Automated Single Car Test Device Gen III User s Guide

Automated Single Car Test Device Gen III User s Guide Home Introduction > Introduction Setup Specifications Parts List > View Parts List Parts and Accessories Daily Test > Daily Test Setup Troubleshooting s > Daily Test s Single Car Test s Test Sequence > 4 Port Test Sequence End of Car Test Sequence About SiteMap Page 1 of 23

Introduction The Wabtec Automated Single Car Test Device (ASCTD) Gen III was designed to perform freight car brake air tests in accordance with AAR Specification S-4027. It is capable of performing single car tests through the end of car hose or through Wabtec s 4-port receiver and provides a record of the test results. The purpose of this manual is to describe appropriate procedures for setting up the Wabtec Automated Single Car Test Device (ASCTD). It is important the operator observe all AAR requirements for air brake testing on a freight car. For this reason, copies of all applicable AAR standards should readily available to the operator at time of testing. Important: It is the responsibility of those receiving these instructions to ensure they are followed scrupulously during the operation of the Automated Single Car Test Device (ASCTD). The individuals receiving these instructions are responsible for properly informing other designated operators of the intended purpose of this device. Page 2 of 23

Setup General The Wabtec Automated Single Car Test Device (ASCTD) Gen III was developed to comply with AAR Specification S-4027. It is capable of performing single car tests through the end of car hose or through Wabtec s 4-port connector. Setup A. Unpack tester and verify that you have received Items #1 6. B. Install appropriate fitting to supply air inlet (⅜ NPT Connection) (9). C. Connect 110 Volt GFCI power supply to AC inlet (13). Allow battery to charge for 24 hours before first use. D. Connect keyboard (2) to keyboard cable connection on test device (11). E. Blow out air supply line and connect to fitting installed at supply inlet (9). Supply air pressure must not fall below 100 psi. F. Press ON button and hold for 3 seconds. Wait approximately 2 minutes for system to initialize and screen to display time and date. Confirm AC battery light (18) on tester is illuminated. G. Verify date and time screen. Push YES to accept and NO to change. H. The main menu will appear. Before performing single car testing, a successful daily test must be completed. (See Daily Test page) J. Once you have successfully passed a daily test press YES. The tester will reboot, returning to the time and date screen. K. Your Wabtec Automated Single Car Test Device is now ready to perform freight car air brake testing Select 1, Single Car Test from Main Menu. Select 1 for Access Plate/Receiver Test or Select 2 for End of Car Test. Follow on-screen prompts. Note: Some applications require a password. All new testers are shipped with the password set as WABCO. recommends training before running the single car test. Wabtec Page 3 of 23

Specifications Compliance Complies with AAR S-4027. Electrical Unit can be operated from 3 power sources. The power sources are internal battery, 110V AC line power (GFCI protected) or 12VDC vehicle system. A unit connected to ac power will not charge back into a vehicle system. Internal Battery The internal battery will power the unit for up to 4 hours under normal use conditions. For low temperature operations less than 32 F (0 C) battery life is reduced substantially due to the draw from internal heaters. 110VAC AC power source must be GFCI protected Units are designed for 110VAC operation. 12 VDC Power Supply Unit can be operated and charged from a 12 VDC power supply such as a vehicle system. The ASCTD unit has an automatic low voltage shut down at 10.5 volts. Therefore a unit left on while the vehicle is turned off will not drain the vehicle system completely but it is recommended that an additional deep cycle battery be installed with a battery isolator to keep from draining vehicle battery if unit is left on for an extended period of time. Auxiliary power port- this port is supplied directly from the battery and protected by a 7.5 Amp fuse under the main cover. Continuous draw from this port must be limited to less than 2 amps or battery power will drop resulting in an automatic power shutdown. Accessories run from this power port must be disconnected when the unit is not in use. Otherwise battery damage may occur if battery voltage drops below 10.5 V Supply Air The recommended minimum supply air pressure is 100 psi. Maximum supply air pressure should not exceed 120 psi. An internal pressure relief valve will release supply pressure if it exceeds approximately 140 psi. Regulator Regulator adjustments should only be made when necessary. Check for supply problems before adjusting. The regulator cannot compensate for low supply pressure. Page 4 of 23

Air Filtration The test device comes equipped with particulate (replacement element Parker P/N PS701P) and coalescing (replacement element Parker P/N PS724P) filters located on the left side of the tester. The particulate filter is located toward the front and the coalescing filter is located toward the rear. NOTE: The automatic drain valve on the coalescing filter is equipped with a drain cock that is to be left open for normal operation and closed manually for cold temperatures below 32 F. AC Line 115VAC 60 Hz 1.0Amp Internal Battery Type Dry cell Size 7 1/4 x 3 x 6 5/8 Voltage 12vdc Capacity 17AH 15A blade fuse type DC Power 12VDC nominal 2amp typical draw 10A Internal Resettable Fuse Protection Environnemental Operating temperature range of -10 F to +130 F (-23 C to +54 C). Page 5 of 23

Parts List Parts List: 6 1. ASCTD Gen III 2. Keyboard 3. 4 Port Access Hoses 20 4. 50 Brake Cylinder Hose with Fittings 5. Glad-hand Adapter 6. Dummy Coupling 7. 12V Power Connection 8. Hose Manifold 9. Cover Plate 10. Supply Air Inlet 11. Regulator Adjustment 12. Keyboard Cable Connections 13. 110 VAC Power Connection 14. USB/Data/Printer Ports 15. Cart (optional) 16. Brake Cylinder Hose/Hose Reel (optional) 17. ON and OFF Switch 18. Indicator Lights 19. Downstream/Brake Cylinder Pressure Tap 20. Auxiliary 12V Power Port 21. Particulate Filter (Manual Drain) 22. Coalescing Filter (Autodrain Manual Override) 23. Drain Cock (leave open for normal operation and close for cold temperature operation) 24. Truck Mounting Rails Kit 4 5 13 10 00 00 00 7 14 16 12 19 20 2 17 9 8 15 1 18 24 11 23 22 21 Page 6 of 23

Parts and Accessories Replacement Parts: 2 Keyboard P/N 666197 3 4 Port Access Hoses 20 P/N 665597 4 50 Brake Cylinder Hose with Fittings P/N 665356 5 Glad-Hand Adapter with Dummy Coupling P/N 667331 6 Dummy Coupling P/N 020806 12 Daily Test Fitting Adapter P/N 665372 Not Shown Particulate Filter Replacement Element P/N 667419 Not Shown Coalescing Filter Replacement Element P/N 667420 Not Shown 10 Amp Fuse P/N 666573 Not Shown 7.5 Amp Fuse P/N 666574 Not Shown Double Gasket P/N 305401 Not Shown Double Gasket P/N 305402 Not Shown O-ring P/N 666078 Not Shown Battery P/N 666075 Not Shown Quick Disconnect Coupling P/N 665244 Options and Accessories: Cart P/N 667310 24 - Truck Mounting Rails Kit P/N 666170 16 - Brake Cylinder Hose/Hose Reel P/N 665819 Brake Cylinder Tubing with Fittings P/N 665356 12V Power Harness P/N 667209 20 Keyboard Extension Cable P/N 667206 20 End of Car Hose P/N 665655 14 End of Car Hose P/N 665859 Page 7 of 23

Daily Test Setup Perform daily test to ensure test car does not fail as a result of a faulty test device. Before attaching supply air to test device, blow supply line clear of moisture and foreign particles. 1. Attach the Access Plate/Interface Connector Hose Assembly to the front of the test device. 2. Attached the Glad Hand Adapter with Dummy Coupling to the Access Plate/ Interface Connector Hose Assembly. 3. Connect the Daily Test Adapter Fitting to the Downstream Transducer on the front of the Test Device. 4. Connect the female fitting of the Brake Cylinder Hose to the Daily Test Adapter Fitting. 5. Connect the male fitting of the Brake Cylinder Hose to the female fitting on the Glad Hand Adapter. 6. Select 4, Daily Test from the Main Menu on the test device. Press YES to confirm daily test. Follow on-screen prompts. Downstream Pressure Transducer Brake Cylinder Hose Glad Hand Adapter with Dummy Connector Access Plate/Interface Connector Hose Assembly Page 8 of 23

Troubleshooting Before suspecting there is a problem with the test device: Ensure all steps have been followed as described in the set up procedure. Ensure air supply matches the requirements as stated in Item E. Ensure all connections are secure. Battery is sufficiently charged per Item C. Problem: Unit indicates low air supply, unable to test. Possible correction: Air supply must be maintained at 110 psi. Problem: Display on keyboard doesn't work. Possible correction: Wait approximately two minutes for display to appear or disconnect keyboard cable at unit and reconnect ensuring positive connection. Page 9 of 23

DAILY TEST ERROR CODES Indication 100 Quit key pressed. 50 ASCT hardware issue, system check failed. 37 Audible warning defective. 24 Interface pistons sticking or control line issue. 25 Interface pistons sticking. 1 Pressure transducer zero out of range. Check Calibration or pressure transducers. 2 Flow sensor zero out of range. Check calibration or flow sensor. 3 Regulator adjustment low or malfunction, pressure transducer calibration or malfunction, supply pressure or leakage issue. 4 Regulator adjustment high or malfunction, pressure transducer calibration or malfunction. 5 BP pressure rising over regulated level. Check regulator or supply leakage into brake pipe. 6 Leakage from BP line. Reservoir lines not increasing. Check interface connector and hose for external leakage. 7 Flow sensor span out of range. Flow sensor calibration or malfunctioning. 8 BC pressure rising from regulated setting. 9 Auxiliary leakage, decreasing. 10 Leakage detected into reservoir or cylinder lines. BP and Interface connector lines pressurized. Probable internal interface connector leakage. Possible B1, B2, BCC valve leakage. 11 BC rising. Check Interface connector leakage. 12 Emergency leakage, decreasing. 13 Pressure transducer zero issue. Check hardware and calibration. 15 BC leakage, decreasing. 18 Unable to drain brake pipe or brake cylinder. 19 Leakage from AUX to BP. 20 Leakage from EM to BP. 21 BP rising from zero. Possible interface connector leakage. 22 Unable to drain brake pipe during CBP test. 23 CBP valve leakage when closed. 38 Unable to charge BP to regulated pressure. Calibration, or supply problem. 39 Unable to charge BC to regulated pressure. Calibration, or supply problem. Indication 40 Pressure transducer zero out of range. Check calibration or transducer. 43 Aux decreasing. Possible interface connector. 44 EM decreasing. Possible interface connector. 45 Transducer voltage out of range. Check calibration. 46 Flow transducer output voltages out of range. Check calibration. 47 Transducer voltage out of range. Check calibration. 51 ASCT hardware fault. 26 Unable to reach regulated pressure. Check supply or regulator problem. 27 Unable to reach regulated pressure. Check supply or regulator problem. 28 Check supply or regulator. Unable to reach regulated pressure. Check supply or regulator problem. 29 Unable to reach regulated pressure. Check supply or regulator problem. 30 Unable to drain pressure. 31 Unable to control pressure. Check supply. 32 Unable to reach regulated pressure. Check supply or regulator problem. 33 Unable to reach regulated pressure. Check supply or regulator problem. 34 Unable to drain pressure. 35 Unable to drain pressure. 36 Open Valve cannot drop to set pressure. Possible matrix valve. 41 Unable to drain pressure. 48 Valve driver error. Possible matrix valve. 49 Open Valve cannot rise to set pressure. Possible matrix valve. Page 10 of 23

ERROR CODES [T5] No. General Inspection Message 50089 89 General inspection failed. [T7] Connect The Test Device To The Car 70002 2 Aborted. [T9] Flow Through 90003 3 Excessive BP buildup. 90004 4 Failed flow through. 90160 160 Unable to drain BP. 90300 300 Excessive restriction detected. 90301 301 BP line restricted. Insure that angle cocks open. [T11] Draining Reservoirs and BC 110104 104 Unable to vent system. Check transducer calibration. 110105 105 Trans zero voltage fault. 110106 106 Transducer zero failed. [T12] Charge BP to 20 PSI 120007 7 AUX reservoir charging too quickly. Probable defective service portion. 120011 11 Unable to charge brake pipe to 20 psi. 120012 12 Excessive retainer blow. 120017 17 AUX not charging properly. 120020 20 Emergency not charging properly. 120349 349 Excessive system leakage or low supply. [T13] Retainer Test 130008 8 Defective retainer. Unable to exhaust brake cylinder pressure. 130010 10 Unable build brake pipe to set brake for retainer test. BP<87 130013 13 Excessive retainer blow. 130016 16 Unable to charge BC to 30 psi. Probable excessive BC/retainer leakage. 130023 23 Retainer/brake cylinder leakage. Apply valve to determine which. 130108 108 Unable to drain BC to 16 psi. 130316 316 Probable defective emergency portion. 130317 317 Probable defective service portion. 130318 318 Defective retainer or brake cylinder leakage. 130366 366 Unable to set brake for retainer test. BC <17 psi [T14] 140009 9 [T15] No. Message Hand Brake Inspection Hand brake system must pass inspection. System Leakage 150010 10 Unable to charge BP to 90 psi. 150024 24 Excessive system leakage. 150025 25 Excessive system leakage. 150109 109 Flow meter faulty or calibration incorrect. 150110 110 Faulty flow meter or flow valve. 150111 111 Regulator pressure incorrect. 150161 161 Unable to recharge the car. 150162 162 Unable to recharge the car. 150302 302 Unable to charge BP to 95 psi. 150303 303 Excessive BP line leakage detected. 150304 304 BP line leakage detected. 150305 305 Excessive system leakage detected. 150306 306 System leakage detected. 150364 364 Flow reading not valid. Check supply and rerun test. [T16] B-1 AAV Test 160028 28 Probable defective service portion. 160029 29 Probable defective vent valve or emergency valve. 160030 30 No-B1 activity detected. Probable defective B1 valve. 160116 116 Unable to recharge BP to 92 psi. Check supply pressure. 160117 117 Unable to recharge BP to 92 psi. Check supply pressure. 160307 307 Unable to exhaust BP. 160308 308 Emergency application detected. Probable defective vent valve. 160309 309 Emergency application detected. Check that BPCC closed. [T17] VV Stability Test / 30 Psi Reduction (no VV) 170031 31 Unable to exhaust BP. Possible defective service portion. 170033 33 Possibly defective emergency portion. Check that BPCC is open. 170034 34 Likely EMERG. Portion AAV not shutting down. Check vent valve exhaust for flow. 170095 95 Drop in emergency detected, first check service and emergency portions. Check separation plate in reservoir last. 170037 37 Failed system no-go test. Page 11 of 23

No. Message 170068 68 Control valve stability test failure, emergency valve defective. 170166 166 Unable to drop BP. 170310 310 Unable to exhaust BP. 170311 311 Venting too quickly for VV test. 170312 312 Defective vent valve. 170313 313 Check vent exhaust for flow. 170319 319 Unable to exhaust BP. Possible defective service portion. 170320 320 Check VV plug. 170321 321 Check that VV plug is properly plugged and bleed stem pulled if equipped. 170328 328 Unable to exhaust BP. Possible defective service portion. 170329 329 Defective emergency portion. 170330 330 Likely emergency portion AAV not shutting down. Check vent exhaust for flow. [T18] Check Piston Travel 180035 35 Adjust piston travel. 180042 42 Slack adjuster needs attention. 180323 323 Adjust piston travel or slack adjuster. [T20] Check Rigging 200036 36 Drain system and repair brake rigging. 200073 73 Rigging system not ok. 200322 322 Low BC pressure on full service likely BC leakage, bad service portion, or branch pipe cut-out cock not opened. [T22] Drain BP to 0 PSI 220118 118 Unable to vent BP. Possible defective service portion. [T23] Manual Release Test 230044 44 Defective service portion. 230045 45 Defective service portion. 230046 46 Defective service portion. 230047 47 Defective service portion. 230049 49 Defective brake cylinder or rigging. 230331 331 Defective service portion. [T26] Vent Valve Test Setup 260048 48 Defective emergency portion or BPCC opened too fast. 260119 119 Can t charge BP to 60 psi. 260120 120 Can t drain BP. No. Message 260158 158 Probable defective service portion. [T27] Vent Valve Test 270054 54 Defective vent valve. 270158 158 Probable defective service portion. 270314 314 Defective vent valve. 270315 315 Defective vent valve. [T28] Remove Dummies/Close BPCC Warning dangerous condition. Test 280055 55 aborted. [T29] Minimum Application Test 290056 56 Defective service portion. 290123 123 Unable to charge BP. 290124 124 Unable to charge BP to 95 psi. 290158 158 Probable defective service portion. 290324 324 Unintended release on min application. Possible defective service or emergency. 290325 325 Leakage detected on min application. 290326 326 Excessive BC leakage or unintended release. 290327 327 Excessive BC increase detected. 290341 341 Applied leakage diagnostic for BC increasing. No increase after full service. 290342 342 Applied leakage diagnostic for BC increasing. Increase continues after full service 290343 343 Applied leakage diagnostic for BC increasing. Increase continues after full service 290346 346 Possible defective service portion. [T30] Applied Leakage Test 300057 57 Excessive auxiliary reservoir leakage. 300058 58 Excessive BC pressure. Probable defective service or emergency portion. 300061 61 Excessive applied leakage. 300063 63 Brake cylinder leakage. 300126 126 Unable to charge BC to 20 psi. 300127 127 Regulator needs adjustment. [T31] AAV Test 310059 59 Defective emergency portion. 310128 128 Unable to drop BP by 5 psi. 310129 129 Run choke calibration test. 310159 159 Unable to charge BC to 60 psi. Page 12 of 23

[T32] No. Limiting Valve Test Message 320060 60 Defective service portion. 320130 130 Unable to drop BC < 2 psi. [T33] Service Release Test 330067 67 Release failure, suspect service portion. 330134 134 Unable to charge BC to 20 psi. [T34] Service Stability Test 340068 68 Stability test failure. Defective emergency portion. 340069 69 Defective emergency portion. AAV runs on. 340094 94 Probable defective service, possible emergency. 340135 135 Unable to drop BP 25 psi. 340160 160 Unable to drain BP. [T35] Emergency Test 350070 70 Defective emergency portion. 350344 344 BP must be > 40 psi for emergency test. 350345 345 Probable defective emergency portion. 350137 137 Unable to drop BP. 350139 139 Unable to exhaust BC. 350157 157 Probable defective emergency portion. [T36] High Pressure Movement Test 360071 71 Defective emergency portion. 360090 90 Probable defective service portion. [T37] Leakage Into BP Test. 370345 345 Emergency pressure not higher than full service 370072 72 Probable defective service, possible emergency. [T38] Emergency Accelerated Release Test 380076 76 Defective emergency portion. 380146 146 Unable to charge BP to 28 psi. 380074 74 Slack adjuster needs attention. [T39] Receiver Check Valve Leakage Test 390077 77 Leakage into test device. Check receiver check valves or run daily test. 390078 78 Leakage into test device. Check receiver check valves or run daily test. 390147 147 Unable to charge BP to 60 psi. 390148 148 Unable to drain BP to 60 psi. No. Message 390149 149 Unable to drain BP to 50 psi. 390150 150 Unable to charge BC to 57 psi. 390151 151 Unable to drain the tester. [T40] Disconnect Procedure 400079 79 Defective receiver. [T41] Flow Through Diagnostics 410005 5 Likely blockage in brake pipe between branch pipe and restricted side. 410006 6 Blockage between pipe bracket & BP tee. 410101 101 Check tester supply pressure or tester requires maintenance. 410102 102 Unable to drain BP and BC to 2 psi. 410103 103 Test device requires maintenance. [T42] Unable To Charge Brake Pipe To 20 Psi 420080 80 Hold BP at 20 psi to find excessive brake pipe leakage. [T43] Excessive Retainer Blow 430014 14 Probable defective emergency portion. 430015 15 Probable defective service portion. [T44] AUX Not Charging Properly 440018 18 Defective service portion. 440019 19 Probable defective service portion. 440081 81 AX RES piping leak or service portion gasket. Soap to determine. [T45] Emergency Not Charging Properly 450021 21 Probable defective service portion. 450022 22 Probable defective service portion. 450082 82 EM RES piping leak or service portion gasket. Soap to determine. [T46] Excessive Retainer Blow 460087 87 Probable defective emergency portion. 460088 88 Probable defective service portion. [T47] Unable To Charge BC To 30 Psi 470083 83 Hold BC at 30 psi and soap BC to find leaks. [T48] Retainer/Brake Cylinder Leakage 480084 84 Maintain BC at 15 psi to soap retainer, BC and related piping for leakage. 480085 85 BC pipe/cylinder/service portion leakage. Maintain BC at 15 psi to find leak. 480086 86 Hold BC at 15 psi to soap retainer Page 13 of 23

No. Message and related piping to find leak. 480112 112 Unable to charge BP to 90 psi. 480113 113 Regulator pressure incorrect. 480114 114 Unable to charge BP to 95 psi. 480115 115 Unable to drop BP 3 psi to apply valve. [T49] Excessive System Leakage 490026 26 Car must pass leakage test. 490027 27 Car must pass leakage test. [T50] Excessive System Leakage 500025 25 Car must pass leakage test. Heavy system leakage above range of flow meter. 500027 27 Car must pass leakage test. Light system leakage. Over 225 limit. [T51] Failed System No-Go Test 510038 38 Diagnostics aborted! Check air supply. 510039 39 Diagnostics aborted! Check air supply. 510040 40 Defective emergency portion. 510041 41 Probable defective vent valve. Possibly incorrect BP length. 510121 121 Unable to drain BP. 510153 153 Unable to drop BP 25 psi. [T52] Check Piston Travel 520043 43 Slack adjuster needs attention. [T53] Manual Release Diagnostics 530050 50 Defective service portion. 530051 51 Defective service portion. 530052 52 Defective brake cylinder or rigging. 530053 53 Defective service portion. [T54] Applied Leakage Test In Progress 540062 62 Defective branch pipe cut-out cock. 540091 91 Defective service portion. 540092 92 Defective emergency portion. 540093 93 Probable defective BPCC. Possible BP leakage at control valve. 540131 131 BP was not charged sufficient for release. 540132 132 Unable to drop BP by 5 psi. [T55] Brake Cylinder Leakage 550064 64 Soap BC and all associated BC piping to find leak. 550065 65 Defective emergency portion. 550066 66 Defective service portion. No. Message 550133 133 Unable to drop BP to 50 psi. [T56] Check Piston Travel 560074 74 Slack adjuster needs attention. 560075 75 Adjust piston travel and re-test car. 560141 141 Unable to charge BP to 70 psi. 560142 142 Unable to charge system to 80 psi. 560143 143 Unable to exhaust BC. 560144 144 Unable to drop BP to 70 psi. 560145 145 Unable to charge BC to 67 psi. [T57] Empty/Load Test 570154 154 Unable to charge the system. 570123 123 Unable to charge BP. 570165 165 Unable to drain BP. 570096 96 E/l device defective or leakage. 570097 97 E/l device defective or leakage. 570098 98 E/l soap detected leakage. 570121 121 Unable to drain BP. 570161 161 Unable to recharge the car. 570162 162 Unable to recharge the car. 570164 164 Unable to vent BP. To recharge BP to 92 psi. Check supply pressure. 570165 165 Unable to drain BP. 570332 332 BC detected. Manual release failed. Defective service portion. 570333 333 Manual release reset fail. 570334 334 Bad BC pressure tap. 570335 335 E/L device defective leakage or manual release portion defective. 570336 336 E/L device defective or leakage. 570337 337 E/L soap detected leakage. 570365 365 UDE occurred on E/L [T58] Apply and Release Test 580338 338 Probable defective emergency portion. 580340 340 Unable to charge BP. [T61] Charging Up System 610172 172 Unable to release brake. Possible bad service portion or tester. 610173 173 Unable to release brake. Possible bad service portion or tester. 610174 174 Can t maintain 70 psi. Possible supply or system leakage problem. Check supply or run SCT test. [T62] Setting Up For Alternate 4 Hour Test 620171 171 Unable to drain BP to 2 psi. Possible Page 14 of 23

620175 175 No. Message calibration or exhaust valve problem. Failed because of excessive BC leakage (BC < 30 psi). 620176 176 4 hour test failed. 620177 177 Leakage into BP. 620178 178 Unexpected emergency application or excessive BP leakage. Test aborted. [T63] Receiver Check Valve Leakage Test 630077 77 Leakage into test device. Check receiver check valves or run daily test. 630078 78 Leakage into test device. Check receiver check valves or run daily test. 630147 147 Unable to charge BP to 60 psi. 630148 148 Unable to drain BP to 60 psi. 630149 149 Unable to drain BP to 50 psi. 630150 150 Unable to charge BC to 57 psi. 630151 151 Unable to drain the tester. [T64] Disconnect Procedure 640079 79 Defective receiver. [T66] Charging Up System 660172 172 Unable to release brake. Possible bad service portion or tester. 660173 173 Unable to release brake. Possible bad service portion or tester. 660174 174 Can't maintain 70 psi. Possible supply or system leakage problem. Check supply or run SCT test. [TTX] Miscellaneous (s found under multiple tests) XXX340 340 Unable to charge BP. XXX341 341 Unable to drop BP. XXX342 342 Defective service portion. XXX343 343 Probable defective emergency portion. XXX344 344 Aborted. XXX345 345 Probable defective emergency portion. XXX346 346 Possible defective service portion. XXX347 347 E/L soap detected leakage. XXX348 348 Excessive restriction detected. XXX349 349 Excessive system leakage or low supply. XXX350 350 Check for supply problem. XXX351 351 Check for supply problem. No. Message XXX352 352 Check for supply problem. XXX353 353 Can t maintain charge pressure. Possible supply or system leakage problem. XXX354 354 Can t maintain charge pressure. Possible supply or system leakage problem. XXX355 355 Check for supply problem. XXX356 356 Check for supply problem. XXX357 357 Check for supply problem. XXX358 358 Check for supply problem. XXX359 359 Check for supply problem. XXX360 360 Check for supply problem. XXX361 361 Check for supply problem. XXX363 363 System leakage failed possible supply pressure problem. XXX364 364 System leakage failed possible supply pressure problem. Page 15 of 23

4-PORT TEST SEQUENCE Test S4027 S486 Description [T5] General Inspection 3.1 3.1 Walks operator through general car inspections [T7] Connect The Test Device To 3.2 3.2 Connect to car The Car [T9] Train line Flow Through 3.4.1 3.3 This test starts out with an automated restriction test that will automatically detect restrictions in the branch pipe and cut out cock. It is followed by a manual check for train line restrictions by having operator feel for blow of air from both glad hand. The device limits the air pressure from rising above 6 psi for this test. This allows glad hands to be installed. If the device cannot keep the pressure from building more than 20 psi, the device will stop and issue an error. [T11] Draining Reservoirs and BC Residual air in reservoirs is drained before the test can continue. If the bulk of the air is not drained when initially instructed this step will not be able to drain it all and the test may stop. [T12] Charge BP to 20 PSI This is a charging pretest. Brake pipe pressure is held at 20 psi and the charging rates of AUX and EM reservoirs are evaluated. If the reservoir pressure is not increasing in pressure that usually indicates reservoir piping leakage. If it is building to quickly that usually indicates internal leakage in the control valve. [T13] Retainer Test 3.13 3.12 The retainer test is performed while the car system is charging. With the retainer set the first check detects air blowing into the retainer/brake cylinder line. This usually indicates that a control valve portion is leaking air into the cylinder line at a rate that will fail the system leakage test. If this test passes, the Brake cylinder pressure is built up to between 15 and 20 psi and the retainer/ cylinder leakage is noted as a pressure drop. This could be due to leakage at the retainer, retainer pipe or cylinder piping and packing cup. [T14] Hand Brake Inspection 3.7 3.6 Directs operator to manually inspect and test. [T15] System Leakage 3.6,3.3 3.5,3.4.2 Train line and system leakage is combined. If system leakage fails then the diagnostics will direct operator to close cut out cock to diagnose leakage location. [T16] B-1 AAV Test 3.5 3.4 The device will try to automatically detect the B-1 activity. If it cannot the operator will be directed to check manually. [T17] VV Stability Test / 30 Psi Reduction (no VV) 3.5 3.4 The auxiliary vent valve stability test is performed with the system cut in. A 30 psi reduction is applied with position 5 rate. To diagnose a failure, plug the vent valve and repeat the stability test on the control valve only. Page 16 of 23

[T18] Check Piston Travel 3.8.5 3.8 The device prompts the operator to check the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. [T20] Check Rigging 3.8.5 3.8 Directs operator to manually inspect [T22] Drain BP to 0 PSI Sets up the car to test the manual release function and if equipped, the vent valve sensitivity (go) test. If there is a vent valve, the operator is instructed to close cut out cock. This traps air in the train line and vent valve for the stability test that will follow after the manual release check. [T23] Manual Release Test 3.18 3.16 The operator is instructed to pull the release rod and manually check that the cylinder retracted. The device then does a quick evaluation of brake pipe, cylinder and reservoir leakage such would occur if the release rod was stuck open or air was leaking back into brake pipe or if the manual release did not fully lock up. [T26] Vent Valve Test Setup If there is a vent valve, the system is drained to set up for the vent valve sensitivity test. This effectively deactivates the control valve emergency venting so a valid sensitivity test can be performed on the auxiliary vent valve. [T27] Vent Valve Test 3.5 3.4 The operator is instructed to slowly open the cutout cock. The device senses when the cutout cock is open and automatically runs the vent valve sensitivity (go) test on the pre-charged vent valve that was previously isolated. If the brake pipe had dropped below 40 psi due to unusual leakage or an extended time to evaluate the manual operations, the system will reset and attempt to rerun the test. [T28] Remove Dummies/Close BP Cutout Cock Sets up the car to run the control valve tests on the internal device volume [T29] Minimum Application Test 3.13 3.12 The system is recharged to a slightly higher 95 psi and a minimum application is made to check the application sensitivity. The application is held at the 90 psi regulator setting and the brake cylinder is adjusted to the equivalent of a 10 psi brake pipe reduction for the applied leakage test. Page 17 of 23

[T30] Applied Leakage Test 3.14 3.12 The applied leakage test is performed over an 80 second period. Therefore, 1.3 psi change in 80 seconds is equivalent to 1 psi change in 60 seconds. In addition to evaluating the brake cylinder leakage, the brake pipe flow is measured along with the AUX and EM pressure drops. [T31] AAV Test 3.16 3.14 The device will try to automatically detect the AAV activity. If it cannot the operator will be directed to check manually. [T32] Limiting Valve Test The limiting valve function in the service portion should maintain a minimum amount of brake cylinder pressure if it is functioning correctly. The device drains brake cylinder pressure while it is in the applied condition and evaluates that the limiting valve can open and resupply the brake cylinder pressure. [T33] Service Release Test 3.15 3.13 The brake cylinder is readjusted for the service slow release test. The brake pipe is built up at the position 2 rate and the release function is evaluated. In addition to meeting the specified release timing, the service release differential pressure is evaluated as well. [T34] Service Stability Test 3.8 3.7 After the system recharges the service stability test is performed. [T35] Emergency Test 3.9 3.9 The device performs the emergency stability test. The device automatically detects that the pressure is 5 psi higher than the full service and quickly goes into a venting routine that limits the pressure so that a 2nd piston travel check can be performed without excessive brake cylinder pressure affecting the travel measurements. [T36] High Pressure Movement Test After the emergency test, the brake cylinder, emergency and auxiliary should equalize. [T37] Leakage Into BP Test. 3.11 3.10 The device will measure the leakage into brake pipe after the emergency. Internal leakage in the control valve is usually the indication. [T38] Emergency Accelerated Release Test 3.11 3.10 The device builds up the brake pipe pressure to 28 psi and detects that the brake pipe continues to rise on its own. Page 18 of 23

[T57] Empty/Load Test 3.19 3.16 The device will recharge the system and make a brake application to evaluate the empty load equipment if equipped. [T39] Receiver Check Valve Leakage Test A quick check of the check valves in the 4 port receiver will be made before the operator is instructed to disconnect. [T40] Disconnect Procedure 3.20 3.17 Page 19 of 23

End Of Car TEST SEQUENCE Test S4027 S486 Description [T5] General Inspection 3.1 3.1 Walks operator through general car inspections [T7] Connect The Test Device To The Car 3.2 3.2 Connect to car [T9] Train line Flow Through 3.4.1 3.3 A manual check for train line restrictions by having operator feel for blow of air from the opposite glad hand. The device limits the air pressure from rising above 6 psi for this test. This allows glad hands to be installed. If the device cannot keep the pressure from building more than 20 psi, the device will stop and issue an error. [T15] Train line charge and flowrate 3.4.2 3.3 Leakage from the train line only is evaluated with the cut out cock closed. [T16] B-1 AAV Test 3.5 3.4 The device will try to automatically detect the B-1 activity. If it cannot the operator will be directed to check manually. [T17] VV Stability Test 3.5 3.4 The auxiliary vent valve stability test is performed on the train line only. A 30 psi reduction is applied with position 5 rate. [T27] Vent Valve sensitivity Test 3.5 3.4 The emergency rate is applied and the device notes that vent valve activated as noted by brake pipe pressure venting. [T13] Retainer Test 3.13 3.12 The retainer test is performed while the car system is charging. With the retainer set the device first detects air blowing into the retainer/brake cylinder line. This usually indicates that a control valve portion is leaking air into the cylinder line at a rate that will fail the system leakage test. Next a quick Brake application is made before the system is fully charged. This will build cylinder pressure to between 15 and 20 psi and the retainer/ cylinder leakage is noted as a pressure drop. This could be due to leakage at the retainer, retainer pipe or cylinder piping and packing cup. If the quick application does not build any brake cylinder pressure, an error will be issued. This usually indicates that there is major issue with the system since a brake application cannot be made. [T14] Hand Brake Inspection 3.7 3.6 Directs operator to manually inspect [T15] System Leakage 3.6 3.5 The device evaluates system leakage using the flow sensor. The test will automatically end early if there is excessive leakage. Page 20 of 23

[T34] Service Stability Test 3.8 3.7 After the system recharges the service stability test is performed. [T18] Check Piston Travel 3.8.5 3.8 The device prompts the operator to check the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. [T20] Check Rigging 3.8.5 3.8 Directs operator to manually inspect [T35] Emergency Test 3.9 3.9 The device performs the emergency stability test. The device automatically detects that the pressure is 5 psi higher than the full service and quickly goes into a venting routine that limits the pressure so that a 2nd piston travel check can be performed without excessive brake cylinder pressure affecting the travel measurements. [T37] Leakage Into BP Test. 3.11 3.10 The device will measure the leakage into brake pipe after the emergency. Internal leakage in the control valve is usually the indication. [T38] Emergency Accelerated Release Test 3.11 3.10 The device builds up the brake pipe pressure to 28 psi and detects that the brake pipe continues to rise on its own. [T29] Minimum Application Test 3.13 3.12 The system is recharged and a position 4 minimum application is made to check the application sensitivity. [T30] Applied Leakage Test 3.14 3.12 The applied leakage test checks for 1 psi change in brake cylinder pressure over 60 seconds. [T33] Service Release Test 3.15 3.13 The brake pipe is built up at the position 2 rate and the release function is evaluated. Meeting the specified release time. [T31] AAV Test 3.16 3.14 The device will try to automatically detect the AAV activity. If it cannot, the operator will be directed to check manually. [T18] Check Piston Travel 2nd 3.17 3.15 The device prompts the operator to recheck the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. Page 21 of 23

[T23] Manual Release Test 3.18 3.16 The operator is instructed to pull the release rod and manually check that the cylinder retracted. The device then does a quick evaluation of brake pipe, and brake cylinder pressure to confirm release. [T57] Empty/Load Test 3.19 3.16 The device will recharge the system and make a brake application to evaluate the empty load equipment if equipped. [T40] Disconnect Procedure 3.20 3.17 Page 22 of 23

About Important: It is the responsibility of those receiving these instructions to ensure they are followed scrupulously during the operation of the Automated Single Car Test Device (ASCTD). The individuals receiving these instructions are responsible for properly informing other designated operators of the intended purpose of this device. Disclaimer: The Wabtec Corporation accepts no responsibility for injury or damage to personnel or equipment resulting from either direct or indirect use of this manual. This includes liability for injury or property damage as a result of conditions on or around the car prior to or during car testing and the presence and/or actions of workers or bystanders causing incidental or consequential damages of any kind. Revision: C Copyright 2013 by Wabco Freight Car Products All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright law. Page 23 of 23