P-1 LOAD PROPORTIONAL VALVE, (60%), Pc.No

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1 P-1 LOAD PROPORTIONAL VALVE, (60%), Pc.No DECEMBER, 1988 Supersedes issue dated November, 1976 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. 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 WABCO Freight Car Products. A Wabtec Company. All rights reserved December, 1988 Page 1 of 8

2 Piston Spring Diaphragm-Piston Assembly Check Valve Check Valve Spring Figure 2 - Assembly View (Partial) 1.0 DESCRIPTION The P-1 Load Proportional Valve, Pc.No consists of a Pipe Bracket, Pc.No , and a P-1 Load Proportional Valve Portion, Pc.No The P-1 Load Proportional Valve Portion is mounted on the Pipe Bracket in such a manner that it can be removed for servicing or maintenance without disturbing the piping of the equipment arrangement. The Pipe Bracket is designed to be semipermanently attached to the vehicle and all pipe connections are made directly to the body of the Bracket. The P- 1 Load Proportional Valve is a major component of the WABCO SC-1 Type Empty and Load Equipment and may be used in specific equipment arrangements where the air pressure does not exceed 150 psig. IMPORTANT: Specific installation procedures MUST BE followed when installing the P-1 Load Proportional Valve in an equipment arrangement. Consult your Wabtec Corporation Representative for information on a desired application. The P-1 Load Proportional Valve Portion, Pc.No , is a diaphragm operated, piston type valve that functions to provide an output (delivery) air pressure in proportion to the control (input) air pressure directed into it. This P-1 Load Proportional Valve Portion is designed to provide an output (delivery) pressure of approximately 60% of the control (input) pressure directed into it. As an example, if the control (input) pressure entering the Portion is 50 psig, the Portion should function to provide and out put (delivery) pressure of approximately 30 psig. 2.0 OPERATION (Figure 2) When there is no air pressure entering the P-1 Proportional Valve at control valve port 3, or brake cylinder control port 6, the force exerted by the piston spring will hold the diaphragm-piston assembly in its upward position. Cavity A and the passages above the diaphragm - piston assembly are connected to atmosphere through the equalizing volume port 8. When a brake application occurs, air, under pressure, entering the control valve port 3 is directed through the internal passages of the P-1 Load Proportional Valve into cavity B above the check valve and to the brake cylinder control port 6. Equalizing volume air pressure directed into port 8 of the P-1 Load Proportional Valve is directed through the internal valve passages and into cavity A above the diaphragm - piston assembly. When the equalizing volume pressure in cavity A builds up to a value to overcome the force exerted on the piston by the piston spring, the diaphragm - piston assembly will move downward to close off the flow of air between the control valve port 3 and the brake cylinder control port 6. Page 2 of 8 December, 1988

3 During a brake release, control volume air pressure is vented at control volume port 3. When the air pressure in cavity B above the check valve is reduced and the brake cylinder air pressure directed through port 6 into cavity C below the check valve builds up to overcome the force of the check valve spring, the check valve will be moved from its seat. This unseating of the check valve permits brake cylinder air pressure to be exhausted through port 6. Equalizing volume air pressure in cavity A and the passages above the diaphragm piston assembly is vented through port 8. When the air pressure in cavity A is reduced to a value that is less than the force exerted on the piston assembly by the piston spring, the force of the piston spring will return the piston assembly to its upmost position. 3.0 MAINTENANCE SCHEDULE IMPORTANT: The P-1 Load Proportional Valve Portion is to be removed from the equipment arrangement, taken to the shop, be completely disassembled, the parts cleaned and inspected. The Portion is to be reassembled using NEW rubber parts and other specified NEW parts, and then tested for correct operation according to the following application schedule, or more frequently if service conditions so indicate. RECOMMENDED FREQUENCY - TYPE OF APPLICATION AT LEAST ONCE EVERY Freight 144 Months 4.0 PARTS CATALOG & REPLACEMENT PARTS INFORMATION 4.1 PARTS CATALOG IMPORTANT: When ordering replacement parts for the P-1 Load Proportional Valve, Pc.No , or any of its Component Portions, refer to the current issue of the Wabtec Corporation Parts Catalog NOTE: The reference numbers used in the Parts Catalog and those used in this Publication may differ. Check the descriptive parts name to be sure that the desired part is ordered. 4.2 REPLACEMENT PARTS IMPORTANT: To obtain satisfactory operation and reliability of the P-1 Load Proportional Valve and/or its Component Portions, ONLY Wabtec Corporation replacement parts are to be used in the maintenance of the P-1 Load Proportional Valve and/or its Component Portions. 5.0 SAFETY PROCEDURES AND WARNINGS Regular owner-operating property and 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. 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. December, 1988 Page 3 of 8

4 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. An adequate support or lifting device must be available to support the Device and/or Valve Portion(s) during removal, installation and maintenance procedures. 6.0 CLEANING SOLVENT & LUBRICANT 6.1 The solvent used for cleaning reusable parts of the P- 1 Load Proportional Valve Portion MUST BE an aliphatic organic solution, such as mineral spirits or naphtha, that will dissolve oil or grease and that will permit the parts to be cleaned without abrasion. 6.2 Number 2 Silicone Grease, Wabtec Corporation Specification M , such as Dow Corning Corporation Molykote 55M, is required for the lubrication of o-rings, o- ring grooves and the bearing surface of bushings into which o-ring assemblies are installed. 7.0 ON-CAR MAINTENANCE PROCEDURES IMPORTANT: On-Car Maintenance Procedures are limited to the removal and installation of the P-1 Load Proportional Valve Portion. NO ON-CAR REPAIRS TO THE P-1 LOAD PROPORTIONAL VALVE OR ANY OF ITS COM- PONENT PORTIONS ARE PERMITTED. 7.1 PARTS REQUIRED A NEW P-1 Load Proportional Valve Portion, Pc.No , or a P-1 Load Proportional Valve Portion, Pc.No , that has been overhauled and then tested following the procedures of the current issue of the Wabtec Corporation Test Specification T-3369-O A NEW mounting (pipe bracket) gasket, Pc.No PORTION REMOVAL AND REPLACEMENT PROCEDURES IMPORTANT: ALL owner-operating safety procedures and the procedures and Warnings listed in Section 5 of this publication MUST BE adhered to IMPORTANT: ALL air supply to the P-1 Load Proportional Valve MUST BE cut off. The vehicle handbrake(s) MUST BE applied and the wheels of the vehicle chocked to prevent any unintentional vehicle movement. Suitable warning placards, indicating that work is being performed should be placed on and about the vehicle. WARNING: Failure to adhere to the preceding procedures may result in conditions leading to damage to equipment and/or possible bodily injury to workers and/ or bystanders. (Figures 1 and 3) Using a dry, clean, lint-free cloth, remove all free dirt from the exterior surfaces of the P-1 Load Proportional Valve, or blow the surfaces clean with a low pressure jet of clean, dry air Remove the two 1 /2-13 hex nuts (1) which secure the P-1 Load Proportional Valve Portion and mounting gasket to the pipe bracket (2) Remove the P-1 Load Proportional Valve Portion and the mounting gasket (4). SCRAP the mounting gasket (4) It is not necessary to remove the pipe Bracket (2) from the equipment arrangement unless it is broken or damaged. Should it be necessary to remove the pipe bracket, car builder and/or owner-operating property procedures are to be followed Visually inspect the exposed mounting surface of the pipe bracket (2) to be sure that it is clean and free of damage. Pay particular attention to the ports which should be free of dirt and restrictions. If necessary, the ports may be blown out with a low pressure jet of clean, dry air. Exercise care so that no dirt is blown into the ports or passages of the pipe bracket Remove ALL protective materials from the NEW, or overhauled and tested P-1 Load Proportional Valve Portion, Pc.No Be sure that ALL tape is removed from the pipe bracket mounting face of the body and vent (wasp excluder) of the body. Page 4 of 8 December, 1988

5 Figure 3 - Exploded View December, 1988 Page 5 of 8

6 7.2.9 Install a NEW mounting (pipe bracket) gasket (2), Pc.No , and the replacement P-1 Load Proportional Valve Portion on the pipe bracket (2) and secure the parts in place by installing two 1 /2-13 hex nuts (1). Equally tighten the nuts Provide adequate protection to prevent dirt and/or moisture from entering the removed P-1 Load Proportional Valve Portion, and transport it to the shop area for servicing IMPORTANT: Whenever the P-1 Load Proportional Valve and/or any of its Component Portions are removed from an equipment arrangement for any reason, and the Valve or Component Portion is replaced with a NEW or overhauled and tested Valve or Portion, a stationary vehicle test MUST BE performed to be sure that the P-1 Load Proportional Valve functions properly in the total equipment arrangement IMPORTANT: Remove ALL warning placards and wheel chocks before attempting to move the vehicle. 8.0 P-1 LOAD PROPORTIONAL VALVE PORTION - MAINTENANCE PROCEDURES - IN-SHOP IMPORTANT: When performing the procedures which follow, DO NOT use hard or sharp metal tools to remove the ring gasket, o-ring or the diaphragm. Exercise care so that no damage is done to metal parts. 8.1 DISASSEMBLY (Figure 3) WARNING: The piston spring (13) and check valve spring (10) may be, or will be, under tension during the procedures which follow. Exercise care so that no parts are inadvertently expelled from the sub-assemblies. Inadvertently expelled parts may possibly cause bodily injury and/or damage to equipment Carefully remove the four 3 /8-16 x 1" hex head cap screws (5) which secure the cover (6) to the body (14), then slowly remove the cover (6) Remove and SCRAP the 1 1 /8" O.D. ring gasket (7) from its groove in the cover mounting face of the body (14) Remove the diaphragm (8) from the head of the piston (12) and the body (14). SCRAP the diaphragm (8) Remove the piston with check valve sub-assembly (9 to 12) as a unit from the body (14) Carefully depress the check valve (9) and check valve spring (10) far enough into the cavity of the piston (12) so that the check valve (9) can be tilted. Be sure that the tabs of the check valve are free of the retaining lip of the piston, then remove the check valve (9) and check valve spring (10) from the cavity of the piston (12). SCRAP the check valve (9) Remove and SCRAP the 2 5 /8" O.D. o-ring (11) from its groove on the piston (12) Remove the piston spring (13) from the body (14). 8.2 CLEANING AND INSPECTING NON-REUSABLE PARTS IMPORTANT: The ring gasket (7), o-ring (11), and the diaphragm (8) ARE TO BE SCRAPPED and replaced with NEW Wabtec Corporation parts during the assembly procedure. Refer to the current issue of the Wabtec Corporation Parts Catalog for information on WABCO Rubber Parts Repair Kit(s) REUSABLE PARTS Wash ALL of the remaining parts in a bath of the cleaning solvent as described in Section 6.1. A clean, lintfree cloth which has been saturated with the cleaning solvent may be used to assist in the cleaning of the interior and exterior surfaces of the cover (6) and body (14). The springs may be wire brushed to assist in the removal of any dirt, rust, or scale 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. Be sure that the interior of the body is completely dried Inspect the springs. Replace any spring that is rusted, pitted, distorted, or that has taken a permanent set. Refer to Parts Catalog for spring information and identification Inspect the body (14) Replace the body if it is cracked, broken, damaged in any way, or if it shows signs of excessive wear. Page 6 of 8 December, 1988

7 Inspect the wasp excluder (15) of the body (14). If it is damaged in any way, or if it cannot be easily cleaned out, it is to be replaced. The wasp excluder (15) can be removed from the body (14) by inserting a small screw driver blade between the tangs of the excluder, then, using a twisting motion, turn the excluder out of the body. Press a NEW wasp excluder (15) in place Inspect the remaining parts. Replace any part that is cracked, cut, nicked, broken, excessively worn, or if the part is in such a condition that may result in the unsatisfactory operation of the P-1 Load Proportional Valve Portion. 8.3 ASSEMBLY Install the check valve spring (10) into the spring cavity of the piston (12) WARNING: During the procedure which follows, the check valve spring (10) will be placed under tension. Exercise care so that no parts are inadvertently expelled from the parts assembly. Inadvertently expelled parts may cause bodily injury and/or damage to equipment. Carefully install a NEW check valve (9) in place in the cavity of the piston (12) so that the spring guide of the check valve (9) fits inside of the spring (10). It will be necessary to tilt the check valve (9) so that the retaining tabs of the check valve clear the retaining shoulder of the piston cavity. Slowly straighten the check valve (9) and slowly release the hold until the retaining tabs on the check valve (9) contact the retaining shoulder in the cavity of the piston (12) Coat the surfaces of a NEW 2 5 /8" O.D. o-ring (11) with Number 2 Silicone Grease, Wabtec Corporation Specification M , also fill the o-ring groove on the piston (12) and lightly lubricate the bearing surfaces of the piston bushing of the body (14) with the lubricant Install the NEW, lubricated 2 5 /8" O.D. o-ring (11) into its groove on the piston (12). Any excess lubricant may be removed by wiping with a clean, dry, lint-free cloth Install the piston spring (13) into the body (14) so that spring guide in the body (14) fits inside of the spring (13) Install a NEW diaphragm (8) on the head of the piston (12) so that the raised, smaller diameter, surface of the diaphragm (8) is exposed and so that the bead of the diaphragm (8) fits into the bead groove in the cover mounting face of the body (14). Using finger pressure, carefully press the bead of the diaphragm (18) into the bead groove of the body (14) Install a NEW 1 1 /8" O.D. ring gasket (7) into its groove in the cover (6) Carefully install the cover with gasket sub-assembly (6, 7) in position on the body (14). Exercise care so that no damage is done to the diaphragm (8). Secure the cover (6) in place by installing four 3 /8-16 x 1" hex head cap screws (5). Torque the screws (5) uniformly to 19 to 21 foot-pounds. 8.4 TESTING & ADDITIONAL INFORMATION IMPORTANT: After the P-1 Load Proportional Valve Portion, Pc.No , 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 IMPORTANT: Whenever a P-1 Load Proportional Valve Portion, Pc.No , is removed from an 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 Portion and the P-1 Load Proportional Valve function properly in the total equipment arrangement IMPORTANT: Whenever a P-1 Load Proportional Valve Portion, Pc.No , is removed from an equipment arrangement for any reason, and it is reinstalled or replaced with a NEW or repaired and tested Portion, a NEW mounting gasket, Pc.No , MUST BE used. NOTE: Refer to Parts Catalog for an available Rubber Parts Kit that contains this mounting gasket Consult your Wabtec Corporation Representative if additional information is required Carefully install the piston with check valve and o-ring sub-assembly (9 to 12) as a unit in place in the body (14). BE SURE that the check valve cylinder portion of the piston (12) fits inside of the piston spring (13). December, 1988 Page 7 of 8

8 WABCO Freight Car Products 1001 Air Brake Avenue Seaman Street Wilmerding, Pennsylvania Stoney Creek, Ontario L8E 2R2 (412) Fax (412) (905) Fax (905) Page 8 of 8 December, 1988

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