Air Brake Part

Engineering Standard
Rolling Stock
Engineering Standard
ESR 0310
AIR BRAKE MAINTENANCE
Version 1.1
Issued May 2013
Owner: Technical Specialist Rolling Stock Performance Standards
Approved Stephen White, Authorised Michael Uhlig,

by: A/Manager, by: Chief Engineer Rolling Stock
Rolling Stock Access Integrity
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
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RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
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The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
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UNCONTROLLED WHEN PRINTED Page 1 of 37

RailCorp Engineering Standard — Rolling Stock
Air brake maintenance ESR 0310
Document control
Version Date Summary of change
(RSS 0060) 1.0 August 2007 Based on TRS 1024
(RSS 0310) 1.0 May 2008 Renumbered RSS 0310
(ESR 0310) 1.0 June 2010 Reformatted and renumbered ESR 0310
1.1 May 2013
Summary of changes from previous version

Summary of change Section
Version 1.1
Minor reformatting
Reference to ESR 0311 added 4
D&M ESR500B distributor valve added 6.5
Variable volume device added 6.7.3
D&M brake cylinder added
Heading corrected was Brake cylinders 6.8
D&M Stopex slack adjuster added 6.8.2
D&M manual empty/load valve added 6.10.1
Greasing of D&M brake cylinder added 7.4
© RailCorp Page 2 of 37
Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1.1
Contents
1 Introduction .............................................................................................................................5
2 Scope........................................................................................................................................5
3 Purpose ....................................................................................................................................5
4 Application...............................................................................................................................5
5 Reference documents.............................................................................................................5
5.1 RailCorp standards ...................................................................................................................5
5.2 RailCorp drawings.....................................................................................................................6
6 When must air brake maintenance take place?...................................................................6
7 Requirements ..........................................................................................................................6
8 Equipment to be checked.......................................................................................................6
8.1 Hoses ........................................................................................................................................7
8.1.1 Air brake coupling hoses ...........................................................................................7
8.1.2 Body to bogie hoses (found on some passenger cars) .............................................7
8.1.3 All other hoses ...........................................................................................................7
8.1.4 Air brake coupling hose heads ..................................................................................7
8.2 Coupling cocks..........................................................................................................................8
8.2.1 Brake pipe (and main reservoir coupling cocks - if applicable). ................................8
8.3 Brake pipe (and main reservoir pipe, if applicable)...................................................................8
8.4 Branch pipe and isolating cocks ...............................................................................................9
8.5 Control valves (triple valves, distributing valves and relay valves).........................................10
8.5.1 Diaphragm type triple valves (Westinghouse ‘W’)...................................................10
8.6 Reservoirs and associated pipework ......................................................................................11
8.7 Brake cylinders........................................................................................................................12
8.7.1 Old push rod type brake cylinder.............................................................................12
8.7.2 Westinghouse AF and WF type brake cylinders .....................................................12
8.7.3 Westinghouse variable volume devices ..................................................................13
8.7.4 Davies & Metcalf brake cylinders ............................................................................13
8.8 Slack adjusters........................................................................................................................14
8.8.1 'J' type ratchet (pneumatic)......................................................................................14
8.8.2 In-line slack adjusters ..............................................................................................15
8.9 Grade control valve equipment ...............................................................................................16
8.9.1 Fixed exhaust chokes ..............................................................................................17
8.10 Load Compensation Equipment (Empty/Load) .......................................................................17
8.10.1 Manual Equipment...................................................................................................17
8.10.2 Automatic equipment ...............................................................................................20
8.11 Release valve..........................................................................................................................20
8.12 Handbrake...............................................................................................................................21
8.13 Brake rigging/brake blocks......................................................................................................21
8.13.1 Wagons....................................................................................................................21
8.13.2 Passenger cars........................................................................................................22
8.14 Water service (passenger cars) ..............................................................................................23
8.14.1 Water service gauges (passenger cars)..................................................................23

8.15 Main reservoir system (where applicable) ..............................................................................23
9 Greasing of brake cylinders.................................................................................................24
9.1 Lubricants and cleaning fluids.................................................................................................24
9.2 Westinghouse push rod brake cylinders .................................................................................24
9.3 Westinghouse AF and WF diaphragm brake cylinders...........................................................25
9.4 Westinghouse variable volume devices..................................................................................27
9.5 Davies & Metcalf brake cylinders............................................................................................28
10 Maintenance of ‘J’ type slack adjuster ...............................................................................30
11 Dummy brake block ..............................................................................................................32
12 Approved lubricants and cleaning fluids ...........................................................................32
13 Brake equipment diagrams ..................................................................................................33
13.1 Westinghouse non-relayed system.........................................................................................33
13.2 Westinghouse relayed system – reservoir mounted...............................................................34
13.3 Westinghouse relayed system – ‘D’ mounting bracket ...........................................................35
13.4 Westinghouse relayed system – ‘SW’ mounting bracket........................................................36
13.5 Davies& Metcalf relayed brake equipment with ESR-500B....................................................37

1 Introduction
All RailCorp infrastructure maintenance vehicles are to be maintained to maintenance
standards.
2 Scope
This standard details the requirements for periodic maintenance of air brake equipment
on all locomotive hauled freight and passenger vehicles.
This standard may also be used when required for the maintenance of locomotive hauled
vehicles prior to departure from workshops after overhaul or major repairs.
3 Purpose
The purpose of this standard is to ensure rolling stock are maintained to an adequate
level of safety and reliability.
4 Application
This standard is intended for use by maintenance staff when conducting periodic
maintenance of freight or locomotive hauled passenger vehicles.
5 Reference documents
5.1 RailCorp standards

ESR 0010 Ballast wagon specific maintenance policy
ESR 0011 Base R1/R2 wagon maintenance policy
ESR 0012 Container wagon specific maintenance policy
ESR 0013 Side dump wagon specific maintenance policy
ESR 0014 Railset wagon specific maintenance policy
ESR 0015 Ballast plough wagon specific maintenance policy
ESR 0016 Concrete sleeper wagon specific maintenance policy
ESR 0017 Spoil wagon specific maintenance policy
ESR 0018 Robel railset wagon specific maintenance policy
ESR 0065 Fixed exhaust chokes
ESR 0311 Single car air test
ESR 0313 Security of brake gear
ESR 0314 Brake pipework sealant compounds
ESR 0316 Air brake hoses
ESR 0406 Specification for lubricants & cleaning fluids for use on air brake equipment
ESR 0510 Maintenance, repair & overhaul of air brake equipment
5.2 RailCorp drawings

207-657 Dummy brake block
6 When must air brake maintenance take place?

Wagons maintained under R1/R2 maintenance programme are to be maintained and
tested at every R1 or R2 inspection.
Exception: All locomotive hauled freight and passenger vehicles brake systems, not
under R1/R2 maintenance are to be periodically maintained and tested as follows each
12 months.
When specified, locomotive hauled vehicles are to be maintained and/or tested prior to
departing workshops.
A single car air test must be carried out at every R2 inspection and after the replacement
of any defective air brake equipment or rectification of major air leaks. Single car air tests
are to be carried out in accordance with ESR 0311.
Maintenance, repair or overhaul of air brake equipment must be carried out in

accordance with ESR 0510.
7 Requirements
Equipment listed in section 8 must be inspected to determine that it is intact, secure and
in a condition fit for service.
Correct fitting tools only should be used. Single car air testers should be kept in good
condition and chokes screwed onto spare plugs when not in use. Pressure gauges
should be regularly calibrated to ensure accuracy.
P.T.F.E. (Teflon) tape, hemp or compounds containing lead MUST not be used on pipe
joints or when fitting any item of air brake equipment. The preferred type of pipe sealant
is Loctite 567 Master Pipe Sealant.
8 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)
8.1 H
oses
8.1.1 Air brake coupling hoses

(Brake pipe, main reservoir)
Check condition of all hoses.
Replace if cut, abraded or perished.
8.1.2 Body to bogie hoses (found on some passenger cars)

Check hose condition
Replace if cut, abraded or perished.
8.1.3 All other hoses

Check hose condition
Replace if hose is cut, abraded or perished.
8.1.4 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
8.2 Coupling cocks
8.2.1 Brake pipe (and main reservoir coupling cocks - if applicable).
Old Style New Style
Figure 3 Coupling cocks
(a) O
perate 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) S
hake coupling cock
If loose tighten or replace "U" bolt
8.3 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.
8.4 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 4 Isolating cock
(c) Remove bowl from centrifugal dirt collector (old equipment) - Clean
Key ( Figures 4 & 5)
2 Body
3 Bowl
4 Valve Stem
5 Valve
6 Gasket
8 Cock Plug
9 Cock Spring
10 Cock Cap
11 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
Figure 6 Isolating cock handle (Westinghouse WF triple valve)
(e) Remove paper filter (Westinghouse only)
Paper element dirt collector
Figure 7 Paper filter

(f) Clean or replace
8.5 Control valves (triple valves, distributing valves and relay

valves)
8.5.1 Diaphragm type triple valves (Westinghouse ‘W’)
Figure 8 Westinghouse WF2 triple valve
Check date - replace if 16 years old (or more)
– replace if undated
– replace if 16 year life is due before the next R2 inspection. Refer to ESR 0011.
– send replaced triple valves to an authorised brake component repair workshop
Note: With Westinghouse relayed equipment the following must also be replaced:
• relay valve
• release valve
• accelerated application valve (where fitted)
• isolating cock.
Figure 9 Davies & Metcalf ESR 500B distributor valve
Note: With D&M equipment the isolating cock must also be replaced,
8.6 Reservoirs and associated pipework
Figure 13 Westinghouse Combined Reservoir Unit
1 Auxiliary Reservoir
2 Dummy Brake Cylinder
3 Supplementary Reservoir
4 Accelerated Release Reservoir
5 Triple Valve
6 Relay Valve
7 Automatic Release Valve
Figure 10 Combined reservoir
Visually check reservoirs for damage and corrosion.
If in doubt have reservoir checked by your Supervisor who will if necessary arrange for
examination by a Pressure Vessel Inspector.
(b) Remove drain plug from each reservoir and drain any water that has accumulated.
(c) Check pipework between reservoirs and control valve bracket for loose or worn
fittings, loose clamps and wear marks from rubbing.
tighten or replace where necessary.
8.7 Brake cylinders
8.7.1 Old push rod type brake cylinder
Figure 11 Westinghouse push rod brake cylinder
These brake cylinders require greasing every 12 months.
Refer to Section 9.2 for details.
These brake cylinders must be greased at every R1 or R2 inspection.
8.7.2 Westinghouse AF and WF type brake cylinders
Figure 12 AF brake cylinder Figure 13 WF brake cylinder
These brake cylinders require greasing at every R2 inspection.
Refer to Section 9.3 for details of greasing.
No other periodic maintenance is required.
8.7.3 Westinghouse variable volume devices

Note: These devices must not be dismantled except by an accredited repairer.
Variable volume devices require greasing at every R2 inspection.
Figure 14 Westinghouse variable volume device
8.7.4 Davies & Metcalf brake cylinders

Note: These brake cylinders must be dismantled during maintenance for greasing.
These brake cylinders require greasing at every R2 inspection.
Figure 15 Davies & Metcalfe Brake Cylinder
8.8 Slack adjusters
8.8.1 'J' type ratchet (pneumatic)
Figure 16 'J' type slack adjuster
1 Slotted cross head 8 Casing
2 Slack adjuster port in brake cylinder 9 Ratchet nut
3 Adjuster cylinder pipe 10 Stop screw
4 Adjuster body 11 Dead cylinder lever
5 Crosshead 12 Connecting rod
6 Adjuster screw 13 Live cylinder lever
7 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 undue effort.
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 brake cylinder
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 in ESR 0311 or
the vehicle is in workshops.
In these cases refer to Section 10 for maintenance procedure.
8.8.2 In-line slack adjusters
Figure 17 Westinghouse SAB slack adjuster
Figure 18 Davies & Metcalf Stopex Slack Adjuster
Apply handbrake
Check - control rod clearance reduces to zero
- control rod and control lever do not distort
Note: a bent control rod must be replaced
No further work is required on in-line slack adjuster unless it fails to operate correctly
during the single car air test in which case it must be replaced.
Note 1: Some Davies & Metcalf in-line slack adjusters have grease nipples fitted to the
regulating fork end. These must be greased (one or two pumps) during periodic
inspection.
Note 2: In-line slack adjusters must not be dismantled under any circumstances unless
undergoing overhaul at an authorised air brake component repair workshop - Refer to
ESR 0510.
8.9 Grade control valve equipment
Figure 19 Westinghouse grade control valve
Remove the grade control valve equipment and replace with a fixed exhaust choke as
detailed in ESR 0065.
If the grade control valve can not be replaced with a choke:
Check pipework for looseness, damage, rubbing etc - Repair and tighten as necessary.
Check operation of handle
If too stiff (can't operate with one hand) repair or replace grade control valve
Check size of grade control valve corresponds to brake cylinder for non-relayed
equipment or dummy volume reservoir (ie 6" or 150mm) for relayed equipment.
Note: On relayed equipment only Westinghouse grade control valves are to be used
with Westinghouse equipment.
Type of brake equipment Allowable grade control valve
Westinghouse relayed Westinghouse 6"
Westinghouse non-relayed Westinghouse GCV matching brake cylinder size
Table 1
Note: Wagons with the wrong grade control valves fitted will have incorrect brake release
times
8.9.1 Fixed exhaust chokes

On vehicles fitted with a fixed exhaust choke in place of the grade control valve, check
that the correct choke is fitted as detailed in ESR 0065.
Figure 20 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.
8.10 Load Compensation Equipment (Empty/Load)
8.10.1 Manual Equipment
Figure 21 Davies & Metcalf manual empty/load valve
Figure 22 Westinghouse manual empty/load valves
Check pipework for looseness, damage, rubbing etc - repair and tighten as 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 to wagons. The
valve type is marked by the letter "R", "M" or "B" stamped on the valve body.
Davies & Metcalf equipment has an integral E/L changeover valve included in the
distributer valve.
Type of brake equipment Manual load compensation valve
Westinghouse relayed Westinghouse Type "R"
Westinghouse non-relayed Westinghouse Type "M"
Table 2
Figure 18 Westinghouse Manual Empty Load Valves
Figure 23 Westinghouse manual empty load valves
8.10.2 Automatic equipment
Figure 24 SAB type VTA automatic load valve
Check that SAB (type VTA) load valve is fitted with Westinghouse equipment.
Check condition of hoses - change if necessary.
Check clearance between plunger and adjusting plate with the wagon empty - should be
25mm - adjust if necessary.
8.11 Release valve
Figure 25 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 valve operates.
Repair or Replace if faulty.
8.12 Handbrake
Figure 26 Handbrake
Operate handbrake
Check -ease of operation

-gears remain engaged
-chain for damage
-release lever operation (must drop down and engage pawl when release
lever is released)
-handle not loose
Handbrake should be lubricated with anti-scuffing spray.
8.13 Brake rigging/brake blocks
8.13.1 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.
Refer to ESR 0063
Check safety loops - repair or replace if necessary.
Apply handbrake - check for any signs of brake rigging fouling points or rubbing on
axles.
For vehicles fitted with slack adjusters:
Check bogie rigging adjustment as follows:
Fit dummy brake blocks (see section 11 for details of dummy brake block)
Or Fit new brake blocks (old blocks may be replaced later)
Apply hand brake
Measure distance "X"
Figure 27 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 service unless new wheelsets
are fitted to bogie.
Note 2: Piston travel will be checked and adjusted during a single car air test.
Bogie type Dimension "X"
Three-piece 300 mm
(except AVA,BVA, CQA, CQB & CQC)
AVA & BVA 430 mm
CQA, CQB & CQC 485 mm
Table 3
8.13.2 Passenger cars

The following procedure should be taken as a guide to adjust the brake rigging on
passenger car bogies.
Check bogie rigging adjustment as follows:
Fit dummy brake blocks (Refer section 11) 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 the levers will
approach the right angle position).
Check rigging is not fouling the bogie frame or axle
Adjust bogie rigging as necessary.
8.14 W
ater service (passenger cars)
Figure 28 Water service unit
Check date -must not be more than 5 years old -replace if older than 5 years
Check pipework for looseness, damage, rubbing etc repair or tighten as necessary.
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 ESR 0311. Overhaul shall be done at an
approved workshop.
8.14.1 Water service gauges (passenger cars)

Check gauge connections are secure and air tight and gauge is secured correctly.
Check HP and LP gauges on water service - replace if damaged.
Check any internal gauges for damage - replace if necessary
Clean gauge faces
8.15 Main reservoir system (where applicable)

Clean or replace strainers in pipeline to supplementary reservoir and door cylinder
reservoir.
Clean or replace filter elements in door reservoir system.
9 Greasing of brake cylinders

This Instruction describes the methods of greasing the following types of brake cylinders:
• Westinghouse pushrod type brake cylinders.

• Westinghouse type AF and WF diaphragm type brake cylinders.
• Westinghouse variable volume devices
• Davies & Metcalfe brake cylinders
9.1 Lubricants and cleaning fluids

Refer to section 12 for approved lubricants and cleaning fluids.
9.2 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.
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 on reassembly.
4. Check condition of piston follower plate, release spring, crosshead and crosshead pin
for wear or other defects - replace if necessary.
5. Examine dome head and piston rod for excessive wear - replace if necessary.
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 not damaged in any
way.
9. After piston has been reassembled, rotate one quarter of a turn in each direction to
ensure no binding is taking place.
10. Replace dome head and connect cross head to brake rigging.
Key:
2. Pressure Head
3. Dome head
4. Push rod
5. Piston
6. Piston follower
7. Piston seal
8. Piston packing expander
9. Release spring
10. Stud and nut
11 Pressure head gasket
12. Pipe plug.
Figure 29 Typical pushrod brake cylinder
9.3 Westinghouse AF and WF diaphragm brake cylinders

Note: These brake cylinders must not be dismantled except in an accredited repairer.
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 piston stroke then applying
the brake.
2 Remove cap plug from nipple at pressure end of brake cylinder. Attach grease gun
and insert half of the grease specified in clause 4 below. To ensure even application
of grease to the piston seal, rotate piston trunk by 180 degrees. This can be achieved
by applying a suitable pipe wrench to the ring at the end of the piston trunk. Insert the
remainder of the grease and rotate the piston by 360 degrees. Replace cap plug
ensuring it is air tight.
3 Remove cap plug from trunk or dome end. Attach grease gun and insert half of the
grease specified in clause 4 below. To ensure even application of grease to the piston
seal, rotate piston trunk by 180 degrees. This can be achieved by applying a suitable
pipe wrench to the ring at the end of the piston trunk. Insert the remainder of the
grease and rotate the piston by 360 degrees. 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) to grease the
above brake cylinders is –
Brake cylinder diameter Strokes of grease gun

Pressure head end Trunk or dome end
inch mm R2 (3 year R2 (5 year R2 (3 year R2 (5 year
inspection) inspection) inspection) 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
Table 4
Figure 30 Westinghouse ‘AF’ type brake cylinder
Figure 31 Westinghouse ‘WF’ type brake cylinder
9.4 Westinghouse variable volume devices

Note: These devices must not be dismantled except by an accredited repairer. Refer to
standards ESR 0510.
2 Remove cap plug from nipple at pressure end of the device. Attach grease gun and
operate it according to clause 2 below. Replace cap plug ensuring it is air tight.
2 Amount of lubricant to be used:-
The number of strokes of the standard grease gun (such as a J.C. 10) to grease
the device is -
Variable Volume Device Strokes of grease gun

Pressure Head end
inch mm
12 305 9
14 356 10
Table 5
Figure 32 Westinghouse variable volume device
9.5 Davies & Metcalf brake cylinders

Note: These brake cylinders must be dismantled during maintenance for greasing.
1 Remove pin connecting piston end to brake rigging.
2 Loosen nuts (10) and remove the piston and cover assembly
3 Wipe the cylinder walls clean to remove all lubricating grease which have become
contaminated with dust and moisture etc after prolonged periods of 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.
Note: On hopper vehicles, position the pressure head so that the breather is on the
underside of the pressure head.
7 Remove cap plug from trunk or dome end.

Attach a standard grease gun (such as a J.C. 10) and grease piston with 8 strokes
of the grease gun.
Replace cap plug.
Figure 33 Davies & Metcalfe Brake Cylinder
Item Part Item Part Item Part
1 Cylinder Assembly 7 Spring ring 13 Bush
2 Cylinder Cover 8 Bush 14 Cylinder with fulcrum

head
3 Piston rod 9 Spring washer 15 Fulcrum head

assembly
4 Piston assembly 10 Hexagonal Nut 16 Washer
5 Spring 11 Square head bolt 17 Pin
6 Piston sealing ring 12 Plug
Table 6
10 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 ports to the
brake cylinder or slack adjuster.
2 Remove casing bolts and withdraw cylinder and casing over the long ratchet 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 either direction
without contacting the pawl.
Inspect condition of check pawl and ensure there is sufficient tension on the ratchet 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 on
reassembly.
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 not damaged in
any way.
9. After piston has been reassembled, rotate one quarter of a turn in each direction to
ensure no binding is taking place.
10 Refit pipe between brake cylinder and slack adjuster.
Figure 34

11 Dummy brake block

The dummy brake block is used for checking the adjustment of brake rigging.
Figure 35 Dummy brake block
Full details of the dummy brake block are found in Drawing No. 207-657.
12 Approved lubricants and cleaning fluids

This section lists the approved lubricants and cleaning fluids for use on the air brake
equipment on freight and passenger vehicles.
Refer to ESR 0406 for approved lubricants, anti-scuffing spray, cleaning fluids and thread
sealants.
13 Brake equipment diagrams
13.1 Westinghouse non-relayed system
Figure 36

13.2 Westinghouse relayed system – reservoir mounted
Figure 37

13.3 Westinghouse relayed system – ‘D’ mounting bracket
Figure 38

13.4 Westinghouse relayed system – ‘SW’ mounting bracket
Figure 39

13.5 Davies& Metcalf relayed brake equipment with ESR-500B
Figure 40

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Engineering Standard

AIR BRAKE MAINTENANCE

Issued May 2013

Owner: Technical Specialist Rolling Stock Performance Standards

Approved Stephen White, Authorised Michael Uhlig,

UNCONTROLLED WHEN PRINTED Page 1 of 37

Summary of changes from previous version

5.1 RailCorp standards ...................................................................................................................5

5.2 RailCorp drawings.....................................................................................................................6

6 When must air brake maintenance take place?...................................................................6

8.1 Hoses ........................................................................................................................................7

8.1.1 Air brake coupling hoses ...........................................................................................7

8.1.2 Body to bogie hoses (found on some passenger cars) .............................................7

8.1.3 All other hoses ...........................................................................................................7

8.1.4 Air brake coupling hose heads ..................................................................................7

8.2 Coupling cocks..........................................................................................................................8

8.3 Brake pipe (and main reservoir pipe, if applicable)...................................................................8

8.4 Branch pipe and isolating cocks ...............................................................................................9

8.5.1 Diaphragm type triple valves (Westinghouse ‘W’)...................................................10

8.6 Reservoirs and associated pipework ......................................................................................11

8.7 Brake cylinders........................................................................................................................12

8.7.1 Old push rod type brake cylinder.............................................................................12

8.7.2 Westinghouse AF and WF type brake cylinders .....................................................12

8.7.3 Westinghouse variable volume devices ..................................................................13

8.7.4 Davies & Metcalf brake cylinders ............................................................................13

8.8 Slack adjusters........................................................................................................................14

8.8.1 'J' type ratchet (pneumatic)......................................................................................14

8.8.2 In-line slack adjusters ..............................................................................................15

8.9 Grade control valve equipment ...............................................................................................16

8.9.1 Fixed exhaust chokes ..............................................................................................17

8.10 Load Compensation Equipment (Empty/Load) .......................................................................17

8.10.1 Manual Equipment...................................................................................................17

8.10.2 Automatic equipment ...............................................................................................20

8.11 Release valve..........................................................................................................................20

8.13 Brake rigging/brake blocks......................................................................................................21

8.13.2 Passenger cars........................................................................................................22

8.14 Water service (passenger cars) ..............................................................................................23

8.14.1 Water service gauges (passenger cars)..................................................................23

Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1.1

8.15 Main reservoir system (where applicable) ..............................................................................23

9 Greasing of brake cylinders.................................................................................................24

9.1 Lubricants and cleaning fluids.................................................................................................24

9.2 Westinghouse push rod brake cylinders .................................................................................24

9.3 Westinghouse AF and WF diaphragm brake cylinders...........................................................25

9.4 Westinghouse variable volume devices..................................................................................27

9.5 Davies & Metcalf brake cylinders............................................................................................28

10 Maintenance of ‘J’ type slack adjuster ...............................................................................30

11 Dummy brake block ..............................................................................................................32

12 Approved lubricants and cleaning fluids ...........................................................................32

13 Brake equipment diagrams ..................................................................................................33

13.1 Westinghouse non-relayed system.........................................................................................33

13.2 Westinghouse relayed system – reservoir mounted...............................................................34

13.3 Westinghouse relayed system – ‘D’ mounting bracket ...........................................................35

13.4 Westinghouse relayed system – ‘SW’ mounting bracket........................................................36

13.5 Davies& Metcalf relayed brake equipment with ESR-500B....................................................37

Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1.1

5.1 RailCorp standards

ESR 0011 Base R1/R2 wagon maintenance policy

ESR 0012 Container wagon specific maintenance policy

ESR 0013 Side dump wagon specific maintenance policy

ESR 0014 Railset wagon specific maintenance policy

ESR 0015 Ballast plough wagon specific maintenance policy

ESR 0016 Concrete sleeper wagon specific maintenance policy

ESR 0017 Spoil wagon specific maintenance policy