4241-1

operation & maintenance instruction

“C-1” SUPPRESSION VALVE, Pc.No. 562606

AUGUST, 1989

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 Suppression Valve Split Reduction Valve
Portion Portion
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
Representative for identity of the test
specification, with latest revision date, that
covers this device.)
Pipe Bracket
IMPORTANT: Only Wabtec 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

August, 1989 Page 1 of 18

4241-1
operation & maintenance instruction
1. DESCRIPTION
IMPORTANT: The “C-1” Suppression Valve is offered
for use in specific equipment arrangements when speci-
fied by the locomotive builder and/or owner-operating
property. This valve is intended for use ONLY in spe-
cific applications which are requested in writing and
should never be used to initiate a split reduction when
operating trains whose overall length IS LESS THAN
4000 FEET. The use of the “C-1” Suppression Valve IS
NOT recommended by the Wabtec Corporation.
The “C-1” Suppression Valve, which may be used in spe-
cific equipment arrangements where the air pressure does
not exceed 150 psig, functions to provide the means for
obtaining an automatic split reduction during a penalty brake
application with temporary and permanent suppression of
train control application when this feature is specified by
the locomotive builder and/or owner-operating prop-
erty.
The “C-1” Suppression Valve consists of a suppression valve
portion, a split reduction valve portion, and a pipe bracket.
The pipe bracket is designed so that it can be semi-perma-
nently mounted on the locomotive. All pipe connections are
made to the pipe bracket. Ports and pipe connections are
disignated numerically. These numeric port and/or pipe
connections are listed in the diagrammatic view, Figure 2.
The suppression valve portion and the split reduction valve
portion are mounted on the pipe bracket. Air connection
between the two operating portions and piping are made
through the internal passages of the pipe bracket.
2.0 OPERATION
NOTE: Refer to the Wabtec Corporation Publication
5076-6 for a typical equipment operating application
which relates to the following description of operation.
(Figure 2)
2.1 During a normal release operation, air pressure in
switch pipe 3 holds the charging valve up in release posi-
tion. The remaining spool valves and diaphragms are held
in release position by spring force. Brake pipe air directed
into port 1 flows to the diaphragm chamber of the tempo-
rary suppression valve, the spill-over check valve and the
charging valve. From the charging valve, brake pipe air
flows through; (a) port 22 and the split reduction spool valve
to port 23 to charge the first suppression reservoir, and, (b)
the charging check valve to the temporary suppression valve
diaphragm and check valve and to port 2 to charge the
Page 2 of 18
temporary suppression reservoir. Equalizing reservoir
charging air, port 15, flows to the differential check valve
which is held seated by spring force.
2.2 During a penalty brake application the “C-1” Suppres-
sion Valve is arranged to receive air from an external de-
vice in the equipment arrangement such as the Wabtec
Corporation “P-2-A” Brake Application Valve as follows:
2.2.1 First reduction reservoir (equalizing reservoir) air in
pipe 24 to the split reduction diaphragm valve.
2.2.2 Power knockout air in pipe 25 to the underside of
the split reduction spool valve and to the spring side of the
permanent suppression valve.
2.3 The direction of equalizing reservoir air into connect-
ing pipe 24 by the “P-2-A” Brake Application Valve causes
a reduction in equalizing reservoir air pressure for the first
part of the split reduction.
2.4 The split reduction spool valve is moved upward by air
pressure in port 25 to connect passages and direct air flow
as follows:
2.4.1 First suppression reservoir air in port 23 to port 31
and the split reduction valve diaphragm chamber.
2.4.2 Brake pipe air in port 22 is blanked off.
2.5 The split reduction diaphragm valve is moved upward
by air pressure in port 31, causing the spool valve to blank
off reduction limiting reservoir air in port 24 and retain this
pressure at the first reduction level of a split reduction.
2.5.1 IMPORTANT: The volume of the first suppres-
sion reservoir in the equipment arrangement IS CRITI-
CAL to the operation described in the preceding para-
graph. Consult your Wabtec Corporation Representa-
tive for recommendations and information on specific
equipment arrangements.
2.6 The time delay between the first and second parts of
the split reduction is determined by the exhaust of the first
suppression reservoir air through the diaphragm cover
choke.
2.7 After the pressure of the first suppression reservoir is
depleted, the split reduction valve will be forced downward
by the spring. The spool valve will direct reduction limiting
reservoir air in port 24 to port 24b and reduction limiting
valve exhaust.
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 4241-1

operation & maintenance instruction

Split Reduction Spool Valve

Charging Check Valve Reduction

Limiting Valve
Temporary
Suppression Valve
Charging Valve

22

Temporary
Suppression Differential
Valve Check Valve
Check Valve

24b

Split
Reduction
Valve Portion

Split Reduction
Diaphragm Valve

Spillover
Permanent Suppression 41 2 25 42 8 23 24
Check Valve 17 3 6 26 1 15
Suppression Valve Back Flow Spool Valve
Check Valve Back Flow
Check Valve
LEGEND
Designation Port This diagrammatic representation
Designation is for functional analysis only. It is
Brake Pipe 17
Temporary Suppression Volume Reservoir 23 Brake Valve Exhaust not to be used as an actual
Switch Pipe 24 First Suppression Reservoir physical representation of portion
Temporary Suppression Volume (Blowdown) 25 Power Knock-Out or pipe bracket configurations.
Timing Valve 26 Suppression Pipe
Lockover Pipe 41 Suppression Gauge
Equalizing Reservoir Charging 42 Stop Reservoir

Figure 2 - Diagrammatic View

2.8 The exhausting of reduction limiting reservoir air in
port 24 is the second part of the split reduction and is in-
tended to continue to reduce until the automatic brake valve
handle is manually moved to suppression position.
2.9 When the controlling automatic brake valve handle is
moved to suppression position the following occurs:
2.9.1 Air is directed through suppression pipe 26 to the
reduction limiting valve.
2.9.2 Air in switch pipe 3 is exhausted immediately and
power knockout port 25 is exhausted when the “P-2-A” Brake
Application Valve resets (releases).
duction limiting valve upward to blank off port 24b from ex-
haust to terminate the reduction.
2.11 The differential check valve controls a total service
reduction in reduction limiting reservoir (equalizing reser-
voir) air pressure during penalty brake applications. Mov-
ing the controlling automatic brake valve handle to “Sup-
pression” position will reduce equalizing reservoir charging
air, port 15, to a total service reduction. Any reduction
limiting reservoir air pressure in excess of the total service
reduction pressure will flow through ports 24, 24b and the
differential check valve to port 15. If desired, a greater
equalizing reservoir reduction can be made by moving the
controlling brake valve handle past “Suppression” position.

2.12 The exhaust of air pressure in port 3 permits the

2.10 Air pressure in suppression port 26 moves the re- charging valve spool valve to be moved downward by the

August, 1989 Page 3 of 18

4241-1
operation & maintenance instruction
force of the spring to blank off brake pipe air in port 1. Also
port 22 is connected to exhaust.
2.13 The exhaust of air pressure in port 25 permits the
split reduction spool valve to be moved downward by the
force of the spring. Port 22 is connected to port 23.
2.14 When a penalty brake application occurs after an
automatic brake valve initiated application, the split reduc-
tion is eliminated and a direct reduction of reduction limit-
ing reservoir air (equalizing reservoir) is provided. When
the controlling automatic brake valve handle is manually
moved to “Service” position the air pressure in switch pipe
3 is exhausted. The charging valve will be moved down-
ward by the force of the spring to make passage connec-
tions and direct air flow as follows:
2.14.1 Brake pipe air in port 1 is blanked off.
2.14.2 First suppression reservoir air pressure trapped
only in passage 22 is exhausted.
2.14.3 The split reduction feature described in the previ-
ous paragraphs remains operative, whereby equalizing res-
ervoir pressure is further reduced when connected to the
24 pipe (and the volume therein) during the first phase of
the split as the first suppression reservoir pressure is de-
pleting. Eventually, equalizing reservoir pressure via 24
pipe will continue to reduce further at the reduction limiting
valve exhaust when passages 24 and 24b re-connect in the
split reduction portion, if the controlling automatic brake valve
handle has not been moved to suppression position as the
stated events occur.
2.15 The exhausting of first suppression reservoir air will
nullify the time delay provided by the split reduction dia-
phragm and allow reduction limiting reservoir air to flow di-
rectly to exhaust. If an automatic brake application is made
before a penalty brake application occurs, the first sup-
pression reservoir pressure is then used during the first
phase of the temporary suppression function in part as fol-
lows:
2.15.1 Port 3 depletion, upon the controlling automatic
brake valve handle movement from release, permits the
charging valve to assume its spring applied position, per-
mits the charging valve to assume its spring applied posi-
tion. The first suppression reservoir then begins to deplete
to atmosphere at a controlled rate by way of passages 22,
23, and the choke in the top cover of the suppression por-
tion. This pressure also travels a path to the non-spring
diaphragm chamber (port 41) of the permanent suppres-
sion valve from the top cover by way of a choke at the top
Page 4 of 18
cover/body interface, and body/sup- pression spool valve
passages as long as the controlling automatic brake valve
handle remains in the quadrant between the minimum serv-
ice and suppression positions.
2.15.2 In effect, there is no split reduction function, as
such, in operation during the foregoing situation.
2.16 If the cut-out cock in the pipe to the first suppression
reservoir is closed, the split reduction feature will also be
eliminated. This cut-out cock should be closed when oper-
ating trains with an overall length of less than 4000 feet.
2.17 When specified by the locomotive builder and/or
owner-operating property, a train control initiated pen-
alty brake application may be temporarily suppressed by
making light service applications at the controlling automatic
brake valve. Initial movement of the controlling brake valve
handle will exhaust the air pressure in port 3 and permit the
charging valve spool valve to be moved downward by the
force of the spring. This downward movement of the charg-
ing valve spool valve will blank off brake pipe air in port 1.
Air under pressure from port 22, along with the air from the
first suppression reservoir will flow to the top of the perma-
nent suppression valve piston and to the suppression gage
port 41. This air exhausts through the exhaust port of the
cover to provide a time period which should be adequate to
permit adjustment of train slack before a further service
application is made. When a service application is made,
brake pipe prssure at port 1 and under the piston diaphragm
of the temporary suppression valve is reduced. The pres-
sure differential on the diaphragm will move the piston down-
ward to unseat the temporary supression valve check valve
and allow temporary suppression reservoir air from port 2
to flow to the top of the permanent suppression valve piston
and to suppression gage port 41. When the air pressure
reduction of the suppression reservoir is sufficient to re-
move the differential across the temporary suppression valve
piston diaphragm, the force of the spring below the dia-
phragm assembly will move the piston up and close the
check valve.
2.18 The air pressure directed into gage port 41 will move
the permanent suppression valve down to blank off the flow
of timing valve in pipe 6 and prevent a penalty brake appli-
cation from this source. This valve will remain down until air
pressure in gage pipe 41 exhausts through the cover ex-
haust at which time the spring action will move the valve up
and direct timing valve air to exhaust. Also brake pipe ex-
haust air in pipe 17 flows through the back flow check valve
to gage port 41 for additional suppression air pressure.
The pending penalty application may be suppressed sev-
eral times through successive service applications in the
August, 1989

operation & maintenance instruction
above manner.
2.19 If sufficient pressure is not maintained in the perma-
nent suppression valve to overcome the force of the spring,
air flow from the timing valve at port 6 will resume and cause
the “P-2-A” Brake Application Valve to apply. When this
occurs, air pressure in port 25 on the spring side of the
permanent suppression valve will nullify any further attempt
to suppress the penalty brake application.
2.20 WARNING: Temporary or permanent sup-
pression of a brake application WILL result in an ex-
tended slowdown and/or stop distance for any given
train. This extended distance could possibly contrib-
ute to a situation which may result in damage to equip-
ment and/or injury to personnel and/or bystanders.
Therefore, this feature IS NOT recommended by the
Wabtec Corporation.
2.21 Permanent suppression is obtained by manually
moving the controlling automatic brake valve handle to “Sup-
pression” position. With the controlling automatic brake
valve handle in “Suppression” position, the brake pipe pres-
sure should be permitted to drop at a service rate, without
interruption, until a full service brake application is achieved.
This should provide the shortest train stopping distance un-
less an emergency brake application is called for due to the
operating circumstances.
2.21.1 Lockover port 8 is blanked at the brake valve.
2.21.2 Air pressure is directed through suppression pipe
26 to the suppression spool valve.
The air pressure in suppression pipe 26 will move the sup-
pression spool valve down and direct brake pipe air in port
1 to suppression pipe 41 and the permanent suppression
valve diaphragm. The flow of timing valve air in pipe 6 is
blanked.
3.0 MAINTENANCE SCHEDULE
3.1 IMPORTANT: At least ONCE every twenty-four
months, or more frequently if service conditions so in-
dicate, the Suppression Valve Portion and the Split
Reduction Portion of the “C-1” Suppression Valve are
to be removed from the equipment arrangement, taken
to the shop, be completely disassembled, the parts
cleaned, inspected and lubricated, then reassembled
using specified NEW parts. Each assembled Portion is
then to be tested following the procedure of the appli-
cable test specification.
August, 1989
4241-1
4.0 PARTS CATALOG & REPLACEMENT
PARTS INFORMATION
4.1 PARTS CATALOG
4.1.1 When ordering replacement parts for the “C-1” Sup-
pression Valve, Pc.No. 562606, or any of its Component
Portions, refer to the current issue of the Wabtec Corpora-
tion Parts Catalog 3241-1.
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 correct part is
ordered.
4.2 REPLACEMENT PARTS
4.2.1 IMPORTANT: To obtain satisfactory operation
and reliability of the “C-1” Suppression Valve and its
Component Portions, ONLY Wabtec Corporation re-
placement parts are to be used in the maintenance of
the “C-1” Suppression Valve and/or its Component
Portions.
4.2.2 IMPORTANT: Rubber Parts Kits for the “C-1”
Suppression Valve and/or its Component Portions are
available. Consult Parts Catalog 3241-1 for Kit infor-
mation.
5.0 SAFETY PROCEDURES & WARNINGS
Regular owner-operating property and shop safety proce-
dures are to be followed.
The work area is to be clean.
WARNING
The following statements of warning apply all or in part wher-
ever 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.
y 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 af-
ter 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.
y When using an air jet, do not direct it toward an-
other person. Improper use of air jet could result in
bodily injury.
Page 5 of 18
4241-1
operation & maintenance instruction
y Personal eye protection must be worn when per-
forming any work on this device or its components
parts to avoid any possible injury to the eyes.
y The use of solvents as cleaning agents and the use
of lubricants can involve health and/or safety haz-
ards. The manufacturers of the solvents and lubri-
cants should be contacted for safety data (such as
OSHA Form OSHA-20 or its equivalent). The rec-
ommended precautions and procedures of the manu-
facturers should be followed.
y When performing any test or work on devices or
equipment while they are on the vehicle (on car test,
etc.) special precautions must be taken to insure
that vehicle movement will not occur which could
result in injury to personnel and/or damage to equip-
ment.
y Assembly may be under a spring load. Exercise cau-
tion during disassembly so that no parts “Fly Out”
and cause bodily injury.
y All air supply and/or electric current to this device
and/or to any components part must be cut-off be-
fore this device and/or any component part is re-
moved from the equipment arrangement.
y “Bottled” up air under pressure (even though air
supply is cut-off) may cause gaskets and/or parti-
cles 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.
y 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.
y An adequate support or lifting device must be avail-
able to support the Device and/or Valve Portion(s)
during removal, installation and maintenance pro-
cedures.
6.0 CLEANING SOLVENT & LUBRICANTS
6.1 CLEANING SOLVENT
6.1.1 The solvent used to clean reusable parts MUST BE
an aliphatic organic solution such as mineral spirits or naph-
tha that will dissolve oil or grease and that will permit the
parts to be cleaned without abrasion.
Page 6 of 18
6.2 LUBRICANTS
6.2.1 Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2, such as Dow Corning Corp.
Molykote 55M, is required for the lubrication of o-rings, o-
ring grooves, and the bearing surfaces of 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 Co. Superflake Number 597; J. Dixon Crucible
Co. Microfyne Graphite; or National Carbon Co. Number
38 or 39 Graphite, and two parts of SAE-20 oil, by weight,
is to be used to coat the threads of choke plugs after the
plugs have been cleaned.
7.0 SPECIAL TOOLS
IMPORTANT: In addition to the regular shop tools, the fol-
lowing tools are required to maintain the Component Por-
tions of the “C-1” Suppression Valve.
7.1 A hook type tool (a wire hook) is required when remov-
ing the limiting valve from the body of the Split Reduction
Valve Portion.
7.2 A Hand Tool for use when assembling the NEW piston
diaphragm of the Split Reduction Valve Portion. The nec-
essary information and specications for making this tool
are shown in Figure 3 (Drawing R-42-3).
1/4” R.
Material: Steel
3/4”
1”
3/32”
Approx. 8”
3/4”
Round Corners
Figure 3 - Hand tool for assembling diaphragms
August, 1989
 4241-1

operation & maintenance instruction

7.3 A Spanner Wrench for use when servicing the Sup- or a Split Reduction Portion, Pc.No. 561885, that has been
pression Valve Portion piston. The necessary information overhauled, and then tested following the procedures of the
and specifications for making this tool are shown in Figure current issue of the Wabtec Corporation Test Specification
4 (Drawing R-82). T-2592-O.

8.1.5 A NEW Split Reduction Valve Portion mounting gas-

Material: Steel ket, Pc.No. 561907.
3/8”
3/4” 1/4”
8.2 “ON-CAR” REMOVAL AND REPLACEMENT
5/8” OF COMPONENT PORTIONS

33/64”
8.2.1 IMPORTANT: All owner-operating property safety
Drill procedures and the safety procedures and warning listed
.088 to .089 3/32 x 5/16” in Section 5.0 MUST BE adhered to.
2 holes Steel Dowel
Pin Pc. No.
535655 8.2.2 IMPORTANT: ALL air flow to the “C-1” Suppression
2 Required Valve MUST BE cut-off.
Press in
place
8.2.3 IMPORTANT: The wheels of the vehicle are to be
5” chocked and the handbrake(s) applied to prevent any unin-
tentional vehicle movement.

5/8” New Warning placards indicating that work is being per-

Round sharp 1-1/4” formed should be placed on and about the vehicle.
corners
Figure 4 - Suppression Piston Spanner Wrench (R-81) (Figure 5)

7.4 IMPORTANT: The information shown in Figures 3
and 4 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 of the use of any tools
(including claims by third parties).
8.2.4 Remove the four 3/8" hex nuts (4) which secure the
Split Reduction Valve Portion (5) and its mounting gasket
(6) to the Pipe Bracket (7).
8.2.5 With the aid of a support device, which will hold an
excess of 50 pounds, carefully remove the Split Reduction
Portion (5) from the Pipe Bracket (7).

8.0 MAINTENANCE PROCEDURES - “ON-CAR” 8.2.6 Remove and SCRAP the mounting gasket (6).

8.1 PARTS REQUIRED
8.1.1 A NEW Suppression Valve Portion, Pc.No. 562798,
or a Suppression Valve Portion, Pc.No. 562798, that has
been overhauled, and then tested following the procedures
of the current issue of the Wabtec Corporation Test Speci-
fication T-2634-O.
8.2.7 Remove the four 1/2" hex nuts (1) which secure the
Suppression Valve Portion (2) and its mounting gasket (3)
to the Pipe Bracket (7).
8.2.8 With the aid of a support device, which will hold an
excess of 50 pounds, carefully remove the Suppression
Valve Portion (2) from the Pipe Bracket (7).

8.1.2 A NEW suppression valve mounting gasket, Pc.No.
562370.
8.1.3 A NEW 3/8" Choke Plug (1/8" drill), Pc.No. 50715 or a
Choke Plug, Pc.No. 50715, that has been cleaned and in-
spected for correct choke size.
8.1.4 A NEW Split Reduction Valve Portion, Pc.No. 561885,
8.2.9 Remove and SCRAP the mounting gasket (3).
(Figure 6)
8.2.10 Remove the 3/8" Choke Plug (5) from port 17 of the
Suppression Valve Portion mounting face of the pipe bracket
body (7).

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4241-1
operation & maintenance instruction
7
2 4
1
5
23
41
15
17
42
25
2 2
3 6
Figure 5 - Exterior Side View
Tag or place this choke plug in a plastic bag which has
been marked or tagged with Pc.No. 50715.
8.2.11 Visually inspect the Pipe Bracket (7) to be sure that
the valve mounting faces are clean and undamaged.
The Pipe Bracket need not be removed from the equipment
arrangement unless it is damaged. If damaged in any way,
the Pipe Bracket (7) should be removed and replaced fol-
lowing car builder and/or owner-operating property instruc-
tions.
8.2.11.1 Be sure that ALL ports in the Pipe Bracket Valve
Portion mounting faces are clear and unrestricted. If nec-
essary, ports may be blown out using a low-pressure jet of
clean dry air. Exercise care so that no dirt is blown into the
ports and passages of the Pipe Bracket.
(Figure 6)
8.2.12 Remove ALL protective materials from a NEW or
cleaned and inspected 3/8" Choke Plug (1/8" drill) (5), Pc.No.
50715.
8.2.13 Apply a light coating of the graphite and oil com-
pound, as described in Section 6.2.1, to the threads of a
NEW or cleaned and inspected 3/8" choke plug (5), Pc.No.
50715.
8.2.14 Install the lubricated 3/8" choke plug (5) into port 17
of the Suppression Valve Portion mounting face of the Pipe
Bracket (7). The choke plug (5) is to be installed so that it
is flush with, or just below, the surface of the mounting face.
Page 8 of 18
3
5
4
1
All pipe taps are 3/8-18 NPT
Figure 6 - Exterior View - Pipe Bracket
(Figure 5)
8.2.15 Remove ALL protective materials from a NEW or
overhauled and tested Suppression Valve Portion, Pc.No.
562798. Be sure that ALL tape is removed from the sur-
faces of the Portion.
8.2.16 Install a NEW Suppression Valve Portion mounting
gasket (2), Pc.No. 562370, and the Suppression Valve Portion
(2) on the Pipe Bracket (7) and secure the parts in place
by installing the four 1/2" hex nuts (1). Equally tighten the
nuts (1).
8.2.17 Remove ALL protective materials from a NEW or
overhauled and tested Split Reduction Valve Portion (5),
Pc.No. 561885. Be sure that ALL tape is removed from
the surfaces of the Portion.
8.2.18 Install a NEW Split Reduction Valve Portion mount-
ing gasket, Pc.No. 561907, and the Split Reduction Valve
Portion, Pc.No. 561885, on the Pipe Bracket (7) and se-
cure the Parts in place by installing the four 3/8" hex nuts
(4). Equally tighten the nuts (4).
8.2.19 Transport the removed Suppression Valve Portion,
Split Reduction Valve Portion, and 3/8" Choke Plug to the
shop area.
8.2.20 IMPORTANT: Whenever the “C-1” Suppres-
sion Valve, or any of its Component Portions, are re-
moved from an equipment arrangement for any rea-
son, and the Valve or any Component Portion is re-
installed or replaced with a NEW or overhauled and
August, 1989

operation & maintenance instruction
tested Valve or Portion, a stationary test MUST BE per-
formed to be sure that the “C-1” Suppression Valve
and ALL of its Component Portions function properly
in the equipment arrangement.
8.2.21 IMPORTANT: When ANY Component Portion of
the “C-1” Suppression Valve is removed from an equip-
ment arrangement for any reason, and it is re-installed
or replaced with a NEW or overhauled and tested Por-
tion, NEW mounting gaskets MUST BE used.
8.2.22 Remove ALL warning placards and wheel chocks
before attempting to move the vehicle.
9.0 CHOKE PLUGS - MAINTENANCE
PROCEDURE - “IN-SHOP”
9.1 CLEANING & INSPECTING
9.1.1 Choke plugs are to be cleaned individually - one at
a time - in order to avoid mixing chokes of different sizes in
the same bag or storage area.
9.1.1.1 Wash the choke plug in a bath of the cleaning
solvent as described in Section 6.1.1.
DO NOT use metal tools to clean the choke as the size and
shape of the orifice MUST NOT BE changed.
9.1.2 Remove the choke plug from the solvent bath and
blow it completely dry with a low pressure jet of clean, dry
air.
9.1.3 Inspect the choke plug for damage. If it is damaged
in any way, or if the size or shape of the orifice has been
changed in any way, the plug is to be SCRAPPED.
Refer to Parts Catalog 3241-1 for correct drill size of the
various choke plugs.
9.1.4 Use the graphite-oil compound as described in Sec-
tion 6.1.2 to coat the threads of the choke plug. Put the
choke plug in a suitable plastic bag with tag indicating piece
number and size of choke plug if it is going to be stored.
9.1.5 Continue the procedure for each of the choke plugs,
until all are cleaned and inspected.
10.0 SUPPRESSION VALVE PORTION,
MAINTENANCE PROCEDURES - “IN-SHOP”
IMPORTANT: When performing the procedures which
follow, DO NOT use hard or sharp metal tools to re-
August, 1989 Page 9 of 18
4241-1
move o-rings, gaskets, check valves or diaphragms.
Exercise care so that no damage is done to metal parts.
(Figure 7)
10.1 DISASSEMBLY
10.1.1 Remove the four 3/8" x 1" hex head cap screws (20)
which secure the permanent suppression valve cover (21)
to the body (38), then remove the cover (21) from the body
(38).
10.1.2 Remove the large piston spring (30), temporary
suppression check valve spring (28) and the three check
valve springs (26).
10.1.3 Remove and SCRAP the temporary suppression
check valve (29), the two back flow and the spillover check
valves (27).
10.1.4 Remove the permanent suppression valve and dia-
phragm sub-assembly with o-rings (31 to 35 incl.) as a unit
from the body (38).
10.1.5 Remove and SCRAP the three 1/2" O.D. o-rings
(34) from their grooves in the stem of the permanent sup-
pression valve piston (35).
10.1.6 Using the special spanner wrench, as illustrated in
Figure 4, to hold the permanent suppression valve piston
(35), carefully remove the 3/8" hex nut (31) from the piston
(35).
10.1.7 Remove the diaphragm follower (32) and diaphragm
(33) from the piston (35). SCRAP the diaphragm (33).
10.1.7.1 Remove the spanner wrench from the piston (35).
10.1.8 Carefully install a #10-24 x 2" machine screw part
way into the tapped hole in the spool valve piston (37).
10.1.8.1 Using the machine screw as a handle, carefully
pull the spool valve with o-ring sub-assembly (36, 37) from
the body (38) as a unit.
10.1.9 Remove and SCRAP the four 5/8" O.D. o-rings (36)
from their grooves in the spool valve piston (37).
10.1.10 Remove and SCRAP the following ring gaskets
from their grooves in the body (38).
10.1.10.1 The 11/2" O.D. ring gasket (25).
4241-1

operation & maintenance instruction

Figure 7 - Suppression Valve Portion - Assembly View

Page 10 of 18 August, 1989


operation & maintenance instruction
10.1.10.2 The 13/8" O.D. ring gasket (24).
10.1.10.3 The 15/16" O.D. ring gasket (23).
10.1.10.4 The three 1" O.D. ring gaskets (22).
10.1.11 Remove the four 3/8" x 13/8" hex head cap screws
(2) which secure the temporary suppression valve cover
(3) to the body (38). Remove the cover (3) from the body
(38).
10.1.12 Remove the check valve spring (7) and the charg-
ing valve spring (9) from the body (38).
10.1.13 Remove and SCRAP the check valve (8).
10.1.14 Carefully install a #10-24 x 2" machine screw part
way into the tapped hole in the charging valve (11), then
using the screw as a handle, carefully pull the charging
valve with o-ring sub-assembly (10, 11) from the body (38)
as a unit.
10.1.15 Remove and SCRAP the two 9/16" O.D. o-rings
(10) from their grooves in the charging valve (11).
10.1.16 Remove and SCRAP the 13/8" O.D. ring (4), the 1"
O.D. ring gasket (5), and the 11/8" O.D. ring gasket (6) from
their grooves in the body (38).
10.1.17 Remove the temporary suppression spool valve -
diaphragm - piston sub-assembly with o-rings (12 to 19
incl.) as a unit from the body (38).
10.1.18 Remove and SCRAP the two 1/2" O.D. o-rings
(18) from their grooves on the spool valve piston (19).
10.1.19 Using an open end wrench on the flats of the
spool valve piston (19) and the appropriate tools, carefully
remove the 1/2" hex nut (12) and the diaphragm follower
(13) from the spool valve piston (19).
10.1.19.1 Remove and SCRAP the diaphragm (14), then
remove the spool valve piston head (15) from the spool valve
piston (19).
10.1.19.2 Remove and SCRAP the 5/8" O.D. o-ring (17)
from its groove in the spool valve piston (19).
10.2 CLEANING & INSPECTING
10.2.1 NON-REUSABLE PARTS
10.2.1.1 IMPORTANT: ALL o-rings, gaskets, rubber seated
August, 1989 Page 11 of 18
4241-1
check valves, felt strainer, and diaphragms ARE TO BE
SCRAPPED AND REPLACED WITH NEW WABTEC
CORPORATION PARTS.
10.2.2 BODY (Figure 7)
10.2.2.1 Remove the 3/8" strainer and choke plug assem-
bly (38A) from port 4 in the temporary suppression cover
mounting face of the body (38).
(Figure 8)
10.2.2.1.1 Remove the retainer (1) and filter from the 3/8"
choke plug (3). SCRAP the filter (2).
10.2.2.1.2 Following the procedure of Section 9.0, clean
and inspect the choke plug (3). The orifice size of this
choke plug MUST BE 0.0292" (Number 69 drill).
10.2.2.1.3 Wash the retainer (1) in a bath of the cleaning
solvent as described in Section 6.1.1. After the retainer is
cleaned, it MUST BE completely dried. A low pressure jet
of clean dry air may be used to blow it dry.
Figure 8 - Choke Plug with Filter - Assembly View
10.2.2.1.4 Install a NEW Filter (2), Pc.No. 525032, on the
cleaned and inspected choke plug (3). Secure the NEW
filter in place by installing the spring type retainer (1). If
required, a NEW retainer may be obtained by ordering
Pc.No. 525033. Set the assembled strainer and choke plug
aside in a clean, protected area.
(Figure 7)
10.2.2.2 Wash the body (38) in a bath of the cleaning
solvent as described in Section 6.1.1. A clean, lint-free
cloth or rag, which has been saturated with the cleaning
solvent may be used to assist in the cleaning of the exterior
and interior parts of the body.
10.2.2.3 After the body has been cleaned, it MUST BE
completely dried. Use a low pressure jet of clean dry air to
blow the body dry. Be sure that all ports and passages are
dried, BUT EXERCISE CARE so that no dirt is blown
4241-1
operation & maintenance instruction
into the ports and/or passages of the body.
10.2.2.4 Visually inspect the bushings, passages, and
mounting faces of the body. There MUST BE no damage.
If the body is cracked, cut, nicked, damaged in any way,
shows signs of excessive wear or if it is in such a condition
that may result in the unsatisfactory operation of the “C-1”
Suppression Valve IT IS TO BE REPLACED.
10.2.2.5 Inspect the wasp excluder (38B, and 38C) of the
body (38). If a wasp excluder is damaged in any way, or if
it cannot be easily cleaned out, it is to be replaced with a
NEW wasp excluder.
A damaged wasp excluder can be removed from the body
by inserting a small screw driver blade between the tangs of
the excluder and then prying it out of the body with a twist-
ing motion. Press a NEW wasp excluder in place. The 7/8"
wasp excluder, reference 38B, is Pc.No. 552074. The 1/2"
wasp excluder, reference 38C, is Pc.No. 555250.
10.2.2.6 Coat the threads of the cleaned and inspected 3/8"
choke plug with strainer (38A) with a light coating of the oil
and graphite compound as described in Section 6.2.2. In-
stall the choke plug (38A) into port 4 of the body (38) its full
travel.
10.2.2.7 Set the body aside in a clean, protected area.
10.2.3 SPRINGS
10.2.3.1 Wash all of the springs in a bath of the cleaning
solvent as described in Section 6.1. A wire brush may be
used to assist in the removal of any dirt, rust or scale.
10.2.3.2 After the springs are cleaned, they MUST BE
completely dried. Use a low pressure jet of clean dry air to
blow the springs dry.
10.2.3.3 Inspect each spring.
Replace any spring that is rusted, pitted, distorted, dam-
aged in any way, or if it has taken a permanent set. Refer
to the current issue of the Wabtec Corporation Parts Catalog
3241-1 for spring identification and information.
10.2.4 REMAINING PARTS
10.2.4.1 Wash ALL of the remaining parts in a bath of the
cleaning solvent as described in Section 6.1.
10.2.4.2 After the parts have been cleaned, they MUST
BE completely dried. Use a low pressure jet of clean, dry
Page 12 of 18
air to blow the parts dry.
10.2.4.3 Inspect the parts.
Replace any part that is cracked, cut, broken, bent, exces-
sively worn, damaged in any way, or if it is in such a condi-
tion that may result in the unsatisfactory operation of the
Suppression Valve Portion and/or the “C-1” Suppression
Valve.
10.3 ASSEMBLY (Figure 7)
10.3.1 Install a NEW diaphragm (33) on to the permanent
suppression valve piston (35) so that the small bead of the
diaphragm (33) fits into the bead groove of the head of the
piston (35).
10.3.2 Install the diaphragm follower (32) on to the piston
(35) so that the spring seat of the follower (32) faces away
from the diaphragm (33) and is toward the threaded end of
the piston (35).
10.3.3 Using the special spanner wrench, as shown in
Figure 4, to hold the piston (35), secure the follower (32)
and diaphragm (33) in place by installing the 3/8" hex nut
(31).
10.3.4 Coat th surfaces of three NEW 1/2" O.D. o-rings
(34) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also fill the o-ring grooves on the
stem of the piston (35) and lightly coat the bearing surfaces
of the permanent suppression valve piston bushing of the
body (38) with the lubricant.
10.3.5 Install a NEW lubricated 1/2" O.D. o-ring (34) into
each of the three o-ring grooves on the stem of the piston
(35). Any excess lubricant may be removed by wiping with
a soft, dry, lint-free cloth.
10.3.6 Carefully install the permanent suppression valve
piston - diaphragm - follower sub-assembly with o-rings (31
to 34) as a unit into its bushing in the body (38).
10.3.7 Install a NEW temporary check valve (29) on its
seat in the body (38).
10.3.8 Install three NEW check valves (27) in place on
their seats in the body (38). These check valves are identi-
cal and are designated as the spill-over check valve and
back flow check valves, (see Figure 2).
(Figure 7)
August, 1989

operation & maintenance instruction
10.3.9 Coat the surfaces of four NEW 5/8" O.D. o-rings
(36) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also fill the o-ring grooves on the
spool valve piston (37) and lightly lubricate the bearing sur-
faces of the spool valve piston bushing on the body (38)
with the lubricant.
10.3.10 Install a NEW, lubricated 5/8" O.D. o-ring (36) into
each of the four o-ring grooves of the spool valve piston
(37). Any excess lubricant may be removed by wiping with
a soft, clean, dry, lint-free cloth.
10.3.11 Install the spool valve piston with o-ring sub-as-
sembly (37, 36) into its bushing in the body (38).
IMPORTANT: If not already removed, carefully remove
the #10-24 x 2" machine screw which was installed in
the spool valve piston during the disassembly proce-
dure, Section 10.1.8.
10.3.12 Install the permanent suppression valve piston
spring (30) in place in its seat in the diaphragm follower
(32).
10.3.13 Install the temporary check valve spring (29) in
place on its seat on the temporary check valve (28).
10.3.14 Install a check valve spring (26) in place on the
spring seat of the two back flow and the spillover check
valves (26).
10.3.15 Install a NEW 11/2" O.D. ring gasket (25), a NEW
13/8" O.D. ring gasket (24), a NEW 15/16" O.D. ring gasket
(23), and three NEW 1" O.D. ring gaskets (22) into their
grooves on the permanent suppression valve cover mount-
ing face of the body (38).
10.3.16 Carefully install the permanent suppression valve
cover (21) on the body (38) so that the spring (26, 28, 30)
are properly positioned in their recesses of the cover (21).
Secure the cover (21) to the body (38) by installing the four
3
/8" x 1" hex head cap screws (20). Equally tighten the
screws.
10.3.17 Install the spool valve piston return spring (16) in
its cavity in the body (38).
10.3.18 Coat the surfaces of a NEW 5/8" O.D. o-ring (17)
with Number 2 Silicone Grease, Wabtec Corporation Speci-
fication M-7680-2. Also fill the o-ring groove nearest the
threaded end of the spool valve piston (19) with the lubri-
cant.
August, 1989 Page 13 of 18
4241-1
10.3.19 Install the NEW lubricated 5/8" O.D. o-ring (17)
into its groove near the threaded end of the spool valve
piston (19). Any excess lubricant may be removed by wip-
ing with a soft, clean, dry, lint-free cloth.
10.3.20 Carefully install the spool valve piston head (15)
onto the spool valve piston (19) so that the spring seat of the
spool valve piston head (15) fits around the spring (16),
which was previously installed in the body (38). The dia-
phragm bead groove in the spool valve piston head (15)
should be facing the threaded end of the spool valve piston
(19). Be sure that the o-ring (17) remains in its groove.
10.3.21 Install a NEW diaphragm (14) onto the spool valve
piston head (15) so that the inner bead of the diaphragm
(14) fits into the diaphragm bead groove of the piston head
(15). The outside bead of the diaphragm should be facing
in the direction of the stem of the spool valve piston (19).
10.3.22 Install the diaphragm follower (13) on the spool
valve piston (19) making sure that the bead of the diaphragm
(14) remains seated in the bead groove of the piston head
(15). Secure the parts together by installing the 1/2" hex nut
(12). Using an open end wrench to hold the spool valve
piston (19) and the proper tool, tighten the nut (12) se-
curely, BUT DO NOT over-tighten it, as crimping of the
diaphragm may occur.
10.3.23 Coat the surfaces of two NEW 1/2" O.D. o-rings
(18) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also fill the o-ring grooves on the
stem of the spool valve piston (19) and lightly coat the bear-
ing surfaces of the spool valve piston bushing of the body
(38) with the lubricant.
10.3.24 Install the two NEW 1/2" O.D. o-rings (18) into
their grooves on the stem of the spool valve piston (19).
Any excess lubricant may be removed by wiping with a
soft, clean, dry, lint-free cloth.
10.3.25 Install the spool valve piston - diaphragm - dia-
phragm follower with o-ring sub-assembly (12 to 19) as a
unit into the body (38) so that the stem of the piston (19)
goes through the center of the spring (16) and into the
piston bushing of the body (38). The spool valve head (15)
spring seat should sit evenly on the spring (16).
Carefully work the bead of the diaphragm (14) into the bead
groove of the body (38) with finger pressure.
10.3.26 Coat the surfaces of two NEW 9/16" O.D. o-rings
(10) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also, fill the o-ring grooves of the
4241-1
operation & maintenance instruction
charging valve (11) and lightly coat the bearing surfaces of
the charging valve bushing of the body (38) with the lubri-
cant.
10.3.27 Install a NEW, lubricated 9/16" O.D. o-ring (10)
into each of the two o-ring grooves on the stem of the charg-
ing valve (11). Any excess lubricant may be removed by
wiping with a soft, clean, dry lint-free cloth.
10.3.28 Carefully install the charging valve with o-ring
sub-assembly (10, 11) into its bushing in the body (38).
IMPORTANT: If not already removed, carefully remove
the #10-24 x 2" machine screw, which was installed
during the disassembly procedure, Section 10.1.14, from
the charging valve (11).
10.3.29 Install the charging valve spring (9) in place on the
charging valve (11).
10.3.30 Install a NEW charging check valve (8) in its
cavity in the body (38).
10.3.31 Install the check valve spring (7) in its seat on the
check valve (8).
10.3.32 Install a NEW 11/8" O.D. ring gasket (6), a NEW
1" O.D. ring gasket (5), and a NEW 13/8" O.D. ring gasket
(4) in place in their grooves on the temporary suppression
mounting cover face of the body (38).
10.3.33 Carefully position the temporary suppression valve
cover (3) onto the body (38) being sure that the check valve
spring (8) and charging valve spring (9) fit properly in their
recesses in the cover (3). Secure the cover (3) to the body
(38) by installing four 3/8" x 1" hex head cap screws (2).
Equally tighten the screw (2).
10.4 TESTING AND ADDITIONAL INFORMATION
10.4.1 IMPORTANT: After the Suppression Valve Por-
tion, Pc.No. 562798 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-2634-O.
10.4.2 IMPORTANT: Whenever the Suppression Valve
Portion, Pc.No. 562798, is removed from an equipment
arrangement for any reason, and it is reinstalled or re-
placed with a NEW or repaired and tested Portion, a
NEW mounting gasket MUST BE used. This mounting
gasket MUST BE ordered as an individual item. See
Section 8.2.16.
Page 14 of 18
10.4.3 IMPORTANT: Whenever the Suppression Valve
Portion is removed from an equipment arrangement
for any reason, and it is reinstalled or replaced with a
NEW or repaired and tested Portion, a stationary vehi-
cle test MUST BE made to be sure that the Suppres-
sion Valve Portion and the “C-1” Suppression Valve
function properly in the total equipment arrangement.
10.4.4 Consult your Wabtec Corporation Representative if
additional information is required.
11.0 SPLIT REDUCTION VALVE PORTION -
MAINTENANCE PROCEDURES - “IN-SHOP”
IMPORTANT: When performing the procedures which
follow, DO NOT use hard or sharp tools to remove gas-
kets, o-rings, the check valve or diaphragm. Exercise
care so that no damage is done to metal parts.
11.1 DISASSEMBLY (Figure 9)
11.1.1 Position the Split Reduction Valve Portion on the
bench so that the bottom cover (12) can be removed.
11.1.2 Remove the four 3/8" x 1" hex head cap screws (11)
which secure the bottom cover (12) to the body (21), then
remove the cover (12) from the body (21).
11.1.3 Remove and SCRAP the 9/16" O.D. ring gasket (20)
from its groove in the cover mounting face of the body (21).
11.1.4 Remove the diaphragm - piston with o-ring sub-
assembly (13 to 15) as a unit from the body (21).
11.1.5 Remove and SCRAP the diaphragm (13) from the
head of the piston (15).
11.1.6 Remove and SCRAP the 1/2" O.D. o-ring (14) from
its groove in the stem of the piston (15).
11.1.7 WARNING: During the procedure which fol-
lows, the piston spring (18) and spring cage (17) will
be placed under tension. Exercise care so that no parts
are inadvertently expelled from the assembly. Inad-
vertently expelled parts may cause bodily injury and/or
damage to equipment.
Carefully depress and hold the spring cage (17) and spring
(18) far enough into the body (21) to permit access to the
retaining ring (16). Remove the retaining ring (16) from its
groove in the body (21), then slowly release the hold on the
spring cage (17) and spring (18) to permit the spring (18)
to extend its full travel.
August, 1989
 4241-1

operation & maintenance instruction

2A

8
3

19 18
10

6 17
9
5

7 16

4 19 14

15

21
13

12

20
11

11.1.8 Remove the spring cage (17) and piston spring (18) duction limiting valve spring (8), and the check valve spring
from the body (21). (6) from the body (21).

11.1.9 Turn the Portion to permit access to the top cover 11.1.12 Remove and SCRAP the four 13/8" O.D. ring gas-
(2), but exercise care so that NO DAMAGE is done to the kets (19) from their grooves in the top cover mounting face
bottom cover mounting surface of the body (21). of the body (21).

11.1.10 Remove the three 3/8" x 1" hex head cap screws
(1) that secure the top cover to the body (21), then remove
the top cover (2) from the body (21).
11.1.11 Remove the spool valve piston spring (3), the re-
11.1.13 Install a #10-24 x 2" machine screw into the tapped
hole in the spool valve piston (5), then, using the screw for
a handle, carefully remove the spool valve piston with o-ring
sub- assembly (4, 5) as a unit from the body (21).

August, 1989 Page 15 of 18

4241-1
operation & maintenance instruction
11.1.14 Remove and SCRAP the three 9/16" O.D. o-rings
(4) from their grooves in the stem of the spool valve piston
(5).
11.1.15 Insert a hook type tool (wire hook) into the 3/64"
drilled hole in the reduction limiting valve (10) and carefully
pull the reduction limiting valve with o-ring sub-assembly (9,
10) from the body (21) as a unit. Remove the tool from the
reduction limiting valve (10).
11.1.16 Remove and SCRAP the two 11/16" O.D. o-rings
(9) from their grooves in the reduction limiting valve (10).
11.1.17 Remove and SCRAP the differential check valve
(7) from the body (21).
11.2 CLEANING AND INSPECTING
11.2.1 NON-REUSABLE PARTS
11.2.1 IMPORTANT: ALL o-rings, gaskets, and the dia-
phragm ARE TO BE SCRAPPED AND REPLACED WITH
NEW WABTEC CORPORATION PARTS.
11.2.2 SPRINGS
11.2.2.1 Wash the springs in a bath of the cleaning solvent
as described in Section 6.1.1. A wire brush may be used
to assist in the removal of any dirt, rust, or scale.
11.2.2.2 After the spring have been cleaned, they MUST
BE completely dried. Us a low pressure jet of clean, dry air
to blow them dry.
11.2.2.3 Inspect the springs.
Replace ANY spring that is rusted, pitted, distorted, or if it
has taken a permanent set. Refer to Parts Catalog 3241-1
for spring information and identification.
11.2.2.4 REMAINING PARTS
11.2.2.4.1 Wash all of the remaining parts in a bath of the
cleaning solvent as described in Section 6.1.1. A clean,
soft, lint-free cloth that has been saturated with the pre-
scribed cleaning solvent may be used to assist in the clean-
ing of the interior and exterior surfaces of the body.
11.2.2.4.2 After the parts have been cleaned, they MUST
BE completely dried. Use a low pressure jet of clean, dry
air to blow the parts dry. Be sure that the internal passages
of the valves and the body are dried. Exercise care so that
no dirt is blown into the passages.
Page 16 of 18
11.2.2.4.3 Inspect the parts.
11.2.2.4.3.1 Replace the retaining ring if it is not elastic
enough to hold securely. When installed, the retaining ring
should “snap” into its groove when it is installed.
11.2.2.4.3.2 Inspect the top cover (2) to be sure that the
wasp excluder (2A) is not restricted or damaged. If the
wasp excluder is damaged, or if it cannot be easily cleaned,
it is to be replaced.
The wasp excluder can be removed by inserting the blade
of a small screwdriver between the tangs of the wasp ex-
cluder and prying it out of the cover with a twisting motion.
11.2.2.4.3.3 Replace any part that is cracked, cut, bro-
ken, excessively worn, damaged in any way, or that is in
such a condition that may result in the unsatisfactory op-
eration of the Split Reduction Valve Portion and/or the “C-1”
Suppression Valve.
11.3 ASSEMBLY
11.3.1 Coat the surfaces of two NEW 11/16" O.D. o-rings
(9) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also, fill the o-ring grooves of the
reduction limiting valve (10) and lightly lubricate the bearing
surfaces of the reduction limiting valve bushing of the body
(21) with the lubricant.
11.3.2 Install a NEW lubricated 11/16" O.D. o-ring (9) into
each of the two o-ring grooves of the reduction limiting valve
(10). Any excess lubricant may be removed by wiping with
a soft, clean, dry, lint-free cloth.
11.3.3 Install the reduction limiting valve with o-ring sub-
assembly (9, 10) into its bushing in the body (21).
11.3.4 Coat the surfaces of three NEW 9/16" O.D. o-rings
(4) with Number 2 Silicone Grease, Wabtec Corporation
Specification M-7680-2. Also fill the o-ring grooves on the
spool valve piston (5) and lightly lubricate the bearing sur-
faces of the spool valve piston bushing of the body (21) with
the lubricant.
11.3.5 Install a NEW lubricated 9/16" O.D. o-ring (4) into
each of the three o-ring grooves of the spool valve piston
(5). Any excess lubricant may be removed by wiping with a
soft, clean, dry, lint-free cloth.
11.3.6 Install the spool valve piston with o-ring sub-as-
sembly (4, 5) into its bushing in the body (21).
August, 1989

operation & maintenance instruction
IMPORTANT: If not already removed, carefully remove
the #10-24 x 2" machine screw, which was installed
during the disassembly procedure, Section 11.1.12, from
the spool valve piston (5).
11.3.7 Install four NEW 13/8" O.D. ring gaskets (19) into
their grooves on the top cover mounting face of the body
(21).
11.3.8 Install a NEW differential check valve (7) into its
bushing in the body (21), then install the check valve spring
(6) being sure that it is properly seated on the NEW check
valve (7).
11.3.9 Install the spool valve piston spring (3) in place in
the spool valve piston (5).
11.3.10 Install the reduction limiting valve spring (8) in
place in the reduction limiting valve (10).
11.3.11 Carefully install the top cover over the three springs
(3, 6, 8), being sure that the springs enter the proper re-
cesses in the cover, and onto the body (21). Secure the
cover (2) in place by installing the three 3/8" x 1" hex head
cap screws (1). Equally tighten the screws.
11.3.12 Position the body (21) to expose the bottom cover
mounting face. Exercise care so that no damage is done to
the body.
11.3.13 WARNING: During the procedures which fol-
low, the piston spring (18) and spring cage (17) will be
placed under tension. Exercise care so that no parts
are inadvertently expelled from the assembly. Inad-
vertently expelled parts could possibly cause bodily
injury and/or damage to equipment.
11.3.13.1 Install the spool valve piston spring (18) and the
spring cage (17) into its bushing in the body (21). Be sure
that the spring (18) is properly seated in the cage.
11.3.13.2 Have the retaining ring (16) ready.
Depress and hold the spring (18) and spring cage (17) far
enough into the body (21) to expose the retaining ring groove
of the body (21). Install the retaining ring (16) into its groove
in the body (21). Be sure that the retaining ring (16) “snaps”
into the groove. SLOWLY release the hold on the spring
cage (17) to allow the spring (18) to extend so that the
spring cage (17) engages the retaining ring (16).
11.3.14 Coat the surfaces of two NEW 1/2" O.D. o-rings
(14) with Number 2 Silicone Grease, Wabtec Corporation
August, 1989 Page 17 of 18
4241-1
Specification M-7680-2. Also fill the o-ring grooves on the
stem of the piston (15) and lightly lubricate the bearing sur-
faces of the piston bushing of the body (21) with the lubri-
cant.
11.3.15 Install a NEW lubricated 1/2" O.D. o-ring (14) into
each of the two o-ring grooves on the stem of the piston
(15). Any excess lubricant may be removed by wiping with
a soft, clean, dry, lint-free cloth.
11.3.16 Install the piston with o-ring sub- assembly (14,
15) into its bushing in the body (21).
11.3.17 Install a NEW diaphragm (13) on the head of the
piston (15) so that the side of the diaphragm with the raised
areas and markings can be seen and so that the bead of
the diaphragm (13) is toward the bead groove in the body
(21).
11.3.18 Using the narrow end of the Diaphragm Assembly
Tool, as shown in Figure 3, CAREFULLY push the sides of
the diaphragm (13) down between the head of the piston
(15) and the cavity in the body (21) until the bead of the
diaphragm (13) is seated in the bead groove of the body
(21). Work the bead of the diaphragm (13) into its groove
in the body (21) by applying light finger pressure.
11.3.19 Install a NEW 9/16" O.D. ring gasket (20) into its
groove on the bottom cover mounting face of the body (21).
11.3.20 Carefully place the bottom cover (12) in position
on the body (21) being sure that the diaphragm (13) and
ring gasket (20) remain in position.
11.3.21 Secure the bottom cover to the body by installing
four 3/8" x 1" hex head cap screws (11). Equally tighten the
screws.
11.4 TESTING AND ADDITIONAL INFORMATION
11.4.1 IMPORTANT: After the Split Reduction Valve
Portion, Pc.No. 561885, has been assembled, BUT BE-
FORE it is returned to service, IT MUST PASS a series
of tests following the procedure of the current issue of
the Wabtec Corporation Test Specification T-2592-O.
11.4.2 IMPORTANT: Whenever a Split Reduction Valve
Portion, Pc.No. 561885, is removed from an equipment
arrangement for any reason, and it is re-installed or
replaced with a NEW or repaired and tested Split Re-
duction Valve Portion, a NEW mounting gasket MUST
BE used. This gasket IS NOT a part of the Portion and
MUST BE ordered as an individual item. See Section
4241-1

operation & maintenance instruction

8.2.18.

11.4.3 IMPORTANT: Whenever a Split Reduction Valve

Portion, Pc.No. 561885, is removed from an equipment
arrangement for any reason, and it is re-installed or
replaced with a NEW or repaired and tested Portion, a
stationary vehicle test MUST BE made to be sure that
the Split Reduction Valve Portion and the “C-1” Sup-
pression Valve function properly in the total equipment
arrangement.

11.4.4 Consult your Wabtec Corporation Representative if

additional information is required.

WABCO Locomotive Products

1001 Air Brake Avenue • Wilmerding, PA 15148
(412) 825-1000 • Fax (412) 825-1019
www.wabtec.com

Page 18 of 18 August, 1989