Rail Vehicle Systems NYR-467 Rev 02 2-25-2015 - en Maintenance Specification P/N 790240
Contact Address New York Air Brake 748 Starbuck Avenue Watertown, NY 13601 USA Phone: +1 315 786 5200 Fax: +1 315 786 5676 www.nyab.com Confidentiality The information in this document and the document itself, in whole or in part, in any form ("Information") is proprietary and/or confidential property of New York Air Brake, a Knorr Brake company, and its affiliates and its successors and assignees, who retain and reserve all right, title and interest in this Information in whole or in part and in all forms. This Information is provided to the original recipient only for confidential use, with the understanding that it will not be used in any manner detrimental to the interests of New York Air Brake, and subject to return on request. Reproduction, transmission, distribution or publication of this Information in any form, in whole or in part, for any purpose without prior written permission of New York Air Brake is strictly prohibited. Copyright New York Air Brake All rights reserved. CONFIDENTIAL Page 2 / 21
Revision History Rev Date Name Para Description of change 01 9-24-2013 J. Shippee All Original Issue 02 2-25-2015 J. Shippee Sec. 3, 6, 8, 10 Sec. 6 & 8 Sec. 6 Added Danger messages. Provided details for proper fixturing. Added Note regarding welded pieces. The original document was issued in English language. Page 3 / 21
Table of Contents 1 General Information 5 2 Product Identification 8 3 Safety Awareness 9 4 Tools 10 5 Adhesives, Lubricants, Sealants and Solvents 10 6 Disassembly 11 7 Cleaning, Inspecting and Repairing 14 8 Lubricating and Reassembly 15 9 Test Requirements 18 10 Material Handling 18 11 Supporting Information 19 Page 4 / 21
1 General Information 1.1 Introduction This document contains particulars specific to the KRD-482-E Slack Adjuster P/N 790240. This document defines the various procedures and information required to disassemble, clean, reassemble and test the Slack Adjuster. 1.2 Technical Changes New York Air Brake reserves the right to change the equipment or this document at any time without giving special notice. 1.3 Target Group This maintenance specification is intended for use by trained technicians who: Have the skill, experience, safety awareness and professional ability to - Disassemble and re-assemble air brake products - Inspect and gauge critical components Have read and understand this document in its entirety Are familiar with the safety codes and accident prevention regulations for these activities 1.4 Referenced Documents Doc. ID Doc. No Issue (Index,..) Title /1/ PC-790240 Parts Catalog /2/ AAR S-423 Slack Adjuster Reclamation Page 5 / 21
1.5 Danger and Warning, Caution, and Notes (Notices) Messages These symbols indicate that important personal safety information follows. Carefully read and understand each safety related text message and apply the message to the operation and maintenance of the system as defined in the safety alert message. The following are definitions associated with the different safety alert message categories. The words DANGER, WARNING, and CAUTION are used to identify levels of hazard seriousness for the safety of the personnel and the equipment. The word DANGER is used to signify an immediate hazard and is used throughout this manual in the following manner: DANGER Indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury. This word is to be limited to the most extreme situations. The word WARNING is used to signify hazards or unsafe practices and is used throughout this manual in the following manner: WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. The word CAUTION just like the word WARNING is used to signify hazards or unsafe practice in addition to equipment damage and is used throughout this manual in the following manner: CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment. The NOTE (NOTICE) messages are used throughout this manual in the following manner: NOTE Notes do not contain any messages relevant to safety. Notes contain useful hints and additional information used to highlight suggestions which will result in enhanced installation, reliability, or operation. Page 6 / 21
Safety messages/notes have a specific structure which is explained here for DANGER (This also applies to WARNINGS and CAUTIONS): 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. Page 7 / 21
2 Product Identification 2.1 Serial Prefix Identification The Slack Adjuster has a nameplate that contains a serial number made up of Alpha and Numeric characters. The prefix characters of the serial number are an alpha/numeric combination located before the numeric characters. They identify the original manufacture revision level (ex: first rev. level starts with A0, second rev. level is B0, etc.). The numeric characters identify the valve production number (this number runs consecutively starting with 00001). The suffix characters (if present), are an alpha/numeric combination and are located after the numeric characters. They identify the revision level of modifications, performed after original manufacture (ex: B0-00789-F0 -or- C0-00045-E1, etc.). This suffix is added by the facility that performs the modifications. 2.2 Name Plate Location Refer to Section 11.1 for Exploded View of Slack Adjuster showing proper location of name plate. Page 8 / 21
3 Safety Awareness 3.1 General Safety Awareness 3.1.1 Observe all Railroad rules and regulations. Whenever there is a conflict between the instructions given in this specification, the Railroads rules and regulations will govern. 3.1.2 The use of an air jet, which must be less than 30 PSIG, to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. These particles and droplets may cause skin and /or eye irritation. Personal eye protection must be worn to protect the eyes from possible injury. When using an air jet do not direct it toward another person. Improper use of air jet could result in bodily injury. 3.1.3 If degreasing fluids are used for cleaning purposes, the current local safety regulations plus the safety precautionary statements of the manufacturer of the cleaning agent must be adhered to. Otherwise, physical harm could result from the inhalation of toxic fumes. Make sure the area is well ventilated when working with materials that produce harmful fumes. 3.1.4 Personal eye protection must be worn when doing any work to protect eyes from possible injury. 3.1.5 Follow all WARNING, CAUTIONS, and NOTES found throughout this specification. If you must use a work procedure or tool which is not recommended, you must first satisfy yourself that neither your safety, nor your fellow workers safety, nor that of the equipment will be jeopardized by the method selected. 3.1.6 Appropriate tool selection is required when performing all maintenance operations to avoid personal injury. DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. 3.1.7 Person(s) having the appropriate job skill level as governed by the Railroad are required when performing maintenance and/or operational tasks with the brake system and system components. Page 9 / 21
4 Tools 4.1 Standard Tools: Flat screwdriver Large pipe wrenches (2) Long-handled punch Long breaker bar Short breaker bar Large snap ring pliers Small snap ring pliers 4.2 Special Tools: Torque Adapter Tool (TD-3002) 5 Adhesives, Lubricants, Sealants and Solvents The followings lubricants and sealants are used when assembling the slack adjuster. Adhesives and solvents are not specified. 5.1 Lubricants Precision Slack Adjuster Grease M949-076 5.2 Sealants Loctite 242 Retaining Compound Page 10 / 21
6 Disassembly DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. Proper Fixturing During Disassembly: Slack Adjuster must be secured by proper fixturing (see Figure 6-1). Safety Guards must be installed on fixturing to prevent injury. All parts must be contained by the fixturing. Fixture must absorb spring tension within Slack Adjuster. All parts must be kept in a straight horizontal line. Hydraulic press must be used to help absorb spring energy. Figure 6-1 Example of Proper Fixturing Page 11 / 21
(Refer to Figure 11-1) NOTE The control rod assembly (4) and the actuating collar (2) are typically welded together during assembly. Grinding of the welds may be necessary to separate the two pieces during disassembly. WARNING If the rear clevis (31) is missing from the Slack Adjuster, DO NOT attempt to disassemble the Slack Adjuster. 6.1 Use short breaker bar to remove front clevis (1) from rod guide (14). Remove actuating collar (2) from rod guide (14). 6.2 Remove actuating tube (6) from rod guide (14). 6.3 Use a flat screwdriver to remove wiper ring (5) from actuating tube (6). Discard wiper ring (5). Remove band clamp (8) and protective boot (7) from overtravel housing (12). Discard clamp (8) and boot (7). DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. 6.4 Use a pipe wrench to hold coupling (22) from turning while using another pipe wrench to remove overtravel housing (12) from coupling (22). 6.5 Use flat screwdriver to remove internal retaining ring (9). Use long-handled punch from opposite end to remove wiper ring (10) from overtravel housing (12). Discard retaining ring (9) and wiper ring (10). 6.6 Use large snap ring pliers to remove large retaining ring (11) from overtravel housing (12). Discard retaining ring (11). 6.7 Remove overtravel assembly (13) and three trigger pins (15) from rod guide (14). 6.8 Use small snap ring pliers to remove small retaining ring (17) from tension rod assembly (24). Discard retaining ring (17). Page 12 / 21
WARNING If the rear clevis (31) slides out during removal of the rod guide (14) in the next step, STOP. Use the breaker bar to turn the rear clevis until it is back in a secure position. 6.9 With the Torque Adapter Tool on the end of the tension rod assembly (24) and a pipe wrench holding the coupling (22), remove rod guide (14) and safety washer (18) from coupling (22). Remove front clutch (16) from coupling (22). 6.10 Remove clutch (20) and two thrust bearings (19) from tension rod (24). Discard thrust bearings (19). 6.11 Remove conical spring (21) from coupling (22). Discard conical spring (21). DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. 6.12 Remove band clamp (8) and protective boot (30) from housing (28). Discard clamp (8) and boot (30). 6.13 Use a Hydraulic Press against the acme threaded end of the tension rod to hold spring in place while using a pipe wrench to remove coupling (22) from housing (28). 6.14 Back Hydraulic Press off enough to allow welded washer to be held with pipe wrench. Keeping Hydraulic Press held against tension rod, use the long breaker bar to loosen rear clevis (31) from tension rod (24). 6.15 Retract Hydraulic Press and ensure no spring force exists at this point. Remove tension rod (24) from housing (28). 6.16 Remove small spring (25), spring guide (26), and large spring (27) from housing (28). 6.17 Use a flat screwdriver to remove wiper (29) from housing (28). Discard wiper (29). 6.18 Remove and discard installation decal (32) from side of spring housing (28). Page 13 / 21
7 Cleaning, Inspecting and Repairing 7.1 Cleaning WARNING DANGER OF PERSONAL INJURY EXISTS. WHEN USING SOLVENTS, BE SURE TO: WEAR EYE, SKIN, AND RESPIRATORY PROTECTION. WORK IN A WELL VENTILATED AREA. AVOID REPEATED OR PROLONGED CONTACT. KEEP SOLVENT CONTAINER CLOSED. KEEP SOLVENT AWAY FROM SPARKS, FLAMES, AND HEAT. FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS CAN LEAD TO INJURY OR INTOXICATION. 7.1.1 After complete disassembly, all parts must be thoroughly cleaned by an approved method that will dissolve oil and grease without damage or abrasion to the parts. WARNING DANGER OF PERSONAL INJURY EXISTS. WHEN USING COMPRESSED AIR, BE SURE TO: WEAR EYE PROTECTION. DO NOT EXCEED 30 PSI. 7.1.2 All parts must be blown dry after cleaning. 7.2 Inspecting Carefully inspect the following parts for damage such as excessive corrosion, wear, distortion, deformation, cracks, etc. Scrap and replace with new any parts not meeting these requirements: Trigger Pin (Item 15) Small Compression Spring (Item 25) Large Compression Spring (Item 27) Page 14 / 21
8 Lubricating and Reassembly 8.1 Lubricating Refer to assembly steps in Section 8.2 for lubricating instructions. 8.2 Assembly of Slack Adjuster Proper Fixturing During Assembly: (Refer to Figure 11-1) DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. Slack Adjuster must be secured by proper fixturing (see Figure 6-1). Safety Guards must be installed on fixturing to prevent injury. All parts must be contained by the fixturing. Fixture must absorb spring tension within Slack Adjuster. All parts must be kept in a straight horizontal line. Coupling (Item 22) must be installed carefully and in a controlled manner. 8.2.1 Insert new wiper (29) by hand into housing assembly while it is in vertical position. Install new protective boot (30) and new band clamp (8) onto end of spring housing assembly (28) with drilled holes. Place boot opening to expose downward drain hole in spring housing (28). Torque clamp to 35 in-lbs. 8.2.2 Place housing (28) in horizontal position on assembly bench and secure with clamps. Insert large spring (27), then spring guide (26), then small spring (25) into spring housing (28). 8.2.3 Insert tension rod (24) into spring housing (28). Insert clutch seat (23) over tension rod (24), then coupling (22) over the tension rod (24). Coupling (22) must be in correct orientation. Page 15 / 21
DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. 8.2.4 Prepare to compress the spring into the spring housing (28). 8.2.5 Once spring is fully compressed into spring housing (28), apply Loctite 242 Retaining Compound to coupling (22) and spring housing threads. Hand tighten the coupling (22) onto the spring housing (28) to secure the spring. Torque coupling (22) and spring housing (28) connection to 150 +/-20 ftlbs. 8.2.6 Apply Loctite 242 Retaining Compound to rear clevis (31) threads and tension rod (24) threads and start to hand thread clevis (31) onto tension rod (24). 8.2.7 Torque rear clevis (31) to tension rod (24) to 150 +/-20 ft-lbs. 8.2.8 Insert new conical spring (21) into coupling (22). Be sure large diameter of spring (21) goes into coupling (22) first. Also, be sure to push spring (21) into coupling (22) until fully seated. NOTE Each thrust bearing (19) has two washers that separate from main bearing and require an application of precision slack adjuster grease. 8.2.9 Grease new thrust washers and new bearings (19). Make sure to assemble bearing washers in correct orientation with grooves of washers contacting the thrust bearings (19). 8.2.10 Place one new thrust bearing (19) onto each end of the clutch (20). 8.2.11 Hand thread the clutch (20) and thrust bearings (19) onto the tension rod (24). NOTE Make sure front bearings are fully seated into the coupling and be careful not to let the bearing assembly fall off the clutch and tension rod. 8.2.12 Grease acme threads on tension rod (24) with Precision Slack Adjuster Grease. Page 16 / 21
8.2.13 Install front clutch (16) into coupling (22). 8.2.14 Apply Loctite 242 Retaining Compound to rod guide (14) and coupling (22) threads. Hand thread rod guide (14) into the coupling (22). Torque to 150 +/-20 ft-lbs. 8.2.15 Install safety washer (18) and new retaining ring (17). 8.2.16 Install 3 trigger pins (15) into rod guide (14). 8.2.17 Install the overtravel assembly (13) over the rod guide (14). Make sure overtravel assembly (13) is seated onto trigger pins (15). 8.2.18 Install new larger retaining ring (11) into overtravel housing (12). Make sure it is seated in groove in overtravel housing (12). 8.2.19 Clamp overtravel housing (12) onto assembly table. Press new wiper ring (10) into overtravel housing (12). Be sure wiper ring (10) is in correct orientation. 8.2.20 Install new internal retaining ring (9) into overtravel housing by hand. Install new protective boot (7) and new band clamp (8) onto end of overtravel housing (12) with drilled holes. Place boot opening to expose downward drain hole in overtravel housing (12). Torque clamp to 35 in-lbs. 8.2.21 Apply Loctite 242 to threads of overtravel housing (12) and coupling (22). Hand thread overtravel housing (12) into coupling (22). Torque to 150 +/-20 ft-lbs. 8.2.22 Install new wiper ring (5) into actuating tube (6) by hand. 8.2.23 Install actuating tube (6) and actuating collar (2) onto rod guide (14) in correct orientation. 8.2.24 Apply Loctite 242 to front clevis (1) threads and rod guide (14) threads. Torque front clevis (1) to rod guide (14) to 150 +/-20 ft-lbs. 8.2.25 Be sure to pin front and rear clevis (1 & 31) and actuating collar (2) before starting test. 8.2.26 Load finished slack adjuster into Automated Test Rack. Refer to Section 9 for Test Requirements. Scan nameplate sticker with correct serial number. 8.2.27 After test has passed, insert control rod assembly (4) into actuating collar (2). Torque hex head cap screw (3) into actuating collar (2) to 25 +/-7 ft-lbs. 8.2.28 Place new installation decal (32) on side of spring housing (28) opposite side of drain hole. Page 17 / 21
9 Test Requirements The reconditioned Slack Adjuster must pass the code of tests per AAR S-423, Slack Adjuster Reclamation. 10 Material Handling 10.1 Storage Store with boot openings pointed downward to optimize function of drain holes. 10.2 Shipping Prior to shipment, secure control rod assembly (4) to front clevis (1) with new cable tie (33). Place Slack Adjusters onto pallet, 3 layers, 11 pieces on layer #1, 10 pieces on layer #2, and 9 pieces on layer #3. Use wooden slat dividers between each layer. Strap each layer to itself and use 4 straps to attach the entire load to the pallet. A total of 7 straps are to be used. 10.3 Special Handling / Hazards DANGER Extreme internal spring forces! All parts of Slack Adjuster must be contained by proper fixturing during disassembly or reassembly to prevent parts from becoming airborne. Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. Page 18 / 21
11 Supporting Information 11.1 Exploded View Figure 11-1 KRD-482-E Slack Adjuster (P/N 790240) Page 19 / 21
KEY for FIGURE 11-1 Item No. Description 1 Front Clevis 2 Actuating Collar 3 Hex Head Cap Screw 4 Control Rod Assembly 5 Wiper Ring 6 Actuating Tube 7 Protective Boot 8 Band Clamp 9 Retaining Ring (Internal) 10 Wiper Ring 11 Retaining Ring (Large) 12 Overtravel Housing (w/drilled holes) 13 Overtravel Assembly 14 Rod Guide 15 Trigger Pins 16 Front Clutch 17 Retaining Ring (Small) 18 Safety Washer 19 Thrust Bearing 20 Clutch 21 Conical Compression Spring 22 Body Coupling 23 Clutch Spring Seat 24 Tension Rod Assembly 25 Compression Spring (Small) 26 Spring Guide 27 Compression Spring (Large) 28 Spring Housing Assembly (w/drilled holes) 29 Wiper 30 Protective Boot 31 Rear Clevis 32 Installation Decal 33 Cable Tie Page 20 / 21
11.2 Abbreviations and Acronyms Abbreviation or Acronym AAR Doc. Ex. ID No. NYR NYS NYT Para. PC P/N PSIG Rev. TD Definition Association of American Railroads Document Example Identification Number Maintenance Specification Service Instructions Test Code Paragraph Parts Catalog Part Number Pounds per square inch gauge Revision Tool Drawing Page 21 / 21