DEAD ENGINE FIXTURE PORTION

V 4243-1 Operation & Maintance Information DEAD ENGINE FIXTURE PORTION "U-1-65-8" Dead Engine Fixture, PART NO. 653968 "U-1-40-8" Dead Engine Fixture, PART NO. 569299 AUGUST, 2000 Supersedes issue dated May, 1998 NOTE: The following description and operation is based on this device and its components being new or this device and its components having been repaired, tested, installed and maintained in accordance with instructions issued by this and any other applicable Wabtec Corporation publications. WARNING: At the time any part is replaced in this device, the operation of the complete device must pass a series of tests prescribed in the latest issue of the applicable Wabtec Test Specification. At the time this device is applied to the brake equipment arrangement, a stationary vehicle test must be made to insure that this device functions properly in the total brake equipment arrangement. (Consult your local Wabtec Corporation Representative for identity of the test specification, with latest revision date, that covers this device.) E I L IMPORTANT: Only Wabtec Corporation supplied parts are to be used in the repair of this device in order to obtain satisfactory operation. Commercially available non- O.E.M. parts are unacceptable. NOTE: The part numbers and their associated descriptions are the property of Wabtec Corporation and may not be replicated in any manner or form without the prior sole written consent of an Officer of Wabtec Corporation. 2000 WABCO Locomotive Products A Wabtec Company. All rights reserved Page 1 of 8 August, 2000

Operation & Maintenance Information NOTE: The following description and operation is based on this device and its components being new or this device and its components having been repaired, tested, installed and maintained in accordance with instructions of this and any other applicable publications issued of this and any other applicable publications issued by the Wabtec Corporation. 1.0 DESCRIPTION The U-1-65-8 and U-1-40-8 Dead Engine Fixture Portions, Part Numbers 653968 and 569299 are manually set, two position type valves that function to direct air flow between two ports or passages or to block the flow of air between these two ports or passages, depending on the position of the handle and shaft subassembly. The two handle positions are LIVE and DEAD. These positions are designated on an escutcheon plate which is attached to the valve body by three machine screws. This panel mounted portion is commonly used as a component portion of Wabtec Corporation Unitized Brake Equipment such as 26-LU-M and 26 LU-L Carriage and Equipment Brackets. The U-1-40-8 and U-1-65-8 Dead Engine Fixture Portions are designed for use in equipment arrangements where the air pressure does not exceed 150 psig. These portions have a coded designation which contains four groups of characters. The first group, the letter U and second group, the number 1, indicate a type U Dead Engine Fixture Portion. The third group, the Number 65 or 40 indicates the pressure differential in psi across the valve as provided by the valve spring. The fourth group, the Number 8, indicates the choke plug in port 30 of the body in 1 /64 of an inch ( 1 /8 ). As an example: The designation U-1-65-8 indicates a U-1 Dead Engine Fixture Portion with a 65 psig differential spring and a 1 /8 choke in the body (port 30). Consult your Wabtec Corporation Representative for information as to the correct application of this device. 2.0 OPERATION Reference Figure 1 When the handle is manually depressed (toward the body) and moved into the detented LIVE setting, the attached shaft moves the piston to block any air flow between ports 1 and 30. Air under pressure entering port 30 is directed into cavity C on the spring side of the valve. This air pressure together with the force exerted by the spring inside the valve holds the valve against its retaining ring stop. Air under pressure entering port 1 flows into cavity A of the body on the non spring side of the valve where air is directed through a body passage to port B on the spring side of the piston. When the handle is manually depressed towards the body D C 30 1 Figure 1 - Diagrammatic View and moved into the detented DEAD setting, the attached shaft moves the piston to connect the choked port 30 passage to passage D and the unchoked passage 30 to cavity C on the spring side of the valve. Air under pressure entering port 1 flows into cavity A of the non spring side of the pistons and is directed through the body back into the spring side of the piston B. When the air pressure in cavity A builds up enough pressure to overcome the force exerted by the spring on the valve, the valve will move to permit air in pressure cavity A and port 1 to flow through D and the choke to port 30 and cavity C. When the air pressure in cavity C and the force exerted by the valve s spring is greater than the air pressure in cavity A the valve will move against its retaining ring stop to cut off air flow between port 1 and 30. The force of the valve s spring will determine the amount of main reservoir pressure available when hauling locomotives DEAD in a consist. Example: 90 psi BP and 65 psi spring in the dead engine fixture would provide 25 psi main reservoir pressure. The 40 psi spring would provide 50 psi main reservoir using the same brake pipe pressure. A B August, 2000 Page 2 of 8

Operation & Maintance Information 3.0 MAINTENANCE SCHEDULE IMPORTANT: AT LEAST ONCE EVERY TWENTY-FOUR MONTHS, OR MORE FREQUENTLY IF SERVICE CONDITIONS SO INDICATE, THE U-1-65-8 OR U-1-40-8 DEAD ENGINE FIXTURE PORTIONS ARE TO BE REMOVED FROM THE EQUIPMENT ARRANGEMENT, TAKEN TO THE SHOP, BE COMPLETELY DISASSEMBLED, THE PARTS CLEANED, INSPECTED, LUBRICATED, ASSEMBLED USING SPECIFIED NEW PARTS, AND THE PORTION TESTED FOR CORRECT OPERATION. 4.0 PARTS CATALOG AND REPLACEMENT PARTS 4.1 PARTS CATALOG Refer to the current issue of the Wabtec Corporation Parts Catalog 3243-1 when ordering replacement parts for the U- 1-65-8 or U-1-40-8 Dead Engine Fixture Portions, Part Numbers 653968 or 569299. NOTE: The reference numbers used in this publication and those used in the parts catalog may differ. Check the descriptive parts name and the parts number to be sure that the desired part is ordered. 4.2 REPLACEMENT PARTS IMPORTANT: To obtain satisfactory operation and reliability of the U-1-65-8 or U-1-40-8 Dead Engine Fixture Portions, ONLY Wabtec Corporation replacement parts are to be used in the maintenance of this device. 5.0 SAFETY PROCEDURES AND WARNINGS Regular operating property and shop safety procedures must be followed when working on or maintaining this device. The work area should be clean. WARNING: Extreme care must be taken when handling this device and its components and while performing the many tasks associated with its repair. It is of utmost importance that the workman read, understand and comply with the appropiate warnings listed below during maintenance procedure. Failure to observe these precautions may result in serious injury to those performing the work and/or bystanders. The use of an air jet, which must be less than 30 psig, to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/ or droplets of the cleaning solvent to become airborne. These conditions may cause skin and/or eye irritation. When using an air jet do not direct it toward another person. Improper use of air jet could result in bodily injury. Personal eye protection must be worn when performing any work on this device or its component parts to avoid any possible injury to the eyes. The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The manufacturers of the solvents and lubricants should be contacted for safety data (such as OSHA Form OSHA-20 or its equivalent). The recommended precautions and procedures of the manufacturers should be followed. When performing any test or work on devices or equipment while they are on the vehicle, special precautions must be taken to insure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment. Assembly may be under a spring load, Exercise caution during disassembly so that no parts Fly Out and cause bodily injury. All air supply and/or electric current to this device and/or to any components part must be cut-off before this device and/or any component part is removed from the equipment arrangement. Bottled up air under pressure (even though air supply is cut-off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when this device and/or any component part is removed from the equipment arrangement. Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on this device and/or component part. To prevent receiving electrical shock when performing electrical test, hands must be clear of electrical components, contacts and housing and required inlab grounding procedures must be strictly adhered to. A wooden work bench should be used. Failure to heed this WARNING could result in severe injury or death. Page 3 of 8 August, 2000

Operation & Maintenance Information 20 1 3 2 18 5 19 4 17 11 14 10 9 8 16 7 15 13 6 12 Figure 2 - U-1-65-8 Dead Engine Fixture Portion August, 2000 Page 4 of 8

Operation & Maintance Information An adequate support or lifting device must be available to support the complete unit or its major components during removal, installation and maintenance procedures. 6.0 CLEANING SOLVENT and LUBRICANT 6.1 CLEANING SOLVENT The cleaning solvent used to clean reusable parts MUST BE and aliphatic organic solution such as mineral spirits or naphta that dissolve oil or grease, and that will permit all parts to be cleaned without abrasion. 6.2 LUBRICANTS 6.2.1 No. 2 Silicon Grease, Wabtec Corporation Specification M-7680-2, such as Dow Corning Corporation No. 55 O-ring Lubricant, is required for lubrication of specified o-rings, o-ring grooves or shoulders and the bearing surfaces of the bushings into which o-ring assemblies are installed. 6.2.2 A compound consisting of one part graphite, Wabtec Corporation Specification M-7695-2, such as Superior Flake Graphite Company Superflake Number 597; Joseph Dixon Crucible Company Microfyne Graphite, and two parts of SAE- 20 oil be weight is to be used to coat the threads of the choke plug after the plug has been cleaned. 6.2.3 EPO Grease-Lithium Base with 3% Molybdenum Disulfide, Wabtec Corporation Company Specification M- 7672-1, such as Texaco Inc. 1920 Molytex Grease; or Tribol Molube-Alloy Multi-Purpose Grease, Grade 0, is required for the lubrication of the operating shaft. 7.0 MAINTENANCE PROCEDURES - IN SHOP IMPORTANT: When performing the procedures which follow, DO NOT use hard or sharp metal tools to remove o- rings or gaskets. Care MUST BE exercised so that no damages is done to metal parts. 7.1 DISASSEMBLY Reference Figure 2 7.1.1 If the two 15 /16 O.D. ring gaskets (20) are still in their grooves on the mounting face of the body (19), they are to be removed and SCRAPPED. These gaskets ARE NOT a part of the Dead Engine Fixture Portion, BUT ARE required when mounting the portion to a pipe bracket or panel. 7.1.2 Manually move the handle (4) so that it is midway between DEAD and LIVE positions, then remove the three 4-40 x 3 /8 flat head screws (1) which secure the escutcheon plate (5) to the body (19). 7.1.3 Manually turn the handle (5) to the LIVE position, then remove the handle (4), escutcheon plate (5) and the spring (3) from the shaft (2). 7.1.4 Remove the cover (7) from the bottom of the body (19) by first removing the two 5 /16 x 7 /8 hex head cap screws (6). 7.1.5 Remove and SCRAP the 1 3 /4 O.D. ring gasket (8) from its groove in the body (19). 7.1.6 Carefully press and hold the piston - valve subassembly (9 to 17) into the body (19) and then remove the shaft (2) from the body (19). Release the hold on the piston - valve subassembly (9 to 17). 7.1.7 Remove the piston assembly (9 to 17) as a unit from the body (19). Scrap the o-rings (14 and 15). 7.1.8 Remove the spring (17) from the piston (16). 7.1.9. Using the proper tool, carefully remove the internal retaining ring (9) from its groove in piston (16). 7.1.10 Remove the valve with o-ring subassembly (11 & 10) the shims (12) and the valve spring (13) from the piston (16). Scrap the o-ring (10). 7.2.2 SPRINGS 7.2.2.1 Wash the springs in a bath of the cleaning solvent as described in Section 6.1 of this publication. Springs may be wire brushed to assist in the removal of any dirt, rust, or scale. 7.2.2.2 After the springs have been cleaned, they MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the parts dry. 7.2.2.3 Inspect the springs. Replace ANY spring that is rusted, pitted, distorted, damaged in any way, has taken a permanent set, or if it is in such a condition that may result in the unsatisfactory operation of the Dead Engine Fixture Portions. Refer to the current Parts Catalog 3243-1 for spring information identification. Page 5 of 8 August, 2000

Operation & Maintenance Information 7.2.3 BODY 7.2.3.1 Remove the 1 /8 fluted choke plug (18) from the body (19) and place in a bath of the cleaning solvent to soak. 7.2.3.2 Clean the interior and exterior surfaces of the body using a clean, soft, lint-free cloth that has been saturated with the cleaning solvent as described in Section 6.1. DO NOT permit the body to soak in the cleaning solvent. 7.2.3.3 After the body is cleaned, it MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the body dry. 7.2.3.4 Inspect the body. Visually inspect the choke plug port to be sure that it is clean and unrestricted. If necessary, use a low pressure jet of clean dry air to blow out the port. Inspect the body for damage and/or excessive wear. Replace the body if it is cracked, damaged, broken, if the piston bushing is scored, has nicks or shows signs of excessive wear. Replace the body if it is in such a condition that may result in the unsatisfactory operation of the Dead Engine Fixture Portion. 7.2.3.5 Remove the choke plug from the solvent bath and blow it completely dry with a low pressure jet of clean dry air. 7.2.3.6 Inspect the choke plug to be sure that it is free of damage and that the orifice is clean and that the size, 1 /8 drill, has not been changed. DO NOT use hard or metal tools to clean the orifice. 7.2.4 Inspect the remaining parts. 7.2.4.1 Replace the retaining ring if it is cracked or broken, or if it is not elastic enough to hold securely. The retaining ring should snap into its groove when it is installed. 7.2.4.2 Replace ANY part that is cracked, cut, broken, excessively worn, damaged in any way, or if it is in such a condition that may result in the unsatisfactory operation of the U-1-65-8 or U-1-40-8 Dead Engine Fixture Portions. 7.3 ASSEMBLY Reference Figure 2 7.3.1 Apply a light coating of the oil and graphite compound, as described in Section 6.2.2 to the threads of the cleaned choke plug, then install the choke plug into its passage in the body port 30. The plug is to be installed so that it is even with or just below the surface of the body. 7.3.2 Apply a light coating of No. 2 Silicon Grease, Wabtec Corporation Specification M-7680-2, to the surfaces of a NEW 3 /4 O.D. o-ring (10). Also fill the o-ring groove of the valve (11) and lightly coat the bearing surface of the bushing in the piston (16) with lubricant. 7.3.3 Install the NEW lubricated 3 /4 O.D. o-ring (10) into its groove on the valve (11). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 7.3.4 Install the shims (12) into the valve (11), then install the valve spring (13) so it seats on the shims (12). 7.3.5 Install the valve with shims and spring subassembly (10 to 13) into the bushing of the piston (16). 7.3.6 Depress and hold the valve (11) in the bushing of the piston (16) far enough to expose the retaining ring groove, then install the retaining ring (9) in its groove. Be sure that the retaining ring (9) snaps into its groove. Slowly release the hold on the valve (11) to permit the force of the spring (13) to seat the valve (11). 7.3.7 Apply a light coating of No. 2 Silicon Grease, Wabtec Corporation Specifications M-7680-2, to the surfaces of a NEW 7 /16 O.D. o-ring (14) and to the surfaces of three NEW 1 1 /8 O.D. o-rings (15). Also fill the o-ring grooves of the piston (16) and lightly lubricate the piston bushing of the body (19) with the lubricant. 7.3.8 Install the NEW lubricated 7 /16 O.D. o-ring (14) and the three NEW lubricated 1 1 /8 O.D. o-rings (15) into their grooves on the piston (16). Remove any excess lubricant by wiping with a clean, dry, lint-free cloth. 7.3.9 Place the piston return spring (17) over the shaft of the piston (16) so that it comes to rest on the shoulder of the body of the piston (16), then insert the piston and spring subassembly (9 to 17) as a unit, stem end first, into the piston bushing of the body (19). Rotate the piston (16) until the slot in the shaft of the piston (16) can be seen in the operating shaft bushing of the body (19). August, 2000 Page 6 of 8

Operation & Maintance Information 7.3.10 Apply a coating of EPO Grease - Lithium Base with 3% Molybdenum Disulfide, Wabtec Corporation Specification M-7672-1, to the surfaces of the operating shaft (2). 7.3.11Position the operating shaft (2) so that the slot of the operating shaft (2) is aligned with the slot on the right hand side of the escutcheon plate mounting face of the body (19). Press the piston subassembly (9-17) into the body (19) and hold it in the inward position while installing the operating shaft (2) in place in the body (19). This will permit the dog of the shaft of the piston (16) to enter the slot in the stem of the piston (16). Slowly release the hold on the piston (16). 7.3.12 Install the handle spring (3) into the opening of the operating shaft (2). 7.3.13 Place the escutcheon plate (5) on the handle (4) so that the printed ( LIVE - DEAD ) side of the escutcheon plate (5) faces the knob of the handle (4). 7.3.14 Carefully install the handle-escutcheon plate subassembly (4 & 5) in the body (19) making sure that the pin in the handle (4) is properly positioned in the slot of the operating shaft (2). Push inward on the handle (4) and turn it to the left to secure the handle (4) in place. 1-40-8 Dead Engine Fixture Portion is removed from an equipment arrangement for ANY reason, and is reinstalled or replaced with a NEW or REPAIRED AND TESTED Portion, two new 15 /16 O.D. ring gaskets, Part Number 532092, MUST BE used when installing the portion. These gaskets are not a part of the Portion and MUST BE ordered as individual items. These gaskets are shown as Reference 20 in Figure 2. 7.4.3 IMPORTANT: Whenever either the U-1-65-8 Dead Engine Fixture Portion Part Number 653968 or the U- 1-40-8 Dead Engine Fixture Portion Part Number 569299 is removed from an equipment arrangement for ANY reason, and is reinstalled or replaced with a NEW or REPAIRED AND TESTED Portion, a stationary vehicle test MUST BE made to be sure that either the U-1-65-8 or U-1-40-8 Dead Engine Fixture Portion functions properly in the total equipment arrangement. 7.4.4 Consult your Wabtec Corporation Representative if additional information is required. 7.3.15 Rotate the escutcheon plate (5) on the body (19) so that the three screw holes of the plate (5) are aligned with the tapped holes in the body (19). Secure the escutcheon plate (5) in place by installing the three 4-40 x 3 /8 flat head screws (1). 7.3.16 Install a NEW 1 3 /4 O.D. ring gasket (8) into its groove on the corner mounting face of the body (19). 7.3.17 Install the cover (7) on the body (19) and secure it in place by installing two 5 /16 x 7 /8 hex head cap screws (6). Equally tighten the screws (6). 7.4 TESTING and ADDITIONAL INFORMATION 7.4.1 IMPORTANT: After either the U-1-65-8 or U-1-40- 8 Dead Engine Fixture Portions, Part Numbers 653968 or 564299 respectively has been assembled, BUT BEFORE it is returned to service, it MUST PASS a series of tests following the procedures of the current issue of the Wabtec Corporation Test Specification T-2974-D. 7.4.2 IMPORTANT: Whenever either the U-1-65-8 or U- Page 7 of 8 August, 2000

Operation & Maintenance Information WABCO Locomotive Products 1001 Air Brake Avenue Wilmerding, Pennsylvania 15148 (412) 825-1000 Fax (412) 825-1019 www.wabtec.com August, 2000 Page 8 of 8