INSTRUCTION LEAFLET. Standard No , Sup. September, CODE OF TESTS FREIGHT BRAKE ABD, ABDT, ABDW, PORTIONS.

Transcription

1 INSTRUCTION LEAFLET Standard No , Sup. September, CODE OF S FREIGHT BRAKE ABD, ABDT, ABDW, PORTIONS abtec

2

3 Quick Flowrator Mechanical Mechanical General Air Mechanical Mechanical Drawings Test Test Specification Function Final Completion Drawings Test Service SCOPE This leaflet is intended to cover only the testing. ABDT Service Portions and ABD. ABDS. ABDW, ABDWS Emergency Portions and Maintenance of the "ABH Test Rack, as approved by the Association of American Railroads for use by Certified Air Brake 0 TABLE OF The AB Test Rack General Description and Accessories General Description of Electronic Accessories Description of Cocks Opening Diaphragm Cock Meter Manometer Safety Procedures and Warning Test Rack Maintenance Manometer Quick Opening Diaphragm Cock Electronic Calibration Switch PSI Mechanical Pressure Switch Tuning Chokes Cleaning and Lubrication Testing The Rack Requirements Leakage Gauges Manometer Pressure Switch Calibration Code of Tests ABD and ABDT Service Portion Test Code and Other Information Equipment Requirements Procedure Requirements Compliance Capacity Set- Test Leakage and Capacity Leakage of Test ABD and ABDS Emergency Portion Test Code and Other Information Test Equipment Requirements Test Procedure Requirements Specification Compliance Set- Leakage Charging Stability Emergency Sensitivity High Pressure Valve and Inshot Valve 11 Emergency Accelerated Release Function Quick Action Blowdown, Service Inshot and Final Leakage Completion of Test

4 Drawings AA Service ABDW and ABDWS Emergency Portion Test Code and Other Information Test Equipment Requirements Test Procedure Requirements Specification Compliance Leakage Charging V Stability Stability Emergency Sensitivity 11 High Pressure Valve and Inshot Valve Emergency Accelerated Release Function Quick Action Blowdown, Service Inshot and Final Leakage Completion of Test Index of Plates Test Set- -4-

5 0 THE AB 1 General Description and Accessories To obtain the best results in air comprising the complete equipment be efficiency. The test rack is whether the valves are up to proper standard of workmanship and general condition and if not, where they deviate from the standard. The following standard accessories are 1. Blanking 2300-C). 2. Pipe, Pc (TA-1301). 3. A where required by law, Pc. 1264). ABD- 1 Test Plate Combination (Includes 4-7) Pc (TA-2972-D). 4. ABD- 1 Test Plate, Pc (TA-2972-C). 5., Pc (TA A). 6. AB-2 Test Plate, Pc (TA-1479-C). 7. Emergency, Pc (TA-1300). General Description of Electronic Accessories An emergency valve s response time to an emergency rate of brake pipe reduction is recorded in the emergency response test. The new cock 23, using the test rack devices as shown in sensitivity/stability for ABDX type and stabilized valves. Two are used in conjunction with a timer enclosed in a switch box and an external battery circuit for measurement of this response time. The switch box/timer allows the test rack operator to conveniently change the timer to a choke capacities during test rack emergency valve response time during valve testing and a connected to a foot switch, allowing the timer to function as a foot controlled that frees up the rack operators hands for other duties. The battery pull-up circuit has been added to enhance the timer response. The battery pull-up circuit has a battery test feature which must be checked periodically. Three AA alkaline batteries must be replaced as required. The following electronic accessories are illustrated in Figure Switch 3. Cock 23 bb1) and choke assembly. 4. (BARKSDALE Model bb1). 5. Foot 632D or equivalent.

6 AB Test Figure 1 Rack Equipped with Mechanical Manometer

7 ..... Description of Cocks Cock 1 Cock 2 Cock 3 Cock 4 Cock 5 Cock 6 Cock 7 Cock 8 Cock 9 Cock 11 Cock 12 Cock 13 Cock 14 Cock 15 Cock 16 Cock 17 Cock 18 Cock 19 Cock 20 Cock 21 Cock 22 Cock 23 %" Brake Pipe Cut-Out Cock %H Auxiliary Reservoir Cut- Out Cock %" Brake Cylinder Cut-Out Cock 3/&" %" Emergency Reservoir Cut-Out Cock 0/8" Emergency Reservoir 3/8" Aux. Res. Vent Cock with No. 63 Drill (.037") Choke 3/8 Exhaust Cock 3/&" By-Pass Cock, Main Res. to Emer. Res. 0/8" Brake Cylinder Res. Cut-Out Cock 3/8" Brake Cylinder Vent Cock 3/8" By-Pass Cock, Main Res. to Brake Cylinder By-Pass Cock with No. 50 Drill (.070") Choke, Main Reservoir to Auxiliary 3/&" Cock 3/&" By-Pass Cock, Brake Pipe Reservoir to Auxiliary Reservoir 0/8" By-Pass Cock, with 3/16" (. 1875") Choke Auxiliary Reservoir to Brake Cylinder 3/&" Aux. 0240") Choke 3/8" By-Pass Cock. Aux. Res. to Q.A. Cham. 3/8" Quick Action Chamber Cut-Out Cock W' Vent Valve 3/&", Pc /8 Choke Plug (No. 30 Drill), Pc. 3/8" BP Vent Cock Pc No. 29 Drill Choke (See Fig. 3 - Item 3) Figure 2 Accessories Used With AS Test Rack

8 Figure 3 Electronic Accessories with -AB" Test Rack

9 .! Quick Opening Diaphragm Cock The distinctive features of this improved diaphragm cock, as illustrated in Figure 4, are: (a) the quick opening lever type handle, the radial position of which is adjustable to any angle. and (b) regulates the amount of diaphragm. Flowrator Meter, be The FLOWRATOR Meter, as illustrated in Figure 5, is an instrument to provide a means of observing and determining quickly and accurately the brake devices. It tapered glass tube and the flow of air to be measured is admitted to the bottom of the tube. The rate of flow is then float to rise in the tube. A indicates this rate of flow in cubic-inches of free air per minute. By at which the float balances in a stationary position, the rate of flow can be instantly. The instrument is used in the same manner as the Leakage Indicator and the standard hose fittings, hose and hose nozzle attached to it. Also, the test rack in the same changes in fastening the L / Figure 4 Sectional View of the Quick Diaphragm Cock with lever Type Handle Figure 5 FlOWRATOR Meter for

10 Mechanical Manometer The mechanical manometer is a pressure differential readings. The manometer dial is graduated to read in pounds per square inch (psi). See Figure Alternate Standard Mechanical Manometer Standard Mechanical Manometer Figure 6 Manometer Valve "S" position. Cut- " Position (To Right for rotary valve type and Pulled-Out for spool valve type): connects manometer to auxiliary and brake pipe reservoir. Cut-Out" Position (To Left for rotary valve type and Pushed-In for spool valve type): connects manometer to atmosphere. Safety Procedures and Warnings: General shop specification instructions. The work area should be clean and free of debris. Before applying portion to be tested, a visual inspection should assure integrity of valve covers and castings, mounting hardware etc. of a damaged or partially assembled valve portion to the test personal injury. Due to the possibility of exhausting air and high decibel levels of noise associated with it from the device during eye protection be used. This injury to the operator or persons near the test rack. 10-

11 The following statements of warning apply all or in part wherever the symbol appears in the maintenance procedures. Failure to observe these performing the work and/or the bystanders. Before starting the test, make certain that all test equipment and the device to be tested are fastened and/or personal injury from parts that may be HBLOWW from the test arrangement when air is admitted to the test rack. Before starting the test, make certain that the cap screws and pipe plugs are fastened securely to minimize the possibility of personal injury from parts that may be "BLOWN" from the downstream of the leakage or capacity reservoir. Air will vent from specific cock openings or ports cocks are opened or valves operated. To injury from the effects of venting, make certain that all persons stand clear of the exhaust stream. As required during any of the following loosened before they are removed in order to minimize the possibility of personal injury from the, pressurized air that may be arrangement. Before continuing the test, make certain that all test equipment and the device to be tested are fastened and/or connected securely to minimize the possibility personal injury from parts that may be "BLOWW from the test arrangement when air is admitted to the test rack. To minimize the possibility of electrical shock and bodily injury, prior to making any electrical connections or disconnections, make certain that all electrical power switches are in the.off' position. Air will vent from the test rack during possibility of personal injury from the effects of venting pressurized air, make certain that all persons stand clear of the exhaust stream. The test equipment used to connect the device to the test rack must be carefully loosened before they are removed in order to minimize the injury from the effects of residual RACK MAINTENANCE To secure reliable and uniform results with the "AB" Test Rack, it must be tested as often as required but not less frequently than every 30 days to keep the rack accurate and free from leakage. Each test rack must be tagged, noting the most recent test date., valve " and diaphragm cocks and any leakage discovered must be corrected before valves are tested. Air gauges must be maintained in a condition to within ranges of pressure which they are used and must be sensitive to slight variations of pressure. Strainer and/or filter must be frequently than once each year. 11-

12 Mechanical Manometer A calibration check on the mechanical manometer, as described in Section 5. 5, must be made as often as necessary to assure proper calibration but not less frequently than once every six months. Once each year, or as often as necessary, the mechanical manometer must be removed from the "AS" Test Rack, cleaned and calibrated by traceable to the national standard or accepted industrial Quick Opening Diaphragm Cock To adjust the diaphragm tension (or deflection), loosen the cap screw which serves to clamp the split coupling on the threaded portion of the cover and screw down or back off the imparted to the diaphragm by the cam portion of the handle plunger and disc) is just handle in closed position. The clamping screw should be tightened when the desired tension on the diaphragm is obtained. The handle position can then be adjusted to the desired angle by loosening three set screws in the handle fulcrum and rotating clamped coupling. The three set screws must be place and to permit operation of the diaphragm. Care should be exercised in operating the diaphragm type cocks in order to realize the benefits to be derived from the use of this, that is, eliminating leakage (thereby giving consistent and dependable test results) and obviating the delay and annoyance incident to res When the test rack is not in use, all diaphragm cocks should be open. This practice will prolong the life of the diaphragm by preventing permanent set as the diaphragm is in normal position with the cock open. Electronic Calibration Pressure Switch The electronic pressure switch, lit Model800P 4S9, is used in the This device is a highly accurate, field adjustable pressure switch/pressure gauge. Its digital LE.D. display facilitates exact control over the switching circuitry and displays a gauge pressure to one tenth of a psi. This level of performance and accuracy is required Substitutions for this device shall meet or exceed specifications of this model although substitutions are not recommended by WABCO. Calibration of this pressure switch must be checked to 1 psi, annually or as frequently as necessary in order to traceability to a national standard. instructions supplied with the unit. 3 PSI Mechanical Pressure Switches In the mode, two mechanical cock 23 and a special vent valve leakage test fitting for emergency portion qualification in Sections 8.0 and 9.0. These mechanical pressure switches are bb1 or equivalent and are factory set at 3 psi on increasing pressure. Calibration of these pressure switches must be checked annually or as frequently as necessary as described in Section 5.6 in order to maintain proper operation. 12-

13 Tuning Chokes Due to the tolerance variations in the actual necessary to accurately size certain chokes according to each individual test rack. This is done by blowing down the particular choke and comparing the blowdown times as performed in Section 5.0. If necessary, the choke may need to be cleaned, peened or reamed to provide the correct flow capacity. In order to obtain the accuracy in capacity the IIT800P electronic pressure switch as outlined in 1. This switch must be set to a window mode with pressure settings as described in paragraph 5.4. Cleaning and Lubrication The greatest freedom from wear and leakage in the operating parts of the rack will be obtained by keeping them properly lubricated at time of testing rack disassembled, cleaned and lubricated more often, leakage test should be made when this is done. Spool valve type valve HBH requires no case, the spool valve stem and O-rings must be removed, cleaned, and O-rings replaced if necessary, then lubricated and reassembled into the valve " SH body. then be tested for leakage according to paragraph ING THE RACK General Requirements When preparing to test the rack for leakage, secure the (T A-2300-C) furnished with the rack, to the rack pipe bracket. & 5. In order to avoid the necessity of frequently a new gauge fitting connection is racks. This connection permits a master test gauge and a comparison to be made manipulation of the proper vent cock. limit specified in the air gauge test when necessary. Since only one master or room, this master gauge is not avarable as an incorporated digital pressure readout, can be substituted for the master gauge. All test plate(s) used on the racks must be soap, grease. etc. which may have plates. Test plates must be dry before performed whenever rack is tested. Leakage The internal passages of the test rack manifold must be wiped clean with a dry, clean rag (as far in the passages as possible). rack is tested. Initial Conditions: -13-

14 Commence test with all cocks closed except the FLOWRATOR Meter, if used, which must remain position NO. 8 and valve "BH in "Cut-Out" position. A" handle in Drain residual air from rack by opening cocks 15, 19, 20, 1, 16, 2, 12, 3, 5 and 6. When air has drained, close cocks and adjust test rack feed valve to close at 100 VALVE "A" ROTARY VALVE Coat the exhaust port of valve ua" with soap suds with valve "A" handle in position Nos. 8, 7, 6, 5 and 4. respective position. Move valve "A- handle in position NO. 1 and charge B. P. VOL GAUGE to 100 psi, then repeat the soap suds test at valve "A" exhaust port with valve "A" handle in position Nos. 1, 2 and 3. A 1/2" bubble in not position. Move valve HA" handle to position NO. 5 and reduce B. P. VOL GAUGE pressure to 78 psi, then return valve HA" handle to position No. 3. Allow 2 minutes effect, then observe B.P. VOL pressure. No pressure rise or drop is At completion of test move valve "N handle to position DIAPHRAGM COCKS - CASTING AND DIAPHRAGM In the subsequent tests of cocks,, 5. 3, 5. 5 and 12 may also be caused by valve "B" rotary valve and for these four tests, a 1/2H bubble in not less than 10 seconds is permitted at the opening coated with soap suds. No leakage is permitted for the remaining cock tests. Cock 16 (also cock 24, if so equipped) - Open cocks 8 and with soap suds. Cock 14 - Open cock 2. Repeat the soap suds test at cock 8 opening. Cock 19 - Close cocks 8 and 19 and open cocks 14, 15 and 16 and charge AUX. GAUGE to 100 psi. Cock 2 - Close cocks 2, 15 and 16 and open cocks 8 and test at cock 8 opening. Cock 13 - Open cocks 3 and 4. Coat cock 4 opening 2.3. Cock 17 - Open cock Repeat the soap suds test at cock 4 Cock 11 - Close cock opening. Cock 3 - Close cock 3 and open cock Coat the opening of cock 4 with soap suds. Close cock 4 and open cock 3. Cock 9 - Open cocks 5 and 6. Coat cock 6 14-

15 Cock 5 - Close cock 6, then open cock 9 and charge Close cock 5 and open cock 6. Coat cock 6 opening with soap and open cock 5. Cock 20 - Close cocks 2, 16 and 20 and open cock 8. suds. Cock 1 (also Cock 25, If so cover from the test rack pipe bracket and note: Pipe Bracket Opening - Soap Test - no leakage. Replace the yoke cover and tighten to seal over the pipe bracket opening. Vent cocks - close cock 8 and open cocks 1, 2, 11, 16 and 20. Coat the openings of all vent cocks Nos. 4, 6, 7, 8, 12, 15, VALVE M Manometer Line Test To check Aux. to Close all cocks except 2, 16 and the supply cock. 1, charge AUX. AM handle in Cut-in valve "BM handle. N handle into position No. 3. Close cocks 16 and Air Gauges Partly open cock 7 to generate approximately 3 psi differential. Close cock 7. Wait seconds and then note manometer reading. No change in indication in 30 seconds. IF FAILURE: P. LINE, B.P. VOL ASSOCIATED. ALSO CHECK Cut-out valve "BM handle and, 13, 14, 16, 17, 19 and 20. Move valve MA" handle into position No. RESERVOIRS, PIPE FITTINGS AND COCK CONNECTIONS Commence test with cocks 1 11, 13, 14, 16, 17, 19 and 20 open, all others closed and valve loa- handle in position NO. 1. With all close cocks 9,, 19 and supply cock, then move valve "A. handle to position No. 3. Allow one minute for temperature effect, then observe the hands of all gauges for one minute to detect any drop in pressure. No pressure drop is permitted. If leakage Is indicated, coat all pipe fittings, cock connections and reservoir fittings with soap suds to locate source of Close cocks 1, 2, 3, 5, 11 and 20 and again observe the hands of all gauges for one minute to detect a drop in pressure. No pressure drop is permitted. Commence test with all cocks closed, valve loa" handle in position No. 3 and valve " in MCut-Out. position. 15-

16 Move valve nap handle to position No. 8, then, open cocks 12 and 13 and drain brake pipe and connection. Close cock 12 and open the A" handle to position No. 1 and open cocks 1, 2, 3, 5, 9, 11, 14, 16, 17, 19 and 20 and charge entire test rack to 100 psi. Note that each test rack gauge Close the supply cock. Partly open cock of 10 psi, and note after each step that the gauge hand registers within 1/2 psi master gauge hand between 100 and 10 psi, and Capacity Note also if there is any excessive friction in the gauge as pressure is being reduced, which will be indicated by the gauge hand At completion of test drain air from rack by opening cocks 12 and 15 and then the master gauge. Commence test with feed valve set at 80 psi, cocks 1, 2, 3, 5, 9, 11, 12, 13, 14, 15, 16, 17, 19 and 20 open, all other cocks closed, valve "A" handle in position No. 1, valve H in "Cut-OutH position and test rack drained of VALVE "An ROTARY VALVE Move valve "A" handle to position No. 3. Close cocks 1, 12, 15 and 16, then open the supply cock. The A" rotary valve must be checked to insure that they are within the limits specified for each respective position. Be sure that pressures do not change for at least one minute before starting any of the following calibration tests. Position No. 1-1/4H Drill Port (.25" Move valve "AH handle to position No. 1 and charge B. P. VOL GAUGE to 55 psi. Then move valve "A" handle to position No. 3 lap. Note that B.P. VOL charged at a rapid rate. Position NO. 2-1/32H Drill Port (.03125" Move valve "A" handle to position No. 2 and note, B.P. VOL charge from 60 to 70 psi in 10 to 12 seconds. Then move NO. 3 Lap. A" handle to position Position No. 3 - Lap Note that B.P. VOL GAUGE pressure does not increase or decrease from 70 psi. Position No. 4-1/32H Drill Port (.03125" Move valve -A" handle to position No. 4 and note; B.P. VOL reduce from 70 to 50 psi in 20 to 25 seconds. Move A" handle to position No. 1 and charge B.P. VOL A" handle to position No. 3 lap. Position No. 5 - No. 45 Drill Port (.082H 16-

17 Move valve. handle to position No. 5 and note; B.P. VOL reduce from 70 to 40 psi in 3% to 4% A. handle to position No. 1 and charge B.P. VOL. GAUGE to 80 psi. Then move A" handle to position No. 3 lap. Position No. 6 - No. 37 Drill Port (. 104 H Move valve "A. handle to position No. 6 and note; B.P. VOL reduce from 80 to 10 psi in 9~ to 10~ AH handle to position No. 1 and charge B. P. VOL A" to position No. 3 lap. Position NO. 7 - No. 27 Drill Port (. 1440" Move valve "A" handle to position No. 7 and note; B.P. VOL reduce from 80 to 10 psi in 5.2 to 5.6 seconds. Move valve "A" handle to position No. 1 and charge B. P. VOL. GAUGE pressure to 80 psi. AH handle to position No. 3 lap. Position No. 8-9/32" Drill Port (.2812H Move valve "A" handle to position NO. 8 and note; B.P. VOL reduce from 80 to 10 psi in,. 5. At the completion of test move valve nah handle to position No. AUXIUARY RESERVOIR COCKS WITH CHOKES Close cocks 14 and 17. Partly open cock then close cocks 15 and 19. Allow one Cock 7 (No. 63 Drill Choke) (for test rack without Ring Leakage Open cock 7 and note that seconds. Close cock 7, open cock 16 and minutes. Close cock Cock 7 choke plug capacity (for test rack with Ring Leakage Open Cock 7 and note that seconds. Close cock 7, open cock 16 and minutes. Then close cock Cock 18 (No. 73 Drill Choke) - Open cock 18 and note that AUX. from psi in 26 to 30 seconds. Close cock 18. Open cock 15 reducing AUX. RES. minute for temperature effect. Cock 14 (No. 50 Drill Choke) - Open cock 14 and note that AUX. from 45 to 55 psi in 9 to Cock 22 (No. 30 Drill Choke used for Service Stability Test). Commence test with cocks 2, 3, 5, 9,, 14 and 20 closed, valve -A" handle in position No. 1 and valve.b" in.cut-out" Position. Close cocks 3, 5, 9, 11, 13 and 14, then open cocks 1, 16 and 19 and charge B. P. VOL, AUX. RES and a.a. CH. GAUGES to 80 psi. 17-

18 Allow two minutes for temperature effect, then move valve HA" handle to position NO. Quickly open cock 22 and note that the P. VOL. GAUGE reduces from 80 to 30 psi in 31 to 32 seconds. Close cock 22. NOTE: This test is based on a predetermined rate of brake pipe be obtained if the recommended standard choke is used. If however, due to tolerance variation in reservoir volumes, deviation from the above blowdown time is encountered, it can and must be corrected by carefully increasing or decreasing as the case may be. In all cases, the orifice face of the choke plug should be lapped smooth to produce a sharp leading edge. Cock 23 (No. 29 Drill Choke used for Emergency Close all cocks except CALIBRATION mode and electronic pressure switch vertically, directly to and as close as GAUGE fitting. P. VOL. To insure that the ITT 800P is in the WINDOW mode, the default code must be checked. This is done by going into the The display should show "DEFS". Then press the should be displayed is "0010H. If this is not correct, change the code by pressing the ENTER button until the digit blinking is the one to be altered. arrow keys to change the digit to the correct ENTER until "DEFS" is displayed. Then press the LOCK button twice to return to the OPERATING mode. The test rack operator qualifying the choke capacity for the test rack be required to set the switch's pressure setpoints to that specified in Section 5.0. The setpoints are changed by pressing the UNLOCK button once. The display should PR06". Then press the upper row INCR button to display the high NOTE: This high setpoint must be 1.0 psi higher than the actual switching pressure specified. This is due to a trigger window of 70 to 50 psi is called for, the actual high setpoint entered should be 71.0 psi and the lower setpoint should be entered as 50.0 psi. If the high setpoint needs to be changed, press the changed is blinking. Then press the UP or DOWN arrow keys to enter the correct digit. After the high setpoint is correct, repeat the procedure for the lower setpoint by pressing the changed in the same fashion by using the setpoints are corrected, press the LOCK button to return to the choke qualification. For more detailed instructions refer to the installation and operation manual supplied with the ITT 800P pressure switch. To check electronic switch operation, close all cocks except supply and cock 1. Set time switch to P. VOL. GAUGE to a pressure at least 2 psi above the upper setpoint using valve -A" handle in position NO. 1. Move valve U handle to position No. 4 and slowly decrease B. P. VOL GAUGE. As the digital pressure readout on the electronic switch passes the upper setpoint limit, the timer should start. As the readout passes the lower inconsistent with this, inspect wiring, switch box/timer or electronic pressure switch for possible defects. Move valve "AU handle to position No. 1 and charge B. P. VOL minutes. Move valve "A" handle between positions 2 and 4 until the digital gauge reads 80 psi 10 psi, then place valve "A" handle into position No. 3 and reset timer. 18-

19 I TT r 1 r 1 r 1 r 1 L J L J L J L J TO FOOT SI./ITCH PSIG JUMPER 1,/IRE BRN/VIO RED/VIO BP VOL GAGE TO BP VOL BATTERY PLl..L -UP CIRCUIT CALIS. ""'I"" S\JITCH BOX/TIMER CALIB. r 1 r 1 FOOT L J L J L J L J FOOT C!=UB. LO~ BATTERY LIGHT ~/ BUTTON TO SP VOLUME 1/4 X 3/8 BUSH PURPLE BLUE RED S\JITCH I'D 5/16 CHOKE TO EXHAUST SPECIAL 3/8 UNION TAPPED TO ACCEPT 1/4" NO. 29 DRILL SENSITIVITY CHOKE 3/8 DIAPH. COCK NO. 22 BLUE RED NEW VENT VALVE LKG. FITTING PURPLE C 1/4 X NIPPLE OPEN EXHAUST COCK NO. 21 LEAKAGE POINT Figure 7 Addition of Electronic Accessories to AB Test Rack 19-

20 Quickly open cock 23 and hold handle P. VOL below 50 psi. The clock must record a psi 06 and 1. seconds. Repeat and four times. The average of the last three recorded times should fall between 1.06 and 1.08 seconds. If this time these limits, clean, ream or peen the No. 29 drill choke at cock 23 to match the choke to the B.P. VOL reassembly to reassure no leakage. Mechanical Manometer Apply the AB-160 test plate, Pc (T A-2942-C) to the face of the rack pipe bracket. Open cocks 3, 16 and 13 and move valve "A" handle to position No. 1. Move valve li to "Cut- " position and close cock manometer indicates between 1.8 and 2.2 psi on its dial. If it does not, the manometer must be removed for recalibration. At completion of this test open cock 16 and move valve "B" to "Cut-Out" Position. Then close cock 13, open cock 4, and move valve "AH handle to position No. 8. Then close all cocks and remove the test plate. Mechanical Pressure Switch Calibration Disconnect wiring and unscrew both 3 psi special vent valve test fitting and cock 23 assembly. Install switches into a regulated low pressure supply. switches while monitoring the continuity with a continuity tester. 1 - The vent valve switch should show continuity between the purple (common) and blue (normally closed) wires until a nominal 3 psi (2 * continuity should be broken. The cock 23 pressure switch should show no continuity at the purple (common) and red (normally open) wires below the nominal 3 psi (2 to show continuity as pressure rises above the CODE OF S 1 General Requirements The following is a Code of Tests and Instructions for operating the "AB" Test Rack. The instructions are complete for each specified test without reference to any other test. The sequence of the tests, however, should be followed as given, in order that defects may be disclosed and corrected before making subsequent tests, which may be adversely affected by the defects. Valves must be within the limits of all tests prescribed in the code, to insure proper service operation. All tests which require time limits must be timed with an approved timing device, or its equivalent, and be clearly visible for ease of observation. 0 ABC AND ABCT Drawings and Other Information Diagrammatic view and arrangement of the AB Test Rack. - Section 10, Plate

21 The following can be tested according to this DESIGNATION ABD SERVICE PORTION ABDT SERVICE PORTION PC. NO IMPORTANT: MAKE CERTAIN that the piece covered by this Test Specification. If the procedure number of the device being tested, the results obtained WILL NOT BE CORRECT and the device WILL NOT BE SATISFACTORY for service. IMPORTANT: This document may be revised at any time by the Westinghouse Air Brake Company to include changes in the test procedure or values covered by this test specification to be satisfactory for the service responsibility of the owner/user of this product and the company/person making the necessary tests covering the operation of this device to see to it that the latest issue of this test specification is being Company representative or the offices at Wilmerding, PA, before using this document to assure that you have the latest revision. Test Equipment Requirements IMPORTANT: The test rack requirements in the current issue of Section 5 of Instruction Pamphlet No , Sup. ABD-1 Test Plate Complete (Cock "C" must have No. 44 drill choke for 100 psi testing - Pc ) One Gasket Pc Three 5/8" Special Hex. Nuts Pc Test Procedure Requirements Do not deviate from Test Specification. Throughout this Specification the ABD or ABDT Control Valve referred to as the "portion When testing leakage with flowmeter, press the hose nozzle of the flowmeter against the opening specified and note that the float does not rise higher than specified for each respective test. IMPORTANT: Throughout this specification, valve "BH handle Cut-Out" position unless otherwise specified. If in the following tests, it becomes necessary to remove any service portion cover due to leakage or other defects, it will be necessary to again coat the cover seal with soap suds after the valve is reassembled and the pressure restored to detect any leakage that may have occurred. Specification Compliance IMPORTANT: The ABD or ABDT Control Valve Service Portion being tested ALL the requirements of this specification before being 21-

22 CAUTION: BEFORE STARTING, MAKE CERTAIN THAT AIR UNE PLATE AND DEVICE TO BE ED ARE FASTENED SECURELY TO PREVENT POSSIBLE PERSONAL INJURY. WARNING: AIR WILL VENT VALVE DURING OPERATIONS. CARE SHOULD BE EXERCISED SO MATERIAL AND OR PERSONNEL ARE OPERATIONS. Supply pressure must be maintained at 120 Using the gasket and the three 5/8" special hex. to the ABD- 1 Test Plate. Move valve "A" handle to position No. Close all test rack and test plate cocks except the test rack supply cock. & 7. Leakage Set the test rack feed valve such that the All test rack and test plate cocks closed except the test rack supply cock. Valve "A" handle in position NO. Open cocks 1, 2, 5. 8 and 9. Move valve "A" handle to position No. Open cock 16, allow the AUX. RES. GAUGE indication to increase to 100 psi, then close cock 16. Operate the portion by moving valve "A" handle slowly from position No. 1 to position No. 8 and then back to position No., four times. Finally No. 8. On each cycle B.C. RES. GAUGE should increase in pressure and exhaust. Open cock 3. SERVICE POSITION. Slide Valve and Retaining Check Valve. COCK 8 OPENING - FLOWRATOR Meter - 13 cu. in./min. maximum. Slide Valve. Close cock 5. Open cock 6, allow the note: Test Set- 22-

23 1 COCK 6 OPENING - /min. maximum. Close cock 6. Open cock 5 and allow the Slide Valve. QUICK SERVICE EXHAUST PORT - /min. maximum. Quick Service Umiting Valve Diaphragm. QUICK SERVICE LIMITING seconds. Auxiliary and Emergency Valve and Pusher Pin, Service Piston Diaphragm, Release Valve Seal and O-Ring, Retaining Check Valve and Limiting Valve O-Ring and Diaphragm. Close cocks 2, 3 and 5 and note: 1 EMER. RES. AND AUX. seconds. 2 RELEASE VALVE EXHAUST PORT - Soap Test - Release Valve Diaphragm and O-Ring and Reset Valve O-Ring. Open cocks 2, 3 and 5. Pull the Release Valve handle through its full travel, hold the handle in this position for 1 to 2 seconds, then release the When the B.C. RES. GAUGE indication has decreased to zero psi, close cocks 2, 3 and 5 and note: 1 EMER. RES. AND AUX. seconds. Move valve "A" handle to position No. Open cocks 2, 5 and 16. RELEASE POSITION. Cocks 1, 2, 5. 8, 9, 16 and the test rack supply cock open. Valve "A" handle in position No. 1 and wait 5 seconds. 23-

24 Slide Valve. COCK 8 OPENING - Slide Valve and Graduating Valve. Close cock 8. Open cock 19 and note: /min. maximum. 1 QUICK SERVICE EXHAUST PORT - FLOWRATOR Meter - 13 cu. in./min. maximum. Slide Valve. Close cocks 16 and 19. Open cocks 4 and 15. When the B.C. RES. GAUGE indication has decreased to zero psi, open cock 8. Partly open cock 19, allow the AUX. close cocks 19, 15 and 4 and immediately note:, then 1 QUICK SERVICE EXHAUST PORT - FLOWRATOR Meter - 13 cu. in./min. maximum. 2 COCK 8 OPENING. /min. maximum. Open cocks 3, 12 and 16. SERVICE LAP POSITION. Cocks 1, 2. 3, 5, 8, 9, 12, 16 and the test rack supply cock open. Valve "A" handle in position NO. Graduating Valve and Slide Valve, Accelerated Service Release Check Valve, Umiting Valve O-Ring and Retaining Check Valve. Close cocks 12 and 16. Move valve -A" handle to position No. 5, allow the B. P. VOL. GAUGE indication to decrease to 88 psi, then move valve "AD handle to position No. Partly open cock 4, allow the B.C. RES. GAUGE indication to decrease to 30 psi, then close cocks 3, 4 and 5 and note: 1 B.C. RES. GAUGE - indication 1 psi 1 B.C. RES. GAUGE - indication no decrease 24-

25 2 EMER. RES. GAUGE - indication 1 psi maximum decrease in 20 seconds. 3 QUICK SERVICE EXHAUST PORT - FLOWRATOR Meter - 13 cu. Return Flow Check Valve Plug, Reset Check Valve, Reset Valve O-Ring and Back Flow Check Valve Port. Close cocks 1 and 2 and note: 1 B.P. LINE GAUGE - indication 1 psi maximum decrease in 10 Open cocks 2 and 6 and note: 1 B.P. LINE GAUGE - Between 8 and 2 psi drop in 5 seconds Close cocks 6 and 8. Open cocks 1 and 5. GASKETS. Move valve "N handle to 1 and wait 5 seconds. Open cocks 16 and Indications (except, and then note: 1 AROUND ALL Close cocks 11, 13, 16 and Open cock 12 and allow the B.C. RES. GAUGE indication to open cock 8. Function and Capacity Cocks 1, 2, 3, 5, 8, 9, 12 and the test rack supply cock open. Valve HA" handle in position No. SERVICE PISTON BODY AND SLIDE VALVE. Brake Cylinder Application. Close cock Move valve "A" handle to position No. Move valve "A" handle to, allow the B.P. VOL decrease to 70 psi, then move valve HA" handle to position No. 3 and note: 25-

26 1 B.C. RES. GAUGE - indication must increase from zero to 60 psi in 4 Service Piston Release and Brake Cylinder Release Port. Open cock Close cock 5. 1 Open cock 6. Wait for, then close cock 6. Move valve DAD handle to position No. 2 and note: 1 B.P. VOL and AUX. RES. pressure exhausts. 2 B.C. RES. GAUGE - indication must decrease from 40 to 20 psi in 8 Open cock 5. Move valve HA" handle to position No. Open cocks 12 and increase to 100 psi, then close When the B.C. RES. GAUGE indication has decreased to zero psi, then close cock Preliminary Quick Service Choke and Volume. 1 Cocks 1, 2, 3, 5, 8, 9 and test rack supply cock open. 2 Valve "A" handle in position NO. Move valve "A" handle to position No. 4 and note: 1 QUICK SERVICE EXHAUST PORT - a light blow by feel) and continue for 5 to 16 seconds. When the B.P. VOL GAUGE indication has decreased to 78 to 79 psi, move valve " handle to position NO. Stability Port. Wait 5 seconds, then open cock 16. Move valve "A" handle to position 5 and reduce the B.P. VOL GAUGE to 61 to 62 psi then move valve "A" handle to position No. H position Adjust the B.P. VOL. and AUX. RES. GAUGES indications to 64 Wait 45 seconds, then move valve "B" handle to the.cut- 26-

27 1 If the gauge indications are greater than 64 to 65 psi, move valve "AN handle to position No., allow the B.P. VOL and AUX. psi, then move valve HA" handle to position NO. 2 If the gauge indications are less than 64 to 65 psi, move valve "A" handle to position No. 2, allow the B.P. VOL. and AUX. then move valve "A" handle to position No. Press the hose nozzle of the and then adjust cock "B" such that the flowmeter indicates 13~ to 141h cu. in./min. Close cocks 2 and 16 and note: B" opening 1 MANOMETER - indication 2 to 0.7 psi. Move valve " B" handle to the HCut-Out" position. Close cock " Open cock Move N handle to 11 Open cock, then close cock Open cock 12, allow the B. C. RES. GAUGE indication to decrease to, then close cock 2nd Quick Service Umiting Valve Port, Spring and a-ring. 1 Cocks 1, 2, 3, 5, 8, 9 and the test rack supply cock open. 2 Valve "A" handle in position No. Move valve "A" handle to position No. 4, allow the B. P. VOL. GAUGE indication to decrease to 98 psi (such that the B.C. RES. GAUGE indication move valve "A" handle to position No. Wait until the blow at quick service volume exhaust cock 16, then open cock 12, allow the B.C. RES. GAUGE indication psi. then close cock 12 and note: 1 B.C. RES. GAUGE - indication must increase 2 B.C. RES. GAUGE - must cease to obtained for reference in 7. Partly open cock 4, allow the B.C. RES. GAUGE indication to decrease to 4 psi, then close cock 4 and note: 27-

28 1 B.C. RES. GAUGE - indication must increase to the value obtained in Close cock 3 and note: 1 B.C. RES. GAUGE - indication Close cock 16. Move valve "A" handle to position No. Open cocks 3, 12 and 16 and allow the AUX. RES. GAUGE indication to increase to 100 psi. Accelerated Service Release. 1 Cocks 1, 12, 16 and the test rack supply cock open. 2 Valve HAH handle in When the B. C. RES. GAUGE indication has decreased to zero psi, close cocks 12 and Move valve HA" handle to position No. 5, allow the B.P. VOL decrease to 92 psi, then move valve "A" handle to position No. Move valve US" handle to the HCut- " position. Adjust the AUX. 1 If the AUX. RES., move valve "A" handle to position No. 4, allow the AUX. RES. GAUGE indication to decrease, then move valve "A" handle to position NO. 2 If the AUX. RES. GAUGE indication is less than 92 psi, move valve UA" handle to position No., allow the AUX. RES. GAUGE indication to, then move valve " handle to position No. Close cock 16. IMPORTANT: In item 7. 1, when cocks 5 and "CU are opened, the B. P. VOL GAUGE indication begins to immediately read and valve -S" handle moved to the "Cut-OutH position. Open cocks 5 and "C" and when the B.P. VOL GAUGE indication begins to increase at a faster rate, note: 1 MANOMETER - indication must be 1. 6 to 2.0 psi. 2 Immediately move valve " B" handle to the HCut-OutH position P. VOL. GAUGE - indication must have increased to 28-

29 Close cock " 10 Move A" handle to position No Open cock 16 and allow the Close cocks 3. 5 and 16. Port 5 to Port 2. 1 Cocks 1, 2, 8, 9 and the test rack supply 2 Valve "AM handle in position No. Open cock 6 and note: 1 AUX. RES. GAUGE - and must continue to decrease. 3. Close cocks 6 and Open cock 5. Move valve "A" handle to position No. Auxiliary and Emergency Reservoir Release Pull the Release Valve handle s full travel, hold the handle in this position for 8 seconds, then release the handle and note: 1 AUX. RES. GAUGE - 2 EMER. RES. GAUGE - indication Close cock 5. Open cocks 4, 6 and 16, allow the B.C. RES., EMER. RES. and AUX. RES. GAUGE indications to decrease to zero psi. complete drain, then close cocks 4, 6 and Auxiliary Charging Port. Move valve "A" handle to position No. 1 and note: 1 AUX. RES. GAUGE - Close cock 8. Open cocks 3, 5, 9, increase to 100 psi, then close cocks C. RES. GAUGE indication to 29-

30 RELEASE VALVE. Cocks 1, 2, 3, 5, 9 and the test rack supply cock open. Valve "AH handle in Release Valve Lock-Up Brake Cylinder Port. Move valve "AH handle to position No. 8 and allow the B. P. VOL. GAUGE indication to decrease to zero psi. Pull the Release Valve handle through it' s full travel, hold the handle in this position for 1 to 2 seconds, then release the handle and note: C. RES. GAUGE - indication must decrease from 100 to 10 psi in Move valve HAH handle to position No. Open cock 4, allow the B.C. RES. GAUGE indication to decrease to zero psi, then close cock 4. Port 10 to EX. and Retaining Check Valve Spring. Close cock 3. Open cock 20 and note: QA A. CH. GAUGE - indication must cease to decrease at 4 psi, or less but greater than 1 psi. Reset Spool Valve Differential and Port, and Reset Check Valve Spring. Close cock 20. Move valve.a" handle partly into 1, allow the B.P. VOL. indication to increase to 30 psi, and then move valve HA" handle to position No. and when the B.P. VOL. GAUGE indication begins to charge at a faster rate, note: BP. VOL GAUGE - indication must be 35 to 50 psi. Immediately move valve "A" handle to position No. 3 and note: 1 B.P. VOL seconds. When the B.P. VOL. GAUGE indication has stabilized, note: 30-

31 1 B. P. VOL GAUGE - indication must be 3 to 8 psi lower than the AUX. indication. Release Valve Spring. Open cock 16. Move valve "A" handle to position No. 8 and when the B. C. RES. GAUGE indication starts to increase, note: AUX. RES. GAUGE - indication Final Leakage Close cock 16, move "A" handle to position No. 1 and wait 3 seconds, then open cocks 8 and 16 and charge AUX. RES. Slide Valve and Graduating Valve. Commence test with cocks 1, 2, 5, 8, 9 and 16 open and valve "A. handle in position No. COCK 8 LEAKAGE FITTING - FLOWRATOR Meter - 13 cu. in. /min. maximum. Close cock 8. Open cock QUICK SERVICE EXHAUST PORT - FLOWRATOR Meter - 13 cu. in./min. maximum. Completion of Test Close cocks 16 and 19. Open cocks 8, 4 and AUX. RES. GAUGE to 80 psi, then close cocks 19, 15 and 4. QUICK SERVICE EXHAUST PORT - FLOWRATOR Meter - 13 cu. in. /min. maximum. COCK 8 LEAKAGE FITTING - FLOWRATOR Meter - 13 cu. in. /min. maximum. Close cocks 2 and 5. Move "A" handle to position No. Open cocks 3, 4, 6, 8, GAUGE indications to decrease to zero psi. C. RES. and EMER. RES. After all test rack gauge indications (except MAIN zero psi, close all test rack and test plate cocks except the test rack supply cock. WARNING: THE PLATE, REMOVED. Remove the tested portion from the Test Plate. 31-

32 If the device just removed from the test rack is the last of a series (or is the only device) being tested, proceed to item If Section 7. Test Rack Shutdown. Close test rack supply cock. Open cocks 3, 2, 16 and drain the B., B. AUX., EM., and Main Open all cocks except the test rack supply cock. FOR ABD AND ABDS Drawings and Other Information Diagrammatic view and arrangement of AB test rack - Section 10, Plate 2. The following devices can be tested according to this DESIGNATION ABD EMERGENCY ABDS EMERGENCY PORTION PC. NO IMPORTANT: Make certain that the piece number of the device being covered by this piece number of the CORRECT and the device WILL NOT BE SATISFACTORY for IMPORTANT: This document may be revised at any time by the Westinghouse Air Brake Company to include changes in the test procedure or values required for the device covered by this test specification to be satisfactory for the service intended. It is the responsibility of the owner juser of this product and making the necessary tests covering the operation of this device to see to it that the latest issue of this test specification is being used. Consult your local Westinghouse Air Brake Company representative or the offices at Wilmerding, PA, before using this document to assure that you have the Test Equipment Requirements IMPORTANT: The test rack used in requirements in the current issue of Section 5 of Instruction Pamphlet No Sup. 1. AB-2 Test Plate Complete Pc Gasket Pc A special plunger to hold the vent valve test standard plunger in the AB-2 test plate. See Figure Test Procedure Requirements Do not deviate from test specification. 32-

33 When testing leakage with the FLOWRATOR Meter against the exhaust opening specified and does not rise higher than IMPORTANT: Throughout this specification, valve HB" handle must be in the "Cut- Out: position unless otherwise 8REA~ CORNER 1/32 x 4' PRESS fit 11j --L. 2.!.. Materia" Stainless Steel Note: Finish All Over Figure 8 Special Plunger for AB - 2 Test Plate If in the following tests, it cover due to leakage or other defects, it will be necessary to again coat the cover seal with soap suds after the valve is detect any leakage that may have occurred. Specification Compliance IMPORTANT: The ABD or ABDS Control Valve MUST meet ALL the requirements of this specification before shipment. CAUTION: BEFORE STARTING DEVICE TO BE ED ARE PERSONAL INJURY. WARNING: VENT VALVE DURING OPERATIONS. CARE SHOULD BE ALL LOOSE MATERIAL AND OR PERSONNEL ARE CLEAR OF VENTING. Supply pressure must be maintained Secure the emergency portion, less vent protector, to the test rack. Put valve "AH handle in Close all cocks except 1, 2 and the rack supply cock. Test Set- 33-

34 Set test rack feed valve so that MAIN leakage Cocks 1, 2 and 9 open. Valve MAM handle in position No. Move valve -AM handle to position No. Open cocks 5, 16, 19 and 20. Allow the B.P. VOL and Close cocks 16 and 19. Move valve MAM handle to position No. Operate the portion by A" handle slowly from position No. 3 to position No. 5 and then back to position No., a minimum of four times. move the handle to position No. 8. An emergency should Open cock Move valve MA" handle to position NO. Close cock 15. Open cocks 4, 16 and 19. RELEASE POSITION. Cocks 1, 2, 4, 5, and 20 open. Valve MAM handle in position No. WARNING: KEEP FITTING INTO PLACE. Close cock 5. pressure switch (See Figure 3, Item 4) in place and secure by closing cock 6 and opening cock 5. High Pressure Valve O-Ring and Emergency Accelerated Release COCK 4 LEAKAGE FITTING - FLOWRATOR Meter - No Close cock 4. Ring. Move valve MA" handle to position No. 3. Open cocks 3 and 13 and C. RES. GAUGE to build up to 100 psi. then move valve "A- handle to position No. Slide Valve, Vent Valve Seal, and High Pressure Valve O-Ring. 34-

35 For ABDS Portion Only - Soap the added volume fitting and gasket - No permitted during Test VENT VALVE FITTING - FLOWRATOR Meter - 14 cu. in./min. maximum. EMERGENCY ACCELERATED RELEASE POSITION. Cocks 1, 2, 3, 5, 9, 13, 16, 19 and 20 open. Valve "A" handle in position No. Close cocks 13 and 16. Partly open cock 15, and allow AUX. then close cock 15. Slide Valve. VENT VALVE FITTING - FLOWRATOR Meter - 14 cu. in./min. maximum. Emergency Accelerated Release Check Valve and O-Ring on Dump Spool. Close cock 3. Open cock 4. COCK 4 LEAKAGE FITTING - Close cocks 4 and 19. Open cocks 3 and 15. Emergency Accelerated Release Ring. Partly open cock 4, allow the B.C. RES. GAUGE indication to decrease to 80 psi, then close cock 4. Close cock 3. C. RES. GAUGE - No decrease of indication in 10 seconds. Close cock 15. Open cocks 16 and 19. EMERGENCY POSITION. Initial conditions. Cocks 1, 2, 5, 9, 16, 19 and 20 open. 35-

36 Valve "A" handle in position No. Emergency Accelerated Release Close cocks 16 and 19. Move valve "A- handle to position No. Ring and Spillover Check Valve Plug. Allow a.a. CH. GAUGE to reduce to 80 psi. Close cock 5. EMER. RES. GAUGE - No decrease Open cock 3 B.C. RES. GAUGE - No psi drop in High Pressure Valve O-Ring, Emergency Valve O-Ring, Accelerated Release Valve Ring and Spillover Check Valve Plug. Close cocks 1, 15 and 20. VENT VALVE FITTING - FLOWRATOR Meter - 8 cu. in./min. maximum. Vent Valve. Open cock 1. Move valve "A" handle to position NO. 2 and allow B. P. VOL GAUGE indication to increase to 5 psi, then 3. Wait 5 seconds. VENT VALVE FITTING - FLOWRATOR Meter - 10 cu. in./min. maximum. CASTING AND GASKETS Cocks 1, 2 and 9 open. Valve "A- handle in position No. Move valve -A" handle to position No. Open cocks 3, 5. 13, 16, 19 and 20 and allow all gauge indications to increase to 100 psi. ENTIRE PORTION - Soap Test - No Close cocks

37 14. Open cock 6, remove Open cocks 12 and 15 and allow Q.A. C. RES. decrease to zero, then move valve "N handle to position NO. Charging Cocks 1, 2, 3, 6, 9. 12, 15 and 20 open. Valve "N handle in Close cocks 3, 9 and 15. Quick Action Chamber. Move valve -A" handle to position No. 1 and note: Q.A. CH. GAUGE - indication most increase from 0 to 20 psi in 12 to 16 EMER. RES. GAUGE - indication must NOT increase. Open cocks 3, and 19. Service application. Cocks 1, 2, 3. 5, 12, Valve "A" handle in position NO. Close cock Open cock 17 and note: C. RES. maximum and no inshot delay (slow down of B.C. RES. Close cock 17. Open cocks 9 and Service Stability Cocks 1, 2, 3, 5, 9, 12, 16, 19 and 20 open. Valve "A" handle in position No. Move valve -A" handle to position No. Partly open cock, B.P. VOL and Q.A. CH. indications to decrease to 90 psi, then close cocks 15, 12, 16 and