Rail Vehicle Systems NYR-455 Rev 02 02-23-2017 - en Maintenance Specification 9 x 8 UAH Brake Cylinders P/N 709928, 709932
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 / 19
Revision History Rev Date Name Para Description of change 01 1/6/05 All Original Issue 02 2/23/17 J. Shippee All Removed obsolete part numbers 709933 and 709938. Added references to parts catalogs PC- 709928 and PC-709932. Updated Figure 9-1. Reformatted in COPE. The original document was issued in English language. Page 3 / 19
Table of Contents 1 General Information 5 2 Safety Awareness 8 3 Tools Required 9 4 Adhesives, Lubricants, Sealants, and Solvents 9 5 Disassembly 10 6 Cleaning, Inspecting, and Repairing 11 7 Lubricating and Reassembly 13 8 Test Requirements 14 9 Supporting Information 15 List of Figures Figure 9-1 9 x 8 UAH Brake Cylinder without Push Rod. 15 Figure 9-2 Brake Cylinder Non-Pressure Head Disassembly.. 16 Figure 9-3 Brake Cylinder Non-Pressure Head Assembly 17 Figure 9-4 Mounting Cone.. 18 Page 4 / 19
1 General Information 1.1 Introduction This document contains particulars specific to the overhaul of UAH Brake Cylinders P/N 709928 and 709932. This document defines the various procedures and information required to disassemble, clean, inspect, and re-assemble the Brake Cylinders. Part Number Drawing Number Size DESCRIPTION 709928 N-4478 9" x 8" UAH Brake Cylinder w/push Rod 709932 N-6016 9" x 8" UAH Brake Cylinder without Push Rod 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 Title /1/ 709928 Assembly Drawing, 9x8 UAH Brake Cylinder w/push Rod /2/ 709932 Assembly Drawing, 9x8 UAH Brake Cylinder /3/ PC-709928 Parts Catalog, 9x8 UAH Brake Cylinder w/push Rod /4/ PC-709932 Parts Catalog, 9x8 UAH Brake Cylinder Page 5 / 19
1.5 Danger and Warning, Caution, and Note (Notice) 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 / 19
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 / 19
2 Safety Awareness 2.1 General Safety Awareness 2.1.1 Observe all rules and regulations where the equipment is being used. Whenever there is a conflict between the instructions in this manual and the instructions of the user, the rules and regulations of the user will govern. 2.1.2 De-pressurize air system before loosening connections or components. Before removing any component from its mountings, the train must be safely parked. To prevent personal injury, all main reservoir, brake supply reservoir, and brake cylinder air pressure on the affected vehicle must be vented. 2.1.3 "Bottled" up air under pressure (even though air supply is cut off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when any component part is removed from the equipment arrangement. Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on these component parts. 2.1.4 The use of an air jet, which must be less than 30 PSI, 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. 2.1.5 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. 2.1.6 Personal eye protection must be worn when doing any work to protect eyes from possible injury. 2.1.7 Where fasteners removed from the equipment are not satisfactory for reuse, care must be taken to select replacements that match the originals. Mismatched or incorrect fasteners can result in equipment damage or malfunction, or possible personal injury. 2.1.8 To ensure the correct functioning of each component, use only the manufacturers genuine spare parts as replacements. 2.1.9 Follow all DANGERS, WARNINGS, 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. 2.1.10 Person(s) having the appropriate job skill level, as governed by the user, are required when performing maintenance and/or operational tasks with the brake system and system components. Page 8 / 19
3 Tools Required 3.1 Standard Tools Socket, 1/2", 3/4" and Socket Wrench Retaining Ring Pliers Mounting Tube Press 3.2 Special Tools Mounting Cone (see Fig. 9-4) 4 Adhesives, Lubricants, Sealants, and Solvents 4.1 Lubricants AAR Spec. M-914 Grease or brake cylinder lubricant New Journal Box Oil or Triple Valve Oil (AAR Spec. M-912) 4.2 Solvents Mineral Spirits (or equivalent) Page 9 / 19
5 Disassembly (See Figure 9-1) 5.1 If complete brake cylinder (1-18) was removed from rail car, remove four nuts (13) from screws (2). Remove the remaining parts (3-18) from cylinder body (1). 5.2 Remove and discard packing cup (3) from piston and pipe assembly (4). Remove and discard gasket (6) from body (1). 5.3 Remove cotter pin (17) from pin (16), then remove pin (16) from push rod holder (14). 5.4 Place the brake cylinder piston and non-pressure head assembly (4-15) in a suitable holding fixture. With the aid of a press and a mounting tube, hold the release spring partially compressed. WARNING Compression spring (5) is pre-compressed to 180 lbs. (800 newtons). Care must be exercised during further disassembly. 5.5 With the press securely locked, loosen screws (15) and then remove push rod holder (14). Discard screws (15). Slowly release the press to relieve compression on spring (5). 5.6 Remove non-pressure head (10), release spring (5), piston and pipe assembly (4), swab and retainer assembly (7) and spring seat (9). Separate all parts. Discard swab and retainer assembly (7). 5.7 Remove retaining ring (12) and strainer (11). Page 10 / 19
6 Cleaning, Inspecting, and Repairing (See Figure 9-1) 6.1 Wash all parts in a suitable solvent that will dissolve oil or grease and permit all the parts to be thoroughly cleaned without abrasion (i.e. mineral spirits). WARNING Solvents and solvent fumes can be harmful to health. 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. WARNING Cleaning using compressed air can cause particles to become airborne, be sure to: Wear eye protection. Do not exceed 30 PSIG. Failure to observe these safety precautions can lead to injury. 6.2 Blow all parts dry using clean, dry, low-pressure compressed air. 6.3 Clean piston and pipe assembly (4), removing any rust or rough surfaces, using emery cloth, if necessary. 6.4 Clean release spring (5), remove rust spots and apply rust preventative or brake cylinder lubricant (AAR Spec. M-914). 6.5 Replace all parts previously discarded. Page 11 / 19
6.6 Replace all parts that are cracked, broken, worn, damaged, or in such a condition as would result in unsatisfactory operation. 6.7 Ordering Spare Parts To order spare parts, reference parts catalogs PC-709928 and PC-709932. Page 12 / 19
7 Lubricating and Reassembly 7.1 Prior to assembly, saturate the swab and retainer assembly (7) in New Journal Box Oil or Triple Valve Oil (AAR Spec. M-912) for at least ten minutes. 7.2 Insert new strainer (11) into non-pressure head assembly (10) and secure in place with retaining ring (12). 7.3 Apply brake cylinder lubricant (AAR Spec. M-914) to spring (5) 7.4 After completely coating the piston and pipe assembly (4) with a light film of brake cylinder lubricant (AAR Spec. M-914), place the piston end in a holding fixture and slip the mounting cone (see Fig. 9-4) into the piston and pipe assembly (4). 7.5 Install spring (5) over the piston and pipe assembly (4). Place spring seat (9) on top of spring (5). 7.6 Place the swab and retainer assembly (7) onto spring seat (9). Place non-pressure head assembly (10) over the swab and retainer assembly (7). With the aid of a press and a mounting tube partly compress release spring (5) until there is a sufficient amount of the piston and pipe assembly (4) visible to install push rod holder (14). WARNING Spring will be compressed to 180 lbs. (800 Newtons). Care must be exercised during further assembly. 7.6.1 With the press securely locked, place push rod holder (14) onto piston and pipe assembly (4). Install new self-locking set screws (15). Tighten screws (15) to 8 ± 2 ft-lbs (dry torque). 7.6.2 Slowly release the press. Remove the mounting cone and the mounting tube, and then remove the assembly from the holding fixture. 7.7 Install pin (16) in push rod holder (14), and then install new cotter pins (17) in pin (16). 7.8 Apply new packing cup (3) to piston and pipe assembly (4) by starting the cup over one edge of piston and, while holding it in this position, work the cup into place with the hands. If the cup does not seat properly due to trapped air, the air can be removed by raising one side of the cup, using a wooden tool, and pushing the cup into place using the hands. NOTE If the complete cylinder was removed from the car, complete step 7.9. Page 13 / 19
7.9 Place new, greased gasket (6) onto body (1). Insert piston and non-pressure head assembly (3-18) into body (1) and secure to body (1) using screws (2) and nuts (13). Tighten nuts (13) to 35 ± 2 ftlbs (dry torque). NOTE If ONLY the piston assembly with the non-pressure head was removed from the car, suitable covers or containers must be provided so that all parts will be adequately protected against damage and contact with any kind of dirt. 8 Test Requirements If the complete cylinder assembly was overhauled, the complete UAH Brake Cylinder must be tested in accordance with instructions given in Test Document NYT-689-C. If ONLY the piston assembly with the non-pressure head, as received from the Repair Track, was overhauled, the UAH brake cylinder must be tested per S-486 latest issue when re-installed on the car. Page 14 / 19
9 Supporting Information 9.1 Exploded View 1. Cylinder Body 10. Non-Pressure Head 2. Tee Head Bolt 11. Strainer 3. Packing cup 12. Retaining Ring 4. Piston and Pipe Assembly 13. Hex Locknut 5. Compression Spring 14. Push Rod Holder 6. Gasket 15. Self-Locking Set Screw 7. Swab and Retainer Assembly 16. Push Rod Holder Pin 8. Spring Guide 17. Cotter Pin 9. Spring Seat 18. Flange Protector Figure 9-1 9 x 8 UAH Brake Cylinder without Push Rod Page 15 / 19
9.2 Special Tool Drawings Figure 9-2 Brake Cylinder Non-Pressure Head Disassembly Page 16 / 19
Figure 9-3 Brake Cylinder Non-Pressure Head Assembly Page 17 / 19
Figure 9-4 Mounting Cone Page 18 / 19
9.3 Abbreviations and Acronyms Abbreviation or Acronym Definition AAR Association of American Railroads Dia. Diameter Doc. Document En English Fig. Figure Ft-lbs. Foot-Pounds (torque) ID Identification Lbs. Pounds Mm Millimeters N Newtons No. Number NYR Repair Code NYT Test Code Para. Paragraph PC Parts Catalog P/N Part Number PSI Pounds per square inch PSIG Pounds per square inch (gauge) Rev. Revision µm Micrometer µin Microinch Page 19 / 19