J-1 RELAY VALVE, Part No J-1 RELAY VALVE PORTION, Part No

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1 J-1 RELAY VALVE, Part No J-1 RELAY VALVE PORTION, Part No (Single Diaphragm Type) NOVEMBER, 1984 Supersedes issue dated November, 1981 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 non- O.E.M. parts are unacceptable. "J-1" Relay Valve Portion Mounting Bracket /2 NPT EX SAP 16 1" Flange with /2 NPT MR 6 BC 30 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. Pipe Bracket Portion 1/2" Flange with 1/2-14 NPT 2000 WABCO Locomotive Products. A Wabtec Company. All rights reserved Page 1 of 8 November, 1984

2 1.2 J-1 RELAY VALVE PORTION, Pc.No EX. 16 Check Valve Piston Stem "B" The J-1 Relay Valve Portion, Pc.No , is a diaphragm operated self-lapping valve that functions to direct air to or exhaust air from the brake cylinder pipe in accordance with a brake cylinder control pressure during the operation of air brake equipment. This Portion is designed to be mounted to a manifold or a pipe bracket in such a way that it can be removed for servicing or maintenance without disturbing the equipment piping. It is often used as component of a WABCO Pneumatic Operating Unit or a SERVOTROL Control Unit. Consult your Wabtec Corporation representative for specific application information. 2.0 OPERATION (Figure 2) 1.0 DESCRIPTION "A" LEGEND 6 Supply 30 Brake Cylinder Pipe 16 Brake Cylinder Control Ex. Exhaust 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 - Diagrammatic View Diaphragm 1.1 J-1 RELAY VALVE, Pc.No (Figure 1) This J-1 Relay Valve, which is designed for use in equipment arrangements where the air pressure does not exceed 150 psig, is comprised of a J-1 Relay Valve Portion, Pc.No ; a Pipe Bracket Portion, Pc.No ; a Right Hand Mounting Bracket Pc.No and a Left Hand Mounting Bracket Pc.No The Mounting Brackets are designed so that they can be used for either floor or suspension mounting of the Relay Valve. These Brackets are semi-permanently attached to the car piping and to the Pipe Bracket Portion. The Pipe Bracket Portion is used to provide an interface between the J-1 Relay Valve Portion and the car piping. A four digit suffix code number has been added to the assembly piece number to indicate suspension or floor mounting. Pc.No indicates a J-1 Relay Valve arranged for suspension mounting. Pc.No indicates a J-1 Relay Valve arranged for floor mounting. November, 1984 Page 2 of 8 A controlled air pressure build-up in passage 16 results in a corresponding build-up in pressure on the relay valve diaphragm in chamber A which causes a movement of the diaphragm assembly and piston stem. The piston stem is forced to close against the check valve which blanks off passage 30 (brake cylinder) from exhaust. The check valve is then lifted from its seat by the piston stem permitting supply air (passage 6) to flow into passage 30 that is connected to the brake cylinder pipe. Passage 30 is also connected to chamber B on the spring side of the diaphragm. The build-up of air at brake cylinder pipe pressure in chamber B along with the spring force oppose the movement of the diaphragm assembly initiated by the controlled air pressure admitted into passage 16. An equalization of forces across the diaphragm positions the diaphragm assembly to allow the check valve to seat and remain in a lap position. The maintaining feature of the relay valve portion will function if pressure fluctuates in the brake cylinder pipe. If the pressure in passage 30 as well as the pressure in chamber B drops, the piston stem will move to open the check valve. Supply air will then flow into passage 30 as well as chamber B until an equalization of forces across the diaphragm is reached. The diaphragm assembly is then positioned to permit the valve to reassume a lap position. A decrease of air pressure in passage 16 (brake cylinder control) results in a corresponding decrease in pressure in the relay valve diaphragm chamber A which causes a movement of the diaphragm assembly and piston stem. The piston stem is forced to unseat from the check valve, permitting air at brake cylinder pipe pressure (passage 30) to flow to atmosphere at the exhaust port. A graduated release of brake cylinder air out of passage 30 can be obtained if the control pressure in passage 16 is intermittently depleted. When an equalization of forces exists across the diaphragm, the valve will again assume a lap position. The

3 amount of air pressure available for braking is a function of the pressure in chamber A. 3.0 MAINTENANCE SCHEDULE IMPORTANT: The J-1 Relay Valve Portion should be removed from the equipment arrangement, taken to the shop, be thoroughly disassembled, the parts cleaned, inspected, lubricated, assembled and the Portion tested according to the following vehicle application schedule or more frequently if service conditions so indicate. RECOMMENDED FREQUENCY - TYPE OF APPLICATION AT LEAST ONCE EVERY Locomotive Freight Cars Transit Passenger (Interstate) 12 Months 144 Months 24 Months 36 Months 4.0 PARTS CATALOG & RUBBER PARTS KIT INFORMATION 4.1 When ordering replacement parts for the J-1 Relay Valve, Pc.No or for the J-1 Relay Valve Portion Pc.No refer to the Wabtec Corporation Parts Catalog In some cases the J-1 Relay Valve Portion may also be shown in the Operating Unit or SERVOTROL Control Unit Parts Catalog of which the Portion is a component. NOTE: The reference numbers listed in this publication and those listed in the Parts Catalog(s) may differ. Check the descriptive parts name to be sure that the desired part is ordered. 4.2 A Rubber Parts Maintenance Kit for this J-1 Relay Valve Portion may be obtained by ordering Pc.No Check Parts Catalog to identify parts included in this Kit. 5.0 SAFETY PROCEDURES AND WARNINGS Regular owner-operating property and shop safety procedures MUST BE followed when working on the J-1 Relay Valve or Valve Portion. 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. 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. Page 3 of 8 November, 1984

4 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. An adequate support or lifting device must be available to support the Device and/or Valve Portion(s) during removal, installation and maintenance procedures. 4A 4C 4 18C 4B CLEANING SOLVENT & LUBRICANT 6.1 The solvent used for cleaning the metal parts of the Relay Valve and Relay Valve Portion 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 cleaned without abrasion B 18A 6.2 #2 Silicone Grease, Wabtec Corporation Specification M , is required for lubrication of all o-rings, o-ring grooves and the bearing surface of the bushings into which o-ring assemblies are installed. 6.3 A compound consisting of one part graphite, Wabtec Corporation Specification M (AAR Specification M- 913) and two parts of SAE-20 oil by weight is to be used to coat the threads of the choke plug after the plug has been cleaned REMOVAL & REPLACEMENT OF THE J-1 RELAY VALVE PORTION- ON-CAR The repair person will require a NEW or repaired and tested J-1 Relay Valve Portion, Pc.No , a NEW mounting or pipe bracket gasket Pc.No if the Portion is being used as a component of the J-1 Relay Valve, Pc.No , a NEW mounting or manifold gasket Pc.No when the Portion is being used as a component of a Pneumatic Operating Unit or SERVOTROL Control Unit, and four NEW 5 /8" self-locking nuts Pc.No All safety procedures and warnings listed in Section 5.0 MUST BE followed. 7.3 Remove and SCRAP the self-locking nuts which secure the Relay Valve Portion to the Pipe Bracket or Manifold. Figure 3 - Exploded View 7 (Figure 3) 7.4 Remove and SCRAP the mounting or pipe bracket gasket (19). November, 1984 Page 4 of 8

5 7.5 Visually inspect the mounting surface of the Pipe Bracket or Manifold to see that it is clean. Be sure that the ports are clean and unrestricted. 7.6 Remove all protective material from the NEW J-1 Relay Valve Portion. 7.7 Install a NEW mounting or pipe bracket gasket (19) in place on the manifold or pipe bracket so that the Wabtec part number on the gasket will be against the mounting face of the Relay Valve Portion. 7.8 Install the Relay Valve Portion in position on the pipe bracket or manifold and secure it in place using four NEW 5 /8" self-locking nuts Pc.No Equally tighten the nuts. 7.9 Provide adequate protection for the removed Relay Valve Portion so that dirt and/or moisture is prevented from entering the body and transport it to the shop area for maintenance IMPORTANT: Whenever a J-1 Relay Valve Portion is removed from an equipment arrangement for any reason and it is re-installed 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 functions properly in the equipment arrangement. 8.0 MAINTENANCE PROCEDURES - IN SHOP (Figure 3) 8.1 DISASSEMBLY NOTE: DO NOT use any hard or sharp metal tools to remove gaskets, o-rings, or the diaphragm. Care MUST BE exercised so that no damage is done to metal parts. The carrier spring (3) and piston spring (13) may be under tension. Exercise care during the procedures which follow so that no injury is caused by inadvertantly expelled parts Remove the three 3 /8" x 1" hex head cap screws (1) which secure the check valve cover (2) to the body (18). Then remove the cover (2) Remove the carrier spring (3) from the check valve and carrier assembly (4) Remove the check valve and carrier assembly (4) from the body (18) Remove and SCRAP the 1 1 /8" O.D. o-ring (5) from the carrier (4C) Remove the 1 /8" x 15 /16" cylindrical roll pin (4A) which secures the check valve (4B) to the carrier (4C), then remove and SCRAP the check valve (4B) Remove and SCRAP the cover gasket (6) Carefully remove the five 1 /2" x 1 3 /4" hex head cap screws (7) which secure the bottom diaphragm cover (8) to the body (18) Remove the bottom cover (8) Remove the diaphragm-piston assembly (9 to 12, 14, 15, 16) as a unit and the piston return spring (13) from the body (18) Disassemble the diaphragm-piston assembly as follows: Remove and SCRAP the two 1 1 /8" O.D. o-rings (15) from the piston stem (16) Hold the piston stem with an open end wrench, then remove the 3 /4" self-locking hex nut (9), follower (10), diaphragm (11), and piston head (12). Remove the 7 /8" O.D. o-ring (14) from the piston stem (16). SCRAP the self-locking nut (9), diaphragm (11) and o-ring (14) Remove and SCRAP the three 3 /4" O.D. ring gaskets (17) from the bottom cover mounting face of the body (18). 8.2 CLEANING & INSPECTING NON-REUSABLE PARTS ALL o-rings, gaskets, self-locking or elastic stop nuts, the diaphragm and the check valve MUST BE SCRAPPED and replaced with NEW Wabtec Corporation Parts BODY Remove the 1 /4" choke plug (18A) from the mounting face of the body and place it in a bath of the cleaning solvent described in Section 6.1 to soak Wash the body (18) using the prescribed cleaning solvent, Section 6.1. A clean lint-free cloth which has Page 5 of 8 November, 1984

6 been saturated with the cleaning solvent may be used to clean the interior surfaces of the body After the body is cleaned, it MUST BE completely dried. Use a low pressure jet of clean dry air to blow the body dry. Inspect the body. If it is damaged in any way or there are signs of excessive wear the body is to be replaced. Be sure that all passages are clear, dry and unrestricted Remove the choke plug (18A) from the solvent bath and blow it dry using a low pressure jet of clean, dry air Inspect the choke plug to see that the orifice is clear and unrestricted. DO NOT use metal tools to clean the choke as its size (7/ 64" drill) and shape MUST NOT be changed. If the size of the choke or shape has changed or if the choke plug is damaged in any way it MUST BE replaced Using the graphite and oil compound, as described in Section 6.3, lightly coat the threads of the choke plug (18A). Install the choke plug (18A) in place in the body (18) so that the plug (18A) is flush or below the pipe bracket mounting face of the body (18) REMAINING PARTS Wash all of the remaining parts in the prescribed cleaning solvent, Sectuion 6.1. Springs may be wire brushed to assist in the removal of any dirt, rust, or scale After cleaning, blow all of the parts dry with a low pressure jet of clean, dry air Inspect the parts. Replace any spring that is rusted, distorted, pitted or if it has taken a permanent set. Refer to Parts Catalog for spring identification and information. Replace any cylindrical spring (roll) pin that is broken or not elastic enough to hold securely. Replace any part that is cracked, broken, cut, damaged in any way, worn excessively, or that is in such a condition that may result in unsatisfactory operation of the Relay Valve Portion. 8.3 ASSEMBLY (Figure 3) Install the piston return spring (13) in place in the body (18) Insert three NEW 3/4" O.D. ring gaskets (17) into the grooves in bottom cover mounting face of the body (18) Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of two NEW 1-1/8" O.D. o-rings (15) and a NEW 7/8" O.D. o-ring (14). Also fill the o-ring grooves of the piston stem (16) and lightly lubricate the bearing surfaces of the bushings in the body (18) with the lubricant Install the two NEW lubricated 1-1/8" O.D. o-rings (15) into their grooves on the piston stem (16). Install the NEW lubricated 7/8" O.D. o-ring (14) into its groove on the threaded end of the piston stem (16). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth Place the piston head (12) on the piston stem (16) with the diaphragm bead groove of the piston head in the direction of the nut end of the stem (16) Place a NEW diaphragm (11) on the piston head (12) so that the small diameter bead fits into the groove on the piston head (12) Place the diaphragm follower (10) on the piston stem (16) with the flat (smooth) side of the follower (10) facing the diaphragm (11) and secure it in place with a NEW 3/4" self-locking nut (9). Using an open end wrench to hold the piston stem (16) tighten the nut (9) to a torque value of 60 to 65 foot-pounds. IMPORTANT: The nut (9) used MUST BE Wabtec Corporation Part Number NO OTHER nut is to be used Install the diaphragm-piston assembly (9 to 12, 14, 15, 16) into the body (18). Be sure that the large diameter bead of the diaphragm (11) fits into the groove in the bottom cover mounting face of the body (18). November, 1984 Page 6 of 8

7 8.3.9 Place the bottom diaphragm cover (8) in position on the body (18) and secure it in place by installing five 1/2" x 1 3 /4" hex head cap screws (7). Equally tighten the screws Position a NEW check valve (4B) on the check valve carrier (4C) and secure the parts together using the 1 /8" x 15 /16" roll pin (4A) Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of a NEW 1 1 /8" O.D. o-ring (5). Also fill the o-ring groove of the carrier (4C) with the lubricant Install the NEW lubricated 1 1 /8" O.D. o-ring (5) into the groove of the carrier (4C). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth Place a NEW cover gasket (6) on the top cover mounting face of the body (18). Be sure the gasket is properly positioned Place the check valve and carrier assembly (4) into the body (18) Insert the carrier spring (3) into the check valve carrier (4C) Place the top check valve cover (2) on the body (18) and secure it in place with three 3/8" x 1" hex head cap screws (1). Equally tighten the screws. 9.0 TESTING & ADDITIONAL INFORMATION 9.1 After the J-1 Relay Valve Portion, Pc.No 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 one of the following Wabtec Corporation Test Specifications. T for use with the AB Test Rack. T-2332-O for use with the 4D Test Rack. T-2381-O for use with the 4C Test Rack. Check the various Test Specification for specific piece number. 9.2 Refer to Sections 7.6 through 7.10 for installation information. 9.3 IMPORTANT: Whenever a J-1 Relay Valve Portion is removed from an equipment arrangement for any reason and it is re-installed 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 functions properly in the equipment arrangement. 9.4 Consult your Wabtec Corporation Representative if additional information is required. Page 7 of 8 November, 1984

8 WABCO Locomotive Products 1001 Air Brake Avenue Wilmerding, PA (412) Fax (412) November, 1984 Page 8 of 8