Discipline Category Title Air Brake Maintenance RSS 0060 · 2021. 3. 11. · Manual Equipment 21...

DisciplineRolling Stock Engineering

CategoryMaintenance

Title

Air Brake Maintenance

Reference Number

RSS 0060

Version1.1

Date of IssueJuly 2004

StatusApproved

Copy No:(Controlled copies are numbered in red)

Rolling Stock Engineering Standard RSS 0060MaintenanceAir Brake Maintenance

Version 1.1 – July 2004 © Rail Infrastructure Corporation of 46

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About This StandardThe specification was previously TRS 1024 Brake Maintenance & Single Car AirTesting.

This standard has been revised and published as a RIC Standard.

Single Car Air Testing has been separated from Brake Maintenance and published inRSS0013.

Version HistoryVersion 1. First issued January 2004

Draft 1 numbered RSS 0012Draft 2 renumbered as RSS 0060

Version 1.1 Issued July 2004Section 4.1.4 Air brake coupling hoses with old type coupling heads to be replaced.Section 4.11.1 Dimension X amended Section 5.3 The amount of grease to be added to a Westinghouse AF & WF brakecylinders has been altered. Reference to UC brake cylinders deleted.



This page has been intentionally left blank



Table of ContentsAbout This Standard 3Version History 3

1 Scope 7

2 When must air brake maintenance take place? 7

3 Requirements 7

4 Equipment to be checked 8

4.1 Hoses 84.1.1 Air Brake Coupling Hoses 84.1.2 Body to bogie hoses (found on some passenger cars) 84.1.3 All Other Hoses 94.1.4 Air Brake Coupling Hose Heads 9

4.2 Coupling Cocks 10Brake pipe (and Main Reservoir coupling cocks - if applicable). 104.2.2 Independent Brake Latching Cocks - where applicable 10

4.3 Brake Pipe (and Main Reservoir Pipe, if applicable) 11

4.4 Branch Pipe and Isolating Cocks 11

4.5 Control Valves (Triple valves, distributing valves and relay valves) 13Diaphragm Type Triple Valves (Westinghouse ‘W’) and Distributors (Davies & Metcalfe ‘ES’ &‘ESR’) 13

4.6 Reservoirs and Associated Pipework 14

4.7 Brake Cylinders 154.7.1 Old push rod type brake cylinder 154.7.2 Westinghouse AF and WF type brake cylinders 154.7.3 Davies and Metcalfe type brake cylinders 16

4.8 Slack Adjusters 164.8.1 'J' type ratchet (pneumatic) 174.8.2 In-line Slack Adjusters 18

4.9 Grade Control Valve Equipment 194.9.1 Fixed Exhaust Chokes 204.9.2 Load Compensation Equipment (Empty/Load) 21Manual Equipment 214.9.4 Automatic Equipment 23

4.10 Release Valve 244.10.1 Handbrake 24

4.11 Brake Rigging/Brake Blocks 254.11.1 Wagons 254.11.2 Passenger Cars 26

4.12 Water Service (passenger cars) 274.12.1 Water Service Gauges (passenger cars) 27



4.13 Main Reservoir System (where applicable) 28

5 Greasing of Brake Cylinders 29

5.1 Lubricants And Cleaning Fluids 29

5.2 Westinghouse Push Rod Brake Cylinders 29

5.3 Westinghouse AF and WF Diaphragm Brake Cylinders 30

5.4 Davies & Metcalfe Brake Cylinders 33

6 Maintenance of ‘J’ type Slack Adjuster 34

7 Dummy Brake Block 36

8 Approved Lubricants and Cleaning Fluids 37

8.1 Approved Lubricants 378.1.1 The correct grease to use on air brake equipment is as listed below:- 378.1.2 The correct grease for synthetic rubber materials is:- 378.1.3 Anti scuffing spray. 378.1.4 Light machine oil. 37

8.2 Approved Cleaning Fluids 38

9 Brake Equipment Diagrams 39

9.1 Westinghouse Non-relayed System 39

9.2 Westinghouse Relayed System – Reservoir Mounted 40

9.3 Westinghouse Relayed System – ‘D’ Mounting Bracket 41

9.4 Westinghouse Relayed System – ‘SW’ Mounting Bracket 42

9.5 Davies & Metcalfe Non-relayed System – ‘ES-500B’ Distributor 43

9.6 Davies & Metcalfe Relayed System – ‘ESR-500’ Distributor 44

9.7 Davies & Metcalfe Relayed System – ‘ESR-500B’ Distributor 45

10 References 46

10.1 RIC Standards 46



1 Scope

This standard details the requirements for periodic maintenance of air brakeequipment on all locomotive hauled freight and passenger vehicles.

This standard may also be used when required for the maintenance oflocomotive hauled vehicles prior to departure from workshops after overhaul ormajor repairs.

2 When must air brake maintenance take place?

All locomotive hauled freight and passenger vehicles brake systems are to beperiodically maintained and tested as follows each 12 months.

EXCEPTION: Wagons maintained under R1/R2/R3 maintenance programme areto be maintained and tested at every R1, R2 or R3 Inspection.

When specified, locomotive hauled vehicles are to be maintained and/or testedprior to departing workshops.

A single car air test must be carried out at every R2 or R3 inspection and afterthe replacement of any defective air brake equipment or rectification of major airleaks.

3 Requirements

Equipment listed in Section 3 must be inspected to determine that it is intact,secure and in a condition fit for service.

All vehicles must be air tested as described in Sections 4 or 5.

Correct fitting tools only should be used. Single car air testers should be kept ingood condition and chokes screwed onto spare plugs when not in use. Pressuregauges should be regularly calibrated to ensure accuracy.

P.T.F.E. (Teflon) tape, hemp or compounds containing lead MUST not be usedon pipe joints or when fitting any item of air brake equipment. Preferred type ofpipe sealant is Loctite 567 Master Pipe Sealant. (MI 70052402 for 50ml or70071006 for 250ml.)



4 Equipment to be checked

On each vehicle the following must be checked -

Hoses

Coupling Cocks

Brake Pipe

Branch Pipe

Control Valves (Triple Valves, Relay Valves)

Reservoirs and associated Pipe Work

Brake Cylinder

Slack Adjuster

Grade Control Valve Equipment (Freight only)

Load Compensation Equipment - Empty/Load (Freight only)

Release Valve

Hand Brake

Brake Rigging/Brake Blocks

Water Service Unit (Passenger only)

Emergency Valves (Passenger only)

Gauges (Passenger only)

Main Reservoir system (Where Applicable)

4.1 Hoses

4.1.1 Air Brake Coupling Hoses

(Brake Pipe, Main Reservoir)

Check condition of all hoses.

Replace if cut, abraded or perished.

4.1.2 Body to bogie hoses (found on some passenger cars)

Check hose condition

Replace if cut, abraded or perished.



4.1.3 All Other Hoses

Check hose condition

Replace if hose is cut, abraded or perished.

4.1.4 Air Brake Coupling Hose Heads

(Brake Pipe & Main Reservoir)

Check Coupling Head

Replace if old style.

Old Style New Style

Figure 1 Coupling Heads

Replace Coupling hose if fitted with old type coupling head.

Check Coupling head seal.

Replace if there is any visual damage.

Figure 2 Coupling Head Seal



4.2 Coupling Cocks

4.2.1 Brake pipe (and Main Reservoir coupling cocks - if applicable).

Old Style New Style

Figure 3 Coupling Cocks

(a) Operate Handle

If too stiff (can't operate with one hand) – replace

If too loose (can operate with one finger) – replace

If handle operates outside normal closed/open range - replace

(b) Shake coupling cock

If loose tighten or replace "U" bolt

4.2.2 Independent Brake Latching Cocks - where applicable

(a) Operate Handle

Ensure locking mechanism stops handle from moving

Ensure locking mechanism can be released to allow handle to turn.

If too stiff (can't operate with one hand) – replace

If too loose (can operate with one finger) – replace

If handle operates outside normal closed/open range – replace

(b) Shake coupling cock

If loose tighten or replace "U" bolt



4.3 Brake Pipe (and Main Reservoir Pipe, if applicable)

Follow brake pipe from one end to the other shaking the pipe as you proceed.

Check all unions and clamps for looseness - tighten as necessary

Check for restrictions such as damage, kinks etc - repair as necessary

HINT: A damp union or pipe joint often indicates a leak.

4.4 Branch Pipe and Isolating Cocks

(a) Shake branch pipe

Check unions and clamps for looseness – tighten if necessary

(b) Operate isolating cocks - Replace if faulty.

Figure 5 Isolating Cock

(c) Remove bowl from centrifugal dirt collector (old equipment) - Clean

Key ( Fig 5)

2 Body3 Bowl4 Valve Stem5 Valve6 Gasket8 Cock Plug9 Cock Spring10 Cock Cap11 Cock Handle

Figure 5 Centrifugal Dirt Collector



(d) Operate triple valve isolating cock handle (new equipment)

If too stiff or loose - replace isolating cock

handle in open position

Westinghouse Davies & Metcalfe

Figure 6 Isolating Cock Handle

(e) Remove paper filter (Westinghouse only)

Paper Element Dirt Collector

Figure 7 Paper Filter

Clean or Replace



4.5 Control Valves (Triple valves, distributing valves and relayvalves)

4.5.1 Diaphragm Type Triple Valves (Westinghouse ‘W’)and Distributors (Davies & Metcalfe ‘ES’ & ‘ESR’)

Figure 9 Westinghouse Figure 10 Davies & MetcalfeWF2 Triple Valve ES 500 Distributor Valve

Check date - replace if 16 years old (or more)- replace if undated- replace if 16 year life is due before the next R2 or R2 inspection- send replaced triple valves to an Authorised Brake Component Repair

Workshop

NOTE With Westinghouse relayed equipment the following must also bereplaced:

relay valverelease valveaccelerated application valve (where fitted)isolating cock.

With D&M equipment the isolating cock must also be replaced.

Figure 11 Davies & Metcalfe ESR 500B Distributor Valve



4.6 Reservoirs and Associated Pipework

Figure 13 Westinghouse Combined Reservoir Unit

1 Auxiliary Reservoir2 Dummy Brake Cylinder3 Supplementary Reservoir4 Accelerated Release Reservoir5 Triple Valve6 Relay Valve7 Automatic Release Valve

(a) Visually check reservoirs for damage and corrosion.

If in doubt have reservoir checked by your Supervisor who will if necessaryarrange for examination by a Pressure Vessel Inspector.

(b) Remove drain plug from each reservoir and drain any water that hasaccumulated.

(c) Check pipework between reservoirs and control valve bracket for loose orworn fittings, loose clamps and wear marks from rubbing.

tighten or replace where necessary.



4.7 Brake Cylinders

4.7.1 Old push rod type brake cylinder

Figure 13 Westinghouse Push Rod Brake Cylinder

These brake cylinders require maintenance every 12 months.Refer to Section 5.1 for details.

These brake cylinders must be greased at every R2, R3 or DWI inspection.

4.7.2 Westinghouse AF and WF type brake cylinders

Figure 14 AF Brake Cylinder Figure 15 WF Brake Cylinder

These brake cylinders require greasing at every DWI, R2 or R3 inspection.

No other periodic maintenance is required.

Refer to Section 5.2 for details of greasing.



4.7.3 Davies and Metcalfe type brake cylinders

Figure 16 Davies & Metcalfe Brake Cylinder

These brake cylinders must be stripped down and greased every 12 months

These brake cylinders must be greased at every R2/R3 or DWI inspection.

No other periodic maintenance is required.

Refer to Section 5.3 for details of greasing.

4.8 Slack Adjusters



4.8.1 'J' type ratchet (pneumatic)

Figure 18 'J' Type Slack Adjuster1 Slotted Cross Head 8 Casing2 Slack Adjuster Port in Brake Cylinder 9 Ratchet Nut3 Adjuster Cylinder Pipe 10 Stop Screw4 Adjuster Body 11 Dead Cylinder Lever5 Crosshead 12 Connecting Rod6 Adjuster Screw 13 Live Cylinder Lever7 Adjuster Cylinder

Clean main adjusting screw thread - do not grease or oil.

Spray main adjusting screw with anti-scuffing spray.

Check that adjuster can be manually wound in either direction without undueeffort.

Replace if too stiff.

Check that slack adjuster take off port on brake cylinder is:

Relayed brake - in the position closest to the pressure head end of the brakecylinder to give a piston travel of 100mm.

Non-relayed brake - in the middle position to give a piston travel of 150mm.

No further work is required on slack adjuster unless it fails the air test inRSS00061 or the vehicle is in workshops.

In these cases refer to Section 6 for maintenance procedure.



4.8.2 In-line Slack Adjusters

Figure 19 Westinghouse SAB Slack Adjuster

Figure 20Davies & Metcalfe Stopex Slack Adjuster

Apply handbrake

Check - control rod clearance reduces to zero

- control rod and control lever do not distort (Note: a bent control rodmust be replaced)

No further work is required on in-line slack adjuster unless it fails to operatecorrectly during the single car air test in which case it must bereplaced.

NOTE 1: Some Davies & Metcalfe in line slack adjusters have greasenipples fitted to the regulating fork end. These must be greased (one ortwo pumps) during periodic maintenance.

NOTE 2: In-line slack adjusters must not be dismantled under anycircumstances unless undergoing overhaul at an Authorised Air BrakeComponent Repair Workshop



4.9 Grade Control Valve Equipment


Figure 21 Grade Control valves

Check pipework for looseness, damage, rubbing etc - Repair and tighten asnecessary.

Check operation of handle

If too stiff (can't operate with one hand) repair or replace grade controlvalve

Check size of grade control valve corresponds to brake cylinder for non-relayedequipment or dummy volume reservoir (ie 6" or 150mm) for relayedequipment.

NOTE 1: If a vehicle is fitted with a 3-position Davies & Metcalfe gradecontrol valve, replace with a standard 4-position grade control valve.

If the vehicle has markings relating to the 3-position grade controlvalve, paint over the markings.

NOTE 2: On relayed equipment only Westinghouse grade control valvesare to be used with Westinghouse equipment and only Davies andMetcalfe grade control valves are to be used with Davies and Metcalfeequipment.

EXCEPTION: Davies & Metcalfe grade control valves branded 'W6" are onlyto be fitted to Westinghouse relay brake equipment and NOT onDavies & Metcalfe equipment.



Type Of Brake Equipment Allowable Grade Control Valve

D & M ES 500B or ESR 500 D&M GCV matching brake cylinder size

D & M ESR 500B or ESR 500E D & M 6" standard GCV

Westinghouse relayed Westinghouse 6" or D & M type 'W6'

Westinghouse non-relayed Westinghouse GCV matching brakecylinder size

Wagons with the wrong GCV's fitted will have incorrect brake release times

4.9.1 Fixed Exhaust Chokes

On vehicles fitted with a fixed exhaust choke in place of the grade controlvalve, check that the correct choke is fitted as detailed in RSS 0065.

Figure 22 40 second exhaust choke with wasp excluder

The 0.9mm choke replaces the old type 1.05mm choke.The 0.6mm choke replaces the old type 0.7mm choke.



4.9.2 Load Compensation Equipment (Empty/Load)

4.9.3 Manual Equipment


Figure 23 Manual Empty/Load valves

Check pipework for looseness, damage, rubbing etc - repair and tightenas necessary.

Check operation of handle and adjustment of connecting rod.

If too stiff (can't operate with one hand) repair or replace load compensator

NOTE: It is important that the correct Westinghouse E/L valve is fitted towagons. The valve type is marked by the letter "R", "M" or "B" stamped onthe valve body. Davies & Metcalfe equipment has an integral E/Lchangeover valve included in the distributor valve.

Type Of Brake Equipment Manual Load Compensation Valve

Westinghouse relayed Westinghouse Type "R"

Westinghouse non-relayed Westinghouse Type "M"



Figure 24 Westinghouse Manual Empty Load Valves



4.9.4 Automatic Equipment

]

Figure 25 SAB type VTA Automatic Load Valve

Check that SAB (type VTA) load valve is fitted with Westinghouse equipmentand Davies and Metcalfe (type LEC) is fitted with Davies and Metcalfeequipment.

Check condition of hoses - change if necessary.

Check clearance between plunger and adjusting plate with the wagon empty -should be 25mm - adjust if necessary.

Figure 26 Davies & Metcalfe type LEC Automatic Load Valve



4.10 Release Valve

Figure 27 Release Valve

Check release valve pull chain or wire from both sides of vehicle.

Pull release chain or wire or operate handle and check release valveoperates.

Repair or Replace if faulty.

4.10.1 Handbrake

Figure 29 handbrake

Operate handbrake Check -ease of operation

-gears remain engaged-chain for damage-release lever operation (must drop down and engage pawl when releaselever is released)-handle not loose

Handbrake should be lubricated with anti-scuffing spray.



4.11 Brake Rigging/Brake Blocks

4.11.1 Wagons

Check rigging not fouling on bogie frame or axles

Check all pins on rigging for correct size and placement

Fit new pins if necessary

Check all split pins and split cotters for placement and fitting

Fit new split pins or cotters if necessary

NOTE: Lynch pins or 'R' clips must not be used below axle centreline.Replace with split pins or cotters if found below axle centreline. Referto RSS 0063

Check safety loops - repair or replace if necessary.

Apply handbrake - check for any signs of brake rigging fouling points orrubbing on axles.

For vehicles fitted with slack adjusters:

Check bogie rigging adjustment as follows:-

Fit dummy brake blocks (see Section 7 for details of dummy brake block)

or

Fit new brake blocks (old blocks may be replaced later)

Apply hand brake

Measure distance "X"

X

Figure 30 Adjustment Of Bogie Brake Rigging



"X" should be as close as possible to dimensions shown in table below,.

Adjust if necessary.

NOTE: 1: After adjustment bogie must not be re-pinned in serviceunless new wheelsets are fitted to bogie.

NOTE: 2: Piston travel will be checked and adjusted during a single carair test.

Bogie Type Dimension "X"

Three-Piece (except AVA,BVA,CQA, CQB & CQC)

300 mm

AVA & BVA 430 mm

CQA, CQB & CQC 485 mm

4.11.2 Passenger Cars

The following procedure should be taken as a guide to adjust the brake riggingon passenger car bogies.

Check bogie rigging adjustment as follows:-

Fit dummy brake blocks ( Refer Section 7) or

Fit new brake blocks (old blocks may be put back on later)

Apply handbrake

Check slack adjuster is within 50 mm of being fully wound in

Check angle of levers is in the correct direction (ie. as brake blocks wear thelevers will approach the right angle position).

Check rigging is not fouling the bogie frame or axle

Adjust bogie rigging as necessary.



4.12 Water Service (passenger cars)

Figure 31 Water Service Unit

Check date -must not be more than 5 years old -replace if older than 5years

Check pipework for looseness, damage, rubbing etc repair or tighten asnecessary.

Check operation of water tank fill handle (3-way cock)

Fill tank with water - Check for any water leaks repair as necessary.

NOTE: Air test on water service is carried out in RSS 0061.

Overhaul shall be done at an Approved Workshop.

4.12.1 Water Service Gauges (passenger cars)

Check gauge connections are secure and air tight and gauge is securedcorrectly.

Check HP and LP gauges on water service - replace if damaged.

Check any internal gauges for damage - replace if necessary

Clean gauge faces



4.13 Main Reservoir System (where applicable)

Clean or replace strainers in pipeline to Supplementary reservoir and doorcylinder reservoir.

Clean or replace filter elements in door reservoir system.



5 Greasing of Brake Cylinders

This Instruction describes the methods of greasing the following types of brakecylinders:-

Westinghouse Pushrod type brake cylinders.

Westinghouse Type AF and WF Diaphragm type brake cylinders.

Davies & Metcalfe brake cylinders.

Westinghouse ‘UC’ type brake cylinders

5.1 Lubricants And Cleaning Fluids

Refer to Section 8 for approved lubricants and cleaning fluids.

5.2 Westinghouse Push Rod Brake Cylinders

1 Disconnect push rod from brake rigging. Remove dome head nuts. Withdraw piston from brake cylinder.

2. Clean inside of brake cylinder making sure leakage groove is clear. Check for rust in cylinder. If badly rusted brake cylinder must be changed.

3. Remove expander ring from piston leather. Clean leather with scraper and dry waste (not cleaning fluid). Check leather carefully for cracks and excessive wear. Replace if necessary. Any thin portion of the leather should be brought tothe top of the piston on reassembly.

4. Check condition of piston follower plate, release spring, crosshead andcrosshead pin for wear or other defects - replace if necessary.

5. Examine dome head and piston rod for excessive wear - replace ifnecessary.

6. Grease piston leather liberally on cylinder side and in expander ring recess.Leather should be made pliable by working in the grease.Replace expander ring. Gap should be at top of piston.

7. Grease inside brake cylinder evenly.

8. Replace piston into brake cylinder taking great care that leather is notdamaged in any way.

9. After piston has been reassembled, rotate one quarter of a turn in eachdirection to ensure no binding is taking place.

10. Replace dome head and connect cross head to brake rigging.



KEY:2. Pressure Head3. Dome head4. Push rod5. Piston6. Piston follower7. Piston seal8. Piston packing expander9. Release spring10. Stud and nut11 Pressure head gasket12. Pipe plug. Figure 32 Typical Pushrod Brake Cylinder

5.3 Westinghouse AF and WF Diaphragm Brake Cylinders

Note: These brake cylinders must not be dismantled except in an accreditedrepairer.

1 Clean dirt and old grease off as much of trunk as possible. If air is available,the trunk can be cleaned by adjusting brake rigging to give a long pistonstroke then applying the brake.

2 Remove cap plug from nipple at pressure end of brake cylinder. Attachgrease gun and insert half of the grease specified in clause 4 below. Toensure even application of grease to the piston seal, rotate piston trunk by180 degrees. This can be achieved by applying a suitable pipe wrench tothe ring at the end of the piston trunk. Insert the remainder of the greaseand rotate the piston by 360 degrees. Replace cap plug ensuring it is airtight.

3 Remove cap plug from trunk or dome end. Attach grease gun and inserthalf of the grease specified in clause 4 below. To ensure even applicationof grease to the piston seal, rotate piston trunk by 180 degrees. This can beachieved by applying a suitable pipe wrench to the ring at the end of thepiston trunk. Insert the remainder of the grease and rotate the piston by 360degrees. Replace cap plug.



4 Amount of lubricant to be used:-

The number of strokes of the standard grease gun (such as a J.C. 10) togrease the above brake cylinders is –

Strokes of Grease GunBrake CylinderDiameter

Pressure Head End Trunk or Dome End

inch mm DWI & R2/R33 year

inspection

R25 year

inspection

DWI & R2/R33 year

inspection

R25 year

inspection

10 254 8 15 2 2

12 305 10 18 2 4

14 356 12 20 2 4

16 406 14 24 2 4

Figure 33 Westinghouse ‘AF’ Type Brake Cylinder



Figure 34 Westinghouse ‘WF’ Type Brake Cylinder



5.4 Davies & Metcalfe Brake Cylinders

Note: These brake cylinders must be dismantled during maintenance forgreasing.

1 Remove pin connecting piston end to brake rigging.

2 Loosen nuts (10) and remove the piston and cover assemblyOn some vehicles such as coal hoppers, a little jiggling of the piston isrequired to clear the brake rigging.

3 Wipe the cylinder walls clean to remove all lubricating grease which havebecome contaminated with dust and moisture etc after prolonged periodsof service.

4 Remove piston seal and inspect for wear or damage.Replace if necessary.

5 Smear the inside of the piston cylinder body with clean grease.Smear grease on the piston seal and refit to piston

6 Refit piston and cover assembly.Tighten nuts and refit pin to brake rigging.

7 Remove cap plug from trunk or dome end.Attach a standard grease gun (such as a J.C. 10) and grease piston with 8strokes of the grease gun.Replace cap plug.

Figure 35 Davies & Metcalfe Brake Cylinder

1. Cylinder Assembly 7. Spring ring 13. Bush2. Cylinder Cover 8. Bush 14. Cylinder with fulcrum3. Piston rod assembly 9. Spring washer head4. Piston assembly 10. Hexagonal Nut 15. Fulcrum head5. Spring 11. Square head bolt 16. Washer6. Piston sealing ring 12. Plug 17. Pin



6 Maintenance of ‘J’ type Slack Adjuster

1 Remove pipe between brake cylinder and slack adjuster.

Check condition of pipe and that there are no blockages in the pipe or portsto the brake cylinder or slack adjuster.

2 Remove casing bolts and withdraw cylinder and casing over the longratchet nut.Remove ratchet nut by unscrewing it.

Clean main adjuster screw thread.Do not grease or oil. Spray with anti-scuffing spray

3 Carefully check ratchet nut and pawl condition.

Place ratchet nut into housing and ensure nut can rotate freely in eitherdirection without contacting the pawl.

Inspect condition of check pawl and ensure there is sufficient tension on theratchet to prevent rotation under normal working conditions.

4 Refit ratchet nut and casing.

5 Remove cylinder bolts and cylinder from casing.

Remove expander ring from piston leather.Clean leather with scraper and dry waste (not cleaning fluid).Check leather carefully for cracks and excessive wear.Replace if necessary.Any thin portion of the leather should be brought to the top of the piston onreassembly.

Check piston follower plate and nut for defects and looseness.

6. Grease piston leather liberally on cylinder side and in expander ring recess.Leather should be made pliable by working in the grease.Replace expander ring. Gap should be at top of piston.

7. Grease inside of cylinder evenly.

8 Refit cylinder over piston and bolt up taking great care that leather is notdamaged in any way.

9. After piston has been reassembled, rotate one quarter of a turn in eachdirection to ensure no binding is taking place.

10 Refit pipe between brake cylinder and slack adjuster.



Figure 37



7 Dummy Brake Block

The dummy brake block is used for checking the adjustment of brake rigging.

Full details of the dummy brake block are found in SRA Drawing No. 207-657.

Figure 38 Dummy Brake Block



8 Approved Lubricants and Cleaning Fluids

This section lists the approved lubricants and cleaning fluids for use on the air brakeequipment on freight and passenger vehicles.

8.1 Approved Lubricants

8.1.1 The correct grease to use on air brake equipment is as listed below:-

Approved brands:

Ampol RR2

B.P. Annagrease 12

Caltex Marfak MP2

Mobilux 2

Shell Alvania R2.

NOTE:- Do not use these greases on components made from synthetic rubber.Refer to 8.1.2 below.

8.1.2 The correct grease for synthetic rubber materials is:-

Caltex Aquatec Premium Marine Grease.

WARNING:- Silicon grease must not be used on synthetic rubber.

8.1.3 Anti scuffing spray.

For use on surfaces such as the adjuster screw threads on pneumatic slackadjusters.

Approved spray:-

Rocol A.S. Dry Film Anti-Scuffing Spray

8.1.4 Light machine oil.

Light machine oil where nominated is Shell Tellus 46 or equivalent.

Light machine oil shall not be used to lubricate components made of syntheticrubber.



8.2 Approved Cleaning Fluids

For cleaning use Exoll D60



9 Brake Equipment Diagrams

9.1 Westinghouse Non-relayed System

Figure 38



9.2 Westinghouse Relayed System – Reservoir Mounted

Figure 39



9.3 Westinghouse Relayed System – ‘D’ Mounting Bracket

Figure 40



9.4 Westinghouse Relayed System – ‘SW’ Mounting Bracket

Figure 41



9.5 Davies & Metcalfe Non-relayed System – ‘ES-500B’ Distributor

Figure 42



9.6 Davies & Metcalfe Relayed System – ‘ESR-500’ Distributor

Figure 43



9.7 Davies & Metcalfe Relayed System – ‘ESR-500B’ Distributor

Figure 44



10 References

10.1 RIC Standards

RSS 0010 Ballast Wagon Maintenance Policy

RSS 0011 Wagon Maintenance Policy (1996)

RSS 0061 Single car Air Test

RSS 0063 Security of Brake Gear

RSS 0064 Brake Pipework Sealant Compounds

RSS 0065 Fixed Exhaust Chokes

RSS 0066 Air Brake Hoses

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