MEWP Direct Rail Wheel Braking system operation and ......6.6.4 Brake filter change – Renew (GENIE...

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MEWP Direct Rail Wheel Braking system operation and maintenance

Document no AJH077

Author P. Hargreaves

Issue Status: Issue 6

Date: 09/10/2015

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AJH077 09/10/2015

ISSUE 6 Page 2 of 30

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 Staff Competency 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

6.6.1 Brake pad wear - Adjust 18

6.6.2 Brake pressure - Test 20

6.6.3 Drawbar pull - Test 21

6.6.4 Brake filter change – Renew (GENIE Z60 ONLY) 22

6.7.1 Brake pad change - Overhaul 23

6.7.2 Emergency recovery - Procedure 27

7 Torque Table 29

8 Parts List 30

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 relevant to each issue.

Issue/ Revision

Description Date Revised

Page No.

Revised

By.

1 Initial Issue 11/02/2014

2 Addition of record keeping, minor descriptive changes,

schematic references. 19/02/2014 6,8 P.H

3

New locknut added to solenoid valve to avoid

inadvertent overriding of valve

19/03/2014 All P.H

4 Minor amendments &

references 25/07/2014 All P.H

5 Cleaning of brake discs,

Clarification of emergency recovery, Parts list addition

18/04/2015 13,14,25,28,

29,30 P.H

6 Amendments to arising work for sections 6.3.1 and 6.4.1

09/10/2015 13,14 P.H

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2. Introduction This manual has been produced to cover the safe use and maintenance of the direct rail wheel braking system for rail mounted MEWPS. 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.

3. Always confirm with manufacturer to ensure the latest issue of this document is being used.

Requirements The vehicle log book must be updated with the date and examination type of the last maintenance carried out. Record Keeping Auditable records of maintenance carried out in accordance with this manual shall be kept, this includes any measurements taken, brake tests, rail wheel dimensional checks, tyre pressure / condition.

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5. General Arrangement Each rail wheel is 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 is operated by releasing the drive control lever. Refer to the base machine operating manual for more information. The following Hydraulic Schematics can be used for reference and can be obtained from Allan Hargreaves Plant Engineers. AJH/RWB/SCH/016 – GENIE Z60 HYDRAULIC SCHEMATIC AJH/RWB/SCH/017 – RR14 EVO HYDRAULIC SCHEMATIC AJH/RWB/SCH/018 – RR14 EVO ELECTRICAL SCHEMATIC 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. Staff Competency 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 ∗ ∗

Yearly Maintenance 6.6

Brake pad wear Adjust 6.6.1 ∗

Brake pressure Test 6.6.2 ∗

Drawbar pull test Test 6.6.3 ∗

Brake filter change (GENIE Z60) Renew 6.6.4 ∗

As required 6.7

Brake pad change Overhaul 6.7.1

Emergency recovery Procedure 6.7.2

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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. Place machine on track, drive for a short distance and release the drive

control lever which in turn operates the service brake. 4. Ensure the rail wheel brakes are now applied. 5. Ensure the system operates effectively and the trailer breakaway alarm

does not sound for more than 2 seconds.


Arising work 1. Renew missing / Faulty components. 2. Remove brake disc contamination with brake cleaner. 4. Carry out job 6.4.1 & 6.6.2. 5. Renew faulty wiring, resecure loose connections, check flow switch operation.

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6.4.1. System Integrity – Check Scheduled Work

1. Check brake pad linings and discs for damage, contamination and security, a mirror should be used to check the brake pads on the outboard side of the brake disc.

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 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 or damaged brake discs, worn or contaminated brake pads. 3. Renew defective or damaged hoses and fittings. 4. Renew loose or missing fasteners. 5. 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.

BRAKE PAD LININGS

FLOATING PINS

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4. Start the machine and override the park brake solenoid by pushing in the red

override button and turning quarter of a turn anti clockwise Fig 4 (Red poppet will be in the ‘OUT’ position), the rail wheels should now turn freely, the barrel nut will require removing to carry out this operation. (For RR14 EVO machines it is necessary to try and drive the vehicle to build up pressure to allow the brakes to release, this will need to be repeated every few minutes). Fig 4

MANUAL OVERRIDE

BARREL NUT FITTED TO PROTECT MANUAL OVERRIDE FROM INADVERTANT OPERATION

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5. Check the brake pads for adjustment by pushing the brake caliper so the outboard brake pad touches on the outboard side of the brake disc, measure the gap between the disc and the inboard brake pad, if the gap is greater than 4mm carry out job 6.6.1

Fig 5

6. Check for loose or missing fasteners. 7. Clean and lubricate floating pins with graphite grease. 8. Return the park brake solenoid to its normal operating state by pushing in and

turning quarter of a turn clockwise (Red poppet will be in the ‘IN’ position). The barrel nut must then be refitted to the override.

9. Visually check that the pads are engaged with the disc and the wheel cannot be turned by hand and return the machine to a safe pre-start condition.

Arising Work 1. Renew defective, damaged, worn or contaminated brake pads. 2. Adjust brake pads to compensate for wear refer to job 6.6.1. 6. Renew loose or missing fasteners. After replacing any components carry out job 6.6.3.

CHECK GAP BETWEEN BRAKE PAD AND DISC AT THIS POSITION.

ENSURE THE BRAKE IS FULLY SLID INBOARD ON ITS SLIDING PINS.

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6.6.1. Brake Pad Wear – Adjust 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 override the park brake solenoid by pushing in the red override button and turning quarter of a turn anti clockwise Fig 4 (Red poppet will be in the ‘OUT’ position), the barrel nut will require removing to carry out this operation, the rail wheels should now turn freely. (For RR14 EVO machines it is necessary to try and drive the vehicle to build up pressure to allow the brakes to release, this will need to be repeated every few minutes).

3. Push the brake caliper so the outboard brake pad touches on the outboard side of the brake disc as per Fig 6.

Fig 6

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

ENSURE THE BRAKE IS FULLY SLID INBOARD ON ITS SLIDING PINS.

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Fig 7

4. To adjust the brake pad, turn the two compensator bolts (Fig 7) 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 6).

5. Repeat the procedure for all 4 rail wheel brakes. 6. Return the park brake solenoid to its normal operating state by pushing in and

turning quarter of a turn clockwise (Red poppet will be in the ‘IN’ position). The barrel nut must then be refitted to the override.

7. Visually check that the pads are engaged with the disc and the wheels cannot be turned by hand.

8. Check that the emergency recovery plates are securely stowed and compensator bolts are secure.

9. Return the machine to a safe pre-start condition. Arising Work 8. Renew any faulty/damaged or missing parts.

BRAKE PAD WEAR COMPENSATOR BOLTS

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6.6.2. Brake Pressure – Test Scheduled Work

1. Locate and Install a pressure test gauge to the park brake pressure line. 2. Set up the machine on rail and drive for a short distance. 3. The park brake pressure should be 105bar +/- 3bar. 4. Upon release of the drive control lever the pressure should drop off to a

maximum of 4bar over a period greater than 2 seconds but less than 10 seconds.

5. Reinstate the machine to a pre use condition.

Arising Work 3. Adjust pressure reducing valve to achieve correct brake pressures. 4. Renew defective items, refer to manufacturer. Repeat test after making any repairs or adjustments.

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6.6.3. 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. Using the towing vehicle apply the load specified in Table 1 to the machine in

the direction of the track.

Table 1

MACHINE VARIANT

PULL FORCE REQUIRED

GENIE Z60 2000kg

RR14 EVO 1500kg

4. The machine should not move, neither should any of the four rail wheels move. 5. Record results in accordance with RIS-1530-PLT.


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. Examine the rail wheel brake system pads in accordance with job 6.5.1. Renew defective items. Carry out brake system pressure test in accordance with job 6.6.2 Repeat test after making any repairs or adjustments.

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6.6.4. Brake Filter Change – Renew (GENIE Z60 ONLY) Scheduled Work

1. Locate brake system filter on the underside of the machine Fig 8.

Fig 8

2. Renew brake filter element and O-ring seal, torque to 50Nm. Filter element part number - (CHP281F03XN)

3. Manually override the brake Fig 4 with the machine running, whilst using

the brake bleed nipple Fig 10 to purge the system of air, whilst taking

care due to the high pressure in the system, this must be repeated for all

4 wheels. It is advised to place a piece of small bore hose over the bleed

nipple to avoid contaminating the disc and pads with oil.

4. Return the park brake solenoid to its normal operating state by pushing in and turning quarter of a turn clockwise. The barrel nut must then be refitted to the override.

5. Return the machine to a safe pre-start condition. Arising Work 2. Renew missing / Faulty components.

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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 override the park brake solenoid by pushing in the red

override button and turning quarter of a turn anti clockwise Fig 4 (Red poppet will be in the ‘OUT’ position), the rail wheels should now turn freely. (For RR14 EVO machines it is necessary to try and drive the vehicle to build up pressure to allow the brakes to release, this will need to be repeated every few minutes).

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. Return the park brake solenoid to its normal operating state by pushing in and turning quarter of a turn clockwise (Red poppet will be in the ‘IN’ position).

7. Turn off the machine and remove the hydraulic lines connected to the caliper.

Checking that the rail wheel is still free to rotate.

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

axle.

9. Remove the bolts from the brake disc.

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

pads.

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11. 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.

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

13. Rotate the 2 compensator plates (Fig 9) 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 9

PARK BRAKE COMPENSATOR PLATES

FLOATING PINS

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14. 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).

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

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

17. Refit the brake caliper to the axle by installing the 2 main bolts and reinstall the brake disc bolts.

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

19. Refit the hydraulic connections and manually override the brake with the

machine running, whilst using the brake bleed nipple Fig 10 to purge the

system of air, this must be repeated for all 4 wheels, 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 10

20. Carry out the brake pad adjustment job 6.6.1

21. Clean brake discs with brake cleaner.

22. Return the park brake solenoid to its normal operating state by pushing in and turning quarter of a turn clockwise (Red poppet will be in the ‘IN’ position). The barrel nut must then be refitted to the override.

23. Reinstate the machine to a pre use condition.

24. Carry out drawbar pull test job 6.6.3

Arising Work Renew any faulty/damaged parts

BRAKE BLEED NIPPLES

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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 11

2. Install the Manual Retractor Plates (Located under canopy) 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 12

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 6.6.1

Arising Work Renew any faulty/damaged parts

MANUAL RETRACTOR PLATE

MANUAL RETRACTOR BOLT

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7. Torque Tables

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8. Parts List

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