Rail Vehicle Systems ... IP-203. Rev. 03 (10/17/12) -en ... Instruction Pamphlet. TMB-60 Truck Mounted Brake System Brake Head and Shoe Replacement

Transcription

1 Rail Vehicle Systems IP-203 Rev. 03 (10/17/12) -en TMB-60 Truck Mounted Brake System Brake Head and Shoe Replacement

2 Contact address New York Air Brake Corporation 748 Starbuck Avenue Watertown, NY USA Phone: Fax: This document was originally written in English. Knorr-Bremse Group Page 2 / 15

3 Revision History Rev. Date Name Para Description of Change 01 Sept/04 S. Newton ALL Original Release 02 Oct/10 S. Newton ALL pages 8 & 9 03 Oct/12 S. Newton pages 13 & 14 Illustration pg 14 Reformat add brake head kits Cotter pin was removed grease fitting on cylinder Knorr-Bremse Group Page 3 / 15

4 Table of contents TMB-60 Brake Head and Shoe Replacement 1 General information Technical changes Target group for this document Notes and warning messages 6 2 Introduction Car Configuration TMB-60 Truckset Parts Individual Drawings Tools Required for General Service 7 3 Safety Recommendations 8 4 Service Procedures Change Out Procedure Five Year Maintenance 11 5 Return Material Authorization Process 12 6 Individual Drawings 13 Knorr-Bremse Group Page 4 / 15

5 1 General information DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment. 1.1 Technical changes NYAB reserves the right to change the equipment or this document at any time without giving special notice. 1.2 Target group for this document This document is intended for use by NYAB trained technicians and end users who have the skill, experience, safety awareness and professional ability: operate and debug the equipment, have read and understood this document from start to finish, and are familiar with the safety codes and accident prevention regulations for these activities. NOTE This document will be useful to other target groups as well, e.g. project engineers and road crews. However, it does not claim to provide complete information for such target groups. Knorr-Bremse Group Page 5 / 15

6 1.3 Notes and warning messages Warning messages are subdivided into the following hazard levels in this document: DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment. WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment. Safety notes have a specific structure which is explained here for DANGER: DANGER Source of the danger Consequences of the danger Remedial measures Notes do not contain any messages relevant to safety and are included only for the sake of completeness. NOTE Notes contain useful hints and additional information about the unit. Warning messages in other parts of this Description draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications. Knorr-Bremse Group Page 6 / 15

7 2 Introduction 2.1 Car Configuration All TMB-60 installations have removable brake heads. All brake heads can be replaced without de-trucking or beam removal. The simple removal of two pins (1 cotter and 1 clevis) is all that is required. 2.2 TMB-60 Truckset Parts Replacement parts for the system can be obtained by referring to the part numbers on the parts lists for Figures IP and IP Replacement parts for the beams and cylinder assemblies can be obtained by referring to NYAB s TMB-60 Brake Assemblies Parts Catalog. 2.3 Individual Drawings IP Shows a standard truck set of TMB-60 brake equipment. IP Shows a typical brake cylinder w/handbrake and beam truckset parts. IP Shows a typical brake cylinder less handbrake and beam truckset parts 2.4 Tools Required for General Service Large Pry Bar Pliers Knorr-Bremse Group Page 7 / 15

8 3 Safety Recommendations WARNING Use approved handling equipment when lifting the beams. Failure to use approved equipment may result in personal injury. WARNING All applicable railroad safety procedures and equipment must be in place. Failure to observe required procedures or use required equipment may result in personal injury and/or equipment damage. WARNING Brake cylinder air pressure must be turned off and brakes must be in the released position before performing any of the following procedures. Failure to follow this procedure may result in personal injury and/or equipment damage. CAUTION All cotter pins must be properly bent, using pliers, after installation. Failure to properly bend the cotter pins may result in parts coming apart and equipment damage. Knorr-Bremse Group Page 8 / 15

9 4 Service Procedures 4.1 Change Out Procedure The TMB-60 Brake System requires little periodic maintenance. To keep the system performing optimally, the following periodic maintenance requirements must be performed Brake Shoe (14) Change-Out (see Figures IP and IP-203-2) Place a large pry bar between the center of any brake shoe (preferably on the Secondary beam assembly (8)) and the wheel. Using the pry bar force the brake shoe away from the wheel. Repeat this on the opposite side of beam (8) using a block placed between the wheel and the shoe on the side just separated to increase the clearance with the wheels, thus retracting the double acting slack adjuster inside the brake cylinder. Figure IP Brake Shoe Change-Out Knorr-Bremse Group Page 9 / 15

10 Remove the brake shoe keys (13) and brake shoes (14) as needed from the brake heads (4). Install a new 2" brake shoe (14) to the brake head (4) using the brake shoe key (13) (reference Figure IP-203-2). Figure IP Brake Shoe Change-Out WARNING To avoid personal injury from movement of the various parts when operating the system, all personnel must be clear of truck and brake pads before the cylinder is pressurized Apply low pressure air (20-30 psi) 1-3 times to the cylinder (12) in order to restore the internal slack adjuster s position. The piston stroke should be 2 ±1/4". This can be verified by measuring the extension of the piston stroke indicator (15). Knorr-Bremse Group Page 10 / 15

11 4.1.2 Brake Head (4) Change-Out (reference Figure IP-203-3) Figure IP Brake Head Change-Out After obtaining enough clearance between the wheel and brake heads (4), remove cotter pins (3) and brake head pins (2) to remove the desired brake heads (4). Install a new brake head (4) using brake head pin (2) then cotter pin (3). Bend cotter pin (3) legs a minimum of 45. WARNING To avoid personal injury from movement of the various parts when operating the system, all personnel must be clear of truck and brake pads before the cylinder is pressurizes Apply low pressure air (20-30 psi) 1-3 times to the cylinder (12) in order to restore the internal slack adjuster s position. The piston stroke should be 2 1/4". This can be verified by measuring the extension of the piston stroke indicator (15). 4.2 FIVE YEAR MAINTENANCE (or as Required by regulatory agency) All pneumatic components must be overhauled. For spare parts, contact New York Air Brake at TEN-NYAB ( ). Knorr-Bremse Group Page 11 / 15

12 5 Return Material Authorization Process All material returned from the field to New York Air Brake (NYAB)/Knorr, must have a Return Material Authorization (RMA) number. A NYAB/Knorr representative will provide the RMA number. To receive an RMA number and to get additional information regarding the RMA process call: NYAB/KNORR (315) Watertown, New York Knorr-Bremse Group Page 12 / 15

13 6 Individual Drawings Figure IP TMB-60 Truck Mounted Brake System Knorr-Bremse Group Page 13 / 15

14 TMB-60 TRUCK MOUNTED BRAKE SYSTEM TRUCKSET WITH HANDBRAKE 1. BEAM ASSEMBLY, PRIMARY PIN, BRAKE HEAD PIN, COTTER BRAKE HEAD PIN, LEVER 6. LEVER ASSEMBLY 7. PIN, COTTER 8. BEAM ASSEMBLY, SECONDARY PUSH ROD ASSEMBLY 10. PIN, ROD EYE 11. PIN, ROD CLEVIS 12. CYLINDER ASSEMBLY, 8-1/2" W/HANDBRAKE KEY, BRAKE SHOE 14. BRAKE PAD 15. PISTON STROKE INDICATOR CABLE ASSEMBLY 17. PIN, CABLE 18. PIN, COTTER 19. BRACKET 20. EQUALIZER 21. CAP SCREW 22. NUT 23. CHAIN, 1/2" HERC-ALLOY 800 GRADE MULTIPLIER 25. PIN, MULTIPLIER 26. KIT, BRAKE HEAD (Includes items 2, 3, and 4) Figure IP Knorr-Bremse Group Page 14 / 15

15 TMB-60 TRUCK MOUNTED BRAKE SYSTEM TRUCKSET LESS HANDBRAKE 1. BEAM ASSEMBLY, PRIMARY PIN, BRAKE HEAD PIN, COTTER BRAKE HEAD PIN, LEVER 6. LEVER ASSEMBLY 7. PIN, COTTER 8. BEAM ASSEMBLY, SECONDARY PUSH ROD ASSEMBLY 10. PIN, ROD EYE 11. PIN, ROD CLEVIS 12. CYLINDER ASSEMBLY, 8-1/2" WITHOUT HANDBRAKE KEY, BRAKE SHOE 14. BRAKE PAD 15. PISTON STROKE INDICATOR KIT, BRAKE HEAD (Includes items 2, 3, and 4) Figure IP Knorr-Bremse Group Page 15 / 15