Operation & Maintenance Instruction , S.9. MARCH, 2005 Supersedes issue dated March, 2003

Transcription

1 S-1 LOAD SENSOR VALVES, SUSPENSION MOUNTING - PART NO SUSPENSION MOUNTING - PART NO FLOOR MOUNTING - PART NO FLOOR MOUNTING - PART NO MARCH, 2005 Supersedes issue dated March, 2003 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 ensure that this device functions properly in the total brake equipment arrangement. (Consult your local Wabtec Corporation Representative for identity of the test specification, with latest revision date, that covers this device.) IMPORTANT: Only Wabtec Corporation 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 Page 1 of 10

2 Part Nos or Suspension Mounting 3/8 Flange Part No or Floor Mounting Figure 1 - Exterior Views Showing Floor & Suspension Mounting 1.0 DESCRIPTION Designed for use in specific equipment arrangements, where the air pressure does not exceed 150 psig, this car mounted valve functions to measure truck spring deflections between a light and loaded car, and regulates air flow to another device, such as the Wabtec Corporation P-1 Load Proportional Valve, for the purpose of providing proper braking pressures. IMPORTANT: "S-1" Load Sensor Valves, Part Nos and do NOT comply with AAR Specification S These valves are provided for replacement of existing equipment for cars ordered before July 1, 2004 and are NOT intended for new car applications. "S-1" Load Sensor Valves, Part Nos and are equipped with an empty pressure indicator and comply with AAR Specification S These valves are intended for NEW cars ordered after July 1, NOTE: The S-1 Load Sensor Valve, Part No and , are designed for floor or suspension mounting, (See Figure 1). A four digit suffix code number has been added to the basic piece number to indicate the type of mounting. Part Nos and indicates an S-1 Load Sensor designed for suspension mounting. Part Nos and indicates an S-1 Load Sensor designed for floor mounting. The four digit suffix code MUST BE included in the piece number when ordering this S-1 Load Sensor Valve. The S-1 Load Sensor Valve, Part Nos and , are comprised of a Pipe Bracket Portion, Part No ; and a S-1 Load Sensor Valve Portion, Part No The S-1 Load Sensor Valve with an empty pressure indicator, Part Nos and , are comprised of a Pipe Bracket Portion, Part No ; and a S-1 Load Sensor Valve Portion, Part No The Pipe Bracket Portion is designed to be semipermanently mounted on the rail car. The S-1 Load Sensor Valve Portion is mounted on the Pipe Bracket Portion. Two 3 /8" flanges are provided on the body of the Pipe Bracket for pipe connections. This arrangement permits the S-1 Load Sensor Valve Portion to be removed for service or maintenance without disturbing the piping of the equipment arrangement. The S-1 Load Sensor Valve Portion is designed to be mounted on a Pipe Bracket Portion or a laminated manifold. It is a diaphragm operated, spool valve piston type valve which functions to direct air flow between two devices in reference to the position (deflection) of the portion s lever arm. IMPORTANT: Specific installation procedures MUST BE followed when the S-1 Load Proportion Valve and/or the S-1 Load Proportion Valve Portion are used in an equipment arrangement. Contact your Wabtec Corporation Representative for installation procedures and specification on desired applications. Page 2 of 10

3 2.0 MAINTENANCE SCHEDULE IMPORTANT: The S-1 Load Sensor 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 3.0 PARTS CATALOG & REPLACEMENT PARTS INFORMATION 3.1 PARTS CATALOG IMPORTANT: When ordering replacement parts for the S-1 Load Sensor Valves, Part Nos , , and or any of its component portions, refer to the current issue of the Wabtec Corporation Parts Catalog , S.9. NOTE: The reference numbers used in this publication and those used in the parts catalog may differ. 3.2 REPLACEMENT PARTS IMPORTANT: To obtain satisfactory operation and reliability of the S-1 Load Sensor Valve and/or its Component Portions, ONLY Wabtec Corporation replacement parts are to be used in the maintenance of the S-1 Load Sensor Valve and/or its Component Portions. 4.0 SAFETY PROCEDURES & 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 or yourself. 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 component 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. 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. 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. Page 3 of 10

4 5.0 CLEANING SOLVENT & LUBRICANT 5.1 CLEANING SOLVENT IMPORTANT: The solvent used to clean reusable parts of the S-1 Load Sensor 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 the parts to be cleaned without abrasion. 5.2 LUBRICANT IMPORTANT: Number 2 Silicone Grease, Wabtec Corporation Specification M , such as Dow Corning Corporation Molykote 55M, MUST BE available for the lubrication of o-rings, o-ring grooves, and the bearing surfaces of bushings into which o-ring assemblies are installed. 6.0 ON-CAR MAINTENANCE PROCEDURES IMPORTANT: ON-CAR Maintenance is limited to the removal and replacement of Component Portions. NO ON- CAR repair of the valve is to be attempted. 6.1 PARTS REQUIRED A NEW S-1 Load Sensor Valve Portion, Part No or , that has been overhauled and that has been tested following the procedures of the current issue of the Wabtec Corporation Test Specification T-3366-O A NEW mounting gasket, Part No PORTION REMOVAL & INSTALLATION - ON-CAR IMPORTANT: ALL car builder and owner-operating property safety procedures and the safety procedures and warnings as listed in Section 4.0 of this publication MUST BE adhered to IMPORTANT: ALL air flow to the S-1 Load Sensor Valve MUST BE cut-off IMPORTANT: The handbrake(s) of the car MUST BE applied and the wheels of the car chocked to prevent unintentional car movement. Warning placards indicating that work is being performed are to be placed on and about the car Remove ALL free dirt from the exterior surfaces of the S-1 Load Sensor Valve by wiping with a clean, lint-free cloth or by blowing the surfaces clean with a low pressure jet of clean dry air Carefully remove the two 1 /2" x 2 1 /4" hex screws (2) which secure the S-1 Load Sensor Valve Portion and mounting gasket (3) to the Pipe Bracket Portion (1) Remove the S-1 Load Sensor Valve Portion and the mounting gasket (3) from the Pipe Bracket Portion (1). SCRAP the mounting gasket (3) Visually inspect the Pipe Bracket Portion (1). It need not be removed from the equipment arrangement unless it is damaged. If it is necessary to replace the Pipe Bracket Portion, car builder and/or owner-operating property procedures are to be followed During the inspection procedure, pay particular attention to the Load Sensor Valve Portion mounting face of the Pipe Bracket body. The surface MUST BE clean and free of cuts, scratches, nicks, and damage. The ports are to be clean and unrestricted. 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 and/or passages of the Pipe Bracket Portion Remove ALL protective materials from the surfaces of a NEW or overhauled and tested S-1 Load Sensor Valve Portion. Be sure that ALL tape is removed from the ports on the mounting face of the Portion body and from the wasp excluders of the cover and body Install a NEW mounting gasket (3), and the replacement S-1 Load Sensor Valve Portion on the Pipe Bracket Portion (1) and secure the parts in place by installing the two 1 /2 x 2 1 /4" hex screws (2). Equally tighten the screws IMPORTANT: Whenever the S-1 Load Sensor Valve Portion 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, Part No , MUST BE used. This gasket IS NOT a part of the S-1 Load Sensor Valve Portion and MUST BE ordered as an individual item IMPORTANT: Whenever the S-1 Load Sensor Valve Portion 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 S-1 Load Sensor Valve and its component portions function properly in the total equipment arrangement. NOTE: The mounting gasket, Part No , is included in the Load Sensor Valve Rubber Repair Parts Kit, Part No or See Parts Catalog , S.9 for the parts included in this kit. Page 4 of 10

5 23 Wasp Excluders Pressure Indicator for S-1 Sensor Valve Portion, Part No Orientation of Pipe Bracket for Floor Mounting Figure 2 - Assembly View Page 5 of 10

6 Provide adequate protection to prevent dirt and/or moisture from entering the ports of the removed S-1 Load Sensor Valve Portion and transport it to the shop area for service Remove all wheel chocks and warning placards before attempting to move the car. 7.0 MAINTENANCE PROCEDURES - "IN-SHOP" IMPORTANT: When performing the procedures which follow, DO NOT use hard or sharp metal tools to remove gaskets, o-rings, the dust boot, or diaphragm. Exercise care so that no damage is done to metal parts. Refer to Figure DISASSEMBLY Remove and SCRAP the two 1 /4" elastic stop nuts (6) from the two shouldered lever bolts (7) which secure the lever (8) with 3" composite sensor screw (5) subassembly to the cover (10). Remove the two bolts (7) and lever (8) with 3" composite sensor screw (5) subassembly from the cover (10) as a unit. Set this subassembly aside for later disassembly Remove the dust boot (12) from the cover (10) by first removing the dust boot clamp (11). SCRAP the dust boot IMPORTANT: When performing the procedures which follow, care MUST BE exercised to prevent the spool valve (21) from being damaged by falling or dropping from the subassembly of parts Remove the cover (10) from the body (23) by first removing the four 3 /8" x 7 /8" hex head screws (9) Carefully remove the piston - spring - spool valve subassembly (13 to 22) as a unit from the body (23). Exercise care so that the spool valve (21) does not fall or drop from the subassembly Separate the spool valve with o-rings and pin subassembly (20, 21, 22) as a unit from the piston follower (19) Remove and SCRAP the three 1 /2" O.D. o-rings (20) from spool valve (21) Remove the spring (13) from the piston rod (14) Disassemble the piston rod, piston, diaphragm follower subassembly (14 to 19) as follows: Use an open end wrench on the flats of the piston follower (19) to hold the follower. Insert a suitable metal rod through the 0.328" diameter hole in the end of the piston rod (14), then, using the rod as a handle, carefully unscrew the piston rod (14) from the piston follower (19) Remove the shim (15) from the piston rod (14) Separate the piston (16) with diaphragm (17) and the piston follower (19) Remove and SCRAP the diaphragm (17) from the piston (16) Remove and SCRAP the 1 5 /16" O.D. o-ring (18) from the piston follower (19) Using retaining ring pliers remove retaining ring (25) from body (23). WARNING: The indicator housing (26) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may do bodily injury Remove the indicator housing (26), 1" O.D. o-ring (27) and 7 /16" O.D. o-ring (28) from the body (23). Remove and SCRAP the 1" O.D. o-ring (27) and the 7 /16" O.D. o-ring (28) from the indicator housing (26). NOTE: To remove the 7 /16" O.D. o-ring (28) from the indicator housing (26) a 90 dental pick tool will be needed. The tool can be inserted directly into the o-ring and then pulled from its o-ring groove by using a turning motion. Exercise care so that no damage is done to metal surfaces Remove the indicator spring (29) and indicator piston (30) from the body (23) Remove and SCRAP the 1 1 /8" o-ring (31) from the body. NOTE: To remove the 1 1 /8" o-ring (31) from the body (23) a 90 dental pick tool will be needed. The tool can be inserted directly into the o-ring and then pulled from its o-ring groove by using a turning motion. Exercise care so that no damage is done to metal surfaces Disassemble the lever with 3" composite sensor screw subassembly (4, 5, 8) as follows. Loosen the two self-locking hex nuts (4) which secure the 3" composite sensor screw (5) to the lever (8). Remove the top hex nut (4) from the adjusting screw (5), then remove the 3" composite sensor screw and bottom lock nut subassembly (4, 5) from Page 6 of 10

7 the lever (8). Remove the 3" composite sensor screw (5). SCRAP the two self-locking nuts (4). 7.2 CLEANING & INSPECTING NON-REUSABLE PARTS IMPORTANT: ALL gaskets, o-rings, self-locking or elastic stop nuts, the diaphragm and the dust boot ARE TO BE SCRAPPED AND REPLACED WITH NEW WABTEC CORPORATION PARTS REMAINING PARTS Wash ALL of the remaining parts in a bath of the cleaning solvent as described in Section 5.1. A clean, lint-free cloth, that has been saturated with the prescribed cleaning solvent, may be used to assist in the cleaning of the interior and exterior surfaces of the body and cover 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 Inspect the body The spool valve bushing of the body (23) MUST BE FREE OF RUST, SCORE MARKS, SCRATCHES AND/OR NICKS. If this bushing is damaged in any way, or shows signs of excessive wear, the body is to be replaced Be sure that the wasp excluder of the body (23) is clean and free of damage. If this excluder cannot be easily cleaned, or if it is damaged in any way, it is to be removed and replaced with a NEW wasp excluder, Part No The wasp excluder can be removed from the body by inserting the blade of a small screwdriver between the tangs of the wasp excluder and then turning the excluder from the body with a twisting motion. Press the NEW wasp excluder in place For "S-1" Load Sensor Valves, Part Nos and be sure that the 1 /4" pipe plug (24) is tight and securely in place in the body (23) Inspect the cover (10) Replace the cover (10) if it is cracked, cut, broken, shows signs of excessive wear, damaged in any way, or if it is in such a condition that may result in the unsatisfactory operation of the S-1 Load Sensor Valve Portion Be sure that the wasp excluder of the cover (10) is clean and free of damage. If this excluder cannot be easily cleaned, or if it is damaged in any way, it is to be removed and replaced with a NEW wasp excluder, Part No The wasp excluder can be removed from the cover by inserting the blade of a small screwdriver between the tangs of the wasp excluder and then turning the excluder from the cover with a twisting motion. Press the NEW wasp excluder in place Inspect the spool valve (21) Replace the spool valve if it is nicked, bent, cut, broken, shows signs of excessive wear, damaged in any way, or if it is in such a condition that may result in the unsatisfactory operation of the S-1 Load Sensor Valve Portion If the cylindrical spring pin (22) is bent, loose, or damaged in any way, it is to be replaced. Using the proper tools, remove the pin (22) by drifting it from the spool valve. Carefully install a NEW 1 /8" x 1 1 /8" cylindrical spring pin (22) in place. Exercise care so that no damage is done to the spool valve (21) Inspect ALL of the remaining parts Replace any part that is cracked, cut, nicked, broken, excessively worn, damaged in any way, or that is in such a condition that may result in the unsatisfactory operation of the S-1 Load Sensor Valve Portion. 7.3 ASSEMBLY Place a NEW diaphragm (17) in position on the piston follower (19) so that the part number side of the diaphragm (17) is facing away from the follower (19), then install piston (16) on the follower (19) so that the raised ridge on the head of the piston (16) contacts the part numbered side of the diaphragm (17) Install the shim (15) onto the threaded end of the piston rod (14), then install the piston rod (14) through the opening in the piston (16) and into the piston follower (19). Secure the piston rod (14) in place by tightening to 10 to 14 footpounds torque. Use a wrench on the flats of the piston follower (19) and a suitable metal rod inserted through the 0.328" diameter hole in the end of the piston rod (14) to assist in tightening the piston rod Coat the surfaces of three NEW 1 /2" O.D. o-rings (20) and the surfaces of a NEW 1 5 /16" O.D. o-ring (18) with Number 2 Silicone Grease, Wabtec Corporation Page 7 of 10

8 Specification M Also fill the o-ring grooves of the spool valve (21) and the o-ring groove of the piston follower (19) with the lubricant. Apply a light coating of the lubricant to the bearing surfaces of the spool valve and piston follower bushing of the body (23) Install the NEW, lubricated 1 5 /16" O.D. o-ring (18) into its groove on the piston follower (19). Any excess lubricant may be removed by wiping with a clean, dry, lint-free cloth Install a NEW lubricated 1 /2" O.D. o-ring (20) into each of the o-ring grooves of the spool valve (21). Any excess lubricant may be removed by wiping with a clean, dry, lintfree cloth Position the spool valve with o-rings and cylindrical spring pin subassembly (20, 21, 22) in place in the piston follower (19) so that the ends of the cylindrical spring pin (22) fit into the slots of the piston follower (19) Carefully install the spool valve - piston follower - piston - piston rod subassembly (14 to 22) as a unit into the body (23). Be sure that the 0.328" hole in the end of the piston rod (14) is perpendicular to the pipe bracket mounting face of the body (23). Using finger pressure, secure the bead of the diaphragm (17) in place on the cover mounting face of the body (23) Install the piston spring (13) over the piston rod (14) and shim (15) so that it seats on the piston (16) Position the cover (10) so that the wasp excluder is on the same side as the wasp excluder of the body (23), then install the cover (10) on the body (23) and secure it in place by installing four 3 /8" x 7 /8" hex screws (9). Equally tighten the screws (9) by torquing to 18 to 22 foot-pounds Install a NEW dust boot (12) over the end of the piston rod (14) and on the cover (10). Secure the dust boot (12) in place by installing the boot clamp (11) Carefully position the lever (8) so that the lower holes of the lever are aligned with the hole in the end of the piston rod (14). Install a shouldered lever bolt (7) through the aligned holes so that the head of the bolt (7) is on the same side of the cover (10) as the pipe bracket mounting face of the body (23). Secure the bolt (7) in place by installing a NEW 1 /4" elastic stop nut (6) Install a NEW 7 /16" self-locking hex nut (4) on the adjusting screw (5) being sure that the nut (4) is positioned toward the head end of the adjusting screw (5). Insert the adjusting screw (5) through the bottom of the lever (8) and then install a second NEW 7 /16" self-locking nut (4) Coat the surface of the NEW 1 1 /8" O.D. o-ring (31) with Number 2 Silicone Grease, Wabtec Corporation Specification M Also fill the o-ring groove of the indicator bore with lubricant Install the NEW lubricated 1 1 /8" O.D. o-ring (31) into the indicator bore of the body (23). make sure that the o- ring is correctly positioned into the o-ring groove Apply a light coating of the lubricant to the two bearing surfaces of the indicator piston (30) Install the indicator piston (30) and indicator spring (29) into the indicator bore of the body (23) Coat the surface of the 1" O.D. o-ring (27) and the surface of the NEW 7 /16" O.D. o-ring (28) with Number 2 Silicone Grease Wabtec Specification M Also fill the two o-ring grooves of the indicator housing with lubricant Install the NEW lubricated 1" o-ring (27) and NEW 7 /16" O.D. o-ring (28) into each of the o-ring grooves on the indicator housing (26). Apply a light coating of the lubricant to the bearing surface of the indicator bore of the body (23) Install the indicator housing (26) with o-rings into the indicator bore of the body (23). Make sure the 1" O.D. o-ring (27) does not pinch on the body when inserting into the bore. Using retaining ring pliers install retaining ring (25) into the retaining ring groove in the body (23). Any excess lubricant may be removed by wiping with a clean, dry, lintfree cloth IMPORTANT: Position the adjusting screw (5) in the lever (8) and tighten the two 7 /16" self-locking nuts (4) so that the lever (8) is at the approximate midpoint of screw (5) Align the top holes of the lever (8) with hole of the cover (10), then install a shouldered lever bolt (7) through the aligned holes and secure it in place by installing a NEW 1 /4" elastic stop nut (6). Page 8 of 10

9 8.0 TESTING & ADDITIONAL INFORMATION 8.1 IMPORTANT: After the S-1 Load Sensor Portion, Part Nos or 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-3366-O. 8.2 IMPORTANT: Whenever an S-1 Load Sensor Valve Portion 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, Part No , MUST BE used. This gasket IS NOT a part of the S-1 Load Sensor Valve Portion but it is part of the Repair Rubber Kit, Part No IMPORTANT: Whenever an S-1 Load Sensor Portion 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 S-1 Load Sensor Portion, Part Nos or and the S-1 Load Sensor Valve Part No , , or , function properly in the total equipment arrangement. 8.4 Consult your Wabtec Corporation Representative if additional information is required. Page 9 of 10

10 WABCO Freight Car Products 1001 Air Brake Avenue Seaman Street Wilmerding, Pennsylvania Stoney Creek, Ontario L8E 2R2 (412) Fax (412) (905) Fax (905) Page 10 of 10