Freight Air Brake Control Valve Portions: ABDX, ABDXL, ABDX-R, ABDXL-R

Transcription

1 SHOP MAINTENANCE 2391, S.4 MARCH, 2007 (SUPERCEDES ALL PREVIOUS ISSUES OF 2391, S.4 & S-4018 AND COMPLIES WITH AAR CIRCULAR LETTER C FOR VIBRATION PROTECTION UPGRADES DURING COT-S) Freight Air Brake Control Valve Portions: ABDX, ABDXL, ABDX-R, ABDXL-R F070327A 2004 WABCO Freight Car Products, A Wabtec Corporation

2 TABLE OF CONTENTS 1.0 GENERAL GENERAL PROCEDURES CLEANING SOLVENTS, LUBRICANTS, AND SEALANTS RUBBER CHOKES SPRINGS ABDX, ABDX-R SERVICE PORTION DISASSEMBLY ABDX, ABDX-R SERVICE PORTION ASSEMBLY ABDX, ABDX-R, ABDXL, ABDXL-R EMERGENCY PORTION DISASSEMBLY ABDX, ABDX-R, ABDXL, ABDXL-R EMERGENCY PORTION ASSEMBLY TESTING PROCEDURES SHIPPING REQUIREMENTS EXPLODED VIEWS SPECIAL TOOLS APPENDIX...48 Service Bulletin 68-19: New Quick Service Limiting Valve Details Service Bulletin 68-22: New Emergency Accelerated Release "E.A.R." Filter Details Service Bulletin 68-26: Lubrication of AB Type Service & Emergency Portions Page 2 of 61

3 Figure 1 ABDX Emergency Portion Figure 2 ABDXL Emergency Portion Page 3 of 61

4 NOTE: Metal identification P tags no longer required after April 1, 2007 Figure 3 ABDX-R Control Valve SR designates Remanufactured Short Car P designates Vibration Protection LR designates Remanufactured Long Car XR designates Converted ABD to ABDX (Remanufactured ABDX) NOTE: Metal identification P tags no longer required after April 1, 2007 Figure 4 ABDXL-R Control Valve Page 4 of 61

5 1.0 GENERAL 1.1 The purpose of this manual is to describe appropriate shop procedures to be followed by maintainers of these control valve portions and to avoid unnecessary expense due to careless handling of parts. For example, it is readily possible to assemble or dismantle all parts of the valve. If excessive force is required, investigation must be made immediately as to the cause of the difficulty. 1.2 The ABDX Type Control Valve is composed of a pipe bracket and two primary operating portions. Pipe connections are semi-permanently made to the pipe bracket, which is bolted to the car body. The service and emergency operating portions, which are bolted to the pipe bracket, are to be removed from the pipe bracket when cleaning brakes on a repair track environment and must be replaced by operating portions that are new or have been repaired, cleaned and tested satisfactory as per Wabtec Corporation recommendations. 1.3 When the car brake equipment is maintained or tested at repair track facilities, the instructions for cleaning, gaging, and testing ABDX Type Control Valves as contained in the current issues of Instruction Manual 2391, S.5, and the Code of Air Brake System Tests for Freight Equipment, AAR Standard S-486 (latest revision) must be followed. IMPORTANT: The ABDX Type Control Valve operating portions and the associated air brake devices on the freight car are to be removed from the equipment arrangement, taken to the shop, be completely disassembled, all rubber parts replaced with new Wabtec Corporation supplied material, the parts cleaned, inspected, repaired, lubricated, assembled and tested for correct operation, in accordance with Wabtec Corporation recommendation for each device at least once every 144 months, or more frequently if service conditions so indicate. 1.4 The ABDX Type Control Valve Portion Identifications are shown in Figures 1, 2, 3 and 4, pages 3 and 4. Note that after April 1, 2007, metal identification P tags will no longer be required to be put back on valve portions. 1.5 The ABDX and ABDX-R Emergency Portions are tuned to optimize the accelerated application feature on short cars with less than 75 feet of brake pipe. The ABDXL and ABDXL-R Emergency Portions are tuned to optimize the accelerated application feature on long cars with more than 75 feet of brake pipe. 1.6 In order to preclude the misapplication of operating valve portions, the ABDXL and ABDXL-R Pipe Brackets have one slightly longer mounting stud than the ABDX and ABDX-R Pipe Brackets. This special stud located on the emergency side of the pipe bracket near the bottom, is intended to prevent a long car valve portion from being mounted to a short car. 2.0 GENERAL PROCEDURES 2.1 All disassembly, cleaning, lubricating and assembly of the valve portion parts must be done at a suitable bench in a clean, well lit location at an AAR approved facility. 2.2 The operating portions must be completely dismantled and all parts inspected and cleaned. Parts, including the body interior, must be cleaned by an approved method that will dissolve oil and grease without damage to the parts. The body must not be submerged in a solution. A wire brush may be used to assist in the removal of any light surface dirt, rust or scale on cast parts. The exterior of the body must be thoroughly cleaned. 2.3 When dismantling and assembling the operating portions, care must be exercised to avoid distortion of bolts, studs, nuts, etc. This can best be done by using tools especially adapted for this work. Special tools are shown in Section 14.0, page 45. However, other designs may be found acceptable to the user. Page 5 of 61

6 Similar care must be taken to avoid mutilation or damage to pistons, springs, rubber parts, slide valves, graduating valves, etc. when assembling the valves. 2.4 All pistons, slide valves, graduating valves and bushings must be thoroughly cleaned. To do this, the piston, slide valve and graduating valve assembly must be dismantled. 2.5 DO NOT use hard or sharp metal tools to remove or install o-rings, seals, gaskets, or diaphragms. Exercise care so that NO damage is done to all metal surfaces and plastic parts. 2.6 Precaution must be used to protect against contamination from dirt and other foreign matter that would cause damage to o-rings and lubricant. 2.7 Where a multiple o-ring arrangement is used, a thin wall type mandrel may be used to insert the o-ring into its groove to minimize possible damage if the o-ring is pushed over an adjacent groove. Figure 17, page 45, illustrates a typical design. The supply of o-rings kept on the mandrel must not exceed daily requirements to prevent permanent stretch. 2.8 Before reassembly, the slide and graduating valves must be gaged after lapping. The body plug gages must be available and used prior to reassembly. The current issue of Instruction Manual , Sup. 1, AAR Standard S-480, describes gages to be used. 2.9 When reassembling valve portions, it is important that cap screws and nuts are tightened sufficiently to prevent gasket leakage and yet not excessively to cause distortion of covers and gaskets. 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. Wabtec Corporation shall not support the performance of portions containing parts supplied by others. NOTE: Replacement part piece numbers are identified in Wabtec Corporation issued parts catalogs. Contact your local Wabtec Corporation Representative or Marketing Headquarters in Wilmerding, PA for the appropriate documents Cleaned and repaired service and emergency operating portions must pass prescribed tests on the AAR standard test rack or AAR approved automated test rack in accordance with the Code of Tests contained in the current issue of Wabtec Corporation Instruction Manual No , Sup. 2, AAR Standard S Safety Procedures and Warnings: General shop safety procedures must be followed when performing these specification instructions. The following statements of warning apply all or in part wherever the maintenance procedures. symbol appears in the Failure to observe these precautions may result in serious injury to those performing the work and/or the bystanders. The work area should be clean and free of debris. Cast iron portions weigh in excess of 50 pounds. Use care when lifting and hauling portions to preclude injury. Page 6 of 61

7 Wabtec recommends that sufficient hearing and eye protection be used by the individual(s) or others nearby the work area when performing any work on the equipment to avoid possible injury to both ears and eyes. The use of an air jet, which must be less than 30 psi, to blow parts clean or to blow them dry after being cleaned will cause particles of dirt, contaminants and/or droplets of the cleaning liquid to be air borne. These conditions may cause skin and/or eye irritation. Avoid direct contact with this air stream or possible flying debris. When using an air jet do not direct it toward another person. Improper use of the air jet could result in bodily injury. When handling valve portions, care must be taken to prevent the portion from falling which could result in portion damage and/or injury to personnel. 3.0 CLEANING SOLVENTS, LUBRICANTS, AND SEALANTS 3.1 Cleaning Solvents The means used to clean the reusable parts of the ABDX Type Control Valves MUST BE an aliphatic hydrocarbon solvent, such as mineral spirits or naphtha, or a heated aqueous biodegradable detergent and recommended rinse. Exposure of all re-usable plastic components should be limited as follows: Aliphatic hydrocarbon solvent 20 minutes maximum exposure at room temperature, wipe or blow dry. Heated aqueous biodegradable detergent 15 minutes maximum exposure, solution temperature 160 F (71.1 C) maximum, solution ph 5 to 10, wipe or blow dry after rinsing. IMPORTANT: Cleaning materials are to be used in a well ventilated area. 3.2 Lubricants Air brake shop containers with known approved AAR lubricants must be appropriately stenciled with AAR specification identification. Lubricant Current AAR Specification Triple Valve Oil M-912* Dry Graphite M-913 Brake Cylinder Lubricant M-914 *NOTE: Refer to Service Bulletin in the Appendix on Page Wabtec recommends using a clean foam-tipped swab applicator to evenly spread Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on all parts required to have this specific type of lubricant The o-ring, o-ring grooves and the o-ring bearing surfaces of the bushing(s) must be lubricated with # 2 Silicone Grease, Wabtec Corporation Specification M (Industry Designation MIL-G-4343), Page 7 of 61

8 such as Dow Corning Corporation, Molykote 55. Wabtec recommends using a clean foam-tipped swab applicator to evenly spread #2 Silicone Grease, Wabtec Corporation Specification M (Industry Designation MIL-G-4343), such as Molykote 55, on all pistons, spool valves, and bushing bearing surfaces required to have this specific type of lubricant As a minimum guideline, the threads of solid choke plugs and all other removable plugs, as well as other threaded parts which may later be difficult to remove, must be pre-coated with Loctite product called Vibraseal #517, Wabtec Specification M , or with brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight, or anti-seize compounds such as lithium or graphite based greases, such as Wabtec Specification M , unless otherwise specified. If additional sealing capability is needed, application of a standard commercially available non-curing pipe sealant to the threads is recommended. Teflon ribbon or tape should not be used on any chokes or removable plugs. All solid choke plugs are to be secured in place to prevent leakage; however, discretion should be used when tightening the choke plug, to facilitate removal As a minimum guideline, the threads of all brass chokes in the control valve body must be pre-coated with brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight, or anti-seize compounds such as lithium or graphite based greases, such as Wabtec Specification M , unless otherwise specified. Teflon ribbon or tape should not be used on any chokes. 3.3 Sealants Locking Sealant, Wabtec Corporation Specification M , such as Loctite Corporation TL-242, is required for application to certain threads. 4.0 RUBBER 4.1 All rubber parts must be renewed at the time of reconditioning with new Wabtec Corporation manufactured rubber. 4.2 All NEW rubber parts including gaskets, o-rings, rubber seated check valves, seals, diaphragms, etc., must not be applied if either the date on the part or its shelf life is over five years old. 4.3 The storage area for rubber parts must be cool, dark and free from dampness and mildew. Since most rubber goods are affected by ozone, they must not be stored near electrical equipment that may generate ozone. 4.4 To determine shelf life, new Wabtec Corporation rubber repair kits are dated with the oldest date (half year) of rubber components contained within the kit. 4.5 Rubber Repair Kits - Refer to the latest parts catalog of the valve being disassembled for NEW rubber repair kit part numbers required for valve reassembly. 5.0 CHOKES 5.1 The size and cleanliness of chokes is important for proper valve performance. Whenever a portion is dismantled, the choke fittings must be removed, cleaned and inspected to insure that they are not restricted. When cleaning chokes, the orifice size and shape must not be changed. Metallic filters must be cleaned and felt filters must be renewed. 5.2 The choke plug should be soaked in a bath of cleaning material as described in Section 3.1. Do NOT use metallic tools to clean chokes, as their size and shape must NOT be changed. Page 8 of 61

9 5.3 Splined socket choke plugs can generally be removed or applied without damage to the choke plug or to the thread in the tapped hole. If it is necessary to drill or tap, all drill chips must be thoroughly blown out of all passages. The choke fittings for each portion are described later in the section under the heading for that particular portion. 5.4 While the plug is soaking, inspect the passage from which it was removed to be sure that it is clean and unrestricted. A low pressure jet of clean, dry air may be used to blow the passage out. Exercise care so that dirt is not blown back into the passage or passages of the device. NOTE: When removing the AAV choke (57) and filter (58) assembly from the body (60) for cleaning (see Figure 9, page 37), remove and SCRAP the mesh screen filter (58) from the AAV choke plug (57), see Figure 23, page 47. Tap filter removal tool into filter (58) until there is enough engagement for removal. Tighten a tee-handle onto the removal tool then twist and rotate until the filter is removed. Clean the choke as described in Section 5.2. Carefully position and install the NEW mesh screen filter (58) into the AAV choke (57). 5.5 For proper choke identification, see Table 1, page 9, for the ABDX and ABDX-R Service Portions and Table 2, page 9, for the ABDX, ABDX-R, ABDXL and ABDXL-R Emergency Portions. IMPORTANT: Choke diameters are shown for identification ONLY. If choke size is not correct, DO NOT ATTEMPT TO REPAIR. A new choke obtained from Wabtec Corporation is to be installed at the correct location. NOTE: Discretion should be used when tightening brass chokes back into the control valve body. Securely fasten each brass choke in its proper location; however, do not over tighten to facilitate future removal. TABLE 1 - Choke Identification Table - ABDX, ABDX-R Service Portion (Figure 11, page 41) Ref. No. Description Diameter (Inches) Part No. 48 Brake Cylinder Exhaust 3/32 (0.0938) Brake Pipe Charging No. 18 (0.1695) Auxiliary Reservoir Charging No. 55 (0.0520) a Auxiliary Reservoir Charging No. 54 (0.055) Quick Service Volume Exhaust 1/32 (0.0312) TABLE 2 - Choke Identification Table - ABDX, ABDX-R, ABDXL, ABDXL-R Emergency Portion (Figure 9, page 37 & Figure 10, page 39) Ref. No. Description Diameter (Inches) Part No. 51 Inshot Bypass No. 41 (0.096) Inshot Volume No. 46 (0.081) Quick Action Blowdown No. 76 (0.020) AAV (ABDX, ABDX-R) No. 73 (0.024) AAV (ABDXL, ABDXL-R) No. 67 (0.032) Quick Action Breather No. 46 (0.081) NOTE: ABDX emergency portion body type configuration control C does not contain removable chokes (51) and (52), and also does NOT have the two removable plugs (56) in the side of the body (near bottom). Page 9 of 61

10 6.0 SPRINGS 6.1 When the portion is dismantled for general cleaning, all springs must be inspected after cleaning. Springs which show rust pits, distortion, or have permanent set, must be rejected and replaced by springs known to be correct. 6.2 Wash the springs in the cleaning material described in Section 3.1. A wire brush may be used to assist in the removal of any dirt, rust or scale, using special care with small, light wire springs. 6.3 After cleaning, the springs MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the springs dry. 6.4 For proper spring identification, see Table 3, page 10, for the ABDX and ABDX-R Service Portions and Table 4, page 11, for the ABDX, ABDX-R, ABDXL and ABDXL-R Emergency Portions. IMPORTANT: Dimensions given are for identification purposes only. If replacement spring is required, it must be obtained by part number identification from Wabtec Corporation. No substitute springs are permitted. No spring adjustment by stretching or compressing is permitted. TABLE 3 - Spring Identification Table ABDX, ABDX-R Service Portion (Figure 11, page 41 & Figure 15, page 44) Ref. No. Description Part No. Approx. Outside Dia. Approx. Wire Dia. Approx Free Height Approx. Number Turns Material 9 Piston Spring /8 1/ / / 2 Steel 13 Graduating Valve /32 1/64 21/ / 8 Bronze 27 Acc. Rel. Check Valve ½ 3/ / 16 8 Steel 33 Back Flow Check Valve /32 1/ / 64 7 ½ Bronze 35 Piston Return / 8 9/ / / 8 Steel 36 & 36a Brake Cylinder Limiting Valve /64 5/ / 64 5 Steel (blue) 41a Upper Limiting Valve Spring Steel Ref. No. Description Release Valve Portion (Figure 15, page 44) Part No. Approx. Outside Dia. Approx. Wire Dia. Approx Free Height Approx. Number Turns Material 4 Release Spool Valve /64 5/ / 64 5 Steel 12 Emer. & Aux. Res. Valve /32 1/32 15/ / 8 Steel 16 Reset Spool Valve /64 1/ / / 2 Steel 19 Retaining Check Valve /32 1/ / / 2 Steel 22 Reset Check Valve /32 1/ / / 2 Steel 23 Lifter Spring /64 3/ / / 2 Steel Page 10 of 61

11 Ref. No. TABLE 4 - Spring Identification Table - ABDX, ABDX-R, ABDXL, ABDXL-R Emergency Portion (Figure 9, page 37 & Figure 10, page 39) Description Part No. Approx. Outside Dia. Approx. Wire Dia. Approx Free Height Approx. Number Turns Material 7 Emergency Slide Valve /64 1/32 13/ / 2 Steel (Blue) 12 High Pressure Spool Return Music Wire (Green) 12a High Pressure Spool Return Steel (Blue) 14 High Pressure Spool (Bottom) / 16 1/8 7/16 3 Stainless 16 Emer. Acc. Rel. Check Valve /16 3/64 55/64 6 Steel 25 Inshot Check Valve /32 1/ / / 2 Steel 28 Vent Valve / 64 7/ / / 2 Steel 40 Inshot Piston Valve Music Wire (50% Red) 40a Inshot Piston Valve /8 5/ / / 4 Steel 48 Emer. Acc. Rel. Spool Valve / / / 2 Steel NOTE: The actual springs will vary somewhat, due to small differences in wire diameter, coil diameter, number of coils, etc. This tabulation is intended for identification only and should not be used for any other purposes. It does not represent a specification for springs mentioned. 7.0 ABDX, ABDX-R SERVICE PORTION DISASSEMBLY (Refer to Figure 11, page 41) 7.1 Remove the release valve portion (57) from the body (47) by first removing the three ⅜" flanged hex nuts (52). 7.2 Remove and SCRAP the five 13/16" O.D. ring gaskets (55) and the 7/8" O.D. ring gasket (54) from the mounting face of the release valve portion (57). Remove and SCRAP the wire mesh strainers (56) from the mounting face of the release valve portion (57). 7.3 Set the release valve portion (57) aside in a clean, protected area for later disassembly. Service Diaphragm Piston 7.4 Remove the top cover (2) from the body (47) by removing the four ½" x 1¾" hex head cap screws (1) Remove and SCRAP the metal identification tag(s) (1a or 1b), if applicable, from the hex head cap screw(s) (1). 7.5 Remove and SCRAP the 1 1 / 16 " O.D. ring gasket (3) from the top cover (2). 7.6 Carefully remove the service piston assembly (4 to 16b) as a unit from the body (47). 7.7 Place the service piston assembly (4 to 16b) on the piston assembly fixture, Part No , as shown in Figure 18, page 46. Hold the service piston assembly in position so that the slide valve spring (12) rests on the fixture with the seat of the slide valve (15) facing upward. 7.8 Using the driver pin that is furnished with the piston holding fixture, carefully drift the 3/32" x 1" cylindrical spring pin (11) from the slide valve (15). Page 11 of 61

12 7.9 Remove the slide valve spring (12), slide valve (15), graduating valve (14) and graduating valve spring (13) from the service piston (16 or 16a) Remove the ⅝" x 1" hex head cap screw (4) which secures the diaphragm follower (5) and diaphragm (6) to the service piston (16 or 16a) Remove the diaphragm follower (5) and diaphragm (6) from the service piston (16 or 16a). SCRAP the diaphragm (6) Remove the spring seat retaining ring (7) from the tail of the service piston (16 or 16a), then remove the spring seat (8), spring (9) and spring guide (10). If spring guide (10) is metal, then SCRAP metal spring guide (10). NOTE: Plastic spring seat (8) and plastic spring guide (10) should NOT be scrapped unless they are damaged Remove and SCRAP both service top and bottom wear protection rings (16b) from service piston (16), if applicable SCRAP the service main piston (16a) that does NOT contain two machined grooves for wear rings (16b). NOTE: Do NOT SCRAP service main piston (16) that does contain two machined grooves for wear rings (16b) unless it is damaged. Limiting Valve, Back Flow Check Valve 7.13 Remove the four ½" x 1¼" hex head cap screws (31) which secure the bottom cover (45 or 45a) to the body (47). WARNING: The bottom cover (45 or 45a) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may cause bodily injury Remove the bottom cover (45 or 45a) from the body (47) Inspect bottom cover (45 or 45a) for number of exhaust ports (brass wasp excluders). Refer to Figure 11, page 41. If cover (45a) has only one exhaust port, refer to Service Bulletin 68-19: New Quick Service Limiting Valve Details located in the Appendix on page 49. NOTE: Bottom cover (45a) that contains only one exhaust port and felt filter (46) must be SCRAPPED Remove and SCRAP the 11/16" O.D. ring gasket (44), the 2" O.D. ring gasket (43) and the 3⅜" O.D. ring gasket (42) from the cover (45) Remove the check valve spring (33) and the check valve (32) from the body (47). SCRAP the check valve (32). NOTE: Configuration control C service body (67) (Figure 13, Page 42) which contains the new standard SAR Valve Assembly, does NOT contain check valve (32) or check valve spring (33) Remove the brake cylinder limiting valve spring (36 or 36a) and the brake cylinder limiting valve diaphragm - piston assembly (37 to 41b) or (38 to 41a) from the body (47). NOTE: Plastic follower (38) should NOT be scrapped unless it is damaged Remove and SCRAP the o-rings (40, 40a) from the plastic limiting valve stem (41) and SCRAP diaphragm (39). SCRAP all o-rings (40b) from brass limiting valve piston (41b). NOTE: Plastic limiting valve stem (41) should NOT be scrapped unless it is damaged. Page 12 of 61

13 NOTE: ABDX-R Portions have three o-rings on the brass limiting valve piston (41b) With brass limiting valve piston (41b) use the Limiting Valve Piston Spanner Wrench, as shown in Figure 19, page 46, to hold the limiting valve piston (41b), remove the ⅜" self-locking nut (37), diaphragm follower (38a) and diaphragm (39a) from the threaded end of the brass limiting valve piston (41b). SCRAP the diaphragm (39a). NOTE: If required, use an open end wrench to hold the limiting valve piston (41b) while removing the self-locking nut (37) Remove the piston return spring (35) and the spring cage (34 or 34a) from the body (47). SCRAP metal spring cage (34). NOTE: Plastic spring cage (34a) should NOT be scrapped unless it is damaged. Service Accelerated Release Valve (Old Standard SAR Valve Assembly) NOTE: 7.21 through 7.28 for ABDX service valve body configuration A that contains old standard SAR assembly. Refer to Figure 11, page Remove the four ½" x 2¾" hex head cap screws (17) which secure the service accelerated release valve assembly (18 to 30) to the body (47). Remove the service accelerated release valve cover (18), wear shield (18a) if applicable, and diaphragm - piston assembly (19 to 22) or (19 to 22a) as a unit from the filling piece (29). SCRAP the wear shield (18a), if applicable Remove the service accelerated release valve piston - diaphragm assembly (19 to 22) or (19 to 22a) from the cover (18) Use either the Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 20, page 46, or a flat bar placed in the slot to retain the service accelerated release valve piston (22 or 22a), remove the 9/16" hex head nut (19), diaphragm follower (20) and the diaphragm (21) from the threaded end of the piston (22 or 22a). SCRAP the diaphragm (21) and the service accelerated release valve piston (22a) that does NOT contain a plastic wear pellet. NOTE: Do NOT scrap service accelerated release valve piston (22) that contains a plastic wear pellet unless it is damaged or the plastic pellet is missing in piston (22). NOTE: If diaphragm follower (20) has significant wear, then SCRAP diaphragm follower (20) Remove the service portion filling piece, plunger, check valve assembly, and mounting gasket (23 to 30) as a unit from the body (47) Remove and SCRAP the filling piece mounting gasket (30) Compress and remove the spring seat (26), check valve spring (27), and accelerated release check valve (28) from the filling piece (29). SCRAP the accelerated release check valve (28) Remove the service accelerated release valve plunger with o-ring (23, 24) by pushing it out of the cover end of the filling piece (29). Remove and SCRAP the ¼" O.D. o-ring (24) from the plunger (23). NOTE: The service accelerated release valve plunger (23) must be inspected as per the instructions outlined in Service Bulletin 68-23a to determine if plunger (23) can be re-used Remove and SCRAP the 11/16" O.D. ring gasket (25) from its groove in the filling piece (29). Page 13 of 61

14 Service Accelerated Release Valve (NEW Standard SAR Valve Assembly) NOTE: 7.29 through 7.33 for ABDX service valve body configuration control C that contains the NEW standard SAR valve assembly. Refer to Figures 13 & 14, page 42. WARNING: The service accelerated release valve cover (59) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Accidentally expelled parts may cause bodily injury Remove the service accelerated release valve cover (59) by first removing the four ½" x 1½" hex head cap screws (58) Remove and SCRAP the 9/16" O.D. ring gasket (61) from the cover (59) Remove the top cover spring (60), plastic follower (62), and diaphragm (63) from the body (67). SCRAP diaphragm (63). NOTE: Plastic follower (62) should NOT be scrapped unless it is damaged Remove the plastic piston (64) with o-ring (65) assembly and the kick up spring (66) from the body (67) Remove and SCRAP o-ring (65) from plastic piston (64). NOTE: Plastic piston (64) should NOT be scrapped unless it is damaged. (Refer to Figure 11, Page 41) 7.34 Retrieve the release valve portion (57) which was previously set aside in a clean, protected area. Release Valve Portion (Refer to Figure 15, page 44) 7.35 Remove the five ⅜" x 1½" hex head cap screws (1) which secure the top cover (2) of the release valve portion to the release valve body (35) Remove the top cover (2) from the body (35) Remove and SCRAP the two 1" O.D. ring gaskets (3) from their grooves in the top cover (2) Remove the two check valve springs (12), both the auxiliary and emergency reservoir check valves (13), and the two plastic check valve plungers (14) from the body (35). SCRAP the two check valves (13). NOTE: The two plastic check valve plungers (14) should NOT be scrapped unless they are damaged Remove the spool valve spring (4) from the body (35) Remove the spool valve - diaphragm follower - diaphragm assembly (5 to 11) from the body (35) as a unit. NOTE: Care should be taken when spool valve is removed from its bush so that the seat end of the spool is NOT damaged in any way Remove and SCRAP the three ¾" O.D. o-rings (11) from their grooves on the spool valve (10) Using an open end wrench to hold the spool valve (10), remove the 3/8" self-locking nut (5), diaphragm follower (6), diaphragm (7) and the piston with o-ring (9, 8) from the threaded end of the spool valve (10). Remove the ½" O.D. o-ring (8) from its groove in the piston (9). SCRAP the o-ring (8) and diaphragm (7). Page 14 of 61

15 7.43 Remove and SCRAP the 3/16" x 2" cotter pin (24) which secures the release valve stem guard (25) to the stem and end plate (27). Remove the stem guard (25). Do NOT scrap plastic stem guard (25) unless it is cracked or broken. WARNING: The bottom cover (31) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Accidentally expelled parts may cause bodily injury Remove the five ⅜" x 1¾" hex head cap screws (15) that secure the bottom cover, valve seal, exhaust seal stem, and end plate assembly (27 to 33) to the body (35). Remove the cover assembly from the body (35) Remove the stem and end plate (27), bottom cover gasket (28), seal (30) and 5/8" O.D. ring gasket (29) from the bottom cover (31). SCRAP both gaskets (28 & 29) and seal (30) Remove the lifter (26) and lifter spring (23) from the body (35). NOTE: Plastic lifter (26) should NOT be scrapped unless it is damaged Remove the plastic sleeve (34) from the bottom cover (31). Visually inspect plastic sleeve (34) for either excessive wear or damage. If the plastic sleeve (34) contains excessive wear and/or is damaged in any fashion, then SCRAP the plastic sleeve (34) Either drill out or cut off the head of the 3/16" x ½" aluminum pop rivet (33) and remove the rivet (33) and seal (32) from the bottom cover (31). SCRAP the both rivet (33) and seal (32) Remove the retaining check valve (20) and its spring (19) from the body (35). SCRAP the check valve (20) Remove the reset check valve spring (22) and the reset check valve (21) from the body (35). SCRAP the check valve (21) Remove the reset spool valve with o-ring assembly (18, 17) and the reset spool valve spring (16) from the body (35) Remove and SCRAP the three ¾" O.D. o-rings (17) from the reset spool valve (18). 8.0 ABDX, ABDX-R SERVICE PORTION ASSEMBLY Service Diaphragm Piston (Refer to Figure 11, page 41) 8.1 Install NEW service piston top ring (16b) and NEW service piston bottom ring (16b) on the service piston (16). NOTE: Service piston (16a) that does NOT contain two machined grooves for wear rings (16b) must NOT be re-used. IMPORTANT: Care should be taken when expanding or opening the wear protection rings during installation onto the service piston. Do not over expand the rings causing them to deform which would result in difficult installation of the piston into the bore. Both protective rings must be installed with the gap facing the slide valve area of the service piston. The positioning of the rings will ease the assembly. 8.2 Position a NEW diaphragm (6) on the service piston (16) so that the part number on the diaphragm (6) faces away from the piston (16). After positioning the diaphragm bead into the groove of the piston, flip the diaphragm (6) so that the large cone shaped opening is facing the follower (5). 8.3 Position the diaphragm follower (5) on the diaphragm (6) and piston (16). Page 15 of 61

16 8.4 Lightly coat the threads of the ⅝" x 1" hex head cap screw (4) with Loctite Sealant TL-242, Wabtec Corporation Specification M Install the cap screw (4) through the diaphragm follower (5) and into the piston (16) to secure the piston (16), diaphragm (6), and follower (5) together. Hand tighten the cap screw (4) and then tighten in a manner to securely fasten the assembly to prevent leakage and yet not excessively to cause distortion of piston threads. Flip the diaphragm (6) in the opposite direction so that the large cone shaped opening is facing the piston (16). (NOTE: Wabtec recommends torquing cap screw (4) between 45 and 50 foot-pounds.) NOTE: Refer to Service Bulletin 68-26, page 59 for application of Triple Valve Oil on specified parts in Sections 8.5 & Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) around the outer surfaces of the plastic spring guide (10). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on all required parts.) NOTE: Metal spring guide (10) must NOT be re-used. 8.6 Install the plastic spring guide (10), closed end first, into the open end of the service piston (16). 8.7 Install the piston spring (9) and spring seat (8) into the open end of the plastic spring guide (10) and secure the parts in place by installing the spring retainer (7). 8.8 Place the slide valve spring (12) on the holding fixture, Part No , as shown in Figure 18, page Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M , (AAR Specification M-912) on the face of the graduating valve (14) and over the graduating valve seat of the slide valve (15). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on both graduating valve face and seat.) 8.10 Install the graduating valve spring (13), graduating valve (14), and slide valve (15) on to the piston (16). NOTE: Ensure graduating valve spring (13) remains in its proper position in both the piston (16) and graduating valve (14) Place the piston assembly on the slide valve spring (12) which is still in the holding fixture Make sure that the graduating valve (14) is on its seat in the slide valve (15) and that the slide valve side wings are down tight in the fixture Install the 3/32" x 1" cylindrical spring pin (11) through the pin holes of each of the wings of the slide valve (15) and the aligned pin hole of the slide valve spring (12). With the aid of the pin driver supplied with the holding fixture, Part No , secure the pin (11) in place Remove the assembly from the holding fixture. Exercise care so that slide valve (15) face is NOT damaged in anyway. NOTE: Refer to Service Bulletin 68-26, page 59, for application of Triple Valve Oil on specified parts in Sections 8.15 and Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) over the face of the slide valve (15) and to the outer surface area Page 16 of 61

17 of both the top and bottom wear protection rings (16b) on the service piston (16). Also apply a liberal coating of the Triple Valve Oil specifically to the slide valve seat and the entire internal walls of the main piston bushing in the body (47), and to the collars and fins of the piston (16) near the piston head. (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on all required parts.) IMPORTANT: Care must be taken when compressing the graduating valve and slide valve in preparation for inserting the service piston assembly with guide rings (7 to 16b) into the body bushing. While using minimal force, the assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face (15) must be retracted from the bushing face for as long as possible. Care must be taken not to damage the slide valve face. Applying a force to the slide valve spring (12) while inserting service piston assembly into body bushing is NOT recommended Install the piston - diaphragm - slide valve assembly (7 to 16b) into the body (47) from the top, exercising care so that NO damage is done to the slide valve seat in the body bushing Using only finger and thumb pressure, position the sealing bead of the diaphragm (6) into the diaphragm bead groove on the top cover mounting face of the body (47) Install a NEW 1 1 / 16 " O.D. ring gasket (3) into its groove in the top cover (2) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four ½" x 1¾" hex head cap screws (1) Insert a NEW metal identification tag (1a) through the bottom of one of the four hex head cap screws (1). Carefully position the top cover assembly (2, 3) into proper position on the body (47). NOTE: The metal identification tag (1a) must be located in specific location as shown in Figure 11, page Install and tighten by hand all four ½" x 1¾" hex head cap screws (1). Securely fasten all four hex head cap screws (1) to prevent leakage and yet not excessively to cause distortion of cover and gasket. (NOTE: Wabtec recommends the specific top cover fastening method: Ensure that all four hex head cap screws have been hand tightened first. Looking down directly on the top side of the service top cover, partially torque all four hex head cap screws between 12 to 16 ft-lbs in the following order: 7 o clock position, 1 o clock position, 5 o clock position, 11 o clock position. Then following the same tightening sequence, re-torque all four hex head cap screws to the body with between 35 and 45 foot-pounds. Lastly, apply a final torque to the four hex head cap screws with between 35 and 55 foot-pounds in the following specific order: 1 o clock position, 7 o clock position, 11 o clock position, 5 o clock position) NOTE: Metal identification P tag (1b) is no longer required on service valve portion after April 1, Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) around the collar on each end of the plastic spring cage (34a). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on all required parts.) NOTE: Metal spring cage (34) must NOT be re-used Install the piston return spring (35) into the plastic spring cage (34a), then install the cage with spring (34a & 35) as a unit into the body (47) so that the assembly (34a & 35) goes over and around the end of the shaft of the piston (16), which has already been installed in the body (47). Page 17 of 61

18 Limiting Valve Brass Style Limiting Valve Piston with Three O-rings Assemble quick service volume exhaust choke (51) into the bottom of the body (47). NOTE: Refer to alternate configuration of limiting valve in Figure 11, Page 41, for steps 8.22 through Position a NEW diaphragm (39a) onto the brass limiting valve piston (41b) so that the flat surface of the diaphragm, which shows the part number, faces away from the piston towards the threaded end Lightly coat the threads of the brass limiting valve piston (41b) with Loctite Sealant TL-242, Wabtec Corporation Specification M Using the limiting valve spanner wrench, as shown in Figure 19, page 46, to hold the piston (41b), install the diaphragm follower (38a) and a ⅜"-16 hex nut (37) on the threaded end of the brass limiting valve piston (41b). Tighten nut (37) in a manner to securely fasten assembly to prevent leakage and yet not excessively to cause distortion of threads. (NOTE: Wabtec recommends torquing nut (37) between 9 to 12 foot-pounds.) NOTE: If required, use an open end wrench to hold the brass limiting valve piston (41b) while installing the hex nut (37) Using #2 Silicone Grease, Wabtec Corporation Specification M , lubricate the surfaces of the three NEW o-rings (40b). Also lightly lubricate the o-ring grooves on the shaft of the brass limiting valve piston (41b) and the internal walls of the limiting valve bushing in the body (47). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to both the o-ring grooves on the brass limiting valve piston (41b) and the internal walls of the limiting valve bushing in the body (47).) Carefully install all three NEW lubricated o-rings (40b) into their grooves on the brass limiting valve piston (41b) Install the piston - diaphragm assembly (37 to 41b) into the lubricated limiting valve bushing in body (47), o-ring end first. Be sure that the bead of the diaphragm (39a) is properly seated in its groove in the body (47). Use finger pressure to seat the diaphragm bead Install the limiting valve spring (36a) onto the end of the brass limiting valve piston (41b) so that it seats on the diaphragm follower (38a). Plastic Limiting Valve Piston Assembly Using #2 Silicone Grease, Wabtec Corporation Specification M lubricate the surface of the two NEW o-rings (40 & 40a). Also, lightly lubricate the o-ring grooves of the plastic limiting valve stem (41) as well as the internal walls of the limiting valve bushing in the body (47). (NOTE: Wabtec recommends using a clean foam-tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M to the o-ring grooves in the plastic limiting valve stem (41) and to the internal walls of the limiting valve bushing in the body (47) Install a NEW lubricated 9/32" O.D. o-ring (40) and a NEW lubricated 7/32" O.D. o-ring (40a) into their proper grooves on the plastic limiting valve stem (41) Install spring (41a) into the lubricated limiting valve bushing in body (47). Insert the limiting valve stem assembly (40, 40a, 41) into the limiting valve bushing on top of spring (41a). Page 18 of 61

19 Position a NEW diaphragm (39) on top of the limiting valve stem assembly (40, 40a, 41) so that the flat surface of the diaphragm, which shows the part number, is facing away from the stem. Use finger to properly seat the diaphragm (39) bead in its groove in the body (47) Install the plastic diaphragm follower (38) on top of the NEW diaphragm (39). Install spring (36) into the plastic diaphragm follower (38). Back Flow Check Valve 8.27 Install a NEW back flow check valve (32) and the check valve spring (33) into the proper cavity of the body (47). NOTE: Service valve body, configuration control C (Figures 13 & 14, Page 42), which contains the NEW standard SAR valve assembly does NOT require use of both the back flow check valve (32) and check valve spring (33) in body (67) Install a NEW 3⅜" O.D. ring gasket (42), a NEW 2" O.D. ring gasket (43) and a NEW 11/16" O.D. ring gasket (44) into their grooves in the bottom cover (45). NOTE: Bottom cover (45a), which contains only one exhaust port, must NOT be re-used Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four ½" x 1¼" hex head cap screws (31). Carefully position the bottom cover assembly (42 to 45) on the body (47) making sure that all ring gaskets and assemblies of the body are properly in place. Secure the bottom cover (45) to the body (47) by installing four ½" x 1¼" hex head cap screws (31) in a manner to securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the four cap screws (31) between 35 and 55 foot-pounds.) NOTE: ABDX Service Portions that previously had bottom cover (45a), which contains only one exhaust port, may also need a previous modification reversed to the body (47). If Service body (47) contains either a splined brass choke or vent protector ABDX umbrella fitting assembly located directly below the bottom right stud hole on the body (47), either of these two assemblies MUST BE removed from the body (47). Either of these fittings MUST BE replaced with an allen head plug (Part No ), which is threaded directly into the body (47). Service Accelerated Release Valve (Old Standard SAR Valve Assembly) NOTE: 8.30 through 8.40 for service valve assembly configuration control A that contains the old standard SAR valve assembly. Refer to Figure 11, Page Install a NEW accelerated release check valve (28) into the service portion filling piece (29) Install the check valve spring (27) into the filling piece (29) so that it seats on the check valve (28), then install the spring seat (26) to retain the parts in place Place a NEW filling piece gasket (30) that contains two brass reinforced ports and the service portion filling piece (29) in position on the body (47) Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of a NEW ¼" O.D. o-ring (24). Also lightly lubricate the o-ring groove on the service accelerated Page 19 of 61

20 release valve plunger (23) and the internal walls of the plunger bushing in the filling piece (29). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to the o-ring groove and the internal walls of the plunger bushing in the filling piece (29). NOTE: Each plunger (23) must comply with the inspection procedure outlined in Wabtec Service Bulletin 68-23A before being re-used From the smaller diameter end of the plunger (23), install the NEW lubricated ¼" O.D. o-ring (24) into its groove on the short end of the service accelerated release valve plunger (23). Then install the plunger with o-ring (23, 24) into the filling piece (29), longer end of the plunger first Use either the Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 20, page 46, or a flat bar placed in the slot to retain the service accelerated release valve piston (22), install a NEW diaphragm (21) onto the piston (22) so that the part number on the diaphragm faces away from the piston toward the threaded end. NOTE: Service accelerated release valve piston (22a) that does NOT contain plastic wear pellet must NOT be re-used Install the diaphragm follower (20) and lightly coat the threads of the service accelerated release valve piston (22) with Loctite Sealant TL-242, Wabtec Corporation Specification M Install a 9/16"-18 hex nut (19) on the threaded end of the piston (22), and tighten the hex nut (19) in a manner to securely fasten diaphragm to prevent leakage and yet not excessively to cause distortion of piston threads. (NOTE: Wabtec recommends torquing hex nut (19) between 30 and 40 foot-pounds.). NOTE: Diaphragm follower (20) being re-used must contain NO significant damage or wear Install the diaphragm - piston assembly (19 to 22), piston end first, into the filling piece (29). Be sure that the bead of the diaphragm is properly seated in its groove on the filling piece (29). Use finger pressure to properly seat the diaphragm bead Install a NEW wear shield (18a) over the hex nut (19). The wear shield lies on the follower (20) and is not held in place by any means. The body (47) will have to be positioned so the wear shield (18a) remains in place while installing the cover (18) Install a NEW 11/16" O.D. ring gasket (25) into its groove on the cover mounting face of the filling piece (29) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four ½" x 2¾" hex head cap screws (17). Place the service accelerated release valve cover (18) in position on the filling piece (29). Be sure that all parts are properly positioned, then using the four ½" x 2¾" hex head cap screws (17), secure the cover and filling piece assemblies (18 to 30) to the body (47). Tighten the four cap screws (17) in a manner to securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the four hex head cap screws (17) between 35 to 55 foot-pounds.) Service Accelerated Release Valve (NEW Standard SAR Valve Assembly) NOTE: 8.41 through 8.49 for service valve body configuration control C that contains the NEW standard SAR valve assembly. Refer to Figure 14, Page Install kickup spring (66) into its proper position in the body (67) Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of a NEW ¼" O.D. o-ring (65) and to the o-ring groove in the NEW plastic piston (64). Also apply a light coating of #2 Silicone Grease to the internal bush walls which o-ring (65) contacts in Page 20 of 61

21 body (67). (NOTE: Wabtec Corporation recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to the o-ring groove in the plastic piston (64) and to the internal bushing walls in which o-ring (65) contacts.) 8.43 Install the NEW lubricated ¼" O.D. o-ring (65) into its groove on the plastic piston (64), then install plastic piston with o-ring assembly (64, 65) into its respective bushing in body (67) Install a NEW diaphragm (63) into the body (67). Be sure that the bead of the diaphragm (63) is properly seated into its groove in the body (67) Install a plastic follower (62) on top and in the center of diaphragm (63) Install spring (60) into the plastic follower (62) Install a NEW 9/16" O.D. ring gasket (61) into its groove in the cover (59) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four ½" x 1½" hex head cap screws (58) Place the service accelerated release valve cover (59) in position on the body (67). Be sure that all parts are properly positioned, then using the four ½" x 1½" hex head cap screws (58), secure the cover (59) to the body (67). Tighten the four hex head cap screws (58) in a manner to securely fasten the cover assembly to prevent leakage and yet not excessively to cause distortion of cover and gasket. (NOTE: Wabtec recommends torquing all four hex head cap screws (58) between 35 to 55 foot-pounds). Release Valve Portion Assembly (Refer to Figure 15, page 44) 8.50 Using #2 Silicone Grease, Wabtec Corporation Specification M , fill all o-ring grooves in the reset spool valve (18). Then, lightly lubricate both the internal walls of the reset spool valve bushing in the body (35) and the surfaces of all three NEW ¾" O.D. o-rings (17). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to all the o-ring grooves in the reset spool valve (18) and to the internal walls of the reset spool valve bushing.) 8.51 Install the three NEW lubricated ¾" O.D. o-rings (17) into their respective grooves on the reset spool valve (18). Wipe any excess grease off of the reset spool valve assembly (17, 18); however, leave a liberal coating of #2 Silicone Grease (M ) on each of the three o-rings (17). (NOTE: Wabtec recommends using a clean, dry, lint-free cloth to remove any excess lubricant.) 8.52 Install the reset spool valve spring (16) and reset spool valve with o-ring assembly (17, 18) into its lubricated bushing in the release valve body (35) Install the lifter spring (23) and plastic lifter (26) into the proper cavity in the release valve body (35) Install a NEW reset check valve (21) and the check valve spring (22) into the proper cavity of the release valve body (35) Install the check valve spring (19) and a NEW retaining check valve (20) in the proper cavity of the release valve body (35). The seat for the retaining check valve is located in the bottom cover (31) Install the plastic sleeve (34) and secure a NEW seal (32) with a NEW 3/16" x ½" aluminum pop rivet (33) in the bottom cover (31). Page 21 of 61

22 NOTE: Ensure that plastic sleeve (34) used contains no significant wear or is NOT damaged Install a NEW valve seal (30), stem and end plate (27), a NEW ⅝" O.D. ring gasket (29) and a NEW bottom cover gasket (28) in place on the bottom cover (31) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all five ⅜" x 1¾" hex head cap screws (15). Carefully position the bottom cover assembly (27 to 34) on the body (35) without applying heavy pressure, then insert the five ⅜" x 1¾" hex head cap screws (15) into the cover (31). Observe the retaining check valve (20) to be sure that it is in alignment with the check valve seat in the cover (31). Also be sure that the reset check valve spring (22) is properly positioned in the cover (31), then hand press the cover (31) to the body (35) and secure it in place by equally tightening the five ⅜" x 1¾" hex head cap screws (15) in a manner to securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of cover and tapped threads. (NOTE: Wabtec recommends torquing the five cap screws (15) between 15 and 25 foot-pounds.) 8.59 Using #2 Silicone Grease, Wabtec Corporation Specification M , lightly coat the surfaces of a NEW ½" O.D. o-ring (8) and three NEW ¾" O.D. o-rings (11). Fill all o-ring grooves in release spool valve (10) with #2 Silicone Grease (M ). Lightly lubricate the internal walls of the release spool valve bushing in the body (35). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to the o-ring grooves in the release spool valve (10) and to the internal walls of the release spool valve bushing in the body (35) Using an open end wrench to hold the release spool valve (10), install the piston (9) on the threaded end of the release spool valve (10) Install the NEW lubricated ½" O.D. o-ring (8) in place on the piston (9), then install a NEW diaphragm (7) so that the part number on the diaphragm faces away from the piston toward the threaded end of the release spool valve (10) Install the diaphragm follower (6) on the threaded end of the release spool valve (10). Lightly coat the threads of the release spool valve (10) with Loctite Sealant TL-242, Wabtec Corporation Specification M Install ⅜"-16 hex nut (5) on the threaded end of the release spool valve (10) and tighten in a manner to securely fasten nut (5) to the release spool valve (10) to prevent leakage and yet not excessively to cause distortion of threads. (NOTE: Wabtec recommends torquing hex nut (5) between 10 to 12 foot-pounds.) 8.63 Install the three NEW lubricated ¾" O.D. o-rings (11) into the three o-ring grooves of the release spool valve (10). Wipe off excess grease from the release spool valve assembly (10, 11); however, leave a liberal coating of #2 Silicone Grease on each of the three o-rings (11). (NOTE: Wabtec recommends using a clean, dry, lint-free cloth to remove any excess lubricant.) 8.64 Install the diaphragm piston assembly (5 to 11) into the body (35). Be sure that the bead of the diaphragm (7) is properly seated in the bead groove of the body (35). Use finger pressure to seat the bead in the groove Install the release spool valve spring (4) in body (35) so that it is seated on the diaphragm follower (6) Install the plastic emergency and auxiliary reservoir check valve plungers (14) into their proper cavities in the body (35). Page 22 of 61

23 8.67 Install two NEW check valves (13) into the body (35) on top of the two plastic plungers (14), then install the two check valve springs (12). NOTE: Position the check valve springs (12) so that they are centered on top of the NEW check valves (13) Install two NEW 1" O.D. ring gaskets (3) into their grooves in the top cover (2) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all five ⅜" x 1½" hex head cap screws (1). Carefully place the top cover assembly (2, 3) onto the body (35) being sure that the springs (4 and 12) are properly positioned in the spring cavities of the cover. Secure the top cover (2) to the body (35) by installing the five ⅜" x 1½" hex head cap screws (1). Tighten the five cap screws (1) in a manner to securely fasten top cover assembly (2, 3) to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the five cap screws (1) between 15 and 25 foot-pounds.) (Refer to Figure 11, page 41) 8.70 Install three NEW wire mesh filter screens (56) into their proper location in the release valve portion body (57). NOTE: The three clean wire mesh filter screens must be placed in the auxiliary reservoir, emergency reservoir, and retainer ports Install a NEW 7/8" O.D. ring gasket (54) and five NEW 13/16" O.D. ring gaskets (55) into their grooves on the mounting face of the release valve portion (57) Place the release valve portion (57) on the service portion body (47) and secure it in place by installing three ⅜" flanged hex nuts (52). Tighten the three hex nuts (52) in a manner to securely fasten the release valve portion (57) to body (47) to prevent leakage and yet not excessively to cause distortion of stud threads. (NOTE: Wabtec recommends torquing the three hex nuts (52) between 11 and 30 footpounds.) (Refer to Figure 6, page 34 and Figure 15, page 44) 8.73 The release valve stem guard (25) is to be installed after the service portion has been tested. Use a NEW 3/16" x 2" cotter pin (24) when installing the guard (25). NOTE: All ABDX-L/ABDX-R/RL service valve portions that have been clean, oil, and tested must contain either a nameplate tag or paint stencil that includes the date of reconditioning (MM/YY) and shop identification. If the nameplate tag is used, it must be located under the specific hex head cap screw as shown in Figure 11, page 41. If the paint stencil is used, the specific information described above must be shown in ½ minimum height letters on the valve body. 9.0 ABDX, ABDX-R, ABDXL, ABDXL-R EMERGENCY PORTION DISASSEMBLY (Refer to Figure 9, page 37 and Figure 10, page 39) 9.1 Remove the vent protector assembly from the emergency portion body (60) if it is still in place External style vent protector assembly can be removed by unscrewing the assembly out of the body. Refer to Figure 8, page 35 for illustration of the external style vent protector assembly (16) If the ABDX or ABDX-L valve is equipped with internal style vent protector assembly (64), use snap ring pliers to remove snap ring (68) from body (60). Then remove assembly (65 to 67) from body (60). Either Page 23 of 61

24 drill out or cut off the head of the 3/16" x ½" aluminum pop rivet (67) and remove the rivet and seal (66) from the retainer (65). SCRAP the pop rivet (67) and seal (66). Inshot Check Valve 9.2 Depress the spring retainer (24) into the body (60) and tilt it so that it is free of the retaining lip of the body (60) and remove the spring retainer (24), inshot check valve spring (25), and the inshot check valve (26) from the body (60). SCRAP the check valve (26). NOTE: Plastic spring retainer (24) should NOT be scrapped unless it is damaged. Small Vent Valve Piston 9.3 Depress the spring retainer (27) into the body (60) and tilt it so that it is free of the retaining lip of the body (60) and remove the retainer (27), vent valve spring (28), and the small vent valve piston with seal (29 to 31 or 32) from the body (60). 9.4 SCRAP the entire small vent valve piston assembly (29 to 31 or 32). Emergency Accelerated Release Check Valve 9.5 Remove the four ½" x 1¾" hex head cap screws (1) which secure the top cover (2) to the body (60). Remove the cover (2) Remove and SCRAP the metal identification tag (1a), if applicable, from the hex head cap screw (1). 9.6 Remove and SCRAP the ring gaskets (21, 22, 23) from the top cover (2). 9.7 Remove the emergency accelerated release check valve spring (16), check valve spring seat (17), if applicable, emergency accelerated release check valve (18), and the plastic air strainer (20a) from the body (60). SCRAP the check valve (18) and the plastic air strainer (20a). NOTE: The plastic air strainer (20a) can be removed by lifting at the lip section on the top of the strainer frame. When removing the plastic strainer (20a), care should be taken not to damage the emergency accelerated release check valve seat. NOTE: If body (60) is equipped with wire strainer (20) under the emergency accelerated release check valve (18), refer to Service Bulletin 68-22, page 53, Figures 1 & 3, for specific removal & installation procedures of the wire strainer (20). High Pressure Spool 9.8 Remove the high pressure spool valve return spring (12 or 12a) and the high pressure spool valve with o-rings (13, 15 or 13, 15a) from the body (60). NOTE: For easier removal, thread a 3/8"-16 cap screw into the top of the high pressure spool valve (15 or 15a). (Refer to Figure 9, page 37 and Figure 10, page 39) 9.9 If high pressure spool valve bushing in body (60) does NOT contain bottom spring (14), then SCRAP the entire high pressure spool valve assembly with o-rings (15a, 13), and also SCRAP high pressure spool valve blue return spring (12a). NOTE: Green high pressure spool valve return spring (12) should NOT be scrapped unless it is damaged. Page 24 of 61

25 9.9.1 If high pressure spool valve bushing in body (60) contains bottom spring (14), then remove and SCRAP the five 1 3 / 16 " o-rings (13) from the high pressure spool valve (15). NOTE: Do NOT scrap the high pressure spool valve (15) if bushing in body (60) contains bottom spring (14) If applicable, carefully remove the bottom high pressure spool valve spring (14) from the high pressure spool valve bushing in the body (60). NOTE: Exercise care when removing high pressure spool valve bottom spring (14) from body (60) in order to prevent scratching the high pressure spool valve bushing internal walls. NOTE: High pressure spool valve bottom spring (14) should NOT be scrapped unless it is damaged. Emergency Diaphragm Piston 9.10 Carefully remove the emergency diaphragm piston assembly (3 to 11 or 3 to 11a) as a unit from the body (60) Carefully drift the 3/32" x ¾" cylindrical spring pin (6) from the emergency slide valve (8). Remove the emergency slide valve (8) and spring (7) from the emergency piston (11 or 11a) Remove and SCRAP the mesh screen filter (8a) from the emergency slide valve (8). See Figure 23, page 47 for filter removal. Tap filter removal tool into filter (8a) until there is enough engagement for removal. Tighten a tee-handle onto the removal tool and twist and rotate until the filter (8a) is removed from the slide valve (8) Remove the ⅝" x 1" hex head cap screw (3) that secures the diaphragm follower (4) and diaphragm (5) to the emergency piston (11 or 11a). Remove follower (4) and diaphragm (5) from the piston (11 or 11a). SCRAP the diaphragm (5) SCRAP emergency main piston (11a) that does NOT contain two machined grooves for wear rings (9 & 10) Remove and SCRAP the two emergency piston wear protection rings (9, 10) from the emergency piston (11). NOTE: Do NOT scrap emergency piston (11) that does contain two machined grooves for wear rings (9 & 10) unless it is damaged. NOTE: 9.14 through 9.17 for ABDX-R and ABDXL-R only; for ABDX and ABDXL proceed to Section For ABDX-R and ABDXL-R portions refer to Figure 10, page 39. Remove the two ½" x 1⅛" hex head cap screws (33), the metal identification tag (33a), the ½" x 1¾" hex head cap screw (34), and the ½" x 3" hex head cap screw (66) that secures the vent valve cover (35) to the body (60) SCRAP the metal identification tag (33a) Remove the volume (67) from the volume fitting (68) Remove the volume fitting (68) from the body (60) and SCRAP the 7/16" O.D. o-ring (69) Remove and SCRAP the seal(s) (70) from the volume fitting (68) or the body (60) For ABDX and ABDXL portions refer to Figure 9, page 37. Remove the two ½" x 1¾" hex head cap screws (34) and the two ½" x 1⅛" hex head cap screws (33) that secures the vent valve cover (35) to the body (60). Page 25 of 61

26 Remove the cover (35) from the body (60). Remove and SCRAP the metal identification tag (33a), if applicable, from the hex head cap screw (33). Inshot Piston 9.19 Remove and SCRAP the 15/16" O.D. ring gasket (36) and the ⅝" O.D. ring gasket (37) from the vent valve cover (35). NOTE: 9.20 through 9.23 for the brass inshot valve piston assembly Remove the inshot piston spring (40a) and the inshot piston assembly (41 to 45a) from the body (60) Remove and SCRAP the ⅜" O.D. o-ring (44) from the inshot piston (45a) Use the inshot piston spanner wrench, as shown in Figure 21, page 47, to hold the inshot piston (45a), then remove the ⅜" self-locking hex nut (41) from the piston (45a). NOTE: If required, use an open end wrench to hold inshot piston (45a) while removing the 3/8" self-locking hex nut (41) Remove the diaphragm follower (42a) and diaphragm (43a) from the piston (45a). SCRAP the diaphragm (43a). NOTE: for latest style inshot valve piston assembly Remove the inshot piston spring (40), plastic follower (42) and diaphragm (43). SCRAP the diaphragm (43). Remove the plastic inshot piston pushrod (45) from the body (60). If inshot piston pushrod (45) is a clear plastic material, then SCRAP the clear plastic piston pushrod (45). NOTE: Black plastic inshot piston pushrod (45) and plastic follower (42) should NOT be scrapped unless they are damaged. Vent Valve 9.24 Remove the vent valve piston diaphragm (38) and the vent valve piston (39) from the body (60). SCRAP the diaphragm (38) If vent valve piston (39) is metal, then SCRAP the metal vent valve piston (39). NOTE: Plastic vent valve piston (39) should NOT be scrapped unless it is damaged. Emergency Accelerated Release Spool WARNING: The cap nut (47) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may cause bodily injury Using a 7/8" square wrench, remove the cap nut with o-ring (47, 46), which secures the emergency accelerated release spool valve spring (48) and spool valve assembly (50 or 50a, 49) in the body (60) Remove the spool valve spring (48) and spool valve with o-rings (50 or 50a, 49) from the bottom of the body (60) If spool valve (50) does NOT contain plastic insert on top side, then SCRAP entire spool valve assembly (50, 49). Page 26 of 61

27 9.27 Remove and SCRAP the four 1½" O.D. o-rings (49) from the spool valve assembly (50a). NOTE: Spool valve (50a) containing the top plastic insert must NOT be scrapped unless it is damaged. Plastic insert in top of spool valve (50a) should only be replaced if it contains significant wear or if it is damaged Remove and SCRAP the 1½" O.D. o-ring (46) from the cap nut (47). NOTE: Plastic cap nut (47) should NOT be scrapped unless it is damaged. Alternative Filter Configuration (Refer to Figure 10, page 39) NOTE: 9.29 to 9.31 is for ABDX-R/ABDXL-R bodies ONLY that do NOT contain plug/ring/filter assembly (61, 62, 63) in the internal vent valve exhaust cavity in the body (60) Using a proper size allen wrench, completely remove the set screw (65) in the vent valve diaphragm cavity in the body (60) that holds the alternative filter configuration assembly (59) in place in the internal vent valve exhaust cavity Using pliers, carefully remove the entire alternative filter configuration assembly (59) from the vent valve exhaust cavity in body (60) SCRAP the entire alternative filter configuration assembly (59) ABDX, ABDX-R, ABDXL, ABDXL-R EMERGENCY PORTION ASSEMBLY (Refer to Figure 9, page 37 and Figure 10, page 39) Emergency Accelerated Release Spool 10.1 Using #2 Silicone Grease, Wabtec Corporation Specification M , coat the surfaces of four NEW 1½" O.D. o-rings (49). Fill all o-ring grooves in spool valve assembly (50a) with #2 Silicone Grease, Wabtec Corporation Specification M and lightly lubricate the internal walls of the emergency accelerated release spool valve bushing in the body (60). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M , to the four o-ring grooves on the spool valve assembly (50a) and to the internal walls of the emergency accelerated release spool valve bushing in the body.) 10.2 Install the four NEW lubricated 1½" O.D. o-rings (49) into their grooves on the spool valve assembly (50a). Wipe excess grease off of the spool valve assembly (50a, 49); however, leave a liberal coating of #2 Silicone Grease on each of the four o-rings (49). NOTE: Spool valve (50) that does NOT contain a top plastic insert must NOT be re-used. (NOTE: Wabtec recommends using a clean, dry, lint-free cloth to remove any excess lubricant.) 10.3 Install the accelerated release spool valve assembly with o-rings (50a, 49) into its lubricated bush in the body (60), closed end first Install the spool valve spring (48) into the spool valve assembly (50a) Apply #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of a NEW 1½" O.D. o-ring (46) and lightly lubricate the o-ring groove of the cap nut (47) Install the NEW lubricated 1½" O.D. o-ring (46) into its groove on the cap nut (47). Page 27 of 61

28 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of the cap nut (47) Install the cap nut with o-ring (47, 46) into the body (60) to secure the spring (48) and accelerated release spool valve assembly (50a, 49) in place. Using a 7/8" square wrench, tighten the cap nut (47) in a manner to securely fasten cap nut to body to prevent leakage and yet not excessively to cause distortion of threads. (NOTE: Wabtec recommends torquing the plastic cap nut (47) between 25 and 35 footpounds and the metal cap nut (47) between 55 and 65 foot pounds.) Emergency Diaphragm Piston 10.8 Install NEW emergency piston wear protection rings (9, 10) on the emergency piston (11). NOTE: Emergency piston (11a) that does NOT contain two machined grooves for wear rings (9 & 10) must NOT be re-used. IMPORTANT: Care should be taken when expanding or opening the wear protection rings during installation onto the emergency piston. Do not over expand the rings causing them to deform which would result in difficult installation of the piston into the bore. Each wear protection ring should be installed with the gap facing the slide valve area of the emergency piston. The positioning of the rings will ease the assembly Install a NEW emergency piston diaphragm (5) on the emergency piston (11) so that the piece number on the diaphragm is facing away from the piston Carefully install a NEW mesh screen filter (8a) into the emergency slide valve (8). Exercise care so that no damage is done to the emergency slide valve (8). Using the pressure of the thumb or finger, position the wire mesh filter (8a) so that it can be pressed into the emergency slide valve (8) Lightly coat the threads of the ⅝" x 1" hex head cap screw (3) with LOCTITE Sealant TL-242, Wabtec Corporation Specification M Install the cap screw (3) through the diaphragm follower (4) and into the piston (11) to secure the piston (11), diaphragm (5) and follower (4) together. Hand tighten the hex head cap screw (3) first and then properly tighten cap screw (3) to securely fasten piston assembly (4, 5, 11) to prevent leakage and yet not excessively to cause distortion of piston threads. Flip the diaphragm (5) in the opposite direction so that the large cone shaped opening is facing the piston (11). (NOTE: Wabtec recommends torquing cap screw (3) between 45 and 50 foot-pounds.) Insert the emergency slide valve spring (7) into the emergency slide valve (8) Carefully place the emergency slide valve with spring (8, 7) on the stem of the piston (11) and secure the parts in place by installing the 3/32" x ¾" cylindrical spring pin (6). NOTE: Refer to Service Bulletin 68-26, page 59 for application of Triple Valve Oil on specified parts in Sections 10.13, & Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M , (AAR Specification M-912) over the entire face of emergency slide valve (8). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M (AAR Specification M-912) on all required parts in steps through ) Page 28 of 61

29 10.14 Apply and evenly spread a liberal coating of the Triple Valve Oil on the slide valve bushing seat in body (60) and to the entire internal walls of the main piston bushing in body (60) Apply and evenly spread a liberal coating of Triple Valve Oil to the entire outer surface area of both the top and bottom wear protection rings (9 & 10). IMPORTANT: Care must be taken when compressing the slide valve spring (7) in preparation for inserting the emergency piston assembly (3 to 11) into the body bushing. While using minimal force, the assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face (8) must be retracted from the bushing face for as long as possible Install the diaphragm - piston - emergency slide valve assembly (3 to 11) into the body (60). Exercise care so that NO damage is done to the emergency slide valve bushing seat Using the pressure of the thumb or finger, position the sealing bead of the diaphragm in the diaphragm bead groove of the body (60). High Pressure Spool Coat the surfaces of five NEW 1 3 / 16 " O.D. o-rings (13) with #2 Silicone Grease, Wabtec Corporation Specification M Fill all o-ring grooves on the spool valve (15) with #2 Silicone Grease, Wabtec Corporation Specification M Evenly spread a light coating of #2 Silicone Grease, Wabtec Corporation M to the entire internal walls of the high pressure spool valve bushing in the body (60). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M to the o-ring grooves of spool valve (15) and to the internal walls of the high pressure spool valve bushing in the body (60) Install the five NEW lubricated 13/16" O.D. o-rings (13) into their grooves on the high pressure spool valve (15). Wipe excess grease off of the spool valve assembly (15, 13); however, leave a liberal coating of #2 Silicone Grease on each of the five o-rings (13). (NOTE: Wabtec recommends using a clean, dry, lint-free cloth to remove any excess lubricant.) NOTE: Ensure that correct high pressure spool valve (15) is being used. Bottom high pressure spool valve spring (14) must be able to slide over the bottom of spool (15). High pressure spool valve (15a) must NOT be re-used Carefully install bottom high pressure spool valve spring (14) into the lubricated high pressure spool valve bushing in body (60) Install the high pressure spool valve with o-rings (15, 13) into its lubricated bushing in body (60) on top of the bottom high pressure spool valve spring (14) Install high pressure spool valve return spring (12) into the top of the high pressure spool valve (15). NOTE: Half the length of the high pressure spool valve return spring (12) must contain a dark green transparent dye to indicate correct top spring. Painted blue high pressure spool valve return spring (12a) must NOT be re-used. Emergency Accelerated Release Check Valve Install a clean wire strainer (20) into the body (60) as outlined in Service Bulletin 68-22, page 53, in the Appendix. Page 29 of 61

30 10.23 Install a NEW emergency accelerated release check valve (18) and check valve spring seat (17) and the check valve spring (16) into the body (60) Install a NEW 1¾" O.D. ring gasket (21), two NEW 1½" O.D. ring gaskets (22) and a NEW 1⅛" O.D. ring gasket (23) into their grooves in the top cover (2) Place the top cover assembly (2, 21 to 23) on the body (60) making sure that the diaphragm (5) and gaskets (21 to 23) remain in proper position Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four ½" x 1¾" hex head cap screws (1) Insert a NEW metal identification tag (1a) through the bottom of one of the four hex head cap screws (1). NOTE: The metal identification tag (1a) must be located in specific location as shown in Figure 9, page 37, or in Figure 10, page Fasten the cover assembly (2, 21 to 23) to the body (60) by installing the four ½" x 1¾" hex head cap screws (1). Securely fasten all four hex head cap screws (1) to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing all four hex head cap screws (1) between 35 and 55 foot-pounds.) Inshot Check Valve Install a NEW inshot check valve (26) and the inshot check valve spring (25) into the body (60). Align properly and secure these parts in place by installing the inshot spring retainer (24). Small Vent Valve Piston Install a NEW plastic small vent valve piston assembly (32) seal end first into the body (60) Install the small vent valve piston spring (28) into the NEW plastic small vent valve piston (32) and secure it in place by installing the spring retainer (27) in the body (60). Be sure that the retainer (27) is properly secured. NOTE: Metal small vent valve piston assembly (29, 30, 31) must NOT be re-used. Brass Inshot Valve Piston Install a NEW inshot diaphragm (43a) on the inshot piston (45a) so that the flat surface of the diaphragm which shows the part number faces away from the piston Install the diaphragm follower (42a) on the piston (45a) so that the small diameter of the follower (42a) is facing the diaphragm (43a). Lightly coat the threads of the brass inshot piston (45a) with Loctite Sealant TL-242, Wabtec Corporation Specification M Secure the follower (42a) and the diaphragm (43a) on the inshot piston (45a) by installing a ⅜"-16 hex nut (41). Tighten hex nut (41) in a manner to securely fasten assembly to prevent leakage and not yet excessively to cause distortion of piston threads. (NOTE: Wabtec recommends torquing hex nut (41) between 9 to 12 foot-pounds.) NOTE: Use either an inshot piston spanner wrench as shown in Figure 21, page 47, or an open end wrench to hold inshot piston (45a) while installing the ⅜" self-locking hex nut (41) Apply #2 Silicone Grease, Wabtec Corporation Specification M , to the surfaces of a NEW ⅜" O.D. o-ring (44). Lightly lubricate the o-ring groove on the shaft of the inshot piston (45a) and the entire Page 30 of 61

31 internal walls of the inshot piston bushing in the body (60). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M to the o-ring groove in the inshot piston (45a) and to the internal walls of the inshot piston bushing in the body.) Install the NEW lubricated ⅜" O.D. o-ring (44) into its groove on the shaft of the inshot piston (45a) Install the inshot diaphragm piston assembly (41 to 45a) into its lubricated bushing in the body (60). Using the pressure of the thumb or finger, position the sealing bead of the diaphragm (43a) in its groove in the body (60) Install the inshot piston spring (40a) over the hex nut (41) on the exposed end of the inshot piston (45a) so that the spring seats in the diaphragm follower (42a). Latest Inshot Valve Assembly Insert a black plastic inshot piston pushrod (45) into its respective bushing in the valve body (60). DO NOT lubricate the black pushrod or internal walls of the inshot piston bushing in body (60). NOTE: Only black in color plastic inshot piston pushrods (45) must be re-used. Clear plastic inshot pushrods (45) must NOT be re-used Position a NEW diaphragm (43) on top of inshot piston pushrod (45) so that the flat surface of the diaphragm, which shows the part number, is facing away from piston pushrod (45). Use a finger to properly seat the diaphragm (43) in its groove in the body (60) Install the plastic diaphragm follower (42) on top of the NEW diaphragm (43). Install spring (40) into the plastic diaphragm follower (42). NOTE: Inshot piston spring (40) used should be 50% red in color. Vent Valve Carefully insert a clean, plastic vent valve piston (39) into the body (60). NOTE: Metal vent valve piston (39) must NOT be re-used Place a NEW vent valve piston diaphragm (38) on the plastic vent valve piston (39) ensuring that the part number on the diaphragm faces the piston. With the aid of the hand tool, shown in Figure 22, page 47, properly position the diaphragm (38) so that the loop of the diaphragm sits between the plastic piston (39) and body (60) Install a NEW 15/16" O.D. ring gasket (36) and a NEW ⅝" O.D. ring gasket (37) in their grooves in the vent valve cover (35). NOTE: thru for ABDX-R & ABDXL-R only; for ABDX & ABDXL proceed to Section (Refer to Figure 10, page 39) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four hex head cap screws (33, 34, 66) Place the vent valve cover (35) on the body (60) and install the two ½" x 1⅛" hex head cap screws (33) and the ½" x 1¾" hex head cap screw (34). Do not tighten at this time. Page 31 of 61

32 NOTE: Metal identification P tag (33a) is no longer required to be put back on emergency valve portions after April 1, Place a NEW seal (70) onto the volume fitting (68) from the threaded end, leaving just the threads exposed. Two seals (70) may be required Coat the threads of the volume fitting (68) with a compound as described in Section 3.2.3, page 8. Secure the volume fitting (68) into the body Coat the surface of the NEW 7/16" O.D. o-ring (69) with #2 Silicone Grease, Wabtec Corporation Specification M Also lightly lubricate the o-ring groove of the volume fitting (68) and the bearing surface bore of the volume (67) with #2 Silicone Grease, Wabtec Corporation Specification M (NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M to both the o-ring groove on the volume fitting (68) and the bearing surface bore of the volume (67) Install the NEW lubricated 7/16" O.D. o-ring (69) into the groove on the volume fitting (68) Align the volume (67) with the volume fitting (68) and the vent valve cover hole. Secure the volume (67) in its position by installing the ½" x 3" hex head cap screw (66) Tighten the four vent valve cover hex head cap screws (33, 34, 66) in a manner to securely fasten assembly to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the four cap screws (32, 34, 66) between 35 and 55 foot-pounds.) Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of all four hex head cap screws (33, 34). Place the vent valve cover assembly (35 to 37) on the body (60) and secure it in position by installing two ½" x 1⅛" hex head cap screws (33) and two ½" x 1¾" hex head cap screws (34). Tighten the four cap screws (33, 34) in a manner to securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of cover gaskets. (NOTE: Wabtec recommends torquing the four cap screws (33, 34) between 35 and 55 foot-pounds.) NOTE: Metal identification P tag is no longer required to be put back on emergency valve portion after April 1, Alternative Filter Configuration (Refer to Figure 10, Page 39) NOTE: to for ABDX-R bodies only that do NOT contain plug/ring/filter assembly (61, 62, 63) in the internal vent valve exhaust cavity in the body (60) Carefully position a NEW alternative filter configuration assembly (59) into its proper place inside of the vent valve exhaust cavity of the body (60) Apply Loctite 242 to the threads of set screw (65) and start set screw into tapped threads in body (60), located in vent valve diaphragm cavity in body (60) Align up the NEW alternative filter configuration assembly (59) so the set screw (65) passes through the brass loop on the filter assembly (59) Using an allen wrench, tighten set screw until it goes flush with the body (60). NOTE: With a lint free cloth, wipe away excess Loctite 242 from vent valve diaphragm cavity in body (60). Page 32 of 61

33 10.56 Using a rigid but blunt object, position the alternative filter configuration assembly (59) inside of the valve body (60) to completely cover the entire internal exhaust cavity in the body (60). NOTE: The bottom of the alternative filter configuration assembly (59) should be wedged underneath the brass pin in the body (60) to retain its position inside of the body (60). Internal Vent Protector (Refer to Figure 9, page 37) If the body (60) was originally equipped with an internal vent protector assembly (64), then secure a NEW seal (66) with a NEW 3/16" x ½" aluminum pop rivet (67) into the retainer (65) Secure the retainer/seal assembly (65, 66, 67) in place into the body (60) by installing the retainer ring (68) using snap ring pliers. Be sure the snap ring (68) is fully seated into its groove in the body (60). NOTE: All ABDX-L/ABDX-R/RL emergency valve portions that have been clean, oil, and tested must contain a nameplate tag or paint stencil that includes the date of reconditioning (MM/YY) and shop identification. If the nameplate tag is used, it must be located under the specific hex head cap screw as shown in Figure 9, page 37 or in Figure 10, page 39. If the paint stencil is used, the specific information described above must be shown in ½ minimum height letters on the valve body TESTING PROCEDURES 11.1 The reassembled operating portions must be tested and pass the AAR approved shop test rack tests stated in the Code of Tests in the current issue of Wabtec Corporation Instruction Manual Standard No , Sup. 2, AAR Standard S Contact your local Wabtec Corporation Representative or Marketing Headquarters in Wilmerding, Pennsylvania for the latest issue of the Code of Tests SHIPPING REQUIREMENTS 12.1 When the operating portions are not attached to the pipe bracket, the ports are exposed to dirt and, therefore, special covers and stem guards must be fitted for protection against dirt and damage. To secure this protection, special shipping covers as illustrated in Figure 5, page 34, or approved equivalents, are required. These covers and guards, in Figure 6, must be applied to the portions as soon as they have passed the Code of Tests and removed from the test rack, and must not be removed until just ready to apply each cleaned portion to the car. Even then, special precautions must be taken to avoid damaging the parts or getting dirt into the operating portions when applying them Release valve stem guard, Figure 6, page 34, is required to protect the internal parts from damage. This stem guard must be applied to release valve stem and held in place by cotter pin before transporting service portion A vent protector plug, Figure 7, page 34, is also required for emergency portions that take the external style vent protector assembly (16) located in Figure 8, page 35. This plug must be applied when this type of emergency portion is removed from the test rack and must not be removed until ready to apply the portion to the car. On emergency portions containing the internal vent protector assembly (64) (Figure 9, page 37), duct tape (or equivalent) must be used to completely cover the entire internal vent protector assembly when the emergency portion is removed from the test rack. The duct tape (or equivalent) must NOT be removed until the emergency portion is ready to be installed onto the car. Page 33 of 61

34 Figure 5 Approved Shipping Covers Figure 6 Release Valve Stem Guard Figure 7 Vent Protector Plug Page 34 of 61

35 13.0 EXPLODED VIEWS Figure 8 - Control Valve Parts 1 STRAINER (2 Req d.) 2 HEX NUT, 5/8" (3 Req d.) 3 EMERGENCY PORTION 4 GASKET, Emergency Portion 5 HEX NUT, 5/8" (3 Req d.) 6 SERVICE PORTION 7 GASKET, Service Portion 8 STRAINER NUT 9 STRAINER 10 STUD, 5/8" x 3" 11 STUD, 5/8" x 73/8" 12 STUD, 5/8" x 71/8" 13 STUD, 5/8" x 65/8" (3 Req d.) 14 STUD, 5/8" x 73/8" (ABDXL Only) 15 PIPE BRACKET 16 VENT PROTECTOR ASSEMBLY (external style) a VENT PROTECTOR BODY b RIVET c VENT PROTECTOR SEAL Page 35 of 61

36 ABDX, ABDXL Emergency Portion Parts (Figure 9, page 37) 1 CAP SCREW (4 Req d.) 1a COT-S TAG NAMEPLATE 2 COVER 3 CAP SCREW 4 FOLLOWER 5 DIAPHRAGM 6 PIN 7 SPRING, Emergency Slide Valve 8 VALVE, Emergency Slide 8a FILTER 9 RING, Top Emergency Piston 10 RING, Bottom Emergency Piston 11 PISTON (with two machined grooves) 11a PISTON (without two machined grooves) 12 SPRING, High Pressure Return (green) 12a SPRING, High Pressure Return (blue) 13 O-RING (5 Req d.) 14 SPRING, Bottom H.P. Spool 15 VALVE, High Pressure Spool (latest design) 15a VALVE, High Pressure Spool (old design) 16 SPRING, Check Valve 17 SEAT 18 CHECK VALVE, Emergency Acc. Release 19 SNAP RING 20 STRAINER 20a STRAINER (Plastic) 21 RING GASKET 22 RING GASKET (2 Req d.) 23 RING GASKET 24 RETAINER 25 SPRING, Check Valve 26 CHECK VALVE, Inshot 27 RETAINER 28 SPRING, Vent Valve 29 CAP SCREW 30 SEAL 31 PISTON (metal) 32 PLASTIC SMALL VENT VALVE PISTON ASSEMBLY 33 CAP SCREW (2 Req d.) 33a METAL IDENTIFICATION P TAG 34 CAP SCREW (2 Req d.) 35 COVER 36 RING GASKET 37 RING GASKET 38 DIAPHRAGM 39 PISTON 40 or 40a SPRING, Inshot Piston 41 HEX NUT 42 FOLLOWER (Plastic) 42a FOLLOWER (Aluminum) 43 or 43a DIAPHRAGM 44 O-RING 45 PISTON, Inshot (Plastic) 45a PISTON, Inshot (Brass) 46 O-RING 47 CAP NUT 48 SPRING, Spool Valve 49 O-RING (4 Req d.) 50 VALVE, Emerg. Acc. Release Spool 50a VALVE, Vibration Protected Emergency Acc. Release Spool 51 CHOKE PLUG, Number 41 Drill 52 CHOKE PLUG, Number 46 Drill 53 CHOKE PLUG, Number 76 Drill 54 FILTER 55 RETAINER 56 PIPE PLUG (5 Req d.) 57 CHOKE PLUG, Number 73 Drill - ABDX 57 CHOKE PLUG, Number 67 Drill - ABDXL 58 FILTER 59 CHOKE PLUG, Number 46 Drill 60 BODY 61 PLUG 62 RING 63 FILTER 64 INTERNAL VENT PROTECTOR ASSEMBLY 65 RETAINER 66 SEAL 67 POP RIVET 68 SNAP RING Page 36 of 61

37 Page 37 of 61

38 ABDX-R, ABDXL-R Emergency Portion Parts (Figure 10, page 39) 1 CAP SCREW (4 Req d.) 1a COT-S TAG NAMEPLATE 2 COVER 3 CAP SCREW 4 FOLLOWER 5 DIAPHRAGM 6 PIN 7 SPRING, Emergency Slide Valve 8 VALVE, Emergency Slide 8a FILTER 9 RING, Top Emergency Piston 10 RING, Bottom Emergency Piston 11 PISTON (with two machined grooves) 11a PISTON (without two machined grooves) 12 SPRING, High Pressure Return (green) 12a SPRING, High Pressure Return (blue) 13 O-RING (5 Req d.) 14 SPRING, Bottom H.P. Spool 15 VALVE, High Pressure Spool (latest design) 15a VALVE, High Pressure Spool (old design) 16 SPRING, Check Valve 17 SEAT 18 CHECK VALVE, Emergency Accelerated Release 19 SNAP RING 20 STRAINER 21 RING GASKET 22 RING GASKET (2 Req d.) 23 RING GASKET 24 RETAINER 25 SPRING, Check Valve 26 CHECK VALVE, Inshot 27 RETAINER 28 SPRING, Vent Valve 29 CAP SCREW 30 SEAL 31 PISTON (metal) 32 PLASTIC SMALL VENT VALVE PISTON ASSEMBLY 33 CAP SCREW (2 Req d.) 33a METAL IDENTIFICATION P TAG 34 CAP SCREW 35 COVER 36 RING GASKET 37 RING GASKET 38 DIAPHRAGM 39 PISTON 40a SPRING, Inshot Piston 41 HEX NUT 42a FOLLOWER (Aluminum) 43a DIAPHRAGM 44 O-RING 45a PISTON, Inshot (Brass) 46 O-RING 47 CAP NUT 48 SPRING, Spool Valve 49 O-RING (4 Req d.) 50 VALVE, Emerg. Acc. Release Spool 50a VALVE, Vibration Protected Emergency Acc. Release Spool 51 CHOKE PLUG, Number 41 Drill 52 CHOKE PLUG, Number 46 Drill 53 CHOKE PLUG, Number 76 Drill 54 FILTER 55 RETAINER 56 PIPE PLUG (3 Req d.) 57 CHOKE PLUG, Number 73 Drill - ABDX-R 57 CHOKE PLUG, Number 67 Drill - ABDXL-R 58 FILTER 59 FILTER 60 BODY 61 PLUG 62 RING 63 FILTER 64 PIPE PLUG 65 SCREW, Set 66 CAP SCREW 67 VOLUME 68 FITTING, Volume 69 O-RING 70 SEAL Page 38 of 61

39 Figure 10 ABDX-R, ABDXL-R Emergency Portion Parts Page 39 of 61

40 ABDX, ABDX-R Service Portion Parts (Figure 11, page 41 & Figure 14, page 42) 1 CAP SCREW, (4 Req d.) 1a COT-S TAG NAMEPLATE 1b METAL IDENTIFICATION P TAG 2 COVER 3 RING GASKET 4 CAP SCREW 5 FOLLOWER 6 DIAPHRAGM 7 RETAINER 8 SEAT 9 SPRING, Piston 10 GUIDE 11 PIN 12 SPRING, Slide Valve 13 SPRING, Graduating Valve 14 VALVE, Graduating 15 VALVE, Slide 16 PISTON (with two machined grooves) 16a PISTON (without two machined grooves) 16b RINGS, Top & Bottom Service Piston 17 CAP SCREW (4 Req d.) 18 COVER 18a WEAR SHIELD 19 HEX NUT 20 FOLLOWER 21 DIAPHRAGM 22 PISTON (with plastic wear pellet) 22a PISTON (without plastic wear pellet) 23 PLUNGER 24 O-RING 25 RING GASKET 26 SEAT 27 SPRING, Check Valve 28 CHECK VALVE, Acc. Release 29 FILLING PIECE 30 GASKET 31 CAP SCREW (4 Req d.) 32 CHECK VALVE, Back Flow 33 SPRING, Check Valve 34 CAGE (Aluminum) 34a CAGE (Plastic) 35 SPRING, Piston Return 36 or 36a SPRING, Limiting Valve, Bottom 37 HEX NUT 38 FOLLOWER (Plastic) 38a FOLLOWER (Aluminum) 39 or 39a DIAPHRAGM 40 O-RING 40a O-RING 40b O-RING (3 Req d.) 41 STEM (plastic) 41a SPRING, Limiting Valve, Upper 41b PISTON, Limiting Valve (brass) 42 RING GASKET 43 RING GASKET 44 RING GASKET 45 COVER, Bottom (2 Exhaust Ports) 45a COVER, Bottom (1 Exhaust Port) 46 FELT FILTER 47 BODY (Configuration Control A on Nameplate) 48 CHOKE PLUG, 3/32" Drill 49 CHOKE PLUG, Number 18 Drill 50 CHOKE PLUG, Number 55 Drill 50a CHOKE PLUG, Number 54 Drill 51 CHOKE PLUG, 1/32" Drill 52 HEX NUT (3 Req d.) 53 STUD (3 Req d.) 54 RING GASKET 55 RING GASKET (5 Req d.) 56 SCREEN (3 Req d.) 57 RELEASE VALVE PORTION Refer to Figure 14, Page 42 for Latest SAR Valve Details 58 CAP SCREW (4 Req d.) 59 COVER 60 SPRING 61 GASKET 62 FOLLOWER (plastic) 63 DIAPHRAGM 64 PISTON (plastic) 65 O-RING 66 SPRING 67 BODY (Configuration Control C on Nameplate) Page 40 of 61

41 Figure 11 ABDX, ABDX-R Service Portion Parts Page 41 of 61

42 Figure 12 ABDX Service Valve with OLD Standard SAR Valve Assembly (Configuration Control A on Valve Nameplate) Figure 13 ABDX Service Valve with NEW Standard SAR Valve Assembly (Configuration Control C on Valve Nameplate) Figure 14 NEW Standard SAR Valve Details (Configuration Control C on Valve Nameplate) Page 42 of 61

43 1 CAP SCREW (5 Req d.) 2 COVER 3 RING GASKET (2 Req d.) 4 SPRING, Release Spool Valve 5 HEX NUT 6 FOLLOWER 7 DIAPHRAGM 8 O-RING 9 PISTON 10 VALVE, Release Spool 11 O-RING (3 Req d.) 12 SPRING, Check Valve (2 Req d.) 13 CHECK VALVE (2 Req d.) 14 PLUNGER (2 Req d.) (plastic) 15 CAP SCREW (5 Req d.) 16 SPRING, Reset Spool Valve 17 O-RING (3 Req d.) 18 VALVE, Reset Spool 19 SPRING, Retaining 20 CHECK VALVE, Retaining 21 CHECK VALVE, Reset 22 SPRING, Reset 23 SPRING, Lifter 24 PIN, Cotter 25 GUARD 26 LIFTER (plastic) 27 STEM AND END PLATE 28 GASKET 29 RING GASKET 30 SEAL 31 COVER 32 SEAL 33 POP RIVET 34 SLEEVE (plastic) 35 BODY Release Valve Portion Parts (Figure 15, page 44) Page 43 of 61

44 Figure 15 - Release Valve Portion Parts Page 44 of 61

45 14.0 SPECIAL TOOLS IMPORTANT: The information shown in Figures 16 thru 23 for making tools 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 of the specified tools (including claims by third parties.) Figure 16 - Hand Tool for Diaphragm Figure 17 - Mandrel for Installing O-rings Page 45 of 61

46 Figure 18 Service Piston Assembly Fixture, Part No Figure 19 - Limiting Valve Piston Spanner Wrench Figure 20 - Service Accelerated Release Valve Piston Spanner Wrench Page 46 of 61

47 Figure 21 - Inshot Piston Spanner Wrench Figure 22 - Vent Valve Diaphragm Installation Figure 23 - Filter Removal Page 47 of 61

48 APPENDIX Service Bulletin 68-19: New Quick Service Limiting Valve Details; April 1997 Service Bulletin 68-22: New Emergency Accelerated Release E.A.R. Filter Details; May 1999 Service Bulletin 68-26: Lubrication of AB Type Service & Emergency Portions; September 2004 Page 48 of 61

49 68-19 Service Bulletin FREIGHT CONTROL VALVES New Quick Service Limiting Valve Details April 1997 ABDX Service Portions incorporating a bottom cover with one exhaust port, as shown in Figure 1, have a quick service limiting valve configuration requiring updated details. Updated limiting valve details, see Figure 3, must be installed during the next COT&S. The limiting valve assembly, with one exhaust port in the bottom cover, requires five details to be scrapped with four of those being replaced. At the time of COT&S, Service Portions having two exhaust ports in the bottom cover, as shown in Figure 1, do not need updated details added to the limiting valve configuration. Portions equipped with the 3 O-ring, brass limiting valves should be handled as usual. Figure 1 - Bottom Cover illustrations to determine Limiting Valve configuration Page 49 of 61

50 68-19 Service Bulletin Figure 2 - Bottom Cover Assembly (1 Exhaust Port) Figure 3 - Bottom Cover Assembly (2 Exhaust Ports) NOTE: During disassembly the following details should be SCRAPPED: Ref. No. Description Pc. No. 2-2 Bottom Cover Assembly (with 1 exhaust port) 2-2A Quick Service Volume Exhaust Choke 2-6 Filter Spring Follower NOTE: The bottom cover, quick service volume choke and follower will be replaced with the following new style details: Ref. No. Description Part No. 3-2 Bottom Cover Assembly (with 2 exhaust ports) 3-2A Quick Service Volume Exhaust Choke 3-9 Spring Follower Page 50 of 61

51 68-22 Service Bulletin Disassembly of Limiting Valve Configuration with One Exhaust Port (See Figure 2) WARNING: DO NOT use hard or sharp metal tools to remove or install O-rings, seals, gaskets, or diaphragms. Exercise care so that NO damage is done to surfaces and parts. WARNING: The bottom cover (2) is under spring load. Exercise care so that no parts are inadvertently expelled from the assembly. Inadvertently expelled parts may cause bodily injury. 1. Remove the four ½" x 1¼" hex head screws (1) which secure the bottom cover (2) to the body (18). 2. Remove the bottom cover (2) from the body (18). NOTE The quick service volume exhaust choke (2A) located in the bottom cover (2) does not have to be removed. It can be scrapped with the bottom cover. 3. Remove and SCRAP the bottom cover (2) which includes the 1-1/16" O.D. ring gasket (3), the 2" O.D. ring gasket (4), the 3⅜" ring gasket (5), and the filter (6). 4. Remove the check valve spring (7) and the check valve (8) from the body (18). SCRAP the check valve (8). 5. Remove the brake cylinder limiting valve spring (9), follower (10), diaphragm (11), brake cylinder limiting valve stem (12), and spring (15). SCRAP the spring (9), the follower (10) and diaphragm (11). 6. Remove and SCRAP the O-rings (13, 14) from the brake cylinder limiting valve stem (12). 7. Remove the piston return spring (16) and the spring cage (17) from the body (18). Assembly of Limiting Valve Configuration with Two Exhaust Ports (See Figure 3) NOTE: Part piece numbers are identified in WABCO Freight Car Products issued parts catalogs. Contact your local Wabtec Corporation Representative for the appropriate documents. NOTE: The quick service volume exhaust choke (2A) is to be assembled in the body (18). The quick service volume exhaust choke in the body takes the place of the choke that was scrapped in the cover with one exhaust port. 1. Using #2 Silicone Grease, Wabtec Corporation Specification M , lubricate the surface of the two NEW O-rings (13, 14). Also lightly lubricate the O-ring grooves of the brake cylinder limiting valve stem (12). Using a foam-tipped swab applicator, lightly lubricate the internal walls of the piston bushing in the body (18). 2. Install the NEW 9/32" O.D. O-ring (13) and the NEW 7/32" O.D. O-ring (14) into their grooves on the brake cylinder limiting valve (12). 3. Install spring (15) into the proper bushing in the body (18). Insert the brake cylinder limiting valve stem (12) with O-rings into the bushing on top of spring (15). Page 51 of 61

52 68-22 Service Bulletin 4. Position a NEW diaphragm (11) on the top of the brake cylinder limiting valve stem (12) so that the flat surface of the diaphragm, which shows the part number, is facing away from the stem. Be sure the bead of the diaphragm (11) is properly seated in its groove in the body. Use finger pressure to seat the bead. 5. Install the new style diaphragm follower (10) into the body (18) on the top of the diaphragm (11). Install the new style brake cylinder limiting valve spring (9) into the diaphragm follower (10). 6. Install a NEW back flow check valve (8) and check valve spring (7) into the proper cavity of the body (18). 7. Install cage (17) and spring (16) into the proper cavity of the body (18). 8. Install a NEW 3⅜" O.D. O-ring gasket (5), a NEW 2" O.D. ring gasket (4), and a NEW 11/16" O.D. ring gasket (3) into their grooves in the bottom cover (2). 9. Carefully position the new style bottom cover assembly (2 to 5) on the body (18) making sure that all gaskets and assemblies are properly in place. Secure bottom cover (2) to the body (18) by installing four ½" x 1¼" hex head cap screws (1). Equally torque the screws between 35 and 55 foot-pounds. NOTE: ABDX Service Portions, with one exhaust port in the bottom cover, may also need a previous modification reversed. This modification installed a choke fitting in place of an allen head plug in the side wall of the portion. The two variations of choke fittings installed were: 1) Splined Brass Choke (Figure 4) 2) Vent Protector Assembly - Vent Protector, Pipe Nipple and Fitting (Figure 5) During the updating of limiting valve details, if the Service Portion body is equipped with either combination of choke fitting, the fitting will have to be removed. The fitting combination should be replaced with an allen head Figure 4 - Service Portion with Splined Brass Choke Figure 5 - Service Portion with Vent Protector Assembly Page 52 of 61

53 68-22 Service Bulletin FREIGHT CONTROL VALVES New Emergency Accelerated Release E.A.R. Filter Details May 1999 A NEW thimble type stainless steel air filter, Pc. No , protecting the Emergency Accelerated Release (E.A.R.) check valve is being standardized for use in the ABD/S/W/X type control valves. This new stainless steel air filter (Figure 1) replaces the nylon air filter, Pc. No (Figure 2). The stainless steel filter has been used in the new O.E.M. and remanufactured ABDX and ABDX-L control valves since September 9, Figure 1 New Stainless Steel Air Filter Note: Figure 2 illustrates the old style nylon air filter used with O.E.M. and remanufactured emergency valves built prior to September 9, Figure 2 - Old Nylon Air Filter Page 53 of 61

54 68-22 Service Bulletin The installation and removal procedure for the new strainer is as follows: Note: During C.O.T. & S., retrofit, and/or repair of the emergency portion of the control valves, FOLLOW STANDARD PROCEDURE for disassembly and reassembly of the valve, with the following additions. Note: Use the NEW stainless steel air filter, and SCRAP the nylon air filter. Required/recommended equipment for installation/removal: Ring Installation Tool, Pc. No Arbor Press, such as 12½" capacity RKBO-3 Ring Removal Tool, Pc. No Ergonomic Roto Clip Pliers, No. EPL-100 1¼" Wrench New Stainless Steel E.A.R. Filter Installation (Using Assembly Views): Note: Assembly requires the insertion of two new internally threaded brass retaining rings, Pc. No into the internal brass bushing, Pc. No , utilizing tool, Pc. No Step 1: a) Place emergency valve body on the arbor press and position such that the emergency accelerated release check valve bushing, Pc. No , is approximately centered under the press ram. b) Place retaining ring, Pc. No , onto ring installation tool, Pc. No , and position carefully on top of the bushing seat as illustrated. Caution: Take care not to damage the seat of bushing, Pc. No Note: In the unlikely event that the retaining ring freely enters the inside diameter of the bush without interference, the emergency body is not suitable for use with this filter/ring arrangement. DO NOT PROCEED. This valve body should be scrapped or returned to the nearest WABCO Service Center for repair. Page 54 of 61

55 68-22 Service Bulletin Step 2: Press retaining ring into place until tool contacts the top of the portion body as illustrated, then carefully remove the installation tool. Step 3: Carefully insert filter, Pc. No , as illustrated. Note: Make certain that the filter is fully seated on top of the brass retaining ring. Step 4: Place upper retaining ring onto installation tool and position carefully on top of bushing seat. Step 5: Press the upper retaining ring into position in the bushing until the installation tool contacts the top of the emergency portion. Carefully remove the installation tool. Page 55 of 61

56 68-22 Service Bulletin New Stainless Steel E.A.R. Filter Removal (Using Assembly Views): Note: Removal of the new stainless steel filter, Pc. No , for cleaning or replacement, requires utilizing a special tool, complete Pc. No , which consists of a stud, Pc. No and a flanged nut, Pc. No , as illustrated below. Step 1: Engage the removal tool threaded stud fully into the upper retaining ring threads as shown. Step 2: Screw the flanged nut of the removal tool (clockwise) until it contacts the top of the emergency portion. Page 56 of 61

57 68-22 Service Bulletin Step 3: Continue to tighten (clockwise) the flanged nut of the removal tool with an 1¼" wrench. This will cause the stud of the removal tool and the retaining ring to rise out of the bushing. Remove the retaining ring from the stud. SCRAP the upper retaining ring. Step 4: Use pliers, Roto Clip No. EPL-100 (or equivalent), to gently grab the filter and remove from the bushing. Caution: DO NOT remove the bottom brass retaining ring. Note: Stainless steel air filter, Pc. No , may be cleaned and reused if NOT damaged. For installation of cleaned or new air filter use steps 3, 4 & 5 of the assembly procedure shown on page 3 of this bulletin. Page 57 of 61

58 68-22 Service Bulletin Note: Figure 3 illustrates O.E.M. emergency portions manufactured after September 9, These bodies include internal brass bushings, Pc. No , with a machined shoulder and annular groove for retaining snap ring. Figure 3 - New Stainless Steel Air Filter w/ Grooved Bushing & Snap Ring The installation and removal procedure for the new strainer in this configuration is as follows: Note: During C.O.T. & S., retrofit, and/or repair of the emergency portion of the control valves, FOLLOW STANDARD PROCEDURE for disassembly and reassembly of the valve, with the following additions. Using pliers, Roto Clip No. EPL-100 (or equivalent), carefully remove the retaining ring which secures the filter in the bushing. Remove the filter with Roto Clip No. EPL-100 pliers (or equivalent) as in step 4, page 5 of this bulletin. Note: Stainless steel air filter, Pc. No , may be cleaned and reused if NOT damaged. Carefully insert filter, Pc. No , as illustrated in step 3, page 3 of this bulletin. Note: Make certain the filter is fully seated on the shoulder of the brass bushing. Secure the filter in place by installing the retaining ring using pliers, Roto Clip No. EPL-100 (or equivalent). Be sure the retaining ring snaps in its groove in the brass bushing. Page 58 of 61

59 68-26 Service Bulletin LUBRICATION OF AB TYPE SERVICE & EMERGENCY PORTIONS SEPTEMBER 2004 Supersedes issue dated January 2003 This service bulletin is to provide graphic instruction on the recommended amounts and specific locations for the application of AAR Specification M-912 lubrication. It is recommended that the AAR Specification M-912 lubricant be applied, then spread with a clean foam tipped applicator (or equivalent) resulting in an even, light coating on the components identified in these instructions, as well as in the 2391 instruction leaflets. These instructions are meant to supplement the current instructions found in: 2391 Sup. 3 - Paragraphs 3.5.1, and Sup. 4 (Sept. 2004) - Paragraphs 8.5, 8.9, 8.15, 8.20, 10.13, 10.14, 10.15, 10.30, & Page 59 of 61

60 68-26 Service Bulletin Page 60 of 61

61 68-26 Service Bulletin Page 61 of 61