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R a i l V e h i c l e S y s t e m s

NYR-469 Rev 06 8-7-2015 - en

Maintenance Specification TMB-60 Brake Cylinder with Mechanical Handbrake

Maintenance Specification TMB-60 w/Mech. Handbrake Doc.-No.: NYR-469 Revision: 06 8-7-2015 - en

Copyright 2015© New York Air Brake AG. All rights reserved, including industrial property rights applications. New York Air Brake AG retains any power of disposal, such as copying and transferring.

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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 as-signees, 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 detri-mental 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



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Revision History

Rev Date Name Para Description of change

01 10-12-2009 T. Baty Original Issue

02 11-30-2009 T. Baty 1.0, 6.1.11.4, 6.1.14.1, 6.1.14.2, 6.1.14.3, 10.1.6, 10.1.19, 10.1.22, 10.1.29, 10.1.38.2, 10.1.38.3, 10.1.38.5, 10.1.42, 12.0

Corrected typo and item number errors

03 12-14-2009 T. Baty 6.1.2, 10.1.22, 10.1.25, 10.1.28, 10.1.29, 10.1.42

Anti-rotation rods was anti-rotation tubes

04 8-8-2013 J. Shippee Sections 1.2, 1.3, 2, 5, 9 & 10;

Section 4;

Section 8.

Added sections to document;

Added recommended tools to list;

Added Step 8.48.

05 11-1-2013 J. Shippee Section 1.1;

Section 6;

Section 7;

Section 8.

Added Note referencing NYR-426;

Updated disassembly steps;

Moved spare parts reference to Sec.7.4;

Updated assembly steps and added Notice regarding packing cup seal.

06 8-7-2015 J. Shippee 6.24

8.6

Added step to discard bearing (24).

Added ‘new’ to ‘Install bearing (24)’...

The original document was issued in English language.



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Table of Contents

1 General Information 6 1.1 Introduction 6 1.2 Technical Changes 6 1.3 Target Group 6 1.4 Referenced Documents 7 1.5 Danger and Warning, Caution, and Notes (Notices) Messages 7

2 Product Identification 9 2.1 Serial Prefix Identification 9 2.2 Special Markings 9 2.3 Name Plate Location 9 2.4 Product structure 9

3 Safety Awareness 10 3.1 General Safety Awareness 10

4 Tools Required 11 4.1 Standard Tools 11 4.2 Special Tools 11

5 Adhesives, Lubricants, Sealants and Solvents 12 5.1 Adhesives 12 5.2 Lubricants 12

6 Disassembly 13

7 Cleaning, Inspecting and Repairing 17 7.1 Cleaning 17 7.2 Inspecting 17 7.3 Rubber Parts 20 7.4 Spare Parts 20

8 Lubricating and Reassembly 21



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9 Test Requirements 26

10 Material Handling 26

11 Supporting Information 27 11.1 Exploded Views 27 11.2 Assembly Photographs 31 11.3 Abbreviations and Acronyms 43

List of Figures

Figure 11-1 TMB-60 Brake Cylinder Mechanical Handbrake ..................................................................... 27

Figure 11-2 TMB-60 Brake Cylinder Assembly ........................................................................................... 29

Figure 11-3 Holding Fixture ........................................................................................................................ 31

Figure 11-4 Bearing Installation ................................................................................................................. 32

Figure 11-5 Snap Ring Installation ............................................................................................................. 33

Figure 11-6 Snap Ring Installation ............................................................................................................. 34

Figure 11-7 Clutch Lubrication ................................................................................................................... 35

Figure 11-8 Piston Alignment Pin ............................................................................................................... 36

Figure 11-9 Spring Compression ............................................................................................................... 37

Figure 11-10 Bushing Installation/Removal ............................................................................................... 38

Figure 11-11 Body & Non-Pressure Head Fixture ..................................................................................... 39

Figure 11-12 Press on Non-Pressure Head ............................................................................................... 40

Figure 11-13 Aligning Body & Non-Pressure Head .................................................................................... 41

Figure 11-14 Ram Installation .................................................................................................................... 42



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1 General Information

This maintenance specification covers procedures for repairing TMB-60 brake cylinder assemblies with mechanical type handbrake.

1.1 Introduction

Cylinder Size Cylinder Assembly With Mechanical Handbrake

8-1/2" 781419

8-1/2" 784652

9" 781307

10" 781420

NOTE

For maintenance specification covering procedures for repairing TMB-60 brake cylinder assemblies with cable or no handbrake, refer to NYR-426.

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



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1.4 Referenced Documents

Doc. ID Doc. No Issue (Index, ..) Title

/1/ PC-191 Parts Catalog

/2/ NYT-1443-S Code of Tests

/3/ 781419 Assembly Drawing




/7/ NYR-426 Maintenance Specification – TMB-60 w/Cable Handbrake

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 fol-lowing 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.



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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 inju-ries 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.

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 complete-ness.

NOTE

Notes contain useful hints and additional information about the unit.



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2 Product Identification

2.1 Serial Prefix Identification The TMB60 Brake Cylinder Assembly 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 Special Markings The nameplate has the part number of the Brake Cylinder Assembly, as well as the type of TMB-60 it is: MHB = Mechanical Hand Brake

2.3 Name Plate Location Installed on top of non-pressure head assembly (Item 32 in Figure 11-2)

2.4 Product structure

The TMB-60 is a Truck Mounted Brake System that is available in various configurations in order to fit most car types. It consists of a Brake Cylinder that contains an Automatic Slack Adjuster and Cast Beams with Replaceable Brake Heads.



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3 Safety Awareness

3.1 General Safety Awareness

3.1.1 Observe all rules and regulations where the equipment is being used. Whenever there is a con-flict between the instructions in this manual and the instructions of the user, the rules and regula-tions of the user will govern.

3.1.2 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 on the affected vehicle must be vent-ed.

3.1.3 "Bottled" up air under pressure (even though air supply is cut off) may cause gaskets and/or par-ticles of dirt to become airborne and an increase in sound level when any component part is re-moved 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.

3.1.4 The use of an air jet, which must be less than 30 PSI, to blow parts clean or to blow them dry af-ter 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 di-rect it toward another person.

3.1.5 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.

3.1.6 Personal eye protection must be worn when doing any work to protect eyes from possible injury.

3.1.7 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.

3.1.8 To ensure the correct functioning of each component, use only the manufacturers genuine spare parts as replacements.

3.1.9 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 your-self that neither your safety, nor your fellow workers safety, nor that of the equipment will be jeopardized by the method selected.

3.1.10 Person(s) having the appropriate job skill level, as governed by the user, are required when per-forming maintenance and/or operational tasks with the brake system and system components.



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4 Tools Required

4.1 Standard Tools Repair of the TMB-60 Brake Cylinder will be accomplished in a more efficient and safe manner through the use of the following standard tools.

Socket, 1/2"

Socket, 3/4"

Impact Wrench, 1/2"

Socket Extension, 4"

Hammer, 16 oz.

Press

Retaining Ring Pliers

Torque Driver

Screwdriver

Delrin Tube

Box Wrench

Ratchet Wrench

Rubber Hammer

Weed Eater String

Paintbrush

1 ½” Bristle Brush

4.2 Special Tools

Special tools may be either fabricated by the user or purchased through the OEM.

Cotter Pin Tool (TD 2551)

Press Tool (TD 2522)

TD1 Tool (776538)

TD1 Press Plug

TD1A Tool

Ring Guide Tool

Alignment Pin Tool



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Spacer

C-Ring Applicator

Metal Plate

Plug TD Tool

Hole Alignment Tool

TD2 Press

TD1 Fixture (776521)

O-Ring Applicator

5 Adhesives, Lubricants, Sealants and Solvents

The following adhesives and lubricants are used when assembling the TMB-60 Brake Cylinder Assem-blies. Sealants and solvents are not identified within this document.

5.1 Adhesives Loctite 242

Loctite 609

5.2 Lubricants AAR M-914 Grease

Dow-Corning 55 Lubricant



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6 Disassembly

Parts may be inadvertently expelled by force of com-ponent springs. Wear eye protection and exercise care during disassembly. Failure to observe these safety precautions can lead to serious injury.

(Reference Figure 11-1 for the handbrake parts)

6.1 Remove and discard cotter pins (4) from pins (1).

6.2 Remove pins (1), washers (3) and links (2) from lever (5) and the anti-rotation rods.

6.3 Remove and discard cotter pin (7) from pin (6).

6.4 Remove pin (6) and lever (5) from cylinder body.

(Reference Figure 11-2 for the cylinder parts)

6.5 Remove and discard expansion plug (37) from ram (36).

For ease of disassembly and safety, cylinder must be in a verti-cal position with ram (36) facing up.

6.6 Connect ram (36) to the upper fixture on the press with a pin inserted in bushings (10). Press and fully collapse ram (36) and spring (35) by applying steady downward pressure until no movement is observed.

6.7 Remove cylinder assembly from the press. Remove cap screw (20) and spacer (19) from screw (18). Discard cap screw (20).

Parts may be inadvertently expelled by force of spring (35) as ram (36) clears the end of the guide tube. Wear eye protection and exercise care during disas-sembly. Failure to observe these safety precautions can lead to serious injury.



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6.8 Install cylinder in press and connect ram (36) to the upper fixture on the press with a pin inserted in bushings (10). Carefully unscrew ram (36) while slowly releasing pressure on the press, by turning the pin clockwise in the upper fixture (See Figure 11-14). As ram (36) clears the end of the guide tube, it must be guided to prevent spring (35) from buckling and expelling the parts. Remove ram (36) and spring (35).

6.9 Remove and discard wiper rings (33 and 34) from non-pressure head (32).

Parts may be inadvertently expelled by force of spring (28). Wear eye protection and exercise care during disassembly. Failure to observe these safety precau-tions can lead to serious injury.

Pressing on the aluminum tube that fits into non-pressure head (32) will cause damage to the tube. Use a pipe that is free from hitting aluminum tube.

6.10 Press down onto non-pressure head (32) shoulder that the aluminum tube fits into (See Figure 11-13).

6.11 Remove nuts (39), lockwasher (38) and bolt (8) from body (9). Discard lockwasher (38).

6.12 Carefully release load from press.

6.13 Remove non-pressure head (32) from body (9).

6.14 Remove spring (28) and spring tube (27)

6.15 Remove and discard gasket (11) from body (9).

The use of air pressure may be required in the next step. Only 10 PSI maximum is to be used.

The use of air pressure greater than 10 psi may cause parts to be expelled rapidly and become airborne. Failure to follow this safety precaution may result in injury or damage to parts.



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6.16 Remove piston assembly (12 through 27) by pulling straight up on screw (18) while applying 10 psi to the flange fitting port on body (9).

6.17 Place piston assembly (12 through 27) vertically in press fixture with packing cup (12) facing up (See Figure 11-8).

6.18 Remove packing cup (12) and guide ring (13) from piston (16). Discard packing cup (12) and guide ring (13).

6.19 Press down on piston (16) to hold in place. Remove and discard four flat head socket screws (14) that hold the front clutch (21) to piston (16).

6.20 Slowly release pressure on the press until the force of spring (22) is fully reduced. Remove piston (16) and spring (22) from screw (18). Then remove screw assembly (18 & 23 - 26) from the fix-ture.

6.21 Remove and discard two flat head socket screws (15) and remove back clutch (17) from piston (16).

6.22 Place screw (18) into holder and lock in place (See Figure 11-3). Remove retaining ring (25) from bearing cup (23) (See Figure 11-6). Remove retaining ring (26) from screw (18) (See Figure 11-5). Discard retaining rings (25 & 26).

6.23 Remove bearing cup (23) from screw (18).

6.24 Remove bearing (24) from bearing cup (23). Discard bearing (24).

6.25 Remove front clutch (21) from screw (18).

6.26 Remove screw (18) from holder.

6.27 Place non-pressure head (32) in a press fixture (see Figure 11-9). With press tool, compress spring (31) by pressing on ring (30). Remove retaining ring (29). Carefully release the load from the press. Remove ring (30) and slack adjuster spring (31).

6.28 Remove breather assembly (44) from non-pressure head (32). Discard breather assembly (44).



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6.29 Remove piston indicator assembly (46 thru 50) from non-pressure head (32).

6.30 Remove retaining ring (45) and O-ring (46) from indicator (50). Discard retaining ring (45) and O-ring (46).

6.31 Remove indicator (50) and spring (49) from indicator fitting (47). Discard spring (49) and indicator (50).

6.32 Remove O-ring (48) from indicator fitting (47). Discard O-ring (48) and indicator fitting (47).

6.33 Remove screws (40) and sleeves (42) from non-pressure head (32). Discard screws (40).

6.34 Remove wipers (43) and O-rings (41) from sleeves (42). Discard wipers (43) and O-rings (41).

6.35 If bushings (10) do not pass the inspection criteria, they must be replaced.

Pressing on body (9) or ram (36) will cause damage to them. Use proper support to prevent pressing directly on them when removing bushings (10) (See Figure 11-10).



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7 Cleaning, Inspecting and Repairing

7.1 Cleaning

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 serious injury or intoxication.

7.1.1 Wash all parts in a suitable solvent that will dissolve oil and grease and permit all parts to be thor-oughly cleaned without abrasion (i.e. mineral spirits).

Cleaning using compressed air can cause particles to be-come airborne,

be sure to:

Wear eye protection.

Do not exceed 30 psi.

Failure to observe these safety precautions can lead to serious injury.

7.1.2 Blow all parts dry using clean, dry, low pressure compressed air.

7.2 Inspecting

7.2.1 In general, replace all parts that are cracked, broken, worn, damaged, or in such a condition as would result in unsatisfactory operation.

7.2.2 Replace all rubber parts, wiper rings, O-rings, gaskets, expansion plugs and self-locking screws.

7.2.3 Inspect all springs for rust pits, distortion, or permanent set, and replace where necessary. Exam-ine springs to verify conformity to spring details as follows and replace where necessary.



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When inspecting springs, do not compress springs beyond the test deflection height, otherwise damage to springs may occur.

Refer to tables below for spring inspection:

UNLOAD INSPECTION

Approx. Approx. Approx. Approx.

Ref. Outside Wire Free No. of

No. Mat'l. Dia. Dia. Height Coils

22 Steel 3-3/4" (95.3 mm) 15/64" (5.9 mm) 4-7/8" (123.8 mm) 4-7/8

28 Steel 5" (127 mm) 0.306" (7.8 mm) 22-3/8" (568.3 mm) 10-5/8 31 Steel 4-3/32" (104 mm) 5/16" (7.9 mm) 6-13/32" (162.7 mm) 5-1/4

35 Music wire 2-39/64" (66.3 mm) 1/4" (6.4 mm) 51-1/2" (1308.1 mm) 60

49 Music wire 21/32" (16.7 mm) 0.07" (1.8 mm) 6-1/2" (165.1 mm) 28-1/2

LOAD INSPECTION

Ref. Deflect Load

No. To Ibs.

22 1-1/4" (63.5 mm) 119-147 lbs. (444.8 - 533.8 N)

28 5" (209.6 mm) 231-261 lbs. (618.3 - 751.8 N)

31 2" (101.6 mm) 279-341 lbs. (680.5 - 831.8 N)

35 19-1/2" (603.3 mm) 220-248 lbs. (467.0 - 511.5 N)

49 2-1/2" (25.4 mm) 21-31 lbs. (14.8 N)



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7.2.4 Replace any retaining ring or snap ring that is not elastic enough or is stretched too much to clamp on securely or has deformation.

Body Assembly (9)

7.2.5 Inspect body (9). If damaged or worn, body (9) must be replaced.

7.2.6 Body assembly (9) must be thoroughly cleaned by means of a cloth or rag saturated with a suita-ble solvent and blown dry with a jet of compressed air.

7.2.7 Inspect compensator screw (18). If damaged or worn in any way, compensator screw (18) must be replaced.

Ram Assembly (36)

7.2.8 Inspect ram (36). If threads are damaged or worn in any way, ram (36) must be replaced.

Non-Pressure Head (32)

7.2.9 Check tube end of non-pressure head (32). If damaged in any way, the tube must be removed from non-pressure head (32), and a new tube must be pressed back in.

7.2.10 Inspect tube ring (30). If damaged or worn in any way, tube ring (30) must be replaced.

7.2.11 Inspect piston (16). If damaged or worn in any way, piston (16) must be replaced.

7.2.12 Inspect back clutch (17). If damaged or worn in any way, clutch (17) must be replaced.

7.2.13 Inspect front clutch (21). If damaged or worn in any way, clutch (21) must be replaced.



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7.3 Rubber Parts

7.3.1 New rubber parts that have been in storage for more than five years must not be used.

7.3.2 The storage area for rubber parts must be cool, dark, and free from dampness and mildew. Since most rubber goods are affected by ozone, they must not be stored near electrical equipment that may generate ozone.

7.3.3 To determine shelf life, new rubber repair kits must be dated with the oldest date (half-year) of rubber components contained within the repair kit.

7.4 Spare Parts

To order replacement parts, refer to NYAB Parts Catalog PC-191.



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8 Lubricating and Reassembly

(Reference Figure 11-2 for cylinder parts)

8.1 If bushings (10) were removed from body (9) or ram (36), new bushings (10) must be installed.

Pressing on body (9) or ram (36) will cause damage to them. Use proper support to prevent pressing directly on them when installing bushings (10).

8.2 Install new bushings (10) using press (See Figure 11-10).

8.3 Place screw (18) into holder and lock in place (See Figure 11-3). Apply a thin layer of AAR M-914 GREASE to top tooth faces of screw (18).

8.4 Slide front clutch (21) onto screw (18).

8.5 Install bearing cup (23) over screw (18).

8.6 Install new bearing (24) into bearing cup (23) using Delrin tube (See Figure 11-4). Tap Delrin tube lightly to seat bearing (24) into bearing cup (23) and onto screw (18).

8.7 Install new retaining ring (26) into groove on screw (18) (See Figure 11-5).

Ensure that retaining ring (26) is fully seated in its groove on screw (18).

8.8 Lift up on bearing cup (23) using spacer so that retaining ring groove in bearing cup (23) is visible (See Figure 11-6).

8.9 Install new retaining ring (25) into groove on bearing cup (23) (See Figure 11-6).

Ensure that retaining ring (25) is fully seated in its groove in bearing cup (23).



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8.10 Remove screw (18) from holder, turn over and place into groove on pressing fixture (See Figure 11-7).

8.11 Apply a thin layer of AAR M-914 GREASE to the tooth face of screw (18).

8.12 Install back clutch (17) into its key slot on piston (16) using two new screws (15). Tighten screws (15) to 12 ± 2 ft lb. Apply a thin layer of AAR M-914 GREASE to the tooth face of back clutch (17).

8.13 Install slack adjuster spring (22) onto bearing cup (23).

8.14 Place piston (16) onto slack adjuster spring (22) so that spring (22) seats in the groove on the back side of piston (16).

8.15 Install two alignment pins into piston (16) so they engage two of the holes in front clutch (21) See Figure 11-8).

8.16 Install two new screws (14) into piston (16) so they engage the threaded holes in front clutch (21). Remove the two alignment pins from piston (16) and install two new screws (14) in their place into piston (16) so they engage the threaded holes in front clutch (21). Tighten screws (14) to 12 ± 2 ft lb.

8.17 Place new guide ring (13) onto piston (16) and tap lightly to seat against piston (16) shoulder.

8.18 Lay a short length of weed eater string extending from the center of piston (16) over the edge of guide ring (13).

8.19 Install new packing cup (12) onto piston (16) and burp packing cup (12) to release any air that may be trapped by pulling the weed eater string from under packing cup (12). Lubricate the outer sur-face of packing cup (12) and ring (13) with a thick layer of AAR M-914 Grease.

8.20 Apply Loctite 242 to new breather (44). Install new breather (44) into non-pressure head (32).

8.21 Place non-pressure head in press with inside facing up. Install slack adjuster spring (31) and ring (30) into non-pressure head (32) making sure that flat side of ring (30) is against spring (31). Apply load to press with Press Tool on ring (30) so that spring (31) is compressed (See Figure 11-9). In-stall retaining ring (29) to secure ring (30) in non-pressure head (32). Slowly release the press to make sure retaining ring (29) is securely in its groove. Remove from press.



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Wipe the inside of the body (9) with a clean, dry cloth to ensure the inside surface is free of foreign materials. This will help to ensure a proper seal between the packing cup (12) and the body (9) during installation of the piston (16) assembly.

8.22 Place Body (9) in press fixture with bore of body (9) facing up (See Figure 11). Lubricate the bore of body (9) with a thin film of AAR M-914 Grease. Install piston (16) into body (9) with anti-rotation rods on piston (16), aligned so that they are 90° to the 1/2" flange on body (9).

8.23 Fill the entire length of the threads of screw (18) with AAR M-914 GREASE.

8.24 Apply a thin layer of AAR M-914 GREASE to OD of spring tube (27) and install spring tube (27) into the slots on bearing cup (23).

8.25 Apply a thin layer of AAR M-914 GREASE to OD of anti-rotation rods on the back of piston (16).

Install spring (28) onto piston (16).

8.26 Install new gasket (11) onto body (9).

8.27 Apply a thin layer of AAR M-914 GREASE to the non-pressure head (32) where the anti-rotation rods fit.

8.28 Place non-pressure head (32) onto body (9). Press only on shoulder of non-pressure head (32) that the aluminum tube fits into (See Figure 11-12). Slowly press down on non-pressure head (32) while lining up piston anti-rotation rods into non-pressure head (32). Insert metal rod in bolt holes to align them. Install bolts (8), new lockwashers (38) and nuts (39) (See Figure 11-13). Tighten nuts (39) to 32 ± 3 ft lb. Remove assembly from press.

8.29 Install new wiper ring (33) into the end of the guide tube on non-pressure head (32).

8.30 Apply 3 – 5 squirts of AAR SPEC. M-914 grease to the top of the guide tube inside of non-pressure head (32).

8.31 Install new wiper ring (34) into the end of the guide tube on non-pressure head (32).

8.32 Install spring (35) into non-pressure head (32).



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8.33 Place ram (36) onto spring (35). Connect ram (36) to the fixture in the press by inserting a pin into bushings (10).

Ram (36) may be inadvertently expelled by spring (35) forces. Wear eye protection and exercise care during assembly. Failure to observe these safety precautions can lead to serious injury.

8.34 Carefully align ram (36) into the guide tube on non-pressure head (32) while slowly pressing down (See Figure 11-14).

8.35 When press stops moving down, turn the ram in a counter-clockwise direction, using the pin con-necting ram (36) to the press, to engage the threads of screw (18) with ram (36).

8.36 When threads engage, resume pressing down on ram (36) to remove excess slack, screw (18) may turn in press as ram (36) is compressed.

8.37 Remove the assembly from press. Place spacer (19) onto screw (18) and secure spacer (19) in place with a new cap screw (20). Tighten cap screw (20) to 12 ± 2 ft lb.

Hold ram (36) while tightening cap screw (20).

8.38 Install new expansion plug (37) into end of ram (36).

8.39 Seat expansion plug (37) by lightly tapping it with a hammer.

8.40 Assemble piston indicator assembly (45 thru 50).

8.41 Insert new O-ring (48) onto new indicator fitting (47).

8.42 Place new spring (49) onto new indicator (50).

8.43 Install indicator (50) and spring (49) into indicator fitting (47), install new O-Ring (46) into indicator

fitting (47) and secure in place using new retaining ring (45).

8.44 Fill entire length of spring (49) with AAR M-914 Grease.



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8.45 Apply Loctite 242 to the threads of indicator fitting (47). Install indicator body assembly (45 thru 50) into non-pressure head (32).

8.46 Install new wiper (43) and new O-ring (41) into sleeve (42).

8.47 Install sleeve (42) into non-pressure head (32) and secure with new screws (40). Tighten screws (40) to 8 ± 2 ft lb.

8.48 TEST UNIT PER NYT-1443-S.

NOTE:

Reference Figure 11-1 for handbrake parts

8.49 Install pin (6) into lever (5) and body. Then install a new cotter pin (7) into pin (6).

8.50 Install links (2) to lever (5) and anti-rotation rods with pins (1), washers (3) at the lever (5) end, and new cotter pins (4).



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9 Test Requirements

Cleaned and repaired TMB-60 Brake Cylinder Assemblies must pass prescribed tests in accordance with Test Instructions, NYT-1443-S (Individual Test Rack).

10 Material Handling

WARNING

Approved handling equipment must be used when lifting brake cylinder assemblies. Failure to use approved equipment may re-sult in personal injury.



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11 Supporting Information

11.1 Exploded Views

Figure 11-1 TMB-60 Brake Cylinder Mechanical Handbrake



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Key for Figure 11-1

1. Pin

2. Link

3. Washer

4. Cotter Pin

5. Lever

6. Pin

7. Cotter Pin



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Figure 11-2 TMB-60 Brake Cylinder Assembly



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Key for Figure 11-2

8. Bolt 38. Lockwasher

9. Body 39. Nut

10. Bushing 40. Screw

11. Gasket 41. O-ring

12. Packing Cup 42. Sleeve

13. Guide Ring 43. Wiper

14. Flat head socket screw 44. Breather Assembly

15. Flat head socket screw 45. Retaining Ring

16. Piston Assembly 46. O-ring

17. Back clutch 47. Indicator Fitting

18. Compensator Screw Assembly 48. O-ring

19. Spacer 49. Spring

20. Cap screw 50. Indicator

21. Front clutch

22. Spring

23. Bearing Cup

24. Bearing

25. Retaining Ring

26. Retaining Ring

27. Spring tube assembly

28. Spring

29. Retaining Ring

30. Tube Ring

31. Slack adjuster spring

32. Non-pressure head assembly

33. Wiper Ring

34. Wiper Ring

35. Ram spring

36. Ram assembly

37. Expansion plug



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11.2 Assembly Photographs

Figure 11-3 Holding Fixture



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Figure 11-4 Bearing Installation



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Figure 11-5 Snap Ring Installation



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Figure 11-6 Snap Ring Installation



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Figure 11-7 Clutch Lubrication



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Figure 11-8 Piston Alignment Pin



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Figure 11-9 Spring Compression



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Figure 11-10 Bushing Installation/Removal



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Figure 11-11 Body & Non-Pressure Head Fixture



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Figure 11-12 Press on Non-Pressure Head



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Figure 11-13 Aligning Body & Non-Pressure Head



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Figure 11-14 Ram Installation



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11.3 Abbreviations and Acronyms

Abbreviation or Acronym Definition

AAR Association of American Railroads

Doc. Document

Ft lb Foot-Pound

ID Identification

No. Number

NYAB New York Air Brake

NYT Test Code

OD Outside diameter

Oz Ounce

PC Parts catalog

PSI Pounds per square inch

TD Tool Drawing

TMB Truck mounted brake

w/ With

w/o Without