101
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Table of Contents1.Scope ..................................................................... 62.TruckandBodySideBearings..............................7 Products ExtendedTravelCCSB...................................8 RetroXTTankCarCCSBUpgrade.................11 RetroXTCCSBElementKitUpgrade..............15 StandardTravelCCSB..................................18 RollerSideBearings......................................28 PlateandWedge...........................................30 YardandShopInspection......................................31 FreeHeightMeasurement.............................36 ShelfLifeCriteriaandDateCodes...................38 VerticalSetupHeightInspection....................40 VerticalSetupHeightCorrectRepairs............47 VerticalSetupHeightandWearIndicators.......513.SnubbingSystems...............................................54 GeneralRequirements.......................................54 FrictionWedges ProductCrossReferenceTable..................56 S-2-A......................................................59 S-2-BandS-2-C.........................57,60,62 S-2-HD.......................................58,60,61 RideControl®.....................................57,61 SuperServiceRideControl®.....................58 SuperServiceRideMaster®......................59 YardInspection...........................................63 ShopInspection...........................................64 WearIndicator.............................................66
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Table of Contents ControlandLoadSprings...................................67 ProductReferenceTables ControlCoils.................................................68 LoadCoils....................................................69 YardInspection................................................70 ShopInspection...............................................704.HydraulicStabilizers............................................71 Products HydraShox™Platinum....................................72 HydraShox™Gold..........................................72 HS-7-100RB...................................................73 YardandShopInspection.....................................745.BrakeSystems.....................................................78 BrakeBeams ProductReferenceTable.................................79 Inspection.......................................................79 ReversibleBrakeBeamProcedure..................80 ReplaceableBrakeHeadProcedure................82 RollGuard™HandBrake.....................................83 BrakeSystemAccessories..................................86 BrakeBeamCenteringWearLiner....................866.DraftSystems......................................................87 Products PowRGuard™XE..........................................88 PowRGuard™GXE..........................................88 PowRGuard™GX..........................................89 PowRGuard™InspectionCriteria.......................897.RepairandReconditioning.................................90 AmericanIndustries............................................90 AmericanIndustriesMidwest..............................92 IndependentDraftGear.......................................93 ProductIndex.......................................................97
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1.Scope
Thispocketguideprovidesrecommendedprocedures for the inspectionofproductsmanufactured and reconditioned by A.Stucki Company, including truck sidebearings, body side bearings, frictionwedges, column guide wear plates,springs,hydraulicstabilizers,handbrakes,brakebeams,centerbowlandbrakebeamliners,couplersandyokes,anddraftgears.
Thisguideisintendedprimarilyforproductidentification,inspection,andmaintenanceguidanceanddoesnotcoverintialproductinstallation procedures. To obtain thelatest news and information on all ofStucki’sproducts, includingdrawingsandinstallation instructions, please visit ourwebsiteatwww.stucki.com.
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2.TruckandBodySideBearings
SideBearings
8 www.stucki.com
Fig.2.1-ShearSideBearing(SSB®)Note: Replacement cages are ordered by specifying preload, i.e. 6000XT Cage, where 6000 = preload, XT for extended travel.
SideBearin
gs
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Fig.2.2-ColumnSideBearing(CSB®)Note: Replacement cages are ordered by specifying preload, i.e. 6000XT Cage, where 6000 = preload, XT for extended travel.
SideBearings
10 www.stucki.com
Fig.2.3-CompactColumnSideBearingNote: Replacement cages are ordered by specifying preload, i.e. CCB6000XT Cage, where 6000 = preload, XT for extended travel. Also available in 2200lb & 3000lb preload. The 2200lb & 3000lb models are not for interchange service.
SideBearin
gs
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Fig.2.4-RetroXTLPBolt-On,4500lb.Preload
SideBearings
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Fig.2.5-RetroXTLPDrop-In,4500lb.PreloadNote: For monocast or welded bolster pocket, approximately 4-1/4” x 9-1/4”, low profile design.
SideBearin
gs
13www.stucki.com
Fig.2.6-RetroXTLPCDrop-In,4500lb.PreloadNote: For monocast or welded bolster pocket, approximately 3-1/2” x 8-1/4”, low profile design.
SideBearings
14 www.stucki.com
Fig.2.7-RetroXTSPDrop-In,4500lb.PreloadNote: For monocast or welded bolster pocket, approximately 4-1/4” x 9-1/4”, standard profile design.
SideBearin
gs
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Fig.2.8-RetroXT5400B(previouslyCCU-5400XT),5400lb.Preload
Note: This is an extended travel upgrade for the 688-BR, the ISB-9DR, the ISB-12 and the 688-B. This drop-in kit is for application to existing cages and does not include a new cage.
SideBearings
16 www.stucki.com
Fig.2.9-RetroXT5400C,5400lb.PreloadNote: This is an extended travel upgrade for the 656-CR, the 656-CRH and the 656-C. This drop-in kit is for application to existing cages and does not include a new cage.
SideBearin
gs
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Fig.2.10-RetroXT4500,4500lb.PreloadNote: This is an extended travel upgrade for the 690-RL. This drop-in kit is for application to existing cages and does not include a new cage.
SideBearings
18 www.stucki.com
Fig.2.11-656-CR,6000lb.PreloadNote: The 656-C cage can accept the RetroXT 5400C upgrade kit to convert to extended travel. Model 656-CRL uses RB-14s with a preload of 3500lb.
SideBearin
gs
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Fig.2.12-688-BR,6000lb.PreloadNote: This 688-B cage can accept the RetroXT 5400B upgrade kit to convert to extended travel.
SideBearings
20 www.stucki.com
Fig.2.13-690-RL,3600lb.PreloadNote: The 690 cage can accept the RetroXT 4500 upgrade kit to convert to extended travel.
SideBearin
gs
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Fig.2.14-656-CRH,5400lb.PreloadNote: This 656-C cage can accept the RetroXT 5400C upgrade kit to convert to extended travel.
SideBearings
22 www.stucki.com
Fig.2.15-675-RL,3000lb.PreloadNote: Model 675-RXL uses RB-35s with a preload of 2200lb.
SideBearin
gs
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Fig.2.16-685-RM,4500lb.Preload
SideBearings
24 www.stucki.com
Fig.2.17-ISB-9DR,4500lb.PreloadNote: The RB 36 / 46 combination is no longer available and should be replaced with RB 46 / 52. In addition, the 688-B cage can accept the RetroXT 5400B upgrade kit to convert to extended travel.
SideBearin
gs
25www.stucki.com
Fig.2.18-ISB-9DRL,4500lb.PreloadNote: The RB 36 / 46 combination is no longer available and should be replaced with RB 46 / 52.
SideBearings
26 www.stucki.com
Fig.2.19-ISB-10,4500lb.Preload
SideBearin
gs
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Fig.2.20-ISB-12,5400lb.PreloadNote: This 688-B cage can accept the RetroXT 5400B upgrade kit to convert to extended travel. Model ISB-12L uses RB24s with a preload of 3000lb.
SideBearings
28 www.stucki.com
Fig.2.21-656-CNote: The 656-C cage can accept the RetroXT 5400C upgrade kit to convert to extended travel.
SideBearin
gs
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Fig.2.22-688-BNote: This 688-B cage can accept the RetroXT 5400B upgrade kit to convert to extended travel.
SideBearings
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Fig.2.23-BodySideBearings(Plate&Wedge)Note: Various length and hole center combinations are available for models 438P, 458P, 558P, 4W and 5W. Contact A. Stucki Company for specific applications.
SideBearin
gs
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YardandShopInspection
Physicallyidentifythesidebearingmodelfrom the illustrations in Section 2 Truckand Body Side Bearings. Be sure allcomponents for that model are presentandinthecorrectorientation.Missingordamagedcomponentsshouldbereplacedinkind.
If the car is shopped, chock thewheels,safelyliftthecar,andfollowstandardsafeoperatingprocedures.
Cage:Inspectcagesforcracks,flaws,orunusualdeformation. Thecagemustbesecurely fastened to the truck bolster. Ifshopped,tightenorreplaceloosefastenersaccording to A. Stucki Company’sinstallationinstructionsforrespectivesidebearings.Brokenorcrackedcagesmustbereplaced.
SideBearings
32 www.stucki.com
Body Side Bearing: Plates or wedgesmust be securely tightened (torque tominimum of 300 ft-lb) and tack welded.Fastenerheadsmustbe recessedbelowthe bearing surface of the wear plateor wedge. All bearing surfaces shouldbe flat or convex (1/16” maximum). Ifshopped, replace plates or wedges ifsurfacevariationsbetweenfastenerholesaregreaterthan1/8”orgreaterthan1/16”over any 4” span. The wear surface oftheplateorwedgemustbeparalleltothesidebearingmountingsurfaceofthetruckbolstertowithin1/16”acrossthewidthand1/8”alongthelength.Heavyrustorsurfaceprojectionsmaybe removedbygrinding.Please refer toAAR Specification S-235andRule61intheAARFieldManaualforadditionalrequirements.
SideBearin
gs
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Roller:Forshopinspection,rollersshouldbe replaced if they havea diameter lessthanthatshowninthetablebelow:
RollerSize(in)Minimum
Diameter(in)2X3 1-15/163X3 2-7/84X3 3-13/16
The roller should also be replaced if theedgesaredeformed to thepoint that therollerwillnotrollfreelyinthecage.
EndClosure: End closuresmust be inplaceandnotbroken. ISBmodelshaveonlyoneendclosure.
Resilient Element: Resilient elementsshould be checked for any excessivedeformation. If signsofseverecracking,bulging or deformation exist, replace theblockinkind.
Table2.1
SideBearings
34 www.stucki.com
RefertoRule62intheAARFieldManualfor additional requirements. Note thatthe 688-BR and 690-RL cars should notbeshopped for repairs forasingleblockhaving a missing top portion. Replacethe defective block when the car is nextshopped for required maintenance orotherrepairs.Bad-orderthecaronlyiftwoormoreblocktopsaremissing.
Shop inspection additionally requireschecking for cracks and gouges. Someelements (RB-46, RB-56, RB-57, RB-58,RB-59&CSB®Column)arecomposedofasinglematerial,whileothersconsistoftwomaterials.Mostdualmaterialdesignswillexhibit slight separation at the horizontalinterface of those twomaterials. Blocksshowing superficial horizontal separationdo not need replaced. As a rule, if theinterface can be manually opened toreveal 50% or more of the interfacesurface, the block should be replaced.
SideBearin
gs
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Vertical cracks are acceptable unlessthere are more than two cracks, greaterthan1/2” in length, located in thebottomportionof theblock. Crackedormissingtopedgesofwedge-shapedblocksdonotaffectitsperformanceandisnotcauseforrenewal.
Rocker: Rockers may not always beseated on the bottom of the cage, andclearanceshouldnotbeusedasasetupheightcriterion. While inservice,verticalmovementmayoccur.Thishasnoeffecton the performance of the side bearing.Rockerscontactthebodysidebearingasthecarrocksor leans. Lightwearof theupper and lower surfaces of the rockersis normal and should be replaced if thediameterislessthan3-7/8”.
SideBearings
36 www.stucki.com
FreeHeightMeasurement:Thesuitabilityoftheresilientblocksforcontinuedservicecan be determined by their free heightmeasurement.Allowtheblockstorelaxatleastonehourat room temperatureafterremovalfromthecar. Thenmeasuretheheight from thebase to thehighestpointontheblock(seeTable2.2).
SideBearin
gs
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BlockTypeMinimumAllowable
FreeHeightRB-9 4-3/16”RB-11 4-5/16”RB-14 4-1/4”RB-17 4-3/16”RB-24 3-5/8”RB-27 3-13/16”RB-34 3-3/4”RB-35 3-17/32”RB-36 4-7/16”RB-42 3-7/16”RB-46 4-3/16”RB-52 4-7/16”
SSB®CapAssembly 4-15/16”CSB®Column 4-5/16”
RB-56 3-11/16”RB-57 2-5/16”RB-58 2-5/16”RB-59 3-11/16”
Table2.2
SideBearings
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ShelfLifeCriteriaandDateCodes
A. Stucki Company recommends amaximumshelflifeof5yearsforallofourelastomercomponents,whichincludesRBBlocks, CSB® Columns, SSB® Elements,andRFEPads. The shelf life is definedas the time from themanufacturing dateofthepartsuntil theyareinstalledonthecar.PleaserefertoFigures2.24and2.25forthepropermethodsofdeterminingthemanufacturingdate.
SideBearin
gs
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Figure2.25
Figure2.24
SideBearings
40 www.stucki.com
VerticalSetupHeightInspection
Rule62oftheAARFieldManualcontainsdetailed condemning limits for theinspectionofsidebearingsetupheightsintheshop,onarepairtrack,oratanytime.Tables 2.3 and 2.4 provide the specificlocation in Rule 62 to find these criteriabased on the particular side bearingapplication.
SideBearin
gs
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SideBearing
Application
Rule62SetupHeight
CondemningLimit
StuckiM
easurement
Technique
4-AxleCarsandEnd
TrucksofArticulated
Cars
SectionA.1.h.(1)
StuckiFigure2.26
(Page42)
ArticulatedPositions
ofArticulatedCars
SectionA.1.h.(2)
StuckiFigure2.26
(Page42)
CarswithSolidBlock
StyleSideBearing
Pockets(R
etroXTLP,
LPCandSP)
SectionA.1.h.(3)
StuckiFigure2.27
(Page43)andStucki
Figure2.28(Page44)
Not
e: I
f app
lyin
g ne
w, 1
2” g
raph
ite lu
be d
isks
or n
on-m
etal
lic b
owl l
iner
whe
n co
nsta
nt c
onta
ct
side
bea
ring
mea
sure
men
ts a
re b
eing
mad
e, a
dd a
n ad
ditio
nal 1
/16”
to
the
nom
inal
hei
ght
for
any
sing
le s
ide
bear
ing
mea
sure
men
t and
1/8
” to
any
nom
inal
sum
-of-t
he-p
air m
easu
rem
ents
.
Table2.3VerticalSetup
Heigh
t(AnyTime)
SideBearings
42 www.stucki.com
Fig.2.26-HowtoMeasureVerticalSetupHeightNote: Place measuring tool as close to SB center as possible.
SideBearin
gs
BodySideBearingWearPlate
BolsterPad
43www.stucki.com
CarBody
BodySideBearingWearPlate
BolsterPocket
TruckBolster
TopofRetroXTBase
Fig.2.27-VerticalSetupHeightforRetroXTLPDrop-In,Bolt-OnandSPDrop-In
SideBearings
44 www.stucki.com
Fig.2.28-VeritcalSetupHeightforRetroXTLPC
SideBearin
gs
45www.stucki.com
SideBearing
Application
Rule62SetupHeight
CondemningLimit
StuckiM
easurement
Technique
4-AxleCarsandEnd
TrucksofArticulated
Cars
SectionA.2.a.(1)
StuckiFigure2.26
(Page42)
ArticulatedPositions
ofArticulatedCars
SectionA.2.a.(2)
StuckiFigure2.26
(Page42)
CarswithSolidBlock
StyleSideBearing
Pockets(R
etroXTLP,
LPCandSP)
SectionA.2.a.(3)
StuckiFigure2.27
(Page43)andStucki
Figure2.28(Page44)
Not
e: I
f app
lyin
g ne
w, 1
2” g
raph
ite lu
be d
isks
or n
on-m
etal
lic b
owl l
iner
whe
n co
nsta
nt c
onta
ct
side
bea
ring
mea
sure
men
ts a
re b
eing
mad
e, a
dd a
n ad
ditio
nal 1
/16”
to
the
nom
inal
hei
ght
for
any
sing
le s
ide
bear
ing
mea
sure
men
t and
1/8
” to
any
nom
inal
sum
-of-t
he-p
air m
easu
rem
ents
.
Table2.4VerticalSetup
Heigh
t(Sh
oporR
epairT
rack)
SideBearings
46 www.stucki.com
Allsidebearingsetupheightmeasurementsshouldbetaken...
• Onstraightandleveltrack• As close to the center of the side
bearingaspossible
Bealert to thepossibilityofencounteringshims under side bearing cages. Thispractice should be avoided, but whenpresent, measurement must referencetothetopoftheseshims,ratherthanthemountingsurfaceofthebolster.
If the appropriate Rule 62 setup heightcondemning limits are exceededand thecar isempty, itmustbeshoppedandthecar body side bearing shims adjusted toobtainthespecifiedsetupheight.RefertoVerticalSetupHeightCorrectRepairsonPage47.
SideBearin
gs
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VerticalSetupHeightCorrectRepairs
If inspection measurements reveal thatthesidebearingsetupheightviolatestheRule62condemninglimits,thenbodysidebearingshimadjustmentsarerequiredtocorrect the out-of-specification condition.
Toincreasethesetupheight,shimsmustbe removed. Likewise, to reduce thesetupheight,shimsmustbeaddedtothecarbodysidebearing.Donotplaceshimsundersidebearingcages toadjustsetupheights, unless shimming beneath cagesistheonlyoption.
SideBearings
48 www.stucki.com
When adjusting side bearing setupheight in the shop, the vertical distancebetweenthebodysidebearingwearplateor wedge and the truck bolster surfaceto which the side bearing is mountedmustbe5-1/16”±1/16”unlessotherwisestenciled on the car body (Figure 2.29).
Fig.2.29
SideBearin
gs
49www.stucki.com
Fig.2.30
FortheRetroXTLPandSPsidebearings,the vertical space between the top ofthe cage and the underside, or wearingsurface of the body side bearing wearplateorwedgemustbe11/16”±1/16”.FortheRetroXTLPCsidebearing,theverticalspace between the top of the notch andthe underside, or wearing surface of thebody side bearing wear plate or wedgemust be 11/16” ± 1/16” (Figure 2.30).
SideBearings
50 www.stucki.com
Thesemeasurementsassumethatthecaris empty, positioned on reasonably leveltrack,andhaspositivecenterplatecontact.Topsofmetalrockersorrollersshouldnotbeusedasreferencepointstomeasuresetupheightforconstantcontactsidebearings.
Ifthecarisequippedwithanytypeofnew12” graphite lube discs or elastomericcenterbowlliner,itmustbeinplacewhenmeasuringforsetupheightadjustment.Inaddition,sidebearingsetupheightsshouldbeadjustedto3/4”±1/16”forallRetroXTLP,LPCorSPsidebearingsand5-1/8”±1/16” for all other side bearing products.
Neverrelubricateasidebearinginservice,unlessthemetalcapsorbodysidebearingsare being replaced. In this case, applya 1-1/2” diameter dab of lithium basedgrease to the center of the side bearingcap. This allows the body side bearingwear plate surface to polish, resulting insmooth consistent turning of the truck.
SideBearin
gs
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VerticalSetupHeightandWearIndicators
Figures 2.31, 2.32, 2.33, 2.34 and 2.35highlight reference indicators which canbeusedforquickvisualinspectionofwearorpropersetupheight. Pleasenote, thesetup height indicators are for referenceonlyandshouldnotbeusedwheninstallingnewsidebearingsormakingsidebearingsetupheightadjustmentsonarepairtrackorintheshop.
Capwear limit indicators forallCCBandmetal capped/rolled steel cage designsare shown in Figures 2.31 and 2.32.Capsshouldbereplacedwhenanywearindicatorlimitiswornoff.CapwearlimitsforallLP,SP,LPC,CSB®andSSB®designsarereachedwhenapplyingastraightedgeacrossthecapandreachingbothoutsideedges of the cap at the same time asshowninFigures2.33and2.35.Replacethecapwhenthisconditionismet.
SideBearings
52 www.stucki.com
Fig.2.31-SetupHeightIndicatorforCompactColumnSideBearing
Fig.2.32-SetupHeightIndicatorforMetalCapped,Rolled-SteelCageDesigns
Note: Setup is at 5-1/16” when bottom cap cutout is aligned with top of cage. Side bearing is shown at free height.
Note: If the top of cage is aligned at lateral center of top notch, setup height is at 5-1/16”.
SideBearin
gs
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Fig.2.33-WearLimitIndicatorforRetroXTLP,LPC,SPandSSB®SideBearings
Fig.2.34-SetupHeightIndicatorforRetroXTLPCSideBearings
Note: Caps are condemnable when both vertical walls are contacted using a straight edge placed across the top of the cap.
Note: Setup is at 11/16” when the bottom of cap is aligned with the base step of the LP and SP models or when cap step is aligned with top of base for the LPC model. All side bearings are shown at free height.
SideBearings
Fig.2.35-CSB®andSSB®Cap
Basestep
Verticalwall
54 www.stucki.com
ColumnGuideWearPlate Friction
Wedge
ControlSprings
3.SnubbingSystems
GeneralRequirements
SnubbingSystemsarecomposedofthreemain product groups, including frictionelements, springs and column guidewear plates. These are responsible forstabilizationofthetruck.Systemwearofthe snubbing column can be measuredby checking friction wedge rise with amustache gage per AAR Field ManualRule46andAAROfficeManualRule88.
Snub
bing
Systems
55www.stucki.com
SnubbingSystems
The following illustrations identify eachfrictionelementanditscomponents.It isimportant that all components shown foraspecificwedgearepresentandingoodcondition.PadsmanufacturedbyA.StuckiCompany are identified by their orangecolor.Table3.1crossreferencesproduct.
56 www.stucki.com
StuckiFrictionWedgeEquivalent
Manufacturer
TruckType
ResilientP
adConventionalW
edge
SplitWedge
Barber609-D
70T&100TBarber
S-2-A
RFE
-16*
ASC-609D
Barber888R,888N,
787C
&925SW
70T&100TBarber
S-2-B,C
RFE
-16
ASC-787
ASC-925SW,925L,
925R
,5824(Thick)
&5286(Thin)
Barber834-C&
915S
W100TS-2-HDHeavy
Duty
RFE
-41
ASC-834CB
ASC-915SW,915L,
915R
&5821
ASF17803&17849
70T,100T&125T
RideControl
RFE
-18
ASC-17803
ASF17815&17852
100TSuperService
RideControl
RFE
-26
ASF17882
100TSuperService
Ridem
aster
RFE
-53
Table3.1Frictio
nWedgeCrossReferenceTable
* R
equi
res
use
of S
tuck
i RFE
-16
D-5
wed
ge s
prin
gs (
or B
arbe
r B
432/
B43
3 co
mbi
natio
n) w
ith 3
/8”
Stuc
ki s
him
pla
te.
Snub
bing
Systems
57www.stucki.com
Fig.3.1-RFE-16,forBarber®S-2-B,CTrucks
Fig.3.2-RFE-18,forRideControl®Trucks
SnubbingSystems
58 www.stucki.com
Fig.3.3-RFE-26,forSuperServiceRideControl®Trucks
Fig.3.4-RFE-41,forBarber®S-2-HDTrucks
Snub
bing
Systems
59www.stucki.com
Fig.3.5-RFE-53,forSuperServiceRideMaster®Trucks
SnubbingSystems
Fig.3.6-ASC-609DFrictionCasting,forBarber®S-2-ATrucks
60 www.stucki.com
Snub
bing
Systems
Fig.3.7-ASC-787CFrictionCasting,forBarber®S-2-B,CTrucks
Fig.3.8-ASC-834CBFrictionCasting,forBarber®S-2-HDTrucks
61www.stucki.com
Fig.3.9-ASC-17803,forRideControl®Trucks
Fig.3.10-ASC-915SplitWedge,forBarber®S-2-HDTrucks
Note: ASC-5821 Wedge Insert also available.
SnubbingSystems
62 www.stucki.com
Fig.3.12-ColumnGuideWearPlate-AllPopularSizesNote: Contact A. Stucki Company for specific applications.
Snub
bing
Systems
Fig.3.11-ASC-925SplitWedge,forBarber®S-2-B,CTrucks
Note: ASC-5824 (Thick) & ASC-5286 (Thin)Wedge Inserts also available.
63www.stucki.com
YardInspection
Inspectwearindicatorsontheverticalfaceofthewedge.Replacewedgeswhenthewearindicatorsarenolongervisible.Newwedges will have approximately 3/8” ofwear indicator visible. Amustache gagecan be used to check wedge rise for allwedgedesigns.WedgeriselimitsforRFEsandsplitwedgesarethesameasfortheconventional friction shoes they replace(seeAARFieldManual,Rule46).FortheRFEs18and26,wedgeriseisexcessivewhentheholeonthefrontofthecastingisentirelyabovethetopplateofthebolster.TheRFE-16wedge rise limit indicator isthebottomofthefacewearindicatoritself.
Checktopedgeofresilienturethanepadsfor flush seating against the wedge andbolsterpocket.Anypadcracksabovetheareaofcontactwiththebolsterpocketareacceptableandarenotcauseforrenewal.
SnubbingSystems
64 www.stucki.com
ShopInspection
Inadditiontothepreviousyardinspectionprocedures, inspection in the repairshopshould include the following procedures:
ColumnGuideWearPlate:Check closely for cracks, loose ormissing fasteners, or excessive wear,and replace as necessary. Refer toAAR Specification S-3003 and FieldManualRule48,Table1. Columnguidewear platesmust be reasonably parallel,and spacing between plates must bein accordance with AAR requirements.
RFE Casting: Wedges having obviouscracksmustbereplaced.
Wedge: If wedge rise measurementsindicatewedgesareabovecondemnableheights, both complete wedges shouldbe replaced. Theexception is if resilientpad(s)areseverelydamaged,andcasting
Snub
bing
Systems
65www.stucki.com
has at least 3/16” face wear indicatorremaining,thenitisacceptabletoreplacethe pads only. Pry old pads from thecastingwithascrewdriver,andinstallnewpadsbyaligning theposton thebackofthe padwith the hole in the sloped faceofthecasting.Strikethepadfacewithamallettoseatitontothecasting.
Elastomer Pads:Patches of dark, flakymaterial on the faces of the pads arecommon, and produce no detrimentaleffects.Thisisnotcauseforrenewal.
In the case of the RFE-18, RFE-26 andRFE-53, if cracks emanating from theupper or lower corners of the padshaveextendeddownward toward thecenterofthepadmorethan3/4”,thencrackedpadsshouldbereplaced.
SnubbingSystems
66 www.stucki.com
Fig.3.13-WearIndicatorSideView(MostWedges)
Snub
bing
Systems
67www.stucki.com
Control and Load Springs: Springscanbe identifiedby themarkings on thetaperedendsorbyphysicalidentificationusing Tables 3.2 an 3.3. Brokenwedgespringsmustbereplaced.Freeheightsofspringsshouldbechecked.
SnubbingSystems
68 www.stucki.com
PartN
umber
BarDiameter
OuterDiameter
SolidHeight
FreeHeight
ScrapHeight
B353
13/16
47/8
69/16
113/16
105/8
B354
17/32
31/8
69/16
111/2
1015/16
B421
43/64
311/16
69/16
103/8
915/16
B422
13/32
23/16
61/16
93/4
95/16
B432
43/64
37/8
69/16
111/16
101/2
B433
7/16
213/32
615/16
113/8
1013/16
3023
9/16
31/4
47/8
79/16
7.125
3024
3/8
247/8
71/4
73091
19/32
31/4
47/8
75/16
73092
3/8
115/16
47/8
73/16
75062
25/32
561/2
129/16
5063
17/32
35/16
61/2
1211/16
Table3.2Con
trolCoilsTable(inches)
Snub
bing
Systems
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PartN
umber
BarDiameter
OuterDiameter
SolidHeight
FreeHeight
ScrapHeight
D2Inner
11/16
215/16
65/8
81/4
715/16
D2Outer
17/32
51/2
65/8
81/4
715/16
D3Inner
21/32
31/4
69/16
91/16
85/8
D3Outer
11/16
51/2
69/16
91/16
85/8
D4Inner
5/8
33/8
69/16
95/8
91/16
D4Outer
151/2
69/16
95/8
91/16
D5Inner
5/8
33/8
69/16
105/16
95/8
D5Outer
61/64
51/2
69/16
101/4
95/8
D6Inner
21/32
37/16
69/16
915/16
95/16
D6A
Inner
3/8
2511/16
983/8
D7Inner
5/8
31/2
69/16
103/4
10D7Outer
15/16
51/2
69/16
1013/16
10
Table3.3Lo
adCoilsTable(inches)
SnubbingSystems
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YardInspection
Any cracked, broken or missing springsshouldbereplacedinkind.Anyflatteningof the spring coil toponallwindings toptobottom,aresignsofspringoverloadorbottoming. Theseshouldbechecked forfreeheight.
ShopInspection
Usingastraightedgeheldacrossthetopofafreestandingspring,comparethefreeheightmeasurement of the spring to theminimum recommended scrap height inTables3.2and3.3.Ifthespringdoesnotreturntothescrapheight,replaceinkind.
Fig.3.14-SpringMeasurement
Snub
bing
Systems
71www.stucki.com
4.HydraulicStabilizers
Stucki hydraulic stabilizers are the onlyhydraulic damping units guaranteed tomeetAARSpecificationM-965andFieldManualRule50 toensuresafeoperationofthefreightcarwhilecontrollingresonantrocking of high-center-of-gravity cars.The Stucki HS-7, HS-7-100 and HS-10incorporate a low pressure seal on thepistonrod,whichmaypassslightamountsof oil under normal operating conditions.Thisfluid loss is compensated forby thereserve oil. The Stucki HydraShox™productsutilizeahighpressuresealwhichprovides superior performance and lifewhilepreservingoilreservelevels.
HydraulicStabilizers
72 www.stucki.com
Fig.4.1-HydraShox™PlatinumNote: HS-7 available unpainted / reconditioned only.
Fig.4.2-HydraShox™Gold
HydraulicStabilizers
73www.stucki.com
Fig.4.3-HS-7-100RBNote: Available unpainted / reconditioned only.
HydraulicStabilizers
74 www.stucki.com
YardandShopInspection
Hydraulicstabilizersshouldbepositionedvertically upright with the body springproperly seated between the stabilizerand the bolster. Units not properlypositioned or seated on the side framemust be repositioned correctly. The unitmust be replaced if stabilizer body hasbeen damaged due to bolster or sideframeluginterferencetoallowoilleakageat damaged area. Damaged stabilizershouldbescrapped.
Stucki hydraulic stabilizers have a sightglassononesideofthereservoirtocheckfor proper operating fluid level. On theHS-7 and HydraShox™ Platinum, thewindowisprotectedfromdirtbyaplasticcap,whichmustberemovedtomakethevisualcheck.Ifthecapismissing,cleanoutanydirtonthesurfaceoftheglass.(Asliveroftiewoodworkswellforthistask.)Be sure the unit is sitting in its normaluprightpositionwheninspectingthesightglass.
HydraulicStabilizers
75www.stucki.com
A.WindowFullUnitOK
B.PartiallyFullReplaceatthenextmaintenanceinterval
C.EmptyReplaceASAP
A flashlight may be helpful in makingthe sight glass inspection. Figure 4.4illustratesoneofthreeconditionsthatmaybeencounteredduringinspection.
Fig.4.4-HydraulicStabilizerSightGlassWindow
HydraulicStabilizers
76 www.stucki.com
ConditionA.Theoillevelinthereservoiris full. Theentire glass areawill appeardark, and the unit should be left inservice,regardlessofanyexternalsludgeaccumulation.
ConditionB. Theoil level has droppedto the sight glass window, and only theupperportionoftwoshinyringsappearstobereflectinglight.Thisindicatessufficientfluid remaining in the reservoir foradequateoperation;however,itisthefirstwarning theunitshouldbescheduled forreplacementwhenthecarisnextshoppedfor routine maintenance. This is not anAAR or FRA defect as foreign cars areconcerned. Forsystemcars,however, itisadvisabletoreplacewhenthisconditionisfound.
ConditionC. Theoil level has droppedbelow the sight glass area, and the twoshinyringsarecompletelyvisible.Theunitshould be replaced as soon as possible.ThisconditionconstitutesaviableAARorFRAdefect.
HydraulicStabilizers
77www.stucki.com
Stabilizersequippedwithasightglassmustbeinspectedaccordingtoabovefluidlevelguidelines.Onlystabilizersnotequippedwithasightglasscanberemovedonthebasisofwetfluidorbuildup>3”fromtheunit.SeeAARFieldManualRule50.HS-7, HS-7-100 and HydraShox™ Platinumunits removeddue to lowoil levelshouldbereturnedto:
A.StuckiCompanyc/oRandMachine
2072AllenStreetExtensionFalconer,NY14733
Pleasecall716-665-5217inadvanceforarequireddeliveryappointment.
HS-10s cannot be rebuilt. Once theirreserve oil has been depleted, theyshould be discarded. Stabilizers shouldbe replaced in kind or upgraded toHydraShox™Gold.
HydraulicStabilizers
78 www.stucki.com
Fig.5.1-BrakeBeam
5.BrakeSystemsBrakeSystems
Note: All Stucki Brake Heads are replaceable. Quick Change Beams and Cast Iron Beams also available.
BrakeBeam PartnumbersforComp.ShoeBeams
#18Fixed 18-LSRC-CH(LorR)
#18Reversible 18-LRRC-CH(LorR)
#24Fixed 24-LSRC-CH(LorR)
#24Reversible 24-LRRC-CH(LorR)
Specify(L)Leftor(R)Right
Table5.1
79www.stucki.com
Inspection
Replacement of brake beams can beconsidered for any of the inspectioncriteriabelow.RefertoAARFieldManualof Interchange, Rule 6 for a detailed listof wear limits, gauging and causes forrenewal.
1. Any brake beam parts which arecracked,brokenormissing
2. Damageorwearonbrakebeamhead(headsalonecanbereplacedinlieuofentirebeams-RCbeams)
3. Twisted beams (greater than 1 inchwhen comparing opposite headsagainstwheels)
4. Wornendextensions5. Bentortwistedstruts6. Strutpinholesworn3/16”ormore7. Slotleverworn1/8”ormore8. Brake shoe wear is >1” from top to
bottom
BrakeSystem
s
80 www.stucki.com
ReversibleBrakeBeamProcedure
ThreestepsforswitchingstrutpositionRHorLHinthefield(refertoFigure5.2).
First• Use screwdriver to pull retainer
(e-clip) and pin (if tight, pin may bepushedfromtheoppositeend,bythescrewdriver).
Second• Insertsteelbarinstrutleverslot.• Tiltrotatingstrut90degrees,untilthe
slotsinendcastingmatchslotsinstrut.Third• Re-insertpinwithgrooveendlast.• Reapply retainer by hand at pin
groove(pushitsecurelyinplacewithscrewdriver).
BrakeSystems
81www.stucki.com
Fig.5.2-StrutandPin
Pin
Strut
E-Clip
BrakeSystem
s
82 www.stucki.com
Fig.5.3-BrakeBeamHead
Fig.5.4-ReplaceableHeadKit
ReplaceableBrakeHeadProcedure1. Removeshoe.2. Cut Huck™ with torch and remove
damaged head from brake beamassembly.
3. Position replaceable head to alignholes
4. Insert bolt through replaceable headandbeamassemblycombined.Applywasher assembly (largewasher first,small washer next), and lock nut tothreaded bolt. Tighten lock nut untilorangesilicon isvisible (or300 ft-lbsequivalent).
5. Install brake shoe and return toservice.
BrakeSystems
83www.stucki.com
Fig.5.5-RollGuard™HandBrakeGroupN-LongLeverNote: Short Lever also available.
BrakeSystem
s
84 www.stucki.com
RollGuard™HandBrake
GroupNFeatures
• Longorshortreleaselevers• Sealed, wider bearings for extended
lifeandvalue• Roller bearing at wheel/clutch axle
forsuperiorperformanceandsmoothoperation
• Lubricationfree• E-coatedinrust-proofblackoxide• Certified under Hand Brake AAR
SpecificationS-475• Tight tolerances for reliable and
consistentbraking
BrakeSystems
85www.stucki.com
A. Stucki Company offers RollGuard™handbrakeaccessoriessuchasthehandwheel,chainjoiner,clevisandpin,sheavewheel,bell crank, shortand long releaselever separately for new rail cars or asreplacementparts.
Fig.5.6SheaveWheel
Fig.5.7Clevis&Pin
Fig.5.8HandWheel
Fig.5.9BellCrank
Fig.5.11ChainJoiner
Fig.5.10ShortReleaseLever
Fig.5.12LongReleaseLever
BrakeSystem
s
86 www.stucki.com
StuckiBrakeSystemAccessories
• MetallicBrakeBeamWearGuide• Non-MetallicBrakeBeamWearGuide• BrakeShoeKey• BrakeRodConnector (1-1/8”, 3/4” &
7/8”)• TruckBottomRods• BrakeBeamCenteringWearLiner
The Stucki Brake BeamCenteringWearLiner(Figures5.13and5.14)isdesignedto work with any size or manufacture ofbrakebeam.Itshouldbeinstalledononlyonesideofeachaxle,oppositetheproblemcontactareaofthebrakebeamandwheelflange.Iftheflangewearistypicallyfoundat the L1, R2, L3 and R4 locations, theBBCWL should be installed opposite ontheR1,L2,R3andL4locations.Onlyoneperaxleset.
Fig.5.13 Fig.5.14
BrakeSystems
87www.stucki.com
6.DraftSystems
Fig.6.1-PowRGuard™DraftGearModelXE,GXE&GX
DraftSystem
s
88 www.stucki.com
ModelsAvailable
PowRGuard™XE• Fits24-5/8”standardpocket• ApprovalreceivedunderM-901E• Officialratingcapacity:47,054ft-lb• Approximateweight:367lb• GroupJ,Rule21• 3-1/4”travel• Fitsallstandardyokeandcar
construction
PowRGuard™GXE• Allsteelwithelastomerinsert• Fits24-5/8”standardpocket• ApprovalreceivedunderM-901E• Officialratingcapacity:45,643ft-lb• Approximateweight:367lb• 3-1/4”travel• Fitsallstandardyokeandcar
construction
DraftSy
stem
s
89www.stucki.com
PowRGuard™GX• Allsteelwithelastomerinsert• Fits24-5/8”standardpocket• ApprovalreceivedunderM-901G• Ratingimpactvelocity:5.1mph• Approximateweight:367lb• 3-1/4”travel• Fitsallstandardyokeandcar
construction
• AllmodelsrequireAARY44standardfollowerforEcouplerapplication,orY46followerforFcouplerapplication.
PowRGuard™ Inspection Criteria - allconditionsinoroutofcar
Contactof themovableplate to theweartab is cause for renewal. AAR FieldManualRule21SectionAalsoapplies.
DraftSystem
s
WearTab
MovablePlate
90 www.stucki.com
7.RepairandReconditioning
AmericanIndustries
American Industries in Sharon, PA andIndependence, MO, and the MidlandDivision in Jerseyville, IL provide railcarrepair and reconditioning services tothe railroad industry. This includes new,secondhand, gauged and reconditionedrailroadparts.FacilitiesinSharon,PAarecertifiedunderAARM-212andM-214,aswellasQAcertificationM-1003.Facilitiesin Jerseyville, IL are certified underAARM-212,aswellasQAcertificationM-1003.
Reconditioningservicesinclude:• WheelSets• AirBrakes• Bolsters• Sideframes• Couplers• Yokes• DraftGears• CompleteTruckAssemblies
Recon
ditio
ning
Services
91www.stucki.com
Secondhandpartsinclude:
• AirBrakeParts• Yokes• C10Pins• Couplers• FollowerTrucks• Knuckles
Wheels
American Industries is certified to re-profile freight car and locomotive wheelsets to any profile. American IndustriesisalsoAARcertifiedformountingneworreconditionedwheelsandrollerbearings.
AmericanIndustriesprovidesinterchangeusable or second hand repairable axlesandrollerbearingsatcompetitiveprices.
ReconditioningServices
92 www.stucki.com
Recon
ditio
ning
Services
AmericanIndustriesMidwest
DistributionandReconditioningServices
American Industries Midwest businessoffersturnkeyreconditioningservices,anddistributesmany railcar components thatA. Stucki Company manufactures. Thebusiness is a leading provider of railcar-reconditionedcomponentsincluding:
• Bolsters• Sideframes• Duff-NortonAirJacks• Couplers• YokeAssemblies• BrakeBeams
All reconditioningand repairservicesarecertified under AAR M-1003 and M-214,so the highest quality and reliability isguaranteed.
93www.stucki.com
DraftGear
Independent Draft Gear, a division ofA.Stucki Company, reconditions, tests andpins the most commonly available draftgear per AAR M-901B Specifications.RefertoAARInterchangeRule21,SectionB,GroupsJ&Mforanoverviewofthedraftgearmodelsqualified. Locomotivegear/yokeassembliesarealsoreconditioned.
Other group type gears can bereconditionedandusedforcaptiveservice.
Inspection
Reconditioning of a draft gear can beconsidered when any of the defectslisted in Section A of the AAR FieldManual Rule 21 are present. Refer tothe manual for a detailed list of wearlimits, gauging and cause for renewal.
ReconditioningServices
94 www.stucki.com
Recon
ditio
ning
Services
Also,refertomanufacturer’sspecificationsfor In-Car and Out-of-Car inspectionrequirements for each individual model.
FrictionComponentClassification:
Agearmustbe reconditioned ifanyof itsfriction components are broken, damagedinanyway,ormissing.
Gears are classified as FC/C/D (FrictionComponent / Case / Damage) per thefollowingcriteria:
1. More than one broken or missingfrictioncomponent
2. Centerwedgeisdamaged3. The gear is stuck in a compressed
position
95www.stucki.com
Case Classification: As in the case offriction component damage, a draft gearmustberebuiltifthecasehasbeensubjecttoexcessivewearorisdamaged.GearswithcasesthatmeetthefollowingarealsoconsideredFC/C/D:
1. Wallthickness-visiblyworncasewall2. Torchcut-1inchormore
ScrapClassification:Gearswithbulges,splitcasesorcracksinexcessof2inchescannot be repaired and are classifiedas scrap. Also, gears not listed on theIDG list of acceptable gears are eithernot reconditionable or are obsolete andtherefore classified as scrap. Refer toAARRule21.
ReconditioningServices
96 www.stucki.com
Recon
ditio
ning
Services
Gears which meet the criteria forreconditioningshouldbeshippedto:
IndependentDraftGear1000MartinLutherKingJr.Blvd.
Farrell,PA16121Phone:724-981-2251FAX:724-981-2256
97www.stucki.com
ProductIndex
18-LSRC-CH(LorR)...................................................7818-LRRC-CH(LorR)...................................................7824-LSRC-CH(LorR)...................................................7824-LRRC-CH(LorR)...................................................78656-C.........................................................................28656-CR......................................................................18656-CRH....................................................................21675-RL.......................................................................22685-RM......................................................................23688-B.........................................................................29688-BR ......................................................................19690-RL.......................................................................20ASC-609D .................................................................59ASC-787C .................................................................60ASC-834CB...............................................................60ASC-915SW................................................................61ASC-925SW................................................................62ASC-17803..................................................................61BellCrank....................................................................85BrakeBeamCenteringWearLiner...............................86CCB.............................................................................10CSB®............................................................................9ChainJoiner................................................................85Clevis&Pin..................................................................85ColumnGuideWearPlate.............................................62HandWheel.................................................................85HydraShox™Platinum..............................................72HydraShox™Gold.....................................................72HS-7-100RB................................................................73
98 www.stucki.com
ProductIndex(continued)
ISB-9DR.....................................................................24ISB-9DRL...................................................................25ISB-10........................................................................26ISB-12........................................................................27LongReleaseLever....................................................85Plate...........................................................................30PowRGuard™GX.....................................................89PowRGuard™GXE...................................................88PowRGuard™XE......................................................88RetroXT4500............................................................17RetroXT5400B..........................................................15RetroXT5400C..........................................................16RetroXTLPBolt-On...................................................11RetroXTLPDrop-In...................................................12RetroXTLPC.............................................................13RetroXTSP................................................................14RFE-16......................................................................57RFE-18......................................................................57RFE-26......................................................................58RFE-41......................................................................58RFE-53......................................................................59RollGuard™HandBrake............................................83SheaveWheel.............................................................85ShortReleaseLever....................................................85SSB®............................................................................8Wedge........................................................................30
RideControl,SuperServiceRideControl,LowLevelRideControl,andSuperServiceRidemasterarefederallyregisteredtrademarksofASF-Keystone,Inc.BarberisafederallyregisteredtrademarkofBarber,Inc.MinerisafederallyregisteredtrademarkofMinerEnterprise,Inc.Cardwell-WestinghouseisafederallyregisteredtrademarkofWabtecCorporation.
Thispageisintentionallyleftblank.
Stucki de Mexico, S. de R.L. de C.V. +52 (81) 8007 7300
A. Stucki do Brasil Ltda +55 (11) 3842 4630
A. Stucki CompanyPittsburgh, PA
412 - 771 - 7300FAX: 412 - 771 - 7308
IndependentDraft Gear Farrell, PA
724 - 981 - 2251
American Industries Midwest
Independence, MO816 - 836 - 1901
Hill RailroadCar Company
New Castle, PA724 - 654 - 8257
American Industries Sharon, PA
724 - 981 - 4100
Alco SpringChicago
Heights, IL708 - 755 - 0438
American Industries Midland Division
Jerseyville, IL618 - 498 - 4442
A. Stucki Co. Warehousec/o SECO MachineNorth Canton, OH
330 - 499 - 2150
