, and a pressure modulation control switch. The assembly is resiliently hung underframe from the car support members. I. Condenser Coil - Cat. No. B-1566 The coil is arranged for counterflow of refrigerant and the cooling medium. A heavy duty all steel six blade axial flow fan which operates in a venturi for high efficiency draws the air through the coil surface. An expanded metal guard protects the coil inlet face from flying road ballast, and a removable hot dipped galvanized fan guard is provided at the fan discharge. Superheated refrigerant vapor from the compressor enters near the top of the coil and the liquified subcooled refrigerant flows to the receiver. 2. Liquid Receiver - Cat. No. M-1782 The liquid receiver is mounted vertically consists of a welded steel shell with two glasses, liquid inlet and outlet shut off and purge valve (I/4" OD flare). This is to insure that l._quid is not stored above and outlet valves are closed. on the supporting frame and dished heads, two sight valves (5/8" OD flare), also used as a test valve this point when both inlet A I/4" OD flare connection is provided as an integral part of the receiver outlet valve for charging the system with liquid refrigerant. This is a backseating type valve and, in the fully open position, the charging port i_sclosed. 3. Condenser Fan and Motor The condenser fan, Cat. No. M-1890-2, is driven by a 2 HP, 1725 RPM, totally enclosed, 145T frame size motor arranged for 460/3/60 hz power supply. The design load for this motor_ Cat. No. T-16822, is approximately 1.3 HP. The compressor taneously. and condenser fan motor must start and stop simul- II-3 C. Evaporator and Blower To deliver conditioned air duct, the evaporator components: I. 20 KW Electric (2) Evaporator (3) Drain to (4) Flexible (5) Blower Heat Coil Cat. the No. overhead assembly B-1444-17 centerline includes distribution the following Assembly Assembly with Associated Piping Pan Plenum and Motor Heat The overhead the evaporator rosion-proof 2. - and blower (I) Electric Assembly Assembly Assembly - Cat. No. B-4319-I electric heat assembly is mounted down stream of coil assembly. It is an open design type (corbare wire elements with ceramic insulators.) (a) The overhead heat is arranged for two stage operation of I0 KW each at 460/3/60 hz power supply. Each stage is spread out over the entire air path. The heater elements will not be damaged by sustained operation at + 10% rated voltage swings. (b) To provide protection against excessive heat build up, loss of air, etc., a single pole, single throw N.C. thermoswitch (set to eden at 200°F and with an automatic reset of 185 ° ) is mounted atthe top of the casing. The switch, Cat. No. T-14045, has a silicone rubber overmold, is preset, nonadjustable, and not field serviceable. This thermoswitch operates a shunt trip circuit breaker. The N.O. contacts are in series with a shunt coil which is physically a part of the circuit breaker feeding the overhead heatassembly. With a rising temperature caused by loss of air and, should the heat contactor remain closed for any reason, the thermoswitch contacts will close as the internal temperature passes the set point. This then energizes the shunt coil in the circuit breaker which causes an immediate trip, thus shutting down power to the overhead electric heat assembly. To reestablish power to the heater assembly, the circuit breaker must be reset. Evaporator Coil Assembly - Cat. No.M-4142-1 The evaporator coil, Cat. No. B-2488-I, is a six row 3/8" OD copper tube coil with extended surface of .OlO" copper plate fins spaced eight to the inch. 11-4 (a) The coil is divided horizontally into two halves for modulated control when other than full cooling is required. Each section is multi-circuited and fed by an expansion valve which consists of a power assembly cage, and valve body. The valve power assembly is equipped with a thermal bulb which is securely attached to the suction line header fed by the valve. (b) Expansion Valves - Cat. No. T-3695-I The two expansion valves are located at the side of the evaporator assembly. They feed liquid refrigerant to the two multi-circuited sections of the evaporator coil. See Parts List 5775 in the Appendix. Each expansion valve has a liquid distributor, I/4" SAE external equalizer connection, and an external superheat adjusting stem. NOTE; In service, the equalizer line must always be connected to the suction header fed by the valve to sense the suction pressure leaving the coil, otherwise, the valve may flood, starve, or regulate the flow of refrigerant erratically. The expansion valves are operated by the pressure differential between the suction pressure in the evaporator and the pressure in the thermostatic charge of the thermal bulb. Since the thermal (feeler) bulb is in thermal contact with the suction line, the pressure in the bulb is a function of the suction line temperature. Since the valve operates on a pressure differential, it cannot be set to produce a fixed evaporator pressure. After the evaporation of the liquid refrigerant in the evaporator, the suction vapor is superheated and its temperature will increase. However, the evaporator pressure, neglecting the pressure drop, is unchanged, The warmer vapor flowing through the suction line increases the bulb temperature. Since the thermal bulb contains both a liquid and vapor charge, the temperature and pressure will increase. The higher bulb pressure causes the valve to open and admit more refrigerant to the evaporator. Conversely, if the valve feeds too much refrigerant, the bulb temperature is decreased, or the evaporator pressure is increased, to cause the valve to close and adjust to the new load condition. II-5 (c) Modulation Control Solenoid Valve - Cat. No. T-3330-II For capacity reduction, the admission of refrigerant to the top evaporator circuit is controlled by a normally closed solenoid valve (with 120/I/60 coil, Cat. No. T-7820-4) which responds to the temperature modulation thermostat. To open the valve manually in the event of failure of the coil, a side adjusting stem opens a by-pass for liquid refrigerant. To open the valve manually, the stem must be turned a maximum of one-half revolution counterclockwise. Under normal service conditions, the manual opening stem is positioned to the closed setting. 3. Drain Pan - Cat. No. M-1485-I A stainless steel drain pan extends under the evaporator coil and electric heat assemblies to collect condensate which is formed on the evaporator coil surface. The pan is pitched to drain to the back edge where two copper tube lines are connected. The exterior of the pan is insulated to prevent condensation of the cold surface. A premolded vinyl plastic insulation with a minimum thickness of I/4" is applied to the outside surface. Baffles and splash angles are provided within the pan to prevent condensate from spilling over on grades or during periods of acceleration or deceleration. 4. Flexible Plenum - Cat. No. B-4409 A fire resistant and water-proof flexible duct of neoprene covered glass fiber is provided between the fan and motor assembly and the evaporator. This duct may be detached easily to permit _ccess to the coil surface for cleaning and inspection. 5. Blower and Motor Assembly - Cat. No. B-1434-15 The blower motor assembly is resisiently mounted to overhead car support members. The assembly is rated 2400 CFM at 1.25" wg TSP and includes: two forward curved, double width, double inlet (DWDI) centrifugal blower wheels which are flange mounted to shaft extensions on a 182T frame size, one horsepower motor. The motor, Cat. No. T-16807-I, is open, drip-proof, equipped with sealed bearings for normal service life and will operate at 1725 RPI4 on a 460/3/60 hz power supply. After uncoupling the mating flanges for the shaft extensions to which the blower wheels are applied, the motor may be lowered by removing four mounting bolts. II-6 D. Motor Start and Control Panel Assembly The motor control panel contain_ compressor motor, condenser fan heat assembly and the essential - Cat. the components for starting the motor, blower fan motor and electric overload protective devices. The panel is arranged so that any ration may be serviced or replaced panel from the electrical locker. component from the SYSTEM AUXILIARIES The Refrigerant schematically in the liquid a. Moisture Flow Diagram, MSK-2396, the various system optional refrigerant lines. and Liquid No. B-4290-I Indicator_ subject to wear or deteriofront without removing the (Optional) Figure 1 in auxiliaries the Appendix which are lists piped Cat. No. T-15521-2. This assembly is installed in the liquid line to the evaporator section immediately ahead of the expansion valves. This indicator shows the adequacy of the refrigerant charge as well as the quality or relative dryness of the liquid in the system• The indicator element is highly sensitive to moisture and will gradually change color in direct relation to an increase or decrease in the moisture content of the system• The dry-caution-wet system operating conditions are then easily determined by matching the element color with the four colors displayed on the reference label. Colors vary as often as the moisture content in the system changes. An unsafe (wet) indication would call for replacement of filter-drier cores. The indicator element before installation will indicate an unsafe condition. This is normal and simply reflects the room humidity condition. Also, LIQUID refrigerant must be in contact with the indicator element, with the system in operation, to insure a positive and true color reading. The fused g lass eyepiece in the indicator provides a clear wide angle • * i view of the llquld refrlgerant flow so that bubbles or flash gas may be L,asily seen. This condition indicates an insufficient system charge, low discharge (head) pressure, insufficient liquid subcooling or some form of restriction in the liquid line. Low discharge pressure will occur when reduced cooling load demands prevail or low outside ambient conditions prevent the build up of the high side pressure in the condenser. Thus the discharge pressure must be at least 180 psig and 37 psig suction before the determination of low charge of refrigerant is made. Following installation of the moisture and liquid indicator or filter-drier cores, the system should be allowed to reach equilibrium after a minimum of twelve (12) hours operation before attempting to determine safely the moisture content in the system. If a caution or unsafe condition is still indicated following this period, the filter-drier core assembly must be replaced. This practice should be continued until the system is dry and a safe condition is indicated. II-7 b. Line Solenoid Valve - Cat. No. T-3330-II A normally closed solenoid valve is located in the main liquid line to the evaporator and also in the coil modulation (top) circuit. These valves are also equipped with a manual opening stem which serves as a liquid by-pass so that the system may continue to operate in the event of failure of the coil. To open the valve manually, the stem must be turned counterclockwise a maximum of one-half revolution. For normal system operation, the valve must be operated with the manual stem in the closed position. The system does not require pump down operation but since the quantity and location of the refrigerant within the system piping cannot be definitely controlled, the main line solenoid, along with the check valve in the compressor discharge line, will stop the migration of refrigerant after shut down. In this way oil dilution and carry off from the compressor are avoided. In service, advance of c. the line compressor solenoid valve start up. opens ten Refer to Form 5453-A in the Appendix ment parts and service instructions. for Liquid No. T-15531 Line Strainer Assembly - Cat. the (I0) list seconds of in replace- A cleanable "Y" type forged brass strainer with 5/8" ODF solder end connections contains a replaceable monel screen #80 mesh size with a screw clean out plug. A 44 micron (#325) mesh "cleanup" screen is installed in the liquid line strainer for use during the first 6 - lO hours of operational tests to collect and remove any foreign contaminants from the system piping. However, the standard #8_mesh screen, Cat. No. T-15532-I, is applied prior to the release of the car to service operation. Shutoff isolate replaced. valves are provided at the refrigerant charge the inlet when the and outlet connections monel screen is cleaned to or To clean or replace the screen, isolate the refrigerant charge by pumping down the system. Close the inlet valve at the assembly and operate the compressor until the suction pressure is approximately 2 psig. Close the outlet valve. Set the selector switch to the OFF position. Loosen the strainer screw plug slowly to relieve residual line pressure. USE CAUTION TO PREVENT INJURY TO THE EYES, FACE, AND HANDS. Unscrew the plug and remove the screen nested within the recess. Wash the screen in a clean solvent. (Do not use carbon tetrachloride.) Dry the screen thoroughly and insert the non-reinforced end within the recess in the plug. Replace the plug loosely and open the inlet valve at the assembly momentarily to purge the line. Tighten the cap and test for leaks. Open the inlet and outlet valves. 11-8 d. Check Valve - Cat. No. T-14691-I A check valve is installed in the discharge line between the compressor and condenser coil. This is to insure that refrigerant entrained in the high side of the system is not permitted to return to the compressor during periods of shut down. e. Liquid Line Filter Drier - Cat. No. 163088 A filter-drier of the replaceable core type is mounted in the liquid line at the outlet of the receiver. Its purpose is to filter out particles in the piping system (copper, solder, dirt) and to retain any moisture left in the system at installation or introduced while servicing. Valves are provided that the two cores, opening the entire The procedure for replacement parts f. Flexible Line at the inlet and outlet of the assembly Cat. No. 163089, may be replaced without system. renewing the is described core assembly and the on Form 5287-A in the so list of Appendix: Connectors The refrigerant liquid, suction, and discharge lines at the resilient mounted condenser and compressor assemblies are equipped with neoprene jacketed flexible tube connectors. These are a mechanical bellows type with neoprene coverings over the flexible seamless bronze hose and bronze wire braid to provide resistance to abrasion, and to prevent condensation and moisture from freezing behind the ferrules. 11-9 I SUCTION VALVE W/LOW SIDE CHARGING CONNECTION (VAPOR) RESILIENT MOUNTS (4) "'-'"-_,,_.--_"_._._.7 --_-_ DI SCIIARGE VALVE ,IJ FLEXIBLE COF_TROLSASSEMBLY _II-LOW PRESSURE CONTROL __l_Cil COUPLING COMPRESSOR SUPPORT FR_IE 5ELECTOR REMOVABLE STRUT FIGURE Type B-3988 II-l Less Unit Adapter MOTOR-COMPRESSOR and Undercar ASSEMBLIES ---SUCTIOII(LOW)SIDE CONNECTION (AS A VAPOR) DISCIIARGE(IIIGII)SI[_E - PURGE ASSEMBLY Mountin 9 Support SWITCH Frame CON_. RESILIENT MOUNTS CONDENSER SUPPORT COIL FRAME RECEIVER _'_'INLET PURGE VALVE VALVE ,SIGHT GLASS (2) OUTLET VALVE _UID REFRIGERANT CHARGING CONNECTION) PRESSURE MODULATION MOTOR FAN GUARD ACCESS DOOR TYPE B-2447 I FIGURE II-2 AIR COOLED LESS UNIT ADAPTER CONDENSER AND UNDERCAR UNIT MOUNTING SUPPORT FRAME CONTROL SWITCH EXPANSION VALVES EVAPORATOR MODULATION SOLENOID VALVE RESILIENT MOUNTS FLEXIBLE SUPPORT PLENUM It BLOWER AND MOTOR ASSEMBLY . LIQUID LINE CONNECTION HEATING COIL DRIP PAN EVAPORATOR COIL MOTOR FAN SUCTION LINE CONNECTION FIGURE H-3 EVAPORATOR AND TYPE 11-12 BLOWER B-1444 UNIT SECTION 3 OPERATION SECTION 0 PE With all circuit breakers RAT arranged 3 I0 N in the "ON" position, switches closed, and the compressor motor control switch in the AUTOMATIC setting, the control circuit is energized. This permits current flowing to the evaporator blower motor circuit to operate the air circulating fans in the overhead unit. The system is now capable of automatic functioning in either the full or modulated cooling cycles to satisfy the given load conditions. The operation of the controls is described in Section 7 and also illustrated schematically in the wiring diagram, Figure 2 in the Appendix. If the car body temperature is above the high thermostat setting and calls for full cooling, the compressor motor and condenser fan motor will start. The system then operates at rated capacity, that is, with all cylinders of the compressor loaded and pumping and both sections of the evaporator coil in use. Also, I. 2. 3. the: Evaporator Compressor Evaporator Blower Motor is operating. Motor and Condenser Fan Motor run. modulating solenoid valve is energized (open). This mode of operation continues until the car body temperature is reduced to the setting of the high thermostat. The controls then function to reduce the cooling capacity. During this modulated operation as the evaporator solenoid valve closes the compressor automatically unloads in response to the lowering of the suction pressure. The functioning of the unloading compressor with pressure type capacity control mechanism is contained in the Appendix, Form 5297. If the car temperature continues to fall to the setting of the low thermostat, the controls function to stop operation. The condition of the equipment then is: I. 2. 3. Evaporator Compressor Evaporator Blower Fan Motor is operating. Motor and Condenser Fan Motor are stopped. modulation solenoid valve is closed. This arrangement provides for the automatic adjusting capacity to approximate the cooling load requirements. of the system It should be noted that the conditions under which the equipment is called upon to operate are not constant. Together with changes in the outside temperature, the internal cooling load varies with the temperature and the number of passengers. This combination of variables affects the operating performance. Under light cooling loads or low outside temperatures, the suction and discharge pressures will also be lower than conditions of heavy loads when a build-up in operating pressures will be noted. When the system is not operating, the suction and discharge pressures will tend to equalize. The final pressure depends upon the car temperature and the outside temperature. III-l OPERATING Initial INSTRUCTIONS Startin 9 Check: I. Check oil level in compressor sight glass. sight 2. Check all electrical for tight connections• 3. Refrigerant lines should leak detector torch. 4. Open and backseat valves. 5. Open Starting l • o . 4. • circuits be checked the compressor the inlet and outlet glass. for tightness discharge using and suction be I/2 a Halide shut off valves at the receiver. Instructions: Arrange the circuit breakers at the temperature control panel to the "ON" position and close the cooling switch to set the evaporator blower motor in operation• To operate the cooling cycle, the compressor motor control switch should be set to the "Automatic" position. The equipment will then operate at rated capacity if the high thermostat setting is exceeded or at reduced capacity if the low thermostat is in control. For test purposes where by-passing the control thermostats is necessary for operation of the system, the compressor motor selector switch should be set to the "Manual" position. It is essential that the condenser fan be arranged for proper rotation. (Draw through operation). Since the compressor is equipped with a gear type positive displacement oil pump, the directional arrow on the top of the cover plate must be checked. If the arrow does not point in the direction of rotation, the oil pump must be reversed by following the procedure outlined in Form 5297. Trouble diagnosis Form 5297• charts are given in Section 5 and, in the Appendix, The nominal settings for the high and low pressure controls and the pressure modulation control switch are provided in the following table: Pressure Control Switch Type High Pressure Control Low Pressure Control Modulation Pressure Control TABLE III-I PRESSURE III-2 This level should CONTROL Cut-Out (Open) 275 2-5 235 SWITCH SETTINGS Cut-ln (Closed) 225 12-15 205 Nominal) NOMINAL OPERATING DATA 460/3/60 hz. 8 TON SYSTEM (REFRIGEP_ANT R-12) POWER SUPPLY AND 120/I/60 CONTROL VOLTAGE Evaporator Cooling Load ................................ Air Volume ................................. 2400 Air to Condenser ............................................ Suction Pressure (at Compressor) ............................ Discharge Pressure (at Compressor) .......................... Compressor Motor, 15 HP............................ Speed (approximately) ..................................... Current, (EL) approximately .............................. Power (FL) approximately ..................................... Condenser Fan Motor, 2 HP ......................... Speed (approximately) .................................... Current (FL) approximately ............................... Blower Fan Motor, 1HP ............................. Speed (approximately) .................................... Current (approximately) .................................. Control Voltage Nominal .................................................. Compressor Discharge Line Temperature .................................... Suction Line Temperature ........................... Oil Charg_ ........................................ Oil Level In Crankcase When Operating (approximately) When Not Operating .................... Refrigerant Level in Receiver(*) (*)at 180 psig Discharge ........ .... Pressure TABLE 111-2 - 96000 BTU/HR @ 1.25 ° wg TSP 95°F DB 32 psig 195 psig 460/3/60 hz power 1760 RPM 17 amps 13 HP 460/3/60 hz power 1725 RPM 3.0 amps 460/3/60 hz power 1725 RPM 1.6 amps cfm J20/I/60 Hot Cool - No Frost 12 pints (U.S.) Half Level in I/3 - 2/3 Sight Half Level in Lower and 37 psig Suction Sight Glass Sight Glass Level Glass Pressure TABLE OF OPERATING DATA (Nominal) 111-3 SECTION 4 ROUTINE SERVICE INSTRUCTIONS 4 SECTION ROUTINE More satisfactory SERVICE operation with INSTRUCTIONS fewer failures will be obtained if the equipment is put in first class condition during prescribed car shopping periods, by adhering to preventive maintenance schedules, and implementing systematic service procedures. Weekly: I. Clean air filters, 2. 3. 4. 5. 6. Check Check Check Clean Check 7. Operate unit to check oil and refrigerant levels under steady operating conditions. Note any signs of leakage which will be indicated by oil at the point of leakage. See Service Instructions for adding oil and refrigerant. Inspect motor brushes and commutators. 8. grilles, and screens. evaporator blowers and condenser fan for tightness motor and compressor mounting bolts for tightness. motor compressor coupling for tightness. surface of condenser coil. operation of control panel. on shafts. Monthly: I. 2. 3. 4. 5. Clean the surface of the evaporator coil. Flush the drip pan under the evaporator coil. Clean drain lines to provide for free drainage. Inspect and, if necessary, clean contacts on motor Follow all steps outlined for weekly servicing. control panel. Annually: r i. , .., .,,n, 2. 3. The equipment should be given a thorough inspection and a complete check of the controls made prior to seasonal changeovers. All steps listed for weekly and monthly servicing should be followed. Inspect all motors. 4. 5. Thoroughly clean all coil surfaces. Blow dirt from interior of casing. CAUTION Where established maintenance schedules require the pumping down of the system and the isolation of the refrigerant charge in the receiver, care should be taken to insure that the top of the liquid level is visible in the upper sight glass to allow for expansion. PREPAPJ_TIONS FOR WINTER Although no special precautions are required during the winter heating season, the refrigerant circuit should be inspected for le_ks. Necessary repairs should be effected in order that positive pressure will be maintained within the system during the winter shut down period. IV-I SECTION TROUBLE 5 DIAGNOSIS CHART SECTION TROUBLE 5 DIAGNOSIS CHART Faulty operation of the system is indicated by very definite symptoms. These symptoms may be caused by one or more incorrect conditions which must be eliminated in a step by step process of corrective measures. The following chart of symptoms, their causes and corrections, will be of assistance in quickly and efficiently locating faults. The procedures to be followed in making repairs are given in Section 6. HIGH HEAD PRESSURE n Correction: May be due to: a. b. Air or non-condensable system. Insufficient condenser Co Dirty condenser. d. Too much e. Discharge liquid gases in a. Purge air. from the receiver. b. Clean air screen and the condenser surface. c. Clean the condenser surface. d. Draw off some of the liquid. e. Open the valve. in the receiver. valve closed. LOW HEAD PRESSURE a. b. C, d. Liquid refrigerant flooding from the evaporator. back Leaky compressor discharge valve. Suction valve closed. Liquid valve on the receiver closed. HIGH SUCTION a. Overfeeding valves. of the expansion b. Leaky compressor c. Excessive cooling suction valves. load on system. a. Examine fastening of feeler bulbs to suction lines. b. Test; if leaking, c. Open the valve. d. Open the valve. replace. PRESSURE a. Check the bulb attachments. b. Pump down, remove the cylinder head, examine the valve discs or rings; replace if worn. C. When pre-cooling car in hot weather the suction pressure will be high, but should gradually decrease as the car is cooled. V-l LOW SUCTION Maybe c. d. e. Correction: due to: Insufficient system. b. refrigerant *a. in b. Too much oil circulating in system. Suction valve closed. Liquid valve at the receiver is closed. Little or no cooling load on the evaporator coil c. d. g. h. High pressure cut-out switch incorrectly set. Low pressure cut-out switch incorrectly set. Air circulating fans not running. a. Check setting of switch. b. Check setting of switch. c. Thermal bulb on the expansion valve has lost charge. d. Check the fan motor, protective overload devices and connections. Detach the bulb from the suction line and hold in the palm of one hand. With the other hand grip the suction line. If flooding through is observed, the bulb has not lost its charge. If no flooding is noticed, replace valve power element. Add refrigerant. Clogged liquid g. h. Evaporator coil is dirty. Faulty unloader mechanism. e. f. filter-drier. FREQUENT b. c. de *e. f. Check the liquid level in the lower receiver sight glass; add refrigerant if necessary. Check for too much oil; remove some if necessary. Open the valve. Open the valve. This will occur if the air circulating fan is not operating. Pump down and apply new filter-drier core. Clean the coil. Apply new unloader control unit. f. a. PRESSURE Insufficient refrigerant system. Suction valve or liquid valve closed. CYCLING *e. in f. Open the valves. Align the motor with housings. Tighten. Check the refrigerant flow and level in lower receiver NOISES a. b. c. Fan striking housing. Ticking or rattling,loose bolts Hissing - at expansion valves. a. b. c. d. Bearing noise - worn motor bearings. Rattle - inadequately supported piping, loose unit covers. d. sight glass. Replace bearings. e. Tighten. e. V-2 ii C_PRESSOR IS NOISY Ma_ be due to: Correction: a. Vibration. a. b. Too much oil C. do in circulation. b. Slugging due to the expansion valves feeding too much refrigerant. c. Wear of parts, such as pistons, pins, bearings, etc. d. COMPRESSOR a. Thermostat b. Overload protective device tripped. Switches open. High-pressure cut-out switch open. c. Low-pressure e. Dirty contacts. f. Cooling hl WILL cause. Repair or replace the compressor. NOlL START set too low. do cut-out control a. switch f. Equipment will operate only on manual setting of compressor control switch if car temperature is below thermostat setting. Reset overload protective device and close switches. Check the setting of the switch and adjust if necessary. Check the setting of the switch and adjust if necessary. Check and clean the contacts on all switches. Turn to the ON position. h. "Jump" b. c. open. d. e. switch OFF. Low-pressure cut-out switch open (after pump down). CYLINDERS a. Too much b. Too much refrigerant circulation. AND CRANKCASE oll in circulation. in Tighten the compressor mounting bolts. Check coupling. Check the oil level in the crankcase and for oil in the refrigerant. Check to see if the thermal bulbs are securely clamped and make good contact with the suction lines. Determine the location of terminals to close contacts. This ,then,permits flow of refrigerant and pressure buildup to reset. SWEATING a. b. Make oil test. Remove, if necessary, to maintain oil level at I/2 sight glass. Check setting of expansion valves and contact between the thermal bulbs and the suction lines. V-3 FAILURE TO COOL Correction: Ma_ be due to: a. Air circulating b. Compressor *c. Insufficient fans not running. b. not operating. refrigerant a. in *c. system. d. e. Air filters dirty. Compressor speed too low. d. e. f. Evaporator modulation solenoid valve closed. f. AIR CIRCULATING a. Fan switch b. Too much refrigerant circulation. *Note: V-4 is in OFF position. in Check the motor, overload protective devices, contacts. Check the thermostat, overload protective devices, contacts, etc. Check the level in the lower sight glass of receiver. Clean the filters. Check the voltage and the motor. Check operation of coil. FAN NOT OPERATING a. b. Make oil test. Remove, if necessary, to maintain oil level at I/2 sight glass. Check setting of expansion valves and the contact between the thermal bulbs and the suction lines. To prevent overcharging the system, the determination of low charge should be made when the discharge (high side) pressure is not less than 180 psig. SECTION 6 MAINTENANCE AND SERVICE INSTRUCTIONS SECTION MAII_TENANCE AND SERVICE 6 INSTRUCTIONS This section provides procedures for establishing preventive maintenance and systematic servicing schedules which are the keys to successful operation. l. GEilERA__ a. Safety: When any work is to be done on the components of the air conditioning system, always make sure that the equipment cannot be started automatically or accidentally. If valves are closed and/or circuits interrupted during service procedures, the control switches should be suitably tagged with such notations. (I) Importance of Dehydration: Too much emphasis cannot be placed on the importance of maintaining the system free of moisture. Slight amounts of water in the system will inevitably lead to trouble in the following forms: a. b. c. d. e. f. Corrosion of steel parts. Intercrystalline corrosion of the bellows. Copper plating of the shaft and bearings. Sludging or gumming of the oil. Plugging of the strainers. Freezing and plugging of expansion valves. Whenever it is necessary to open the system for any reason, always take precautions to prevent the entrance of air into the system, as air always contains some water vapor. Isolate as much of the system as possible from the portion to be opened by closing suitablevalves and tightly plugging the open pipe ends. Purge the opened section immediately prior to reclosing. (2) Use of Alcohol: The introduction of alcohol or other similar commercial preparations for the purpose ef overcoming freezing trouble at the expansion valves due to moisture in the system is not recommended. The cure leads to trouble worse than the cause. VI-I (3) Grease Solvents: Many grease and oil solvents can be used without harmful effects. When washing compressor parts or cleaning new components use naphtha, gasoline (non-leaded) or benzine. Thoroughly dry the parts before placing them in use. Carbon tetrachloride SHOULD NOT be used. (4) Soldered Connections: The use of 'EASY-FLO" silver solder, in the refrigerant system piping. or equivalent, is recommended Prior to disturbing any connections, the type solder originally used should first be verified and then continued. By taking this precaution, the contamination of the joint will be avoided. (5) Openin 9 the System Whenever it is necessary to open a charged or functioning system to make repairs or replacements, it is necessary to evacuate the refrigerant from that part of the refrigerant circuit. The final evacuation should be to a slight positive pressure before the system is opened. If the final evacuation is reduced to less than atmospheric, sufficient refrigerant should be bled into the evacuated part of the system to raise the pressure to approximately 2 psig. Connections may then be broken and the necessary repairs made. One connection should be made first so the air in that part may be swept out throu_, the free end by purging with refrigerant gas bled from the charge in the system. The other connection or connections should then be promptly made. If, after breaking connections, more than a few minutes must elapse, the free ends of the system should be capped. Extreme care must always be taken to prevent the entrance of moisture and dirt into the system. It is essential when soldered joints are to be unsweated that the residual pressure in the line be vented to the atmosphere prior to the application of heat. (6) Evacuatin 9 Air from the System PRECAUTIONS Donot use the compressor as a vacuum pump nor as an air compressor. It was not designed to handle air and will not pull down to as low a vacuum as a pump designed for that service. Similarly, if used to compress air, serious overheating and consequent damage may result. VI-2 Connect a pumpcapable of drawing a vacuumof .2" mercury absolute or higher to that part of the system which has been opened. Continue until all air and moisture have been removed. To evacuate the air from the system it is essential that the normally closed liquid line solenoid valves located at the Evaporator Assembly be open. See Figure 2 in the Appendix. This is accomplished by energizing the coils or manually turning the lifting stem located at the side of the valves approximately one-quarter to one-half turn counterclockwise. The final evacuation may be accelerated, however, by manifolding the connections to the vacuumpumpand evacuating simultaneously the high and low sides of the system. The vacuumshould be broken by introducing refrigerant. (7) Testing for Leaks: The preferred method for finding leaks is to use a Halide Leak Detector Torch. Testinq with soap suds at joints will reveal only the larger leaks and is, therefore, ineffective in determining the tightness of a system. Much time will be saved by the use of the detector. Several types are available. Some are small units burning alcohol while others are arranged for attaching to small acetylene cylinders. Study and follow carefully the directions which are furnished with the detector. In checking for leaks, slowly pass the end of the exploring tube over joints or other points where leakage might Occur and note the color of the detector flame. Small leaks will give a greenish tint to the flame while large leaks color,the flame a vivid blue. (8) To Add Refrigerant to the System: It is important to have the correct amount of Refrigerant 22 in the system. If there is too little, the expansion valves will pass vapor and reduce the capacity of the evaporator. Too much refrigerant will result in higher head pressures and oil dilution. It is equally important to ascertain that the receiver is level before charging the system or adding refrigerant. If it is not level, a false reading will be indicated in the sight glass. Under steady operating conditons of 275 psig discharge pressure and 70 psig suction pressure, the liquid refrigerant level should be approximately at the center of tile lower sight glass. NOTE: Build-up the high side pressure to at least 180 psig before making a determination of the refrigerant level. This can be done by partially blocking the inlet air to the condenser. VI-3 Whether the refrigerant charge is added in the vapor or the liquid state, it is important initially to purge the air from the transfer tube. Also, a greater pressure must be maintained at all times in the refrigerant c_cylinder or the charging operation stopped• (a,) Low Side Chargin 9 as a Vapor NOTE: When adding refrigerant vapor to the low side of the system, always charge with the refrigerant cylinder in the upright position; that is, with the service valve up so as to avoid the slugging of liquid to the compressor. During this operation, the cylinder will become cold and the pressure will drop accordingly. The transfer of refrigerant can be accelerated, however, by gently applying heat to the cylinder. A I/4" SAE charging connection is provided at the low (suction) pressure gauge shut off valve in the Refrigeration Control Unit. To charge the system at the suction as follows: • With one end of the transfer pressure gauge tube connected valve port, proceed to a refrigerant service cylinder, attach the other end loosely to the charging port. Purge the charging line for a few seconds by cracking the cylinder to allow gas to escape and sweep air through the loose connection. . 3. . 5. (bo) Chargin9 Tighten the flare connection, open the cylinder valve to admit refrigerant vapor only, and the suction pressure gauge valve. Use the cylinder valve to control the flow of refrigerant vapor, being careful to avoid any sudden rise in pressure. Under steady operation conditions, observe the liquid level in the receiver. When this has risen to approximately one-half in the lower sight glass close the service cylinder and suction pressure gauge valve. Remove the transfer charging port. tube and replace the seal cap at the as a Liquid To add refrigerant to the system through the high side, it is necessary to charge as a liquid. The refrigerant cylinder must be inverted or inclined to insure liquid refrigerant will be drawn into the liquid line. A I/4" SAE charging port connection is incorporated in the outlet valve of the receiver for this purpose. VI-4 NOTE: Some new style refrigerant tubes. This allows the liquid in the upright position• l service refrigerant cylinders are equipped with to be drawn off with the dip tank • Backseat the liquid outlet valve at the receiver by turning the valve stem counter-clockwise to the fully open position. This closes the port. m With a refrigerant service cylinder tube loosely to the charging port. tighten the flare connection. . Frontseat the receiver outlet valve by turning in the valve stem clockwise to the closed position. This opens the port and permits the flow of refrigerant into the system. inverted, attach the transfer Purge air from the line and 4. With the equipment operating, observe the rise of the level the lower sight glass of the receiver• 5. Backseat the valve to close the charging port. Under steady operating conditions and the discharge pressure not less than 180 psi, the refrigerant level should be at half the lower sight glass in the receiver. 6. Remove port. the transfer tube and replace in the seal cap at the charging CAUTION: To prevent overcharging the system it may be necessary to repeat steps 3, 4 and 5 during the charging cycle with small amounts added at intervals. 9. Removal of Non-Condensable Gases: Air and non-condensable gases in any system collect in the receiver above the liquid. These can be removed by purging at the valve provided for this purpose at the top of the receiver. To purge, open the valve for a few seconds. Note any decided difference from the initial pressure when the valve is again closed. Repeat the operation until the pressure is approximately equal to the refrigerant vapor pressure corresponding to the temperature of the receiver. (See TABLE I-l, Section l). 10. Addin_ or Removin 9 0ii a. Compressor Lubrication To insure proper lubrication of the compressor and functioning of the unloader mechanism, the level of oil in the crankcase should be approximately I/3 bull's-eye during steady operating conditions. Prior to adding oil, however, it is important that the amount of oil in the system be checked. This should be dete_ined only if the head pressure is above 180 psig and the SYstem has been in operation at least 30 minutes. The procedure to add or remove excess oil is given in the Appendix. (See Section I, Form 5297). VI-5 2. SERVICING THE COMPRESSOR-MOTOR ASSEMBLY As illustrated in Figure II-l, the components Motor Assembly are carried on a common supporting resiliently hung from the underframe of the car. of the Compressorbase which is ,_ Under shop conditions or where space and equipment factors are favorable, the assembly may be removed and replaced as a unit using a fork lift truck. The following components: _. To Remove I. o procedures the steps Remove the bolts compressor base, damage to gauge control assembly position. Remove the short bolts from the flange mounted on the motor shaft. 4. Block up under the motor. 5. Remove four bolts which support base. 6. Remove 7. Slide motor o 3. secure two bolts mounting Disconnect and tag motor of the coupling the motor which is to the compressor feet to the support channel. to the right and remove. the Compressor: Note: It is not necessary the compressor motor. • the individual which secure the control box assembly to the" and support it from the car frame to prevent lines. (Close compressor shut off valves if is removed). 3. l to remove the Motor: Set the control switch to the "off" the motor leads. b. To Remove VI-6 outline to unsolder the refrigerant lines nor move Pump down the system to remove the refrigerant from the compressor. Close (front seat) the suction valve at the compressor by advancing the valve stem in a clockwise direction. Operate the compressor until the suction pressure does not rise above 2 psi. Allow the compressor to cycle 2-3 times at low pressure. Set the control switch to the "off" position. . 5. Remove 6. Remove short bolts of the flexible coupling the flange on the compressor shaft. , o. Close (front seat) the discharge valve and disconnect the I/4" flare discharge pressure gauge connection at the compressor body to bleed off residual pressure in the compressor. the cap screws which secure the compressor which shut-off extend Loosen the jack screws used for horizontal alignment, the compressor hold-down bolts. Slide the compressor through the end of the support frame. To Replace After valves. through and remove assembly the Compressor: it is in position. I* Attach the discharge and suction valves and make up loosely the gauge connections to the compressor. Open the discharge and suction shut-off valve momentarily to purge the compressor through the gauge connections. 2. Tighten 3. Replace the bolts in the coupling under "Flexible Coupling." 4. Open all valves the gauge connections. flange and align it as described and test for leaks. Note: It is recommended that new gaskets be used when re-applying the suction and discharge valves. Insure that the direction of rotation of the oil pump is the same as that of the motor. d. Compressor: The general description, principles of operation, procedures are contained in the Appendix, Form 5297. e. Compressor Service and maintenance Valves: The compressor discharge and suction stop valves are provided with a double seat and gauge tapping as shown in Figure VI-I. Turning the valve stem all the way to the right (forward) closes the outlet of the valve and in this position the gauge connection is open to the pressure in the compressor. Turning the valve stem all the way out backseats the valve, and closes off the gauge connection. Therefore, when attaching a gauge or charging line to gauge opening, the valve must be backseated to prevent escape of refrigerant from gauge tapping. Excessive use of force should be avoided when the valve stem is turned all the way in or all the way out. Always use a square ratchet w_rench or box end wrench when operating or closing a valve. Never use an adjustable wrench or pliers since their use will soon round the valve stems making it impossible to close the valve tightly. If the Vl-7 valve stem turns hard it may be necessary to loosen the packing slightly while adjusting. See Figure VI-l. nut TO ¢_PI||_Q COMPRESSOR SERVICE FIGURE f, FLEXIBLE I. COUPLING Caliper VALVE VI- 1 ALIGNMENT and Straight Edge Hethod The coupling is a flexible type in whicll the torque is transmitted by _n assembly of thin stainless steel discs. To operate satisfactorily, the elements of the coupling must be aligned within certain limits. Whenever the compressor or motor has been moved, it will be necessary to check the alignment of the coupling. See Figure Vl-3. * ........... For vertical alignment, shims must be placed under the compressor feet. To obtain hori- BEVEL RING WASHER __ • _-- __ zontal alignment, use the jackscrews on the compressor base for lateral adjustment. The following procedure - if executed with care - will establish the desired alignment. Tools required are: LAMINATED ............ FtANGE ASSEMBLy .... _'_ TAP[REO i I t............... ............... BORE tOC_ CENTER NUT RfNG ASSEMBLY I. 2. 3. 4. 5. 6. Straight edge (6") Inside calipers Steel rule (graduated FIGURE in 64ths) Two 7/16" socket wrenches One 7/16" open end wrench Allen screw wrench VI-2 FLEXIBLE COUPLING Clean the compressor and motor shafts and inspect for burrs. Fit the compressor flange to the compressor shaft. {lote that this flange has a tapered bore. Do not use the shaft center hex screw and washer to draw the flange into place. After it is in place, tighten hex screw securely. Next fit the motor flange to the motor shaft. Note that this flange has a straight bore and is keyed to the shaft. All parts should fit together snugly, but easily. DO NOT FORCE. VI-8 Views 1 and 2 Figure Vl-3 illustrates the coupling with correct alignment. With the motor bolted to the supporting frame, it is then necessary to align the compressor frame with the motor frame. During initial to permit movement alignment, the hold-down bolts should be loose enough of the compressor. • Place a straight edge on the rims at the top and sides. When the coupling is in alignment, the straight edge should rest in full contact. . With the coupling completely assembled on the shafts, check dimension "E" (the distance between flanges) at several points around the circumference. This dimension should be exactly 2-7/16" at all points. Secure the motor flange to the motor shaft with the two set screws provided. . Referring to View 2, if the coupling is in correct alignment, dimensions "A", "B", "C': AND "D" are equal within 1/64" at all points around the circumference. I 4, Tighten the compressor hold-down bolts and recheck dimensions "A", "B", "C"_Ar_D "D". If these dimensions are now not equal within the tolerance of 1/64", either angular and/or-_-arallel misalignment exists. Note that all measurements are made to the outside edges of the flanges. 5. View first. 3 illustrates angular misalignment which should be corrected . To correct this condition, move and/or shim the compressor as required, until dimensions "A" and "B" are equal to "C" and "D" within 1/64". Q View 4 i11ustrates parallel misalignment. Note that dimensions "A" and "D" are not equal to "B" and "C". Approximate parallel misalignment can be checked by lining up flanges with a straight edge placed across the two flanges at four points equally spaced around the circumference as shown in View I. . To correct this condition, move and/or shim the compressor as required until dimensions "A" and "D" are equal to "B" and "C" within 1/64" All final checks must be made with the compressor hold-down bolts tight. After this initial alignment, run the unit long enough to let the motor and compressor warm up, then make the final check for alignment and tightness• When operating at full speed, both laminated ring assemblies should have a distinct and clearly defined appearance - not blurred when viewed from the top or side. 2. DIAl. INDICATOR METHOD An alternate procedure for aligning the coupling is the Indicator Method. For details, contact the nearest "Safety" office. VI-9 FLEXIBLE COUPLING FLEXIBLE LUse ::I]: I straight alignment ference. I I COUPLING edge at all Dimension VIEW Check -T 1- with __ CORRECT ,-_, r" -- A LIGNM ENT E equals initial of circum- 2-7/16"o dimensions inside A, ALL B, calipers. C,and D If dimensions the same within is satisfactory. E is correct. BOLTS UP TIGHT 2 ANGULAR A and shown MISALIGNMENT VIEW points A, B, C and D are 1/64", the alignment Be sure dimension PULL VIEW to secure 1 J --- ALIGNMENT B are not equal to C and D as at left. Move and/or shim compressor is secured. until correct alignment 3 A and shown PARALLEL MISA ° LIGNM ENT -- D are not equal to B and C as at Ieft. Move and/or shim compressor is secured. until correct alignment Fo-" VIEW 4 FIGURE VI-lO VI-3 FLEXIBLE COUPLING ALIGNMENT (Caliper and Straight Edge 3. ALIGNMENT GAUGE METHOD The use of the gauge illustrated convenient. It may be obtained from 161983. in Figure VI-4 will be found very the Safety Company as Catalog No. With the coupling on the shafts and completely ass_nbled, place the gauge between the faces of the flanges at the top of the coupling as shown in Figure Vl-4o Loosen set screw in flange on the motor shaft and move the flange to right or left so that gauge can be applied without play. Place a mark at the point where the gauge was applied and by turning the shaft bring this mark to the bottom and apply gauge at the mark. If it cannot be inserted, the outboard end of the compressor must be shimmed up; if there is clearance, shinning is required at the shaft end of the compressor. After adding shims it will" be necessary to readjust position of the flange on the motor shaft. Continue shimming until the gauge will just pass between at the mark_with the mark at the top and at the bottom. the flanges Next, make a mark on the front of the coupling and apply gauge at this point. If gauge will not enter, move the outboard end of the compressor toward the rear by means of the jack screws at the compressor base. Iftoomuch clearance, move the compressor to the front. Now turn the motor shaft to bring the mark at the back of the coupling and apply the gauge at that point. Nhen adjustments have been made so that the gauge will just pass between the flanges at all points and with the coupling turned at various positions, the shafts will be parallel. A further operation must be made to bring them in line. --z fJ(, • }i: °--°'_- ._-- i CASE SAf(T_ CAT NO MAroON II_$$_ For this, apply a straight edge to the rims of the flanges as shown in Figure Vl-4. Shim compressor UP or down and move it sidewise until the flanges are in line with the straight edge applied at the top, bottom, front and back. When shi_ing, equal thickness must be'added or removed from both sides of the compressor and the two jack screws on a side must be screwed in or out the same amount so as to maintain parallelism. After compressor mounting bolts and coupling set screw have been tightened the coupling should be re-checked as follows: i _ ti / ___L_ AI_'_T FIGURE FLEXIBLE I. 2. 3. , These dimensions should be equal. This flexible ooupling requires adjustment after alignment. VI-4 COUPLING (Alignment |_l_ With straight edge on rims of flanges. With gauge between flanges. ff_th inside calipers check dimensions A, B, C, and D. no lubrication nor ALIGNMENT Gauge) Vl-ll g. Refrigeration l , Controls Assembly The refrigeration controls are installed in a weatherproof enclosure adjacent to the compressor motor. These controls include a three position manual selector switch, high and low pressure gauge and shutoff valve assemblies, and a dual pressurestat having high and low pressure control switches. The evaporator coil pressure modulation on the air cooled condenser casing. (a) Selector control switch is mounted Switch The operation of the compressor and condenser by the three-position selector switch. fan motor is controlled The selector switch is a heavy duty, three-position, snap action, rotary type which is operated by a pistol grip handle to position to the MANUAL-OFF-AUTOMATIC modes of operation. In the MANUAL position, the temperature control circuit is by-passed. This permits the operation of the system for testpurposes at intervals when the thermostatic controls are satisfied. For normal operation, however, the AUTOMATIC setting is used. Stops are positioned on the interior of the cover to prevent the closing and latching of the cover unless the switch is position to the AUTOMATIC setting. (b) Gauge and Valve Assemblies The valved gauge assemblies are used to determine the operating pressures within the system and during the evacuating or purging procedures. The gauge to the upper left indicates the discharge (high side) pressure a' the lower gauge, the suction (low side) pressure. The valves are a pac_less type with I/4" MPT x 1/4 FPT and a I/4" SAE flare connection. The valve must be kept closed and the flare connection capped unless the pressure is being checked. Master gauges or a service test manifold similar to SAFETY Cat. No. T-12497 (Form 5285 in the Appendix) may be applied during these operations orto calibrate the existing gauges. DISCHARGE PRESSURE (HIGH) GAUGE CONTROL SWITCH SHUT OFF VALVE WITH PURGE CONNECTION \ SUCTION PRESSURE SHUT (LOW) GAUGE OFF WITH LOW CHARGING CONNECTION FIGURE VI-5 VI-12 SIDE DUAL PRESSURE SWITCH - REFRIGERATION CONTROLS - CAT. NO. B-2899 TYPE (c) Dual-Pressure Control NOTE: A non-adjustable dual pressure control switch assembly is being used in some applications and may be substituted for the adjustable dual pressure control type. The adjustable dual pressure control is a protective device which incorporates two independently actuated bellows and microswitch assemblies, one for each circuit. The functioning of one switch does not affect the operation of the other. O) The high pressure switch acts to stop operation whenever the discharge pressure becomes abnormally high. The low pressure switch stops operation when the suction pressure falls too low for safe operation. The high pressure switch should be set to open at 275 psig and the low pressure switch no lower than 2 psig. (2) The high side pressure control switch is actuated by the refrigerant pressure which expands the bellows against the force of a spring. This then gives straight line motion to an operating pin which throws the precision snap action switch to its opposite position when the setting is reached. The switch is restored to its normal setting when the pressure in the bellows drops enough to allow the force of the main spring to compress the bellows. The straight line motion eliminates friction and wear and assures continuous accuracy and reliability. Tefmnol C_ostd Nortr_Ny Cont_'l ' FIGURE I _ Norrr_lly Op_ Cont_l £-'- VI-6 RANGE AND DIFFERENTIAL ADJUSTMENT PRESSURE SWITCH -- ALLEN BRADLEY TYPE CONTROL Vl-13 (1) Adjustments: When the range adjustment screw on the front plate of the control is turned clockwise, both the cut-in and cut-out pressures are raised equally. Turning the range adjustment screw counterclockwise will lower the cut-in and cut-out settings an equal amount. (b) When the differential wise, the differential adjustment screw is turned of the switch is reduced clockby _the lower setting only. The top setting remains unchanged. Turning the screw counterclockwise widens the differential by lowering only the lower setting with the top setting unchanged. (c) On the high pressure side, the upper setting is the cutout point (control opens) and the lower setting the cutin point. Wh_le on the low pressure side of the system, the upper setting is the cut-in point, and the lower setting the cut-out (control opens). (c) At the high side, the cut-out should be set first using the range adjustment screw, and the cut-in point is set by changing the differential until the proper cut-in of approximately is achieved. (e) For the low side, the cut-in (upper setting) of is first established using the range adjustment and the cut-out of 2 psig is then set using the ential screw. (f) Do not force any adjustments. If an adjustment screw suddenly becomes very hard to turn, the limit of adjustment has been reached. Forced turning beyond this point can damage the control. NOTE: Vl-14 275 psig 12 psig screw differ- With the time delay provided in the compressor motor start circuit, the pressure at which the switch resets during the time delay interval can be very different from the pressures existing in the system when the compressor motor starts to run. The correct reset pressures are when the switches close, not when the compressor motor starts to run. Listen for the audible click as the contacts of the control switches close. The pressure modulation control switch (MPS)should also be removed from the circuit while the high pressure switch is being checked. This will allow the pressure to build up quickly without the unit going into modulation before the high pressure safety switch trips. (I) High Pressure Switch Operate the equipment and reduce condenser by covering the inlet Observe the high pressure gauge This should be approximately 275 and condenser fan motors cycle. when the contacts of the switch approximately 225 psig. CAUTION: (2) Do not LowPressure permit the the flow of air to the screen with cardboard. as the switch opens. psig as the compressor Note the cut-in point reset. This setting is pressure to exceed 285 psig. Switch Remove the cardboard from the condenser air inlet and operate the system. Slowly close the compressor suction valve and note the pressure at which the switch opens. This should be not lower than 2 psi 9. Do not permit the pressure to go below zero. With the compressor stopped, allow the pressure to rise to the desired cutin point of approximately 12 psig. Should further range or differential adjustments for the high or low side setting be required, refer to Figure Vl-6. Recycle the equipment to insure proper functioning of the control. The wiring diagram in Fig. VI-7. (i,) for the refrigeration controls assembly is shown R_eIDairs There are no field replaceable parts. Accordingly, any defective switches should be returned to SAFETY ELECTRICAL EQUIPMENT CORP. for repairs or service. bo PRESSURE MODULATION CONTROL SWITCH (MPS) The Pressure cut-out with Modulation automatic Control reset at Switch is 205 psig. designed to operate at 235 NAIqUAL-OFF._I)'I'O_I_TIC Lo_ pressuPe DIAGRAM S[L_CTOR _ 71:H Con'_rol S, it:h FIGURE VI-7 - WIRING psig - REFRIGERATION _'---- ---3 _. m,mL CONTROLS ASSEMBLY (W, it.,_. - CAT. NO. D-2899 TYPF h. Pressure Modulation Control Switch (LIPS) - Cat. No. 163748 (Cont%nued) The type.pressure switch used to control the functioning of pressure modulation of the upper circuit of the evaporator coil is shown in Figure Vl-8 Adjustment Should it be necessary to reset this type control, proceed as follows: The Range Adjusting Screw "A" raises or lowers the cut-out point (this also raises the cut-in point by a like amount). Set the cut-out point first with the Adjusting Screw "A". The cut-in (differential) Adjusting Screw "B" changes the cut-in point only. Pressure Switch Application Cat. No. Settin 9 (PSIG) Cut-Out Reset t Evaporator Coil Hodulation T_BLE VI-I Note: PRESSURE 163748 235 205 SWITCH SETTING (NOMIIIAL) Adjusting Screws "A" and "B" Extended Outside Casing for C Ia ri_y/./X D IFFERENTI AL --k ADJUSTING SCREW "B" RANGE ADJUSTING SCREW "A" CLOSE DIFFERENTIAL SCREW CONTACT BLOCK CONTROL P_;JGE AND DIFFERENTIAL VI-16 SWITCH ADJUSTMENT SCREW ! POWER ELFMENT MODULATION RANGE | . AI_I FIGURE Vl-8 - PRESSURE OFF CAPS (MPS) 3. SERVICIIIG a. THE COMPDNENTS OF THE AIR COOLED CONDENSER ASSEMBLY Condenser Coil Maintenance Normal maintenance of the condenser consists coil surface. The frequency with which the will be determined by the operating service road bed. of cleaning the finned coil must be cleaned and the condition of the If dirt is allowed to accumulate, the condenser capacity will be decreased. This may also result in short cycling (on high pressure cut out) and failure of the equipment as excessive operating pressures are encountered. Examination in service (I) To Clean of will the the condenser indicate the Condenser surface proper of time Coil (a) Using an air jet, blow back and forth over the face of the coil from both sides until all areas are covered. Continue until the leaving air is clean. Exercise care to insure that no damage is done to the fan nor fins on the coil surface. (b) Blow dirt from the casing. NOTE.: In "dirty" locations, periodic removal of lint or bristle brush, washing with where the pressure does not (2) after a short period cleaning schedule. To Remove the Condenser Coil from the condenser may require leaves. Use either a long a hose, or compressed air exceed 50 psig. the Unit Should it become necessary to remove the condenser or for mere extensive cleaning: coil for repairs (,) Set the compressor motor control selector switch (MANUALOFF-AUTOMATIC) and circuit breaker to the OFF position to remove power. Remove the side close off sets at the ends of the Condenser Coil section. Close the Receiver outlet valve and the Compressor discharge valve. (b) Should recovery of refrigerant not be required, move to step S. To recover refrigerant, transfer the charge to the receiver. Apply moderate heat to the Condenser coil surface using steam or hot water while cooling the receiver with cold water or ice bath. This will cause the refrigerant to pass over to the receiver. Continue for approximately 15 minutes. Close the Receiver inlet valve. (c) Loosen the 5/8" SAE flare connection at the Receiver inlet valve to relieve the residual pressure in the condenser coil. Remove the clampwhich secures the discharge line near the check valve to the support member. (d) Apply heat to the I-I/8" OD copper tube joint at the condenser discharge header connection (top joint). The brazing material used is "Easy Flo #45" silver solder with a melting point of 1125°F. and a flow point of l145°F. Use the flexible tube connector in the discharge line as a hinge point to remove the tube from the solder cup. Vl-17 (2) To Remove the (,,) Condenser Coil Unit (continued) tube liquid approximately around the the insulation covering from damUnsweat the joint by forcing the cup at the condenser liquid header. (f) Support the condenser using blocking on a hydraulic lift table. Remove the mounting bolts to the coil flanges. Lower the hydraulic lift table sufficiently to clear the condenser coil, with protective screen, from the unit. Seal the open tube ends to prevent entrance of moisture and foreign matter into the system piping. (g) Remove the or service To Replace the condenser coil may be effected. Condenser to the service area where repairs Coil (a) Apply the protective entering air side of (b) Position the coil on a hydraulic lift table. Elevate to position within the unit. Insure that no damage is done to the coil surface, headers, nor return bends. When positioned, secure with mounting bolts. (c) Make up the silver soldered joints with "Easy FIo #45", or equivalent. At the liquid line, pull back the insulation covering to approximately 5 inches from the joint. Wrap the tube and covering with a wet cloth to protect from damage during brazing. NOTE: Vl-18 the Prior to applying heat to the 5/8" OD copper line, force back the insulation covering to 5" from the solder joint. Wrap a wet cloth copper tube to protect age caused by torch. tube from the solder (3) from screen to the coil. the coil flange at the (1) If the entire refrigerant charge has been removed, evacuate the condenser and receiver circuit by connecting a vacuum pump to the purge valve of the receiver and follow the procedures outlined on page VI-2. (2) If a residual refrigerant charge has been retained, open the compressor and receiver shutoff valves. Operate the system. Purge at the receiver to remove air and noncondensable gases after 30 minutes of operation. (3) Observe the refrigerant and oil levels after steady operating conditions are reached. Replace as necessary as outlined on pages VI-3 and Vl-6. b. CONDENSER FAN MOTOR - CAT. NO. T-16822 This totally enclosed fan cooled motor is equipped with sealed-for-life ball bearings which require no relubrication under normal service conditions. The motor is designed to operate satisfactorily with line voltages which are within I0% of name plate values. (1) Maintenance NOTE: Contact with operating voltage may be fatal. Observe al] safety precautions. Always make sure that the electrical power is OFF while making electrical connections and while working on the motor during maintenance or repair. Keep fingers and tools away from the ventilation openings on motors and from rotating parts when operating the equipment. (b) Motor operating under feel hot to the touch. cause for concern. rated load and ambient conditions This is normal and should not may be \ FIGURE Vl-9 - CONDENSER FAN MOTOR - CAT. 2 HP, 1725 RPrl, 400/3/60 NO. hz, TEFC, T-16822 Frame Size 145T VI-19 (I) Maintenance (c) (2) (3) (Continued) Inspect the motor on a monthly basis for excessive dirt, friction, vibration, unusual noises or abnormal temperatures. Dust may be blown from inaccessible locations using a compressed air jet not in excess of 50 psig. Be sure that the drain holes are kept open. Inspect the motor mountings. Damaging vibrations may be caused by loose retaining bolts. To Remove the Motor (8) Set the compressor motor control switch (MANUAL-OFFAUTOMATIC) and the circuit breaker to the OFF position to remove power. Disconnect leads at the junction box. I4ark or tag for proper phase sequence when reconnecting. (b) Remove four hex head cap screws which secure the uDDer square fan guard for accessibility to the two 5/16-18 x5/8" head set screws in the fan hub. Remove the fan. (c) Remove four hex head mounting from the base. To Assemble, (a) Locate Reverse the finger tight. or equivalent, VI-20 the motor bolts and. lift the motor Sequence on the base Apply "Never to the motor and make up mounting Seez", shaft. SAFETY Spec. bolts MI-IO00 (b) Apply the fan to the motor shaft and align the fan within the orifice ring. Tighten the motor holddown bolts. Set the trailing edge of the fan blade 13/16" beyond the venturi. Torque the two square head knurled cup set screws in the fan hub to lO lb. ft. Apply upper fan guard. Reconnect the motor leads. (c) Operate Facing the motor to the motor end insure bell, proper fan the rotation rotation. Note: is clockwise. c. LIQUID RECEIVER, COMPLETE - CAT. NO.,M-1782 The liquid receiver is mounted vertically to the support frame and is located adjacent to the condenser coil. This tank provides the storage capacity for the charge of liquid refrigerant when the system is pumped down for servicing. The receiver consists of a welded steel shell with two dished heads. Two sight glasses are provided at different heights in order to gauge the liquid refrigerant level in the tank. Two shut off valves with 5/8" SAE flare connections are provided at the inlet and outlet connections. A purge valve with I/4" SAE flare connection is located near the top of the receiver tank. This valve is used during service operations, such as: purging (the release of noncondensable gases which may collect above the liquid refrigerant level in the receiver when the system is in operation), or evacuating the receiver-condenser circuit (by connecting a vacuum pump to this port). This valve also serves as a test cock to insure that liquid refrigerant is never stored above the upper sight glass level when both the inlet and outlet valves are closed. NOTE: An increased pressure in the rupturing of _he tank the receiver when both inlet caused by a rise in temperature under conditions of excessive and outlet valves are closed. may result liquid charge in A I/4" SAE flare connection is provided as an integral part of the receiver outlet valve. During operation, liquid refrigerant may be charged through this port. The valve is a backseating type and in the fully open position (stem turned counterclockwise to the backstop) the charging port is closed. This is the normal mode during system operation. Refer to Page Vl-4 for guidance in adding liquid refrigerant to the system. (1) To Transfer the Refrigerant to the Receiver the receiver outlet (Pump down) (a) Close (b) Open the suction pressure gauge valve at the Refrigeration Controls Assembly. Operate the compressor to pump down the system exceed 2 psig. until valve. the suction pressure does not (c) Set the motor control selector switch (MANUAL-OFF-AUTOMATIC) to the OFF position and circuit breaker to remove power. Close the compressor shutoff service valves. (d) Apply moderate heat to the condenser coil using steam or hot water and, at the same time, cool the receiver with cold water. Continue for approximately 15 minutes. This will transfer the refrigerant from the condenser to the receiver. Vl-21 (e) Close should above level tarily the receiver inlet valve. The liquid level be visible in the upper sight glass. If it is the upper sight glass, check the refrigerant in _he receiver by opening the purge valve momento lower to this level. CAUTION: Do not fill the receiver beyond 80% of its capacity. ,Remove the excess liquid refrigerant through the purge valve until the level appears (2.) To Remove Refrigerant in the upper receiver sight glass. From the Receiver: After the charge has been transferred to the receiver by pumping down the system, the refrigerant should then be stored in a service cylinder with sufficient volume and strength to accon_)date the.charge safely. (a) VI-22 For the Maximum Figure 1 in the Recovery Appendix of Refrigerant. - Refrigerant Flow (Refer to Diagram). (i) Close the line shut off valve at the inlet to the filter-drier assembly. Open the receiver outlet valve to the backseated position to close the charging port. Apply a transfer tube to connect the charging port to a standard Refrigerant 12 service cylinder. Purge the line and then tighten the flare nut at the service cylinder. Close the receiver outlet valve approximately two full turns in (to open the charging port and permit the flow of refrigerant). The receiver valve is a backseating type and in the closed or front seated position, the charging port is open. (2) Apply heat gently to the receiver using steam or hot water, and at the same time, cool the cylinder in an ice bath or with cold water. This will raise the pressure in the receiver and lower the pressure in the cylinder to accelerate the rate of removal. When all the liquid has been transferred from the receiver, close the cylinder valve and backseat the receiver outlet valve to close the charging port. Disconnect the transfer tube. Replace the seal cap, (J) A potential hazard in salvaging refrigerants from a system is overfilling the cylinder used to collect the refrigerant. The hazard is due to the increase in pressure with temperature should the storage cylinder become liquid, filled. For example, the increase pressure with R-12 is about 25 psi per degree rise in temperature. The bursting pressure of the container may be exceeded with a relatively small rise in temperature -- with hazardous results. in (3) To Remove the Receiver Should it become follows: (a) necessary For Maximum Q) to remove the receiver, Recovery proceed as of Refrigerant Close the receiver outlet valve and pump down the system until the suction pressure does not rise above 2 psig. Set the compressor motor control switch and circuit breaker to the OFF position to remove power. Close the compressor service shut off valves. Heat the condenser coil with steam or hot water, and at the same time, cool the receiver with cold water. This will cause the refrigerant in the condenser to pass over to the receiver. Continue for approximately 15 minutes. Then close the receiver inlet valve and the line inlet and outlet shut off valves at the filter drier assembly. Open the receiver outlet valve to close the charging port. Connect a transfer tube from the charging port at the receiver outlet valve to a standard Refrigerantl2 service cylinder. Purge the line and then tighten the flare nut at the service cylinder. (2) Following the same procedure to heat the receiver with steam or hot water and cool the cylinder in an ice bath or with cold water, transfer the refrigerant into a refrigerant 12 service cylinder. When the transfer is completed, close the valves, remove the transfer tube and apply the seal caps. (3) Loosen the two 5/8" SAE flare connections at the inlet and outlet receiver shut off valves slowly to release any residual pressure within the system piping. Disconnect the flare connections. (b) Support the receiver from below and remove four hex head mounting bolts. Lift the receiver outward from the side of the unit. Seal the tube ends and connections with protective caps to prevent entrance of foreign matter and moisture. (5) The removal of refrigerant from a system and the storage must be done by experienced and knowledgeable personnel. An understanding of potential hazards in overfilling cylinders, the reuse of contaminated refrigerant which may result in premature failure of equipment in later years, and the mixing of refrigerants in the same cylinder will increase the problems of storage and reuse. VI-23 (a) Loosen the 5/8" SAE flare connections at the receiver to release any residual pressure within the condenser and receiver. Disconnect the flare connections. (b) Support the receiver from below and remove four hex head mounting bolts. Lift the receiver outward from the side of the unit. Seal the tube (b) To Replace (a) ends and connections protective caps. the Receiver Position the receiver mounting bolts. Apply outlet connections. VI-24 with within the unit and. secure with the liquid lines to the inlet the and (i) If a residual charge of refrigerant remains within the system, open the receiver inlet valve and evacuate the receiver and condenser coil circuit by connecting a vacuum pump to the purge valve at the receiver. Evacuate this circuit to at least 29.7" Hg to remove air and moisture. Break the vacuum by adding approximately ten (I0) pounds of liquid refrigerant through the purge valve of the receiver. Open all valves which had been closed, and operate the system for approximately one-half hour. Raise the discharge pressure to 180 psig and the suction pressure to 37 psig to check the refrigerant and oil levels. The refrigerant should be at half level in the lower receiver sight glass during operation, and the oil level at approximately half level in the compressor crankcase sight glass at shut down. If either level is low, add to the specified level. (2) If no refrigerant charge remains within the system, evacuate the entire system by connecting a vacuum pump to the high and low sides of the system. When the vacuum has been lowered to 29.7" Hg, pump for approximately four (4) additional hours. Charge the system with approximately thirty (30) pounds of Refrigerant 12 to break the vacuum. (_) Servicing the Components Cat. No. B-1444-17 of the Evaporator and Blower Assembly - Figure 11-3 shows the arrangement of components which include: an evaporator coil assembly, an electric heat assembly, evaporator and blower assembly, a drain pan, and a flexible plenum. (a) The Evaporator Coil Assembly, Cat. I_o. M-4142-I, an evaporator coil with two liquid distributors, pansion valves, and a modulation solenoid valve top circuit. (1) includes: two exfeeding the Evaporator For efficient heat transfer, the finned surfaces of the evaporator must be cleaned periodically to remove any accumulations of dirt and lint. The application of a high pressure air jet (approximately 50 psig) blowing back and forth over the face of the coil from both sides stlould be continued until the leaving air is clean. Use caution to insure that no damage is done to the finned surfaces of the evaporator coil nor elements of the electric heat assembly. Remove dirt from the casing Flush the drip pan and clear drain lines. after the cleaning any obstructions operation. in the If it becomes necessary to remove the evaporator the system must be pumped down and the refrigerant charge stored in the receiver. (a) To remove the Evaporator Coil coil, Assembly Close the liquid outlet valve at the receiver. Operate the compressor until the suction pressure does not exceed 2 psig, then close the compressor suction shutoff valve. Remove the suction line insulation tape, SAFETY Spec. N-302, from the piping at the evaporator. Loosen a I/4" SAE flare connection at an equalizer line to an expansion valve to remove any residual pressure within the coil. Remove the thermal bulbs from the suction lines to protect against the effects of the open flame or heat from the torch as the 5/8" OD liquid and the I-3/8" OD copper tube suction lines are unsweated. (Z) (2) Disconnect the flexible duct face by loosening the #10-32 cure the duct clip fasteners side of the coil. Remove the flexible to the drip pan. connections at the evaporator wing nuts which at the entering at the drain seair lines VI-25 Detach the flexible electric (4) Remove the duct heat drain at the outlet of assembly. I pan. (51 Support the evaporator coil from below. Remove mounting bolts which secure the coil assembly to the car support members. (6) Disconnect electrical connections electric heat assembly. Tag for when reassembling. to the guidance (7) Lower the evaporator and electric assemblies as a unit through the opening in the ceiling. (2) (8) Effect (9) Apply the sequence. Expansion the Valves necessary coil sections - Cat. No. repairs in or heat access service. reverse T-3695-I q The two expansion valves which feed liquid refrigerant to the two multi-circuited sections of the evaporator are located at the side of the evaporator coil assembly. Each valve has a liquid distributor I/4" external equalizer connection, and an external superheat adjusting stem. SAE q V1-26 The thermo expansion valve has three component parts: Power assembly, cage assembly, and body flange. There are no working parts in the body flange. It is not necessary to break the solder connections to service the valve. To inspect, clean, or off the power assembly and are properly replaced when lugs on the cage assembly replace parts, remove two cap screws. Lift remove the cage assembly. Be sure gaskets reassembling valve and that the two 2) fit into the grooves provided for them(in the power assembly. DO NOT FORCE VALVE TOGETHER, INSURE THAT THE CAGE ASSEMBLY IS PROPERLY APPLIED BEFORE TIGHTENING BODY FLANGE. Expansion valves are accurately tested and preset for 6 - lO°F. superheat. Accordingly, no adjustments in the field unless absolutely necessary. at the factory should be made To adjust, remove seal cap at the side of the valve and turn the superheat adjusting stem. Turning the stem to the right decreases flow and raises superheat. Turning stem to the left increases flow and lowers superheat. Adjust valve two turns (l°F.) at a time. Adjust each valve separately observe results. Always tighten seal cap after adjusting. and wait between each adjustment to any loosened connections and replace The sensitivity and response of the valve is largely dependent upon proper installation and application of the feeler bulb. The bulb should always be firmly clamped to the suction line fed by the valve. It should be applied to the suction line close to the evaporator and on the evaporator side of the equalizer connection, 45 ° down from the horizontal centerline. Important Before replacing or otherwise attempting to service the expansion valves, make sure that the trouble is not in some other part of the system. Also, check initially the application of the valve bulb to the suction line. On new installations, some valve trouble may be .caused by dirt left in the lines when the piping was installed. Trouble from this source will disappear after a short period of service and the liquid line filter-drier or strainer will likewise take care of dirt which may enter the system thereafter. VI-27 If investigation of faulty operation of the system indicates the trouble is in an expansion valve, proceed as follow.is: l SEAL . Close valve . Operate the comnressor until the suction or low side pressure cutout point of approximately 2 psig is reached. EQUALIZER CONNECTION CAP ADJUSTING STEM The pressure will build un again. Repeat this operation until the pressure does not rise above 2 pounds. (If, by chance, the pressure is lo_vered below zero and it does not rise to one or two pounds, open the liquid valve momentarily to build up to a slight positive pressure.) CAGE ASSEMBLY BODY FLANGE GASKET SEAT GASKET . 4. ./j_ CAP SCREW BODY FLANGE FIGURE VI-lO - EXPANSION (WITH EXTERNAL VALVE SUPERHEAT - CAT. NO. T-3695-I ADJUSTMENT) the liquid outlet at the receiver. Close the compressor valve. sucti( If a replacement power element or cage assembly is to be applied, unclamp the remote bulb from suction line. Disconnect the flare connection at the equalizer line. Remove two $1ange bolts. The power element and cage asse_)ly may then be removed. Remove any foreign material (solder, dirt, chips, etc.) from the valve body. Insert the replacement valve components without undue force and position the gaskets properly. Clamp the remote bulb securely to the suction line on a 45 ° plane below the horizontal centerline. Reconnect VI-28 the equalizer line loosely. . Purge through the equalizer line. Tighten and test for leaks, wrap the suction line remote bulb with insulation tape, SAFETY Spec. N-302. CAUTION: (3) Evaporator Coil Do not apply heat near of the remote (feeler) expansion valve without ing the bulb. Modulating Solenoid Valve - the location bulb of the first remov- Cat. No. The solenoid valve is equipped with a manual opening permits the main port to be opened without energizing or for use in the event of the failure of the coil. movement energize the coil. of the plunger is the control circuit audible, it is to determine Refer to Parts List 5453, Solenoid Valve, replacement parts and service instructions. (4) Motor - Cat. No. and T-3330 stem which the coil, Since the only necessary the functioning for the Type list to of of T-16807-I The blower motor is designed for long service life. It is necessary, however, to keep it clean and dry for prolonged trouble-f_ee operation. Stator troubles usually may be traced to one of the following caused: worn bearings, moisture, overloading, operating single p_ase, or insulation faults. Dust and dirt are normal contrihdting factors. (a) Maintenance Inspect the motor on a monthly basis for excessive dirt, friction, vibration, unusual noises, or abnormal temperatures. Dust may be blown from inaccessible locations by using a compressed air jet (approximately 50 psig). Be sure that the drain holes in the motor are kept open. Inspect the motor mountings since damaging vibrations may result from loose mounting bolts. Motor troubles may also be traced to low volta_,e conditions, loose connections, or lack of m_iptenance. (b) To Remove the Motor (1) Set the control switch and circuit breaker to the OFF position. Disconnect the leads. Mark or tag for phase sequence and 9roper rotation when reconnecting. (2) Support the motor to position the mounting bolts. (3) Lower (4) Replace in reverse proper rotation. while removing from the unit. order, operate to check for VI-29 (c) To Remove the Blower (1) Proceed housing through Wheels as above. Remove the inboard (motor side) inlet rings and withdraw the blower wheels the opening. (2) Reassemble in reverse sequence. however, that the blowers which in design be properly applied. 5. Repairin 9 Leaks CAUTION: A. Prior to attempting any repairs, it is essential that the residual pressure in the lines be relieved before disassembling connections or unsweating soldered joints. To Repair I. . 3. . 5. Leaks in . . . a. The liquid and blower line from the receiver unit. b. The evaporator valves. c. The suction compressor. coil, connections, to the evaporator and expansion line from the evaporator Close the liquid outlet valve the suction gauge valve. coil to the at the receiver and open Operate the compressor and pump down until the pressure does not rise above two pounds. Avoid reducing the pressure below zero psig. Close the compressor NOTE: VI-30 It is important, are forward curved suction valve. The solenoid valves piped in the liquid line and at the evaporator are normally closed when de-energized. To open the valve, turn the manual opening stem a maximum of I/4 to I/2 turn counterclockwise. Relieve the residual pressure in the circuit by loosening either flare connection at an equalizer line to the expansion valves. Make the required repairs. 6. Purge. 7. Crack the liquid pressure in the Test . 9. B. If Tighten repairs tight, any connections outlet circuit, for which valve then may have at the receiver close the valve. been loosened. to build up leaks. evacuate air and moisture from the lines. 10. Open the compressor suction valve and the liquid valves at the receiver and filter-drier assembly. Close the liquid line solenoid valve by turning the manual opening stem to ½.turn clockwise. Build up pressure in the low side of the system to reset contacts of the low pressure control switch, if necessary. 11. Operate the equipment sable Gases". 12. After steady operating conditions are obtained, observe the levels of refrigerant in the receiver and the oil in the compressor sight glass. Add, if necessary. To Repair a. b. c. Leaks in . and purge. The line between The condenser. The line between the compressor the condenser Turn the compressor position. 2. Close the liquid outlet valve compressor discharge-valve. 4. of Non Conden- . l. . See "Removal motor control and condenser. and receiver. switch to the at the receiver "OFF" and the Apply moderate heat to the condenser using steam or hot water. At the same time, cool the receiver with cold water or ice bath. This will cause the refrigerant to pass over into the receiver. Continue this for about fifteen minutes. Close the receiver NOTE: inlet valve. The check valve in the discharge line will remain in the closed position when the system is not operating. To vent the pressure remaining in the discharge line and condenser, loosen the 5/8" OD flare connection at the inlet valve to the receiver. 5. Make the required repairs. have been loosened. 6. Crack the receiver Then purge. 7. Test the repairs inlet Tighten valve for leaks. any connections slightly to build Open the compressor which may up pressure, discharge valve. Vl-31 8. Operate Gases". . After level the steady at the pressor. C. To Repair equipment operation receiver Add, if and purge. of the and the See "Removal of system, observe the refrigerant rate of oil return to the com- necessary. Leaks at the Receiver Sight Glass If a leak is detected at a sight glass assembly, necessary to renew the sealant used at the threaded . 2. . Non-Condensable it is Joint. With the minimum level of refrigerant in the receiver, close the inlet and outlet valves. For maximum recovery of refrigerant, follow S.eps 2, 3, and 4. Connect tube. a service cylinder to the purge valve with a transfer Open the purge and cylinder valves. Transfer the refrigerant to the cylinder by warming the receiver and cooling the service cylinder as outlined above. 4. Close the cylinder and purge valves. Disconnect the transfer tube from the purge valve and open the purge valve to bleed off the residual pressure. S. Remove the sight glass assembly (normally the bonded parts can be disassembled with ordinary hand tools. If the holding power is too great, however, gently heat the joint to approximately 450OF. to weaken the sealant. Disassemble while hot.) Note: o 7. Bonded parts cannot be loosened with solvents. To reassemble, remove powder accumulation from the threads. Apply sealant Prlmer and Catalyst, "Safety" Catalog No. T-13624, and allow five minutes drying time. Apply thread sealant, "Safety" reassemble sight glass. Note: Catalog No. T-13625, and Only the sealant down in the threads will harden. Wipe off any accumulation on the outside of the sight glass. The cure time for the sealant is a function of the temperature--aperoximately two hours at 72°F. and up to 48 hours at 40UF. . 9. 10. VI-32 Close the purge valve and open receiver to build up pressure. for leaks. the inlet valve on the Purge and then test repairs Evacuate the receiver. air and moisture from Open the outlet valve at the receiver and return the refrigerant previously removed to the system as outlined under To Add Refrigerant Operate Gases." of oil the equipment Observe the return to the 6, I. to the System and purge. refrigerant compressor See "Removal of Non-Condensable level in the receiver and the rate after steady operation is obtained. SAFETY PRECAUTIONS IN HANDLING REFRIGERANT 12 FROSTBITE If Refrigerant 12 in the liquid phase comes in contact with the skin, the rapid evaporation may cause freezing. The presence of fluorocarbon vapors in the air surrounding the point of contact does not affect the skin nor frozen area. Treatment is the same as for frostbite from any other source. The following a. is suggested: If treatment is begun within 20-30 minutes soak the exposed area in lukewarm water. CAUTION: DO NOT SOAK IN ICE COLD WATER after exposure, NOR IN HOT WATER. b. If treatment is begun more than 30 minutes eliminate the preliminary soaking. c. Apply a very light petroleum jelly. d. Apply a light bandage if the exposure is at a location where the presence of the ointment would be awkward. el 2. treatment b. of any bland ointment, such as If the frostbite is severe and the frozen area large, administration of an anticoagulant or vasodilator should be considered by a physician to avoid the development of gangrene. Effects a. coating after exposure, on the Eyes The vapors have little effect on the eyes. Exposure to Refrigerant 12in the liquid phase or to solutions of fluorocarbons dissolved in oil may produce temporary redness. (No permanent damage was found in tests with rabbits). If Refrigerant 12 liquid contacts the eye, serious damage from freezing may occur. Eye protection should be worn at all times. Get medical attention immediately. Flush eyes for several minutes with running water. VI-33 3. Effects on the Skin Refrigerant 12 liquids will dissolve and extract the natural oils present in the skin. If contact is prolonged, the skin may become dry and perhaps cracked. Neoprene gloves are recommended, if exposure to the liquid refrigerant is possible, to avoid irritation to dry, sensitive skin. NOTE: There is very little evidence of the absorption of Refrigerant 12 through the skin or effect on internal organs similar to that found with some chlorinated compounds, such as carbon tetrachloride. Refrigerant 12 vapor is 4 to 5 times heavier than air. High concentrations may tend to accumulate in lower areas. A well accepted authoritative source for first aid procedures should be used for training all service personnel, and the physician on call at your facility will best be able to provide recommendations to suit the AMTRAK operating conditions. The fourth edition of the American Red Cross First Aid Handbook, for example, provides fifteen pages on a description of artificial respiration and three pages on treating frostbite. After contact with liquid refrigerant, any contaminated clothing should be removed at once and not worn again until completely dry. All affected body areas should be washed with soap and water. After washing, a lanolin-based ointment should be applied to help replace the natural skin oils. If persistent signs of skin irritation appear, consult a physician. 4. Environmental Considerations Ozone Depletion Theory Do not deliberately discharge in Handling R-12 and the R-12 Refrigerant to the atmosphere. Recent environmental studies have shown that there may be a link between R-12 refrigerant in the atmosphere and a possible increase in skin cancer caused by a reduction in atmospheric ozone. VI-34 SECTION 7 AIR CONDITIONING STARTER PANEL The panel is arranged so that any component subject to wear ation can be easily removed from the front without disturbing ing components or wiring. All nuts for mounting components to the back of the panel so that the panel does not have to for replacement of individual components. The following panel: components Refrigerant Condenser are Compressor Fan Motor mounted Motor Overload on the air conditioning Starter RCMS Relay OL3 Heat Contactor No. 1 HCl Heat Contactor No. 2 HC2 Blower Terminal Fan Motor Starter or deteriorthe remainare welded be removed starter BFMS Board TBI The refrigerant compressor motor starter and the contactors for applying both stages of electric heat are interlocked by means of auxiliary contacts on the blower fan motor starter. Therefore, whether heat or cooling is called for, the blower fans must be on. The condenser fan motor uses the same contactor as the compressor motor, except that it has its own overload relay (OL3). The overload relay that the compressor motor uses is OL2. The condenser fan motor, therefore, starts at the same time as the compressor motor. In addition to the requirement that the blower pressor motor is further interlocked with the relay (OL2), the condenser fan motor overload sure switch, and the low pressure switch. The two stages of heat are initiated HC2). In addition to the requirement the heat contactors are interlocked (PT) which will open the circuit at fan motor be on, the comcompressor motor overload relay (OL3), the high pres- by the two heat contactors (HCl and that the blower fan motor be on, with a heat protective thermostat 200°F. Vll-I The heat or cooling is initiated by signals from an external temperature control which is not supplied by "SAFETY". The cooling function can be initiated by "overriding" the temperature control with the "MANUAL-AUTOMATIC" switch located on the compressor motor control box. By turning this switch to "MANUAL" (the cover must be opened first), the compressor motor will start, even though the temperature control is not calling for cooling. This switch can then be considered a "test switch" for checking out the cooling function. The control circuit operates on 120 volts, 60 hz, single phase power, while the motors and heating elements operate on 460 volts, 60 hz, 3 phase power. TROUBLESHOOTING In order to isolate the problem if the a_r conditioning starter box is not functioning properly, the external wires that terminate on TB-I should be removed and a power source of 120 volts, 60 hz, single phase be made available to power the control box. Apply 120 volts across TBl-l and TBI-7. The blower fan motor starter should energize. If not, then either OLl has been tripped or the starter coil is defective. With power applied as above, jumper TBI-2 to TBI-4, and TBI-7 to TBI-6. HC2 contactor should energize. If not, then either the auxiliary contact on the blower fan motor starter is defective or the contactor coil is defective. Change jumper from TBI-7 to TBI-6 to TBI-7 to TBI-5. HCI contactor should energize. If not, then the contactor coil is defective. Remove jumpers between TBI-7 to TBI-5 and TBI-2 to TBI-4. Add jumper from TBI-7 to TBI-3. The refrigerant compressor motor starter should energize. If not, then the faulty component is either the auxiliary contact on the blower fan motor starter or the coil of the compressor motor starter, or OL2 or OL3 has been tripped. Of course, in addition to the actual closing of the contactons, it must be ascertained that there is continuity through the contacts and overload heaters when that particular contact or starter closes. That is, when RCMS closes there should be continuity from Ll to 2Tl and 3Tl; L2 to 2T2 and 3T2, etc. VII-2 Evaporator and Blower cat .o B-l_,_-l_ Liquid Line SAFETY Assembly\ _. Solenoid T-3330-II Valve Evaporator Modulation ,_l_otF d _-_ ___ _'20X14 __ \ at /Moisture Heat Electric Heat Assembly 2 Equal lO KW Stages * Expansion Valve ODM Connections (2) I-3/_ I Valve _1_o/_/_o) _---l'Jl'_-_'l Liquid Line Strainer_._.____ (C_eanable) SAFETY T-15531 Solenoid each end and of Drain liquid Exchanger Pan Indicator SAFETY SAFETY T-2669-2, T-15521-2 Dwg S-2351 Floor Air O Cooled SAFETY Inlet Valve Condenser Motor B-2247-I0 _..____ "n ;oil Compressor . \Check _Va1_eS_3/80D _1I ill / I re and Discharge Line Assembly B-39S8-h _ R.frtge*'atton Li_Lx__. Controls_ SALTY 163021 j_ ,f_l_'_"..."Jk-_ PI, ! modular _° SAFETY Ik 16302 0 _F _r _ Dwg Pilter _q_xible SAFETY _otos: I * Indicates system. Main Power Suction 163020,Dwg component_ Supply Connection assemoleo h60/3/60, SAFETY 163088,Dwg Core (2 Reqd) _,,.,:'_TY I_Io_ 2h7_39 to Control maDor unit, Voltage others 120/I/60 are furnished T-J,hh5 Drie r__/ separately as 150917 _J.., LL-_4 _:'_ _4__ accessOries to the AIR COOLED CAT. NO. CONDENSER PARTS CAPACITY I REFRIGERANT B-2442-I0 8-Ton I R-12 I LIST 5777 (4/78) VOLTAGE_ [460/3/60h_ 14 NOTE: Undercar Item No. Mounting Support Frame Adapter - Cat. No. M-4113, Description l 2 3 4 5 6 7 8 9 lO Access Door Cemplete (Left Side) *Access Door Complete (Right Side) Bracket, Complete (Fan Guard) Condenser Coil Cover, Coil End (Left Side) *Cover, Coil End (Right Side) Guard, Screen (Condenser Air Inlet) Fan, Complete *Fan Guard (Rectangular) 12 13 14 15 16 17 18 19 20 21 22 23 24 Inlet Piping (Condenser to Receiver) Insulation (Covering for Item 12) *Key, Motor Shaft (I/4 x I/4 x I-I/32) Motor, Complete (P/L Motor Mount, Complete *Pressure Control Switch (Modulation) **Receiver, Complete Sight Glass Resilient Mount Set Bolt Nut Rebound Cushion Washer *Fan Guard (Circular) Cat. No. Not Shown No. Req'd. S-2213-2 S-2213-1 T-3605 B-1566 S-2179-I S-2179-2 S-2178 M-1890-2 S-2281 M-1831 l 1 2 l l l l l l l T-3597 T-7222-I 304760 T-16807-I S-6071-2 163748 M-1782 T-12967-2 T-13706 S-2199-I T-4435 T-3367-4 500202 l l l l l 1 l (2) 6 (I) (1) (2) (1) * Not Shown ** Note: Receiver - Item 18. Use Pipe Thread Joint Seal Primer "Safety" Cat. No. T-13624 and Sealant, Cat. No. T-13625 when assembling one piece(threaded) sight glass, Cat. No. T-12967-I (Item 19). EVAPORATOR AND BLOWER ASSEMBLY CAT. NO. B-1444-17 CAPACITYREFRIGERANT 8-Ton RI2 VOLTAGE CONTROL 460/3/60 VOLTAGE 120/I/60 2 18 41 / 15 16-19 l i Item No. I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Cat. No. Description B-1434-15 M-4142-I B-2488-I T-3695-I T-11550 T-733g-I T-7823 T-7824 T-3330-I T-7820-4 Blower Fan and Motor Assembly (Page 2) Evaporator Coil Assembly ***Evaporator Coil (w/o distributors) Expansion Valve (Alco) *Cage Assembly **Power Element *Gasket (Body Flange) *Gasket (Seat) Solenoid Valve *Coil *Gasket, Body *Gasket, Seal *Seal Cap *Diaphragm Drain Pan T-7822 T-15061-2 T-15061-I T-7821 M-1485-I T-7784 "0" Ring Cap Duct Clip Heating Coil Plenum Wing Nut B-4319-I B-4409 154458 No. Req'd. l l (I) (2) (I) (I) (2) (I) (I) (1) (1) (1) 1 1B 1 1 18 * Not Shown ** Includes two (2) Body Gaskets, one (I) Seat Gasket and two (2) Remote Bulb Clamps. *** When reordering item, specify"Evaporator Coil to be furnished with distributors, Cat. No. T-3696-7, arranged for R.H. piping application." NEW YORK • CHICAGO , PHILAOELPHIA • RICHMOND • ST LOUIS , S'AN ITREAL Page 2 - AIR CONDITIONING UNIT, CATALOG NO. B-1444-]7 16 -- ]7-18-|9-20-2l 15 ] 13 \ 2 i 4-22 EVAPORATOR Itern No. I 2 3 4 5 6 7 8 9 I0 11 12 13 14 15 16 17 18 19 20 21 22 BLOWER FAN AND MOTOR, CATALOG Description Blower Blower Fan Fan Bracket, Mounting Duct Clip Entrance Ring (Venturi Plate) Housing Motor (Parts List 5784) Shaft Extension Assembly Extension Hub * Key (1/4 x I/4 x I-7/16) Nut Screw * Set Screw Shaft Extension, Complete Support Mount Resilient Mount Set Bolt Nut Resilient Bushing Washer (Rubber) Washer (Steel) Wing Nut Not Shown NO. B-1434-15 Cat. No. T-1793-3 I"-1793-4 S-180l-I T-7784 S-1802 M-1542 T-16807-I T-14037-3 S-7187-3 T-1603-3 T-4435-3 22099 59107 S-7188-3 M-6426-I T-13706-5 51327 T-4435-2 163770 163771 163782 154458 No. Req'u. l 2 12 4 2 l 2 (1) (1) (3) (3) (1) (1) l 4 (I) (I) (1) (I) (I) 12 i l DIRECTDRIVENMOTOR COMPRESSOR UNIT TYPE-PRESSURE OPERATED CAPACITY CONTROL CAT. NO. B-3988-4 CAPACITY I REFRIGERANT VOLTAGE 8-Ton R-12 460/3/60 PARTSLIST 5776 4/78) hz I i 6 3-17 \ 9 NOTE: Item No. Undercar Mounting Bracket, Description Bracket, Screen Chain (Form - Cat. No. M-5999-3, Cat. No. B-I023 162156 164188 Complete Compressor 10 11 12 13 14 15 16 17 Support 5295) 161705 Flexible Coupling (page 2) Motor, Complete (P/L Form Motor Support Refrigeration Controls Assembly * Gauge, High Pressure * Gauge, Low Pressure * Manual Selector Switch * Pressure Control (High-Low) 161685 T-18554 B-2002-I B-2899-2 T-16284-I T-IbZB3 Resilient Mount Set Bearing Cup Bolt Rebound Cushion Resilient Bushing Nut Washer Shackle T-13623-2 307505 59390 307504 159167 T-4435 500202 163139 * NOT SHOWN S-8816-2 T-14059 Not Shown No. Req'd. 1 (I) 2 1 1 I 1 1 (I) (I) (1) (1) 4 (I) (I) (l) (I) (i) (1) 4 FLEXIBLE Item No. I 2 3 4 5 6 q 8 9 l 8 2 COUPLING...Catalog Description Beveled Washer ................ Bolt (Short).................... Bolt (Long) .................... Compressor Flange Complete .... Laminated Disc Assembly ........ Center Ring .................... Motor Flange Complete .......... Locknut ........................ Spacer ......................... No. Cat.No. 161555 161556 161557 161712 161713 161714 161715 161563 164077 161685 No. Req'd 18 6 3 1 2 1 1 9 6 I. Flexible Coupling, Cat. No. 161685 FORM 5310 2. Refrigeration Type B-2899 Controls i 6 7 4 9 2 5 h/7_ • FLEXIBLE t COUPLING-CATALOG Item No. 7 8 9 1 A Assemb1_, 8 NO. 16168! Cat. No. Description Beveled Washer Bolt (Long) Bolt (Short) Center Ring Flange Complete, (Compressor End) Flange Complete, (Motor End) Laminated Disc Assy. Locknut Spacer 161555 161557 161556 161714 No. Req'd. 18 3 6 1 161712 161715 161713 161563 164077 1 2 9 6 3 REFRIGERATION CONTROLS ASSEMBLY CAT. NO. B-2899-2 I t t Item No. Description Cat. No. NO, Req'd. t 1 2 3 4 5 6 7 8 12-11-16 \, g 10 11 12 9 7 13 14 15 16 Block Control Box Elbow, Half Union Flare Nut Gasket Gauge, High Pressure Gauge, Low Pressure High-Low Pressure Control Switch Manual Selector Switch Nut Nut Strain Relief Bushing Valves Complete * Flare Gasket Seal Cap Washer * Not Shown I-I0 5 4 T-2961 B-1489=2 155966 151693 T12964 T16284-I T-]6283 T-14059 S-8816-2 55770 158057 305756 T-18169 163820 151439 24948 I 2 (I) (I) I FORM 5297 COMPRESSOR 11167) CAT. NO. 161705 I Open Type - With Pressure Operated Capacity Control Mechanism SERVICE INSTRUCTIONS TABLE AND PARTS I I LIST OF CONTENTS Section I. SERVICING II. CAPACITY Ill. PARTS NEW YORK • THE COMPRESSOR CONTROL FOR UNLOADING COMPRESSORS LIST CHICAGO " PHILADELPHIA - RICHMOND . ST LOUIS • SAN FRANCISCO • NEW HAVEN • MONTREAL SECTION SERVICING 1. Compressor the To insure crankcase proper must be the system just ] THE COMPRESSOR Lubrication is as lubrication maintained harmful of the between as too little. Initial charge at factory Level when opc:ating Minimum level after standing These a lower larly ly below levels level the 15 minutes are average, when operating. bottom of the the Prior system pressure thirty system, rather to adding be properly is above minutes. compressor added it. it always warm crankcase, more foaming The will slightly and the the vents the crankcase in the The warm up speed may in about in the oil can the a half system compressor at or particuslight- is running. the dropping If a oil charge that oil that the determined been are: is permissible, be safely crankcase, be seen has refrigerant amount only in operation from check release cool for hour. the excess pressure is must of oil in if the head for gas is released latter crankcase a short at least loss oil should be after the the in turn, the remain warm starting the in circulation, from raises from always it enters of oil it will be seen the oil returning will period when excess which, Thus, from the an increases valve. of gas this valves, which, with thereby suction of the be the may it is important This should be Thus which at which temperature eye when some released check - 1/2 some variation The oil level foaming. result, above eye bull's of the oil in much oil in levels - 12 pints - 1/3 bull's falling or no the contains closing of the oil return no balance between the case and level Too to a unit which already has an excess of oil in the it will tend to lower the oil level in the crankcase This is due to the fact that when oil returns to the causes refrigerant pressure psig the limits. Recommended glass oil, however, checked. 180 Should oil be paradoxically, than to raise and sight good quantity of oil is observed adequate; it is only when little be added. compressor, certain crankcase. crankcase results in the that, if there to the crankcrankcase through closed. to the up, touch. While it should is Under some conditions, it may run hotter than 105 ° F, but it should not run colder. A crankcase which is running colder than normal is an indication of one or both of the following 1. The . expansion There valves is excessive cool, the crankcase that the case refrigerant the of oil CONTROL and OIL at the PRSSSUR( is causing At the in excess return in the which system. crankcase GAUGE oil adjusted to pass system. the of the SHUT oil suction liquid. crankcase from to foam, time, much than it would The reason evaporating same proper too If the oil level will always be lower were at normal temperature. is cooling into are conditions: the thus pressure is running be if the for this oil in the carrying it out is maintained pressure which is crankin the prevents the rate. OFF VALVS VALV E PLATE GONNSCTION GASKET (DtSCHARG(} _ GASKET CYLINDER rAND MOLE COVER VALV S HSAD PLATE YLINDSS HAND AND HOLE SIGHT HSAO COVER GLASS ASSEMBLY VALVE DISCHARGE VALVE ASSEMBLY HAND HOLE AND COVER GAFIkCITY VALVE CONTROL ASSEMBLY OIL OIL I_MP SAUO£ FILL PLUG M4NO PRSSSURS CONNECTION OFF VALVE SUCTION ¢AIAIIliCAI_ FIGURE I-i HOLE COVER GASKETSHUT _SS_SB i'3)MIIGCTIOll COMPRESSOR, PUMP END VIEW {SIGHT GLASS S_D() Test for excessive This test is oil in system: made at the clean white paper close quantity of the refrigerant is in circulation, ant should not than to make Removing the best drain plug compressor hour. ping oil to the valve to spray paper appear way to remove in the crankcase is will be is being is no running. than oil the time assumed that It should all level be excess oil is to loosen allow the oil to bleed and rate or removal in the the trace should noted has be that, level Continue of excess oil removed. as at high start has of refrigerintensity be (do not out remove) slowly about in the in spite this as one be up, quart the per by oil dropreduced, of the process fact until that there system. If it has can the while not done time for the level at about so, it may satisfactorily maintained. OIL PRESSURE GAUGE CONNECTION PUMP DIRECTIONAL ARROWS depending on been absorbed. Oil: To add oil, the compressor be emptied of refrigerant by must pump- ing-down as 1. Close compressor 2. Pump down by operating the compressor until the suction gauge pressure does not rise above two 3. of the greater slowly enough to allow ample the oil should rise to a normal been will crankcase crankcase. this procedure crankcase, excess the the rise from oil will begin to return, how much refrigerant This is normal. first a piece and crack slightly to permit a small on the paper. If a proper amount of oil the compressor will lose considerable oil; sometimes to the point where splash in the crankcase almost ceases. It may be from 20 minutes to an hour before the Adding Hold water-marked. The a slight By following to return to the that valve. from the crankcase, it will be replaced As the amount of excess oil is gradually a noticeable removed more charging oil: As oil is drained out of circulation. there line the oily residue left after the evaporation be more than enough to produce a stain of no excess The oil liquid pounds. Close valve. the follows: compressor suction valve. discharge OIL FIGURE I-2 DRAIN PLUG PUMP COMPRESSOR END OF be NOTE: h. Unscrew 5. pressure to bleed Pour oll through sight glass. the oil fill plug off. this on the opening compressor to bring slowly oil level 6. Replace the plug loosely, the compressor discharge crack suction valve and suction valves. 7. Operate level to Always keep atmosphere the system. ascertain compressor will absorb oil under oil stored in moisture which Use only dehydrated wax free grades of for Refrigerant 12 compressor lubrication and as to have the necessary low moisture content. Oil Requirement permit middle purge, tighten at at IOO°F. 210°F. Oil when Also Cat. No. T-9387 (24 Quart T-9387-I T-9387-2 (5 Gallon) (Quart Can) Pour -25°F. Oil The the Compressor compressor is equipped This pump is located and is direct driven cover starting the be reversed, To suitable oils plate show compressor this can the in the from Crankcase correct with Vendor for the first time, done manually by be reverse the I. Close suction valve. Pump down. Set the motor Close discharge o 3. Vent plug. pump, the a gear proceed pressure as Oil Co. Oil Dual Inhibited Suniso bG Co. type positive DI when displacement oil head opposite the shaft Direction arrows cast viewed this should rotating the from the top. Upon be checked. cover plate If it need 180 ° . to the "OFF" position. follows: control switch valve. from the crankcase are: Desi_nntion Oil pump end bearing the crankshaft. rotation the into Case) Pump pump. extension on of open are listed used up -50°F. Maximum Properties to 0 25 25 KV Physical 2. 4G Capella DI Dielectric, Minimum Floc Point Point, exposed introduced 300 _ 20 _5 - 50 Suniso the plug, compressor crankcase oil enough so that it will be Texas Viscosity Index Dual Inhibited of oli which are suitable and recommended which have been specially processed ao "Safety" SSU SSU residual conditions. Sun Viscosity Viscosity the to the containers. cause trouble The physical properties of the recommended below. Oil should be ordered in containers small when the containers are opened. Compressor to stabilized sealed can to by loosening the oil fill 4. Remove the ing . the six cap cover, Rotate the bottom motor. arrow cover Open compressor fill plug. 7. Open from care that one-half is 6. now on top valve If the and The in the necessary to pump down before again to remove the gauge. may be bearing The oil pressure to the which requires no Complete assemblies to the factory the bearing furnished seal regulator jacent housing. adjustment. in exchange head and separately. pump is for must new pump. service or It is well and also on the the shaft and the in position seal housing. of the oil pressure. cover plate and the factory. Refer to "A", defective and indicated by the oil will be the actual oil screen in the crank- of the pumps The block gauge crankcase ad- relief valve be returned I-3. Individual a wood the Figure oil a gauge to the I-2. It will be pressure returned. by wedging the to check the oil presswhen a replacement side type When removing the pump end bearing head and crankshaft should be blocked to prevent the seal end down on the shaft and being pinched when the bearing Block flange oil to apply assemblies. be that Tighten applying Figure note the pressures The difference caused by the oil Detail of worn gasket. rotation the by See plug a cartridge See the one obtained from pump clearance. the is located This so the checked head. removing wear in the is put into re-apply crankcase_ between in remov- in maintaining adequate lubrication The correct oil pressure should be after steady operating conditions have To determine the oil pressure, gauge and the suction pressure gauge. pyessure. A lower pressure may be case being clogged or by ure when a new equipment compressor is installed. and, to the to check it only with affects the CLEARANCES. pressure pump end cover is done with to purge gasket Correct oil pressure is important and satisfactory unloader operation. 45-55 psig above the suction pressure been established. tapping provided and operate special pump agrees valve and pump is damaged, replace The thickness of the gasket page 1-15_ OIL PUMP the no damage revolution suction discharge CAUTION screws take may complete pump spacer head between assembly pump parts of are assembly, the from dropping is replaced. the coupling not m 73 61 74 DETAIL HIGH PRESSURE CONTROL CONNECTION OIL REGULATOR (NON-ADJUSTABLE) \ SUCTION GASKET PRESSURE "A" STRAINER \ SUCTION CONTROL OIL PRESSURE GAUGE CONNECTION STRAINER ASSEMBLY SUCTION COVER _AATIC COMPENSATING CONTROL CONNECTION MANIFOLD I CAPACITY CONTROL VALVE SHAFT COVER SEAL PLATE OIL PRESSURE REGULATOR (see DETAIL "A") FIGURE 3. Shaft COMPRESSOR - SEAL END Seal If the However, seal has I-3 shaft seal fails, fresh a slight oil film at this failed. A small seepage essary for lubrication. It is well body surfaces wiped clean so that amounts can be detected. oil will be evident point may not of oil between to keep the the presence on the necessarily the sealing seal cover plate. mean that the surfaces is nec- cover plate and compressor of fresh oil in unusually large Generally a Halide torch leak detector is sensitive enough to determine excessive refrigerant losses at the seal. Electronic detectors normally will pick up the small traces of refrigerant in the seepage oil. This may give a false indication of a shaft seal failure. Removing motor to the Shaft Seal: effect changeout). (It is not necessary to move Should leakage make repairs necessary, seal assembly be applied rather than trying the seal, proceed as follows: Operate the compressor valve until the suction it above two 2. Stop tion. 3. Unscrew compressor. 5. Installing oil on the Remove the seal The contents 1. Spring 2. Spring, Band of the shaft Sleeve the and slide from seal cover the the 4. Flange 5. Retainer that a new To remove to the residual shut rise flange in the Remove screws toward Seal shaft - Integral seal the shaft, the in the motor and also plate. and Seat assembly Driving Type are illustrated 6. Carbon 7. Seal in Figure Seal Seat Washer and Cover Plate Retainer 8. Cover 9. Instruction 5H40-1915 Plate Gasket Sheet, Shell with posi- parts. Bellows seal off "OFF" pressure compressor Assembly Neoprene switch the flexible coupling. a unit. Loosen the set Guide 3. the shaft flange Shaft to relieve from as the seal set the control shut off valve. plug motor and the Rotary fill short bolts disc assembly head. Remove Handle the the dust it is recommended to relap the old one. nor pounds. flange the compressor and gradually close the suction pressure is reduced and does not the compressor and Close the discharge Remove laminated o the care at all times as it is a precision product. I-4. PREPARATION 1. Polish the 2. Remove damage 3. Clean crankshaft with all sharp edges to the Neoprene the seal cavity fine crocus from the bellows. cloth. crankshaft keyway to prevent thoroughly. INSTALLATION 1. Use refrigerant the Neoprene oil to lubricate the bellows which comes CAUTION: driving band. 2. . Slide the just starts Do seal 5. oil onto the to get the NOTE: Views which has been Using crankshaft until the 2, 3 and 4 show removed and the Neoprene the seal be seen cover the seal installed on a crankshaft from more plate, the compressor in order push the seal assembly into Remove not the cover plate, to become Grasp the seal Lubricate being careful 8. Reinstall assembly may evenly show of operation carbon the seal cover to prevent slight should to allow its proper be tight the pencil the carbon in seal damaged. nose the that parts readily. guide should as shown by down period bellows location on the crankshaft. The spring against the side of the bearing surface View 3. 7. seal the of shaft. and turn driving band drop back into the slots 4 shows the lugs of the driving band center of the slots in the seal retainer The between and the surface with the shaft. Holding the spring and sleeve assembly, pull forward on the seal nose assembly at the same time, turning it so that the lugs on the driving band are out of the slots in the retainer shell and rest on the surface of the retainer shell (See View 2). washer . allow assembly to grasp of the seal may Q not crankshaft into contact leakage correct seal washer plate and damage the and seal seat. the dust seal. to the immediately this it until condition lugs on the in the retainer shell. View properly positioned in the shell. carbon after Draw seal installation, the bolts but a short washer. view ]. - Rotary Service Sea| (SJeeve Type) Replacement View _. Slots View 3- Spring Retainer Tight View I-4 Driving ROTARY SHAFT SEAL Band in Seal 4 Center Agoinst Short Shoulder FIGURE - - Lugs Refainer Driving of Out of Shell Band Retaine_ Lugs S|c4s - Integral Seat Type in SECTI0t! CAPACITY In order tant well CONTROL to analyze The obtained capacity by plished by holding the cylinder during valve to the suction the ure the providing Capacity change. mechanism cylinder ing the service with of the step compressor the the valve. use 100%, control manner type system in which in which cylinders it is impor- it operates, variation in sequence. As a result, cylinder of power. Three of the 75%, 50% and 25% of full control is automatically obtained The lubrication oil supply is used which is so arranged that in the suction COMPRESSORS as in capacity This is is accom- the suction valve open continuously. The gas drawn into the suction stroke is thus forced back through the suction manifold instead of being compressed and discharged through the discharge zero with the minimum loaded UNLOADING and familiar control.is unloading FOR troubles to become thoroughly as its construction. 2 valves compressor are held without SUCT_0N open. This capacity is reduced four cylinders can capacity. in response to suction pressto furnish the power to operate absence of oil pressure, the automatically provides load. U,mfOtO OiL PUU, H_ D_ AULIC R_LAY FIGURE II-I CAPACITY to be un- CONTROL SYSTEM for start- II-1 Fig. shows the control system diagrammatically and how it operates. It consists of four major elements: I. The Capacity 2. The Hydraulic Control Valve. 3. The Power Element 4. The Valve Lifting Mechanism Relay. (one for each 1. The capacity control valve is pressure acts upon the inside of its bellows while the pressure and the force of the range adjustment bellows, with variation closely fitted push in suction pressure. the crankcase. the range at which 2. will hydraulic the spring open. relay piston valve. at "A" (Fig. pressure, adjustment so as to vary oil oil II-1) the pressure pressure and fills of three is transmitted range is an Full cylinders). actuated. The outside is under spring. The to the control valve. Oil passes through the Turning adjustment the valve The action, assembly of suction rods of three (one for each The valve changes value of the actuated, means the loading suction multiple oil of three opens with a decrease and then drains into stem from the the annular suction pressure atmospheric movement of the by valve seat cylinders). pressure port, pump enters space around snap the relay the piston. The drilled hole in the piston permits oil to flow into the control oil chamber at the end of the cylinder and thence to the capacity control Depending the right upon the end of the nular groove is located. The position cylinder in the position piston or of the piston trol oil pressure chamber oil pressure at this point valve. The snap piston, prevents of the piston are supplied action the are vented in the cylinder, the with full oil pressure to the is determined ball, piston the The power element lever. Oil pressure piston, forces the by working in opposition is determined by the working from moving the oil gradually pressure piston of the with as the the oil pressure valve. outlet ports from the in which to the position in connection The piston can make only abrupt steps equal since the outlet ports have the same spacings, either sudden unrestricted application of the elements or venting to the crankcase. 3. forked crankcase, the flange of the unloader sleeve when the compressor is not the spring returns the piston up and lowers running to the the forked at anrelay in the spring. capacity grooves pressure conThe control in the changes. to the spacing of the grooves, piston movement provides full oil pressure to the power consists of a cylinder, spring loaded piston supplied by the hydraulic relay and applied piston of end of the lever acting and a under on the it. In the absence of oil pressure, as or when the relay has cut off the supply, bottom of the cylinder. Oil leaking past the piston located load. is returned in the 4. The slides normal valve crankcase. and lifting If-1. upper end the lifter pins are mechanism of its There adjacent consists are three power to the cylinders of the unloader elements which they sleeve, 2. the lifter , . of the of the cylinders are valve and allows to hold The position lifting capacity of the fork is power in its off un- which the control cordance with stem. the (full pump the capacity pressure) the right. elements loaded). In this allowing When capacity the piston removes to unseat suction element lower of the by its control holding seat off suction valve piston valve to operate to individual piston in the in the which hydraulic valve off element. When full the lifting oil fork normally. power hydraulic relay varies the in should suction power the seat. system the by the lifter When relay, which its at position, the of the sleeve valve For shown the elements relay. ac- is determined control oil by pressure piston. capacity When by action unloader is operated by oil pressure. supplied to the power element, control relay the unloaded is lifted of the adjusting relay This piston operation Oil pump pressure is supplied cording to the position of the The the power element This raises the upward features on the . end the The power element pump pressure is the Q holds the pins suction drops . stroke; Individual its seat. The . pressure have pushed the unloader sleeve down, so that to allow the suction valve to operate normally. The following in mind: . oil is removed from moves downward. pushes be kept The springs retracted oil pressure power piston turn to the manifold on the outside of the cylinder sleeve, the lifter pins and springs. operation (the cylinder working), the parts are in the position in Figure the suction the is valve varies suction pressure control valve is applied way, full controlled control valves control and is pressure cylinders valve on the closed, to the relieved and the oil pressure from suction the oil setting control relay is is wide piston admitted to operate open, the pressure in ac- of the oil external pressure s forcing it to to all the normally power (fully pressure on the spring moves the piston to the left. the power elements causing them all the controlled cylinders. Note that the oil result pressure arrangement, of this for the one is established uncontrolled by the SERVICING There are three tries 2. The cylinder forced feed unloading oil system. 3. The pressure compressor The until the air and ure. the The falls check of the pressure as box. Operate steady conditions pressure should gradually, to check observing not more suction above), the pressure 1. Remove crankcase 2. Turn the obtained. the cap cover. valve cylinders does stem it is only four compressor gauge, and to cut not remain be stem about the should slowly the until necessary to ob- gauge in the full evaporator the comworking suction press- suction listening cuts out, there Now gradually from the capacity (See Figure Turning work. capacity above suction setting rated assumed, properly. the pressure the pounds is to close Control the this range, it may be control is functioning control for If the does its observe than is within that the valve given causes However, to improve decylinder unloading is delayed control, the the which to produce evap- compressor actually established, As each cylinder of the compressor. listening pressure the psig. been vary with by the force of 36 psig. conditions, ation of the unloaders. change in sound level again, oil capacity low 32 pounds. If the pressure the absence of other indications, A way determining indicated by the pressure the equipment with the have pressure capacity is powered the to 32 oil SYSTEM compressor is designed pressure full load pressure a routine when is the equipment at a suction at less than suction control the but until CONTROL mechanism to unload, starting As a (except to remember: to balance conditioning suction For serve pressor points The control orator load. on CAPACITY important suction cylinder) pump. oil THE 1. when operating humidification is required to load a cylinder. the compressor is unloaded To control H-2). the valve for the oper- will be a noticeable open the suction at 32 pounds (within proper raises the limits do this: valve. This suction the is on the pressure suction bein in. adjusted. clockwise or is pressure; lowers counter-clockwise 3. Replace The above the stem adjustment it. cap. should be made after the operation long enough for the conditions to become or to warm up. Once the control has been adjusted, further attention unless trouble develops. CONTROl. GA DC3E OtL PRI[SSURE SHUT GONNEGTION 'lAND HOLE OfF VALVE VALVI[ (D;SCHARGE) equipment has steady and it should PLATE the not GI'LINDER GASKET been in compressrequire HEAD GASKET COVER _ VALVE PLatTE / ¢YLtNDER HAND AND HOLE SIGHT HEAD GOVER GLASS ASSEMBLY GAPAGITY VALV[ DISCHARGE VALV[ ASSEMBLY HAND HOLE COVER /LMD-GAPAGITY VALV[ CONTROL ASSEMBLY OIL OiL PUMP Should IqU[SS_JRE II-2 control there 1. Open VAL¥( IStGHT GLASS $_D() COMMECTiOM COMPRESSOR WITH CAPACITY CONTROL system: be indications a more thorough check must be make the necessary corrections. CAPACITY CONTROL SYSTEM make OFF COVER SUCTION FIGURE the HAND HOLE GASKETSMUT GONNSGTION GMANJCCAK To PLUG PSSSSUB( GAUSS Checking FILL of faulty operation of the control system, made to locate the source of the trouble TABLE II-2 TROUBLE DIAGNOSIS will be of assistance in this connection. this check, it is necessary the suction gauge valve. to take these preliminary steps: and . Pumpdown Loosen 3. o 5. A_ the oil Apply a control oil gauge gauges connection indicate as illustrated accurately. the the pump to relieve an as If control C. and the discharge in the gauge to the valves. compressor. connection control in Figure suction valves and the all should oil II-2. as indi- and operate foaming has pressure Be sure the these system un- The square pump inch subsided. the way counter-clockwise. read 45 to 50 pounds pressure. range. Replace is lower than the thread protector of the capacity control frigerant Fig. leakage II-3. Remove capacity is control the threaded If steps a and b do not remedy draulic relay, a broken should stem drop oil compressor valve the pump pump side the if the pressures pressure: of the stem block the tube is out trouble, or way bellows. assembly and of its conreSee check if guide. a defective stuck disassembly all per from the pneumatic control valve stem and check for valve or and the to atmospheric broken control pressure stem pressure sponsible Turn pressure to the gauge is warm valve pressures oil stem and follows: Remove nection b. the gauge pressure discharge than the suction fall within this al pressure suction II-2. crankcase proceed higher do not B. plug compressor in Figure Turn the control and control oil 1. fill the cated Open oil close Apply til Now and control hy- valve is re- is necessary. clockwise. to not more than seven valve stem counter-clockwise The pounds control oil above the suction until control pressure. Cw Turn capacity control pressure starts to rise. the number of cylinders at which trol lo oil the control pressure is and pressure needle number quietly checking oil gauge If correct done Continue that are required. stem There changes suddenly, very slowly and should be three causing the count points con- to jump. of unloading rapidly, turning loaded. oil the steps operation is counted is normal and and unloading no further is Do If the correct valve occurs for partial at a rapid stabilize after 2. number and If the swings pressure does a new not correct steps the cover are swing Install . Pump secure a. new control valve lifter differential with Inspect valve lifter and hydraulic through suction valve fork shoes should be and fork ment Co Operate sleeves unload cl. top be centered cover. Replace compressor and for Valve valve lifter seats element heads pins when and and 0.33 valve re- operation. valve above plates, suction to 0.36 inches lifter and power looking sleeves. sleeve points plates off control valve the following: or springs the cylinders should are smooth, up, but light touch needed. Replace finger. hydraulic unloader height causes down Unloader flange, on power ele- parts. element stroke should be lifter spring may remain of the loading the parts, on fulcrum defective with oil is defective and recheck springs Adjust capacity and observe but substituted. ports in the cylinder in position under lifter should secured. compressor relay be momentary duration, is defective. power rapid if pounds with each cycle, and replace if necessary. valve seats. They should project from above the seats. If incorrect, replace element parts found off tolerance. b. with cycling, or if unloading and control Adjust, remove cylinder heads and proceed as follows: pins the unloader cycling and does not setting. should assembly down compressor, cylinder sleeves Check four counted, cover step widely cycling, suction valve noise of more than lay or the valve lifting mechanism 1. the assembly not When intervals) superheat drops more than for axial clearance, not adjust and: beyond valve does control unloader is counted, operation, expansion pressure oil pump If this E. check If suction pump check minutes pressure cycling, necessary. steps unloading of the compressor. rate, (two or three second a few If suction . of unloading retract loaded. and cylinder to load below the Power not jumpy. should drop defective and The with a parts as c2. Operate capacity control valve slowly through control range and watch control oil pressure and valve lifter pins. As successive cylinders unload, control pressure should dip abruptly and regain its former value. Any marked hesitancy in the pressure dip or regain, indicates a defective relay or a leaking oil line. Cylinders should load or unload in sequence. c3. Nominal control oil and unloading steps pressures take place at which cylinder should be: loading Unloader St ep Number Table * II-1 Note: * CONTROL To Load - Control Control oil suction the Adjusting 1. o Control Screw o . 26 15 23 12 for is equal adjusting See Operate refrigerant Figure control Reduce crankcase the suction shut Turn loads. 19 Capacity to the stem on the control system to obtain 6. reading minus the all the way out pressure higher point, off pressure valve. to the control point the by slowly closing first cylinder unset and the compressis 3 psi above the conis 4 psi below the point. Recheck by opening suction shut off valve Watch suction pressure gauge and listen cut out. Open Operation valve a suction or will load fully when the suction pressure trol point and unload fully when the pressure 1 Control II-1. adjusting screw in (CW) slowly until The control system is now correctly controi gauge (psig) Point external the 28 Pressure pressure PRESSURE To Unload pressure. (CCW). than Oil OIL but do not backseat the suction valve. and then slowly closing. for the first cylinder to The control oil pressure change between loading steps change should between be about loading and 3 pounds. The unloading any successive control one unloading oil step or pressure should be about 11 pounds. Pneumatic Compensation of the When pneumatic it is still necessary controls to set the Air pressure ic control be off while the control should is to reset Capacity Control are connected capacity control Valve to the capacity in the manner this is being point upward done. by the control valve, just described. The effect of a pneumatamount of the air press- ure that is applied. For example, if a system is operating at a suction pressure of 40 psig and the control point has been set at 35 psig, the application of 5 psig air pressure will cause the first cylinder to unload. Not over 25 psig air pressure should be applied. SUCTION SUCTION DISC VALVE (OPEN) VALVE SEAT- CONTROL CO NNECIION • LIFTING _ _ LIFTER PIN P_UMAT¢C // " r_ \ [XT[RNAL $T[M _$T_ UNLOAOER FIG. 2-3 \ POWER ELEMEI CAPACITY CONTROL VALVE II-4 FIG. I u_,L._,u_ _ \ SUCTION n\ _r.r..r.._ VALVE LIFTING MECHANISM sembly In order The valve lifter mechanism which is mounted on the to check the the control assembly, before removing the stem. plate. in good operation condition. of the lifter in Figure H-4, and control ascover is shown in Figure II-3. mechanism or it is first necessary to pump down cylinder heads or crankcase cover. It is not necessary R can be removed In replacing is shown crankcase the to pump down by unscrewing stem assembly, to remove the the hexagonal be sure the replace the parts of compressor external adjusting body from the cover gasket is in place and If parts of the above, plete require new control valve replacement, control valve do assembly, not attempt other than to make those repairs. mentioned Apply a com- assembly. SUCTION Iu MANIFOLD EQUALIZER LINE TO _" IPS CONTROL OIL PRESSURE GAUGE CONNECTION LINE CAPACITY CONTROL VALVE HAND HOLE COVER HYDRAULIC -- TO UNLOADER POWER ELEMENTS" FIGURE II-5 FROM COMPRESSOR OIL PUMP CRANKCASE COVER TO UNLOADER POWER ELEMENTS AND CONTROL ASSEMBLY COMPLAINT POSSIBLE Compressor will not unload. Broken stem. MEANS OF IDENTIFICATION CAUSES control *Inlet strainer valve Remove stem and inspect. Control stopped. oil remains CORRECTION housing Remove pressure high Replace for all cover and clean. positions of adjustment Stem. Stuck hydraulic re- Control lay. can oil be pressure adjusted Replace from pump pressure to psi above crankcase pressure Compressor l will not load. Control valve traveling guide or stem un- compressor. Remove stem and inspect. nut out of stem brok- control assembly. 6 without loading cover housing Engage replace nut or stem assembly. en. Control Stopped control oil strainer. oil cannot be control ment. Refrigerant leakage to atmospheric of control valve bellows. valve Remove side pressure raised by Clean or strainer. replace adjust- pipe plug above adjusting and check for erant leaks. stem refrig- Temporary correction of slight leakage is to leave plug out. Replace cover assembly. Low oil pressure. Check pump pressure Adjust with adjusting stem at full counter-clock- Control open Any one cylinder will not unload valve or wise position. Low oil stuck orifice in all adjustment relay stopped (rare). positions. Inlet in con- Control cannot strainer trol valve (rare). stopped pressure 6 psi for stem crankcase pressure. *Omitted on later models TABLE II-2 TROUBLE DIAGNOSIS CAPACITY CONTROL Replace cover assembly, to SYSTEM press- to 45-50 Clean oil pressure he dropped above ure oil strainer. inlet psi. MEANS COMPLAINT POSSIBLE Any one cylinder will not unload. Stuck CAUSES hydraulic re- lay. IDENTIFICATION Operate lifter anism defective. mech- compressor by adjusting valve check concon- trol four oil pressure movements for of Remove cylinder heads and valve Remove plates. and replace fective parts. 5F does should Control can not pump Low pump pressure. cylinder sleeve lifter ject.33"to.36" above valve Control valve not close. Replace control cover assembly. relay. springs Any one cylinder will not load. CORRECTION and trol hydraulic Valve OF pro- and piston de- seats. oil pressure be raised to Replace valve. control pressure. Pump and control pressure low. oil Clean control oil strainer, adjust oil pressure. Replace pump if necessary. Broken power oil line to element. Low control pressure with in pump one step Stuck hydraulic re- lay. Operate and by oil Repair line. drop pressure at of unloading. Replace compressor adjusting con- cover control assembly. trol valve, check control oil pressure for four movements of hydraulic Valve lifter anism defective. mech- relay. Remove Remove cylinder heads and valve plates, secure cylinder sleeves. Operate compressor and by adjustment of control valve, check that lifter pins and springs retract below valve seats. will replace remove sleeve lifter piston rod to replace element. to parts, and power MEANS COMPLAINT POSSIBLE CAUSES Noisy compressor oper- or ation with Loose coupling parts keying. OF IDENTIFICATION Hammering CORRECTION sound at Tighten coupling parts and set coupling coincident with unloader operation. varying unloading. screws. poorly tor Vibration discharge of disc stop Insufficient in Rattle or howl valve. nating at stop clear- ance between piston and valve plate. Sluggish key. valve. valve. medium hammer cylinder head cylinder is unloaded. when relay. shaft Backseat origi- Sharp, metallic Control hydraulic Replace fitted mo- pitched at when pressure over erance tol- parts. a dip cylinder Replace unloads Replace control cover assembly. is not abrupt. Valve hammer or clatter when ing Insufficient oil loading takes cylinder com- pressor operation varying with unload- Defective er valve unload- place. Increased and steady valve clatter when a pressure. Noisy or lift- mechanism. is unloaded. Valve hammer clatter when ing or place. loading or unloadtakes ing. Clean control strainer, oil adjust oil pressure, replace oil as indicated. a) Replace lifter pins or pump stuck (or) b) Check unloading fork for alignment (or) c) Check element piston power for sticky (or) d) Leakage of oil at tube connection to power Insufficient valve lifter pin lift when cylinder is unloaded. element. Increased and steady valve clatter when a Replace defective valve lifter mech- cylinder anism is unloaded. parts. " COMPLAINT POSSIBLE CAUSES Rapid Inter-action between er unload- cycling. capacity control valve to expansion valve. MEANS OF IDENTIFICATION Rapidly varying suction pressure equal or than step differential control valve. greater of CORRECTION a) Use ferential valve wide difcontrol spring. b) Resize sion valve. c) expan- Reduce pump pressure 45-50 psi. d) Tighten pack- ing push around pins in expansion valve. e) Remove equalizer line from control valve suction manifold to and plug line to suction manifold. Partially control oil plugged strainer. Oil pump at control pressure read oil strainer Replace strainer. access plug drops more than 5 lbs when cylinder is loaded. Weak oil pump. Improperly ined or hydraulic machadjusted relay. Oil pump pressure more than 5 lbs cylinder loads. Rapidly varying oil pressure and unloading place without panying suction as drops when Replace. control a) Replace trol cover loading takes accom- bly. b) Disconnect pressure swings beyond the differential of the conassem- step control. equalizer control plug line manifold. the line to valve and to suction SECTION PARTS LIST COMPRESSOR Ill ASSEMBLY 161705 (5F40) 94 SEE DETAIL DETAIL 78 19" 20 80 79 ____ 93 89 93 92 90 89 "_' II I 16 _/.-57 9l 42 43 31 20 81-82- 72.73-7,-75 67 68 69 70 7 .57.2o 41 23 21 28 36 26 30 34 22 3 _ 6 _i d/4._ _,_ _ 3,3,4o32 3, 77 ", _.62 _ "63 25 3 4 14 t3 Service Parts 5F-40 Compressor Item NO. DelJeription I C;'iq]_-IJt _el | 3 4 $ 6 ? 8 9 1 0_e_t Check C_lnder o 162489 162028 (1) (1) 2 16:t487 162032 163520 2 1 4 Filler Screen F'ack_ge r-qcludes: Otl Filter S_reen Gasket Man,old Cover Plate Man,old Cover Gasket _.1 Rel_[all Valve Package lnoludes: G4ulke t _8") T-2485 162496 162031 16:Z488 T-2466 To|468 1 (2) I I 1 (]) Cap Screw 3/8 ° 16 • r, (Manffot Cap Screw 3/8-16 • 3"' (Cylinder _ct Io_ Ma_UC4d ) Cap Screw Gaeket (3/8) 5ha_t Sea_ PacKage, _¢ludel: Cover Plate Gasket mCubon Washer 187S57 6 162424 151286 T.1401 T-2458 28 34 1 {1) 151375 T-2462 8 1 162493 162429 162416 (1) (1) (I) Oft 20 2] 22 23 24 25 26 (3) (*) Head Strainer _eeve gas_cet Guke_ AJsembly _Wlth Holes) d cover) Head, scGver Pills Cap Screw 3/8-16 • ]-1/4 (Shaft Seal Co_er ) Bearing Head and Oil !_mp AssembLy includes: Bear in( Head Gasket Main Bear_ag, P_mp Mq:net _¢ PI.¢ 2T 28 (2) 29 30 (25) 31 _d 32 33 34 36 38 3"/ 38 39 40 41 42 43 44 46 46 47 40 49 {10) 50 51 52 53 64 55 56 57 56 (53) 59 60 (181 (20) 61 62 T-2466 (3) • 3/4 181286 164363 (12) (6) Part&) 162534 T-2462 T-130_0 (6) (1) (11 scorer, Idler, Rotor and B_shm_ Or) P_mp Cover G.,sget Bearing Head Gasket *coanv:t lng Co¢mectlng Rod Rod Comnect kP._ R_i Coc_neclxng Rod _cka,ge Bolt Nut _earir_l FIaU _earin_ Washer, F_mp sod Seal End "_rust Washer (sleel) Seal End _eartn 8 Washer (brae) PLSlOn and Pt_ Package (Unassembled) includes: Ptst_ Pin !_ston P,n LoCk Rtng s Ptsto_ PIStOQ _n_ lnclud_l: *Oil _t-Z Valve Plate Includes: _¢'k_,ge 1_tck_ge sValve Plaie Valve Flats Gasket Cy[u_der Head Gasket S_¢_ton y;dve Disc :_ction Valve Sprin_ _JIde L<)Ckw asher *'S_ctlon Valve ClIp Cap Scrfw 1/4-2g • 1 (G'_lde to Valve Plate) Dtseh_r ge Valve Guide la¢]udes: _ hlner Seat Glass !=_cl_ge T-12682 162493 (l) (1} T.2459 12 (l) (21 T-2462 162466 (2) (_.) 162461 162460 162459 162462 ] 1 1 4 162464 T-_456 - (I) (2) (I) T-7690 I 16_488 182487 162468 182469 1_2476 161984 162426 Assembly T-13007 I_ole Includes: 66 Cat. Sight GlaSS AosembJy StEM GI_ Gasket Cover and Cm_r01 70 71 7_ Valve G_•ket, Valve Gasket, Co.teol Valve Lnclude•: ?3 74 ?5 78 Aslem Cap Cover Cap Screw Gasket 3/8" 14andhole Covee Gasket with SLIht Glasl) Un_ceder S]eeve Valve*Lt[ler SFrm ¢ Valve Ldler Ptn 78 ?_ 80 8} (*) U_loader Includes: powsr Unloader Unloader UnlOader 82 _lan(t_ole R-600) Gracket Casket 84 85 86 e? (e3) 88 (Bottom) FeLt Seal g Assembly Gaskel. Shut O(f Valve to Cra,_/(case Shut Off Valve (D_scharge) I-3/8 OIlS (*) Valve (Mueller) Includes: I (*) (') S_al Cap Seal Cap Gasket Valve (Henry) 1-3/B blcludes: Seal Cap Seal Cap Gasket Ta_] P_ece Adapter Gaske_ (Tad Fi_e Companion Flaage Compamc, n Flange 0/2"13 • I-3/4) Shut Off (Suction) I-5/8" (*) Valve {M_eller) I_C Lc,des: (') (*) T-12870 T*12671 1636|7 (1) (1) 1 183632 (1) (1) x6435a 164359 184380 (2) (2) (I) 163533 1_3631 164361 (1) (l) (1) 183529 163528 164362 (I) (I) (I) 162423 1512_ 24 24 162490 163635 1626_6 16353? 1 3 18 18 163624 3 T-4923 (I) (I) (2) T-94C_ 16.1526 T-2457 , 163530 163521 (1) (1) (1) (1) (1) ()) (1) (3) (3) (1) (1) (1) (I) 3 6 T-94_ T.2661 6 ] | T-2661-1 T-2661-2 162497 (I) (l) 2 1624P_ 16435? 164356 T-4924 ODS Act_pter) (I) {1) (l) (I) (I) (l) T-2520 (1) BOIls 5139g (_) I ODS 162401 Seal Cap Seal CaD C_sket Valvo (Henry} _cludes: 16438? 164356 T-4945 (I) (1) SCul Cap Seal Cap Ga_kH Ta_l p]ece Adapter (8) 2 92 (1) (1) (1) (2) (12) {6) (4) (6) 93 94 (4} 96 . • o T+2:.20 Gasket, CJp Scre_ _'alve Cap Gaskel. V_lv_ Cap Comnr e_.sor (Serv,ce 151303 T-2467 T-2466 T- 11902- o o o (2) (]) (I) G_sket (TaLl Piece Ad_.r) Companlun Fla n_e Comp.,nmn Fl_r,_e _oJis Cap Screw For Valves T-4924 & T-4945 For V:_Lve_ 162480 & 162481 Accessor_ o Gasket s Usodal _*_1 _CllOn Valve He._rulg P_lIrr Sleev,. F_lh.r Req'd. Cover UnlOader P, slnn Unlcader F_slon Rod Unl_der Spring Retalnx_g Washer U_l_der Spring (2") UnlOader Spring (I 13/16") Uniter Cyhnder Gasket (Top) Cyhnder Cover Plate Aasembly L_ck_asher (I/4") So_kel Head Cap Screw I/4_28 • 1-3/4' Co_ler P_n 0/16 • 3/8") Ptale Washer CLevis F_n Unlca_er Fork Unlcader Bracket Gaskel SoCket Head Cap Screw I/4 28 • r. Unlt_der As|embly _o crankcase Cap Screw Lock_asher (I/4") D_Sl SC_I _ck_e C_stsls (_ 83 i * Element Cyhnder Cylinder Cyhr_er No. • Inner (X_tee Assembly Spring C/# - Ic." R-12 and EXlerr_l Valve A*sembly Valve Body w*t_ Betimes _'rew 3/0-18 • 2-1/4 .+ (H_._ol (20) 77 91 Valve HX,.(_ole Cover G_eket _ H)_t_s_l$c Relay SOCket Head Cap Screw _/16o24 ] -?/8") Cap Screw Gasket (5/16") Coqteol Valve ^say. P_¢k=q_e I_cludes: 87 ) I I 1 ] 4 16_466 T-2453 Discharge Valve Gilds l_ach_r_e Valve I_|ct,_ge Valve Spring Seal LOCk Plate Cap Scre_ (1/4-28 • r') (Lo_k Plate to Gmd_) DOWel Pin -.3/16 • 3/4 (Guide) DOwel Pin1/4 • 1/2" (C._lde) Cap Screw 3/8-16 • I (Valve PLate to Crankcase) Cap Screw Gasket (3/8") ltandhole Cover _md S_ght Glass Assy. Includes: Sight 83 64 65 89 90 162452 162505 162450 44] 1 _62502 T-_461 NO. Oescrlp(ton 6S 8_ (_) (I) (]) (1) Cap Screw Gaskel (5/8") Cap Screw Gasket (3/'6") (_ear i_g Head) H_ Head Cap Screw 1/4-28 (O1] 1_dmp Co_er) Cap Screw Gaskel (I/4") Dowel Fin (Bear*n_ Washer) St] P_mp P_ck,v_e (Matched Includes: HaHeadCapScrew(3/8-16xl-3/4") (Bearing Head C0_er) C r au'.kld_a/I Assembly Woedr_f Key #21 Retaining Washer (3/0'*) Lc*ckwa she r (5/8") Cap Scr_ (2/8°|4 • 7/8") Coo_lectln| Rnd and _e&rtng Includes: : . 162126 O1_ By-Fffi_s Pl_ Conlrol St ra_nee Ho)lc,* Lock Screw M,_dating Valve A_apter (4) (20) HO. (1) (I) (I) {I) (4) - 13 ]4 :S }8 18 19 Eem 143510 VJdve Valve Head [.clLdeJ: • $18" NO. Req'd. T-|463 142418 T-24_S 161918 T-|464 . Cylinder Suctlc_ Cylinder ASJel=bly Pin 3116" NO, _e_r t WKWaoher ) bte.rnetic Pt.4 Mat'netlc PIq. Guket (5/1") Mab_ _.trm(. Set] End Dowel Fin. Valve Prate #L_dtder C_I S_l_ly Tube8 tot] SJp_ T Tube* (_ube Ferrules St1 Ret_.n Check VaJve l_clu_e _nclude0: 10 11 1= 1(_) CIr. (1) (I) (4) b 5139g 54825 _62482 Reolacemenl) 8 I I I C..rrhaul Clips ]62510 I 161984 T-2460 162_07 4 I I * 162471 182472 ]62474 162475 162425 (I) {1) (6) (11 (3) 162478 163519 (11 (11 • o NO_ sold separately No¢ Showy. (*) 157557 t51266 162426 (4} (4) I T-13004 (I) 90, • r,g rvpl 9] and 92 specIIy portents proper _change available. Helur. EL[_CTRICAL f_QUIpM_NT llem 73 Ior Relrl£eranl p_rt _or. ur d_.lec(l_e CORP. Ior cred,t. 22 service, I,_r _tents _mb_,r. spec_ly _en_ Cat. I_) _AFLeTy N_. 164310. PART SERVICE (FOR CHARGING, MANIFOLD EVACUATING, AND SYSTEM TESTING OPERATIONS1. 2 SUCTION 3 PRESSURE DISCHARGE GAUGE LOW SIDE 6 I COMPRESSOR PRESSURE CONTROL VALVE MANIFOLD ASSEMBLY (as a VAPOR) Service Cylinder) _ """_ I SYSTEM EVA CUA TION (To Vacuum Pump) .__..__..___._ | Item No. Description 1 2 3 4 5 6 7 8 PRESSURE GAUGE CHARGING (To Refrigerant LIST 5285 AND GAUGE ASSEMBLY • - 2497 Manifold. and Gauge Assembly Gauge (30" -.250 psi) Gauge (0 - 500 psi) * Cap, Quick Seal * Gasket, Cap and Couplers Charging Line Set (36" Lines with 1/4" SAE Quick Couplers and * Elbow at one End) * Metal Carrying Case * Support Hook * Not Shown (High Side) (Low Side) Catalog No. T-12497-I T-12497-3 T-12497-4 T-12497-6 T-12497-7 T-12497-2 No. Req'd. I (I) (I) (3) (6) ! (3j T-12497-8 T-12497-9 FILTER-DRIER *Cat.No. 163088 164177 164312 ASSEMBLY No.Cores 2 1 1 (LESS CORES)* Connections/Snld_rl Inlet Outlet 7/80DF 5/80DF 7/80DF 7/80DF 5/80DF 7/80DF Description --T,E .00S 4--12 -- CO,E*14-*15 INTERMEDIATE CO,ESFACE"13 PLATE --CORE 6 Note: Shell Gasket,Outlet Core Retainer Plate Outlet Core Retaining Plate Tie Rods Core Positioning Plate (Solid) End Spring Gasket, End Plate End Plate Flange Bolts Nuts (5/16 x I-3/4) Shell Outlet Core Retaining Plate Tie Rods Intermediate Core Spacer Plate Filter-Drier Core Filter-Drier Core *Drier Cores, Items 8 9 11 'l( r',. ('_J C) t_ +'-" _') CP ,l_r No.Req'd T-13784-I T-13784-2 T-13784-3 T-13784-4 T-13784-5 T-13784-6 T-13784-7 T-13784-8 T-13784-g T-13784-10 T-13784-11 T-13784-12 T-13784-13 T-9973 163089 14, 15 are not included components of Filter-Drier Assembly be specified when ordering. GASKET FLANGE BOLTS 1 2 3 4 S 6 7 8 9 10 11 12 13 14" 15" Cat.No. •ll CO as and must 1 1 1 1 l 8 1 l 3 1 1 l I 3 1 1 l l 8 I 2 LIQUID LINE FILTER DRIER ASS]_4BLIES, Catalog Numbers A replaceable core type Filter liquid line near the outlet of Drier assembly, the receiver. and the outlet connections so that core(s) 163088, 164177, and 164312 as shown on Page i, is installed in the Shut off valves are provided at the inlet may be replaced without opening the entire system. The function of the Filter Drier is to keep the circulating liquid free nants such as moisture, acid, and foreign matter. The assembly includes steel shell for high efficient desiccants from the refrigerant burst strength which are held and oil mixture and a porous core molded from a blend of highly together by an inert binder. Moisture and acid are adsorbed and retained on the surface of the desiccant granules. The porous structure of the also serve to filter out the solid contaminants liquid refrigerant. core and the which may be tapered carried After is effective the core assembly has become from contamia hea_ saturated, it no longer mesh over screen in the and must be replaced with a new one. Similarly, after a period of time the core may become restricted by dirt and entrained foreign matter which will reduce the flow of refrigerant. This condition may be determined by feeling the inlet and oUtlet lines when the equipment is operating. There should be no appreciable difference in temperature. Should the outlet connection be much colder or the Moisture Indicator show other than a "dry" condition, a new core assembly should be applied. Under normal often than it is well The TO APPLY A Make NEW it a season. to install construction CAUTION: install. i. conditions, once also of CORE the should not be necessary to If the system is opened for a new core assembly at that Filter Drier is shown on Page renew that core of assembly making more repairs, I. ASSEMBLY: Do not remove the core from the sealed shipping Also handle the core carefully to avoid scraping sure the the purpose time. the Filter Drier shell is completely container until or chipping. pumped down and ready free of to re- frigerant. Close the line shut off valves tightly. Loosen flange bolts to bleed off residual pressure. 2 Remove the flange bolts, end plate, and internal core assembly.. 3. After withdrawing the end plate, item 8, and the core assembly, remove the rods, discard the used core(s), and remove the flange gasket. Then: a. b. Place the end plate on a flat Center the spring, item 6, on surface with the gasket the plate and with the side upward. core poeitioning plate, item 5, (outer flange upturned) fit the recess into the spring coil. c. Remove the core from the sealed shipping container and place it on the core positioning plate. Apply a new cover plate gasket. d. Add the core and apply the outlet core retaining plate (rim down turned) where Filter Driers, Catalog Number 164177 and 164312 areused. e. On the multi core,(2), Filter Drier Assembly, Catalog Number 163088, locate the intermediate core edge that fits in the outlet core retaining Take extreme care to NOTE: last f. h. to be positioned on the outlet core core, Align the holes in the g. plate tapplngs spacer plate (this core hole) and add plate, item ii. make sure that the in the - always retaining the core end Wipe clean the inside assembly, insert into maximum. Test for leaks. plate plates plate to on must and a snug plate core, has a center hole with lip Catalog Number 163089 and outlet top be of core the inserted secure the retaining last into three plate core. the (3) The is the screen center long bolts of the into seat. of the shell, and after the shell. Tighten the blowing flange the dust from the core bolts evenly to the SOLENOID CATALOG PARTS LIST 5453-A VALVE NO. VALVE T-14315-2 T-3330-I0 T-3330-6 T-_-ll COIL(ITEM T-14270 T-7820-6 T-7820-3 T-7820-4 S-8132- 3 S-8132-4 !T-14270-I T-14270-I 4) VOLTAGE 32 V.DC 64 V.DC I15 V.DC I15 V.AC COIL HOUSING-ELECTRICAL ENTRANCE Std.Ounction Box Std.Junction Box I/2 NPT Conn. Std.Junction Box 64 V DC 64 V DC Std.Junction Std.Junction Box Box REMARKS With Transient Suppressor, T-16896-II lo Item No. I 2 3 4 5 6 7 8 9 I0 11 12 13 14 IS Description Body Assembly Body and Bonnet Screws Bonnet and Enclosing Tube Coil (See Table) Coil Bottom Plate Coil Housing w/Junction Box Coil Retaining Screw Coil Sleeve Coil Spring Diaphragm "O"-Ring, Body-Bonnet *"O"-Ring, Locating Sleeve Plunger Seal Cap Seal Cap Gasket * Not Shown 1/74 Catalog No. T-15133-1 T-15133-2 T-15133-3 T-15133-4 T-15133-5 T-15133-6 T-15133-7 T-15133-8 T-TB21 T-7822 T-7822-2 T-15133-9 T-15061-1 T-15061-2 No. Req'd. 1 4 1 1 1 1 1 2 1 1 1 1 1 1 1 To Remove Solenoid Coil First remove the retaining screw at the top of the coil housing. entire coil assembly may then be lifted off the enclosing tube. The To Reassemble Coil Housing Components, make sure that the parts are placed on the enclosing tube in the following order: I. The coil bottom plate with the outer 2. The lower coil sleeve with the flange on the bottom. 3. The coil 4. The coil spring with the flat edges 5. The upper coil sleeve with flange at top (flange projects through the coil spring. 6. The coil housing. under the coil. . itself (or its replacement) edge up. with lead exits (Flange down) at the bottom. up. Make sure coil lead wires up). The sleeve do not catch over or The electrical data plate. Press down firmly and insert coil retaining screw. Rotate housing to proper position and tighten screw securely. To Disassemble Valve The valve may be taken apart by removing which hold the body and bonnet together. the four socket head body screws After removing the screws, carefully lift off the bonnet assembly (upper part of the valve). Do not drop the plunger. The diaphragm may now be lifted out. Use caution not to damage the machine faces when the valve is apart. NOTE: THE ABOVE PROCEDURE MUST BE FOLLOWED BODIES INTO THE LINE. BEFORE BRAZING SOLDER TYPE To Reassemble Place the diaphragm in the body with the pilot port extension UP. Hold the plunger With the synthetic seal against the pilot port. Make sure the bonnet "0" rings are in place, then lower the bonnet assembly over the plunger, make sure that the locating sleeve in the bonnet enters the mating hole in the body. Insert body screws and tighten uniformly. To Operate the Valv_e Manually The valve is equipped with a manual operating stem which port to be opened without the coil being energized. permits the main The manual stem is located in the bonnet assembly above the outlet connection. It is'a 3/16" square wrench stem under a seal cap which opens an auxiliary pilot port, allowing system pressures to actuate the diaphragm in a normal manner, identical to the action involved when the plunger is raised electrically to open the pilot port. A slight turn (approximately 1/2 revolution) counter-clockwise opens the auxiliary port. Tightening stem clockwise causes the port to be well sealed by pressing the stainless steel stem against the brass seat and returns the valve to automatic operation. The manual stem is sealed with an "0" ring to provide a leak-free construction. Do not attempt to screw the manual stem in too far. Do not continue to screw the stem in if resistance to turning increases suddenly. When this occurs, the diaphragm is up as far as it should go and any further movement will bend or distort the buffer plate. To return to automatic operation, back the stem out. Always replace the seal cap after operating the manual stem. General Service.Hints Note: Diaphragms and plunger assemblies will not withstand soldering heat an-'_-d-must be removed when the valve body is being soldered into the line. When this is necessary, follow the steps previously outlined for disassembly and reassembly. To check operation of the valve, first cycle the switch controlling the solenoid coil. Movement of the plunger will be audible if the coil is okay. Otherwise, check for proper voltage at coll terminals. If the voltage is okay, replace coil. Be sure the manual stem is properly positioned for automatic operation. Otherwise cemplaints of failure to open or failure to close tightly can involve only the plunger and diaphragm. Disassemble the valve and inspect the diaphragm and synthetic seat on the plunger. Foreign material interferring with the action of the Plunger or diaphragm is often responsible for the difficulty. Inspect both plunger seat and diaphragm for damage. Make sure difficulty was not caused by incorrect assembly of parts. Generally, the installation of a new diaphragm, a new plunger, or both will correct such complaints. The junction box or conduit connections on the coil housing can be moved to any desired position by loosening the retaining screw at the top of the coil housing and rotating the housing to the desired position. Be sure to tighten the retaining screw after this operation. INSTRUCTIONS FOR FIELD REPLACEMENT OF RESISTANCE COILS IN BLAST COIL HEATERS l . The replacement resistance coil is shipped prewound on the proper size arbor and with the terminals assembled to its ends. Insulators for the return bends made by the coil when strung thrnuah the heater and replacement terminal insulators are provided when required. . The enclosed diagrams must be followed when positioning the coils in the frame of the heater, installing the bus, locatina supply connections, and reconnecting any built-in components which were disconnected to facilitate coil replacement. . It may not be necessary to remove the terminal nan if the first bracket is spaced 3-I/2" behind it. Otherwise the pan may be removed by drilling out the spot-welds by which it is attached. It will be necessary, likewise, to remove the back pan if insulators are to be installed at the return bends of the resistance coils. The terminal pans which have been removed may be reassembled to the heater and attached with sheet metal screws after all terminals have been inserted through their insulator bushings. 1 The replacement coil is shipped close-wound, and must be stretched by the electrician to the proper length before placement in the heater is attempted. This proper stretched length is determined by the width of the heater and by the number of passes which the coil makes through the heater, and is found by the formula: Stretched It is important t Length = Number of Passes X (Heater Width Minus I") that the coil not be over-stretched. The stringing of the properly stretched resistance coil commences with the determination of its mid-point. Both ends are massed through the heater frame simultaneously. Care must be taken to insure that these passes are made through the correct location, and In the direction that will place the center return bend at the prooer end of the heater. For example, if the coil is to make four passes, the mid-polnt of the coll must bend across the front bracket (i.e. at terminal end). -2- ° If.the return bends of the coil are to be insulated, the center insulator must be carefully positioned in the coil before it is passed through the heater. The insulator should be placed on the straightened section of coil, so that the resistance wire lays in the groove of the insulator, and the wire must then be bent down sharply through the grooves at the ends of the insulator. It is important that the wire passing through the end groove of the insulator be centered on the adjacent windings of the coil. If the coil is to receive additional return bend insulators, it should be similarly formed about them before through the heater is commenced. . o the return pass of the coil The male half of the phenolic terminal insulator bushing must be placed in the terminal pan from the side internal to the duct, before the coil terminal is passed through the terminal pan. (If the terminal pan has been removed, all of the coils should be strung before this phase of the job is attempted). Care must be taken that the terminal is completely seated into this section of the insulator bushing, so that the terminal is prevented from rotating when its hardware is installed. The terminals are fastened into their insulator bushinas by a nut tightened* down against a washer on top of the female section of the bushing. It is essential to insure that the terminal is completely seated into the bushing so that it is prevented from turning. *Bushing g. lO. may be cracked if over-tightened. In some cases where the replacement resistance coils are intended to convert the heater to a different electrical specification, the supply conduit knockout originally provided in the terminal nan may no longer be suitable, flew knockouts must then be providedln accordance with the rlational Electrical Code. The factory assumes no responsibility for the workmanship of electrlcians 4n the field, nor does the Underwriters' Laboratories allow their label to remain on heaters which have been reworked in the field. A new nameplate is included with the replacement coils whenever the electrical characteristics of the heater have been changed by installation of replacement coils. This nameplate must replace the original nameplate on the heater. PARTS 6" RUBBER BLADE AIR CIRCULATING Catalog Nos. M-3897-I M-3897-2 M-_Rq7-_ M-3897-4 Voltage 36 Vdc 72 Vdc 12B V_r I15 Vac FAN FOR ROOMETTES & BEDROOMS Current 1.6 .8 .26 i . . . E ITEM NO l 2 3 4 S 6 7* B 9 lO II 12 13" 14" 15' 16" 17" 18" 19 20 21 22 23 24 25" 26* 27" 28* 29 30 31 32 33 34 35 DESCRIPTION Ball Rivot Bracket, Complete Cover, Complete Fan Grommet Grommet Insulator Lockwasher #8 Lockwasher #10 Motor (36 VDC) Motor (72 VDC) Motor (If5 V AC/DC) Armature Armature Armature Bearing Brush & Spring Assembly Brush & Spring Assembly Brush Cap Motor Band Mounting Base Nut, l-I/8-12 NF-3B Nut #8-32 Rectifier Resistor, 15 ohms Resistor, 150 ohms Resistor, lO0 ohms Resistor, 250 ohms Screw, Truss Head NYLOK #I0-32 x 3/8" Screw #I0-32 x 3/4" Set Screw,Headless #I0-32 Socket Bushing Socket Bushing Terminal (Faston) Washer #10 * NOT SHOWN CATALOG NO. F-12435 F-18013-1 F-12463-I F-12462 156393 T-12532 T-12525 53884 52909 T-12461-I T-12461-2 T-12461-3 T-14592 T-14593 T-14610 T-14614 T-14611 T-14612 T-14613 T-12449 M-3885-2 T-12440 52884 T-17278-I T-12460-7 T-12460-13 T-12460-12 T-12460-15 T-12527-I 4089 T-12464-3 T-12438 T-12439 T-13585-I 52832 NO REQ'D l l l l 1 1 1 1 4 l 1 1 1 1 4 l 1 1 1 1 4 l l l l 1 1 2 l l l l l 2 l 2 l 2 2 2 1 1 1 4 2 2 1 1 1 4 2 2 1 1 1 2 l l l 2 2 2 1 1 1 4 2 l l 2 3 3 3 2 1 1 2 1 1 2 1 1 3 1 2 1 1 4 1 IST 5778 _/78) AIR CIRCULATING I. FAN ASSEMBLIES FOR ROOMETTES AND BEDROOMS INTRODUCTION This description covers the line of rubber blade air circulating for use in roomettes and/or bedrooms of battery powered sleeping 2. MECHANICAL DESIGN The fan assembly a. b. fans designed cars. design incorporates provisions for mounting a motor and a blade. The method of mounting permits not less than 90 ° horizontal and 45 ° (15 ° up and 30 ° down) vertical adjustment in the direction of air flow. After being positioned within the established limits, the fan will remain _n the set position under normal vibrational acceleration levels experienced in a rail car. Position retention is accomplished without requiring any action other than directing the air flow. The mounting will retain full capability for the life of the fan assembly. Motor The motor incorporates two permanently lubricated bearings, one at the blade, and one at the commutator end of the armature shaft. The material used does not support combustion nor will the motor frame exceed 20°F above the ambient when the fan is operated on high speed setting at 125% of rated voltage for a minimum of 8 hours. The brushholders are integral with the housing and located so that the brushes may be changed without removing the fan from the wall bracket. c. Fan Blade The 3 blade rubber fan is 6" in diameter and supplied with a screw and adapter to maintain shaft and blade concentricity. The material hardness of the individual blades is no greater than a durometer reading of 60-65 shore A. d. General The assembly, astic enamel, 3. less the fan blade, medium gray color. hub, and motor, is painted The motors are arranged for three switch provided by the customer. speed operation through ELECTRICAL a. b. DESIGN Motor a remote control Brushes Nominal . with a metal- brush life is of the order of 17500 hours of operation. PERFORMANCE At high speed, Nominal the air delivery Performance Voltage Switch Settin 9 36 VDC 72 VDC 125 VDC ll5 VAC 120 VAC 125 VAC is not less than 250 CFM Data Pos. 1 .95 .48 .3 .452 .417 •398 Current Pos. 2 Pos. 3 .7 .55 .3 .2 .14 .17 Pos. l 25/2600 25/2600 26/2800 3540 3450 3390 Speed Pos. 2 Pos. 3 19/2000 19/2000 17/1900 25/1600 16/1700 13/1500, i T_,_ I 7l;I r_la.t _ r ll(}_.l f I _111- l 9.104 I ./7 .......... ; /8 /9-t 0-11 /7 I _I0-I 5TI 512 5T3 I - 5TI 5T2 5T_ ,2J I /22 i + / 17 i_ '_T-"_--=--'_- --=" _._ i Z _ • _1 5 o_i _f CF- £_'L_f C_*v_h_,t_e. ._jnE,4E_aa_ Jr-_lb_ .,_cf,41_,,_-_"_ l _4Z" _,.Z* I_-_. I;_ , _-_._-..-=_-.,. ,n_'_'-_l C-3-17 3.2 Temperature Controls The temperature control panel mounted, in the switch locker, controls ventilation, heating, air conditioning. One model of panel is used on both car series, it is unique to these 31 cars, as are the thermostats. 3.2.1 Panel Description (See Fig. 3.6 & 3.7) The panel has three controls, the selector switch, cool bypass and the circuit breakers. The selector switch is used to select either heat (day, 72 ° or night, 74 ° ) cooling (day 72 ° or night, 74 ° ) or OFF (Layover, 50°). In the OFF position, the blower and exhaust fans are off; in the other positions they are on. temperature The lights Seven neon pilot control panel do not indicate lights illuminate to indicate desires a specific function. whether the car is doing as The blower light indicates without regard to whether the blower check for this vital safety feature blower stops. the air vane is running, to make sure the See Fig. requested. 3.8. switch is picked up, thus providing a it drops out when the The cool bypass light illuminates to indicate this feature has been activated. This feature bypasses the cooling thermostats for 30 minutes, running the A/C unit in half cool for that time. Once the timer runs out, control is restored to the thermostats. Cool override is initiated by pressing the "Cool Override" push button, and is cancelled by pressing "Override Cancel." When cool override is in effect, the override lamp is illuminated. The temperature control panel is connected with the A/C pressure switches such that if the unit should shut off for either excessive head pressure or low suction pressure, the HP/LP light will come one. Unlike the later HEP cars, the HP/LP light here will only light while the The two fault condition circuit exists. breakers on the panel protect equipment from faults: 1. . "temperature "control" control" feeds the including feeds loads 120 VAC to the of the panel. internal functions of thermostats and bottle external the panel relays. The bottle relays on the panel and thermostats are fed 120 VDC power, derived from a bridge rectifier on the panel. All relay circuits are the series thermostat type, with an increase in temperature energizing the relay. C-3-18 There are 2 MS type connectors on the bottom of the temperature control panel: the left is for power and control outputs, the right is for thermostats. The thermostat connector is intended for use with the "Bruss Box" test unit. The thermostat plug is detached, and the test unit connected to both the temperature contro] panel and the thermostat plug. This allows test of the complete temperature control system including contactor operation. Refer to test spec. PQ-79-I Section 3.3 for this procedure. The connectors also allow for easy removal of the panel from the car. by the The temperature temperature-control locker. There are transformer primary control panel operates control transformer 2 circuit and the from 120 VAC, in the electric breakers contained there also, 120 V transformer secondary. provided the 480 i_ear the temperature control panel is a blue "shunt trip" pilot light. This light illuminates to indicate power is available operate the shunt trip feature on the overhead heat. It should be lighted whenever the car is on 480V HEP. Refer to Section 3.3. V to C-3 FIGURE TEMPERATURE 0 3.6 CONTROL PANEL @ FL_C,f .'_ (b 0000cool c_0.c _rJ. CONT_ OFF 0 S'TOp •"-_' ((o))( _,ucT "_"" _- _P-LP I _OFF(_ _A£AT i_ I _TCH _ OV_, SCHEMATIC OPERATING INSTRUCTIONS 0 I ) m--_J 0 =19 C- -20 3.7 FIGURE TEMPERATURE COVER CONTROL PANEL INSTRUCTIONS IMSTBUCTION CHAI,ITOPERATION BCHEDUL£ FOBIll156_2S TE,MPERATURE CONTROL PANEL CONTROLSNITCH POSITION FUNCTIONAT INTERIORTFJIPERATURE "F SIGNAL LJVIPINBIEATION COOL BLONZR FLOORIOUCTI "COOL COOL _D CONTACTOR HEAT iEATIBY-PASS "'HP-LP ON LAYOVER BELOW _" COOL - NIGHT ABOVE 76" l_'- 76" BELOW 7R" (VENT) ON ON ON ON ON ON COOL - DAY ABOVE 74" 12"- 74" BELOW 72" (VENT) ON ON ON ON ON ON HEAT - NIGHT BELOW 7R" ABOVE IR" A_VE IR" (VENT) ON ON ON ON ON HEAT - DAY BELOW 72" ABOVE 72" ABOVE 72" (VENT) ON OH ON ON ON "COOLBY-PASSSTART: NOTE: SELECTORSWITCH_UST BE IN COOL _SITION. MARUALCOOL CONTROLSTART: DEPNDSSCOOL BY-PASSBLFFTON. INITIATESPARTIALCOOLINGFOR 30 MINUTESOVERRIDIN&COOL THER/_OSTATS, _AHUALCOOL BY-PASSSTOP : DEPRESSCOOL BY-PASSSTOP BU'FIOH TO STOP C_PRZSSOB INITIATEDON PRIOR 30 MINUTE TIMINGCYCLE. "'ND-LPSIGNAL LIGHT WHEN ENERGIZEDINDICATESA FAULT CONDITIONOF TEE C_PRES_R AND MUST E REPORTED, C-3-21 Fig. Pilot Light LIGHT 3.8 Assignment MEANING Blower Fan Blower Fan R'unning Cool Request Cool Mod Call For Duct Heat Call (HC1 For Overhead Heat or HCl + HC2) Floor Heat Heat Selected Call for Layover Selected Call heat for bedroom, roomette (FH1, FH2 & FH3) For I/2 Full Pass & Air Cool Cool Cool Bypass Cool By in HP-LP High Pressure/Low Vane Switch Picked Up (RCMS) (Mod. Effect Valve) On - 1 or hall - Pressure 1/2 2 Stages heat Cool A/C (FH3) (RMCS) System Fault & hall TEMPERATURE RELAY DESIGNATION RELAY Time Delay HeR Heating/Cooling FUNCTIONS FUNCTION NAME TDR Figure 3.9 CONTROL PANEL RELAY Relay Relay WHEN Provides 30 minute cool override: Causes I/2 cool mode. During Heating Selected - provides control circuit to hall floor heat contactor FH3. When 74 ° Hall Heat thermostat Is satisfied (i.e., hall is warm enough). When 50 ° Layover Heat thermostat is satisfied (i.e., car is warm enough). Layover Selected - provides control circuit to bedroom, roomette and hall floor heat contactors DR Duct Relay OAR Cooling Modulation Relay PICKED UP FHI, FH2, Cool Bypass R13. Coolin_ Selected - provides control circuit to A/C panel to start A/C contactor ROAS. When 72° Cool thermostat is closed (i.e., I/2 cooling is required). Provides control circuit overhead heat contactors HCf and HC2. When 74° duct thermostat is satisfied (i.e., duct is warm enough). to Provides control circuit to modulation solenoid valve for full cool. When 76 ° full cool thermostat is closed (full cooling required). I Ld C-3-23 3.2.2 Thermostats equiplnent: Three types of (See figure 1. Fenwal thermostats 3.10) differential a. Antifreeze b. Outside are • These bottle relays, Chromolox units are each room. directly, adjustable on expansion, thermostats thermostats The thermostat is used control the corresponding • used this used converted HEP for; (2) (3) in a series contactor. circuit to directly WR-80 direct acting wall mounted. These 18 used I per room to control the floor heat in The thermostat switches the heater power 240 volt single phase. They are passenger over a range of 40 ° to BO°F. _lercury Tube (5) are used to control the bottle relays of the Temperature Control Panel. These are plug-in types; all except the layover thermostat are equipped with a heater winding (compensator). By applying a voltage continuously to these windings, it is possible to make the thermostat think it is slightly warmer than the car actually is. This is how day and night settings (2 ° difference) are provided. In addition, anticipation is provided. This is similar to the procedure just explained except that here the voltage is applied only during times when the heat is on. This is useful to prevent heating overshoot. When a heater is turned off, there is still heat in the elements, and thus the car temperature will continue to climb for a little while after the heat is turned off. With anticipation, the heat is turned off just soon enough to prevent this overshoot. thermostats which in are turn do all the used in actual series circuit circuits with the switching. Occasionally a mercury tube thermostat acquires a "split column;" there is a break in the column of mercury. It can usually seen, but can be checked easily with an ohmmeter. It is sometimes possible to repair this defect: With a match (NOTHING LARGER OR HOTTER), very gently heat the bulb of the thermostat while watching the mercury column. When it starts to rise, remove the heat. If the mercury rises far enough, it will rejoin the rest of the column and the thermostat will function normally. be C-3-24 NOTES: i. Do not use a work properly. 2. Use care easily. • 4, in thermostat handling Avoid mercury poisonous and breathing the temperature). with mercury a split column thermostats it they wil] not break from broken thermostats it is quite can be absorbed through the skin or by fumes (which are produced at room _ake sure the hatch key hole in cooling thermostats is plugged. blow out from the overhead duct the car will not cool properly( the ceiling hatch over the If it is not, air will onto these thermostats, and C-3-25 C FENWAL i CHROMOLOX EXCEPT LAYOVER= 13 VAPOR FIGURE 3-10 HEATER -PINS 3,q WINDING READS-600 OHMS TYPICAL THERMOSTAT TYPES C-3-25 part list temperature Fig. 3.11 lists thermostats and Figures 3.13 indicates Figures 3.14 3.18 show the control system in heating, Each of the 18 rooms has and functions. the location control cooling individual of Figure 3.12 is a the thermostats. points of the and off positions. room control via an in-line thermostat, mounted on the wall of the room. Also associated with each room is an Auto-OFF toggle switch, which allows turning off the individual room heat. Each room has its own pair of pushbutton type circuit breakers, mounted inside the wall between room and passage behind the service hatch. inspected air. Thermostats require periodically, and little maintenance, but if dirty, gently cleaned Use care to not break the glass and can be absorbed through the skin or temperature) inhaled. on the should be with compressed mercury tubes-it fumes (produced is toxic at room C-3-27 Fig. Thermostat OR = OPEN Outside Function & CR = CLOSE ON Staging (OR) Floor Heat 1/2 Cooling Full Cooling Heat Lockout 74 ° Layover 50 ° (CR) (CR) Thermostat: Hall Heat Bedroom RISE (CR) (OR) 9 Thermostats: 74 o Duct RISE Overhead Heat A/C Lockout Bedroom/Roomette 74 ° 76 ° Hall Assignment Thermostats: 20 ° 50 ° 70 ° _u_lin ON 3.11 F|oor Heat (CR) Thermostat: Duct Heat Heat (CR) Thermostat: Layover Floor & Roomette Adjustable 40-80 Room Heat (CR) Thermostat: ° , I per room (OR) Heating ITEM I 2 3 4 5 6 7 8 9 10 11 DESCRIPTION FUNCTION --- 20° O.H. Heat Staging 50 ° Cool Lockout 70 ° E,H, Lockout 50 ° Layover 74 ° Hall Heat 74 ° Duct Heat 74° Cool 76 ° Cool Mod. Room Thermostat Cover, Thermostat Figure 3.12 and A/C Thermostat Outside Thermostat Assembly, Complete with 20,50 Thermostats Thermostat, Differential Expansion, 20° O.R. & 70° Part List MFG MFG # AMI Vapor 17651764-1 25Pgoog123 Fenwal 17000-0 Set 20 ° 25N6003934 Thermostat, Differential Expansion, 50° C.R. Fenwal 17021-0 Set 50° Thermostat, Differential Expansion, 70° O.R. Fenwal 17000-0 Set 70° 25K6003935 Vapor 15033278 50° 15033270 74° 25X9009122 Vapor 74° 16820180 Mercury Tube, Plug-ln Mercury Tube, with 600 ohm Heater, Plug-ln Mercury Tube, with 600 ohm Heater, Plug-ln Mercury Tube, with 600 ohm Heater, Plug-ln Vapor Mercury Tube, with 600 ohm Heater, Plug-ln Vapor Heavy Duty, 2ZA, 240V Adjustable For Items 5, 6, 8, and 9 Wall Mount Vapor 15033269 74 ° 15033269 76 ° Chromolox WI_-80 Vapor 15436442 AMMS # 25B9009121 25E9009120 2_4000162 25Kg011822 N t t pa o0 k,-_Np B-END H@ OUTSIDE "T_ERMOSTATS |- SINGLE ASSV NOTE: - tO',SO'_70" B,OOM THERMOSTATS H_,VE ON-OFF SWITCH _AOUNTED BENEATH THEM FIGURE 3.13 THERMOSTAT LOCATIONS I0- 6 SLEEPER TYPICAL I ,,.O I -0 C-3-30 3.2.3 Blower Logic The blower fan is controlled by the BFMS contactor and operates in either the heating or cooling position of the selector switch of the temperature control panel. The blower is OFF in the selector OFF position. The exhaust fans, controlled by the exhaust fan contactor, EFC, operate in either heat or cool, but not during OFF. center of to enable An emergency the car at someone to switch is accidental fan switch is mounted high on the wall near the hall offset. The purpose of this switch turn off the blowers in case of a car fire. labeled, and turn off. is covered MANU. SPST Toggle Switch Red Switch Protection Cover by a flip-top MANU# Cutler Hammer 7580K4 Cutler Hammer 8497K2 door to AMT# the is The prevent AMMS# NOTE: IN CASE OF A CAR FIRE, IMMEDIATELY TURN OFF EITHER THE TEMPERATURE CONTROL SELECTOR SWITCH OR THE EMERGENCY FAN SWITCH. THIS IS IMPORTANT TO REDUCE THE AMOUNT OF FRESH AIR BROUGHT INTO THE CAR WHICH WOULD HELP THE FIRE TO BURN AND SPREAD. 3.2.4 Cooling Logic Refer to Figure 3.14 for the cooling temperatures. Note in the day position, the the night position. The following discussion controls are in "day." control point car is 2 ° cooler than assumes temperature in Cooling is available only when the outside temperature is above 50 ° , as sensed by the fresh air thermostat. Return air (on the wall) thermostats sense the car interior te_nperature and enable the cooling to start if it is above 72 ° As the car temperature rises above 72 ° , the cool thermostat closes, energizing HCR relay, which in turn starts the A/C compressor and condenser fan. Freon flows into 1/2 of the evaporator, that is, 1/2 cool. Half cool is in effect up to 74 ° . The cool pilot light comes on to indicate 1/2 cool request. Above 74 ° , the cool modulation thermostat is closed, energizing CMR, which energizes the modulation solenoid. Freon now flows into the entire evaporator; full cooling is in effect. The cool mod pilot light comes on to indicate request for full cooling. FIGURE 76_ 5.14 FULL COOL (IF COMPRESSOR HEAD PRESSURE IS LESS THAN C-5-31 235 PSIG 74 _ I / 2 COOL L.d r'_ (I) Z -- 70" I 45" i 50 _ I 60 _ OUTSIDE TEMR 70 _ DAY 78 _- FULL COOL ( IF COMPRESSOR HEAD PRESSURE IS LESS THAN 255 Q_" pLd E3 I/2 PSIG COOL GO z 74 °- 72" 45 ° I 50" ' I i 60 ° OUTSIDE TEMP NIGHT I 70 _ C-3-32 If during full cool operation the head pressure should rise above 235 psig and thus actuate the modulation pressure switch, MPS, the switch will open and put the unit back into 1/2 cool. The purpose of this feature is as follows: in a very hot ambient or if condenser air flow is restricted, it is harder to condense the freon in the condenser and the head pressure rises. If allowed to get too high, eventually the high pressure switch will open and shut the system down. If a modulation pressure switch is used and is set to open at pressures slightly below the high pressure switch, it can keep the system running. By shutting off the full cool solenoid, the condenser does not have to work as hard, does not get as hot and the freon pressures are lower. Thus the system stays on line, providing 1/2 cooling, (far better than no cooling). If the freon pressure drops after a time, the modulation switch again closes and restores the evaportor to full cool. In very hot weather, say above 110°F, the system may oscillate between full and I/2 cooling via the _IPS. below drop will As the car temperature drops, eventually it it will drop 74 o , establishing 1/2 cool. As the temperature continues to over a period of time, it will fall below 72 ° and the A/C unit shut off. This system does not use pump down. This discussion was based on the temperature control panel selector in day position. If it is in the night position, the temperatures are 2 ° higher. A 1/2 hour timing relay is incorporated on the Vapor panel, for cooling override, which allows operation of the A/C system without regard to car interior temperature, although the syste_n still locks out below 5O°F outside temperature. Start and stop pushbuttons are located on the panel to control this timer. The red cool bypass pilot lamp illuminates to indicate the timer is in "operation. The pressure switches used with this A/C system following: PRESSURE SWITCH LP HP MPS SWITCH SETTINGS OPENS CLOSES 2 PSIG 275 235 7 PSIG 225 205 include the C-3-33 The A/C 1. 2. logic includes the safety features: Lockout below 50 ° outside temperature. Overload relays for blower fan, condenser fan and compressor motors to protect against overload. Manual reset is required for each. Air vane switch and blower fan interlock to prevent evaporator freezeup should the blower fail to operate. Low pressure shutdown (but not lockout) self resetting. High pressure shutdown (but not lockout) self resetting. 3. 4. 5. For complete tests of the refer to Test Specification 3.9. 3.2.5 following Overhead Heat Logic (See A/C system PQ-79-1, Figures and control logic, Section 3.3, 3.6 and 3-15 & 3-16) The car is equipped with a 2-stage overhead heater. This heater is not intended to actually heat the car, but rather to warm the incoming fresh air to the car temperature (approx. 74°). Accordingly, air delivered from this duct will not feel very warm; do not confuse this with a overhead heating defect. (Floor heat actually provides most car heating. Duct air temperature is used to control the overhead heat. A 74 ° duct heat thermostat (located in the ceiling outside bedroom F) controls the Duct Heat relay. At a temperature of less than 72 ° day (74 ° night) the DR relay is dropped out bringing on the overhead heat contactors. Whether one or 2 stages of heat is on depends only upon outside temperature: if it is above 20 ° , one stage is on; if it is below 20 ° both stages are on. The Duct Heat pilot light indicates when overhead heat is requested. Cycling they are rates rarely The overhead overheating heat does protective circuits • up to 4 per minute are heater not must and possible come on are fire, unless though air it the flow across the elements. is important that blower is operating. the Three employed: Interlock (running on BFMS blower). Air switch Vane have must contactor sense must air blower pilot lamp being on). It the evaporator blower or slightly evaporator in the main air duct. 3. acceptable, observed. To avoid overhead 1. of Shunt trip last resort of the overhead to turn off an be flow. picked (Indicated is located downstream heat circuit overheating up, by either with of the breaker is the unit. Powered by C-3-34 a separate transformer, (the bottom of the 2 in the 480 locker) this circuit consists of a 200°F thermostat located near the heater elements and the shunt trip coil of the overhead heat circuit breaker. AT 200°F and above, the thermostat will close and turn off the circuit breaker. The shunt trip pilot lamp in the switch locker should be illuminated whenever the car is on power. This indicates that shunt trip power is available to operate the emergency shut down should be called upon to do so. Since this is an important safety feature, the cause of this bulb not lighting be investigated. (See Section 3.3) FIRE MAY NEVER _ JUMPER OUT OR BYPASS AND INJURIES RESULT. ANY OF The air vane switch, figure 3.15, mercury switch, hung in the air stream of significant air flow is present the paddle switch contacts. Loss of air flow allows opening switch. the switch. Car safety depends THESE SAFETY FEATURES. it must A is a paddle operated the main air duct. When swings upward, making the the switch back down, upon proper operation of this Care must be taken that the switch turns off every time, not only marginally. Never test the switch by raising it and then releasing it and letting it swing: this will often give a false turnoff. Instead, use the car blower to move the switch, and turn off the EVAPORATOR Breaker to let the fan coast down as it would be in a real situation. If the vane switch works reliably, then it should be okay. If it does not turn off, the black tube can be moved back and forth to adjust the trip point. If this is done, however, use Glyptol or RTV to lock the tube into place once the final setting is made. It is extremely vane switch periodical]y, PQ-79-1, Section 3.4. important to as described check the operation of the in the Map form and test. air I I ,jI-._L4 ] SLIDE TUBE CHANGE TRIP TO POINT TILT SWITCH [0] VANE POSITION AT ABOUT 700 FPN SWITCH CLOSED AIR |LO_E FLOW R OPERATING AIR VANE SWITCM OGONT_. _ 83-/3 -2k_ AM-I" _ _5N9010345 AMMS_ 0 FIGURE 3.15 I OJ AIR VANE SWITCH I OJ (.;1 C-5 FIGURE 3.16 74d NO OVERHEAD HEAT 72' DUCT TEMP. 70"- I OUTSIDE 30 o TEMP. I 40 _ DAY 76 _. NO OVERHEAD HEAT 74_ DUCT TEMP. t'x k 72"- O" I0 ° 20' OUTSIDE NIGHT 50" TEMP. 40" -,56 C-3-37 3.2.6 Floor Bedrooms Heat & Roomettes Logic (Fig. 3-17) On these cars, each the temperature control panel does this by causing the two when the outside temperature heating. compartment has its own thermostat, and only provides a lockout feature. It room floor heat contactors to pick up is below 70°F; and the panel is set for The contactors FH1 (bedrooms) and FH2 (roomettes, toilet porter's room) control the 240 volt feed to the buses feeding the heat. There is no pilot light indication for these buses. & room Each of the 18 rooms of the car (10 roomettes, 6 bedrooms, public toilet and porter's room) has a 240 volt, individually thermostatically controlled heater. The thermostat is in-line with the element, and has a passenger-adjustable range of 40-80 ° . Each room is separately protected with its own circuit breaker (accessed from the hall outside the room) and has an OFF-AUTO switch, which is merely an OFF/ON switch to turn the heat off should the room thermostat fail. Each room heater is equipped with an internal high temperature cutout, set to 135°F, to turn it off should it get excessively hot. Hall (Fig. 3.17) The floor heat for the hall is controlled by the FH3 contactor. This in turn is controlled by the Vapor panel HCR relay. The wall mounted thermostat in the hall between rooms A & B controls the HCR relay. If the HCR is dropped out, hall heat will come on. ilall heat is controlled at 72 ° day, 74 ° night. The floor heat pilot light indicates the call for hall heat. Laxover Heat (Fig. 3.18) When the car is set for Layover heat (the Vapor selector switch in OFF) the blowers are turned off and heating is done by floor heat alone. Now the 50°F layover thermostat (located at the bend in the hallway) is used to control the HCR relay, and this controls the FH1, FH2 and FH3 contactors. Room thermostats still operate to turn off any rooms which might get above the setting of their respective thermostats. The floor, heat pilot lamp lights to indicate layover heat being requested. Test 3.2.7 For complete tests Specification PQ-79-1, Damper NIA Logic of the heating Sections 3.3, system 3.5 and and logic, 3.9. refer to 72 ° .///."/."7)/7", 50 FIGURE 3.17 FLOOR HEAT C -3 -38 40"-80 ° PER ROOM THERMO. °. I 50 = 50" 70 = 70 ° OUTSIDE TEMP. BEDROOMS & ROOMETTS HALL DAY DAY 74 = 40- 80 PER ROOM THERMO. 50' I 50 ° HALL NIGHT t 70" 50 OUTSIDE BEDROOMS 70" TEMR & ROOMETTS NIGHT C-3-39 54"- 52 _ 50 NO HEAT "_, 48 % I 50" 60" FIGURE 5.18 LAYOVER C-3-41 Section TEMPERATURE CONTROL Temperature Part 3.2.8 PANEL Vapor Control #17756475 MANUAL Panel TB4PERATURE ITEM DESCRIPTION PART LIST MFG MFG # Vapor 177X6475 2 3 Tmperature Control Panel, Smi-automatic HEP sleeping car, 120 VAC CI4R Relay, Bottle, 120 VDC HCR Relay, Bottle, 120 VDC Vapor Vapor 35040175-17 35040180-09 4 5 6 DR Relay, Bottle, 120 VDC CR Rectifier, Bridge TDR Relay, 30 Minute Vapor Vapor Vapor 35040176-09 17511123 97411034-03 7 8 9 Varistor, 120 VAC Line Pushbutton (Cool Bypass) Circuit Breaker, 5 Amp Vapor Vapor Vapor 17620640-04 56310013 97320543-03 10 11 12 Pilot Lamp, Neon, NE2D Supressor, Relay Coil Switch, Selector - Heat Vapor Vapor Vapor 16910131-01 97510339 15432882-21 13 14 15 Knob for Selector Switch Resistor, Anticipation, 55K, COW (RT, Rg) Resistor, Setdown 2OK, 3W (RI, R2, R6, RS) Vapor Vapor Vapor 15010465 95010020 95020021 16 Resistor, Vapor 95020021-26 I QTY Figure 3.20 CONTROL PANEL Series - Cool 3K, 3W AMT # AMMS # 25X9009119 C_ I LP I OPERATING INSTRUCTIONS AND Vapor Co. Temperature Control Part #17756475 SERVICE Panel r4ANUAL Table • Contents Page i-I Introduction 2. Installation 3. System OperationCircuit 4. Periodic Maintenance 5. Schematic 6. Location 7. Repair 8. Tools and Operation 2-1 Description 3-1 4-I 5-1 Diagram Procedure & Test List and Part and Trouble 6-1 Shooting Equipment 7-1 8-I List 2.1 2.2 5.1 5.2 6,1 7.1 of Front View of Panel with Panel Operating Instructions System Schematic Temperature Control Panel Drawing List Trouble Shooting Chart of 111ustrations Cover Wiring 2-2 2-3 5-I 5-2 6-1 7-2 1. 1.1 Introduction General This system control 1.2 manual describes as supplied for the use Vapor #17756475 temperature on the 2900 series sleeping Features A. B. Panel i. Selector 2. 3. 4. Cool Bypass Cool Bypass Cancel Circuit Breakers (2) InputsI. 2. 3. 4. 5. C. D. - Heat - day & Cool - day & Off (layover) night night 8-Thermostats: 50, 70 ° Outside (differential Layover Mercury Tube Hall Heat Compensated Mercury Duct Heat Compensated Mercury 76 ° Cool Compensated Mercury 1. 2. 3. 4. Blower & exhaust fan ON/OFF Overhead heat, 2 stages Layover heat (floor heat) Hall heat 5. Cooling, expansion) Tube Tube Tube 2 stages Pilot Light Indications 7 Lamps indicating Blower fan Heat: floor and duct Cool: 1/2 and full Cool Bypass HP-LP shutdown Connections 2 Military I. 2. F. 20, 50 ° 74 ° 74 ° 74, Switch Ou__t__puts 1. 2. 3. 4. 5. E. Controls: 14 35 Size ITwide, (overhead) Connectors - Pin - Pin 16" power thermostats high, 6" deep, 1-I weight 18# cars. 2. Installation 2.1 Installation bolts The panel is mounted near the corners. Operation Thermostats and freedom access, 2.2 & on should be from local a vertical mounted heat or surface to ensure cold air using 4-1/4-20 good air sources. flow, easy Operation A. Circuit off B. NOTE: Selector required: D • Breakers for should be left on at all times; turn servicing. Switch - select The blower Floor heat temperature either heat, cool or layover, as fan and exhaust fan are off. is controlled to maintain car of 50°F. I. Layover: 2. Heat: Day = 72 ° , Night = 74 °. Car will run blower fan and exhaust fans. Overhead and hall heat will each cycle to maintain the selected temperature. Bedroom and roomette heat is available if outside temperature is below 70 ° . 3. Cool: Day 72 ° , Night = 74 ° . Car will run blower fan and exhaust fans. Car will operate in I/2 cool if temperature is 72-74 (DAY) or 74-76 (NIGHT). If above that temperature, full cool in effect. Change Co only from heat to cool is not automatic. Pilot Lights Neon pilot lights function requested by temperature Amtrak manual Section 3.2 come on control Cool Bypass - The car regard to car interior into by can be put temperature to indicate panel. 1/2 cool pressing Refer to without the cool button. The system will operate in this mode for ur at which time the system reverts back to normal thermostat control. Cool bypass can be shut off by merely pressing cool bypass stop. 2-1 ,._ _ II I_- _,0_,_._ _c'r . coo. ,_. .,_, © .. _._-_: _*%_"_.._ -. _ :- _o_'Q : IkPST'IZU CT101,,i I.,/k_ P_..L. © © _r_oiq,T Vl P.-'W'0t= PAI,,I_.L. WITt--I 2-'Z. COVP__.IZ. INSTRUCTION CHARTOPERATION SCHEDULE FOI_#I775_75 TEMPERATURE CONTROL PANEL CONTROLSWITCH POSITION LAYOVER SIONALLAMPINDICATION FUNCTIONAT COOL BLOWER FLOORDUCT "COOL INTERIORTEMPE_TURE "F COOL MOB CONTACTON HEAT HEAT BY-PASS "'HP-LP BELOW 50" ON COOL - NIGHT ABOVE2B" 74"- /6" BELOW 14" (VENT) ON ON ON OH ON OH COOL- BAY AROVE7q" 72"- 7_" BELOW 72" (VENT) OH ON ON OH ON ON HEAT - NIGHT BELOW 7q" ABOVE 7N" ABOVE /4" (VENT) BELOW /2" ABOVE 72" ABOVE 72' (VENT) HEAT - DAY ON ON ON ON OH ON ON ON ON ON "COOLBY-PASSSTART: MUTE: SELECTORSWITCHMUST BE IN COOL POSITION, MANUAL COOL CONTROLSTART: DEPRESSCOOL BY-PASSBUTTON,INITIATESPARTIALCOOLINGFOR 30 MINUTESOVERRID[MUCOOL THERMOSTATS, _ULNUAL COOL BY-PASSSTOP : DEPRESSCOOL BY-PASSSTOP BUTTONTO STOP CO_PRESSON INITIATEDON PRIOR 30 MINUTE TIMINGCYCLE, *'HP-LPSIGNALLIGHT WHEN ENERGIZEDINDICATESA FAULT CONDITIONOF THE COMPRESSOR AND MUST BE REPORTED, GL,.J P-P-..2,1 O# .. ATIt,,4G 3. System Refer 120 Operation/Circuit to the panel Description schematic, drw. 17756475. Input power is VAC. The panel circuitry is relatively simple. All thermostats are connected in series with the corresponding relay coils. Thus when the thermostat is warmed, the circuit is made, and the relay is energized. The selector switch chooses between heating circuits and thermostats and cooling circuits and thermostats in the Heat-OFF-Cool selection. rectified rectifier present. The relays and by the bridge and time delay thermostats rectifier. relay from operate on 120V DC power, The varistor protects the electrical spikes which might be Cooling, duct and hall heat thermostats are each equipped with a heater winding, which allows two special operations: set down and anticipation. The thermostat can be made to think the air temperature is slightly warmer than it actually is by supplying a little heat from this winding. The winding is supplied with a low voltage from anticipation and setdown resistors. Setdown is the process in which the same thermostat can be made to operate at 2 different temperatures at different times. This is the technique used to achieve the Day-Night temperature settings on the temperature control panel. In the Night position, no voltage is applied to the heater winding, and the thermostat operates at the rated temperature. In the Day position, a small voltage is applied continuously to the heater winding via the selector switch and setdown resistor. This lowers the effective operating temperature by 2°F, thus a 74 ° thermostat then makes at 74-2 ° = 72°F. Anticipation is similar to setdown, but here the heater winding is only activated when the car heat is cycled ON. The circuit is made via a set of contacts on the heating relay. When the heat is cycled off, the car temperature will continue to rise for a short time because it takes a while for the heater elements to cool off. Anticipation is chosen to compensate for this heat, thus the thermostat turns off the heat a little before reaching the desired temperature, and the heat left in the heater elements brings the car up to the desired temperature. This approach allows more accurate control of car temperature than a non-anticipation system. Anticipation is used on the duct and floor heat thermostats. and, in Note: Setdown fact, are used and anticipation in the Day-Heat 3-1 can be position. used simultaneously, Cool bypass is a 30-minute cycle initiated by pressing the Cool Bypass button. This energizes the time delay relay TDR which remains energized for 30 minutes before dropping out. The Cool Bypass Stop button interrupts the coil circuit of the relay, causing it to drop out. Relay contacts close to put the A/C into partial cool during the bypass mode. Two 5 AMP circuit breakers are used to protect the temperature controls. The "temperature control" breaker feeds loads external to the panel, namely heating and A/C contactors. The "control" circuit breaker protects the logic of the panel itself relays and thermostats. 3-2 . 4.1 Periodic Maintenance Mechanical A. Temperature Control Panel The No. 17756475 temperature control panel should be cleaned and inspected at the three month intervals. No other maintenance requirements are anticipated. Follow procedure outlined below at each inspection period. the Step Procedure 1. Set system temperature control transformer (in electric locker) and panel circuit breakers to OFF. Remove panel cover. Blow all dust and lint from panel assembly; use 30 psig dry compressed air. Closely inspect all wiring connections. Repair or replace any wiring with worn or frayed insulation. Tighten all wiring connections as required. 2. 3. 4. 5. CAUTION: . USE CARE RESISTOR ING WILL Closely inspect relay contacts. Do not attempt to file or dress burned contacts. Where relay contacts are burned to such an extent as might cause a malfunction, replace the relay. Relay contacts may turn black (tarnish) from oxidation without impairing operation. Excessively tarnished contacts may be cleaned with a standard burnishing tool, or with a clean piece of hard stock paper similar to a business card. Use care, do not bend or attempt to file or dress relay contacts. This will change the contour and ruin the contact wipe. 7. Check all relay, screws. Tighten 8. Check coils; 9. Replace 10. DO NOT OVERTIGHTEN SET DOWN MOUNTING SCREWS. OVERTIGHTENCRACK THE RESISTOR. Check HP/LP that all resolder panel switch and terminal as required. thyrector if broken cover operation is red in and of all color. 4-1 leads are or loose. reactivate pilot lamps, strip secure mounting to control and that relay system. the B. Mercury Tube Thermostats Vapor double bulb mercury tube thermostats should be cleaned at the time of inspection. Use low pressure air (30 psig) or a fine brush to remove any dust from the sensing end of the thermostat. Thermostats should not be unplugged from their sockets unless a malfunction is suspected. Use care not to insert thermostats in wrong sockets when replacing or reinstalling. Double bulb mercury tube thermostats may be tested with an ohmmeter. Connect an ohmmeter (accurate to ±3 percent across connector pins #3 and #4. A 600 ohm reading ±5 percent should be obtained. Where this reading cannot be obtained, the thermostat is presumed to be defective and must be replaced. The layover thermostat is a single bulb thermostat, lacking the heater winding. The thermostat setting may also be checked (for functional operation) with an ohmmeter by connecting the meter across connector pins #1 and #2 (pins 1 & 3 on the layover thermostat). Where the ambient is above the "fixed" setting, the ohmmeter should read zero ohms. Below the fixed setting, the ohmmeter should read infinite resistance. NOTE: The "fixed" manufactured thermostat setting setting (without is any the actual setdown applied). Check the ambient of the test area with a thermometer. Where the ambient is lower than the setting, holding the thermostat sensing portion in a warm air stream will cause the mercury to rise and make contact. The ohmmeter should read "zero" ohms. Do not use an air stream above 90°F. Similarly, a cold air stream will cause the mercury column to drop and break contact. A calibrated control box must be used to check actual thermostat settings. Defective thermostats should be returned to the factory for repairs. 4-2 CAUTION: C. Bi-Metal DO NOT USE HIGH CURRENTOR HIGH VOLTAGETEST DEVICES SUCHAS TEST LAMPS WHENCHECKING THERMOSTATSFOR CONTINUITY. SUCH DEVICES WILL CAUSE THE MERCURYCOLUMNTO RUPTUREAND DAMAGE THE THERMOSTAT. Type Thermostats The three outside thermostats, located below the floor of the electric locker are the bi-metal type. They can be tested with an ohmmeter, which should read zero when the thermostat is closed. These thermostats are non-repairable, field adjustment of the thermostats is not permitted. The only way these thermostats can be calibrated is in a oil bath designed for the purpose; other approaches will certainly result in incorrect settings which will cause car malfunctions. 4.2 Electrical There is no independent test it is tested through the use procedure is given in Amtrak 3.3. This should be done as preseason tests. 4-3 of of the temperature a test unit. test part control The test specification of the heating panel PQ-79-I Section and A/C m,l_= .tLl, _ I i _ J d _ ie T I I i > ,..... _, ._..z ..>,) 5"{5"[" _ ,',,4 9Cl-_ B_.4,a,.'[._ " V,.-X?O_ OwG. tff'iOZ.._'i9 Figure Temperature Vapor 5.2 Control Panel Drwg. #17756451 5-2 Wiring Diagram Sht.-2 6. Location Diagram and Part Drawings Figure DRAWING Temperature Control Panel Temperature Control Panel Wiring Cover and Bracket Assembly Label, Instruction Label, Circuit Thermostat Box Assembly (Outside) Thermostat (Cooling and Cool Mod.) Thermostat (Duct) Thermostat (Floor Heat) Thermostat (Layover) 6-I 6.1 LIST 17756475-1 17756475-2 17731469 17721472 17721471 17651764-1 15033269 16820188 15033270 15033278 ....... r_l ................ [..,,.,_ ) I I£- LI- _'1J I ,J ( I F rt _, _ / o _ ,=. , J " i 48 I 1 # I I 5 fie- m O_ I i • I" -F 0 1o L_ --t i i i I- . l ** _-_-{:-_-_1_Jr_" A_v I , [ICSTI_ICTIOll ¢HA_T OP_UTIOIt 5(_1K_ #XT_W475 TF_P_TU_ C_TR_- pA_[_, COnla_d. _IT{# POSII[Oi FUN(T(ON AT INTEitO_ T[i_l_i'_ LAY_I "F {_t. COOL PrO I£LOV _* SlC,q_4. LA/_P IIKQI(ATION iO_l FLOW OU(T *CC_ (_i(TA(IAt Hr_T Pi£AT |y*PAS_ ON .._%p 76' 7_i*- 75' KLO_ 7_' (V[iT) r,_ . OAy m _ H(XT - iLGXl m OR rl (WKT) flF_T - _y _L W _ "(_L BY-PASS $TMTI "'W-LP $I(4AL L[_T m _ Ill'I; Vl(ll [_RGI_I) I_ICAT£$ A FAULTCOKOITIOq O_ TH[ CO_l_$5rJ k_ I_T E _F_TI_, OPR_'IM _,ATIq_,qlB Ilaeqll_al_n Nm C_f,TA fW_F_D MlN fWI_'N U;4_N). ;_.e,.IN_¢IOL AN0 _ane_U. _ Dt _'T ntVl0i • A_, ,_,LL _-._...._O'_'_l_.. _ 17721472 !l II li i li! l:i ./ _ FI_j_ jm I I 0 o 0 0 0 tL_, m_ 0 _ tL 1 W_'tUL_**_ 0 II_ _ miTt I.E. o o 0 0 0 0 0 I .,j • ....o o /-2 _ _ - -4 m5 J sr_ll;_ 20 ('_ll _ 19_ _ 2 _T S. r_ll vzl_. _T s&z_,l_ _'t rf. tt WO_l 9_ ICqP, m • I BL_C_ Co,v.,_.."c reo.v ,1_,,4q. I 2 t O+ 3 ) ('41_..s,w._r ._p_,.,*.mvdr,*,_a'_,,_..,,_" ? 0 I k 1 SINGER. L Oc I I 'Li_. I _iVll,_, DAVl ,a_ CN'I ¢. Cl, I.¢I, LIT, '" K_m_A_D Imt_ET ,., ..... •/'¢_" o,'_ _ (_). 7"..,/_'._4 o s Ta¢7--z;) o,,_ _, :"" ";. '_:" "=*" '_' ml¥1110N I........ " ="" wnl """"P _" "1"='_'1'_ J'_'* I*>'_°**'[v'*--_0_7 '' LIST PARTS I WIRING DIAGRAM r---_--i. _"_1 _ 53 I-i] If"=-,,.,,,"""- f_.,,,,_4 _-_--_ ! O _ 0 "3 rl l t".JH I _ 0 _-+-+ BAC K VIEW .1 (,_,_ _'''_,_ SECTION I I I , l , i i ; i,_+s_+,_ +'--I -.... am_...... l-"'l I l....... , I-} ' I--"l -;2:oT.,:;::--, ' 1""+'°"_" _"P'°"2+'°" I"_ '_" I __.,._ IA_.o,e,.-,_,,"* O_ _ , °----.-9 o 'B WIRINIG DIAGRAM V PARTS LIST .._>_-<.,_-, ._._,, o ,,v ]_.._ L_.,_ .-,v_ 7. Repair 7.1 Field Procedures and Trouble Shootin_ Repairs Minor repairs can be done on the car, such as changing defective lamps, etc. More complicated problems require removal the panel from the car. Use test procedure PQ-79-1 to determine the panel is operating properly, or if the panel is elsewhere. refer to trouble shooting chart, Fig. 7.1. of if Also, General Diagnosis diagrams, schematic operation. connections When troubleshooting the temperature control system with Chart refer to the schematic and connection wiring drawing No. 17704173 and 17756475, respectively. The diagram indicates the general "scheme" of the system's The connection diagram indicates actual system wiring to specific terminals and components. Where resistance suitable multi-meter such should be used. or as voltage measurements are the Simpson Model 260 or to be made equivalent Before deciding a particular system in a car is malfunctioning check that all switches and circuit breakers are properly set and there is 120 VAC, and 480 VAC supplied to the system. Also check that the system has been activated from the temperature control switch as required. 7-1 the and a Figure Trouble Symptom No 2. 1st stage overhead heat OK, no second stage Overhead heat stays 3. 1. 2. I. 1. 2. overhead No hall Hall heat floor heat stays heat on No roomette and bedroom floor heat No layover heat Layover heat stays on 1. No A/C Car cools, cool no full Chart Correction Cause 1. 2. 3. 1. Selector switch not in heat Defective DR relay Defective selector switch Defective 20 ° outside thermostat. I. 1. 1. 1. Select Replace Replace Replace 1. 1. Replace 2. 3. Defective 74 ° duct thermostat Open series resistor Open DR relay coil 1. 1. Replace Replace 1. Selector 1. Select 2. 3. 1. Defective Defective Defective thermostat 1. 1. 1. Replace Replace Replace 2. 3. Open Open 1. 1. Replace Replace 1. 2. I. Select 1. Replace 3. Selector Defective thermostat Defective I. Defective 1. 2. 3. 4. Defective 50 ° layover Open series resistor Open HCR relay coil Defective selector switch 1. 2. Selector Defective thermostat Defective 1 2. Shooting Probable I. 7.1 4. 5. 6. 7. I. switch not HCR relay selector 74 ° hall in heat switch series resistor HCR relay coil switch not in 70 ° outside heat selector switch 1. Replace selector switch 1. I. 1. 1. 1. Replace Replace Replace Replace Replace 1. Select I. Replace I 1 1 1 1 1 Replace Replace Replace Replace Replace Replace 1. I. 1. Replace Replace Replace switch not in 50 ° outside 74 ° cool cool thermostat 2. 3. Open series resistor Open HCR relay coil Defective HCR contacts Defective selector switch Defective 76 ° cool mod thermostat Open series resistor Defective CMR contacts 4. Open CMR relay coil heat heat he_ cool Figure 7.1 Trouble Shooting (Continued} Probable S_mptom i • 1. 2. Day & Night settings of selector produce no temperature change (should be 2 ° ) 1. Open "Temperature Control" breaker on panel trips "Control" breaker 1. Fault in or wiring on 1. 2. 3. 4. panel trips Internal setdown Chart Cause Correction resistor(s) external contactors 1. Replace 1. Repair 1. I. I. 1. Replace Replace Replace Repair fault: Shorted varistor Shorted bridge rectifier Shorted TDR Defective thermostat wiringground or short 7.2 tools, 7.3 Shop Major panel repairs are best done in parts and test equipment is available. Factor_ If contact: Repairs a shop where adequate Repair shop repairs cannot be made, Vapor Corp. 6420 West Howard St. Chicago, IL 60648 312-631-9200 7-4 or parts are required 8. Tools and Test Screw Driver, 1/4" Screw Driver, Phillips Volt-ohmmeter, Amtrak Test Equipment blade O-200VAC, 20,000 260 or 270 Unit, per PQ-79-1 8-1 ohms/volt test spec. such as Simpson C-3-43 3.3 Shunt Trip Pilot Lamp A blue shunt trip pilot light is temperature control panel. It is important illuminated whenever the car is on power, availability 120V AC required for operation protection of the overhead heater. Should the cause and correct it. located adjacent to the that this light be because it indicates of the overheat the light not be on, check ITEM MANU I 2 3 4 3.4 DESCRIPTION Lamp, Cand Lens, 6W, 120V, MANU Socket, Candelabra, Screw Term. Resistor, 250 ohm, 5 watt Air Vaporizer NIA 3.5 Fans Refer to Main 6S6/3 $6, Blue Manual # Chicago Miniature 78A436 Blue Chicago Miniature Ohmite 5786-523 435 Style 9955B 250-Ohm AMT # 25D9011698 AMMS # C-3-44 3.6 Heating General The HEP converted cars are electrically combination of floor and overhead heat. The two independent, and are controlled by the temperature into the heating, heated through a systems are control panel. Overhead heat is generally used to warm the fresh air taken car to about 74 ° . It is not intended to do much of the car and thus the delivery air will not feel very warm. The floor heat is intended to do most of the car heating. Since warm air (not heat) rises, using baseboard floor heat causes natural air convection, keeping the car a uniform temperature. Fig. 3.21 Car FUNCTION CONTACTOR 1st Stage 2nd Stage Bedrooms Overhead Overhead Roomettes, Porter Hall Toilet Total Total Total Heating Capacity KW HCl HC2 FHI 10 10 FH2 FH3 8.8 4.5 & Overhead Heat Floor Heat Car Heat 20 KW 19.3 39.3 C-3-45 3.6.1 Overhead Heat The overhead heat operates from 480 volts, divided into 2 equal stages of 10 KW each, fed by HC2. The heater is bolted to the downstream side This heater is similar to but not the same as the NON-2900 cars, and must not be interchanged the properly with the wrong heater. (Likewise do not heater on a non-2900 car - it will not perform 3 phase, and is contactors HC1 & of the evaporator. heater used on the car will not heat use a 2900 overhead properly either). A Klixon thermostat is mounted on top of the heater to protect against overheating. If this thermostat should rise above 200 ° , it will close and actuate the shunt trip circuit breaker cutting off the overhead heat. See Section 3.2.5 for a more detailed explanation of the protective circuitry, and test PQ-79-1, test 3.4. Refer to figure 3.22 for heater element replacement. Some of the heaters were wired delta, and some wye by the manufacturer - do not change this. Note the importance of keeping air filters filters restrict air flow and can cause the overhead excessively hot. Be careful to install them facing direction - observe air flow arrows on the filters. PQ-79-1 For tests of the Section 3.3, 3.4, heating 3.5 and system, 3.9. refer to clean. Dirty heaters to get the right Specification C-3-46 Figure 3.22A INSTRUCTIONS FOR FIELD REPLACEMENTOF RESISTANCE i • • . BLAST COIL HEATERS The enclosed diagrams must be followed when positioning the coils in the frame of the heater, installing the bus, locating supply connections, and reconnecting any built-in components which were disconnected to facilitate coil replacement• It may bracket not is be necessary to remove the terminal pan if the first spaced 3-1/2" behind it. Otherwise the pan may be removed by drilling out the s_ot-welds by which it is attached• It will be necessary, likewise, to remove the back pan if insulators are to be installed at the return bends of the resistance coils• The terminal pans which have been removed may be reassembled to the heater and attached with sheet metal screws terminals have been inserted through their insulator The replacement coil is shipped close-wound, and must be stretched by the electrician to the proper length before placement in the heater is attempted• This proper stretched length is determined by the width of the heater and by the number of passes which the coil makes through the heater, and is found by the formula: Stretched I") It So IN The replacement resistance coil is shipped prewound on the proper size arbor and with the terminals assembled to its ends. Insulators for the return bends made by the coil when strung through the heater and replacement terminal insulators are provided when required. after all bushings• • COILS is Length important = Number that the of Passes coil not X be (Heater Width Minus over-stretched. The stringing of the properly stretched resistance coil commences with the determination of its mid-point. Both ends are passed through the heater frame simultaneously• Care must be taken to insure that these passes are made through the correct location, and in the direction that will place the center return bend at the proper end of the heater• For example, if the coil is to make four passes, the mid-point of the coil must bend across the front bracket (i.e. at terminal end). C-3-47 . If the return bends of the coil are to be insulated, the center insulator must be carefully positioned in the coil before it is passed through the heater. The insulator should be placed on the straightened section of coil, so that the resistance wire lays in the groove of the insulator, and the wire must then be bent down sharply through the grooves at the ends of the insulator. It is important that the wire passing through the end groove of the insulator be centered on the adjacent windings of the coil. If the coil is to receive additional return bend insulators, it should be similarly formed about them before the return pass of the coil through the heater is commenced. . The male half of the phenolic terminal insulator bushing must placed in the terminal pan from the side internal to the duct, before the coil terminal is passed through the terminal pan. the terminal pan has been removed, all of the coils should be strung before this phase of the job is attempted). Care must taken that the terminal is completely seated into this section the insulator bushing, so that the terminal is prevented from rotating when its hardware is installed. . be (If be of The terminals are fastened into their insulator bushings by a nut tightened* down against a washer on top of the female section of the bushing. It is essential to insure that the terminal is completely seated into the bushing so that it is prevented from turning. *Bushing may be cracked if over-tightened. 'TYT i n fl fl fl I0 '® 0 I m C CJ C C 1F_ 'b CU . , U U ! @ QTY 1 6 156 ! 18 6 DESCRIPTION Overhead Htr. Bank, Complete, 480V, I0/I0 KW 3.3-KW Heating Element 480V Insulator, Porcelin HI Temp Limit Thennostat, 200 ° Close on Rise Duct Clip Lug High Temp (For Car Wiring) m m m i *HAND IS DEFINED LOOKING THROUGH HEATER IN DIRECTION AIR FLOWS. RIGHT HAND TERMI_LS MEAN RIGHT HAND HEATER. DO NOT SUBSTITUTE A 8112 KW iIIXl_E'I(, THE CAR WILL NOT OPERATE PROPERLY ITEM U MFG MFG # ART _ Safety Safety Safety Texas Inst. Safety Amp B4319-I 25P9011518 C4391S7442-06A T-7744 323680 25D4013801 AMMS # tp 25D9000660 C-3-49 3.6.2 Floor There (Also system. Room Heat are two general refer to Section approaches 3.2) used on the floor heat Heat Each of the 18 rooms of the car (10 roomettes, 6 bedrooms, public toilet and porter's room) has a 240 volt, individually thermostatically controlled heater. The thermostat is In-llne with the element. Each room is separately protected with its own circuit breaker, mounted inside the wall between room and hallway. (See fig. 3.23), which is accessed from the hall outside the room. In addition, switch to set to each turn Each 135°F, room has the heat room heater to turn it an OFF-AUTO off should is off switch, the room equipped with should it get which is thermostat merely fail. a high temperature excessively hot. an OFF/ON cutout, The contactors FH1 (bedrooms) and FH2 (roomettes, toilet and porter's room) control the 240 volt feed to the busses feeding the room heat, and are energized if the outside car temperature is below 70 ° . Room Floor heat power comes from the secondary of 3 delta connected 480/240 volt transformers. Hall Heat The hall is equipped with single floor heaters, fed from the FH3 contactor. controlled by the hall heat thermostat. Heater stage 480 volt This contactor 3-phase is Construction The floor heater assemblies consist of 2 of the familiar strip heater elements, connected in series. These are in turn housed behind a grill assembly. Room heaters are also equipped with a high limit thermostat to prevent excessive grill temperatures should air flow be blocked. Refer to Fig. 3.24. Thermal Characteristics Strip heaters are constant wattage devices which produce the same heat output regardless of surrounding air temperature. On these heater assemblies, if the grill is covered, the temperature will continue to climb and can become dangerously high. For this reason, each of the room heaters is equipped with a high limit thermostat, (set at 135 _ for Beech Grove units and 200 ° for Vapor units) to prevent excessive grill temperatures if the grill should be covered and stop air flow. Placement of this thermostat is critical; IT MUST NOT BE MOVED NOR ADJUSTED. C-3-50 Mountln 9 Strip are mounted on electrical and be live. heaters porcelain thermal are high temperature devices and accordingly secondary insulators, These provide both insulation. Be careful) the element body can Strip heater elements are wired either single or in seriesconnected groups of two to obtain the necessary wattage. This connection must not be disturbed. Jumping out an element in a series connection will greatly increase the heat output of the assembly, and is likely to damage the interior car finish from overheating. Strip heater assemblies operate on either 480 or 240 volts; each assembly is single phase. Refer to figure 3.24. Terminals Because of the high element operating temperatures, of strip heaters, care must be taken when servicing the heater to only use high temperature silicone wire, high temperature lugs and insulating tape. Regular components must not be used since they will either melt, or weaken from the heat. See figure 6.1 and 6.3 of the main manual. Maintenance In the periodic checks of the heating system for grounds, as described in the maintenance section chapter 15, the system must read at least 3 MEG to ground with all heater elements in service. Before MEG tests, operate car heat for at least 2 hours. This is necessary to drive moisture from the elements, which might otherwise give erroneous low meg readings. Strip heaters are easily changed in the field. Use an exact replacement; the wrong element will cause the heater assembly to overheat or underheat. Never jumper out an element: the remaining elements will get very hot, will damage the heater and side wall of the car, and could cause a fire. Likewise, never jumper out or adjust the high limit thermostat. PQ-79-1 For test tests of the complete 3.3, 3.4, 3.5 and 3.9 heating system, refer to test spec /_ FLOOR HEAT CIRCUIT BREAKERS ",_ @@ OFF "_ THERMOST_ ROOM HEAT ITEM QTY DESCRIPTION 1 Room Thermostat 2 Room 3 Guard 4 Push-Pull Circuit Breaker (Porter room and Toilet) - 1 Pole 5 Push-Pull (Roomette - 1 Pole 6 Sign 7 Sign - Room Feature Instructions 8 Sign - Room Feature Instructions Floor Heat Off/Auto For Item 2 Switch Toggle Switch DPDT Lever Circuit Breaker and Bedroom) LOCAL ROOM FLOOR HEAT TOGGLE SWITCH Figure 3.23 CIRCUIT BREAKERS & CONTROL PARTS MFG MFG # Chromolox WR-80 25K9011822 Arrow 80421 25L9011567 Hart Cutler Hammer 8492KI 3.0A Potter Brumfield 374-203-101 5.OA Potter Br_field 449-205-101 "Off-Auto" OFF -AUTO SWITCH AMT # ........ 23T5005140 - Bedroom ........ 23K5005139 - Roomette ........ 23NBOO5138 AMMS # ! I ,/l n _,,.) I I I IL fh ! Figure 3.24B TELEWELD FLOOR HEATERS ITEM QTY DESCRIPTION MFG MFG # 325-054-1 S-3075VW 325-052-1 1 2 3 Floor Heater Assby., Hall, 500W, 4BOV Element for Item - I, 5OOW, 480V, 30 I/2" Floor Heater Assby., Roomette, R.H. Term 650W, 240V Teleweld Chromalox Teleweld 4 5 6 Floor Heater Assby., Roomette, L.H. Term 650W, 240V Element for Item 3 or 4: 325W, 120V, 25 I/2" Floor Heater Assby., Bedroom R.H. Term gOOW, 240V Teleweld Chromalox Teleweld 325-052-I S-2575W 325-053-1 7 8 9 Floor Heater Assby., Bedroom L.H. Term 900W, 240V Element for Item 6 or 7: 450W, 120V, 30 1/2" Floor Heater Assby., Toilet and Porter Room, 40OW, Teleweld Chromalox Teleweld 325-053-I S-3075VW 325-055-I 240V AMT # 25P6003522 RH 25B6003520 LH 25B6003520 RH 25X6003518 LH 25X6003518 25P6003519 10 II 12 Ele_lent for Item 9, 200W, 120V, 12" Thermostat, High Limit, 135 ° for item 3, 4, 6, 7 or 9 Insulator, Element Chromalox Teleweld Chromalox SI225W 30002-000 PCN 255716 25xg012240 13 14 Insulator, Electrical Lug, High Temperature Chromalox AMP 32368D 25Pg000660 Stud Electrical AM)IS # F_ I I ol C_ C-3-54 3.6.3 Antifreeze Protection The cars are equipped with an antifreeze protection system similar to that of the later series cars. The only difference is in the location of the antifreeze circuit breakers, which on the 2900's are located in the electric locker. Refer to Section 6.7 of this manual for contactor and circuit breaker details, and section 3.6.3 in the 3.7 3.7.1 main Air manual Distribution Fresh Air The 3.7.2 for cars heat tape installation details. Dampers Intake Damper are not the main equipped with fresh air intake dampers. Annemostats Refer to manual, section 3.7.2 for details. C-3-55 Section 3.8 Drawing Function Drawing A/C & Temperature Control Schematic Fans & Auxiliaries Schematic 2900-41 Fans & Auxiliaries Schematic - 2980-97 Floor Heat Schematic 2900-41 Floor Heat Schematic 2980-97 Antifreeze Schematic 2900-97 Temperature Temperature Control Control List Panel Panel Schematic Number D-O4-440-Sht. D-04-440D-04-440D-04-440D-04-440D-04-440D-01-473 E-00-474 6 9 10 7 8 5 C-4-1 Chapter i 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 List of Illustrations General Power Source 4.1 4.2 4.3 Car Lighting Shutdown Night Lights Emergency Lights Controls & Operation Night Lights Emergency Lights Lamp Schedules Interior Fixtures Marker Lights Interior Consist Signs Exterior Consist Signs Switches Convenience Outlets Drawing List List of 4 Lighting Refer Refer Refer to to to Main Main Main Manual Manual Manual Refer to Main Manual Page C-4-I C-4-3 C-4-3 C-4-3 C-4-5 C-4-5 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-7 C-4-8 Illustrations C-4-4 C-4-6 C-4-6 C-4-3 Chapter 4.1 4 Li_htin_ General The HEP converted cars are equipped with both incandescent and fluorescent lighting. While most fixtures are original to the cars, many have been replaced as part of the HEP upgrade. Whenever possible, standard Amtrak fixtures were used in these new installations, using both Amfleet and Superliner parts. room. Convenience They are not 4.1.1 Power receptacles were replaced as required in GFCI protected, unlike later series cars. each Source All car lighting power comes VAC or 75/64 VDC. When the car is on operates on 120 VAC, a few miscellaneous 75/64 VDC source. When the 480V power powered from the 64 VDC battery. from either of two sources, 480V power, most lighting lights operate from the is off, emergency lighting 120 is Three 480V to 120V 5KVA transformers supply the 120 VAC lighting power. The battery charger supplies about 75 VDC (ranging from 60 - 80V depending upon outside temperature and state of battery charge) to the DC circuits when the car is on 480 power, and 64 VDC when trainline power is off and the battery is stil| fully charged. Refer to Chapter 6.4 for details. Lighting and convenience outlet circuits are individually protected by circ uit breakers on the lighting switchboard. The 120V transformer prima ry and battery charger circuit breakers are on the 480V switchboard. 4.1.2 Controls and Operation In normal operation of the car, all lighting circuit breakers are to be on. Switches are provided for turning OFF the car consist signs and alternate passageway lights. They are located in the switch locker on the 2900-41, and in the passage near the annunciator panel on the 2980-97. To shut down a car at the end of a run, turn off only the 2 circuit breakers: Main AC Lighting and Main DC Lighting, located at the top right of the lighting switch board. See figure 4.1. All other breakers should remain on at all times. c-_-4- rSATT, T_._J N. (_oA 50A CA_, TO _M_T -_oA M_,IN 9©A L_G_TI_-IC_ 5_UTDOw_ DOwel ¢J_¢_,TU_-N 0_ O_4uy MAI_I D,C, C-4-5 4.1.3 Night Lights All cars are equipped with night lights: see figure 4.2. Alternate passage lights can be switched off; some bedroom and roomette fixtures are equipped with 6 watt blue bulb in addition to the main lamp. This can be switched on to give a low level of light. Note that the passage night lights are activated by merely flipping one toggle switch at the lighting switchboard; no breakers are involved. Refer to test 4.1 of PQ-79-1 for night light system tests. 4.1.4 Emergency Lights All cars are equipped with emergency lights (see figure 4.3) which will stay on for several hours after HEP power goes off. Two approaches were used: I) separate set of emergency lamps which are used only if AC power is off, or 2) a transfer contactor circuit in which if 120 VAC is lost, the circuit is reconnected to the 64 VDC battery. Two transfer contactors (TR1, TR2) are used to provide the emergency lighting switching. A load shed relay is incorporated into the lighting circuitry of the cars. Its purpose is to disconnect some of the less essential lighting loads from the battery during a prolonged power outage, thus extending the length of time the critical lighting loads will stay on. Passage and vestibule lights as well as marker and electric locker lights stay on after other loads are disconnected. The load shed relay is part of the battery charger, and is explained in section 6.4. Refer to PQ-79-1 section 4.1 for emergency lighting tests. Figure 4.2 NIGHT LIGHTS SERIES LIGHTS SWITCH LOCATION 2900-41 Passage (Alternate Fixtures) Switch in Switch 2980-97 Passage (Alternate Fixtures) Switch near Annunciator Switch part of each 2900-41 2980-97 & Bedrooms A,C,E 2 sofa, + Upper Berth Bedrooms B,D,F Reading, Upper & Lower Berths, Roomette Berth Locker fixture Figure 4.3 EMERGENCY LIGHTS SERIES 2900-41 & 2980-97 LO_D Bedroom Ceiling, SHED LIGHTS Roomette Ceiling NON LOAD SHED Passage, Vest., Toilet, Signs, Blind end Number r_ l 4_ I C-4-7 4.2 Lamp lighting and part Schedules HEP connected cars use an assortment of lamps for the system. Refer to figure 4.4 in the main manual for a number list, and figure 4.5 for lamp schedule by car: 2900-41: 2980-97: wrong lens. 4.5. 4.3 See See 2880-94 2457-60 to main see 4.5 main 4.6 See See 2880-94 2457-60 & 2900-41 & 2980-97 Lights The cars are equipped manual for details. Interior end doors. cards for and manual: 2900-41: 2980-97: Marker The Fixtures Refer 4.4 & 2900-41 & 2980-97 Do not substitute lamps unless absolutely necessary. lamp can damage a fixture, especially if it has a plastic Fluorescent Lamp starters are also listed on figure 4.4 Use only the correct starter for a given lamp. Interior I amp Consist These signs They are displaying Exterior with the standard HEP marker lights; Signs are non-illuminated the the type which car number. Consist uses and are cardboard located on the number-bearing body Signs The cars are equipped with illuminated car consist signs, located one in the general toilet, and one in the porter room. Some of the signs are original while some are new Translite #FH4579-I, for replacement details, refer to the main manual. 4.7 Switches Refer 4.8 Convenience convenience receptacles to the main manual. Outlet Each roomette, and each bedroom annex is equipped with a outlet. Most of them are original to the car. These are not GFCI protected, unlike later car series. Should grounding-type a receptacle receptacle as require described replacement, use a in the main manual. C-4-8 4.9 Drawin_ List Function AC Lighting Schematic, AC Lighting Schematic, DC Lighting Schematic, Razor and Auxiliaries, Razor and Auxiliaries, Drawin 2900-41 2980-97 2900-97 2900-41 2980-97 9 D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht # 11 12 13 9 10 C-5-I CHAPTER 5.1 51.1 51.2 52 53 54 55 56 57 5 COMMUNICATIONS General Conductor Signal Public Address and List PUBLIC ADDRESS Intercom Tape Player Public Telephone Operating Instructions Audio Instructions Manual Safetran Annunciator Drawing AND System System N/A N/A N/A N/A Page C-5-3 C-5-3 C-5-3 C-5-3 C-5-4 C-5-4 C-5-4 C-5-4 C-5-4 C-5-3 CHAPTER 5.1 5 COMMUNICATIONS, PUBLIC ADDRESS SYSTEM General Several different types of communication systems are employed on the HEP converted cars, including conductor signal, annunciator and call buzzer. The conductor signal is a new installation, while the others are original to car. These cars are not equipped with a PA system, though they will operate in a trai-_--so equipped. 5.1.1 Conductor Signal Each car is equipped with 2 conductor signal pushbuttons, one at each end of the car. They allow a communicating signal to be given the locomotive cabs. Power is from the DC main breaker, via a fuse pair on the loop relay panel, and finally a diode on the loop relay panel. The number 22 wire of the 27 point trainline cable carries this signal to the locomotives. Refer to test spec PQ-79-1 test 2.4, and section 6.6.4 for loop relay details. If the conductor signal button should weld closed and/or the CS diode fail (short or open, with evidence of heat) the likely cause is 1) shorted trainline wires 22 to 2, and 2) shorted suppressor diode on locomotive magnet valve. Locate the fault before replacing the diode or signal button. DESCRIPTION Conductor Signal Conductor Signal 6A 800 PIV 5.1.2 Public MANU MANU Pushbutton Per Amt. Drawing SK-A-120980 23P9007473 Diode International Rectifier 60S8 25H9008685 Address and # AMT Tape Player N/A. AMMS Intercom These cars are not equipped with a public address system. However they can be operated in a train which is these cars will carry the signal through. 5.2 # intercom equipped # C-5-4 5.3 Public Telephone N/A. 5.4 Operatin 9 Instructions Audio S_stem NIA. 5.5 Instruction Manual Safetran S_stem N/A. 5.6 Annunciator The annunciator system on these cars is similar to that of the standard installation as described in the main manual. However, these cars use a different power supply. The transformer and rectifier are the same, but they are mounted within the lighting switchboard, and only the transformer primary is protected with a fuse. This small cartridge fuse is accessed from the front of the lighting switchboard. Cartridge Fusetron 5.7 Fuse, Slow Drawin 9 IA, 250V Blow Bussman List Function 27 Point Annunciator Annunciator MDL-1 Trainline and and Drawing Schematic Auxiliaries, Auxiliaries, 2900-41 2980-97 D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht # 14 9 10 C-6-I CHAPTER i 6.1 6.2 6.3 6.4 6.5 6.5.1 6.5.2 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.7 6.7.1 6.7.2 6.7.3 6.7.4 6.7.5 6.7.6 6.7.7 6.8 6.9 6.10 6 ELECTRICAL List of Illustrations General 480 Volt Main Power Distribution Refer to Main Manual 27 Point Trainline Circuits SYSTEM and Cable Battery and Battery Charging System Transformers External Transformers Internal Transformers Switch Locker Lighting Switchboard Temperature Controls GFCI Receptacles Loop Relay Panel Food Service Switchboards Electric Locker Main 480 Volt Circuit Breaker Panel Contactor Panels General A/C Starter Panel Contactors and Overload Relays E-5 Decelostat Marker Light Resistors Annunciator Power Supply Food Service Electric Locker Service Procedures Refer to Drawing List Panels Main Manual NIA N/A N/A System Page C-6-2 C-6-3 C-6-3 C-6-3 C-6-3 C-6-4 C-6-4 C-6-4 C-6-8 C-6-8 C-6-12 C-6-12 C-6-12 C-6-12 C-6-15 C-6-20 C-6-21 C-6-22 C-6-22 C-6-28 C-6-28 C-6-28 C-6-28 C-6-28 C-6-29 C-6-2 CHAPTER LIST 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6 ELECTRICAL OF SYSTEM ILLUSTRATIONS Transformer Usage Transformer Connections Undercar Transformer Seals Lighting Switchboards Lighting Switchboards Part List Loop Relay Panel Electric Locker Components 480 V Switchboard 480 V Switchboard Part List Contactor Functions Antifreeze, Heating, Lighting and Heating, Lighting, Antifreeze and Part List A/C Starter Panel A/C Starter Panel Part List Misc. Misc. Contactors Contactor Page C-6-5 C-6-6 C-6-7 C-6-9 C-6-11 C-6-13 C-6-17 C-6-18 C-6-19 C-6-23 C-6-24 C-6-25 C-6-26 C-6-27 C-6-3 CHAPTER 6.1 the main 480 These manual cars for have the standard general details, Volt Point Main main Power manual 6.3 27 with The 27 point 3 exceptions: 1. 2. 3. Batterx Trainline Distribution HEP such for and electrical as wire, system. Refer lugs, terminal to Cable System details. Circuits trainline cable system is the basic HEP system No PA unit is used. The ground for the shielded cables is in the B-end 27 point J-box, rather than at the PA unit, as in later series cars with PA units. No pressure switches are used in the brake applied and released wires, #20 and 19 respectively. Refer to the main manual for all other details. and Batter_ Char_in 9 S_stem The standard HEP battery and or Ni Fe. One system difference with a Low Voltage Relay equipped Edision not SYSTEM etc. See 6.4 ELECTRICAL General blocks, 6.2 6 charger are used either McGraw is that these cars (2900) are (LVR), unlike later series cars. C-6-4 6.5 Transformers On all types of HEP converted cars, transformers are used convert 480V, 3 Phase power to the proper voltages as required. Efforts have been made to use standard transformers as much as possible. Refer to figure 6.1 for transformer usage, 6.2 for connections, and Section 6.9 (of main manual) for trouble shooting procedures. 6.5.1 External They are to Transformers The larger transformers safety hung, resting on are mounted under in groups a cradle, with the bolts in of 3. from the top. Each car has 3 delta/delta connected 480/120, 5 KVA lighting transformers. Car lighting, antifreeze systems, and water cooler are fed from them. KVA floor In addition, each car heating transformers. has 3 delta/delta connected 480/240 5 These undercar mounted transformers require little maintenance. However, it is extremely important to keep them dry inside. RTV is used to caulk all joints of the transformer cases, as well as all conduit entry points. Should water get into a transformer, after a time the bottom of the transformer will be blown off by the steam formed. See figure 6.28 for sealing procedures. In replacing transformers of a delta (or wye) connection, 3 transformers must be identical, Do not mix manufacturers. The slight diffe.rences between "equal" transformers of different manufacturers will make one run hot, and fail. 6.5.2 Internal Small all Transformers control transformers are mounted inside the car in the electric locker. Refer to figure 6.1 and 6.2. In addition, a control transformer is used in the water heater (see Chapter 12.3) and a filament transformer is used in the lighting switchboard for the annunciator system (see Chapter 5.6). Figure 6.1 TRANSFORMER USAGE ITEM DESCRIPTION VOLTAGE RATING MFG MFG # AMT # AMMS # USE I 480/120 5 KVA Lighting Westinghouse 6E5657 25L9011682 2A 480/240 5 KVA Floor Heat Westinghouse 6E5658 25EgOI1546 2B 480/240 5 KVA Floor Neat Acme T-l-B3014 3 480/120 250 VA Temp. Acme TA-I-81213 4 480/120 150 VA Water Heater Control Micron B-150BTZ13 5 120/6.3 10 A and Buzzer Stancor P6464 Controls Annunclator and Shunt Trip O0 NOT SUBSTITUTE MOUNTINGS ARE DIFFERENT; ELECTRICAL DIFFERENCES 25DgOO866g 25Dg010468 AS WELL. NOTES: I. 2B was the original transformer installed. a different shape and are not electrically ?_A can be used as a substitute provlded all 3 transformers identical, Hew mounting holes may _ required as well. are changed over. Do not mix; they are C_ I I Primary 480V 480V XI_ 120V 240V Secondary II"=M i 4 480V - J L2 X 120V _X4 X2 . IX 4 C-G-7 Fi 9. 6.5 Undercar The transformers watertight. If moisture or phase to phase fault fail. To prevent this, 1. • 3. replaced, should be damaged• Transformer used enters at the several Drill 1/4" drain wire compartment. 9 Procedures undercar are not inherently the enclosure, it can cause a connections or cause a winding things are required: hole-apply Seal all seams, knockouts, equivalent (clean before water marked (X). If knockouts blanks (bend Sealin cotter key in bottom ground to of and wire entries with RTV or applying) to prevent entry of are missing, back pronts), close then This procedure should be followed or the terminal box opened. In resealed whenever existing seals holes with snap seal with RTV. in whenever a transformer addition, the transformer are ineffective or is Materials Item Description IA 1B 1C 2 3 Snap RTV Caulk, White RTV Caulk, Black RTV Caulk, Translucent Snap-in Blank, 3/4" Cotter Key, 3/16" x 1" in ® blank Manu GE GE GE Thomas & Betts McMaster Manu # RTV-102 RTV-I03 RTV-lO8 1452 98311A510 Amt # C-6-8 6.6 Switch Locker The switch locker contains the daily - used controls of the car including: 120/64 volt lighting switchboard, temperature control panel and associated shunt trip pilot light. In addition, 2900-41 cars have toggle switches to operate car loading number signs and passage night lights. The loop relay panel is located in the bottom of the switch locker. 6.6.1 Lighting Switchboard The lighting switchboard consists mostly of lighting controls but also includes breakers for razor receptacles, fans, etc. The marker light selector switch is located on this panel. The AC main and DC main breakers are located at the top right of the panel. on at NOTE: to be all All circuit times when when turned a car is OFF are the OFF top breakers at layup. 6.4 and For 6.5. For at circuit breakers the car except the is on power. laid up 2: The after the end of a run, DC MAIN and AC LIGHTING the right. breaker switchboard No names tests, other and refer battery trainline breakers part to listing test should be the only breakers MAIN. These are need to refer PQ-79-1, be turned to figures number 4.1. C °_ -9 m ® ® %-- ®-_- _oMETT_ i ,_, _ W_T r-_. J|E×t TL _9OO-4.1 U__T_G 5w_TC_4 _OA_D p4:x3_4 LIGHTING ITE_I QTY DESCRIPTION Figure 6.5 SWITCHBOARD PART LIST MFG MFG # AMT # I 2 3 Circuit Breaker, Circuit Breaker, Circuit Breaker, 60A, 240V, 2 Po|e 50A, 240V, 2 Pole 50A, 480V, 3 Pole Westinghouse Westinghouse Westinghouse EB2060 EB2050 EHB3050 25L4010715 25H9009075 25X4010821 4 5 Circuit Circuit 20A, 240V, 15A, 240V, Westinghouse Westinghouse EB2020 EB2015 2BD9008672 25N6003545 Vapor 37741141 25H4013800 GE GE CR205C022 15D21G22 25Bg011693 GE 546A301 G2 Stancor P-6464 6 7 8 9 Breaker, Breaker, 2 Pole 2 Pole AMMS # .... Contactor, Transfer, DPDT w/120V Coil refer to main manual figure 6.44) Contactor, 3 Pole, 480V, NEr_-I Coil, Contactor for Item-8 (for parts, I0 11 Contacts, .... for Item-8 12 Transformer, 13 14 15 Rectifier, Bridge, 600 PIV, 10 Amp Switch, DPDT Center Off Switch, SPST Westinghouse Arrow Hart Cutler Hammer MBI2A10V60 80638D 82600 16 17 Bussman Bussman MDL-I HTA 18 Fuse, IA, 250V SLO BLO Cartridge Fuse Holder, Panel Ilount Space Saver I/4 x 1 1/4 Fuse Fuse, IOA, 250V, Cartridge, Type Non Bussman NON-tO 19 Fuse Holder, Bussman 2604 Filament, O-30A, 120V to 6.3 VAC 10 Amps 250V, 2 Pole 25N9010944 25P9008666 25P9008667 O_ I C-6-12 6.6.2 Temperature The switchboard. which selects Control and Shunt Trip Pilot Light temperature control panel is located below It has only one control; the heat-off-cool temperature control setup. the lighting selector NOTE: The selection between heating or cooling is not automatic this switch must be in the correct position. In the off position, car fans are shut off and the car is in layover and enables floor to maintain 50°F. Day position is 2 ° cooler than night position. The pilot lights illuminate to is requested by the temperature control and 3.3 for details. indicate panel. the heat a specific function Refer to Chapter 3.2 The temperature control panel is equipped with 30 minute override feature and a high pressure/low pressure (HP/LP) warning light which lights and stays on when the A/C system has shut down to a problem. For further explanation of heating and A/C control, Chapter 3.2. cool due see The thermostat plug on the temperature control panel is intended for test purposes. When used in conjunction with the "BRUSS BOX" quick and complete tests of the thermostats and the heating, cooling and systems can be effected. The shunt trip pilot light, located adjacent to the temperature controls, lights to indicate power is available for the shunt trip circuit on the overhead heater. This is important for passenger safety, and should the light not be lighted, the cause should be located and corrected. Refer to Chapter 3.2 for details. 6.6.3 GFCI Receptacles N/A. 6.6.4 Loop Relay Panel This panel provides power for the door control and brake applied and released trainline to the locomotive. It is the power source for the conductor signal push button. The 3 diodes on the panel prevent backfeed between cars; one is for the conductor signal, and one each for the loop relays. Power for the panel is system, via the 2 fuses located the pair provides the route for point #2 wire. PQ-79-1 6.6.5 Refer to figure 6.6 test 2.4 for tests. Food N/A. Service Switchboards for provided by the battery charger on the panel. The negative fuse of the car battery negative to the 27 the loop relay parts, and test spec. LOOP _ELAy © © i De+ DeJ + "t- Jr t6 -II 19 gO i 4.. + t- "t- 2DA CS+i © Q m Figure 6.6 LOOP RELAY PANEL PART LIST ITEM DESCRIPTION QTY Loop Relay Panel, MFG MFG # AMT # # P Beech Grove Complete AMMS i Relay, 4 Pole, Diode, 6 Amp, Terminal Block Struthers 64 VDC Coil 800 PIV Strip, Series B, 600V Dunn 8DXX183 25L4010779 International Rectifier 60S8 25H9008685 Allen 1492CD3-130 25A9003953 Bradley C-6-15 6.7 Electric Locker The electric locker contains the high power electrical controls for the car, including the 480V switchboard, A/C starter panel, heating and antifreeze contactors. Also located there are antifreeze circuit breakers, and the temperature control and shunt trip transformers. The general approach used in electric locker panel construction is the "super panel", incorporating the 480 switchboard and all contactor panels on one assembly. Refer to figure 6.7. the © @ @ I I © @ @ le ® ® ® ® _IGur2_P_ _,,"/A EL.F...CTI_IC I_OC_r-iZ. COMPOMP.I,,IT5 Figure 6.7B ELECTRIC LOCKER COMPONENTS ITEM DESCRIPTION QTY 480V Switch Board 120V Antifreeze/Temp (See Figure 6.8) 3 A/C 4 Control 5 Antlfreeze/Heat Starter MFG (See Figure Control 6.B) Bkr. Panel Panel Transformer, 480V to 120V ZSOVA Contactor Panel (See Figure 6.11) MFB # Beech Grove Beech Grove AMI Safety B-4290-I 25Dg011510 Acme TA-I-81213 25Dg008669 Beech AMMS # Grove I 0_ I C,. &- 14_ _. (-4 , 'ZOA © W,_,TF..._ M_,NTIN_ Ne,_,TS_ 15A 2OA ® _,,kT"r. _46,_,T- I 1.4eAT. 2 '?.OA © @ IOA @ COM_ L_A'-L 9OA @ @ @ 5WJ_.,,.T ZSA ® 15A @ 4_OV @ @ 5W l 'T'¢..14D O,a,r"< D © 480V ITEM I 2 QTY DESCRIPTION Figure 6.9 SWITCHBOARD PART LIST MFG MFG # AMT # 150 Amp 30 Amp Westinghouse Westinghouse FB3150 EHB3O30 25L4010748 25K6003515 30 Amp Westinghouse EHB3030 25L4010913 3 Circuit Breaker, 6OOV, 3 Pole, Circuit Breaker, 480V, 3 Pole, with 120VAC Shunt Trip Circuit Breaker, 480V, 3 Pole, 4 5 6 Circuit Circuit Circuit Breaker, Breaker, Breaker, 480V, 480V, 480V, 3 Pole, 3 Pole, 3 Pole, 20 Amp 15 Amp 10 Amp Westinghouse Westinghouse Westinghouse EHB3020 EHB3015 EHB3010 25D4010820 25H4010749 25X4010844 7 8 g Circuit Breaker, Circuit Breaker, Terminal Block 480V, --- 3 Pole, 5 Amp Westinghouse EHB3005 25AgOO402g Marathon 143356 25A 7004463 Westinghouse Westinghouse Westinghouse QC-3025H QC-2015H 624B10O-G14 25X9011556 25P5000198 25X9010469 10 11 12 Circuit Breaker, 240V, 3 Pole, Circuit Breaker, 240V, 2 Pole, Clip, Circuit Breaker Holddown 25 Amp 15 Amp AMMS # I O_ I $ C-6-20 6.7.1 contains breaker to Main 480 Volt Circuit Breaker Panel Located at the top of the electric locker, this panel all the major power circuits of the car. The 480V main can be locked off with a padlock for servicing the car. figures 6.7 and Summary 6.8 of for panel circuits controlled A. Main Supply 150 Amp. Supplies trainline 480 services• This breaker B. Heating Transformer Supplies the 480 to floor heat. C. D • E. F. Water Heater Supplies 480 by "typical" Battery Supplies Floor Charger - 10 480 V power Heat Floor Heat Supplies 480 V. heating transformer Amp. 480 V. to the battery 240 V power to bedroom to roomette floor heat. #2. 240 V power floor heat. I. A/C Evaporator Supplies 480 Motor 5 Amp 480 V to Blower Motor. J Temperature Controls 5 Amp 480 V. Supplies 480 V to temperature control primary. V. transformer Heat Supplies L. which #1. and Condenser 30 Amp, 480 V. V to Air Conditioning Equipment. Hall for charger. A/C Compressor Supplies 480 K. are: 480 V. Heater. H. • panel 480 V. V power to all the various car must be "ON" for car operation. Primary 240 volt Amp. Water this Transformer Primary - 30 Amp. 480 V. Supplies 480 V to the three 5 KVA transformers convert 480 V 120 V for Lighting Circuits• Supplies G. - 15 V to Refer information• 480 V power to Hall Heat. Overhead Heat - 30 Amp 480 V with 120 VAC Shunt Trip. Supplies 480 V to O.H. Heating Unit. The shunt trip feature trips the breaker off if the O. H. Heater gets too hot. C-6-21 6.7.2 electric Contactor Panels General Most contactors and locker• Exceptions contactor include: panels are located Function I. 2. 3. Exhaust Transfer Water Effort contactor fleet. Refer made only to figure six the Location fad contactor relays TR1 heater contactor were types; in to use types 6.10 EFC & TR2 WHC the minimum are for To left of lighting switchboard water heater a used for list of number the all of different entire Heritage contactors, and their function. A summary A/C startin_ This panel condenser 6.13, 6.14 manual. a. B of • Other These contactor group Heatin 9 Contactors: contactors are used (FH1, FH2, FH3) to accommodate all Refer 3.2 in to figure 6.11, main manual. and figure floor 6.12 here Antifreeze Contactors: (AF1, AF2, AF3) A group of 3 contactors controlling the electric heat tape providing freeze protection for the water tanks and under car piping. Refer to figure 6.11, 6.12 here and sections 3.2 and 3.6 and 6.7.4 in the main manual. Co E• follows: panel: (BFMS, RCMS, HCI, HC2) controls the blower fan, A/C compressor fan, as well as overhead heat. Refer to here and; sections 6.7.4 and 3.2 in main heating requirements. and section 6.7.4 and D functions • Exhaust Fan Contactor (EFC) A contactor used to control figure 6.11, 6.12 here and the main manual. Water Heater Contractor This contactor controls located nearby. Refer here, and section 6.7.4 the exhuast fans. sections 3.2, 3.5, Refer 6.7.4 (WHC) the 6KW water heater, and to figure 6.11 and section in the main manual. to in is 12.3 C-6-22 Lighting Transfer Relays (TR1, TR2) These contactors are used to switch on emergency lighting when A/C power goes off. Connections different car types differ, but must generally their lighting loads to 120 VAC when picked up battery when dropped out. Fo on connect and Contactor TR2 is fed from non-load shed, and feeds vital emergency light loads such as vestibule and passage. Contactor TRI is used to feed load-shed loads such as roomette and bedroom ceiling lights on 2900-41, and bedroom and roomette emergency lights on 2980-97. Refer to section 6.7.4 of the main manual for maintenance details, 6.7.3 A/C Starting and Panel figure 6.10 (Figure and 6.13 and This panel controls the blower fan, as well as the 2 stages condenser Overload Relays are used measure the motor current, and if cause the corresponding contactor burnout. in it to 6.11 here for parts. 6.14) fan, A/C compressor of overhead heat. and each of 3 motor circuits. exceeds the motor rating, drop out and prevent motor They it will OL1 Blower white Fan Motor button. - Thermal Overload Reset by pressing OL2 Compressor Motor white button. - Thermal Overload Reset by pressing OL3 Condenser pressing NOTE: If either 6.7.4 Contactor Standard Fan Motor - Thermal white button. OL2 or and Overload HEP OL3 trips, components RCMS will Overload drop reset by out. Relays are used. Refer to the main manual. C-6-23 Figure CONTACTOR 6.10 FUNCTIONS BFMS Blower HCI Ist Stage Overhead Heat HC2 2nd Stage Overhead Heat RCMS A/C Compressor FH1 Bedroom FH2 Roomette FH3 Hall AF1 Antifreeze-1 Tanks AF2 Antifreeze-2 Tanks AF3 Antifreeze-3 Pipes EFC Exhaust WHC Water TRI Bedroom Bedroom TR2 Vestibule, Porter Fan and Floor Fan Heat Floor Floor Condenser Heat Heat and Fill Valves Ceiling Ceiling Lts., Emg. Fan Heater and and Roomette Roomette Blind End, Passage, Room and Plenum Lts. 2900-41 Lts., 2980-97 Number Signs, C- _-_4 4, _ 4, I L._4TL_JG _w _Tc..N8OA_D ','k /' /,- AI,4.TtF_F---F...ZF_-.., NF__._T_4_,L.._NTI N_ AND MISC.., r..,ONTA, r...T'_,,,_ -/' ANTIFREEZE, ITE_ QTY HEATING, DESCRIPTION Contactor, 480V, 3 Po|e, NEMA-I Contactor, Transfer, DPDT (for parts, main manual, Figure 6.44) Coil, for Contacts, Item-l, NEMA-I, 120VAC for Item-l, NEM_-I refer to Figure 6.12 LIGHTING AND MISCELLANEOUS CONTACTOR PART LIST MFG MFG # AMT # GE CR205C022 25Bg011693 Vapor 37741141 25H4013800 GE I$D21G22 GE 546A301-G2 AMMS # r_ I I D_ C... _° _,_ © 0 A Ii_'l v _a_5 I o,..¢ 0 £' © / AIR ITEM QTY Figure 6.14 CONDITIONING STARTER PANEL DESCRIPTION PART LIST MFG MFG # B4290-I CR206B022 CR224C310A 25D9011510 25Pg011521 OLI) Safety GE GE CR123C2.39A CR206D022 CR224C310A 25X9612120 25L9012119 OL2) GE GE GE GE GE GE CR123CZ1.4B CR224C310A CRI23CO3.56A I 2 3 1 1 A/C Starter Panel, Complete Motor Starter, BFMS NEMA-O Overload Relay (for Blower Fan Motor, 4 5 6 3 I I Overload Heater (for OLI) Motor Starter, RCMS NEMA-2 Overload Relay (for Compressor 7 8 9 3 1 3 Overload Overload Overload 10 11 12 I 2 (I) Auxiliary Contact Set for BFMS Contactor, HCI & HC2, NEMA-I Contact Set Main for RCMS GE GE GE CR205XIOOD CR205C022 546A780G2 13 14 15 (1) (I) (1) Contact Set, Main for BFMS, HCI, HC2 Coil, Contactor for RCMA, 120V 50/60 Hz Coil, Contactor for BFMS, HCl, HC2, 120V, GE GE GE 546A301G2 15D22G22 15D21G22 16 4 Safety T-22010 Suppressor Heater (for OL2) Relay (for Condenser Heater (for OL3) Contactor Coil Motor, Fan Motor, OL3) 50/60 Hz AMT # AMMS # 25B9012116 F_ I I N -j C-6-28 6.7.5 cars E-5 have 6.7.6 the Decelostat These cars are not equipped with the original pneumatic units. Maker car Light Decelostats, since the Resistors The marker ends, unlike light later They are used to volts as required for the adjusted to give 35 volts test spec section 4.2 for resistors are car series. Resistor, 30 OHM, IOOW with Slider Insulator, Teflon Bracket, Mounting Annunciator Power mounted in the overhead near set down the battery charger voltage to marker lights. These resistors must be at the marker light (not the resistor). the adjustment procedure. Part 6.7.7 E-5 MANU MANU # AMT # WardLeonard ........ WardLeonard I00A30 25X4010780 805 11N9004105 33K7000596 AMMS 35 See # Supply The annunciator and room buzzers are powered from a 6.3 volt filament transformer combined with a bridge rectifier to produce about 8 VDC. These components are located to the left side of the lighting switchboard, behind the cover. A 1-amp slow blow fuse protects the transformer and is contained in a surface-mount holder on the lower ]eft on the information. 6.8 Food lighting Service switchboard. Electric Locker N/A. 6.9 Service Refer Procedures to Main Manual. Refer Panels to figure 6.4 for part C-6-29 6.10 Drawin 9 List Function Single Line Power Schematic, 2900-41 Single Line Power Schematic, 2980-97 480 Main Trainline Power Schematic Water Heater and Antifreeze Schematic A/C and Heating Controls Schematic Floor Heat Schematic 2900-41 Floor Heat Schematic 2980-97 Auxiliaries Schematic 2900-41 Auxiliaries Schematic 2980-97 Lighting Schematic 2900-41 Lighting Schematic 2980-97 DC System Schematic 27 Point Communication Trainline Schematic Drawin 9 Number D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht D-O4-440-Sht. D-O4-440-Sht. D-O4-440-Sht D-O4-440-Sht. D-O4-440-Sht. D-O4-440-Sht. D-O4-440-Sht. D-O4-440-Sht. D-O4-440-Sht. 2 3 4 5A 6 7 8 9 10 11 12 13 14 C-7-1 CHAPTER7 i 7.0 7.1 7.2 7.3 7.3.1 7.3.2 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.5 7.6 7.7 7.8 List of General BRAKE SYSTEM Illustration Brake System Operation - Refer to Carbody Components - Refer to Truck Mounted Components Tread Brake Components N/A Disc Brake Components Decelostat Wheel Slide Protection System Operation Decelostat System Components General Maintenance Periodic Maintenance Brake Condition Indication Maintenance and Overhaul Brazing Piping Procedures Drawing List LIST 7.1 7.2 7.3 7.4 7.5 AIR OF System Procedures Refer Main Main Manual Manual System to Main Manual Page C-7-1 C-7-3 C-7-3 C-7-3 C-7-3 C-7-3 C-7-3 C-7-13 C-7-13 C-7-15 C-7-18 C-7-19 C-7-23 C-7-23 C-7-23 C-7-23 ILLUSTRATIONS Truck Disc Brake Components Truck Disc Brake Component Part List 3-AP Decelostat System Components Decelostat System Component Locations 3-AP Decelostat System Component Part List Page C-7-5 C-7-6 C-7-14 C-7-16 C-7-17 C-7-3 CHAPTER 7.0 7 AIR BRAKE SYSTEM General The system. brake cars are equipped Both car series Differences between with the standard HEP automatic air use a D-22 schedule and disc brakes. the 2900's and other HEP converted cars include: 1. 2. 2900's use CF disc brake arrangement. 2900's use AP-3 pneumatic Decelostat wheel slide protection rather than electronic E-5. 2900's 27-point trainline does not have brake applied and released pressure switches. 3. main All manual. 7.1 Brake other System Refer 7.2 Carbodx Truck of the brake system are detailed in the Operation Main Manual. Components Refer 7.3 to aspects to Main - Mounted Manual. Components series These cars are equipped with cars which have TFM. Refer to 7.3.1 Tread Brake CF disc section brakes, 7.6 for unlike later details. Components N/A. 7.3.2 Disc Brake Components Air flows between the carbody and trucks via a semi-metallic hose, armoured to protect against road damage. Extra heavy iron pipe and hose is used to distribute air to the 4 brake cylinders on each truck, one per disc. One size of brake cylinder is used as required by car weight. Refer to figure 7.1 of main manual for cylinder size. correct cylinder size must be used or braking will be inadequate excessive. forcing retracts The or Air entering the brake cylinder forces the piston out, the brake pads against the disc. On release, a large spring the piston and releases the brakes. C-7-4 These cars are equipped with the original C-frame mounted disc brakes. The brake cylinder and caliper assembly is suspended from the truck and supported by a C-shaped arm which rests on the bearing adapater. This causes the brake caliper to follow up-down motion of the axles and properly follow the discs. The caliper assembly can move laterally to follow the lateral axle-to-truck motion, and can also swivel vertically to follow truck frame-to-axle roll. wired brake The brake to the brake heading with ITEM wheel. lining is a high friction composition material, shoe. The complete pad assembly is attached to the the spring retainer, spring and brake shoe key. DESCRIPTION The brake discs are wheel mounted, The discs are self-ventilated. AMT # bolted to AMMS# the hub of The handbrake applies the brakes on the B-end truck by pulling on the handbrake lever of one brake unit per axle, forcing pads against these 2 discs. Refer to section 7.6 for WABCO instructions on these truck brake parts. an to Disc anti-wheel the journal brake cars are equipped with speed sensors slide system. One sensor is used on each bearing adapter. Refer to section 7.4. for axle, the the use with bolted C-7-5 Figure 7.1 TRUCK DISC BRAKE COMPONENTS To be supplied TRUCK ITEM MFG MFG # Frame Assby. See Wabco Manual Bolt (Bridge to Brake Frame) Lockwasher (Bridge to Brake Frame) Nut (Bridge to Brake Frame) WABCO RABCO W_BCO WABCO 86 04923 71A40M 21J26M 2 3 Pin, Tong at Cylinder Pin, Handbrake Crank at Cylinder WABCO W_BCO 8604173 8604191 4 5 6 Pin, Handbrake Crank Lever at Cylinder Pin, Handbrake Crank and Lever Cotter Pin, 3/8" x 2" for Item 5 WABCO WABCO WABCO 8606654 8605691 576246 18A2300254 7 8 9 Cover, Spring Spring, Tong Pin Washer, Flat, 3/4" _BCO _BCO W_BCO 8605061 8605060 575988 23X9009665 22A9000519 22P9003935 _BCO WABCO WABCO 576065 8609717 8605023 22A9000204 2{_0100174 WABCO WABCO 93841 8604912 22A9000108 WABCO WABCO 8604913 8604914 1 QTY DESCRIPTION Figure 7.2 BRAKE DISC BRAKE COMPONENTS 10 11 12 Nut, Slotted Hex Crank, Handbrake Lever, Handbrake 3/4" - 10" 13 14 15 Gasket hose to brake cylinder, Brake Head Assby., Outside .... 16 17 18 Brake Head Assby., Brake Head Assby., .... 3/4" AMT # AMMS # C_ R.H. L.H. Inside Inside ! I TRUCK Figure 7.2 BRAKE DISC BRAKE COMPONENTS Page 2 ITEM QTY DESCRIPTION MFG MFG # AMT # WABCO WABCO WABCO 8605688 8605689 8605791 18A2300252 18A2300253 19 20 21 Tong Assby., R.H. Tong Assby., L.H. Bridge Assby. 24 Brake R.H. WABCO 8605116 23E4003457 25 26 27 Brake Shoe and Lining L.H. Spring, Brake Shoe Key, Brake Shoe _BCO WABCO W_BCO 8605117 8604586 8604901 23B4003458 14 Brake Head Assemblies Brake Head Assby., Outside WABCO ......... 8604912 16 17 28 Brake Head Assby., Brake Head Assby., Stop Pin WABCO WABCO W_BCO 8604913 8604914 8605114 29 30 31 Wear Plate Bushing, Flanged Bushing, Plain for Guide WABCO _,_BCO _BCO 8604578 8606516 8601577 32 Pin, _BCO 8605114 Shoe and Lining Guide R.H. L.H. Inside Inside Pin AMMS # I I Figure7.2 TRUCK 33 34 35 36 Brake Brake Brake Brake Washer C_l inder Assemblies Cylinder, Complete, Cylinder, Complete, Cylinder, Complete, 6½" 7" 7_" BRAKE DISC BRAKE Page 3 COMPONENTS WABCO WABCO WABCO WABCO ...... 8605080 8605050 8605047 524387 22A0100233 25L9005915 18A2300225 37 38 39 .CLAMP, Piston End .CLAMP, Cover End .BOOT, Dust _BCO WABCO W_BCO 8611983 8611984 8504186 40 41 42 .COVER, Assby. .BUSH, Cover .LUBRICATOR, Felt WABCO WABCO WABCO 8605162 8604181 8604182 43 44 45 .GASKET, Cover .SPRING, Piston .GUIDE, Spring WABCO W_BCO WABCO 8605157 8605088 8606339 23E9008845 22T9004316 6½" Cylinder 7" Cylinder 7_" Cylinder WABO0 WABCO WABCO 531244 531328 531329 22A2300137 22A2600006 6½" Cylinder 7" Cylinder 7½" Cylinder WABCO _BCO WABCO 8605738 8606419 8606428 22P9003627 6½" 7" WABCO WABCO WABCO 8504172 8605122 8605161 46 47 48 Cup, Cup, Cup, Packing Packing Packing 49 50 51 Piston Assby. Piston Assby. Piston Assby. 52 53 54 Bushing Cylinder Cylinder Return 22X9003626 C_ I Body Body Cylinder Cylinder IBA2300222 -J I CO TRUCK 55 Cylinder Body 7½" Cylinder 19 20 Ton 9 Assemblies Tong Assembly, R.H. Tong Assembly, L.H. 56 57 58 BRAKE Figure 7.2 DISC BRAKE COMPONENTS Page 4 WABCO 8605163 22A0100104 ......... WABCO WABCO 8605688 8605689 18A2300252 18A2300253 Pin, Shoe Pin, Fulcrum Key WABCO WABCO WABCO 8605087 8604163 8604901 18A2300241 18A2300220 59 Retainer WABCO 8604899 18A2300233 60 Spring _BCO 8604586 21 61 62 Bridge Assemb|_ Bridge Assembly Bushing Cap Screw ......... WABCO WABCO _BCO 8605791 8605635 8602190 63 64 65 Fulcrum Cover Gasket Lockwasher WABCO WABCO WABCO 8605079 8604921 71A24M 66 67 68 Hanger Rubber Bolt W_BCO _BCO WABCO 8605601 8604469 8605603 Complete Complete (w/bushing) C_ Box Cap Segment I P .0 Figure7.2 TRUCK BRAKE DISCBRAKE COMPONENTS Page5 69 70 71 Nut Lockwasher HangerBoxAssembly W_BCO WABCO WABCO 21LI8M 71A32M 8604471 72 73 Hanger Box HangerBoxCap WABCO _BCO 8605083 8605085 74 Rubbber Segment WABCO 8604469 75 76 Bolt Lock Washer _BCO WABCO 8601883 71A34M 77 78 79 Bolt Lockwasher Nut WABCO WABCO W_BCO E860198 71A32M ZIL18M ......... WABCO WABCO 8605637 I 2 Brake Frame _ Bushing Complete (See W_BCO Manual) 80 81 82 Air Hose Assembl_-C_linder Fitting, Elbow Air Hose to Cylinder Fitting, Elbow Air Hose to Cylinder Fitting, Elbow Brake Line to Air Hose ......... WABCO _BCO WABCO 8609735 8609736 8609749 23T9011465 22xg003732 23xg011464 83 84 85 Fitting, Elbow Brake Line to Air Hose Clamp, Hose, 2 3/4" ID Open End Gasket, 3/4" WABCO Punchlock W_BCO 8609750 #11 93841 23H9010280 45Ag000322 22A9000108 C_ i I TRUCK Figure 7.2 BRAKE DISC BRAKE COMPONENTS Page 6 86 87 88 Hose, to Brake Cylinder Lock Washer Cap Screw for Item 72 & 73 W._BCO _BCO WABCO 8609753 514281 8605598 89 Cap Screw WABCO 8602190 Brake for Item 70 & 71 Disc ......... 90 91 92 Disc, Brake, 28" Cap Screw, 3/4" 1 3/4" Grade Locking Plate WABCO WABCO W_BCO 8609370 8606154 8610859 20A0100179 18A2300255 23X9007317 93 94 Brake Re]inin9 Fixture Brake Lining Assembly Fixture Lock Washer ......... WABCO WABCO 8610476 514415 22N9004124 22A9000206 24 25 95 Brake Shoe and Lining Assemblies Brake Shoe and Lining Assby., R.H. Brake Shoe and Lining Assby., L.H. Brake Shoe and Stud Assby., R.H. ......... WABCO WABCO WABCO 8605116 8605117 8605139 23E4003457 23B4003458 20A0100456 96 97 98 Brake Shoe and Stud Assby., Stud Pad, Rubber WABCO WABCO WABCO 8605140 8605177 8605137 23X9009262 22A9000511 5 L.H. 0 I -q 99 i00 Lining Wire, Brake Shoe See Page C-7-4 WABCO ...... 8608990 C-7-13 7.4 7.4.1 use Decelostat System During maintained Wheel Slide Protection System Operation the HEP on these upgrade, cars. the original 3-AP Decelostat system The 3-AP Decelostat is an anti-wheel slide system used to keep the occurrence of spalled and slid flat wheels low. During heavy braking, especially on slippery rail, the brake system is capable of sliding the wheels. This is especially true of disc brake cars; tread brake cars are less susceptible because the brake shoes have a cleaning effect on the wheel treads making them less likely to slide. The 3-AP system uses a "P3" speed sensor mounted on one journal of each axle to measure axle speed. It does this with a loosely - coupled flywheel which tries to turn at the same speed the axle. If the wheel speed changes quickly, the flywheel turns faster spee_ than the axle, a slide is detected, and the brakes released on that truck. as at a Before a wheel goes into a slide, it creeps along the rail. The P3 sensor senses this creep before a slide occurs, and activates the A-end or B-end dump valve as requTred. This reaction must be quick, because the creep condition does not last long before a slide occurs. The 3-AP system will respond only when it senses excessive wheel deceleration rate. While the B3 dump valve is activated, the brake cylinders on the corresponding truck are vented to the atmosphere. The P3 controller will deactivate the dump valve and thus reapply that truck's brakes whenever it senses the wheels are no longer sliding (neither axle on a truck can be sliding). C.'7- I_- B._I_ D_C_I.-OSTAT 5'T'GT=--M C_O_._OLI_kIT5 C-7-15 The 3-AP Decelostat system operates including emergency. Variations range for a 36 inch multiple wear conditions, allowable system. important Using things: 1. 2. a decelostat Reduces wheels Greatly sliding. system train (contrary reduces to control stopping distance to the common wheel spalling under all in wheel wheel will wheel braking size within not effect slide does the the two over that of sliding belief). and flat wheels caused Spalling is caused largely by sliding wheels. Small produce great temperatures over very small areas of the wheel high enough to cause local heat treating. This heat treating these small areas to become brittle, and the constant pounding the affected spot on the wheel endures causes these areas to which is spalling. Since the Decelostat prevents serious or wheel slides, it prevents most spalling. by slides tread, causes over fall out, large Most flat and spalling wheels have been shown to be related to a defective wheel slide system. When wheel defects of this type occur, try to determine why they occurred -wheel spalling is very costly to correct, especially if it reoccurs. The brake system itself especially control and relay valves is the second most likely cause of wheel slide defects. 7.4.2 Decelostat Components The 3-AP Decelostat 1. 2. 4 -2 -- P-3 speed B-3 dump truck. 3. Interconnecting Refer adapter, unit is Sxstem The one purely to figure system 7-4 sensors, valves, consists of: one per axle. one per truck air lines. for component P-3 Decelostat controllers per axle. A spline drives pneumatic, drawing air mounted on the location. are mounted on the journal box the unit from the axle. The from the brake cylinder line. OUT_I_4E. Or= ¢.A_% J \ / #L_, "/,4. 5._P De_&L-05TAT 5ySme.M Co_POklSNT LO_TfO_ Figure 7.5 3-AP DECELOSTAT SYSTEM PART LIST ITEM DESCRIPTION QTY MFG P-3 Decelostat Controller, Complete WABCO B-3 Dump Valve, Complete WAB'CO MFG # AMT # AMMS # F) C-7-18 The P-3 has a self test feature monthly to ensure proper operation. flywheel by rotating the knob the release. Refer to test spec PQ-79-1 procedure. bolted It is tightly which To test, brakes on test 7.2 should important to check periodically that the to the journal, and properly lock wired. The B-3 dump valves on each truck. When activated sensors, the valve immediately that truck to the atmosphere. is restored to the cylinders, which might start a new wheel Refer to test spec instructions which WABCO on components. 7.4.3 General checked P-3 unit is are installed in the brake cylinder line by one or both of the P-3 speed opens, venting the brake cylinders on When both the P-3 are turned off, air gently through a choke to prevent a jolt slide. The dump valves rarely fail, but there of sluggish action, caused by foreign matter in piping or pipe brackets at the dump valves. to be spin the internal that truck should for details of the PQ-79-1 follow test 7.2 in section have been the brake occurrences system for system tests. 7.6 for further Refer details Maintenance The truck inspection is effectively the only maintenance item of the system. Care must be taken to inspect the truck areas upon arrival of the train at the terminal. Any loose, damaged or leaking P-3 sensors should be repaired before dispatching the car. An inopeative wheel slide system can easily cause wheel spalling, which is very expensive maintenance item. A few minutes of inspection and repair will save many thousands of dollars in wheel costs. If a car is found with badly spalled or flat wheels, check the decelostat system to determine if it is functioning properly. If the 3-AP is functioning, the problem is likely to be the brake system itself, the control or relay valve. operation, The P-3 controller should be periodically as described below in section 7.4.4. checked for proper C-7-19 Dump valves require little maintenance, however, one may occasionally become sluggish. It is imperative that the valve react quickly for the decelostat system to be effective. Should a sluggish valve be found, remove and examine the valve. If foreign material is found, it is likely that the entire car's brake system is contaminated and must be cleaned. Check the strainers on the control valve, etc. to see. If much contamination is found: 1. 2. 3. 4. 7.4.4 Dismount all brake valves (control, relay, dump) and the A-I-A water system governor-reducing valve. Blow out the entire air system. Reinstall the valves removed. Fully test the brake system using the test sequence in test spec PQ-79-I tests 7.1 and 7.2. Periodic On I. 2. Maintenance a monthly basis, do the following: Inspect the P-3 installation on all 4 axles, checking for loose bolts, air leaks, and proper lock wiring. Perform the self test on each P-3 speed sensor (refer test spec PQ-79-1 for details). to WABCO Figure PAGE W_BCO PART NUMBER COMPONENT Budd Disc Brake Manual and Part Model CF 3-AP Decelostat 7.21 Figure 7.6 REPAIR AND TEST SPECIFICATIONS WI_BCO Repair and Test INTRODUCTION # Specification Index REPAIR PROCEDURE # TEST PROCEDURE # D8-54 Catalog G-g-5067-3 2612-I c) I _4 I Ir_,._-__._ ./_:. _ !_._'.,_'4_ '_ _._.-_ . _-_]m • BUDD D_C BRAKE MANUAL AND PARTS THE BUDD COMPANY Customer Service Department Red Lion Plant Philadelphia IS, Penn-,. CATALOG _'ABCO CF DISC 8RAK£S Vlestinghouse Westinghouse Wilmerding_ Air Air Pa. Brake Brake 15148 Division Company O844 FOREWORD This Stores manual was Department BRAKE. prepared personnel It is divided 1 briefly describes Section 2 PARTS is the section of up, two the the for portion parts and ordinary their guidance of the maintenance Where part from functions covering by illustration, item. proper the components, CATALOG replacement select information Mechanical of the and BUDD DISC sections'. the main identifies each the responsible into Section for the malntensaee the normal giving similar sad tabulation maintenance the PART appearing or procedure. itenu,. NUMBER parts vary illnsbatlon and in size This NAME or make- covering the item desired. Where Schedule" more drawing in question. or your and These BUDD should we The Of parts Budd described illustrations by such alteration, "Disc many BRAKES attempt is desired Brake Hum shown Assembly" are obtainable from in thi, manuul, drawings specificul]y the of your office consult "Disc applicable Chief Broke to the Mechanical car Officer Engineer. of the DISC data drawings Mechanical Because to the detail variations are being applied, illush'ate and to fully Company reserves in this manual or descriptions the in truck_, under change the and herein. shall this brochure llst the right Where be publicized different would application to alter to furnish many when interchangeability by a bulletin. of cars to which become to every or improve the parts types the too cumbermme car. design so altezed of parts or construction without would reference be affected LIST Page ii. 2. 3, 5. 6. 13. 14. IS. 16. 19. 19. 19. 20. 22. 23. 24. 25. 26. 27. 28. 29. 30. 32. 33. 34. !1. 1. 2. 3. 4. S. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. CONTENTS FOR SF..CTION ! Item F_'onl]spiece Foreword Description of Budd Disc Brake Brake Shoe and Lining Assembly Brake Heads Brake Cylinders Tongs Bridge Assembly Brake Frame Assembly Brake Disc Hand Brakes Air "On-Off" Indicator. Lubrication Wheel Changes Use of Thickness Gage for Condemning Shoe Lining Fig. I. Fig. 2. Sectional View of Brake Assembly Fig. 3. Applying Rubber Backed Bearings to Side Bearing Arm Rivet Set for Brake Shoe Studs Fig. 4. Fig. 5. Half Section through Brake Cylinder Fig. 6. Modernizing Older Style Cylinders Fig. 7. Piston and Tong Pin Bushing Assemblies Fig. 8. Tong Assemblies Fig. 9. Clearance Grinding of Thrust Washers Fig. 12. Application Disc B86-04636 & B86-O9370to Wheel Fig. 13. Application Disc BS6-05792& BB6-09360to Wheel B ullefins lAST Page OF OF CONTENTS Illustration FOR SECTION 2 and Parts Identification Typical Truck with BUDD DISC BRAKE Installation Brake Assembly (Typical) and Major Parts Nomenclature Brake Frame Assemblies (Conventional Style) Brake Frame Assembly (One Special Style) Brake Shoes and Brake Linings Brake Head Assemblies Brake Cylinders (2 facing pages) Brake Tong Assemblies (2 facing pages) Brake Pins Hand Brake Lever Assembly Hand Brake Crank Assemblies Hand Brake Crank Assemblies Slide--Hand Brake Lever Bridge Assembly Hanger Box Assembly (Welded-to-Truck Style) Hanger Box Assembly (Bolted-to-Truck Style) Air "on-Off" Indicator (Diaphragm Style) Air "on-Off" Indicator (Piston Style) Air Hose Assemblies (Single Rubber Hose) Air Hose Assemblies (Single Armored Hose) Air Hose Assemblies (Two Rubber Hoses in Unit) Disc Assemblies Support Cables Guide Point Brake Lining Assemblying Fixture Section 1 Page I D044 DF.,SCRIP_ON Briefly, the BUDD OF BUDD DISC BRAKE (o) Two (b) Brake Assembly. DISC BRAKE per rode unit conakts brake dh_s securely attached, oft one to each wheel. This unit is composed of the Brake Frame, CyUndms, Brake Tons's, Brake Heads and Brake S_om. (e) Hunger Boz Assembly which atria:has to the truck Irmumm. A typical hutalintlon disc brake is readily is illustrated apparent. on Pnge !1 of Section To maintain brake disc, the brakin8 •nits are mounted proper oa of truck frame _cany the brake braked between rubber and the other brake supported two •t consists or sprhtz the shoes and with the journal box. regm'dlms deflections. of • disc, or best exchanger, by composition d _ame in the same plane as the axle and the discs at Idl times, tiltlng incident to track cm_s each wheel and allgumext a three-point one polnt at the hanger box on the h'uch hansom Thus the brake remains 2, where the shnplidty lined braise -koes. mounted to the Inner hub d Each pair of shoes is actuated by an air cy_sder ezert_ force on • simple tongdever system producini; shoe preannl the disc which crextes the friction needed to retard the caw. With this design, guld/nii the car whaeb the car as it moves along the rails. drums, bat been transferred The brake flexible faces to permit expansion which forces surface as the These vide the secondary to .i deep-d/shed ribs. stsmplng. wheels These create a simple friction irrespectlve brake cylinder governor Section I Page 2 control preuure, of supportl:q that of •cth_ and 8s brake only that function. The Jhtmphqi distortion 18 radially of the Imddnlr by • double e_c_ent row of ".Sh,occo" (in the 28" d/so) type of rad/atlng revolve. combination chasecterlstlcs of speed but squsre inches with the composition of frictional materials. after years of service prove that the disc wears very little. take the wear. The fundamental use, to perform thus minimising air over 7,000 cast iron bralr.h_ feces together best poulble prbne bract/on engineered a8 the brake heats, the cooling disc sad to the_ The braking face on each side is separated red/sash z fms and structural blower Their to s disc precisely disc is cast intelyally of the disc casting. ere rmtored on of this aersngement or inertia loads. providinz eontrolled, Torque, there_oret cylinder me_mromexb The easily replseeable provide tmlform or manual Irraduation of brake brake lining mater_l Micrometer • constant is always braking without pressure. protaken shoe _t of proporttema! the need to for speed -4)O44 BRAKE SHOE AND LINING Each Bndse Shoe und Lb_eZ Amembly Assembly mounted the lining auembl7 b mounted The shoe of backing Pin on the lower self-locking CONDEMNING LIMIT The need mended for wedge OF condemning It is recommended work Lining and to make Auembly. NO-GO brake gauge, lining The lining This Backing accurate thlckness RENEWING While replacement only the complete with |. For 2. To removed 3. Note: brake W_._. the b. Remove Remove Care prevent should by the Page d ammnbly Joddn8 whw. unit pre_we obtained F_e pom_e. Shoe Pin of the Tons, Retainer • Spring, 23). and guuge Lining the 1_ of the Brake the Lining lining stock. gauge Segments. 4000 miles of service normally wears out and to from Lining the (See Brake as • _ GO- and F'qr. I, Pagu as each in normal ullmlnate each It is used betweeB ;- important recom. Disc. nuleage steel The by in•pedro5 maximum inch were'. thne tlm Brake to the be used inserting brake Brake Shoe thickness then by is 1/4 inch at whlch Brake from shoe Shoe most shoe brake of lining, 1/32 inch the 22). brake opecatlon. with shoe brake shut shoe replacement, in making th_ the fo"owh_ _ut:. llni•g. should having then new brake be returned Jh_r auembly. to store or brake shop later. Lining oft for Assemblies are R.H. and I..14. air supply Retainer Brake Shoe Assembly be taken to avoid brake to the truck. removal: use ,._ a hammer Spring damaging worn assembly and economical assembly described requires SHOES reasons a. Lining railroad proves brake BRAKE the the uniform long shoe Fag. 2, to the of the linlng Brake safety fo_ and secured st the top with be made to one another chenge-out free inch brakes, experience Replace OF Brake to over brake method CAUTION: This _ by the Lhdng 8qments LINING Remove REMOVAL next is equivalent BRAKE The the measurement !. for can and and is governed to the available Plate 2. 3. of the by applying Heed K_'y. (See damage gauge used capacity shoes a % rehdned Brdm 8/x compo,dt/_ LINING brake that The is held in position type thickness at a mtdaemi_ Shoe. and matorlah BRAKE to avoid pads thermal ._utunnldy changing be changed guess frict/un high Brake to • thin/qmu'ldesteel clasping. rubber end of the Brake and should the Shoe end Lining Retainer attached three make b eempomd on • reusable over combinatiun The studs are f_mly to the by the fle0u'ble Stop over ASSEMBLY remove and the self-lochlng Spring by from rals;ng a brake Brake the Shoe it vertlcally application Shoe Key. Pin. oft Shoe while brake Pin. shoe is removed to heads. Section Page ! 3 US.S4 INSTALLATION Broke Note: OF shoe Be b applied certain Cure BRAKE the should engage attention and Key Spring. Spring, remedy with be used to wear, permanent Brake 1. wear, chafing Excessive Excessive Bolts. cuttinl, off one l J/,," at I.D. shim between For out BRAKE economy Brake DISASSEMBLY Remove assembly may portion worn brake Brake shoe, _emove ti,e three be and I 4 in good off and Fig. 3, be due Rubber at Box Bearing. Hanger down in service the Hanger less, 24). to loose Box or worn Segment outside x 29z_ edge " long if gap the by diameter Castings. ex- and or be remedied a '/4'" thick x 3_/2" wide and Becked Page broken 1 t/_,, or rubber exceeds be replaced. the Brake requircs Shoe is designed Assembly replacement, which should be so that handled only the as follows: Lini_,g then the rubbe: pull worn pa,i_, A:_sembly wires I],,ing by cutting out of the brake the wires shoe which hold the lining studs. assee_hly. titan off by brushing, Shoe for flatness, examine, and discard carefully examine any that condition. inspect in shoe tighten about 7/s" by:. Rubber I/4" between Segment is be caused either of height INSPECTION dlsca-_! for looseness Section Page Lining and Brush ones in malnten_,nce, the Segment by Free sprlng. Arm may be continued adding should may height is found, be achieved retainer. new (See This less than Sc_,.ent Disc may and the Retainer SHOES Lif_ ..ff not then with C°nome" of Retainer tightness relief this Bearings. may Rubber edge, segment AND to the of the Rubber t/_,,' rubber RELINING end of must in unnecescery insufficient of Bearing to Rubber Frame ben& surface the Retainer, the spring replace Assembly. A gap Tube" of Brake result Key, Where with the Brake Box notched Shoe Key b driven 1-1/32"--when Backed be due by chafing. Hanger and also Shoe and or breakdown in Hanger It may ce,ively Shoe of the brake irood compression A tempmary spring or breakage, Rubber play Head. is about set of the the The subsequently the Brake p;,rt or parts. new Key. that the Brake this will the Brake between when Shoe *,,d PuKe 23). be tllrht, indicatlnlr Pin slot, the worn a washer Remedy--replace worn and 2, to v_ it must Shoe Pin at the Ioww Brake Fig. is any looseness, Misalignment 2. respplyinli should Shoe spring of above. the Stop (See on the Brake the retainer due when by replacing shimming engages retainer. there wear the order is in position Where destructive shoe taken spring particular when in reverse broke be the SHOES any the Brake or wear, remaining partlcul._rly ones whi,:h and at the wire bole. arc loose. Replace all worn the studs 8 studs with new us44 To remove brake doe, defective mine into brake shoe. • l/s" drill _ound • new stud, the mating stud. (An riveting). e_y Rivet ASSEMBLING Brake almost bead fist at point. in the eo_:t_bamd hole d Take care that drt_ does not cut doe. take care that its wire hole is in ullznmant with the hole in way is to insert and keep • wire through the two _ studs in place LINING TO BRAKE F'ncha_ T86-06224, the the rlveted-over Punch stud out of Inks in applying while studs, cut d mlng • rivet studs set, such as shown in F'q. 4, Page 25. SHOE illustrated on Page 24 in Section 2, was deemed to an_ instal] Lining on the Brake Shoe. To mount Lining on Brake Shoe I. Lay Brake Lining assembly 2. Set one Rubber face down on bench. Pad in each of the three recesses, or pockets, of the Lining Back Plate. 3. Place the Brake Shoe on top so Studs tit into the stud holes of the _ 4. Grasping the shove parts _rmJy, back plate. turn them over as • unit end place on the slid;ug Carriage of Fixture T86-06224. S. Slide carriage along fixture center of preuure Key over base to position _r_t pair of brake shoe studs in line with spindle. 6. Place 7. Screw down Hendwbeel studs. just enough to allow inserting Iron Wire through the holes of that pair of studs. Note: It is important that this compression travel be I_nnJtedso as to prevent bending lining back plate which would gauge (.135 Shoes. die.) If smaller destructive 5-7/16" result in loose wires. of Wire size used MUST be #10 long for 28" disc Shoes and 5-1/16" long for 26" disc wire is used, the lining will chatter on the brake shoe resulting in wear on the stud body by the lining buck plate, also elongation of holes in studs and breaking of lining beck plate. 8. Lock in place by bending away 9. Repeat both ends of support. assemblies They and downward over edge of shoe and from lining. 6, 7 and 8 for each of the retaining BRAKE Installation wire of Brake Heads become anchored their retainer HEADS on the brake and held springs, 3 pairs of studs. tongs utilizes the tong and its shoe pin for in position retainers by the installation of brake shoe and keys. _.ctton "J Page 5 Dl44 REMOVING BRAKE To remove Shoes. HEADS Brake Heads first remove Then llft brake heeds because of interlocking vertically of outside the brake shoe auemblles off shoe pin in pairs. and inside heads as outlined under Brake This must be done in pairs by the guide pin which is an integral part of the inside head. BRAKE HEAD OVERHAUL--SE OF BRAKE INSTALLATION Before Page inside clean and lubricate also the shoe pin head and Assemble the out*ida and brake heads ere is used at the location to obtain maximum R.H. difficulty railroads end L.H. -- worked on. may be experienced Cylinders be removed diameter. The position, also if wrong guide arms file offset would hand inside brake ride head is used brake shoes. and wear pert* lubricated at least once a year -- some are changed. CYLINDERS DISC BRAKES amount are light and compact of abuse encountered yet rugged in high speed are made in several sizes. to service. The size used on each truck is in proper All cylinders on one truck are the same size "braking is a sealed in the non-pressure filter material The c,'t!!r.der is self-lul_;"cated Most Railroads brake levers, special "brake which provides by oversized cylinders, lever in drilling". are used in all locations. into the bellows-type by disconnecting of cylinder without through the hollow-rod added atmosphere. boot which extends The air as the brakes portion of the piston which is pecked protection against dirt and moisture. swabs. keep • few reconditioned (accomplished to the light weight are obtained unit that does not breath to the outside area is displaced This air is moved and reassembled ratios" which are in effect The cylinder with rubberized cars, a truck on one end may have while the truck st other end may require larger or smaller proper The same tongs, Section 1 Page 6 the guide pin. brake heads have offset hand is applied On some type cars, llke diners or observation this manner air dating inside in applying to the weight carried by that truck. one size cylinders nre applied. used on BUDD LUBRICATION, is used for each disc location. Brake cylinders proportion (See out of the tongs. to do this each time brake shoes with long life the amazing One cylinder protruding sill, if wrong BRAKE Brake lubricant care must be taken that proper hand brake head This became at center find it advantageous withstand with graphite inside brake heads in pairs by engaging clearance Brake heads should 16, li _ shoe pin bushings and wear plates on the brake shank portiotn brake disc when brakes are in applied some NO, HEADS the guide pin, guide pin bushing, 19) heads; installation, E BULLETINS cylinders on hand for speedy replacement one air fitting and removing requires one man). Removed in groups inside a building at considerable at two pins, and due cylinders may then be cleaned savings in time and material. 0144 REMOVAL To Fig. 2, OF remove Page !. 2. BRAKE CYLINDER a Brake Cylindar 23, and proceed Close cut-out cock safety precaution. Break the ur 3. two Note: Nut, Tong bold pin the tong pin. Release S. Remove Due the complete Brake Ammmlgy rder to as follows:. in brake not c341nder at lose Washer, while the line to the truck Cylindm. bahai by mvfmg the Ring Casket Spring end Spring remov_g Cyl;,,der the by the between Cover wodked the two from Fitting the ore. _ Cap Screws. and Cylinder. bottom of each b • of the and nut ruislng insert both • Tong drift or pumch in the hole at the top d Pins. Cylinder. to clearance shoes from Pins. To 4. Note: Do Remove Auembly connection CAUTION: ASSEMBLY restrictions spread the on some tongs. This trucks, it may would be desirable allow cylinder to remove to be the brake or raised the center lowered vertically. INSTALLING I. . CYLINDER ASSEMBLY Clean and lubricate Place the Cylinder tong pins between and bushings. the Tongs with (See Lubrication, the "tlr 19). Page connection" toward of the truck. Be sure proper 3. Apply 4. After aligning in the tong apply S. 6. guide will and permit the second the Spring Remove apply the the gasket and locking serve each truck. Section 2, Page 23) outboard tape is in good the e_d end of the cylinder holes pin to be applied Spring and to of the assembly tong with the pins. holes pin. to line up the tong the Nut wire for in the Cover, mask;ng that is used the first tong point then (See the holes guide A_;:y cylinder points "[he Pin, 7° the size and Pin. covering the condition end _r the inboard with the Wl,:her Cotter •t seeted and of the cylinder use of m barmier. in this order inlet end on the end install correctly, the of each Tong taking care are tight air fitting, cap screws is added. Sect;_n Page 7 I 0144 OVERHAULING DESCRIPTION OF CYLINDER Fig. 5 _ a sectional lubricating CYLINDER MAKE.UP sketch of the Cylinder. Thls -l, etch shows swab used with the piston head and the the replaceable The cylinder bronze bushing which is pressed cover in conventional groove ASSEMBLY hollow piston into the cylinder holds an oil saturated felt the p_/dng cup and rod which slides cover (non.pressure ring which lubricates within head). the piston rod manner. The Cover is attached to the cylinder body with three bolts, and (with its spring guide) retains the piston return spring. A cork composition gasket is used to seal the joint between cylinder and cylinder A bellows cover and prevents corrosion clamp The cylinder by a stainless to the cylinder breather in extended wear hair type filter pusitlon of the bronze from dirt and bushing of the on rele,_se sUroke. One end steel clamp to the grooved piston and the other end cover. feature side of piston into the boot. volume the piston of the piston, reduces dirt or water being pulled into the cylinder of this boot is attached by a stainless dirt and water. type rubber boot protects water, thus preventing cover, against is a matter This air is forced in the hollow of displacing via the air from the non-pressure the breather ports through piston rod each time piston moves the large on brake applica- tion or release. The stainless steel guides the return spring The two flanged piston provide the bottom easily the cylinder CYLINDER and prevents replaceable the bushing spring wearing bushings for the tong pin long-life by changing cylinder over at the outer surfaces for to opposite ends of cylinder the tong pins. W_en and only wear service can he obtslned side of brake frame DISMANTLING AND which re- OVERHAUL Remove Root from piston and cylinder cover. Examine these boot and clamps. Usually If boot is torn, discard Remove the three cylinder sbou!4 cylinder nlways bolts. are in suitable and replace Suitable fixture be used whLn rcmovl.iS condition compression force. 3, Remove cylinder cover assembly. 4. Remove return spring and piston assembly. for several with new one. for clamping cylinder cover to or installing cylinder bolts as safety against injury from spring action of return spring which has approximately Section I Page 8 cover the boss. holes wearing boss of the cylinder 180"'. reapplications. 2. over flanges of these bushings are worn thin, additional from these bushings volves Spring Guide placed 180 Ibs. Clean , and Felt in cylinder cover, parts otherwise Replace tong bushings use Crozier 684 of a Machine New bushing may damage Cylinder Cover Remove and let excess Wash remove into Piston and grease Convenient way or puller. A Bushing Exhraetor" made Driving seat very in these to remove efficient worn and inex- by:- bushings in the aluminum If not worn, with a hammer cylinder. wash out in suitable then brush to remove surface before again installing, soak and bushing worn bu,hing by slitting dirt and in Cover with and thoroughly for wear. replace with hacksaw dirt and in warm solvent bang light to dissolve in clean machine place oil, then in two dry If worn new the Cover beyond bushing. places and Assembly. 3BS" Old "peeling" along bushing out. largest may Press inside easiest new be bushing cover. machine new after bushing Is pressed Release dirt A Extractor" bushing ring. grease, Finish Piston not to scratch off. bronze removed of Head). dry off all old Inspect dis., old dirty drain Be cardul old lubricant. in with a press. lubricating After Replacement Avenue or distort (Non-Pressure out. Boot. of Bushing Company he pressed bushing remove to dry Rubber Bronze California. =hould felt piston the requires. 86-RR Tool Prairie Hawthorne, and to condition in piston, for. so "Bushing Model North Cupp be siren and wall. if condition is "Crozier should in cylinde_r of all dirt and cylinder bushings one Pacing cylinder attention Bushings be arranged clean is with pensive Pin Piston damage Particular Tong should m Thoroughly or all parts. Lubricators, defective Cylinder examine Ring Spring. falling on m corroded and or other on inside pitted, wall apply dis. to 3.604"-3.607", finish to be 63 Micro inch, in place. Thoroughly cylinder anent set bushing clean and later a coat condemnable spring causing of dirt scoring. of approved defec_t, all and old If in good rust preventive. replace with grease new to prevent condition If broken, reuse; taken if perm- spring. Assembly:(a) Piston any (b) Packing questionable Felt Swab dry out any tlon Cup--follow w indicates as if the felt replaced. standard practice in cleaning and condemning, replase cups. remove, cleaning that does carefully solution, the swab not extend clean and then saturate brush would shove not have the slot off with light full any machine contact in piston surface with head), oil. dirt, if visual cylinder the thoroughly swab wall inspec(such should Section Page be ! 9 {e) Piston m In cleaning the Piston Assembly, care must be taken to •void the h4_r filter inside of piston tube with denning saturating solution. If dirt or corrosion sticks on the hollow piston rod, place the piston in • rotating fixture and using s fine grit cloth, remove dirt or corrosion The hair type _ter, located it is not recommended in the hollow unless the cylinder clogged that it does not permit out the breather is excessively sir to pass freely can be replaced, dirty and the _tur through the _ter but is so when blowing ports. If it is necessary to change from the hollow as the piston is rotated. rod of the piston, the Glter, the piston head will have to be removed rod by drilling out the rivets. Remove the hair filter and discard. Clean Replace the hair filter with new hair. individual Assemble parts in solvent the head to the hollow solution. rod and rivet in place. Examine tong pin bushings fit) is worn excessively, st end of piston or if the are worn thin, bushings should press to install new ones. piston must be ground pressed in place. flanged be replaced. IMPORTANT off at four places See section A-A inside of cylinder coat of approved On the clean urated dry and brake cylinder reconditioned pin on tong) -- The comers of bushing flanges on the dis. after new bushing_ are This is to permit piston without forcing and without assembly damaging Swab cylinder wan over entire surface with lubricant. piston assembly cup, and insert apply the felt lubricating into cylinder after swab well sat- coating all over with lubricant. To a clean good spring. (tong cylinder Use puller to remove old bushing and of Fig. 7. clean. brake cylinder with oil, also the packing lubricator, of bushing ASSEMBLING Wipe generous H bore (supporting to 3-9116" passing through the cylinder cbver assembly the bronze, bushing. CYLINDER rod. collars condition the cork cylinder Holding cylinder cover gasket, cover assembly, the stainless these parts as a unit slide over Using the same clamping 5xture guide and the piston piston rod into place against as for dismantling, _og_,he_ i.-_king s_,,_ _i_ u_'_s fit prooerl/. apply the oil saturated piston felt spring with the three (L',o not let cylinder cover belts, gasket return cylinder. bolt cylinder kink or get out of place). Re_ove wood leakage cylinder from fixture and make block or by some other means should not exceed Section I Page 10 leakage restricting piston test. To air test, stroke to 3s/_ ". 2 Ibs. per minute from SO Ibs. pressure. put cylinder in • In this position, Pit44 After I/16 cylinder vent holes (on cylinder passes lank•g• arc at top and cover) preferred tests, •pply bottom the booL Boot should of cylinder •s cylinder is reader car. The large clamp position is w/th screw on bottom of cylinder, while the smaller centarline nearest to bol,tes tape to •void dust and foreign clamp (on piston) preferred position is with screw on horizontal and farthest from disc when instaBed on car. Cover the Air Inlet Boss on the cylinder articles from entering the cylinder The tong pin bushings with raphite lubricant or tapped •t each end for protection. GENERAL be so turned that the with masking holes when it is stored. of the air dated cylinder (See Lubrication, NOTICE ABOUT Page mcmbly should be coated 19). CYLINDERS The foregoing disco.ion on Brake Cylinderl end their component parts covers these as furnished from 1952 to the present time. Several revisions were made •t varlous times be. tween the initial "CF" style and 1952 to improve the operation and reduce maintenance requirements. It is recommended br•ke overhaul (e) that existing older style Cylinders to incorporate Piston changes Assembly. extension in some became •ctually imbedded breaking in the rubber had an integral for the piston return spring. Experience excessively off small packing ( 1 ) Machine aluminum _1, on Note Fig. 6. (2) heeds into this aluminum pieces. cup, :_2, Fig. 6. piston heed Install E56-06339, No ••chining These scoring the extension, aluminum cylinder part]des walls (b) Lubricator Swab. Examine and wall scoring Reduce O.D. on aluminum to file Cylinder Cover, but off burrs or roughness for beyond O.D. of aluminum If steel grcose piston, this may cause or cutting. of lubricator piston. necessary us shown Steel Spring Guide, as shown lubricator sw•b while in pl•ce on piston. retainer or swab retainer project cylinder by cutting off extension Stainle, is required if casting is not smooth it may be spring guide to seat properly. aluminum piston in Fag. 6. •Jr blow-by. Remedy -in Note as • guide at •Jr d•ting or general illustrated aluminum that the return spring wore instances be reworked below end of the earlier sleeve which served has proved causing Some described swab steel Install new sw•b part to slightly felt. See Note less than O.D. suffeca of :_3, Fig. 6. Thi_ ..-F, es t., 7" e.d 7Z/_" Cyl;qd-..'s only. (c) Gasket E86-05157. joint between of Neoprene See Note _4, Cylinder Rubber which occasionally sulted in water leakage. gaskets (same Fig. 6. This gasket provides • weather seal in Body and the Cover Assembly. Replace got distorted any Neoprene piece number F.86-05157). Formerly this gasket during application was •nd re- gaskets with new cork composition Neoprene gaskets are d;-continu, ed. Page 11 DS.S4 (d) Rubber Boot D86.04186 Boot Clump (1) EB6-08777 In all caJes apply nect;on holds of boot a water the p;-ton. new (for -- shown in Note _6, Th;, el-rap rod with cloth. fine grit If torn, replace vent holes Cylinder elr Attach leakage boot Piston and or blow-by firmly'to Bushing D86-05739 for ?" D86-05740 for 7:/2"' Above piston replacement and must past Assemblies (See Fig. ,_-e_bl7 corrosion obsolete punch these pressure packing clamp, makes dirt products F86-062S8 be ,saored 6, vent cylinder with from on Gader tee piston do not have the vent build-up ud holes in boot caused by any cup. F86-05699. 7 for illustration.) Cylinder. Air Cylinder. assemblies give the at plsCm coD- if present boots Fig holes the clamp _lo,ld :_5, These cover bushing assemblies over cylinder Air This D86-04186. in Note to cylinder, (E.86-08777) thus redue/nff corrm_n Boot, as shown reapplication small F'W. 6. ;- an improvement of rust or other ]/16" AMembl7 tight 0eel of boot to p;-ton, accumulation before Piston ,-,d). Boot Clamp Any (2) (e) AMembly the ere part no longer number furnished for the new and all future improved assemblies orde_ for ,,, shown below: Old Assemblies Piston & Bushing Piston The & Bushing lubricator ordered Ass'y. Ass'y. swab New 7"--D86-05739 Piston 7_,_"--D86-05740 Piston & Bushing used with the new For The piston 7 l/_,, Air lubricator must New & Bushing improved piston and Part No. E86-06375 Assembne| Ass'),. 7"mD86-06419 Ass'y. 71/s"_D86-06428 bushing assemblies must be as follows: For 7" Air Cylinder Note: Improved swab be ordered heads For may Cylinder as a separate be ordered For 71/_ '' Air Cylinder Rivets for the attachment by specifying $: :t:'on 1 Ps_e 12 use Part is not furnished 7" Air Cylinder be ordered use E86-06378 as p',"t of the piston and bushing assembly and part. as follows: use Part No. use Part No. of the new piston Part No. No. 60A!620. head D86-06377 D86-06376 to the piston tube, for all assemblies, may TONGS The Brake Tongs are the connecting heads and operate as levers when the brakes pin is press fitted into the tongs and fitted into the fulcrum hardened fulcrum llnk between operates support assembly, wear resistant bushing, _ are applied. brake cytlnder A hardened in • hardened wear and the brake wear resistant fulcrm'n resistant bushing, press which is part of the main Brake Frame, and another press fitted into the Bridge Assembly, which is bolted to the support. REMOVAL To remove the Brake Tongs shoes with brake lining assemblies, from • complete The tong may now be lifted vertically the brake frame To remove hammer first nunove the brake cylinder and the bridge assembly. out of the fulcrum bushings, the latter be;,g a part of assembly. the bridge assembly, drive down the bolts INSPECTION brake assembly, the brake heads, the brake AND take off the nuts and lock washers and with a rawhide (bridge to brake frame) until bolts drop out. REPAIR Clean entire tong assembly The tong forging and inspect for excessive wear or other does not normally wear and, except for accidental defects. damage, will seldom require replacement. All wear normally are the bushings, Replace occurs only on the replaeeable pins, wear plate and wear washers. worn or defect;re The tong pin bushings, forging. To replace replacement the fulcrum To replace to tong at ;t_ head (take these See Fig. 8. parts as required. pin, and the shoe pin are press fitted into the tong tong pin bushings or fulcrum part. parts of the tong assembly -- pin, press out old and press the shoe pin, first grind or chip off weld care not to damage tong in grinding in the new which safeties or chipping weld) pin then press out old I_,;n; press new pie"home" and safety with about s/s" long arc-brazing along cir.. cumference of pin head to tong as shown in Fig. 8, taking care to properly llne-up key slot The wear plate and three thrust washers off old weld and remove worn part. Apply are welded to tong. To replace, grind or chip new part as shown in Fig. 8, us;,_ stalnles_ steel rod and bead size specified. SPECIAL WARNING NOTE: On cars using Free Lateral type journal boxes and having brake frames fitted with Stop Pin (item away _3 sho,*ln on P_8"e 2, Se:t;on fron_ the edges the Bridge Assembly the surfaces of wheel adjacent of the fulcrum 2_ it "s "rorortsnt _t_ a l/a" depth ffot is ground pin thrust washers, also the flanges of the }Jx,shlngs of and the Fulcrum bushings in the Brake Frame. to the wheel, when lateral displacement and assures ample clearance This is required only on to prevent rubbing on rim comes in that direction. See sketch in Fig. 9. %_.ct;on1 DS.M INSTALLATION Lubricate cant. (See least once all exposed Lubrication, each Install *udaeas of pins, Im_ Page 19). Note: AH plna and using reverse primary procedure rcasom to that called for this unit (I) to resist upward (2) to keep brake shoes in proper (3) to hold shoes (4) to resist (S) to provide For bushing, with gropblte lubrl. should be mo lubricated at 7ear. BRIDGE The and thrust wauhm brake forces lateral forcer readily illustration of ASSEMBLY by brake alignment cylinder with and means of component reactions. in proper cylinder accessible removal are:- produced and for under lateral brake of parts disc. see alignment. shoes. tonz removal. Page 13, Section nuts and 2. REMOVAL To remove hide hammer the Bridge drive dov/n It is important that Assembly, the bolts take (Bridge off the to Brake lock Frame) washers, tatS] bolts then drop with a raw- ouL MAINTENANCE Frame Bridge Assembly be bolted t_ht to Fulcrum service, the only wearing parts are the two flanged bushings, into the bridge body. These busJ_ngs should be cleaned and lubricated lubricant each time tongs are replaced, but not Im than once 8 year. SPECIAL WARNING On cars using (Item away the on the Brake Assembly. In normal Pin Support _3 from Brid_e the surfaces prevent sketch the ._jacent rubbing in Fig. On brake ._t and edges Assem_)1.y condition Section 1 Padre 14 on are pre_med with specified frames fitted gcaphite NOTE: Free shown which Lateral on Page of the and type journal 2, Section fulcrum the 2) vin Fula'm'l boxes thrust _,:_eeI, and rim of when] when having washers, J_vsh!ags to the and it is important also m 1/8" depth the _mges :e d,_. FLrulce Fr-z-_. is desirable lateral brake that to assure displacement that of with the bushings "this ir required ample comes c_eacanca in that Stop /1at _- zround of only on exists to dlrect/on. See 9. installations requiring of the Fulcnan Fulcrum Cover Gasket Cover, care to provide should a good be taken water and to huure dirt proper tilrht ,seal. SeA The functions (1) of the Brake Frame Assembly to maintain proper alignment (2) eAME ASSaiL',' a resilient, yet substantially of the brake shoes and the brakas disc, mad r_d, means frame and wheels without producing A conventional of tzanden.h_ type is illustrated OF BRAKE This is seldom wheel FRAME required, (1) Drop (2) Disconnect (3) Remove (4) Entire I_rake assembly hansom on Page 3, Section are supported on the truck equalizer, conventional type. rmu_ons instead FROM and 2. 2, Section h'dck 2. This with one pohst suspension, the other two points one each The two outside of journal to the riding qmd/tins. on Page in the truck is a three point rubber-becked at the hanger box attached to the truck frame nn the rear enclosure of each journal box. REMOVAL bra]dnz disturbing noises or _Forting type brake frame asmnubly is mmtrated brake frame mounting Another ms: m box po_ts of this style as is accomplished on the TRUCK but when desired may be done by:- unit. connection hanger to cylinder brake hose. box cap. can then be removed. MAINTENANCE In normal (Refer service, to illustration (!) Rubber Backed These the following parts of the Brake Frame Assembly on Pag,_ 2, Section Bearings, ere most important It is not necessary attention Item 6. to eumure proper brake shoe alignment. the rubber torn, or the manganese Bearings should be replaced. item. requ_e 2):-- to remove It can he made accessible wear liner worn excessively the Brake Frame by dropping from the H missing, loose, these Rubber Backed truck for replacing the wheels and lowering this brake frame. Firs: remove th_ _dective rubber hacked bearing by chipping or fp'_ding off welds fastening this unit to the side bearing arm of brake frame. DO NOT BURN OFF with a torch or carbon arcl Next grind off any remaining seating of new part. weld depoait. Failure to do this may prevent propes' Page 15 DI.S4 Apply new rubber IMPORTANT are located diEficu]ty rear enclosure backed bearing, CAUTION: accurately ward, backed be when bearings It is very on the side will had wheels are followhxg method important bearing arc forced, being that arm. in "srmpplng" the brake too frame in truck, in damage in F'qr. 3. the Rubber If located installed res_ting dehdled to, Backed Bsarings far forward or back- over the in such or even jourmd eases the rubber destruchon of, this part. For convenience in getting replacements arc the rubber backed (2) bearing Fulcrum These (3) Pin before hearing Bushings, shot,ld he replaced support of brake Wear Plate, Item These wear plates arm. Plate These hole remove the Stop Pin (Item These lateral clearance of withlmi_ z-----require_. where lateral bushings travel (6) is flush and HANGER and The Brake and with safety MOUNTING The with wheel and rod to the side 8 STAINLESS Pin of the type Section 1 Page 16 A.,scmbly disc and may the TO style (Item tongs in position support o,tside face of I/2" as used respect brake bearing 3) to journal frame side box, bearing arm. where during shown to position them fulcrum support. long bead used. released on brake illustration. laterally position, so outside If shifted, drive They are edge of back to of weld. BULLETIN NO. 15. DISC is an integral to provide unit of special attachment tn the cast iron for the braking wheel. WHEELS be applied axle or on thrust fit in the fulcrum and wearing when brakes are released. STAINLESS STEEL ROD. _' STOP PiNS IF LESS THAN 6 I_ EB6-O4924,SEE stamping DISC be slld over The Disc a pressed frame be maintained with _hr,ut TUBE s steel rubber condition. BRAKE surfaces through in the pin hole are brake or Stop limits position should position either between steel IB- used to the fulcrum bushing pin After Item 4. in suitable tack-welded din. ann. when assembly. lateral 7) Bushing, Maintain 1_,, bearing bem.h_ pin. bushings thereby preventing shoe linings ""d,agglng" WELD ON WEAR PLATES W THIB-O Maintain in suitable condition. REPLACE t.5) backed use a in side excessively flanged control welded m'a;ntaln rubber or welding, the worn These frame as condition Replace Wear are the 5. controlling They d 2. when of flange. the and in place, Item smface location clamping hole is welded bearing thereby (4) made, backed proper loose of wheel to the wheel and fastened press either to the us_,d would prior wh_-el govern to pressing wheel on axle after wheel is pressed the procedure used. on or it may the axle. LONG° 0t-N Application of Discs to Wheels, Disc BS6-O4636a 886-09370 (28" with ll_/s" D;-c B86.05792 &B86-09360 ALSO SEE BULLETIN N0, (26" IT. bolt ek_ele) to 36" wheel (F"_. 12) with 10t,_" bolt eir:le) two different futemu's were meal to secuse the dim: to the wheel and each Heretofore, used a different depth of tapped hole in the wheel adopted as the standard fastener for 8U discs Bolt and Nut 21LISM or 21JI8M will be discontinued. Figures 12 and tapping requirements. 13 illustrate approved 71A32M The Budd Use all wheel railroads have does not bottom be within limits specified in some instances omitted Company of Stud hub machining To assure proper spacing of discs, satisfactory that machining Some hub. Fae-0elS4. dimensionally face on wheel hub, and to assure that bolt fastener important to 33" 8t 34" wheel (Flit. ES6-01763 and bolt bole bearing of disc mounting in the tapped hole, it is on the sketches. Lock Washers 71A32M. by The Budd Company. We strongly urge use of Bolt F86-061S4 and that these bolts be safetied as specified. REMOVAL has now This is not and Washer OF DISC I. Cut and remove 2. Remove 3, Press 4. Disc should all w_'es from fasteners. safety fasteners. wheel another off axle and remove be cleaned wheel disc is reused, Under normal the service and inspected for continued Where operating disc. clean service, if suitable or condemned all cooling conditions, life of the wheel. to determine for re4pplicstion to for scrapping. fins to assure unrestricted air flow. the service life of the disc is much greater than Therefore, discs should be carefully examined before they are sczapped. REASONS FOR CONDEMNING OF BUDD BRAKE DISC NICKS it is fairly common in normal service. interfere for the outside edges of the brake discs to become nicked occasionally This is not cause for removal of the disc unless the nick is severe enough to with braking. As long as the brake lining wiU not be damaged and will puss smoothly over the nick when the brakes are set, the brake will operate satisfactorily. SC;_ATCHE5 It is common for the braking surfaces of the discs to become Such surface scratches not recommend continued are not cause for removal machining to remove scratched in normal service. and will not interfere with braking. We do recommend that such discs be such scratches. We in service. Section 1 Page 17 13) DJ44 WEAR m There is very little wear on the disc brtddn8 mrf_ be removed or mchined THERMAL CRACKS It is possible for mama under condit/ons d ny We'do mot recommend wQ_r dmt will be found of unusmd overlund form cl_ tlmf, dlecm in normal service. to be thermld crtdked. In pr•ctlcally all cases, • thermal cracked br'ke dhc will be preceded by abnormally r•pld shoe lining wear. If this condition of rapid lining wear is noticed and corrective measures applied t,_ the cause, it should be possible Wh,'n they do appear, h_ve to prevent serious thermal cracks. thermal cracks will usually mn mppcarRnce similmr to thermal recommend that a disc be condemned lining during • brake application. up to more than l/32" cracks be in small in wheels end will develop clusters radially. only when a crack widens to • point'•hat Cracks running out at the edges are reasons darkened and We it cuts the of the disc and opening for condemning. MACHINING We do not recommend machining brake discs to remove thermal cracks. There are two r_'e_nns for this: !. By reducing' the thickness the brake. of the braking surface, it reduces the thermal capacity Thus more harm than good cracks may have been removed 2. Brake discs have continued cracks have appeared thing is to correct in unusual cases, by machining. providing without the condition of may result even though some small thermal satisfactory the cracks service necessarily for years after thermal progressing. that caused the small thermal such us a badly scored The important cracks. disc resulting from n missing brake shoe, the disc face may be machined by taking • thin cut to return the face to a more satlsf•ctory surface. Under this condition, the disc"face does not have to be absolutely smooth am it will be smoothed ultimately by the action of the brake lining. In no case should the thick- hess of the disc face be made less than 7/16% SEE FI6, 14 8 I4A ON MACHINING wORN DiSC SURFACES, WELDING The material of the Budd brake disc is not suitable for satisfactory' a br,-ke di c by welding RUST welding. Repairing is nf,t recommended. PROTECTION While corrosion. Section 1 PaRe 18 in service under the car, dis. require no attention for preventing harmful DI-S4 When new discs are shipped for mounting, paint. Until normally the machined Discs from The Budd Company surfaces are mounted are protected against and put in service to the Rm'lroad or Car Builder rusting by a coating of aluminum in a truck, no further rust protection is requfi'ed. After storage, Discs are once or shipment, in serv/ee and wheels the disc braking surfaces preventive, such u • mixture wash away but which may be wiped removed If preferred, _J,_ting need the protective not be cleaned disc under a ear r_dy coating used may coated product, for service, he aluminum off when DiscJ are placed the braking HAND paint. in service, surfaces with a rust which will not the coating must In such eases, this but care must be t;tken of the Disc. BRAKES A right hand or left hand hand brake crank and These completely proprietary for handling, solvent. of the fins between ns requir_.d to actuate be from truekl off emily. with a suitable r,ot to coot the area should of paint and oil or iome Before placing wheels with coated Le carefully are removed hand brake truck lever is provided the brakes manually. cranks are coupled to the conventional hand brake chain through an equalizer ,,,chanisrn." AIR Wh,.ro "ON-OFF" used, this indicator INDICATOR is attached ASSEMBLY to the car body, four to a ear or one on each _ide for each truck. It indicates truck. It indicates mmlntenance "brakes personnel of elr pressure in the brake cylinders on that particular or absence applied" or "brakes WII.L NOT detect This indicator will not detect off a run will show disc should function show or indicate or indicate of the truck brake mechanism. a car comes released" to train crews, inspectors mad in mai_ing air testa. This indicator tionlng each presence whether any mechanical failure or possible m_dfune- A look at both faces ot the disc immediately if brakes are functioning a brlght clean hand brake is eat or released. surface, properly. Both braking free of rust or discoloration alter faces of when brakes properly. LUBRICATION (a) A good grade fication M-914, of AAR approved Brake Cylinder latest issue, il recommended Cup, rubbing surface of Piston Head Lubricant meeting AAR Speci- for the Brake Cylinder Wall, Paeklng and the Piston Rod. Section Page | 19 DI.S4 (b) A good cator (c) grade of light machine Swab and for the Piston Rod Lubricator For ull other metal-tu-melal LUBRICANT 8 Ibs. Dixon 2. I quart thinner This lubricant Crucible No. (made 1924 of 60% quick evaporating as required GR,I_HrYE of ingredlant_ Naphtha FO-128 made by Geo. #602 made Glocosol made made and 40% is not permitted, W. Hesslngto_ by Penetone Carbon by Globe Solvents Mix only the quantity immediately 4. Apply with a brush, allowing parts, (3 hours if possible). dry, they will have tendency or one of the following: Co. of Lindenwold, Co. of Tenafly, required and time N. J. N. J. Pa. keep in s closed for drying If parts are assembled to "freeze" m N. J. Co. Inc. of Philadelphia, sufficient WHEEL Tetntehlorlde). Railroad may substitute any by John B. Moore Corp. of Nutley, 3. is accoml)lished Paste. thinner like lacquer tHnner Formula Per-Trolene _;ven is mixed Graphite Where use of carbon tetrachloride (This Felt Ring. proportJons:_ 1. good for the Cyllndor Felt _- wearing surfaces a spedul QUICK DRYING should be used. in following oil is recommended before before container. 8ssemblht8 Graphite Pate is that attention is or stick together. CHANGES by using your normal methods making certain to the following:) B[-MOVAL PROCEDURE Before 1. When Support Cables proceeding with wheel removal are requlred-- a. Determine whether or not bra_e support cables are required. These are necessary if support cable lugs are on the truck frame over the journal boxes. Support cables loop must be attached on the bearing both sides between the lug on the truck frame and the arm of the brake frame. b. If provided, the safety hanger linkage must be disconnected bolt and nut that attaches it to the truck frame. 2. When Support Cables are not requlred-- rl. If prnvlded, the safety hanger linkage must be extended by removing by removing the the upper pin that retniJ,_, it _n safety pos;tic_nat t_e truck frame. 3. Continue with your normal Caution: While dropping the hose and This should Section I Page 20 wheel removal the wheels fittings procedure. case must be taken to avoid damage of the air supply be d;sconqected if necessary. llne to the brake to cylinder. UIJ_',4 INSTALLATION I. PROCEDURE B_ore (see installing lubrication ipu_de the 2, the When Bearing.. rubber page brake raising the wheels the Connect air supply 4. Remove brake 5. Reinstall the No axle assembly, to the wear apply a coat of graphite that luhrlcant plates un each journal box must be taken to avoid damag_ to the Rubber assembly is line support bolts care wheel bearings 3. Note: 19) and support and .t'rame. When becked wheel with journal to the brake cables if used. or pins sd._mhnents the of that brake were properly boxes cylinder removed rigging positioned, is easily of the accomplished. if it has been from en[agement Backed the removed. safety hanger lirJkage. _ecesa,_ry. $ecilo,. ! Page _.! Di44 IJltAK| IIILAKI UNING UNING |ACK IIIIAK| PLATE SHOe FACE OF IIILAKIE DISC USE OF THICKH[.S5 To Detemine Condemnlng GAUGE: "l'l_ckneu F'q[. ! of Brake I_n_,t8 Section ! Pme_ 99 DIRC KEY (NOTCH DOWN) \ FULCRUM COVEN I_GKET SPRING RETAINER TONG q FITTING BRAKI DRAKE SHOE BRAKE FULCRUM HEAD SUPPORT STOP PIN(FOR LOWER END OF DRAKE SHOE) ,,-r_ o SECTIONAL VIEW OF BRAKE FiE. 2 ASSEMBLY D|44 [_ RUI_I_n IbACKIO BEARING _:LUSH SIDE "C" BEAi_ING THIS CLAMP \,_ SIDE FACE HOLE FOB _" TO POSITION DIA. STEEL LOCATING PIN RUBBER BACKED BEARIN{_ RUBBER ARM \ BACKED USED BEARING TIGHTEN "C" CLAMP UNTIL CHANN|P. iS PROPERLY LOCATED. THE INStDE DOT. TOM SURFACE OF THE CHANNEL MUST BE HELD TIQHTI. Y AGAINST THE IN_]{_ SURFACE OF THE SIDE BEARING AN 1_" WELDING. METHOD OF CLAMPING RUBBER BACKED BEARING FOR WELDING TO SIDE BEARING ARM Fig. 3 Sect;on I Pqe 24 0144 T CIRCLE"A" ,.O FLAT MAT'L,:- J DRAW END L_ I/8" X 45' CHAMFER HAND RIVETING SET For Riveting Brake Shoe Studs Section ! ]PJqKe25 F_g. 4 TOO/. STEEL HARDENED 48-S2 ROCKWELL "C" . LUBRICATOR SWAB SPRING-PISTON RETURN BRONZE BUSHING Go,_,KET SPQ!NG PISTON P_KING BREATHER CUP PISTON HEAD HOLLOW BOOT PISTON ;CYLINDER COVER) BOOT GC!OE CLA._P ICYIL. COVER)' FELT RING PORT (PISTON BREATHER END) PO_T BUSHING / ,T1 uI t BUSHING// HAIR FILTER / _2 0 CYLINDER, HALF S_N /'HROUGH F'_. S AIR CYLINDER I =N 0 Z 411 a MODERNIZING CF BRAKE CYLINDER IHI-M / ,/ /,/ OLD f PISTON B BUSHINO ASSEMBJ,.Y . F(_R "/"AIR CY'LINDER-_S PART NO.Dee-OSTler) FOR TVI*,ArR CYLINOER-WAS Pt4RT NO.O86-OaT'40 LONGER FURNISHED.REPLACED • BYASSEMBLY ILLUSTRATED BELOW) NOTE, NEW TYPE LUBRICATOR SWAB MUST BE ORDERED. (NOT FURNISHED AS PART OF PISTON 8 BUSHING ASSEMBLY). FOR 7"AIR CYLINDER USE PART NO,D88-0637'7 FOR 71._'AIR CYLINDER USE PART [email protected]_)8:p70 BUSHING- E86- 04172 .FOR T°AIR CYLINDP.R USE PART NO•D86-O64(B FOR 7.t/e°AIR PISTON CyLiNOER AND USE, PART NO.DBS-OB42B BUSHING FiB. 7 ASSEMBLY Pa_'e 28 ....... FLO _ KEY SLOT IN SLOT IN 5)4 SHOE PIN A" r eo _'CONVEX FLAT SIDE SIDE MUST MUST 'BE FACE TONG UP ..- (:r, £N C BE ONLY ON Sine OF TONG AWAY FROM DtSC m_ BRIDGE _SSY I I BUSHING IN BRIDGE ASSY I WHEEL TOP THR _JS...S_T WASHER ON TONG FACE REF. GRIND OFF--_MIN. DEPTH TO PROVIDE WHEEL RIM ."!. m WHEN FULL IN THIS f,O TONG LATERAL FLAT CLEARANCE TAKES UP DIRECTION. ASSY THRUST BOTTOM REQUIRED ONLY. WASHER ON SIDE ADJACENT TO WHEEL OF TONG ill REQUIRED ONLY ON CARS FREE LATERAL JOURNAL FULCRUM HAVlN$ BOXES. BUSHING CLEARANCE OF THRUST GRINDING WASI'IE,R5 o ¢ o|.q4 B3 _/8 +Oj,-I/IG t I ! 49 114 -t-0,._46 BETWEEN DISC FITFACFS OF WHE_LS i_I._-_OlSC FACES • I I ROTATE ', '| ANGLES CENTER ;_! + 71A3ZM DISC, I/2"BOLT Z8" DfA. CIRCLF LOCKWASHER -rB6-06154 BOLT TIGHTEN BOLTS TO 180-200 FOOT LBS. TORQUE. _,AFEi"Y BOLTS IN PAIRS USING lIB"SOFT IRON WIRE AND METHOD PER SKETCH "A = BELOW. I MINIMUM FULL THD..L I I/Z" "T" IN WHEEL HUB tZBOLT HOLES EQUALLY SPACED IN WHEEt. 4_/B4"DIA.TAPDRILL FOR 3/4--tBNr i'HRFA,9 PITCH DIA..7094--.7126 NO. Z LIMIT lAP CHAMr'ER 1/16 X 45* SKETCH Section 1 P.ge 32 Fig. 12 TO AXLE WITHIN OR--.OI3" i ;--09370 WITH II "A'* TO AT RIGHT 00-641 _-*:_ ...,m, o,s¢,_ _. c* ,_.= r_ISC 986-09360 APPLIGATION C F-{_ISG B B6-O6'T¢_ TO 33" WHEEL Fie. n3 SECTION i PA_E 3 3; 2(l'DiSC : _ ZS" : _ 886-04636& APPRox. DIA. D1SC BS6-ODSTO APPROX. DIA. 26"DISC B86-05792 16V4"AT 2V2" FROM 8 26" DISC 886-09360 ISIS" AT 2t*_" FROM HUB HUD (OOTTED FACF (SOLID FACE OUTLINE) OUTLINE} THIS WIDTH RINi_ USUALLY ANO WILL HAVE "BUILO UP" PRODUCTS. o "_ r0 o_ TYPE "C" WEA SHOWS NO Wf.AR OF CORROSION O_J4 SECTION 2 PARTS CATALOG AND ILLUSTRATION SECTION CONTENTS Page mmtrutlon and Parts Truck with BUDD Identification IL Typical 1. Brake Auembly 2. Brake Frame AuembHes 3. Brake Frame Assembly 4. Brake Shoe. and Brake S. Brake Head A..emblles 6. Brake Cylinders 7. Brake Tong 8. Brake Pim 9'. Hand Brake Lever 10. Hand Brake Crank Assemblies 11. Hand Brake Crank Auemblies 12. Slide- 13. Bridge 14. Hanger Box Anembly (Welded-to-Truck IS. Hanger Box Auemb_y (Bolted-to-Truck 16. Air "On-Off,' Indicator (Diaphragm 17. Air "On-Off,' Indicator (Piston 18. Air Hose Auemblies (Single Rubber 19. Air Ho.e Auemblies (Single Armored 20. Air Hose Auemblie. (Two 21. INse A.semblies 22. Support 23. Guide Point 24. Brake Lining (Typical) BRAKE and Major (One Special Installation Parts Nomendatm'e (Conventional Style) Style) Linings (2 facing Assemblies Hand DISC pages) (2 facing page.) Auembly Brake Lever Assembly Style) Style) Style) Style) Rubber Hose) Hose) Hoses in Unit) Cable. AssemblylnE Fixture Section Page 2 ! Og.t4 TYPICAL TRUCK WITH Hand Non-Hand Sect;on Pa_e 2 II Brake Installation BUDD |_rake Similar DISC Truck Excepl BRAKE INSTALLATION Shown Less Ha.d Brake Parts OM4 7 8 2 9 \ IO I 13 14 15 I? 16 22 23 20 18 19 20.21 BRAKE ASSEMBLY (Typical) Item No. Item No. Part Name Part Name 14. Hand iS. Pin 16. Hind 17. Hanger 18. Air Key 19. Tong Assembly, 7. Retainer 20. Tong Pin 8. Spring 21. Stop 9. Pin 22. A_r Cylinder 23. Tong Assembly, 24. Bo|t (Bridge 25. Nut 26. Lockwasher I. Brake Frame 2. Brake _hoe 3. Brake Head hss'y. (Outside) 4. Brake Head Ass'y. (Inside, S. Brake Shoe 6. (Hand Assembly & & Lining Lining Brake 10. Bridge Assembly ii. Brake Head 12. Fulcrum 13. Pin Ass'y., Ass')'., Link) (Inside. L.H.) Cover (Hand Brake Lever) L.H. R.H.) R.H. Brake (Hand Lever Box Hose Bushing A_'y Crank) Brake Brake 3, Crank Au'y. Assembly Assembly L.H. Pin Assembly R.H. to Brake-Frame) Order MUST Give PART NUMBER and NAME of Part Wanted ) $ectlon Page 2 ! Oiht4 I PART 8PAKE FRAME AGSEMBLY [ GU_M_N_ GROUP NI?MG(P STOP ITEM GROUP NO.q 2 PIN 8USHINO |WEAR ITEM J PLATE I1EM [8G-O_G37 E06-05637 NUMBERS 4 _ EG6*OSG3T RUBBE_ 8EARfNO RACKED ITEM G WEAR PLAT( ITEM • EGG'O442G itEM 5 DeS-oGstO [86"O1923 OGG'OSOTG EGG-O411E FGG'OG53G 080"05074 EOG"O4tl( GROUP NO. 4 _G6"05657 FG6"OGI35 FRG'OG$70 EGG'_G2B 080"05076 OROUP MO.G _OG OGG$7 FEG-OGf56 FRG'OG$TO FGG-O(S3G OGG-oGorG ER6*04112 I GROUP NUMBER 6RAK[ FRAMES IN THE GROUP GROUP NO, I 986-055J8 BRA-OISGG$ GROUP NO. 2 986"05037 G86"05732 086"0679"r 88e-06150 806-06199 GROUP NO. 3 886"06240 886"09684 886*06430 686-09669 886"08868 GO6"OGTES 086"09269 GGG'IOSl9 ItG6"OgE?G ORe-OR440 006"00244 906"00809 BRe'Og350(b OIG-OBaE8 886-09:58';' IIGG-OGGGG IIR6*OgSGG GROUP 006-06205 806-06471 OOG'O8900 966-09380 OOO'O91G8 OGl-Oe;30 NO.4 GROU a NO.E 89e'OG387 886"0923) BRAKE Note: FRAME ASSEMBLIES The Following p*rtj Are Not Furnished As Pa.rt of the Brake Frame Assembly and Mat Re Ordered Repmrstely. Item No. PMrt No. 8. F.,86-O4923 9. 7]A40M 10. Order Section 2 P*l[e 2 Pert Name MUST 21J26M Give Bolt (Bridge to Brake FrmJme) Lockwa_her (Bridge Nut (Bridge to Brake PART NUMBER to _'lke Frame) FrMme) and NAME of Part Wanted E uIl-I_ B 2 BB6.06264 Item No. Part BRAKE FRAME No. Part ASSEMBLY Name 1. A86-04925 Side Arm, R.H. 2. A86-04926 Side Arm, L.H. 3. E86-05637 Buahing Pin) (Fulcrum (, 4. E86-04112 Wear S. E86-04931 Rubber 6. E86-04923 Bolt (Br;dge 7. 71A40M Lock Washer 8. 21J26M Note: Order MUST Give Not Nut Segment (Hanger to Brake (For (For Item 6.) -- Items 6, NUMBER and Illultrated PART Plate Box) Frame) Item 6.) 7, and NAME of 8. Part Wanted Section 2 Pale 3 P_ 5_ , 9 //,#. , / L.H.'Shown 8 7 5 6 2 _,.H. - Opposife BRAKE SHOE AND LINING |,1. Part OpposHe Numl_r| Name For 26" Brake Disc For 28" Brake Brake Shoe & Lining Au'y.. LH. _86-05770 D86.05117 Brake Shoe & Lininl¢ A.'y., R.H. D86-05771 086-05116 3. Brake Shoe & Stud A.'y., R.H. D86-05758 D86-05139 4. Brake Shoe & Stud As,').., L.H. D86-05759 D86-05140 S. Stud E86-05177 E86.06177 6.-"- Rubber 71 " w,r_NO, I. - Shown 4 L.H.- ASSEMBLIES Part Item 3 R.H.- . 2_.._: I)i.e F..86-05137 ' • 8. -'. B_ke Pad -- F86-00183 IO SOFT L;ning As,;yl IRON "_ _- L06-08990 (Standard) L86-08990 D86-05134 D86-05772 D86-08869 _" Order and cut from L 86-08990 Orde_ ";ection _'_.e 2 4 MUST (_ve X I0 FT, LONG. PART NUMBER and NAME of Part Wanted 08-_4 S 7 8 i0 9 BRAKE HEAD ASSEMBLIES Item Part Part Neun_e Brake Head Ass'y. (Out'de) Brake Head Ass'y. (Inside, No: I. D86-04912 2. D86-049 3. D86-04913 Brake 4. E86-06364 Arm -_ Guide Pin Au'y., R.H. 5. E86-06363 Arm & Pin Au'y., L.H. 6. E86-04898 Guide 7. F..86-01577 Bushing 8. E86-06516 Bmhing 9. F-.86-04578 Wear 10. F.,86-05114 Stop II. E86°09257 Order MUST !4 Give PART Head,Ass'y. Guide (Inside, Complete L.H.) Complete R.H.) Complete Pin Plate P;ARM _ BUSH. NUMBER and ASSY. NAME of Part Wanted .Section 2 Page $ t)m I0. FOR 7" 6. t2. FOR 6_** 7_" CYL CYL 17 lJ_ / _-__-2_. ' __i_" l Style See Page 2 5 4 Style "B" "A" 6s, 6 Section 2, For Ordering 13 Reference 12 10 |1 9 8 7 3 / 17 IS 14 t / ., ." ,....,,., Ig 21 22 I{_:_;_ /'_ 23 For Part Numbers Oraer Secti,'m 2 I'age 6 MUST Give 23 22 24 20 See Opposite Page AIR CYLINDERS AND PARTS PART NUMBER and NAME of Part Wanted AIR Item No. 6½" Part 7" Cylinder Cylinder CYLINDER A$SEMBUES Past Nmnben, '7%" Cylinder Nms_ 8" cTrmder !. D88-05080 D86-050S0 DB6.0B047 D86.¢884,1 Ai. 2. F.86-05122 F,86-06161 F.,86-06163 E86-08843 Cylinder Ammmbly 3. E86-04172 E86-04172 E88-041'72 F.86.0,1172 Bushing (Piston 4. 7AI243M 7AI243M 'TAI243M 7AI243M Bolt 5. 70A24M 70A24M 70A24M 70A24M WMber 6. cyrmder As_mbb, (Cover 21F13M 21FI2M 21FI2M 21FI2M Nut 086-05738 D86-06419 D86-06428 D86.08842 Piston 8. D86.05733 D86.06377 D86-08376 D86-08841 Piston Head 9. 60AI620 60A1620 60A1620 6CA!620 Rivet (Pbton (Cover ES6-00673 1:86-01888 ........ Lubrleator aii F,86-05133-E4 ES6-05133-ES ........ Felt Swab to Swab F,86-06375 F-.86-06378 F.,86-08839 Felt E86-05156 E86-05158 E86-04188 F.,86-05095 Psckln8 14. F.,86-05162 E86-05162 EM-OSI62 E86.05162 Cover IS. F.86-04181 F,86.04181 E.86-04181 F..86-04181 Bulh_ 16. E86-05157 E86-05157 E86-05157 F.86-0S157 Gasket 17. E86-06339 F,86.06339 F..86-06339 F,.86-06339 Sprh_ (;";'de i 8. _86-05088 F..86.05088 F._6-0B088 F_.86-05088 Piston Return 19. E86-04182 E86.04 E86-04 E86.04 Felt 20. D86-04186 D86-04186 D86-04186 D86-04186 Boot 21. F86-05699 F86-05699 F86-05699 F86-05699 Clamp 22. 20A04M 20A04M 20A04M 20A04M Nut 23. 31N9432M 31N9432M 31N9432M 31N9432M Screw 24. E86-08777 ESG-0&7"17 E86.08777 E86-08777 Clamp _Note: Illustration "B" Style Piston Assembly Piston Assembly, Item No. 7, parts must Air Cylinder Swab Item No. Air Cylinder shown in_tyla Piston be Felt "A" Assembly a replacement following an improved for Style by the improved When shows Assembly ! 82 Assembly 12 and Assembly, Spring is no Cup (Cover) (Cover Rin 8 to Lubricator (Boot--Cover ( Clsmpi----Boot incorporates Guide Item No. |umlslied 17. and is required for Style "A" Air Cylinder Piston Assembly Item No. 7 only. Assembly- Piston Assembly Item No. 7 and Felt Swab Item No. 12. For 7t/e '' Air Cylinder Piston Assembly Item No. 7 and Felt Item No. 12. Lubricator are Assembly available Head Swab as Item th_ ordered: Assembly- Piston replacc_ A_semblie_,, Air Cylinder m.,t _ "B". Air Cylinder parts End) an improved 7" following ) (Boot_Pi,ton 6:/_" replacement End) (Cinmpe---Boot) For a Cylinder) Sprinir For When Tube) Assembly which longer to AmMunnbly Swab F,S6-0SI51 ! 82 Cylinder) Head 13. ! 82 to Cylinder) Auembly "_10 ......... "i2. Cylinder) to Cylinder) (Cover '_ 7. ......... & -Piston be Head is required for Style "A" Swab 7" and 7½" Air Cylindc_m the ordered: Item No. replacement No. 10 g and and Felt Felt Swab Swab Item No. Nn, 11, for 12. Style "A" Air Cylinder Aasm'nblics, parts. Pa::_ '_.:: / 4 TONG Note: For Tongs ASSEMBLIES with Special Frame Clearance See Page 7a Item No. Order Section _;e 2 7 MUST Part Part No. Name !. D86-05689 Tong Asse_bly--LH 2. D86-05688 Tong A.embly_R.H. 3. F86-05690 Thrust 4. E86-04171 Bushing--Tong Upper 5. E86-04172 Bush;ng_Tong Lower 6. E86-0490! Key 7. 1:86-04899 Retainer 8. F86-04586 Spring 9. E86-05087 Shoe Pin 10. 1:86-04163 Fu|crum | I. E86-05636 Thrust 12. E86.041|2 Wear Give PART NUMBER Washer Pin Washer Pi'te and NAME of Part Wonted I. RIGHT BAND 2. SHOWN LI:I::THAND OPPOSITE I I I I i \ Note: Surface Clearance TONG for Special Frame Only. ASSEMBLIES Item No. Part No.' Pert Name !. B86-0634S Tong Assembly--R.H. 2. B86-06346 Tong A.embly--L.H. All parts, except compiete Assemblies, Items are the same as shown on Page 7, Section 2. Order MUST Give PART NUMBER and NAME 1 and of Part 2, Wanted Seetlo._ 2 Pese 7-" DI-M =. e, i m .-i , I I I d '_I 21 o_ J _ i: /r*'II NOTE:-ITEM_ _ TO6 INCLUSIVE ARE USED WITH 3 TO 6 BRAKE I ITEMS 1,7lt8 ITEM II PINS TrM N 0 • PART _F 'j P 2 IL It'_l . "3. F86-O9 _50 E86-O4 _96 E86-O4173 F86-O5691 t'_e EE6 .o_(_4 Order MUST Give NAME BR_KE COVER SPRING (TONG CRANK) PiN) FLAT WASHER, 3/_ SLOTTED HEx'NuT, ANGLE IHAND P,N IToNG) PIN (HAND PIN PART 3/_-IO WIRE PIN 9= A;'.O_'iM 11. (HANO SPRING COTTER I ,"J. Section 2 P_ 8 . PIN Ety_-050 _ E86-O5060 7OA3_M J PART No. E8_-O_ I. BRAKE LEVER) BRAKE CRANK BRA':E LEVER) & LEVER) PiN (HAND NUMBER and NAME of Part Wanted DIM 2. HAND BRAKE LEVER ASSEMBLY Item No. Order Part No. Pail 1. E86-05023 Hand 2. 1:'86-01746 Bulhing MUST Give PART Brmke NUMBER Name Lever and Bushing and NAME Assembly of Port Wanted Section 2 Page 9 Di-t4 I.D.,"C" UBal__ _.SECTION i \ "A" / "Y-Y" I=RIGHT 2 LEFT 5 HAND HAND I.D.="D" .TL." "q" _ "y" SECTION'X-X" .RIGHT HAND SHOWN ,LEFT HAND OPPOSITE HAND BRAKE (;:RANK ASSEMBLIES PART NUMBERS DIMENSIONS AS|T .-:m_. :o _. ..... 4 .... . ,-,°?,.. ? • -RH ITEM I s" o I _,."....... '_,.-" 71e" T/," t._:_L';t _" /-"-"._-_:.i ;'." ...... -"*" "-'.:...... _'-'.'.... | I°_1-L "_ -L '/" ITEM L.H. 2 BUSHING ITEM BUSHING 3 ITEM [e_-o_o4o EO6-Ol?*U [O*-O*_OT iu-017,i* EU 03TOe -'EN-OIT*O E66-0504S [M-00_ll [ _'_-E]___ AS$¥.* _ "0 8UIk_N° 4 [D6"O41TE ITEM Eedi-041_ Section 2 P_le ]0 MUST Give PART [84 [I4"¢HSTT EN-0411_ Ell-041|| EB8"0411_ [I_-04IS| [ll'OlSTT lii1-0411_ 1[141-0_? I[111-01171 i[I)4 E BG-04171 £M-O4192 NUMBER and NAME of iTEM [M-O_STT [14-O_lll *04II| E8G-O4rgE I Order BUSHING 6 _:o_ti-- £_6-0979T IT2 ITEM (N-OSOII EO4-O419Z (o*-o*_fi (86-041Ti c**-o**oo _ • 02-c-,___ [-86"_4 llUS_N_ § Part Wanted Eil_* T O_STT 06011 ( TRIO] T ,, .;,.M $ECTION'X-X_" RIOHT LEFT HAND r_'r BRAKE CRANK ',_'ONS HANO SHOWN HAN_ QPpOSITE ASSEMBLIES PART NUMSLrRS IlUSk_a *A* . J *01 _ "C* mlS_.._qOE _ 0!_ i _NgrO[ --_ OIA , J ASSY-R H_ J! ASSY-L,_ IT[U _ I?[U 2 OOl-O'_e,4 OU-OMeS eUSH_Q II(U 3 [i_-0.46 BLqHINe IT[N 4 [e4"O4iY2 I_$HiNG _7[M S [el-O41t2 _g IT[M • [Im-O41St I?[ll ? IlDO'O_?I' ............ I --! _ t i.................. 2----_£.... ] ....................... I--- Order MUST Give PART NUMBER and NAME of Part Wanted Section 3 PCge 11 :,__t_'_;._ •, , _%'__-_ I BRAKE LEVER I SLIDE--HAND hem No. To be welded Assembly D86-05864 Order Section 2 Page 12 MUST No. F86-05872 !. Note: Per! Give PART P_r_ Brake Sllde---Hand |o Hand Brake ESG-OSO23,'when and D86-05865 NUMBER and Name Lever Lever and Bushing Hand Brake are used. NAME of Crankl Part Wanted DIkM 1 il¸_, 2 , q _1_ __:" p ! / 3 6 BRIDGE ASSEMBLY Item N_. Order MUST [_prt No. Part I. E86-05791 Bridge 2. E86-05635 Bushing 3. i:.86-0S079 Fulcrum 4. E86-0"9_ 5. 1"_6-02190 Cap 6. 71A24M Lockwasher Gi_r: PART ! Name Assembly Cover G_shet NUMBER Screw and NAME of Port Wonted Section 2 Page 13 0|._4 ] 2 4 5 HANGER 3 BOX ASSEMBLY Item _art Order Sect;on 2 PaRe 14 MUST No. Part Name I. D86-0560l Hanger Box Cap 2. D86-04469 Rubber Segment 3. E86.05603 Bolt 4. 2ILI&M Nut 5. 71A32M Lockwa=her Give PART NUMBER and NAME of Part Wan_ed HANGER BOX ASSEMBLY hem No. 1. 2. 3. 4. 5. 6. 7. 8. 9, Order MUST Give Part No. B86-04471 B86-05083 D86-05085 D86-04469 E86-01883 71A34M F56-01918 71A32M 21LI8M PART Part Name Hanger Bcx Assembly Hanger Box Hanger Box Cap Rubber Segment Bolt Lock _asbe_ Bolt Lockwasher Nut NUMBER and NAME of Part Wanted Section 2 Page 15 DI44 I_ d-._'r_'I/,'i_:,. '"_ iP--*'_'_'..J '". _ '.;,:.';_=.._,_ _.:,_-_,,_. _,......._.1_7..:_ _ .. INDICATOR APPLIEI 9 PARTS AIR "ON-OFF" FOR TO 10 INDICATOR INDICATOR Item ASSEMBLY Item .N_o._ _Part._mo.:. Part 1, D86-00195 Air 2. X86-06187 Pressure 3. X86.0618S Diaphragm 4. X86-06186 Non.Pre.ure S. X86-06181 Push 6. X86-06184 t Release 7. _L86-061L:3 Push _'_ 8. X86-06182 Boot Order Section Page 2 16 Name "On-Off" Indicator No. Ass'}.. Plate Head Rod MUST Spring Guld,_ Give PART NUMBER 9. Part Part No. 21AI3M Indicator IO. F86-00167 Indicator II. 7A0420M 12. Name Stop Nut Press_e Plate Bolt 71BI6M Pressure Plate Wuher 13. 21A04M Preuure Plate Nut 14. X86-0£188 Stud 15. 7|A22M Lockwasher 16. 21AIIM Nut and NAME of Port Bolt Wanted M INDICATOR ASSEMBLY 7 PARTS AIR Item No. Order FOR "ON-OFF" Pert 8 INDICATOR INDICATOR No. Part h E86-01707 Air 2. E86-01693 End Plug 3. F..86-02009 Felt Swab 4. E86-01695 Spring 5. F.86-0!708 Piston 6. E86-02008 Felt 7. F.86o01709 Packing 8. E86-01692 Cylinder MUST Give PART "On-Off" Swab ASSEMBLY Name Indicator Ass'y. (Plug) (Piston) Cup NUMBER and NAME of Part Wanted Section 2 Page _7 Dl.fl 4 2 3 6 \\ .______ / .4 t'f 1 7 ? GASKETS WIREDTO FITTING / PU THIS CLAMP ORIGINALLYUSED ON HOSE_ D86" 05;36.FOR REPLACEMENTSIUSE BANDITEM 6 AND BUCKLEITEM 7. AIR HOSE ASSEMBLIES (Single Rubber PART ITi[IJ I_&tIP I?[tl _ _ HOSE _TEM$ n Am FITT_NG I IT_,d4 CYLINDER Hose) NUMBERS , &1¢_ #gTTSNQ ITI[M IS llAND IT[M| ILt_Lt tTrll ' pOa-00_Oo 10e*.O0!'_;] _o_,_, oo*-oo,,z "(_'r*'0?.*O t''0_4'_3 _,AIIKE? rTl[il Q ? Iqll_ Pt.U_ CtA *A" ZOO-O,T0m-OO*_ ........ CAP SCREWS,BOI.TS,NUTS (I I.OCKV_SHERS • .*.o. ,c.,*c_,,o* I I c-,.c*.n,o* T I_g|'_'.go _ITTWOITitU4 ! I _,TT_OiT[_*_ I Order Section 2 Ps_e _8 ' MUST F'I_.O_|[ Give I [06"01 PART p" |ill NUMBER AIR : ¢I.M_IT[iI| ,_..-o_L.__._:os.'___. L m-oz_.o _ q_-O@ $4 FOR ._.,o* MO$[ AS_IEId_ ._?.,o* t_n.,a_,_ ¢L_UPITEtIII _¢_ITI[MS|,@r.B oz,_o .,_,z. _... O_llO _IJII[M ?tAIEGM and NAME of Part Wanted ,,," 5 M / AIR HOSE ASSEMBLIES--CYLINDER (Sbq[le ._ored HoN) _ll _31[ A$i'Y. Illhl I CAP Am MOlE A|ry.NO, ole*m .... Order SCR(WS,EOLTS Cad* |CJl_ _ pi TTId(q ITI[U 4 i,i4-0e41e ,NUTS (I LOCKIiI_SH(R$ _ CAp |Claim FOlt P_TTRQ _TgM • ¢La41P fTl_ IJle-oz _IK) [IW_tlllO AIR HOSE A$S[MgL_3 | ;NTI FOA O.JLMB ;TI[M | |_UlM k.OOZrlUIZ4[U Irge rams z,4 4_S lflAI4M t ....... MUST Give PART NUMBER and NAME of Part Wanted Set, on _.. 6 2 7 6 5 5 6 .+ i. J QASKETS WIRED TO FITTIN G FOR SHIPPING. 7 6 AIR HOSE (Two 6 7 ASSEMBLIES-- CYLINDER HoJes in • Unit) Rubber PART NUMBERS AIR NOSE ASS'T. ,TEMI i AIR FITTING i AIR FITTING i 1 ITEM2 ITEMS ' DeS-OG597 -°-s.e-°J-eL° • -L°ss'Y°lT" •_._-o.*a_oL.j osq._0o_TI " .i o.-oeu.7 ......... GASKET NOSE BAND BUCKLE ITEM4 EB6-O09SS ITEMS (BG-Oe,g7 ITEM6 BOO-OlTl IT(MT SO0-OlTO !ll'00135 Eli-O4|51S |O0"OITl EOO.OI'/'O i .......... I 6. ........... ,.4 ........... ! LOCKWASI4ERS FOR AIR HOSE ASSEMBLIES CAP SCREWS,BOLTS,NUTS AIR HOSE ASS'Y, NO. CAP SCREWS FITTING ITEM FOR BOLTS 2 FITTING FOR ITEM D86"08829 ESG-021SO T*IZSSM J011704511 lll'O|ltO FA 12:jlIM LOCK 3 NUTS FITTING .... FOR LOCKWASNI[RB ITEMS FITTINGIT(M 2 ZW!__....... _7_._t_.+ ....... ElF IIM TIAI4M I Order S_.',¢tlon2 ' Pale 20 MUST Give PART NUMB_-R and NAME of Port Wonted Dll-Sl SUPPORT Part No. CABLES Dimeneion "A" E86-00 ] 78 21" 1:86-05611 19" E86-05731 24" £86-OS79S 17 %" E86.08798 23 l/a" Support Cable ere reed only when maki_ r wheel chanB,*0 ,rod rzlust be removed _tur wheels Order Section 2 Paa'e 22 MUST Give are in assembled PART NUMBER position in truck. and NAME of Part Wonted 1 GUIDE For Inserting Ton8 POINT Pins st Brake Cylinders Item No. I. Order MUST Give Part No. E86-0_413 PART NUMBER Part Name Guide Point and NAME of Port Wonted Sed_i_ _ Pqe 23 01-14 !! 4 S 6 BRAKE LINING 7 ASSEMBLY FIXTURE Item No__.__.Par......._t No.___. Order Secl_on 9 Page 2'; MUST Part Name |. T86-06224 I_n|ng .'_lsemb]y Fixture 2. 3. F86-05627 F.86-05625 Coil Spring Collar 4. B86-05623 Carriage 6. F86-05629 Key 6. F86-05624 Handle 7. B86-05621 Base 8. 9. F..86-00194 B86-06225 Spindle Frame 10. F.86-05628 Handwheel 1 !. F86-05630 Washer Give PAR'I NUMBER ond NAME of Port Wanted THE BUDD COMPANY CUSTOMER SERVICE PHILADELPHIA 15, DEPARTMENT PENNSYLVANIA NUMBER ]1 DATE : 12715h DISC BRAKE & ROLOKRON SERVICE BULLETIN MODEL CF DISC BRAKE D86.O_912, D86-0_913 SUBJECT: This Bulletin is %o advise method of salvaging arm forgings damaged or showing abnormal wear. w_th Company ,_elow: R-;,Jaeement arm assemblies may to the following part numbers E86-O6363 E86-O636_ E86-09257 PROCEDURE (Refer to Sketch (a) smooth Careful]¥ remove to provide.good (b) We]d A "t_D . Brake Heads and D86.0_91_ _,old_n£ '. Or new fixtur_ arm DBB be purchased and applied Arm & Guide Arm Arm & Guide Pin Assy. (with No. Pin assembly be to brake used Heads from The Budd per procedure Assy. R.H. Inside Assy. L.H. Inside bushings) Outside ii I arm forging from brake surface for welding. should Brake when head as welding head shown and on grind Sketch to maintain head DBB proper D_r_,s, Use mild steel welding rod (AWS E-6015) Customer ENCLOSURE: Sketch DBB No. ii Service Department No. align. ii. .d"-- _o I.H D86°04914 OPPOEIT If [, ff BRAKE HEAD ASSEMBLY-INSIDE _OTE USE MILD ROD (AW$ STEEL WELDING Ir-15015) / / / I" MIN. C Lit ARAN C Jr --,._ AFTER WELDINO / V / i / I i I I .! RAKE I BRAKE 12-27-54 HEAD HEAD ARgY. DRR-O411Z ASSEMBLY-OUTSIDE RKETCH DBR He, iI THE BUDD COMPANY CUSTOMER NUMBER SERVICE PHILADElpHIA 15, DEPARTMENT PENNSYLVANIA DATE DISC BRAKE & ROLOKRON SERVICE BULLETIN SUBJECT: Model CF DI.3c Brake Stainless PraY,e Frame Steel - Application Liner After many years became evident in in prevent thls Brake of Frame service, irregular some instances. wear lq not from abra_lon alone _a]llng_ of %he rubber segment,, To to wear but on starts the Tube wear" on ][anger Tube Inventlgatlon pl'_ves as Hanger Hanger earlier Tube corrosi.,n (Part of the that this Inltlated No.. E86..04924), by eliminate n_ed for replacing worn tubes, and to increase life of _ubber S_gment D86-Ohh69, all future Model CF Brake Frame Assemblies will incorporate replaceable stainless _+eel Liner_ E86.-09538 on the Hanger Tube This is illustrated on attached _ket_h DB.15 S_,,era] .ervice for lln_rs _how 8a]].Ing but ca_ set_ of brake frame_ havlr_, Pubber Se6ment _ D86..0h469 supplied "]_met_r (pr_vlou$1y wa_ h..3/8" I.D.). The ).n;fer av_lisb]_ h_v_ the the_e liner_ arc approximately two year._, @_ perlodic Inspcetlon_ no wear or corrosion and only few small Indicat_ons no ad-h¢.r_nce of rubber to the llners., We recon_nend that all _tainless steel Liner_ from now on smaller I.D. in regular the}c hanger of rubber tube _cgment are h..5/8" inside rubber segments are Mode] CF Dlsc Brake Frames, now E86.09538 applled to the Hanger no in service, Tube per _t%aened r=qulro= C'_mp_ny sketch DB.15. This to be don_ at truck overhaul or when rubber segment replacement. Llner% are obtainable by purchase order placed on The Budd specifying "E86.,095_8 Hanger Tube Liner." W_en makinc liner application, pre_en_ hanger wlr wheel.. !ube, and any th_ tub _ ]t In tube emergency ":-'_,ent= D86..0ah69 "ut off one end of wlde at ?9 ]/2" _t_" _n_ide dla,.) long be_we-n Sketch shou/d be Coarse Eralned _rindlng _hou/d is not necessary DB..15 only, carefully cleaned of a]l dirt and corrosion, grinding wndel _nould not be used %0 clean be done longitudlna].]y (nc_clreumferential]y) to r_place pre_cnt worn banger tub_s it" nece=_ry to apply n_w a,.5/8" 1 D_ to an old frame witaout -_talnle.3.-,liners on rubber segment t'ab---o_t--_,.]./,'" wide at. outside Then add a rubber beltln 8 sh_m 1/4" O.D of rubber segment and the }lan_er Rubber its hanger dla.. and thick x 3.1/2" Box Castlngs_ C,2_I.ome_ Se,*vice using hanger with tube. i..I/_" wlde Department x NOTES I. _ LONGITUDINAL _ TO CONTOUR OF sT. ST1,,.. UNER-BOTH SIDES. SURFACE MUST BE FLUSH AND SMOOTH TO PREVENT I_IA_ TO RUBBER SEGMENTS. _ _ GRIND FRONT AND REAR CONTINUOUS _'_.L__ .................. WE].,D-_ _ v_--_ -- [_ _ s- NOTE, _'''__"_?:,,, ................. ._, r_"_,.,._ , Tu_ L.J ............... .ANGER ARM -.. _.____:::.=._._ • '_._ ._ _ _] - L".,_Z. _-, : i ; __',_-_._ NOTE I 2. USE FOR CAUTION USE ONLY RUBBI_ _GMENTS (DB6-04469) WITH 4_'I.D. ON BRAKE FRAMES w1"rN ST. b'_'L. LINERS IN STALL_rD. SECTION 2_ a 'C-C' -" -_ oF.AN_RTUBE _--'_r"J SECTION APPLICATION DISC THE BUOO COMPANY "_TOMER SERVICE DEPT. LADELPHIA I_ PENNA. RO0 FRAME -,_C a L_'_"_A S'_ _. SEE u_s E_o_ 2 REQUIRED PER BRAKE 18-8 STAINLESS ALL WELD(I/G. OF STAINLESS BRAKE FRAME STEEL HANGER 'A-A' LINER,S TUB, E SKETCH O IS It. @YI,IIOY K.31i I'XI J@'J THE BUDD COMPANY CUSTOMER 8ERVICE DEPARTMENT PHILADELPHIA 18. PENNSYLVANIA NUMBER 16 DATE lqlb. lO, l_ I DISC B KE SUBJECT: & ROLOKRON SERVICE BULLETIN Passenser Disc Brakes - Cnaase in al_lieation.of Wear Plate F_6-04578 to Brake Beads. The appllcatlon of Wear Plate F_6-0_578 to Brake Heads used in Budd Disc Brakes on passenger cars has been revised to provide a better and more secure attachment. For your ready reference, both the old and revised methods of attachment are illustrated on attached Sketch DB-16. In the older method, attachment was by means of a weld bead at each vertical edge of the wear plate. In the revised method, the welds are along the top and bottom curved edges of the wear plate We recommend that when brake heads are reqnoved from the brake assembly at truck or brake overhaul time, the brake head be wire brushed and cleaned in the wear plate region and the welds carefully examined. If old weld or the wear plate edge along the weld is cracked or broken, reweld existing wear liner to brake head by new welds at top and bottom of liner as shown for new style on Sketch DB-16. Any heads found on routine inspections defective weld should be removed immediately for with missing F_6-0_578 wear plates are continued desirable conditions result and cause unnecessary (a) (h) (c) Uneven wear and shorter Uneven and excessive in brake head. life with missing wear plate or rework. Where brake heads in service following unincreased maintenance costs of brake shoe lining. wear on Shoe Pin, also Bushing Brake Head wears rapidly and excessively in bearing area for the E86-0_578. This may soon make head unsuitable for proper application of wear liner and require scrapping the brake head. Existing parts in service or stock are not obsoleted Customer Art : Sketch E86-06516 DB-16 by this Service change. Department :- _A SECT. A-A Ol_O_ WEAR PLATE ATTACHMENT .../T , . -1"1L CLAMP WEAR POSITION AND ALONG Z.K[FP TOP PLATI[ ClENTER ¢LAMpFO ANO FIRMLY TIQtCr BOTTOM _I_T IN #,GAJJ4ST PAOP[R BRAKI_ SECT. A-A LINE. UNTtL WELOS _A BO'I_ ARE COtq_ETED. 3. USE STJUNLESS STEEL ROO 8 ARC WIELD I't_CESS,¢OO NOT e_S Wl_Lm. 4. GRIND oft EXCESS OF WELD O(POS_T FLUSH wrm _ re.ATE SO WILD 00)osrr DOES NOT PI_TR_I( ASO_E _ PLATE WEAR SURFACE. .m-octopi! ' ' SECT. B'B -t-" NEW STYLE WEAR PLATEATT_ WEAR plATE APR.£ATION BJI)O PAS_ E86-04578 TO BRAKE HEADS DISC BRAKES THE BUDD COMPANY CUSTOMER SERVICE PHILADELPHIA NUMBER 17 DATE 3/ /59 DEPARTMENT 15, PENNSYLVANIA DISC BPJ KE & ROLOKRON SERVICE BULLETIN _UBJECT: end MODELCF USE OF S8" T_ DISCS DISC This is to CATYTTON _odel TFM brakes. - B86-04636.and It has come to our attention sod R86-O9370 are betn_ applied to both CF and TFM disc brakes. with PRAKES B86-09570 recently wheels end a_alnst the tbet used prsctlce brake discs B86-04636 indiscriminately with of using brake disc B86-O4636 Disc B86-04636 was developed for end provides satisfactory service wlth Model CF brakes. The _del Tl_ brake however, whlcb wee developed for greeter economy end lower maintenance cost and which is rigidly mounted to the truck frame, requires _reeter clearance between the cold rolled steel back plate of esse'*_;]y then the that disc end provided the by steel back plate PR6-O4636 disc. of the brake shoe and lining With the CF brake, the brake shoe end lining assemblies mOVe vertically with the vertlcal movere_t of the axle in the pedestal le_s tr,r'_ er.}me. Tbls is nnt true nf the T_ brakes. whe_] w_ th_ _rake mo,mtlng dlse srd j:rnvlded by disc n_e_bly Use of Ra6-O93VO the same ws_ disc deliberately brekln_ face cb_n_In,, the shape nf the _s shm_r on the attached disc PP6-O46:_6 with desIP_ed to locations. will _ecsuse type brake, ment. dlsc it Is Interchsn_eable RP6-O9:_VO DO _!OT IISE B86-04636 A_.: is and c.rrer_tly DISCS WITH sstlsfsctory the only bsckln_ Inevitably dsme_e to the beck plate of the disc wltb the possibility fell',r_. The stresses imposed on other brake parts sss lrterfererce can cause failure of these parts. _,{ODEL TI_I DISC result plate in use with supplied either for replace- BRAKES. F_D-II03 Customer of of complete result of this for £8 _ disc the provide the same Additlensl clearance .old rolled steel print F_D-IIO3. TF_bre_es of Service Department -r m C ..r Fou)r_ APPROX.DIA. 16 I/4_ AT 21/2"FROM HUB FACE '_ _-_<_ "o oz m-< o ill "10 28"DISC BSG-O9370(SOLID APPROX,DIA.15 I/|;AT OUTLINE) 2 I/2" FROM HUB FACE- -J I |1 tl v lU)izlr11 o6)(-) 9 ._IZ ; 1-4 0, Zl-r _FIm oo10 mml'r ®oi o_ I? _lu) 91o1(1 I RL I? J I I*007 M qX@ 'qi THE BUDD COMPANY CUSTOMER SERVICE PHILADELPHIA 15, PENNSYLVANIA DISC BRAKE & ROLOKRON SUBJECT: Locking For This bulletin attaching cap greatly Plates F86-I0855 Safetylng 20 DATE 9/13/60 Brake and Disc SERVICE BULLETIN F86-I0859 Attaching Bolts is to advise of the change in method of safetylng the Brake screws. This revision will result in a better installation reduced labor Primarily, the cap straps) which - and screw (a) (b) eliminate eliminate (c) cap screws eliminate need (d) NUMBER DEPARTMENT safety need need eliminate the is a difficult material cost wiring for for 12 lock drilled for about in wheel shops. is replaced by washers 71A32M per wire holes in head 10 feet labor required and long time of 1/8" to apply consuming soft locking plates disc of the iron the safety operation Disc at (bolt lock F86-06154 wire wiring. due to per disc This poor accessibility. Disc application sketch ESD-1243. and should be F86-IO859 F86-10855 using the new locking plates is illustrated Locking plates are now available from The ordered by part Bolt Bolt Locking Locking numbers Plate. Plate. The revised F86-06154 cap screws nomber. The only change will be holes in the hex become effective is exhausted and shall be made. Effective or using Bu_ahrake ACt: Sketch as Used Used will the on attached Budd Company stock follows:on on 28" 26" not change omission of Discs Discs B86-O9370 B86-09360 & B86-0_636 &B86-O5792 in ordering reference the two 3/16" dia. or drilled part head formerly required for the safety wire - this change to when our present stock of F86-061_ drilled head cap screws at that time an appreciable reduction in our selling price with use of Locking 71A32M Lock Washers discs. ESD-1243 Plates, wheel and the 212-00_ shops should discontinue ord_rln_ soft iron wire in mounting IlL f ! Q yl°O_T qH( 7XQI THE BUDD CUSTOMER COMPANY SERVICE PHILADELPHIA 15. PENNSYLVANIA DISC BRAKE & ROLOKRON Brake Disc Reco_ended SUBJECT: This NUMBER 20-A DATE "(/10/63 DEPARTMENT bulletin Mounting Torqul_ No. 20-A Bolts Values is issued SERVICE BULLETIN - as a supplement to Disc Brake Bulletin No. _ _-ted9/13/60. Bulletin No. 20 advised means wiring of locking method. plates Sketch ESD-1243 attached of change instead to in of safetylng the Bulletin (cap screws) be tightened to 180-200 had been changed to 130-150 ft.-ib_, former No. 20 brake lock disc washer specified attaching and bolts by safety F86-06154 ft.-ibs, torque. This torque value when used with clean smooth surface locking plates. If the lock plate surface is rusted, oll should be applied in area under belt head. a light coat of Some Railroads prefer to continue older standard, using lockwasher 71A2_M instead of locking plate and safety wiring the cap screws in pairs. For this type application cap screw has head drilled for wire insertion. Cap screw part n,-.ber is now F86-I1257. Cap screw torque tightening values application. Att: S_etch of 180-200 E_D-'_21_3, Rev. ft.-ibs, 7/10/63 are recomaended for this type "" f ! JT_ rATGIGI THE BUDD CUSTOMER COMPANY SERVICE PHILADELPHIA 15, PENNSYLVANIA DISC BRAKE & ROLOKRON SUBJECT: Brake Disc Recomended This bulletin and No. 20-A. Because of NUMBER 20-B DATE n/ll/_ DEPARTMENT Is Mounting Bolts SAE Grade 5 Bolts issued change to & Torquing supplement in material of SERVICE BULLETIN _isc Disc Values Brake mounting Bulletins bolts No. to SAE 20 Grade 5, change in torque value to 200 ft. lhs. is r_co_ended. This torque value applies when used wlth clean, smooth surface locking plates. If the lock plate surface is rusted, a light coat of oll should be applied on area under bolt Grade 5 bolts F86-0615_, drilled for safety wire, June, 196_. head. used have wlth been lockln_ plates, and F86-I1257, furnished on all orders following Grade 5 bolts may be identified by a ,ye on the head; see illustration attached. Only grade 5 bolts should be used the on when 3 raised lines sketch ESD-12_3 mounting ust_mer Att: Sketch ESD-1243, Rev. ll/ll/6_ new in the form Rev. B_ discs. Ser_ee Department oi' m BEND UP LOCK PLATE END SNUG AGAINST ONE FLAT OF EACH BOLT HEAD AFTER BOLTS ARE FULLY TIGHTENED TO SPECIFIE D 200 FToLB. TORQUE © A IDENTIFICATION SYMBOL OF SAE GRADE 5 BOLT CIRCLE LOCKING PLATE F86-10855 FOR 9'6 = DISC IF86-10859 FOR 28 "X" I DISC A VIEW 164 DIA. TAP DRILL, 344-16 N.F. THREAD L,M,T TAP BOLT F86-06154 HOLES EQUALLY SPACED IN WHEEL APPLICAT;ON OF LOCKING PLATES DISC • ENLARGED ' _-_-h/2"MINoFULL VIEW_CIRCL THREAD A-A MOUNTING BOLTS IN WHEEL ESD-1243 E'X" ,,. q=;% s Jo-19-_ NRUBANT 9-9-60 J i lit, THE il? ,.OOT BUDD CUSTOMER COMPANY SERVICE PHILADELPHIA 15. PENNSYLVANIA DISC BRAKE & ROLOKRON SUBJECT: NUMBER 21 DATE Aug. DEPARTMENT Metal Toe Brake BDC Disc Brakes Shoe with 8, 1960 SERVICE BULLETIN Linlng I_6-0_00 26" Diameter Disc This bulletin is to advise of change in design of Metal Toe Brake Shoe Lining D86-08800 for use with 26" diameter discs on RDCs The orlglnal ])86-08800 linings were developed to meet strlngent braking requirements encountered by some railroads during seasonal adverse weather conditions. Attached proven n_ber Sketch DB-21 illustrates the primary chan_es. The major advantages resulting from the new design which were in dynamometer runs and in regular road service performance on of cars over several months' operations are: i. Reduced 2., Longer . original service cost. llfe of shoe lining Pronounced improvement in wear l_fe of disc, partlcularly on the diametrically inner wear path of outboard (wheel braklng face of dlsc. 4. Eliminate The redeslgned seasonal Metal a change Toe of Lining brake pipe carries pressure the same side) adjustments. D86-08800 part nt_ber as the 1959 version. 'l_is is _o avold need for revlslng Rallroaau' purchasing and stores departments ordering and stock references. All orderb for ]986-08800 Brake Llnlng Assembiy will be filled by the new design ty_e linings. RDCs, when should be operated when equi!m@ed with T_is equlpped wi_h the standard eliminates need wlln the new b86-08800 same 90 psi brake plpe linings (D86-05572)_ for seasonal changes Mete/ Toe Brake Linings, pressure that is used in air brake system setti_s. I Page Bukletln No. 21 RDC Bulletin No. 43 dated 7/20/56 - "Winter Braking - Use of Met_l Toe Brake Linlng Assemblies" applies only to older style D86-08800 Brake Linings shipped from The Budd Company prior to August 1960, This RDC Bulletin No. 43 must be disregarded and voided for RDCs equipped with new design Brake Linings D86-08800 shipped from The Budd Company after August .;;, 196o. Limit of Wear Brake Shoes - Brake with Brake Linings D86-O8800 Lining D86-08800 service when worn to bottom of grooves about 13/32 lining thickness. If linings rivets which steel and dabble _pplies the are used with less than fasten the bronze metal The 1/4" limit of wear on brake to standard linings (D86-05772), SKkTCH the should metal this toes toe be removed block, condemning will be in from TbJ_ _ ._L thickness, th_ contact with disc. cms ATT : in DB-21 linlngs shown In Disc not Metal Toe LJnlngs Brake Manual D86-0_800 \ I QUANTITY ITEM _ASSY. ' 11959 I--_ __!___!_. 2 ___ 4 5 6 7 8 9 STYLE i 4 2 4 2 8 2 0 4 2 2 2 0 I I I I ..... LINING BACK-UP I RRONZE T_TE PLATE ....... iINSULATION RACK-UP FOR TUBULAR RIVET--STEEL BRAKE BRAKE |RAKE BRAKE BRAKE BRONZE TOE PLATE LINING--WOVEN.= n._,RTIAL O,D. END SEGMENT LINING--WOV_ I.D. END SEGMENT LINING_WOVEN, PARTIAL I.D. E-NDSEGMEN_F LINING_MOLDEDtO.D. MIDDLE SEGMENT LINING'---'MOLDED_ I.O. MIDDLE SE-GMEN--E"N"T_ CHANGES IN D86-08800 BRAKE LINING ASSEMBLY (METAL TOED FOR 26" DIA. DISC) SKETCH DB-21 THE BUDD COMPANY CUSTOMER NUMBER SERVICE PHILADELPHIA 22 DEPARTMENT 15, DA E pi1516 o PENNSYLVANIA DISC BRAKE & ROLOKRON SERVICE BULLETIN SUBJECT: both to E86-0_921 Omission To standard eliminate regular or Gasket and from future reduce Model labor CFamd Fulcrt_m _ wheel application of this E86-05079 plus wlll labor 16 16 E86-0_921 E86-05079 Fulcrum Fulcrum 32 E86-02190 Cap 32 and 71A24M safety save Cover Cover to omit Fulcrum service in 1955 of fulcrum pin compared with On associated and items. material On a expeuded of changed car having on maintenance future Gasket ]386-05791 was based on for several years. with i0 cars on one and no fulcrum results of trial Thls on 31 full car sets Railroad. There was no difference In rate of wear on fulcrum pin cover equipped brakes in same service. Bridge Brakes, the bridge forging will cover or its gasket and without screw. Covers Starting with late October Disc Brakes will be without CF Brakes Screw Lock Washer wiring the cap installation in regular on _ Railroads starting Model Cover CF Disc - Decision "freezing" or bushings Fulcrum & Model and material costs, especially at overhaul, Model TFH Budd Disc Brakes, the design Is Covers trucks E86-05079 Model TI_ 1960 delivery, fulcrum covers. Assemblies be without the tapped all used new with Model T_M standard and Model machined seats for the fulcrum holes for the cover attaching CF cap screws. Equivalent provisions for application of fulcrum covers are omitted from the casting used in making Fulcrum Pivot Assembly I)86-09719 (free lateral type) and ]386-06616 (non fre_ lateral type) used with standard Model TFM Brakes. E86-0_921 after our present We general Gasket stock recon=end overhaul and E86-OSO79Fulcrum Cover will not be availab]= is exhausted. omitting or whenever the work fulcrom about the covers cover from is existing required. brakes at BY ! F J 4FJ H@J THE BUDD COMPANY CUSTOMER SERVICE DEPARTMENT PHILADELPHIA 15. PENNSYLVANIA DISC BRAKE & ROLOKRON SUBJECT: Budd Brake Cylinder Cylinder Assemblies and D86-OS&I+4 (8"). SERVICE BULLETIN Modifications D86-05080 (6_"), D86-05050 (T'), D86-05047 (7½" ) This bulletin is to advise of changes made by The Budd Company in make-up of Budd common standard disc brake cylinders to improve their operation at extreme low temperatures. The changes I. in brief consist of:- Lubrication Brake cylinder lubricant adopted is Molylube 80-18 Grease made by Bel-Ray Co., Inc., Farmingdale, N.J. This replaces former standard AAR M914-h2 Brake Cylinder Lubricant and also replaces light machine oil formerly used for the felt swabs. 2. Cylinder Pistou Packing Cups. Composition of piston packing cup was changed to a special grade WRT type Neoprene. This assures sufficient flexibility to provide seal at ex%reme]y low temperatures in combination with the specified lubricant. 3. Eliminated _. Reduced piston piston head lubricator outside Tlli_ to _ncrease swab felt. diameter. nominal clearance between piston head and cyllnd_:r '_i! We suggcs_ above _ changes be incorporated in these brake cylinders at air-dat: eluaning or other periodic maintenance overhaul. For this purpose we _lve beJo_r and in the attached sketches LN-21 and I_/A22 more detailed information. i. LU_RIC_TION Many greases were tested. Molylube 80-18 Grease was the only one which successfully passed al:_ of t_ t_sts considered applicable to all operating requirements and pscki:_ cup compatibility. Tois grease sells within reasonable price limits. Following lubrication instructions are presently used in assemblylng new cylinders at Red Idon plant and it is suggested these also be followed when brake cylinders are given periodic maintenance or repairs. -i- Brake C_linder Lubrication Instructions:- Cylinder Wall Apply a light coat of cylinder surface of cylinder head. lubricant Do not coat to entire wall. inside Felt Rin_ E86-04182 j Piston tube felt ring to be smeared with same cylinder lubricant, undiluted. Hand rub inside diameter surface of felt ring which contacts piston tube so as to work in a generous quantity of lubricant into the felt. Piston Tube Apply a light coat of cylinder lubricant over entire working surface. ,._ring Guide E86-06339 Apply a light coat of cylinder lubricant contact with the return spring. over entire surface which Piston Return Spring E86-05088 Apply a light coat of cylinder seats in piston head. lubricant to end surface Packin_ Cup Apply a light coat of cylinder contacts cylinder wall. lubricant on outside 2. PISTON PACKING may come of spring where lip surface where In it cup CUPS There is no change in part number ordering reference for the new composition packing cup. For ready identification these cups now have 1/4" high letters "LT" in raised molded characters located directly under the cup part number. 3. LU_RICATGR FELT SWAB IN PISTON HEAD The piston lubricator swab (felt) is omltted from all new brake cylinder az_,blies. Tests brought out that the piston swab felt contributes to cylln:1<_ leakage a:_ b_ow-by at sub-zero temperatures and especially at low brake cyi_t, pressures as felt fibers tear out in the stiffened grease. _lese loose fibc_-; and felt segments then collect under packing cup lip and destroy cup-to-wall seal. Felt swabs E86-05151, E86-06375, E86-06378 and E86-08839 will no longer De supplied by The Budd Company. This item should be canceled in all stock liu,_. Piston lubricator swab felt should periodic overhaul. SPECIAL be omitted when brake cylinders are given NOTICE:- This speciaA notice applies to old style piston assemblies equipped with separate metal s_b retainers like in lubricator swab assemblies E86-00673 and E86-01888. These are 7" and 7½" piston assemblies manufactured prior to 1552_ assembly part numbers T-S159-E (7" with steel head), I)86-05739 (7" with al_in_ head), T4428-F (7½" with steel head) and D86-05740 (7½" with aluminum head). -2- On be I_ture service orders lubricator supplied without the felt swabs. will no longer be When overhauling remove and omit The swab metal support of brake cylinders having any of above the felt swab only of the lubricator packing Cautio_______n _ Check O.D. less avoid does possible not of metal project scoring the clearance diameter. This was i, 1962. Attached maximum swab, must 4 piston head swab assembly. be reapplied to assemblies, the of retainers between before application sketch LW-22 O.D. to which piston for beyond newly aluminum cylinder REDUCED piston reduced and PISTON cylinder to piston O.D. wall sketch LW-21 illustrates etc., for use in cylinder in packing cup working area without lightest cut needed of to The by of piston the steel head - this to retainer. DIAMETER wall under heading "when reworked existing piston heads should Old style piston assemblies turned on O.D. correspond/ng head. for 7" cylinder or not over reduction is required so metal was increased to This clearance increase is obtained by reducing O.D. of made effective with all new piston assemblies manufactured overhaul. should be Attached of wear, felt not be over 6-27/32" This diametral size 4. Nominal will cup. metal retainer O.D. should 7-11/32" for 7½" cylinder. retainer and E86-O1888 and E86-OSI33-E5 supplied. retainer_ the swab assemblies E,6-00673 Felt swabs E86-OSI33-E4 T-_28-E, to sketch 1/8" piston after use" for dimension be turned at brake T-5159-E LW-22. 1 I)86-05739 on the heads. March D-3 shows cylinder and D86-057_0 cylinder body t giving certain suggested limits reconditioning. Deep score marks or grooves cylinder wall may be removed Just remove the sharp grooves by honing or score or machinla& marks. Where cylinder wall has only a few llght scratches or small ridges, removal by machining may not be needed so lon6 as cylinder passes leakage test. If desired these imperfections may be smoothed out by hand, using emery cloth over a rounded wood block. Att: Sketch Sketch I_-21 LW-_.2 NOM, NEW ! MAX, MIN. NEW NEW UMtT REWORKEE WEAR 7,000 6,508i 6.50C 7.00B I 7•000 7-5081 8.000 j.:_o_o 8.455 7.50¢ LaST 1_80RE WHEN OF LIMIT USE 6.686 6.625 6PIf" CYL. 7.1HB 7.12_ 7,6;)5 R'I _ (t'1 " " 7 " 7=h¢ ' CYL, _;.I;_S B-I " 8 ° CYI.. B*2 BORE FOR RUSH 7,688 e.ooe L_-e.oooR.,SR "_' l"_'_l ,._o4 ,.SO0 8.460 Z.S02 R,430 2.500 [ R.450 I _,498l i 2.3T_ I i FOR I L'I 2.875 3,000 3.000 B-I I H-( RI_HtNG _0S$ I W't FOR F_I/IP CyL. 7" 7_t" _, CYL. CYL. 2.R75 1t-0¢9 I 3-000 3.000 3.000 .875 .R77 .875 .93R I NEW PART °250 .250 .245 ,IR? I NEW FART 111'-I ! W*I w- I " " ! D-I I t-I 6DOF RUSH RUSH. FLANGI r =___i____I_______ I B'2 DRILL a REAM m T ",-Nol[:'-_:-v" _(l_T._e_ a O:a g-3 M_UST BE CONCENTRIC T'HIS _QETC_ FOR I CYL. _._L CYLINDER BODY LW-21 ROOY ASSY. I_ L-Z(RET _,_ -7-.] I • •+ L-, -- "___• ] -- ! ,+,, ......... I.o.,E. "".E."".E.o, ' --'_CTI,,ET_+ rEmI++_ WEAB r i __ ' ,_ _ _,_,,_;%,'_'__L-.-'_;._'.¥_++,+\\W; i +_m IITq_N _EWOI_EO _)00 1.499 .,_01 USE LSO0 1.504 _--+--. \\ I,_ s.+oo ++,+,+ +sB, \\ "+ z , | .B7S .B77 .8TS NEW PART NI_W _T .938 6.430 ",£1+.es+ I +.+,+e-++9:,++,+e++--+6_-- I_t BORE _ _t!,-3 _t_-Ht_t_I_'_=-G_._. [I_ '-_-" _--_" -----_'_ ----_. 4 S-9 -- !_. --_.9_ ¸ _ ' _ re.m..,,.. _ -- +TK'_,_; -, ,-_"_+-_+_I-_!P` III++, +, .... , i III ', I I III III ' i _ I L \ q_ _I'_----'-"o+( q l _ ", _$'--"==_ ",H_ GRIND NOT_ = ,.T..o. oT+",TH,. .0.*..'. _ll CLEARANCE AFTER BUSHINGS #_E INSERT H.'IR PINCHED OBIVLrTS PI_T_N TO SO THAT _'_r /,-_;.x ,• "V-++ /, -,_ +4'. .. / _----Jmt.Ln--( O_MI[NSION &PPLJ(O. hO -__ / -_ _ \ 2 498 : _ _ 2.37" + _ I _ / NOTE FOR E_ II_n_'_ NEW " TUI_I_ --_,l_ --_-qB" _. 2.500 ! _-_ _STON II'l/l)l lll_3_ JL-i L-Z LENGTH T 9 EIU_N " OVER Ir'13-rON HE_"IT _ 14=I_ L G.-_C 7. c 6.B75 O-3 7" Y._TS 7.87:_ D-S 0+3 7Ve" r - - ;._. ' i S.)7SJ 6+3?O : G.aSO lLe7S S_STS 6,870 7.375 7.375 ?.STQ J } 7.8751 T.8_51 7.070 6250 T.aSO +'oPSO PRODUCTION WORK _I_NSI(_I D-3 SHOWN IS FOR FULLY FINISHED PISTON'ASSEMBLY REAOY FOR INSTALLATION. NEW RI_PLACEMENT PISTON HEADS ARE SUPPt.IED ROUG_ TURNED OvERsizE ON O:A. 0"3 JIMO MUST eE FINI_HEI) P_R NOTE °A" &N_) DIMENSION D-3 ArT_R PISTON _EA0 IS ASSEMBLED TO THE PISTC +` TUBE. liI&CI,IIN_NG Of LUBRICATING OiSCONTJNUE[ _ NOVE_'IBER S'_,AS +96_. 41, H_AD ! ; ; 6._75" rrFrrT_¢ . " _.__o ,am .a,,+: .,.T F-[=_; ........ [ ARE BETWEEN THESE SURFACES. MUST PROTRUDE BEYON0 HF&_ rlllT MnT _rl_ nor+ . 2.502 _,.--"_ _+.+'='-.--, _ HAIRS 2 S00 , FON BUSHING I!0ol LARGEST LD, OF BUSH. !!3-2 PISTON TUBE O.D. GROOVE IT_IS SKETCH FO_ I _STO_ _R1 ASSY NO. j USE_ IN ' CY_NDE_i , ] ! OS_" O64_8 I 7_" ' l • D86+0_4+9 086"05738 ; , 7" 6_" PISTON ASSEMBLY ILW-22 CYL. B71 THE BUDD CUSTOMER COMPANY SERVICE PHILADELPHIA 15, PENNSYLVANIA DISC BPJ ,KE & ROLOKRON Budd SUBJECT: Brake Cylinder Lubricant B86-050_7 the bulletin Disc is Brake and to (7½") 7/26/65 to in Cylinder Assemblies:- B86-I1912 (7") (Cast Iron) D86-OSS_ (8") I_6-12o57 (8") advise of Cylinders to provide better change In lubricant improve their operation corrosion protectton to be used In at extreme to interior low of cylinders. Brake cylinder furnished by Bel-Ray standard This DATE B86-]2051 (7") D_;-12054 (7½") standard temperatures 26A SERVICE BULLETIN used _36-_2o_8 (6}-) This NUMBER DEPARTMENT Molylube lubricant nov recommended Co. Inc., Farmlngdale, 80-18 The thickener used substance wilJ not and cause them to be hollow forged piston cylinder Grease "Molylube #850 This replaces in this lubricant is an alm_inum soap or absorb water which tends to harden other wlll the provlde surface w_l] be Grease" former lubricant. wiped off the surfaces tube assembly). This same propert.y cylinders by maintaining sorption of water. Molylube #850 Molylube 80-18. brake is N.J. to be lubricated corrosion protection in coating and eliminating supplied on all future complex. thlckener_ (such as cast iron the ab- orders for the "" f f J.JP qHwNwn THE BUDD CUSTOMER COMPANY SERVICE PHILADELPHIA 15. PENNSYLVANIA DISC BP.AKE & ROLOKRON SUBJECT: Charge in Bc.ake Cylinder Budd Stand_krd Type Brake Starting March 196_, new Budd Budd Re_ Lion Plant will new style Boot Clamps. Purposa of this be is chan6e at the direct Boots and Cylinders standard fitted to Boot type with re_uce cylinder cover from Punch-Lok (a) Boot ord2ring part, (b) Boot clamp large These at style style two Boot c_amps clamp nm_ber clamp clamp used with elthe_ is discontlnued. (c) at end a _ake Cylinders slightly BOOT costs or D86-0_186 r_'malns on old or the cy3:nder E86.o0.5699 and _v style is be Budd used boot. manufactured changed ma!ntenance I_ l_,dd part is Budd part _t_ai'i end New style clamp This clamp must old 2/26/64 Clamps Boot while sams cover n_be_ number piston boo_. payt with attached setting with more application of boot by "plnchlng" action which may be D$6,-0_186. (_on..pressure head): E86-O5699. I_..I'A98/_ (Punch-Lok L86-1198h style at & CLAMPS are interchangeable FA_nufacture of #0-358). and may be (,]amp E86-05699 end: Old styla clamp l_ Budd part number E86-,O8/,;7. Thls used with old st21e boot. _nls clamp _s _o,. suitable be used with new _.>le t,_.,e_., with DATE end. This with lower cost clamps Company or their distributors. CYLINDE_ Old New 27 SERVICE BULLETIN trouble-free service by obtaining more positive clamping at piston end and eliminating "chances of puncturing boot of clamp obtained NUMBER DEPARTMENT number L86-.11983 new style booL clamp must b= and should no_. (Punch°Lok #O-332). only; It must not be u_ed Bulletin #27 To permit re_appllcation of old style boots which are in good condltir-n, old style clamp assemblies E86-08777 will be available fro= Budd stock and will be s_pplled on purchase orders specifyioSE86-08777. Old style boots D86-O_186will boot D86-0_1_6 the new style (Punch-Lok _O-332 ) should be Boot D86-0 6 is - used no longer be stocked. On orders boot will be supplied. New style ordered for use with the new style on the 7½" standard following callin6 clamps boot. for L_-11983 cylinders: cylinder (al_ln_. bod_) D86-0 50 -05080 D86-08840 86- 9Z2 - 7" s_ndArd cylinder (with iron body) B86-0999"2 - 7_" cylinder used with hydraulic hand brake. o 7 tT |t t! ;f 8 n It iI ft SKETCH _! DBD-27 Attached sketch DRD-27 illustrates position of boot and clamps on a completely assembled brake cylinder assembly. Sketch also shows difference in shape of old style and new style boot D86-04186 by means of enlar6ed views of reglon designated as "clr61e A". APPLYING The new style clamps are 3/8 inch Because of close clearances Locking Tool Is reco_en_ed (_,,_ll) end of boot. Attached sketch DB-27-B wide NEW STYLE CIAMPS Open-End with boot w_lls, to use in makin@ Punch-Lok. Punch-Lok Model P-38 Clamp-F_s_er application of clamp at piston i3].ustrates the P-38 tool and how it is to be used. Attached sketch DB_-27-A Is an illustrated instruction notice showing recommended "lacln6-up" of the open-end tYge clamp_ preparatory to use of P-38 tool for final tishtening of clamp. Sketch DB-27-B illustrates and Instructs the use of tool P-38 In a normal manner for locking the clamp by means of hammer blow punch indentation lock. Where punching is difficult because of restricted clearance for a goodj clean hammer blow (like possible obstruction by the boot wall) many users prefer a[, alternate method of locking the clamp and obtain better results. This alternate method c_lts steps 6 and 7 illustrated in sketch DB-27 and substitute_ the following: Bulletln After desired tension is obtained by step 5: (a) raise Clamp-Master tool P-38 to bend clamp tall pieces angle (b) remove winder and withdraw tool part way out fold the i/_" projection down PUNCH-LOK CCMFANY 321 North Justine Chicago, Illinois Street 60607 or att : Sketch " " D_D_27 DB-27-A DB-27-B PUN_H-LOK at right over the Lok. The Model P-38 Clamp Master Locking Tool, also 3/8" wide open-end Punch-Lok _0-332 and l_nch-Lok #0-358, may be purchased from: through #27 distributors clamps tln..l_rged View Circle A 01_ 8'_yle Boot _arged View Circle A New Style Boot Cha_e _n Boot & Boot Clamps DBD-27 ,db A Ld4C'rMO PUNCH-LOK OPBN END, i:mAVY _DO_ i •.., 3-1/2" PZK'CE POR AT LEAST PUT • • CLAMP AROUIqD WRAP THROUGH PULL WHILE UP TIGHT "LACING AND THE "LACE" FIRST "LOW'. AND UP" DON'T LET IT SLIP TO COMPLETE 2"nd WRAP. 4. USING THE EXTRA GET A HAND HOLD PUSH o 6. SECOND ONE HAND THE OTHER WORK THE READY DO NOT SIZE TRY CLAMP. TO SAVE THE ANY EXTRA STEEL IN THE LENGTH MAKES TAIL AN WRAP WHILE FOR LENGTH ON THE OF STEEL TO TAIL PIECE - THROUGH HOLDING LOK BOTH WITH WRAPS HAND. TAIL PIECE THE TOOL. PIECE EASIER BY AND THROUGH ORDERING FASTER LOK. A SMALLER APPLICATION• SK DB-27"A _'27-64 WI_ ._.:--. 6 The CLAMP-MASTER is en usembly Push punch down holding blow .=,. hnudon f,:.- on LOK and whilo with Wrench, with I_Jmmeer, thu strike locking firm Clamp. _ ]Pum_ e_ of Clamp completely i,'to slotted end of _-)4AS'T_]_ Yo: =A" 4=:==aum=mL width Clam_ use na_,_ow...ulott_d end. . _;%, _ Raiso punch holding Winder 8wtog Frame 8goJut edge off _ with gaging Clamp =dot on- where one love engage 5 Apply Wrench R_tehot toWJndor. with 8ULHictent strokes until destrod tenslon is obtained. it i_ of to free, oomess in hole= tail end, hoJdoz at of end o_t punch othe_ l_uch up I_11 move up _g Pomu the from =_aoese and OPlpOelto _end. I To use Open End Clamp, wrap and lace the clamp twice around, threadin_ each wrap through LOK, then apply and use P-38 tool. &, See Sketch lacing MODEL _ L_)_ Twist To end while Wrench, fonuazd of smooth. Windor. end. with piece. LOK Frame and toms|on DB-27-A for clamp instructions. P-38 SK -, s?t F J KJ fBC# H THE BUDD COMPANY CUSTOMER SERVICE DEPARTMENT PHILADELPHIA iS, PENNSYLVANIA DISC BITJUCE& ROLOKRON SUBJECT: Change in Brake Budd Type This bulletin Cylinder Special is to advise Brake NUMBER 27-A DATE 212610 SERVICE BULLETIN Boot Clamps Cylinders of change In clamps for brake BOot D86-O9874 and boot clamps covered following Budd brake cylinders :- cylinder Boot D86-098'[4. by this Bu] letin No. 27-A are foz u._e o. D86-O9893- 6_" dla. (P.R.R.Cars#1_0, [5:', 151,) I)86-11801 - T' dla. (H.U. Cars:- (a) Boot D86-O9874 remains the same contour service; no change in boot. (b) Boot clamp Readlr_ Cars 9OO1-9017 & P.R.R. Car_ _01-219 & 251-269) or cross section at,small end or piston end:01d style clamp is Budd part number F86-09869 New style clamp is Budd number L86-11981 (Punch-Lok These two clamps may be used interchangeably. (e) Boot clamp at 01d style New style These two large end or cylinder cover end:clamp is Budd part namber F86-09868 clamp is Budd number I_-11982 (Punch-Lok clamps may be used luterchangeably. The new style clamps have two advantages over as those now In #0-320 ) #0-342). the old:- i. New style is considerably 2, New style clamp, properly applled_ m.akes a better seal and more secure f_stenlng due to eliminating posslblllty of gathering a "buckle" of boot at clamp ends or " puncturing" of boot due to pinching by old style clam_. Old style clamps F86-09868 less expense. and F86-09869 will no longer be stocked. The same P-38 tool and the same method of application with these hey style clamps Punch-Lok #0-320 and #0-3&2 are reco---ended as that descrlbed In Bulletin #27 for the larger diameter clamps. "' THE f I BUDD COMPANY CUSTOMER SERVICE PHILADELPHIA 15, PENNSYLVANIA DISC BRAKE & ROLOKRON SUBJECT: REVISED AIR THIS ttON'OTTtt BULLETIN IS TO ADVISE BE OBSOLETE [_6-OOl95 WILL ASSEMBLY bX.,_b-|2151 AS SHOWN ON ALL FOR A _8 DATE HARCH REPLACEMENT WILL BE PERIOD PARTS STOChED OF TIME. ASSEMBLY THAT AIR AND THE THE INDICATOR REPLACED OBSOLETE BUOD HOWEVENp "ON-OFF" BY AN |HPHOVI'_ DSD-1296o ATTACHED FOR BY II, SERVICE BULLETIN INDICATOR ASSEMULY ASSEMBLY NUMBER DEPARTMENT D_-OO]9_ COMPANY COMPLETE" IN MODEST ASSEMBLIES QUANTITIE_ WILL NO| U[ STOCKED, D_-121_1 COMPLETE PARTS WILL BE STOCKED EXTERNAL ASSEMBLIES MOUNTING ARE DIRECTLY ASSEMDLICS BY THE SAME THE AS BUDO DIMENSIONS AS THE WELL AS ALL REPLACEHENT COMPANY. Or THE L_6-121_1 NEW D_-O01_ OLD UNITS MAKING IH[M INTERCHANGEABLE. MAINTENANCE As REMOVED WITH FROM CLEAN AND INSPECT AND ALL METAL THEM DIAPHRAGM FOR WITH D|APHRAGH, THE PUSH BC PARTS FOR REPLACE CHECKING WEAR AIR OR OR USING ALL WEAR DAMAGE UNIT SHOULD BE DATING. THOROUGHLY DAMAGE, OF THIS AT CLEANING DAMAGED AND AND 5OLVCt_T PARTS, REPLACE IF REPLACE IF INSPECT FOUND. REQUIREU T[ST THE NUST BOOT INDICATOR DISASSEMBLED _OR SIGNS INSPECT _.L_AKAG( D86-OOI95 THE CAR ROD AIR APPLIED REMOVE CLEARANCE TO THE HOLE. THE INDICATOR RUBBER IF BOOT LEAKAGE s CHECK AND FOR APPLY IS FOUNDp LEAKAGL SOAP THE SUDS TttHU AROUND DIAPItRAGI4 REPLACED. TMENT Art: DSD-1296 I !JC,L, | ; / | | | D86-12151 AIR"ON-OFF"INDICATOR ASSEMBLY ITEM PC.NO. DESCRIPTION I 1_86-12156 PLATE,PRESSURE 2 L86-12155 PIPE PLUG 3 L86-12157 DIAPHRAGM 4 L86-12158 CLAMP 5 L86-12159 PUSH'ROD 6 L86-12160 PLATE,NON-PRESSURE 7 L86-12161 SPRING-RELEASE 8 71A22M LOCKWASHER-SPRING 9 21AIIM NUT I0 L86-12162 BOOT II 21AI3M ,NUT 12 F86-00167 INDICATOR DSD-1296 "" K l WT"t I THE BUDD COMPANY CUSTOMER SERVICE DEPARTMENT PHILADELPHIA 15, PENNSYLVANIA DISC BPJ KE & ROLOKRON SUBJECT: Model CF &_ Repair Disc Brake Pin Bushing & Ouide Is bulletin to (a) Change (b) Method of salvaging all dan_aged or vith abnormal single All brake heads, full This time change conditions. _brake is head advise:length guide 3 types wear. of pin bushing Brake with a single made to eliminate We rec_end that repair In brake Heads both CF & TFM tMpe, manufactured My, 196S have been furnished rather than 2 short bushings. eertain Head Replacement This to issued - Brake SERVICE BULLETIN with arm forgings since approximately full length guide bending of the single head. pin buehlng brake head arms under bushing be installed at oroverhaul. PR _UPJ Refer to sketches:CF type DBB-29A D_-29B t_ (Zong) T_ l_y_ (short) D_-_C i. Press out existing 2. Bore and ream arm forging 5. Remove i/_" from bushln6 boss to provide brake operation; brake headsl)86-04912, oaly. _. Press 5. Are tack 2 places B-shinge Co_pan_. new bushing F66-ll793 bushings D86-O_gL?. D86-0663.l a D86-O66L? D86-10578 & D86-10579 (E86-01577). to 1.37_ plus .002, minus additional clearance at X)86-06611 and D86-O6612 (F86-I1793 or i_36-I1726) in place. as shown. Use stainless and F86-ll726 steel rod. should be purchased -i- .000. from The Budd Bulletin Superseding _nualsj method as follows : information of salvaging covered in Bulletin No. 11 and current Brake Reads with arm forgin6s damaged 29 Service or worn is PROCEDURE Refer £nvolved. to sketches D_-29A, DBB-29B or DBB-29C for respective brake (a) Carefully remove arm forging from brake provide good surface for welding. (h) Weld new arm assembly to brake head as shown. A holding fixture be used when welding to maintain proper alignment of parts. Use mild Replacement The Budd Company Brake Rnclostn'es : steel welding head and grind head Replacement Arm Assy. D86-0_912 D86-04913 D86-0491_ E86-09257 I)86-o6611 I)86-06612 D86-06613 D86-0661_ E86-09637 E86-09638 D86-I0578 D86-10579 D86-I0525 D86-I0526 E86-I1733 E86-I1734 Sketches should D_-29B D_Rgc Lnoul(l be purchased from Replacement Arm & Guide Pin AB_y: 986-06363 E86-06364 E86-09635 E86-0_36 E86-I1736 E86-I1737 DBB-29A to rod AWS E-6015. arm assemblies (with single bushing) to following part nmnbers: Head Assy. head smooth BRAKE ROD (AW$ E-6OIS) HEAD ASSEMBLY-INSIDIE CF TYPE EXCEPT As NOT[O f l_ 3/s ! - / / , _JJfllJllJlfil_ \j BRAKE HEAD ASSEMBLYCF ,.,,.,, OUTSIDE TYPE DBB - 29A i : / / I // / t,_ .......... //_ BRAKE H_Ap ,_#SEMBLY DBE-06611 R,H. SHOWN _U_ _X _ DBG-OBSl2 L,H. OPPOSITE 8375 J. BRAKE HEAD TFM ASSEMBLY-OUTSIDE TYPE (LON,G) •DBB-; 9 1-17-68 I B / / / 90 ° BRAKE ,_,,.,_. HEAD ASS.EMBLY -OUTSIDE TFM TYPE (SHORT) DBB -.29 C "" THE J ! BUDD COMPANY NUMBER 30 DATE 9/12166 CUSTOMER SERVICE DEPARTMENT PHILADELPHIA 15, PENNSYLVANIA DISC BRAKE & ROLOKRON Type CF and TFM Disc Brake Improved Tong to Cylinder Pin SUBJECT: This bulletin arrangement than the Briefly shoulder bushinge to ie the on ty_es acc_odate following 1. 2 buehings in 2, Eliminates anti-rattle 3. Simplified pin, _o Point on 5. of Dew these improved tong to cylinder pin brake. involvee increase the uee of a straight inside diameter of in the pin rather various pin. modifications new tong pins caused the cylinder be thue pins lees t made at brake overhaul for the diameter of need for ring and cover, of corrosion the pieton washer and Guide Point at tube space between aseembly. nut. costly. eliminates to by cover spring cylinder Ls/6er adviee :frozen assemble TFM diec that reasons Eliminates the to CF and the We recc_end Arrangement iesued this modification type pin and SERVICE BULLETIN need for E86-05_13, required to tongs. pin permits increased hand brake March, 1964 shoe loading when required. 6. Eliminates All TFM brake lubrication. assembliee manufactured since are n_ thls Improved. design. MC_IFICATION lo 2. PROCEDURES - Refer to Figures Remove cylinder ton6S, hand brake (part numhare vary with loc_tion), _-t_ and lt_-O_. Bp.,-tng Cover. Remove Replace E86-0_172 with nsv Outside diameter for grinding the cylinder cover frc_ _ushlnge I_-12030. of new pteten over the bushing flange rod bushinge pieton and levers and F86-123_ Cylinder Bushings 1 rod. -1- Body 2. cranks. Discard shoulder pine Nut, 70A32M Waeherp E86-05060 and hae been 1;o provide Piston reduced clearance Tube to Assembly. eliminate need when installing _L11etin o Remove lower bushing F_6-0_172 from _o_s. NO. 30 Press in nev _shi_ E_-12030. Remove smaller I.D. bushing E86-0_172 frc_ hand brake lever (TFM brake only) and repl_ee with new bushln8 F86-12031. Insert bushlng £rca opposite side of lever. Remove bushings F_6-017461 E86-O_171 and E86-0_172, as used, locations in hand brake eranks and replace vith new bushings _o NOTE.- o All bushin6s should be pressed in vith these bushings with a bander may _--_ge bushing fit in par%. an arbor press. the bushing or Reinstall cylinder; tongs, hand brake levers and fasteners. Note that pins vary in length brake lever or crank is used. and cranks_ depending TFM arransement with F86-120_. Refer to E86-12035 PARTS hand brake requires sketch, Figure 2. Pin from shoe pin F66*12030. Driving distort using new pins on whether hand and Retainer INFORMATION New parts and assemblies should be ordered from The Budd Company as shorn on the following sEetehes. Note that l_rts are shown as type 1 and type 2. After mod/fications have been completed per this bulletin, replacement l_Xts shown as type 2 mupt be ordered Fig. 3 - Brake Cylinder Assemblies Pig. _, - Tong As6emblles. Fig. 5 - I_nd Brake Fig. 6 - Pins and Retainer. Levers. Figs. 7, 8, 9, 10 & 11 - Hand Fig. ]2 - Hand Brake Crank Brake Crsnk Assembly Assemblles. - RDC LUBR ICAT I ON' Following Enels, _ffication, F'J.gtn,es 1 thru lubri_tion 12. of pine and bushings is not recommended. ,'- E86-0417,__._.__5 PIN EB6"04171_ EB6-041#I-_ BUSHING_ ," BUSHING _ ! / _'-+-----K f _._-,-'Pk _ i-.J__ F86-12030-- \\ / _ E86"12033 PIN _ - (J_"'l_'... _<...-> ,,,-i::r:l_.. _-,,, CYLINDERCYLINDER - _ .... ___ y_ \ : _\ -- ,t l_"1-2TO_N6 L_I;J I r_,_:_ IIi /-/_ _ ti.,,,_7 Fe6-12030 _ _" ,'_ ' -"-.. IEB6-05060 "17OA32M L_ SHOULDER TYPE NON"_ PART NUMBERS INFORMATION- VARY--REFER FI(}UR[S "_¢/ \_... "_..L , y . tw ..'_.. t .... H / _" • " ! _J __ 95A2043M_ COTTERPiN PIN STRAIGHT ARRANGEMENT- TYPE CF PIN P, TFM TO PARTS 7 TO I0 IN(;LUSIVE .---EB6-04191 PIN BUSHING _ , "_---_ ti) EB6-04171 BUSHING t!t ' tt _ HANDBRAKE TONG _ SPRING WASHER i BUSHING ) ,k-. - _\ L _- t _. E86-04171 CRANK ..--\ • f--, ::J k "Lb,. EB6-12030 •' t- ;I-._ .. - E86-12036 ,, Pill , HANDBRAKI_ CRANK __ - , W__y......., ASSEMBLY pISTON TU_E ASSEMBLY 86-0417; BUSHING _ HANDBRAKE CRANK _ _,! BUSHING _ " ,t I E86-05060 _SUSHtNG t _RAKt I J_ _ SPRING CRANK I "_5A2043M COTTERPIN f I SHOULDER TYPE HANDBRAKE PIN CRANK STRAIGHT ARRANGEMENT TONG PIN AND -TYPE CF BUSHING PIN 8, TFM MODIFICATION FIGURE,./ BUSHING E86-04171 -'-_ .- E86-12035 PI ;..t --FB6-12031 _USHrNG • 95A2047M COTTI_RPIN F86-12032 RETAINER SHOULDER TYPE PIN HAN.DBRAKE ,-EB6-05023 // LEVER BUSHING STRAIGHT LEVER ARRANGEMENT - TYPE PIN TFM 8 ASSEMBLY / /-- EB6-04171 E86 o04196 PIN --- ;HING \ E86-05060 \ SPRING COTTERPIN SHOULDER TYPE HANDBRAKE PIN STRAIGHT LEVER ARRANGEMENT-TYPE TONG PiN AND BUSHING PIN CF MODIFICATION FIGURE 2 II I0 12 / 9 13 15 14 ,\ \ 16 17 \ _ 7 t /18 \ I _ / 3 2 AIR T_'P_ I TYPE 2 ° USE WIT_H__,_.__ " UgE WITH CYLINDERS TyPE STRAIGHT AIR Z CTUNO(R CYLINDER PLhL_ -)_ A5$Y H 7"¢_'LINDER T .-o,_eo_eo.,z o, e IDe6.C_OSO 420 CI,'_MPLET( "_ " WITM 0USHING, ITEM? IAEiM WASHER 4 NUT 5 BOLT "_-COVE R &SSY. WiT H ............... 7 OUSIIlNG-CYLIND_R BUSHING AN0 IIEM J_.......... PI_TON ,t p.CYLINO(R _86-1t912 ] 70AZIM I YOA24M iA2_ 70AZ4M CAST t B86-IEG$0 :_z_.if_'_'_, T,_-• 8+._j__. _ :,20_* D 80DY 6 PARTS PIN_._ _/_'CYLINOE I AND '4 5 _ p/Z" 70A_4M ;-O41?2 IFuO.t2u30 IEOi.O417Z T_- _,TsfoN-_¢_--o I_STON I-%-_ CLAMP-BOOT I_ 800T (PUN_ 7,'B AND OeTAIN L0K NO _NC. FROM:- Z,e_'Z_4t z]elzu t z,v,zm i 7A_243;d _iZ43_ I 321 NOHTH 0-_Ske) OHICAOO_ILL LOK [e6.04;¢_ I 7OA;_4M /A_2_ I /GAZ4M '_-_ _ I 70A24M Ub I B86"B?Q IIPI" I_ 7_+245_ ,ZOSOIEBO-OIITZ[_._'_ _OAIGZ0 LO 6- 041B I 60Ai620 O ILBI_-050951E e_u: I la_Ib,c_ l I i ) 8t_.o'.'.'.'.'.'.'.'.'._',5 ! toe6 06_;'_- ;:OS-'_']86-0----_] Z 5_IO'----{;--O5i_----T £ i;" ,.:u@-/,gd;_ L-_i,_# _-IlgO41L86-_198_-1_6-11_9_-; .0418_ COxNO O'_Z) PONON i_,'-o_ _B&.Oe84 Typ( 2 ;_57_BI-DB_-120--'_S-OiD6]-O$_ - C_.*.e-.OOT • ,_#55 ITEM5 EOV_-;-o--_-OO_---....... 16 e _T ....... A_,S_: -fh_CLUD[S F_O-120_4 I Zik'_'M 60ALOE0 _--0__ Ie-eO:OSmB I£e@b_,i_ B " CTLIND(N /0A24M E8_'O4172 -t_'O BODY CWL INOER ..... -_yp_-_---)--y'p[ :6IE.;_-_'d,', ._6'o 15 INUN I OB_ .0418G IL_ ,-_T]_B_._6:.SeS E_.04J,B6 _-._ _-_T_6 _ _: .'E_ ,,.o.,,+.fl+o..t+o.fl _I16,11+-98_ LBI_*IIg83 LGO-IJ906 k,86.119_f, COMPA._._ JUSTINE_._T_ 60607 FIGURE 3 2 tl io I1 \12 TONG ASSEMBLIES PART ITEM NO. I.. NO. TP_.Y.._=_.L TYPE 2 D86-05689 $S6-12063 TONG ASSEMBLY L. tt 2. D86-05688 B86-12062 TONG ASSEMBLY R.H. 3. F86- F86- THRUST 4. E86-04171 E86-04171 BUSHING - UPPER 5. E86-04172 F86-12030 BUSHING - LOWER 6. Et:}6-04901 E86-04901 KEY 7. E86-04899 E86-04899 RETAINEk 8. E86-O458G E86-04586 SPRING 9. E86-05087 E86-05087 SHOE I0. E86-0416.3 E86-04163 FULCRUM II. E86-05636 E86-05636 THRUST 12. E86-04112 E86-04112 WEAR 05690 TYPE I- USE WITH SHOULDER TYPE 2- USE WITH STRAIGHT 05690 TYPE WASHER PiN PiN WASHER PLATE PIN PIN FIGURE 4 I 2 .,HAND BRAKE LEVER ASSEMBLIES .P_ART N O. .ITEM NO. E____._I TY P TYPE2 h EB6-06652 E86-12064 LEVER 2. E86-04172 FB6-12031 BUSHING TYPE I- USE WITH SHOULDER .TYPE 2- USE WITH STRAIGHT TYPE 8_ BUSHING ASSY, PIN PIN FIGURE 5 I I I il , I '1 I ,.,_oj o4,7 i I 2 :3. Io% s_ I .. IOS/_e 4. : I J , I i I \, I 5 I. E86-12036 PIN (CF Z. E86-12035. PIN (TFM 3. E86-12034 PiN (CF 4. E86-12033 PiN (CF 5. F86-12032 RETAINER 8 TFM HANDBRAKE HANDBRAKE HANDBRAKE 8. TFM CRANK) LEVER) LEVER) TONG) PINS A.{) RETAINER FIGURE 6 .6 X ,-,,- DIA. C ....... ," ," 7 Bi"- DIA. D SECTION A .... " LEFT HAND Y-Y OPPOSITE SECTION ASSEMBLY R.H. 2 SHOWN NUMGER$ L.H. DIMENSIONS OPPOSITE *' n E86 -05045 E86-05046 8-2 0 E86-12079 E86-12080 8_ P C D ITEM 3 A R T ITEM UM 4 X mX OER ITEM 5 ITEM G ] ITEM 7 I_//i 0 II/o ?/e F86-12030 F86-12030 E86- 04192 E8_6:04192 1E86-01577 q i U lESS-osse6 _'a E86"01746 E86-04172 2 7/e F86"12030 F86-12030 E86-120T7 . E86-04192 E86"04192 I E86-05785 2 E86-12073 _'u E86 _'0/746 E86-12075 E8620.4192 j E86- 01___';( I. LUt., 0.:11',_2 Lu6 c;l'_, " E86:041"/2 E86-0419._ F86-12030 i E86-04192 E6£-O419Z E86-04172 E86-0417l E86-04192 E86-04192 F86-120_ E86-06658 E86-O4:92IE86_-O/5/t Eb_,-OIb _. f-- IEE86-0i5"// ;'8 TYPE I.-USE WITH SHOULDER TYPE TYPE 2_-USE WITH STRAIGHT PIN HANDBR .F :E PIN CRANK ASSEMBLIES FIGURE 7 6 A ..o • SECTION I AN{:) 2 .// B-B t, B * • L. . • ,. / / B \ 3 RIGHT HAND LEFT ITEM HAND .PART NO. TYPE I. 4 SHOWN SECTION OPPOSITE A-A NUMBER TYPE 2. I. E86-O8BI2 E86-12081 HANDBRAKE CRANK ASSY R H 2. E86-08813 E86-12082 HANDBRAKE CRANK ASSY. L.H. 3. E86-04172 F86-12030 BUSHING 4. E86-01746 F86-12030 BUSHING 5. E86-01577 E86-01577 BUSHING 6. E86-04192 E86-04192 BUSHING TYPE I.- USE TYPE2.-USE WITH SHOULDER TYPE WITH STRAIGHT PIN HANDBRAKE PIN CRANK ASSEMBLIES FIGURE ,8 l 7 3 X-X SECTION RIGHT HAND SHOWN LEFT HAND OPPOSITE PAR TYPE R H SHOWN L.H.OPPOSIT[ E_-O971S I z- A E86-097/7 B I0 '4'7/i iT;_>-,_o_i; !_d6-,2-o69/,o I ..... ; " - " C D 't'l ITEM 3 E86-04172 N _ rnE%,l__ 86-04171 ,;,_';'i',. iF_;:iio;o 86-12030 U i b ITEM S I [86-04192 E86-04192 - .... TYPE I. -USE WITH SHOULDER TYPE TYPE 2.- WITH STRAIGHT PIN USE HANDBRAKE R 5 nE__6 ..... ;,_" Ee6-o419z iE86-o4i9z Ee6-Ol_>,, ' 1 ie6;o4_71 17-U! ........ 1- E Ee6.0419z :B_-,2o3o E86.04192__ !E86-041_2 Ig86-0419z : Lu,, ,-,,.. ,'' ! LLt_, _i_, :' Lb_ (,i'.,#'7' I i PIN CRANK ASSEMBI._!E_S FIGURE ._ 6 .'j__ i j -_6 .5 SECTION B-B -I ANO2 . " -_°_° . e,_-.% B JA 4 RIGHT LEFT HAND HAND ITEM SHOWN TYPE SECTION A- A OPPOSITE PART NO.._.= 3 NUMBER I. TYPE 2 I. E86- 09378 E86-12085 HANDBRAKE CRANK ASSY 2. E86-09379 E86-12086 HANDBRAKE CRANK ASSY 3. E86-04172 F86-12030 BUSHING 4. E86-04171 F86-12030 BUSHING 5 E86-01577 E86-01577 BUSHING 6 E86-041_:" E86-04192 BUSHING TYPE TYPE I.-USE 2.- USE ° WITH SHOULDER TYPE WITH STRAIGHT PIN HANDBRAKE L.H. PIN CRANK ASSEMBLIE.S, FIGURE I0 6 SECTION / B-B . I AND2 4 5 AL SECTION RIGHT LEFT HAND HAND ITEM NO,._; A-A SHOWN OPPOSITE TYPE PART I. NUMBER, TYPE 2 I. E86-06266 E86-12087 HANDBRAKE CRANK ASS¥ R. H. 2. E86-06267 E86-12088 HANDBRAKE CRANK ASS¥ LH. 3. E86-04192 E86-04192 BUSHING 4. E86-04172. E86-04172 BUSHING 5. E86- 01746 t:86-12050 BUSHING 6. E86-05011 E86-05011 BUSHING TYPE I USE WITH SHOULDER TYPE TYPE 2. USE WITH STRAIGHT PIN H.ANDBRAKE CRANK PIN ASSEMBLIES FIGURE I__!1 6 S S(OllON,'_-Z" RIGHT HAND SHOWN LEFT HAND OPPOSITE SEC_ON "Y-Y" HAND BRAKE CRANK ASSEMBLIES I PART ITEM NO, NO. TYP E._.__.__I TYPE2 I De6- 05864 D86-12070 CRANK 2. 3. D86-05865 Ea6-01746 B86. 12071 F86-12030 CRANK ASSEMBLY BUSHING 4 E86-04172 FB6-12030 BUSHING 5. E86-04192 E86-04192 BUSHING 6. E86-01577 E86-01577 BUSHING TYPE I - USE WITH SHO. ULDER TYPE TYPE 2- WITH STRAIGHT PIN USE ASSEMBLY R.H. L.H PiN FIQURE 12 171 J / M_ THE BUDD qHCXQH COMPANY CUSTOMER SERVICE PHILADELPHIA 15, DEPARTMENT PENNSYLVANIA DISC BRAKE & ROLOKRON "=UBJECI: TF_4 8< Unit _ Disc 'Uh[:: bu]]el In is I/,'.kJn% P.[._te, part. n,_ber followi issued these Eliminates the bridge the need bolts. e Loose single is no longer safety bar. - locking for plates arc bolt is more supported by 12/19/66 Bolt I_,:kln8 ELate ,f ,'el,",_,,c)f"RTJ,_p,,"P_>]_ be used welding In the safety bar future to heads for the of readily detected because each bolt the other bolt through the welded _uantity Locking, of 8 is Plates F86-O9939 may required per car. 3bs. Insta]l bend up locking corners and DATE SERVICE BULLETIN Bridge to advJ._e 31 F86-O9939. We recommend nK reasons :- I. Brakes NUMBER be obtained plate under bolt heads, of plate firmly against from The Budd torque bolts to flat of nuts. Company. 500 ft. =-2: THE BUDD COMPANY CUSTOMER 8ERV|CE DEPARTMENT PHILADELPHIA 18, PENNSYLVANIA II DISC BRAKE & ROLOKRON j_J ' SERVICE BULLETIN I SUBJECT: . BTaEe Discs - Serial I_6-09370 B86-10425 Numbers Disc Asse:bly " " 28" 28" (NYC'TA R- 3b,) B86-o936o B86-09768 ;_6-n254 " " " " " " aS" 2b," (with Locking Plate Holes) 24" (without Locking Plate Holc._) _'_33 B86-2.2187 " " " " 24" 21" (Industrial Installation) (NYCTA Pioneer Trucks) Thi's bulletin is issued to advise of change in location serial numbers and date manufactured on the disc assemblies. This information was formerly stamped of the d/sc castin6 and it became illegible New location plate. is on the machined Refer to Figure of on the outer periphery after extended service. surface of the stsunped back 31-1 attached. _tomer Serv_e Dupar tmcnt G-g.5057-3 MECHANICAL-PNEUMATIC WHEELSLIPCONTROL for PASSENGER CARS "3-AP" DECELOSTAT ® EQUIPMENT Instruction Pamphlet WESTINGHOUSE AIR WILMERDING, WESTINGHOUSE PENNSYLVANIA BRAKE AtR DIVISION BRAKE COMPANY CO_E_S "3-AP" DECELOSTAT ® Equipment Parts of the Equipment .......................... Description of the Parts P-3 DECELOSTAT .......................... Controtler B-3 DECELOSTAT Valve Operation _)fthe Equipment Testing ............... .................. Westi_l]houll Wilm+dir.g, [ I L .................... 4 ...................... 5 ....................................... WESTINGHOUSE I 6 AIR Air Po., BRAKE Brol_l 1514B. COMPANY Oivls+on U.S,A. W_BCO "3-AP" DECELOSTAT ® EQUIPMEHT Tile The wheel slide matic means protecting It "3-AP" of wheel brake mittingtlle sufficient gamed train tored. Any to speed, car tained a wheel prt_,Sstlrc to enable the brake wheel cylinder to operates occurs ;1 low speed repeat its use of the pcr- have (b) either are tile 3-Ap shaft means fronl "['ht' an Ihc res- OSTAT its Further, forward or not occur conditions. during advantages Improves train even (C) sliding under sliding during brake by Protects car wheel Cam atlvcrse preventing 4. The simple AP DECELOSTAT is imum caused construction easily nf and tile 3- complete requires min- maintenance. consists of of the 3-Ap Equipment onecar for following: A P-3 tyox of each nizes to cause soften The slip the brake A B-3 2. axle. a wile, el ates IIIOunletl in on tile iournal DECELOSTAT its P-3 early 44 anti pilot recl,g- stages and DECELOSTAT Valve OSTAT quickly allowitlg the promptly vious when located reduces wbe_l restores brake to return cylinder on cylinder to DECELpressure, tt_ speed and to then its tile I)I:CELOSTAT to llosc lie which view, is tile It'lick ant] tile each counl.,cts DECEL()STAT 70 I)I,:CEI.OSTAT valve operation, each truck OSTAT P-3 pipe. tllc 7.1 bypilut axle valve determined quickly re_tlnlus and to its quickly [evt:l when restore the trabl spOed. brake is l_low, pilot pipe function is adjust brake wheel slidhlg cylinder Io pilot on the cylinder impends, pressure one anti as the of end B-3 air housing 411 phil valve "711lo operalllln. volume, e, owhich 70 ]telling cheek tl.'rmined uf the valve xalve I?) valve _1 lot air air tile ples- quick ventIo a il tltllL,;I Ihrougll choke quick _lnd t..xtCrll_l[ lilt vlduille Vidllnlt: C-C) or dia- lhu 143, lilt' purllllltltl_ vohlmc (Section the 7.1 Io operatl_ cht:ck operating valve by llperating presstirt, rt.- diaph[a_ln st> that plst,Ju DECI+I+OSTAT pihlt permits be +lperatc.d venting thL LOSTAT above valvc cl,vc.rs contains: DI-CF. pressure ilia) qnick Of lilts 6"% which thu tliapilra_lll DECELto a preIhou car DI'CELOSTAT, and rrltillt's a> tit rusI. th'ive tile re- o7, tile rcchargt.. internal t:xllausl showll Whu.n shall [ l0 in Ihc ex- vilIvu the car lhr, lugh 1(1 c(,nlleCted shdfl whlt'h ;itl;ICIiut] 90, asseulbly _s running, Ihc sphne It) tilt: wheel wheel I_:aring iriovu C_lln the rldler. rate t2tl I)) 3:3 ¢onlhnie 29 t'all_ ffrlill lilt' lilt.' The aml 32:40 roller-44 If inc'llia Iorcc IhOl 113 drivu Ihc sllaft cdr illnl inerti.i wile.el al lilt' c'atll lt?tilldill tff lilt' _2. lhL. ficc until sit,pc Ihc. 2_ 27 and antl speed IIII)\£ 2S i\le hi !lie,n -hoes TM c'tlllt;I, 17 _11 tff [t,i(_w trilL'el fat chlicll M,,pc • can! i(ln Ib InillHIg . orlgiilal Ill .l:_ I_ 27 shaft 27 ;illd tlrlvt' _,l',ll(,_ltt ,t,;h, ]lllllt -,4 t'alll wht't'l whcl.'l nltlde _hafi miler dtivt" frifllllll d is and alld lilt'Ilia DI'.CI'I.()ST.\T lhe of sprillg drlkl., 'lilt' 110 .iud to rnlatc, IhL, shafl forct" .ti ,is 42 C(lllt.lcl pretJ_.lerUlillL, ovel-travc.I <lnd luvcl autl applicatil,n shaft retarded. ball a brake thi\'m "_7. H) a,_ hmg [k.'vont] it rularded, rtdler Ill shot's WhL'I'] I,y shaft rt,lartlcd Cant Nllalt t.'lulch Illt'llKI driven nol I I I. with Ihriillgh lion 34 t'ap 4:_ rt)tatu' \Vlletl mounted air piston StlrC t21,tlpling thus R DECELOSTAT pin DECEI.OSTAT choke piston d":[c likewise Tile ls hiring nlllving pilot ilperating of Ihe P'3 ;Intl is CONTROLLF, wheel 37 fulcrunl V.alve initiatc._ (hlction I)ECELOSTAT DESCRIPTION OFTHEPARTS DECI3LOSTAT cam :32 and unseat boll_ lhu wtlich im,i)cralivc :t2, and p-3 clutch io.t:r-lravc, on around and of valve chock by f_f Flexible 43 ;t2, \Vlit:n pre- value:. A piece cam 3:3. ull shaft who, el each the by pressure It) the inertia wlwel spring DECP'LOSTAT OU shaft 3. end dtiction oper- Valve actuated inerlia 4-1 lllo_+t.s valve ouler haust valve -14, DECt+_Lt)ST.,\T tile The This with on 37 Ihv _-Ilel:l lhl2 shall the pft:tlt, action. DECELOSTAT truck. and tidier pressure DECEI.OSTAT 28 DI_t;I':I.OS'I'AT ndlcr friction _(/ Io t'ontat'l ing I. lganl c_llnprosging phragnl DECELOSTAT screws sclc, ws 47 drives Ilia 1{), Tile PARTSOFTHEEQUIPMENT A set and nlounled by affords tested, Io I_ar- IS attached 35 42 Lillac'hcd ofcnrs lhLis wheel (d) equipment Wilt*C[ is ball DECEL- 27 29 cap .3-1, anti slip rail braking. mechanical protection, flats wheel by thret, cap tllrotlgh rutl against during d Ihe o1" tht: I_aring Frictiim lever shoes will applications. wheels sliding shaft 2 tllnlailis Iocalt, Inerila ball wheel iniliale 3. are mountillg 10. row lO. inertia shall retardation fnr shaft roller 2. 113 provide ob- thai'wheel braking, slfline DECt£1.OS'IAT br:lCkt'l which 20 double shaft re- DECELOSTAT engineman its Ihc ;idallh.i ill 19 anti 27 the asscinbly a×lt.. bllX 13, I() by fnur Reassures and truck jotitlia] ings Equipment. l, I10 of tlriving housing re- is quickly function. in in lh¢ MI,v.,.'n piKIl<lns: to rap- After to as I<dlnwing tllc A drive Ihe the Following the (a) l0 value, speed. pressure similarly movement. through by applications. slip to to train return equipment equipment verse brake IJECEI.OSTAT i,f anti- cars re-occuranceofwheelslippingcauses DECELOSTAT the speed passenger during when is an a mecbanical-lmeU on sliding cylinder wheel equipment provides braking automatically d_crt:ast' interval that improving against l'uncti(ms idly DECELOSTAT equipment p-3 consists view dWtly I$ a ilhrllta[ is I_ilanc- all. W_BCO YAM The lion DI.X;FL()STAT correspundhlg Io Wh._+n lhc shaft cam shaft the value, I0 c_Iusing slope. rotates crum pin 40 which n+ovcs valve 70 quickly DECELOSTAT 76 upward venting unseating control pipe release of air the Venting the past hausted roller 44 inward ed moves and of air pipe C-C) DECELOSTAT the tile to and pressure is unseated chamber air also air 1_7. remainder slope, build the up the right permitting 7S 52 Ihrough inoves wHve At side quick a exdia* check and choke pipe. is returns exhatlsl decreases pilot hand vents of which spriug control quickly spring pennits for level. to a predetermined rod 50 701o be (_6 to Ehe predetermin- check valve recharge of V,cw Iho of p-9, DI_.CI:[ h2V_.'l volume. Cam OSTAT lelllq)v_d, PIIOI Valve s]l(_WJllg Wllh Calll h)c[l_ll)n Cam Relief Sho(t Volvo Cam p-3 AT lhc valve Cam Pilot I)I'CEI.t)S'I diaphragm a predetermined which This to 76 lhu ful- vent DECELOSTAT pipe c_ml 10. pressure diaphragJn control (Section off clmkc d:,'.'d Jllll* [flu c,,inL,d l,Jp_:p;igl 7h. moves _3 to quickly chamlx_,r (_7 after stmft and lull tlp on lh(J diaphragnl below downward and spring 84 so[its Thus when wheel retardation toward seated top air 81, clloke air B-3 control check.valve phtagm 70 valve 83. the volume through 81 is vented [urther over- shaft 43 around ahovc valve cylinder of the DECELOSTAT level air volume operate |_rake , ,,I hraku pull rod St) over to tlnse+it pilot exhaust to valve check Illu air J_ q,lickly chamfer raiL,. roller 44 to move lever 42 and the chamber Whcu ,'1 posi- _:xc_ssiv(a antl r_cl1_s inertia wheel cant This retard_llion |_conles the lakt's thus inSlalllan¢ous tetardalion a predetermined travels inultia wheel DECELOSTAT with L,v,r pilot valve body removed,showing 2 pilot valve and cam lever dctads ,Intl cam W_CD V_,"N,/ _:. +a_'_"_ z" a-+i +,+ p-3 Arrow ]ndicatt_s Testing DECE LOSTAT R_nlovablc of Exhat_sl DECELOSTAT Cap to p_'rmit ,"quiIPLnent I I '; p-3 DECI{I.OS'I'AT Mounted on .rournal ' I'-3 Box P-3 . DECELOSTAT-Assem!_Iy 3 View I)I'_CI{I +='- (+S'l'AT-St'ct1+m:tl + .... --7"i \'. x_ _BCO B-t DI'CFIJt)STAT VAI,VE DECI_LOSTAT curs. The truck, B-3 operates controlled as Tile pipe the moving or assembly bracket connections therefore ale the ix are pipe bracket replacing the located in the 41) and the as lease in on. slip of ftzattlre bolted tu not portions. bracket which illstlres the P-3 the truck to Ihe and bracket, when re- 4(l this as A drilled choke relay valve spring 27 spring air is to nnd 49, to lhus in these sure which 47 48 when top of to move • (c) follows: unseated chamber to around wheel from brake slip its air to a brake 47 drops tea 5 which plug air to recharge Ille chuck valve DECELOSTAT ul the at 1'-3 a rapidly of Another function the loss control pipe brake operation of pipe flow to thai air (d) choke brake to P-3 relay the plug 8 which the tile from p-3 21 Protection _lat]sI of side of diaphragm used to) may I)e returned permitting to its dischargtz move is justs tile brake cylinder DECELOSTAT cation. 22, when brok- It consists piston of spring the (g) position 48 housed In in for and piston cover is held seated on 20, from during piston 27 27 under occurs air venting side is brake the operating air Ix:low the of In normal and valve 21 the brake Protection pipe bracket cylinder tbat piston the pressure its of the air Valve 2 is 21, seal 22 (h) I)ECELOSTAT in attached body portion a predetermined 4_, tlowevt2r, 4g thus is un_eatcd yr.'aline This adjust the permits brake valve its 48 normal air ptston cylinder so:lied wbtH1 lilt' position. 40. which permits bracket diaphragm of quick chamb,:r 47 operation prevents check valve of the air on the In thu and insure I_u air pres- DECEI.OSTAT any back 69 which permits pipe bracket in the lower face fh_w when whc_l provides time a quick chamber of diaphragln cycle This Tile seal is initiated for uniform regardless of 47 due wh_..n a to wlleel I)ECELOSTAT pipt, bracket pressure. release lease of the check the air lower relay valve pipe of diaphragm face valve which in the permits bracket 47 a re- chambur during and a nor- release. by spring wheel slip the upward portion seated, when cylinders, valve valve release on vented, it pisair p-3 appli- piston off to a predetermined housed to is in Timing chamber ad- the brake When 21 moves cylinder The insure piston which 21. pipe DECELOSTAT 28. conditions. above sealing c vtindtzr of lh_l{eleas_Valv¢ braking holds is the but mal Piston perto occurs. and lye seat- body controlled 20, 48, and check face slip 46 inactive occurs body thus brake occurs, 49 of lower lower piston valve as slip This presSllle level. 47 charging with the that normal check pressure wheel diallhr'lgnl forlhcex- and so portion, 21, the of piston spring slip. Valve the upward functioning Release air v,'ht2n of level, follower lop A charging the ed. The [ac¢.. and Valve a prcdt:termhled Valve (f) a- rp case in connection air, tliaphragnr downward Iowt,r functioning slip diaphragm protect air chafnl_2r 47 pros- 1)13- permit II provides bracket 21 cylinder equipment. S is to Feature. pipe Ibe off from the to In slip DECELOSTAT is the piston returns 47 piston Check wheel valve, Choke which reseat rl_arlllal to anti sure 3. 45 of by diaphragll_ valves wheel and cylinder the from level. on top air brake tliaphragnl to valve UllSeal i)ermitting adjust culling Discharge and to empty DECELOSTAT of of the when application pall._, allllospbere, i)urJtlits spring anti such can control during gainst tile chaml_rs a rmt. on and It_ vented and 4_ up flow predctermblod piston I)ECELOSTAT CELOSTAT occuls controls diaphragln hmk- following: val'it_ns Thus i}redetermincd v_llve 21 fqnctions spring i'ffessnre when valve the uCctlrs. is 4fi and air ton houst2tl predetermined a Ilic air Choke 21 upward build 48 level. 2. is the i moves width to pres- are slip piston mils valve then seat t:ylinder in air during air relay piston check of " and pipe consists which wheel Diaphragm valve a drop valve upward flower around when Relay ttlf2 the chamlmr permitting due 21 vents the the chamfers application. pislon conlmls ipc- ph,ft'_ applicalic_n control potlion ill which fidlower I, slip portion. stir{2 Threechokeplugs ate wht.t.I DIt;CI:_I.I_S'I'AT llOl'l)IzII brnke Valvc Ihnly of por- body disturbed when Ib,, DECELOSTAT Protection (11) I)iapllragnl be valve which (a) bracket permanently need funcli_nls illcorpl_l'_llcs a a protection pipe il case The view. made pipe air wheel consists 211, lion tile cylinth_r wben in body in body in pipe brake It housed housed shown re,tore application. portion portion 2, anti on inountetl DECELOSTAT brake Valve Valve tion adjust p-3 duringa Release all to by the occurs Valve, DECI._LOSTAT ullnilmlenl Ftlrlht'r, Thus relay its ting seat level. to the the lower the timing left Its purpose adjusts the point quick once face When the control providing of check initiates the the charging charging of B-3 pipe, the pipe diaphragm valve wheel the check the slip 47 69 valve and and the occurs necessary choke volume the P-3 Valve 5 in restriction tht., to permitchamber, chambers release the DECELOS'FAT with is tmsuatud bracket below check valve. DECELOSTAT to operate by DECELOSTA'P prew-4_t loss '¢J..nting Valve of tilt., W/:_B brake c_lh_dL, ,:ontrlll pipe i_lgln )c.r and pr(J_ldiu_ vent il air Relay ton 21 conical to wheel thus Iower of piston air its on seM of ill lower tile side brake brake Ibc c iulch of pis- wlicel as shoes Iollg as the cat 69 is {b) pipe to its charge l'urthcl B-3 48 Ilten huild exhaust of to reapplied close up brake the is is first btdldup Ihus the pisloa moving quickly seats the of pislon dis- Whell tile unrest[icted B-3 air. The to cut broke Valve as and previously vohlme and ed the past :ire to Relay the cunnected check Relay In aft_, le 5. Valve the top l_ (in of wheel maclc occurs. The brake 14 vctlliug Dalld air this piston and when [o further valve air pressure discharge operate Relay Call not piston 21 aittoand against 48 Ihe air build up whicll from not brake loss of Relay the 29 The "AT r` DECELOSTAT Jllllnatlcally to show "Ap" gralnmalic brake so *2asily as xlntlelslood, the actual to make The force conslruetion O_OELOSTAT i_ 8 )'Stelll. in non-ol_c'ralive the of of lhe 5 P-3 iI(iSlllllll equipment position as tale. 5 air. pilot in lie shall ftcc whccl lhe Ihe xahic,, shdfl I0 This friCl loll tl[*t ball chllch shoes _*ll_pc /I/OVL'S slope c(lilldCtS ,I illllill;i! tl ;l%\'Ll\" [IIII// lilt' hilt, i,,llel. Iht, irlef- by lilt. illl)\'t.'s quickly t'hllke DEC[:I.OSTNI" valve venl DECI_LOSTAT ,i t, xct.,SSlVe illellla Ca[ll itlllt:r It:t'_r 42 pidl lhe roll -14 Ill _0 air over Oll Io ililSC,il C al-_wc bnildup lrllill .lir ui upward pipe lip 43 amlmd Ln cha:nl'-.,r 7;I cilil[rol alltl l*lirlhet nlllVl_, sh_ll r \ohunc' I'lqhr,ver Ihc. wile'el al/d ot_ rc,slrlClS 71_ and l,ikt,s It.t'onlt.s iht. chanllt, 1_3 Io IInis [t.l.lld.llltU! relating 7_ since whccl iIl,_l_lnlallt'llllS _.'atlslng curates 40 which 7tl dialdlragnl of 2 _; and speed liE- 42 ,ire -iS is I,alanced illerha l(i lelardal[on discharge ing 27 ,,led alld 52, B moves [/-3 arid shall 3a, lhe 27 ,i prt.dctcrlnlncd pin Ic_ct or [k, low I)F,I.;I't.OSTAT valve i_,llcq l alll is al I__,¢omes t-.till I0 unlll opposilc chailllt'T (_ I Ill tlrlve le/- _'heck shdfi l[ vohimt. to d p(_tlc, drier, wheel call_ body -0 _1[ Ihc" tlllgill, the Ihe tgil\w chcck p.lsClidmlt'f tlTlsealln_ {lit and llpt, fdll_. Valve. operation dt_viees. sllown the diaphragnl Dia- inerila (b) ql. apphcdiilm aHachc,I tlvl.,r-lravel x,litt to C]ldlII- chat_ing chLirgc, Illakc, fr,,nl (.i) ,if dlsc'h.ltge Dh tl, lhe with Tht' shlpu,. fntc'ftllll of III alhl WllCll iS 13ot intended with 3 which .lit .la: hlis plhll is relatdetl, t'llrll:sponthllg reacllt.s Choke oporathlg and r 13 _I/ plpt' \'a/\e check r I_ I(,p h} itllale spring cam anti O ch,il_ltk, I .till[ lilt' choke :\s it, lardailon "rht, r-liaVl_.ls connections chanll_.*r COlilrol 2 Chalnber _,lb, t, 4Sa dtapht.lgnl chanllt, axle and ul Ihc O{_glavnwlalie t.lr shaft llvt, is shown (_) air Cllargt's 7{_, 44 rtdlt'r to equipment lla._>aTc lo _ alltt [itnillng Valve lhTollgb Calll 47, Valve (d} _1_ SO that diapllragm flow (b} lit discharge Iroin IlL'lay It bc, lt,w Io shall 1_2 unseated normal (c) rt, larded, force pipe. c,]lindets. quickly ,{5 contilltit, dcs- and ,lit passage Rehly Illl)xII. ' {',lilt ira Valve through t'haml__,r Ihe If lhc choke control below insures the excessive Valve broken 41{ call its release through =\ _lll lllp el clleck 47 and 2b, I_tl st,<ll 2 ibl_tTh ,t icatllng chambml 2, _,.il_e li_ • ll,llnit.r 40 tt.'- K I,_ hold I" ,_il lop tdsR,n itll- the i_ass.igt, V.ilxc dlr flees passages check chai_lng pressure dlaphragnl hcf)ring due DI'_CF.I: Fol- of , illlmlt+r lethe Valtt. t-,ippl} Ihrongh 131_CELOS'I'A'I', (if lilt, d prl-'sslue wheel is Relay anti lifts diaphfdgul P-,{ r and hkcwisc as OPERATION OFTHEEQOIPMENT The a I)FCEI.OSTAT, N21.1ant[ sage molt2 Ill I_')'_lltl '2 ,ind Ill linllng bracket 17 whcre CI;.LOST:VI" Io 47 21 flows lop elfcctive broken previously flowing lilt} to chanlber above seated. lop (if vak, c ,%3 ,ll_tl restored made [o 414 as the valve IX_'r J on Cllainlt, is the ,tilt! P.etay air pipe p-3 pipe va[v£, 1o pressme returned DECELOSTAT lhrough ,2beck release Valve protects B-3 check nlallllOr then is is check Valve sallle 46 application lost does DECELOSTAT valve discharge the as is N to pislon and is pipe volume check Relay is vent- pipe Ihe AI Ct;iltlOI DECELOSTAT and cyliuders charge th,tt that discharge Ilowcvcr, THE.4 I;i shall Itcl.l,, pipe 5 IO (_1) pasFagc Valet! sillt_ Io AI 2 1 returns cylinder brake DE('ELOSTAT so so a brake Ihe and 21 cril__,d. to pipe, position flows Chalnber El-3 the to choke contlol .charging ill [lie pressure OSTA'I" tile piston control i'nlllledi/lle]y slip 47 Valve, control lhe IL_ a predeternlined Iowblg int'll I,) lt't.lhlt'_l iltadc. and IO ch,linl%'r diaphragnl t'ha[gus 2a I'b_wS fgtlllhct, choke, Rt, lay Iowt'r and 47;. IOp of nlint, ad/us:ted lo_cl III hlhll*ilgh flows bracket Relay past of If the is pipe diaphragm DECELOSTAT application opurales the air vented, O. Feature operative. .i hrake eql,llllllt'll[ air on it is froln the pipe air P-3 air to cylindel where t',elow choke Protection t'_coinus when The through cam: tile the valve control cllol, brake Valve chamber release and released Valve DECEI.OSTAT ValxL' (._,llll S]l,ill /12,W]llc ilia 21, dnd (_ k%-hlch It,ill> 21 valve, i_ J hillthng ;tit" ;l/sl_ Val\'c' Ihrough where' des- to ehalnber piston flows the 2, > {_ Ill pa_sagi., t.qlc, ck off cylinders ptessuTe recharged brakes DECE;LOSTAT ba,_.-n .llltl 2. sealctl, t'hokt leads the t'ap. with itrlvcn Ihrl'uith 4Sb I_,ehly qtliekly ,alvc hD.t" sh.m t =, arid allachcll is IllUS apiqit'ali_,n passages ed, lhe tile E , din ltlrllil/_ passagE's valve la rE,lease Relay 21 check Ib alld c rilx2d. back is t'linlllln),, .1.1 rol.llc whccq 27 DI_Ct'I.OST:VI" through leasi_ in a brakt, _-_ through brakes; valve DECELOSTAT atria lilt' restricted re- check P-3 ellleFS (a) exhaustopening. top Relay Valve 47 47 the oa cylinder to DECELOSTAT Valve 49 until timing in file Spring valve quickly 83 of cliaphragm position. unseated past Relay Ol1 lop keld of cliaphragm valve can air is pressure check altd 48 stele permits lower check Valve lower exhaust This control are on valve a predetermined closed. 45 check prc'ssure to and ion I,I!.HL._ I ISI',V]" linlil. When duced axl_ lilt' drivin whcel .l\_ I)l_(ll sliding. Discharge *.he air .ll% shall fi'icl ineilia predelernlhlcd prevent- shall ;llld 34 dliVt.'s Tht' t, ,_ ; t]lc I.I on miler 4.1 conlacIing 77. II_ 113 and dllvt' .12 alld miler tlll_llillg sphT,c I.o lilt' h.vcr from air lhrough tonllt,cled wilh cylin-Jer and ill Ill) rllllt,i a choke recharging and shaft check Ihv' t 31 I', l,Vh_.'ll the (lia- si(Ic 21, the 22 softening of [ace discharge to prevent off exhaust, upper lln Ibc. top Valve upward mducthm the hi unst:al the Relay it on pressLIre restrktioll Vak'e. m_wes complete air upwal_l flora sufficieut the pc[mit pipe Tbc 17 inow:s yah',,.18 ing and Canltrol 17 is vcnled. .,dlphlagJll is i air air. C{21 air Ihe ill Vei',tillg Dia- valve Ille which l_XllatlS[ the _l P-3 loa I)f tile predclcrlllilled is exhatlstetl Irom ct)l/Ir_)l pipe DECI':LOS'IAT chamlx..r Llll pt.'fmils chanllt'l pr¢ssuft: lhlotigh Ilnling ll prcvenls [t ,lit Iht, chiJkt, qlli_.'k ii,lSl yr..Ill - check (¢.'lllalllder i_7. Ih_' downward (if This lllncd return of - Vl/.q El re lgl V,,_V pisKotl 73 and seating DECEI,OST/C]" anti tilt, permitted Then 84 sprhlg seats rfl ch(:_:k cyt:iu has car whculs T:3 returns check valve h)itiatcd to rCILITll diaphragm valve _,3 unlil a blake after the cylhldcr Rclua,qe and spring 83. AI lhc vides the air in chamber The of air flail) piston 21. prevent in to valve Thus venting discharge from cylinder sir and the is connected preventing to wheel 48 its To face air the air pressure ed point and 83 and P-3 valve chamber 40. 4c, la, Ib, check tile is cam slope air DF.CELOSTAT seats up t,_ cdt off cylinder sure to then the chamlx_.r valve F anti the of exhaust quickly 50 hrake built up oi_ltion shaft in ate recharged as toward 70. Thus pipe aml Relay Valve air seating Relay The of is When Imck vented. tile At the chambers D, and through flows brakes unrestricted N, B-3 H, the Relay DECEI.OSTAT L and passage Valve Mlifts 20 brake Val_'e to release the Relay pre- exhaust cap is follows: from tile trniM outside by ill Ihe L*X_]_ll/Sl _lfl the the imlicated a finger the opening OCCIIt'_ a complete as whull on t operating thct? tx.,- cycle of p-.l at DI:,CI'I,OSTAT followed lhe 11-3 dist'hargu of bya exilaust ilt,avydisclmrge DI:.('I_L('sSTAT brake Valve. cylinder sir stops, Ihe inln_edialtaly. tile To cap titan in Valve p-3 air air uqtlipmelll from valve pipe the 48h 1'-3 to posiliou. exct!pt r_cctlrs [)ECEI.OSTAT When p-3 after cause an the' thelc reverse inertia wheel DECELOSTAT finger covcl, DECELOSTAT Valve 6 - Assembly View as tillle operation in the tiNt:real" the (in ex- cycle of duscril'.cd ttntil Ci;lll]l_tlt.*S tim Thus. described is lttrned a conlpletc place after 2,: _ lhat removed for as is hehl How /,1 g it t)pvlllng slops. is tesled 131:_C1'. exhaust wheel exhaust a slighl is 3-Ap intc_the inertia takes c'xhausl the the is a brit'f and tile insulted DU stllc'd (,potation Ihat is DECELOSTAT It should OSTAT equipment lion of car travel. 2. /.I B-3 fl)r t_rll of t'i)lgcr case DISCELOSTAT applied. it is the this direction) haust the Ih¢ of hut eilher pres- cylinder ihe tim Cxccpl testtheprotectionfcature opening above, check of itlaoocr direction. l_(luipnlenl above, 21 DECELO- witere operation ,_lllte opposite OSTAT 45, air ihe P,e- described. released arc to air ai[ heavy ru-applil'atJ_m flows Ilntil immt.diately in the B-3 brake Valve P-3 previously and I)I'7.CF.I.OSTAT made which that occurs Check piston air. DECELOSTATValveamlthe chaml_..r during 3-AP is first Inst.rt whc'cI Note re-apply off spring to brakes when A, Iht: tile below. cylindt:r thu and valve cylinder brake When moves with 83. of passage E which chamber of remove irterlia which q4 cmllrol of DECELOSTAT inward pilot Ihat pipe. position I)F, CI'_I.OSTAT LlpplicatJon fillger. equipment above, roller rod seat charge check is then STAT moves 69 in chamber antlB-3 and Ihc I)ECELOSTAT A bhlw passage 69. The of past Val,.'u to Iowc'f its attd Valve Relay D prior 4(_ hi operation view [he Ihe occurs valve DECELOSTAT through described I_elay the pipt" IRa until check valve lilt: p-3 Ihe a prudetermil_- B-3 exhaust. as 52 Valve discharge bnihls Tile decreases can to discharge reduced C to spring unseated til'eingcheck seated, spring Valve held reducetl seated. past retardation 10permitting lay are Band 83 D is is quickly L, chamber wheel tile 70 chamber is tile [(l(n move DECELOSTAT D air valve 48 test Then on arid softening sliding. valve in chamber the pilot Valve check in chailllx:r i/istoll a hrake of arrow and tile Discharge and _ f_llltt_J check to Ihc x'ettt 2a operation is standing. 22 Ihus air undesired I:_qtlipnlunl lop Valve seal exhaust. of holding and A on Relay off passage Iht' TESTING is restriction'to Valve. upward M to _1 It_ litl 47 valve sufficient 21 47 chamber i.survs pL'lllIl[ :ltr pipe diaphragm check Relay piston of 6 alld X provides B moves brake side cllalllhet" 481,, II (; chanllx_,r releasE,, of brake Control of diapllragrn lower F. passage Choke loss with ','enls pro- 5, is vented. face the unseal chalDI)cr recharging brake pipe E on the upper on choke to prevent control pressure chamber the the it upward vent Valve. restriction when vented. moves DECELOSTAT necessary cylinder air B-3 t'h,lnlt)_.'l I.! and check E from llir chaulbcr t'otlncct lo"trahl spe(:d. 76 downward of aml [¢luase tile al brakes exhaust 3-Ap f_,r mlhcr lilt' tht I are of air DECELthrec- reat P-3 p.3 DECELOSTAT \ DECELOSTAT / 83a _7 83_ 42 I 8_ 66 113 619 43 / / 35 3:_ 2a 8*3 48a\49a DECELOSTAT • 69 VALVE 70 48tJ 27 22 Diagrammatic of the "AP" DECELOSTAT Equtpment BRAKE CYUNDER 3227-11 Ah AlnlrIcIm_-$t aRd_lrd "P-3" DECELOSTA T°CONTROLLER PARTS (SUPERSEDES ISSUE CATALOG DATED MARCH, Westinghouse WESTINGHOUSE ]975) Air Brake AIR BRAKE COMPANYJWilmerding, Division Pennsylvania 15148 C¢*_ r 3227-11 WF_Br_-o 39 40 75 76 77 88 \ 97 95 94 93 55" 20 21 92 48 47 SH_P PING ARRANGEMENT 51 52 49 87 _85 17 15 56 64 102 • \45 67 103 66 I0I'_'_ IO0-- 82 99 SECTION 78 73 E-E 81 A 58 59 37 26 27 34.. 28 57--_ O 1 SECTIO_ B*I_. (PILOT SECTION VALVE BODY REMOVED) D-D Figure 33 SECTIONc-c 32 1 50 -3227-11 W_BCO VAN," "p.3 °' DECELOSTAT CONTROLLERS Bracket Shaft with Control Assembly Pc.No. Portion Clamp Ring 38 1 Axle Adapter Remarks 46 Ref.No. Fig. 533146 533144 529755 UN440596 5-1/2 6xll x 10 AAR 532452 533144 530795 UN440596 5-1/2 x 10 I11. C. 550860 533144 529755 UN440714 5-I/2 6xll x 10 AAR Std. Journal 544146 555368 529755 UN440596 5-1/2 6xll x 10 AAP, Std. Journal 544251 555368 529755 UN440714 5-1/2 6xll x 10 AAR Std. Journal 545840 555368 529755 UN440720 5- 1/2 6xll x 10 A.AR Std. Journal 546202 535689 529755 546190 • Adapter for Std. R.R. 6 x 11 Timken Journal Replacement with AP-3 Decelostat • Additional The fiMfowing Repair Portions are also Journal Items of Rolokron Required, See page 5. available 533145 535690 550859 • "P-Y' 533144 533144 533144 .PORTION, DECELOSTAT UN440596 UM440452 UN440714 540113 553835 544252 544619 "P-Y' 535689 533144 555368 555368 .PORTION, LrN440720 LrN440714 UN440596 .SHAFT, Drive Drive 554576 545841 551865 535633 "P-3" 555368 555368 555368 533144 .PORTION, UN440720 UN440720 UN440783 UN440596 529428 548404 540114 541234 "P-Y' 555368 555368 533144 533144 .PORTION, UN440596 I.TN440714 UM441M52 529428 529428 529428 .GASKET, Shaft Asy. 1 ....... 1 1 PORTION, Drive Shaft Asy. .......... 1 1 .................... 1 CONTROLLER CONTROLLER, Drive PORTION, Drive ....................... DECELOSTAT .SHAFT, 529428 less Supporting 551369 less CONTROLLER Controller, Drive .GASKET, 1 .................... DECELOSTAT 529428 Asy. ....... ....................... Supporting .SHAFT, Shaft 1 CONTROLLER CON_FROLLER, .GASKET, PORTION, less Drive ....................... DECELOSTAT .SHAFT, 529428 CONTROLLER CONTROLLER, less PORTION, Drive Shaft Asy. ....... 1 ....................... Supporting 1 .................... Approx. Net 1 Weight 32 [bs. "P-3" DECELOSTAT®CONTROLLER PORTION No Fig. & Ref.No. 1- 1- Pc.No. 533144 Name "P-Y' DECELOSTAqTD 555368 CONTROLLER 1-1 540296 .WIRE, 1-2 529722 .SCREW, 1-3 534542 .WIRE, Coupling Lock, Cap, Lock, PORTION, Ref. Nos. 1 thru 109) CONTROLLER PORTION, Device, less Drive "P-Y' DECELOSTAT Drive • Req'd Drive Shaft (Incl. "P-Y' DECELOSTAT 535689 1- Parts Shaft (Incl. Ref. Nos..1 CONTROLLER PORTION, (Incl. Ref. Nos. 1 thru lid., 3/8 x 7/8 5 in .......................... ASY., less .with thrn 112) ASY., with Checking OLDHAM 106) 15 in .......................... H. ASY., 1 in ................. 2 2 3227-11 W_BCD DECELOSTAT®CONTROLLER PORTION[Cont'd) "P-3" Fig. & No. Ref• No. Pc. No. I 1-4 1-5 Parts 533136 533143 Name Req'd I 533143 .SCREW, 544190 531691 • .WIRE, 1-7 536963 • .SCREW, 17173 1-9 533133 1-10 H• VALVE, 1-6 1-8 Cap, • PILOT Lock, 3/8 x 3-3/8 (Incl, Ref• in ................ Nos• 2 6 thru 34) .......... 2 10 in ......................... 1 H. 4 Cap, ..WASHER, Hd•, Asy• Hd., Lock, 3/8 3/8 x 1 in ................. in ....................... 4 533097 • .COVER, Diaphragm ........................ • .DIAPHRAGM ............................ I 1 1-11 533125 ..FOLLOWER, 1 1-12 533134 1-13 501006 • .O-RING, . .SPRING Diaphragm ....................... 5/16 in. O.D ....................... ............................... 1 1 1-14 99458 1-15 533135 1-16 533886 l- 17 1-18 534705 530250 • .VALVE, Pilot • .SPRING, Valve 1-19 531691 • .WIRE, 1-20 536963 • .SCREW, 1-21 • .WASHER, 1-22 . 17173 533148 1-23 533132 • .GASKET, 1-24 515215 • .VALVE, Check 1-25 533137 • .SPRING, Check Valve ....................... 2 1-26 524101 • .SPRING, Valve (Press. Lira.) ................... 1 1-27 532715 • .VALVE, Check (Press. Lira.) ................... 1 1-28 521663 • •STRAINER, 52961O • .VENT 1-29 529610 1-29 • .GASKET, • .NUT, • .SHIM, Ring Cap, .006 1 1 ......................... 1 10 in ....................... 2 H. 4 Cap, Hd., Lock, 3/8 3/8 Valve x 1 in ............... in ..................... 4 ......................... Cover 1 ........................ 1 ........................... Wire CAP 1 3 ........................... Lock, • .COVER, 542665 .......................... Pilot V ....................... in. Thick ..................... 2 .......................... NUT (Incl. Ref. 1 30) .................. 1 .................. 1 1 513047 .CHECKING DEVICE (See Page 6) •..DIAPHRAGM, Vent ........................ 1-31 533142 • .BODY, (Incl. Ref. Nos. 1-32 504013 ...PLUG, Choke, 1/8 NIT (#61 Dr.) 1-33 900946 ...PLUG, Choke, 1/4 NFF (#57Dr.) 1-34 505842 .•,PLUG, Pipe, 1-35 529427 .GASKET, Housing 1-30 513047 1-37 D 531741 1-38 529775 531741 .WIRE, 530795 529721 .BRACKET • .SCREW, 1-40 15951 ..WASHER, 1-41 1-42 529617 1-39 562172 531741 Pilot 0 0 3/8 Lock, Lock, 1/2 529428 .GASKET, Supporting 1-45 529175 •GASKET, Ring, SHAFT, • •COTTER, 3/8 1-48 ..NUT... • • 1-49 1-50 • .SPLINE, Drive #2 • • KEY , • • 1-51 • .CAP, Coupling • .SHAFT, 531872 Noa. 39 - 43). 1 4 In ....................... 4 1 with Relief Fitting .................... Relief .......................... 1-47 531872 1 .......................... 1-44 1-53 1 ....................... CLAMPING RING, Aay, (Incl. Ref. H. Hd., 1/2 x 1-3/4 in ............... 555057 1-52 1 ................. 1 Clamping •DRIVE I 2 1-43 0 34) .......... 20 in .......................... • .BRACKET • ..FITTING, 1-46 NFT 31 thru ................. .......................... with Cap, ..RING, 530796 Valve Drive . ......................... in. Asy. (Incl. x 5/8 in ...................... • • Shaft • 1 6-7/8 • • • • O•D ................... • Ref• • B . Nos. • • • • . • • . • • • • . . • • • • • • • • • • • • • • • • • • • • • • • • • .......................... ........................... 533110 • SCREW, 1-56 519821 .WASHER, 1-57 550549 .SLEEVE 1-58 .PIN, 1-59 550548 524620 .PING, 1-60 533120 .BEARING, Or. Fil. Hd., #12 ......................... ............................... ............................ Ball 4 1 • 1-55 Packing 52) ........ • 533674 Fulcrum 46 thru . 1-54 LOck, 1 ....................... .THREAD PROTECTOR (Shipping Only) • WIRE, Lock, 5 in. Long ....................... Mach. 1 I .216 ............... x 5/8 in ............ 1 2 4 4 1 1 ............................ 2 ............................ 2 3227-11 I_BCD Fig• & Ref. No. No. Pc • No. Parts 1-61 533069 .SPRING, 1-62 533067 •SEAT, 1-63 .ROD, 1-64 533068 533036 .LEVER, Fulcrum 1-65 533054 • LEVER, Cam 1-66 521200 • •COTTER, 1-67 77787 1-68 526804 ..ROLLER, 1-69 533053 • •SHAFT, Cam Roller ....................... 1-70 533052 • .LEVER, Cam Roller ........................ 1-71 533674 •WIRE, 1-72 536962 .SCREW, 1-73 Name Cam Lever Spring Pull • .NUT, 9469 Req'd ......................... Roller 1/16 Hex, (Incl. x 1/2 1/4 H• Hd., 3/8 bck, WHEEL Friction 533075 • .SHOE, 1-77 533108 • •SPRING, 1-78 1-79 533058 • .CA-M ................................. 533892 • .SHI.M, 1-80 533038 • .WHEEL, Inertia, Drilled 1-81 533891 • .WI.EEL, Inertia, Threaded Clutch 533121 • .BE_RING, 533061 .WASHER, 1-84 537046 .SHI'], 1-85 554999 .SLE 1-86 555000 .SLEZVE, 1-87 524719 .RIXG, Packing, 1-88 536967 .WIR£, Lock, 1-89 536961 .SCREW, J :: 1 in ............... 71, 3 . ........... 72, 73 and 75 thgu 3, 82). • , I 1 3 3 I Plate ............. Double 1-5/16 x 1-5/8 ........................... Row 1-5/16x ............ I ..................... 1 .................... I ....................... I x .398 x 1 x .010in .1 in ................... ..................... 3 Small ........................... 1 Small ........................... _i 1-1/4 15 in. Cap, .WASHER, 533128 532045 1 ............................ Clutch 1-82 533128 532045 I , (Incl. Ref• Nos. .......................... Clutch 1-83 1-93 1-94 1 2 5/16 1-76 H. Lock, .BEARING, .NUT, Lock I in ............. .INERTIA ..WHEEL, 526801 1 . ........... 533123 .DISC, ............ in ....................... 533122 9469 70) ............................. Cap, 533073 66 thru ............... .WASHER, ".VE, 1 Ref. in .......................... Cant Lock 1 .......................... 1-75 1-91 1-92 1 .............................. 1-74 1-90 1 ............................ in ....................... Long Hd,, 3/8 Retainer I ...................... 5/16 x 3/4 1 in ................ 6 in ........................ 6 ........................... 1 Ball, Double Row .............................. .................... 1 2 1-95 1-96 533074 .WASHER, Lock ........................... • PLATE, Baffle ............................ 2 1 555056 • SEAL, 1 1-97 526802 • BEARING, 1-98 531147 .NUT, 1-99 • .RING, Retaining 1-100 531150 533147 • .SEAT, Spring 1-101 94581 • .SPRING, Check V .......................... 1 1-102 529900 • .VALVE, Check ........................... 1 1- 103 531145 • .BODY, ........................... 1 1-104 533119 • SHAFT 1-105 533035 1- 106 515794 • HOUSING, Controller • .PLUG, Fluted Socket, 543075 • .COUPLING, 543076 • .NUT, 534542 • .WIRE, 1- 109 5- 1-110 1-111 1-112 • Additional a NOTE: 534352 Items 534352 Required Not a part of the _r "P-3" Pc. No. .TAG, 546202, Decelostat Oil .............................. Cap, Cap Ball, Single ........................ Ex. Valve (Incl. Ref. 1 Nos. 99 thru 103) ........ 1 .......................... 1 ............................ Nut 1 ................................ Drive 1 (Incl. Ref. Pipe, 1/8 1 1 .......................... Special ............................. Lock ............................. Instructions No. 106) ............. in ................. . (N.S.) 1 1 1 ..................... 1 Assembly. Controller Portion, but of the complete device; See Ass_wnbly Pc. No. Index. 3227-11 "P-3" DECELOSTAT ®CHECKING DEVICE 2 3 4 5 7 Fig. 6 \ 8 & No. Ref.No. Pc.No. Parts Name 1- 542665 "P-3" DECELOSTAT DEVICE, Figure This page 1 supersedes An Fabrua_, 1977 P. C. Arlifi¢lrl-Sllndlrd Req'd Asy. CHECKING (Incl. 1-1 545705 .PIN, 1-2 542670 .KNOB 1-3 542669 .SPRING I-4 1-5 542667 .RETAINER, 1-6 541827 542668 .DIAPHRAGM, Vent .SHAFT ............... 1-7 542666 .BODY, 3227-11P, ,( dated .081x3/4in Ref. 1 thru 7) .......... 1 ................ 1 ............... Device 1 Ven_ Diaphragm . . . ......... l 1 1 ........... 1 11-20-53. Comptny P_inlad in U.S.A. G-h-3227-11, Sup. 4 _S_NQNOU_[ _lR I_A_| CO AMERtCAN-STANDA "B.3" TYPE DECELOSTAT VALVES (Supersedes issue dated November, 1969) Ports Cotoleg WESTINGHOUSE WILMERDING, PENNSYLVANIA AIR BRAKE DIVISION G,h-3227.11, Sup. 4 W/_Df"O "8-3" TYPEDECELOSTAT VALVES-INDEX ,I Potions Release _ Protection Bracket Pipe TYPE Pc. No. Valve B-3 533356 533334 533338 ...... o.l°*l 533492 533334 533497 ...... °**o.* 566735 533334 ...... 566739 574304 575966 533334 575968 ...... 574308 B-3-C • Pipe Magnet NOTE: • NOTE: Pa_ of Pipe lndlcatesHpe Bracket Potion Bracket less Bracket • 575967 Asy. Detail Pa_s connecUngTtfl_and I with Tube ...... for Magnetsmaybefound Fittings. © 2' Pc.No. Volts Valve Pages .° 533355 3, °° 533355 3.5. 529327 32 533355 3. 5. 528569 529327 64 32 533355 ...... 3. 3. 5. 8 in Pa_s Catalog 3228-1 5, G-h-3227-11, S_p. 4 W/:_g i,-,,D ! 16 /' / I5 13 Figure 1 ;ELEASE VALVEPORTION Fig. & Ref.No. Pc.No. Parts 5333341575968 No. Req*d Name RELEASE 1_1 t2505 .NUT, 1-2 17129 .SCREW, 3/8 VALVE Hex., 1/2 Hex.Hd. x 1-5/8 PORTION, in ..... .RETAINER, 1-4 533333 .GASKET, .COVER, Top Cover Top ......... .SPRING. Piston 8333311575963 569160 1-9 520320 1-10 500430 .PISTON, ..SCREW, Cap, 552346 1-6 Parts 4 Gasket 27660 501331 • .SEAL, ..... 1 1-13 532456 ..... 1 I 1-14 1-15 571140 502465 .VENT PROTECTOR, ..RIVET, Pop, 3/16 1 1-16 536419 ....... t .RING, Piston, 2-1/2 in. Dia. 1 1-17 t .RING, Piston, 1-5/8 in. Dia, l 1-18 Complete Device. NOTE: § NOTE: part of Pipe Not a part We are Bracket, of any prepared Fig. Portion, to furnish • .WASHER, 533329 tt533336 the a part of the following Fig. & Ref. No. Size 1-7 2-1/2 1-8 1-5/8 Repair Rings for the Release O.D, Pc.No. Remarks in, 505865 505866 505867 Standard 2nd Repair 3rd Repair 505868 4th 504236 530728 Standard in. 2nd Valve Vent .NIPPLE, .BODY, Pipe, Release GASKET, Body Piston: and Ist Repair and Ist Repai_ Repair Repair 9/16in. Piston • .SEAL, 3 but Asy ......... Retainer 1-12 1-8 f NOTE: Req_d 1-11 1-7 tt NO. Name 4 in ........ 1-3 1-5 Pc.No. ASY. Fig. & Ref.No. ...... O.D... ........ 1 I I I Asy. . x 1/2 in. l I I x I-I/2 in.. Valve . .- . . I I ........ 1 ......... I G-h-3227- 11, Sup. 4 W/:_BCO I I ' I I I I I I I I I --8 F7 SECTION C-C -41 41 SECTION 18 I7 SECTION 4 5 B-B 2 D-D / 2O © l / II I0 16 SECTION 15 13 21 A-A Figure 4 2 G-h-3227- 11, Sop. 4 W_B,.-. r., PROTECTION VALVEPORTION ' Fig• & :Ref.No. 2- Pc.No• Parts Name 533355 PROTECTION VALVE PORTION, .GASKET, Ring ............ • DIAPHRAGM ............. 4 2-14 534662 .O-RING, 1 1 2-15 533348 .FOLLOWER, 2-16 569675 .SPRING, ........ 3 2-17 521309 .SCREW,Ov.FiI.Hd., ........... Check ........ 3 1 2-18 33775 2-19 537055 •SHIELD, I 2-20 533354 .BODY, 1 2-20A 4 1 2-21 .SCREW,Hex.Hd.C.ap. 3/8 x I-1/4in. -533345 .COVER, .GASKET. Check Valve Cheek Valve ........ Covet • SPRING, Check Valve Check Valve .VALVE, .SPRING, 2-8 534528 .SEAT, 2-9 534663 .VALVE, 2-10 2-11 t NOTE: 15784 527566 Not • SCREW, • COVER, a part of any Check Check Valve in. .... ......... ........... Hex.Hd.Cap, Bottom ............ Portion, Req Jd 522980 2-3 536515 Name 523619 x 4-3/4 535022 Parts 2-13 3/8 2-7 No. Pc. No. 2-12 .SCREW,Hex.Hd.Cap, 2-6 ,_ No. 4 t 555416 3210 533346 533347 Fig. Ref. ASY. 2-1 2-2 2-4 2-5 No• Reqld but 3/8 of the x 1-1/8 Complete in. Device. 503476 t 533337 3/8 O.D ........ Diaphragm Return .WASHER, Body .190 3 3 ....... 1 Valve ............ l/2in. in ...... .......... Wasp 1 1 .190x Lock, Protection 1 ...... ........... Exhaust ..EXCLUDER, GASKET, in. l 1 ......... 1 1 1 G-b.32_- I1, Sup. 4 4 Figure i 3 PiPEBRACKET PORTION (B-3only) Fig. _ Ref.No. Pc.No. Parts No. Req_d Name Fig. & Ref.No. No. Pc. NO. Parts Name Reqad 1 3- 5333581533497 3-1 2505 3-2 500871 PIPE BRACKET .NUT, Ref. 3-3 6983 .... .STUD, .BUSH, (Not Hex., PORTION, 1/2 in, (Fig. ASY. 3-5 1) ............ 1/2 4 x 1-3/4 Reducing, Shown) 3-4 1, ......... in .... ! to 3/4 78727 534163 .PLUG, Choke, 1/8 in. (1/8 .PLUG, Choke, 1/4 in. (Not 4 in. 1 6 Shown) ......... (#70 Dr.) I Or.) I G-h-3227- 11, Sup. 4 W_EICn I I I 0 O0 t 13 2 \ 4 7 1 8 Figure 4 PiPEBRACKET PORTION [B-3-Conly) Fig. Ref.No. 4- 5667391574308 4-1 3134 4-2 93840 4-3 574305 Parts Name PIPE 541507 Req'd BRACKET PORTION, .GASKET, Fitting, .PAD, Tapped, 1/2 Stud, • . 541506 3/8 4-6 566741 4-7 5951 in. .TUBE, .SCREW, 1-1/2 4-8 93986 4-9 3134 .GASKET, .SCREW, I-1/4 -J NOTE: 15951 Name .WASHER, Lock [ ...... .MAGNET, FB-2 1 4-11 ...... 1528569 • MAGNET, 1 4-12 566740 .STRAP, 4- 567547 .PIPE See P.C. 2505 O.D ......... 1 4-14 500871 3/8 in ......... Hex.Hd.Cap, l 4-15 2 4-16 517999 • .PLUG, 1 4-17 534163 • •PLUG, 2 4- 576441 SCREW, 1/2 Mounting ......... Hex.Hd.Cap, 6983 1/2 Reducing, Used to secure the Mounting Valve Su'ap Not a part of the Pipe Bracket, but a part (Not x (#70 and Flange Fitting furnished of the Complete Device by customer Shown) (Fig. (Not Pipe 4 I to 3/4 I 1/8 in. 1/4 in. 1 Shown) 1/2 1 1, 4 in .... .......... Cap, to the l ....... Choke, De.) in. x 1-3/4 Choke, De.) 1 ...... Asy ..... • .BUSH, 0/16 0 ....... 1/2 Strap in ........... 3228-1 Mounting • .STUD, in. 1 (64 Volt) • .NUT, Hex., 1/2 Ref. 1) ............ x 2 1 ....... FB-2 BRACKET, 4-13 Threaded, ....... (32 Volt) 3228- P.C. 1 in ........... Req'd 529327 See 3/8 4-5 4-10 Parts 4-11 Threaded in. O.D ......... .FITTING, Elbow, No. Pc.No• 2 1/2 in. in. (1/4 ............. • FITTING, & Ref.No. ASY. •SCREW, Hex. Hd. Gap, 1/2 x 1-1/4 in ........ NPT) 4-4 Fig• No. Pc.No• .... x 2 in.... Bracket. 1 2 G-h-3227- 11, Sup. 4 2 [ 16 3 \ 15 / 7 9 5 14 f d: J: FCRT I - MACE PCI_ I . _P/ILY _l_r J . I_I_ED v_¢Ll_ 5 Figure PiPEBRACKET [B-3-C)LessTube Fig. & Ref.No. Pc.No• Pa_s 5- 575967 PIPE BRACKET 5-1 514274 .SCREW, 5-2 533337 •GASKET 5-3 565964 .COVER ................ 5-4 3134 • SCREW, Hex.Hd.Cap, 5-5 93840 .GASKET, Fitting, 5-6 507620 5-7 5-8 i 541507 t 541506 • PAD, t 575965 5-10 5-11 5951 93986 5-L2 3134 t NOTE: Not a pa_ 15951 .WASHER, Lock ........... 529327 .MAGNET, FB-2 (32 Volt) See l 5-15 566740 2 5- 567547 .STRAP, Mounting .PIPE BRACKET, ........... Asy ........ 1 5-16 • .NUT, in.(Fig. 1 5-17 I 5-18 , 3/8 • , I 5-19 517999 . .PLUG, in. 2 5-20 534163 . •PLUG, Strap(Not Shown) 1/2 x 1-1/4 in. 2 1/2 1/2 x 1-1/4 • • in ...... , • • 3/8 • • In. O.D. 3/8 in. • • • • Parts Catalog 3228- L Hex.Hd.Cap, .GASKBT, • SCREW, Mounting Hex.Hd.Cap, Bracket I/2 Portinn, 2505 1/2 x 1-3/4 6983 ..BUSH, Reducing, Shown) Choke, (Not Shown) I but of the Complete 1/2 • .STUD, I x 1-I/2 Hex., 500871 (Not Ln. O.O ......... .SCREW, of the Pipe in. ............ • 4 1 Stud Threaded, Elbow Threaded, , No. Req'd Parts Name 5-14 ASY. 3/8 x I In• • . ............... • FITTING, .FITTING, Pc.No. 5-13 PORTION, Hex•Hd•Cap, Blanking .TUBE, F[g. Ps Ref.No. No. Req'd Name O•D, 5-9 ./ (Not Choke, Shown) 2 ........ I 1 L, Ref. 1972 1) 4 in ........ l to 3/4 4 in. ............. 1/8 1 in. (I/16 IX.) ............. 1/4 ": in. (#70 IX.) 1 ............. Device. PHmed U_,, [ in U.S.A. C-7-23 7.5 Brake pressure Condition Indication System These cars are not equipped with brake switches, unlike later series cars. applied and released The 2900 series cars are equipped with 4 local brake indicators along the side sill. This is the standard HEP installation. Refer to the main manual for details. 7.6 Maintenance the 2900 components 7.7 Overhaul Procedures The WABCO manuals included here are for components series; CF brakes and 3-AP Decelostat. All other are discussed in the main manual, section 7.6. Brazing Refer 7.8 and Drawing Piping to Procedure Main Manual. List Function Air Brake Schematic applied Drawing Number D-03-441 unique brake to C-8-1 C-9-I C-I0-1 C-11-1 CHAPTER Refer CHAPTER 9 8 to FOOD HANDBRAKE Main Manual SERVICE EQUIPMENT N/A CHAPTER Refer CHAPTER 11 Refer to 10 Main COUPLER to Main TRUCKS Manual AND DRAFT Manual GEAR C-12-1 CHAPTER i 12.0 12.1 12.2 12.3 12.3.1 12.3.2 12.3.3 12.4 12.5 12.6 12.7 List of General Illustrations - Refer to main WATER SYSTEM manual Undercar and Interior Equipment Refer to main manual Water Cooler - Refer to main manual Water Heater Hatco 16 Gallon Upright Water Heater TET 10, 18 and 50 Gallon Heater N/A TET 1 Gallon Heater N/A Insulation Refer to main manual Water System Food Service Area N/A Water Draining, Filling and Flushing Instructions Refer to Main Manual Dra_ving List LIST 12.1 12.2 12 Hatco Hatco Electrical Parts List OF Schematic Page C-12-1 C-12-3 C-12-3 C-12-3 C-12-3 C-12-3 C-12-4 C-12-4 C-12-8 C-12-8 C-12-8 C-12-8 C-12-8 ILLUSTRATIONS Page C-12-5 C-12-6 C-12-3 12.0 General - Refer 12.1 Undercar 12.2 Water Cooler 12.3 Water Heater and to Main Manual Interior Refer Equipment to Main - Refer to Main Manual Manual The 2900 series cars are equipped with a single 16 gallon upright water heater located under the liner locker near the center the car. The heaters are equipped with pressure/temperature relief valve, set at 125 psig and 210°F. For freeze protection, the water heaters are equipped with an Ogontz automatic drain valve, opening 39°F water temperature. The units also have a manual drain valve, have a feed shut off valve. 12.3.1 Hatco 16 This control system small control Gallon Water is an upright unit is 120V, produced transformer located figure 12.1 and NOTE: This heater is for the except Upright of at and Heater with a 480V Kw heater element. from the 480V contactor feed by within the heater control box. The a See 12.2. identical control to that used on successive orders transformer. Hatco uses a water sensing probe and relay for low water burnout protection. The probe extends into the tank. Since water is a conductor of electricity, when the probe touches water, a circuit is made to the low water relay (LWR), picking it up. Closure of the relay completes a circuit to the thermostat, enabling it to energize the water heater contactor. The contractor controls the 2 heater elements to heat the water. The thermostat is set at 135°F. C-12-4 There the contactor temperature. contactor and are also 2 high temperature limit thermostats (ECO) in coil circuit to protect against excessive water The control circuits are 120 VAC, elements 480 VAC. The LWR are contained in the front box on the water heater. In the unlikely event that the LWR will not pick up, short terminal 3 to 5 of the LWR. If the relay then picks up, the fault is the water probe, which may be covered with scale, and should be cleaned. The water heater tank must be grounded to the carbody with a wire. For tests, refer to test Spec PQ-79-1 test 12.3 To service the unit, make sure to turn off the water heater breaker in the electric locker. 12.3.2 TET 10_ 18 and 50 N/A 12.3.3 TET N/A I Gallon Heater Gallon Heaters _CONTROL PANEl. I i I WATER i I I.Y/CO CUT-OFF PROBE O i SET TO 135 ° F CONTACt'OR 480 V-5 I PH. BLACK _.ELEMENTS ._KW _4_,TCO ELEC.Tr_.IC_L EACH ._CI4[_M_TIC I ITEM 1 Z ] S 6 ? 9 !0 11 I::_ 1_, ';__, TGZ)O$';_OVOL_" 13 318" - 16 x 3/R'# Sq. Hd. (4 per elemerr:) ............... cpMS PI_,'(-¢.O I_,I_.'C_ LI.5* F HATCO ITB4 1 QTY DESCRIPTION Figure 12.2B 16 GALLON WATER HEATER MFG MFG # AMT # HATCO 2 3 HATCO HATCO HL 4934 S-5-12 4 5 Element Gasket Heater Element HATCO HATCO 1-16717 TG 2303 480 Volt 6 Pressure/Temperature Relief 125 PSI/210°F 3/4" WATTS IOOXL 23P6005954 7 Vacuum Relief WATTS 36A 23L9010715 8 9 "Ogontz" Automatic Drain Valve Water Heater Contactor "WHC" (Replaces Alien Bradley Contactor OGONTZ GE PP 39FRH CR205C022 23A9000040 25E9011692 10 Ii 12 Water Heater Water Heater Transformer, GE GE Micron 150D21G22 546A301G2 B-160BTZI3 13 14 Fuse, for Low Water Primary, LWR Relay Rod 316 Bussman B&W BBS-1 TYPE-L B&W Rod 316SS PVC Insulator 15 Valve Valve 3/4" Contactor Contactor Control Coil 120 VAC Contacts Transformer Relay "LWR" 120 V 220 V Secondary Water Probe SS RV # 25B9008678 16 Gallon Water Heater Complete 480 V 6KW 3Phase ECO High Temperature Limit Switch Thermostat 3KW, 480 Volt AMMS 25K9007995 D 16 Thermometer/Pressure .50 NPT Gage 0-200 PSI, 60-200 ° Marshaltown FIG 107 23N9012942 I -.J C-12-8 12.4 Insulation Refer 12.5 Water to Main System Food Draining r Manual. Service Areas N/A 12.6 Water Refer 12.7 Drawfng to Main Fillin 9 and Flushing Instructions Manual. List Function Drawing Number Water Heater Electrical Schematic D-O4-440-Sht. Water Piping Schematic, 2900-41 2980-97 D-03-442 D-03-443 5A C-13-I C-14-1 C-15-1 C-16-1 CHAPTER 13 Toilet Refer CHAPTER 14 to 15 PERIODIC Main Manual MISCELLAENOUS Refer CHAPTER Appointments to Main INSPECTION Refer to CHAPTER Refer Main 16 to Main EQUIPMENT Manual AND MAINTENANCE Manual RETROFITS Manual SCHEDULES D-O-1 Amtrak Maintenance Manual G-79-6 Supplement Section 10400-03 D Wheel Car This book is meant as a supplement to the Amtrak Maintenance Manual #G-79-6. _ost details of these cars are described in the main manual; things unique to these cars are described here in the supplement. D-O-2 Figure 0.I Maintenance Manual Revisions DATE CHAPTER PAGES CHANGES D-O-3 Table of Contents PREFACE Title Table Page D-O-I D-O-3 Page of Contents CHAPTER 1.0 1.1 1.2 General Car Numbers Floor Plan and Equipment CHAPTER 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 3 Page D-1-1 D-1-2 D-1-3 Weight 2 HEATING CAR BODY AND See See See See List of General Main Main Main Main Manual Manual Manual Manual Page D-2-I D-2-1 D-2-1 D-2 -2 D-2-2 D-2-2 D-2-2 D-2-5 D-2-18 D-2-18 D-2-18 D-2-18 D-2-18 VENTILATION Page D-3-1 General CHAPTER i 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 GENERAL General Structure Faceplate and Diaphragm Doors Sash & Glazing Vestibule Step and Trap Door Trainlines and End Connections Interior Safety Appliances Dead Heading Interior and Exterior Finishes Signs Drawing List CHAPTER 3.0 I 4 Illustrations Lamp Schedule Interior Fixtures Marker Lights Interior Consist Signs Exterior Consist Signs Switches Convenience Outlets Drawing List N/A N/A LIGHTING Page D-4-1 D-4-1 D-4-2 D-4-4 D-4-4 D-4-4 D-4-4 D-4-4 D-4-4 D°4-4 D-O-4 CHAPTER 5.0 5 SYSTEM Page D-5-I General CHAPTER i 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 COMMUNICATION List of General 6 ELECTRICAL SYSTEM Illustrations 480 Volt Power Distribution 27 Point Trainline Circuits Battery and Charging System Transformers and Cable System Lighting Switchboard Electric Locker Food Service Electric Locker Panels N/A Service Procedures refer to Main Manual Drawing List CHAPTER Refer 7 BRAKE to Main CHAPTER Refer CHAPTER 9 8 to FOOD SYSTEM Manual HANDBRAKE Main Manual SERVICE EQUIPMENT N/A CHAPTER Refer to 10 Main Trucks Manual Page D-6-1 D-6-1 D-6-I D-6-1 D-6-I D-6-1 D-6-2 D-6-2 D-6-6 D-6-6 O-6-6 D-O-5 CHAPTER 11 COUPLER Refer to CHAPTER AND Main 12 DRAFT GEAR Manual WATER SYSTEM N/A CHAPTER 13 TOILET APPOINTMENTS NIA CHAPTER 14 MISCELLANEOUS Refer CHAPTER 15 PERIODIC to Main INSPECTION Refer CHAPTER Refer to 16 EQUIPMENT Manual AND Main MAINTENANCE Manual RETROFITS to Main Manual SCHEDULES D-I-I CHAPTER1 GENERAL Page i List Fig. Fig. 1.1 1.2 1.0 General cars. Grove, Amtrak, of Illustrations Conceptual Floor Plan View of Wheelcar D-1-3 D-1-2 This manual is prepared for the 4 head end power wheel Cars were modified in late 1981 at Amtrak facilities in Beech Indiana; engineering was provided by Equipment Engineering, Washington, DC. The maximum operating speed for these The cars were converted from diesel equipment was stripped, and the service. Unnecessary HEP train Standard I • HEP Power Equipment trainlines, 2 480 3 Communication 4 Batteries 5 Conductors 6 Marker 7 Circuit 8 Truck 9 Wire. volt power receptacles junction battery signal Breakers. Ground Straps. jumpers. box. receptacles charger• pushbuttons. lamps. and and is 105 MPH. bagdorm cars. cars rewired for Used: trainline and cars jumpers. standard D-1-2 Since these cars will be used basically cars, they have minimal equipment. freight Features Unique to 1. Wheel 2. Electrical 3. Car 4. Electric 5. Can be coupled modifications 6. No PA 7. No Loop 8. Looping 9. No I0. Transformers. 1.1 QTY 4 These as unoccupied Cars: Hoist. System lighting and (except available switch std. from locker 4BO standby located to Superliners required. or and 27 power, in PT T/L). 230V-3_ or 120-1_. vestibule. hi-level cars without system. Relays. procedure of 27 Point cable. Heating. Car Numbers New HEP Number 10400-03 Original Number 1400-28 Year Built 1954 Builder St. Louis Car .Fiqure Conceptual ANITRAK View 1.1 of Wheelcar WHEEL CAR .- CAPACITY: 16 WHEELSETS CAR INTERIOR GUTTED IS WHEELS SLOTS f WHEEL TRACK BEING LIFTED TO SLOT WHEEL ROLLS MOVEMENT SLOTS "l LOCATED FOR 8 wHEELs IN ON.TRACK IN FROM FOR CAR AT EACH CAR END _ RAISED DIAMOND AT DOORWAY CAR ONLY END PLATE OF I I WT_'_A'ENO: TOTAL WT. : I101700 00 00 { II WT.' II I B 'END. I I&° t CLEAR ,T)OEi\!iNG : _LO"W× 6'-ZT/e" H LRP. ELECT L_.__.__j . , A Br_ j 7 B ! END I I-------, /._ C - _ 0 1 i-- :'_._A W I--IE E L Poc KET5 0 c A ]_% i o4oo- 'tYPE v# I-.IE EL CAgA, C,TY -.-----I0' 0 .1_ VJvEE_ o3 Cf_P SETS "--'-" Figure 1.2 I Floor Plan ! ul D-2-I CHAPTER 2 CARBODY Page i 2.1 2.2 2.3 2.4 List of Illustrations 27 Point Communication Cable Wayside Power Connections Wheelcar Loading & Unloading Traveling Hoist Instructions D-2-3 D-2-4 D-2-6 D-2-17 Connections Procedure and Part List 2.0 General main This chapter is meant as a supplement to Chapter manual, and describes items unique to these cars. 2.1 Structure The requirements: I. 2. 3. 4. 5. 6. 7. 8. 2.2 Faceplate The car to allow In addition, the car with carbody has been modified to accommodate the 2 in wheel the car Interior of car stripped. Floor equipped with track to allow moving of wheels within the car. Floor equipped with slots to hold wheels in position for shipping. Diamond plate flooring installed at side loading doors to aid in loading/unloading. Traveling hoist installed, overhead on lengthwise rail for wheel movement. Electric locker moved to vestibule for easy access and increased cargo space. Structural reinforcement to accommodate heavy wheel weight. Sliding loading doors, one per side. and Diaphragms diaphragm and faceplate was removed unrestricted coupling to Superliner this required covering the lifting a plate. from each end of the and hi-level cars. lugs on each end of D-2-2 2.3 Doors The car maintains the side doors. The cargo loading original. The electric locker 2.4 Sash and original body end doors and vestibule doors were enlarged from the door is new. Glazin_ Car windows were maintained the car when power is not available, since the car is not occupied. 2.5 Vestibule and Power Trainlines The installation. 2.6.2 Trap steps Trainlines 2.6.1 End trap No brake used. 2. No 480 loop applied relays If a wheel car is trainline jumpers 2.6.3 Battery The connections. maintained. Refer to Volt on main these manual cars for are the details. trainline and are released standard is similar pressure to switches the are used. the last car in the train, must be installed as shown wheel car is used anywhere should be followed. else in the 27 point in figure D-2.1. the train, Trainline car main Trainline I. If the procedures were Connections The 27 point communication application except: jumper illumination to are not used Door and power trainlines Refer to the Communication standard Note: and The original for details. manual 2.6 Steps to give natural Emergency sashes is equipped with the standard battery trainline normal L_P , (BLU wH--GEh _VHEEL CAR I LJUMPER LOCO I_IORM A L _ CASEI: WHEEL LOCO OKIE JUMPER At, lb. CAR.TO EITHER SiDE I--I BETWEEN LOCOI_AO'IIVE. OF CAR. _h_ I I CAR X EAO -_, CA, R} LOCOMOTIVE_ JUIVIPER CAkl BE Oil O I p,) ! FIGURE _7 POIktT COMMUNICATIONS 2. I CABLE ua CONNECTIONS FIG 2. Z gg Og WAYSIDE I POWER II II II _ '-' e"ib INSTRUCT/ON CONNECTIONS I [] ,,P #" S : I (Die--b:LIGNT (IN I. OR. CONNECT _A. 8. 230 120 15 ,2. CAR V v STANDBY OUTLET EQUIPPED SELECT Swl'TcN TURN ON YARD POWER. (VJNEEL OR, CAR 50' 12GV CoP. Q D). OI,4 l_Oi,,'.-_.b. CAR LIC, HT5 P,5 DESIR.ED. w _0' IT_ _I_ CORD ''__ _ _ KZPD-1056042R _BPD-107542R 1 2 3 Standby RE_e_cac le Standby Plug Receptacle, Male Twistlock Pyle-National Pyle--National Hubbell 4 5 Plug, Plug, Hubbell Hubbell 6 Cable, Female Twist]oc_ Male Twistlodc (50 Feet) Tjpe 50, 5,?Y':TCI'.'-L,OAPD VESTIBULE) POWER: WITH Z_OV LIGHT 3. TO 7_ 12 Gauge, 300V, 2 conductor -- I A)f_ I _ l 25A9001666 I -- 25P9004942 I D-2-5 2.6.4 230 Wayside Standby Power (see figure D-2.2) V The car receptacles. By lighting will be source. is equipped with 2-230V standard wayside connecting yard power to either of these provided, as well as a 120V convenience points, outlet car 120V extension cord with The car is also equipped with a 50 foot 120V plug, stored in the electric locker. The car can also be lighted by connecting this cord to yard power. 2.6.5 64V Battery The car Standby is not equipped with standby battery charging receptacles. 2.6.6 Brake The System Trainlines car equipped is with standard manual, Chapter brake trainline 7 further connections: Main 2.7 Reservoir Brake Pipe Refer to Interior the main for details. Furnishings The interior of the car has been stripped. A traveling hoist has been installed to facilitate moving wheels within the Refer to figure D-2.3 for loading procedure, and Fig. D-2.4 for instructions and part list. DESCRIPTION Trolley Hoist, Head Room with Geared Trolley Low MANU. MANU. McMaster-Carr (Coffing) 3313W25 AG6135 # AMMS car. hoist # D-2-6 Fig. Wheelcar I. Loadin,q & Unloading D-2-3 Procedure (taken from SMP-25003) PREPARATION Step I. Car Placement Wheelcar should be placed in such a position that allows for safe access, including clearances, during all loading/unloading activities. The approach to the car should be level enough and without bumps to prevent the wheelset from slipping or "jumping" during loading/unloading. Step 2. Select Property Forklift Wheelsets are loaded/unloaded with special fork extension; therefore, the forklift selected for loading the wheelsets should be of sufficient size taking into account the cantilever affect and the lifting height. Step 3. Use Proper Number of safe loading/unloading. Step 4. Use Trained or Experienced Personnel - Be sure personnel selected know how to load/unload the car if they have never done it review the _rocedures - don't assume they know how to do t. Step 5. Insure car is clean and free of will help prevent injuries from tripping. Personnel To assure debris. slipping the This and/or D--2-7 Step II. 6. For loading: are installed. when wheelset wells. Covers the three end (Loading End). LOADING WHEN Loading l 3 ¥ 51, I. Place sure as 2. 91011121J X X special fork the extension far Pick (See ONLY Diagram 2 3 ¥ 5 _, 7 X 1,3_12 Step WHEELSETS 3 4 5 6 7 8 14t _ Step sure all wheel well covers Covers are to be removed only is ready to be placed in wheel are supplied for wheel wells for pair of wheels on A end of Car. TRANSPORTING Sequence 1(,, _12 Be as it will t'F I& IS X 8 _101112 Pt13 X X _ # _ IO 12.11 extension is mounted on forklift. Be over the forklift go. up wheelset in diagram below.) line with fork extension. D-Z- Step 3.0 Loading B (Vestibule) End End. Wheelsets 1 through wheelsets. Step 3.1 Transport wheelset forks. Step 3.2 Square wheelset with track by rolling wheelset against end stops. If this is done the wheelset may be skewed and not readily or it may go off the track. wheelset on track Step 3.3 Roll wheel slowly overhead crane is position to avoid Step 3.4 Place overhead wheelset axle. Step 3.5 Place hook ends wheelset wheels and partial 14 for 16 to car and place inside of car. Remove to position. Be sure well enough beyond personal injury. crane over over and as shown. center inside of the not roll D-2-? Step 3.7 Raise wheelset enough to clear track and swing into position over wheel wells lower wheel set into wheel wells - be careful to avoid having person in a position where swinging or falling set could cause personal injury. Remove crane hooks. Step 4.0 Loading wheelsets track - other wheelsets at A End - two must be loaded at A End beyond sets number 15 & 16 as shown in loadin sequence 9 Step 4.1 Transport car. DO Step 4.2 Remove for wheelset NOT REMOVE wheel well 16 wheelsets. to car FORKS. covers and to wheelsets - hang the covers appropriate place. (Covers Doorway area) Step 4.3 Place crane over center Step 4.4 Place hooks as shown, over and of inside E@cD place inside receive in the only in A wheelset wheelset end axle. wheels D- NOTE: Step 4.5 Lift wheelset from Step 4.6 Remove forks from Step 4.7 Move wheelset wheelwells. via Step 4.8 Lower hooks. Step 5. Be sure equal number each end of car when (See loading sequence Step 6. After hooks. Step 7. Be Step 8. Secure wheelset sure loading all all forks. car. crane into all to wheelwells. over Remove of wheelsets are at loading is completed. diagram.) wheelsets material position is secure adequately crane secured. doors. Nothing is to be loaded in the center area of the car; i.e., the space between the wheelset groups at each end of the car. (See loading sequence diagram). 7__- I0 O-Z-II LOADING I • Load equal of car. quantities 2. Always wheels 3. What car has be at extreme 4. Do not load heaviest toward center over of PROCEDURES same wheels at of car. less wheels than ends of car. load of wheels ends of car capacity, at with equal each lighter weight should WEIGHTS Total Wheels that may be loaded in kind Type 9115 3200 16 Amfleet 3500 16 9123 3700 16 Superliner 4000 16 F-40 4000 16 9083 4200 P-30 4500 Capacity end capacity. WHEEL Load style - 68,000 Ibs. 16 14 D-Z-I?- Ill. LOADING MATERIAL Other WHEN truck TRANSPORTING components and WHEELSETS certain AND materials OTHER can be transported via a wheelcar; however_ careful consideration must be 9iven to equal weight distribution it each end of the car. Material other than wheelsets can be transported on1_ in the area as shown in the loadin 9 sequence diagram below. NOTE: When loading less than 14 wheelsets and other material, wheel wells left vacant will depend upon the number of wheelsets and the weight of the other material. The wheelcar must have the least concentration of weight toward the center of the car and the largest concentration of weight toward and/or over the car trucks - the total car load is to be equally distributed over the car trucks. For correct method through 3.7. of loading wheelsets see Section I, StePs 3.1 D -Z-/_ IV. UNLOADING - WHEN WHEELSETS Unloading Sequence ONLY ARE TRANSPORTED Diagram. /f--'_'N_' fT"ArAC_ =x lll I III I&_I_ IS I¥13121110 III_I¥ I$12 /2_12 ///0.9 /I I0 _ 8 Ill I 1. Place Step 2.0 Unloading 1 & 2 as wheelsets. [.2 _ B ? _ 5 ¢ X X 7 6 5 Y B 8 _" X X Step ,,S_"_._ special 3 /2. X X _, _" Sl 3 fork wheelsets shown in extension on 1,2 forklift. at A End - sets unloadin 9 sequence Step 2.1 Place wheelset wheelset axle. crane over Step 2.2 Position fork inside to receive wheelset Step 2.3 Place crane hook ends over wheelset wheels as shown. car from center of in such crane. and number for 16 a manner inside D-Z- Step 2.4 Raise wells Step 2.5 Position wheelset Step 2.6 Remove Step 2.7 Clear Step 2.8 Remove Step 2.9 Replace wheel well cover before unloading other wheelset. Covers are supplied for wheel wells for the three end pair of wheels on A end (Loading End). Step 3.0 Step 3.1 wheelset and move enough toward wheelset over onto forks as crane crane hook from wheelset Unloading wheelset (wheelsets 3 thru unloading sequence of unloading.) Place to clear unloading crane over ends forks shown. from wheel position. and lower wheelset. wheelset. from car. adjacent to track 14 for 16 wheelsets diagram for proper center of wheelset - see order axle. b-z-15" Step 3.2 Place wheels hook ends as shown. over and inside _N_ S wheelset Step 3.3 Raise wheelset enough to clear track and swing into position over track - lower wheelset onto track remove hooks. Step 3.4 Roll wheelset slowly stops at A End. Step 3.5 Position wheelset in order for forklift to pickup and without causin 9 damage to end stops or door area. Keep personnel sufficientl_ to prevent clear injury. Step 3.6 Position forks shown and raise Step 3.7 Remove Step 3.8 Replace wheel next wheelset. Step 4. Secure of track from well hooks. toward wheelset in line with wheelset. wheelset crane on and wheelset end forks as car. cover before unloadin 9 D-Z-t6 Step V. 5. Secure UNLOADING MAIERIALS - WHEN When unloading other material diagram car doors. UNLOADING wheelsets first as WHEELSETS AND OTHER and other materials, shown in the unloading unload the sequence below. L/q.'_.'_, "_t,,o _7#£R M,_7"L_.J, Sro,ea_.. UNy..o,_z:_/m_ For 3.1 correct through method 3.8 of unloading ttR _ m S_.(?uL,vc.L wheelsets, see Section IV, Steps QZ,. D-2-17 Figure Traveling Instructions D-2.4 Hoist and Part List D-2-18 2.8 Safety Appliances Refer 2.9 Dead to to Interior and Refer 2.11 main manual. Exterior Finishes to main manual. to main manual. Signs Refer 2.12 manual. Heading Refer 2.10 main Drawing List Drawing Function Floor Plan Exterior Markings Loading Door Drawin 9 E-00-1425 X-002-5029 E-00-1423 # D-3-I D-4-1 CHAPTER 3.0 3 HEATING_ VENTILATION AND AIR CONDITIONING General ventilation Since the car is an unoccupied nor air conditioning system. CHAPTER 4 car, it has no heating, LIGHTING Page i 4.1 4.1 List of Lighting D-4-3 General lights, 4.1.1 Illustrations Switchboard The car is in addition Power Power I. 2. 3. 4. equipped with vestibule, ceiling and to the standard HEP marker lights. loading Source for car lighting comes from Head end power (via transformer) Battery (charged from HEP) 230V Wayside Power 120V Wayside Power either of 4 See section 2.6.4 sources: door D-4-2 4.1.2 Controls located except in the battery All and Operation lighting controls vestibule. trainline are contained The wayside voltage selector switch voltage of wayside power from which the car 230V 3 phase, or 120V single phase. The marker in In normal operation, should be on. Refer light switch selects the electric locker all circuit breakers to figure 4.1. is used is power between to select the when in the yard A-end, B-end and OFF. To lay up a car at circuit breakers: following 1. 2. 4.1.3 Night Ceiling Marker the end of a run turn off ONLY the lights lights Lights N/A 4.1.4 Emergency outage. not from 4.2 QTY 4 10 Lamp Lights All car lighting will operate off the battery (Note, the battery gets charged only when HEP wayside 230 or 120V. during power a HEP is on, Schedule TYPE 60/PAR/2/R 50W 80V A19 NOTES Red Inside USED Frosted FOR Marker Light All Other Lights D-4-3 FIG 4;I LIGHTING SWITCHBOARD _T'DBY MARKER _P.V,/R .LIGHT5 i20V A-END BATTERY -eo_A R_ I,"_10_'F "TRAINLIN_ BATTER i,,-, CHARGER Z_IOV STDBY B-END lZO v, J_oow [] @URN "TWO OFF ONLY A'r CAR, -FNESE LAY_PP, D-4-4 4.3 Interior Fixtures Interior # fixtures LOCATION are follows: as MANU. MANU. # AMMS # Main Manual 1. Vestibule Luminator L6482 See 2. 3. 4. Ceiling Locker Marker Kenall Translite Luminator 3737 194550001 0103086001 25A9003768 25H9011540 4.4 Marker Lights The car is equipped resistors and selector switch to main manual for details. with the located 4.5 Interior Consist Number Signs N/A 4.6 Exterior Consist Number Signs N/A 4.7 Switches Two switches are used for standard 4 marker lights in the electric locker. lighting, both in the with Refer electric locker: # FUNCTION TYPE 4PDT Arrow Hart 80899 23K9012523 2. 230/120V Selector Marker DPDT Arrow Hart 80634 25A9002684 Light Selector Center Off I. 4.8 Convenience locker. provide 4.9 9 MANU. # AMMS # Outlet One duplex It operates 1500 watts. Drawin MANU. convenience only when outlet car is is provided in on Wayside Power List Function Electrical Drawin Schematic 9 # SK-C-071681-1 the electric and can D-5-1 CHAPTER 5.0 5 COMMUNICATION SYSTEM General The pushbuttons. The a different 2.6.2. car is Refer equipped to main with manual 2 standard conductor for details. car does not have loop 27 point jumper procedure Since the car is unoccupied, relays, than it is signal and accordingly normal. Refer no___t_t equipped to requires section with a system. Drawing Function 27 Point Communication List Drawing Schematic SK-C-071681-2 # PA D-6-1 CHAPTER 6 ELECTRICAL SYSTEM Page i 6.1 6.2 6.1 List of Electric Electric Illustrations Locker Switchboard Locker Components D-6-3 D-6-4 General Because the car is unoccupied, the electrical system is minimal. The trainline systems are essentially the standard HEP installation, while the rest of the system is unique to these cars. Nearly all electrical parts are standard HEP components; refer to the main manual for details. All car lighting operates on 75V. If the car is on HEP mode the battery charger provides this voltage when HEP is available, or the battery if it is not. If the car is powered from wayside power, either 230 or 120 VAC, a transformer and variac provides 75 VAC to the lighting. A transfer contactor selects between HEP or standby power. 6.2 480 Volt The 6.3 27 car Point uses The car 1. 2. 3. No No No Battery the uses and Transformers a and standard Communication Standard 6.5 Distribution system Charging uses refer to main manual. modified slightly released the car - refer from pressure is standard. standard: switches Refer to main System Volt (See System Trainline exceptions, 64 Cable system loop relays dummy receptacles brake applied and With these for details. manual 6.4 Power system figure only to main manual. 6.2) The car 2 transformers, contained in the electric 1. 240/120 to 120V at 2 KVA Used to convert 230V wayside into 120V for car use. Also used as an isolation transformer for the variac. 120V to 75V Variac locker: 2. Used to source. power. provide It is 75 VAC powered to the car lighting only when car is on from 120 wayside VAC D-6-2 ITEM I 2 6.6 VOLTAGE RATING MANU. MANU. # 120/240 to 120 1201N,0-130 Out Variac 2 KVA GE 9T51Y32 15 Amps STACO 3PNlSIO Liqhtinq Switchboard The lighting switchboard is contained accessed from the vestibule. Refer to of circuit breakers and switches for: locker, consists I. 2. 3. 4. 5. 6. 7. addition, receptacle the car to 6.7 the panel is equipped (1500 watt maximum) yard 120V power. To lay up a car at circuit breakers: following 1. 2. Marker Ceiling electric 6.1. It Electric Locker the end of a with a duplex 120V and a male receptacle run, merely turn off for the light lights The electric circuit breakers, car in the figure Ceiling lights Marker lights Convenience receptacle 240 standby 120 standby Marker light selector switch Wayside voltage selector switch In convenience attaching AMMS# locker, switches located off the and transformers. vestibule, Refer contains to figure 6.2. 6.7.1 The to 480 Volt The 480 I. 2. 3. Battery Battery Battery functions figure Circuit 6.1 of for Volt Breaker Panel switchboard has charger (only trainline these parts. breakers is 480V 3 circuit car standard breakers: load) to all HEP cars. Refer all D-G-3 FIG G.3 LI.GNTING SWITCHBOARD - T_.T_.P____ _ PWR 120V MARKER _L.I GN'T5 A-END BA, TTERYZ S_ARE I,-,IOFF TRAINLINE BATTEE_ I,-.. CHARGER Z_OV STDBY Z4OV ZOV MKI_ IRECPT L @liT ISlDBy STDBYI ITS I ISPAREI I B-END IZOV, fsooW © _W Figure ELECTRIC LOCKER 6.2A P- G-4- COMPONENTS U_ Q ® ® m h n m m Figure 6.2B ELECTRIC LOCKER PART LIST ITEM DESCRIPTION MFG MFG # AMT # 1 2 3 Marker Light Resistor Panel Circuit Breaker IOA 480V 3 Pole Circuit Breaker 50A 240V 2 Pole Shop Westinghouse Westinghouse D-00-686 EHB3OlO EB2050 ...... 25X4010844 25H9009075 4 5 6 Circuit Breaker 60A 240V 2 Pole Clip, Circuit Breaker Holddown Circuit Breaker 16A 240V 2 Pole Westinghouse Westinghouse Westinghouse EB2060 624BIOOG14. QC2015-H 25L4010715 25xgo1046g 25H4010783 7 8 , 9 Circuit Breaker 20A 240V 2 Pole Switch, Toggle, 4 PDT Switch, Toggle, DPDT Center Off Westinghouse Arrow Hart Arrow Hart QC2020-H 80899 80634 25D4010784 25K9012523 25A9002684 LO L1 12 Receptacle, Duplex Receptacle, Male Twistlock Plug, Female Twistlock Bryant Hubbell Hubbell GFR83 25L9012346 Plug, Male Twistlock Cable, (50 Feet) Type SO, 12 Gauge, 3OOV, 2 conductor Transfer Relay, DPDT Hubbell --Vapor 37741141 25Pg004942 25H4013800 Transformer 240 x 120 to 120V 2KVA "Variac" 120 to 0 - 130V 15 Amp GE Staco 9T51Y32 3PN1510 AMMS # | Terminal Block Diode 6A, 800 PIV Refer to Main Book, Section 6.1.2 International Rectifier 60S8 25H9008685 f D-6-6 6.7.2 Contactors The car has only one contactor, TR1 which is used to connect car lighting loads to either 75VAC or DC. It is energized only when the car is on wayside power, at which time it supplies 75VAC to the lighting. Refer to figure 6.2. 6.7.3 A/C Starting Panel N/A 6.7.4 Contactor and Refer 6.7.5 E-5 to Overload section Relay 6.7.4 of Maintenance the main manual for details. Decelostat N/A 6.7.6 Marker The Refer panel. 6.7.7 Light car to Annunciator Resistor Panel is equipped with section 6.7.6 of Power the the standard marker main manual. light Supply N/A 6.8 Food Service Electric Locker Panels N/A 6.9 Service Procedures Refer 6.10 Drawin to main manual for details. 9 List Function Drawin Electrical Symbols 480V Trainline Schematic 480V J-Box 27 Point Communication Trainline Single Line Schematic Marker Light Resistor Panel Car Wiring Schematic Overhead Conduit Undercar Conduit D-04-414 D-01-524 E-00-I019 SK-C-071681-2 SK-C-071681-1 D-00-686 9 # resistor D-7-1 CHAPTER 7 Refer BRAKE to Main CHAPTER Refer CHAPTER 9 SYSTEM 8 to Manual HANDBRAKE Main FOOD Manual SERVICE EQUIPMENT N/A CHAPTER Refer CHAPTER 10 to 11 TRUCKS Main COUPLER Refer to CHAPTER 12 Manual AND Main DRAFT GEAR Manual WATER SYSTEM N/A CHAPTER 13 TOILET APPOINTMENTS N/A CHAPTER 14 MISCELLANEOUS EQUIPMENT N/A CHAPTER 15 PERIODIC INSPECTION Refer CHAPTER Refer to 16 to AND Main MAINTENANCE Manual RETROFITS Main Manual SCHEDULES