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Transportation Reference and Training Manuals
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> Maintenance of Railway Car
Chapter 1 Introduction
Chapter 2 Types of Army - Owned Cars
Figure 2-1. Railway car (ice), Refrigerator, 56 -inch gage, 50-ton, 8-wheel
Figure 2-2. Railway car (mechanical), refrigerator, 39 3/8-inch gage, 40-ton 8-wheel
Figure 2-3. Interior view of railway car (ice), refrigerator, 56 -inch gage, 50-ton, 8-wheel
Figure 2-4. High-side, fixed-end, 40-ton gondola, domestic service.
Figure 2-5(1). A 100-ton heavy-duty flatcar.
Figure 2-7. Army Medical Department ambulance unit car, domestic service.
Figure 2-8. US Army guard car.
Chapter 3 Basic Components
Figure 3-1. AAR standard 4-wheel, coil spring, cast bolster car truck.
Couplers, CONUS Cars
Chapter 4 Car Truck Maintenance
Removal of Wheel and Axle Assembly
Figure 4-1. Method of gaging thin flanges, wheel condemnable.
Figure 4-3. Method of measuring high flange.
Figure 4-4. Burnt rim.
Figure 4-7. Subsurface defect found on turning wheel
Figure 4-9. Built-up tread.
Figure 4-10. Grooved tread wheel.
Figure 4-12. Cracked hub.
Figure 4-14(1). Cracked or broken plate.
Figure 4-15. Crack originating from hole burned in wheel.
Section III. Axles and Journals
Figure 4-13. New and limiting dimensions for plain bearing passenger
Figure 4-19. Economical selection of wheels and axles.
Figure 4-22. Typical journal box assembly.
Figure 4-23(1). Tapered roller bearing.
Figure 4-23(2). Heavy duty bearing assembly, application parts
Figure 4-23(3). Nomenclature, heavy-duty bearing assembly.
Figure 4-24. Packing iron and waste grab hook.
Figure 4-25. Recommended method of stacking journal bearings.
Section IV. Journal Box Lubrication
Figure 4-26. Method of packing journal boxes.
Figure 4-27. Typical lubricator pad.
Packing Journal Boxes (Lubricator Pads)
Section V. Truck Side Frame, Bolster, and Springs
Figure 4-28. Typical truck, assembled.
Figure 4-29. Typical truck, disassembled.
Truck Springs
Truck Springs - Cont'd
Chapter 5 Underframe Assembly
Figure 5-1. Typical welded-steel underframe.
Figure 5-2. Component parts being installed on underframe.
Section III. Repair Procedures
Figure 5-4. Marking with templates.
Figure 5-7 Straightening a pushed-in end sill by jacking against the body bolster.
Section IV. Riventing
Rivet Fitting
Rivet Driving
Chapter 6 Draft Gear
Figure 6-1. Typical friction draft gear.
Figure 6-2. Draft gear parts and yoke.
Maintenance - TM-55-2030057
Chapter 7 Couplers
Figure 7-2. Typical type "E" coupler
Figure 7-3. Use of contour gage.
Figure 7-6. Side buffers
Willison Automatic Couplers
Figure 7-7. Typical Willison arrangement.
Figure 7-9. Operating parts type L, Willison coupler.
Chapter 8 Car Brake Equipment
Figure 8-1. Foundation brake gear diagram.
Figure 8-2. Typical brake lever badge and dimension plate.
Figure 8-3. Brakes regulator, automatic type.
Section II. Kandbrakes
Figure 8-5. Straight shaft handbrake.
Figure 8-6. Vertical geared-type handbrake, 50-ton USA boxcar
Figure 8-7. Typical horizontal-type handbrakes.
Section III. Airbrakes
Principal Parts of the Automatic Brake
Definition of Term Used
AB and AB-1-B Brake System Components
Figure 8-9. AB valve showing the operating portions with pipe bracket section
Figure 8-10. Exterior view of A-2-A quick-service value
Figure 8-11. Assembly view of the AB-A brake cylinder with lever brackets.
Figure 8-12. Combined auxiliary and emergency reservoir.
Figure 8-13. Combined dirt collector and cutout cock.
Install Reconditioned Emergency Portion
Test and Adjust Air-Operated Auto-mattec Slac Adjusters
Figure 8-18. Hose with a "soft" bend.
Figure 8-19. Stenciling for cleaning, oiling, testing
Shop Maintenance of AB Control Valve
Table 8-1. Spring Identification AB Service Portion
Figure 8-21. Service portion cover and release insuring parts.
Figure 8-22. Service portion body and parts.
Figure 8-23. Quick-service limiting valve and parts.
Emergency Portion
Table 8-2. Spring Identification AB Emergency Portion
Figure 8-25. Emergency portion body and parts.
Table 8-3. Spring Identification A-2-A Quick-Service Valve
Figure 8-26. Filling piece and selector valve portion.
Figure 8-27. Assembly view of A-2-A qutck-serice valve.
Figure 8-28. AB brake cylinder, showing air pipe connection
Shop Maintenance of Engine Portion of Automatic Slack Adjuster
Section V. Single - Capacity Car Brake equipment (k)
Equipment Parts
Figure 8-30. Piping diagrams of KC freight car brake equipment
Description of Parts
Figure 8-31. K-1 triple valve, actual section and end view
Figure 8-32. K-2 triple valve, actual section and end view
Figure 8-33. Isometric views of triple valve, slide valve and seat
Figure 8-34. Sectional and end view 8 -by 12-inch freight brake cylinder
Figure 8-36. Wabcotite pipe union.
Figure 8-38. Diagrammatic views of standard pressure retaining valve.
Figure 8-39. Sectional view of retaining valve with vent protector
Figure 8-40. Diagrammatic views of four-position release control retainer.
Figure 8-41. The auxiliary reservoir variable release
Figure 8-45. Release and charging position.
Figure 8-46. Quick service position.
Figure 8-46. Quick service position. - Cont'd
Figure 8-48. Quick-service lap position .
Figure 8-49. Retarded release and recharging positions.
Figure 8-50. Emergency position.
Maintenance - TM-55-2030118
General Information for Carmen and Trainmen
Section VI. Special Purpose Equipment
Figure 8-51. Freight single-car testing device with flowrator.
Section VII. Vacuum Automatic Airbrakes
Figure 8-53. Vacuum brake system.
Operation-Steam Locomotives
Chapter 9 Car Superstruckture
Troop Kitchen Cars
Ambulance Trains in Theaters of Operations
Section II. Boxcars
Figure 9-1. Steel reinforced end, composite car.
Figure 9-2. Cutaway of wooden boxcar roof.
Maintenance of Steel Component, Composite Cars
Section III. Refrogerator Cars
Roofs
Section IV. Gondola Cars
Section V. Hopper Cars
Section VI. Dumpcars
Figure 9-4. Dumpcar, body tilted.
Figure 9-5. Arrangement of dome and, bottom discharge outlet.
Maintenance and Repair - TM-55-2030139
Section VIII. Flatcars
Maintenance and Repair
Chapter 10 Train Ligtining
Figure 10-1. Arrangement of an axle-generator belt-drive system.
Figure 10-2. Generator drive gearcase mounted on a standard axle.
Electrical Equipment
Lighting Fixtures
Figure 10-4. Alkaline type of storage cell.
Figure 10-5. Lead-acid type of storage battery.
Figure 10-6. Cutaway view, nickel cadmium battery.
Figure 10-7. Top view, nickel cadmium battery.
Chapter 11 Heating
Figure 11-2. Pressure-reducing valve.
Figure 11-4. Zone system of car heating.
Figure 11-5. Automatic temperature-controlled vapor system.
Maintenance and Repair - TM-55-2030155
Maintenance and Repair - Cont'd - TM-55-2030156
Chapter 12 Air Conditioning
Figure 12-1. Flow diagram for mechanical-compression system.
Maintenance and Repair - TM-55-2030159
Maintenance and Repair - Cont'd - TM-55-2030160
Chapter 13 General
Safety
Chapter 14 Painting of Railway and Passenger Cars
Table 14-1. Spray Gun Air Pressures
Table 14-2. Painting System for Freight Cars and Cabooses
Table 14-2. Painting System for Freight Cars and Cabooses-Continued - TM-55-2030166
Table 14-2. Painting System for Freight Cars and Cabooses-Continued - TM-55-2030167
Table 14-2. Painting System for Freight Cars and Cabooses-Continued - TM-55-2030168
Table 14-2. Painting System for Freight Cars and Cabooses-Continued - TM-55-2030169
Table 14-2. Painting System for Freight Cars and Cabooses-Continued - TM-55-2030170
Section III. Passenger Service Cars - TM-55-2030171
Table 14-5. Painting of Troop Sleeper Cars
Chapter 15 Lettering and Numbering of Railway Freight and Passenger Cars
Section II. Freight Cars - TM-55-2030174
Figure 15-3. Standard markings for gondola cars, CONUS.
Figure 15-4. Standard markings for hopper cars, CONUS.
Figure 15-6. Standard markings for caboose cars, CONUS.
Figure 15-7. Standard markings for tank cars, CONUS.
Army Tank Cars in CONUS
Table 15-1. STANAG 2153 Category Numbers
Figure 15-8. Standard markings for boxcars and refrigerator cars
Figure 15-9. Standard markings for high-side gondola cars
Figure 15-10. Standard markings for low-side gondola cars
Figure 15-11. Standard markings for flatcars
Figure 15-12. Category number for overseas (STANAG) railway cars.
Figure 15-13. Standard markings for caboose cars
Section III. Passenger Service Cars - TM-55-2030187
Figure 15-16. Standard markings for troop kitchen cars
Figure 15-17. Standard Army Medical Department markings for ambulance unit cars
Figure 15-19. Caduceus, Army Medical Department insignia
Chapter 1 General - TM-55-2030191
Inspection Points
Inspection Procedures--Passenger Cars
Table 16-1. Maximum Number of Cars with Inoperative Airbrakes
Terminal Tests
Periodic Repairs
Periodic Repairs - Cont'd - TM-55-2030197
Periodic Repairs - Cont'd - TM-55-2030198
Chapter 17 Inpection Forms
Figure 17-1. DA Form 55-154 (Record of Special Tests Made on Airbrake Equipment).
Figure 17-2. DA Form 55-156 (Battery Removal Record, Battery Application Record).
Figure 17-3(1). DA Form 55-158 (Hospital Car Inspection and Repair Record)
Figure 17-5. DA Form 55-161 (Airbrake Defect Tag).
Figure 17-7. DA Form 55-163 (Car Inspector's Train Report).
Figure 17-9. DA Form 55-237 (Rolling Stock Specification Record).
Chapter 18 Shops, Heavy (DEPOT) Maintenance
Section II. Freight Cars - TM-55-2030207
Shop Procedure
Materials Handling Equipment
Material Storage
Section IV. Wheel and Axle Shop
Figure 18-1. Wheel mounting pressures, in tons.
Figure 18-2. Work flow chart showing course of axles
Handling Loose Wheels
Figure 18-4. Wheel-fit pressure diagram.
Boring-Mill Practice
Figure 18-4. Thirty-three-inch one-wear cast steel freight car wheel.
Figure 18-5. Thirty-three-inch multiple-wear (MW)
Machining Axles
Figure 18-6. Typical center-drive journal lathe.
Figure 18-7. Method of applying steel-wheel gage
Matching Wheels and Axles for Mounting
Section V. Paint Shop, Railway Cars
Chapter 19 Shops, Light (Running) Repairs
Light Repair Track
Shop Buildings
Section III. Light Passenger Car (Running) Repair
Inspection Facilities
Section I. General
Figure 20-1. Preparation of edges.
Limitations on Reclamation
Welding Regulations for Couplers and Cast Steel Yokes
Welding Coupler Cracks
Chapter 21 Safety
Prevention of Burns, Fires, and Explosions
Handling Material
Operation of Portable Power Tools
Electric Arc Welding
Working on or About Machinery
Eye Protection
Rules for Prevention of Falls
Appendix A References - TM-55-2030242
Appendix A References - Cont'd - TM-55-2030243
Glossary
Glossary - Cont'd - TM-55-2030245
Glossary - Cont'd - TM-55-2030246
Glossary - Cont'd - TM-55-2030247
Glossary - Cont'd - TM-55-2030248
Glossary - Cont'd - TM-55-2030249
Maintenance of Railway Car
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