Type 9b rail wheel braking system operation and maintenance · 5.1. System control The Rail wheel...

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Type 9b rail wheel braking system operation and maintenance

Document no AJH038

Author P. Hargreaves

Issue Status: Issue 7

Date: 18/02/2016

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CONTENTS Section Heading Page

Contents 2

1 Issue and revision record 3

2 Introduction 4

3 Defined words 5

4 Document review 6

5 General arrangement 7

5.1 System control 8

5.2 System operation 8

5.3 General 9

6 Maintenance 10

6.1 Maintenance Frequencies 11

6.2 Summary of Jobs 11

6.3.1 Rail wheel brake system - Check 13

6.4.1 System integrity - Check 14

6.5.1 Brake pads - Examine 15

6.5.2 Brake pad wear - Adjust 17

6.6.1 Brake pressure - Test 19

6.6.2 Drawbar pull - Test 20

6.6.3 Static Brake torque test - Test 21

6.7.1 Brake pad change - Overhaul 22

6.7.2 Emergency recovery - Procedure 26

7 Torque Table 28

8 Appendix A 29

9 Parts List 30

10 Appendix B 31

All information, illustrations and specifications in this Maintenance Programme are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe systems of work are in place and in certain circumstances advice and permission from the controlling authority must be sought before any operation, installation or surveying work is carried out.

Prepared by:

Authorised by:

P. Hargreaves C. Chippendale

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1. Issue and Revision Record This document will be updated when necessary by the re-issue of the complete document. Listed below are changes related to each issue.

Issue/ Revision

Description Date Revised

Page No.

Revised

By.

2 General layout change 02/02/2012 ALL P.Hargreaves

3

Change to brake pad adjust frequency, Loctite

grade, drawbar pull requirements

02/11/2012 14 - 28 P.Hargreaves

4

Brake pad adjust frequency, torque of

floating pins, addition of parts list

30/10/2014 14,17,19,

20,29 P.Hargreaves

5 Cleaning of brake discs,

Clarification of emergency recovery, New parts list

18/04/2015 13,14,24,25,29 P.Hargreaves

6 Amendments to arising work for sections 6.3.1,

6.4.1, 6.5.1 15/07/2015 13,14,16 P.Hargreaves

7 Addition of static brake

test 18/02/2016 21-30 P.Hargreaves

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2. Introduction This manual has been produced to cover the safe use and maintenance of the rail wheel braking system for type 9b excavators. It is provided as a supplement to the original manufacturers/converters manual and should be used in conjunction with those to provide safe operation and maintenance. It is important that all personnel are fully trained and familiar with the machine and rail wheel braking system and that they have read and understood the information contained in this manual before operating or maintaining this machine.

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3. Defined Words

The following outlines the defined words used within this Maintenance Programme.

Term Action required

Adjust Correct to defined limits

Change Remove the original and fit a new or overhauled part or assembly in its place.

Check Determine a particular nominated condition before, during or after repair, for example completeness, security, position

Clean Remove all dirt and deposits

Defective Any fault or faults in a component or assembly, for example structural fractures or weld fractures, which may prevent the component or assembly from fulfilling its designed purpose

Dismantle Take to pieces

Examine Determine general condition before repair, for example wear, cracks, splits, leaks, scoring, erosion, breaks, distortion, looseness

Gauge Determine a nominated dimension by using suitable measuring equipment, for example ruler, micrometer, callipers, feeler gauges or Go/No-Go gauge

Inspect Determine general condition after repair and attention, that is, conformity to required standards

Lubricate Apply lubricant

Overhaul Do what is necessary to make an assembly or sub-assembly re-usable, that is dismantle, strip, clean, examine, fit new parts, repair, re-assemble, test and inspect as required

Paint To impart colour to a surface

Re-assemble Put together

Record Put down in writing a finding from examination, test, inspection or special checks.

Rectify To set right

Refit Put back and re-connect

Remove Disconnect and take off

Renew Remove, scrap the original part and put a new part in its place

Repair Restore an original part to the required condition by hand tooling, machining, build-up, welding, patching, bending, setting, heat-treating, re-securing etc

Strip Remove covering, that is, paint, polish, fabric

Test Prove correct operation by trial

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4. Document Review The following Maintenance Programme specified on the appropriate VAB certification for each product is reviewed as follows:

1. The Maintenance Programme is reviewed on an annual basis to investigate:

The potential for improvement.

The maintenance activities.

The vehicle performance and associated components.

National Incident Reports (NIR’s).

Changes in use and/or operating environment.

Manufacturer’s advice.

Directives from Network Rail.

The vehicle’s seven-year review.

2. A record of any decisions taken at this review are retained.

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5. General arrangement Each rail wheel will be fitted with a hydraulically operated brake caliper of fail-safe spring applied design and operate upon a brake disc mounted to the inboard side of the rail wheel.

Fig 1

As the system is of fail-safe design, upon loss of hydraulic pressure the park brake will engage and bring the machine to a halt.

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5.1. System control

The Rail wheel braking system is controlled by the machines OEM controls. The service brake operated by the foot pedal and park brake system operated by a switch. Refer to the base machine operating manual for more information. 5.2. System operation

The system is integrated with the machines OEM controls and does not require additional operator control.

If the Trailer brake-away alarm sounds for more than 2 seconds it may be an indication that the system has developed a leak or sustained damage.

If the machine is not functioning correctly it must be removed from service until repairs have been carried out.

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5.3. General

During the course of maintenance and testing, all missing items must be replaced; defective items must be repaired or renewed; all faults rectified and equipment correctly adjusted. Replacement parts shall be identical to the original parts in fit, function and performance.

In order to carry out this Maintenance Programme, the following minimum level of facilities is required, appropriate to the jobs being undertaken: a) Clean, dry, covered accommodation for dealing with bearings,

mechanical, hydraulic and electrical components, etc. b) Adequate illumination for inspection of components, bogies and

underframes. c) Cleaning facilities which will not cause damage to the components. d) Handling facilities for removal and refitting of components such as rail

bogies and engines. e) Protection from the weather of vulnerable areas of the vehicles and

its components. f) Any specific requirements additional to those listed are identified on

the applicable job description.

Maintenance action is intended to ensure the continued safe operation of the rail wheel braking system and host vehicle. The maintenance programme has been derived from reliability and safety apportionment’s and failure by the owner to follow these activities would invalidate both warranty and safety systems given for the product.

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6. Maintenance The following Maintenance Programme specified on the appropriate VAB certification for each product is as follows: In order to carry out this Maintenance Programme in a manner that

achieves the required safety and quality, the following minimum level of competence is required:

a) For all activities the person leading the task must be able to follow

and carry out the instruction detailed in this document. All Safety Critical Work must be carried out by persons competent in accordance with: Health and Safety Executive publication “Railway safety principles and guidance” part 3 section A.ORR railway safety publication 1 “Developing and maintaining staff competence” March 2007. The railway and other guided transport systems “safety regulations 2006” and “Guidance on regulation, part 4 safety critical work.

b) All work relating to the maintenance and overhaul of axle bearings should be carried out by competent persons. Requirements for axle bearings are set out in GMGN2646; these do not apply to possession-only rail vehicles but may be used as a source of information.

c) Staff undertaking this work must have been trained and hold certificates of competency such as: SCW ID; apprentice-Trained Craftsman/NVQ level 3 in Plant Maintenance; Certificate issued by a CITB/CTA approved body – operation for maintenance purposes only; Re-assessment of competency in accordance with RPA Standards etc.

d) All staff to have undergone the training course for the appropriate equipment, to the extent of the responsibilities and the tasks they are asked to be perform by the machine and equipment owners and their agents.

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6.1. Maintenance Frequencies

The machine is to be examined at frequencies no greater than the limits set out below: Type of exam Calendar Time A Pre Start B Monthly C 3 Monthly D Yearly

6.2. Summary of Jobs Schedule of work

Job Title Intent Job No A B C D

Pre Start 6.3

Rail wheel brake system Check 6.3.1 ∗ ∗ ∗ ∗

Monthly Maintenance 6.4

System integrity Check 6.4.1 ∗ ∗ ∗

Three Monthly Maintenance 6.5

Brake pads Examine 6.5.1 ∗ ∗

Brake pad wear Adjust 6.5.2 ∗ ∗

Yearly Maintenance 6.6

Brake pressure Test 6.6.1 ∗

Drawbar pull test Test 6.6.2 ∗

Static brake torque test Test 6.6.3 ∗

As required 6.7

Brake pad change Overhaul 6.7.1

Emergency recovery Procedure 6.7.2

Note: 6.6.2 or 6.6.3 can be adopted for testing brakes, both do not need to be carried out.

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Maintenance instructions

Scheduled Work is that mandatory work which should be undertaken at the prescribed examinations. Arising Work is that work that is done to rectify the defects found in the course of carrying out Scheduled work. The items numbers of the two parts correspond, i.e. the work to be done to rectify a defect in item 2 of scheduled work will be found in item 2 of the arising work.

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6.3.1. Rail wheel brake system - Check Scheduled Work

1. Check all brake system components are securely attached and without damage.

2. Ensure no leaks or contamination of brake discs is present. 3. Operate the park brake and ensure the brake-away alarm does not

sound for more than 2 seconds. 4. Operate the service brake and ensure the brake-away alarm does not

sound for more than 2 seconds. 5. Place machine on track, drive for a short distance and operate the

service brake to ensure system operates effectively.

If the machine is not functioning correctly it must be removed from service until repairs have been carried out.

Arising work 1. Change missing / Faulty components. 2. Remove brake disc contamination with brake cleaner. 3,4. Renew faulty wiring, resecure loose connections, check flow switch operation. 5. Carry out job 6.4.1

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6.4.1. System Integrity – Check Scheduled Work

1. Check brake pad linings and discs for damage, contamination and security. 2. Check the remaining brake pad lining is greater than 2mm (Fig 2).

Fig 2

3. Check hydraulic hoses to the brake system and associated fittings. 4. Check for loose or missing fasteners. 5. Check brake disc protection for damage and security ensuring that it protrudes

from the brake disc. 6. Check lifeguards for damage and security, ensure the distance between the

rubber and railhead is no greater than 30mm Arising work 1. Remove brake disc contamination with brake cleaner. 1,2. Renew defective, damaged, worn or contaminated brake pads. 3. Renew defective or damaged hoses and fittings. 4. Renew loose or missing fasteners, (Service brake side floating pins to be refit with high strength Loctite 271 and torqued to 35Nm) 5. Renew or repair brake disc protection. 6. Adjust rail scraper rubbers to achieve clearance.

BRAKE PAD LININGS

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6.5.1. Brake pads - Examine Scheduled Work

1. Examine for signs of contamination on the brake pads. 2. Examine brake pad lining for wear (Fig 3). If remaining brake pad lining on any

of the brake pads measures 2mm or less carry out job 6.7.1 Fig 3

3. Ensure the machine is in a safe condition on level ground with the rail bogies raised and the road wheels firmly chocked.

4. Start the machine and set the park brake to off. The rail wheels should now turn freely.

BRAKE PAD LININGS

FLOATING PINS

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5. Check for loose or missing fasteners. 6. Clean and lubricate floating pins with graphite grease. 7. Return the machine to a safe pre-start condition.

Arising work 1. Renew defective, damaged, worn or contaminated brake pads. 2. After replacing any components carry out job 6.6.2 or job 6.6.3. 5. Renew loose or missing fasteners.

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6.5.2. Brake pad wear – Adjust Scheduled Work


2. Start the machine and set the park brake to off. The rail wheels should now turn freely.

3. Push the brake caliper so the outboard brake pad touches on the rail wheel side of the disc (ensuring the service brake pistons are retracted).

Fig 5

1mm GAP BETWEEN BRAKE PAD AND DISC ON INBOARD SIDE.

ENSURE SERVICE BRAKE PISTON IS FULLY RETRACTED BY PUSHING THE CALIPER INBOARD.

PA

RK

BR

AK

E

SID

E O

F C

AL

IPE

R

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Fig 6

4. To adjust the brake pad, turn the two compensator bolts (Fig 6) in a clockwise direction evenly, preferably by 90 degrees at a time until a gap of 1mm is achieved between the pad and the running surface of the disc on the inboard side. (This will give 0.5mm per side clearance with the brake centered on the disc) see (Fig 5).

5. Repeat the procedure for all 4 rail wheel brakes. 6. Set the park brake switch to on and visually check that the pads are engaged

with the disc. 7. Check that the emergency recovery plates are securely stowed and

compensator bolts are secure. 8. Return the machine to a safe pre-start condition.

Arising work Change any faulty/damaged parts

BRAKE PAD WEAR COMPENSATOR BOLTS

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6.6.1. Brake pressure – Test Scheduled Work


2. Locate and Install pressure test gauges to both hydraulic service and park brake pressure lines.

3. Start the machine and engage the service and park brakes in turn. 4. The park brake pressure should be 120bar +5bar / -15bar. 5. The service brake pressure is machine specific and can be found in the

Appendix A for the machine. 6. Reinstate the machine to a pre use condition.

Arising work Details of the system schematic can be found in appendix A. 4, 5. Adjust pressure reducing valve to achieve correct brake pressures. Change defective items. Repeat test after making any repairs or adjustments.

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6.6.2. Drawbar pull – Test Scheduled Work Test to be carried out on clean and dry track.

1. Set up the machine to be tested on track 2. Connect the machine to a suitable load cell and towing vehicle. 3. Apply the parking brake only. 4. Using the towing vehicle apply 3600kg to the machine in the direction of the

track. 5. The machine should not move, neither should any of the four rail wheels move. 6. Apply the service brake only. 7. Using the towing vehicle apply 3600kg to the machine in the direction of the

track. 8. The machine should not move, neither should any of the four rail wheels move. 9. Record results in accordance with RIS-1530-PLT.

Note: In adverse rail conditions where a vehicle under test is more likely to slide a drawbar pull figure of 14% of gross vehicle weight is deemed acceptable. A summary of the prevailing railhead conditions shall be stated on the test record sheet with the drawbar pull test result. If the machine is not functioning correctly it must be removed from service until repairs have been carried out.

Arising work If the machine has failed the park brake test, Check the machine in accordance with the specific machine maintenance manual to ensure correct operation. 8. Carry out a check of the rail wheel brake system pads in accordance with job 6.5.1. Change defective items. 8. Carry out brake system pressure test in accordance with job 6.6.1. Repeat test after making any repairs or adjustments.

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6.6.3. Static brake torque test – Test Note: The figures quoted for the Static brake torque test in Appendix B are derived values calculated to ensure brake performance is maintained until the next maintenance interval.

Scheduled Work

1. Ensure the machine is in a safe condition, chock the road wheels and ensure the rail wheels are positioned so they are not externally influenced by the road wheels or the ground.

2. Visually check the brake components to ensure no contamination is present. 3. Apply the parking brake only. 4. Using a suitable torque wrench / multiplier apply a torque to the 1 inch square

drive of each rail wheel in turn, in line with the values for the park brake torque listed in Appendix B.

5. The rail wheel should not turn below the minimum value, do not exceed a torque of 3000Nm.

6. Apply the service brake only. 7. Using a suitable torque wrench / multiplier apply a torque to the 1 inch square

drive of each rail wheel in turn, in line with the values for the service brake torque listed in Appendix B.

8. The rail wheel should not turn, do not apply a greater torque than that listed. 9. Record results in accordance with RIS-1530-PLT.

If the machine is not functioning correctly it must be removed from service until repairs have been carried out. Arising work If the machine has failed the Static brake torque test, Check the machine in accordance with the specific machine maintenance manual to ensure correct operation. 2. Remove brake disc contamination with brake cleaner, renew defective, damaged, worn or contaminated brake pads. Remove brake disc glazing with emery cloth. 5. Carry out a check of the rail wheel brake system pads in accordance with job 6.5.2. 8. Carry out a pressure test of the rail wheel brake system in accordance with job 6.6.1. Repeat test after making any repairs or adjustments.

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6.7.1. Brake pad change - Overhaul Scheduled Work 1. Ensure the machine is in a safe condition on level ground with the rail bogies

raised and the road wheels firmly chocked. 2. Start the machine and set the park brake to off. The rail wheels should now

turn freely. 3. Using a Micrometer measure the brake disc thickness, if this value is less than

or equal to 10.5mm or the brake disc is found to have excessive scoring or damage the disc must be changed or resurfaced as long as the final thickness is greater than 10.5mm.

4. Using a dial test indicator measure the lateral run-out (side to side movement) of the brake disc, if the value is greater than 1.0mm the brake disc must be checked for correct seating to the rail wheel, if the value is still out of limits the disc must be changed. Once a disc has been changed the run-out should be rechecked ensuring a clean mating surface between the disc and wheel.

5. Install the manual retractor plate to the back of the caliper to hold the park

brake off the disc as per job 6.7.2.

6. Set the park brake switch to on, shut down the machine and remove the

hydraulic lines connected to the caliper. Checking that the rail wheel is still free

to rotate.

7. Remove the 2 main securing bolts attaching the caliper assembly to the rail

axle.

8. The caliper can now be lifted off the brake disc to allow access to the brake

pads. (On some machines with limited access removal of the brake disc bolts

may be required to enable removal).

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9. Remove the nuts from the 4 long bolts holding the caliper assembly together

and split the caliper at the join where the brake disc would normally sit.

10. Remove the 2 screws retaining each brake pad in position to allow removal of the brake pads.

11. Rotate the 2 compensator plates (Fig 7) on the park brake side of the caliper anti-clockwise until the pad adjustment is removed (i.e thread bottoms out but DO NOT TIGHTEN) whilst ensuring alignment with the brake pad screws (this will reset the adjustment previously taken up to compensate for pad wear on the old brake pads).

Fig 7

SERVICE BRAKE

PARK BRAKE COMPENSATOR PLATES

FLOATING PINS

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12. Install the new brake pads to the caliper and tighten the retaining screws. (All pads in the particular caliper must be changed at the same time and screws replaced.

13. Refit the 4 long bolts holding the caliper assembly together and tighten to 54Nm.

14. Ensure the caliper is free to slide on the floating pins and lubricate them with graphite grease.

15. Refit the brake caliper to the axle by installing the 2 main bolts and reinstall any loosened disc bolts. (M16 countersink bolts to be torqued to 150Nm with medium strength Loctite 242).

16. Remove the manual retractor plate and refit the two compensator bolts to the rear of the caliper.

17. Refit the hydraulic connections and operate the park and service brake with

the machine running, whilst using the bleed nipple on both the park and

service connections to purge the system of air, whilst taking care due to the

high pressure in the system. It is advised to place a piece of small bore hose

over the bleed nipple to avoid contaminating the disc and pads with oil.

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Fig 8

18. Carry out the brake pad wear adjustment job 6.5.2

19. Clean brake discs with brake cleaner.

20. Reinstate the machine to a pre use condition.

21. Carry out drawbar pull test job 6.6.2 or Static brake torque test job 6.6.3


SERVICE BRAKE BLEED NIPPLE

PARK BRAKE BLEED NIPPLE

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6.7.2. Emergency recovery – Procedure Scheduled Work

1. Remove the two compensator bolts from the rear of the brake caliper by

turning anti-clockwise.

Fig 9

2. Install the Manual Retractor plates by reinstalling the compensator bolts

through the retractor plate and tighten until they bottom out, do not over

tighten.

BRAKE PAD WEAR COMPENSATOR BOLTS

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Fig 10

3. Tighten the retractor bolt until the brake pads are released from the disc and

the wheel becomes free to move. (Do not over tighten)

4. Repeat the procedure for all 4 rail wheel brakes.

5. To reinstate the braking system, remove the Manual retractor plate and

reinstall the two compensator bolts.

6. Carry out brake pad wear adjust job 6.5.2


MANUAL RETRACTOR PLATE

MANUAL RETRACTOR BOLT

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7. Torque Tables

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EXAMPLE

8. Appendix A Details of rail wheel braking system fitted to machine

Machine manufacturer

Machine model

serial number

Plant number

Original machine converter

Rail wheel diameter

Brake disc diameter

Park brake pressure setting 120bar +5bar / -15bar

Service brake pressure setting

Park & Service brake Drawbar pull test requirements

Brake system schematic drawing AJH/RWB/SCH/

Rail wheel braking system is to be maintained in accordance with AJH038 Latest issue of documents and additional copies can be obtained by contacting ALLAN J HARGREAVES PLANT ENGINEERS direct. Web: www.ajhplant.com Email: [email protected] Tel: 01253 859677

http://www.ajhplant.com/

mailto:[email protected]

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9. Parts List

10.

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10. Appendix B

Type 9b rail wheel braking system operation and maintenance · 5.1. System control The Rail wheel...

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