* CARDWELL WESTINGHOUSE * COBRA RAILROAD FRICTION PRODUCTS * SCHAEFER * WABCO FREIGHT CAR PRODUCTS * WABTEC GLOBAL SERVICES * STANDARD CAR TRUCK COMPANY * WABTEC RAILWAY ELECTRONICS * BARBER SPRING * BARBER BRAKE BEAM * ZEFTEK * COAL CAR CATALOG August 2009 1 Letter f I t d ti L tt of Introduction Dear Valued Customer, The Wabtec Corporation has grown exponentially over the past few years and our product offerings in the Freight Car Locomotive and Transit markets have followed suit The recent addition of The Standard Car Truck Company Car, suit. to the Wabtec family of companies is another exciting step in that direction. Having received numerous customer requests to provide “railcar specific” product catalogs as a quick and easy reference guide, the catalog enclosed herein is assembled specifically to address the high speed, high mileage environment inherent for both Rapid Discharge and Rotary Coal cars. The Catalog is divided into separate sections corresponding to the specific Wabtec subsidiaries that provide the particular components. For example, Cardwell Westinghouse provides the Mark 50 draft gear, long seen as the unquestioned leader in the freight car draft gear sector. TMX and UBX truck mounted brake systems; proven performers that are cost effective and easy to recondition after many years of service. A comprehensive selection of Slack Adjusters, which address the varying requirements of every freight car type in today’s environment. Wabco Air Brake division, in existence for well over 130 years, has for decades and still today continues to set standards for Air Brake Valves, Empty/Load Devices and a myriad of other air brake components. This division, l ih b il l i along with Wabtec Railway Electronics, i at the f f is f developing and i l h forefront of d l i i l i ll d implementing Electronically Controlled Pneumatic (ECP) braking systems. Standard Car Truck Company, recognized as a global leader in railcar truck component design and truck stabilization, provides complete freight car truck packages that offer superior performance with the heavy axle loads seen in today’s railroad environment. Zeftek, acknowledged as the industry leader in wear and damage prevention solutions, addresses many different car types and service environments. Providing engineered-grade non-metallic products that reduce both component wear and life cycle costs, Zeftek offerings also increase rail car utilization with the reduction of out-of-service time. Railroad Friction Products Corporation, the developer of the COBRA® TreadGuard® DayOne™ brake shoe, has earned the coal sector’s highest respect, by providing a supremely effective wheel tread conditioning brake shoe that significantly reduces the number of wheels changed in service. The patented design TreadGuard® is evidence y g p that the entire team is focused on continuously adding value to the product. Schaefer Products, in business for over 90 years, provides high quality accessories like brake levers, rod eyes, jaws, corner caps and bolster bowl rings, while also offering custom fabrication and forging services. You can see why we at Wabtec are truly excited about our recent expansion and everything that means for you, our customer. Contact your Wabtec representative and see what the future of customer service looks like today! Respectfully yours, The Wabtec Freight Car Group 2 TABLE OF CONTENTS 3 Wabtec Freight Car Group Company Contact List Visit us on the web for a complete listing of Wabtec companies. www.WABTEC.com Wabtec Corporation * 1001 Air Brake Avenue * Wilmerding, PA * 15148 * Phone: 412-825-1000 4 5 For Freight Car Products Field Service - call 1-888-264-0011. *Locomotive and Transit products are not included in the chart above. Please contact your local Wabtec Global Service Center for a complete listing. 6 Wabtec Equipment Diagram* *Standard Car Truck Company and ZefTek Shown Separately 1 3 4 15 13 14 7 DESIGNED TO OPTIMIZE Equipment Diagram* PERFORMANCE WabtecTruck and Zeftek shown separately. *Standard Car FREIGHT CAR EQUIPMENT: Wabtec offers an Parts List unmatched menu of freight car products and services. 1 Corner Caps Our reputation for developing advanced braking 2 Dirt Collector & Cut-Out Cock equipment for freight cars is unsurpassed. No other 3 Two-Compartment Reservoir supplier has more experience or has made more distinguished contributions to this sensitive and 4 Release and Hold Hand Brake complex arena. A recent innovation is the 5 Draft Gear development of Electronically Controlled Pneumatic braking equipment that integrates electronic and 6 Brake Pipe End Cock pneumatic communications hardware into one 7 Hose & Coupling package that instantly responds to locomotive braking commands. Wabtec provides field proven 8 TrainLink® End-of-Train Device ECP braking solutions that are AAR-approved under 9 Truck-Mounted Brake Assembly (TMX® & UBX®) or S-4200 series specifications. ECP Options include an overlay to conventional AAR Pneumatic brake Schaefer Conventional Rigging Kits, Brackets, Braces, equipment, as well as “stand-alone” ECP braking. Levers, Rods & Hangers (not shown) 10 Double-Acting Self-Adjusting Slack Adjuster We’ve also developed a unique computerized, 11 Brake Shoe Automated Single Car Tester that permits quick, easy, accurate testing of the car’s air brakes. 12 Retaining Valve Wabtec’s depth of capability and service goes 13 1-1/4” DYNABALL Angle Cock beyond technology and innovations. We’re the only company in North America that offers a definitive 14 ABDX® Freight Brake Control Valve Mounted on selection of components and products, from control Single-Sided Pipe Bracket valves to brake shoes to draft gears and articulated 15 ELX-S™ Empty/Load Valve. Brake Cylinder couplings to End-of-Train devices. Monitoring Taps and Fittings (not shown) And, as an original equipment supplier for such a vast array of products, we can service, replace or upgrade virtually any mechanical, pneumatic or electronic braking component to suit our customers’ particular needs. We offer these capabilities, along with guaranteed workmanship and fast turnaround, through our network of strategically located facilities operated by Wabtec Global Services. 8 ECP BRAKING SYSTEMS 9 ECP-4200 BRAKING SYSTEMS 10 11 ABDX® Systematic Product Improvement Since its introduction in 1989, Enhancements the ABDX control valve has Some of the product undergone numerous enhancements and process improvements to increase improvements incorporated into service life and make the valve the ABDX product line include: more robust in the demanding and ever-evolving railroad •Vibration damage protection. environment. At Wabtec, all •Improved pipe bracket gasket. processes involving design, •New long-life, quick-service test and problem resolution limiting valve. make use of modern statistical •Wire mesh emergency engineering methods. accelerated release filter. The Service Accelerated Release (SAR) valve •Plastic top on back-dump spool has been redesigned to improve vibration protection by reducing metal-to-metal contact. Performance for improved vibration protection. The ABDX control valve •Integral vent protector. provides state-of-the-art brake •Lost foam process used in response times, as well as production of ABX and Single- precise brake cylinder Sided Pipe Bracket for more pressure control under all consistent, cleaner castings. braking conditions, including •Aluminum valve bodies. The Quick Service Limiting Valve significantly long, steep grades. The •100% computer controlled improves initial train service brake ABDX control valve applies testing of all valves after shop application times while further improving internal leakage protection. and laps precisely, assuring assembly. the proper brake cylinder •Redesigned service accelerated pressure. release valve. Protective Guide Rings effectively eliminate internal valve damage caused by high vibration frequently found on lightweight cars. Service and emergency Mounting Gaskets have been redesigned to virtually eliminate leakage or blowout due to uneven torque applications. 12 ABDX® Maintenance and Automated Testing Maintenance/Life Cycle Costs Wabtec ABDX control valves accommodates connection to ABDX control valves include a clearly represent your best a computerized Wabtec combination of poppet and slide value for the long haul. Automatic Single Car Test valve technology for primary Device (ASCTD). The efficient braking functions. Overall, this Automatic Testing system provides a precise combination provides precise brake ABDX control valves can be method for testing freight car cylinder pressure control, while purchased with a unique air brakes while requiring only using 20% fewer working parts. integral automated testing half of the time of the The result is a control valve far receiver built into the pipe conventional manual test, and less costly to clean, oil and test. bracket . This receiver yet providing a far more comprehensive test. It greatly Reduced maintenance costs mean improves the accuracy of reduced operating costs and a testing the car brake system, lower life-cycle cost for your provides documented record braking system. Additionally, of the results, reduces costly Wabtec maintains the most misdiagnosis and the extensive and complete line of erroneous removal of properly Service Centers in the industry for working valve portions. repair of ABDX control valves and all other brake equipment used in North America. Wabtec ABDX Control Valve shown with a single- sided pipe bracket and standard 4-port receiver. 13 ABDX® Features & Benefits Wabtec ABDX Control Valve with conventional ABX pipe bracket shown with optional 4-port receiver and #11 port location. This configuration is also available with top and bottom access plates. 14 30%, 35%, 40%, 50% & 60% Empty and Load Equipment Designed to Optimize Performance On Any Application 15 Why ELX Empty/Load Equipment? Most freight cars built today are designed for gross weights of up to 286,000 lbs. Empty weights can be as low as 41,700 lbs for some aluminum gondola cars, creating a gross to tare weight ratio of 6.9/1. New AAR S-401 specification mandates require higher loaded braking ratios of 11% to 14% on all new cars, putting more emphasis on reducing empty braking ratios to levels that will prevent costly wheel sliding during normal braking. Studies have shown that wheels are less likely to slide, even on poor or slippery track, if the empty braking ratios are kept at or below 25% versus the AAR allowed 32%. Wabtec’s expanded family of ELX Empty/Load equipment now includes 40% units that reduce loaded braking ratios by 60% to ensure that empty cars achieve adequate retardation, while minimizing chances for wheel sliding. Wabtec’s ELX equipment also offers other advantages stemming from its proportioning of up-side high pressure air. This virtually eliminates brake cylinder pressure spikes during initial braking, while reducing reservoir sizes and related weights. ELX equipment is available in three different configurations for simple installation on any car, and is compatible with both body and truck mounted brake equipment. Required brake cylinder pressure taps can be included as part of the ELX unit, eliminating separate installation costs. ELX unit with built-in pressure trap. WABCO ELX EMPTY & LOAD EQUIPMENT CONFIGURATIONS ELX-B Basic Unit-Sensor-arm actuated. Requires detached equalizing volume. Low profile –Sensor-arm actuated. ELX-BRLP Requires detached equalizing volume. ELX-S Slopesheetapplications - Diaphragm actuated. Integral equalizing volume. For more information on part numbers and pricing, call our customer service department toll free 1-877-922-2627 16 ELX-S ELX-S is available in 30%, the slope sheet. Car loading is the ELX-S unit to change from 35%, 40%, 50% and 60% detected directly when the empty to a loaded brake proportioning for use on bulk bulk load depresses a position. commodity cars. The unit is reinforced rubber diaphragm self contained and mounts to in the slope sheet, causing SELF RESETTING LOCK OUT The ELX-S includes a self resetting lock-out button that simplifies single car testing while ensuring that the device automatically resets when the brake pipe is recharged. 17 ELX-B & ELX-BRLP ELX-B is available in 30%, It consists of two assemblies. separately mounted equalizing 35%, 40%, 50% and 60% A sensor/proportioning unit reservoir that can be supplied in proportioning and is a basic mounts to the car body in a varying capacities to meet design with a sensor arm for way that allows the integral specific brake cylinder volume measuring truck spring sensor arm to contact the top requirements. deflection on loaded and of the truck side frame when in empty cars. a loaded car mode. There is a LIGHT WEIGHT ELX units are constructed mainly of alodined aluminum. Weights are significantly lower than most other empty load units. COMPACT SIZE All ELX units utilize up-stream brake cylinder pressure thereby requiring a reduced size equalizing volume resulting in a compact unit. EASY ADJUSTMENT Equipment set up and proper adjustment is simple. Position the empty car on a level track, apply a full service brake and check for: 1. A ¼” gap between the arm stop and the top of the side frame. 2. The empty-car indicator button to be protruding out. * LP version incorporates low profile sensor arm. 18 ASCTD: 4-PORT DIAGNOSTIC SYSTEM The Automated Single Car Test Device is the most effective way of testing air brakes to ensure they are functioning as designed. Instead of trial and error repair, the ASCTD helps to identify the root cause of air brake malfunctions and tests valves in half the time of the industry standard. The Wabtec ASCTD is also equipped to conduct brake tests from the end of the car. This helps to lower maintenance costs by keeping good cars in circulation, fewer cars in repair, and also helps improve life cycle costs associated with improper brake applications (wheel damage, excess brake shoe wear, and other vibration related issues). •Enhanced Rail Car Productivity •Improved Test Quality ASCTD •Helps to Identify Failures in Half the (Automated Single Car Test Device) Test Time The ASCTD can be utilized with either a Single-Sided or Conventional Pipe Bracket equipped with a 4-Port Receiver as shown below. ABDX Control Valve with ABDX Control Valve with SSPB (Single-Sided Pipe Bracket)and Conventional ABX Pipe Bracket Standard 4-Port Receiver ASCTD RECEIVER ASCTD ACCESS PLATE & RECEIVER 19 TRAINLINK™ ES END-OF-TRAIN DEVICE Wabtec Railway Electronics’ TRAINLINK ES improves braking performance by automatically making service brake pipe reductions at the rear of the train. As the locomotive engineer begins making the brake pipe reduction, the desired brake pipe pressure is immediately transmitted to the TRAINLINK ES. The TRAINLINK ES responds by venting the desired brake pipe pressure at the rear of the train. The effect is a dramatic improvement in the brake application response time, while operating entirely transparent to the locomotive engineer. 1-1/4” Dynaball Angle Cock The DYNABALL angle cock features a Teflon-coated ball to provide smooth, effortless hand movement. The large rubber seals, which are self-lubricating, self- cleaning and self-adjusting, reduce leakage and can be replaced quickly. Retaining Valve The RX-3 retaining valve controls airflow from the brake cylinder during brake release. For retaining brake cylinder air pressure to control train speed during the brake recharging process, the valve can be positioned manually to provide three cylinder release modes: full release at either normal or slow air flow rates, or retention of 20 psi. Composite Retaining Valve The Composite Retaining Valve is an AAR S-446 compliant, lighter version of the current brass RX- RX-3 retaining valve and constructed of high strength, UV stabilized, impact resistant thermoplastic resin. The durable lightweight design provides long service life and is interchangeable with the Standard RX-3 Retainer. Two-Compartment Reservoir A two-compartment reservoir on a freight car is used to store compressed air for auxiliary service and emergency brake applications. The fabricated one-piece design has two attachment lugs on the auxiliary side and one lug on the emergency side to ensure proper application on the freight car. 1-1/4” Brake Pipe End Cock The 1-1/4” brake pipe end cock is designed for use on specific rail vehicles where the standard pipe angle cock cannot be used, and where the air pressure and the equipment arrangement does not exceed 150 psi. The cock provides a means for the manual closing of the brake pipe, as on the end of the last car of a train consist, and the continuation of the brake pipe between coupled cars by the connection of an attached brake hose assembly. Hose and Coupling Wabtec provides AAR compliant End of car Hoses, Brake Cylinder Hoses and Empty Load Hoses. 20 45% Less Weight than a Conventional Body Mounted Brake 21 ® Key Features: 22 •Weight: 63 release. •Top quick release Top quick release handle and wheellbs handle and wheel Model 9300 and 7500 Model 4493-3 •AAR approved Interchange Rule 13, •AAR approved Interchange Group O Group N. •Minimum force 4475 lbs. •Minimum force 3350 lbs. •Chain Travel 40” •Chain Travel 18” •Weight: 71 lbs. •Weight” 63 lbs. 23 Continuous Release CRX Hand Brake 9300 CRX and 4493 CRX Introducing the new continuous release CRX Hand Brake… Benefits: •Reverse wind stop. •Helps to extend wheel life. Model Shown: 4493 CRX Hand Brake •Eliminates the potential of partially released hand brakes causing car and wheel vibration damage. Key Features: •Apply with hand wheel, gradual release with hand wheel, quick release with full release handle to activate continuous release feature. •No visible operational differences between Groups Q & R vs. Groups N & O. •Quick release activates the continuous release feature. 24 Universal Slack Adjusters Models 2300-DJ, C1000 25 Benefits •First Draft Gear to Receive Unconditional Approval Under AAR Spec M-901E. •High Performance in any Operating Environment. •Well Suited for ALL Railcar Types with 24-5/8” Pocket and 3-1/4” Travel, up to 286K lbs GRL. •Has Saved Customers Millions of Dollars Since It’s Inception in 1961. 26 27 28 29 Recondition your Universal Slack Adjusters for a second lifetime of Service. All compression slack adjuster rod weldments are re-plated. 30 Recondition your Mark Series Draft Gears for a second lifetime of Service. 31 RAILROAD FRICTION PRODUCTS COBRA® TreadGuard® Brake Shoes Key Features: Cast Iron Insert •Continually Cleans Minor Tread Defects and Damage. •Minimizes Impact Between the Wheel and Rail. •Slightly Roughens Tread to Improve Wheel to Rail Adhesion. AP Design •Prevents Rim Over-Ride , Flange Overheating and Consequent Damage. •Painted Red for Immediate Identification. •Heavy Duty Steel Backing Plate. •Decal Provided at No-Charge for Car Identification. Benefits: •Reduces Wheel Removal for Repair, Shelled Tread, Out-of-Round Conditions and Wheel Bearing Failures. •Prolongs Life Cycle of Wheels. •Reduces Out of Service Time. •Reduces Wheel Set Inventories. •Increased Shoe Life. Test conducted over a 36-month period comparing two Unit Trains (without COBRA TG shoes) with one Test Unit Train (with COBRA TG shoes). All three trains were made up of 119 cars running under identical service and operating conditions. The two trains running without COBRA TG shoes averaged 119 wheelsets removed due to shelling, while the unit with COBRA TG shoes had 20 wheelsets removed. An 83% reduction. TreadGuard® Brake Shoes · Cover a lot of ground. 32 RAILROAD FRICTION PRODUCTS BRAKE SHOE IDENTIFICATION CHART Shoe COBRA® COBRA® Length Standard Brake Shoes TreadGuard® Brake Shoes V472– 1.5” Standard High V625 – 1.5” DayOne Friction Freight Brake Shoe TreadGuard® Brake Shoe 12” V474– 2.0” Standard High V624 – 2.0” DayOne Friction Freight Brake Shoe TreadGuard® Brake Shoe Cobra® and TreadGuard ® are registered trademarks of Railroad Friction Products Corporation. COBRA ® 33 Schaefer Forged Railcar Components … Forging solutions for over 90 years. Our Quality Forgings Keep You On Track From Start To Finish: •Coupler Carrier •Hollow Forged Truck Wear Plates Lever Connections •Air Hose Hangers •Brake Rod Jaws •Link System •Brake Cylinder Push •Bolster Rings Rods •Cross-ridge Brace Foot •Replacement Bolster Gibs •Corner Caps: Bolted or Weld-on. •Forged Truck Brake Levers •Hook Anchors 34 The Schaefer Link System … A low cost solution for improved braking performance. Key Features and Benefits: •Uses standard truck lever arrangement. •Promotes even brake shoe wear. •Improves brake shoe force and shoe alignment. •Extends life of the end guide and wear liner as well as the brake shoe and wheel life. •Equipped with Schaefer 3-hole truck lever connections and equipment links. FORGING SOLUTIONS FOR OVER 90 YEARS This combination of components guides the brake beam in a horizontal configuration, regardless of brake beam end extension wear. The brake beam is prevented from drooping, which can cause the top of the brake shoe to wear more than the bottom as the top of the brake head tilts closer to the wheel tread. It also reduces the frictional losses between the brake beam and the side frame pocket, thereby increasing the rigging efficiency and reducing brake shoe force variations from side to side on the same brake beam. 35 Schaefer Custom Forged Solutions … Specialty Components from Concept to Design Push Rods, Brake Rod Jaws and Brake Rod Eyes •Drop forged from special bar quality steel. •Designed and proven to be stronger than the brake rods themselves. Truck Brake Levers and Body Brake Levers •Weigh approximately one-third less than fabricated levers. •Proportioned for uniform resistance to stress. •Heat treated upon request for maximum pin hole wear. •Longer service life. Clevises •Available in AAR sizes and special sizes upon request. •Straight or twisted. Pedestal Side Frame Keys, Coupler Carrier Wear Plates, Roping Staples and Miscellaneous Car Parts Crossbridge Bracefeet, Vibrator Brackets and Bolted Corner Caps Truck Lever Connections •Hollow design significantly reduces weight. •Available in various lengths and various pin hole sizes. •Straight or offset. Bolster Replacement Rings and Gibs •Weld configuration machines to suit requirements •Heat treated to lessen wear. •Available in sizes from 12” to 16” diameter. · SERVICE · PERFORMANCE · TECHNOLOGY · 36 Schaefer Custom Forged Solutions … Specialty Components from Concept to Design Meeting challenges and exceeding our customers’ expectations is a Schaefer tradition. During the past 90 years, we have worked with virtually every railroad and freight car builder in North America. We forge our commitment into every component we manufacture, from our standard product line of forged freight car brake parts, to the forgings we customize for an ever-growing number of customers. The Schaefer facility includes a professional design and engineering department, a high capacity forging plant and extensive warehousing space for raw materials and standing inventories of the components you need. Schaefer continues to expand its facilities to serve our customers even better. · SERVICE · PERFORMANCE · TECHNOLOGY · TWISTING FORGING HEATING BENDING CNC DIE MACHINING DRILLING 37 S-2 BARBER STABILIZED TRUCK Component Diagram Exploded View 38 Truck Components Bolster Nomenclature 39 Truck Components Side Frame Nomenclature 40 S2HD-9C Design The S2HD is the first true 100 ton three-piece freight car truck, and has been used extensively in heavy axle load service for over thirty years. So, when it came time to arrange the secondary suspension spring group for the S2HD-9C for S-286 service, we decided to go with the proven, full 1.5 reserve ratio, 286K GRL capacity spring group for the truck. As designed, the S2HD-9C offers a substantial load carrying capacity advantage over an alternative truck, which has only 5 inner load springs making it essentially a 263K GRL capacity suspension. The S2HD-9C is also M-976 approved for use on all 110 ton cars. The primary suspension and snubbing components are also featured here to further emphasize the importance of the three component groups together. As illustrated here, the primary suspension is made up of a roller bearing adapter and shear pad, and the snubbing is made up of the wedge, pocket insert, sidewall wear plate, and column wear plate. More detail is provided about these components later in the booklet. Our S2HD-9C is M-976 approved for use on all 110-ton cars and offers a substantial load carrying advantage compared to alternative trucks. 41 Split Wedge Design Bolster Pocket Insert Side Wall Wear Plate The Bolster Pocket Inserts and Side Wall Wear Plates are easily replaced within minimal time and effort. The S2HD-9C also includes the modern standard of wedge performance, the split wedge. Developed in the ’90’s to improve stability and curving, the split wedge accomplished both and has become the preferred wedge of many railroads and car owners alike. Our 915-SW Split Wedge features easy to install and replace bolster pocket inserts and sidewall wear plates. We include these durable, labor saving components in all our S2HD bolster castings standard to ensure that every Standard Car Truck Barber truck exceeds your life cycle expectations, and is easy to restore to new condition with a minimum of time and effort. Instead of time consuming and difficult weld and grind, our pockets are restored by simply replacing the inserts and sidewall wear plates. Our 915 friction castings are made of highly durable friction iron, instead of steel. Our friction iron has proven to be more than twice as durable as steel, creating better longer lasting friction castings. Our friction iron has also proven to have lower friction than steel, creating a smoother acting, better performing friction wedge. The Modern Standard of Wedge Performance 42 One-Piece Wedge vs. Split Wedge Example of a One-Piece Wedge. The gaps (shown by the green arrows) allow movement resulting in wear to the truck. Why are split wedges better? They are because they do a better job of keeping the truck square, and a square truck is a better performing, and longer lasting truck. One-piece wedges leave gaps between the wedge and sidewalls in order to provide space to fit the wedge into the pocket. After installation, these gaps are undesirable, because they leave room for the wedge to move in the pocket. So, the one-piece wedges rotate easily allowing the truck to warp. Truck warp then leads to more wheel wear in curves, and component wear and damage from hunting. Split Wedge =A better performing, longer lasting truck The Split Wedge design eliminates the gap problem, thereby eliminating truck warp caused by wedge rotation. The split wedge solves the gapping problem by bracing two independent wedge halves against the sidewalls. The split wedge bracing action eliminates the possibility of truck warp due to wedge rotation, and raises truck squaring or warp resistance to a much higher level. With the split wedge, a truck cannot warp unless the wedge halves slide in opposite directions to each other, and this action requires much more warp force. As a result, the 915-SW Split Wedge keeps the truck square at higher speeds, under greater loads, in tighter curves, and for more of its life than any one-piece wedge can. 43 SCT Barber Friction Wedges 51 Friction Wedge Interchangeability Matrix Increased high speed 350 degree Most durable iron 51 stability and longer Prolongs wedge life up to material available. deformation component wear life. temperature. 1.4 million miles. 44 45 Barber Split Wedges Split Wedge Assembly = Right Hand + Left Hand + Bolster Pocket Insert 46 Bolster Pocket Wear Plates and Inserts Replaceable Bolster Pocket Wear Plates prevent wear to the casting and help reduce maintenance costs over time. Available in steel or stainless as shown. Convert any Barber Truck to a split wedge with the Bolster Pocket Inserts shown below. Bolster Pocket Side Wall Wear Plates Primarily utilized for split friction wedge conversions. 47 S2-86 Radial Adapter The Barber S2-86 Radial Adapter is based on time tested technology that has been in service for many years and many heavy axle load gross ton miles. The name, as you might have guessed, is a conjunction of our well known Barber S2 truck brand name, including S2-A, S2-B, S2-C, and S2-HD, and the AAR’s S-286 rule which governs cars in the weight category for which the adapter is approved. And, the Radial part of the name is meant to convey the semi-radial steering performance that the shear pad is designed to provide, as well as echo our long history in high performance truck design by recalling to mind trucks like our Barber Radial. The adapter is essentially a trim version of the AAR standard narrow pedestal adapter. And, the primary suspension element is a trim one layer version of our successful, million mile two layer shimmed shear pad. Double Side Tabs act as rejection lugs for the old style lord pad and differentiate the S2-86 from the standard adapter which has Single Side Tabs. Features & Benefits: •Center recess – acts as a wear gauge and like the standard adapter, provides better load distribution for pedestal inconsistencies. •M-924 approved – Roller Bearing Adapter Specification – Gauge Related •Shear pad thickness just under the current Pennsy Adapter Plus. •Vulcanized rubber bonded to steel. Very durable with wide operating temperature range. •Center rejection lug – pad cannot be used on std adapter •Ground wire – static discharge 48 Shear Pads and Pedestal Roof Shims Shear Pads •Can be used with a standard AAR adapter. •S2-86 Approved Truck Design. •Rubber bonded to the steel shear pad, links the wheel set and H-frame, allowing flexibility in the truck suspension. Roof Shims The Roof Shim is used in lieu of a Shear Pad in a frame brace application for a more rigid suspension. 49 Type-3 Column Wear Plates (Bolt & Weld) The 3/8” thick wear plate utilizes mounting hardware that includes a washer as shown above. Each item shown is ordered separately. 50 Barber Side Springs Side Springs 51 Barber Load Springs Load Springs 52 Barber 976-AAR Spring Groups 935-SW/907SW Common Barber AAR Spring Groups 53 Constant Contact Side Bearing (Low Profile) •AAR M-948 Approved Part 6343 Constant Contact Side Bearing Blocks (Standard Travel) 54 Steel Brake Beam Guide Benefits •Meets AAR Standard S-367-83 •Suitable Alternative to Non-metallic Version. 55 Barber Brake Beam Standard Car Truck announced in 2007 the addition of the Barber Uni-Truss Design = Brake Beam to the growing line of Barber Freight Car truck products. Formerly known as the Triax, these world-class brake beams set the industry standard for quality, durability and innovative design features. Barber is the only brake beam made with the Uni-Truss Single Piece design. The one-piece forged steel construction is why Barber is the industry standard for strength and reliability. Formed Steel Construction Benefits •Zero Field Barber Brake Beam Failures •No Welds to Fail •No Fasteners in Shear Uni-Truss Design Barber Brake Beam, Diagonally Corrected End Another innovative and cost saving feature available from Barber Brake Beam is the diagonally corrected end. Conventional brake beam ends, like the one shown in the first frame are designed as though brake beam forces were balanced, but they’re not. Unbalanced forces on conventional brake ends allow the brake beam to rotate in the guide pocket, and wear out brake shoes at the top end. The Barber diagonally corrected end, counteracts brake beam rotation, and provides even pressure across the full face of the shoe. 56 ZEFTEK COMPONENT DIAGRAM 57 f f ld l i d ZefTuf ® Cold Flow Resistance CFR and CFR-P ( (Premium) Full Bowl Liners and Horizontal C i ) ll l i d i l l Center Plate Protectors provide unmatched durability and wear protection regardless of service environment. Available in low (CFR) and high friction (CFR-P) models, each is designed to improve curving and lateral stability performance of truck (bogie) systems. Integrally molded carbon ring/studs provide consistent conductivity over the life of the liner. ZefTuf CFR/CFR-P(Premium) - Superior Cold Flow Resistance ZefTuf® CFR/CFR- Creep Test - Center Bowls ckness Percent Loss of Original Thic L Material Temperature Coefficient of Friction Lubrication Extremes ZefTuf ® CFR 250°F – 60°F 0.17 Static/0.12 Dynamic None Required Yellow ZefTuf ® CFR-P 250°F – 60°F 0.33 Static/ 0.27 Dynamic None Grey ( y (Premium) ) q Required Precaution: Sharp Edges Heat: Use Caution When Welding • Up to Four Times the Resistance to Cold Flow versus competitive non-metallic liners. • Self-lubricating Proprietary Material never needs lubrication. • Meets AAR requirements S-3004 and M-976 Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 58 ZefTuf ® Cold Flow Resistance CFR and CFR-P (Premium) Center Bowl Liners and Center Plate Protectors provide unmatched durability and wear protection regardless of service environment. Available in low (CFR) and high friction (CFR-P) models, each is designed to improve curving and lateral stability performance of truck (bogie) systems. Integrally molded carbon ring/studs provide consistent conductivity over the life of the liner. Quantity 2 required per car. Meets AAR Requirements S-3004 and M-976. ZefTuf® CFR Horizontal Liners ZefTek Description Item Weight Packaging Item# (lbs.) ZT-370 14” Diameter Horizontal Liner, ¼” Thickness. Color: 1.25 lbs 25 per Box/ Yellow . (Replaces WE-1014 models) each 500 per Skid ZT-371 16” Diameter Horizontal Liner, ¼” Thickness. Color: 1.90 lbs 25 per Box/ Yellow. (Replaces WE-1016) each 500 per Skid ZefTuf® CFR Full Bowl Liners ZefTek Description Item Weight Packaging Item# (lbs.) ZT-380 16” Full Bowl Liner, 2” Deep. Color: Yellow 3.0 lbs each 10 per Box/ (Replaces WE-2016-J) 100 per Skid ZT-381 16” Full Bowl Liner, For 2 ¼” Deep, Color: Yellow. 3.10 lbs 10 per Box/ (Replaces WE-2016) each. 100 per Skid Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 59 ZefTuf ® Cold Flow Resistance CFR and CFR-P (Premium) Center Bowl Liners and Center Plate Protectors provide unmatched durability and wear protection regardless of service environment. Available in low (CFR) and high friction (CFR-P) models, each is designed to improve curving and lateral stability performance of truck (bogie) systems. Integrally molded carbon ring/studs provide consistent conductivity over the life of the liner. Meets AAR Requirements S-3004 and M-976. ZefTuf® CFR-P Horizontal Liners ZefTek Item# Description Item Weight Packaging (lbs.) ZT-561 16” Diameter Horizontal Liner, ¼” 2.75 lbs 20 per Box/ Thickness. Color: Grey each 400 per Skid (Replaces WE-1016-XLS) ZefTuf® CFR-P Full Bowl Liners ZefTek Description Item Weight Packaging (lbs.) Item# ZT-350 16” Full Bowl Liner, 2” Deep (for 2” Deep 4.5 lbs 10 per Box/ Bolster Bowls) Color: Grey each 100 per Skid (Replaces WE-2414-J) ZT-351 16” Full Bowl Liner, For 2 ¼” Deep (for 4.6 lbs 10 per Box/ 2 ¼” Deep Bolster Bowls) Color: Grey each 100 per Skid (Replaces WE-2416) Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 60 Inspection Report: ZT-351, 16” Full Bowl Liners for 2-1/4” deep bowls 61 Inspection Report: ZT-351, 16” Full Bowl Liners for 2-1/4” deep bowls 62 Self-Locking Knuckle Pins Self-Locking Knuckle Pins replace worn or broken C-10 pins with non-metallic knuckle pins for superior performance. A 1/16” groove at shear points eliminate stress risers caused by worn or out-of-tolerance castings. No bending fatigue, the primary cause of pin failure. Easy installation, lightweight, and no cotter pin required. Direct replacement of AAR C-10 pins. Replace broken or worn C-10 pins with our ZT-2075 •Less than 1 minute to install. •Self-locking tabs require no tools or cotter pin for application. • Grooved Shear Points reduce Pin Fatigue. • 88% Lighter than steel alternative. • Safe for Thaw Sheds. • Refer to AAR Code 2075 Material Temperature Heat Extremes ZefTuf® - HD 160 F to – 60 F No Temperatures above ZT-2075 200 F. ZefTek Item# Description Item Packaging Weight ZT-2075 ZefTuf® Self Locking .87 lbs 50 per Box/ Knuckle Pin each 900 per Skid ZT-276 Knuckle Pin Removal Tool 4.12 lbs Each each ZT-276 Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 63 64 ‘F’ Type Draft Sills CCWP Eliminate coupler shank and draft sill basket wear with the ZefTek ZT-360 Flexible Coupler Carrier. Weighs over 40 lbs. less per car set than steel carriers and eliminates coupler shank and draft sill basket wear. Requires no lubrication. Available in four sizes for varying coupler height requirements. ZefTek Length Dimension Dimension Dimension Replaces Weight Packaging Item# ‘A’ ‘B’ ‘C’ ZT-360-01 11 5/8” 5/8” 3-3/4” 5-3/8” WE-4001-X 5.0 lbs Each/ WE-4900-X each 90 per Skid ZT-360-02 11 5/8” 7/8” 4” 5-5/8” WE-4001-X 5.0 lbs Each/ WE-4900-X each 90 per Skid ZT-360-03 11 5/8” 1-1/8” 4-1/4” 5-7/8” WE-4001-X 5.0 lbs Each/ WE-4900-X each 150 per Skid ZT-360-04 11 5/8” 1-3/8” 4-1/2” 6-1/8” WE-4001-X 5.0 lbs Each/ WE-4900-X each 90 per Skid Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 65 ‘Weld-On’ CCWP Our ‘Weld-on’ Coupler Carrier Wear Protectors incorporate our patented bonding process (ZefTuf ® – HD bonded to A-36 steel) for easy weld-on application without removing the coupler. Eliminates coupler shank inspection, maintenance and reconditioning costs of conventional coupler carrier wear plates. They surpass competitive products in cold flow and impact resistance. ZefTek Item# Color Width “B” Depth Thickness Weight Packaging “A” ZT-326-3A Green 10 15/16” 4 ½” 3/8” 2.10 lbs each 14 per Box ZT-326-4A Green 10 15/16” 4 ½” ½” 3.00 lbs each 10 per Box ZT-326-5A Green 10 15/16” 4 ½” 5/8” 3.34 lbs each 8 per Box ZT-327-3A Green 18” 4 ½” 3/8” 4.10 lbs each 14 per Box ZT-327-4A Green 18” 4 ½” ½” 4.80 lbs each 10 per Box Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 66 G ‘Drop-In’ CCWP Our ‘one-piece’ coupler carrier wear protectors require no lubrication and eliminate inspection, maintenance and replacement costs associated with conventional coupler carrier wear plates. Constructed of our proprietary ZefTuf ®–’G’ material, they surpass competitive products in cold flow and impact resistance. Patented locking tabs keeps wear plate securely in place. (Color: Lime Green) ZefTek Application Length Width Thick- Weight Packaging Item# ness ZT-121 TTX Front Runner Cars. 16 ¾” 6 3/16” ½” 2.50 lbs 5 per Box each ZT-215-12 AAR Wear Plate 215 on type ‘E’ couplers or 10 ¾” 5 1/16” ½” 1.20 lbs 40 per Box/ similar designs. (Replaces WE-4002 and WE- each 16 Box Skid 4340 models) ZT-215-38 AAR Wear Plate 214 on Type ‘E’ couplers or 10 ¾” 5 1/16” 3/8” 1.00 lbs 44 per Box/ similar designs. (Replaces WE-4002 and WE- each 16 per Skid 4340 models) ZT-215-58 AAR Wear Plate 215 on type ‘E’ couplers or 10 ¾” 5 1/16” 5/8” 1.40 lbs 44 per Box / similar designs. (Replaces WE-4002 and WE- each 16 per Skid 4340 models) ZT-215T-12 AAR Wear Plate 215 on type ‘E’ couplers or 10 ¾” 6 3/16” 1/2” 1.20 lbs 40 per Box / similar designs. (Replaces WE-4002 and WE- each 16 per Skid 4340 models) ZT-217 Keystone & Freightmaster type M-E 10” or 15” 8 ¼” 5 1/16” ½” 1.00 lbs 40 per Box / E.O.C. Cushioning device or similar designs. each 16 per Skid Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 67 Brake Beam Guide 100’s of thousands of miles of testing have proven ZefTek’s Brake Beam Savers outperform the competition. ZefTuf® CFR-P material incorporates the benefits of superior cold flow and impact resistance needed for today’s demanding rail environment. Dramatically extend brake shoe life, reduce brake beam maintenance and improve overall braking performance. Compatible with all beam manufacturers. Quantity 8 per car. • Improve Brake Shoe Life • Reduce Brake Beam Maintenance and Head Extension Wear • Improve Overall Braking Performance. ZT-1696NH ZT-1696B ZefTek Item# Description Replaces Weight Packaging ZT-1696NH Brake Beam Guide. Grey. AAR Standard S-367-78 .61 lbs 80 per Box/ Standard For Diagonally Corrected Holland WE-5500 each 960 per Skid Beams. Holland WE-5505 ZT-1696B Brake Beam Guide. Black. AAR Standard S-367-78 .68 lbs 80 per Box/ Heavy Duty For Standard Beams. Holland WE-5500 XL each 960 per Skid Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 68 Inspection Report: ZT-1696NH, Brake Beam Guide 69 Inspection Report: ZT-1696NH, Brake Beam Guide 70 Brake Rod Wear Protector Brake Rod Wear Protectors are welded directly to the brake rod to prevent metal-to-metal contact and subsequent wear between brake rods, hangers, axles, and truck bolsters. Fits ¾” to 1” diameter rods. • Applied by method of Longitudinal Stitch Weld, preferred by AAR over the Transverse Welds on the “Horse Shoe” stops used with the slotted tube application. • Provides a flat 1 5/16” bearing surface that lasts the life of the car. (The “Point Contact” of the slotted tube application can wear quickly, especially on top of the rough bolster casting.) ZefTek Description Item Weight Packaging Item# (lbs.) ZT-111-12 12” Brake Rod Wear Protector 1.00 lbs 10 pc/Box ZT-111-18 18” Brake Rod Wear Protector 1.50 lbs 40 pc/Box ZT-111-24 24” Brake Rod Wear Protector 2.00 lbs 40 pc/Box Order proper length depending on brake rod travel. Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 71 Release Rod Wear Liner ZefTuf® Release Rod Wear Protector The ZT-377 is a two-piece ZefTuf® assembly that is affixed to the vertical release rod bracket to prevent metal-to-metal contact and subsequent wear between release rod and the bracket. Requires minor modification to standard vertical release rod brackets. Slot opening must be drilled or punched to a 1.625” diameter hole. Example of Release Rod Brackets Equipped with ZT-377 Eliminate Metal to Metal Contact with the ZT-377 ZefTek Description Item Weight (lbs.) Packaging Item# ZT-377 Release Rod Wear Liner .05 lbs Each/400 per Box Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 72 ZefTuf Brake Hanger Wear Protector Brake Hanger Wear Protectors are snap-on units (no welding) that fit all freight cars, protecting brake rods and support hangers from metal-to-metal wear. Available in standard sizes and 8-foot units that can be custom cut to required length. Custom beveled and/or square cut units are available. Example of Brake Rod Equipped with the ZT-151 Brake Example of conventional Brake Rod. Hanger Wear Protector Note the metal to metal contact. Protect Brake Rods and Support Hangers from Metal-to-Metal Wear ZefTek Item# Description Item Weight Packaging ZT-151-4 Square Cut, Dimension A = 4” .14 lbs 100 per Box ZT-151-5 Square Cut, Dimension A = 5” .20 lbs 100 per Box ZT-151-5.875 Square Cut, Dimension A = 5.875” .23 lbs 100 per Box ZT-151-6 Square Cut, Dimension A = 6” .22 lbs 100 per Box ZT-151-7.5 Square Cut, Dimension A = 7.5” .26 lbs 80 per Box ZT-151-8 Square Cut, Dimension A = 8” .24 lbs 80 per Box ZT-151-96 Square Cut, Dimension A = 96” 3.5 lbs 6 per Box * Also available in custom lengths, Standard, Bevel and Single Reverse Bevel. Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 73 Brake Rod Splice The ZefTek two-piece Brake Rod Splice allows for easy field replacement of worn, broken or bent brake rods. Two ZT-368 splices are welded together to join the existing brake rod and new brake rod section and restore rod integrity. Use on ¾” and 7/8” brake rod diameters. Available as a complete assembly (ZT-368- BRS) or individually (ZT-368). Simple field application for replacement of worn, broken or bent brake rods. ZefTek Item# Description Item Weight Packaging (lbs.) ZT-368 Brake Rod Splice for 3/4” or 7/8” .55 lbs each 50 per Box diameter rods. (2 required per rod.) ZT-368-BRS Brake Rod Splice Kit: Includes Qty 2 of the 1.10 lbs 25 per Box ZT-368 and Tie. Each Precautions: Locate away from hangers to prevent fouling or interference. Check direction of brake rod travel. Fax Order to: 847-692-6070 E-mail to: ZefTekSales@Wabtec.com, Inquiries Call: 847-692-6050 www.ZefTek.com ZefTek, A Wabtec Company. 865 Busse Highway, Park Ridge IL 60068 74 Glossary of Terms COLD FLOW Cold Flow, otherwise referred to as creep, is the dimensional change over time of a material under a physical load. All materials cold flow, to varying degrees, when a load is applied. After the load is removed, Memory, it the ability to return to its original dimensions while Compression Set takes place when the material does not return to its original state. Material wear, or loss of material, must not be confused with Cold Flow. A product will weigh less after it wears but will weigh the same after it Cold Flows, or simply changes its shape. A typical value for comparing materials is given in pounds per square inch or p.s.i. Therefore, the higher the PSI rating the more Cold Flow Resistant the material is. Material characteristics will vary with time, temperature, rate of loading, part density and wall thickness. COEFFICIENT OF FRICTION Coefficient of Friction, or C.O.F., is a value (number) used to compare how hard or easy two materials will slide against each other. Lubricated or greased “Steel-on-Steel” is around 0.1 while dry, or un-lubricated, “Steel-on-Steel” can be 0.5 to 0.8 or higher. There are many factors that will effect the C.O.F. between two surfaces. Some of these are of course lubrication, surface texture, material hardness, and the material itself. Generally speaking, constant lubrication is required to maintain low frictional properties. However, some plastics or polymers, like Nylon or UHMWPE, have a very low C.O.F. against a smooth steel surface even without any lubrication. Other polymers, like a soft urethane, can have a very high C.O.F. unless lubricated. MOLECULAR WEIGHT Technically, the Molecular Weight is the average weight of a molecule in a material. It is actually the “sum of atomic weights of all the atoms in that molecule”. In laymans terms, the higher the Molecular Weight – the longer the molecular chains, and therefore the denser the material. For instance Nylons and Polyethylenes can be processed into various molecular weights – less than 50,000 (low) – 50 to 100,000 (medium) – 100,000 to 2 million (high) – 2 to 3 million (very high) – and 3 to 6 million (ultra high). For instance the lowest polyethylene products range from candle wax and shrink film, to the medium and high densities of bottles and toys, to the ultimate Ultra High Molecular Weight Polyethylene, or UHMWPE.