Read 4208-30,S.10 text version

4208-26, S.2.1

operation & maintenance instruction

"26-C" BRAKE VALVE, PART NO. 564315-2000

For use in Freight Service ONLY

FEBRUARY, 1989

Supersedes issue dated June, 1988

NOTE: The following description and operation is based on this device and its components being new or this device and its components having been repaired, tested, installed and maintained in accordance with instructions issued by this and any other applicable Wabtec Corporation publications. WARNING: At the time any part is replaced in this device, the operation of the complete device must pass a series of tests prescribed in the latest issue of the applicable Wabtec Test Specification. At the time this device is applied to the brake equipment arrangement, a stationary vehicle test must be made to insure that this device functions properly in the total brake equipment arrangement. (Consult your local Wabtec Representative for identity of the test specification, with latest revision date, that covers this device.) IMPORTANT: Only Wabtec supplied parts are to be used in the repair of this device in order to obtain satisfactory operation. Commercially available nonO.E.M. parts are unacceptable. NOTE: The part numbers and their associated descriptions are the property of Wabtec Corporation and may not be replicated in any manner or form without the prior sole written consent of an Officer of Wabtec Corporation.

BRAKE

Figure 1 - "26-C" Brake Valve - Exterior Views (1 of 2)

© 2000 WABCO Locomotive Products. A Wabtec Company. All rights reserved September, 1988 Page 1 of 34

4208-26, S.2.1

operation & maintenance instruction

1.0 DESCRIPTION (Figure 1) 1.1 GENERAL INFORMATION Designed for use in "Freight Service" equipment arrangements where the air pressure does not exceed 150 psig, the "26-C" Brake Valve, Pc.No. 564315-2000, is comprised of a "26-C" Brake Valve Portion, Pc.No. 562073-2000; and "SA-26" Independent Brake Valve Portion, Pc.No. 564316; and a Pipe Bracket Portion, Pc.No. 583491. The "26-C" Brake Valve Portion (automatic brake valve) functions to regulate the brake pipe pressure which controls both the locomotive and train air brakes. The "SA26" Independent Brake Valve Portion (independent portion) functions to initiate the application of air pressure into, or the release of air pressure from the locomotive air brake cylinder independent of the train air brakes. The independent portion also functions to control the release of locomotive brake cylinder air initiated by an automatic brake valve application independent of the train air brakes. The "26-C" Brake Valve Portion (automatic brake valve) is mounted on the top of the Pipe Bracket Portion and is secured in position by three 1/2" x 4" hex head cap screws and one 1/2" x 51/2" hex head cap screw. The "SA-26" Independent Brake Valve Portion (independent portion) is mounted on the front of the Pipe Bracket Portion on three 1 /2" x 2" studs, and is secured in position by three 1/2" hex nuts. A 11/4" flange is provided on the body of the "26-C" Brake Valve Portion for the piping of emergency exhaust. All other pipe connections are made to the Pipe Bracket Portion. This arrangement provides for a compact brake valve installation which occupies a minimum amount of space and eliminates much of the air piping in the open part of the cab. The entire valvular section of this "26-C" Brake Valve Portion may be mounted behind a panel, with only the brake valve handle operating portion and the cutoff valve section appearing on the front of the panel. Pipe connections to the Pipe Bracket Portion are designated numerically and are so identified in the diagrammatic view as shown in Figure 2. 2.0 DESCRIPTION OF THE COMPONENTS OF THE "26-C" BRAKE VALVE (Figure 2) 2.1 "26-C" BRAKE VALVE PORTION (automatic brake valve) Pc.No. 562073-2000 2.1.1 BRAKE VALVE HANDLE, SHAFT, & CAMS Initiation of train brake operation is obtained by manually moving the automatic brake valve handle into one of the externally detented quadrant positions, designated as; Release, Initial Reduction, Service, Suppression, Handle Off, and Emergency. The handle may be removed from the "26-C" Brake Valve Portion in "Handle Off" position by first removing the handle cap screw and washer, which are located on the top of the handle, and then lifting the handle upward. Four cams, keyed to the handle shaft, operate the various pneumatic devices housed in the "26-C" Brake Valve Portion. The cams, numbered one through four, are arranged on the shaft in numerical order with cam Number 1 on top, nearest the handle. A brief description of each cam follows: Cam Number 1, the emergency valve cam, operates the emergency valve. Cam Number 2, the regulating valve cam, operates to position the regulating valve and inlet spring housing. Cam Number 3, the suppression valve cam, operates the suppression valve. Cam Number 4, the vent valve cam, operates the emergency vent valve. 2.1.2 MANUAL CUT-OFF VALVE The Manual Cut-Off Valve is used to cut-in or cut-out the Brake Valve and to permit tests for the measurement of brake pipe leakage. This "26-C" Brake Valve is equipped with a two position Manual Cut-Off Valve which is designed for freight service only. The two positions are "IN" and "OUT". The handle of the Manual Cut-Off Valve is firmly held in each of its handle positions and it is necessary to first push the handle inward (toward the body) before it can be manually moved from one position to another. When moving the cut-off valve handle, be sure that it is set in the position desired and that the handle is locked in the extended position. IMPORTANT: When using this "26-C" Control Valve as the controlling brake valve in a freight train consist, the handle of the Manual Cut-Off Valve MUST BE IN THE "IN" (Freight) POSITION. When hauling a "26-C" Brake Valve equipped locomotive "dead" or as a trailing unit in a train consist, the handle of the Manual Cut-Off Valve MUST BE IN THE "OUT" POSITION. The porting of the Manual Cut-Off Valve incorporates two check valves which provide either brake pipe pressure or

September, 1988

Page 2 of 34

4208-26, S.2.1

operation & maintenance instruction

Top View

45

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23

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Automatic Brake Valve Handle se lea Re

Ini tia

on cti du e lR

9" R.

Re lea se

Service

Fu ll I nd .A pp lica tio n

y nc ge er Em f Of le nd Ha

Suppression

10

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8.25 R.

14o

60

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42o 10

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60

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LEGEND Pipe 1 3 5 8 12 13 15 20 21 26 30 53 X&Y Name Brake Pipe Switch Pipe Equal. Res. Cont. Pipe Lock-Over Pipe Emer. Switch Pipe Actuating Pipe Equal. Res. Charg. Pipe Ind. Appl. & Rel. Pipe Safety Control Pipe Suppression Pipe M.R. Pipe B.P. Cut-Off Pipe Brake Pipe Exhaust

26 21 20 8 13 5 15 53 3 12

Bottom View

Figure 1 - "26-C" Brake Valve - Exterior Views (2 of 2)

September, 1988 Page 3 of 34

4208-26, S.2.1

operation & maintenance instruction

Relay Valve X Y

Exhaust Valve Supply Valve

Handle Pos. Regulating Inlet Valve Regulating Exhaust Valve "A" AT. B.P. (1) Regulating Valve Set by Adjustment "A" Initial Service Emergency Suppression Valve

3 AT. 8 26 30 Release Service Suppression Handle-Off Emergency

Vent Valve

Adjusting Screw Regulating Valve Brake Pipe Cut-off Valve Vent Valve Emergency Valve Suppression Valve

"26-C" Brake Valve Portion

Emergency Valve

30 12 AT. 5

Equalizing Reservoir Cut-off Valve Pipe Bracket Portion Cut-off Valve (Freight Position)

Cut-Off Valve (2 Position Freight Service only)

3 7 30 1A 53 AT

B.P.

To Gauges

LEGEND Port Designation 15 12 26 Brake Pipe 1 3 8 Switch Pipe 3 Equal. Res. Control Pipe 5 Lock-over Pipe 8 Emergency Switch Pipe 12 Actuating Pipe 13 Equal. Res. Charging Pipe 15 Ind. Application & Rel. Pipe 20 Safety Control Pipe 21 Suppression Pipe 26 Main Reservoir Pipe 30 B.P. Cut-off Pipe 53 X & Y Brake Pipe Exhaust

21

1

53 13 5 30 20

"SA-26" Independent Brake Valve Portion This diagrammatic representation is for functional analysis only. It is not to be used as an actual physical representation of portion or pipe bracket configurations.

Figure 2 - "26-C" Brake Valve -Diagrammatic View

Page 4 of 34 September, 1988

In Out

4208-26, S.2.1

operation & maintenance instruction

main reservoir pressure for the brake pipe cut-off valve, depending upon the existing higher pressure, when the brake valve is cut-out. 2.1.3 REGULATING VALVE and permissible train leakage. 2.1.5 BRAKE PIPE CUT-OFF VALVE This valve functions to cut-off the flow of brake pipe air to or from the relay valve for the equipment arrangement when air is directed into Port 53 due to the movement of the cut-off valve into the "OUT" position or by the actuation of an "A-1" Charging Cut-Off Pilot Valve during a "break-in-two". Spring action will also close this valve if the brake valve handle is placed in the "Handle-Off" or "Emergency" Position when brake pipe pressure has reduced to a low pressure. 2.1.6 EMERGENCY VALVE This cam operated valve is designed to operate when the brake valve handle is placed in the "Emergency" position. The "Emergency Valve" functions to direct main reservoir air pressure into emergency switch pipe 12, and to exhaust equalizing reservoir air pressure in pipe 5. 2.1.7 VENT VALVE This cam operated valve functions to quickly exhaust brake pipe air to atmosphere when the brake valve handle is moved to the "Emergency" Position. 2.1.8 SUPPRESSION VALVE This cam operated valve functions to direct main reservoir air to suppression pipe 26 in "Suppression", "Handle-Off", and "Emergency" positions of the brake valve to suppress penalty brake applications. This valve also functions in these handle positions to blank lock-over pipe 8 for resetting a brake application valve prior to releasing a penalty brake application. The Suppression Valve also functions to direct main reservoir air to switch pipe 3 and to vent lockover port 8 with the brake valve handle in "Release" Position, and vents switch pipe 3 in all other brake valve handle positions. 2.1.9 EQUALIZING RESERVOIR CUT-OFF VALVE This diaphragm operated valve functions to establish a pressure in the brake pipe equal to the pressure in equalizing reservoir. The Relay Valve either directs or exhausts brake pipe pressure in response to changes in equalizing reservoir pressure on the outer face of the diaphragm. During brake applications, the equalizing reservoir air pressure on the outer face of the diaphragm is reduced and the Relay Valve will exhaust brake pipe air pressure an equal amount. The self-lapping feature of the Relay Valve maintains the brake pipe pressure against overcharges

September, 1988

This cam operated valve functions to regulate the air pressure directed to equalizing reservoir charging pipe 15. This pressure is externally connected into equalizing reservoir control pipe 5 which leads to the outer diaphragm chamber of the relay valve. Movement of the brake valve handle from "Release" position through the service zone causes the regulating valve to reduce the pressure in pipe 15 and pipe 5. The reduction in pressure is proportional to the amount of handle movement, until a total service reduction is obtained when the handle reaches its total travel in the "Service" position. Adjustment of equalizing reservoir pressure may be made in release position by turning adjusting handle "A" of the regulating valve. The self-lapping feature of the regulating valve maintains equalizing reservoir pressure against leakage while the brake valve is in the release position. CAUTION: The preceding method of pressure adjustment is to be performed ONLY while the locomotive and/or train is standing motionless. WARNING: The regulating valve adjustment handle MUST NOT BE turned once the brake pipe pressure has leveled off and the brake pipe leakage test is completed. Any movement of the regulating valve adjustment handle immediately before the departure of the train and/or while the train is in motion WILL CAUSE unpredictable variation in brake pipe air pressure and unpredictable degradation of brake cylinder pressure. Such erratic changes in brake pipe pressure and/or brake cylinder pressure could result in a less effective train retardation with possible damage to equipment and/or injury to personnel or by-standers. 2.1.4 RELAY VALVE

This valve is designed to function to permit the operation of equipment which employs either direct or graduated release type brakes. When the brake valve cut-off valve is positioned for freight service, the equalizing reservoir cut-off valve is held open in "Release" position only. Thus, the equalizing reservoir air pressure can only be restored for release in "Release" position.

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4208-26, S.2.1

operation & maintenance instruction

2.2 "SA-26" INDEPENDENT BRAKE VALVE PORTION, Pc.No. 564316 2.2.1 GENERAL INFORMATION This "SA-26" Independent Brake Valve Portion is a limited capacity, self-lapping, diaphragm operated type regulating valve which provides a manual means of controlling the locomotive brake cylinder pressure regardless of the automatic brake valve handle position or the state of the automatic brake on the train. When the "26-L" Locomotive Air Brake Equipment is properly set up, the independent brake is not restricted in its operation by features such as dynamic interlock or blending of friction and dynamic brake, and is always available to the locomotive operator (engineman). To direct air into the brake cylinders, manually move the independent brake valve handle into the "Application" zone. Air under pressure is then directed through the independent application and release pipe 20 to the relay valve. The relay valve functions to direct air to the brake cylinders proportional to the air pressure in pipe 20. The amount of air pressure in the brake cylinders is directly proportional to the amount of handle movement into the application zone. To release, manually move the independent brake valve handle to "Release" position. This will exhaust the air pressure in pipe 20. To release air from only the locomotive brake cylinders during automatic brake applications, manually depress the independent brake valve handle. Air pressure directed through actuating pipe 13 serves to operate the locomotive control valve to exhaust application air pressure in application pipe 16. Air, under pressure, in the locomotive brake cylinders can be retained or reapplied by moving the independent brake valve handle to the desired location in the Application zone. When operating locomotives arranged for multiple unit operation, it is important when the automatic brake is released on the locomotives by depressing the independent brake valve handle that the independent brake valve handle be held depressed for a sufficient length of time to charge the actuating pipe 13 on the last trailing locomotive unit. A time period equal to 4 seconds for each locomotive unit in the consist should be adequate, (as an example, if there are three locomotives in the consist the independent brake valve handle is to be held depressed for a time period of twelve seconds. 4 seconds x 3 locomotives = 12 seconds). If the automatic service brake has been released on the locomotives by depressing the independent brake valve handle, the pressure in the control reservoir may increase slightly due to the effect of temperature. This pressure increase will be greater when a heavier brake application has been released and may, if the pressure increase is great enough, cause the locomotive brake to reapply. To minimize the possibility of the reapplication of the locomotive brake, when a reapplication is not desired, the independent brake valve handle should be held depressed for a sufficient time period to allow most of the pressure build back to occur. A time period of 2 seconds multiplied by the equalizing reservoir pressure reduction in psi should be adequate, (as an example, if there was a reduction of 2 psi in the equalizing reservoir pressure, the independent brake valve handle is to be held depressed for 4 seconds; 2 seconds x 2 psi = 4 seconds). 2.2.2 EMERGENCY - "LITE LOCOMOTIVE" OPERATION IMPORTANT: The Independent Brake is the primary brake when operating a "Lite Locomotive". Under such circumstances, the following guidelines are recommended. NOTE: The term "LITE LOCOMOTIVE" indicates a single locomotive or consist of locomotives only with NO OTHER VEHICLES in the consist, or to a locomotive or consist of locomotives to which ONLY a caboose is attached. WARNING: In an emergency situation, when operating a "LITE" locomotive, the RAPID MANUAL MOVEMENT of the independent brake valve handle to "Full Application" position is the fastest way to develop brake cylinder pressure on the locomotive up to the full independent brake cylinder pressure setting. Immediately after manually moving the independent brake valve handle to "Full Application" position, the automatic brake valve handle IS TO BE RAPIDLY MOVED MANUALLY to the "Emergency" position. Failure to comply with this procedure during an emergency brake application when operating a "LITE" locomotive consist could extend the stopping distance and increase the likelihood of equipment damage and/ or personal injury. In this equipment arrangement, the "SA-26" Independent Brake Valve Portion is, at the locomotive builder and/or owner-operating property request, equipped with a removable - offset style handle. This independent brake valve handle can be removed from the Independent Brake Valve Portion when the handle is manually moved into the "Release" position.

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4208-26, S.2.1

operation & maintenance instruction

WARNING: BEFORE PROCEEDING TO REMOVE THE INDEPENDENT BRAKE VALVE HANDLE, THE AUTOMATIC BRAKE VALVE HANDLE MUST BE MANUALLY PLACED IN "FULL SERVICE" POSITION, BRAKE CYLINDER PRESSURE MUST BE APPLIED TO THE LOCOMOTIVE, AND THE PROPER PROCEDURES FOLLOWED FOR CUTTING OUT BRAKE OPERATION CONTROL ON THE LOCOMOTIVE. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN UNINTENTIONAL LOCOMOTIVE MOVEMENT WHICH COULD POSSIBLY CAUSE EQUIPMENT DAMAGE AND/ OR INJURY TO PERSONNEL. 3.0 OPERATION OF THE COMPONENT PORTIONS OF THE "26-C" BRAKE VALVE (Figure 2) 3.1 "26-C" BRAKE VALVE PORTION (Automatic Brake Valve) IMPORTANT: The functions of this "26-C" Brake Valve Portion are controlled by the manual movement of the brake valve handle through a zone of six positions. These functions are explained in the paragraphs which follow. 3.1.1 RELEASE WARNING: During the initial charging of the train, when the handle of the "26-C" Brake Valve Portion (automatic brake valve) is manually moved into the "Release" position THERE WILL BE NO brake cylinder pressure available from the automatic brake equipment. The handle of the "SA-26" Independent Brake Valve Portion MUST BE manually moved into the "Full Application" position and ALL handbrakes MUST BE applied to prevent any locomotive and/or train movement while the equipment is being charged. Failure to adhere to this warning may result in conditions which could possibly cause injury to personnel and/ or bystanders and/or equipment damage. "Release" position is used for charging the brake equipment and for releasing brake cylinder air after an automatic brake application. Main reservoir air enters Port 30 at the pipe bracket, flows to the supply valve in the relay valve portion, to the spool of the suppression valve, then to passage 3, and through the spool valve of the manual cutoff valve to passage 7 and the equalizing reservoir cut-off valve piston. Air pressure acting on the face of this piston will move it upward, forcing the charging check valve off its seat and to its open position. Main reservoir air also

September, 1988

flows from Port 30 through the inlet valve in the regulating valve, past the unseated check valve in the equalizing reservoir cut-off valve to passage 15 as well as to the face of the regulating valve diaphragm. Regulating valve handle "A" can be adjusted to regulate the value of the equalizing reservoir pressure to be developed by the regulating valve portion. (NOTE: THIS ADJUSTMENT IS TO BE MADE ONLY WHEN THE LOCOMOTIVE AND/OR TRAIN IS STANDING MOTIONLESS). The pressure developed in Port 15 is likewise developed in the equalizing reservoir volume and Port 5. Port 5 in the pipe bracket is connected to the spool valve of the emergency valve and to the chamber on the outer face of the relay valve diaphragm. WARNING: The regulating valve adjustment handle MUST NOT BE turned once the brake pipe pressure has leveled off and the brake pipe leakage test is completed. Any movement of the regulating valve adjustment handle immediately before the departure of the train and/or while the train is in motion WILL CAUSE unpredictable variation in brake pipe air pressure and unpredictable degradation of brake cylinder pressure. Such erratic changes in brake pipe pressure and/or brake cylinder pressure could result in a less effective train retardation with possible damage to equipment and/or injury to personnel or by-standers. A build-up of equalizing reservoir pressure on the outer face of the relay valve diaphragm will cause the diaphragm assembly and its attached stem to be moved inward to first seat the exhaust valve and then unseat the supply valve. This permits main reservoir air to flow past the unseated supply valve to the brake pipe Port 1 and through the stabilizing choke to the chamber on the inner face of the relay valve diaphragm. Brake pipe air in the Port 1 passages also flows to the brake pipe cut-off valve, vent valve, pipe 1 in the pipe bracket, and to the external brake equipment by way of the brake pipe trainline. When the build-up of brake pipe pressure on the inner face of the relay valve diaphragm approaches the equalizing reservoir pressure acting on the opposite side of the diaphragm, the diaphragm assembly and stem are positioned to move the supply valve toward its seat. This action reduces the flow of air from the main reservoir system to the brake pipe until the brake pipe is fully charged to the regulating valve setting. Any change in brake pipe pressure due to brake pipe leakage will cause the higher equalizing reservoir pressure acting on the outer face of the relay valve diaphragm to move the diaphragm assembly and stem to adjust the supply valve position to maintain the brake pipe pressure equal to the equalizing reservoir pressure.

Page 7 of 34

4208-26, S.2.1

operation & maintenance instruction

3.1.2 SERVICE This position consists of the "Minimum Reduction" position, the service zone and "Full Service" position to the right from "Release" position. As the handle is moved through this sector, the reduction of brake pipe pressure is increased gradually until the handle is in "Full Service" position and a total service brake pipe reduction has been obtained. Movement of the brake valve handle to "Minimum Reduction" position provides a reduction of nominally 6 psi pressure in the equalizing reservoir, which is, in turn, reflected in a similar brake pipe pressure reduction by the relay valve portion. WARNING: AN INITIAL MINIMUM REDUCTION OF LESS THAN 5 PSI WILL PROBABLY RESULT IN UNDESIRED PRESSURE WAVES IN THE BRAKE PIPE WHICH COULD CAUSE THE TRAIN BRAKES TO RELEASE. UNINTENTIONAL BRAKE RELEASE MAY RESULT IN EQUIPMENT DAMAGE AND/OR PERSONAL INJURY AND THEREFORE SUCH REDUCTION MUST NOT BE MADE. When the automatic brake valve handle is manually moved to some intermediate service position, the cam on the brake valve handle shaft allows the exhaust valve in the regulating valve to be unseated to permit an equalizing reservoir pressure reduction. Normally, with Port 3 exhausted and the cut-off valve in the "IN" (Freight) position, the equalizing reservoir cut-off valve is closed. As soon as a pressure differential is set up across the cut-off valve check valve by the reduction of pressure on top of the check valve, the check valve is unseated and equalizing reservoir pressure can then flow past the unseated check valve and the regulating valve exhaust valve to atmosphere to reduce equalizing reservoir pressure in an amount corresponding to brake valve handle position. A reduction in equalizing reservoir pressure creates a pressure differential across the relay valve diaphragm, causing the diaphragm assembly and stem to be moved outward to unseat the relay valve exhaust valve allowing brake pipe air to vent to atmosphere at the brake valve. Brake pipe air will continue to vent to atmosphere until its pressure has been reduced sufficiently to cause a pressure equalization across the relay valve diaphragm. When this occurs, the diaphragm assembly and stem, with the aid of the relay valve springs, positions the assembly to allow the exhaust valve to become seated. The brake valve is then in its Lap position. When the automatic brake valve handle is manually moved to "Full Service" position, the brake valve operates as previously described, except to cause the equalizing reservoir and brake pipe pressures to drop sufficiently to produce a total service brake application. Depletion of brake pipe air pressure at a service rate below 45 psi will not result in any higher brake cylinder pressure and may take away the ability of the equipment to initiate an emergency brake application, therefore, service reductions below 45 psi are not permitted in operation. WARNING: UNDER NO CIRCUMSTANCES SHOULD A TRAIN BE PERMITTED TO CONTINUE IN OPERATION IF THE BRAKE PIPE AIR PRESSURE FALLS BELOW 45 PSI. IN SUCH CASES, THE TRAIN IS TO BE STOPPED AND THE BRAKE PIPE RECHARGED TO THE PRESCRIBED SETTING BEFORE PROCEEDING. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN THE INABILITY TO CONTROL OR STOP THE TRAIN WHICH POTENTIALLY COULD RESULT IN PERSONNEL INJURY AND/OR EQUIPMENT DAMAGE. 3.1.3 SUPPRESSION The suppression position is used to nullify or suppress a penalty brake application. Such a penalty brake application can be avoided if the automatic brake valve handle is manually moved to suppression position before the expiration of a predetermined delay period, which is normally indicated by an audible warning whistle. However, the "26-C" Brake Valve is so designed that when the brake valve handle is placed in suppression position, air at total available service brake pressure is directed to the brake cylinder by means of an external control valve which responds to the accompanying brake pipe pressure reduction. 3.1.3.1 OVER REDUCTION ZONE In certain special operating conditions, the zone provided to the right of "Suppression" position may be used to produce at least a 35 psi reduction in equalizing reservoir pressure. This reduction in pressure is proportional to the amount of the automatic brake valve handle movement as described under "Service" position. Beyond this location (handle position) the equalizing reservoir pressure reduces to 0 psi at a service rate. Under these circumstances, the train is to be brought to a complete stop. WARNING: UNDER NO CIRCUMSTANCES SHOULD A TRAIN BE PERMITTED TO CONTINUE IN OPERATION IF THE BRAKE PIPE AIR PRESSURE FALLS BELOW 45 PSI. IN SUCH CASES, THE TRAIN IS TO BE STOPPED AND THE BRAKE PIPE RECHARGED TO THE PRESCRIBED SETTING BEFORE

September, 1988

Page 8 of 34

4208-26, S.2.1

operation & maintenance instruction

PROCEEDING. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN THE INABILITY TO CONTROL OR STOP THE TRAIN WHICH POTENTIALLY COULD RESULT IN PERSONNEL INJURY AND/OR EQUIPMENT DAMAGE. 3.1.4 HANDLE-OFF The handle may be removed from the automatic brake valve in this position. Handle-Off position is used to condition the brake valve(s) on trailing units of locomotives in multiple unit service, and on locomotives which are being hauled "Dead" in a train consist. Handle-Off Position also results in the depletion of equalizing reservoir pressure at a service rate. WARNING: BEFORE REMOVING THE "26-C" BRAKE VALVE PORTION (AUTOMATIC BRAKE VALVE) HANDLE, SPECIAL ATTENTION IS REQUIRED. AFTER THE COMPLETION OF A BRAKE PIPE REDUCTION, AS NOTED AUDIBLY BY THE CESSATION OF BRAKE PIPE EXHAUST, BE SURE THAT BRAKE CYLINDER PRESSURE IS APPLIED TO THE LOCOMOTIVE, AND THAT THE PROPER PROCEDURES ARE FOLLOWED FOR CUTTING OUT BRAKE OPERATION CONTROL ON THE LOCOMOTIVE. FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN UNINTENTIONAL LOCOMOTIVE MOVEMENT WHICH COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL. 3.1.5 EMERGENCY The emergency position of the automatic brake valve handle is used to vent brake pipe pressure to zero at the fastest possible rate to produce an emergency brake pipe reduction. The flow of air to the brake pipe is cut off in this position. The emergency valve is positioned to vent equalizing reservoir air to zero from passage and Port 5 to supplement the venting at the regulating valve exhaust valve and to allow main reservoir air to flow from Port 30 to Port 12. Also, with equalizing reservoir pressure at the outer face of the relay portion diaphragm reduced to zero, the diaphragm assembly and stem are moved to unseat the relay valve exhaust valve, allowing brake pipe air to also vent to zero. A cam on the automatic brake valve handle shaft functions to unseat a large capacity vent valve to supplement the brake pipe venting, which results in a rapid or emergency rate of brake pipe pressure reduction at the brake valve. WARNING: When the handle of the "26-C" Brake Valve Portion (automatic brake valve) is in the "Release" position, there is no brake cylinder pressure from the automatic brake equipment. The handle of the "SA-26" Independent Brake Valve Portion MUST BE manually moved to the "Full Application" position and the hand brakes of the locomotive and train MUST BE applied to prevent locomotive and/or train movement while the equipment is being recharged. Any attempt to recharge the brake equipment arrangement with the handle of the "26-C" Brake Valve Portion (automatic brake valve) in any position other than (Release) WILL NOT properly recharge the equipment but will release brake cylinder pressure. 3.2 "SA-26" INDEPENDENT BRAKE VALVE PORTION IMPORTANT: This Independent Brake Valve Portion permits air under pressure to be directed normally, by indirect means such as a relay valve, to the locomotive brake cylinders only, regardless of the automatic brake valve handle position if the automatic brake is unapplied or if the automatic brake is of lesser value than the independent brake. The Independent Brake Valve Portion handle has two positions; namely, "Release" position at the extreme left end of the quadrant, and "Full Application" position at the extreme right end of the quadrant. From "Release" to "Full Application" position is an application zone or sector and the further the handle is moved to the right into this sector, the greater will be the application pressure available until full application pressure is obtained at the extreme right end of the handle movement. Manual movement of the Independent Brake Valve Portion handle from "Release" position towards "Full Application" position rotates a cam which in turn positions a supply and exhaust valve assembly to first seat the exhaust valve and then unseat the supply valve. Main reservoir air will then flow past the unseated supply valve from Port 30 to Port 20. Port 20 from the brake valve pipe bracket is connected to a control port at a relay valve. As air pressure develops in Port 20, it also develops on the inner face of the diaphragm in the Independent Brake Valve Portion. The build up of pressure on the diaphragm is opposed by spring load pressure on the opposite side 3.1.6 RELEASE AFTER EMERGENCY Moving the automatic brake valve handle to the "Release" position after an emergency application will cause the equipment to function to recharge as previously described in Section 3.1.1 Release.

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4208-26, S.2.1

operation & maintenance instruction

and when the pressure and pre-adjusted spring load pressure become balanced, the valve assembly will move to its lap position in which the supply valve becomes seated to terminate further flow of main reservoir air to Port 20. If, as a result of leakage in the number 20 line, the air pressure should drop, the diaphragm assembly will move to again unseat the supply valve and permit main reservoir air to restore the pressure in Port 20 to the value of the spring setting. This is the self-lapping pressure maintaining feature of the Independent Brake Valve Portion. Conversely, to partially release a given brake application, manual movement of the Independent Brake Valve handle from "Full-Application" Position back towards "Release" Position will rotate the cam to position the inlet and exhaust valve assembly to close the valve and open the exhaust valve. The opening of the exhaust valve will partially deplete air pressure from passage/port 20 and the diaphragm pressure chamber until the pressure in the diaphragm pressure chamber matches the now slightly relieved spring load and the exhaust valve closes and the inlet and exhaust valve assembly again assumes its selflapping or self-maintaining status. Manual depression of the independent brake valve handle regardless of the position of the independent brake valve handle, will allow for the flow of main reservoir air into Port 13. This connection is generally made to the locomotive control valve, where a function is available to provide for a release of the locomotive automatic air brake. In this equipment arrangement, the "SA-26" Independent Brake Valve Portion is, at the locomotive builder and/or owner-operating property request, equipped with an offset style, removable brake valve handle. The independent brake valve handle may be removed from the Independent Brake Valve Portion by manually moving the handle into the "Release" position, then while exerting a pulling force on the knob of the handle retaining pin, (see Figure 8, Reference 5), pull the handle from the brake valve body. NOTE: It is also necessary to exert a pulling force on the handle retaining pin knob when installing the handle in order to secure it in place. IMPORTANT: The Wabtec Corporation does not recommend the removable style handle for the "SA-26" Independent Brake Valve Portion, but will furnish the removable style handle at locomotive builder and/or owner-operating property request. 3.2.1 EMERGENCY -"LITE" LOCOMOTIVE OPERATION NOTE: The term "LITE LOCOMOTIVE" indicates a locomotive or consist of locomotives only with NO OTHER VEHICLES in the consist, or to a locomotive or consist of locomotives to which ONLY a caboose is attached. WARNING: In an emergency situation, when operating a "LITE" locomotive, the RAPID MANUAL MOVEMENT of the independent brake valve handle to "Full Application" position is the fastest way to develop brake cylinder pressure on the locomotive up to the full independent brake cylinder pressure setting. Immediately after manually moving the independent brake valve handle to "Full Application" position, the automatic brake valve handle IS TO BE RAPIDLY MOVED MANUALLY to the "Emergency" position. Failure to comply with this procedure during an emergency brake application when operating a "LITE" locomotive consist could extend the stopping distance and increase the likelihood of equipment damage and/ or personal injury. 4.0 MAINTENANCE SCHEDULE IMPORTANT: The "26-C" Brake Valve Portion and the "SA-26" Independent Brake Valve Portion should be removed from the equipment arrangement, taken to the shop, be thoroughly disassembled, the parts cleaned, inspected, lubricated, assembled, using NEW specified Wabtec Corporation parts, and the portions tested for correct operation according to the following vehicle application schedule, or more frequently, if service conditions so dictate: RECOMMENDED FREQUENCY TYPE OF APPLICATION AT LEAST ONCE EVERY Locomotives 24 Months 5.0 PARTS CATALOG & REPLACEMENT PARTS INFORMATION 5.1 PARTS CATALOGS 5.1.1 Refer to the current issue of the Wabtec Corporation Parts Catalog 3208-26, Sup. 2, and 3207-6, Sup. 1 when ordering replacement parts for the "26-C" Brake Valve, Pc.No. 564315-2000 and its component parts. NOTE: The reference numbers used in this publication and those used in the parts catalogs may differ. Check the descriptive parts name to be sure that the desired part is ordered.

Page 10 of 34 September, 1988

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operation & maintenance instruction

5.2 REPLACEMENT PARTS INFORMATION 5.2.1 IMPORTANT: To obtain satisfactory operation of the "26-C" Brake Valve and/or its Component Portions, ONLY Wabtec Corporation replacement parts are to be used in the maintenance of the "26-C" Brake Valve and/or its Component Portions. 6.0 SAFETY PROCEDURES & WARNINGS Regular locomotive builder and/or operating property safety procedures and shop safety procedures MUST BE followed when working on or maintaining the brake valve or any of its component portions. The work area should be clean. WARNINGS The following statements of warning apply all or in part wherever the symbol appears in the maintenance procedures. Failure to observe these precautions may result in serious injury to those performing the work and/or bystanders. ! The use of an air jet, which must be less than 30 p.s.i.g., to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. Wire brushing may also cause particles of dirt, rust, and scale to become airborne. These conditions may cause skin and/or eye irritation. ! When using an air jet, do not direct it toward another person. Improper use of air jet could result in bodily injury. ! Personal eye protection must be worn when performing any work on this device or its components parts to avoid any possible injury to the eyes. ! The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The manufacturers of the solvents and lubricants should be contacted for safety data (such as OSHA Form OSHA-20 or its equivalent). The recommended precautions and procedures of the manufacturers should be followed. ! When performing any test or work on devices or equipment while they are on the vehicle (on car test, etc.) special precautions must be taken to

September, 1988

insure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment. ! Assembly may be under a spring load. Exercise caution during disassembly so that no parts "Fly Out" and cause bodily injury. ! All air supply and/or electric current to this device and/or to any components part must be cut-off before this device and/or any component part is removed from the equipment arrangement. ! "Bottled" up air under pressure (even though air supply is cut-off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when this device and/or any component part is removed from the equipment arrangement. ! Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on this device and/or component part. ! To prevent receiving electrical shock when performing electrical test, hands must be clear of electrical components, contacts and housing and the required "in-lab" grounding procedures must be strictly adhered to. A wooden work bench should be used. Failure to heed this WARNING could result in severe injury or death. ! An adequate support or lifting device must be available to support the Device and/or Valve Portion(s) during removal, installation and maintenance procedures. 7.0 CLEANING SOLVENT & LUBRICANTS 7.1 The cleaning solvent used to clean the reusable parts of the "26-C" Brake Valve and/or its Component Portions MUST BE an aliphatic organic solution such as mineral spirits or naphtha that will dissolve oil or grease and that will permit all parts to be thoroughly cleaned without abrasion. 7.2 #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, such as Dow Corning Corp. Molykote 55m, is required for the lubrication of o-rings, o-ring grooves and the bearing surfaces of the bushings into which the o-ring assemblies are installed. 7.3 #1 Calcium Base Grease, Wabtec Corporation Speci-

Page 11 of 34

4208-26, S.2.1

operation & maintenance instruction

.133 Dia. drill (#30) Thru .129 .12 .31

9.00 4.60 "A" 1.50 .75 R. Typ. .16 Typ. 2.2 1.00 15

o

4.46 .12 Dia. x .75 Lg. Steel Rivet 5 Typ. 2 Places .34 .16 .24 2 Places .1875 Dia. Drilled Holes 2 Req'd x .12 Deep

o

.12 Commercial Quality Steel Sheet or Strip 2 Req'd. View in Direction of Arrow "A"

15o .50 1.50 .07 Dia. Drilled Thru Holes, 2 Req'd. 5.00 R. Typ. 15 .34 1.00

o

.16

.185 Dia. Steel Tips .183 2 Req'd

.31

.0625 Dia. Torsion Spring 2 Coils, Approx. .50 Dia. 1 Req'd.

.3125 Steel Bar Stock 2 Req'd.

Figure 3 - Check Valve Seat Removal Tool

fication M-7650-1, such as Union Oil Co. Number 1 Cup Grease, is required for the lubrication of the cam dog pin, the eccentric cam of the operator shaft and the cam dog bearing surface of the Regulating Valve Cam, #2 Cam. 7.4 A compound consisting of one part graphite, Wabtec Corporation Specification M-7695-2, such as Superior Flake Graphite Co. Superflake Number 597; Joseph Dixon Crucible Co. Microfyne Graphite; or, National Carbon Co. Number 38 or 39 Graphite, and two parts of SAE-20 oil by weight is to be used to coat the threads of the choke plugs after they have been cleaned. 8.0 SPECIAL TOOLS In addition to the regular shop tools, the following MUST BE AVAILABLE to the repair person when working on the Brake Valve Portion: 8.1 8.2 8.3 8.4

5

8.7 #3 Truarc Retaining Ring Pliers (external). 8.8 8.9

9

/64 inch Hex Key. /32 inch Open End Wrench.

11

8.10 Tool for removing the Equalizing Reservoir Cut-Off Valve Check Valve Seat. Information for making this Tool is shown in Figure 3. IMPORTANT: The information shown in Figure 3 for making this tool is furnished as a convenience. The Wabtec Corporation shall have no responsibility for tools which they do not manufacture, and will not be responsible for the results when using any tools (including claims by third parties). 9.0 "26-C" BRAKE VALVE PORTION AND "SA-26" INDEPENDENT BRAKE VALVE PORTION REMOVAL & INSTALLATION "ON-CAR" 9.1 The repair person will require the following parts:

/16 inch Multi-Spline Key - Pc.No. 522525.

1

/2 inch Multi-Spline Key - Pc.No. 517557. /4 inch Multi-Spline Key - Pc.No. 518032. /16 inch Hex Key. 9.1.1 A NEW or repaired and tested "26-C" Brake Valve Portion, Pc.No. 564315-2000. 9.1.2 Two NEW wire mesh strainers, Pc.No. 526835. 9.1.3 A NEW pipe bracket gasket, Pc.No. 557395.

Page 12 of 34 September, 1988

3

5

8.5 #1 Truarc Retaining Ring Pliers (internal). 8.6 #3 Truarc Retaining Ring Pliers (internal).

4208-26, S.2.1

operation & maintenance instruction

9.1.4 A NEW or repaired and tested "SA-26" Independent Brake Valve Portion, Pc.No. 564316. 9.1.5 A NEW independent brake valve mounting gasket, Pc.No. 557237. 9.2 ALL locomotive builder and operating property safety procedures and the safety procedures and WARNINGS listed in Section 6.0 MUST be followed. 9.3 The locomotive wheels MUST BE chocked and the handbrake applied to prevent locomotive movement. Suitable placards indicating that work is being performed are to be placed on and about the locomotive. 9.4 Remove any free dirt from the exterior surfaces of the "26-C" Brake Valve by wiping with a clean, dry lint-free cloth or by the use of a low pressure jet of clean dry air. (Figures 1 & 5) 9.5 Providing adequate support for the "SA-26" Independent Brake Valve Portion, which weighs approximately 15 pounds, remove it from the pipe bracket (149) by first removing the three 1/2" hex nuts (149B). 9.6 Remove and SCRAP the independent brake valve mounting gasket (101). 9.7 Disconnect any pipe connection made at the 11/4" flange of the body of the "26-C" Brake Valve Portion. 9.8 Providing adequate support for the "26-C" Brake Valve Portion, which weighs approximately 40 pounds, remove it from the pipe bracket (149) by removing the three 1/2" x 4" hex head cap screws (48) and the 1/2" x 51/2" hex head cap screw (47). 9.9 Remove and SCRAP the pipe bracket gasket (50). 9.10 Remove the wire mesh air strainer (149A) from passage 15 and from passage 30 of the pipe bracket (149). Note the location of these strainers, as NEW strainers MUST BE installed in the same location. 9.11 Visually inspect the pipe bracket mounting faces to be sure that they are clean and undamaged. Inspect all ports to be sure that they are clean and unrestricted. Blow ports out, if necessary, using a low pressure jet of clean, dry air. Be sure that no dirt is blown back into the passages or ports of the pipe bracket. 9.19 IMPORTANT: When any Component Portion of the "26-C" Brake Valve is removed from the equipment arrangement for any reason, and it is reinstalled or replaced with a NEW or repaired and tested Portion, a stationary vehicle air brake test MUST BE made to be sure that the Portion(s) and the "26-C" Brake Valve function properly in the brake equipment arrangement. 9.20 Remove ALL wheels chocks and warning placards before attempting to move the locomotive. NOTE: It is not necessary to remove the pipe bracket (149) from the equipment arrangement unless it is damaged. Should it be necessary to remove the pipe bracket, the locomotive builder and/or owner-operating instructions are to be followed. Damaged pipe brackets are not repairable and are to be replaced with a NEW Wabtec Corporation part. 9.12 Install a NEW wire mesh strainer (149A) into passage 30 and passage 15 of the pipe bracket (149). 9.13 Install a NEW pipe bracket gasket (50) in proper position on the pipe bracket (149). 9.14 Remove ALL protective material from a NEW or repaired and tested "26-C" Brake Valve Portion, Pc.No. 562073-2000. Be sure that ALL tape is removed from ALL ports. 9.15 Carefully place the NEW or repaired and tested "26-C" Brake Valve Portion on to the Pipe Bracket Portion (149) being sure that the gasket (50) remains in position. Install the three 1/2" x 4" hex head cap screws (48) and the 1 /2" x 51/2" hex head cap screw (47) to secure the Portions together. Equally tighten the screws. 9.16 Install a NEW independent brake valve mounting gasket (101) in place on the Pipe Bracket Portion (149). 9.17 Carefully place the NEW or repaired and tested "SA-26" Independent Brake Valve Portion on the Pipe Bracket Portion (149) being sure that the gasket (101) remains in position. Secure the portions together by installing the three 1/2" hex nuts (149B). Equally tighten the nuts (149B). 9.18 Provide adequate protection to prevent dirt or moisture from entering the removed Brake Valve Portions and transport them to the shop area for maintenance.

September, 1988

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4208-26, S.2.1

operation & maintenance instruction

. 4 4A 5 5B 5A 5C 32 33 6 7 13 28 1 5D

8

29 31 29 31 11 14 9 10 24 25 30 12 31A 31 31C 31B 22 23 21 27 15 3

2 17

18

19 26B 26C 26D 26 20 20A

Figure 4 - "26-C" Brake Valve -Exploded View (Reference Numbers 1 to 33 and 100)

Page 14 of 34 September, 1988

4208-26, S.2.1

operation & maintenance instruction

39B 37 38

39D

40 39C 39A 41 43B 43 43C 44 43D3 43D2 43D1 43A

39

45

43D 42 35 35B 46 35A 35B1 35B2 35C 34 35B3 35D 35E 36

52 51

50

56 55

149A

54

149

53

101

47

149C 48

NOTE: "SA-26" Independent Brake Valve Portion mounts here.

Figure 5 - "26-C" Brake Valve - Exploded View (Reference Numbers 34 to 56, 100, 101, and 149 to 149D)

September, 1988 Page 15 of 34

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operation & maintenance instruction

15 21 8 12 3 53 30 30a

5

20 30

13

1

26

"26-C" Brake Valve Portion Pipe Bracket Mounting Face Port Locations

Partial View of Pipe Bracket Showing the Independent Brake Valve Mounting Face Port Locations

Figure 5 A

10.0 "26-C" BRAKE VALVE PORTION MAINTENANCE PROCEDURE - "IN-SHOP" IMPORTANT: When performing the procedures which follow, DO NOT use hard or sharp metal tools to remove gaskets, o-rings or diaphragms. Care MUST BE exercised so that no damage is done to the metal parts. 10.1 DISASSEMBLY (Figure 4) 10.1.1 Place the brake valve handle assembly (5) in the "Handle-Off" position. 10.1.2 If the handle assembly is so equipped, remove the handle cap screw (4) and washer (4A) from the handle assembly (5). 10.1.3 Remove the handle assembly (5) by lifting it vertically with a slight twisting action as the handle comes up and OFF of the shaft (8). 10.1.4 CAUTION: Spring (5C) may be under tension. Exercise care during the following procedures to avoid physical injury should parts be inadvertently expelled. Disassemble the handle assembly (5) as follows: 10.1.4.1 Using the proper tools, carefully remove the 1/8" x 1" cylindrical spring pin (5A) from the latch (5B) and handle body (5D). Remove the latch (5B), and latch spring (5C) from the handle body (5D).

10.1.5 Using a 5/16" hex key, remove the two 3/8" x 7/8" socket head screws (6) which secure the brake valve quadrant (7) to the cam housing body (28). 10.1.5.1 Remove the valve quadrant (7) from the cam housing body (28). (Figure 6) 10.1.6 Turn the regulating valve adjusting handle (58) counterclockwise, its full travel, to release tension on the regulating valve spring (61). (Figure 4) 10.1.7 Remove the cut-off valve (25) from the cam housing body (28) as follows: 10.1.7.1 Place the cut-off valve control knob (20) in the "Out" position. Depress the cut-off valve control knob (20) in the "Out" position, then turn the knob (20) clockwise approximately 45 degrees. 10.1.7.2 Remove the three #4 x 3/8" fillister head machine screws (15) which secure the escutcheon plate (17) to the cam housing body (28). 10.1.7.3 CAREFULLY turn the cut-off valve control knob (20) to the "Out" position. WARNING: Spring (19) may be under tension. Exercise care during the following procedure to avoid physical injury should parts be inadvertently expelled.

Page 16 of 34

September, 1988

4208-26, S.2.1

operation & maintenance instruction

10.1.7.3.1 Remove the control knob (20), spring (19), cut-off valve operating shaft (18), and the escutcheon plate (17) from the cam housing body (28). 10.1.7.4 Compress and remove the retaining ring (21) from the bottom of the cam housing body (28). 10.1.7.5 Remove the cut-off valve position selector plug (23) and the 13/16" O.D. o-ring (22) from the bottom of the cam housing body (28) as a unit. Remove and SCRAP the 13/16" O.D. o-ring (22) from the cut-off valve position selector plug (23). 10.1.7.6 Remove the cut-off valve (25) with 1/2" O.D. orings (24) from the bottom of the cam housing body (28). Remove and SCRAP the five 1/2" O.D. o-rings (24) from the cut-off valve (25). 10.1.8 Remove the two spill-over check valve cap nut assemblies (26) from the bottom of the cam housing body (28). 10.1.9 Remove the check valve (26B) and check valve spring (26C) from each cap nut (26D). SCRAP the check valves (26B). 10.1.10 Remove the five 5/16" hex nuts (1, 2, 3) which secure the cam housing body (28) to the brake valve body (100). 10.1.11 Remove the cam housing body (28) from the brake valve body (100). 10.1.12 Remove the cam shaft (8) from the cam housing body (28). The four cams (9 to 12 incl.) will be freed from the foolproofing pin on the cam shaft (8) as it is removed. 10.1.13 Remove the cam dog pin with retaining ring (13) through the top (quadrant face) of the cam housing body (28), freeing the cam dog (14) as the cam dog pin (13) is removed. 10.1.14 Remove and SCRAP the four 11/16" O.D. ring gaskets (32) and the 7/8" O.D. ring gasket (33) from the cam housing mounting face of the brake valve body (100). 10.1.15 Remove the cam dog assemblies (31) from the brake valve body (100) as follows: 10.1.15.1 Remove the two 1/16" x 7/16" cylindrical spring pins (29) from the top and center portions of the cam dog

September, 1988

pin with retaining ring (30). 10.1.15.2 Remove the cam dog pin with retaining ring (30) through the bottom face of the brake valve body (100). Free the two cam dog assemblies (31) as the cam dog pin with retaining ring (30) is removed. 10.1.15.3 Remove the pin (31A) from each of the two cam dog assemblies (31). Free the rollers (31B) as the pins (31A) are removed. (Figures 5 and 6) 10.1.16 CAUTION: Springs (35D, 43C, 56, 61, 63, 69, 75, 78, 83B, and 85B) may be under tension. Exercise care when performing the procedures which follow to avoid physical injury should parts be inadvertently expelled. (Figure 6) 10.1.17 Remove the four 3/8" hex nuts (73) which secure the back cover (74) in place on the brake valve body (100). 10.1.18 Remove the back cover (74) from the brake valve body (100). 10.1.19 Remove the brake pipe cut-off valve spring (78). 10.1.20 Remove the emergency valve and suppression valve springs (75) from the cavities in the back cover face of the valve body (100). 10.1.21 NOTE: The Suppression and Emergency Valve Springs (75) are identical. One is required for each valve. 10.1.22 Remove and SCRAP the back cover gasket (86) from the brake valve body (100). 10.1.23 Remove the emergency (spool type) valve with o-rings (79, 80) from the brake valve body (100). 10.1.23.1 Remove and SCRAP the four 1/2" O.D. o-rings (79) from the emergency spool valve (100). 10.1.24 Remove the suppression (spool type) valve with o-rings (77, 76) from the brake valve body (100). 10.1.24.1 Remove and SCRAP the five 1/2" O.D. o-rings (76) from the suppression valve (77). 10.1.25 Remove the vent valve assembly (85D) from the brake valve body (100).

Page 17 of 34

4208-26, S.2.1

operation & maintenance instruction

74 73 75

86 78 81 83C 82 83B 84 83D3 83D2 83D1 83

75 76 77 79 80 95 85 85C 85B 85E 82 85D3 85D2 85D1 96 94 89 97

83D 98

83A

100

90

91 66 85D 85A 70

68 64 67

69

71

72 92 93

59 58

60

61

63

65

87

88

62 57

Figure 6 - Exploded View

Page 18 of 34

September, 1988

4208-26, S.2.1

operation & maintenance instruction

10.1.26 Disassemble the vent valve assembly (85D) as follows: 10.1.26.1 Compress and remove the retaining ring (85A) from the smaller diameter bore of the vent valve cage (85C). 10.1.26.2 Remove the vent valve seat assembly (85D) and spring (85B) from the smaller diameter bore of the vent valve cage (85C). 10.1.26.3 Remove and SCRAP the two 13/8" O.D. o-rings (82) from the external diameters of the vent cage (85C). 10.1.26.4 Remove the seal retainer (85D1) and seal (85D2) from the housing (85D3) using the proper size wrench and a 1/2" Multi-Spline Key. SCRAP the seal. 10.1.26.5 Remove and SCRAP the (85E) from the housing (85D3).

15

NOTE: If it becomes necessary to remove the adjusting handle (58) from the spring housing lock nut due to damage, rotate the adjusting handle (58) counterclockwise, as viewed from the rear of the spring housing until the adjusting handle (58) comes free of the spring housing (59). 10.1.30.2 Spring seat (60). 10.1.30.3 Spring (61). 10.1.30.4 Diaphragm, exhaust valve seat, and exhaust valve assembly (62 to 68 incl.) as a unit. 10.1.31 Remove the exhaust valve (68) from the exhaust valve seat (67). 10.1.32 Disassemble the diaphragm and exhaust valve spring seat assembly (62 to 67 incl.) as follows: 10.1.32.1 Remove the exhaust valve spring seat (62) from the exhaust valve seat (67) to free and remove the regulating exhaust spring (63), diaphragm follower (65), diaphragm (66), and spring seat (64). SCRAP the diaphragm (66). 10.1.33 Remove the spring (69) from the regulating valve (70). 10.1.34 Remove the regulating valve (70) with o-ring (71) from the valve body (100). 10.1.35 Remove and SCRAP the two 13/16" O.D. o-ring (71) from the valve (70). 10.1.36 Remove the regulating valve retaining ring (72) from the valve bushing in the valve body (100). (Figure 5)

/16" O.D. o-ring

10.1.27 Remove the brake pipe cut-off valve assembly with o-rings (81 to 83 incl.) from the brake valve body (100). 10.1.28 Disassemble the brake pipe cut-off valve assembly as follows: 10.1.28.1 Compress and remove the retaining ring (83A) from the smaller diameter bore of the valve cage (83C). 10.1.28.2 Remove the valve seal assembly (83D) and spring (83B) from the smaller diameter bore of the valve cage (83C). 10.1.28.3 Remove the 2" O.D. o-ring (81) and the 13/8" O.D. o-ring (82) from the external diameters of the valve cage (83C). SCRAP the o-rings. 10.1.28.4 Using a 3/4" Multi-Spline Key remove the seal retainer (83D1) and seal (83D2) from the housing (83D3). SCRAP the seal. 10.1.28.5 Remove and SCRAP the (84) from the housing (83D3).

15

/16" O.D. o-ring

10.1.37 Install a #10-24 machine screw into the tapped hole in the equalizing reservoir cut-off valve piston (52). Using the screw for a handle, remove the cut-off valve piston with o-ring assembly (51, 52) from the valve body (100). 10.1.38 Remove and SCRAP the 15/8" O.D. o-ring (51) from the piston (52). 10.1.39 Using the special "V" shaped tool, as shown in Figure 4, remove the check valve seat with check valve assembly (53 to 56) from the valve body (100) as a unit. This can be done by inserting the tool so that the two arms of the V engage the openings in the check valve seat.

10.1.29 Remove the four 5/16" hex nuts (57) which secure the spring housing (59) to the brake valve body (100). 10.1.30 Remove the following from the brake valve body (100): 10.1.30.1 Spring housing (59) with adjusting handle (58) as a unit.

September, 1988

Page 19 of 34

4208-26, S.2.1

operation & maintenance instruction

IMPORTANT: Exercise care when pulling the check valve seat from the body so that the seat bushing of the valve is not scratched, nicked, or damaged in any way. 10.1.40 Remove the check valve spring (56) from the check valve (55). Remove and SCRAP the check valve (55) and the two special o-rings (53) from the check valve seat (54). 10.1.41 Remove the six 5/16" hex nuts (37) which secure the relay cover (38) to the brake valve body (100), and then separate the cover (38) from the body (100). 10.1.42 Remove the following from the brake valve body (100): (Figure 6) 10.1.42.1 (Figure 5) 10.1.42.2 Diaphragm assembly (39). NOTE: The diaphragm assembly is held in place by means of a ball socket joint on the end of the diaphragm stem (42) and lower diaphragm follower (39C). 10.1.43 Disassemble the diaphragm assembly (39) as follows: 10.1.43.1 Remove the #10-24 hex nut (39A) from each of the three retaining screws (39B) to free the lower follower (39C), the diaphragm (40), and upper follower (39D). SCRAP the diaphragm (40). 10.1.44 Using the #3 Truarc Retaining Ring Pliers (internal) compress and remove the retaining ring (41) which holds the exhaust valve assembly (43, 45) in the brake valve body (100). 10.1.45 Remove the diaphragm stem (42), the stem spring (46), and the exhaust valve assembly (43 to 45) from the brake valve body (100). 10.1.46 Disassemble the exhaust valve assembly (43 to 45) as follows: 10.1.46.1 Remove and SCRAP the 15/8" O.D. o-ring (45) from the outer diameter of the valve cage (43B). 10.1.46.2 Remove the retaining ring (43A) from the inner bore of the slotted end of the valve cage (43B) to free 10.1.49 Disassemble the supply valve assembly (35, 36) as follows: 10.1.49.1 Remove and SCRAP the 17/16" O.D. o-ring (36) from the outer diameter of the supply valve cage (35E). 10.1.49.2 WARNING: The spring (35D) may be under tension. Exercise care during the procedure which follows to avoid physical injury should parts be inadvertently expelled. Remove the retaining ring (35A) from the inner bore of the slotted end of the supply valve cage (35E) to free and remove the supply valve seat assembly (35B, 35C) and the spring (35D). 10.1.49.3 Remove and SCRAP the 11/16" O.D. o-ring (35C) from the smaller diameter of the seal housing (35B3). 10.1.49.4 Using a 5/16" Multi-Spline Key remove the seal retainer (35B1) from the seal housing (35B3). 10.1.49.5 Remove and SCRAP the seal (35B2) from the seal housing (35B3). 10.2 CLEANING & INSPECTING 10.2.1 NON-REUSABLE PARTS All gaskets, seals, o-rings, diaphragms, rubber seated check valves and any self-locking or elastic stop nuts are to be SCRAPPED and replaced with NEW Wabtec

September, 1988

9

and remove the valve seal assembly (43D, 44) and the valve spring (43C). 10.1.46.3 Remove and SCRAP the 15/16" O.D. o-ring (44) from the smaller diameter of the housing (43D3). 10.1.46.4 Using a 3/4" Multi-Spline key remove the seal retainer (43D1). 10.1.46.5 Remove and SCRAP the seal (43D2) from the housing (43D3). 10.1.47 Using the #3 Truarc Retaining Ring Pliers (internal) compress and remove the retaining ring (34) which holds the supply valve assembly (35, 36) in the brake valve body (100). 10.1.48 Remove the supply valve assembly (35, 36) by CAREFULLY grasping the end of the supply valve cage (35E) with a pair of pliers and pulling outward.

/16" O.D. ring gasket (89). SCRAP the gasket.

Page 20 of 34

4208-26, S.2.1

operation & maintenance instruction

Corporation Parts. 10.2.2 CHOKE PLUGS 10.2.2.1 The size and cleanliness of the choke plugs are important. Choke plugs MUST BE REMOVED ONE AT A TIME for servicing to be sure that they are returned to their proper location. The following procedure MUST BE ADHERED TO when servicing the choke plugs. 10.2.2.1.1 Remove ONLY ONE choke plug and place it in a bath of the cleaning solvent as described in Section 7.1 to soak. IMPORTANT: Metallic tools MUST NOT be used to clean chokes as their size and shape MUST NOT be changed. Refer to Parts Catalog 3208-26, Sup. 2 for choke sizes and locations. 10.2.2.1.2 While the choke plug is soaking in the cleaning solvent, the passage from which it was removed MUST BE checked for cleanliness and blown out if necessary with a low pressure jet of clean, dry air. 10.2.2.1.3 Remove the choke plug from the cleaning solvent bath and blow it dry with a low pressure jet of clean, dry air. 10.2.2.1.4 Inspect the choke plug to see that it is clean and unrestricted. If the choke plug is damaged in any way, or if the size of the choke has been changed, it MUST BE replaced. Refer to the Parts Catalog 3208-26, Sup. 2 for choke size and choke plug part number. 10.2.2.1.5 Lightly coat the threads of the choke plug with the oil and graphite compound described in Section 7.4. Assemble the choke plug into the passage from which it was removed. The choke plug MUST BE flush or below the surface of the component in which it is installed. 10.2.2.1.6 Remove the next choke plug and repeat steps 10.2.2.1.1 through 10.2.2.1.5 until all choke plugs have been serviced. 10.2.3 BODY 10.2.3.1 Wash the body using the cleaning solvent described in Section 7.1. Use a soft, lint-free cloth or rag that has been saturated with the cleaning solvent to clean the interior and exterior surfaces of the brake valve body. 10.2.3.2 After the body has been thoroughly cleaned, it MUST BE blown dry with a low pressure jet of clean, dry air. 10.2.3.3 Inspect the body. Pay particular attention to mounting surface, and to the bushings within the body. Replace the body if it is damaged in any way, or if any of the bushings are damaged or show signs of excessive wear. (Figure 6) 10.2.3.4 IMPORTANT: The choke plugs located in the body (100) MUST BE serviced, one at a time, following the procedures of Section 10.2.2. The procedures of Section 10.2.2 MUST BE strictly adhered to. The choke plugs are shown in Figure 6 as reference numbers 87, 88, 97, 98. The pipe plug 96 should also be checked to be sure that it is securely in place. 10.2.4 REMAINING PARTS 10.2.4.1 Wash all of the remaining parts using the cleaning solvent described in Section 7.1. Use a lint-free cloth, which has been saturated with the cleaning solvent to clean the interior and exterior surfaces of the cam housing body, quadrant, relay cover, spring housing and back cover. 10.2.4.2 The springs may be wire brushed to assist in the removal of rust and scale. 10.2.4.3 After the parts have been cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the parts dry. 10.2.4.4 Inspect the parts. Replace any spring that is rusted, pitted, distorted or that has taken a permanent set. See Parts Catalog 3208-26, S.2 for spring information and identification. Replace any retaining ring that is not elastic enough to hold securely. Replace any part that is cracked, cut, broken, damaged in any way, excessively worn, or that is in such a condition that may result in unsatisfactory operation of the "26C" Brake Valve Portion. 10.3 ASSEMBLY WARNING: During the assembly procedures

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operation & maintenance instruction

springs will be placed under tension. Exercise care during the assembly of the components to avoid physical injury should parts be inadvertently expelled. WARNING: During the assembly procedures, the lapping of seals by mechanical means involving the use of an abrasive substance or medium to "Improve Sealing Qualities" IS NOT PERMISSIBLE. Such lapping procedures will very likely ruin the surface sealing capabilities of the seal and render the seal useless. NEW seals are to be used during the assembly procedures. (Figure 5) 10.3.1 Supply Valve Sub-Assembly 10.3.1.1 Insert a NEW seal (35B2), small sealing bead first, into the seal housing (35B3). DO NOT LAP THE SEAL. 10.3.1.2 Insert the seal retainer (35B1) through the valve seal (35B2) and into the threaded portion of the seal housing (35B3). Using a 5/16" Multi-Spline Key tighten the seal retainer (35B1) into the seal housing (35B3). 10.3.1.3 Coat the surfaces of a NEW 11/16" O.D. o-ring (35C) with #2 Silicone Grease, Wabtec Corporation Specification M-7680-2. Also lubricate the o-ring groove of the seal housing (35B3) and the bearing surfaces of the bushing of the body (100) into which the housing (35B3) will be installed with the lubricant. Install the NEW lubricated 11/16" O.D. o-ring (35C) into the proper groove of the seal housing (35B3). Excess lubricant may be removed by wiping with a clean lint-free cloth. 10.3.1.4 Insert the spring (35D) and supply valve seat assembly (35B, 35C), smaller diameter first, into the slotted opening of the supply valve cage (35E). 10.3.1.5 Depress and hold the supply valve seat assembly and spring (35B, 35C, 35D) far enough into the cage (35E) to expose the retaining ring groove in the inner bore of the supply valve cage (35E). 10.3.1.6 Insert the retaining ring (35A) in the retaining ring groove in the supply valve cage (35E). Be sure the retaining ring (35A) "snaps" into its groove, then slowly release the supply valve seat assembly and spring (35B, 35C, 35D). 10.3.1.7 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of a NEW 17/16" O.D. o-ring (36). Also fill the o-ring groove on the outer diameter of the supply valve cage (35E) with the lubricant. Install the NEW, lubricated 17/16 O.D. o-ring (36) into the o-ring groove of the supply valve cage (35E). Excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.2 Insert the supply valve - o-ring assembly (35, 36), seal end first, into the top front opening on the brake valve body (100) far enough to expose the retaining ring groove in that opening. 10.3.3 Using the #3 Truarc Internal Retaining Ring Pliers, install the retaining ring (34) into the proper groove in the brake valve body (100). 10.3.4 Exhaust Valve Sub-Assembly 10.3.4.1 Insert a NEW valve seal (43D2), small sealing bead first, into the housing (43D3). DO NOT LAP THE SEAL. 10.3.4.2 Insert the seal retainer (43D1) through the seal (43D2) and into the threaded portion of the seal housing (43D3). Using a 3/4" Multi-Spline Key, tighten the seal retainer to secure the seal (43D2) in place in the housing (43D3). 10.3.4.3 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, coat the surfaces of a NEW 15/16" O.D. o-ring (44). Also fill the o-ring groove on the housing (43D3) and lightly lubricant the bearing surfaces of the housing bushing in the body (100) with the lubricant. Install the NEW lubricated o-ring (44) into its groove on the housing (43D3). Excess lubricant may be removed by wiping with a clean, lint-free cloth. 10.3.4.4 Insert the exhaust valve spring (43C) and the valve seal assembly (43D, 44) into the slotted end of the valve cage (43B). 10.3.4.5 Depress and hold the valve seal assembly (43C, 43D) and spring (44) far enough into the valve cage (43B) to expose the retaining ring groove in the inner bore of the cage (43B).

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operation & maintenance instruction

10.3.4.6 Install the retaining ring (43A) into the proper groove in the cage (43B). Be sure the retaining ring (43A) "snaps" into its groove, then slowly release the valve seal assembly and spring (43C, 43D, 44). 10.3.4.7 Lubricate the surfaces of a NEW 15/8" O.D. oring (45) with #2 Silicone Grease, Wabtec Corporation Specification M-7680-2. Also fill the o-ring groove on the large diameter end of the valve cage (43B) with the lubricant. Install the NEW lubricated 15/8" O.D. o-ring (45) into its groove on the valve cage (43B). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 10.3.5 Insert the diaphragm stem (42), larger diameter first, through the seal retainer portion of the exhaust valve seat assembly (43) until the flanged portion of the diaphragm stem (42) is in contact with the seal retainer (43D1). 10.3.6 Assemble the stem spring (46) over the slotted end of the diaphragm stem (42). 10.3.7 Carefully insert the exhaust valve diaphragm stem and spring assembly (46, 42) into the center opening of the relay cover face of the brake valve body (100). 10.3.8 Depress and hold the valve cage (43B) far enough into the brake valve body (100) to expose the retaining ring groove in the body. Using the #3 Truarc Internal Retaining Ring Pliers, insert the retaining ring (41) into the proper groove in the brake valve body (100). Be sure that the retaining ring "snaps" into its groove, then slowly release the valve cage (43B). 10.3.9 Preassemble the diaphragm sub-assembly as follows: 10.3.9.1 Place a NEW diaphragm (40) on the flat face of the lower follower (39C) so that the three small holes are in alignment and the bellows area of the diaphragm extends over the outer diameter of the follower. 10.3.9.2 Place the upper follower (39D) on the diaphragm (40) so that the three small holes are in alignment and the contour of the outer edge of the follower matches that of the bellows area of the diaphragm. 10.3.9.3 Insert a #10-24 retaining screw (39B) through each of the three small holes in the upper follower (39D). 10.3.9.4 Assemble a #10-24 nut (39A) on each of the

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three screws (39B). Equally tighten the nuts (39A) to secure the diaphragm assembly (39, 40) together as a unit. 10.3.10 Insert the diaphragm assembly (39, 40) into the brake valve body (100) making certain that the ball socket joint of the diaphragm stem (42) is engaged in the slot on the lower follower (39C). (Figure 6) 10.3.11 Install a NEW 9/16" O.D. ring gasket (89) into the proper recess in the relay cover face of the brake valve body (100). (Figure 5) 10.3.12 Position the relay cover (38) over the studs (95) and against the diaphragm assembly (56) on the brake valve body (100). Be sure that the bead of the diaphragm (40) is in the proper groove in the brake valve body (100). 10.3.13 Assemble a 5/16" hex nut (37) on each of the six studs (95). Equally tighten the 5/16" hex nuts (37). 10.3.14 Coat the surfaces of two NEW special o-rings (53) and fill the o-ring grooves of the check valve seat (54) with #2 Silicone Grease, Wabtec Corporation Specification M-7680-2. Also lubricate the bearing surfaces of the check valve seat bushing of the valve body (100) with the lubricant. 10.3.15 Install the two NEW, lubricated special o-rings (53) into their grooves on the check valve seat (54). Excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.16 Install the equalizing reservoir cut-off valve check valve spring (56) into the spring seat cavity of the valve body (100). Be sure that the spring (56) is properly seated in the cavity. 10.3.17 Install a NEW equalizing reservoir cut-off valve check valve (55) into the check valve seat (54). Install the check valve seat with check valve assembly (53,54,55) into the valve body (100) being sure that the check valve spring (56) is properly positioned in the body (100) and that it contacts the spring seat area of the check valve (55).

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10.3.18 Coat the surfaces of a NEW 15/8" O.D. o-ring (51) and fill the o-ring groove of the piston (52) with #2 Silicone Grease, Wabtec Corporation Specification M7680-2. Also lightly coat the bearing surface of the inside of the check valve seat (54) where the piston (52) will be installed with the lubricant. 10.3.19 Install the NEW lubricated 15/8" O.D. o-ring (51) into its groove on the piston (52). Excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.20 Install the piston with o-ring assembly (52, 51) into the check valve seat (54) using the #10-24 machine screw which was installed in the piston during disassembly as a handle. Remove the #10-24 machine screw from the piston (52). (Figure 6) 10.3.21 Exercising care so that no damage is done to the regulating valve bushing of the valve body (100) carefully install the regulating valve retaining ring (72) in place in the regulating valve bush of the body (100). (Figure 4) 10.3.22 Preassemble each of the two cam dog assemblies (31) as follows: 10.3.22.1 Place the un-lubricated roller (31B) in the clevis area of the cam dog (31C) so that the pin holes are in alignment. 10.3.22.2 Insert a pin (31A) through the holes in the cam dog (31C) and roller (31B) to secure the roller (31B) in place. 10.3.23 Apply a light coating of #1 Calcium Base Grease, Wabtec Corporation Specification M-7650-1, to the surface of the cam dog pin (30). Place the lower cam dog assembly (31) over the cam dog pin (30) so that the cam dog (31C) faces to the left rear when the cam roller (31B) faces the front. 10.3.24 Insert the cam dog pin (30) upward through the cam pin hole in the front area of the brake valve body (100) far enough to place the upper cam dog assembly (31) over the cam dog pin (30). 10.3.25 Continue to insert the cam pin (30) upward through the hole in the upper cam dog assembly (31) until the hole for the cylindrical spring pin is exposed above the upper cam dog assembly. 10.3.26 Insert a 1/16" x 7/16" cylindrical spring pin (29) through each of the exposed holes in the upper and center portions of the cam dog pin (30) to secure the cam dog assemblies (31) in the brake valve body (100). (Figure 6) 10.3.27 Regulating Valve Spring Housing (Inlet Valve) Sub-Assembly 10.3.27.1 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of two NEW 13/16" O.D. o-rings (71). Also fill the o-ring grooves of the regulating valve and lightly lubricate the bearing surfaces of the regulating valve bushing of the body (100) with the lubricant. Install a NEW lubricated o-ring (71) into each of the two o-ring grooves on the regulating valve (70). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 10.3.28 Install the inlet valve with o-ring assembly (70,71) into the valve body (100). 10.3.29 Install the spring (69) on the inlet valve (70). 10.3.30 Insert the spring seat (64), smaller diameter first, into the bore at the threaded end of the exhaust valve seat (67). 10.3.31 Place the regulating exhaust spring (63) into the recess in the regulating valve spring seat (64). 10.3.32 Place a NEW diaphragm (66), with the loop of the bellows facing upward, down over the threaded portion of the exhaust valve seat (67). 10.3.33 Place the diaphragm follower (65) over the threaded portion of the exhaust valve seat (67). 10.3.34 Inspect and measure the size of the choke in the exhaust valve spring seat (62) which MUST BE 0.046" diam. or #56 drill. If the size or shape of this choke is changed a NEW spring seat (62) MUST BE used. Assemble the exhaust valve spring seat (62) to the threaded portion of the exhaust valve seat (67) and tighten with 35 to 40 foot pounds of torque. 10.3.35 Insert the valve (68), fluted end first, through the opening in the non-threaded end of the exhaust valve seat (67).

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operation & maintenance instruction

10.3.36 Insert the following into the spring housing (59). 10.3.36.1 Spring seat (60). 10.3.36.2 Spring (61). 10.3.36.3 Exhaust valve seat assembly (62 to 67 incl.), diaphragm end first. 10.3.37 Carefully assemble the spring housing assembly (62 to 67 incl.) over the four studs (93) on the regulating valve face on the back of the brake valve body (100). 10.3.38 Assemble a 5/16" hex nut (57) on each of the four studs (93) protruding from the spring housing (59). Equally tighten the hex nuts (57). (Figure 4) 10.3.39 Cam Housing Sub-Assembly 10.3.39.1 Insert the pinned cam shaft (8), small diameter end first, approximately one inch into the larger opening in the top of the cam housing body (28). IMPORTANT: NO LUBRICANTS ARE TO BE USED AT ANY TIME ON THE CAMS, (9, 11, 12) CAM DOGS (31) OR CAM DOG ROLLERS. 10.3.39.2 Place the #1 Cam (9) (Emergency Valve Cam), numbered side up, over the lower end of the pinned cam shaft (8). Do not lubricate the cam (9). 10.3.39.3 Place the #2 Cam (10) (Regulating Valve Cam), numbered side up, over the lower end of the pinned cam shaft (8). Lightly coat the cam dog bearing surface of the Cam (10) with #1 Calcium Base Grease, Wabtec Corporation Specification M-7650-1. 10.3.39.4 Push the pinned cam shaft (8) through the #2 Cam (10) (Regulating Valve Cam). 10.3.39.5 Place the #3 Cam (11) (Suppression Valve Cam), numbered side up, over the lower end of the pinned cam shaft (8). Do not lubricate the cam (11). 10.3.39.6 Push the pinned cam shaft (8) through the #3 Cam (11) (Suppression Valve Cam). 10.3.39.7 Place the #4 Cam (12) (Vent Valve Cam), numbered side up, over the lower end of the pinned cam shaft (8). Do not lubricate the cam (11).

September, 1988

10.3.39.8 Push the pinned cam shaft (8) through the #4 Cam (12) (Vent Valve Cam) and into the lower bushing in the cam housing body (28). 10.3.39.9 Insert the cam dog pin with retaining ring (13) through the small bushed opening in the top face of the cam housing body (28). 10.3.39.10 Assemble the cam dog (14) into the proper cavity in the cam housing body (28) so that the cam dog pin with retaining ring (13), previously installed, may be pushed through the larger opening in the cam dog (14) and into the hole in the cam housing body (28). 10.3.39.11 Push the cam dog pin with retaining ring (13) as far as it will go into the cam housing body (28). 10.3.40 Insert four NEW 11/16" O.D. ring gaskets (32) and one 7/8" O.D. ring gasket (33) into the proper grooves on the cam housing face of the brake valve body (100). 10.3.41 Assemble the quadrant (7) on the cam housing body (34) as follows: 10.3.41.1 Position the quadrant (7) on the top face of the cam housing body (28) so that the two mounting holes are in alignment with the tapped holes in the cam housing body (28). 10.3.41.2 Insert the two 3/8" x 7/8" hex socket head screws (6) through the quadrant (7) and into the cam housing body (28). 10.3.41.3 Equally tighten the screws (6) to secure the quadrant (7) in place. 10.3.42 IMPORTANT: Turn the pinned cam shaft (8) in the cam housing (28) to assume the "Handle Off" position to permit the regulating cam dog (14) to drop into the indent in the Regulating Valve Cam (Cam #2) (10). 10.3.43 Carefully place the cam housing body (28) over the five studs of the brake valve body (100). 10.3.44 Attach a 5/16" hex nut (1, 2, 3) to the threaded portion of each of the five studs of the brake valve body (100). Equally tighten the five 5/16" hex nuts (1, 2, 3) to secure the cam housing body (28) to the brake valve body (100). 10.3.45 Assemble each of the two spill-over check valve assemblies (26) as follows:

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operation & maintenance instruction

10.3.46 Place the spring (26C) and NEW check valve (26B) into the open end of the cap nut (26D). 10.3.47 Depress the check valve and spring (26B, 26C) far enough into the cap nut (26D) to engage the lip in the bore of the cap nut (26D). 10.3.48 Install and tighten each of the two spill-over check valve assemblies (26) into their proper tapped openings in the bottom face of the cam housing body (100). 10.3.49 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of five NEW 1 /2" O.D. o-rings (24). Also fill the o-ring grooves of the cut-off valve (25) and lightly lubricate the bearing surfaces of the cut-off valve bushing of the cam housing body (28) with the lubricant. Install the five NEW lubricated 1/2" O.D. o-rings (24) into their grooves on the cut-off valve (25). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 10.3.50 Insert the cut-off valve with o-rings (25, 24), slotted end first, into the proper opening in the bottom face of the cam housing body (28) so that the milled slot in the cut-off valve (25) is in the approximate center of the operating shaft bushing on the front of the cam housing body (28). 10.3.51 Apply a light coat of #1 Calcium Base Grease, Wabtec Corporation Specification M-7650-1, to the eccentric cam of the cut-off valve operating shaft (18). Insert the cut-off valve operating shaft (18) into the proper opening in the front of the cam housing body (28) so that the eccentric cam of the operating shaft (18) comes to rest in the milled slot in the cut-off valve (25) and the operating shaft (18) is flush with the escutcheon plate mounting face of the cam housing body (28). 10.3.52 Turn the operating shaft (18) so that the slot in the operating shaft (18) is in alignment with any one of the notches in the escutcheon plate mounting face of the cam housing body (28). 10.3.53 CAUTION: During the following procedure spring (19) will be under tension. Exercise care to avoid physical injury should parts be inadvertently expelled. Insert the spring (19) into the opening in the operating shaft (18). 10.3.54 Insert the shaft of the control knob (20) through the face of the escutcheon plate (17) which is marked "OUT" - "IN". 10.3.55 Insert the control knob (20) into the opening on the cut-off valve operating shaft (18). IMPORTANT: Depress and turn the control knob (20) 1/8 turn. The knob MUST LOCK in this position. 10.3.56 Rotate the escutcheon plate (17) to bring the three mounting holes in alignment with the three tapped holes in the cam housing body (28). 10.3.57 Insert and tighten the three #4 x 3/8" fillister head machine screws (15) to secure the escutcheon plate (17) in place. 10.3.58 Depress and move the control knob (20) to its several positions. The knob MUST move freely. Finally, move the control knob (20) to the "OUT" position. 10.3.59 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of a NEW 13 /16" O.D. o-ring (22). Also fill the o-ring groove of the cut-off valve position selector plug (23) with the lubricant. Install the NEW lubricated o-ring (22) in its groove on the position selector plug (23). Any excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.60 Insert the cut-off valve position selector plug assembly (22, 23) into the proper opening in the bottom face of the cam housing body (28), so that the circular projection on the plug (23) extends into the spool valve chamber. IMPORTANT: The piston selector plug (23) MUST BE installed as shown in Figure 7 for the valve portion to function properly. 10.3.61 Depress the cut-off valve position selector plug (23) far enough to expose the retaining ring groove in the cam housing body (28). 10.3.61.1 Compress and insert the retaining ring (21) into the proper groove in the cam housing body (28). Be sure that the retaining ring (21) snaps into its groove, then slowly release the position selector plug (23). 10.3.62 Handle Sub-Assembly 10.3.62.1 Place the latch spring (5C) over the cylindrical portion of the latch (5B). 10.3.62.2 Insert the latch spring (5C) and latch (5B) into the opening in the handgrip portion of the handle body

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(4A) in place, into the tapped opening in the square end of the pinned cam shaft (8). 10.3.65.2 Tighten the cap screw (4) to secure the handle assembly (5) to the pinned cam shaft (8). (Figure 6) 10.3.66 Brake Pipe Cut-Off Valve Sub-Assembly 10.3.66.1 Insert a NEW seal (83D2), small sealing bead first, into the large diameter bore of the housing (83D3). DO NOT LAP THE SEAL. 10.3.66.2 Using a 3/4" Multi-Spline Key, insert and tighten the seal retainer (83D1) through the seal (83D2) and into the housing (83D3). 10.3.66.3 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of a NEW 15/16" O.D. o-ring (84). Also fill the o-ring groove of the seal housing (83D3) with the lubricant. Figure 7 - Escutcheon Plate & Position Selector Plug Orientation View (5D) so that the offset portion of the latch (5B) is facing away from the square hole in the handle body (5D). 10.3.62.3 Depress the latch (5B) against the spring (5C) far enough to permit the insertion of the 1/8" x 1" cylindrical spring pin (5A) through the handle body (5D) and latch (5B). Install the 1/8" x 1" cylindrical spring pin (5A) to secure the latch assembly (5B, 5C) in place in the handle body (5D). 10.3.64 Insert the handle assembly (5) into the handle opening in the quadrant (7). 10.3.64.1 Push the brake valve handle assembly (5) horizontally onto the pinned cam shaft (8) until the handle locks. 10.3.64.2 Push downward on the brake valve handle assembly (5) until the handle is in its normal operating groove in the quadrant (7). 10.3.65 Place the washer (4A) over the threads of handle cap screw (4) so that the washer rests on the head of the screw (4). 10.3.65.1 Insert the handle cap screw (4), with washer

September, 1988

Install the NEW lubricated 15/16" O.D. o-ring (84) in its groove on the seal housing (83D3). Excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.66.4 Insert the spring (83B) and the valve seal assembly (84, 83D) into the cavity in the smaller diameter end of the valve cage (83C). 10.3.66.5 WARNING: The spring (83B) and valve seal assembly (83D, 84) are to be assembled under tension. Exercise care when assembling to avoid physical injury should parts be inadvertently expelled. Depress the valve seal assembly (83D, 84) and spring (83B) far enough into the valve cage (83C) to expose the retaining ring groove. 10.3.66.6 Insert the retaining ring (83A) in the proper groove in the bore of the valve cage (83C). 10.3.67 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of a NEW 13/8" O.D. o-ring (82) and the surfaces of a NEW 2" O.D. o-ring (81). Also fill the o-ring grooves of the valve cage (83C) with the lubricant. Install the NEW lubricated 2" O.D. o-ring (81) and the NEW lubricated 13/8" O.D. o-ring (82) into their grooves on the valve cage (83C). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth.

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operation & maintenance instruction

10.3.68 Carefullly insert the brake pipe cut-off valve assembly with o-rings (81 to 84 incl.), valve seal end first, as far as it will go into the proper cavity in the back cover face of the brake valve body (100). 10.3.69 Vent Valve Sub-Assembly 10.3.69.1 Insert a NEW seal (85D2), small sealing bead face first, into the large diameter bore of the housing (85D3). DO NOT LAP THE SEAL. 10.3.69.2 Insert the seal retainer (85D1) through the seal (85D2) and into the housing (85D3). Tighten the retainer (85D1) to secure the seal (85D2) in place. 10.3.69.3 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, lubricate the surfaces of a NEW 15/16" O.D. o-ring (85E). Also fill the o-ring groove of the seal housing (85D3) with the lubricant. Install the NEW lubricated 15/16" O.D. o-ring (85E) into the o-ring groove of the housing (85D3). Any excess lubricant may be removed by wiping with a clean, dry, lint-free cloth. 10.3.69.4 Insert the spring (85B) and the valve seat assembly (85D) into the cavity in the smaller diameter end of the vent valve cage (85C). 10.3.69.5 WARNING: The Spring (85B) and Valve Seat Assembly (85D) are to be assembled under tension. Exercise care when assembling to avoid physical injury should parts be inadvertently expelled. Depress the valve seat assembly (85D) far enough into the vent valve cage (85C) to expose the retaining ring groove. 10.3.69.6 Insert the retaining ring (85A) in the proper groove in the bore of the vent valve cage (85C). Be sure that the retaining ring (85A) "snaps" into its groove, then slowly release the valve seal assembly (85D). 10.3.69.7 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, coat the surfaces of a NEW 13/8" O.D. o-ring (82). Also fill the o-ring grooves of the vent valve cage (85C) with the lubricant. Install the NEW lubricated 13/8" O.D. o-ring (82) in its groove on the vent valve cage (85C). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 10.3.70 Carefully insert the vent valve assembly (82, 85),

Page 28 of 34 September, 1988

seal end first, as far as it will go into the proper cavity in the back cover face of the brake valve body (100). 10.3.71 Lubricate the surfaces of five NEW 1/2" O.D. orings (76) with #2 Silicone Grease, Wabtec Corporation Specification M-7680-2. Also fill the o-ring grooves of the suppression valve (77) with the lubricant. Install the NEW lubricated 1/2" O.D. o-rings (76) into their grooves on the emergency valve (77). Any excess lubricant may be removed by wiping with a dry, clean, lint-free cloth. 10.3.72 Carefully insert the suppression valve with o-ring assembly (76, 77), tip end first, as far as it will go into the proper cavity in the back cover face of the brake valve body (100). 10.3.73 Using #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, coat the surfaces of four NEW 1/2" O.D. o-rings (79). Also fill the o-ring grooves of the emergency valve (80) with the lubricant. Install the four NEW lubricated 1/2" O.D. o-rings (79) into their grooves on the emergency valve (80). Excess lubricant may be removed by wiping with a dry, clean, lint-free cloth. 10.3.74 Carefully insert the emergency valve with orings (79, 80), tip end first, as far as it will go into the proper cavity in the back cover face of the brake valve body (100). 10.3.75 Assemble a NEW back cover gasket (86) over the four studs (95) and onto the brake valve body (100). 10.3.76 Place the proper spring on each of the following valve assemblies in their respective locations in the brake valve body (100). 10.3.76.1 Spring (78) on the brake pipe cut-off valve assembly (81 to 83A incl.). 10.3.76.2 Spring (75) on the emergency valve assembly (79, 80). 10.3.76.3 Spring (75) on the suppression valve assembly (76, 77). 10.3.77 Place the back cover (74) over the four studs (95) and into position against the cover gasket (86) on the brake valve body (100).

4208-26, S.2.1

operation & maintenance instruction

10.3.78 Assemble a 3/8" hex nut (73) on each of the four studs (95). Equally tighten the nuts (95) to secure the back cover (74) in place. 10.4 TESTING & ADDITIONAL INFORMATION 10.4.1 After the "26-C" Brake Valve Portion, Pc.No. 562073-2000 has been assembled, BUT BEFORE it is returned to service, it MUST PASS a series of tests following the procedure of the current issue of the Wabtec Corporation Test Specification T-2422-O. 10.4.2 Refer to Section 9.0 for installation procedures for the tested "26-C" Brake Valve Portion. A NEW pipe bracket gasket MUST BE used during installation. 10.4.3 IMPORTANT: Whenever the "26-C" Brake Valve Portion is removed from a brake equipment arrangement for any reason, and it is reinstalled or replaced with a new or repaired and tested portion, a stationary vehicle test MUST BE made to be sure that the "26-C" Brake Valve Portion and the "26-C" Brake Valve function properly in the Brake Equipment Arrangement. 10.4.4 IMPORTANT: If the overhauled and tested "26-C" Brake Valve Portion is not being returned to service, but is being placed in storage, adequate steps MUST BE taken to provide protection so that dirt and/or moisture cannot enter the Portion. 10.4.5 Consult your Wabtec Corporation Representative if additional information on the "26-C" Brake Valve Portion is required. 11.0 "SA-26" INDEPENDENT BRAKE VALVE PORTION - MAINTENANCE PROCEDURES - "IN-SHOP" 11.1 DISASSEMBLY (Figure 5) 11.1.1 If the mounting gasket (101) is still on the mounting face of the Independent Brake Valve Portion, the gasket (101) is to be removed and SCRAPPED. The mounting gasket IS NOT a part of the "SA-26" Independent Brake Valve Portion. 11.1.2 Place the brake valve handle (21) in the "Release" position. Remove the handle assembly (21, 21A, 21B) from the brake valve portion by exerting a pulling force on the knob on the handle retaining pin assembly (5). This

September, 1988

should free the handle assembly (21, 21A, 21B) from its internal locking feature. The handle assembly may then be pulled out from the brake valve body (31). 11.1.3 IMPORTANT: Before proceeding with the disassembly, the tension on the regulating valve spring (25) MUST BE released as follows: Using a 1/2" key size, multi-spline wrench, Pc.No. 517557, release the tension on the regulating valve spring (25) by turning the adjusting screw (23A), which is located in the spring housing (23), counterclockwise its full travel. NOTE: It is not necessary to entirely remove the adjusting screw (23A) from the spring housing (23) unless it is damaged. However steps MUST BE taken to be sure that all tension on spring (25) is removed before continuing with the disassembly procedure. 11.1.4 WARNING: Spring (25) and spring seat (24) may be under tension. Exercise care in the procedures which follow in order to prevent injuries should parts be inadvertently expelled from the assembly. Carefully remove the four 5/16" hex nuts (22) which secure the spring housing (25) to the body (25). Then remove the spring housing (23) from the body (31). 11.1.5 Remove the spring (25) and spring seat (24). 11.1.6 Remove the diaphragm - exhaust valve seat assembly (26A to 26D incl.) with 3/4" O.D. o-ring (27) from the valve portion body (31) as a unit. 11.1.7 Remove and SCRAP the 3/4" O.D. o-ring (27) from the exhaust valve seat (26D). 11.1.8 Disassemble the diaphragm - exhaust valve seat assembly (26A to 26D) as follows: 11.1.8.1 Hold the exhaust valve seat (26D) using the proper tool on the flats of the seat, then remove the special hex nut (26A) from the threaded end of the exhaust valve seat (26D). 11.1.8.1 Remove the diaphragm follower (26B) and the diaphragm (26C) from the exhaust valve seat (26D). SCRAP the diaphragm (26C). 11.1.9 Remove the exhaust valve spring (28) from the

Page 29 of 34

4208-26, S.2.1

operation & maintenance instruction

Figure 8 - "SA-26" Independent Brake Valve Portion - Exploded View

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September, 1988

4208-26, S.2.1

operation & maintenance instruction

valve portion body (31). 11.1.10 Remove the exhaust valve unit (30) with o-rings (29) from the valve portion body (31). 11.1.11 Remove and SCRAP the two 3/4" O.D. o-rings (29) from the exhaust valve unit (30). 11.1.12 WARNING: Spring (9) may be under tension. Exercise care during the following procedure to prevent bodily injuries should parts be inadvertently expelled from the assembly. Carefully remove the three 3/8" x 1" hex head cap screws (2) which secure the quick release valve body (7) to the valve portion body (31). 11.1.13 Remove and SCRAP the body gasket (8). 11.1.14 Using the proper tool, carefully remove the retaining ring (3) from the quick release valve body (7), then remove the quick release valve spring seat (4). 11.1.15 Unscrew the handle retaining pin assembly (5) from the quick release valve body (7). 11.1.16 Remove the quick release valve spring (9) from the quick release valve (12), then remove the quick release valve (12) with o-rings (10, 11) as a unit from the valve portion body (31). 11.1.17 Remove and SCRAP the 13/16" O.D. o-ring (10) and the two 15/16" O.D. o-rings (11) from their grooves on the quick release valve (12). 11.1.18 Remove the cam dog pin (13) from the valve portion body (31). 11.1.19 Remove the cam dog with roller assembly (14 to 17 incl.) as a unit from the valve portion body (31). 11.1.20 Remove the cam (20) from the valve portion body (31), then remove the push pin (18) from the cam (20). Figure 9 - Handle Retaining Pin - Assembly View 11.2 CLEANING & INSPECTING 11.2.1 NON-REUSABLE PARTS 11.2.1.1 IMPORTANT: ALL o-rings, gaskets, cotter pins, and the diaphragm ARE TO BE SCRAPPED and replaced with NEW Wabtec Corporation parts. 11.2.3.2 After the assembly is cleaned, it MUST BE completely dried. Use a low pressure jet of clean, dry air to blow it dry. 11.2.3.3 Inspect the assembly for excessive wear, paying particular attention to the end of the pin (4). Check the action of the handle mechanism to be sure that the spring (7) is working properly. If the cam (20) is not damaged and can be reused, be sure that the cylindrical spring pin (19) is properly in position and that it is not damaged or worn excessively. The cylindrical spring pin (19) need not be removed from the cam (20) unless it is damaged. This pin (19) serves to retain the handle when it is installed. 11.2.3 HANDLE RETAINING PIN ASSEMBLY (Figure 9) 11.2.3.1 Wash the handle retaining pin assembly in a bath of the cleaning solvent described in Section 7.1. 11.2.2 CAM 11.2.2.1 Wash the cam assembly (20, 19) in a bath of the cleaning solvent described in Section 7.1 11.2.2.2 After the assembly is cleaned, it MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the assembly dry. 11.2.2.3 Inspect the cam assembly. If the cam (20) is cracked, cut, broken, excessively worn, damaged in any way, or is in such a condition that may result in the unsatisfactory operation of the "SA-26" Independent Brake Valve Portion, the cam (20) and cylindrical spring pin (19) are to be SCRAPPED and replaced with NEW Wabtec Corporation parts.

September, 1988

Page 31 of 34

4208-26, S.2.1

operation & maintenance instruction

11.2.3.4 If the mechanism of the assembly is NOT working properly and/or if damaged or excessively worn parts are found, the handle retaining pin assembly may be disassembled and the parts replaced as follows: 11.2.3.4.1 WARNING: During the procedures which follow, spring (7) will be under tension. Exercise care when performing the procedures which follow in order to prevent possible bodily injuries, should parts be inadvertently expelled from the assembly. 11.2.3.4.1.1 Remove the 5/16" lock washer (1) from the pin housing (8). 11.2.3.4.1.2 Depress and hold the pin (4) into the pin housing (8). Carefully remove the 1/16" x 1/2" cylindrical spring pin (2) from the end of the pin (4), then remove the handle pin washer (3). Slowly release the hold on the pin (4) to permit the spring (7) to expand to its free height. 11.2.3.4.1.3 Slide the pin (4) out of the threaded end of the housing (8). 11.2.3.4.1.4 Using the proper tool, remove the retaining ring (5) from the housing (8), then remove the first spring seat (6), the spring (7), and the second spring seat (6). 11.2.3.4.1.5 Inspect the spring. If it is rusted, pitted, distorted, damaged in any way, or if it has taken a permanent set, it is to be SCRAPPED and replaced with a NEW Wabtec Corporation part. Refer to the current issue of the Wabtec Corporation Parts Catalog 3207-6, S.1 for spring information and identification. 11.2.3.4.1.6 Replace ANY part that is cracked, cut, broken, excessively worn, damaged in any way, or that is in such a condition that may result in the unsatisfactory operation of the handle retaining pin. 11.2.3.4.1.7 Reassemble the parts in reverse order of disassembly using NEW Wabtec Corporation parts as required. 11.2.4 CAM DOG ASSEMBLY (Figure 8) 11.2.4.2 Wash the parts in a bath of the cleaning solvent described in Section 7.1. After the parts are cleaned, blow them dry with a low pressure jet of clean, dry air. 11.2.4.3 Inspect the parts. Replace any part that is cracked, cut, broken, shows signs of wear, or that is damaged in any way. Pay particular attention to the roller pin (15) and surfaces of the roller (16). 11.2.4.4 Reassemble the parts using NEW Wabtec Corporation parts as required as follows: 11.2.4.4.1 Apply a light coating of #1 Calcium Base Grease, Wabtec Corporation Specification M-7650-1 to the surfaces of the roller pin (15). 11.2.4.4.2 Install a NEW 1/16" x 1/2" cotter pin (14) through one of the pin holes in the roller pin (15). 11.2.4.4.3 Place the roller (16) in position in the cam dog (17) so that the roller pin holes of the cam dog (17) and the hole in the roller (16) are aligned, then insert the roller pin (15) through the aligned parts and secure it in place by installing the second NEW 1/16" x 1/2" cotter pin (14) through the exposed pin hole of the roller pin (14). IMPORTANT: DO NOT apply any lubricant of ANY KIND to the cam dog roller (16). The outside surfaces of the roller (16) MUST BE free of any lubricant. 11.2.5 REMAINING PARTS 11.2.5.1 Wash ALL of the remaining parts in a bath of the cleaning solvent as described in Section 7.1. Springs may be wire brushed to assist in the removal of dirt, rust or scale. 11.2.5.2 After the parts are cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the parts dry. 11.2.5.3 Inspect the springs. Replace any spring that is rusted, pitted, distorted, or if it has taken a permanent set. Refer to The Wabtec Corporation Parts Catalog 3207-6, S.1 for spring information and identification. 11.2.5.4 Inspect the remaining parts.

Page 32 of 34 September, 1988

11.2.4.1 Disassemble the cam dog assembly (14 to 17 incl.) by first removing the two cotter pins (14) from the roller pin (15), then remove the roller pin (15) and roller (16) from the cam dog (17). SCRAP the two cotter pins (14).

4208-26, S.2.1

operation & maintenance instruction

11.2.5.4.1 Replace ANY part that is cracked, cut, broken, excessively worn, or is damaged in any way which may result in the unsatisfactory operation of the "SA-26" Independent Brake Valve Portion. 11.2.5.4.2 Retaining rings are to be replaced if they are not elastic enough to hold securely. 11.2.5.4.3 If it is necessary to replace the adjusting screw (23A) of the spring housing (23), the screw may be removed by turning it counter- clockwise until it comes free of the lock nut which is in the body of the housing. release valve bushing of the brake valve portion body (31) and the quick release valve body (5) with the lubricant. 11.3.5 Install the two NEW lubricated 15/16" O.D. o-rings (11) and the NEW lubricated 13/16" O.D. o-ring (10) into their grooves in the quick release valve (12). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 11.3.6 Install the quick release valve spring (9) into the bottom of the quick release valve (12), then install the quick release valve (12) with spring (9) into the quick release valve body (7), spring end first. Be sure that the o-rings (10, 11) remain in their grooves on the release valve (12). 11.3.7 Install the push pin (18) in place in the cam (20), then install the cam (20) into the brake valve portion body (31). 11.3.8 Install the cam dog - roller assembly (14 to 17) as a unit into the brake valve portion body (31) and secure it in place by installing the cam dog pin (13), smaller diameter end first. 11.3.9 Align the cam dog roller (16) so that it contacts the cam (20) correctly. 11.3.10 Place a NEW quick release valve body mounting gasket (8) in position on the brake valve portion body (31). 11.3.11 With the quick release valve (12) in proper position in the quick release valve body (7), carefully Install and align the quick release valve body (7) on the brake valve portion body (31). Be sure that the quick release valve (9) and gasket (8) remain in position. Secure the two bodies (7, 31) together using three 3/8" x 1" hex head cap screws (2). Equally tighten the screws. 11.3.12 Install a NEW diaphragm (26C) on the exhaust valve seat (26D), then install the diaphragm follower (26B) and secure the parts together by installing the special hex nut (26A). 11.3.13 Apply a coating of #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, to the surfaces of a NEW 3/4" O.D. o-ring (27). Also fill the o-ring groove of the exhaust valve seat with the lubricant. 11.3.14 Install the NEW, lubricated, 3/4" O.D. o-ring (27) into its groove on the exhaust valve seat (26D). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth.

Figure 10 - Independent Brake Valve Handle - Assembly View

11.3 ASSEMBLY 11.3.1 IMPORTANT: During the assembly procedure, NO LUBRICANTS are to be used on the contact surface of the cam (20) or the contact surface of the cam dog roller (16). These surfaces MUST BE clean and completely dry to retain a rolling friction surface. 11.3.2 Place the roller (21B) in position in the handle (21) and secure it in place by installing the 3/16" x 1/2" cylindrical spring pin (21A). Check the roller (21B). It should rotate freely in the assembly. 11.3.3 Install the spring seat (4) in position in the quick release valve body (7) and secure it in place by installing the retaining ring (3). Be sure that the retaining ring (3) "snaps" into its groove in the body (7). 11.3.4 Coat the surfaces of two NEW 15/16" O.D. o-rings (11) and the surfaces of a NEW 13/16" O.D. o-ring (10) with #2 Silicone Grease, Wabtec Corporation Specification M7680-1. Also fill the o-ring grooves of the quick release valve and lightly coat the bearing surfaces of the quick

September, 1988

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4208-26, S.2.1

operation & maintenance instruction

11.3.15 Apply a coating of #2 Silicone Grease, Wabtec Corporation Specification M-7680-2, to the surfaces of two NEW 3/4" O.D. o-rings (29). Also fill the o-ring grooves of the exhaust valve unit (30) and lightly coat the bearing surfaces of the exhaust valve unit bushing of the brake valve portion body (31) with the lubricant. 11.3.16 Install the two NEW lubricated 3/4" O.D. o-rings (29) into their grooves on the exhaust valve unit (30). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 11.3.17 Install the exhaust valve unit (30) with o-ring (29) in their grooves, hardened pin end first, into the exhaust valve unit bushing of the brake valve portion body (31). The "ball" end of the exhaust valve unit (30) should be exposed. 11.3.18 Install the exhaust valve spring (28) over the ball end of the exhaust valve unit (30). 11.3.19 Carefully install the diaphragm - exhaust valve seat assembly (26A to 27) on and into the brake valve portion body (31) so that the exhaust valve spring (28) is positioned in the spring bore of the exhaust valve seat (26D) and that the bead of the diaphragm (26C) is in its groove in the body (31). 11.3.20 Install the regulating spring (25) onto the diaphragm - exhaust valve seat assembly (26 to 27) so that the spring (25) fits over the hex nut (26A) and rests on the diaphragm follower (26B). 11.3.21 Install the spring seat (24) on the regulating spring (25). 11.3.22 Place the spring housing assembly (23, 23A) over the spring seat (24) and spring (25) and onto the brake valve portion body (31) so that the exhaust opening of the housing (23) is facing in the same direction as the pipe bracket mounting face of the brake valve portion body (31). (The exhaust opening should be facing away from the handle.) Secure the housing (23) in place by installing four 5/16" hex nuts (22). Equally tighten the nuts (22). 11.3.23 Install the handle retaining pin assembly (5) by turning it into the tapped hole in the quick release valve body (7). 11.3.24 Manually move the cam (20) into the "Release" position, then carefully insert the handle assembly (21) into the cam (20). Pull outward on the knob of the handle retaining pin assembly (5) and push the handle assembly (21) into the cam (20) its full travel. Release the knob of the handle retaining pin assembly (5) to lock the handle assembly (21) in place. Move the handle assembly (21) through the handle positions to be sure it is secure and works properly. 11.4 TESTING & ADDITIONAL INFORMATION 11.4.1 IMPORTANT: After the "SA-26" Independent Brake Valve Portion, Pc.No. 564316, has been assembled, BUT BEFORE it is returned to service, it MUST PASS a series of tests following the procedure of the current issue of The Wabtec Corporation Test Specification T-2403-O. 11.4.2 Refer to Section 9.0 for installation procedures for the tested "SA-26" Independent Brake Valve Portion. A NEW pipe bracket mounting gasket MUST BE used during the installation. 11.4.3 IMPORTANT: Whenever the "SA-26" Independent Brake Valve Portion is removed from a brake equipment arrangement for any reason, and it is reinstalled or replaced with a new or repaired and tested Portion, a stationary vehicle test MUST BE made to be sure that the "SA-26" Independent Brake Valve Portion and the "26-C" Brake Valve function properly in the brake equipment arrangement. 11.4.4 IMPORTANT: If the overhauled and tested "SA26" Independent Brake Valve Portion is not being returned to service, but is being placed in storage, adequate steps MUST BE taken to provide protection so that dirt and/or moisture cannot enter the Portion. 11.4.5 Consult your Wabtec Corporation Representative if any additional information is required.

WABCO Locomotive Products

1001 Air Brake Avenue · Wilmerding, PA 15148 (412) 825-1000 · Fax (412) 825-1019

www.wabtec.com

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September, 1988

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