Pocket Guide OEM Products

Systems for Heavy Haul Rail Vehicles

Engineered to Outperform

www.nyab.com E2O: engineering = 9.5% of gross revenue

OEM Products New York Air Brake offers our AAR freight railroad customers products and services that are Engineered to

Outperform (E2O).

The heavy haul rail industry judges the usefulness of each new technology by tangible, bottom-line results, not by promises. NYAB products are engineered to outperform. Extensive testing done in partnership with the railroads confirms that the benefits of NYAB products are real and substantial. We earn the continued trust of our railroad partners

by working hand-in-hand with them as they deploy AAR Worldwide and operate new train control technology. NYAB Headquarters, Watertown NY Knorr Brake Limited, Kingston ON NYAB is part of the Knorr-Bremse Group, a global leader in brake systems for rail and commercial Anchor Brake Shoe, W. Chicago IL vehicles – with the largest worldwide footprint Premtec Hoses, China Grove NC in the market, operating 45 production and sales Train Dynamic Systems Division, Irving TX facilities in 26 countries. Kansas City Service Center, Riverside MO Knorr-Bremse SfS. GmbH. Headquarters

2 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 3 E2O: 8 years’ maintenance = 16 filter changes

Oil-Free Compressor

NYAB’s clean and green air compressor runs without any oil and will last up to 8 years between rebuilds.

Developed by NYAB and Knorr-Bremse’s Air Supply Group, the leading supplier of rail oil-free compressors in the world, oil-free compressors are highly reliable, inexpensive to operate and easy on the environment – the only outputs are a little water and a lot of compressed air.

The highly-reliable VV1000T oil-free compressor supplies the air required by the long heavy haul trains common to North America. It fits into the same space envelope as conventional air compressors, and uses the same Absolutely oil-free air mounting interfaces, air filters and existing locomotive No more oil-water emulsion problems control scheme with several drive options. The compressor No oil in air dryer spitter valve provides 185 cfm air at 145 psi pressure, and is optimized for extreme temperature operation from -40° F to 158° F. Improved motor performance – no motor rubbing Longer air dryer life Eliminating oil fouling (coking) leads to less downstream Low noise level – 78 dB contamination of the air brake system, which reduces and simplifies maintenance, resulting in lower life-cycle costs. 25 percent lighter than competition

4 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 5 E2O: two years longer service life

DB-60 Featuring a zero-leakage design that reduces air usage, the extremely reliable DB-60 control valve delivers the lowest life-cycle costs in the industry.

The DB-60 pneumatic control valve has proven to provide up to two years longer service life between maintenance intervals than any other freight car control valve on the market. DB-60 features friction-free, soft-seated poppet valves that ensure high reliability and long life with no UDEs. Patented K-rings provide dynamic sealing to eliminate stiction (cold welding) even in the harshest environments, from -40° to 150° F. With the fastest brake signal transmission of any control valve available, DB-60 can reduce stopping distances by up to 21% without DB-60 with 4-port receiver and access plate increasing in-train forces.

DB-60 is available with 4-port automatic single car test capability in both the conventional block style and single- sided pipe bracket configurations.

DB-60’s reliability makes it the control valve of choice on a growing installed fleet of more than 455,000 freight cars of the 1.6 million cars in service today throughout North America.

6 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 7 E2O: 8.5 years overhaul periods

CCB II CCB II (Computer Controlled Brake) is recognized as the industry’s most reliable air brake – The electro-pneumatic control unit (EPCU) (above) responds to the engineer’s handle the data proves it. movements on the electronic brake valve, EBV (below, right).

CCB II features advanced self- diagnostics – seven processors continuously monitor system 1 pressures, signals and each other to ensure a safe and reliable system. Modularized line replaceable units 2 (LRUs) provide a 20-minute mean time to repair (MTTR), reducing costs and locomotive downtime. 3

As a result of FRA inspections and close monitoring of performance standards, CCB II qualifies for a best-in-class cost-reducing extended overhaul period of up to 8.5 years. The most field-proven locomotive computer controlled 1 Electronic Brake Valve (EBV) 2 Integrated Processor Module (IPM) brake in the world, CCB II integrates seamlessly with EP-60 3 Electro-Pneumatic Control Unit (EPCU) and LOCOTROL® EB.

CCB-26 (shown top right in cover photo), the low-cost, highly reliable replacement for 26L, is especially suited for new low-horsepower, low-emissions switcher locomotives.

8 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 9 shortens stopping distances: E2O

EP-60 has logged 600 million car miles of revenue service and meets the latest AAR S-4200 specification in all areas, proving to be the industry’s most advanced and reliable ECP package. In summary, EP-60: End-of-Car (EOC) Junction Box Saves fuel Improves safety Reduces equipment wear

CCD with Vent Valve

Junction Box with Car ID Module

Trainline Power Supply

Operator Interface Unit EP-60

The EP-60 air brake system’s improved Trainline Communications Controller (TCC) stop distance (up to 70%) saves fuel and allows the safe increase of train speeds for higher line capacity.

Graduated application / release and simultaneous, load compensated braking provide faster brake response, decrease in-train forces Trainline Integrity Locomotive for better fuel economy and less lading damage, and reduce Test Device (TILT) track, wheel, shoe and draft gear wear.

CCB II – Integrated Electronic Brake Valve ( EBV) EP-60’s wire-based communication over the Echelon LonWorks™

network delivers real-time monitoring and virtually simultaneous EP-60 is available as an overlay installation or in a standalone configuration control of every car in the train. The system’s low air consumption that eliminates service and emergency portions and fits in the same space allows railroads to run longer trains without additional locomotives. envelope as the DB-60.

10 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 11 E2O: reduces fuel consumption by 8-12%

LEADER LEADER® reduces fuel consumption by up to 8-12 percent while improving train handling, effectively managing schedules and minimizing in-train forces.

Lower fuel costs LEADER has been widely deployed on the current PTC Efficient time management platform standard with an advanced plan to integrate Lower in-train forces LEADER content into the PTC operating screen. Today LEADER operates standalone on the PTC computer and utilizes the Longer equipment / track life entire PTC screen to display content. When PTC comes online, Less lading damage LEADER will provide the same functionality but with a highly Safer operations integrated PTC/LEADER solution. Users do not need to buy a new hardware platform to enjoy the benefits of LEADER LEADER (Locomotive Engineer Assist/Display & Event and PTC, merely upgrade to full PTC capability. New York Air Recorder) technology continues to add functionality. Brake has implemented protocols to leverage PTC data to LEADER DriverAssist™ prompts the locomotive engineer to provide a seamless transition from LEADER standalone to a make optimal decisions to reduce fuel consumption while fully integrated solution. effectively managing time and minimizing in-train forces. LEADER AutoThrottle™ automatically makes throttle The business case for LEADER is quantified through an adjustments and dynamic brake applications while extensive and powerful back office that collects and organizes prompting the engineer to optimize air brake application data to measure the effect of the technology. and release. LEADER AutoPilot™ controls throttle, Other systems may promise benefits – dynamic brake, and air brake, tightly integrating with the LEADER measures and delivers them. railway’s chosen PTC system for fail-safe operation.

12 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 13 E2O: preferred by railroads worldwide

TDS-5000 The TDS family of simuators delivers maximum flexibility at minimum cost.

The modular design of TDS-5000 simulators provides configurations that range from portable to expandable networked operating consoles and training stations for

local or remote use. Portable systems, including the ultra- More than 121 TDS simulators are now deployed around the world. portable new TDS-5100 desktop, provide both operations analysis and fully dynamic training simulations.

TDS-5000 systems offer the most advanced computer- generated graphics in the industry, provide state-of the-art training, and can be configured to meet every railroad’s specific needs.

Train Dynamic Systems, a division of NYAB, is the leading industry expert in train dynamics and training simulators. TDS-5100 control stand

14 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 15 E2O: easy single car testing

Empty & Load

EL-60

EL-60SS

The lightweight, all-aluminum EL-60SS The EL-60 empty & load valve protects wheels by reducing braking forces on empty cars. Available with proportioning includes an innovative test feature levels of 40, 50 or 60%, EL-60 is a fully proportioned, body-mounted design that that makes single car testing easy. senses loaded or empty conditions, and features a visual indicator showing full or proportional brake condition. NYAB’s EL-60SS valve provides empty / load control for bulk-commodity hopper car applications using the proven EL-60 upstream proportioning technology in a slope sheet ELRP package. Additional EL-60SS features include:

40% and 50% proportioning models Sensing and proportioning in one assembly No set up or adjustment required The Empty & Load Remote Proportioning (ELRP) valve, available in 50 and 60% proportioning levels, uses industry-leading upstream Visual system indicator shows empty / loaded condition proportioning technology with separate, lightweight sensing and Works with system pressure up to 110 psig proportioning modules that offer flexibility where the control valve is FDA approved applications mounted in the center of the car. Both AAR approved units include a brake cylinder pressure measurement tap.

16 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 17 E2O: installs in < half the time

TMB-60 A rugged, cost-effective truck mounted brake, TMB-60 installs in less than half the time required for competing brakes.

The simplest (fewest parts) and most robust truck mounted brake in the industry, TMB-60 eliminates through-bolster rods, tapered shoe wear and the risk of equipment damage due to rail car jacking procedures or ice buildup. The system can be installed in any configuration with complete flexibility in cylinder positioning and without changing any parts.

The TMB-60 self-adjusting integral compression slack adjuster maintains a constant 2-1/4” piston stroke, Replaceable brake heads resulting in uniform braking performance even as wheels and shoes wear, and allowing railroads to run heavier loads for increased gross rail cars. Approx Brake Cylinder Piston Cylinder TMB-60 brake heads can be removed and replaced without Size Travel Volume truck disassembly, a unique feature that reduces labor (inches) at 50 PSI (cubic LR LR LR LR (inches) inches) 1:4 1:4.3 1:4.75 1:5.26 and downtime. The lightweight TMB-60 is field proven as highly reliable and features premium #28 (28,000 lb.) cast 8-1/2 2 113.5 11,800 12,700 14,000 15,500 9 2 127.2 13,200 14,200 15,700 17,400 beams, the strongest beam available. 10 2 157.0 16,300 17,600 19,400 21,500

18 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 19 E2O: proven reliability, longer life

Vertical Wheel Hand Brake The robust design provides increased brake longevity, reducing rail car life-cycle costs.

Forged steel gearing and clutch mechanisms provide increased strength and durability. The NYAB / Klasing hand brake product line includes A combination of zinc plating, dichromate coating and internal / external painted AAR approved and qualified vertical wheel, geared hand surfaces ensure the finest corrosion protection in the industry. brake designs – Groups N and O.

Quick release levers are available in short or long handle versions, providing versatility for unobstructed access. The long handle requires less pulling force to activate complete release.

Pinion gear and quick-release mechanisms are hardened to provide improved wear resistance. A shelf-type winding drum protects the chain from bending, twisting or overlap and provides quick chain take-up as well as smooth gradual release of the hand brake with the wheel.

The NYAB / Klasing hand brake incorporates permanently lubricated sealed ball bearings supporting the hand wheel shaft to improve vibration characteristics and to eliminate premature wear.

20 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 21 E2O: no servicing between overhauls

Slack Adjusters NYAB’s automatic, double-acting, AAR-approved slack adjusters for freight car applications require no servicing between overhauls. KRD-482-E KRD-133-L

Designed for body mounted brake applications (BMB-60), Designed for truck mounted brake applications (TMB-60), our new KRD-482-E slack adjuster features include: our new KRD-133-L slack adjuster features include:

Corrosion protection on all parts Corrosion protection on all parts

Wear-resistant seals between sliding parts Wear-resistant seals between sliding parts prevents dirt and moisture from entering unit prevents dirt and moisture from entering unit

Automatically adjusts for brake shoe and Automatically adjusts for brake shoe and wheel wear with each brake application wheel wear with each brake application

Only two brake applications are needed to adjust Only two brake applications are needed to adjust for correct clearance after brake shoe replacement for correct clearance after brake shoe replacement

Control link hole clearance allows for 6° of axial Actuating lever hole clearance allows for 6° of axial alignment in all directions between the slack alignment in all directions between the slack adjuster and the control rod adjuster and the actuating link

Take up capacity – 19” (482 mm) Take up capacity – 5-1/4” (133 mm)

22 | Engineered to Outperform Systems for Heavy Haul Rail Vehicles | 23 Systems for Heavy Haul Rail Vehicles

New York Air Brake Corporation 748 Starbuck Avenue EWatertown,2O: New worldwide York 13601 innovation leader Tel: +1 315 786-5431 Toll free: +1 888 836-6922 Fax: +1 315 786-5676

NYAB leads the heavy haul freight industry worldwide by engineering every product and service to outperform what it is designed to replace.

We continue our commitment to – Innovative new products Exceeding AAR standards Deploying service-proven technology worldwide

For more information, visit our website at www.nyab.com, or contact us at the address or phone numbers listed above. AIR-5068 1000x 09-09-11 AIR-5068 EngineeredEngineered toto OutperformOutperform