4207-6,S.3.

operation & maintenance instruction

“SA-9” INDEPENDENT BRAKE VALVE, Pc. No. 564192

“SA-9” INDEPENDENT BRAKE VALVE PORTION,
Pc.No. 564209

SEPTEMBER, 1988

NOTE: The following description and

operation is based on this device and
its components being new or this
device and its components having
been repaired, tested, installed and
maintained in accordance with
instructions issued by this and any
other applicable Wabtec Corporation
se
publications. ea
el ke
t R ra
e

15°
en tic B
as

WARNING: At the time any part is d

le

n a
replaced in this device, the operation of pe t om
Fu

Re

e
l
lA

d
the complete device must pass a series
77° 46° In f Au
pp

of tests prescribed in the latest issue of o

lic
at

the applicable Wabtec Test Specification.

io

SA-9 Independent
n

At the time this device is applied to the Brake Valve

brake equipment arrangement, a Portion
stationary vehicle test must be made to
insure that this device functions properly
in the total brake equipment arrangement. 30
(Consult your local Wabtec 7
Representative for identity of the test 1 20
specification, with latest revision date, that
covers this device.) Pipe
Bracket
IMPORTANT: Only Wabtec supplied Portion
Rear View
parts are to be used in the repair of this Side View
device in order to obtain satisfactory
operation. Commercially available non-
O.E.M. parts are unacceptable.

NOTE: The part numbers and their

associated descriptions are the property Figure 1 - Exterior Views
of Wabtec Corporation and may not be
replicated in any manner or form without
the prior sole written consent of an Officer
of Wabtec Corporation.

© 2000 WABCO Locomotive Products. A Wabtec Company. All rights reserved

September, 1988 Page 1 of 12

4207-6, S.3.1

operation & maintenance instruction

1.0 DESCRIPTION

Designed for console or panel mounting, the “SA-9” Inde-

pendent Brake Valve provides a means for the manual con- Release Cam Regulating Cam
trol of graduating the application or release of the locomo-
tive air brakes independent of the automatic brake valve.
This Independent Brake Valve also provides the means to
initiate the release of an automatic brake application only
on the locomotive without affecting the application of the Handle
(Cam) Shaft
train brakes.
Regulating
The “SA-9” Independent Brake Valve, Pc.No. 564192, may Cam Dog
be used in locomotive equipment arrangement where the Inlet & Exhaust
air pressure does not exceed 150 psig. It consists of an Valve Unit
“SA-9” Brake Valve Portion, Pc.No. 564209; and a Pipe
Bracket Portion, Pc.No. 561378. Release
Valve 7
1
The “SA-9” Independent Brake Valve Portion is mounted 30
on the Pipe Bracket Portion. All pipe connections are made
20
directly to the Pipe Bracket Portion. This arrangement per-
mits for the removal of the Independent Brake Valve Portion
for maintenance or servicing without disturbing the piping Inlet Valve
of the equipment arrangement.
Exhaust Valve
The “SA-9” Independent Brake Valve Portion is a self-lap- Regulating Valve
Diaphragm Assembly
ping pressure maintaining type valve which is controlled by
Regulating
the manual movement of the independent brake valve han- Valve Spring
dle. This Portion has three designated handle positions: Ex.
~Full Application”, “Release”, and “Independent Release of
Automatic Brake”, which are shown in Figure 1. An “Appli- Housing
Adjusting Handle
cation Zone” is located between the “Full Application” and
“Release” Positions. Regulated air pressure is controlled
(directed/supplied or exhausted) in proportion to the manual
movement of the Independent Valve Handle through this
zone to pilot and graduate the brake cylinder pressure dur-
ing an independent brake application or release.
LEGEND:
When the Independent Brake Valve Handle is moved into
the “Independent Release of Automatic Brake” Position, the Port Description
“SA-9” Independent Brake Valve Portion functions to initi- Control Reservoir
7
ate the release of an automatic brake application only on 1 Brake Pipe
the locomotive. 30 Main Reservoir
20 Independent Application
& Release Pipe
The “SA-9” Independent Brake Valve is normally used in an
equipment arrangement that includes a Control Valve that
utilizes a control reservoir feature. The Control Valve re-
This diagrammatic representation is for functional
sponds to brake pipe pressure changes resulting in the analysis only. It is not to be used as an actual physical
applica- tion and/or release of the automatic brake on the representation of portion or pipe bracket configurations.
locomotive (see Section 2.4 for additional information).

Figure 2 - Diagrammatic View

Page 2 of 12 September, 1988


operation & maintenance instruction
2.0 OPERATION (Figure 2)
2.1 CHARGING
When the Independent Brake Valve handle is manually
placed in the “Release” Position, the combined tension of
the regulating valve spring and the exhaust valve spring will
position the inlet valve at its farthest travel from the regulat-
ing valve diaphragm assembly. The inlet valve assembly will
carry the double ball check away from the regulating valve
diaphragm which will unseat the double ball check valve at
the exhaust valve while being seated at the inlet valve by the
inlet valve spring. With the exhaust valve open, any air
pressure in the independent application and release pipe
(Port 20), will be exhausted to atmosphere.
Main reservoir air is directed through port 30 in the pipe
bracket and a strainer to the spring chamber of the inlet
valve where it is blanked.
Brake pipe control air pressure is directed through port 1 in
the pipe bracket to the spring chamber of the quick release
valve where it is blanked. Control reservoir pressure com-
ing from the control valve is directed through port 7 in the
pipe bracket and is also blanked due to the position of the
release valve.
2.2 INDEPENDENT BRAKE APPLICATION
When the independent brake valve handle is manually moved
into the “Application Zone”, the regulating cam dog on the
brake valve handle shaft forces the inlet valve toward the
regulating valve diaphragm assembly and causes the dou-
ble ball check valve to seat at the exhaust valve and open at
the inlet valve, thus supplying main reservoir air through the
open inlet valve into the independent application and re-
lease pipe (port 20) which will pilot the locomotive brake
application. This “delivered” pressure is also ported through
a choke passage to the face of the regulating valve dia-
phragm.
When the delivery pressure on the face of the regulating
valve diaphragm overcomes the force exerted by the regu-
lating valve spring the regulating valve diaphragm assembly
will move away from the inlet valve assembly. This will allow
the inlet valve spring to move the double ball check assem-
bly to the inlet valve seat; thus the independent brake valve
will assume a lap position, neither adding to nor subtracting
from the pre-set delivered pressure. The valve assembly,
however, will automatically compensate for either a leakage
or an overcasting condition in the delivery pressure line to
maintain a constant, pre-adjusted, pressure output.
September, 1988 Page 3 of 12
4207-6,S.3.1
2.3 RELEASE OF AN INDEPENDENT
BRAKE APPLICATION
When the independent brake valve handle is manually moved
toward “Release” Position, the regulating cam dog on han-
dle shaft allows the combined regulating valve and exhaust
valve spring tension to move the inlet valve assembly toward
its release position, carrying the double ball check valve
assembly with it, the exhaust valve will be unseated opening
the exhaust port while inlet valve remains seated to close
the inlet port. A graduated release of brake cylinder pres-
sure will be in proportion to the movement of the brake valve
handle toward “Release” Position. When the forces across
the regulating valve diaphragm have equalized, the double
ball check valve assembly will be seated at both the inlet
and exhaust valve seats, and thus the independent brake
valve will again assume a lap position.
When the independent brake valve handle is manually moved
back to the “Release” Position, the regulating cam dog on
the brake valve handle shaft will allow the regulating valve
and exhaust valve spring tension to move the inlet valve as-
sembly to its farthest travel from the regulating valve. The
inlet valve assembly will carry the double ball check valve
assembly with it to open the exhaust port while remaining
seated at the inlet port. Thus, the air pressure in the inde-
pendent application and release pipe (port 20) will flow to
exhaust which in turn will pilot the release of brake cylinder
pressure on the locomotive.
2.4 INDEPENDENT RELEASE OF
AUTOMATIC BRAKE
The “Independent Release of Automatic Brake” Position of
the independent brake valve handle provides a means of
releasing an automatic brake application present on the train
brakes. This feature is actuated by the release valve cam
which is located on the independent brake valve handle shaft.
When the independent brake valve handle is manually moved
to the “Independent Release of Automatic Brake” Position,
the release valve cam positions the release spool valve to
connect brake pipe control pipe port 1 to the control reser-
voir port 7 which will initiate the release of an automatic
brake application only on the locomotive. The train brakes
will remain applied.
2.5 EMERGENCY - “LITE” LOCOMOTIVE OPERATION
NOTE: The term “LITE LOCOMOTIVE” indicates a loco-
motive or consist of locomotives only with NO OTHER VE-
HICLES in the consist, or to a locomotive or consist of loco-
motives to which ONLY a caboose is attached.
4207-6, S.3.1
operation & maintenance instruction
WARNING: In an emergency situation, when operating a
“LITE” locomotive, the RAPID MANUAL MOVEMENT of the
independent brake valve handle to “Full Application” Posi-
tion is the fastest way to develop brake cylinder pressure
on the locomotive up to the full independent brake cylinder
pressure setting. Immediately after manually moving the
independent brake valve handle to “Full Application” Posi-
tion, the automatic brake valve handle IS TO BE RAPIDLY
MOVED MANUALLY to the “Emergency” Position. Failure
to comply with this procedure during an emergency brake
application when operating a “LITE” locomotive consist could
extend the stopping distance and increase the likelihood of
equipment damage and/or personal injury.
3.0 MAINTENANCE SCHEDULE
IMPORTANT: At least ONCE EVERY TWENTY- FOUR
MONTHS, or more frequently if service conditions so indi-
cate, the “SA-9” Independent Brake Valve Portion is to be
removed from the equipment arrangement, taken to the shop,
be completely disassembled, the parts cleaned, inspected,
lubricated and reassembled using NEW rubber and other
specified NEW parts. The assembled Portion is then to be
tested for proper operation.
4.0 PARTS CATALOG & REPLACEMENT
PARTS INFORMATION
4.1 PARTS CATALOG
4.1.1 IMPORTANT: Refer to the current issue of the Wabtec
Corporation Division Parts Catalog 3207-6, Sup. 3 when
ordering replacement parts for the “SA-9” Independent Brake
Valve, Pc.No. 564192, the “SA-9” Independent Brake Valve
Portion, Pc.No. 564209, or any of their components.
NOTE: The reference numbers used in this publication
and those used in the parts catalog may differ. Check the
descriptive parts name to be sure that the desired part is
ordered.
4.2 REPLACEMENT PARTS
4.2.1 IMPORTANT: To obtain satisfactory operation and
reliability of the “SA-9” Independent Brake Valve and/or any
of its Component Portions, ONLY Wabtec Corporation Divi-
sion replacement parts are to be used in the maintenance
of this device and/or its Component Portions.
Page 4 of 12
5.0 SAFETY PROCEDURES AND WARNINGS
Regular shop safety procedures are to be followed.
The work area is to be clean.
WARNING
The following statements of warning apply all or in part wher-
ever the symbol appears in the maintenance procedures.
Failure to observe these precautions may result in serious
injury to those performing the work and/or bystanders.
! The use of an air jet, which must be less than 30
p.s.i.g., to blow parts clean or to blow them dry af-
ter being cleaned with a solvent will cause particles
of dirt and/or droplets of the cleaning solvent to be
airborne. Wire brushing may also cause particles
of dirt, rust, and scale to become airborne. These
conditions may cause skin and/or eye irritation.
! When using an air jet, do not direct it toward an-
other person. Improper use of air jet could result in
bodily injury.
! Personal eye protection must be worn when per-
forming any work on this device or its components
parts to avoid any possible injury to the eyes.
! The use of solvents as cleaning agents and the use
of lubricants can involve health and/or safety haz-
ards. The manufacturers of the solvents and lubri-
cants should be contacted for safety data (such as
OSHA Form OSHA-20 or its equivalent). The rec-
ommended precautions and procedures of the manu-
facturers should be followed.
! When performing any test or work on devices or
equipment while they are on the vehicle (on car test,
etc.) special precautions must be taken to insure
that vehicle movement will not occur which could
result in injury to personnel and/or damage to equip-
ment.
! Assembly may be under a spring load. Exercise cau-
tion during disassembly so that no parts “Fly Out”
and cause bodily injury.
! All air supply and/or electric current to this device
and/or to any components part must be cut-off be-
fore this device and/or any component part is re-
moved from the equipment arrangement.
September, 1988
 4207-6,S.3.1

operation & maintenance instruction

! “Bottled” up air under pressure (even though air

supply is cut-off) may cause gaskets and/or parti-
cles of dirt to become airborne and an increase in
sound level when this device and/or any component
part is removed from the equipment arrangement.

! Personal eye and ear protection must be worn and

care taken to avoid possible injury when performing 1” Hex Steel
any work on this device and/or component part.
7/16 Dia. Drill

+.015
7/64”-.000
! An adequate support or lifting device must be avail- 3/16 Steel Rod
able to support the Device and/or Valve Portion(s)
during removal, installation and maintenance pro-
cedures.
2-1/8 1-3/4
6.0 CLEANING SOLVENT, LUBRICANTS,AND
SPECIAL TOOL

6.1 CLEANING SOLVENT Number 12 Drill 1/64 Chamfer

6.1.1 The cleaning solvent used to clean the reusable

parts of the “SA-9” Independent Brake Valve and/or any of
its Component Portions MUST BE an aliphatic organic so-
lution such as mineral spirits or naphtha that will dissolve oil Figure 3 - Holding Fixture (Drawing R-42-1)
or grease and that will permit all parts to be thoroughly
(WABCO) shall have no responsibility for tools which they
cleaned without abrasion.
do not manufacture and will not be responsible for the use
of any tool including claims by third parties.
6.2 LUBRICANTS
7.0 MAINTENANCE PROCEDURES “ON-CAR”
6.2.1 The following lubricants are required:
7.1 REMOVAL & REPLACEMENT OF THE “SA-9”
6.2.1.1 Number 2 Silicone Grease, Wabtec Corporation
INDEPENDENT BRAKE VALVE PORTION
Division Specification M-7680-2, such as Dow Corning Corp.
Molykote 55m, is required for the lubrication of o-rings, o-
7.1.1 PARTS REQUIRED
ring grooves and the bearing surfaces of the bushings into
which the o-ring assemblies are installed.
7.1.1.1 A NEW “SA-9” Independent Brake Valve Portion,
Pc.No. 564209, or an “SA-9” Independent Brake Valve Por-
6.2.1.2 Number 1 Calcium Base Grease, Wabtec Corpo-
tion, Pc.No. 564209, that has been serviced or repaired,
ration Division Specification M-7650-1, such as Union Oil
and then tested following the procedures of the current is-
Co. Number 1 Cup Grease, is required for the lubrication
sue of the Wabtec Corporation Division Test Speci- fication
of the cam dogs and cams.
T-2550-O.
6.3 SPECIAL TOOL
7.1.1.2 A NEW pipe bracket gasket (mounting gasket),
Pc.No. 560009.
6.3.1 In addition to the regular shop tools, a holding fixture
for disassembling and assembling the inlet and exhaust valve
7.1.1.3 If self-locking type hardware is used to secure the
unit MUST BE available to the repair person. Dimensions
“SA-9” Independent Brake Valve Portion to the cab panel
and specifications for making this fixture are shown in Fig-
or console NEW self- locking type hardware MUST BE
ure 3.
used during the installation of the Brake Valve Portion.
IMPORTANT: The information shown in Figure 3 for mak-
NOTE: The mounting hardware IS NOT furnished with the
ing the holding fixture is furnished as a convenience. The
“SA-9” Independent Brake Valve or the “SA-9” Independ-
Wabtec Corporation Division of American Standard Inc.
ent Brake Valve Portion.

September, 1988 Page 5 of 12

4207-6, S.3.1
operation & maintenance instruction
7.1.2 PORTION REMOVAL & REPLACEMENT
7.1.2.1 IMPORTANT: ALL owner-operating property safety
procedures and the warnings listed in Section 5.0 of this
publication MUST BE adhered to.
7.1.2.2 Chock the wheels of the vehicle and apply
handbrake(s) to prevent any unintentional vehicle movement.
7.1.2.3 Suitable warning placards indicating that work is
being performed should be placed on and about the vehi-
cle.
7.1.2.4 Remove ALL free dirt from the exterior surfaces of
the “SA-9” Independent Brake Valve by wiping with a dry,
clean, lint-free cloth or by blowing the surfaces clean using
a low pressure jet of clean, dry air.
7.1.2.5 Following locomotive builder and/or owner-operat-
ing property instructions, remove the mounting hardware
that secures the “SA-9” Independent Brake Valve in place
in the panel or console. If self-locking type hardware is
removed, it is to be scrapped and NEW self- locking hard-
ware used during the installation of the replacement Portion
Valve.
NOTE: The mounting hardware IS NOT furnished with the
“SA-9” Independent Brake Valve and MUST BE ordered
separately. (Figure 4)
7.1.2.6 Remove the two 1/2" x 17/8" hex head bolts (1)
which secures the Brake Valve Portion to the pipe bracket
(3) and then remove the Brake Valve Portion.
7.1.2.7 Remove and SCRAP the bracket gasket (2).
7.1.2.8 Visually inspect the brake valve portion mounting
face of the pipe bracket (3) for imperfections and/or dam-
age. Be sure that ALL exposed ports are clear and unre-
stricted. If necessary, blow the ports clean using a low
pressure jet of clean, dry air. Exercise care so that NO dirt
is blown into the ports or passages of the pipe bracket (3).
The pipe bracket (3) need not be removed from the equip-
ment arrangement unless it is damaged. Car builder and/
or owner-operating instructions are to be followed if it is
necessary to remove the pipe bracket.
7.1.2.9 Remove ALL protective materials from the replace-
ment “SA-9” Independent Brake Valve Portion, Pc.No.
564209. Be sure that ALL tape is removed from ALL ports
and that wire mesh strainer (32) is in place in port 30 of the
portion. This wire mesh strainer IS A PART of the “SA-9”
Page 6 of 12
Independent Brake Valve Portion and MUST BE in place. If
the strainer (32) is not in place, either obtain a NEW strainer,
Pc.No. 561364, and install it in place in port 30 of the brake
valve body or return the Portion to stores and obtain a NEW
or repaired and tested Portion, Pc.No. 564209, with the
strainer (32) in place.
7.1.2.10 Install a NEW bracket gasket (2) and the “SA-9”
Independent Brake Valve Portion on the pipe bracket (3) and
secure the parts together by installing the two 1/2" x 17/8" hex
head bolts (1). Equally tighten the bolts.
7.1.2.11 Install the mounting hardware that secures the “SA-
9” Independent Brake Valve to the panel or console. If self-
locking hardware was removed during the removal proce-
dure, NEW self-locking hardware MUST BE used.
NOTE: The mounting hardware IS NOT a part of the Inde-
pendent Brake Valve.
7.1.2.12 Provide adequate protection to prevent dirt and/
or moisture from entering the removed Portion and trans-
port it to the shop.
7.1.2.13 IMPORTANT: Whenever an “SA-9” Independ-
ent Brake Valve Portion is removed from an equipment
arrangement for any reason, and it is re-installed or
replaced with a NEW or repaired and tested Portion, a
stationary vehicle test MUST BE made to be sure that
the “SA-9” Independent Brake Valve and its Compo-
nent Portions function properly in the equipment ar-
rangement.
7.1.2.14 IMPORTANT: Remove ALL warning placards and
wheel chocks before attempting to move the vehicle.
8.0 “SA-9” INDEPENDENT BRAKE VALVE PORTION -
MAINTENANCE PROCEDURES - “IN-SHOP”
IMPORTANT: When performing the procedures which fol-
low, DO NOT use hard or sharp metal tools to remove gas-
kets, seals, o-rings, or the diaphragm. Exercise care so
that NO damage is done to metal surfaces.
8.1 DISASSEMBLY (Figure 4)
8.1.1 Remove and SCRAP the wire mesh strainer from port
30 in the pipe bracket mounting face of the body (33). This
strainer is not illustrated.
8.1.2 Remove the strainer plug with o-ring assembly (31,
30) as a unit from the chamfered port in the pipe bracket
mounting face of the body (33), then remove the wire mesh
September, 1988
 4207-6,S.3.1

operation & maintenance instruction

55

62
36

63

35

Figure 4, View “B” Partial View showing Cam Housing and Handle

26

25
Figure 4, View “C” Inlet and
24 Exhaust Valve Unit Assembly

22

23

A 10 8 7

6 5 See View “B”

10B
9
10C

27
12 12
28
33
2 29
10A 32
4 11
1
100
See View “C”
34 13
3
20
30 31 15 18
15 21
19
33A 16
17
14A 14B

14

A
Section A - A

Figure 4 - Assembly View

September, 1988 Page 7 of 12

4207-6, S.3.1
operation & maintenance instruction
strainer (32). SCRAP the strainer (32).
8.1.3 Remove and SCRAP the two 7/8" O.D. o-rings (30)
from their grooves on the strainer plug (31).
8.1.4 IMPORTANT: BEFORE PROCEEDING WITH THE
DISASSEMBLY PROCEDURE, TURN THE ADJUSTING
HANDLE (14) COUNTERCLOCK- WISE, ITS FULL
TRAVEL, TO RELIEVE TENSION ON THE ADJUSTING
SPRING (16).
It is not necessary to entirely remove the adjusting handle
assembly from the spring housing (18), unless it is dam-
aged, BUT CARE MUST BE TAKEN to be sure that all
spring tension is removed before proceeding with the dis-
assembly.
8.1.5 WARNING: During the following procedure, ex-
ercise care so that the spring housing (18), spring seat
(17) and/or spring (16) do not “fly out” of the assem-
bled parts and cause bodily injury.
Carefully remove the four 5/16" hex nuts (15) which secure
the spring housing (18) to the body (33).
8.1.6 Remove the spring housing with adjusting handle
(18, 14 to 14B), diaphragm-follower- exhaust valve seat as-
sembly (19 to 23) as a unit, the adjusting spring (16) and
the spring seat (17).
3
8.1.7 Remove and SCRAP the /4" O.D. o-ring (22) from
the exhaust valve seat (23).
9
8.1.8 Remove the /16" hex nut (19) from the exhaust valve
seat (23), then remove the diaphragm follower (20) and
diaphragm (21). SCRAP the diaphragm (21).
8.1.9 Remove the exhaust valve spring (24) from the body
(33).
8.1.10 Manually move the brake valve handle (55) into
“Release” Position, then remove the inlet and exhaust valve
unit with o-ring assembly (25, 26) from the body (33).
8.1.11 Remove and SCRAP the two 3/4" O.D. o-rings (25)
from their grooves on the inlet and exhaust valve unit (26).
8.1.12 Disassemble the inlet and exhaust valve unit (26) as
follows:
8.1.12.1 The use of the holding fixture as shown in Figure
3 is required.
Page 8 of 12
Insert the dumbbell end of the inlet and exhaust valve unit
(26) into the holding fixture so that the cross drill in the
holding fixture aligns with the cross drill in the tapered end
of the inlet valve seat.
8.1.12.2 Insert the 3/16" steel rod, (part of the holding
fixture), through the cross drill of the holding fixture and into
the cross drill of the inlet valve seat.
8.1.12.3 Carefully remove the housing from the valve seat.
8.1.12.4 Remove the spring from the inlet valve seat.
8.1.12.5 Remove the 3/16" steel rod from the inlet valve seat
and holding fixture.
8.1.12.6 Remove the inlet valve seat assembly from the
holding fixture.
8.1.13 Remove and SCRAP the three 3/8" elastic hex nuts
(4) which secure the body (33) to the cam housing (10).
8.1.14 Separate the cam housing assembly (10) with han-
dle and shaft assembly (9, 35, 36, 55, 62, 63) as a unit
from the body (33). Set this unit aside in a clean area.
8.1.15 Remove the release valve with o-ring assembly (11,
12) and the spring (13) from the body (33).
8.1.16 Remove and SCRAP the three 3/4" O.D. o-rings
(11) from their grooves in the release valve (12).
8.1.17 Remove and SCRAP the two 1/16" x 3/8" cotter pins
(27) which secure the cam dog lever pin (28) and cam dog
(29) in the body (33).
8.1.18 Remove the cam dog lever pin (28) and cam dog
(29) from the body (33).
8.1.19 Disassemble the cam housing assembly as follows:
8.1.19.1 Remove the handle nut (36), handle key (35),
and handle (55) from the cam shaft (9).
8.1.19.2 Remove the sprocket stop (62) from the cam
shaft (9) by using the proper tool to drift the 1/4" x 11/4"
cylindrical spring pin (63) from the sprocket stop (62) and
cam shaft (9) and then separating the stop (62) from the
shaft (9).
8.1.19.3 Relieve the tension on the cam latch spring (10C)
by inserting the blade of a small screwdriver between the
cam latch spring (10C) and the regulating cam (8), then
September, 1988

operation & maintenance instruction
rotate the regulating cam (8) and cam shaft (9) to permit
access to the 5/16" cone point set screw (5) which secures
the release valve cam (6) to the cam shaft (9).
8.1.19.3.1 Remove the 5/16" cone point set screw (5) from
the release valve cam (6).
8.1.19.4 Again, relieve the tension on the cam latch spring
(10C) by inserting the blade of a small screwdriver between
the cam latch spring (10C) and regulating cam (8), then
rotate the regulating cam (8) and cam shaft (9) to permit
access to the 5/16" cone point set screw (7) which secures
the regulating cam (8) to the cam shaft (9).
8.1.19.4.1 Remove the 5/16" cone point set screw (7) from
the regulating cam (8).
8.1.19.5 Carefully remove the cam shaft (9) from the cam
housing (10), release valve cam (6) and regulating cam (8),
then remove the release valve cam (6) and regulating cam
(8) from the cam housing (10).
8.2 CLEANING & INSPECTING
8.2.1 NON-REUSABLE PARTS
8.2.1.1 IMPORTANT: ALL o-rings, seals, gaskets, the
diaphragm, cotter pins, wire mesh strainers, and self-lock-
ing screws and/or elastic stop nuts ARE TO BE SCRAPPED
and replaced with NEW Wabtec Corporation Division parts.
8.2.2 REMAINING PARTS
8.2.2.1 Wash all of the remaining parts in a bath of the
cleaning solvent as described in Section 6.1.
8.2.2.2 Springs may be wire brushed to assist in the re-
moval of any dirt, rust, or scale.
8.2.2.3 After the parts are cleaned, they MUST BE com-
pletely dried. Use a low pressure jet of clean, dry air to
blow the parts dry.
IMPORTANT: Be sure that the ports and passages of the
body are completely dried.
8.2.2.4 Inspect the springs. Replace any spring that is
rusted, pitted, distorted, damaged in any way, or if it has
taken a permanent set. Refer to the Wabtec Corporation
Division Parts Catalog 3207-6, Sup. 3 for spring informa-
tion and identification.
8.2.2.5 Visually inspect the cam housing (10). If it is
September, 1988 Page 9 of 12
4207-6,S.3.1
broken, cracked, shows signs of excessive wear, or if it is
damaged in any way, it is to be replaced. Pay particular
attention to the latch spring (10C), latch (10B) and rivets
(10A). If necessary, the latch spring (10C) and latch (10B)
can be replaced by first removing the two 3/32" countersunk
head rivets (10A). Replace the parts in reverse order of
removal using two NEW 3/32" countersunk head rivets (10A),
Pc.No. 549395.
8.2.2.6 Inspect the remaining parts. Replace any part that
is cracked, cut, broken, excessively worn, damaged in any
way, or that is in such a condition that may result to the
unsatisfactory operation of the “SA-9” Independent Brake
Valve Portion.
8.3 ASSEMBLY (Figure 4)
8.3.1 Insert the cam shaft (9) approximately halfway into
the cam housing (10).
8.3.2 Apply a light coating of Number 1 Calcium Base
Grease, Wabtec Corporation Division Specification M-7650-
1 to the surfaces of the regulating cam (8) and to the sur-
faces of the release valve cam (6).
8.3.3 Position the regulating cam (8) so that the boss on
cam is facing toward the handle end of the cam shaft (9),
then install the regulating cam (8) on to the cam shaft (9).
8.3.4 Position the release valve cam (6) so that the boss
on the cam faces away from the handle end of the cam
shaft (9).
8.3.5 Complete the installation of the cam shaft (9) through
the cam housing (10).
8.3.6 Rotate the regulating cam (8) and release valve cam
(6) so that the set screw hole of each cam is aligned with
the set screw holes of the cam shaft (9). Secure the regu-
lating cam (8) to the cam shaft (9) by installing the 5/16"
cone point set screw (7). Be sure that the set screw goes
into the hole provided in the cam shaft and that it is tight-
ened in place.
Secure the release calve cam (6) to the cam shaft (9) by
installing the 5/16" cone point set screw (5). Be sure that the
set screw goes into the hole provided in the cam shaft and
that it is tightened in place.
8.3.7 Install the handle key (35) in place in the cam shaft (9).
8.3.8 Relieve the tension on the latch spring (10C) by
inserting the blade of a small screwdriver between the regu-
4207-6, S.3.1

operation & maintenance instruction

lating cam (8) and latch spring (10C), then rotate the regu-
lating cam (8) and cam shaft (9) until the handle key (35) is
next to (facing) the body mounting face of the cam housing
(10).

8.3.9 Install the handle (55) onto the cam shaft (9) and
secure it in place by installing the handle nut (36). Tighten Prick punch leading thread on assembly or reassembly,
the nut securely. Position the sprocket stop (62) on the sufficient to prevent assembly from working
cam shaft (9) so that the pin holes of each part are aligned. loose during normal operation.
Secure the sprocket stop (62) to the cam shaft (9) by drift-
ing a 1/4" x 11/4" cylindrical spring pin (63) into the aligned
pin holes.

Set this sub-assembly aside in a clean protected area. Housing Pc. 562309
Inlet Valve Seat Assembly
Spring Pc. 566696 Pc. 562329
8.3.10 Apply a light coating of Number 1 Calcium Base
Grease, Wabtec Corporation Division Specification M-7650-
1 to the surface of the cam dog (29) and the surfaces of the
cam dog lever pin (28).
Figure 4 - Inlet and Exhaust Valve Unit - ASSEMBLY
Part No. 564377
8.3.11 Position the cam dog (29) in the body (33) and
then install cam dog lever pin (28) to hold the cam dog (29) cam dog (29). It MUST BE positioned so that it is over the
in place. end of the inlet and exhaust valve bushing of the body (33).

8.3.11.1 Install two NEW 1/16" x 3/8" cotter pins (27), one in
each end of the cam dog lever pin (28) to secure the lever
pin (28) and cam dog (29) in the body (33).
8.3.12 Coat the surfaces of three NEW 3/4" O.D. o-rings
(11) with Number 2 Silicone Grease, Wabtec Corporation
Division Specification M-7680-2. Also fill the o-ring grooves
of the release valve (12) and lightly lubricate the o-ring bear-
ing surfaces of the release valve bushing of the body (33)
with the lubricant.
3
8.3.13 Install a NEW lubricated /4" O.D. o-ring (11) into
each of the three o-ring grooves on the release valve (12).
Any excess lubricant may be removed by wiping with a
clean, dry lint-free cloth.
8.3.17 Carefully place the cam housing - cam - handle
assembly (5 to 10, 35, 36, 55, 62, 63) on the body (33).
Secure the parts together by installing three NEW 3/8" elas-
tic stop nuts (4).
(Figure 5)
8.3.18 The use of the holding fixture shown in Figure 3 is
required during the following procedure.
Assemble the inlet and exhaust valve unit as follows:
8.3.18.1 Insert the dumbbell end of the inlet valve seat into
the holding fixture so that the cross drill in the holding fixture
aligns with the cross drill in the tapered end of the inlet valve
seat.

8.3.14 Install the release valve spring (13) into the release 8.3.18.2 Insert the 3/16" steel rod through the cross drill of
valve bushing of the body (33). Be sure that the spring (13) the holding fixture and into the cross drill of the inlet valve
is properly seated in the body (33) and that it encircles the seat.
guide pin provided in the body. Install the release valve with
o-ring sub-assembly (11, 12) into the release valve bushing 8.3.18.3 Insert the inlet valve spring into the inlet valve
of the body (33). seat.

8.3.15 Position the brake valve body (33) on the work
bench so that the cam housing mounting face of the body
is facing upward.
8.3.16 IMPORTANT: Visually observe the location of the
8.3.18.4 Assemble the housing onto the inlet valve seat.
WARNING: EXERCISE CARE SO THAT THE SPRING
DOES NOT INADVERTENTLY “FLY OUT” AND CAUSE
BODILY INJURY.

Page 10 of 12 September, 1988


operation & maintenance instruction
8.3.18.5 IMPORTANT: Prick punch the leading thread of
the seat assembly sufficiently to prevent the inlet and ex-
haust valve unit from coming apart during normal opera-
tions.
8.3.18.6 Remove the 3/16" steel rod from the inlet valve seat
and the holding fixture.
8.3.18.7 Remove the inlet and exhaust valve unit from the
holding fixture.
8.3.19 Coat the surfaces of the NEW 3/4" O.D. o-rings
(25) with Number 2 Silicone Grease, Wabtec Corporation
Division Specification M-7680-2. Also fill the o-ring grooves
on the inlet and exhaust valve unit (26) and lightly coat the
o-ring bearing surfaces of the inlet and exhaust valve bush-
ing of the body (33) with the lubricant.
8.3.20 Install a NEW, lubricated 3/4" O.D. o-ring (25) into
each of the two o-ring grooves of the inlet and exhaust valve
unit (26). Any excess lubricant may be removed by wiping
with a clean, dry, lint-free cloth.
8.3.21 Install the inlet and exhaust valve unit (26), housing
end first, into its bushing in the body (33). The wear tip on
the housing end of the inlet and exhaust valve unit (26)
should be facing the cam dog (29).
8.3.22 Assemble the diaphragm and exhaust valve seat as
follows:
8.3.22.1 Place a NEW diaphragm (21) and the diaphragm
follower (20) on the exhaust valve seat (23).
8.3.22.2 Secure the diaphragm follower (20), and NEW
diaphragm (21) in place on the exhaust valve seat (23) by
installing the 9/16" hex nut (19).
8.3.22.3 Coat the surfaces of a NEW 3/4" O.D. o-ring (22)
with Number 2 Silicone Grease, Wabtec Corporation Divi-
sion Specification M-7680-2. Also fill the o-ring groove on
the exhaust valve seat (23) with the lubricant.
8.3.22.4 Install the NEW lubricated 3/4" O.D. o-ring (22)
into its groove on the exhaust valve seat (23). Any excess
lubricant may be removed by wiping with a clean, dry, lint-
free cloth.
8.3.23 If the adjusting handle assembly (14, 14A, 14B)
was removed from the spring housing (18), it MUST BE
September, 1988 Page 11 of 12
4207-6,S.3.1
replaced at this time. Insert the adjusting handle assembly
a minimum number of threads to prevent tension on the
adjusting spring during assembly.
8.3.24 Install the spring seat (17), spring (16) and dia-
phragm-exhaust valve seat assembly with o-ring (19 to 23)
as a unit into the spring housing (18). Be sure that the
bead of the diaphragm (21) is properly positioned in the
housing (18).
8.3.25 Install the inlet and exhaust valve spring (24) on to
the inlet and exhaust valve unit (26) which was previously
installed in the body (33). (See Section 8.3.21).
8.3.26 WARNING: During the following procedures, parts
may be under tension. Exercise care so that no parts are
inadvertently expelled from the assembly. Inadvertently ex-
pelled parts could possibly cause bodily injury and/or dam-
age to equipment.
8.3.27 Position the diaphragm - exhaust valve seat - hous-
ing assembly (18 to 23) on the body (33) and secure it in
place by installing four 5/16" hex nuts (15). Equally tighten
the nuts.
8.3.28 Install a NEW wire mesh strainer (32) into the
chamfered port in the body (33).
8.3.29 Apply a light coating of Number 2 Silicone Grease,
Wabtec Corporation Division Specification M-7680-2 to the
surfaces of two NEW 7/8" O.D. o-rings (30). Also fill the o-
ring grooves on the strainer plug (31) with the lubricant.
8.3.30 Install a NEW, lubricated 7/8" O.D. o-ring into each
of the two o-ring grooves on the strainer plug (31). Remove
any excess lubricant by wiping with a clean, dry, lint-free
cloth.
8.3.31 Install the strainer plug with o-ring assembly (30,
31) into the chamfered port of the body (33) so that the end
of the plug (31) contacts the wire mesh strainer (32) which
was previously installed in the body.
8.3.32 Install a NEW wire mesh strainer (32) into port 30
of the body (33). This second strainer is not illustrated in
the assembly view Figure 4.
This completes the assembly of the “SA-9” Independent
Brake Valve Portion, Pc.No. 564209.
4207-6, S.3.1

operation & maintenance instruction

9.0 TESTING & ADDITIONAL INFORMATION

9.1 IMPORTANT: After the “SA-9” Independent Brake
Valve Portion, Pc.No. 564209, has been assembled, BUT
BEFORE it is returned to service, IT MUST PASS a series
of tests following the procedures of the current issue of the
Wabtec Corporation Division Test Specification T-2555-O.
NOTE: Check the Test Specification for the Piece Number
of the Portion being tested.
9.2 IMPORTANT: When installing an “SA-9” Independent
Brake Valve Portion in an equipment arrangement, a NEW
pipe bracket (mounting) gasket MUST BE USED. See Sec-
tion 7.1.2.
9.3 IMPORTANT: Whenever an “SA-9” Independent
Brake Valve Portion is removed from an equipment ar-
rangement for any reason, and it is reinstalled or re-
placed with a NEW or repaired and tested “SA-9” Inde-
pendent Brake Valve Portion, a stationary vehicle test
MUST BE made to be sure that the “SA-9” Independ-
ent Brake Valve Portion and the “SA-9” Independent
Brake Valve function properly in the total equipment
arrangement.
9.4 Consult your Wabtec Corporation Division Representa-
tive if additional information is required.

WABCO Locomotive Products

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

Page 12 of 12 September, 1988