Wabtec ABDX-SS 664742 Manual

Operation & Maintenance Instruction
August, 2003Page 1 of 24
4225-50, S.6
NOTE: The following description and
operation is based on this device and
its components being new or this
device and its components having
been repaired, tested, installed and
maintained in accordance with
instructions issued by this and any
other applicable Wabtec Corporation
publications.
WARNING: At the time any part is
replaced in this device, the operation of
the complete device must pass a
series of tests prescribed in the latest
issue of the applicable Wabtec Test
Specification. At the time this device is
applied to the brake equipment
arrangement, a stationary vehicle test
must be made to ensure that this device
functions properly in the total brake
equipment arrangement. (Consult your
local Wabtec Corporation
Representative for identity of the test
specification, with latest revision date,
that covers this device.)
IMPORTANT: Only Wabtec Corporation
supplied parts are to be used in the
repair of this device in order to obtain
satisfactory operation. Commercially
available non-O.E.M. parts are
unacceptable.
NOTE: The part numbers and their
associated descriptions are the
property of Wabtec Corporation and may
not be replicated in any manner or form
without the prior sole written consent of
an Officer of Wabtec Corporation.
ABDX®-SS CONTROL VALVE, PART NO. 664742
ABDX®-SS ALUMINUM SERVICE PORTION
ABDX®-SS ALUMINUM EMERGENCY PORTION
AUGUST, 2003
® Registered Trademark of Wabtec Corporation
© 2003 WABCO Freight Car Products. A Wabtec Company. All rights reserved
IMPORTANT: This valve is NOT to be applied to freight cars that are assigned to
Interchange Service on the North America Continent Railroads.

Operation & Maintenance Instruction
Page 2 of 24
August, 2003
4225-50, S.6
1.0 DESCRIPTION
The AB Single Capacity Freight Car Air Brake Equipment
with the ABDX Type Control Valve is functionally compatible
with equipments using the AB, ABD or the ABDW Control
Valve. Correct style ofABDX Control Valve must be applied
to specific length cars.
The ABDX Type Control Valve improves service braking by
providing both a shorter response time and a shorter brake
cylinder pressure build up time. The initial quick service
function has been improved through a new service piston,
diaphragm and diaphragm clamping arrangement.
Other benefits of the ABDX Type Control Valve include
improved undesired emergency (UDE) protection, improved
protection against leakage, and the elimination of the need
for auxiliary continuous quick service valves.
1.1 PARTS OF THE EQUIPMENT
The following is a description of the Control Valve which is
part of theAB Freight CarAir Brake Equipment with theABDX
Type Control Valve:
1.1.1 ABDX TYPE CONTROL VALVE
The ABDX Type Control Valve controls the flow of air to and
from the brake cylinder and to charge the reservoirs. It consists
of a Pipe Bracket, a Service Portion and an Emergency
Portion.
1.1.2 PIPE BRACKET
TheABDX Control Valve uses the AAR AB type pipe bracket.
This is a two-face pipe bracket to which are mounted the
service and emergency portions. Figures 2 and 3 show the
port identification on each face. The pipe bracket is semi-
permanently bolted to the car. Pipe connections may be made
by means of adjustable welded fittings secured to machined
flange pads on the pipe bracket. No pipe connections need
to be disturbed when removing or replacing the service or
emergency portion. The pipe bracket contains the quick action
chamber and a removable strainer which provides long life by
minimizing the passage of dirt particles to the valve and brake
cylinder.
Pipe Connections - Figure 4 shows the pipe bracket face
to which the pipe connections are made. Each port
connection is identified by number and name.
Figure 1 - Diagrammatic View

Operation & Maintenance Instruction
August, 2003Page 3 of 24
4225-50, S.6
Figure 2 - Pipe Bracket Service Face
Port Identification
Figure 3 - Pipe Bracket Emergency Face
Port Identification
Figure 4 - Pipe Bracket Face Pipe Connections
e3
b
b4
c
c3 c2
Q.A.C.
c4
c3 b2
EX
a
E2
b
Port
a - To Auxillary Reservoir
b - To Brake Pipe
b2 - To Strainer Nut Cavity
c3 - To Emergency Face and Branches c2 and c4
c4 - To Passage c3
e2 - To Emergency Reservoir and to Emergency Face
EX - To Retaining Valve
Port
b - To Brake Pipe
b4 - To Brake Pipe Passage b
c - To Brake Cylinder
c2 - To Passage c3
c3 - To Service Face and Branch Ports c2 and c4
e3 - To Emergency Reservoir and Service Face
Q.A.C. - To Quick Action Chamber
Port Designation Flange Size
1 Brake Pipe 1 inch
2 Emergency Reservoir 3/4inch
3 Brake Cylinder 3/4inch
5 Auxiliary Reservoir 3/4inch
10 Retainer 3/8inch

Operation & Maintenance Instruction
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August, 2003
4225-50, S.6
1.1.3 SERVICE PORTION
The Service Portion controls the flow of air from the auxiliary
reservoir to the brake cylinder during a service application
and the recharging of the auxiliary and emergency reservoirs,
and exhaust of brake cylinder during a release. The
accelerated release feature speeds up the recharge of brake
pipe during a release of a service application by the use of a
small amount of air from the emergency reservoir. The Service
Portion also includes a large capacity manual release valve.
This release valve offers the choice of exhausting only the
brake cylinder, exhausting the auxiliary reservoir and brake
cylinder, or exhausting both reservoirs and the brake cylinder.
Figure 2 shows the port identification on the service portion
bolting face. The ABDX-SS Service Portion has been tuned
to optimize the Quick Service function for short cars.
1.1.4 EMERGENCY PORTION
The Emergency Portion controls the flow of air from both
reservoirs to the brake cylinder during an emergency
application. An emergency application can be obtained at
any time regardless of the existing state of service application
or release, provided brake pipe pressure has not been reduced
below 45 psi prior to initiating an emergency. Emergency
brake cylinder air pressure is approximately 20% higher than
that obtained from a full service brake application. The
emergency brake cylinder pressure is developed in two
stages, thus reducing train slack action.
The Emergency Portion also contains the accelerated
application feature which accelerates the service buildup of
brake cylinder pressure throughout the train by locally venting
brake pipe at each car. TheABDX-SS Emergency Portion is
tuned to optimize this feature on short cars with less than 45
feet of brake pipe.
The emergency accelerated release feature speeds up the
recharge of brake pipe during a release of emergency
application by the use of air from the brake cylinder and
auxiliary reservoir.
2.0 OPERATION
Refer to Wabtec Publication 5062-19 for the operation of
ABDX-SS Control Valve.
3.0 MAINTENANCE SCHEDULE
IMPORTANT: The ABDX-SS Control Valve should be
removed from the equipment arrangement, taken to the shop,
be completely disassembled, the parts cleaned, lubricated,
assembled, using NEW Wabtec Corporation rubber parts
and other specified NEW Wabtec Corporation parts. The valve
is then tested according to the following vehicle application
schedule, or more frequently if service conditions so indicate.
RECOMMENDED FREQUENCYAT LEAST
TYPE OF APPLICATION ONCE EVERY
FREIGHT Not to exceed 12 YEARS
4.0 PARTS CATALOG INFORMATION
4.1 PARTS CATALOG
IMPORTANT: When ordering replacement parts for the
ABDX-SS Control Valve, Part No. 664742, or any of its
component portions, refer to the current issue of Wabtec
Corporation Parts Catalog 3225-50, S.6.
NOTE: The reference numbers used in this publication and
those used in the parts catalog may differ. Check the
descriptive parts name to be sure that the desired part is
ordered.
4.2 REPLACEMENT PARTS
IMPORTANT: To obtain satisfactory operation and
reliability of the ABDX-SS Control Valve, ONLY Wabtec
Corporation replacement parts are to be used in the
maintenance of the ABDX-SS Control Valve. Commercially
available parts are unacceptable.
5.0 SAFETY PROCEDURES & WARNINGS
Regular car builder and/or owner-operating property and/or
shop safety procedures MUST BE followed when performing
any work on theABDX-SS Control Valve and/or its component
parts.
The work area should be clean.

Operation & Maintenance Instruction
August, 2003Page 5 of 24
4225-50, S.6
WARNING: The following statements of warning apply,
all or in part, wherever the symbol appears in the
maintenance procedures. Failure to observe these precautions
may result in serious injury to those performing the work
and/or bystanders.
 Portions weigh in excess of 30 pounds. Use care
when lifting and hauling portions to preclude injury.
 Due to the possibility of exhausting air, and high
decibel levels of noise associated with it, from the
device during testing, it is recommended that sufficient
hearing and eye protection be used. This is intended
to minimize the possibilities of hearing and eye injury
to the operator or persons near the test rack.
 The use of an air jet, which must be less than 30
p.s.i.g., to blow parts clean or to blow them dry after
being cleaned with a solvent will cause particles of
dirt and/or droplets of the cleaning solvent to be
airborne. Wire brushing may also cause particles of
dirt, rust and scale to become airborne. These
conditions may cause skin and/or eye irritation.
 When using an air jet, do not direct it toward
another person. Improper use of air jet could result in
bodily injury.
 Personal eye protection must be worn when
performing any work on this device or its component
parts to avoid any possible injury to the eyes.
 The use of solvents and lubricants can involve health
and/or safety hazards. The manufacturers of the solvents
and lubricants should be contacted for safety data (such
as OSHA Form OSHA-20 or its equivalent). The
recommended precautions and procedures of the
manufacturers should be followed.
 When performing any test or work on devices or
equipment while they are on the vehicle (on car test
etc.) special precautions must be taken to ensure that
vehicle movement will not occur which could result in
injury to personnel and/or damage to equipment.
Figure 5 - ABDX-SS Control Valve, Part No. 664742
8
A
B
3
4
5
6
10
9
11
7
C
12
2
1
8

Operation & Maintenance Instruction
Page 6 of 24
August, 2003
4225-50, S.6
 When performing the procedures which follow,
springs within the assembly may be under load.
Exercise care so that no parts are inadvertently expelled.
Inadvertently expelled parts may cause bodily injury,
and/or damage to parts.
 All air supply to this device and/or to any component
part must be cut off and any air in the device be allowed
to vent before this device and/or any component part
is removed from the equipment arrangement.
 Bottled up air under pressure (even though air
supply is cut off) may cause gaskets and/or particles of
dirt to become airborne and an increase in sound level
when this device and/or any component part is removed
from the equipment arrangement. Personal eye and
ear protection must be worn and care taken to avoid
possible injury when performing any work on this device
and/or component part.
 An adequate support or lifting device must be
available to support the device and/or valve portion(s)
during removal, installation and maintenance
procedures.
6.0 CLEANING SOLVENT, LUBRICANT & SEALANT
6.1 CLEANING SOLVENT
6.1.1 The means used to clean the reusable parts of the
ABDX-SS Type Control Valves MUST BE an aliphatic
hydrocarbon solvent, such as mineral spirits or naptha, or a
heated aqueous biodegradable detergent and rinse.
IMPORTANT: Cleaning materials are to be used in a well
ventilated area.
6.2 LUBRICANT
Lubricant Current AAR Specification
Triple Valve Oil M-912
Dry Graphite M-913
Brake Cylinder Lubricant M-914
6.2.1 The o-ring, o-ring grooves and the o-ring bearing
surfaces of the bushing(s) must be lubricated with Number 2
Silicone Grease, Wabtec Corporation Specification M-07680-
02 (Industry Designation MIL-G-4343), such as Dow Corning
Corporation, Dow Corning 55.
6.2.2 The threads of choke plugs and all other removable
plugs, as well as all other threaded parts which may later be
difficult to remove, must be pre-coated with a Loctite product
called Vibraseal #517. The Vibraseal plugs are to be fully
threaded into place, however discretion should be used when
tightening the choke plug, to facilitate removal.
6.3 SEALANT
6.3.1 Locking Sealant, WestinghouseAir Brake Company
Specification M-07499-05, such as Loctite Corporation TL-
242, is required for application to certain threads.
7.0 MAINTENANCE PROCEDURE
7.1 ON-CAR MAINTENANCE PROCEDURES
IMPORTANT: ON-CAR Maintenance is limited to the
removal and replacement of Component Portions. No ON-
CAR repair of the valve is to be attempted.
7.1.2 SPECIAL TOOLS
IMPORTANT: The information shown in Figures 6 thru 11,
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).
7.2 PORTION REMOVAL & INSTALLATION - "ON CAR"
7.2.1 IMPORTANT: ALL car builder and owner-
operating property safety procedures, in addition to warnings
as listed in Section 5 of this publication, MUST BE adhered to.
7.2.2 IMPORTANT: The handbrake(s) of the car
MUST BE applied and the wheels of the car chocked to
prevent unintentional car movement. Warning placards
indicating that work is being performed are to be placed on
and about the car.
7.2.3 IMPORTANT: ALL air flow to the ABDX-SS
Control Valve MUST BE allowed to deplete and subsequently
be cut off.

Operation & Maintenance Instruction
August, 2003Page 7 of 24
4225-50, S.6
Figure 8 - Service Piston Assembly Fixture
Figure 6 - Hand Tool for Diaphragm Installation Figure 7 - Mandrel for Installing O-rings
Piston or Spool Valve
O-rings
Mandrel
Air Hole

Graduating Valve Spring
Driver
Roll Pin
Section A-A
Slide Valve Spring
Slide Valve
Graduating Valve
Piston Stem
Slide Valve Spring
Fixture Back Plate
Jaws of Bench Vise
Fixture Body
Roll Pin in Place
A
Graduating Valve
Fixture Back Plate
A


1/4R
3/4
3/4
3/32
Approx. 8
1











Material: Steel
Break Corners and Remove Burrs



Operation & Maintenance Instruction
Page 8 of 24
August, 2003
4225-50, S.6
Figure 9 - Limiting Valve Piston Spanner Wrench Figure 10 - Service Accelerated Release Valve
Piston Spanner Wrench
No. 23
(0.154) Drill (2
Holes)
9/64 Deep
Break Corners
and
Remove Burrs
23/4
21/85/16
7/8
41/4
3/8
1
13/8
23/4







 







5/32 x 9/32
Steel Dowel
Pin (2 Reqd)
Press in Place

Material: Steel
To Be Manufactured
By Customer
Figure 11 - Inshot Piston Spanner Wrench
11/4
7/167/16
5/8
1/4
No. 43
(0.089) Drill
(2 Holes)
25/64 Drill
3/32 x 5/16
Steel Dowel Pin (2
Reqd)
Press in Place
5
Material: Steel
Break Corners and Remove Burrs To Be Manufactured By Customer
5/8














5/16
1/8 x 3/8
Steel Dowel Pin
(2 Reqd)
Press in Place
Material: Steel
Break Corners and Remove Burrs
7/16 Drill
0.120 Drill
(2 Holes)
31/6431/64
3/4
11/2
6
To Be Manufactured By Customer
3/4













Operation & Maintenance Instruction
August, 2003Page 9 of 24
4225-50, S.6
7.2.4 Emergency Portion Removal and Installation
See Figure 5
7.2.4.1 Scrape, wipe and blow off with a jet of low
pressure air (less than 30 psi) all dirt adjacent to the gasket
between the pipe bracket and emergency valve portion. Using
the blower hose, blow off the emergency portion, pipe bracket
hopper slopes, car under frames, etc., to free them of all
loose dirt that may otherwise get into the emergency portion
or pipe bracket when the portion is being removed and
reapplied.
7.2.4.2 Remove the vent protector from the failed emergency
portion and apply a WABCO Freight Car Products standard
vent protector plug, as shown in Figure 17.
7.2.4.3 The cleaned emergency portion must be handled
with care to avoid entrance of dirt or water which could
damage the internal parts.
IMPORTANT: The shipping cover must not be removed
from the clean replacement emergency portion until it is ready
to be mounted to the pipe bracket on the car.
7.2.4.4 Remove the Emergency Portion (1) from the Pipe
Bracket Portion (7) by first removing the three 5/8 hex nuts
(8) and apply a shipping cover, as shown in Figure 15, and
tighten nuts.
7.2.4.5 Remove and SCRAP the Emergency Portion
Mounting Gasket (2) from the mounting face of the Pipe
Bracket (7).
7.2.4.6 Visually inspect the Pipe Bracket Portion (7) for
damage. This portion need not be removed from the
equipment arrangement unless it is damaged. If it is
necessary to remove the Pipe Bracket Portion (7), car builder
and owner-operating property instructions are to be followed.
7.2.4.7 Inspect the Emergency Portion mounting face of the
Pipe Bracket Portion (7) to be sure that it is clean and is not
damaged or scratched. Be sure that ALL parts are clean
and unrestricted. If necessary, the ports can be blown out
with a low pressure jet of clean dry air. Exercise care so that
no dirt is blown into the ports or passages of the Pipe Bracket
Portion (7).
7.2.4.8 Apply a NEW WABCO Freight Car Products
Emergency Portion Mounting Gasket (2) to the Pipe
Bracket (7).
7.2.4.9 Remove the Vent Protector Plug from the new or
satisfactorily repaired and tested Emergency Portion (1).
Install a cleaned or renewed Vent Protector into the new
Emergency Portion (1).
WARNING: TheABDX-SS portions must not be applied
to cars exceeding 39 feet in length. Such incorrect application
may result in undesired brake action that could cause
equipment damage and injury to bystanders.
7.2.4.10 Remove the shipping cover from the new or
satisfactorily repaired and tested Emergency Portion (1) and
immediately apply the Emergency Portion (1) to the Pipe
Bracket (7). Coat the threads of the mounting studs lightly
with brake cylinder lubricant (M-914) or a compound
consisting of one part graphite, Wabtec Specification [M-
07695-02] (AAR Specification M-913), and two parts oil (SAE-
20) by weight.
7.2.4.11 Tighten the three5 /8  hex nuts (8) evenly and firmly
in order to sufficiently prevent gasket leakage and yet not
excessively to cause distortion of the mounting gasket (2).
7.2.4.12 After the Emergency Portion (1) has been
reinstalled and all repairs have been completed, the entire
air brake equipment must be tested in accordance with the
latest issue of the Code of Air Brake System Tests for Freight
Equipment T-664742A/B-O.
7.2.5 Service Portion Removal and Installation
See Figure 5
7.2.5.1 Disconnect the release valve handle or handles,
leaving it attached to the release rod or rods.
7.2.5.2 Scrape, wipe and blow off with a jet of low
pressure air (less than 30 psi) all dirt adjacent to the gasket
between the Pipe Bracket (7) and Service Portion (3). Using
the blower hose, blow off the Service Portion (3), Pipe Bracket
(7), hopper slopes, car underframe, etc., to free them of all
loose dirt that may otherwise get into the Service Portion or
Pipe Bracket when the portion is being removed and
reapplied.
7.2.5.3 The cleaned Service Portion (3) must be handled
with care to avoid entrance of dirt or water which could damage
the internal parts.

Operation & Maintenance Instruction
Page 10 of 24
August, 2003
4225-50, S.6
7.2.5.4 IMPORTANT: The shipping cover must not be
removed from the clean replacement Service Portion until it
is ready to be mounted to the Pipe Bracket on the car.
7.2.5.5 Remove the failed Service Portion (3) and apply the
shipping cover and tighten nuts.
7.2.5.6 Apply standard or alternate stem guard (See Figure
16) to the removed Service Portion and hold in place with
cotter pin.
7.2.5.7 Remove Service Portion Mounting Gasket (4) and
discard properly.
7.2.5.8 Remove the strainer nut (5) using strainer nut wrench
then remove and discard the old air strainer (6).
7.2.5.9 Install a NEW air strainer (6). A wooden mandrel of
suitable form will assist in guiding the strainer into proper
position. Make certain its inner end is in engagement with
the sealing bead (if inserted properly, all nut threads will be
visible), then insert strainer nut (5) and tighten it firmly using
the strainer nut wrench.
7.2.5.10 Install a NEW Service Portion Mounting
Gasket (4).
WARNING: TheABDX-SS portions must not be applied
to cars exceeding 39 feet in length. Such incorrect application
may result in undesired brake action that could cause
equipment damage and injury to bystanders.
7.2.5.11 Remove the shipping cover from the new or
satisfactorily repaired and tested Service Portion (3) and
immediately apply the portion to the Pipe Bracket (7). Coat
the threads of the mounting studs lightly with brake cylinder
lubricant (M-914) or a compound consisting of one part
graphite, Wabtec Specification M-07695-02 (AAR
Specification M-913), and two parts oil (SAE-20) by weight.
7.2.5.12 Tighten the three 5/8 hex nuts (8) evenly and
firmly in order to sufficiently prevent gasket leakage and yet
not excessively to cause distortion of Mounting Gasket (4).
7.2.5.13 Remove release valve stem guard from the new
or repaired service portion and reconnect the release valve
handle or handles (which has been left attached to release
rod) to release valve handle end plate with a new cotter pin.
7.2.5.14 After the Service Portion has been reinstalled
and all repairs have been completed, the entire air brake
equipment must be tested in accordance with the latest issue
of the Code ofAir Brake System Tests for Freight Equipment
T-664742A/B-O.
7.3 "IN-SHOP" MAINTENANCE PROCEDURES
IMPORTANT: The procedures which follow are to be
performed in the repair shop. To obtain satisfactory operation
and reliability of this device only replacement parts supplied
by Wabtec Corporation are to be used in the maintenance of
this device.
IMPORTANT: When performing the procedures which
follow, DO NOT use hard or sharp metal tools to remove
gaskets, o-rings, the dust boot, or diaphragm. Exercise care
so that no damage is done to parts.
WARNING: When performing the procedures which
follow, springs within the assembly may be under load.
Exercise care so that no parts are inadvertently expelled.
Inadvertently expelled parts may cause bodily injury, and/or
damage to parts.
7.4 DISASSEMBLY ofABDX-SS EMERGENCY PORTION
See Figure 12
7.4.1 Remove the vent protector assembly from the
emergency portion body (58) if it is still in place. The vent
protector assembly is not illustrated in Figure 12.
7.4.2 Small Vent Valve Piston, Inshot Check Valve
7.4.3 Depress the spring retainer (28) into the body (58)
and tilt it so that it is free of the retaining lip in the body
(58) and remove the retainer (28), vent valve spring (29),
and the small vent valve (23) from the body (58).
7.4.4 Depress the spring retainer (25) into the body (58)
and tilt it so that it is free of the retaining lip in the body (58)
and remove the retainer (25), inshot check valve spring (26),
and the check valve (27) from the body (58). SCRAP the
check valve (27).
7.4.5 Emergency Diaphragm Piston, High Pressure Spool,
Emergency Accelerated Release Check Valve