GOVERNMENT OF INDIA MINISTRY OF RAILWAYS …...i GOVERNMENT OF INDIA MINISTRY OF RAILWAYS श क कप ऱर क लऱए अन र ण प र क ट स एवम ऩ ओ एच

i

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

शाकू कप्ऱर के लऱए अनुरऺण पे्रक्टिस एवम ऩी ओ एच मेनुअऱ

Maintenance Practices & Manual for POH of Schaku Couplers

कैमिेक/एम/प्रोज/2019-20/एमऩी8/1.0

अटिूबर 2019

CAMTECH/M/PROJ/2019-20/MP8/1.0

October 2019

Maharajpur, Gwalior (M.P.) - 474005

ii

शाकू कप्ऱर के लऱए अनुरऺण पे्रक्टिस एवम ऩी ओ एच मेनुअऱ

Maintenance Practices & Manual for POH of Schaku Couplers

कैमिेक/एम/प्रोज/2019-20/एमऩी8/1.0

अटिूबर 2019

CAMTECH/M/PROJ/2019-20/MP8/1.0

October 2019

i

FOREWORD

Semi-Permanent Coupler (Schaku Coupler) play an important role in running of

DEMU/EMU. The failure of Semi-Permanent Coupler (Schaku Coupler has a great

impact on the reliability of the DEMU/EMU. This Manual has been prepared for

Supervisors and artisan staff of DEMU/EMU sheds and workshops who are involved

in the maintenance of Semi-Permanent Coupler (Schaku Coupler). This Manual not

only cover maintenance of Semi-Permanent Coupler (Schaku Coupler) but care has

been taken to explain basic things including its storage and handling. All

information of components has been covered in this Manual. The book is also

useful for newly appointed artisan. With these important features, I am sure that

the handbook will give necessary help to the concerned staff to ensure problem

free service of the Schaku Coupler.

CAMTECH is continuously making efforts in documentation and up-gradation of information on advanced maintenance practices. This document

contains a Maintenance practices, types of Schaku Coupler and their salient

features etc. being used on Indian Railways.

I am confident that the information given in this Maintenance manual will

help field staff of Mechanical department in improving their knowledge as well as

in correct and efficient maintenance of Schaku Coupler in their Sheds/Workshops.

CAMTECH Lucknow Jitendra Singh

Date: 30.10.2019 Principal Executive Director

ii

PREFACE

The importance of Schaku Couplers cannot be denied in the efficient

operation of DEMU/EMU in railways. On Indian Railways Schaku Couplers have

replaced conventional at a large number of Diesel car Shed and workshops due to

their wide applications and safety reasons. In the current scenario, Schaku Couplers

of different approved manufacturers have been installed in Indian Railways.

To refresh the knowledge of staff involved in maintenance of Schaku

Couplers, CAMTECH has prepared this maintenance Manual which consists of

Maintenance aspects of different approved manufacturers. This manual is also

consist of description of components and their availably to ensure the reliability

and availability to achieve the correct maintenance of Schaku Couplers.

We are sincerely thankful to Officers and supervisors of North Central Railway, West Central Railway, Central railway and Western Railway and all the manufactures of Schaku Couplers who helped us in preparing this manual. Since technological upgradation and learning is a continuous process, you may feel the need for some addition/modification in this question bank. If so, please give your comments on email address [email protected] or write to us at Indian Railways Centre for Advanced Maintenance Technology, In front of Adityaz Hotel, Airport Road, Maharajpur, Gwalior (M.P.) 474005.

CAMTECH Gwalior Manoj Kumar

Date: 30.10.2019. Joint Director (Mechanical)

mailto:[email protected]

iii

Contents

Section Sub- Section Description

Pages

Foreword i

Preface ii

Contents iii

Correction Slip iv

Disclaimer & Our objective v

CAMTECH Publications vi

1 2 3

4.0

5.0

- -

3.1 3.2 3.3 3.4

4.1

4.1.1 4.1.2 4.2 4.3

4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4

4.4.1 4.5

4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8

5.1

Introduction Type of Coupler Salient features of Semi-Permanent Coupler Escorts Sanrok Westing House Blue Bird Main Parts of Semi-Permanent Coupler Main Sub Assemblies of Semi-Permanent Coupler Coupler – End ‘A’ Coupler- End ‘B’ Features of Semi-Permanent Coupler Description & Functional Features of Sub Assemblies Bearing Bracket (Used both in End ‘A’ & End ‘B’) Draw and buffing gear (Used both in End ‘A’ & End ‘B’ Intermediate Tube (Used both in End ‘A’ & End ‘B’) Air Pipe Coupling (Used both in End ’A’ & End ‘B’) Centering Device (Used only in End ‘B’) Adjustable Cup Sleeve (Used only in End ’A’) Center Adjustment Device (Used both in End ‘A’ & End ‘B’) Maintenance Schedules Trip schedule to “C” schedule Periodically Overhauling Overhauling Procedures Polyamide bushes Bearing Bracket with Support Draw and Buffer gear Lower & upper Cup-sleeves Spring sleeves Intermediate tube sub assembly Painting & Assembly Inspection and Replacement of Components and Sub assemblies Inspection and replacement of components of Main Bracket / Bearing Bracket with support drg. No 2ED-181-1001 {SCHAKU DRG. NO. 40-

1

1

1

1

2

2

3

4

4

4

5

6

6

6

7

8

9

9

10

11

12

12

12

12

12

12

13

13

13

13

13

13

iv

6.0

8.0

9.0

10.0 11.0

5.2

5.2.1 5.2.1.1

5.2.1.2 5.2.1.3

5.3

5.3.1

5.4

5.4.1

- 7.0

8.1 8.2

9.1 9.2 9.3 9.4

- -

588.07(2)} Inspection and replacement of components of Draft Gear / Draw and Buff Gear drawing No. 2ED-181-1011 {SCHAKU DRG. NO. 40-586.06(2)} Fixtures and method of use

Fixtures and Method of Using Fixture for pressing Articulation Bearing (Fixture Drawing No. SE-F-134) Procedure for assembly of Draft Gear/ Draw & Buff Gear Method of using the fixture for Draft Gear / Draw & Buff Gear sub assy. Inspection and replacement of components of Centering Device drg. No 2ED-181-1006 { SCHAKU Drg. No. 40-1000.10(2)} Method of using the assembly fixture for Centering Device (Fixture Drawing No. SE-F-135) Inspection and replacement of components of Intermediate Tube Drg. No 2ED-181-1004 {SCHAKU 40-586.01:01(2)}. Device for removal of bearing bolt (Fixture Drawing No. SE-F-140) Lubrication Scheme Spring Condemning Criteria Tools and Gauges for Maintenance For Depot For Workshop Tools, Fixtures and Gauges & method of using gauges Pressing Method of using the Fixture and the Articulation Bearing Assembly Fixture For Draw & Buff Gear

Method of Using the Fixture for Draw & Buff gear Sub-assy. Method of Using the Assembly Fixture for Centering Device Part List & Recommended percentage of Holding for POH Rejectable defects

14

14

14

16

23

23

23

24

24

27

27

27

27

28

28

28

28

38

39

41

v

सुधार ऩर्चियों को जारी करना

ISSUE OF CORRECTION SLIPS

इस प्रश्न फैंक के लरए बविष्म भें जायी की जाने िारी सुधाय ऩर्चिमों के क्रभाॊक इस प्रकाय से यहेंगे:

The correction slips to be issued in future for this question bank will be numbered as follows:

केमिेक/एम/प्रोज/2019-20/एमऩी 8/1.0 # XX दि .................

CAMTECH/M/PROJ/2019-20/MP8/1.0# XX date .......

जहाॊ “XX” सम्फॊर्धत सुधाय ऩची की क्रभ सॊख्मा है (01 से शुरू होकय) Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

सुधार ऩचीयाॉ जारी की गयीॊ

CORRECTION SLIPS ISSUED

सुधाय ऩची की क्रभ सॊख्मा

Sr. No. of

Correction

Slip

जायी कयने की तायीख

Date of

issue

सॊशोर्धत ऩषृ्ठ क्रभाॊक एिॊ भद सॊख्मा

Page no. and Item No.

modified

टिप्ऩणिमाॉ Remarks

vi

डिस्कटऱेमर

मह स्ऩष्ि ककमा जाता है कक इस हस्तऩसु्स्तका भें दी गमी जानकायी, येरिे फोर्ि प्रकाशनों तथा आय र्ी एस ओ प्रकाशनों के ककसी बी ितिभान आरेखों को विस्थावऩत नहीॊ कयतीॊ है | मह दस्तािेज िधैाननक नहीॊ है ियन इसभें टदए गए ननदेश केिर भागि दशिन हेत ुहैं | मटद ककसी बफन्द ुऩय वियोधाबास दृष्िीगोचय होता है, तफ येरिे फोर्ि प्रकाशनों, आय र्ी एस ओ भागिदशिन अथिा जोनर येरिे के ननदेशों का ऩारन कयें |

DISCLAIMER It is clarified that the information given in this handbook does not supersede any existing provisions laid down in the Railway Board and RDSO publications. This document is not statuary and instructions given are for the purpose of guidance only. If at any point contradiction is observed, then Railway Board/RDSO guidelines may be referred or prevalent Zonal Railways instructions may be followed.

----------------------------------------------------------------------------------------------------

हमारा उद्िेश्य

अनयुऺि प्रौद्मोर्गकी औय कामिप्रिारी का उन्नमन कयना तथा उत्ऩादकता औय येरिे की ऩरयसम्ऩवि एिॊ जनशस्तत के ननष्ऩादन भें सधुाय कयना स्जससे अॊतवििषमों भें विश्िसनीमता , उऩमोर्गता औय दऺता प्राप्त की जा सके |

OUR OBJECTIVE To upgrade Maintenance Technologies and Methodologies and achieve improvement in Productivity and Performance of all Railway assets and manpower which inter-alia would cover Reliability, Availability and Utilisation.

मटद आऩ इस सन्दबि भें कोई विचाय औय सझुाि देना चाहत ेहैं तो कृऩमा हभें इस ऩत ेऩय लरखें : सॊऩकि सतू्र : सॊमतुत ननदेशक (माॊबत्रक)

ऩत्राचाय का ऩता : बायतीम येर उच्च अनयुऺि प्रौद्मोर्गकी कें द्र,

भहायाजऩयु, ग्िालरमय (भ. प्र.) वऩन कोर् 474020

िेरीपोन : 0751-2470890

पैतस : 0751-2470841

ई-भेर : [email protected]

If you have any suggestion & any specific comments, please write to us:

Contact person : Joint Director (Mechanical) Postal Address : Centre for Advanced Maintenance Technology, Maharajpur,

Gwalior (M.P.) Pin Code – 474 020

Phone : 0751 - 2470890

Fax : 0751 – 2470841 Email : [email protected]



vii

कैमिेक प्रकाशन CAMTECH Publications

CAMTECH is continuing its efforts in the documentation and up-gradation of information on maintenance

practices of Signalling & Telecom assets. Over the years a large number of publications on Signalling &

Telecom subjects have been prepared in the form of handbooks, pocket books, pamphlets and video films.

These publications have been uploaded on the internet as well as railnet.

For downloading these publications

On Internet:

Visit www.rdso.indianrailways.gov.in

Go to Directorates → CAMTECH → OtherImportant Links→ Publications for download → Mechanical

Engineering Or http://www.rdso.indianrailways.gov.in/view_section.jsp?lang=0&id=0,2,17,5025

On Railnet:

Visit RDSO website at 10.100.2.19

Go to Directorates → CAMTECH → Publications → Mechanical Engineering

Or http://10.100.2.19/camtech/Publications/CAMTECH%20Publications%20Online/CAMTECHMain.htm

A limited number of publications in hard copy are also available in CAMTECH library which can be got

issued by deputing staff with official letter from controllong officer. The letter should be addressed to Joint

Director (Mechanical), CAMTECH, Gwalior.

For any further information regarding publications please contact:

Joint Director (Mechanical) – 0751-2470890 (O)(BSNL)

SSE/Mechanical - 8989473656

Or

Email at [email protected]

Or

FAX to 0751-2470841 (BSNL)

Or

Write at

Joint Director (Mechanical)

Indian Railways Centre for Advanced Maintenance Technology,

In front of Hotel Adityaz, Airport Road, Maharajpur,

Gwalior (M.P.) 474005

http://www.rdso.indianrailways.gov.in/

http://www.rdso.indianrailways.gov.in/view_section.jsp?lang=0&id=0,2,17,5025


CAMTECH/M/PROJ/19-20/MP8 1

Maintenance Practices and manual of SCHAKU Coupler October 2019

Maintenance Practices and manual of SCHAKU Coupler

1.0 Introduction

Semi Permanent Coupler:- DEMU/EMU stock are provided with the Semi Permanent Couplers manufactured by Messers Scharfenburg Kupplung, GmbH, Germany (short formed as “SCHAKU”). When two coaches are coupled by Semi Permanent Couplers, one coach is fitted with “Semi Permanent Coupler – End ‘A’ & the other one is fitted with “Semi Permanent Coupler–End ‘B’.

Semi Permanent Coupler is designed to ensure a permanent connection of railcars which in traffic form a unit and therefore need not be separated unless in an emergency or in the workshop.

The Drawbar / Intermediate Tube are connected by means of an Adjustable muff coupling/Pair of Cup Sleeve set. The set can be detached easily thus allowing quick separation of the cars for repair.

The Drawbar / Intermediate Tube are provided with a centring hole and a centring pin which help to align the drawbars

When being connected and protect the shank of the Drawbars / Intermediate Tube against twisting. Besides the main mechanical connection, the Semi Permanent Coupler also ensures the safe connection of the main air reservoir pipes.

Semi Permanent Coupler is based on the Generic Semi Permanent Couplers being

used on the EMU stock of the Indian Railways currently.

Semi Permanent Coupler is fully interchangeable with the Semi Permanent Coupler of current suppliers.

2.0 Type of Coupler : Following make semi-permanent couplers are being used in Indian Railways.

1. Escorts make

2. Wasting house

3.Blue bird

4. Sanrok

3.0 Salient feature : Salient features of above make couplers are as below-

3.1 Escorts make :

1. Compressed load 100 tons and tensile load 70 tons

2. Dynamic absorption capacity of the rubber draft gear of these couplers is 800 m-kg.

3. Due to rigid connection of this coupler there exists negligible play between them in coupling position and hence no appreciable wear and tear during train operation.



4. Due to rigid and stress transmitting mechanical connection between the coaches by fitting semi-permanent couplers, protection to the coach and the load against undue impacts is secured.

5. Due to high capacity incorporated in semi-permanent couplers, it allows coaches to buffer at high speeds (from 3 km/hr to 15 km/hr) without any damage to the coach and the load.

6. Interlocking arrangement of these couplers prevents to some extent the mounting or telescoping of the coaches when involved in accidents.

7. As the fulcrum of these couplers is located far in the rear of the coach, coupler side displacements in curves and consequently the transverse forces acting on the wheel flange are kept minimum. This reduces the wear of the wheel flange and minimizes the chances of derailment.

8. As the coupling links of semi-permanent couplers from a parallelogram with equilibrium of forces, unintentional disengagement of coaches due to shocks is rendered impossible.

9. The design and construction of the pivoted joint between these couplers and coach permits vertical deflection of ±75 mm and horizontal deflection of 284 mm or 13º on either side and as a consequence enables the coaches to couple up at all track curves and also on points of change of gradient even at maximum height difference between the two coaches.

3.2 Sanrok : S.N Description Specification

Value Detail

1. Coupling Length from pivot point mm

------ 1107 mm

2. Static strength in Buff Mode 100 Tonne 120 Tonne 3. Static strength in Draw Mode 70 Tonne 100 Tonne 4. Ultimate or Fracture strength 150 Tonne 150 Tonne 5. Stroke of the Draw Gear mm 75 max 56 6. Horizontal Swing (o) -- 15 7. Vertical Swing (o) ---- 5-7 8. Energy absorption capacity

dynamic 800 mkg 900 mkg

9. Height from top the rail mm ---- 1035 10. End Force – Sill load 50,000 kg 500 kN +10/-5 kN 11. Coach to Coach interconnection ------ Thru adjustable muff

coupling 3.3 Westing House 1. Semi –permanent couplers are used to couple coaching stock of Electric Multiple

Units which are at present, operating with Central, Western, Eastern, South Eastern, Southern Railways in India.



2. These couplers are designed for taking a maximum comprehensive load 100 tons and maximum tensile load of 70 tons.

3. Due to rigid connection of these Couplers, there exists negligible play between them in coupled position and hence no appreciable wear and tear during the train operation.

4. Due to rigid and stress transmitting mechanical connection between the coaches fitted with “SCHAKU” Couplers, protection to the coach and the load being carried, against undue impacts is secured.

5. The energy absorption capacity of the rubber-draft gear of the Semi-Permanent Coupler is 800 M-kg

6. Due to draft capacity incorporated in the WSF-SCHAKU” Semi- Permanent Couplers, it allows the coaches to buff at higher speeds (3 km/hr to 15 km/hr) before being coupled, without causing any damage to the coach and the load being carried.

7. The interlocking arrangement of these couplers prevent to some extent the dis-mounting or telescoping of the coaches when involved in accidents.

8. As the fulcrum of these coupler is located far inside the rear of the coach coupler side displacement in curved track causes minimum transverse forces acting on the wheel flange of de-railment.

9. The design and construction of the pivoted joint between these couplers and coach permits vertical deflection of ±75 mm and horizontal deflection of 284 mm or 13º on either side and as a consequence enables the coaches to couple up at all track curves and also on points of change of gradient even at maximum height difference between the two coaches.

10. Coupling is done manually by operating one ‘Adjustable Cup sleeve’on straight or curved tracks, gradients with specified height difference ensuring simultaneous coupling of main reservoir pipes (MR) and brake pipes (BP).

3.4 Blue Bird 1. The fixing of coupler to underframe shall be by bolts /welding. The fixing

arrangements and underframe cut away shall be identical for all couplers

(end and intermediate).

2. The draft gear housing shall be capable of taking either rubber springs or

ring springs, and identical spring packs shall be used for both end and

intermediate couplers.

3. The draft/buffing springs shall be of natural or synthetic rubber, available in

India.

4. The attachment of the draw hook to the draft gear shall be designed so that

it can be conveniently replaced automatic Scharfenbarg heads, without

alteration to any other part of the coupler of draft gear.

5. The location of pivot pin centre line of couplers shall not exceed 707 mm

from Headstock face, and should preferably be the same for both end and

intermediate couplers.



6. The distance between the Headstocks of adjacent coaches shall be 800 mm

when Semi-permanent couplers are fitted, and not less than 964 mm for

the end couplers when fitted with automatic heads.

7. The semi-permanent couplers shall be provided with arrangement for

coupling of brake pipes. If required provision should also be made for

coupling of electrical cables for which 76 electrical contacts should be

catered for.

4.0 Main Parts

4.1 MAIN SUB ASSEMBLIES OF SEMI PERMANENT COUPLER

4.1.1 Coupler – End ‘A’ consist of: -

Bearing Bracket with Support – Sub Assembly

Draw and Buffer Gear – Sub Assembly.

Intermediate Tube – Sub Assembly.

Air Pipe Coupling – Sub Assembly.

Center Adjustment Device – Sub Assembly.

Adjustable Cup sleeve – Sub Assembly



4.1.2 Coupler- End ‘B’ consist of: - Bearing Bracket with Support – Sub Assembly. Draw and Buffer Gear – Sub Assembly.

Intermediate Tube – Sub Assembly. Air Pipe Coupling – Sub Assembly.

Center Adjustment Device – Sub Assembly. Centering Device – Sub Assembly.



4.2 FEATURES OF SEMI- PERMANENT COUPLERS

This coupler is designed for taking a maximum tensile load of 70 tons.

Due to rigid connection of these Couplers, there exist negligible play between them in coupled position and hence no appreciable wear and tear during the train operation.



The absorption capacity of the rubber draft gear of the Semi Permanent Couplers is 800 M-kg.

The design and construction of the pivot joint between these Couplers and coaches is achieved by using the “Articulation Bearing” and permits a total deflection of ± 75 mm

and horizontal deflection of 284 mm or 13 on either side. This enables the coaches to couple up easily at all track curves and also on points of changing gradient even at the maximum height difference between two coaches.

4.3 DESCRIPTION & FUNCTIONAL FEATURES OF SUB ASSEMBLIES

4.3.1 Bearing Bracket (Used both in End ‘A’ & End ‘B’)

It is the part of the semi permanent Coupler which is fixed onto the end part of the

coach. This sub-assembly is basically fabricated and machined to house two Ferro zell bushes with concentric vertical axes and connected to the Articulation Bearing of the draw and buffer gear sub-assembly by means of one bearing bolt. One leaf spring holding device which is mounted on this bolt by thread engagement. These leaf springs held together tightly helps to support the overhung portion of the Draw and buffer gear from

under side.

FIG. 1: BEARING BRACKET WITH SUPPORT



Nomenclature of fig. 1

Description Ref.No. Description Ref.No.

Bush 3 Pin 32 d 9 x 200 x 180 17

Bush 4 Unmachined Disc 33 18

Disc Thrust Piece 5 Split Pin 8 x 50 19

Slide Plate 6 Fan Disc V10, 5 20

Plate 7 Spring Washer A8 21

Plate Disc 8 Bearing Bolt (Sub Assly.) 22

Hex. Hd Screw A M30 x 90 10 Bearing bracket (sub Assly.) 24

Hex. Hd Screw A M8 x 15 11 Carrier (Sub Assly.) 32

Csk Hd Screw M10 x 30 12 Fastening (Sub Assly.) 47

Hex. Nut M30 13 Leaf Spring Comp. (Sub Assly.) 52

Split Pin 3/8” dia x 5-1/2” 15 Block (Sub Assly.) 58

Grease Nipple A10 16

4.3.2 Draw and buffing gear (Used both in End ‘A’ & End ‘B’

This part of the semi permanent Coupler accommodates the rubber spring (Perforated

steel plate with rubber moulded on it) and steel plate held alternatively to provide an

energy absorption capacity of about 80M- Kg and a draft capacity of 34 tonnes.

FIG. 2 DRAW AND BUFFING GEAR




DESCRIPTION REF.NO DESCRIPTION REF.NO

Bolt 5 Socket Head Screw M42 x 300 16

Bush 6 Split Pin 10 x 70 17

Upper Part of the Cup Sleeve 7 Clamping Pin 5 x 40 18

Spencer Moulton Rubber Pivoting Bearing – Const’n.

Springs 8 Type-A 19

Spencer Mild Steel lates3/16” 9 Lower Part of Cup Sleeve 22

Hex. Head Screw M16 x 180 11 Front Plate (Sub Assly.) 26

Hex. Nut M16 12 Rear Plate (Sub Assly.) 33

Spring Washer A16 13 Yoke (Sub Assly.) 38

Clamping Pin 8 x 80 14 Eye (Sub Assly.) 44

It comprises of a fabricated yoke which houses the said Rubber springs, plates, one front plate and one rear plate, a fork eye which houses the “Articulation Bearing”. This fork eye is mounted on the yoke by means of two Socket head screws, which also keep the Rubber-spring and plate in position. There is a pin with a polyamide bush, which keeps the fork eye in central axis of the yoke. During the train operation the rubber spring along with plates are subjected to compression only in both the cases when the coupler is under tensile load or compressive load. The draw and buffer gear is connected to bearing bracket in one side and rigidly to the intermediate tube on the other side.

4.3.3 Intermediate Tube (Used both in End ‘A’ & End ‘B’)

The intermediate tube is fabricated by welding two forged rings on both side of a

seamless (heavy) tube piece. Then subsequent stress relieving and machining is done on

it. Intermediate tube being rigidly connected to the draw and buffer gear assembly,

become one single solid stock extending from the pivot center (i.e. articulation bearing)

up to its other free end.

FIG. 3 INTERMEDIATE TUBE ASSLY.




DESCRIPTION REF.NO. DESCRIPTION REF.NO.

Tube 1 Spring Sleeve 10 x 20 10

Ring 2 Lug 5

Plate 3

4.3.4 Air Pipe Coupling (Used both in End ’A’ & End ‘B’)

This is bracket type fabricated structure which houses two male thread mountings for main reservoir pipe and brake pipe and two conical rubber washers fitted inside hex. head sockets which form the coupling face. When both the Semi Permanent Couplers (End ’A’

End ‘B’) are manually coupled. These rubber washers projected outwards coupled

simultaneously to ensure leak proof air passages for MR& BP.

FIG. 4 AIR PIPE COUPLING

4.3.5 Centering Device (Used only in End ‘B’)

This is machined from a circular disc type forging with guide pins welded in it. It forms

the coupling face of the Intermediate tube (End ’B’).



FIG . 5 CENTERING DEVICE

4.3.6 Adjustable Cup Sleeve (Used only in End ’A’)

This subassembly is mounted on the outer part of the Intermediate tube of Semi-permanent Coupler (End ’A’). This comprises of two-semi circular sleeve with tapered slot inside. These sleeves are adjusted and bought in position by means of a spindle with both left hand and right hand thread formed on it. Closing of these two sleeves grips firmly two outer ends of Intermediate Tubes of Semi-permanent Couplers (End ’A’ & End ‘B’) thus forming one rigid connection. The exact centering is done by two guide pins welded onto the centering devices, one housed in the Adjustable Cup sleeve and another fitted at the end of Intermediate Tube (End ’B’).

FIG. 6ADJUSTABLE CUP SLEEVE



4.3.7 Center Adjustment Device (Used both in End ‘A’ & End ‘B’)

This consists of two concentric helical compression springs housed in a barrel with clevis end fitting to facilitate mounting onto the underside of the frame. This combination of springs fitted with a push rod always exert are storing force to keep the coupler end in central position which often gets moved sidewise due to relative lateral displacement of

two compartments during the train operation.

FIG. 7 CENTER ADJUSTMENT DEVICE


DESCRIPTION REF.NO.

Compression Spring 1

Compression Spring 2

Disc Spring 4

M24 x Hex. Nut 6

Hook Spring Nut 7

Bolt, B22, h11 x 65 x 58.5 8

M23 washer 9

Split Pin 5 x36 10

Plug (Sub Assly.) Complete Comprising 12

Eye 30

Spring Casing (Sub Assly.) Comp. Comprising 16

Spring Casing (Sub Assly.) Comp. Comprising 21

Fork Head 25

Clamping Screw 29



4.4 MAINTENANCE SCHEDULES

Following maintenance schedules are carry out in the DEMU car shed and workshop.

4.4.1 Trip schedule to “C” schedule

Check slackness by coupler play inspection gauge between two couplers, which should not more than 4 mm.

Check slackness by coupler play inspection gauge in individual coupler, which should not more than 2 mm.

Visually check for physical damage/ missing components and replace them.

4.5 PERIODICALLY OVERHAULING

4.5.1 Overhauling Procedure

The Semi-Permanent Couplers are to be dismounted for the major overhauling

In every POH schedule. In case of physical damage, deformation or accidents.

The overhauling process involves:

Dismount the coupler from the DEMU car. Completely dismantle the coupler and clean all components. Check all individual stress bearing components with their respective condemning

gauges.

The rubber parts of the air-pipe coupling (MR & BP) must be replaced irrespective of their conditions.

4.5.2 Polyamide bushes

Polyamide bushes of the rear plate should also be replaced at the time of the POH of the

coach. Replacement of polyamide bush is essential to protect excessive wear on the yoke

assembly and socket head screws of draw and buffer gear. The new bush should be

softened by heating it for 20 minutes in boiling water in a specially designed bath shown

in fig. 11. It is done when the new one is kept in a container, which receives heat from

boiling water for about 20 minutes. Then it becomes easier to slide the polyamide bush it

should not be fitted by hammering in cold condition.

4.5.3 Bearing Bracket with SupportInspection and replacement of components of Bearing Bracket with Support involves checking of cracks, damaged shapes etc. found on Bearing bolt, Bearing bracket & Ferrozell bushes.

Bearing bolt should be checked for its wear by the condemning gauge. The grease

passages should be cleansed properly clogged grease should be removed by Kerosene/

steel rods also easy grease flow through all passages it to be removed.



4.5.4 Draw and Buffer gear

The rubber spring and steel plate combination should be checked for: -

Total height of 7 steel plates + rubber spring + front plate + rear plate = Minimum 256.8 mm in unstressed condition.

Energy absorption capacity to be compared with the graph, plotted by the standard one as given in SCHAKU Drg. No. 40-586.06(2).

External condition and appearance of the rubber springs are to be checked for aging and should be replaced by new one if found not satisfactory.

4.5.5 Lower & upper Cup-sleeves

The pair of lower & upper Cup-sleeves should be checked by the condemning gauges. These Cup-sleeves along with socket head screws are to be replaced by new ones if found excessively worn out. Lubrication of Articulation bearing is to be ensured. The gap

between the inner race and the ball should not exceed 0.3 mm. In case this gap is bigger one new articulation bearing is to be fitted. NDT and Die- penetration test on yoke structure should be carried out and if found with any cracks etc. it is to be replaced by new yoke.

4.5.6 Spring sleevesThe spring sleeves used in all the sub assemblies are to be checked for proper shape and

appearance. They should be replaced if not found in satisfactory condition.

4.5.7 Intermediate tube sub assemblyComponent of Intermediate tube sub assembly of Semi Permanent Coupler (End ‘A’ &

End ‘B’) should be replaced if found not satisfactory to withstand the service conditions.

Welded joints should be checked for cracks etc. by NDT & Die-penetration test. Use of

hammer to open Adjustable Cup- sleeves is to be avoided as far as possible.

4.5.8 Painting & AssemblyAfter complete overhauling of the Semi-Permanent Coupler. One coat of black Enamel should be applied all over to protect the main body from rusting. Grease must be applied to all moving parts. Date of overhaul should be punched/ stamped on the Intermediate tube to maintain the overhauling records.

After complete overhauling, the Semi-Permanent Coupler should be assembled again and

kept in a clean & dry place till the time of fitment on the coaches.

5.0 Inspection and Replacement of Components and Sub assemblies 5.1 Inspection and replacement of components of Main Bracket / Bearing

Bracket with support drg. No 2ED-181-1001 {SCHAKU DRG. NO. 40-588.07(2)}. Bearing bolt should be checked for its wear by the condemning gauge. The

grease passage should be absolutely clear. Clogged grease should be

removed by kerosene/steel rods. Also ensure that the grease when applied

through the grease nipple flows easily.



5.2 Inspection and replacement of components of Draft Gear / Draw and Buff Gear drawing No. 2ED-181-1011 {SCHAKU DRG. NO. 40-586.06(2)} The rubber plates are required to be opened out of the yoke during POH and checked for:

a) Total height of 7 steel plates + 6 rubber spring plates + front plate + rear plate which should not be less than 256.8 mm

b) External condition of rubber spring plates. In case of any deformation or ageing effect is found in any of the plates it must be replaced by a new one.

The pair of lower & upper cup sleeves should be checked by the

condemning gauge. Allen screws M42 X 300 are under load at the time of

tension and are prone to wear against the rubbing action by the steel plates.

Allen Bolt should be checked by the condemning gauge and replaced if

found worn-out.

Polyamide bush of rear plate sub assembly should be replaced at time of

POH of the coach. Replacement of Polyamide Bush is essential to protect

excessive wear on the Yoke sub assembly and Allen Screw M42X300 of the

draw and buff gear sub assembly.

5.2.1 Fixtures and Method of Using

5.2.1.1 Fixture for pressing Articulation Bearing (Fixture Drawing No. SE-F-134)

Method of using fixture for pressing the articulation bearing

a) Hold the mandrel into the press ram

b) Keep the fork eye on to the resting fixture and make it horizontal

c) Keep the articulation bearing on the fork eye hole

d) Guide the mandrel into the inner ring of articulation bearing and press it

Replacement of yoke is to be carried out on conditional basis but in case the

yoke must be checked by NDT for internal fatigue stresses/cracks which

might have developed during running period and are not visible to the

naked eye. NDT may include Ultrasonic testing, die penetrant test etc.





Assembly fixture for Draft Gear / Draw and Buff Gear (Fixture Drawing No.SE-F-137 & SE-F-138)

5.2.1.2 Procedure for assembly of Draft Gear/ Draw & Buff Gear

a) Assemble the six spring rubber plates and seven steel plates on two clamps

drg. No SE-G-138 with two pins drawings in the two holes in plates and

press them with the help of a press to a height of 247.3 mm and lock them

by tightening the nuts of the clamps (use Drg. SE-G-136 For checking

dimension 247.3mm)

b) Place yoke in the frame (drg. SE-G-137 Sheet 1) at 90° to normal position along with front and rear plates

c) Place the clamped assembly as per 1 above on the yoke & with the help of press, start introducing it smoothly into the yoke.

d) The lower clamp touches the yoke, and then slides up gradually and ultimately comes out with upper clamp.

e) Ensure proper alignment of holes in the plates & yoke and remove the pins.



f) Assemble the yoke with the fork eye by introducing Allen screws. Tighten Allen screws.

g) The plates should not be loose in the yoke. If so dismantle & reassemble the parts with new plates.













5.2.1.3 Method of using the fixture for Draft Gear / Draw & Buff Gear sub assy.

a) Keep the buffer plates into the holding clamps and inserts the two pins inside.

b) Press the buffer plates and tighten up the nuts

c) Keep the resting blocks on to the press.

d) Keep the yoke on to it.

e) Keep the top block on to the yoke.

f) Now keep the draw & buff gear partial sub-assembly into it and press it

5.3 Inspection and replacement of components of Centering Device drg. No 2ED-181-1006 { SCHAKU Drg. No. 40-1000.10(2)}

Components of Centering Device drg. No 2ED-181-1006 should be replaced on

conditional basis except all the compression springs. The springs which are

always under compressive and tensile loads must be checked for their

strength and should be replaced if they cross the condemning limits as

given in spring condemning criteria.

5.3.1Method of using the assembly fixture for Centering Device (Fixture Drawing No. SE-F-135)

a) Pass the bolt through the spring pot and compression spring (inner & outer)

b) Put the spring plate and tighten up the lock nut

c) Place the complete sub assembly on to the fixture

d) Compress the compression springs with the help of the fixture up to the stop and tighten up the lock nut.

e) Remove the compressed sub assembly from the fixture for final assembly in to the spring casing.



5.4 Inspection and replacement of components of Intermediate Tube Drg. No

2ED-181-1004 {SCHAKU 40-586.01:01(2)}.

Components of intermediate tube sub assembly should be replaced on conditional basis.

Use of hammer to open adjustable cup sleeve is to be avoided as far as possible.

5.4.1 Device for removal of bearing bolt (Fixture Drawing No. SE-F-140)

In the event the removal of bearing bolt 2ED-181-1093 (SCHAKU DRG. 40-

586.07-03(3)) is found to be difficult due to jamming (lack of lubrication) a

special fixture can be used to remove the bearing bolt. The fixture is located

underneath bearing bolt on a platform of 600-700 mm height kept on the

shop floor between the rails of the track. The spindle is moved in upward

direction by turning the handle, and the bolt is pushed out. If the pushing

force exerted to the bolt by this method is not sufficient to remove the bolt,

use of hydraulic jack is suggested.

After complete overhauling of the coupler, a coat of black enamel should be

applied all over to protect the coupler parts from rusting. Grease must be

applied on all moving parts. Date of overhaul should be punched / stamped

on the intermediate tube to maintain the overhauling records.



SPECIAL TOOLS & FIXTURES

FIG. 8 SCISSORS TYPE HYDRAULIC LIFTING PLATFORM



FIG. 9 HYDRAULICALLY POWERED PRESS

FIG. 9 FIXTURE FOR DISMANTLING & ASSEMBLY OF MAIN SOCKET HEAD CAP SCREW OF DRAFT GEAR

FIG.10 BATH FOR SOFTENING OF POLYMIDE BUSH



6.0 Lubrication Scheme

S NO Part Name Periodicity Type of Lubricant

01 Bush Polyamide POH Servo GP grease 2 or HP GP Gerase

or equivalant

02 Bearing Bolt 6 months --------do------

03 Leaf Springs 6 months --------do------

04 Articulation Bearing At the time of POH of the Molykote (Mos2) paste, make OKS

coach or equivalent

7.0 SPRING CONDEMNING CRITERIA:

Springs are to be condemned on condition basis. Springs with corrosion and pitting are to be rejected. Springs are to be checked for serviceability as per the table given below:

Spring Similar Schaku Length (L) Load (min) Free Length (min)

Drawing No. Drawing No. mm kg at L mm

2ED-181-1069 AB-784/13-088.03- 29.5 (comp.) 10 61

14(4)

2ED-181-1115 40-3000.10-1(3) 351 60 510

2ED-181-1116 40-3000.10-2(3) 351 38 510

8.0 Tools and Gauges for Maintenance

8.1 For Depots

S.No. Description

Drawuing No.

1. Fixture for pressing the Articulation bearing RCF 599

2. Assembly fixture for Draw & Buff gear RCF 600,601

3. Fixture for centering device RCF 602

4. Condemning gauges for -

1. Allen Screw SK 338

2. Cup Sleeve 40.SK.2551.01

3. Pair of cup sleeves 40.2251.02

4. Bolt 40.SK.2551.1

5. Front plate S.A (dia 138d) 40.SK.2551.5

6. Front plate & forked head (dia 22h11) 40.SK.2551.6



7. Rear plate SA (dia 30H11) 40.2551.7

8. Yoke S.A 40.SK.2551.8

9. Articulation bearing 40.SK.2551.9

10. Bush (dia 80 B9) [Ferrozal] 40.SK.2551.10

11. Carrier S.A. & Leaf spring 40.SK.2551.11

12. Bearing bolt 40.SK.2551.12

8.2 For Workshops

List of Devices, Fixtures and Standard Tools required for Overhauling of Semi-Permanent

Coupler

Standard Tooling

Spanners : 1. 11-13 mm

2. 18-19 mm

3. 22-24 mm

4.30-32 mm

5. 34-36 mm

Hammer : Approx. 1 kg

Screw Driver 6 mm, 32 mm

Hand Press 6 mm, 32 mm

Bench Vice 6 mm, 32 mm

Allen Keys 6 mm, 32 mm

Fixture

1. Fixture for pressing the draw & buff gear v sub –assy. Into the yoke : RCF 600.

2. GO gauge for draw & buff gear sub-assy : RCF 601

3. Fixture for assembly of centering device & spring holder : RCF 602

4. Fixture for articulation bearing RCF 599 ( for pressing in fork eye)Description of

9.0 Tools, Fixtures and Gauges & method of using gauges

9.1 Pressing Method of using the Fixture and the Articulation Bearing

1. Press the fork eye in which the Articulation Bearing is to be pressed on the set of

adjustment bolts.

2. Position the spring loaded locater in the bore of fork eye.

3. Adjust the adjustment bolts to achieve a free movement of locater within the

bore of fork eye.

4. Place the articulation Bearing on the collar of locater as in figure.

5. Press the articulation Bearing with the help of pressing mandrel.

6. The spring loaded locater will automatically slide down

7. Ensure that Articulation Bearing has fully engaged and in position (observe the

collar)





9.2 Assembly Fixture For Draw & Buff Gear :

Procedure :

1. Assemble the six rubber springs and seven steel plates on two clamps drg. No.

RCF-600 (sheet 4) with two pins drg. No. RCF -600 in the two holes in plates and

press them with the help of a height of 207.3 mm and lock them by tightening the

nuts of the clamps (use RCF-601) for checking dim. 207.3 mm).

2. Place yoke in the frame (RCF – 600) at 90° to normal position along with front and

rear plates.

3. Place the clamped assembly as per (1) above on the yoke and with the help of

press; start introducing it smoothly into yoke.

4. The lower clamp touches the yoke, and then slides up gradually and

ultimatelycomes out with upper clamp.

5. Ensure proper alignment of holes in the plates & yoke and remove the pins.

6. Assemble the yoke with the fork eye the introducing allen screws. Tighten allen

screws.

7. The plates should not be loose in the yoke. If so dismantle and reassemble the

parts with new plates.

9.3 Method of Using the Fixture for Draw & Buff gear Sub-assy.

1. Keep the buffer plates into the holding clamps and insert the two pins inside.

2. Press the buffer plates and tighten up the nuts.

3. Keep the resting block on to the press.

4. Keep the yoke on to it.

5. Keep the top block on to the yoke.

6. Now keep the draw & buff gear partial sub-assy. Into it and press it.

















9.4 Method of Using the Assembly Fixture for Centering Device

1. Place the Tee Head Bolt on the Guide Pin ensure that the centre of the Bolt is on

the centre of the Guide Pin.

2. Insert the spring pot and spring on the Tee Head Bolt.

3. Place the spring plate on the Tee Head Bolt, slightly press it insert it inside the

fixture and then place Centering pin on the upper side of Tee Head bolt.

4. Apply pressure in the cylinder due to which the Tee Head Bolt will move upward

then, then remove the centring pin and tighten the nut on bolt.

5. Release the pressure and then remove the assembly.



10.0 Part List & Recommended percentage of Holding for POH

S.No. Description Ref Drawing No. Recommended % holding for

POH

A. Semi Permanent Coupler End ‘A’ 40-586-(O) 5

a. Draw & Buff Gear 40.586-06(2) 10

Bolt 40.586-06-3(4) 25

Bush (Polymide) 40.586-06-4(40 100

Cup Sleeve Upper Part 13-128-15 (30 25

Rubber Sp. Plate 40-SK-1837(1) A 80

Steel Plate 3/16” 40-SK-1837(1) B 25

Hex Hd. Screw M16x180 40.586-0692) Pt. 15 25

Hex. Nut M16 40.586-06(2) Pt.12 25

Hex. Nut Spring washer A16 40-586-06(2) Pt. 13 25

Spring dowel pin 8x80 40-586-06920 Pt. 14 100

Allen Screw M42x300 40.586-06(2) Pt.16 25

Split pin 40.586-06(2) Pt. 17 100

Spring Dowel Pin 5x40 40.586-06(2) Pt. 18 100

Articulation Bearing (sub-assy.) 40-SK-1960(3) 50

Seal 40-SK-1960-3(3) 100

Cup Sleeve Lower (Sub-assy 40-SK-1960-01(4) 25

Front Plate (sub-assy) 40-586-06-02(4) 10

Rear Plate (Sub-assy) 40-SK-06-02(4)) 10

Yoke (Sub-assy) 40-586-06-04(2) 10

Fork Eye (Sub-assy) 40-586-06-0592) 35

Name plate SK-147 10

Disc for bearing Bkt/Taper washer 40-524-07-0594) 10

Yoke (Sub-assy) 40-586-06-04(2) 10

Fork Eye (Sub-assy.) 40-586-06-05(2) 35

Name plate SK 147 10

Self tapping screws 4x5/18” long 25

Bush SK 331 50

b Intermediate Tube (Assy.) 40-586-01-01(2) 10

Spring dowel Sleeve 10x20 40-586-01-01(2) Pt.1 100

c Air pipe coupling SK-198 25

Angle plate (welded) SK-199 10

Rubber tube 13-088-03-15940 100

Spring 13-088-03-14(4) 30

Sleeve 13-088-03-1394) 25

Sealing ring 13-088-03-16(4) 100

Spring pot SK-365 20

Washer SK-366 20

Hex Nut R1” DIN 431 20

Elbow R1”x3/4” 20

Elbow R1”x1’ DIN 1569 20

Hex Hd. Screw M12x25 SK-198 Pt.10 25

Spring washer B 12 SK-198 Pt.11 25

Spring dowel sleeve 8x25 SK-198Pt. 12 25

d Adjustable cup sleeve 40-317-13(2) 10



Pin of cup sleeves 40-317-17-1(3) 10

Spindle 40-317-17-2(3) 50

Tube 40-317-17-3(5) 10

Winged nut 40-317-13-8(4) 100

Handle 40-317-13-9(4) 100

Split Pin 1/8”x3/4” 40-317-13(2) Pt. 6 50

Pin 10h11x75x67 40-317-13(2) Pt.7 25

Guide Pin 14h11x120 40-317-13(2) Pt. 8 100

Spring Dowel Sleeve 10x60 40-317-13(2) Pt. 9 100

Spring Dowell Sleeve 5x32 40-317-13(2) Pt. 10 100

Spring Dowel sleeve 5x32 40-317-13(2) Pt. 11 25

Adjustable ring B-30 40-317-13(2) Pt. 12 25

Centering Carrier (Sub-assy.) 40-317-13-01(4)

Split Pin 10x90 40-317-13(2) Pt. 14 100

e Bearing Bracket with support 40-588-07(2) 10

Bush (Upper) 40-524-07-3(4) 100

Bush (lower) 40-524-07-4(4) 100

Disc for bearing Bkt/taper washer 40-524-07-5(4) 25

Trust Piece 40-524-07-6(4) 20

Slide Plate 40-524-07-7(4) 100

Plate 40-524-07-8(4) 20

Disc 40-588-07-8(4) 20

Hex Hd Screw AM 30x90 40-588-07(2) Pt.14 25

Hex Hd Screw M8x20 440-588-07(2) Pt.23 50

Counter sunk Hd. Screw AM10x45 40-588-07(2) Pt.24 100

Hex Nut M30 40-588-07(2) Pt.15 25

Split Pin 3/8”x5 “1/2 40-588-07(2) Pt.16 100

Grease Nipple A10 40-588-07(2) Pt.17 100

Pin 31.8C11x200x180 40-588-07(2) Pt.18 25

Washer 33 mm 40-588-07(2) Pt.19 25

Bearing Bolt 40-588-07-03(3) 30

Bearing Bracket (Sub-assy) 40-586-07-01920 10

Trigger carrier 9sub-assy) 40-524-07-03(4) 40

Holder support (Sub-assy.)_ 40-524-07-04(4) 10

Leaf Spring 9sub-assy0 40-524-07-06(4) 40

B Semi Permanent Coupler End ‘B” 40-587-(0) 5

Draw & Buff Gear 40-586-06(2) 10

Intermediate tube 9Assy) 40-586-01-01(2) 10

Centering carrier sub-assy End ‘B’ 40.318.13(40)

Spring Dowel sleeve 10x20 40-586-01(2) Pt. I 100

C Centering Device 40.1000.10(20

Compression Spring 40.3000.10.1

Compression Spring 40.3000.10.2

Tee head bolt 40.3000.10.4

Spring plate 40.3000.10.5

Locking Piece Sub-assy 40.3000.10.01(4)

Spring pot 40.3000.10.03(4)

Spring casing sub-assy 40.3000.10.03(4)

Fork head 40.1000.10.01(4)



Washer 23

Split pin dia 6x35

Hex. Nut M24

Spring ring dia 104

Bolt 22h 11x65x58.5

11.0 Rejectable defects

Overhauling and Reconditioning Criteria of the Components of Semi-Permanent Coupler:-

S.No. Description Drg. No. Similar SCHAKu Drg. No.

Criteria for Determining the Condition

Fixture / Gauge Required

1. Tragger/ Carrier (Sub Assembly)

2ED-181-1200 40-524.07:03(4) Hole dia 32mm is to be Checked Condemn the component if the gauge passes through.

Limit Gauge to Drg. No. SE-G-117

2. Holder Support (Sub Assy.)

2ED-181-1102 40-524.07:04(4) Visible Cracks or damage

Visual

3. Bush Upper 2ED-181-1091 40-524.07-3(4) Internal Diameter 80 +0.200 / +0.274mm is to be Checked. Condemn Bush if gauge passes through it. There should not be any visible crack or damage.


4. Bush Lower 2ED-181-1089 40-524.07-4(4) Internal Diameter 80 +0.200 / +0.274mm is to be Checked. Condemn Bush if gauge passes through it. There should not be any visible crack or damage.


5. Disc Upper/ Taper Disc

2ED-181-1087 40-524.07-5(4) Visible Cracks or damage

Visual

6. Thrust Piece 2ED-181-1095 40-524.07-6(4) Visible Cracks or damage

Visual

7. Slide Plate (Ferrozal)

2ED-181-1246 40-524.07-7(4) Plate Thickness of 10mm is to be Checked. Replaced if wear exceeding 3mm.

Vernier calliper

8. Plate 2ED-181-1216 40-524.07-8(4) Visible Cracks or damage

Visual

9. Leaf Spring Complete (Sub Assy.)

2ED-181-1106 40-524.07.06(3) If wear of more than 2mm on the top leaf it has to be replaced

Vernier Calliper

10. Bearing Bracket/ Main Bracket

2ED-181-1088 40-586.07:01(2) Internal Fatigue stresses / Cracks.

NDT (Ultrasonic testing, Die penetrant test etc.)



11. Bearing Bolt 2ED-181-1093 40-586.07:03(3) External diameter Ø80 mm is to be checked. Condemn Bolt if it passes through the gauge.

Snap gauge to drg. No. SE-G-119

12. Disc Lower/Flat Disc

2ED-181-1086 40-588.07-3(4) Visible Cracks or damage

Visual

13. Plate 2ED-181-1105 AB/742 Visible Cracks or damage

Visual

14. Pin (31.8c11x200) DIN 1433 40-588.07(2) Prt. 18

External diameter Ø31.8 c11 mm is to be checked. Condemn Pin if gauge passes through

Snap Gauge to drg. No. SE-G-120

15. Cup Sleeve Lower (Sub Assy.)

2ED-181-1153 40-586.06:01(4) External diameter Ø31.8 c11 mm is to be checked. Condemn Pin if gauge passes through

Profile Gauge to drg. No. SE-G-121

16. Front Plate (Sub Assy.)

2ED-181-1156 40-586.06:02(4) External diameter of tube 138mm and diameter 22H11 of bush is to be checked. Condemn Front Plate Sub. Assy. If gauge passes over it.And Check for Straightness of Plates, Visible Cracks or damage.

Limit Snap Gauge to Drg. No. SE-G- 122 Limit gauge to Drg. No. SE-G-132

17. Rear Plate (Sub Assy.)

2ED-181-1157 2ED-181-1157 Inner Diameter Ø30mm of guide tube is to be checked. Condemn Rear Plate Sub. Assy. If gauge passes over it. And Check for Straightness of Plates, Visible Cracks/damage

Limit Snap Gauge to Drg. No. SE-G- 123

18. Bush Polymide 2ED-181-1182 40-586.06-4(4) Check the exsesive wear and for Visible Crack or Damage

--------------------

19. Yoke (Sub assy.) 2ED-181-1183 40-586.06:04(2) Internal diameter Ø138mm and Ø47 mm are to be checked. Condemn Yoke if the Gauge Passes Through it.Internal Fatigue stresses / Cracks.

Limit gauge to drg. No. SE-G-124 NDT (Ultrasonic testing, Die penetrant test etc.)



20. Fork Eye with Bolt (Sub Assy.)

2ED-181-1383 2-SK.399 ------------------ -----------

21. Fork Eye 2ED-181-1168 40-586.06:05(2) Internal Fatigue stresses / Cracks.


22. Bolt 2ED-181-1181 40-586.06-3(4) Outer Diameter Ø30mm d11 is to be checked. Condemn bolt if gauge passes over bolt

Snap Gauge to drg. No. SE-G-126

23. Cup Sleeve Upper 2ED-181-1149 40-624.06-4(3) Check the Profile & for Visible Crack/damage

Profile Gauge to drg. No. SE-G-121

24. Rubber Spring Plate

2ED-181-1245 40-SK-1837(1) Length of unstressed spring should not go below 256.8 mm. Check for Straightness of Plates, Visible Cracks or damage.

Vernier Calliper

25. Steel Plate 2ED-181-1250 40-SK 1837(1) Visible Cracks or Damage

Visual

26. Articulation Bearing

2ED-181-1151 40-SK 1960(3) Diameter 80mm is to be checked and slack between inner and outer ring should be more than 0.3mm. Condemn the Inner Ring if the gauge passes through it.

Limit Gauge to Drg. No. SE-G- 127 & Filler Gauge

27. Allen Screw / Bolt (M42X300)

2ED-181-1189 40-586.06(2) Prt. 16

Outer Diameter of shank & Thread. Condemn the Screw if gauge passes over the shank or threads

Snap Gauge to drg. No.SE-G- 128

28. Sealing ring 2ED-181-1071 13-088.03-16(4) Visible Cracks or Damage

--------------------

29. Sleeve 2ED-181-1069 AB-785/13-088.03- 13(4)

Visible Cracks or Damage

Visual

30. Spring 2ED-181-1069 AB-784/13-088.03- 14(4)

Condemning limits as given in spring condemning criteria.

-----------------

31. Rubber Tube 2ED-181-1070 AB-782/13-088.03- 15(4)

Check for damage, ageing and apperance

---------------------

32. Spring Pot 2ED-181-1065 AB/781 Visible Cracks or Damage

Visual

33. Angle Plate 2ED-181-1062 40-587.04:01(2) Visible Cracks or Damage

Visual

34. Support Washer 2ED-181-1066 AB/783 Visible Cracks or Damage

Visual

35. Hex. Nut R1” DIN 431 40-587.04(3) Prt. 5


Visual



36. Elbow R 1”X3/4”

DIN 1569 40-587.04(3) Prt. 9


Visual

37. Elbow R 1” X 1”

DIN 1569 40-587.04(3) Prt. 8

40-587.04(3) Prt. 8 Visual

38. Pair of Cup Sleeve

2ED-181-1074 40-317.13-1(3) Visible Cracks or Damage

Visual

39. Spindle 2ED-181-1080 40-317.13-1(3) Visible Cracks or Damage

Visual

40. Tube 2ED-181-1081 40-317.13-3(5) Visible Cracks or Damage

Visual

41. Winged Nut 2ED-181-1082 40-317.13-8(4) Check for Thread, Visible Cracks or Damage

Thread Plug Gauge /Visual

42. Handle 2ED-181-1083 40-317.13-9(4) Visible Cracks or Damage

Visual

43. Guide Pin 14h11x120

DIN 1433 IA 71153/40- 317.13(2) Prt.8


Visual

44. Adjusting Nut B-30

2ED-181-1198 IA 71154/40- 317.13(2)Prt.12


Visual

45. Centering Carrier End –A (Sub Assy.)

2ED-181-1076 40-317.13:01(4) Visible Cracks or Damage

Visual

46. Intermediate Tube/Draw Bar

2ED-181-1058 ------------------ Internal Fatigue stresses / Cracks.


47. Eye 2ED-181-1060 AB-735/40- 586.01:01(2) Prt.5


Visual

48. Centering Carrier End-B / Centering Device Carrier

2ED-182-1132 40-318.13-1(3) Visible Cracks or Damage

Visual

49. Centering Pin 2ED-181-1079 40-281.01-6(4) Visible Cracks or Damage

Visual

50. Compression Spring

2ED-181-1115 40-3000.10-1(3) Condemning limits as given in spring condemning criteria.

-------------

51. Compression Spring

2ED-181-1116 40-3000.10-2(3) Condemning limits as given in spring condemning criteria

------------------

52. Tee Head Bolt 2ED-181-1117 40-1000.10-5(4) Visible Cracks or Damage

Visual

53. Spring Plate 2ED-181-1118 40-3000.10-5(4) Visible Cracks or Damage

Visual

54. Locking Piece (Sub Assy.)


Visual

55. Spring Pot (Sub Assy.)


Visual

56. Spring Casing (Sub Assy.)


Visual



57. Fork Head (Sub Assy.)

2ED-181-1204 40-1000.10-6(3) Visible Cracks or Damage.Internal Diameter 22 H11 mm is to be Checked. Condemn Forked Head if gauge passes through it.

Visual Limit Gauge to Drg. No. SE-G- 132

58. Washer 23 mm DIN 1441 40-1000.10(2) Prt.9


Visual

59. Bolt 22h11x65 DIN 1435 40-1000.10(2) Prt. 8


Visual

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS …...i GOVERNMENT OF INDIA MINISTRY OF RAILWAYS श क कप ऱर क लऱए अन र ण प र क ट स एवम ऩ ओ एच