EP-60 END OF CAR JUNCTION BOX KIT 786282 and 786438 ASSEMBLY AND INSTALLATION INSTRUCTIONS Figure 1 EP-60 End of Car Junction Box Kit Item No. Qty. Description P/N Kit No. 786282 Kit No. 786438 1 2 Screw, Hex Head, Washer Faced 786279 X X 2 1 Cover, EOC Junction Box 786278 X X 3 1 O-Ring 766776 X X 4 1 Insert Assembly, EOC Junction Box 786281 X X 5 1 Sleeve, Wire Spacer 786273 X X 6 1 Spacer, Wire 786272 X X 7 1 Body Assembly, EOC Junction Box 786400 X 1 Body Assembly, EOC Junction Box 786438 X 8 1 Tubing, Cold Shrink 786704 X Knorr-Bremse Group Page 1 / 11
1.0 Installation Procedure: Trainline Cable Connection to EOC Junction Box - Armored Cable Figure 2 Trainline Cable Connection to End of Car Junction Box (Armored Cable) Avoid contacting cable pins with abrasive materials / files Ideal Yellow 77 Pulling Lubricant P/N 789745, or equivalent subject to engineering approval, may be required. 1.1 Slide the shrink tubing, connector, stop washer, and rubber grommet onto the trainline cable. 1.2 Insert the trainline cable through the male fitting and junction box until it protrudes approximately 5" on the opposite end of the junction box. Figure 3 Trainline Cable Connection in Wire Spacer Knorr-Bremse Group Page 2 / 11
1.3 With the F on the wire spacer in front, snap the trainline cable pins and trainline ground into the wire spacer at the positions identified in Figure 3 (Reference Figure 4 for car body ground positioning). Pins should extend 3/4" from wire spacer. Figure 4 Wire Spacer Sleeve 1.4 Slide the wire spacer sleeve over the wire spacer and snap the car body ground pin into the bottom of the spacer sleeve (reference Figure 4). Figure 5 EOC Insert Assembly 1.5 Slide the EOC Junction Box Insert Assembly onto the trainline cable pins and spacer sleeve. Knorr-Bremse Group Page 3 / 11
It is recommended that the flat of the EOC Insert Assembly runs parallel to the ground (reference Figure 6). Figure 6 Flat of EOC Insert Assembly Figure 7 Trainline Cable Connection Use caution when inserting the Insert Assembly into the junction box to avoid rolling the Insert Assembly O-Ring 1.6 Slowly push/pull the trainline cable back through the junction box until the spacer sleeve with EOC insert assembly bottoms out within the junction box body. Use caution to avoid rolling the insert assembly o-rings. (Reference Figure 7). 1.7 Install the Junction Box Cover with O-Ring onto the junction box body using cover screws. Torque screws to 25 to 30 ft-lbs (34-41 N-M). (Use of cover screws may aid in drawing down the spacer sleeve and insert assembly.) (Reference Figure 7). 1.8 Position the rubber grommet so it has entered the male fitting and slide the stop washer against the grommet. Knorr-Bremse Group Page 4 / 11
Figure 8 Trainline Cable Connection to EOC Junction Box 1.9 After ensuring that the EOC junction box cover is in place and tightened to specifications (see section 1.7), carefully thread the connector onto the male fitting and hand tighten. Use caution when tightening the connector onto the male fitting to avoid cross threading. Ensure the EOC junction box cover is in place and tightened to specifications before installing connector. 1.10 Using channel locks, continue tightening the connector onto the strain relief fitting until 1/16" of the stop washer protrudes through the connector. Before applying shrink tubing, ensure that it is correctly positioned over the strain relief connector and flush against the strain relief nut. 1.11 Slide the shrink tubing over the armored and non-armored cable until it covers the strain relief connector and is flush with the strain relief connecting nut (reference Figure 8). Knorr-Bremse Group Page 5 / 11
2.0 Installation Procedure: Trainline Cable Connection to EOC Junction Box - 1" Liqutight Conduit Figure 9 Trainline Cable Connection to End of Car Junction Box (1" Liquidtight Conduit) Avoid contacting cable pins with abrasive materials / files 2.1 Slide the connector and stop washer onto the 1" Liquidtight Conduit. Slide the metal grommet into the end of the 1" Liquidtight Conduit. 2.2 Insert the trainline cable through the male fitting and junction box until it protrudes approximately 5" on the opposite end of the junction box. Figure 10 Trainline Cable Connection in Wire Spacer 2.3 With the F on the wire spacer in front, snap the trainline cable pins and trainline ground into the wire spacer at the positions identified in Figure 10 (Reference Figure 11 for car body ground positioning). Pins should extend 3/4" from wire spacer. Knorr-Bremse Group Page 6 / 11
Figure 11 Wire Spacer Sleeve 2.4 Slide the wire spacer sleeve over the wire spacer and snap the car body ground pin into the bottom of the spacer sleeve. Figure 12 EOC Insert Assembly 2.5 Slide the EOC Junction Box Insert Assembly onto the trainline cable pins and spacer sleeve. Knorr-Bremse Group Page 7 / 11
It is recommended that the flat of the EOC Insert Assembly runs parallel to the ground (reference Figure 13). Figure 13 Flat of EOC Insert Assembly Figure 14 Trainline Cable Connection Use caution when inserting the Insert Assembly into the junction box to avoid rolling the Insert Assembly O-Ring 2.6 Slowly push/pull the trainline cable back through the junction box until the spacer sleeve with EOC insert assembly bottoms out within the junction box body. Use caution to avoid rolling the insert assembly o-rings. (Reference Figure 14). 2.7 Install the Junction Box Cover with O-Ring onto the junction box body using cover screws. Torque screws to 25 to 30 ft-lbs (34-41 N-M). (Use of cover screws may aid in drawing down the spacer sleeve and insert assembly.) (Reference Figure 14). Knorr-Bremse Group Page 8 / 11
2.8 Insert the 1" Liquidtight Conduit with installed metal grommet into the female socket of the 1" Liquidtight Connector. 2.9 Slide the stop washer against the installed metal grommet. 2.10 After ensuring that the EOC junction box cover is in place and tightened to specifications (see section 1.7), carefully thread the connector onto the male fitting and hand tighten. Use caution when tightening the connector onto the male fitting to avoid cross threading. Ensure the EOC junction box cover is in place and tightened to specifications before installing connector. Figure 15 Trainline Cable Connection to EOC Junction Box 2.11 Using channel locks, continue tightening the connector onto the strain relief fitting to 42 ft-lbs (56.5 N-M) torque. Knorr-Bremse Group Page 9 / 11
3.0 End Of Car Junction Box Installation Instructions Figure 15 End Of Car Junction Box 3.1 Mount the EOC Junction Box Assembly using an AAR Standard Angle Cock U-Bolt (p/n 786686), washer (p/n 744640), and nut (p/n 734764). Evenly torque nut (p/n 734764) to 90 ft-lbs (122 +/-1 N-M). 3.2 The front of the ECP connector must be clear of obstacles for wrench installation of coupling nut. Knorr-Bremse Group Page 10 / 11
4.0 Installation Procedure: Inter-Car Cable Assembly Connection to EOC Junction Box and EOC Termination Figure 16 Inter-Car Cable Assembly Connection 4.1 Ensure the o-ring is installed in the machined groove on the face of the hex nut. 4.2 Plug the inter-car cable assembly into the EOC and carefully thread the nut of the inter-car cable assembly into the female threads of the EOC assembly. Use caution when threading the cable assembly into the EOC to avoid cross threading 4.3 The hex nut should be hand tightened to junction box until tight. Then, using a 2-1/4" open end or adjustable wrench, tighten an additional 1/3 turn. Ensure that the o-ring is not exposed outside of the hex nut after tightening the hex nut. Over tightening of the inter-car cable assembly nut may result in O-Ring damage. 4.4 Clip the inter-car connector lanyard so it is positioned as outlined in AAR Specification S-4210. Knorr-Bremse Group Page 11 / 11