Read 42070601 text version

4224-1.5

operation & maintenance instruction

"P-1" PUSH BUTTON WHISTLE VALVES

Pc. Nos. 92441, 515869, 570628

MAY, 1987

Supersedes all previous issues of this publication

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.

Exhaust Check Pusher

Pipe Tap "A"

"OUT" Valve with Stem

Return Spring

Thread "B"

"IN" Pipe Tap "A"

© 2000 WABCO Locomotive Products. A Wabtec Company. All rights reserved June, 1986 Page 1 of 6

4224-1.5

operation & maintenance instruction

1.0 DESCRIPTION Designed for use in equipment arrangements where the air pressure does not exceed 150 psig, this manually operated device functions, when manually held in its open position, to direct air flow between two devices. It is most commonly used to direct air flow to the horn alarm on rail vehicles. Pipe taps are provided for the connection of supply and delivery lines. The following tabulation shows the various "P-1" Whistle Valves. Consult your Wabtec Corporation Representative for the correct "P-1" Whistle Valve for your specific application. "P-1" WHISTLE VALVE PC. NO. 92441 4.0 PARTS CATALOG INFORMATION When ordering replacement parts for the "P-1" Whistle Valve refer to the current issue of the Wabtec Corporation Parts Catalog 3224-1. NOTE: The reference numbers used in this publication and those used in the parts catalog may differ. Check the descriptive parts name to be sure that the desired part is ordered.

5.0 SAFETY PROCEDURES AND WARNINGS PIPE TAP "A"

1

PIPE THREAD "B"

3

PUSHER PC. NO. (STYLE) 92450

Regular shop safety procedures are to be followed. The work area is to be clean. WARNING 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 insure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment.

June, 1986

/8"

/4"-10UNC-2A (Brass)

515869

1

/4"

13

/16"-16-UN-2A (Chrome Plated)

13

515846

570628

1

/4"

/16"-16-UN-2A (Blue Aluminum)

570629

2.0 OPERATION (Figure 1) When the pusher is manually depressed to its full travel and held, the pusher will contact the exhaust check-stem and valve assembly and move it so as to unseat the valve. Air under pressure entering the "In" port will flow past the unseated valve and be directed through the body to the "Out" port. When the pusher is released, the force of the return spring will move the valve with stem to its seat. This will block air flow between the "In" and the "Out" port. 3.0 MAINTENANCE SCHEDULE IMPORTANT: At least ONCE EVERY TWENTY FOUR MONTHS, o more frequently if service conditions so indicate, the "P-1" Whistle Valve is to be removed from the equipment arrangement, taken to the shop, be completely disassembled, all of the metal parts cleaned, inspected, the valve reassembled using NEW gaskets and then tested for correct operation.

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operation & maintenance instruction

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 tests, hands must be clear of electrical components, contacts and housing and there must be no bodily contact with the work bench. Failure to heed this warning could result in severe injury or death. 6.3.2 Abrasive Grinding Compound, "Kwik-Ak- Shun", Grade 1000: available from The U.S. Products Co., 518 Melwood Avenue, Pittsburgh, PA 15213. 6.3.3 Wright's Silver Polish: available from many retail stores. 7.0 MAINTENANCE PROCEDURES IMPORTANT: To obtain satisfactory operation and reliability of this device, ONLY replacement parts supplied by the Wabtec Corporation are to be used in the maintenance of this device. In the procedures which follow, DO NOT use sharp or hard metal tools to remove the gasket. Exercise care so that no damage is done to the metal parts. 7.1 DISASSEMBLY (Figure 2) 7.1.1 Remove the pusher (1) from the body (3). 7.1.2 Remove the exhaust check (2) from the body (3). 7.1.3 Remove hex nut (8) from the adapter nut (7). 7.1.4 Remove the adapter nut (7) with ring gasket (6), the spring (5) and valve with stem (4) from the body (3). 7.1.5 Remove and SCRAP the ring gasket (6) from the adapter nut (7). 7.2 CLEANING & INSPECTING 7.2.1 NON-REUSABLE PARTS 7.2.1.1 The ring gasket (6) is to be SCRAPPED and replaced with a NEW Wabtec Corporation Part. 7.2.2 BODY, EXHAUST CHECK, & VALVE WITH STEM 7.2.2.1 Wash the body (3), exhaust check (2), and the valve with stem (4) in a bath of the cleaning solvent as described in Section 6.0. Exercise care so that NO damage occurs to the surfaces of the parts. 7.2.2.2 After the parts are cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the parts dry. 7.2.2.3 Visually inspect the parts. Pay particular attention to the tapered surfaces of the body (3) where the exhaust

6.0

CLEANING SOLVENT, LUBRICANTS & LAPPING COMPOUND CLEANING SOLVENT

6.1

The solvent used to clean the metal parts of the "P-1" Whistle Valve MUST BE an aliphatic organic solution, such as mineral spirits or napatha, that will dissolve oil or grease and that will permit the parts to be cleaned without abrasion. 6.2 LUBRICANT

#0 Calcium Base Grease compounded with Zinc Oxide (Lubriplate #105), Wabtec Corporation Specification M7675-O, is required for the lubrication of the valve stem during the assembly procedure. 6.3 LAPPING COMPOUNDS

One of the following may be used as a lapping compound if it is necessary to lap the exhaust check to the body, or to lap the valve with stem to the body. 6.3.1 Lapping Compound #38-1200: available from the U.S. Products Co., 518 Melwood Avenue, Pittsburgh, PA 15213.

June, 1986

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4224-1.5

operation & maintenance instruction

valve check and the valve with stem seat; the tapered (rounded) surfaces of the exhaust check (2), and the tapered surfaces of the valve with stem (4). These surfaces are sealing surfaces and MUST BE free of nicks, scratches, and imperfections. Minor nicks, scratches and imperfections may be removed by "lapping" the various part(s) to its seating surface. Replace the part(s) if the imperfections cannot be "lapped out", or if any part is excessively worn, damaged in any way, or if it is in such a condition that may result in the unsatisfactory operation of the "P-1" Whistle Valve.

2

1

If "lapping" is required, the following procedure is to be used: (Figures 1 & 2)

3

4

7.2.2.3.1 Use one of the lapping compounds as listed in Section 6.3. Apply the lapping compound to the tapered surface area of the exhaust check (2) or the tapered surface area of the valve with stem (4), whichever part is being lapped, and to the respective tapered sealing (seating) surface of the body (3). 7.2.2.3.2 Install the part to be lapped, exhaust check (2), or valve with stem (4), in place in the body (3), then, using a screwdriver, lap the part to the body using a rotating motion.

5

6

IMPORTANT: Whenever parts are "lapped" together, they become a matched set or mated pair. These parts CANNOT BE separated for use in other valve assemblies without additional lapping. 7.2.2.3.3 After lapping is completed, rewash the parts in the cleaning solvent as described in Section 6.1.

7

Completely dry the parts by blowing them dry with a low pressure jet of clean, dry air. Inspect the parts. If imperfections, nicks, or scratches still are visible, repeat lapping and cleaning procedure or SCRAP and replace the part(s) with NEW Wabtec Corporation parts.

8

7.2.3

REMAINING PARTS

Figure 2 - Exploded View

7.2.3.1 Wash all remaining parts in the cleaning solvent described in Section 6.0. A clean, lint-free cloth, which has been saturated with the cleaning solvent, may be used to clean the interior surfaces of the pusher (1), and adapter nut (7).

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June, 1986

4224-1.5

operation & maintenance instruction

7.2.3.2 The spring (5) may be wire brushed to assist in the removal of any dirt, rust, or scale. 7.2.3.3 After the parts are cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry airto blow the parts dry. 7.2.3.4 Inspect the spring (5). It is to be replaced if it is rusted, pitted, distorted, damaged in any way, or if it has taken a permanent set. Refer to Parts Catalog 3224-1 for spring information and identification. 7.2.3.5 Inspect all of the remaining parts. Replace any part that is cracked, cut, broken, excessively worn, bent, damaged in any way, or that is in such a condition that may result in the unsatisfactory operation of the "P-1" Whistle Valve. 7.3 ASSEMBLY (Figure 2) 7.3.1 IMPORTANT: Before beginning the assembly procedure, visually inspect the valve with stem and the exhaust check seating surfaces of the body (3) and the tapered sealing surfaces of the valve with stem (4) and the exhaust check (2) to be sure that they are free of all imperfections, nicks and scratches. If imperfections are found in any of these parts, either replace it with a NEW part or perform the inspection and lapping procedures described in Section 7.2.2. (Figures 1 & 2) 7.3.2 Install a NEW ring gasket (6) in position on the adapter nut (7) so that the gasket seats on the body mounting sealing surface of the nut. 7.3.3 Install the exhaust check (2) into the body (3), tapered (rounded) end first. 7.3.4 Lightly lubricate the stem of the valve and stem (4) with a small amount of #0 Calcium Base Grease compounded with Zinc Oxide, Wabtec Corporation Specification M-7650O. Install the valve with stem (4) into the top of the body (3) stem end first through the adapter nut end of the body and into the cavity in the end of the exhaust check (2). 7.3.5 Place the spring (5) on its seat on the valve with stem (4) and secure it in place by installing the adapter nut with gasket assembly (6,7). Be sure that the spring remains properly positioned. Tighten the adapter nut with gasket to air seal. 7.3.6 Install the hex. nut (8) onto the adapter nut (7) and tighten. 7.3.7 Install the pusher (1) on the body (3) so that the open area on the side of the pusher is aligned with the pipe tap on the side of the body. 7.4 TESTING & ADDITIONAL INFORMATION

7.4.1 After the "P-1" Whistle Valve has been assembled, BUT BEFORE it is returned to service it MUST pass a series of tests following the procedures of the current issue of the Wabtec Corporation Test Specification T-4008-O. Check the test specification procedures concerning specific part numbers. 7.4.2 IMPORTANT: Whenever the "P-1" Whistle Valve is removed from an equipment arrangement for any reason and it is reinstalled or replaced with a NEW or repaired and tested "P-1" Whistle Valve a stationary vehicle test MUST BE performed to be sure that the "P-1" Whistle Valve functions properly in the equipment arrangement. 7.4.3 Consult your Wabtec Corporation Representative if additional information is required.

June, 1986

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4224-1.5

operation & maintenance instruction

WABCO Locomotive Products

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

www.wabtec.com

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June, 1986

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