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February 2000(Supersedes August 1994)

DB-60 Control ValveInstruction Manual MU-21

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PLANT AND GENERAL OFFICES

NEW YORK AIR BRAKE CORPORATION KNORR BRAKE LTD.WATERTOWN, NEW YORK, USA KINGSTON, ONTARIO, CANADA748 Starbuck Avenue 675 Development DriveWatertown, NY 13601 .................... (315) 786-5200 Kingston, Ontario K7M 4W6 .............. (613) 389-4660

Fax ...................... (315) 786-5676 Fax .............. (613) 389-8703

SALES OFFICES

TROPHY CLUB, TEXAS ORLAND PARK, ILLINOIS36 Fair Green Drive 15774 S. LaGrange Rd.Trophy Club, TX 76262 ................. (817) 491-4774 Orland Park, IL 60462 .......................... (708) 460-1973

Fax .................. (817) 491-4723 Fax .......................... (708) 460-2323

GRAND PRAIRIE, TEXAS OMAHA, NEBRASKA2518 Nottingham P.O. Box 45067Grand Prairie, TX 75050 ................ (972) 206-2468 Omaha, NE 68145 ................................. (402) 895-4046

Fax ................ (972) 602-0168 Fax ................................ (402) 895-3369

FORT WORTH, TEXAS ROANOKE, VIRGINIAP.O. Box 16089 P.O. Box 13853Fort Worth, TX 76162 ................... (817) 263-6155 Roanoke, VA 24037 .............................. (540) 989-5044

Fax .................... (817) 361-0300 Fax .............................. (540) 989-9208

DYER, INDIANA GREENVILLE, PENNSYLVANIA2750 Squire Court 10 Country Club LaneDyer, IN 46311 ................................. (219) 322-0965 Greenville, PA 16126 ........................... (724) 588-8492

Fax .................................. (219) 322-0478 Fax .......................... (724) 588-8495

KANSAS CITY, MISSOURI FERNANDINA BEACH, FLORIDA9119 N.W. 86' Court 127 North 14"' StreetKansas City, MO 64153 ................. (816) 505-9062 Fernandina Beach, FL 32034 ............. (904) 261-2195

Fax ................ (816) 505 9029 Fax ............ (904) 261-4458

SERVICE CENTERS

LITTLE ROCK, ARKANSAS RIVERSIDE, MISSOURI315 Industrial Drive Platte Valley Industrial CenterLittle Rock, AR 72202 .................... (501) 374-3724 Building #11

Fax .................... (501) 376-1374 701 N. Parkway DriveRiverside, MO 64150 ........................ (816) 584-1500

Fax ........................ (816) 584-1400

Fig. 1 DB-60 and DB-60L Control Valve (photographic views, front cover) Rev. 2/00

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TABLE OF CONTENTS

CHAPTER .......................................................................PAGE

1.0 Documentation References ..... ...... ..... ..... 4

2.0 General .................................................... 4

2.1 Compliance ....................................................4

2.2 Installation ......................................................8

2.3 Maintenance....................................................8

2.4 Technical Data .............................................10

3.0 Design Features (General).......... ...... ..... . 10

3.1 DB-30 and DB-30L Pipe Bracket ..............12

3.2 DB-10 Service Portion ................................12

3.3 DB-20 Emergency Portion .........................16

4.0 Performance Features............................ 17

4.1 DB-30 and DB-30L Pipe Bracket ..............17

4.2 DB-10 Service Portion ................................17

4.3 DB-20 and DB-20LEmergency Portion.......................................19

5.0 Operation of the DB-60 and DB-60LControl Valves......................................... 20

5.1 DB-60 and DB-60L Control ValvesSubcomponents - Plate 1 ...........................20

5.2 Charging Lap Position - Plate 2 .................20

5.3 Preliminary Quick Service - Plate 3 ...........21

5.4 Service Application - Plate 4.......................22

5.5 Accelerated Application - Plate 5...............23

5.6 Service Lap Position - Plate 6 ...................23

5.7 Release from Service Application- Plate 7 .........................................................24

5.8 Service Accelerated Releaseand Retarded Recharge - Plate 8..............24

5.9 Emergency Application, First Stage- Plate 9 .........................................................25

5.10 Emergency Application, Final Stage

- Plate 10 ......................................................26

5.11 Release from Emergency- Plate 11 ......................................................26

5.12 Manual Release after ServiceApplication - Plate 12...................................27

5.13 Manual Release after EmergencyApplication - Plate 13...................................27

6.0 List of Diagrammatic Views ..... ...... ..... ... 28

Color Guide to Diagrammatic Views ....................28

LIST OF ILLUSTRATIONS ............................................PAGE

Figure 1 ................................................. .............1DB-60 and DB-60L Control Valves

(Photographic View, Front Cover)Figure 2 ................................................. .............5

Piping Diagram of BasicDB-60 Type Single CapacityFreight Brake Equipment

Figure 3 ................................................. .............6Outline Views of the

DB-60 Control Valve

Figure 4 ................................................. .............7

Outline Views of theDB-60L Control Valve

Figure 5 ................................................. .............8

Port Identification Valve Portions

Figure 6 ................................................. .............9Port Identification Pipe Bracket

Figure 7 .................................................. ........... 11

DB-60 Control Valve

Figure 8 ................................................. ........... 11

DB-60L Control Valve

Figure 9 ................................................. ........... 12

DB-30 and DB-30L Pipe Bracket

Figures 10 and 11 ................................... 13 and 14

Service Portion Basic Valve(Assembly View)

Figure 12 ............................. .............................. 15

Release Valve(Assembly View)

Figures 13 and 14 ................................... 16 and 17Emergency Portion(Assembly View)

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Documentation

References

This manual covers the descrip-tion of the design and functionof

the DB-60 and DB-60L ControlValves.

AAR Standard S-4016

Instruction Manual AB TestRack Code of Tests, DB-60

Control Valve Portions

AAR Standard S-4015

Instruction Manual, ShopMaintenance Brake DB -60Control Valve Portions

AAR Standard S-4014

Instruction Manual, RepairTrack Maintenance, Freight Car

Equipment, DB-60 ControlValve

The DB-60 and DB-60L ControlValves (Figure 1) are the main components of the Freight Car Brake

Equipment (Figure 2). The DB-60and DB-60L Control Valves are boapproved by the AAR and meet alcorresponding specifications of theManual of Standards and Recom-mended Practices, in particular:

Specification No. 2518, FreighCar Brake Equipment InstallaSpecifications, Standard S-40

Performance Specification forSingle Capacity Freight BrakeStandard S-461.

Specification for Approval ofFreight Car Air Brake ControlValve in Interchange Service,Standard S-462.

Performance Testing Procedufor Freight Brake Single Car TRack for Individual Valve Por-tions, Standard S-466.

Specification for ConductingEnvironmental Tests on FreighBrake Control Valves, StandaS-467.

Performance Testing Procedufor Freight Brakes on a 150 CTest Rack, Standard S-464.

Specification for Freight BrakeControl Valve Pipe Bracket,Standard S-468.

1.0 2.0General Features

2.1 Compliance

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Figure 2: Piping Diagram of Basic DB-60 Type Single Capacity Freight Brake Equipment

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Figure 3: Outline Views of the DB-60 Control Valve

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Figure 4: Outline Views of the DB-60L Control Valve

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The installation of the DB-60 and DB-60LControl Valves is to be made in accor-dance with installation drawings (Figures3 and 4) as well as in compliance with

AAR Specification No. 2518, StandardS-400.

The DB-60 Control Valve is interchange-able as a complete unit or on a portion-per-portion basis with all control valvespresently approved by the AAR.

The DB-60L is interchangeable on longcars as a complete unit or on a portion-per-portion basis on long car pipebrackets presently approved by the AAR.

Note in particular that installation clear-ance required for the DB-60 and DB-60LControl Valve portions is within those

required for any other currently approvedcontrol valve portions.

For proper port identification,see Figures 5 and 6.

The DB-60 and DB-60L Control Valvesrequire no special maintenance duringcleaning intervals.

Figure 5: Port Identification Valve Portions

2.2 Installation

2.3 Maintenance

Port Designations in Figure 5

1 Brake Pipe Pressure

1 A Brake Pipe Pressure(to Vent Valve)

2 Emergency ReservoirPressure

3 Brake Cylinder Pressure

3A Brake Cylinder Pressure(to Inshot Valve)

4 Quick Action ChamberPressure

5 Auxiliary ReservoirPressure

6 Exhaust(Retainer)

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Figure 6: Port Identification Pipe Bracket

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Operating pressure

The DB-60 Control Valve oper-ates with standard brake pipepressures commonly used in

AAR interchange service.

Weight

DB-30 Pipe Bracket

52.8 lbs. (23.9 kg.)

DB-10 Service Portion(Including Release Valve)

62.4 lbs. (28.3 kg.)

DB-20 Emergency Portion

52.3 lbs. (23.7 kg.)

DB-20L Emergency Portion

52.3 lbs. (23.7 kg.)

The DB-60 and DB-60L Control

Valve design is modern, simpleand durable. The DB-60 ControlValve (Figure 7) consists of thefollowing:

DB-10 Service Portion

DB-20 Emergency Portion

DB-30 Pipe Bracket

The DB-60L Control Valve(Figure 8) consists of the following:

DB-1 0 Service Portion

DB-20L Emergency Portion

DB-30L Pipe Bracket

Portions can easily be applied toand removed from the pipe brack-et since the 5/8" standard hex nutswhich are used for fastening theportions are openly accessible tosocket wrenches used with powertools.

All functions of the control valveportions are performed in a mannerwhich permits interchange on aportion-per-portion basis with allcontrol valves presently approvedby the AAR.

The DB-30L Pipe Bracket has onestud longer than the others to ac-

commodate the DB-20L EmergencyPortion and thus prevent applying aDB-20 Emergency Portion.

The modern design is reflected inthe exclusive utilization of softseatedpoppet valves, textile reinforceddiaphragms, and rubber seatingrings for the control of the flow ofcompressed air. One of the uniquefeatures of the DB-60 and DB-60LControl Valves is the use of K Ringsin larger diameter pistons. This de-sign, which is an exclusive KNORR

development, features low friction,easy installation, and automaticwear composition. Thus, by design,the DB-60 and DB-60L ControlValves are free of any leakage.

New York Air Brake's and KNORR'sbackground of experience with simi-lar equipment assures positivesealing of all corresponding parts.The Test Codes for the DB-60 andDB-60L Control Valves thereforedoes not allow leakage.

The design advantages areapparent:

1. Positive, repeatable test resultsof actual performance.

2. Less "AB" rack testing time, asleakage test section is shortened.

3. Simplified AB rack testingprocedure allowing positivelyclear decision on test result.

4. Energy saving, as no air is

wasted through designdeficiencies.

Since the DB-60 Control Valve doesnot utilize slide or "spool" valve com-ponents with varying friction condi-tions, operation is reliable and con-sistent over long service periods.

The simplicity of the design is re-flected in the easy assembly anddisassembly of the valve portionsand in the easy maintenance ofthe valve.

Only one size hex bolt - 3/8" - isused for all control valve covers,including the release valve. All

bolts are openly accessible to9/16" socket wrenches applied topower tools.

Corresponding parts can be freelymixed between like portions andneed not be paired. Only elastomerparts and some accessory parts,such as filters, must be replacedduring overhaul. No gauging ofparts is required; thus, no speciallytrained personnel are required toperform maintenance of the valveexcept for testing.

Durability in design is character-ized by the use of rigid gray castiron for body and covers of thevalve, featuring mechanical andchemical strength and superiorcorrosion resistance. All springsare made of stainless steel to elim -inate corrosion problems. Stainlesssteel and brass interior parts willnot suffer from corrosion and donot require lubrication during ex-tended service periods. Soft-seated poppet valves feature lowcompression resulting in limitedand controlled permanent set.Note that small "vital" chokes areprotected with filter elements toprovide long, reliable performance.

2.4 Technical Data

3.0Design Features

(General)

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Figure 7: DB-60 Control Valve

Figure 8: DB60L Control Valve

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The pipe bracket contains:

a high capacity pleated paperstrainer to filter brake pipe air fromthe combined dirt collector and cut-out cock before the air flows to thecontrol valve portions;

wire type strainers in the auxiliaryreservoir and emergency reservoirsto protect the control valve portionsagainst dirt and foreign matter fromthe combined reservoir and theassociated piping.

NOTE: Position numbers shown inFigures 10, 11 and 12 are also used

in the nomenclature in Section 5,"Operation of the DB-60 ControlValve."

The service portion consists of theService Portion Basic Valve(Figures 10 and 11)and the attached Release Valve(Figure 12).

3.1DB-30 and DB-30L

Pipe Bracket

(Figure 9)

3.1DB-10 Service

Portion

(Figures 10,

11 and 12

Figure 9: DB-30 and DB-30L Pipe Bracket

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Figure 10: Service Portion Basic Valve (Assembly View)

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Figure 11: Service Portion Basic Valve (Assembly View)

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Figure 12: Release Valve (Assembly View)

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NOTE: Position numbers shown in Figures 13 and 14 are also used in the nomenclature in Section 5, "Operation of the DB-60 Control Valve. "

Figure 13: Emergency Portion (Assembly View)

3.3DB-20 Emergency Portion (Figures 13 and 14)

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Figure 14: Emergency Portion (Assembly View)

The pipe bracket supports and alignsboth service and emergency portionsand supplies air to the valvular com-ponents.. The precontrolled flow of airto and from the brake pipe, brake cyl-inder, combined auxiliary, emergencyreservoir and retaining valve is alsodirected through the pipe bracket towhich all connections are made, withbutt or socket welded flange fittings.

The DB-30L Pipe Bracket has onestud longer than the others to accom-

Modate the DB-20L Emergency PorTion and thus prevent applying aDB-20 Emergency Portion.

The specific functions of the serviceportion are:

1. a) to supply air to the combinedreservoir during initial charginof the system and rechargingfollowing release of an application,

4.0Performance

Features4.1

DB-30 and DB-30L

Pipe Bracket

4.2DB-10 Service

Portion

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b) to direct auxiliary reservoirair into the brake cylinderdepending on a predeter-mined rate and amount ofbrake pipe pressure reduc-tion,

c) to exhaust brake cylinderair during release after an

application,

d) to guarantee stability of thebrake system in releasecondition against undesiredapplication of the brakes whichmay result from permissiblebrake system leakage,

e) to guarantee stability of thebrake system in service lapcondition against undesiredrelease of the. brakes whichmay result from permissible

auxiliary reservoir leakage;

2. to support recharge of thebrake system during the re-lease of a service applicationby feeding emergency reservoirair into the brake pipe indepen-dent from the main pistonsystem;

3. to guarantee minimum reduc-tion during initial brake pipe re-duction and maintain minimumbrake cylinder pressure by

connecting quick service cham-ber and brake cylinder pres-sures;

4. to support initial brake pipe re-duction by venting brake pipeair to the atmosphere duringthe preliminary quick servicestage;

5. a) to support recharge of thebrake system after manualrelease subsequent to anemergency application by

connecting the pressure ofthe auxiliary reservoir to thebrake pipe,

b) to permit exhaust of retainerheld brake cylinder pressurein the retainer pipe and vol-umes during manual releasesubsequent to a service re-duction;

6. a) to directly release brakecylinder pressure indepen-dent of the main piston sys-tem after any application bymanual activation of the re-lease handle,

b) to provide manual drainmeans for auxiliary reser-

voir and emergency reser-voir pressures,

c) to release the main pistonsystem after a service appli -cation by manual activationof release handle.

In order to perform these func-tions, the service portion is equip-ped with the following subcompo-nents (See Plate 1):

1. Service Main

Piston System (1)

The service main Piston comparesbrake pipe and auxiliary reservoirpressures acting on equal areas.

Auxiliary reservoir charging, emer-gency reservoir charging and bal-ancing valves are spaced uniform-ly at 120 intervals around thesame diameter and are mechani-cally operated by the bottom sideof the piston.

The coaxially arranged balancingpiston is pressurized with auxiliaryreservoir air by the balancing valveand acts on the balancing springwhich stabilizes the main pistonsystem in service lap position.

The main piston operates thequick service inlet valve, which al-lows brake pipe air to flow to thequick service chamber (OS-Ch.).The auxiliary reservoir/brake cylin-der inlet and brake cylinder/retain-er outlet valves are also mechan-

ically operated by the main piston.

Stability of the main piston systemin the release position is providedby means of the sensitivity andstability chokes; stability in theservice lap positions is providedby means of the stability choke.

A separate emergency reservoircharging check valve/choke

arrangement prevents uncontrolledreturn flow of emergency reservoirair into the auxiliary reservoir whenreleasing the brakes from a serviceapplication. Thus, no undesiredreapplication of the brakes willoccur during release.

2. Service Accelerated

Release Valve (2)

The service accelerated releasevalve's metal reinforced rubber dia-phragm also compares brake pipeand auxiliary reservoir pressuresacting on equal areas; this compo-nent operates independently of theservice main piston system. Whenthe service accelerated release valvis triggered, emergency reservoir aipasses by the high sensitivity backflow check valve into the brake pipe

3. Quick ServiceLimiting Valve (3)

The quick service limiting valve'smetal reinforced rubber diaphragmis pressurized by brake cylinder airand allows restricted flow of brakepipe/quick service air to the brakecylinder to a predetermined value.The quick service limiting checkvalve prevents return flow of brakecylinder air to atmosphere duringemergency applications and in theevent of a retainer is being set in

"high pressure retaining" positionwith the service main piston systemin the release position.

4. Emergency Release AuxiliaryReservoir Reduction Valve (4

The emergency release auxiliaryreservoir reduction valve's metal re-inforced rubber diaphragm is pres-surized by brake pipe and brake cylinder air in opposite sides. Aftermanual release of brake cylinderpressure subsequent to an emer-

gency application, increasing brakepipe pressure during rechargingoperates the valve and allows aux-iliary reservoir air to flow via theemergency release auxiliary res-ervoir reduction check valve into thebrake pipe and assists during brakepipe recharging.

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The retaining check valve, bymeans of a choke, allows reduc-tion of retainer held brake cylinderair to a pressure level which allowsthe brake cylinder piston to moveto release position.

5. Quick Service Valve (5)

The quick service valve piston ispressurized by auxiliary reservoirair on one side and controls theflow of quick service air to atmos-phere. As soon as the servicemain piston system allows the bal-ancing valve to pressurize thelarger opposite area of the quickservice valve piston with auxiliaryreservoir air, the venting of quickservice/brake pipe air will be inter-rupted.

6. Release Valve (6)

The release valve piston is pres-surized on both sides with brakecylinder air and seals the connec-tion from brake cylinder to atmos -phere.

Upon activation of the releasevalve handle, the upper side of thepiston is vented through the re-lease exhaust valve which allowsthe piston to open the passagefrom brake cylinder to atmosphere.

The piston remains in this positionuntil brake cylinder lockup pres-sure below the piston is releasedby the service main piston systemupon its release. Auxiliary reser-voir exhaust and emergency res-ervoir exhaust valves are mechan-ically operated by the releasevalve lifter and allow high capacityflow of auxiliary reservoir/emergen-cy reservoir air to the atmospherein order to drain the brake system.

This pamphlet applies to both theDB-20 and DB-20L EmergencyPortion operation. While there aresubtle differences between the twoportions, to affect the strength ofthe service brake pipe venting

function, both portions operate in thesame manner with small changes toorifice size and covers.

The specific functions of the emer-gency portion are:

1. to stabilize the brake systemagainst an emergency applicationduring a service application bycontrolling the rate of reductionof the quick action pressure,

2. to support recharge of the brakesystem during release of anemergency application by con-necting auxiliary and brake cylin-der pressures to the brake pipedepending on a predeterminedrate and amount of brake pipepressure increase;

3. to increase the rate of brake pipereduction during service applica-tion by venting a predeterminedamount of brake pipe air to theatmosphere;

4. to time a two-stage brake cylin-der pressure build-up during anemergency application;

5. a) to rapidly vent brake pipe airto the atmosphere during anemergency application byconnecting the brake pipe

directly to the atmosphere,via a separate vent port,which remains open untilquick action pressure blow-down has ceased,

b) to increase brake cylinderpressure during an emer-gency application by connect-ing the emergency reservoirto the brake cylinder untilquick action pressure blow-down has ceased,

c) to protect the brake systemagainst premature releaseafter an emergency applica-tion by means of a quick ac-tion pressure blow-downchoke to time the reset fea-ture of the brake system afteran emergency application.

In order to perform these functions,

the emergency portion is equippedwith the following subcomponents(See Plate 1.):

1. Emergency MainPiston System (7)

The emergency main piston com-pares brake pipe and quick actionpressures acting on equal areas.

The piston is designed to mechan-ically operate the quick actionpressure discharging valve in or-der to stabilize the system againstan emergency application duringa service application.

A lost motion arrangement pro-vides piston travel to independent-ly operate the accelerated applica-tion sensor valve located on the

upper side of the piston.

2. Emergency AcceleratedRelease Valve (8)

The emergency accelerated re-lease valve's metal reinforced rub-ber diaphragm is pressurized bybrake pipe and quick action pres -sures on opposite sides. Indepen-dently of the emergency main pis -ton system, it allows brake cylin-der and auxiliary reservoir air to as-sist the brake pipe pressure build-

up during recharging following anemergency application.

The emergency accelerated re-lease check valve prevents returnflow of brake pipe air into the brakecylinder during (initial) charging ofthe system.

3. Accelerated ApplicationValve (9)

The metal reinforced rubber dia-phragms of the brake pipe dis-charging valve and the pulsatingvalve are pressurized on one sideby quick action air supplied by theaccelerated application sensorvalve.

A choke provides the stability mar-gin of the valve by permanentlybleeding quick action air to atmos -phere.

4.3

DB-20 and DB-20L

Emergency Portion

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Quick action pressure build-up atthe brake pipe discharging valveopens the valve seat at a prede-termined value and allows brakepipe air to flow to the pulsatingvalve and further on to atmosphere.

4. Inshot Valve (10)

The inshot valve piston is pressur-ized by brake cylinder air on bothsides during service applications.

Upon an emergency application,the piston switches to its lefthandstop (restricted brake cylinder flowposition) to time a two-stage pres -sure build-up.

5. High Pressure/VentValve (11)

The vent valve piston on differentareas compares quick actionchamber pressure and quick ac-tion pressure controlled by theemergency main piston system.

Upon emergency applications, theemergency main piston systemcreates a pressure differential be-tween quick action chamber air andcontrolled quick action air to allowthe vent valve to open against itsspring forces.

The mechanically coupled highpressure valve switches to openthe emergency reservoir/brakecylinder connection and increasesthe final brake cylinder pressure.

Quick action pressure blow-downchoke prohibits premature charg-ing of brake pipe by holding thevent valve in the open position fora predetermined time.

The DB-60 and DB-60L ControlValves are shown in unpressur-ized condition; all subcomponentsare designated and numbered forreference throughout the instruc-tion manual.

Compressed air from the brakepipe flows into the pipe bracket viathe combined dirt collector andcut-out cock. One flow path leadsthrough the pipe bracket strainerinto the service and emergencyportions to s upply those with fil-tered air. The other flow path by-

passes the pipe bracket strainerand leads to the vent valve in theemergency portion to allow unre-stricted venting of brake pipe airduring an emergency application.During charging, brake pipe airpressurizes the following valvecomponents:

Service Portion/Service MainPiston System (1)

Brake pipe air pressurizes mainpiston 1.46, the valve seat area

V1.3, and flows to the serviceaccelerated release valve (2) andthe emergency release auxiliaryreservoir reduction valve (4).

The auxiliary reservoir is chargeddirectly by the service main pistonsystem. From the brake pipe, theair flows via choke C 1.6 and theopen valve seat V1.8 to the volume

below main piston 1.46, pressurizinthe upper side of balancing piston1.59. Auxiliary reservoir air furtherflows to the AR/BC inlet valve 1.38.to the service accelerated releasevalve (2), to the release valve (6), tothe valve seat V1.9 in the balancingvalve, to the quick service valve (5)and the auxiliary reservoir via the

pipe bracket. Additional auxiliaryreservoir charging is accomplishedby air flow via stability choke C1.3.

If, during charging, the pressure dif-ferential created by chokes C1.6 anC1.3 across the main piston exceeda predetermined value, main piston1.46 moves into retarded rechargeposition (See Plate 8.) and returnsto charging lap position when brakepipe and auxiliary reservoir pressurapproach equalization.

The emergency reservoir is chargedfrom auxiliary reservoir air via openvalve seat V1.6. The auxiliary reservoir air in the volume below the mapiston 1.46 flows via the open valveseat V1.5 in the emergency reservocharging check valve 1.62 to the sevice accelerated release valve (2), tthe release valve (6), to the emer-gency portion and via the pipe bracet into the emergency reservoir.

Service Portion/ServiceAccelerated Release Valve (2)

The left side of diaphragm 2.83 ispressurized with brake pipe air, theright side with auxiliary reservoir airEmergency reservoir air flows toclosed valve seat V2.2 via backflow check valve 2.89.

Service Portion/EmergencyRelease Auxiliary Reservoir

Reduction Valve (4)

The left side of diaphragm 4.74 ispressurized with brake pipe air. Thediaphragm is thereby forced on itsrighthand stop against the force ofspring 4.90. Simultaneously, theemergency release auxiliary reser-voir reduction check valve is forcedon valve seat V4.1 by the combinedforces of spring 4.91 and brake pipepressure.

5.0 Operation of theDB-60 andDB-60LControl Valves

5.1 DB-60 and DB0-60LControl ValvesSubcomponents

--- Pl ate 1 ---

Charging Lap

Position--- Plate 2---

5.2

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Service Portion/QuickService Valve (5)

Auxiliary reservoir air in the volumebelow main piston 1.46 also pres -surizes the upper area of piston5.104. The piston is thereby forceddownward and opens valve seatV5.1 against the force of spring

5.108.

Service Portion/ReleaseValve (6)

Auxiliary reservoir air pressurizesauxiliary reservoir exhaust valve6.32.1. Emergency reservoir airpressurizes emergency reservoirexhaust valve 6.32.2.

Emergency Portion/EmergencyMain Piston System (7)

Brake pipe air pressurizes mainpiston 7.34 on its upper side andvalve stem 7.24 of the acceleratedapplication sensor valve 7.28 onits lower side. Brake pipe air alsoflows to the emergency accelerat-ed release valve (8) and to the ac-celerated application valve (9).Valve seat V7.3 is closed by springforce acting on the quick actionpressure discharging valve 7.10.

Quick action chamber chargingchoke C7.1 allows flow of air tothe quick action volume belowmain piston 7.34, the quick actionchamber in the pipe bracket, to theemergency accelerated releasevalve (8) and to the high pressure/vent valve (11). The acceleratedapplication sensor valve 7.28seals its corresponding valve seatby quick action pressure and theaid of spring 7.29.

Emergency Portion/EmergencyAccelerated Release Valve (8)

Diaphragm 8.40 is pressurized

with brake pipe air on its left sideand allows air to flow to the seatedemergency accelerated releasecheck valve 8.74. With the pres-sure differential brake pipe/quickaction across diaphragm 8.40becoming smaller, spring 8.39forces the diaphragm on its seat.

Emergency Portion/AcceleratedApplication Valve (9)

Brake pipe air pressurizes the dia-phragm area of valve seat V9.1after charging the volume of thebrake pipe discharging valvethrough choke C9.1; however, dia-phragm 9.40 seals valve seat V9.1

permanently by spring force 9.51.

Emergency Portion/HighPressure/Vent Valve (11)

Brake pipe air pressurizes the ventvalve piston 11.72 on its right sideand assists spring 11.61 in sealingvalve seat V1 1. 1. Quick Action airpressurizes both sides of ventvalve piston 11.72 on differentareas. Springs 11.61, 11.63 and11.84 are balanced to force highpressure valve 11.10 on its valve

seat by means of valve guide 11.57and valve stem 11.56. Thus, emer-gency reservoir air is isolated fromthe brake cylinder air flow path.

In fully charged condition, brakepipe, quick action, auxiliary reser-voir and emergency reservoir pres -sures are equalized on the desiredbrake pipe level. All subcomponentvalves have assumed stablecharging lap positions and havereached equilibrium of forces.

When an application of the brakesis initiated by a brake pipe reduc-tion at a minimum predeterminedrate, the following sequence during"Preliminary Quick Service" isestablished:


and Quick Service Valve (5)

During this brake pipe reduction,chokes C1.6 and C1.3 preventauxiliary reservoir pressure reduc-tion at the same rate as brake pipepressure.

The pressure difference building

up across the main piston 1.46moves the piston upward and openthe quick service inlet valve seatV1.3 at a value primarily defined bythe spring 1.43. Brake pipe air flowsto quick service chamber (QS-Ch.)via the restricted cross section be-tween the upper end of the stem ofmain piston 1.46 and the free flow

area of valve seat V1.3, further onto the atmosphere via open valveseat V5.1 and choke C5.1 of thequick service valve. This increasesthe pressure differential and accel-erates the upward movement of theservice main piston system. After thmain piston 1.46 has lifted the quickservice inlet valve 1.38.2, the quickservice pressure moves the servicemain piston stem 1.41 upward in relation to the spring guide 1.44, sothat the passage from brake cylindeto retainer via valve seat V1.2 isclosed. The valve seat V1.1 is still

closed at this time. The chargingconnections from brake pipe to aux-iliary reservoir via valve seat V1.8,and from auxiliary reservoir to emergency reservoir via valve seat V1.6are closed. Following this, valve seaV1. 10 closes and valve seat V1.9 othe balancing valve opens, pressur-izing the balancing piston 1.59 andthe piston 5.104 of the quick servicevalve with auxiliary reservoir air.The piston 1.59 moves upwardagainst the spring guide 1.67 andintroduces a force into the servicemain piston system.

Service Portion/QuickService Limiting Valve (3)

Air from the quick service chamberflows through choke C3.1, opens thquick service limiting check valve3.12.2 and passes across the openvalve seats 3.1 and V3.2 to the left-hand side of the diaphragm 3.74 anon to the brake cylinder.


The reduction of brake pipe pressurcauses the main piston 7.34 to un-balance. As soon as the quick actiopressure cannot follow the brakepipe pressure reduction at the samerate via choke C7.1, the quick actio

PreliminaryQuick Service

--- Plate 3---

5.3

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pressure moves the main piston7.34 upward, and opens valve seatV7.1 of the accelerated appli-cation sensor valve 7.28 by meansof valve stem 7.24. Quick actionair flows via choke C7.3 to the ac-celerated application valve (9) andthrough further restrictions to at-mosphere. As the maximum rate

of quick action pressure reductionis therefore limited, additionalpressure reduction is necessary inorder to obtain stability at the emer-gency main piston system, valveseat V7.3 of the quick action pres-sure discharging valve 7.10 opensafter piston 7.34 has passed thelost motion travel stem 7.13 andafter spring 7.15 engages its stop.The quick action pressure dis -charging valve 7.10 is opened byspring 7.8 in such a way that thedifference between brake pipe andquick action pressure does not

surpass a predetermined level asquick action air passes to atmos -phere through the open valveseats V7.2 and V7.3 and throughchoke C7.2.

Emergency Portion/AcceleratedApplication Valve (9)

As far as the sequential operationof the accelerated applicationvalve is concerned, refer toPlate 5, "Accelerated Application."

The control valve moves from"Preliminary Quick Service" to"Service" position once the initialquick service activity has ceased.


Upon pressurization with auxiliaryreservoir air, piston 5.104 of thequick service valve has moved up-ward, allowing check valve 5.32to seal valve seat V5.1 under theforce of spring 5.108. Thus, thequick service chamber is isolatedfrom atmosphere but remains con-

nected to brake pipe via valve seatV1.3. The main piston 1.46, thequick service inlet valve 1.38.2 andthe spring guide 1.44 move furtherupward until the quick service inletvalve 1.38.2 applies force to theservice main piston stem 1.41. Thisresults in lifting the auxiliary reser-voir/brake cylinder inlet valve

1.38.1, which is forced by spring1.37 onto the service main pistonstem 1.41, from the valve seat V1.1and opens a flow path from auxil-iary reservoir to brake cylinder.Brake cylinder air flows throughthe quick service limiting valve (3)to the area of the valve seat V4.1of the emergency release auxiliaryreservoir reduction valve (4) andthrough the release valve (6) tothe right side of the emergency re-lease auxiliary reservoir reductionvalve (4) and the retaining checkvalve 4.32; further on to the emer-

gency portion and via the pipebracket to the brake cylinder.

The valve stem 1.50 of the balanc-ing valve follows the main piston1.46 by the force of spring 1.53 toits stop. The balancing piston 1.59moves to its upper stop under theforce of auxiliary reservoir pressure.

Service Portion/Quick ServiceLimiting Valve (3)

Brake cylinder air pressurizes theleft side of diaphragm 3.74 andmoves it against the force of spring3.76 to its right. As soon as thebrake cylinder pressure hasreached a predetermined value,diaphragm 3.74 rests against springguide 3.75.

This results in closing valve seatV3.2 with check valve 3.12.1 bythe force of the spring 3.79, andinterrupts the flow between quickservice chamber and brake cylin-der. Quick service limiting check

valve 3.12.2 closes the valve seatV3.1 by spring force 3.79 and pre-vailing pressure.

Service Portion/EmergencyRelease Auxiliary Reservoir

Reduction Valve (4)

Brake cylinder pressure acts on therighthand side of diaphragm 4.74 inthe emergency release auxiliaryreservoir reduction valve, whichmoves toward the left under

assistance of the force of spring4.90, against the prevailing brakepipe pressure, forcing theemergency release auxiliaryreservoir reduction check valve4.38 further on the valve seat V4.1via spring guide 4.86.


Brake cylinder air entering therelease valve flows via choke C6.3to the bottom side of piston 6.17,

and via choke C6.2 and open valveseat V6.3 to the upper side ofpiston 6.17. The valve seat V6.2 isclosed, the passage for brakecylinder air flow via valve seat V6.1is open.


During a service application, theemergency main piston systemremains in a "stabilizing position,"i.e. venting quick action pressure as

described in Plate 3.

Emergency Portion/EmergencyAccelerated Release Valve (8)

The brake cylinder pressure passesfrom the service portion through thepipe bracket and the open inshotvalve (10) to the emergency accel-erated release check valve 8.74,which remains in its closed positionbecause of spring force and pressuaction on its left side.

Emergency Portion/InshotValve (10)

and High Pressure/VentValve (11)

Brake cylinder pressure from theservice portion passes through thepipe bracket to the high pressure/vent valve. Air flows via valve seatV1 1.2 and choke C1 0.2 to the left-hand side of the inshot valve piston

ServiceApplication

--- Plate 4---

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10.78. Spring 10.79 keeps the pis-ton in its neutral position. Brakecylinder air also flows through theannular section of the open inshotvalve to the righthand side of thepiston 10.78 via choke C1 0.1 andthrough the pipe bracket to thebrake cylinder.


During a brake pipe pressure re-duction which cannot be performedat the same rate by quick actionpressure via choke C7.1, a pres-sure differential builds up at the

main piston 7.34, which opens theaccelerated application sensorvalve 7.28. This establishes a flowpath to reduce the pressure differ-ential by connecting quick actionpressure to atmosphere via valveseat V7.1 and chokes C7.3, C9.2and C9.3.

Further increase of the pressuredifferential across piston 7.34 pro-vides sufficient quick action air toactivate the accelerated applica-tion valve (9) as described in the

following sequences.

For further reduction of quick actionpressure as may be required dur-ing a service application, the mainpiston 7.34 moves further upwardand opens the quick action pres -sure discharging valve 7.10 (asdescribed in Plate 3, "PreliminaryQuick Service").

Stage 1

Quick action air passes through

choke C7.3 to the annular lefthandside of the brake pipe dischargingvalve diaphragm 9.40 and to thevalve seat area V9.2 of the pulsat-ing valve diaphragm 9.42. Simul-taneously, quick action air is vent-ed to atmosphere through chokesC9.2 and C9.3. The valve seatarea V9.1 of the brake pipe dis -

charging valve 9.40 is already pres-surized by brake pipe air throughchoke C9.1 in the initial stage. How-ever, springs 9.51 and 9.49 keep thevalves closed in this stage.

Stage 2

By suitable sizing of chokes C7.3and C9.2, pressure increases on theannular lefthand side of the dia-phragm 9.40 and in the valve seatarea V9.2 of diaphragm 9.42. Thebrake pipe discharging valve dia-phragm 9.40 is opened against theforce of spring 9.51 with assistanceof the brake pipe pressure acting onthe valve seat area V9.1. The sud-den pressurization of the total left-hand diaphragm area with the high-er brake pipe/quick action "mixed"pressure assures that the diaphragm9.40 snaps against the righthand

stop. This allows the flow of air fromthe brake pipe via choke C9.1 andthe volume to the pulsating valvediaphragm 9.42.

Stage 3

The "mixed" air flow cannot be vent-ed fast enough to atmosphere viachokes C9.2 and C9.3 to prevent apressure build-up within the valveseat area V9.2. Subsequently, dia-phragm 9.42 of the pulsating valveis moved against the force of spring

9.49 and snaps safely to the right-hand stop with "mixed" pressure act-ing on the total diaphragm area.Brake pipe and quick action air flowthrough choke C9.3 to atmosphere.Valve seat V9.1 of the brake pipedischarging valve remains open dur-ing this stage.

Stage 4

The sizing of chokes C7.3, C9.1,C9.2 and C9.3 is such that the valveseats V9.1 and V9.2 do not remain

open permanently. Reduction of the"mixed" pressure allows diaphragm9.40 of the brake pipe dischargingvalve to close valve seat V9.1 bymeans of spring 9.51. Subsequently,the brake pipe volume is rechargedthrough choke C9.1.

Stage 4

Further reduction of the pressureacting on diaphragm 9.42 of thepulsating valve enables spring9.49 to close the valve seat V9.2.

In the meantime, pressure in thebrake pipe volume has been fully

reestablished via choke C9.1. Assoon as quick action pressure act-ing on the diaphragm 9.40 hasrisen to the required level, thebrake pipe discharging valveswitches and the cycle describedabove starts anew.

This process is repeated until theaccelerated application sensorvalve 7.28 no longer provides suffi-cient quick action air to operate theaccelerated application valve (9).

Service Portion/ServiceMain Piston System (1)

During a service brake application,the brake cylinder is charged fromthe auxiliary reservoir by the ser-vice main piston system. As soonas the auxiliary reservoir pressure

is reduced to approximately thevalue of the brake pipe pressure,the service main piston systemmoves from the service position tothe service lap position. Herewith,valve seat V1.1 is closed and theflow path between auxiliary reser-voir and brake cylinder is interrupt-ed. The balancing piston 1.59acts on the balancing spring 1.69through the spring guide 1.67. Thisintroduces a defined force in theservice main piston system, whichholds it in the service lap position.

Brake pipe and auxiliary reservoirare connected through the verysmall stability choke C1.3 whichdetermines the release stability.

During a further brake pipe reduc-tion, the service main piston sys -tem will again move the service

Accelerated

Application--- Plate 5---

5.5

Service Lap

Position--- Plate 6---

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position, and the flow path fromauxiliary reservoir to brake cylin-der will be opened. Subsequently,the same procedure as describedabove will take place and movethe service main piston systemback again to service lap positionThe reduction of brake pipe pres -sure and hence the increase in

brake cylinder pressure can becontinued until the auxiliary reser-voir pressure is equal to the brakecylinder pressure. A further reduc-tion of brake pipe pressure doesnot affect the level of the brake cyl-inder pressure during a service ap-plication, but moves the main pis -ton system to the service position.

Service Portion/Quick ServiceLimiting Valve (3)

The quick service limiting valve

assures a predetermined minimumbrake cylinder pressure. Shouldthe brake cylinder pressure dropbelow this value - for example,due to brake cylinder leakage -the quick service limiting valve willopen and feed brake pipe pressurevia the quick service chamber tobrake cylinder. (Refer to Plate 3.)


After reduction of quick action

pressure to brake pipe via chokeC7.1 to atmosphere via the accel-erated application sensor valve7.28 and the quick action pressuredischarging valve 7. 10, the bal-ance of forces is reestablished atthe main piston 7.34, and allvalves are in their neutral position.

To release the brakes, the brakepipe pressure has to be increasedby a predetermined margin abovethe level of the auxiliary reservoirpressure of the individual controlvalve. The complete release se-quence is shown in Plates 7 and8 and their descriptions.


The increase of brake pipe pres -sure produces a pressure differ-ence at the main piston 1.46. Thepneumatic force acts against themechanical force of the balancingspring 1.69. At a predetermined

pressure difference, the main pis -ton 1.46 moves downward andcontacts the valve stem 1.50 ofthe balancing valve. The servicemain piston stem 1.41 remains inthe service lap position under theaction of the quick service pres -sure, while the spring guide 1.44and the quick service inlet valve1.38.2 follow the main piston 1.46by spring force 1.43. The valveseat V1.2 of the BURET outletvalve is still closed during this re-lease stage. Further downwardmovement of the main piston 1.46closes valve seat V1.9 and opensvalve seat V1. 10 through valvestem 1.50. Auxiliary reservoir airunder the balancing piston 1.59and under the piston 5.104 of the,quick service valve (5) starts tovent to atmosphere via choke C1.7.The main piston 1.46 moves furtherinto the release position corres -ponding to the pressure reductionunder the balancing piston 1.59.


The prevailing brake pipe pressurepushes the main piston 7.34 down-ward against its stop. The quick ac-tion chamber is recharged frombrake pipe via QA chamber charg-ing choke C7.1 to the brake pipepressure level.

During release of a service appli-cation, the service accelerated re-lease valve (2) is activated. It con-nects the emergency reservoir tothe brake pipe, such that the re-lease impulse is locally amplified

and passes rapidly through the train


and Quick Service Valve (5)

During further downward travel ofthe service main piston system, the

following functions are performed:

The connection between brake cylinder and retainer is opened since thelost motion between spring guide1.44 and service main piston stem1.41 has been exceeded by the fur-ther travel of the service main pistosystem to the release position. Brakcylinder pressure is vented throughopen valve seat V1.2 and via the release choke C1.8 to atmosphere.Subsequently, the charging connections from brake pipe to auxiliary reervoir and from auxiliary reservoir to

emergency reservoir are opened bythe valve stems 1.95.1 and 1.95.2.Emergency and auxiliary reservoirpressures can only equalize viachoke C1.5, thus preventing an undsired brake reapplication caused bya fast increase in auxiliary reservoirpressure under main piston 1.46.

After balancing piston 1.59 hasmoved downward to its stop, theflow path from brake pipe to quickservice chamber is safely closed bythe quick service inlet valve 1.38.2,which seals on valve seat V1.3.

As soon as the auxiliary reservoir aunder piston 5.104 has been ventedto atmosphere via choke C1.7, thequick service valve piston 5.104opens the flow path for quick servicchamber air to atmosphere, via valvseat V5.1 and choke C5.1.

As long as the pressure differentialbetween brake pipe and auxiliaryreservoir across the main piston 1.4exceeds the forces of the balancingspring 1.69 and the charging andbalancing valve springs, the service

main piston system is locked to itslower stop in the retarded rechargeposition. This allows the valve stem1.95.1 to seat on the sealing ring1.100, and charging of auxiliary reservoir is now performed via chokesC1.6 and C1.4. When the pressuredifference drops, the service main

Release from

Service Application--- Plate 7---

5.7 Service AcceleratedRelease andRetarded Recharge

--- Plate 8---

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piston moves back to the charginglap position (See Plate 2.), andonly choke C1.6 determines thefurther charging time.

Service Portion/ServiceAccelerated Release Valve (2)

When the pressure difference be-tween brake pipe and auxiliaryreservoir across the diaphragm2.83 overcomes the force of thespring 2.87, the emergency reser-voir pressure at valve seat V2.2lifts check valve 2.38, thus estab-lishing a flow path from emergen-cy reservoir to brake pipe via thebackflow check valve 2.89 andvalve seat V2.1. The diaphragm2.83 is moved to its righthand stopagainst the force of spring 2.87.This flow path remains open untilbrake pipe and emergency reser-

voir pressures have nearly equal-ized. Then the backflow checkvalve 2.89 closes the valve seatV2.1. When the pressure differ-ence between brake pipe and aux-iliary reservoir is reduced, the dia-phragm 2.83 moves back to itsneutral position closing the valveseat V2.2 by the force of spring2.87.


As long as the difference betweenbrake pipe and quick action pres -sures across the main piston 7.34exceeds the balance of the springforces acting on the emergencymain piston system, the main pis -ton remains in its lowermost posi-tion; the quick action chamber ischarged through QA-chambercharging choke C7.1. When thepressure difference is reduced, themain piston 7.34 moves back toits neutral position. (See Plate 2.)


The service main piston systemoperates during an emergency ap-plication in general as described inPlates 3 and 4.

However, deviating from above,the main piston 1.46 is forcedagainst its upper stop by auxiliaryreservoir pressure, because brake-pipe pressure is completely vented.The stability choke C1.3 is closedby sealing ring 1.99. Auxiliary res-ervoir and brake pipe are separate-

ed. A constant connection betweenauxiliary reservoir and brake cyl-inder pressures remains open viavalve seat V1.1


A rapid brake pipe pressure reduc-tion disturbs the balance of forcesat the main piston 7.34 such thatit cannot be reestablished by vent-ing of quick action chamber air toatmosphere.

The difference between brake pipeand quick action pressure, causedby chokes C7.1, C7.2 and C7.3,leads to an emergency application.During the resulting upward move-ment of the main piston 7.34, theaccelerated application sensorvalve 7.28 opens first. After pass-ing through the lost motion travelof piston stem 7.13, the valve seatV7.3 at the quick action pressuredischarging valve 7.10 opens, too.However, quick action pressure re-duction rate through choke C7.2 is

insufficient, and the main piston7.34 moves further upward to itsuppermost position. Valve seatV7.2 is closed, thereby separatingquick action pressure in the QA-Ch., the volumes under the mainpiston 7.34 and the lefthand sideof the piston 11.72 from a smallervolume of quick action pressure

between the valve seat V7.2 andthe righthand side of the vent valvepiston 11.72. This volume is rapidlyvented to atmosphere through thechoke C7.2.


The resulting sole pressurization ofpiston 11. 72 with quick action pressure on its lefthand side moves pis -ton 11.72 quickly to its righthandstop against the force of spring 11.6and pressurized valve seat areaV11.1. Valve seat V1 1.1 opens andbrake pipe air flows rapidly to atmosphere through a large cross-sectionport. Simultaneously, the quick actiochamber is vented through chokesC 11. 1, C7. 1, C7.3, C9.2 and C9.3the accelerated application valve (9

Spring 11.84 forces the high pres -sure valve 11. 10 and the piston ste11 . 56 to follow the movement of thvent valve piston 11.72 to the right.This causes valve seat V1 1.3 to opand valve seat V1 1.2 to close. Airfrom the emergency reservoir cannow enter the brake cylinder to pro-duce a higher equalization pressurewith the emergency/auxiliary reser-voirs and the brake cylinder than thobtained during a full service appli-cation.

Emergency Portion/InshotValve (10)

The brake cylinder pressure, pro-duced in the service portion fromauxiliary reservoir air and in theemergency portion from emergencyreservoir air flows through the openpassage on the righthand end of theinshot valve piston 10.78 to the bracylinder. By closing valve seat V11.of the high pressure valve (11), brakcylinder pressure in the spring chamber on the lefthand side of the inshovalve piston 10.78 cannot occur. Th

brake cylinder pressure on the righthand side of the piston, therefore,can move the inshot piston 10.78against the force of spring 10.79 tothe left. The previously open passato the brake cylinder is thus reducedto a gap cross-section at the right-hand end of the piston stem

Emergency

ApplicationFirst Stage--- Plate 9---

5.9

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During final venting of the quick ac-tion chamber, the main piston 7.34moves back to its neutral position.


During final venting of the quickaction chamber, spring 11.61moves piston 11.72 toward theleft, which closes valve seat V11.1and thereby interrupts the passagefrom brake pipe to atmosphere.

High pressure valve 11.10 sealsvalve seat V1 1.3 by means ofspring force 11.63, valve guide11.57 and valve stem 11.56 andinterrupts the air flow from emer-gency reservoir to brake cylinder;both pressures, however, areequal and also equalized with aux-iIiary reservoir pressure throughthe open auxiliary reservoir/brakecylinder inlet valve in the servicemain piston system (1).

Emergency Portion/inshot

Valve (10)

After reset of the vent valve piston11.72 and the high pressure valve11. 10, brake cylinder pressureson both sides of the inshot piston10.78 are equalized via chokeC 10.2, which allows the piston tomove back to its neutral positionunder the force of spring 10.79.

Release Valve not operatedEmergency Portion/EmergencyAccelerated Release Valve (8)

Dependent from a previous release

valve operation, two subcompo-nents in the control valve assist afast recharging of the brake pipeafter an emergency application.

Release Valve not operatedEmergency Portion/EmergencyAccelerated Release Valve (8)

Recharging of the brake pipe sub-sequent to an emergency applica-tion causes quick action pressureto rise via quick action chambercharging choke C7.1. At a prede-termined difference between brakepipe and quick action pressuresacross the emergency main piston7.34, it moves to its lowermostposition. The diaphragm 8.40 inthe emergency accelerated releasevalve moves to its righthand stopwhen the pressure differenceacross diaphragm 8.40 overcomes

spring force 8.39 and opens valveseat V8.1. Brake cylinder and aux-iliary reservoir air flow into thebrake pipe through the open valveseat V8.2 of the emergency acccel-erated release check valve 8.74.Spring 8.76 prevents full equaliza-tion of auxiliary reservoir/brakecylinder and brake pipe pressures.

With decreasing difference of brakepipe and quick action pressure,the emergency accelerated releasevalve closes.

Further increase of brake pipepressure also activates the serviceaccelerated release valve (2) in theservice portion, which connects theemergency reservoir to the brakepipe. The flow of emergency reser-voir air into the brake pipe alsosupports the recharge of the brakesystem subsequent to an emer-gency application. Brake cylinderpressure in the control valve por-tions and the brake cylinder is re-leased to atmosphere once theservice main piston system (1) has

moved to release position. (SeePlate 8.)

Release Valve operatedService Portion/EmergencyRelease Auxiliary Reservoir

Reduction Valve (4)

Subsequent to an emergency appli-cation, brake cylinder pressure isvented by activation of the releasevalve (6) as described under

Plate 13, "Manual Release afterEmergency Application."

During recharge of the brake pipe,the following functional sequence isestablished:

Brake pipe air pressurizes the leftside of diaphragm 4.74 while theright side is connected to atmosphethrough the open valve seat V6.2 inthe release valve. At a predeterminbrake pipe pressure, the force ofspring 4.90 is compensated and dia

phragm 4.74 is forced against itsrighthand stop.

Emergency release auxiliary reser-voir reduction check valve 4.38 islifted from its valve seat V4.1 by auxiliary reservoir pressure. Throughthis connection, auxiliary reservoirand brake pipe pressure equalize;only a small pressure differential -caused by the spring 4.91 - ismaintained.

Further increase of brake pipe pres

sure also activates the service acceerated release valve (2) in the ser-vice portion, which connects theemergency reservoir to the brakepipe. The flow of emergency reser-voir air into the brake pipe also sup-ports the recharge of the brake sys-tem subsequent to an emergencyapplication.

The increase of the brake pipe pressure will cause the service main piston system to move to release posi-tion, thereby venting the lock-up

pressure acting on the lower side ofpiston 6.17 in the release valve (6).Spring 6.20 moves piston 6.17 to itslowermost position, thus reestablishing the connection to the brake cyl-inder via valve seat V6.1 and closinvalve seat V6.2.

Emergency

ApplicationFinal Stage--- Plate 10---

5.10

Release fromEmergency

--- Plate 11---

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Aftera service application, theservice main piston system (1)has stabilized in service lap posi-tion as described in Plate 6.

A short pull at the release valvehandle 6.1 to its fullest extentagainst the force of spring 6.6 willestablish the following functionalsequence:

Release valve lifter 6.9 and theexhaust valve stems 6.27.1, 6.10and 6.27.2 are moved upward.

The auxiliary reservoir exhaustvalve 6.32.1 opens and auxiliaryreservoir air is vented to atmos -phere through valve seat V6.5.This will cause the service mainpiston s ystem (1) to move to re-lease position and will also triggerthe service accelerated releasevalve (2).

The release exhaust valve 6.12 islifted off its seat V6.4 and subse-quently valve seat V6.3 is closed.Brake cylinder air pressurizing theupper side of position 6.17 is vent-ed to atmosphere via open valveseat V6.4 and choke C6.1. Piston6.17 moves upward, as soon asthe pressure difference across thepiston overcomes the force ofspring 6.20. Valve seat V6.2 isopened, valve seat V6.1 is closedand brake cylinder pressure is ra-pidly vented.

The emergency reservoir exhaustvalve 6.32.2 opens and emergen-

cy reservoir air is vented to atmos-phere through valve seat V6.6.

When the release valve handle 6.1is released, venting of auxiliary andemergency reservoir air throughexhaust valves 6.32.1 and 6.32.2is terminated. Release exhaustvalve stem 6.10 returns to its

neutral position and the releaseexhaust valve opens valve seatV6.3 and closes valve seat V6.4.

Herewith, the upper side of piston6.17 is again connected to thebrake cylinder line; as the mainpiston system has already movedto release position, the lower side

of piston 6.17 is connected toatmosphere. This causes piston6.17 to move downward by the aidof spring 6.20, thereby openingvalve seat V6.1 and closing valveseat V6.2.


Afteran emergency application,the service main piston system (1)has stabilized in emergency posi-tion. (See Plate 10.)

A short pull at the release valvehandle 6.1 to its fullest extentagainst the force of spring 6.6 willestablish the same functional se-quence as described underPlate 12, "Manual Release afterService Application," with thefollowing exception:

The release of auxiliary reservoirair through the auxiliary reservoirexhaust valve 6.32.1 cannot causethe service main piston system tomove to release position. There-fore, the lock-up pressure beneathpiston 6.17 keeps it in the upper-most position, thereby venting allbrake cylinder air to atmosphere.The locked position of piston 6.17can only be released by:

a) initiation of a regular"Release from Emergency"(See description ofPlate 11, "Release ValveOperated.');

b) continuous venting of auxiliarreservoir air via the open valvseat V6.5 of the auxiliary reservoir exhaust valve 6.32.1 bpermanently pulling the releavalve handle 6.1. At an auxil-iary reservoir pressure whichallows the service main pistosystem (1) to move to releas

position by the forces of itssprings, air from the lowerside of piston 6.17 flows viachoke C6.3 and the now opebrake cylinder release passato atmosphere, thus allowingspring 6.20 to move the pisto6.17 to its lowermost position

Release of Reservoir Air

In order to drain the auxiliary reser-voir, it is necessary to pull the re-lease valve handle 6.1 far enough t

open the auxiliary reservoir exhaustvalve 6.32.1.

In order to drain the auxiliary andemergency reservoirs, it is neces -sary to pull the release valve handle6.1 through the full travel to open thauxiliary and emergency reservoirexhaust valves 6.32.1 and 6.32.2.

Manual Releaseafter Service


5.12

Manual Releaseafter Emergency


5.13

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Plate 1 .................DB-60 Control Valve Subcomponents (shown unpressurized)

Plate 2 .................Charging Lap Position

Plate 3 .................Preliminary Quick Service

Plate 4 .................Service Application

Plate 5 .................Accelerated Application

Plate 6 .................Service Lap Position

Plate 7 .................Release from Service Application

Plate 8 .................Service Accelerated Release and Retarded Recharge

Plate 9 .................Emergency Application, First Stage

Plate 10 ..............Emergency Application, Final Stage

Plate 11 ..............Release from Emergency

Emergency Accelerated Release Valve(Release Valve operated)

Emergency Release Auxiliary ReservoirReduction Valve (Release Valve operated)

Plate 12 ..............Manual Release after Service Application

Plate 13 ..............Manual Release after Emergency Application

Color Guide

Orange ............... Brake Pipe (BP)

Yellow ............... Auxiliary Reservoir (AR)

Red .............. Emergency Reservoir (ER)

Pink .............. Brake Cylinder (BC)

Blue .............. Quick Action (QA)

6.0 List of Diagrammatic Viewsof the DB-60 and DB-60LControl Valve

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LIST OF COUNTRIES WHERE REPRESENTATIVES ARE LOCATED

Africa Finland Malaysia TaiwanArgentina France Mexico Tanzania

Australia Morocco ThailandAustria Gabon TurkeyGermany Netherlands Tunisia

Bangladesh Great Britain New ZealandBelgium Greenland Nigeria USSRBrazil Norway USABurma Hong Kong

Hungary Pakistan VenezuelaCameroon PolandCanada India Peru YugoslaviaChile Indonesia PortugalChina Iran Zambia

Colombia Israel Romania ZimbabweCzechoslovakia ItalySouth Africa

Denmark Japan South KoreaJordan Spain

Egypt Sri LankaLuxembourg Sweden

SwitzerlandSudanSyria

For information on agents and addresses, please contact:

New York Air Brake Corporation Knorr-Bremse AGInternational Services Moosacher Strasse 80748 Starbuck Avenue D-8000 Munchen 40Watertown, New York 13601 Germany

Telephone: (315) 786-5200 Telephone: 49-89-35470Telefax: (315) 786-5676 Telefax: 49-89-3544469

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