PC-202 Single Car Test Device - New York Air Brake...Rail Vehicle Systems PC-202 Rev. E (8/20/13)...

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R a i l V e h i c l e S y s t e m s

P C - 2 0 2Rev. E (8/20/13) -en

Selection GuideFreight Single Car Test DeviceP/N 770604, 770606

FREIGHT SINGLE CAR TEST DEVICESelection Guide Doc. No. PC-202

Revision: E 8/20/13-en

This document was originally written in English.

Knorr-Bremse Group Page 2 / 31

Copyright 2009© NYAB. All rights reserved, including industrial property rights applications.NYAB retains any power of disposal, such as copying and transferring.

Contact addressNew York Air Brake748 Starbuck AvenueWatertown, NY 13601USAPhone: +1 315 786 5200Fax: +1 315 786 5676www.nyab.com

Technical ChangesTTechnical ChangesNYAB reserves the right to change the unit or this document at any time without giving special notice

Replacement Plan Category:

Meanings of the letters in the Replacement Plan column of the following tables:

CAUTIONWhen repairing this assembly, use only NYAB supplied parts. Use of com-mercially available parts may result in unsatisfactory performance ofthis assembly and the brake system it becomes a part of.

CAUTIONThe purpose of this catalog is to identify the detail parts that make up thiscomplete assembly. To avoid damage to this assembly and/or personalinjury, utilize the applicable maintenance publications before attempting todisassembly or assembly this device.

WARNINGWhenever a part in this assembly is replaced, the assembly must pass thetests in the latest issue of the applicable New York Air Brake Corporation(NYAB) Test Specification. Additionally, a stationary vehicle test must bemade to ensure that this device functions properly when installed in thetotal brake equipment arrangement. Consult your local NYAB representa-tive to identify the applicable test specification.

Replacement Plan Definition

A 100% Replacement at every scheduled overhaul

B Replacement dependent upon condition of part

C Replace if damaged during repair, maintenance, or overhaul.

FREIGHT SINGLE CAR TEST DEVICEParts Catalog Doc. No. PC-202




FREIGHT SINGLE CAR TEST DEVICE

FREIGHT SINGLE CAR TEST DEVICEP/N 770604

FREIGHT SINGLE CAR TEST DEVICEP/N 770606

NOTE: As indicated by the circled areas below, the only difference between Freight Single Car Test Device P/N 770604 and P/N 770606 is the filter assembly.






Figure 1

FIG. & REPL. PART DWG. NO.INDEX PLAN NO. NO. REQ’D. DESCRIPTION






Replacement Plan:A = 100% Replacement at every scheduled overhaul.B = Replacement dependent upon condition of part.C = Replace if damaged during repair, maintenance or overhaul.

1- 770604 770604 FREIGHT SINGLE CAR TESTDEVICE, Complete(Includes items 1, 2, 3, and 4 thru 13)

770606 770606 FREIGHT SINGLE CAR TESTDEVICE, Complete(Includes items 1, 2, 3A and 4 thru 13)

1 B 702953 N2300 2 . COUPLING, FR-2 Hose, Complete (Includes item 2.)

2 A 739882 HC5137 2 . . GASKET

3 705131 705131 1 . IN-LINE FILTER, 1/2" NPT Used with P/N 770604 (See Figure 2)

3A 770603 770603 1 . COMPLETE FILTER, 1/2 NPT Used with P/N 770606 (See Figure 3)

4 C 771151 771151 1 . NIPPLE, Reducing Male 1/2" x 3/8" NPT

5 770602 770602 1 . VALVE, Regulating (See Figure 4.)

6 C 757661 PF189 1 . NIPPLE 3/8" NPT x 5" Long

7 C 740503 PF73 1 . BUSHING, Reducing 1/2" x 3/8" NPT

8 N/A N/A 1 . SINGLE CAR TEST DEVICE BODY ASSEMBLY (See Figure 5.)

9 C 740505 PF77 1 . NIPPLE 3/8" NPT x 2" Long

10 702159 N6911 1 . COCK, 3/8" Diaphragm (See Figure 6.)






Figure 1








1-

11 B 756348 EV5465 1 . PLUG, Choke 3/8" NPT (5/16" Drill)

12 705684 N9846 1 . 1/2" DIAPHRAGM COCK with INTEGRAL FLOWRATOR

(See Figure 7.)

13 769099 769099 1 . COUPLING, Choked Test, Complete (See Figure 8.)






Figure 2

- In-Line Filter -








2- 705131 705131 . FILTER, 1/2" NPT In-Line, Complete (For use with Single Car Test Device P/N 770604.)

1 C 752044 DC1175 2 . . NUT, Cap

2 C 734874 DC72 2 . . STRAINER

3 C 752043 DC1174 1 . . BODY, Strainer

4 A 734877 DC77 1 . . HAIR, Curled

- In-Line Filter -






Figure 3

- Filter -








3- 770603 770603 . FILTER, Complete (For use with Single Car Test Device P/N 770606.)

1 C 771038 771038 1 . . CAP, End

2 A 771039 771039 1 . . FILTER

3 C 771040 771040 1 . . BODY

- Filter -






Figure 4

- Pressure Regulating Valve -








4- 770602 770602 . VALVE, Pressure Regulating, Complete

772022 772022 1 . . HANDLE ASSEMBLY (Includes items 1 through 3.)

1 C 771130 771130 3 . . . SCREW, Set, Socket Head Steel #8-32 x 3/16"

2 C 752954 CR1871 2 . . . SCREW, Set, Socket Head Steel #8-32 x 1/2"

3 C 771131 771131 1 . . . HANDLE

4 C 771132 771132 1 . . HEX NUT, Panel Steel 7/16" x 20

5 C 757388 PR292 1 . . HEX NUT, Jam Steel 7/16" x 20

6 C 771133 771133 1 . . HANDLE STOP

7 C 771134 771134 2 . . SCREW, Round Head Machine Steel #8-32 x 2"

8 C 771135 771135 2 . . SCREW, Fillister Head Machine Steel #8-32 x 1-3/4"

9 C 771136 771136 1 . . BONNET AND BUSHING ASSEMBLY (Includes item 10.)

10 C N/A N/A 1 . . . CAPSULE ASSEMBLY

11 A 771138 771138 1 . . GASKET, Bonnet







Figure 4









4-

12 C 771139 771139 1 . . HOUSING

A 771140 771140 1 . . SCREW ASSEMBLY, Bleed (Includes items 13 and 14.)

13 A 771141 771141 1 . . . SCREEN, Bleed

14 A 771142 771142 1 . . . SCREW, Bleed

15 B 771143 771143 1 . . SPRING, Control

16 A 771144 771144 1 . . DIAPHRAGM AND PROTECTOR ASSEMBLY

17 C 771145 771145 1 . . SPACER

18 A 771146 771146 1 . . DIAPHRAGM ASSEMBLY, Control

19 C 771147 771147 1 . . BODY

20 C 740735 PF618 2 . . PLUG Steel, Cadmium Plated 1/4" NPT

21 B 771148 771148 1 . . SPRING, Supply Pintle

22 C 771149 771149 1 . . PLUG, Bottom

23 C 771633 771633 2 . . SPACER

771150 771150 1 REPAIR KIT







Figure 5

- Single Care Test Device Body Assembly -








5- N/A N/A . SINGLE CAR TEST DEVICE BODY ASSEMBLY

C 745971 TA800C 1 . . HANDLE, Complete (Includes items 1 through 5.)

1 C 779901 779901 1 . . . BODY, Handle

2 C 779898 779898 1 . . . PIN, Rivet

3 C 745973 TA802 1 . . . LATCH, Handle

4 B 745974 TA803 1 . . . SPRING, Handle Latch Phosphorous Bronze 3/8" od x 0.0508" dia. x 1-1/4" high

5 C 779893 779893 1 . . . PLUG, Handle

746767 TA2741D 1 . . GAUGE BRACKET AND HANDLE ASSEMBLY (Includes items 6 through 14.)

6 C 736552 MV224 3 . . . SCREW, Round Head Machine Brass, Pltd. #12-24 x 3/4"

7 B 702838 N7885 1 . . . GAUGE, 4-1/2" Duplex Air

700311 N1263 2 . . . CONNECTOR ASSEMBLY, Female (Includes items 8, 9 and 10) 1/4" NPT x 1/4" Tube

8 C 745997 TA853 2 . . . . STUD, Union, 1/4" NPT

9 C 745984 TA816 4 . . . . SLEEVE, Union

10 C 745983 TA815 4 . . . . NUT

11 C 746756 TA2743 1 . . . TUBE, Supply Gauge







Figure 5









5-

12 C 746755 TA2742 1 . . . TUBE, Brake Pipe Gauge

700312 N1264 2 . . . CONNECTOR ASSEMBLY, Male (Includes items 9, 10 and 13) 1/8" NPT x 1/4" Tube

13 C 745982 TA814 2 . . . . BODY, Connector

14 C 746754 TA2741 1 . . . BRACKET AND HANDLE, Gauge

15 C 763602 763602 3 . . SCREW, Hex Head Cap Steel, Pltd. 5/16"-18 x 5/8"

16 C 745979 TA811 1 . . SCREW, Set, Fillister Head Dog Point Steel 5/16"-18 x 25/32"

17 C 734874 DC72 2 . . PLATES, Strainer

18 A 734877 DC77 . . HAIR, Curled

19 C 745977 TA807 1 . . NUT, Strainer Cap

20 C 745987 TA843C 1 . . BODY, Complete (Includes item 21.)

21 C 746403 TA2261 1 . . . PLUG, 1/4" NPT

22 A 737700 EV5050 1 . . O-RING Buna 7/8" od x 43/64" id x 0.103" t

23 C 745991 TA847 1 . . WASHER, Rotary Valve Key

24 C 745990 TA846 1 . . KEY, Rotary Valve







Figure 5









5-

25 B 736827 EV685 1 . . SPRING, Rotary Valve Key Music Wire 11/32" od x 0.051" dia x 1-1/16" high

26 C 771599 771599 1 . . ROTARY VALVE, Complete

27 A 745994 TA850 1 . . GASKET, Rotary Valve Seat

28 B 745995 TA851 1 . . SEAT, Rotary Valve

29 C 745996 TA852 4 . . SCREW, Hex Head Cap Steel 5/16" x 1-1/4" long







Figure 6

- Diaphragm Cock -








6- 702159 N6911 . 3/8" DIAPHRAGM COCK, Complete

1 C 737395 EV3207 3 . . SCREW, Set, Hex Head Steel 1/4"-20 x 1/2" long

2 B 746085 TA1240 1 . . HANDLE

3 B 746035 TA1147 1 . . PIN, Fulcrum Stainless Steel 0.311 dia x 15/16" long

4 C 746040 TA1162 1 . . FULCRUM

5 A 735202 DC501 1 . . PIN Stainless Steel 0.0640" dia x 15/16" long

6 C 748230 UV254 1 . . SCREW, Oval Fillister Head Steel 1/4"-20 UNC-2A x 7/8" long

7 B 746041 TA1163 1 . . COUPLING

8 C 746140 TA1320 4 . . SCREW, Hex Head Cap Steel 5/16" x 3/4" long

9 B 746088 TA1242 1 . . COVER

10 B 746725 TA1260 1 . . STEM Stainless Steel 0.498" dia x 1-15/16" long

11 C 746377 TA2157 1 . . DISC

12 A 746522 TA2537 1 . . DIAPHRAGM

13 B 746527 TA2542 1 . . BODY

- Diaphragm Cock -






Figure 7

- Diaphragm Cock w/Integral Flowrator -








7- 705684 N9846 . 1/2" DIAPHRAGM COCK with INTEGRAL FLOWRATOR, Complete

1 B 746085 TA1240 1 . . HANDLE

2 B 746035 TA1147 1 . . PIN, Fulcrum Stainless Steel 0.311 dia x 15/16" long

3 C 746040 TA1162 1 . . FULCRUM

4 C 737395 EV3207 3 . . SCREW, Hex Head Cap Steel 1/4"-20 UNC x 1/2"

5 B 746041 TA1163 1 . . COUPLING

6 C 748230 UV254 1 . . SCREW, Oval Fillister Head Steel 1/4"-20 UNC-2A x 7/8" long

7 C 740256 OC174 4 . . SCREW, Hex Head Cap Steel, Pltd. 3/8"-16 UNC x 1" long

8 B 746777 TA2758 1 . . COVER

9 B 746725 TA1260 1 . . STEM Stainless Steel 0.498" dia x 1-15/16" long

10 C 746098 TA1258 1 . . DISC

11 A 746525 TA2538 1 . . DIAPHRAGM

12 C 740603 PF440 1 . . . PLUG, 1/8" NPT

13 B 746925 TA2915C 1 . . BODY (Includes items 12 and 14.)







Figure 7









7-

14 C 746403 TA2261 1 . . . PLUG, 1/4" NPT

15 A 772683 772683 1 . . GASKET, Port Elastomer

19/32" od x 11/32" id x 5/32" t

16 A 744401 SC1102 4 . . . O-RING Buna 41/54" od x 27/64" id x 0.103" t

17 C 746779 TA2759 1 . . STOP, Ball Float

18 A 736540 MV84 2 . . . GASKET, Tube

19 C 746780 TA2760 1 . . . GUARD, Tube

768556 768556 1 . . TUBE AND BALL ASSEMBLY (Includes items 15, 16, and 18 thru 20.)

20 C 772383 772383 1 . . . TUBE and BALL (Includes item 21.)

21 C 768643 768643 1 . . . . FLOAT, Ball

22 C 757634 TA3026 1 . . CHOKE, Ball Stop

23 C 740645 PF431 1 . . NIPPLE, Close 1/2" NPT x 1-1/2" Long

24 A 735202 DC501 1 . . PIN Stainless Steel 0.0640" dia x 15/16" long







Figure 8

- Test Coupling -








8- 769099 769099 . COUPLING, Choked Test, Complete

768558 768558 1 . . PLUG, Choke, 1/4" NPT, Complete .011 diameter drill (Includes items 1, 2 and 3.)

1 B 768557 768557 1 . . . PLUG, Choke 1/4" NPT (.011 diameter drill)

2 A 734562 CV600 1 . . . FILTER, Choke

3 A 734563 CV601 1 . . . RETAINER, Filter

4 C 746702 TA723 1 . . BUSHING, Reducing 3/4" x 1/4" NPT

5 B 782884 N2127 1 . . COUPLING, FS-3 Hose (Includes item 7.)

6 C 739712 HC431 1 . . CHAIN, Hose Coupling

7 A 739882 HC5137 1 . . . GASKET, Hose Coupling

- Test Coupling -






This tabulation is intended for identification only and should not be used for anyother purpose. It does not represent a specification for the springs mentioned.It is based on calculated figures and the actual spring will vary somewhat, due tosmall differences in wire diameter, coil diameter, number of turns, etc.

Spring Identification

APPROX. APPROX. APPROX. APPR0X.PART NYAB OUTSIDE DIA. FREE FREE MATERIALNO. NO. DIA. WIRE HEIGHT TURNS

736827 EV685 11/32" 0.051" 1-1/16" 7-3/4 Music Wire

745974 TA803 3/8" 0.051" 1-1/4" 12-3/4 Bronze






Installation Data

APPROXIMATENET WEIGHT

37 Lbs.

PC-202 Single Car Test Device - New York Air Brake...Rail Vehicle Systems PC-202 Rev. E (8/20/13)...

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