TABLE OF CONTENTS. Overview Introduction... 2 List of Illustrations... 2

Transcription

1 Pe f e c t i n gr i l c Pe f o m n c e I NSTALLATI ON AND I NSPECTI ON GUI DE Si d ebe i n g s D f t Ge s B k ebe ms VERSI ON 6 3/ 2012

2 TABLE OF CONTENTS Oveview Intoduction... 2 List of Illusttions... 2 TecsPk Constnt Contct Side Beings Genel Desciption... 4 Poduct Identifiction... 5 Shelf Life...9 Instlltion Set Up Height C Body We Plte Side Being Instlltion Bolt-on Style Stndd Tvel Retofit Instlltion Long Tvel Retofit Selection Guide Long Tvel Retofit Instlltion TecsPk Pds Inspection Set Up Height Field o Yd Inspection Shop o Repi Tck Inspection Genel Top Cp We Indictos TecsPk Pd Fee Height Mesuement Dft Ges Genel Desciption Pocedue fo Detemining Sevicebility of Mine Dft Ges Bke Bems Genel Desciption Inspection Stut Hnd Chnge Pocedue... 33

3 OVERVIEW INTRODUCTION This convenient Instlltion nd Inspection Guide povides impotnt technicl infomtion egding Mine s full-line of TecsPk constnt contct side beings, dft ges nd bke bems. In it you will find sections coveing poduct identifiction, instlltion, nd inspection. LIST OF ILLUSTRATIONS TecsPk Constnt Contct (TCC) Side Beings Fig. 1 TCC Style... 5 Fig. 2 TCC-II... 5 Fig. 3 TCC-III ST... 5 Fig. 4 TCC-III RA... 5 Fig. 5 TCC-III LT... 6 Fig. 6 TCC-IV LT... 6 Fig. 7 TCC-8000 RL... 6 Fig. 8 TCC-8000 RS...6 Fig. 9 TCC-4500 RA... 7 Fig. 10 TCC-45 LTR... 7 Fig. 11 TCC-60 LTR... 7 Fig. 12 TCC-45 LTRB... 7 Fig. 13 TCC-45 LTLP... 8 Fig. 14 TCC-45 LTLP-B... 8 Fig. 15 Clipe Mesuement Fig. 16 Block Style Retofit Set Up Height (LTLP, LTLP-B, LTRB) Fig. 17 Block Style Retofit Set Up Height Gge Fig. 18 TCC-45/60 LTR Solid Stop Instlltion Fig. 19 TCC-45 LTLP Pocket Instlltion Fig. 20 TCC-45 LTLP-B Fig. 21 TCC-45 LTRB Housing Secuement Fig. 22 Welding Pocedue Coss Section Fig. 23 Pocket Size Adjustment

4 TecsPk Constnt Contct (TCC) Side Beings (con t.) Fig. 24 Stndd Set Up Height Indictos Inspection Fig. 25 Block Style Retofit Set Up Height Indictos Inspection Fig. 26 TCC-IV We Indicto Fig. 27 TCC-45/60 LTR & LTRB We Indicto Fig. 28 TCC-45 LTLP-B We Indicto Fig. 29 TCC-45 LTLP We Indicto Fig. 30 TecsPk Pd Fee Height Mesuement Dft Ges Fig. 31 Cown SE nd Cown SG In-C Inspection Fig. 32 Cown SE nd Cown SG Out-of-C Inspection Fig. 33 TF-880 In-C Inspection Fig. 34 TF-880 Out-of-C Inspection Fig. 35 SL-76 In-C Inspection Fig. 36 SL-76 Out-of-C Inspection Bke Bems Fig. 37 Mine Seies 2008 Bke Bem - # Fig. 38 Mine Seies 2008 Bke Bem - # Fig. 39 Mine Seies 2008 Bke Bem Stut Chnge

5 Pe f e c t i n gr i l c Pe f o m n c e I NSTALLATI ON AND I NSPECTI ON GUI DE Si d ebe i n g s D f t Ge s B k ebe ms VERSI ON 6

6 TECS PAK CONSTANT CONTACT (TCC) SIDE BEARINGS GENERAL DESCRIPTION Mine s TecsPk constnt contct side beings fetue unique metl-on-metl design enbling them to povide moe stble ide by instntneously countecting the ottionl motion of tuck hunting. Thei supeio design beks fiction nd dissiptes enegy befoe tuck hunting impcts c stbility nd component we. When instlling nd/o inspecting ny of Mine s side beings, it is citicl to identify the pope being nd its components. Mine side beings include: TCC, TCC-II, TCC-III, TCC-IV nd Retofit models. Plese efe to the Poduct Identifiction section (Pge 5) befoe ny instlltion nd/o inspection pocedues. Mine s TecsPk constnt contct side beings e vilble in nge of pelods nd designs. The model nme will designte the side being pelod in pounds (e.g. TCC-8000) o hundeds of pounds (e.g. TCC-IV-60 LT). Some models e lso vilble in: Stndd Tvel Rolle Assist Long Tvel 5/16 tvel fom 5-1/16 set up height 5/16 tvel fom 5-1/16 set up height 5/8 tvel fom 5-1/16 set up height The fist genetion of Mine TCC side beings, TCC-2600, nd -8000, e Stndd Tvel (ST). The TCC-4500 RA is Rolle Assist model. The second genetion of beings, TCC-II-25, -35, -60 nd -80S, e ll Long Tvel (LT). The thid genetion of beings, TCC-III-30, -45, -60 nd -80, e vilble s eithe Stndd Tvel (ST), Long Tvel (LT) o Rolle Assist (RA) models. The fouth genetion of beings, TCC-IV-30, -45, -60 nd -80, e ll Long Tvel (LT). The TCC-8000 RS etofit beings e designed to fit into single olle cge nd e Stndd Tvel (ST). The TCC-45 LTR nd TCC-60 LTR e designed to fit into double olle cge nd e Long Tvel (LT). The TCC-45 LTLP is designed to fit into low pofile smll pocket nd the TCC-45 LTLP-B is designed to fit into lge pocket low pofile block style side being pocket nd e both Long Tvel (LT). The TCC-45 LTRB is designed to fit into stndd height block style side being pocket nd is Long Tvel (LT). 4

7 PRODUCT IDENTIFICATION Fig. 1 TCC Style Stndd Tvel Fig. 2 TCC-II* Long Tvel TOP CAP ASSY. HOUSING *No longe in poduction. MODEL TOP CAP ASSY. HOUSING TCC-2600* TCC TCC * No longe in poduction. Replce with TCC-III-30 ST on both sides of xle. MODEL REPLACE WITH: TCC-II-25 TCC-III-30 LT on both sides of xle TCC-II-35 TCC-III-45 LT on both sides of xle TCC-II-60 TCC-III-60 LT on both sides of xle TCC-II-80S TCC-III-80 LT on both sides of xle Fig. 3 TCC-III ST Stndd Tvel Fig. 4 TCC-III RA Rolle Assist Stndd Tvel PAD TOP CAP (40136) ROLLER (29792) TOP CAP (40136) HOUSING PAD BASE PLATE (29794) HOUSING MODEL HOUSING PAD TCC-III-30 ST T-0305 TCC-III-45 ST T-0300 TCC-III-60 ST T-0306 TCC-III-80 ST T-0307 MODEL HOUSING PAD TCC-III-30 RA T-0305 TCC-III-45 RA T-0300 TCC-III-60 RA T-0306 TCC-III-80 RA T

8 Fig. 5 TCC-III LT Long Tvel Fig. 6 TCC-IV LT Long Tvel PAD PAD TOP CAP (40136) HOUSING TOP CAP (40482) HOUSING MODEL HOUSING PAD TCC-III-30 LT T-0305 TCC-III-45 LT T-0300 TCC-III-60 LT T-0306 TCC-III-80 LT T-0307 MODEL HOUSING PAD TCC-IV-30 LT T-0432 (Geen Insulto) TCC-IV-45 LT T-0430 (Red Insulto) TCC-IV-60 LT T-0431 (Blue Insulto) TCC-IV-80 LT T-0434 (Gey Insulto) Fig. 7 TCC-8000 RL* Stndd Tvel TOP CAP ASSY. (29125) Fig. 8 TCC-8000 RS* Stndd Tvel TOP CAP ASSY. (29125) OVER-SOLID STOP (D-11994) OVER-SOLID STOP (D-11997) SHIM 1/16 Shim (D-11999) 1/8 Shim (D-11998) SHIM 1/16 Shim (D-11999) 1/8 Shim (D-11998) * No longe in poduction. Replce with TCC-60 LTR. * No longe in poduction. Contct custome sevice fo eplcement ecommendtions 6

9 Fig. 9 TCC-4500 RA* Rolle Assist Stndd Tvel Fig. 10 TCC-45 LTR Long Tvel TOP CAP ASSY. (29126) TOP CAP ASSY. (40624) SOLID STOP (40625) 4 x 2 ROLLER (29651) 1/16 SHIM (D-11999) HOUSING (29650) 1/8 SHIM (D-11998) * No longe in poduction. Contct custome sevice fo eplcement ecommendtions. Fig. 11 TCC-60 LTR Long Tvel TOP CAP ASSY. (40575) SOLID STOP (40576) Fig. 12 TCC-45 LTRB Long Tvel TOP CAP ASSY. (40624) 1/16 SHIM (D-11999) HOUSING (40596) 1/8 SHIM (D-11998) LONG WEDGE (40887) 7

10 Fig. 13 TCC-45 LTLP Long Tvel TOP CAP ASSY. (40570) SMALL WEDGE (40672) Fig. 14 TCC-45 LTLP-B TOP CAP ASSY. (40865) HOUSING (40569) LONG WEDGE (40887) HOUSING (40864) 8

11 SHELF LIFE The ecommended shelf life fo Mine TecsPk pds is 5 yes fom the dte of mnufctue. Thee is n lph-numeic code on the outside of TecsPk pd tht cn be used to detemine the dte it ws poduced. The fist 5 digits e the ones tht intepet the dte mnufctued. Exmple: 1 st five digits on TecsPk pd: = = the 25th dy of the ye, Jnuy 25th. The est of the numbes e fo Mine s intenl tcking. Occsionlly, the fist zeo ws left off. So the dte code might look like this; 7025 This is still the sme s bove. In most cses, the pd will need to be clened to see the dte code. Sometimes just simply wiping it with you hnds is fine nd othe times you my need some wte to wsh off the dust nd dit. 9

12 INSTALLATION SET UP HEIGHT The set up height, o the veticl distnce between the c body side being we plte nd the housing mounting sufce, should be mesued using inside clipes nd steel ule. A twelveinch steel stightedge is helpful fo checking the fltness of the body we plte nd the bolste mounting sufce. Stndd Set Up Height CAR BODY WEAR PLATE Fig. 15 Clipe Mesuement Models TCC, TCC II, TCC III,TCC IV, TCC 45/60 LTR Instlltion o Adjustment*^ Metl Line New Non-Metllic Line o Lube Disc Nominl Tolence Nominl Tolence 5-1/16 ± 1/16 5-1/8 ± 1/16 Rnge Mx: 5-1/8 Mx: 5-3/16 Min: 5 Min: 5-1/16 * Instlltion nd djustment should be done in empty condition on level tck ^ Mle end of ticulted connected cs my hve nominl vlue of 5-3/16 Altentive Set Up Height Mine side beings llow gete flexibility in the set up height. On some ticulted intemodl cs, t the mle loction of the ticulted connection, the side being cn hve set up height of 5-3/16, ± 1/16. On selected utock cs, the long tvel side being cn hve set up height of 5-1/16, ± 1/8. (Refe to ownes instuctions, o stenciling, on these types of cs.) If new elstomeic hoizontl cente bowl line is used, it is ecommended tht you dd 1/16 to the nominl dimension. Block Style Retofit Set Up Height CAR BODY WEAR PLATE Fig. 16 Block Style Retofit Set Up Height Models CC 45 LTLP, CC 45 LTLP-B CC 45 LTRB Instlltion o Adjustment Metl Line New Non-Metllic Line o Lube Disc Nominl Tolence Nominl Tolence 5/8 ± 1/16 11/16 ± 1/16 Rnge Mx: 11/16 Mx: 3/4 Min: 9/16 Min: 5/8 10

13 The housing must extend minimum of 1/16, up to mximum of 3/8, beyond the top of the pocket wll ound the entie peimete. If the pocket wll is tlle thn ny housing, eithe: Add shims unde the bottom of the housing coveing the entie pocket floo; o Remove enough mteil fom the top of wll to insue the 1/16 minimum extension. In some cses, djusting the shim thickness is not n option. It is pemissible to use 3/8 we plte on cetin cs ccoding to AAR Field Mnul Rule 61 E.2. Othe cses my equie shimming of the cente bowl. Plese efe to AAR Field Mnul Rule 47 fo specifics on the cente bowl shimming. Block Style Retofit Set Up Height Gge Mine s #40766-B (W11525) tingul luminum gge is designed to be used fo set up height check nd djustment fo the TCC-45 LTLP, LTLP-B nd LTRB constnt contct side beings. The gge fce nges fom 3/16 to 1 in 1/16 incements. The desied distnce between the housing (pt #40569, #40864 o #40596) nd the c body we plte is 5/8, ± 1/16. If n elstomeic hoizontl cente bowl line is used, dd 1/16 to the nominl dimension. So the desied distnce would become 11/16, ± 1/16. 7/8 CAR BODY WEAR PLATE 3/4 5/8 1/2 3/8 1/4 Mine Gge #40766-B (W11525) Fig. 17 Block Style Retofit Set Up Height Gge To check the set up height, put flt end of gge up to the c body we plte nd slide the gge in until it contcts the housing. If the gp is below 5/8 then emove the coect mount of shims nd if the gp is bove 5/8 dd the coect mount of shims. The gge hs 1/8 incements lined nd lbeled with 1/16 incements lined, but not lbeled. The thickness of the gge is 1/8 nd cn be used s the smllest mesuement incement on the gge. Simply tun the gge flt nd put one side ginst the we plte nd slide the gge in. 11

14 C Body We Plte The c body we plte must confom to AAR stndd S-235. The c body side being we plte must be smooth. Any weld sptte, hevy ust o sufce pojections must be emoved by ginding. Fstene heds must be smooth nd flush below we plte sufce, nd the fstenes secuely tightened. Pltes with sufce vitions between fstene holes gete thn 1/8, o gete thn 1/16 ove ny 4 spce between the fstene holes, must be eplced. Sufce must be esonbly pllel to side being mounting sufce. Vitions should not exceed 1/16 coss width o 1/8 end-to-end. Minimum We Plte Size MODEL TCC, TCC-II, TCC-III LT, TCC-III ST, TCC-IV LT, TCC-45 LTLP-B TCC RA, TCC-III RA MINIMUM SIZE 4 wide by 12 long Consult c builde TCC-45 LTR, LTRB, LTLP nd TCC-60 LTR Tuck Centes Min. Width Min. Length Less thn o equl to Ove 70 to Ove 82 to Gete thn Plese efe to AAR Field Mnul Rule 61 fo moe detiled infomtion egding body we pltes. Lubiction (Fo new cs only) Due to the stiffness of new c tucks nd othe components ( new c syndome ), it is ecommended tht the fictionl esistnce between the c body we plte nd the side being top cp be held to minimum duing the bek in peiod. In ode to educe the fiction duing the initil bek in, pply thin cot of lubicnt (No. 2 lithium gese o equl) to the top sufce of the top cp. Do not use Molybdenum disulfide type lubicnts since they e too pemnent. The lubicnt is fo initil bek in peiod only nd fte shot peiod of sevice will be wiped wy nd the side being will function to povide pope hunting contol. Some ecommended lubicnts e Texco Multifk 2, Amoco Amolith EP-2, Citgo H-2, Mobil Gese 2, Shell Alvni 2 o Exxon Lidok EP-2. Mine does not ecommend lubiction when new side beings e pplied fo mintennce, howeve with the dvent of field pefomnce detecto technology it is ecognized tht cetin c types my ect positively with modest ppliction of lubiction. Ce should be execised when pplying lubiction duing mintennce to insue hunting pefomnce is not compomised. 12

15 Side Being Instlltion Bolt-on Style The housing should be mounted to the tuck bolste pd utilizing one of the following fstenes: Mine does not hve pefeence whethe the bolt-hed be on top of the housing o unde the bolste. The oienttion of the bolt-hed is left up to the c owne. Acceptble fstenes on ll models EXCEPT the TCC-III RA: Cmc stndd dome hed fstene (efeence pt # ). Huck fstene (efeence pt #C71LR-BR24-28/32 nd #3LC-2R24GL). 7/8-9 Gde 5 o bette HEX hed bolt with self-locking nut. Toque: Dy: ft.-lbs. (Poduces clmping foce of 20,000-30,000 lbs. pe bolt). Wxed o well lubicted: ft.-lbs. (Roughly 25% eduction fom dy vlues). Acceptble fstenes fo the TCC-III RA ONLY: Cmc flt hed fstene (efeence pt # /160). 7/8-9 Gde 5 o bette FLAT hed bolt with self-locking nut. Toque: Dy: ft.-lbs. (Poduces clmping foce of 20,000-30,000 lbs. pe bolt). Wxed o well lubicted: ft.-lbs. (Roughly 25% eduction fom dy vlues). Wning Remove ll C-Pep pds when instlling constnt contct side beings. TCC Instll top cp ssembly into housing with the metl cp up. Ensue tht top cp end slots mte with housing lugs. (Refeence Fig.1 nd 2, Pge 5) TCC-III LT/ST/RA The TecsPk pd inside dimete should esily slide onto the post inside the housing. Thee is 1/32 clence between the post dimete t bottom nd the inside dimete of the pd. Theefoe, if the clence is gete thn 1/32, the wong pd hs been pplied. The top cp post should slide esily into the pd. With the TCC-III RA, instll the bse plte into the ectngul section of the housing with the witing fcing up, then plce the olle on it. The c body we plte must cove the 3 -wide flt on the top cp. (Refeence Figs. 4-6, Pges 5-6) TCC-IV LT Ech TCC-IV pd is supplied with colo-coded insulto ttched to the top. Ech pd ssembly is colo coded s follows: TCC-IV-30 (Geen), TCC-IV-45 (Red), TCC-IV-60 (Blue) nd TCC-IV-80 (Gey). The TecsPk pd inside dimete should esily slide onto the post inside the housing with the insulto fcing up. Thee is 1/32 clence between the post dimete t bottom nd the inside dimete of the pd. Theefoe, if the clence is gete thn 1/32, o it is difficult to ssemble the pd ove the housing post, the wong pd hs been pplied. The top cp post should slide esily into the insulto/pd. The c body we plte must cove the 3 -wide flt on the top cp. (Refeence Fig. 7, Pge 6) 13

16 Stndd Tvel Retofit Instlltion TCC-8000 RL/RS TCC-8000 RL Mine ecommends eplcing the TCC-8000 RL with the TCC-60 LTR. Fo the TCC-8000 RS, plese contct custome sevice fo eplcement ecommendtions. Long Tvel Retofit Selection Guide Stndd Height TCC-45 LTR TCC-60 LTR Set Up Height 5-1/16, +/- 1/16 Cge Size Only fo use in 688-B Double Rolle Cges Minimum C Body Weight TCC-45 LTR 21,176 lbs. TCC-60 LTR 28,235 lbs. Instlltion instuctions vilble on Pge 16. Low Pofile TCC-45 LTLP Pocket Height: 1-1/2-2-1/2 Mine housing MUST extend 1/16 to 3/8 bove pocket wll. Shim unde Mine housing if pocket is 2 o tlle. Min. Pocket Width 3-1/4 Instll with housing shifted towd the outbod side. Min. Pocket Length 8-1/8 Optiml inside length fo shimming should be 8-1/4. Mx. Pocket Length Shimming on the inside ends of the housing will be needed if the inside length is gete thn 8-11/16. Instlltion instuctions vilble on Pge 16. IF POCKET HEIGHT IS BETWEEN 2-1/2 AND 3-1/8, CALL MINER FOR RECOMMENDATION. 14

17 Low Pofile TCC-45 LTLP-B Pocket Height 1-1/2-2-1/2 Mine housing MUST extend 1/16 to 3/8 bove pocket wll. Shim unde Mine housing if pocket is 2 o tlle. Min. Pocket Width 4-1/4 Instll with housing shifted towd the outbod side. Min. Pocket Length 9-1/4 Optiml inside length fo shimming should be 9-3/8. Mx. Pocket Length Shimming on the inside ends of the housing will be needed if the inside length is gete thn 9-5/8. Instlltion instuctions vilble on Pge 17. Stndd Height TCC-45 LTRB Pocket Height 3-1/8-4-1/4 Min. Pocket Width 4-1/8 Instll with housing shifted towd the outbod side. Min. Pocket Length 9 Optiml inside length fo shimming should be 9-1/8. Mx. Pocket Length Shimming on the inside ends of the housing will be needed if the inside length is gete thn 9-1/4. Instlltion instuctions vilble on Pge 18. IF POCKET HEIGHT IS BETWEEN 2-1/2 AND 3-1/8, CALL MINER FOR RECOMMENDATION. IF POCKET HEIGHT IS BETWEEN 2-1/2 AND 3-1/8, CALL MINER FOR RECOMMENDATION. 15

18 Long Tvel Retofit Instlltion TCC-45/60 LTR Peption Remove the double olles nd clen the inside of the cge of ny foeign mteil. The existing cge must be fee of ccks, tes nd defomtion. The inside edges of the gibs t ech end must be fee of upset metl tht would pevent the ove-solid stops o shims fom fitting flush ginst the inside of the gibs. The heds of the cge fstenes must be flush o below the contou of the bottom of the cge. Cge fstenes must be tight. Solid Stop Instlltion The ssembly equies tht the two solid stops be plced on eithe end of the cge with the legs fcing outwd nd oientted with the mked topside fcing up. MAXIMUM 1/16 GAP SOLID STOP VERTICAL DIRECTION SOLID STOP LEGS FACE TOWARD CAGE GIBS PUSH SOLID STOP TO OPPOSITE END Fig. 18 TCC-45/60 LTR Solid Stop Instlltion Shim Adjustment Instll 1/16 shim on both ends. Afte instlling the top cp, push one solid stop towds the opposite end of the housing. If the esulting gp between the shim nd solid stop is gete tht 1/16, instll thicke, 1/8 shim on one end nd echeck. If the gp is too smll nd does not llow the cp to move feely up nd down, emove shims s necessy. (Refeence Figs. 8 nd 9, Pge 7). TCC-45 LTLP Peption - Remove the metl block nd clen the pocket of ny foeign mteil. Inspect the pocket fo ccks o ny othe dmge, nd epi if necessy. Insue tht the pocket bottom nd end wlls e eltively smooth nd fee of ny weld sptte, bumps, etc. Remove ll C-Pep pds when instlling constnt contct side beings. Housing Plcement - Thee e mny diffeent sizes of pockets tht e cuently in sevice. Smlle to medium sized pockets (see below dimensions) my only equie two smll wedges. Mine ecommends using the TCC-45 LTLP-B fo pockets equl to o lge thn 9-1/4 x 4-1/4. The smll wedges e designed to instll the TCC-45 LTLP into the following smlle pocket dimensions: Minimum Inside Length: 8-1/8 Mximum Inside Length: 8-11/16 Minimum Inside Width: 3-1/4 16

19 TCC-45 LTLP Instlltion 1. Shift the housing in the pocket to the outbod side of the bolste. 2. Cente housing long its length in the pocket nd inset smll wedges in both ends. 3. Insue tht the flt side of the wedge is ginst the Mine housing nd the ounded side is ginst the pocket wll. 4. Insue tht the wedges on the ends e ppoximtely t the sme height nd tht ll wedges do not extend beyond the housing top sufce. 5. Secuing the housing to the pocket equies welding. See welding equiements on Pge 19. OUTBOARD SIDE OF BOLSTER Fig. 19 Pocket Instlltion POCKET TCC-45 LTLP-B Peption - Remove the metl block nd clen the pocket of ny foeign mteil. Inspect the pocket fo ccks o ny othe dmge, nd epi if necessy. Insue tht the pocket bottom nd end wlls e eltively smooth nd fee of ny weld sptte, bumps, etc. Remove ll C-Pep pds when instlling constnt contct side beings. Housing Plcement - The long wedges e designed to instll the TCC-45 LTLP-B into the following pocket dimensions: Minimum Inside Length: 9-1/4 Mximum Inside Length: 9-5/8 Optiml Inside Length when Shimming: 9-3/8 Minimum Inside Width: 4-1/4 (Fo ovesized pockets, see Pocket Adjustment instuctions on Pge 19.) Fig. 20 TCC-45 LTLP-B 17

20 TCC-45 LTLP-B Instlltion 1.Shift the housing in the pocket to the outbod side of the bolste. 2.Cente housing long its length in the pocket nd inset wedges in both ends. 3.Insue tht the flt side of the wedge is ginst the Mine housing nd ounded side is ginst the pocket wll. 4.Insue tht the wedges do not extend beyond the housing top sufce. 5.Secuing the housing to the pocket equies welding. See welding equiements on Pge 19. TCC-45 LTRB Peption - Remove the metl block nd clen the pocket of ny foeign mteil. Inspect the pocket fo ccks o ny othe dmge, nd epi if necessy. Insue tht the pocket bottom nd end wlls e eltively smooth nd fee of ny weld sptte, bumps, etc. Remove ll C-Pep pds when instlling constnt contct side beings. Housing Plcement The ssembly only equies one set of wedges. Cente housing in pocket nd inset pope wedges in both ends. 1. Mke sue tht the flt side of the wedge is ginst the Mine housing nd the ounded side is ginst the pocket. 2. Insue tht both wedges e ppoximtely t the sme height nd tht they do not extend beyond the housing top sufce. 3. Secuing the housing to the pocket equies welding. See welding equiements on Pge 19. Wning Do not weld diectly on Mine housing. Instll top cp ssembly into housing with the metl cp up. (Refeence Fig.14, Pge 8) FILL GROOVE WITH 70KSI MINIMUM TENSILE STRENGTH WELD MATERIAL Fig. 21 TCC-45 LTRB Housing Secuement 18

21 Housing Secuement Welding Pocedue (TCC-45 LTLP, LTLP-B AND LTRB) Remove the top cp ssembly fom housing pio to welding. Wning Do not weld ne the top cp ssembly. Wning Do not weld diectly to eithe Mine housing otop cp. Fle bevel goove weld wedge to pocket wll (1-1/2 minimum length) with 70-ksi minimum tensile stength weld mteil. If the wedge is below the pocket wll, dd einfocement fillet weld on top. Insue tht weld nd pocket wll e t lest 1/16 below housing wll. All sufce peption nd welding must comply with ANSI/AWS D15.1 Rilod Welding Specifiction Cs nd Locomotives, ltest edition, including pehet when equied. POCKET WALL WEDGE Fig. 22 Welding Pocedue Coss Section Pocket Size Adjustment Some pockets my be slightly lge thn the TCC-45 LTLP o LTLP-B e designed to fit into. Fo these pplictions, follow the pocedues below. TCC-45 LTLP Inside Length - If the wedges hit the pocket floo befoe contcting the end wll (inside length gete thn 8-11/16 ), shim ppliction is equied. Optiml inside length fte shimming should be 8-1/4. Fbicte the shim so tht it is 1/4 shote thn the pocket wll nd no wide thn the flt potion of the end wll. Leve enough oom on the shim width fo welding. Fillet weld the shim to one end of the pocket using 70-ksi minimum tensile stength weld mteil. Inside Width - If the ddition of wedges to the inbod side of the pocket still leves gp of gete thn 1/8 (inside width gete thn 4-5/16 ), plese use the TCC-45 LTLP-B. Estimte the shim thickness needed to educe the gp between wedge nd the pocket wll to 1/8 o less. Fbicte the shim so tht it is ppoximtely 1/4 shote thn the pocket wll nd no longe thn the flt potion of the pocket side wll. Leve enough oom on the shim length fo welding. Fillet weld the shim to the outbod side of the pocket using 70-ksi minimum tensile stength weld mteil. 19

22 TCC-45 LTLP-B Inside Length - If the wedges hit the pocket floo befoe contcting the end wll (inside length oughly gete thn 9-5/8 ), shim ppliction is equied. Optiml inside length fte shimming should be 9-3/8. Fbicte the shim so tht it is 1/4 shote thn the pocket wll nd no wide thn the flt potion of the end wll. Leve enough oom on the shim width fo welding. Fillet weld the shim to one end of the pocket using 70-ksi minimum tensile stength weld mteil. If the pocket hs ovl cut outs t the ech end of it, it is ecommended, if spce is vilble, tht shims be inseted to ech end to insue good sufce to weld the wedge too. Inside Width If the inside width of the pocket exceeds 4-5/8, shimming will be equied. Estimte the shim thickness needed to educe the pocket width to between 4-1/4 nd 4-1/2. Fbicte the shim so tht it is ppoximtely 1/4 shote thn the pocket wll nd no longe thn the flt potion of the pocket side wll. Leve enough oom on the shim length fo welding. Fillet weld the shim to the outbod side of the pocket using 70-ksi minimum tensile stength weld mteil. 1/4 Fig. 23 Pocket Size Adjustment OUTBOARD SIDE OF BOLSTER TecsPk Pds The TecsPk pd must not be exposed to tempetue envionments highe thn 200 F., o 175 F. fo extended peiods of time (2-3 hous). Afte the side beings hve been instlled, nd the c body loweed onto the tucks, the set up height will pobbly be gete thn the oiginl set up. Initil set needs to tke plce nd this height will gdully ech the designed set up height. At tempetues lowe thn 40 F., this my equie t lest 24 hous. Fo this eson, the TecsPk pds should be mintined t 40 F. o highe tempetue fo t lest 24 hous befoe ssembly on c. Remove TecsPk pds nd top cp ssemblies pio to welding. Allow mple time fo cooling befoe eplcingpd o top cp ssembly. Wning Do not weld ne TecsPk pds. 20

23 INSPECTION Fo side being we limits nd cuse fo enewl, plese efe to Rule 62 of the Field Mnul of the AAR Intechnge Rules. Rule 62 hs couple of notes tht dictte which loction should be summed. 1. Fo ticulted cs, "sum of the pis" efes to the side beings ltelly coss fom ech othe. 2. Fo stnd lone cs, the following loctions must be summed: AL+AR BL+BR AL+BR AR+BL Set Up Height The set up height is the veticl distnce between the c body side being we plte nd the housing mounting sufce. Field o Yd Inspection Constnt contct side being heights: - Fo cs with 5-1/16 inch setup height nd 8-1/2 inch mounting holes. Typiclly on 4-xle cs nd end tucks of ticulted cs. Height djustment is equied t ny time, empty loded, when height mesued is: Sum-of-the-Pis Mesuement (Condemning Limit) Less thn 9-3/4 inch o Gete thn 10-1/2 inch - Fo ticulted cs t the ticulted tuck loctions. 21

24 Height djustment is equied t ny time, empty o loded, when height mesuement is: Aticulted Nominl Setup Sum-of-the-Pis Connecto Height (o s Mesuement Potion stenciled on c) (Condemning Limit) Femle 5-1/16 inch Less thn 9-3/4 inch o Gete thn 10-3/8 inch Mle 5-3/16 inch Less thn 9-3/4 inch o Gete thn 10-5/8 inch Eithe Any Othe Less thn 9-3/4 inch (Femle o o Mle) Gete thn 1/4 inch bove two times the stenciled set-up height - Fo cs with low pofile o stndd height solid block style side being pockets (integl cst o welded on ing). Height djustment is equied t ny time, empty o loded, when height mesuement is: Sum-of-the-Pis Mesuement (Condemning Limit) Less thn 7/8 inch o Gete thn 1-5/8 inch - Fo ticulted cs t the ticulted tuck loctions. 22

25 Shop o Repi Tck Inspection Constnt contct side being heights: - Fo cs with 5-1/16 inch setup height nd 8-1/2 inch mounting holes. Typiclly on 4-xle cs nd end tucks of ticulted cs. Height djustment is equied t ny time, empty o loded, when on Repi Shop (Fcility)/Repi Tck s defined in Appendix A nd height mesuement is: Single Side Being Mesuement (Condemning Limit) Less thn 4-15/16 inch o Gete thn 5-3/16 inch - Fo ticulted cs t the ticulted tuck loctions. Height djustment is equied t ny time, empty o loded, when on Repi Shop (Fcility)/ Repi Tck s defined in Appendix A nd height mesuement is: Aticulted Nominl Setup Single Side Being Connecto Height (o s Mesuement Potion stenciled on c) (Condemning Limit) Femle 5-1/16 inch Less thn 4-15/16 inch o Gete thn 5-1/8 inch Mle 5-3/16 inch Less thn 4-15/16 inch o Gete thn 5-1/4 inch Eithe Any Othe Less thn 4-15/16 inch (Femle o o Mle) Gete thn 1/16 inch the nominl set-up height 23

26 - Fo cs with low pofile o stndd height solid block style side being pockets (integl cst o welded on ing). Height djustment is equied t ny time, empty o loded, when on Repi Shop (Fcility)/Repi Tck s defined in Appendix A nd height mesuement is: Single Side Being Mesuement (Condemning Limit) Less thn 1/2 inch o Gete thn 3/4 inch Some models include cst-in mkings to ssist in ough estimte of the set up height. NEWER STYLE LONG TRAVEL HOUSING TCC-III TOP CAP 5 TCC LTR TOP CAP 4-7/8 5-1/8 4-7/8 5-1/8 5-1/8 DOUBLE ROLLER CAGE BOTTOM EDGE OF TCC-III OR TCC-IV TOP CAP OLD STYLE TCC-III HOUSING Fig. 24 Stndd Set Up Height Indictos Some models include cst-in mkings to ssist in ough estimte of the set up height. LTLP TOP CAP 2-7/ /16 TCC-45 LTR TOP CAP (PARTING LINE) 5-1/8 4-7/8 LTLP HOUSING TCC-45 LTRB HOUSING Fig. 25 Block Style Retofit Set Up Height Indictos 24

27 Genel Yd o Field The housing nd top cp cstings must be fee of ccks nd be secuely fstened to the tuck bolste. Do not shop c becuse of TCC-II bolt we. The bolt we does not ffect the sfe opetion of the c. Shop o Repi Tck Inspect metl pts fo ccks nd the TecsPk pds fo melting; eplce in kind. Fo optiml pefomnce, it is ecommended if the clence between the top cp OD nd the housing ID is gete thn 1/8, instll new top cp nd e-mesue. If the clence is still gete thn 1/8, eplce both top cp nd housing. Top Cp We Indictos Some of Mine s top cps hve built-in we indictos tht will llow the inspecto to detemine if the top cp hs been won down due to contct with the c body we plte. If the indicto hs been won down flush to the bottom sufce the top cp will need to be eplced. The models tht hve this fetue e the TCC-IV, TCC-45 LTR, LTRB, LTLP, LTLP-B, nd the TCC-60 LTR. TCC-IV WEAR INDICATOR TCC-45 LTLP-B WEAR INDICATOR Fig. 26 TCC-IV We Indicto Fig. 28 TCC-45 LTLP-B We Indicto TCC-45/60 LTR & LTRB WEAR INDICATOR TCC-45 LTLP WEAR INDICATOR Fig. 27 TCC-45/60 LTR & LTRB We Indicto Fig. 29 TCC-45 LTLP We Indicto 25

28 TecsPk Pd Fee Height Mesuement Shop o Repi Tck The sping used in Mine constnt contct side beings is clled TecsPk pd. With use, the pds cn lose some of thei pelod. Fo optiml pefomnce, the fee height of the pd should be mesued to detemine suitbility fo continued sevice. Fig. 30 TecsPk Pd Fee Height Mesuement TCC To detemine if the TecsPk elstome pd hs sufficient pelod, mesue the fee height of the top cp ssembly. To do this, emove the top cp ssembly fom the housing, then llow two hous fo the pd to stbilize. Fo optiml pefomnce, it is ecommended the top cp ssembly be gete thn the following heights: TCC /8 TCC /4 TCC /2 TCC-II The TCC-II side beings e pe-ssembled t the fctoy nd nomlly should not need to be disssembled. The TecsPk pds e contined within the housing nd top cp. The top cp is held in position by two etining bolts, thus mintining ppoximtely 2,000 lbs. on the pds when the side being is t fee height (5-7/8 ). Wning - Unde no cicumstnces should the etining bolts be emoved unless the side being hs been compessed to elieve the lod on the bolts. Both sides of the bolts will develop flt spot fte cetin mount of sevice. If the bolts e boken, missing, o won to less thn 1 4 in thickness, the entie ssembly will need to be eplced. Both sides of the tuck will need to be eplced t the sme time. Contct Mine fo eplcement ecommendtion fo the side being ssembly. Wning - Do not use stndd bolts. Contct Mine fo eplcement ecommendtion fo the side being ssembly. When the c body is ised off the side being, the top cp should extend to fee height. If the bottom of the top cp slot does not mintin contct with the bottom of the etining bolts, eplce side being pe ownes instuctions. 26

29 TCC III AND IV FREE HEIGHT INSPECTION To detemine if the TecsPk elstome pd hs sufficient pelod, mesue the fee height of the pd. To do this, emove the pd fom the ssembly, llow 1 minute fo pd to stbilize. Fo optiml pefomnce, it is ecommended the pd be gete thn: All Models: 3-15/16 TCC LTR, LTLP, LTLP-B nd LTRB To detemine if the TecsPk elstome pd hs sufficient pelod, mesue the fee height of the top cp ssembly. To do this, emove the top cp ssembly fom the housing, then llow two hous fo the pd to stbilize. Fo optiml pefomnce, it is ecommended the top cp ssembly be gete thn the following heights: TCC-45 LTR 4-13/16 TCC-60 LTR 4-7/8 TCC-45 LTLP 2-15/16 TCC-45 LTLP-B 2-15/16 TCC-45 LTRB 4-13/1 27

30 Pe f e c t i n gr i l c Pe f o m n c e I NSTALLATI ON AND I NSPECTI ON GUI DE Si d ebe i n g s D f t Ge s B k ebe ms VERSI ON 6

31 DRAFT GEARS GENERAL DESCRIPTION Mine offes viety of dft ges to stisfy you c potection equiements. Cown SG is Mine s ll-steel dft ge tht meets AAR Specifiction M-901G. Its obust sping pckge povides mximum potection fo the industy s heviest cs. The Cown SG cn be used in ny feight c including intemodl nd stnd-lone 125-ton cs. Cown SE is high cpcity ll-steel dft ge cetified unde AAR specifiction M-901E. The Cown SE is engineeed to povide long sevice life in feight cs with minimum we of dft ge pocket nd ttchments. TF-880 is the lightest weight high pefomnce dft ge meeting AAR specifiction M-901E. The TF-880 incopotes Mine s poven fiction clutch design in combintion with the ptented TecsPk elstome compession sping pckge to povide exceptionl c potection. It is n idel ll-pupose ge, suitble fo ll feight cs up to nd including 110-ton cpcity. SL-76 is specificlly designed to meet the most sevee equiements of tody s ilcs. Mine s sevice poven fiction clutch mechnism nd ntul ubbe sping pckge povide ext hevy-duty c potection nd less opeting slck. 28

32 PROCEDURE FOR DETERMINING SERVICEABILITY OF MINER DRAFT GEARS Cown SE nd Cown SG (In-c Inspection) Inspect fo excessive dft slck, couple hon/stike contct, nd excessive we on cie plte nd sill wlls, indicting possible unstisfctoy dft ge pefomnce. To emin in sevice, dft ge should be tight in pocket nd fee of loose o boken pts. Chnge out dft ge if potusion of both shoes out of the housing veges 11/16 o moe. MEASURE PROTRUSION OF EACH SHOE Fig. 31 Cown SE/SG In-C Inspection Cown SE nd Cown SG (Out-of-c Inspection) 1. Tp fiction plte in with hmme. 2. Bidge wedges nd mesue gp between wedges nd fiction plte. 3. If less thn 1/8 gp, ge should be econditioned (do not epply). Befoe pplying ny dft ge, inspect fo confomnce to AAR Rule 21, Sections A & B. BRIDGE GAP 1/8 MINIMUM 1 - FRICTION PLATE 2 - WEDGES 2 - SHOES Fig. 32 Cown SE/SG Out-of-C Inspection 29

33 TF-880 (In-c Inspection) Inspect fo excessive dft slck, couple hon/stike contct, nd excessive we on cie plte nd sill wlls, indicting possible unstisfctoy dft ge pefomnce. To emin in sevice, dft ge should be tight in pocket nd fee of loose o boken pts. Chnge out dft ge if potusion of the thee shoes out of the housing veges 1-1/8 o moe. MEASURE PROTRUSION OF EACH SHOE Fig. 33 TF-880 In-C Inspection TF-880 (Out-of-c Inspection) 1. Wedge potusion should mesue ppox. 3-5/16 (dft ge not peshotened). 2. If shoe potusion veges 1-5/16 o moe, ge should be econditioned (Do not epply). Befoe pplying ny dft ge, inspect fo confomnce to AAR Rule 21, Sections A & B. MEASURE THE HEIGHT OF EACH SHOE AND AVERAGE WEDGE WEDGE PROTRUSION SHOES HOUSING Fig. 34 TF-880 Out-of-C Inspection 30

34 SL-76 (In-c Inspection) Inspect fo excessive dft slck, couple hon/stike contct, nd excessive we on cie plte nd sill wlls, indicting possible unstisfctoy dft ge pefomnce. To emin in sevice, dft ge should be tight in pocket nd fee of loose o boken pts. Chnge out dft ge if potusion of the thee shoes out of the housing veges 1-1/8 o moe. MEASURE PROTRUSION OF EACH SHOE Fig. 35 SL-76 In-C Inspection SL-76 (Out-of-c Inspection) 1. Wedge potusion should mesue ppox. 3-5/16 (dft ge not peshotened). 2. If shoe potusion veges 1-5/16 o moe, ge should be econditioned (Do not epply). Befoe pplying ny dft ge, inspect fo confomnce to AAR Rule 21, Sections A & B. WEDGE MEASURE THE HEIGHT OF EACH SHOE AND AVERAGE WEDGE PROTRUSION SHOES HOUSING Fig. 36 SL-76 Out-of-C Inspection 31

35 Pe f e c t i n gr i l c Pe f o m n c e I NSTALLATI ON AND I NSPECTI ON GUI DE Si d ebe i n g s D f t Ge s B k ebe ms VERSI ON 6

36 BRAKE BEAMS GENERAL DESCRIPTION Mine Bke Bems fetue ugged design with n ext-study compession membe nd cstings. They cut mintennce costs by educing uneven we on bke shoes nd extending thei sevice life. Mine bke bems e vilble in #18 nd #24 fo both composition nd cst shoe designs. INSPECTION Fo bke bem we limits nd cuse fo enewl plese efe to Rule 6 of the Field Mnul of the AAR Intechnge Rules. Inspection includes but is not limited to checking fo: 1. Ccks o missing pts 2. Twisted bem 3. We on tension nd compession membes 4. Loose bke heds (move ltelly by hnd) 5. Bent o twisted stuts 6. We on stut pin holes nd leve slots 7. Dmge o we on the bke hed csting 8. We on end extensions 9. We on bke bem we lines VISUAL IDENTIFICATION - STAMPED 18 - STAMPED 200 VISUAL IDENTIFICATION - TWO FASTENERS PER HEAD Fig. 37 Mine Bke Bems - #18 VISUAL IDENTIFICATION - STAMPED 24 - STAMPED 201 VISUAL IDENTIFICATION - THREE FASTENERS PER HEAD Fig. 38 Mine Bke Bems - #24 32

37 STRUT HAND CHANGE PROCEDURE 1. Remove two-piece ivet fom stut. Cut off ivet coll b. Remove ivet pin 2. Remove the stut. Tp the stut ne the ivet end to otte it sidewys until the cown end of the stut is fee of the tension membe 3. Revese the stut to the opposite hnd 4. Instll the stut in the bem. With the stut otted ppoximtely 30, plce the cown of the stut ove the tension membe b. Hit the stut ne the ivet end to otte the stut until the holes line up c. Rivet in plce using one of the following i. Huck: Pin LC-2R20G, Coll 3LC-2R20G ii. 5/8 gde 5 bolt nd hex nut, ft-lbs, tck weld nut to bolt o peen bolt to pevent nut fom loosening LEFT HAND BEAM LEVER INSERTS FROM LEFT RIGHT HAND BEAM LEVER INSERTS FROM RIGHT Fig. 39 Mine Bke Bem Stut Chnge 33