2391, S.

Shop Maintenance

SHOP MAINTENANCE
2391, S.3

MARCH, 2007
(SUPERCEDES ALL PREVIOUS ISSUES OF 2391, S.3 & S-4018 AND COMPLIES WITH AAR CIRCULAR
LETTER C-10449 FOR VIBRATION PROTECTION UPGRADE DURING COT-S)

Freight Air Brake Control Valve Portions:

• Service Portions: ABD, ABDP, ABDT, ABDPT

• Emergency Portions: ABD, ABDP, ABDS, ABDPS, ABDW,
ABDWP, ABDWS, ABDWPS

NOTE: After April 1, 2007 as per AAR Circular Letter C-10449, all service portions will be identified as
ABD or ABDT, and all emergency portions will be identified as ABD, ABDS, ABDW or ABDWS.

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TABLE OF CONTENTS

1.0 GENERAL.............................................................................................................................................................8

2.0 GENERAL PROCEDURES ........................................................................................................................... 8 - 9

3.0 CLEANING SOLVENTS, LUBRICANTS AND SEALANTS ..................................................................... 10 - 11

4.0 RUBBER ............................................................................................................................................................11

5.0 CHOKES .................................................................................................................................................... 11 - 12

6.0 SPRINGS ................................................................................................................................................... 12 - 13

7.0 ABD, ABDP, ABDT, ABDPT SERVICE PORTION DISASSEMBLY ....................................................... 14 - 18

8.0 ABD and ABDT SERVICE PORTION ASSEMBLY ................................................................................. 18 - 25

9.0 ABD, ABDS, ABDP, ABDPS, ABDW, ABDWP, ABDWS, ABDWPS EMERGENCY PORTION
DISASSEMBLY ......................................................................................................................................... 25 - 29

10.0 ABD, ABDS, ABDW, ABDWS EMERGENCY PORTION ASSEMBLY ................................................... 29 - 36

11.0 TESTING PROCEDURES .................................................................................................................................36

12.0 SHIPPING REQUIREMENTS ............................................................................................................................36

13.0 EXPLODED VIEWS................................................................................................................................... 38 - 48

14.0 SPECIAL TOOLS ...................................................................................................................................... 49 - 52

15.0 CONTROL VALVE MODIFICATIONS ...................................................................................................... 52 - 53

APPENDIX ......................................................................................................................................................................54

Service Bulletin 68-20: ABD Service Portion Slide Valves Proper Id. During COT Repair...................................55

Service Bulletin 68-22: New Emergency Accelerated Release "E.A.R." Filter Details.................................. 57 - 62

Service Bulletin 68-23a: Inspection Procedures for Service Acc. Release Valve Plunger Pin .................... 63 - 64

Service Bulletin 68-26: Lubrication of AB Type Service & Emergency Portions .......................................... 65 - 68

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Metal COT-S
Nameplate Tag

Figure 1 - ABD and ABDT Service Portions

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Figure 2 - ABDP and ABDPT Service Portions

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Figure 3 - ABD and ABDS Emergency Portions

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Figure 4 - ABDP and ABDPS Emergency Portions

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Figure 5 - ABDW, ABDWP, ABDWS and ABDWPS Emergency Portions

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1.0 GENERAL

1.1 The purpose of this manual is to describe appropriate shop procedures to be followed by maintainer of these
control valve portions and to avoid unnecessary expense due to careless handling of parts. For example, it is
readily possible to assemble or dismantle all parts of the valve. If excessive force is required, investigation
must be made immediately as to the cause of the difficulty.

1.2 The ABD Type Control Valve is composed of a pipe bracket and two primary operating portions. Pipe
connections are semi-permanently made to the pipe bracket, which is bolted to the car body. The service and
emergency operating portions, which are bolted to the pipe bracket, are to be removed from the pipe bracket
when cleaning brakes on the repair tracks and must be replaced by operating portions that are new or have
been repaired, cleaned and tested as per Wabtec Corporation recommendations.

1.3 When the car brake equipment is maintained or tested at repair track facilities, the instructions for cleaning,
gaging, and testing ABD Type Brakes as contained in current issue of Instruction Manual No. 2391, Sup. 6
and the Code of Air Brake System Tests for Freight Equipment, AAR Standard S-486 must be followed.

IMPORTANT: The ABD Type Control Valve operating portions and the associated air brake devices on the
freight car are to be removed from the equipment arrangement, taken to the shop, be completely
disassembled, all rubber parts replaced with new Wabtec Corporation supplied material, the parts cleaned,
inspected, repaired, lubricated, assembled and tested for correct operation, in accordance with Wabtec
Corporation recommendation for each device at least once every 144 months, or more frequently if service
conditions so indicate.

1.4 The ABD Type Control Valve Portion Identifications are shown in Figures 1 through 5, pages 3 through 7.
Note that after April 1, 2007, metal identification ‘P’, ‘PS’, and ‘PT’ tags will no longer be required to be put
back on valve portions.

2.0 GENERAL PROCEDURES

2.1 All disassembly, cleaning, relubricating and assembly of the valve portion parts must be done at a suitable
bench in a clean, well lit location at an AAR approved facility.

2.2 The operating portions must be completely dismantled and all parts inspected and cleaned. Parts, including
the body interior, must be cleaned by an approved method that will dissolve oil and grease without damage to
the parts. The body must not be submerged in a solution. A wire brush may be used to assist in the removal
of any light surface dirt, rust or scale on cast parts. The exterior of the body must be thoroughly cleaned.

2.3 When dismantling and assembling the operating portions, care must be exercised to avoid distortion of bolts,
studs, nuts, etc. This can best be done by using tools especially adapted for this work. Special tools are
shown in Section 14.0, page 49. However, other designs may be found acceptable to the user. Similar care
must be taken to avoid mutilation or damage to pistons, springs, rubber parts, slide valves, graduating valves,
etc. when assembling the valves.

2.4 All pistons, slide valves, graduating valves and bushings must be thoroughly cleaned. To do this, the piston,
slide valve and graduating valve assembly must be dismantled.

2.5 DO NOT use hard or sharp metal tools to remove or install o-rings, seals, gaskets, or diaphragms. Exercise
care so that NO damage is done to metal surfaces and parts.

2.6 Precaution must be used to protect against contamination from dirt and other foreign matter that would cause
damage to o-rings and lubricant.

2.7 Where a multiple o-ring arrangement is used, a thin wall type mandrel may be used to insert the o-ring into its
groove to minimize possible damage if the o-ring is pushed over an adjacent groove. Figure 16, page 49,
illustrates a typical design. The supply of o-rings kept on the mandrel must not exceed daily requirements to
permanent stretch.

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2.8 Before reassembly, the slide and graduating valves must be gaged after lapping. The body plug gages must
be available and used prior to reassembly. The current issue of Instruction Manual No. 2356-3, Sup. 1, AAR
Standard S-480, describes gages to be used.

2.9 When reassembling valve portions, it is important that cap screws and nuts are tightened sufficiently to
prevent gasket leakage and yet not excessively to cause distortion of covers and gaskets.

IMPORTANT: To obtain satisfactory operation and reliability of this device, ONLY replacement parts
supplied by the Wabtec Corporation are to be used in the maintenance of this device. Wabtec Corporation
shall not support the performance of portions containing parts supplied by others.

NOTE: Replacement part piece numbers are identified in Wabtec Corporation issued parts catalogs. Contact your
local Wabtec Corporation Representative or Marketing Headquarters in Wilmerding, PA for the appropriate
documents.

2.10 Cleaned and repaired service and emergency operating portions must pass prescribed tests on the AAR
standard test rack or AAR approved automated test rack in accordance with the Code of Tests contained in
the current issue of Wabtec Corporation Instruction Manual 5039-19, Sup. 1.

2.11 SAFETY PROCEDURES AND WARNINGS:

General shop safety procedures must be followed when performing these specification instructions.

The following statements of warning apply all or in part wherever the symbol appears in the
maintenance procedures.

Failure to observe these precautions may result in serious injury to those performing the work
and/or the bystanders.

The work area should be clean and free of debris.

Cast iron portions weigh in excess of 50 pounds. Use care when lifting and hauling portions to
preclude injury.

Wabtec recommends that sufficient hearing and eye protection be used by the individual(s) or
others nearby the work area when performing any work on the equipment to avoid possible
injury to both ears and eyes.

The use of an air jet, which must be less than 30 psi, to blow parts clean or to blow them dry after
being cleaned will cause particles of dirt, contaminants and/or droplets of the cleaning liquid to be
airborne. These conditions may cause skin and/or eye irritation. Avoid direct contact with this air
stream or possible flying debris.

When using an air jet do not direct it toward another person. Improper use of the air jet could result
in bodily injury.

When handling valve portions, care must be taken to prevent the portion from falling which could
result in portion damage and/or injury to personnel.

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3.0 CLEANING SOLVENTS, LUBRICANTS AND SEALANTS

3.1 Cleaning Solvents

3.1.1 The means used to clean the reusable parts of the ABD Type Control Valves MUST BE an aliphatic
hydrocarbon solvent, such as mineral spirits or naptha, or a heated aqueous biodegradable detergent and
recommended rinse. Exposure of all re-usable plastic components should be limited as follows:

• Aliphatic hydrocarbon solvent – 20 minutes maximum exposure at room temperature, wipe or blow
dry.
• Heated aqueous biodegradable detergent – 15 minutes maximum exposure, solution temperature
160° F (71.1° C) maximum, solution pH 5 to 10, wipe or blow dry after rinsing.

IMPORTANT: Cleaning materials are to be used in a well ventilated area.

3.2 Lubricants

3.2.1 Air brake shop containers with known approved AAR lubricants must be appropriately stenciled with AAR
specification identification.

Lubricant Current AAR Specification

Triple Valve Oil M-912*
Dry Graphite M-913
Brake Cylinder Lubricant M-914

NOTE: Refer to Service Bulletin 68-26 in the Appendix on Page 65.

[Link] Wabtec recommends using a clean foam-tipped swab applicator to evenly spread Triple Valve Oil, Wabtec
Corporation Specification M-07611-20 (AAR Specification M-912) on all parts required to have this specific
type of lubricant.

3.2.2 The o-ring, o-ring grooves and the o-ring bearing surfaces of the bushing(s) must be lubricated with # 2
Silicone Grease, Wabtec Corporation Specification M-07680-02 (Industry Designation MIL-G-4343), such
as Dow Corning Corporation, Molykote® 55. Wabtec recommends using a clean foam-tipped swab
applicator to evenly spread #2 Silicone Grease, Wabtec Corporation Specification M-07680-02 (Industry
Designation MIL-G-4343), such as Molykote® 55, on all pistons, spool valves, and bushing bearing
surfaces required to have this specific type of lubricant.

3.2.3 As a minimum guideline, the threads of solid choke plugs and all other removable plugs, as well as other
threaded parts which may later be difficult to remove, must be pre-coated with Loctite product called
Vibraseal #517, Wabtec Specification M-07499-35, or with brake cylinder lubricant (M-914) or a compound
consisting of one part graphite, Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts
oil (SAE 20) by weight, or anti-seize compounds such as lithium or graphite based greases, such as
Wabtec Specification M-07672-01, unless otherwise specified. If additional sealing capability is needed,
application of a standard commercially available non-curing pipe sealant to the threads is recommended.
Teflon ribbon or tape should not be used on any chokes or removable plugs. All solid choke plugs are to be
secured in place to prevent leakage; however, discretion should be used when tightening the choke plug, to
facilitate removal.

3.2.4 As a minimum guideline, the threads of all brass chokes in the control valve body must be pre-coated with
brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification
M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight, or anti-seize compounds such
as lithium or graphite based greases, such as Wabtec Specification M-07672-01, unless otherwise
specified. Teflon ribbon or tape should not be used on any chokes.
3.3 Sealants

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3.3.1 The following locking sealants are required for application to certain threads.
• Locking Sealant, Wabtec Corporation Specification M-07499-05, such as Loctite Corporation TL-242.
• Locking Sealant, Wabtec Corporation Specification M-07499-08 or M-7499-8, such as Loctite Corporation
TL-271.

4.0 RUBBER

4.1 All rubber parts must be renewed at the time of reconditioning with NEW Wabtec Corporation manufactured
rubber.

4.2 All NEW rubber parts including gaskets, o-rings, rubber seated check valves, seals, diaphragms, etc., must
not be applied if either the date on the part or its shelf life is over five years old.

4.3 The storage area for rubber parts must be cool, dark and free from dampness and mildew. Since most rubber
goods are affected by ozone, they must not be stored near electrical equipment that may generate ozone.

4.4 To determine shelf life, new Wabtec Corporation rubber repair kits are dated with the oldest date (half year) of
rubber components contained within the kit.

4.5 Rubber Repair Kits - Refer to the latest parts catalogs of the valve being disassembled for NEW rubber
repair kit part numbers required for valve reassembly.

5.0 CHOKES

5.1 The size and cleanliness of chokes is important for proper valve performance. Whenever a portion is
dismantled, the choke fittings must be removed, cleaned and inspected to insure that they are not restricted.
When cleaning chokes, the orifice size and shape must not be changed. Metallic filters must be cleaned and
felt filters must be renewed.

5.2 The choke plug should be soaked in a bath of cleaning material as described in Section 3.1. DO NOT use
metallic tools to clean chokes, as their size and shape MUST NOT be changed.

5.3 Splined socket choke plugs can generally be removed or applied without damage to the choke plug or to the
thread in the tapped hole. If it is necessary to drill or tap, all drill chips must be thoroughly blown out of all
passages. The choke fittings for each portion are described later in the section under the heading for that
particular portion.

5.4 While the plug is soaking, inspect the passage from which it was removed to be sure that it is clean and
unrestricted. A low pressure jet of clean, dry air may be used to blow the passage out. Exercise care so that
dirt is not blown back into the passage or passages of the device.

5.5 For proper choke identification, see Table 1, page 12, for ABD, ABDP, ABDT, and ABDPT Service Portions;
Table 2, page 12, for the ABD, ABDP, ABDS, and ABDPS Emergency Portions; and Table 3, page 12, for
ABDW, ABDWP, ABDWS, and ABDWPS Emergency Portions

IMPORTANT: Choke diameters are shown for identification ONLY. If choke size is not correct, DO NOT
ATTEMPT TO REPAIR. A new choke obtained from Wabtec Corporation is to be installed at the correct
location.

NOTE: Discretion should be used when tightening brass chokes back into the control valve body. Securely fasten
each brass choke in its proper location; however, do not over tighten to facilitate future removal.

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TABLE 1 - Choke Identification Table ABD, ABDP, ABDT, ABDPT Service Portions (Figure 10, page 39)
Ref. No. Description Diameter (Inches) Part No.
3
48 Brake Cylinder Exhaust /32” (0.0938) 57585
49 Brake Pipe Charging No. 18 (0.1695) 566219
50 Auxiliary Reservoir Charging No. 55 (0.0520) 538390
50a Auxiliary Reservoir Charging No. 54 (0.055) 87074
1
51 Quick Service Volume Exhaust /32” (0.0312) 95998

TABLE 2 - Choke Identification Table ABD, ABDS, ABDP, ABDPS Emergency Portions (Figure 12, page 43)
Ref. No. Description Diameter (Inches) Part No.

49 Inshot By-Pass No. 41 (0.096) 550069

50 Inshot Volume No. 30 (0.1285) 77882
51 Quick Action Blowdown No. 76 (0.020) 567206
55 Quick Action Breather No. 46 (0.081) 520479
61 Charging No. 76 (0.020) 567206

TABLE 3 - ABDW, ABDWP, ABDWS, ABDWPS Emergency Portions (Figure 13, page 45)
Ref. No. Description Diameter (Inches) Part No.

49 Inshot By-Pass No. 41 (0.096) 550069

50 Inshot Volume No. 30 (0.1285) 77882
51 Quick Action Blowdown No. 76 (0.020) 567206
55 Charging No. 76 (0.020) 567206

Accelerated Application Valve Portion (Figure 14, page 47)

Ref. No. Description Diameter (Inches) Part No.

1
70 Quick Action Exhaust /64” (0.0156) 554755
72 Quick Action Breather No. 46 (0.081) 520479
73 Brake Pipe Supply No. 68 (0.031) 570785
87 Volume Exhaust No. 54 (0.055) 77619

6.0 SPRINGS

6.1 When the portion is dismantled for general cleaning, all springs must be inspected after cleaning. Springs
which show rust pits, distortion, or have permanent set, must be rejected and replaced by springs known to
be correct.

6.2 Wash the springs in the cleaning material described in Section 3.1. A wire brush may be used to assist in
the removal of any dirt, rust or scale, using special care with small, light wire springs.

6.3 After cleaning, the springs MUST BE completely dried. Use a low pressure jet of clean, dry air to blow the
springs dry.

6.4 For proper spring identification, see Table 4, page 13, for the ABD, ABDP, ABDT and ABDPT Service
Portions and Table 5, page 13, for the ABD, ABDP, ABDS, ABDPS, ABDW, ABDWP, ABDWS, and
ABDWPS Emergency Portions.

IMPORTANT: Dimensions given are for identification purposes only. If replacement spring is required, it
must be obtained by part number identification from Wabtec Corporation. No substitute springs are
permitted. No spring adjustment by stretching or compressing is permitted.

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TABLE 4 - Spring Identification Table for ABD, ABDP, ABDT, and ABDPT Service Portions (Figure 10, page 39)
Ref. Part Approx. Approx. Approx. Approx.
No. Description No. Outside Wire Free No. Material
Dia. Dia. Height Turns
5 1
10 Piston Spring 563920 5/8” 1/16” 1 /16” 11 /2 Steel
3
14 Graduating Valve 93940 5/32” 1/64” 21/32” 14 /8 Bronze
1
28 Acc. Rel. Check Valve 571045 1/2” 3/64” 1 /4” 5 Steel (Red)
7 1
34 Back Flow Check Valve 94581 15/32” 1/32” 1 /64” 8 /2 Bronze
5 3 3
36 Piston Return 552280 1 /8” 9/64” 3 /16” 8 /8 Steel
5
37 Brake Cylinder Limiting 566182 55/64” 5/64” 1 /64” 6 Steel (Blue)
Valve

Release Valve Portion (Figure 11, page 41)

17
4 Release Spool Valve 566207 53/64” 5/64” 1 /64” 6 Steel
5
12 Emer. & Aux. Check Valve 552350 9/32” 1/32” 15/16” 11 /8 Steel
5 1
16 Reset Spool Valve 566210 41/64” 1/16” 1 /64” 6 /2 Steel
1 1
19 Retaining Check Valve 32533 13/32” 1/32” 1 /16” 10 /2 Steel
1 1
22 Reset Check Valve 32533 13/32” 1/32” 1 /16” 10 /2 Steel
55 1
23 Lifter Spring 509512 41/64” 3/32” 1 /64” 9 /2 Steel

TABLE 5 - Spring Identification Table for ABD, ABDP, ABDS, ABDPS, ABDW, ABDWP, ABDWS, ABDWPS Emergency
Portions (Figure 12, page 43 and Figure 13, page 45)
Ref. Part Approx. Approx. Approx. Approx.
No. Description No. Outside Wire Free No. Material
Dia. Dia. Height Turns
7 Emergency Slide Valve 560538 7/32” 1/32” 1/2” 9 [Link]
10 High Pressure Spool Return 567212 0.568” 0.054” 1.892” 11 Steel (Blue)
10a High Pressure Spool Return 660914 0.568” 0.063” 1.433” 10 Music Wire (Green)
10b High Pressure Spool (Bottom) 660917 13/16” 1/8” 7/16” 3 Stainless
13 Emer. Acc. Rel. Check Valve 569087 11/16” 3/64” 55/64” 7 Steel
5 1
23 Inshot Check Valve 533932 17/32” 1/32” 1 /16” 6 /2 Steel
23 9 1
26 Vent Valve 567222 1 /64” 7/64” 2 /16” 6 /2 Steel
7
38 Inshot Piston Valve 569088 7/8” 5/64” 2 /32” 8 Steel
23 1
46 Emer. Acc. Rel. Spool Valve 70642 1” 9/64” 2 /32” 10 /2 Steel

Accelerated Application Valve (Figure 14, page 47)

23
63 Diaphragm Check Valve 584197 27/64” 3/64” 1 /64” 7 Music Wire (yellow)
1 1
65 Diaphragm Check Valve 21085 5/16” 3/64” 1 /4” 16 /2 Bronze
19
76 Diaphragm Check Valve 580600 5/8” 3/64” 1 /64” 7 Steel
3
82 Check Valve 581330 23/32” 1/16” 1 /16” 7 Music Wire

NOTE: The actual springs will vary somewhat, due to small differences in wire diameter, coil diameter,
number of coils, etc. This tabulation is intended for identification only and should not be used for
any other purposes. It does not represent a specification for springs mentioned.

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7.0 ABD, ABDP, ABDT, ABDPT SERVICE PORTION DISASSEMBLY
(Refer to Figure 10, page 39)
3
7.1 Remove the release valve portion (57) from the body (47) by first removing the three /8" flanged hex nuts
(52).
1 3
7.1.1 The release valve portion mounting studs (53) on the service portion body (47) must be the special /2" x /8"
studs which utilize flange nuts (52). If the body (47) contains the proper release valve portion mounting studs
(53), then proceed onto Section 7.2. If not, then follow the procedures outlined in Sections 7.1.2 through
7.1.5 to upgrade the release valve portion mounting studs (53) in the body (47).

1
7.1.2 Remove the three existing /2" studs (53) from the service portion body (47). Clean the tapped holes of loose
dirt and chips from the body (47).

NOTE: Use replacement stud and nut kit, Part No. 578468.
1
7.1.3 Apply a few drops of Loctite 271 (stud lock grade) or its equivalent to the threads of the /2" end of the three
1 3
/2" x /8" stainless steel reducing studs (53).

7.1.4 Thread the three studs (53) completely into the service portion body (47) until the shoulder engages the body
(47).

7.1.5 Using a lint free cloth, wipe off excess Loctite from the service portion body.
13 7
7.2 Remove and SCRAP the five /16" O.D. ring gaskets (55) and the /8" O.D. ring gasket (54) from the mounting
face of the release valve portion (57).

7.2.1 Remove and SCRAP the wire mesh strainers (56) from the mounting face of the release valve portion (57).

7.3 Set the release valve portion (57) aside in a clean, protected area for later disassembly.

Service Diaphragm Piston

1 3
7.4 Remove the top cover (3) from the body (47) by removing the four /2" x 1 /4" hex head cap screws (1) and
metal identification tags (1a, 2, 2a or 2b), if applicable.

7.4.1 Remove and SCRAP the metal identification tags (1a, 2, 2a, or 2b), if applicable, from the hex head cap
screws (1).
1
7.5 Remove and SCRAP the 1 /16" O.D. ring gasket (4) from the top cover (3).

7.6 Carefully remove the service piston assembly (5 to 17 or 5 to 17b) as a unit from the body (47).

7.7 Place the service piston assembly (5 to 17 or 5 to 17b) on the piston assembly fixture, Part No. 564522, as
shown in Figure 17, page 50. Hold the service piston assembly in position so that the slide valve spring (13)
rests on the fixture with the seat of the slide valve (16) facing upward.

3
7.8 Using the driver pin that is furnished with the piston holding fixture, carefully drift the /32" x 1" cylindrical
spring pin (12) from the slide valve (16).

7.9 Remove the slide valve spring (13), slide valve (16), graduating valve (15 or 15a) and graduating valve spring
(14) from the service piston (17 or 17a).

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NOTE: If slide valve (16) does NOT contain an “82” stamp on its side, then refer to Service Bulletin 68-20, page
55,
in the Appendix to determine whether slide valve (16) can be reused or scrapped.
5
7.10 Remove the /8" x 1" hex head cap screw (5) which secures the diaphragm follower (6) and diaphragm (7)
to the service piston (17 or 17a).

7.11 Remove the diaphragm follower (6) and diaphragm (7) from the service piston (17 or 17a). SCRAP the
diaphragm (7).

7.12 Remove the spring seat retaining ring (8) from the tail of the service piston (17 or 17a), then remove the
spring seat (9), spring (10) and spring guide (11). If spring guide (11) is metal, then SCRAP metal spring
guide (11). NOTE: Plastic spring seat (9) and plastic spring guide (11) should NOT be scrapped unless they
are damaged.

7.12.1 Remove and SCRAP the service piston top and bottom wear protection rings (17b) from the service piston
(17a), if applicable.

7.12.2 SCRAP service main piston (17) that does NOT contain two machined grooves for wear rings (17b). NOTE:
Do NOT scrap service main piston (17a) that does contain two machined grooves for wear rings (17b) unless
it is damaged.

Limiting Valve, Back Flow Check Valve

1 1
7.13 Remove the four /2" x 1 /4" hex head cap screws (32) which secure the bottom cover (46) to the body (47).

WARNING: The bottom cover (46) is under spring load. Exercise care so that no parts are inadvertently
expelled from the assembly. Inadvertently expelled parts may cause bodily injury.

7.14 Remove the bottom cover (46) from the body (47).
11 3
7.15 Remove and SCRAP the /16" O.D. ring gasket (45), the 2" O.D. ring gasket (44) and the 3 /8" O.D. ring
gasket (43) from the cover (46).

7.16 Remove the check valve spring (34) and the check valve (33) from the body (47). SCRAP the check valve
(33).

7.16.1 Visually check to determine if the back flow check valve bushing contains a drilled hole in its side. If back
flow check valve bush does NOT contain a drilled hole (0.0156” diameter), the bushing must be modified by
1
drilling /64" diameter hole through side of bushing. Refer to Figure 22, page 52.

7.17 Remove the brake cylinder limiting valve spring (37) and the brake cylinder limiting valve diaphragm - piston
assembly (38 to 42 or 38 to 42a) as a unit from the body (47).
3
7.18 Remove and SCRAP the two (or three) /8" O.D. o-rings (41 or 41a) from the brake cylinder limiting valve
piston (42 or 42a).

NOTE: ABDT & ABDPT Portions have three o-rings on the limiting valve piston.

7.19 Using the Limiting Valve Piston Spanner Wrench, as shown in Figure 18, page 50, to hold the limiting valve
3
piston (42 or 42a), remove the /8" self-locking nut (38), diaphragm follower (39) and diaphragm (40) from
the threaded end of the brake cylinder limiting valve piston (42 or 42a). SCRAP the diaphragm (40).

NOTE: If required, use an open end wrench to hold the limiting valve piston (42 or 42a) while removing the self-
locking nut (38).

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7.20 Remove the piston return spring (36) and the spring cage (35 or 35a) from the body (47). If valve contains a
metal spring cage (35), then SCRAP metal spring cage (35). NOTE: Plastic spring cage (35a) should NOT
be scrapped unless it is damaged.

Service Accelerated Release Valve

7.21 Remove the four ½” X 2 ¾” hex head cap screws (18) which secure the service accelerated release valve
assembly (19 to 31) to the body (47). Remove the service accelerated release valve cover (19), wear
shield (19a), if applicable, and diaphragm - piston assembly (20 to 23 or 20 to 23a) as a unit from the filling
1 3
piece (30) by first removing the four /2" x 2 /4" hex head cap screws (18). SCRAP the wear shield (19a), if
applicable.

7.22 Remove the service accelerated release valve piston - diaphragm assembly (20 to 23 or 20 to 23a) from the
cover (19).

7.23 Using the Service Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 19, page 51, or
a flat bar placed in the slot to retain the service accelerated release valve piston (23 or 23a), remove the
9
/16" hex head nut (20), diaphragm follower (21) and the diaphragm (22) from the threaded end of the piston
(23 or 23a). SCRAP the diaphragm (22) and service accelerated release valve piston (23) that does NOT
contain a plastic wear pellet. NOTE: Do NOT scrap service accelerated release valve piston (23a) that
contains a plastic wear pellet unless it is damaged or plastic pellet is missing in piston (23a).

NOTE: If diaphragm follower (21) has significant wear, then SCRAP diaphragm follower (21).

7.24 Remove the service portion filling piece, plunger, check valve assembly, and mounting gasket (24 to 31) as
a unit from the body (47).

7.25 Remove and SCRAP the filling piece mounting gasket (31).

7.26 Compress and remove the spring seat (27), check valve spring (28), and accelerated release check valve
(29) from the filling piece (30). SCRAP the accelerated release check valve (29).

NOTE: If check valve spring (28) is NOT red in color, then SCRAP the check valve spring (28).

7.27 Remove the service accelerated release valve plunger with o-ring (24, 25) by pushing it out of the cover end
1
of the filling piece (30). Remove and SCRAP the /4" O.D. o-ring (25) from the plunger (24).

NOTE: The service accelerated release valve plunger (24) must be inspected as per Service Bulletin 68-23a to
determine if plunger (24) can be reused. Refer to Service Bulletin 68-23a, page 63 in the Appendix.
11
7.28 Remove and SCRAP the /16" O.D. ring gasket (26) from its groove in the filling piece (30).

7.29 Retrieve the release valve portion (57) which was previously set aside in a clean, protected area.

Release Valve Portion (Refer to Figure 11, page 41)

3 1
7.30 Remove the five /8" x 1 /2" hex head cap screws (1) which secure the top cover (2) of the release valve
portion to the release valve body (35 or 35a).

7.31 Remove the top cover (2) from the body (35 or 35a).

7.32 Remove and SCRAP the two 1" O.D. ring gaskets (3) from their grooves in the top cover (2).

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7.33 Remove the two check valve springs (12), both the auxiliary and emergency reservoir check valves (13)
and the two plastic check valve plungers (14) from the body (35 or 35a). SCRAP the two check valves (13).
NOTE: The two plastic check valve plungers should NOT be scrapped unless they are damaged.

7.34 Remove the spool valve spring (4) from the body (35 or 35a).

7.35 Remove the spool valve - diaphragm follower - diaphragm assembly (5 to 11) from the body (35 or 35a)
as a unit. NOTE: Care should be taken when spool valve is removed from its bush so that the seat end
of the spool is NOT damaged in any way.
3
7.36 Remove and SCRAP the three /4" O.D. o-rings (11) from their grooves on the spool valve (10).
3
7.37 Using an open end wrench to hold the spool valve (10), remove the /8" self-locking nut (5), diaphragm
follower (6), diaphragm (7) and the piston with o-ring (8, 9) from the threaded end of the spool valve (10).
1
Remove the /2" O.D. o-ring (9) from its groove in the piston (8). SCRAP the o-ring (9) and diaphragm (7).
3
7.38 Remove and SCRAP the /16" x 2" cotter pin (24) which secures the release valve stem guard (25) to the
stem and end plate (27). Remove the stem guard (25).

WARNING: The bottom cover (31 or 31a) is under spring load. Exercise care so that no parts are
inadvertently expelled from the assembly. Accidentally expelled parts may cause bodily injury.

3 3
7.39 Remove the five /8" x 1 /4" hex head cap screws (15) that secure the bottom cover, valve seal, exhaust
seal stem, and end plate assembly (27 to 33) to the body (35 or 35a). Remove the cover assembly from
the body (35 or 35a).
5
7.40 Remove the stem and end plate (27), bottom cover gasket (28), seal (30) and /8" O.D. ring gasket (29)
from the cover (31 or 31a). SCRAP the gaskets (28, 29) and seal (30). NOTE: If the stem and end plate
(27) contains significant wear or is damaged, then SCRAP the stem and end plate (27).

7.41 Remove the lifter (26) and lifter spring (23) from the body (35 or 35a).

NOTE: If lifter (26) is gray in color, then SCRAP gray colored lifter (26). Do NOT scrap blue or black colored lifter
(26) unless it is damaged otherwise.

7.42 Remove the plastic sleeve (34) from the bottom cover (31 or 31a). Visually inspect bottom cover sleeve
(34) for either excessive wear or damage. If plastic sleeve (34) contains excessive wear and/or is
damaged in any fashion, then SCRAP the plastic sleeve (34).

7.42.1 If bottom cover (31 or 31a) does NOT contain plastic sleeve (34), it must be modified to accept the plastic
cover sleeve (34). Figure 23, page 53, shows the dimension to which the cover must be machined.
Machining may be done in a lathe or drill press as shown in Figure 24, page 53. To prevent corrosion
after the cover is machined, the machined area must be treated with “Alodine 1200” or an approved
equivalent (a commercially available chromatic conversion coating for aluminum) applied according to
treatment instructions and rinsed with water unless otherwise directed. After treatment, the plastic sleeve
(34), Part No. 580075, must be pressed in place without lubrication or sealant. Note that all NEW bottom
covers (31) are equipped with a NEW plastic sleeve (34).

3 1
7.43 Either drill out or cut off the head of the /16" x /2" aluminum pop rivet (33) and remove the rivet (33) and
seal (32) from the bottom cover (31 or 31a). SCRAP the rivet (33) and seal (32).

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7.44 Remove the retaining check valve (20) and its spring (19) from the body (35 or 35a). SCRAP the check
valve (20).

7.45 Remove the reset check valve spring (22) and the reset check valve (21) from the body (35 or 35a).
SCRAP the check valve (21).

7.45.1 If body (35a) contains a return flow check valve (36) and return flow check valve spring (37) then refer to
Service Bulletin 68-6a to delete the return flow function to conform with new equipment. Both the return flow
check valve spring (37) and return flow check valve (36) must be SCRAPPED.

NOTE: When modifying a WABCO release valve body (35a), apply Loctite 242 (or equivalent) to plug, Part No.
585156, and press into 0.950” (approximate) diameter of body. Refer to Service Bulletin 68-6a.

NOTE: When modifying NYAB release valve body, apply Loctite 242 (or equivalent) to plug, NYAB Part No. CV-
1274, and press into 0.939” diameter of check valve seat. Refer to NYAB General Letter GL-372, Sup. 9.

7.46 Remove the reset spool valve with o-ring assembly (18, 17) and the reset spool valve spring (16) from the
body (35 or 35a).
3
7.47 Remove and SCRAP the three /4" O.D. o-rings (17) from the reset spool valve (18).

8.0 ABD and ABDT SERVICE PORTION ASSEMBLY

Service Diaphragm Piston (Refer to Figure 10, page 39)

8.1 Install NEW service piston top ring (17b) and the NEW service piston bottom ring (17b) on the service
piston (17a). NOTE: Service piston (17) that does NOT contain two machined grooves for wear rings (17b)
must NOT be re-used.

IMPORTANT: Care should be taken when expanding or opening the protective rings during installation
onto the service piston. Do not over expand the rings causing them to deform which would result in difficult
installation of the piston into the bore. Both protective rings must be installed with the gap facing the
slide valve area of the service piston. The positioning of the rings will ease the assembly.

8.2 Position a NEW diaphragm (7) on the service piston (17a) so that the part number on the diaphragm (7)
faces away from the piston (17a). After positioning the diaphragm bead into the groove of the piston, flip the
diaphragm (7) so that the large cone shaped opening is facing the follower (6).

8.3 Position the diaphragm follower (6) on the diaphragm (7) and piston (17a).

5
8.4 Lightly coat the threads of the /8" x 1" hex head cap screw (5) with Loctite Sealant TL-242, Wabtec
Corporation Specification M-07499-05. Install the hex head cap screw (5) through the diaphragm follower
(6) and into the piston (17a) to secure the piston (17a), diaphragm (7), and follower (6) together. Hand
tighten the cap screw (5) and then tighten in a manner to securely fasten assembly to prevent leakage and
yet not excessively to cause distortion of piston threads. Flip the diaphragm (7) in the opposite direction so
that the large cone shaped opening is facing the piston (17a). (NOTE: Wabtec recommends torquing cap
screw (5) between 45 and 50 foot-pounds.)

NOTE: Refer to Service Bulletin 68-26, page 65, for application of Triple Valve Oil on specified parts in Sections 8.5
& 8.9.

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8.5 Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20
(AAR Specification M-912) around the outer surfaces of the plastic spring guide (11). (NOTE: Wabtec
recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation
Specification M-07611-20 (AAR Specification M-912) on all required parts.)

NOTE: Metal spring guide (11) must NOT be re-used.

8.6 Install the plastic spring guide (11), closed end first, into the open end of the service piston (17a).

8.7 Install the piston spring (10) and spring seat (9) into the open end of the plastic spring guide (11) and secure
the parts in place by installing the spring retainer (8).

8.8 Place the slide valve spring (13) on the holding fixture, Part No. 564522, as shown in Figure 17, page 50.

8.9 Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M-
07611-20, (AAR Specification M-912) on the face of the graduating valve (15 or 15a) and over
the graduating valve seat of the slide valve (16). (NOTE: Wabtec recommends using a clean foam tipped
swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M-07611-20 (AAR Specification
M-912) on both graduating valve face and seat.)

NOTE: Only slide valves (16) stamped with “82” on its side or containing proper porting as outlined in Service
Bulletin 68-20, page 55, in the Appendix can be used.

8.10 Install the graduating valve spring (14), graduating valve (15 or 15a), and slide valve (16) on to the piston
(17a).

NOTE: The ABDT graduating valve (15a) has a lip on the bottom of the valve.

8.11 Place the piston assembly on the slide valve spring (13) which is still in the holding fixture.

8.12 Make sure that the graduating valve (15 or 15a) is on its seat in the slide valve (16) and that the slide valve
side wings are down tight in the fixture.

3
8.13 Install the /32" x 1" cylindrical spring pin (12) through the pin holes of each of the wings of the slide valve
(16) and the aligned pin hole of the slide valve spring (13). With the aid of the pin driver supplied with the
holding fixture, Part No. 564522, secure the pin (12) in place.

8.14 Remove the piston assembly from the holding fixture. Exercise care so that the slide valve (16) face is NOT
damaged in any way.

NOTE: Refer to Service Bulletin 68-26, page 65, for application of Triple Valve Oil on specified parts in Sections
8.15 & 8.20.

8.15 Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20
(AAR Specification M-912) over the face of the slide valve (16) and to the outer surface area of both the top
and bottom wear protection rings (17b) on the service piston (17a). Also apply a liberal coating of the Triple
Valve Oil specifically to the slide valve seat and the entire internal walls of the main piston bushing in the
body (47), and to the collars and fins of the piston (17 or 17a) near the piston head. (NOTE: Wabtec
recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation
Specification M-07611-20 (AAR Specification M-912) on all required parts.)

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IMPORTANT: Care must be taken when compressing the graduating valve and slide valve in preparation
for inserting the service piston assembly (8 to 17b) into the body bushing. While using minimal force, the
assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face (16)
must be retracted from the bushing face as long as possible. Care must be taken not to damage the slide
valve face. Applying a force to the slide valve spring (13) while inserting service piston assembly into body
bushing is NOT recommended.

8.16 Install the piston - diaphragm - slide valve assembly (8 to 17b) into the body (47) from the top,
exercising care so that NO damage is done to the slide valve seat in the body bushing.

8.17 Using only finger and thumb pressure, position the sealing bead of the diaphragm (7) into the diaphragm
bead groove on the top cover mounting face of the body (47).
1
8.18 Install a NEW 1 /16" O.D. ring gasket (4) into its groove in the top cover (3).

8.19 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 3
threads of all four /2" x 1 /4" hex head cap screws (1).

8.19.1 Insert a NEW metal identification tag (1a) through the bottom of one of the four hex head cap screws
(1). If ABDT portion, insert a NEW metal identification ‘T’ tag (2a) through the bottom of one of the four hex
head cap screws (1). Carefully position the top cover assembly (3, 4) including metal identification tag(s)
(1a) and (2a), if applicable, into proper position on the body (47).

8.19.2 Install and tighten by hand all four 1/2" x 13/4" hex head cap screws (1). Securely fasten all four hex head
cap screws (1) to prevent leakage and yet not excessively to cause distortion of cover and gasket. (NOTE:
Wabtec recommends torquing all four hex head cap screws (1) between 35 and 55 foot-pounds.)

NOTE: Both metal identification tags (1a) and (2a), if applicable, must be located in specific location on the top
cover as shown in Figure 10, page 39.
.
NOTE: Metal identification ‘P’ and ‘PT’ tags (2b & 2) are no longer required to be put back on service valve portion
after April 1, 2007.

8.20 Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20
(AAR Specification M-912) around the collar on each end of the plastic spring cage (35a). (NOTE: Wabtec
recommends using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation
Specification M-07611-20 (AAR Specification M-912) on all required parts.)
NOTE: Metal spring cage (35) must NOT be re-used.

8.21 Install the piston return spring (36) into the plastic spring cage (35a), then install the plastic cage with spring
(35a, 36) as a unit into the body (47) so that the spring (36) goes over and around the end of the shaft of
the piston (17a), which has already been installed.

Limiting Valve

8.21.1 Install a quick service volume exhaust choke (51) into the bottom of the body (47).

8.22 Position a NEW diaphragm (40) onto the brass limiting valve piston (42 or 42a) so that the flat surface of the
diaphragm, which shows the part number, faces away from the piston towards the threaded end.

8.22.1 Lightly coat threads of the limiting valve piston (42 or 42a) with Loctite Sealant TL-242, Wabtec Corporation
Specification M-07499-05.

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8.23 Using the limiting valve spanner wrench, as shown in Figure 18, page 50, to hold the piston (42 or 42a),
3
install the diaphragm follower (39) and a /8”- 16 hex nut (38) on the threaded end of the brass limiting valve
piston (40 or 40a). Tighten the hex nut (38) in a manner to securely fasten assembly to prevent leakage
and not yet excessively to cause distortion of piston threads. (NOTE: Wabtec recommends torquing the nut
(38) between 9 to 12 foot-pounds).

NOTE: If required, use an open wrench to hold the limiting valve piston (42 or 42a) while installing the hex nut (38).

8.24 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lubricate the surfaces of either
the two NEW o-rings (41) or the three NEW o-rings (41a). Also lightly lubricate the o-ring grooves on the
shaft of the piston (42 or 42a) and the internal walls of the limiting valve bushing in the body (47). (NOTE:
Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec
Corporation Specification M-07680-02, to the o-ring grooves and the internal walls of the limiting valve
bushing in the body (47).)

8.24.1 Carefully install either two new o-rings (41) onto piston (42) or three new o-rings (41a) onto piston (42a).

NOTE: ABDT Portions have a limiting valve piston with three o-rings.

8.25 Install the piston - diaphragm assembly (38 to 42 or 42a) into the body (47), o-ring end first. Be sure that the
bead of the diaphragm (40) is properly seated in its groove in the body (47). Use finger pressure to seat the
bead.

8.26 Install the brake cylinder limiting valve spring (37) onto the end of the piston (42 or 42a) so that it seats on
the diaphragm follower (39).

Back Flow Check Valve

NOTE: Visually check to make sure the back flow check valve bushing is drilled to contain a 0.0156” diameter hole.
Refer to Figure 22, page 52.

8.27 Install a NEW back flow check valve (33) and the check valve spring (34) into the proper cavity of the body
(47).
3 11
8.28 Install a NEW 3 /8" O.D. ring gasket (43), a NEW 2" O.D. ring gasket (44), and a NEW /16" O.D. ring
gasket (45) into their grooves in the bottom cover (46).

NOTE: Bottom cover (46) must contain two exhaust ports (wasp excluders). If bottom cover ONLY contains one
exhaust port, then bottom cover must NOT be re-used.

8.29 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 1
threads of all four /2" x 1 /4" hex head cap screws (32). Carefully position the bottom cover assembly (43 to
46) on the body (47) making sure that all ring gaskets and assemblies of the body are properly in place.
1 1
Secure the bottom cover (46) to the body (47) by installing four /2" x 1 /4" hex head cap screws (32) in a
manner to securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of
cover and gaskets. (NOTE: Wabtec recommends torquing the four cap screws (32) between 35 and 55
foot-pounds.)

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Service Accelerated Release Valve

8.30 Install a NEW accelerated release check valve (29) into the service portion filling piece (30).

8.31 Install the check valve spring (28) into the filling piece (30) so that it seats on the check valve (29), then
install the spring seat (27) to retain the parts in place.

NOTE: Check valve spring (28) must be red in color to indicate correct spring for assembly.

8.32 Place a NEW filling piece gasket (31) that contains two brass reinforced ports and the service portion filling
piece (30) in position on the body (47).

8.33 Apply a light coating of #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of
1
a NEW /4" O.D. o-ring (25). Also lightly lubricate the o-ring groove on the service accelerated release valve
plunger (24) and the internal walls of the plunger bushing in the filling piece (30). (NOTE: Wabtec
recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation
Specification M-07680-02, to the o-ring groove and the internal walls of plunger bushing in the filling piece.)

NOTE: Service accelerated release valve plunger (24) must comply with inspection procedure outlined Wabtec
Service Bulletin 68-23a, page 63, before being re-used.
1
8.34 From the smaller diameter end of the plunger (24), carefully install the NEW lubricated /4" O.D. o-ring (25)
into its groove on the service accelerated release valve plunger (24), then install the plunger with o-ring
(24, 25), longer end of the plunger first, into the filling piece (30).

8.35 Using the Accelerated Release Valve Piston Spanner Wrench, as shown in Figure 19, page 51, or a flat bar
placed in the slot to retain the service accelerated release valve piston (23a), install a NEW diaphragm (22)
onto the piston (23a) so that the part number on the diaphragm faces away from the piston toward the
threaded end. NOTE: Service accelerated release valve piston (23) that does NOT contain plastic wear
pellet must NOT be re-used.

8.36 Install the diaphragm follower (21) and lightly coat the threads of the service accelerated release valve piston
9
(23a) with Loctite Sealant TL-242, Wabtec Corporation Specification M-07499-05. Install the /16"-18 hex nut
(20) on the threaded end of the piston (23a), and tighten the hex nut (20) in a manner to securely fasten
diaphragm to prevent leakage and yet not excessively to cause distortion of piston threads. (NOTE: Wabtec
recommends torquing hex nut (20) between 30 and 40 foot-pounds.)

NOTE: Diaphragm follower (21) being reused must contain NO significant wear or damage.

8.37 Install the diaphragm - piston assembly (20 to 23a), piston end first, into the filling piece (30). Be sure that the
bead of the diaphragm is properly seated in its groove on the filling piece (30). Use finger pressure to properly
seat the diaphragm bead.

8.38 Install a NEW wear shield (19a) over the hex nut (20). (NOTE: The wear shield lies on the follower (21) and is
not held in place by any means. The body will have to be positioned so the wear shield (19a) remains in place
while installing the cover (19).
11
8.39 Install a NEW /16" O.D. ring gasket (26) into its groove on the cover mounting face of the filling piece (30).

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8.40 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 3
threads of all four /2" x 2 /4" hex head cap screws (18). Place the service accelerated release valve cover
1
(19) in position on the filling piece (30). Be sure that all parts are properly positioned, then using the four /2" x
3
2 /4" hex head cap screws (18), secure the cover and filling piece assemblies (19 to 31) to the body (47).
Tighten the four cap screws (18) in a manner to securely fasten cover assembly to prevent leakage and yet
not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the four hex
head cap screws between 35 to 55 foot-pounds.)

Release Valve Portion Assembly (Refer to Figure 11, page 41)

8.41 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, fill all o-ring grooves in the reset
spool valve (18). Then, lightly lubricate both the internal walls of the reset spool valve bushing in the body (35
or 35a) and the surfaces of all three NEW ¾” O.D. orings (17). (NOTE: Wabtec recommends using a clean
foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to
all the o-ring grooves of the spool valve (10) and to the internal walls of the reset spool valve bushing.)
3
8.42 Install the three NEW lubricated /4" O.D. o-rings (17) into their grooves on the reset spool valve (18). Wipe
excess grease off of the spool valve assembly (17, 18); however, leave a liberal coating of the #2 Silicone
Grease (M-07680-02) on each of the three o-rings (17). (NOTE: Wabtec recommends using a clean, dry,
lint-free cloth to remove any excess lubricant.)

8.43 Install the spool valve spring (16) and spool valve with o-ring assembly (18, 17) into its lubricated bushing in
the release valve body (35 or 35a).

8.44 Install the lifter spring (23) and plastic lifter (26) into the proper cavity in the release valve body (35 or 35a).

8.45 Install a NEW reset check valve (21) and the check valve spring (22) into the proper cavity of the release
valve body (35 or 35a).

8.46 Install the check valve spring (19) and a NEW retaining check valve (20) in the proper cavity of the release
valve body (35 or 35a). The seat for the retaining check valve is located in the bottom cover (31 or 31a).

NOTE: Bottom cover (31 or 31a) must be modified to accept a clean plastic sleeve (34) before it can be reused.
3 1
8.47 Install the plastic sleeve (34) and secure a NEW seal (32) with a NEW /16" x /2" aluminum pop rivet (33) in
the bottom cover (31 or 31a).

NOTE: Ensure that plastic sleeve (34) used contains no significant wear or is NOT damaged.
5
8.48 Install a NEW valve seal (30), a clean stem and end plate (27), a NEW /8" O.D. ring gasket (29) and a NEW
bottom cover gasket (28) in place on the bottom cover (31 or 31a).

NOTE: The stem and end plate (27) must contain no significant wear or damage.

8.49 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
3 3
threads of all five /8" x 1 /4" hex head cap screws (15). Carefully position the bottom cover assembly (27 to
3 3
34) on the body (35 or 35a) without applying heavy pressure, then insert the five /8" x 1 /4" hex head cap
screws (15) into the cover (31 or 31a). Observe the retaining check valve (20) to be sure that it is in alignment
with the check valve seat in the cover (31 or 31a). Also be sure that the reset check valve spring (22) is

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properly positioned in the cover (31 or 31a), then hand press the cover (31 or 31a) to the body (35 or 35a)
3 3
and secure it in place by equally tightening the five /8" x 1 /4" hex head cap screws (15) in a manner to
securely fasten cover assembly to prevent leakage and yet not excessively to cause distortion of cover and
tapped threads. (NOTE: Wabtec recommends torquing the five cap screws (15) between 15 and 25 foot-
pounds.)

8.50 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lightly coat the surfaces of a NEW
1 3
/2" O.D. o-ring (9) and three NEW /4" O.D. o-rings (11). Fill all o-ring grooves in release spool valve
(10) with #2 Silicone Grease (M-07680-02). Lightly lubricate the internal walls of the release spool valve
bushing in the body (35 or 35a). (NOTE: Wabtec recommends using a clean foam tipped swab applicator to
apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the o-ring grooves in the release
spool valve (10) and to the internal walls of the release spool valve bushing in the body (35 or 35a).

8.51 Using an open end wrench to hold the release spool valve (10), install the piston (8) on the threaded end of
the release spool valve (10).
1
8.52 Install the NEW lubricated /2" O.D. o-ring (9) in place on the piston (8), then install a NEW diaphragm (7) so
that the part number on the diaphragm faces away from the piston toward the threaded end of the spool valve
(10).

8.53 Install the diaphragm follower (6) on the threaded end of the release spool valve (10). Lightly coat the threads
of the release spool valve (10) with Loctite Sealant TL-242 , Wabtec Corporation Specification M-07499-05.
3
Install /8”-16 hex nut (5) on the threaded end of the release spool valve (10) and tighten in a manner to
securely fasten nut (5) to the release spool valve (10) to prevent leakage and yet not excessively to cause
distortion of threads. (NOTE: Wabtec recommends torquing hex nut (5) between 10 to 12 foot-pounds.)
3
8.54 Install the three NEW lubricated /4" O.D. o-rings (11) into the three o-ring grooves of the release spool valve
(10). Wipe off excess grease from the release spool valve assembly (10, 11); however, leave a liberal coating
of #2 Silicone Grease on each of the three o-rings (11). (NOTE: Wabtec recommends using a clean, dry,
lint-free cloth to remove any excess lubricant.)

8.55 Install the diaphragm piston assembly (5 to 11) into the body (35 or 35a). Be sure that the bead of the
diaphragm (7) is properly seated in the bead groove of the body (35 or 35a). Use finger pressure to seat the
bead in the groove.

8.56 Install the spool valve spring (4) in the body (35 or 35a) so that it is seated on the diaphragm follower (6).

8.57 Install the plastic emergency and auxiliary reservoir check valve plungers (14) into their proper cavities of the
body (35 or 35a).

8.58 Install two NEW check valves (13) into the body (35 or 35a) on top of the two plastic plungers (14), then install
the two check valve springs (12). NOTE: Position the check valve springs (12) so that they are centered on
top of the new check valves (13).

8.59 Install two NEW 1" O.D. ring gaskets (3) into their grooves in the top cover (2).

8.60 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec
Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of
3 1
all five /8" x 1 /2" hex head cap screws (1). Carefully place the top cover assembly (2, 3) onto the body (35
or 35a) being sure that the springs (4 and 12) are properly positioned in the spring cavities of the cover.
3 1
Secure the top cover (2) to the body (35 or 35a) by installing the five /8" x 1 /2" hex head cap screws (1).

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Tighten the five cap screws (1) in a manner to securely fasten top cover assembly (2, 3) to prevent leakage
and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the
five cap screws (1) between 15 and 25 foot-pounds.)

(Refer to Figure 10, page 38)

8.61 Install three NEW wire mesh filter screens (56) into the auxiliary reservoir, emergency reservoir, and retainer
ports in the release valve portion body (57).
7 13
8.62 Install a NEW /8" O.D. ring gasket (54) and five NEW /16" O.D. ring gaskets (55) into their grooves on the
mounting face of the release valve portion (57).

8.63 Place the release valve portion (57) on the service portion body (47) and secure it in place by installing three
3
/8" flanged hex nuts (52). Tighten the three hex nuts (52) in a manner to securely fasten the release valve
portion (57) to body (47) to prevent leakage and yet not excessively to cause distortion of stud threads.
(NOTE: Wabtec recommends torquing the three hex nuts (52) between 11 and 30 foot-pounds.)

(Refer to Figure 7, page 37 and Figure 11, page 41)

3
8.64 The release valve stem guard (25) is to be installed after the service portion has been tested. Use a NEW /16"
x 2" cotter pin (24) when installing the guard (25).

NOTE: All ABD and ABDT service valve portions that have been clean, oil, and tested must contain either a
nameplate tag or paint stencil that includes the date of reconditioning (MM/YY) and shop identification. If the
nameplate tag is used, it must be located under the specific hex head cap screw as shown in Figure 10, page
39. If the paint stencil is used, the specific information described above must be shown in ½” minimum height
letters on the valve body.

9.0 ABD, ABDS, ABDP, ABDPS, ABDW, ABDWP, ABDWS, ABDWPS EMERGENCY PORTION
DISASSEMBLY

(Refer to Figure 12, page 43 and Figure 13, page 45)

9.1 Remove the vent protector assembly from the emergency portion body (57) if it is still in place. The external
vent protector assembly (18) is illustrated in Figure 9, page 38.

Inshot Check Valve

9.2 Depress the spring retainer (22) into the body (57) and tilt it so that it is free of the retaining lip of the body
(57) and remove the retainer (22), inshot check valve spring (23), and the inshot check valve (24) from the
body (57). SCRAP the check valve (24). NOTE: Plastic spring retainer (22) should NOT be scrapped unless
it is damaged.

Small Vent Valve Piston

9.3 Depress the spring retainer (25) into the body (57) and tilt it so that it is free of the retaining lip of the body (57)
and remove the retainer (25), vent valve spring (26), and the small vent valve piston with seal (27 to 29 or 30)
from the body (57).

9.4 SCRAP the entire small vent valve assembly (27 to 29 or 30).

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Emergency Accelerated Release Check Valve

1 3
9.5 Remove the four /2" x 1 /4" hex head cap screws (1) which secure the top cover (2) to the body (57). Remove
the cover (2).

9.5.1 Remove and SCRAP the metal identification tag (1a), if applicable, from the hex head cap screw (1).

9.6 Remove and SCRAP the four ring gaskets (18, 19, 20) from the top cover (2).

9.7 Remove the emergency accelerated release check valve spring (13), check valve spring seat (14),
emergency accelerated release check valve (15), and the plastic air strainer (17a) from the body (57). SCRAP
the check valve (15) and the plastic air strainer (17a).

NOTE: The plastic air strainer (17a) can be removed by lifting at the lip section on the top of the strainer frame.
When removing the plastic strainer (17a), care should be taken not to damage the emergency accelerated
release check valve seat.

NOTE: If body (57) is equipped with a wire strainer (17) under the emergency accelerated release check valve (15),
refer to Service Bulletin 68-22, page 57, located in the Appendix for specific removal and installation
procedures of the wire strainer (17).

Spillover Check Valve

9.7.1 Remove the spillover check valve plug (21) from body. SCRAP spillover check valve plug (21).

NOTE: If body (57) is equipped with spillover check valve spring (21a) and spillover check valve (21b), remove and
SCRAP both of these parts.

NOTE: Body (57) may be already equipped with brass plug that blanks off the spillover check valve port.

High Pressure Spool

9.8 Remove the high pressure spool valve return spring (10 or 10a) and the high pressure spool valve with
o-rings (12, 11 or 12a, 11) from the body (57).
3
NOTE: For easier removal, thread a /8”-16 cap screw into the high pressure spool (12 or 12a).

(Refer to Figure 12, page 43 and Figure 13, page 45)

9.9 If high pressure spool valve bushing in body (57) does NOT contain bottom spring (10b), then SCRAP the
entire high pressure spool valve assembly with o-rings (12, 11), and also SCRAP high pressure spool valve
blue return spring (10). NOTE: Green high pressure spool valve return spring (10a) should NOT be scrapped
unless it is damaged.

9.9.1 If high pressure spool valve bushing contains bottom spring (10b), then remove and SCRAP the five 1 3/16”
o-rings (11) from the high pressure spool valve (12a). NOTE: Do NOT scrap the high pressure spool valve
(12a) if bushing in body (57) contains bottom spring (10b).

9.9.2 If applicable, carefully remove the bottom high pressure spool valve bottom spring (10b) from the high
pressure spool valve bushing in the body (57). NOTE: Exercise care when removing high pressure spool
valve bottom spring (10b) from body (57) in order to prevent scratching the high pressure spool valve bushing
internal walls.

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NOTE: High pressure spool valve bottom spring (10b) should NOT be scrapped unless it is damaged.

Emergency Diaphragm Piston

9.10 Carefully remove the emergency diaphragm piston assembly (3 to 9 or 3 to 9c) as a unit from the body (57).

3 3
9.11 Carefully drift the /32" x /4" cylindrical spring pin (6) from the emergency slide valve (8 or 8a). Remove the
emergency slide valve (8 or 8a) and spring (7) from the emergency piston (9 or 9a).
5
9.12 Remove the /8" x 1" hex head cap screw (3) that secures the diaphragm follower (4) and diaphragm (5) to
the emergency piston (9 or 9a). Remove follower (4) and diaphragm (5) from the piston (9 or 9a). SCRAP
the diaphragm (5).

9.12.1 SCRAP emergency piston (9) that does NOT contain two machined grooves for wear rings (9b & 9c).

9.13 Remove and SCRAP the two emergency piston rings (9b & 9c), if applicable, from the emergency piston (9a).
NOTE: Do NOT scrap emergency piston (9a) that does contain two machined grooves for wear rings
(9b & 9c) unless it is damaged.

(Refer to Figure 12, page 43)

1 3
9.14 Remove the two /2” x 1 /4” hex head cap screws (31), the metal identification tag (31a, 31b, or 31c), if
1 1
applicable, and the two /2” x 1 /8” hex head cap screws (32) that secures the vent valve cover (33) to the
body (57).

9.14.1 Remove and SCRAP the metal identification tag (31a, 31b, or 31c), if applicable, from the hex head cap
screw (31).

NOTE: 9.15 through 9.17 for ABDS and ABDPS only; for ABD and ABDP, proceed to Section 9.17.1. For ABDW,
ABDWS, ABDWP, and ABDWPS, proceed to Section 9.18.

9.15 Remove the ½” x 3” hex head cap screw (63) that secures the vent valve cover (33) to the body (57).
Remove the volume (64) from the volume fitting (65).

NOTE: If volume (64) is a brass cylindrical volume, then SCRAP the brass cylindrical volume (64). Refer to Figure 4,
page 6, (bottom most figure) for a view of the brass cylindrical volume.
7
9.16 Remove the cover (33) and the volume fitting (65) from the body (57) and SCRAP the /16” O.D. o-ring (66).

9.17 Remove and SCRAP the seal(s) (67) from the volume fitting (65) or the body (57).

9.17.1 Remove the cover (33) from the body (57).

1 3
9.18 For ABDW, ABDWS, ABDWP, and ABDWPS portions refer to Figure 13, page 45. Remove the two /2" x 1 /4"
1 1
hex head cap screws (32) and the two /2" x 1 /8" hex head cap screws (31) that secure the vent valve cover
(33) to the body (57). Remove the cover (33) and the metal identification tag (31a, 31b, or 31c), if applicable,
from the body (57). SCRAP the metal identification tag (31a, 31b, or 31 c), if applicable, from the hex head
cap screw 31).

Inshot Piston

9.19 Remove the inshot piston spring (38) and the inshot piston assembly (39 to 43) from the body (57).

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15 5
9.20 Remove and SCRAP the /16" O.D. ring gasket (34) and the /8" O.D. ring gasket (35) from the vent valve
cover (33).
3
9.21 Remove and SCRAP the /8" O.D. o-ring (42) from the inshot piston (43).

9.22 Use the inshot piston spanner wrench, as shown in Figure 20, page 51, to hold the inshot piston (43), then
3
remove the /8" self-locking hex nut (39) from the piston (43). NOTE: If required, use an open end wrench
to hold inshot piston (43) while removing the 3/8” self-locking nut.

9.23 Remove the diaphragm follower (40) and diaphragm (41) from the piston (43). SCRAP the diaphragm (41).

Vent Valve

9.24 Remove the vent valve piston diaphragm (36) and the vent valve piston (37) from the body (57). SCRAP
the diaphragm (36).

9.24.1 If vent valve piston (37) is metal, then SCRAP metal vent valve piston (37). NOTE: Plastic vent valve piston
(37) should NOT be scrapped unless it is damaged.

Emergency Accelerated Release Spool

WARNING: The cap nut (45) is under spring load. Exercise care so that no parts are inadvertently expelled
from the assembly. Inadvertently expelled parts may cause bodily injury.
7
9.25 Using a /8" square wrench, remove the cap nut with o-ring (45, 44) which secures the emergency accelerated
release spool valve spring (46) and spool valve assembly (48 or 48a, 47) in the body (57).

9.26 Remove the spool valve spring (46) and spool valve with o-rings (48 or 48a, 47) from the bottom of the body
(57).

9.26.1 If spool valve (48) does NOT contain a plastic insert on top side, then SCRAP entire spool valve assembly
(48, 47).
1
9.27 Remove and SCRAP the four 1 /2" O.D. o-rings (47) from the spool valve assembly (48a). NOTE: Spool
valve (48a) containing the top plastic insert must NOT be scrapped unless it is damaged. Plastic insert in top
of spool valve (48a) should only be replaced if it contains significant wear or if it is damaged.
1
9.28 Remove and SCRAP the 1 /2" O.D. o-ring (44) from the cap nut (45). NOTE: Plastic cap nut (45) should
NOT be scrapped unless it is damaged.

NOTE: If the threads of cap nut (45) are damaged, then SCRAP cap nut (45) and replace with new.

Accelerated Application Valve - ABDW Type Control Valve only (Refer to Figure 9, page 38)

9.29 Remove the accelerated application valve portion (15) from the emergency valve portion body (3) by
1 3
removing the four /2” x 4 /4” hex head cap screws (14).

9.30 Remove and SCRAP the body gasket (16). (Refer to Figure 14, page 47)
1
9.31 Remove the two /4” x 3” self-locking fillister head screws (61) which secure the filling piece (69), body (86),
and cover (62) together.

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9.32 Remove the cover (62) from the body (86).

9.33 Remove and SCRAP the cover gasket (68).

9.34 Remove the diaphragm (64) and diaphragm spring (63). SCRAP the diaphragm (64).

NOTE: If diaphragm spring (63) is NOT colored yellow on end coils, then SCRAP diaphragm spring (63).

9.35 Remove the rubber seated check valve (66, 67) and check valve spring (65). SCRAP the check valve (66,
67).

9.36 Separate the body (86) from the filling piece (69).

9.37 Remove and SCRAP the diaphragm (75).

9.38 Remove the plunger with o-ring (79, 78), spring cage (77), and spring (76) from the body (86).
1
9.39 Remove and SCRAP the /4” O.D. o-ring (78) from the plunger (79).
11
9.40 Remove and SCRAP the three /16” O.D. ring gaskets (88) from their grooves in the filling piece mounting
face of the body (86).
3 7
9.41 Remove the two /8” x /8” cap screws (80) which secure the check valve cover (81) to the body (86). Remove
the cover (81).

9.42 Remove the check valve spring (82), spring seat (84), and check valve (85) from the body (86). SCRAP the
check valve (85).
1
9.43 Remove and SCRAP the 1 /2” O.D. ring gasket (83) from the check valve cover (81).

10.0 ABD, ABDS, ABDW, ABDWS EMERGENCY PORTION ASSEMBLY

Emergency Accelerated Release Spool

(Refer to Figure 12, page 43 and Figure 13, page 45)

1
10.1 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, coat the surfaces of four NEW 1 /2"
O.D. o-rings (47). Fill all o-ring grooves in spool valve assembly (48a) with #2 Silicone Grease, Wabtec
Corporation Specification M-07680-02 and lightly lubricate the internal walls of the emergency accelerated
release spool valve bushing in the body (57). (NOTE: Wabtec recommends using a clean foam tipped swab
applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the three o-ring
grooves on the spool valve assembly (48a) and to the internal walls of the emergency accelerated release
spool valve bushing in the body.)

NOTE: Spool valve assembly (48a) must contain a clean plastic insert on top side of spool valve (48a). Spool valve
(48) that does NOT contain a top plastic insert must NOT be re-used.

10.2 Install the four NEW lubricated 11/2" O.D. o-rings (47) into their grooves on the spool valve assembly (48a).
Wipe excess grease off of the spool valve assembly (48a, 47); however, leave a liberal coating of #2 Silicone
Grease on each of the four o-rings (47). (NOTE: Wabtec recommends using a clean, dry, lint-free cloth to
remove any excess lubricant.)

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10.3 Install the accelerated release spool assembly valve with o-rings (48a, 47) into its lubricated bush in the body
(57), closed end first.

10.4 Install the spool valve spring (46) into the spool valve assembly (48a).

1
10.5 Apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of a NEW 1 /2" O.D.
o-ring (44) and lightly lubricate the o-ring groove of the cap nut (45).
1
10.6 Install the NEW lubricated 1 /2" O.D. o-ring (44) into its groove on the cap nut (45).

10.6.1 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
threads of the cap nut (45).

10.7 Install the cap nut with o-ring (45, 44) into the body (57) to secure the spring (46) and accelerated release
spool valve assembly (48a, 47) in place. Using a 7/8" square wrench, tighten the cap nut (45). (NOTE:
Wabtec recommends torquing metal cap nut (45) between 55 and 65 foot-pounds and plastic cap nut (45)
between 25 and 35 foot-pounds.)

Emergency Diaphragm Piston

10.8 Install the emergency piston wear protection rings (9b & 9c) on the emergency piston (9a).

NOTE: Emergency piston (9) that does NOT contain two machined grooves for wear rings (9b & 9c) must NOT be
re-used.

IMPORTANT: Care should be taken when expanding or opening the protective rings during installation onto
the emergency piston. Do not over-expand the rings causing them to deform which would result in difficult
installation of the piston into the bore. Each wear protection ring should be installed with the gap facing the
slide valve area of the emergency piston. The positioning of the rings will ease the assembly.

10.9 Install a NEW emergency piston diaphragm (5) on the emergency piston (9a) so that the piece number on the
diaphragm is facing away from the piston.
5
10.10 Lightly coat the threads of the /8" x 1" hex head cap screw (3) with Loctite Sealant TL-242, Wabtec
Corporation Specification M-07499-05. Install the cap screw (3) through the diaphragm follower (4) and into
the piston (9a) to secure the piston (9a), diaphragm (5) and follower (4) together. Hand tighten the hex head
cap screw (3) and then tighten in a manner to securely fasten piston assembly (4, 5, 9a) to prevent leakage
and yet not excessively to cause distortion of piston threads. Flip the diaphragm (5) in the opposite direction
so that the large cone shaped opening is facing the piston (9a). (NOTE: Wabtec recommends torquing cap
screw (3) between 45 and 50 foot-pounds.)

10.11 Insert the emergency slide valve spring (7) into the emergency slide valve (8 or 8a).

NOTE: For both ABDS and ABDWS emergency valve portions, emergency slide valve (8a), stamped with an ‘S’ on
part, must be used.

10.12 Carefully place the emergency slide valve with spring (8 or 8a, 7) on the stem of the piston (9a) and secure
3 3
the parts in place by installing the /32" x /4" cylindrical spring pin (6).

NOTE: Refer to Service Bulletin 68-26, page 65, for application of Triple Valve Oil on specified parts in Sections
10.13, 10.14 & 10.15.

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10.13 Apply and evenly spread a liberal coating of Triple Valve Oil, Wabtec Corporation Specification M-07611-20,
(AAR Specification M-912) over the face of the emergency slide valve (8 or 8a). (NOTE: Wabtec recommends
using a clean foam tipped swab applicator to apply Triple Valve Oil, Wabtec Corporation Specification M-
07611-20 (AAR Specification M-912) on all required parts in steps 10.13 through 10.15.)

10.14 Apply and evenly spread a liberal coating of the Triple Valve Oil on the slide valve bushing seat of the body
(57) and to the entire internal walls of the main piston bushing in the body (57).

10.15 Apply and evenly spread a liberal coating of Triple Valve Oil over the entire surface area of both the top and
bottom wear protection rings (9b & 9c).

IMPORTANT: Care must be taken when compressing the slide valve spring (7) in preparation for inserting
the emergency piston assembly (3 to 9c) into the body bushing. While using minimal force, the
assembly must be aligned squarely to prevent any wedging or distortion. The slide valve face must be
retracted from the bushing face as long as possible.

10.16 Install the diaphragm - piston - emergency slide valve assembly (3 to 9c) into the body (57). Exercise care so
that NO damage is done to the emergency slide valve bushing seat.

10.17 Using the pressure of the thumb or finger, position the sealing bead of the diaphragm in the diaphragm bead
groove of the body (57).

High Pressure Spool

3
10.18 Coat the surfaces of five NEW 1 /16" O.D. o-rings (11) with #2 Silicone Grease, Wabtec Corporation
Specification M-07680-02. Fill all o-ring grooves on the spool valve (12a) with #2 Silicone Grease, Wabtec
Corporation Specification M-07680-02. Evenly spread a light coating of #2 Silicone Grease, Wabtec
Corporation M-07680-02 to the entire internal walls of the high pressure spool valve bushing in the body (57).
(NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec
Corporation Specification M-07680-02 to the o-ring grooves of spool valve (12a) and to the internal walls of
the high pressure spool valve bushing in the body.)
3
10.19 Install the five NEW lubricated 1 /16" O.D. o-rings (11) into their grooves on the high pressure spool valve
(12a). Wipe excess grease off of the spool valve assembly (12a, 11); however, leave a liberal coating of #2
Silicone Grease on each of the five o-rings (11). NOTE: Wabtec recommends using a clean, dry, lint-free
cloth to remove any excess lubricant.

NOTE: Ensure that correct high pressure spool valve (12a) is being used. Bottom high pressure spool valve spring
(10b) must be able to slide over bottom of spool (12a). High pressure spool valve (12) must NOT be re-used.

10.19.1 Carefully install bottom high pressure spool valve spring (10b) into the lubricated high pressure spool valve
bushing in body (57).

10.20 Install the high pressure spool valve with o-rings (12a, 11) into its lubricated bushing in the body (57) on top of
the bottom high pressure spool valve spring (10b).

10.21 Install the high pressure spool valve return spring (10a) into the top of the high pressure spool valve (12a).
NOTE: Half the length of the high pressure spool valve return spring (10a) must contain a dark green
transparent dye to indicate correct top spring. Painted blue high pressure spool valve return spring (10) must
NOT be re-used.

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Emergency Accelerated Release Check Valve

10.22 Install lower retaining ring (16), as necessary or if necessary, clean wire strainer (17), and upper retaining ring
(16) as outlined in Service Bulletin 68-22, page 57, in the Appendix.

10.23 Install a NEW emergency accelerated release check valve (15), check valve spring seat (14), and check valve
spring (13) into the body (57).

Spillover Check Valve

10.23.1 Lightly lubricate the entire circumference of a NEW spillover check valve plug (21) with #2 Silicone Grease,
Wabtec Corporation Specification M-07680-02. (NOTE: Wabtec recommends using a clean foam tipped
swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02 to the
circumference of the NEW spillover check valve plug (21).

10.23.2 Install NEW spillover check valve plug (21) into body (57).

10.23.3 Using a clean, dry, lint-free cloth, wipe away any excess lubricant from the top of spillover check valve plug
(21).

NOTE: If body is already equipped with brass plug in spillover port, then plug (21) is NOT required.
3 1 1
10.24 Install a NEW 1 /4" O.D. ring gasket (18), two NEW 1 /2" O.D. ring gaskets (19) and a NEW 1 /8" O.D. ring
gasket (20) into their grooves in the top cover (2).

10.25 Insert a NEW metal identification tag (1a) through the bottom of one of the four hex head cap screws (1).
Place the top cover assembly (2, 18 to 20) on the body (57) making sure that the diaphragm (5) and gaskets
(18 to 20) remain in position. NOTE: The metal identification tag (1a) must be located in specific location as
shown in Figure 12, page 43, or in Figure 13, page 45.

10.26 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 3
threads of the four /2" x 1 /4" hex head cap screws (1). Fasten the cover (2) to the body (57) by installing the
1 3
four /2" x 1 /4" hex head cap screws (1). Tighten the four hex head cap screws (1) to securely fasten cover
assembly (2, 18 to 20) to prevent leakage and yet not excessively to cause distortion of cover and gaskets.
(NOTE: Wabtec recommends torquing four cap screws (1) between 35 and 55 foot-pounds.)

Inshot Piston

10.27 Install a NEW inshot diaphragm (41) on the inshot piston (43) so that the flat surface of the diaphragm which
shows the part number faces away from the piston.

10.28 Install the diaphragm follower (40) on the piston (43) so that the small diameter of the follower (40) is facing
the diaphragm (41). Lightly coat the threads of the brass inshot piston (43) with Loctite Sealant TL-242,
Wabtec Corporation Specification M-07499-05. Secure the follower (40) and the diaphragm (41) on the inshot
3
piston (43) by installing a /8”-16 hex nut (39). Tighten hex nut (39) in a manner to securely fasten assembly to
prevent leakage and not yet excessively to cause distortion of piston threads. (NOTE: Wabtec recommends
torquing hex nut (39) between 9 to 12 foot-pounds.)

NOTE: Use either an inshot piston spanner wrench as shown in Figure 20, page 51, or an open end wrench
to hold the inshot piston (43) while installing the 3/8” self-locking hex nut (39).

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3
10.29 Apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, to the surfaces of a NEW /8"
O.D. o-ring (42). Lightly lubricate the o-ring groove on the shaft of the inshot piston (43) and the entire internal
walls of the inshot piston bushing in the body (57). (NOTE: Wabtec recommends using a clean foam tipped
swab applicator to apply #2 Silicone Grease, Wabtec Corporation Specification M-07680-02 to the o-ring
groove in the inshot piston (43) and to the internal walls of the inshot piston bushing in the body.)
3
10.30 Install the NEW lubricated /8" O.D. o-ring (42) into its groove on the shaft of the inshot piston (43).

10.31 Install the inshot diaphragm piston assembly (39 to 43) into its lubricated bushing in the body (57). Using the
pressure of the thumb or finger, position the sealing bead of the diaphragm in its groove in the body (57).

10.32 Install the inshot piston spring (38) over the nut (39) on the exposed end of the inshot piston (43) so that the
spring seats in the diaphragm follower (40).

Vent Valve

10.33 Carefully insert a clean plastic vent valve piston (37) into the body (57). NOTE: Metal vent valve piston (37)
must NOT be re-used.

10.34 Place a NEW vent valve piston diaphragm (36) on the plastic vent valve piston (37) ensuring that the part
number on the diaphragm faces the piston. With the aid of the hand tool, shown in Figure 21, page 52,
properly position the diaphragm (36) so that the loop of the diaphragm sits between the plastic piston (37) and
body (57).
15 5
10.35 Install a NEW /16" O.D. ring gasket (34) and a NEW /8" O.D. ring gasket (35) in their grooves in the vent
valve cover (33).

NOTE: 10.36 through 10.43 for ABDS only; for ABDWS proceed to Section 10.44; for ABD & ABDW proceed to
Section 10.45

(Refer to Figure 12, page 43)

10.36 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
threads of all four hex head cap screws (31, 32, 63).

10.37 Place the vent valve cover (33) on the body (57) and install the top ½” x 1 1/8” hex head cap screw (31) and
the ½” x 1 ¾” hex head cap screw (32). Do not tighten at this time. Insert a NEW metal identification ‘S’ tag
(31b) through the bottom ½” x 1 1/8” hex head cap screw (31) and install the bottom hex head cap screw to
the body.

NOTE: Metal identification ‘P’ tag (31a) and ‘PS’ tag (31c) are no longer required to be put back on emergency valve
portions after April 1, 2007.

10.38 Place NEW seal(s) (67) onto the volume fitting (65) from the threaded end, leaving just the threads exposed.
Two seals may be required.

10.39 Coat the threads of the volume fitting (65) with a compound as described in Section 3.2.3, page 10. Secure
the volume fitting (65) into the body in a manner to prevent leakage and yet not excessively to cause distortion
of threads on volume fitting.

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7
10.40 Coat the surface of the NEW /16” O.D. o-ring (66) with #2 Silicone Grease, Wabtec Corporation Specification
M-07680-02. Also lightly lubricate the o-ring groove of the volume fitting (65) and the bearing surface bore of
the volume (64) with #2 Silicone Grease, Wabtec Corporation Specification M-07680-02. (NOTE: Wabtec
recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease, Wabtec Corporation
Specification M-07680-02 to both the o-ring groove on the volume fitting (65) and the bearing surface bore of
the volume (64).

7
10.41 Install the NEW lubricated /16” O.D. o-ring (66) into the groove on the volume fitting (65).

10.42 Align the volume (64) with the volume fitting (65) and with the proper bolt hole in the vent valve cover (33).
1
Secure the volume (64) in its position by installing the /2” x 3” hex head cap screw (63).

10.43 Tighten the four vent valve cover hex head cap screws (31, 32, 63) in a manner to securely fasten assembly
to prevent leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec
recommends torquing the four cap screws (31, 32, 63) between 35 and 55 foot-pounds.)

NOTE: Section 10.44 is for ABDWS emergency valve portions ONLY

10.44 Insert a NEW metal identification tag ‘S’ tag (31b) on the bottom cap screw (31). Apply a light coating of
brake cylinder lubricant (M-914) or a compound consisting of one part graphite, Wabtec Specification M-
1 1
07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the threads of the two /2” x 1 /8”
1 3
hex head cap screws (31) and the /2” x 1 /4” hex head cap screw (32). Tighten the four vent valve cover hex
head cap screws (31, 32) in a manner to securely fasten assembly to prevent leakage and yet not excessively
to cause distortion of cover and gaskets. (NOTE: Wabtec recommends torquing the four cap screws (31, 32)
between 35 and 55 foot-pounds.)

NOTE: Section 10.45 is for ABD and ABDW emergency valve portions ONLY

10.45 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 1 1 3
threads of the two /2” x 1 /8” hex head cap screws (31) and the /2” x 1 /4” hex head cap screw (32). Tighten
the four vent valve cover hex head cap screws (31, 32) in a manner to securely fasten assembly to prevent
leakage and yet not excessively to cause distortion of cover and gaskets. (NOTE: Wabtec recommends
torquing the four cap screws (31, 32) between 35 and 55 foot-pounds.)

NOTE: Metal identification ‘P’ tag (31a) is no longer required to be put back on emergency valve portions after April
1, 2007.

Inshot Check Valve

10.46 Install a NEW inshot check valve (24) and the inshot check valve spring (23) into the body (57). Align
properly and secure these parts in place by installing the inshot spring retainer (22).

Small Vent Valve Piston

10.47 Install a NEW plastic small vent valve piston assembly (30) seal first into the body (57).

10.48 Install the small vent valve piston spring (26) into the plastic small vent valve piston (30) and secure it in place
by installing the spring retainer (25) in the body (57). Be sure that the retainer (25) is properly secured.
NOTE: Metal small vent valve piston assembly (27, 28, 29) must NOT be re-used.

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Accelerated Application Valve (ABDW Type Control Valve only) (Refer to Figure 14, page 47)

10.49 Install a NEW check valve (85) into the accelerated application body (86), then install the spring seat (84) and
check valve spring (82).
1
10.50 Install a NEW 1 /2” O.D. o-ring (83) into its groove in the check valve cover (81).

10.51 Position the check valve cover assembly (81, 83) on the accelerated application body (86) and fasten it in
3 7
place by installing two /8” x /8” hex head cap screws (80) in a manner to securely fasten cover assembly to
prevent leakage and yet not excessively to cause distortion of cover gasket. (NOTE: Wabtec recommends
torquing the two cap screws (80) between 15 and 25 foot-pounds.)

10.52 Install the spring (76) into the body (86).

10.53 Install the spring cage (77) into the spring (76).

1
10.54 Using #2 Silicone Grease, Wabtec Corporation Specification M-07680-02, lubricate the surfaces of a NEW /4”
O.D. o-ring (78). Also fill the o-ring groove on the plunger (79) with the lubricant. Spread a light film of #2
Silicone Grease, Wabtec Corporation Specification M-07680-02 over the entire length of the plunger (79).
(NOTE: Wabtec recommends using a clean foam tipped swab applicator to apply #2 Silicone Grease,
Wabtec Corporation Specification M-07680-02 to both the o-ring groove in the plunger (79) and also to the
entire length of the plunger (79).)
1
10.55 Install the NEW lubricated /4” O.D. o-ring (78) into its groove on the plunger (79). Excess lubricant may be
removed by wiping with a clean, dry, lint-free cloth; however, leave a liberal coating of lubricant on surface of
o-ring (78) and light film of lubricant on entire length of the plunger (79).

10.56 Install the plunger with o-ring (79, 78), small end first, into the spring cage (77) and body (86).
11
10.57 Install the three /16” O.D. ring gaskets (88) in their grooves in the body (86).

10.58 Install NEW diaphragm check valve (64) in place in the body (86) so that the diaphragm spring seat faces
away from the body (86).

10.59 Install the spring (65) into the end of a NEW check valve (66, 67). Install the check valve with spring assembly
(67, 66, 65) into its cavity in the cover (62), spring end first.

10.60 Install the diaphragm check valve spring (63) into its cavity in the cover (62).

NOTE: Diaphragm check valve spring (63) MUST be colored yellow on the coils, Part No. 584197 or NYAB Part No.
CV-1225.

10.61 Install a NEW cover gasket (68) in place on the cover (62).

10.62 Position the cover assembly (62, 63, 65, 66, 67, 68) on the body (86) exercising care so that the spring (63) is
properly seated on the spring guide of the check valve diaphragm (64) and so that the check valve (67, 66)
enters its cavity in the body (86).

10.63 Install a NEW diaphragm (75) in place on the filling piece so that the bead of the diaphragm is seated in the
bead groove of the filling piece (69).

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1
10.64 Lightly coat the threads of the two /4”-20 x 3” fillister head screws (61) with Loctite Sealant TL-242, Wabtec
Corporation Specification M-07499-05. Place the filling piece with diaphragm (69, 75) in place on the body
1
(86). Secure the filling piece, body and cover assemblies together by installing two /4”-20 x 3” fillister head
screws (61). Sufficiently tighten the screws to prevent air leak, but do not over tighten to cause distortion of
the parts.

(Refer to Figure 9, page 38)

10.65 Apply a light coating of brake cylinder lubricant (M-914) or a compound consisting of one part graphite,
Wabtec Specification M-07695-02 (AAR Specification M-913) and two parts oil (SAE 20) by weight to the
1 3
threads of the four /2” x 4 /4” hex head cap screws (14). Install a NEW body gasket (16) in place on the
mounting face of the accelerated application valve portion (15). Position this portion on the ABDW
1 3
emergency portion body (3) and secure it in place by installing four /2” x 4 /4” hex head cap screws (14).
Tighten the four hex head cap screws (14) in a manner to securely fasten the accelerated application valve
portion (15) to the ABDW emergency valve body (3) to prevent leakage and yet not excessively to cause
distortion. (NOTE: Wabtec recommends the torquing the four hex head cap screws (14) between 35 and 55
foot-pounds.

NOTE: All ABD, ABDS, ABDW, and ABDWS emergency valve portions that have been clean, oil, and tested must
contain either a nameplate tag or paint stencil that includes the date of reconditioning (MM/YY) and shop
identification. If the nameplate tag is used, it must be located under the specific hex head cap screw as
shown in Figure 12, page 43 or Figure 13, page 45. If the paint stencil is used, the specific information
described above must be shown in ½” minimum height letters on the valve body.

11.0 TESTING PROCEDURES

11.1 The reassembled operating portions must be tested and pass the AAR approved shop test rack tests stated in
the Code of Tests in the current issue of Wabtec Corporation Instruction Leaflet Standard No. 5039-19, Sup. 1.
Contact your local Wabtec Corporation Representative or Wabtec Corporation Headquarters in Wilmerding,
Pennsylvania for the latest issue of the Code of Tests.

12.0 SHIPPING REQUIREMENTS

12.1 When the operating portions are not attached to the pipe bracket, the ports are exposed to dirt and, therefore,
special covers and stem guards must be fitted for protection against dirt and damage. To secure this
protection, special shipping covers as illustrated in Figure 6, page 37, or approved equivalents, are required.
These covers and guards, shown in Figures 6 through 8, page 37, must be applied to the portions as soon as
they have passed the Code of Tests and removed from the test rack, and must not be removed until just
ready to apply each cleaned portion to the car. Even then, special precautions must be taken to avoid
damaging the parts or getting dirt into the operating portions when applying them.

12.2 Release valve stem guard, Figure 7, page 37, is required to protect the internal parts from damage. This stem
guard must be applied to release valve stem and held in place with a cotter pin before transporting portion.

12.3 A vent protector plug, Figure 8, page 37, is also required for the emergency portion. This plug must be applied
when the emergency portion is removed from the test rack and must not be removed until ready to apply the
portion to the car.

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Figure 6 - Approved Shipping Covers

Figure 7 - Release Valve Stem Guard

Figure 8 - Vent Protector Plug

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Figure 9 - Control Valve Parts

1 STRAINER (2 Req’d.) 14 CAP SCREW (4 Req’d.)

5
2 HEX NUT, /8" (3 Req’d.) 15 ACCELERATED APPLICATION VALVE
3 ABDW EMERGENCY PORTION PORTION
4 GASKET, Emergency Portion 16 BODY GASKET (not shown)
5
5 HEX NUT, /8” (3 Req’d.) 17 PIPE BRACKET
6 SERVICE PORTION 18 VENT PROTECTOR ASSEMBLY (External
7 GASKET, Service Portion Style)
8 STRAINER NUT a VENT PROTECTOR (External Style)
9 STRAINER b RIVET
5
10 STUD, /8” x 3” c VENT PROTECTOR SEAL
5 3
11 STUD, /8” x 7 /8”
5 1
12 STUD, /8” x 7 /8”
5 5
13 STUD, /8” x 6 /8” (3 Req’d.)

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Figure 10 - ABD, ABDP, ABDT, ABDPT Service Portion Parts

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ABD, ABDP, ABDT, ABDPT Service Portion Parts (Refer to Figure 10, page 39)

1 CAP SCREW, (4 Req’d.) 29 CHECK VALVE, Acc. Release

1a COT-S NAMEPLATE TAG 30 FILLING PIECE
2, 2a, 2b METAL IDENTIFICATION TAG 31 GASKET
3 COVER 32 CAP SCREW (4 Req’d.)
4 RING GASKET 33 CHECK VALVE, Back Flow
5 CAP SCREW 34 SPRING, Check Valve
6 FOLLOWER 35 CAGE (Aluminum)
7 DIAPHRAGM 35a CAGE (Plastic)
8 RETAINER 36 SPRING, Piston Return
9 SEAT 37 SPRING, Limiting Valve
10 SPRING, Piston 38 HEX NUT
11 GUIDE 39 FOLLOWER
12 PIN 40 DIAPHRAGM
13 SPRING, Slide Valve 41 O-RING (Non-leakage protected) (2 Req’d.)
14 SPRING, Graduating Valve 41a O-RING (Leakage protected) (3 Req’d.)
15 VALVE, Graduating (ABD only) 42 PISTON (ABD)
15a VALVE, Graduating (ABDT only) 42a PISTON (ABDT)
16 VALVE, Slide 43 RING GASKET
17 PISTON (without two machined grooves) 44 RING GASKET
17a PISTON (with two machined grooves) 45 RING GASKET
17b RINGS, Top & Bottom Service Piston 46 COVER
18 CAP SCREW (4 Req’d.) 47 BODY
3
19 COVER 48 CHOKE PLUG, /32" Drill
19a WEAR SHIELD 49 CHOKE PLUG, Number 18 Drill
20 HEX NUT 50 CHOKE PLUG, Number 55 Drill
21 FOLLOWER 50a CHOKE PLUG, Number 54 Drill
1
22 DIAPHRAGM 51 CHOKE PLUG, /32" Drill
23 PISTON (without plastic wear pellet) 52 HEX NUT (3 Req’d.)
23a PISTON (with plastic wear pellet) 53 STUD (3 Req’d.)
24 PLUNGER 54 RING GASKET
25 O-RING 55 RING GASKET (5 Req’d.)
26 RING GASKET 56 SCREEN (3 Req’d.)
27 SEAT 57 RELEASE VALVE PORTION
28 SPRING, Check Valve

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Figure 11 - Release Valve Portion Parts

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Release Valve Portion Parts (Refer to Figure 11, page 41)

1 CAP SCREW (5 Req’d.)

2 COVER
3 RING GASKET (2 Req’d.)
4 SPRING, Release Spool Valve
5 HEX NUT
6 FOLLOWER
7 DIAPHRAGM
8 PISTON
9 O-RING
10 VALVE, Release Spool
11 O-RING (3 Req’d.)
12 SPRING, Check Valve (2 Req’d.)
13 CHECK VALVE (2 Req’d.)
14 PLUNGER (2 Req’d.) (Plastic)
15 CAP SCREW (5 Req’d.)
16 SPRING, Reset Spool Valve
17 O-RING (3 Req’d.)
18 VALVE, Reset Spool
19 SPRING, Retaining
20 CHECK VALVE, Retaining
21 CHECK VALVE, Reset
22 SPRING, Reset
23 SPRING, Lifter
24 PIN, Cotter
25 GUARD
26 LIFTER (Plastic)
27 STEM AND END PLATE
28 GASKET
29 RING GASKET
30 SEAL
31 COVER
31a COVER (Contains Return Flow Check Valve Assembly)
32 SEAL
33 POP RIVET
34 SLEEVE (Plastic)
35 BODY
35a BODY (Contains Return Flow Check Valve Assembly)
36 CHECK VALVE, Return Flow
37 SPRING, Return Flow

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Figure 12 - ABD, ABDP, ABDS, ABDPS Emergency Portion Parts

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ABD, ABDS, ABDP, ABDPS Emergency Portion Parts (Refer to Figure 12, page 43)

1 CAP SCREW (4 Req’d.) 30 PLASTIC SMALL VENT VALVE PISTON

1a COT-S NAMEPLATE TAG ASSY.
2 COVER 31 CAP SCREW (2 Req’d.)
3 CAP SCREW 31a, 31b, 31c METAL IDENTIFICATION TAG
4 FOLLOWER 32 CAP SCREW
5 DIAPHRAGM 33 COVER
6 PIN 34 RING GASKET
7 SPRING, Emergency Slide Valve 35 RING GASKET
8 VALVE, Emergency Slide 36 DIAPHRAGM
8a VALVE, Emergency Slide (Stabilized) 37 PISTON
9 PISTON (without two machined grooves) 38 SPRING, Inshot Piston
9a PISTON (with two machined grooves) 39 HEX NUT
9b RING, Top Emergency Piston 40 FOLLOWER
9c RING, Bottom Emergency Piston 41 DIAPHRAGM
10 SPRING, High Pressure Return (Blue) 42 O-RING
10a SPRING, High Pressure Return (Green) 43 PISTON, Inshot
10b SPRING, Bottom High Pressure 44 O-RING
11 O-RING (5 Req’d.) 45 CAP NUT
12 VALVE, High Pressure Spool (Old 46 SPRING, Spool Valve
Design) 47 O-RING (4 Req’d.)
12a VALVE, High Pressure Spool 48 VALVE, Emerg. Acc. Release Spool
(Latest Design) 48a VALVE, Vibration Protected Emerg. Acc. Rel.
13 SPRING, Check Valve Spool
14 SEAT 49 CHOKE PLUG, Number 41 Drill
15 CHECK VALVE, Emergency Acc. 50 CHOKE PLUG, Number 30 Drill
Release 51 CHOKE PLUG, Number 76 Drill
16 RETAINER RING (2 Req’d.) 52 FILTER
17 WIRE STRAINER 53 RETAINER
17a PLASTIC STRAINER 54 PIPE PLUG (4 Req’d.)
18 RING GASKET 55 CHOKE PLUG, Number 46 Drill
19 RING GASKET (2 Req’d.) 56 FILTER
20 RING GASKET 57 BODY
21 SPILLOVER CHECK VALVE PLUG 58 PLUG
21a SPILLOVER CHECK VALVE SPRING 59 RING
21b SPILLOVER CHECK VALVE 60 FILTER
22 RETAINER 61 CHOKE PLUG, No. 76 Drill
23 SPRING, Check Valve 62 FELT STRAINER
24 CHECK VALVE, Inshot 63 CAP SCREW
25 RETAINER 64 VOLUME
26 SPRING, Vent Valve 65 FITTING, Volume
27 CAP SCREW 66 O-RING
28 SEAL 67 SEAL
29 PISTON (Metal)
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Figure 13 - ABDW, ABDWP, ABDWS, ABDWPS Emergency Portion Parts

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ABDW, ABDWP, ABDWS, ABDWPS Emergency Portion Parts (Refer to Figure 13, page 45)

1 CAP SCREW (4 Req’d.) 29 PISTON (Metal)

1a COT-S NAMEPLATE TAG 30 PLASTIC SMALL VENT VALVE PISTON
2 COVER ASSY.
3 CAP SCREW 31 CAP SCREW (2 Req’d.)
4 FOLLOWER 31a, 31b, 31c METAL IDENTIFICATION TAG
5 DIAPHRAGM 32 CAP SCREW (2 Req’d.)
6 PIN 33 COVER
7 SPRING, Emergency Slide Valve 34 RING GASKET
8 VALVE, Emergency Slide 35 RING GASKET
8a VALVE, Emergency Slide (Stabilized) 36 DIAPHRAGM
9 PISTON (without two machined 37 PISTON
grooves) 38 SPRING, Inshot Piston
9a PISTON (with two machined grooves) 39 HEX NUT
9b RING, Top Emergency Piston 40 FOLLOWER
9c RING, Bottom Emergency Piston 41 DIAPHRAGM
10 SPRING, High Pressure Return (blue) 42 O-RING
10a SPRING, High Pressure Return (green) 43 PISTON, Inshot
10b SPRING, Bottom High Pressure Spool 44 O-RING
11 O-RING (5 Req’d.) 45 CAP NUT
12 VALVE, High Pressure Spool (Old 46 SPRING, Spool Valve
Design) 47 O-RING (4 Req’d.)
12a VALVE, High Pressure Spool (Latest 48 VALVE, Emergency Acc. Release Spool
Design) 48a VALVE, Vibration Protected Emerg. Acc. Rel.
13 SPRING, Check Valve Spool
14 SEAT 49 CHOKE PLUG, Number 41 Drill
15 CHECK VALVE, Emergency Acc. 50 CHOKE PLUG, Number 30 Drill
Release 51 CHOKE PLUG, Number 76 Drill
16 RETAINER RING (2 Req’d.) 52 FILTER
17 WIRE STRAINER 53 RETAINER
17a PLASTIC STRAINER 54 PIPE PLUG (3 Req’d.)
18 RING GASKET 55 CHOKE PLUG, Number 76 Drill
19 RING GASKET (2 Req’d.) 56 FILTER
20 RING GASKET 56a RETAINER
21 SPILLOVER CHECK VALVE PLUG 57 BODY
21a SPILLOVER CHECK VALVE SPRING 58 PLUG
21b SPILLOVER CHECK VALVE 59 RING
22 RETAINER 60 FILTER
23 SPRING, Check Valve
24 CHECK VALVE, Inshot
25 RETAINER
26 SPRING, Vent Valve
27 CAP SCREW
28 SEAL
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Figure 14 - Accelerated Application Valve Portion Parts

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Accelerated Application Valve Portion Parts (Refer to Figure 14, page 47)

61 FILLISTER HEAD SCREW (2 Req’d.)

62 COVER
63 SPRING, Diaphragm Check Valve (yellow)
64 CHECK VALVE, Diaphragm
65 SPRING
66 CHECK VALVE (Includes Ref. No. 67)
67 RUBBER PLUG
68 GASKET, Cover
69 FILLING PIECE
70 CHOKE PLUG, 1/64” Drill
71 FELT STRAINER
72 CHOKE PLUG, Number 46 Drill
73 CHOKE PLUG, Number 68 Drill
74 FELT STRAINER
75 DIAPHRAGM
76 SPRING
77 SPRING CAGE
78 O-RING
79 PLUNGER
80 CAP SCREW (2 Req’d)
81 COVER, Check Valve
82 SPRING, Check Valve
83 RING GASKET
84 SPRING SEAT
85 CHECK VALVE
86 BODY, Accelerated Application Valve Portion
87 CHOKE PLUG, Number 54 Drill
88 RING GASKET (3 Req’d.)

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14.0 SPECIAL TOOLS

IMPORTANT: The information shown in Figures 15 thru 21 for making tools is furnished as a convenience.
Wabtec Corporation shall have NO responsibility for tools which they do not manufacture and will not be
responsible for the results when using any of the specified tools (including claims by third parties.)

Figure 15 - Hand Tool for Diaphragm Installation

Figure 16 - Mandrel for Installing O-rings

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Figure 17 - Service Piston Assembly Fixture, Part No. 564522

Figure 18 - Limiting Valve Piston Spanner Wrench

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Figure 19 - Service Accelerated Release Valve Piston Spanner Wrench

Figure 20 - Inshot Piston Spanner Wrench

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Figure 21 - Vent Valve Diaphragm Installation Tool

15.0 CONTROL VALVE MODIFICATIONS

Figure 22 - View of By-Pass Port Drilled in Back Flow Check Valve Bushing

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Figure 23 - Modified Standard “ABD” Release Valve Bottom Cover with Nylon Wear Sleeve

Figure 24 - One Method for Machining of “ABD” Release Valve Portion Bottom Cover

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APPENDIX

Service Bulletin 68-20: ABD Service Portion Slide Valves; March 1998

Service Bulletin 68-22: New Emergency Accelerated Release “E.A.R.” Filter Details; May, 1999

Service Bulletin 68-23a: Inspection Procedures for Service Acc. Rel. Valve Plunger Pin, Feb. 2003

Service Bulletin 68-26: Lubrication of AB Type Service & Emergency Portions; September, 2004

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Service Bulletin

ABD SERVICE PORTION SLIDE VALVES

Proper Identification During COT Repair

MARCH, 1998

The AAR currently requires exclusive use of ABD Service Portion slide valves stamped with the number “82” during
Clean, Oil, and Test (COT) procedures (per AAR Instruction Leaflet No. 2391, Sup. 3, Standard S-478). These “82” slide
valves have the port configuration necessary for proper ABD control valve function.

There are however, some slide valves which have the proper porting but were manufactured without the “82” marking. A
visual inspection of the unmarked slide valves can be made to confirm the correct arrangement of ports. Since these
unmarked slide valves are functionally acceptable, the AAR has asked that we provide a means to identify them. The
drawings below show the easily recognizable difference on the graduating valve face of the slide valve for an acceptable
versus an unacceptable slide valve.

Slide valves which have the “slot” rather than the “two hole” port configuration MUST BE REPLACED during COT.

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Service Bulletin

THIS PAGE INTENTIONALLY LEFT BLANK

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Service Bulletin

FREIGHT CONTROL VALVES

New Emergency Accelerated Release "E.A.R." Filter Details

MAY, 1999

A NEW thimble type stainless steel air filter, Pc. No. 0661224, protecting the Emergency Accelerated Release (E.A.R.)
check valve is being standardized for use in the ABD/S/W/X type control valves. This new stainless steel air filter (Figure
1) replaces the nylon air filter, Pc. No. 0588105 (Figure 2). The stainless steel filter has been used in the new O.E.M. and
remanufactured ABDX and ABDX-L control valves since September 9, 1998.

Figure 1 - New Stainless Steel Air Filter

Note: Figure 2 illustrates the old style nylon air filter used with O.E.M. and remanufactured emergency valves built prior to
September 9, 1998.

Figure 2 - Old Nylon Air Filter

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Service Bulletin

The installation and removal procedure for the new strainer is as follows:

Note: During C.O.T. & S., retrofit, and/or repair of the emergency portion of the control valves, FOLLOW STANDARD
PROCEDURE for disassembly and reassembly of the valve, with the following additions.

Note: Use the NEW stainless steel air filter, and SCRAP the nylon air filter.

Required/recommended equipment for installation/removal:

• Ring Installation Tool, Pc. No. 0661297
• Arbor Press, such as 121/2" capacity RKBO-3
• Ring Removal Tool, Pc. No. 0661556
• Ergonomic Roto Clip Pliers, No. EPL-100
1
• 1 /4" Wrench

New Stainless Steel E.A.R. Filter Installation (Using Assembly Views):

Note: Assembly requires the insertion of two new internally threaded brass retaining rings, Pc. No. 661296 into the
internal brass bushing, Pc. No. 0567199, utilizing tool, Pc. No. 0661297.

Step 1:

a) Place emergency valve body on the arbor press and

position such that the emergency accelerated release
check valve bushing, Pc. No. 0567199, is approximately
centered under the press ram.

b) Place retaining ring, Pc. No. 0661296, onto ring

installation tool, Pc. No. 0661297, and position carefully
on top of the bushing seat as illustrated.

Caution: Take care not to damage the seat of bushing,

Pc. No. 0567199.

Note: In the unlikely event that the retaining ring freely

enters the inside diameter of the bush without
interference, the emergency body is not suitable for use
with this filter/ring arrangement. DO NOT PROCEED. This
valve body should be scrapped or returned to the nearest
WABCO Service Center for repair.

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Service Bulletin

Step 2 Step 3:
Press retaining ring into place until tool contacts Carefully insert filter, Pc. No. 0661224, as
the top of the portion body as illustrated, then illustrated.
carefully remove the installation tool.
Note: Make certain that the filter is fully seated
on top of the brass retaining ring.

Step 4: Step 5:
Place upper retaining ring onto installation tool Press the upper retaining ring into position in the
and position carefully on top of bushing seat. bushing until the installation tool contacts the top
of the emergency portion. Carefully remove the
installation tool.

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Service Bulletin

New Stainless Steel E.A.R. Filter Removal (Using Assembly Views):

Note: Removal of the new stainless steel filter, Pc. No. 0661224, for cleaning or replacement, requires utilizing a special
tool, complete Pc. No. 0661556, which consists of a stud, Pc. No. 0661342 and a flanged nut, Pc. No. 0661570, as
illustrated below.

Step 1:

Engage the removal tool threaded stud fully into the upper
retaining ring threads as shown.

Step 2:

Screw the flanged nut of the removal tool (clockwise) until it

contacts the top of the emergency portion

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Service Bulletin

Step 3:

Continue to tighten (clockwise) the flanged nut of the removal tool

1
with an 1 /4" wrench. This will cause the stud of the removal tool
and the retaining ring to rise out of the bushing. Remove the
retaining ring from the stud. SCRAP the upper retaining ring.

Step 4:

Use pliers, Roto Clip No. EPL-100 (or equivalent), to gently grab
the filter and remove from the bushing.

Caution: DO NOT remove the bottom brass retaining ring.

Note: Stainless steel air filter, Pc. No. 0661224, may be cleaned
and reused if NOT damaged. For installation of cleaned or new
air filter use steps 3, 4 & 5 of the assembly procedure shown on
page 3 of this bulletin.

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Service Bulletin

Note: Figure 3 illustrates O.E.M. emergency portions manufactured after September 9, 1998. These bodies include
internal brass bushings, Pc. No. 0661295, with a machined shoulder and annular groove for retaining snap ring.

Figure 3 - New Stainless Steel Air Filter w/ Grooved Bushing & Snap Ring

The installation and removal procedure for the new strainer in this configuration is as follows:

Note: During C.O.T. & S., retrofit, and/or repair of the emergency portion of the control valves, FOLLOW STANDARD
PROCEDURE for disassembly and reassembly of the valve, with the following additions.

Using pliers, Roto Clip No. EPL-100 (or equivalent), carefully remove the retaining ring which secures the filter in the
bushing. Remove the filter with Roto Clip No. EPL-100 pliers (or equivalent) as in step 4, page 5 of this bulletin.

Note: Stainless steel air filter, Pc. No. 0661224, may be cleaned and reused if NOT damaged.

Carefully insert filter, Pc. No. 0661224, as illustrated in step 3, page 3 of this bulletin.

Note: Make certain the filter is fully seated on the shoulder of the brass bushing.

Secure the filter in place by installing the retaining ring using pliers, Roto Clip No. EPL-100 (or equivalent). Be sure the
retaining ring snaps in its groove in the brass bushing.

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Service Bulletin

ABD & ABDX SERVICE PORTIONS

Inspection Procedures for Service Accelerated
Release Valve Plunger Pin

FEBRUARY, 2003
Supersedes issue 68-23 dated October, 1999

WABCO Freight Car Products has revised the inspection gauge for the service accelerated release valve plunger pin,
Part No. 566194, to determine whether the plunger pin is bent and not reusable during the C.O.T. of ABD or ABDX type
service portions.

The following changes have been made to drawing 663396 (Figure 1);
• Re-dimensioned the 45° x 0.053 chamfer, to clarify that it is to be referenced from the end surface.
• Added Note 3 to drawing 663396, in order to accommodate the rework of existing gauges.
• Added the requirement to stamp the gauge with Part No. 0663396 and configuration control information ("CC:A"), in
order to identify the gauge as being in conformance with this configuration.

Existing gauges must be re-worked, re-qualified and identified by the stamped configuration control letter.

Figure 1 - Dimensional Drawing - Service Accelerated Release Valve Gauge, Part No. 663396

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Service Bulletin

WABCO Freight Car Products has developed the following procedure to inspect for bent plunger pins. Recommended
mounting of the gauge is at or near eye level for easy viewing during the pin inspection process.

1. All plunger pins must be clean and dry prior to gauging.

2. Pins are to be gauged prior to O-ring installation.

3. Acceptable/straight pins should freely and entirely enter the gauge when the pin is dropped into the gauge bore. The
head of the plunger pin should be, at least, flush with the top of the gauge surface (See Figure 2). Pins that pass this
test are to be reused during assembly.

Figure 2 - Bent vs. Straight Pins

4. If the pin hangs up and does not initially drop freely into the gauge bore, we permit slightly lifting and rotating the pin,
then releasing it to see if it enters the gauge. NO PUSHING.

5. Pins that DO NOT pass this test are to be SCRAPPED and replaced with NEW pins during assembly.

6. The gauge is NOT TO BE USED to straighten any bent pins.

7. Reasonable care must be taken to safeguard gauge placement, storage, etc. Adequate training of personnel in the
use and handling of the gauge is mandatory.

Please contact your local Wabtec Corporation Representative or the Freight Field Service Engineering Department at
(412) 825-1000 with any questions.

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Service Bulletin

LUBRICATION OF AB TYPE SERVICE & EMERGENCY

PORTIONS

SEPTEMBER, 2004
Supersedes issue dated January, 2003

This service bulletin is to provide graphic instruction on the recommended amounts and specific locations for the
application of AAR Specification M - 912 lubrication.

It is recommended that the AAR Specification M - 912 lubricant be applied, then spread with a clean foam tipped
applicator (or equivalent) resulting in an even, light coating on the components identified in these instructions, as well as
in the 2391 instruction leaflets.

These instructions are meant to supplement the current instructions found in:

2391 Sup. 3 - Paragraphs 3.5.1, 3.5.2 and 3.5.3

2391 Sup. 4 (Sept. 2004) - Paragraphs 8.5, 8.9, 8.15, 8.20, 10.13, 10.14, 10.15, 10.30, & 10.41

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 2391, S.3

Shop Maintenance

WABCO Freight Car Products

[Link]
1001 Air Brake Avenue 475 Seaman Street
Wilmerding, Pennsylvania 15148 Stoney Creek, Ontario L8E 2R2
(412) 825-1000 • Fax (412) 825-1019 (905) 561-8700 • Fax (905) 561-8705

F070327A Page 68 of 68 March 2007