New York Air Brake
CCB Brake System
GE CONTRACT
CCB BRAKE EQUIPMENT
MAINTENANCE MANUAL
IP-155-C
For the
METRO NORTH
DUAL MODE LOCOMOTIVE
Operated by
METRO NORTH
AUGUST 96
CCB METRO NORTH DUAL MODE CONTRACT LOCOMOTIVE
MAINTENANCE MANUAL
INSERT LATEST CHANGED PAGES.
DESTROY SUPERSEDED PAGES.
LIST OF EFFECTIVE PAGES
NOTE: The portion of the text effected by the
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ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM:
NEW YORK AIR BRAKE CORPORATION
A KNORR BRAKE COMPANY
748 STARBUCK AVENUE
WATERTOWN, NY 13601
Manual: IP-155-C
The Change No. "0" indicate the Original Issue for Manual
The Change No. "1" indicates the Original Issue for C.W.
The Change No. "1" indicates the Original Issue for NYR
A
DEC/97
CCB METRO NORTH DUAL MODE CONTRACT LOCOMOTIVE
MAINTENANCE MANUAL
INSERT LATEST CHANGED PAGES.
DESTROY SUPERSEDED PAGES.
LIST OF EFFECTIVE PAGES
NOTE: The portion of the text effected by the
changes is indicated by a vertical line
in the outer margin of the page.
The total number of pages in this Maintenance Manual, Vendor Information, is 360, consisting
of:
3-1 through 3-3
3-4 (Blank)
4-1
4-2 through 4-4
4-3
5-1 through 5-27
5-28 (Blank)
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ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED FROM:
NEW YORK AIR BRAKE CORPORATION
A KNORR BRAKE COMPANY
748 STARBUCK AVENUE
WATERTOWN, NEW YORK 13601
DEC/97
The Change No."0" indicates the Original Issue
The Change No. "1" indicates the Original Issue for C.W.
The Change No. "1" indicates the Original Issue for NYR
B
Manual: IP-155-C
CCB METRO NORTH DUAL MODE CONTRACT LOCOMOTIVE
MAINTENANCE MANUAL
TABLE OF CONTENTS
CHAPT/SECT
1.0
TITLE
PAGE
OPERATING PROCEDURES **
1-1
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
AIR BRAKE EQUIPMENT
AIR BRAKE EQUIPMENT IN AIR BRAKE COMPARTMENT
BRAKE VALVE
AIR BRAKE SET-UP
LOSS OF POWER MODE
POWER UP PENALTY
1-1
1-1
1-6
1-7
1-7
1-7
1.2
1.2.1
1.2.2
1.2.3
GENERAL INFORMATION
CCB INTRODUCTION
SYSTEM DESCRIPTION1-10
OPERATION
A. RELEASE POSITION
B. BRAKE CYLINDER PRESSURE CONTROL
C. SERVICE APPLICATION-AUTOMATIC
D. BRAKE CYLINDER CONTROL-AUTOMATIC
E. SUPPRESSION POSITION
F. HANDLE-OFF POSITION
G. EMERGENCY APPLICATION-EMERGENCY
H. EMERGENCY APPLICATION - TRAIN SEPARATION
I. BLENDED BRAKE FUNCTIONAL DESCIPTION
J. TRAIL POSITION - AUTOMATIC BRAKE
K. TRAIL POSITION - ANY EMERG. APPLICATION AND RELEASE
L. INDEPENDENT APPLICATION AND RELEASE
M. TRAILING INDEPENDENT BRAKING
N. LOSS OF POWER OR DEFAULT MODE
O. SERVICE PENALTY DEFAULT
P. INDEPENDENT - BACK UP TRAIL OPERATION
Q. BACK UP BRAKE SYSTEM (DIT/DEAD - IN - TOW)
1-8
1-8
2.0
1-12
1-12
1-17
1-20
1-25
1-25
1-30
1-32
1-40
1-42
1-45
1-45
1-47
1-55
1-55
1-55
1-59
1-61
EQUIPMENT DESCRIPTION
2-1
COMPONENT DESCRIPTIONS
2-1
PREPARATION FOR MAINTENANCE
3-1
3.1
GENERAL INFORMATION
3-1
3.2
SAFETY PRECAUTIONS
3-1
3.3
COMPONENT ASSEMBLY PRECAUTIONS
3-3
2.1
3.0
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MAINTENANCE MANUAL
TABLE OF CONTENTS (Contd.)
CHAPT/SECT
4.0
4-1
4.1
GENERAL INFORMATION
4-1
4.2
INSPECTIONS
4-1
4.3
92 DAY INSPECTION
4-1
4.4
EQUIPMENT REPLACEMENT, REPAIR, AND OVERHAUL
4-4
CHECKOUT AND ANALYSIS
5-1
5.1
GENERAL INFORMATION
5-1
5.2
FUNCTION TESTING
5-1
5.2.1
Code of Tests For Testing Locomotive Computer Controlled
5-1
Brake Equipment Subsystem Procedure For GE/METRO NORTH
(NYT-XXXX-C)
5.3
TROUBLESHOOTING
5.3.1
General Information
5.3.2
Troubleshooting Chart
6.0
6.1
6.2
7.0
7.1
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SCHEDULED INSPECTION
5.0
8.0
TITLE
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5-11
5-12
EQUIPMENT REPLACEMENT **
6-1
General Information
Replacement Procedures
6.2.1
General Procedures
6.2.2
Pneumatic Control Unit Replacement
6.2.3
DIT Valve Replacement
6.2.4
Refer to Carbuilders Manual
NYR-332
NYR-353
NYR-372
6-1
6-1
6-1
6-2
6-2
6-6
SYSTEM EQUIPMENT
7-1
GENERAL INFORMATION
7-1
NYAB/KNORR CCB - GE FAULT CODES
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8-1
CCB METRO NORTH DUAL MODE CONTRACT LOCOMOTIVE
MAINTENANCE MANUAL
LIST OF ABBREVIATIONS
16AW4 .........................................Control Pipe Analog Converter
16E...............................................Exhaust Magnet Valve
16S...............................................Supply Magnet Valve
16T...............................................Control Pipe Transducer
20CP ............................................20 Pipe Control Portion
20T...............................................Independent Application
.....................................................Pipe Transducer (20 Pipe)
AA/PCB........................................Analog Output PCB
AACB ...........................................Air Brake Circuit Breaker
ACO .............................................Alerter Cut-Out
AD/PCB........................................Analog To Digital Converter PCB
AE1 ..............................................Automatic Emergency Switch NO. 1, N.C.
AE2 ..............................................Automatic Emergency Switch NO. 2, N.C.
AP ................................................Automatic Variable Handle Potentiometer
AR ................................................Automatic Release Switch, N.O.
BA ................................................Battery
BAN..............................................Battery Negative
BAP..............................................Battery Positive
BB/PCB........................................Blended Brake I/O PCB
BBR..............................................Blended Brake Relay
BBWS ..........................................Blended Brake Wheelslip
BC ................................................Brake Cylinder
BCCO...........................................Brake Cylinder Cut-Out
BCT..............................................Brake Cylinder Transducer
BEA..............................................Digital I/O PCB
BEA/PCB .....................................Input/Output PCB
BG................................................Blending Signal
BLD/BRK......................................Blended Brake Enable
BO................................................Bail Off Switch, N.O.
BP ................................................Brake Pipe
BPCO...........................................Brake Pipe Cut-Out Switch
BPPB ...........................................Brake Pipe Push Button
BPT ..............................................Brake Pipe Transducer
BRPB ...........................................Brake Release Push Button
BVJ1-BVJ2...................................Brake Valve External Connectors
CAM-F.........................................."F" Cam In Controller
CCB .............................................Computer Controlled Brake
°C .................................................Degree Centigrade
COM/PCB ....................................Communication PCB
CP ................................................Centeal Processor
CRU .............................................Computer Relay Unit
CRU .............................................Computer Relay Unit
CS ................................................Continuous Service
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LIST OF ABBREVIATIONS (Cont.)
CSCO...........................................Cab Signal Cut-Out
DB1/PCB......................................Magnet Valve Driver Board
DB2 ..............................................Relay Driver Board
dc .................................................Direct Current
DCV .............................................Double Check Valve
DI .................................................Digital Input
DO................................................Digital Output
ELV ..............................................Emergency Limiting Valve
EMER...........................................Emergency
EPA1/PCB ...................................Automatic Application Analog
.....................................................Converter Driver PCB
EPA2............................................Analog Converter Driver Board
EPA2/PCB ...................................Control Pipe (16) Analog
.....................................................Converter 16 AW4 Driver PCB
ER ................................................Equalizing Reservoir
ERAW4 ........................................Equalizing Reservoir Analog Converter
ERE..............................................Exhaust Magnet Valve
ERS..............................................Supply Magnet Valve
ERT..............................................Equalizing Reservoir Transducer
ES ................................................Emergency Sanding
ESR..............................................Emergency Sanding Relay
EXC..............................................Excitation Controller
Fig ................................................Figure
FL1/PCB ......................................24 VDC Filter
FOJ1 ............................................Automatic Fiber Optic External Connector
FOJ2 ............................................Independent Fiber Optic External Connector
FOR .............................................Fiber Optic Receiver
FS ................................................Full Service
ft-lbs .............................................Foot Pounds
GFB..............................................Generator Field Breaker
GFTL............................................Generator Field Trainline
HO................................................Handle Off
HSLR ...........................................Hostler Relay
IBS ...............................................Independent Brake Switch
IFC ...............................................Integrated Function Control
IM .................................................Independent Maximum Applied Switch, N.O.
IND...............................................Independent
IP..................................................Independent Variable Handle Potentiometer
IR .................................................Independent Release Switch, N.O.
J1-J11 ..........................................PCB Internal Connectors
K1ES............................................Sanding Relay
K2IBS...........................................Extended Dynamic Range Cut-Out
.....................................................Relay (Not Used)
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MAINTENANCE MANUAL
K3BCPS.......................................Dynamic Brake Cut-Out Relay
LIST OF ABBREVIATIONS (Cont.)
K4HSP .........................................Hostler Power Relay
K5COR.........................................PCR Cut-Out Relay
K7SUPP.......................................Cab Signal Suppression Relay
K9BVPS .......................................Brake Valve Cut-Off Switch Relay
K11BBE .......................................Blended Brake Enable Relay
K12VA..........................................Brake Failure Alarm Relay
KN ................................................Kilo Newtons
lbs ................................................Pounds
LCN..............................................Lcoc Control Negative
LCP ..............................................Loco Control Positive
LT1...............................................Lead/Trail #1 Switch
LT2...............................................Lead/Trail #2 Switch
LT3...............................................Lead/Trail #3 Switch
MC-TH .........................................Master Controller - Throttle
MM ...............................................Millimeter
MIN ..............................................Minimum
MR ...............................................Main Reservoir
MRT .............................................Main Reservoir Transducer
MV13E .........................................Bail Off Exhaust Magnet Valve
MV13S .........................................Bail Off Supply Magnet Valve
MV16T .........................................Control Pipe (16 Pipe) Default Magnet Valve
MV20E .........................................Independent Application Exhaust Magnet Valve
MV20M.........................................Independent Application Maintaining Magnet
.....................................................Valve
MV20S .........................................Independent Application Supply Magnet Valve
MV53............................................Brake Pipe Cut-Out Magnet Valve
MVEM ..........................................Emergency Magnet Valve
MVER...........................................Equalizing Reservoir Default Magnet Valve
N ..................................................Newtons
Nm ...............................................Newton Meters
PARA ...........................................Paragraph
PCB..............................................Printed Circuit Board
PCR .............................................Power Cut-Out Relay
PCU .............................................Pneumatic Control Unit
Pg.................................................Page
PS13 ............................................Bail Off Pressure Switch
PSBP ...........................................Brake Pipe Pressure Switch
PSC..............................................Propulsion System Controller
psig ..............................................Pounds Per Square Inch, Gauge
PVEM...........................................Emergency Pilot Air Valve
Qty ...............................................Quantity
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MAINTENANCE MANUAL
R1 ................................................Resistor
R2 ................................................Resistor
LIST OF ABBREVIATIONS (Cont.)
REL ..............................................Release
REV TL ........................................Reverse Trainline
SC1 ..............................................Signal Conditioning PCB
SC2 ..............................................Signal Conditioning PCB
SG................................................Signal Trainline
SS8 ..............................................Digital I/O PCB
SS9 ..............................................Digital I/O PCB
SV2 ..............................................Power Supply PCB
SVJ ..............................................Power Supply Jumper PCB
TB1 ..............................................Terminal Board 1
TB5 ..............................................Terminal Board 5
TH-IDLE .......................................Throttle - Idle
TJB/PCB ......................................Transducer Jumper Board PCB
TPBP............................................Brake Pipe Test Fitting
TPER ...........................................Equalizing Reservoir Test Fitting
TPMR...........................................Main Reservoir Test Fitting
TP13 ............................................Actuation Pipe Test Fitting
TP20 ............................................20 Pipe Test Fitting
V...................................................Volts
VA ................................................Visual Alarms
VCU .............................................Voltage Conditioning Unit
VO1..............................................Voltage Out-Put 1
VO2..............................................Voltage Out-Put 2
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CCB METRO NORTH DUAL MODE CONTRACT LOCOMOTIVE
MAINTENANCE MANUAL
Introduction
The Purpose of this Manual is to provide necessary information pertaining to
the CCB Brake System for performing an on and off locomotive equipment
check out and analysis of the brake system. Sufficient information of the
introductory overview nature is also included to inform the maintenance
personnel of the nature and function of each of the components in the CCB
Brake System.
1. The information contained within this manual summarizes the features of
the CCB brake equipment and its application to the METRO NORTH
DUAL MODE vehicle.
2. Ensure that you are thoroughly familiar with the instructions for a
component and are familiar with all precautionary notes prior to attempting
a sequence, operation or maintenance. Failure to follow procedures and
precautionary notes in this publication, could cause loss of or serious
injury to personnel and/or malfunction or equipment damage.
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