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645 Russell Street
Batesburg, SC 29006
Service Manual
7077
Digitair
End-of-Train
SBU Model 6699-CC
(NiCad Battery Type)
UPGRADE KIT
Description §§§§
Procedure §§§§
October, 2000 An Ansaldo Signal Company
© 2000 Union Switch & Signal Inc.
Printed in the U.S.A.
Publication History
First Published October, 2000
TABLE OF CONTENTS
2.4 INSTALLING ASSEMBLIES & PARTS INTO THE UPGRADE KIT ......................................... 2-5
List of Figures
Installing Components into the SBU Battery Compartment....................................... 2-9
SM 7077 10/00 i
TABLE OF CONTENTS
List of Figures (continued)
Placement of Air Manifold Assembly for Marking of Holes to Drill........................... 2-13
Completed Assembly of In-Line Exhaust Valve to SBU Coupler Clamp.................. 2-14
List of Tables
Additional Parts Required to Upgrade SBU Model 6695 (Aluminum Case)............... 1-2
Additional Parts for SBUs Equipped with an In-Line Exhaust Valve.......................... 1-3
ii SM 7077 10/00
SECTION I.0 INTRODUCTION
1.0
PURPOSE OF MANUAL
This manual describes how to upgrade the older style Digitair of-Train (EOT) Sense & Brake Unit (SBU) to a new US&S Digitair models are illustrated in Figure 1.0 below.
®
Model 6695 and Model 6695-CC End-
®
Model 6699-CC SBU. These
This manual makes reference to the following Digitair
â
family of EOT manuals:
SBU Model 6695 (Aluminum Case):
SM 6496 - Installation and Operation Manual. SM 6497 - Shop Maintenance Manual
SBU Model 6695-CC (ABS Composite Case):
SM 7065 - Installation and Operation Manual. SM 7066 - Shop Maintenance Manual
SBU Model 6699-CC (Fiberglass Composite Case):
SM 7075 - Installation and Operation Manual. SM 7076 - Shop Maintenance Manual
1.1
INTRODUCTION
US&S is committed to the continuous improvement of the Digitair
®
End-of-Train Sense & Brake Unit
(SBU) and introduced the SBU Model 6699-CC in 1999. This latest model is based on a modular design incorporating a new rugged housing and a new coupler clamp mounting mechanism while retaining the Electronics Cage Assembly common to all three models. This allows users of previous models to cost effectively upgrade to the Model 6699-CC. This manual provides an easy, step-bystep, illustrated procedure for performing the upgrade.
SBU Model 6695
(Aluminum Case)
SBU Model 6695-CC
(ABS Composite Case)
UPGRADE KIT
(P/N: X26600001)
SBU Model 6699-CC
(Fiberglass Composite Case)
Figure 1.0 – Digitair
®
SBU Models and Typical Upgrade Path
SM 7077 10/00 1-1
SECTION I.0 INTRODUCTION
1.2
UPGRADE KIT ORDERING INFORMATION
The Upgrade Kit can be ordered under US&S part number X26600001. Please contact US&S Customer
Service at 1-800-652-7276 or your US&S Sales Representative for further technical information, pricing, and sales information.
1.2.1 Upgrade Kit Components
The Upgrade Kit (X26600001) contains the standard components listed in Table 1.0 below.
Additional components specific to the Model 6695 (aluminum type) and for units equipped with an In-
Line Exhaust Valve are listed in Table 1.1 and 1.2, respectively.
Item Part Number
1 N26604101
2 M26600301
3 M26600601
4 M26601901
5 M24603703
6 J048273-0003 Speed Nut for RF Shield for Rear Cover
7 J500124-0129 Shoulder Screws to Fasten Rear Cover
8 N24701401
9 J500124-0099 Screws for Electronics Cage Assembly
10 J475120-0108 Washers for Electronics Cage Assembly & AEI Tag Holder
11 J065003002
12 M26602001
13 J500128
14 J077373-0024 Double Sided Acrylic Foam 2” Wide
15 N24701301
16 J507298-0106 Screw for Battery Board Assembly
17 J475120-0147 Washer for Battery Board Assembly
18 148-0176-01
19 J507296-0106 Screw for Battery Retainer Nut Assembly
20 M26602601
21 M26602701
22
23
24
M26604001
M26605101
S007077
Gasket for Rear Cover
AEI Tag Holder
Description
Main Housing Assy Complete w/Coupler Clamp & Antenna
Rear Cover for Electronics Compartment
RF Shield for Rear Cover
Foam Strip for Rear Cover
4-Character LED Display Board
Condensation & Corrosion Control Packet
Screws for AEI Tag Holder
NiCad Battery Board Assembly
Battery Retainer Nut Assembly
Battery Holding Post - Long
Battery Holding Post - Short
Label – SBU Nameplate
Instruction Label
Service Manual for Upgrade Kit (this manual)
Table 1.0 - Upgrade Kit Common Components (P/N: X26600001)
1
3
2.6”
2
8
1
1
7
Quantity
1
1
1
1
1
2
10
1
1
2
2
1
2
2
6
6
Item Part Number Description
A J792775-0041 Standoff for LED Display Board
B N24700601 LED Display Extender Board
Quantity
Table 1.1 - Additional Parts Required to Upgrade SBU Model 6695 (Aluminum Case)
2
2
1-2 SM 7077 10/00
SECTION I.0 INTRODUCTION
Item Part Number Description
C J500101-0105 Screw, ¼-20X5/8, Hex Cap Head to secure In-line Valve
D J067584-0018 O-Ring to seal In-Line Valve
Table 1.2 - Additional Parts for SBUs Equipped with an In-Line Exhaust Valve
Quantity
3
1
1.2.2 Main Components Comprising Upgrade Kit
Figure 1.1 below shows the major components comprising the Upgrade Kit (fasteners and other small items not shown).
Item 2 – Rear Cover
Item 3 – RF Shield for Rear Cover
Item 1 – Main Housing
Assembly Complete with Coupler Clamp and Antenna
Item 4 – Gasket for
Rear Cover
Item 5 – Foam Strip for Rear Cover
Item 12 – AEI Tag
Holder
Item 15 – NiCad Battery
Board Assembly
Item 18 – Battery
Retainer Nut Assembly
Item 20 – Long Battery
Holding Post
Item 21 – Short Battery
Holding Post
Figure 1.1 – Major Components in the SBU Upgrade Kit
1.3
R.A.I.L. TEAM AND TECHNICAL SUPPORT
The Rapid Action Information Link (R.A.I.L.) Team is comprised of experienced product and application engineers ready to assist and resolve technical issues concerning DIGITAIR â
US&S product.
End-of-Train equipment or any
Questions regarding the contents of this Service Manual should be directed to the R.A.I.L. Team via telephone at 1-800-652-7276 or via
Internet e-mail at: [email protected].
SM 7077 10/00 1-3
SECTION I.0 INTRODUCTION
This page is intentionally blank.
1-4 SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.0
UPGRADE KIT PROCEDURE
This section provides procedures to perform the upgrade. Where applicable, references are made to existing SBU Shop Maintenance Manuals. In general, upgrading the SBU involves the following four operations:
1. Removing assemblies and parts from the SBU to be upgraded for reuse in the Model 6699-CC.
2. Performing minor modifications to the existing Electronics Cage Assembly.
3. Installing the reused assemblies and parts into the Upgrade Kit.
4. Testing and tuning the upgraded SBU Model 6699-CC to ensure correct operation.
2.1
GOVERNMENT LICENSES AND SAFETY WARNINGS
Only qualified personnel who have the proper government (e.g., FCC, IC, etc) issued radio licenses may perform adjustments to the radio portion of the equipment.
WARNING
COMPRESSED AIR
WHEN WORKING WITH COMPRESSED AIR MAKE SURE THE AIR
SUPPLY IS CLEAN, THE TEST EQUIPMENT IS IN GOOD ORDER AND
THE GLAD-HAND IS FULLY ENGAGED BEFORE APPLYING AIR
PRESSURE.
ALWAYS PRESS THE PRESSURE RELIEF BUTTON ON THE
EMERGENCY VALVE BEFORE DISCONNECTING IT FROM THE GLAD-
HAND.
WHEN PERFORMING EMERGENCY BRAKE EXHAUST VALVE TESTS,
BEWARE OF THE BLAST FROM THE BOTTOM OF THE VALVE. IF THESE
ACTIONS ARE NOT TAKEN, PERSONAL INJURY COULD RESULT.
CAUTION
THE SBU CONTAINS STATIC SENSITIVE COMPONENTS. PRIOR TO
REMOVING THE SBU’S REAR PANEL, AND WHILE WORKING ON THE
INTERNAL ELECTRONICS, ALWAYS FOLLOW PROPER
ELECTROSTATIC DISCHARGE (ESD) HANDLING PRACTICES,
OTHERWISE EQUIPMENT DAMAGE MAY RESULT.
SM 7077 10/00 2-1
SECTION 2.0 UPGRADE KIT PROCEDURE
2.2
REMOVAL OF REUSEABLE ASSEMBLIES & PARTS
The following procedure identifies the assemblies and parts to be removed from the SBU being upgraded for reuse in the Upgrade Kit. These consist of the following:
1. Electronics Cage Assembly (Electronics Chassis complete with Boards, Transceiver Module, and
Motion Sensor Module)
2. AEI Tag (if equipped)
3. ID Code Number Tag (aluminum tag with the 5-digit AAR ID Code)
4. Emergency Exhaust Valve complete with Air Hose
5. TEST Switch Cable Assembly (2 wires complete with FASTON and AMP connectors)
6. Air Hose Support Chain or Steel Cable and associated “S” Hook
2.2.1 General Disassembly Instructions
Unless otherwise stated, refer to the Disassembly Instructions for the model of SBU being upgraded per the following US&S Service Manuals:
A. SBU Model 6695 (Aluminum Case) - Section 2.4 of Service Manual 6497.
B. SBU Model 6695-CC (ABS Composite Case) – Section 2.5 of Service Manual 7066.
2.2.2 Removal of Electronics Cage Assembly
1. Remove the SBU Rear Panel.
2. Remove the Electronics Cage Assembly and set aside for modification later on.
2.2.3 Removal of AEI Tag and ID Code Number Tag
For the SBU Model 6695 (Aluminum Case):
1. Remove the AEI Tag Holder by unscrewing the 6 Allen head screws securing it from inside the electronics compartment.
2. With the AEI Tag Holder removed, this releases the AEI Tag (if equipped) and the ID Code
Number Tag. Place these items aside along with the Electronics Cage Assembly. Remember to group these 3 items together for reinstallation later since the 5-Digit AAR ID Code is common to each.
2-2 SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
For the SBU Model 6695-CC (ABS Composite Case):
1. The AEI Tag on this model is located in a molded pocket above the ID Code Number Tag. To remove the AEI Tag (if equipped), peel off the bead of RTV securing the tag at the pocket opening and then slide the AEI Tag out.
2. The ID Code Number Tag is tacked down against the SBU case with a bead of RTV. Use a thin flat-bladed screwdriver to pry it loose and then slide it out of the case.
3. Set aside the AEI Tag and ID Code Number Tag with the Electronics Cage Assembly. Remember to group these 3 items together for reinstallation later since the 5-Digit AAR ID Code is common to each.
2.2.4 Removal of Emergency Exhaust Valve/Air Hose & Support Chain/Cable “S” Hook
1. For all models, slightly bend the “S” Hook securing the air hose support chain or steel cable to the coupler clamp and unhook it to free it loose.
2. For SBUs equipped with a “small diameter air hose and integral exhaust valve/glad-hand,” use a wrench to unscrew the air hose fitting from the bottom of the SBU. Clean the threads of the air hose fitting of any old pipe sealant that may be present.
4. For SBUs equipped with an “in-line exhaust valve and large diameter hose,” remove the Hose
Support Bracket, and use a wrench to unscrew the in-line valve from the bottom of the SBU via its stainless steel threaded nipple. Remove the threaded nipple from the in-line valve. Clean the threads of the in-line valve of any old pipe sealant that may be present.
2.2.5 Removal of TEST Switch Cable Assembly
1. The TEST Switch Cable Assembly consists of 2 wires (black and white) complete with FASTON and AMP connectors (see Figure 2.4). The AMP connector end of the cable was unplugged when the Electronics Cage Assembly was removed.
2. Remove the cable assembly from the SBU by unplugging the 2 FASTON connectors from the
TEST switch lugs. Set the cable assembly aside for reuse later.
2.3
MODIFICATIONS TO ELECTRONICS CAGE ASSEMBLY
The following procedure describes minor modifications required to the Electronics Cage Assembly before it can be used in the Model 6699-CC.
2.3.1 Increase of Hole Size in Cage Chassis for Antenna BNC Connector
1. Enlarge the hole at the top of the Electronics Cage metal chassis (see Figure 2.0 for location) from the existing ½ inch diameter to ¾ inch diameter. This is required to allow the Antenna BNC
Connector to pass through.
SM 7077 10/00 2-3
SECTION 2.0 UPGRADE KIT PROCEDURE
2. Once the hole has been enlarged (e.g., by drilling, stamping, etc), ensure that there are no sharp edges and that the assembly is clean of any metal shavings.
Increase Hole Size to
3/4 Inch Diameter
Figure 2.0 - Increase of Hole Size in Electronics Cage Chassis
2.3.2 Replacement of 4-Character LED Display Board
For the SBU Model 6695-CC (ABS Composite Case):
1. Replace the existing LED Display Board with the new wider one provided in the Upgrade Kit (listed as Item 8 per Table 1.0). Refer to Figure 2.1.
For the SBU Model 6695 (Aluminum Case):
1. Remove the existing LED Display Board and the 2 standoffs supporting it.
2. Install the 2 new longer Standoffs and Extender Boards (Items A and B per Table 1.1).
3. Install the new wider LED Display Board provided in the Upgrade Kit (Item 8 per Table 1.0). Refer to Figure 2.1 for location of components.
Item 8 – LED
Display Board
Item A - Standoff
(2 per Assembly)
Item B – Extender Board
(2 per Assembly)
2-4
Figure 2.1 - Installation of 4-Character LED Display Board
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4
INSTALLING ASSEMBLIES & PARTS INTO THE UPGRADE KIT
2.4.1 Assembling the Rear Panel
Assemble the components comprising the Rear Panel using the items listed in the Upgrade Kit (Table
1.0). Refer to Figure 2.2 below.
1. Insert Gasket (item 4) into the Rear Cover (item 2).
2. Install the RF Shield (item 3) and secure it using the 2 Speed Nuts (item 6).
3. Cut the Foam Strip (item 5) into 4 pieces and adhere them between the card guide bosses as shown.
4. For Dual Pressure SBUs Only: Drill and tap a 3/4” - 16 hole for the secondary hose fittings in the location shown in Figure 2.2 below. Assemble parts per drawing in SM 7076, page A-9.
Item 4 - Gasket
Item 5 – Foam Strip
Item 6 – Speed Nut
(2 per Assembly)
Item 3 – RF Shield
Item 2 – Rear Cover
FOR DUAL PRESSURE
SBU ONLY: Drill & Tap a
3/4” DIA - 16 Hole
SM 7077 10/00
Figure 2.2 - Assembled Rear Panel
2-5
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.2 Installing the Condensation & Corrosion Control Packet
1. Write the current date on the Condensation & Corrosion Control Packet (item 11) using a permanent black felt tip marker.
2. Adhere the packet to the lower inside surface of the Main Housing Assembly (item 1) in the location shown in Figure 2.3 below.
Item 11 - Packet
Figure 2.3 - Location of Condensation & Corrosion Control Packet
2.4.3 Reusing the TEST Switch Cable Assembly
1. Plug the 2 FASTON connectors onto the TEST Switch terminal lugs (polarity doesn’t matter) as shown in Figure 2.4.
SBU TEST Switch
FASTON Connectors
TEST Switch
Cable Assembly
2-6
Figure 2.4 - Installation of TEST Switch Cable Assembly
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.4 Installing the Modified Electronics Cage Assembly into the Main Housing
NOTE
FOR ALL THREADED METAL FASTENERS, APPLY REMOVABLE THREAD-LOCKER
(E.G., LOCTITE 242 OR EQUIVALENT) PRIOR TO FINAL TIGHTENING.
1. In general, this is the reverse procedure of removal. The seven (7) screws and associated washers removed during removal of the Electronics Cage Assembly (per Section 2.2.2) can be reused, or can be replaced with the ones provided in the Upgrade Kit (items 9 and 10). Note that the screw (item 9) in the Upgrade Kit is a 1/8 inch Allen socket head type screw and may be preferable to the existing slotted Pan head type for some users.
2. Feed the Antenna BNC Cable through the enlarged hole at the top of the cage chassis. Ease the
Electronics Cage Assembly into position ensuring that the Processor Board and 4-Character LED
Display Board engage with the card guide bosses on the inside of the housing.
3. Secure the Electronics Cage Assembly with seven (7) screws and washers located as follows:
A. Two (2) near the base of the Antenna.
B. One (1) in the upper left-hand corner of the Marker Light Board.
C. One (1) in the upper right-hand corner of the Marker Light Board.
D. One (1) above and slightly to the left of the Transceiver Module.
E. Two (2) along the bottom edge of the Marker Light Board.
Be certain to use thread-locker on each of the 7 screws.
NOTE
••••
If the slotted type Pan head screws are used to secure the Electronics
Cage Assembly, use a “leaf-spring” type locking screwdriver (e.g.,
ChanneLock model 77H) to ease the installation of the screw & washer combination.
••••
In Dual-pressure SBUs, pay particular attention to the placement of the
Pressure Transducer connectors J9 and J10. These two connectors are not keyed and could be improperly interchanged.
4. Replace the push-on AMP connectors located along the edge of the Processor Board. From top to bottom, the connectors are:
A. The TEST Switch - J8 marked “ARM.SW”.
B. The secondary pressure transducer (for Dual Pressure SBUs) - J9 marked “AUX.PRES”.
C. The main pressure transducer - J10 marked “BRK.PRES”.
D. The pressure switch - J11 marked as “PRES.SW”.
E. The brake solenoid valve - J12 marked as “BRK.SOL”.
5. Plug the large Ribbon Cable Connector onto the mating Processor Board connector (J3).
SM 7077 10/00 2-7
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.5 Installing the AEI Tag, the ID Code Number Tag, and AEI Tag Holder
1. Mount the AEI Tag (if equipped) in the location shown in Figure 2.5 using the Double Sided Acrylic
Foam (Item 14). Ensure correct orientation of the AEI Tag per its markings.
AEI Tag
AEI Tag Markings
(bottom left corner)
Figure 2.5 - Mounting of AEI Tag to SBU Housing
2. Place the ID Code Number Tag (loosely) in the molded area below the AEI Tag and install the AEI
Tag Holder (Item 12) using 3 Screws (Item 13) as shown in Figure 2.6.
Item 12 - AEI Tag Holder
Item 13 – Mounting Screws
(Use 1 washer, Item 10, on outside screw)
ID Code Number Tag
2-8
Figure 2.6 - Mounting of AEI Tag Holder
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.6 Installing the NiCad Battery Boards, Holding Posts, and Retaining Nuts
Refer to Figure 2.7 for the location of the parts used in the SBU Battery Compartment.
1. Install the 2 Long Battery Holding Posts (Item 20) and the 2 Short Battery Holding Posts (Item 21).
2. Install the 2 NiCad Battery Board Assemblies (Item 15) using Screws (Item 16) and Washers (Item
17). Note that with the screws completely tight, the Battery Boards should “float” slightly.
3. Install the 2 Battery Retainer Nut Assemblies (Item 18) using Screws (Item 19). Ensure that the steel cables are pointing downwards (as shown in Figure 2.7) when the screws are tight.
4. Plug the connector for the left-side Battery Board onto the mating connector marked BAT1 at the top of the battery compartment. The right-side Battery Board plugs onto BAT2.
Remember to use thread-locker on all screws.
Connectors Plug into
BAT1 and BAT2
Item 15 - NiCad Battery
Board Assemblies
Item 20 - Long Battery
Holding Posts
Item 21 - Short Battery
Holding Posts
Item 16 & 17 - Screws and Washers (3 each per Battery Board)
Item 18 – Retainer Nut
Assembly (2 per SBU)
Item 19 - Screw
(2 per SBU)
Ensure Steel Cables
Point Downward
SM 7077 10/00
Figure 2.7 – Installing Components into the SBU Battery Compartment
2-9
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.7 Applying Labels
Refer to Figure 2.8 and Figure 2.9 for the location and orientation of the two Labels used on the SBU.
1. Trim the Instruction Label (Item 23) along the outside black border.
2. The labels have a self-adhesive backing. Peel off the protective paper and adhere the label inside the Battery Door.
Item 23 - Instruction Label
Figure 2.8 - Instruction Label Applied to Battery Door
3. Trim the SBU Nameplate Label (Item 22) along the outside black border, peel off the protective paper, and adhere it behind the Carrying Handle.
Item 22 - SBU Nameplate Label
2-10
Figure 2.9 - Nameplate Label Applied to SBU Housing
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.8 Installing Air Hose/Emergency Exhaust Valve and “S” Hook
This section details both the standard “Small Diameter Air Hose/Exhaust Valve” and the optional “In-
Line Type Exhaust Valve/Large Diameter Hose”.
2.4.8.1 Installing the Small Diameter Air Hose/Exhaust Valve and “S” Hook
1. Apply pipe sealant to the threads of the air hose fitting.
2. Screw the air hose fitting into the air manifold (located underneath the coupler clamp assembly) until it’s tight.
3. Slip the “S” Hook through the hole at the bottom of the coupler clamp assembly and bend it closed.
See Figure 2.10 below.
Install “S” Hook and Bend Closed
Apply Pipe Sealant to Air
Hose Fitting Threads and
Tighten
Figure 2.10 – Installing Air Hose and “S” Hook
SM 7077 10/00 2-11
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.8.2 Installing the In-Line Type Exhaust Valve/Large Diameter Hose
On the Model 6699-CC, the In-Line Exhaust Valve is fastened to the air manifold using 3 screws. An
O-Ring is used between the valve and the air manifold to provide an airtight seal. This method of securing the valve to the SBU results in maximum mechanical strength.
Note that the Air Manifold Assembly on all Model 6699-CC SBUs incorporate the 3 mounting holes required for the in-line valve. The holes are unused on units equipped with the “Small Diameter Air
Hose/Exhaust Valve”. Also note that US&S now supplies the In-Line Exhaust Valve (P/N: J792426-
0017) with the 3 holes pre-drilled and tapped. The following procedure provides all the information required to drill and tap existing In-Line Exhaust Valves being installed into the Upgrade Kit.
The installation is detailed in the following steps.
1. Remove the 4 Allen head screws securing the Air Manifold Assembly to the SBU. These are located as shown in Figure 2.11.
2. Partially slide out the Air Manifold Assembly and disconnect the electrical connections associated with:
A. The Solenoid Valve
B. The Pressure Switch
C. The Pressure Transducer
D. The Manifold Grounding Lug
The Air Manifold Assembly can now be removed.
Air Manifold Assembly
Remove 4 Allen Head Screws
3 Mounting Holes for
In-Line Exhaust Valve
2-12
Figure 2.11 – Removal of Air Manifold Assembly
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
3. Remove the Air Hose. To mark the location of the holes to be drilled, place the Air Manifold
Assembly on top of the In-Line Exhaust Valve as shown in Figure 2.12. To ensure correct alignment, place the O-Ring (Item D) on the valve as shown in Figure 2.13. Apply a coating of light grease (such as LubriPlate) to the O-Ring to lubricate it and to help keep it in place.
4. Rotate the exhaust valve so that the three holes are located on top of the “US&S” and part number markings “J792426-0017” as shown in Figure 2.13.
It is important to ensure the holes be
drilled as far away from the exhaust valve bolts as possible to avoid damage to the bolts.
Use a hole punch centered in the middle of the hole to mark the three spots to drill.
Air Manifold Assembly
Use These 3 Mounting Holes to Mark the Spots to Drill
Figure 2.12 – Placement of Air Manifold Assembly for Marking of Holes to Drill
5. Use a drill press to drill a 1/4 inch hole, 0.44 inches deep, in the 3 locations shown in Figure 2.13.
Tap the holes to a 20 thread pitch.
Protect the valve opening to prevent metal shavings from entering.
In-Line Exhaust Valve
Item D: O-Ring
Drill & Tap 3
Holes (1/4-20 X
0.44” Deep) in
These Locations
SM 7077 10/00
Figure 2.13 – Location of O-Ring and Three Holes to be Drilled
Top View
2-13
SECTION 2.0 UPGRADE KIT PROCEDURE
6. Apply thread-locker (e.g., Loctite 242) to the threads of Screws (Item C) and fasten the Air
Manifold Assembly to the In-Line Exhaust Valve as shown in Figure 2.14.
Secure Air Manifold
Assembly to In-Line
Exhaust Valve using
3 Screws (Item C)
Figure 2.14 – Bolting Air Manifold Assembly to In-Line Exhaust Valve
7. Reconnect the items associated with the Air Manifold Assembly as listed below. Reinstall the Air
Manifold Assembly into the SBU in the same orientation and using the same 4 screws as shown previously in Figure 2.11 (remember to use thread-locker on the 4 screws).
A. The Solenoid Valve
B. The Pressure Switch
C. The Pressure Transducer
D. The Manifold Grounding Lug
8. Reinstall the Air Hose using pipe-sealant and then slip the “S” Hook through the hole at the bottom of the coupler clamp assembly and bend it closed. Figure 2.15 shows the completed assembly.
Install “S” Hook and Bend Closed
2-14
Figure 2.15 – Completed Assembly of In-line Exhaust Valve to SBU Coupler Clamp
SM 7077 10/00
SECTION 2.0 UPGRADE KIT PROCEDURE
2.4.9 Installing the SBU Rear Cover Assembly
Prior to installing the Rear Cover Assembly (as shown in Figure 2.2), it is required that the SBU be fully tested per the next section, Section 2.5 – Testing the Upgraded SBU Model 6699-CC.
Once the testing is complete, install the Rear Cover as follows:
1. Carefully reinstall the Rear Cover, ensuring that the card guide bosses line up with the board edges of the Processor Board and LED Display Board. Do not force it into place.
If the SBU is a Dual Pressure type unit, first plug the auxiliary pressure transducer connector onto
J9 on the Processor Board.
2. Install the 10 Allen head screws in the rear cover. Using a 1/8" Allen wrench, tighten them uniformly, alternating back and forth from top to bottom and side to side till all are tight.
2.5 TESTING THE UPGRADED SBU MODEL 6699-CC
WARNING
COMPRESSED AIR
WHEN WORKING WITH COMPRESSED AIR MAKE SURE THE AIR
SUPPLY IS CLEAN, THE TEST EQUIPMENT IS IN GOOD ORDER AND
THE GLAD-HAND IS FULLY ENGAGED BEFORE APPLYING AIR
PRESSURE.
ALWAYS PRESS THE PRESSURE RELIEF BUTTON ON THE
EMERGENCY VALVE BEFORE DISCONNECTING IT FROM THE GLAD-
HAND.
WHEN PERFORMING EMERGENCY BRAKE EXHAUST VALVE TESTS,
BEWARE OF THE BLAST FROM THE BOTTOM OF THE VALVE. IF THESE
ACTIONS ARE NOT TAKEN, PERSONAL INJURY COULD RESULT.
CAUTION
THE SBU CONTAINS STATIC SENSITIVE COMPONENTS. PRIOR TO
REMOVING THE SBU’S REAR PANEL, AND WHILE WORKING ON THE
INTERNAL ELECTRONICS, ALWAYS FOLLOW PROPER
ELECTROSTATIC DISCHARGE (ESD) HANDLING PRACTICES,
OTHERWISE EQUIPMENT DAMAGE MAY RESULT.
SM 7077 10/00 2-15
SECTION 2.0 UPGRADE KIT PROCEDURE
Fully test the upgraded SBU per the procedures stated in
US&S Service Manual 7076 – Shop
Maintenance, Section 2.3 and Section 2.5. The Operational Test Chart in Section 5.6 can also be used. These cover the following general functions:
1. Power-Up Test Sequence
2. Communications
3. Arming Check
4. Emergency Brake Application
5. HVM Marker Light and Associated Tilt Switch Operation
6. Pressure Switch and Pressure Transducer
7. Motion Sensor
8. Battery Status Sensing
9. Testing the Air Manifold and Hoses for Leaks
10. Transceiver Alignment and Calibration
Once the testing is complete, per FRA regulations, apply a calibration label on the outside of the unit.
End of Manual
2-16 SM 7077 10/00
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