ofStandardsandRecommendedPractices,M-1002,AppendixT,1.4.3.lreliefvalves.PersonnelperforminginspectionandtestmustbecertifiedLevelIperAARManuayOnlyAARclassFfacilitiesarecertifiedtorecondition,repair,retestandqualifytankcarsafet

8ARI118ARI11

:Theseinstructionsareapplicabletothefollowingmodels

eSafetyReliefValv8ARI1118&114

NMAINTENANCEBULLETIINSPECTION&

gasket.Takecarenottomarthesealingsurface.Laythevalveonitsside.Usingapackingremovalpickorathinbladescrewdriver,pryoffthe.8

carenottomartheO-ringgrooves.Useapackingremovalpick,removetheO-rings,items#7&8,fromtheretainertaking.7

lipwithascrewdrivereRemovetheO-ringretainerwiththeuseofawheelpullerorgentlypryingunderandaroundth.6

locknut,item#10,loosenandremovethelocknut.Usingtwowrenches,oneappliedtothehexontheretainer,item#6,andtheothertothe.5

Peeloffthebumperwasher,item#9..4

asoft-hItmaybenecessarytoloosentheguidebytappingwitLiftoffthetopguide,item#2..3

Removethefournutssecuringthetopguide,items#17..2

Removethesealwires,items#14.1

risassemblyoftheTopGuideandO-ringRetaine

sDisassemblyProcedure

ssemblyanddisassemblymustbeperformedbytrained,qualifiedpersonnel.

.Safetyreliefvalvesarespring-loadeddevicesthatcanstoreasignificantamountofenergy

withatestdateolderthan6monthsmusthavetheO-ringsreplacedandretested.

eprovideditisstillinitsoriginalpackagingandtestedwithin6monthsoftheinstallationdate.Avalv

Newvalvesaretested,sealedandpackagedatthetimeofmanufacture.Anewvalvecanbeapplied

tNewValvesforReplacementofExistingEquipmen

theO-

O-ringgrooves.Theymustbefreeofpits,corrosionorgougesthatwouldpreventpropersealingof

CleantheO-ringsettingsurfacesinsidetheretainerwith400gritemerycloth.Visuallyinspectthe

rO-RingRetaine

isnotpermitte

tstraightwithin.015TIR.Ifoutoftolerance,thestemmustbereplaced.Straighteningbybendingorhea

ePlacethesteminasetofV-blocksandmeasurestraightnesswithadialindicator.Thestemmustb

.methods.Crackingisunacceptable.Iffound,thestemmustbereplaced

nThestemmustbeinspectedforcrackingusingeithermagneticparticleordyepenetrationinspectio

arenotpermitte

sthatwouldpreventsealingisgroundsforreplacement.Machining,grinding,weldingorotheralteration

yTheseatingsurfaceandO-ringcontactareascanbecleanedwith400gritemerycloth.Anydiscontinuit

.forsignsofcorrosionorpitting.Anyevidenceofcorrosionorpittingisgroundsforreplacement

mRemoveallscale,residueandotherforeignmaterialfromthestemwithawirebrush.Inspecttheste

ValveSte

wearshouldbereportedtoARIEngineeringforreviewanddisposition.

tVisuallyinspecttheinsideoftheguideandthematingareaontheupperstem.Anysignofsignifican

.Theinsideofthetopstemguideshouldbefreeofpaint,debris,nicks,burrsorotherdiscontinuities

eTopStemGuid

sInspectionofValveComponent

.Laythevalvebodyonitssideandwithdrawthestem.9

droppingouRemovethevalvebodyandstemfromthepresstakingcaretopreventthestemfrom.8

Removethespringfollower,item#5.7

Slowlybackoffthepressheaduntilthevalvespring,item#4,expandstotherelaxedstate..6

springtoremoveallforcefromthenut.Removetheadjustmentnut.eUsingapressyoketoallowaccesstothespringadjustmentnut,item#15,compressthevalv.5

fromdroppingoumPlacethevalveintoapresswiththespringintheupwardpositionandameanstopreventtheste.4

Thisdimensionwillbeusedatreassembly.Measureandrecordthedistancefromtheendofthestemtothespringadjustmentnut..3

atthistim,Loosenandremovethelocknut,item#16.DoNOTremovethespringadjustmentnut,item#15.2

Cleanthestemthreadswithawirebrushandlubricatethethreadswithalightoil,likeWD-40..1

misassemblyofthespringandste

O-ringsmustbereplacedanytimetheretainerisremovedfromthestem.

sO-

nozzle.AnysignofexcessivewearshouldbereportedtoARIEngineeringforreviewanddisposition.

eindicationofabowedspring,misassembledspringormisalignmentofthevalvewiththesafetyvalv

nVisuallyinspecttheoutsidediameterofthefollowerforsignsofsignificantwear.Wearcouldbea

forsignsofcorrosionorpitting.Anyevidenceofcorrosionorpittingisgroundsforreplacement.

rRemoveallscale,residueandotherforeignmaterialfromthestemwithwirebrush.Inspectthefollowe

rSpringFollowe

forreplaceme

cleaning,visuallyinspectthecoating.Anyevidenceofpeelingorflakingofthealuminumisgrounds

rAluminizedspringscannotbeinspectedwithmagneticparticleordyepenetrationmethods.Afte

oftolerance,thestemmustbereplaced

tstraightness.Turnthespring90degreesandmeasureagain.Thespringmuststraightwithin¼”.Ifou

rStandthespringuprightonalevelsurface.Placeastraightedgeagainsttheoutsideandmeasurefo

methods.Crackingisunacceptable.Iffoundthespringmustbereplaced.

nThespringmustbeinspectedforcrackingusingeithermagneticparticleordyepenetrationinspectio

forsignsofcorrosionorpitting.Iffound,thespringmustbereplaced.

gRemoveallscale,residueandotherforeignmaterialfromthespringwithawirebrush.Inspectthesprin

gValveSprin

preventsealingisgroundsforreplacemen

dbefreeforresidualgasketmaterial,corrosion,nicks,burrsandgouges.Anydiscontinuitythatwoul

tTurnthevalvebodyovertoinspectthemountingflangeandgasketgroove.Thegasketgroovemus

grinding,weldingorotheralterationsarenotpermitted

,Anydiscontinuitythatwouldpreventthevalvefromsealingisgroundsforreplacement.Machining

.ofnick,burrsandgouges.Theareashouldbecleanedandlightlypolishedwith400gritemerycloth

accomplishedwithalightbrushoffblastusingglassbeadmedia.Theseatingsurfacemustbefree

eTheareaaroundthevalveseatmustbefreeofdebris,corrosionandforeignobjects.Cleaningcanb

yValveBo

Dsection4.5,TestGaugeStandards.Gaugesmustbedatetagged.

xE21A.TeststandpressuregaugemustmeettherequirementsofAARM-1002,SectionC-III,Appendi

eTheteststandmusthaveamountingthatcomplieswithAARM-1002,SectionC-III,AppendixE,Figur

sTestStandandGaugeRequirement

pressure(STD)mustbe75psig+/-3psigandvapor-tightat60psigminimum.

eTheARI1128andARI1148safetyreliefvalvesaredesignedtooperateat75psig.Thestart-to-discharg

sDeterminingApplicablePressureValue

tGuidelinesforTestingandAdjustmen

..11Installnewsealwires,items#14

50±5ft-.10Aftertestingiscomplete,installthestemlocknutand,usingtwowrenches,tightento

Movethevalvetotheteststand..9

Placethetopguideoverthestudsandsecurewiththe4nuts.Torqueto30±5ft-lbs..8

nut.Torqueto50±5ft-lbseInstallthelocknutonthestemwithawrenchappliedtothehexontheretainerandonetoth.7

Installthebumperwasherontheretainer..6

PlacetheretainerwiththeO-ringsonthestem..5

orotherwisedamagetheO-rings.Sharptoolsshouldneverbeusedforthisoperation.InstalltheO-ringsintheO-ringgroovesoftheO-ringretainertakingcarenottotear,stretch.4

Releasethepressandmovethevalvetotheworkbench..3

thenuttothepreviouslyrecordeddimensionfromthenuttotheendofstem.napplytheadjustmentnut.Withthenutfullyengaged,furthercompressthespringandtighteoInstallthespringandspringfollowerthenpositiontheyoke,andcompressthespringenought.Placethevalveinthepressensuringthespringisseatedinthebodyandthestemisaligned.2

Withthevalvebodyonitsside,insertthestemintothebodythroughthetop..1

eAssemblyProcedur

maintenance,repair,inspectionorotheruseofanyproductpurchasedfromit.,beliableforanydirect,incidental,consequentialorotherdamagesofanykindinconnectionwiththeinstallation,operationIRailcarIndustries,Inc.(ARI)shallvoidARI’swarrantyandrelieveARIofallresponsibility.UndernocircumstancesshallARnTheundertakingofrepairorreplacementbythePurchaser,oritsagents,withouttheexpressedwrittenconsentofAmerica

.13MarkthevalveperAARM-1002,SectionC-III,AppendixA,Paragraph7.1.2.

AssemblyProceduresectioethesettingsthentightenthestemlocknutandinstallthesealwirespersteps10&11inthm.12Oncethestart-to-dischargeandvapor-tightpressuresareattained,testasecondtimetoconfir

discontinuitiesthatarenotreadilyvisible.Anydefectmustbecorrected.ptheretainer.Visuallyinspecttheseatingsurface.AfingernailrunacrossthesurfacecanpickunrO-ringRetaine,steps2-6.VisuallyinspecttheO-ringsfornicks,gougesorimpropersettingi

isassemblyoftheTopGuideandRetainerfollowingtheinstructionsundersection,gringsnotsealingproperly.ReleaseallpressurefromunderthevalveandremovetheO-rin-.11Avapor-tightpressurefallingbelowthespecifiedminimumcouldindicateaproblemwiththeO

bubblesstop.Thisisthevapor-tightpressureandmustbeaminimumof60psig.e.10Oncetheproperstart-to-dischargepressureisattained,slowlydecreasethepressureuntilth

.couldbedefectiveandmustbereplacegIfadjustingthespringtensionproducestheoppositeofthedesiredeffect,thesprin:NO.9

Steps4-ttighteningtheadjustmentnuttoincreasethedischargepressureandloosentodecrease.RepeayIfthestart-to-dischargepressurefallsoutsidethespecifiedrange,adjustthevalvespringb.8

gappears.Thisisthestart-to-dischargepressure(STD)andmustbe75psig+/-3psi.eRefillthechamberandbeginslowlyincreasingpressureunderthevalveuntilthefirstbubbl.7

Reducepressureuntilthevalveisclosedandtherearenobubblespresent..6

Increaseairpressureunderthevalveuntilthevalveopensor“pops.”.5

O-ePlugthevalvebodydrainopeningusingputtyorafoamearplug.Fillthecavitytothetopofth.4

Cyclethevalvebyapplyingshopairornitrogentothestand..3

Applythesafetyvalvetotheteststand..2

AppendixT.TheinspectormustbeLevelIqualifiedorhigher.,SafetyReliefValveleaktestsmustbeconductedinaccordancewithAARM-1002,SectionC-III.1

gValveLeakTestin

002/mssale@americanrailwww.americanrailcar.

0X636.940.602

.,TIAMERICANRALCARINDUSRIESINC1larkStreet,St.harles,Missouri631