8400 South Stewart Avenue

Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

Figure 1 – Typical TMX® truck set assembly applied to a 100T truck

Truck set shown: 592940-0001

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 1 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

Figure 2 - TMX® brake assembly – truck set with hand brake lever
Truck set shown: 592940-0001

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 2 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

SAMPLE TRUCK SET BOM - REF #592940-0001

Part Number Description UOM QTY ITEM #
506401 ANTI RATTLER RING EA 1 38
523190 NY-LOCK NUT (X-270) EA 1 3
526835 STRAINER EA 1 26
569145 COTTER 5/16 X 2.5 EA 5 6, 8, 12, 19, 31
593006 HEX HEAD CAP SCREW 5/8" X 2.5" EA 2 24
593042 T-HEAD BOLT 1/2" X 21/4" EA 3 16, 22
645002-1 HEX LOCK NUT-UNI-TORQUE EA 3 15, 21
645002-2 STOP NUT 5/8-11 UNC EA 2 23
660396 BRAKE BEAM ASSEMBLY - 14 DEGREE EA 2 37
660411 CENTER STRUT PIN EA 2 28, 35
660413 TRANSFER PIN EA 4 7, 9, 20, 32
660414 PUSH ROD ASSEMBLY EA 1 33
660416 SLACK ADJUSTER SUB-ASSEMBLY EA 1 10
660417 TRIGGER EA 1 10C
660418 CONTROL ROD EA 1 5
660420 CONTROL ROD PIN EA 1 2
660421 CONTROL ROD SLEEVE NUT EA 1 4
660432 CYLINDER ASSEMBLY - 9.25" EA 1 25
660493 CYLINDER TRANSFER LEVER ASSY EA 1 29
660494 NON-CYLINDER TRANSFER LEVER ASSY EA 1 36
660497 SPRING PIN EA 1 18
660554 COTTER 5/16" X 3" EA 2 27, 34
660581 PISTON TRAVEL INDICATOR EA 1 11
94977 COTTER EA 1 1
660424 HAND BRAKE LEVER - 14" EA 1 14
660425 STRUT HAND BRAKE BRACKET EA 1 17
660426 HAND BRAKE TRANSFER LINK EA 1 30
660427 HAND BRAKE TRANSFER LINK PIN EA 1 13

Table 1 – TMX® truck set bill of material

Refer to Figure 2 for item # cross reference

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 3 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

Ensure that the following tools are available before you begin installation:

• ¾” Combination wrench

• ¾” Deep wall socket, ½” drive

• ½” Drive ratchet

• 1” Open End Wrench

• 2-½” Pipe Wrench

• 15/16” Open wrench

• 15/16” Deep wall socket ½” drive

• 6” Extension ½” drive

• Pliers

• Hammer

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 4 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

1. Please refer to your TMX® assembly or installation drawing to determine which TMX®
equipment combination is being applied.

2. The TMX® brake beams (37) are to be installed during truck assembly normal to your existing
shop practice. It is optional to mount the brake cylinder (25) and the hand brake strut bracket
(17) (if a hand brake truck is required) to the brake beam prior to the truck assembly.

3. Mount the brake cylinder (25) to the brake beam (37). Align the two rear mounting holes of
the brake cylinder to the two corresponding holes on the brake beam (37). Align the only
side-mounting hole of the brake cylinder (25) to the one corresponding hole on the strut side-
pad. The brake cylinder will be facing outboard from the bolster. Install two 5/8” hex bolts
(24) through the topside of the compression member and fasten using the two 5/8” hex
locknuts (23); do not tighten at this time. Install a ½” T-head bolt (22) from the underside of
the center strut pad and fasten the side mounting with a ½” hex locknut (21). Tighten and
torque the two 5/8” hex locknuts (24) to 110 ft-lbf. (150 N-m) and the ½” hex locknut (21) to
85 ft-lbf (115 N-m).

CAUTION: When tightening or applying torque to a TMX® fastener, always use a

mechanical means; adjustable wrench, box end wrench, socket, etc. To avoid personal injury,
DO NOT MANUALLY HOLD FASTENERS!

4. Install the cylinder transfer lever (29) to the brake cylinder brake beam. For hand brake trucks
only, position the hand brake transfer link (30) around the notch of the cylinder transfer lever.
If the truck is a non-hand brake truck, disregard the hand brake transfer link (30). Position the
cylinder lever (29) and link (30) assembly with the notch side towards the cylinder (see Figure
3). Insert the cylinder transfer lever (29) through the slot in the brake beam strut from the
cylinder side. Secure the cylinder transfer lever (29) with the transfer pin (20) through the
brake cylinder push rod clevis. The piston travel indicator arrow (11) must be installed under
the head of the transfer pin (20) prior to being secured. Pin the cylinder transfer lever (29) to
the brake beam strut with the center strut pin (28).

NOTE: It may be necessary to overcome some slight cylinder bail or angularity to insert the
center strut pin.

5. Insert the slack adjuster (10) through the bolster window with the trigger end jaw of the slack
adjuster toward the cylinder brake beam. Cut the plastic shipping strap from the slack adjuster
front jaw.

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 5 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

6. Install the non-cylinder transfer lever (36) to the non-cylinder brake beam. The non-cylinder
transfer lever (36) will determine your lever ratio. Refer to the car badge plate, ask your air
brake supervisor or look at the installation drawings to determine which side of the non-
cylinder transfer lever (36) is located toward the slack adjuster (10). Insert the non-cylinder
transfer lever (36) through the slot in the brake beam strut from the return push rod side. Align
the center hole of the non-cylinder lever (36) with the strut hole and pin to the strut with the
center strut pin (35).

7. Slide the rubber anti-rattler ring (38) onto the non-clevis end of the return push rod assembly
(33). Position it between the spring pin hole and the end of the return push rod. Insert this
end of the return push rod assembly (33) through the bolster window and into the rear of the
cylinder. Ensure that the anti-rattler ring is between the spring pin hole and the cylinder body
(See Figure 3). Line up the pin hole on the return push rod assembly (33) with the spring pin
hole on the cylinder bracket. Align the return push rod clevis hole to the non-cylinder transfer
lever hole and pin with the transfer pin (32).

8. Align the non-cylinder transfer lever (36) with the proper slack adjuster rack end jaw hole and
pin with a transfer pin (9).

NOTE: Please refer to the proper TMX® installation or assembly drawing or ask your air
brake supervisor for the correct pinning of the non-cylinder transfer lever (36) to the inner or
outer hole of the slack adjuster rear jaw. (See Figure 3)

Insert the trigger (10C) into the trigger end jaw slot of the slack adjuster (10) from the
cylinder side. Next, slide the slack adjuster control rod (5) into the trigger (10C). Both the
slack adjuster (10) and the control rod (5) should be set onto the cylinder transfer lever (29)
simultaneously. Insert the trigger pin (10A) through the trigger pin hole on the slack adjuster
(10).

Secure the slack adjuster (10) to the cylinder transfer lever (29) with transfer pin (7). Insert the
control rod pin (2) through the control rod clevis and the small hole of the cylinder transfer
lever. Turn the spherical flanged sleeved nut (4) clockwise onto the control rod (5) with the
sleeved side toward the trigger of the slack adjuster. Turn the nut clockwise until a ¼” (6mm)
gap is left between the nut and the trigger.

9. Remove the slack adjuster locking bolt (10D). (See Figure 2)

CAUTION: Do not bump the slack adjuster trigger. If bumped, the slack adjuster could
activate and sudden let-out of the rack extension could occur at the rear jaw.

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 6 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

10. Install the 2” (51mm) brake shoes and shim the outboard side of all journal bearings using
1/8” (3mm) shims to prevent outward wheel and axle movement.

11. Attach a regulated air supply to the cylinder inlet flange and slowly apply 50 psi (3.45 bar) to
the cylinder.

CAUTION: This will activate the truck mounted brake assembly. All personnel must be
clear of brake beams, brake shoes, transfer levers, slack adjuster, and all other parts of the
assembly.

12. Release the brake assembly and reapply 50 psi (3.45 bar) or 54 psi (3.72 bar) to the cylinder.
A measurement of 3” ± ¼” (76 ± 6mm) should be taken, as shown in Figure 3, to achieve
actual piston travel of 2” ± ¼” (51 ± 6mm). With air released there is approximately a 1”
(25mm) reference measurement from the edge of the transfer pin to the non-pressure head
face. If piston travel is long, turn the spherical flanged sleeved nut (4) clockwise. If piston
travel is short, turn the spherical flanged sleeved nut (4) counterclockwise. There is a 1 to 2
adjustment ratio from spherical flanged sleeved nut travel to piston travel.

Once the required piston travel is obtained and repeatable, turn the ½” locknut (3) clockwise
against the spherical flanged sleeved nut (4) and torque against each other to 55 ft-lbf (75 N-
m).

13. With the air applied, measure and record the slack adjuster rack; the space between the rear
jaw of the slack adjuster and the rear of the housing (See Figure 3). The slack adjuster rack
should be 1” (25mm) to 1-¾” (44mm) (if measured from the inside of the cap to the rear jaw)
or 0” (0mm) to ¾” (19mm) (if measured from the edge of the cap to the rear jaw). See Figure
3 for details. If the slack adjuster rack is too short, release the brake assembly and turn the
return push rod (39) counterclockwise if facing the back of the cylinder. If the rack is too
long, release the brake assembly and turn the return push rod (39) clockwise if facing the back
of the cylinder. There is approximately a 1 to 1 adjustment ratio from return push rod clevis
travel to slack adjuster rack extension.

When the required slack adjuster rack is obtained and repeatable, align the hole in the return
push rod (39) with the hole in the cylinder bracket (25) and insert the spring pin (18).
Tighten the hex jam nut (40) on the return push rod (39) until the lock washer (41) is closed.

14. Mount the hand brake strut bracket (17) for hand brake trucks to the strut face on the brake
cylinder brake beam. Align the two holes of the hand brake strut bracket (17) to the two
holes on the strut face. Install two ½” T-head bolts (16) from the inside of the hand brake
strut bracket. Fasten with the two ½” hex locknuts (15) to 85 ft-lbf (115 N-m).

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 7 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

15. Install the hand brake lever (14) with the air applied. Insert the flattened end of the hand
brake lever against the hand brake strut bracket and into the pocket. Align the hand brake
center hole with the holes in the hand brake transfer link (30) and pin with the link pin (13).

16. Remove the shims from the outside of all the journal bearings.

17. Install cotters on all of the remaining brake pin connections and verify the cylinder piston
travel and slack adjuster rack with trucks installed under the car body. Make any necessary
adjustments.

Reference: Rebuild programs

It is recommended that new brake shoes are applied to the car. This is important as it establishes
a reference point from which the initial adjustment of the TMX® cylinder is made. On a rebuild
program, at least the first or sample car should have new brake shoes and new wheels so that the
proper rod lengths can be determined.

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 8 of 9

 8400 South Stewart Avenue
Chicago, Illinois 60620

TM-22397 TMX® Installation Manual

Figure 3

Drw. JDM 12/01/09 Apr. PPG 12/01/09 Rev. A TM091213A Page 9 of 9