ICF design Passenger Coaches of Indian Railways

icfbogie

Hanger Block

Brake Gear Bushes

Hytrel Washer

PVC

Rexine

Silent Block: Anchor Link Bogie & U/ Gear: EMU

Upholstery

IRS-R-19 of 1993 (Part II)

Adhesive PVC fixing

Corrosion Repair ICF Steel

ICF Bogie Frame Repair 08/12 Schaku Coupler

RDSO C-7602: 12/92

Coach Basics Air Spring Air Spring 180 KN Performance Air Spring Failure

Head Stock Repair: 12/10

IRS Specifications

Corrosion Repair: EMU

Wheel Failure analysis

LHB Wheel shelling

Rubber Components

Schaku Coupler

Air Spring Fitment ICF-LHB Air Spring Maintenance ICF Dichotomy AS FIBA Performance 180 KN Vendor Manuals Bearing Maintenance Bearing Check Sheet EMU Bearings Periodicity of Inspection Body Construction Contact Corrosion Repair ICF HCR Video Head Stock Repair: 12/10 ICF Bogie Frame Repair 08/12 Inspection: UnderfFrame RDSO C-7602: 12/92 RDSO CMI CK302: 04/03 Sole Bar Cutting Disclaimer Drawings

Originally designed by M/s Scharfenburgkupplung, GmbH, Germany , Semi-Permanent Couplers are used on the EMU stock of Indian Railways. It consists of following main components; Sl 1 2 3 4 Component Draw and buff gear Bearing bracket with support Centering device Air pipe couplings for main air reservoir pipe and brake pipe 5 6 Intermediate tube Adjustable cup sleeve SK-756 SK-198 [for semipermanent coupler End A and End B SK-754 SK-755 40.586.01.01(2) 40.317.13(2) 40.1000.10(2) Drawing No SK-752 SK-753 Reference Drawing No 40.586.06 (2) 40.588.07(2)

In Semi permanent couplers the coupling is done manually and the two couplers after being aligned are secured by means of an adjustable cup

ICF RCF RDSO Electrical Air Conditioning Alternator Batteries Cables Carriage Fan Earthing Electrical Power Supply ERRU Lightening Power Supply Installation in Electrical Traction Train Lightening EMU Maintainance Activities of EMU POH Bogie & U/ Gear: EMU Corrosion Repair: EMU EMU Drawings EMU maintenance & Schedules HCC EMU Bogie(Pneumatic) Maintenance Periodicity MSU (Motor Suspension Unit) Operation of EMU Traction Gear BG EMU BHEL Forged Components Hanger Block Helical Springs History Interiors Berth Construction Flooring Lavatory Mouldings Partition Sunmica Windows LHB Basics Comparison ICF Vs LHB Earthing Device LHB Air Brake LHB Coaches Maintenance Instructions Air Brake with BMBC Bio Toilet AMC BMBC Buffing Gear

sleeve joint. During the process of manual coupling the air pipe connections between the two coaches are also established automatically. The pivoted joints between the coupler and the coaches is designed and constructed in such a way that even in case of maximum difference in level, the coaches are capable of negotiating all track curves and of passing through points of change of gradient occurring during service. This coupler fulfills all other operational requirements. SALIENT FEATURES OF ESCORTS SEMI-PERMANENT 1. Semi-permanent coupler can take up a compressed load of 100 tons and tensile load of 70 tons. 2. The 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 draft capacity incorporated in semi-permanent couplers, it allows coaches to buffer at higher speeds (from 3 km/hr to 15 km/hr) without any damage to the coach and the load. 6. The 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 flanges are kept minimum .This reduces the wear of the wheel flanges and minimizes the chances of derailment. 8. As the coupling links of semi-permanent couplers form 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 75mm and horizontal deflection of 284 mm or 13 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.

ShakuCoupler

CBC Passenger Coach Coupling of CBC Draw Gear Helical Springs PVC Laying Roller Bearing Manuals Air Brake :Knorr Coach Manual Dampers Material Check Sheets Brake Block Hanger BSS Hanger Buffing Pads Draw Gear Pads Guide Bush HPPA Bush Hytrel Front Cover Hytrel Washer Nylon Bush Phenolic Bush Rubber Washer Silent Block Center Pivot Silent Block Old Presentations Air Brake System Bio Diesel Brake Binding Prevention CTRB Maintenance FIAT Bogie ICF BOGIE New Developments: Coaching Screw Coupling Rail Vehicle Dynamics 1 :Introduction 10: Noise & Vibration 11 :Active Suspension 12 :Simulation 13 :Filed Testing 14 :Roller Rigs 15 :Scale Testing 2 :History of Rail Wheel Dynamics 3 :Running Gear 4: Rail Wheel Contact 5: Tribilogy of Rail Wheel 6: Track Issues 7: Gauging Issues 8: Derailment

Semi-permanent coupler End A as per drg. SK-750, Ref. drg. no [40.586.(0)] The semi-permanent coupler End A consists of the intermediate tube (item 1), the air pipe coupling (item 2), the draw and buff gear (item 3) bearing bracket with support (item 4) and adjustable cup sleeve (item 5).

Air Pipe Coupling SK-198, Ref. drg. no. [40.587.04 (3)]

9: Longitudinal Train Dynamics RDSO SMI Rubber Components Schaku Coupler Adjustable Cup Sleeve Air Pipe Coupling articulation Bearing Bearing Bracket with support Centering Device centering Devvice Check Sheet Coupler Photos Draw & Buff Gear Fork Eye Front Plate Sub Assembly Intermediate Tube Sub Assembly Leaf Spring Sub Assembly Lubrication Preventive Maintenance Rear Plate Sub Assembly Rubber Spring Plate Semi-permanent coupler End A Trager Carrier Sub Assembly Yoke Sub Assembly Slide Show Bogie Details Bogie Details1 Details of ICF Coach Hytrel Washer Specifications Adhesive PVC fixing CDTS IRS Specifications IS: Specs Modular Toilet PU foam PVC Steel Sub-Assemblies Air Brake Anchor Link asssembly Bogie Frame Buffing Gear Draw Gear Primary Suspension Rolling Gear Secondary Suspension

The

welded assembly of air pipe coupling (item 6) is fastened to the intermediate tube by means of six hexagonal head screws (item 13). The air pipe coupling consists of sleeve (item 4), spring (item 3), are inserted as a whole from the front side into the welded socket and are installed in position by turning the sleeve by about 90 thus catching the two dogs in the welded socket. With this arrangement it is very simple to replace the worn out components without expensive fitting work. The sealing ring (item 1) projects above the center of the coupling and at the time of coupling it is pressed against the sealing ring of the opposite coupler. After the coupler is coupled, the sealing rings provide a leak proof connection since these remain under the effect of the springs (item 3).. The elbows R3/4 and R1 have been provided for establishing permanent connection with the pneumatic pipe lines.

Toilets Biological Toilet CDTS Green Toilet Vacuum Toilet Upgraded Material Brake Beam Hanger Brake Gear Bushes Compreg DSU Hytrel Washer PVC Recron Rexine Silent Block: Anchor Link SS Air Brake Pipes Sumica Upholstery Videos AXLE PULLEY BOGIE BASICS I BOGIE BASICS II Welding Wheel Cast Vs Forged Cast Wheel = 120 KmPH Fatigue crack initiation IRS-R-19 of 1993 (Part II) LHB Wheel shelling PreInspection: Wheel Rail Wheel Interaction Rail Wheel Interaction: Tunouts Rail Wheel Tribilogy RCF:Rolling Contact Fatigue Residual Stress in Cast Wheels Wheel Defect Wheel Failure analysis Wheel Grazing Wheel Slide Protection

Draw and Buff Gear SK-752, Ref. drg. no. {40.586.06(2)] The rubber spring (9) of the draw & buff gear has an energy absorption capacity of about 800 M Kg , and the draw and buff gear is therefore capable of protecting the coach under frame to a large extent against impact stresses. The cup sleeve joints, (1, 8) connect the draw & buff gear with the intermediate tube . The connection to the bearing bracket with support, arranged on the coaches is effected by the bearing bolt which, when fitting the coupler is put through the bore of the articulation bearing (11) in the fork eye (5) and secured. The compressive forces acting are transmitted to the rubber spring (9) . At the end of the compression stroke of 56 mm, the rear plate of the yoke supports itself upon the fork eye. The tractive forces are transmitted through the cup sleeve joint (1,8), the yoke (4), the rear plate (3) , the rubber spring and the two allen screws (16) to the fork eye . The articulation bearing fitted in the fork eye permits the lateral and the vertical displacement as well as twisting around the longitudinal axis of the coupler. Lubrication of the articulation bearing is effected with the help of a grease nipple in the bearing bolt. When fitting

the coupler into the coach, care must be taken to ensure that the collar of the articulation bearing (11) in the fork eye (5) is located at the top side. Please refer attached drawing.

Bearing Bracket with Support SK-753, Ref. drg. no [40.588.07(2) The bearing bracket with support serves the function of transmitting the traction and impact forces from the coupler to the coach under-frame structure, and to keep the coupler in its horizontal position between the coaches. Arranged in the carrier subassy. (1) there is the leaf spring, which supports the coupler. The thrust piece (6)

is guided in two slots in the carrier. After loosening the hexagonal nut, (15) it is possible to adjust the precise coupler height by the aid of the hexagonal head screw. After effecting this adjustment, the hexagonal nut must be again firmly tightened. Under the draw & buff gear there is the holder (2) for the leaf spring (9). A slide plate (7) protects the bearing surface of the leaf spring from excessive wear. The carrier is screwed on the bearing bolt (11), which passes through the articulation bearing in the fork eye of the draw & buff gear and is housed in the bearing bracket (10), which is a part of the coach under frame. The bushes (3&4) and other bearing spots are greased.

Adjustable Cup Sleeve to drg. no. SK-755, Ref drg. no [40-317-13(2)] The adjusting cup sleeve joint has the function to transmit the tractive forces from one semi-permanent coupler to the other and to facilitate rapid coupling and uncoupling. It consists of a pair of cup sleeves (item 1) which can be radially moved over the spindle (item 2) with the help of the handle (item 5). The centering carrier (item 13) serves as abutment for the spindle and prevents the two couplers from getting twisted. The bolt (item 6) retains the two-cup sleeve halves in the vertical plane. The winged nut (item 4) secures the spindle (item 2) against working loose. The centering pin (item 14) helps to self center the coupler while coupling to ensure maintain of coupling line. Please refer attached drawing.

Centering Device SK-756, Ref drg.no [40.1000.10(2)] The centering device has the function to retain the couplings in their position at centreline between the coaches and to retract them into this central position after every side displacement. On one side, it is hinged on the draw & buff gear. On the other side, it is fitted to the coach structure. The centering device consists of a spring casing (7) for the two compression spring (1,2) the spring pot (6) and the spring plate (4). The spring casing is closed by screwing on the locking piece (5) and a spring ring (12) prevents it from working loose. The shackle welded on the locking piece (5) takes up a bolt for fixing the centering device to the coach. A Tee head (3) guided in the spring pot (6) and the spring plate (4) establishes the connections to the forked head (8). The bolt (13) serves for fixing the forked head (8) to the draw & buff gear. After loosening the hexagonal nuts (11), the centering device can be altered in its length. After adjusting the coupler in its correct central position, the hexagonal nuts (11) must be again firmly tightened.

Description of Semi-permanent Coupler End B as per drg. SK-751, Ref. drg. no [40- 587-(0)] The Semi permanent coupler End-B differs from the End-A to drawing no. 40-586-(0) in respect of the centering carrier and air pipe couplings only. For intermediate tube, draw and buff gear, bearing bracket with support, adjustable cup sleeve and centering device please see drawing for Semi permanent coupler End-A. Outer End Coupler as per drg. SK-849 [40-588-(0)] Outer end coupler consist of draw and buff gear, bearing bracket with support, centering device(sub assy.) and draw hook

Lubrication of Coupler Components Sl 1 2 3 4 5 6 7 8 9 10 Description of the Component Adjustable cup sleeve Hole in Centering Carrier Bush on Rear Plate Bearing bolt and Articulation Bearing Leaf Spring Front pin of Centering Carrier Spindle of Adjustable cup sleeveBolt of Adjustable cup sleeve Pin 31.8 C11 x 200 x 180 (which holds the leaf spring) Threaded portion of carrier sub-assy. Type / Brand of Lubricants Servogem (RR-3) - do - do Molykote paste Servogem (RR-3) do do do -do-doPeriodicity of Lubrication 6 months 6 months POH POH & every 6 months in car sheds 6 months 6 months 6 months 6 months POH POH Lubrication spots I II III IV V VI VII VIII

Preventive maintenance 1 Draw and Buff Gear a) Check the split pin 10x70 of both the Allen Screws. If found deformed or missing should replace. b) The Draw & Buff gear should not be too loose in side the yoke sub-assy. c) Check the fitment condition of Fork Eye Sub-assy. inside Bearing Bracket.. The Fork Eye should be in its proper place and if any abnormality is the coupler should removed, offended and then refitted. d) Check the condition of Polyamide bush if found too much deformed remove the coupler and provide the polyamide bush. 2 Upper and Lower Cup Sleeve a) Check the condition of Upper and Lower Cup Sleeve, these should not be loosen. b) Check the gap between intermediate tube and the periphery of cup sleeve if gap abnormal attend same by replacing the pair of cup sleeve. c) Check the condition of Hex. Hd. Screw M16x180 then should not be loose and should have firm fitment. 3 Adjustable Cup Sleeve a) Check the condition of cup sleeve these should not be loose. If found loose, same should be attended. b) The gap between periphery of intermediate tube and collar of cup sleeve should be observed if gap found too abnormal same should be attended by replacing the cup sleeve.

Bearing bracket with support

a) Check the condition of split pins fitted on the carrier sub-assy. to hold the leaf spring. If split pin found deformed or missing replace them. b) Check the condition of split pin fitted in between bearing bolt and carrier sub-assy. if found deformed or missing replace it.

Support Sub-assy. a) Check all four hex. head screw if found loose or missing attend / replace them. b) Check the condition of slide plate if found worn out replace it.

Greasing of Articulation bearing As mentioned in the lubrication scheme please ensure to lubricate the articulation bearing every 6 months

1. Fork Eye Sub Assy. Sk-784, Ref. drg. no [40.586.06.05](2)] a) Check the dimension 30 mm by means of the limit snap gauge to drg. no. 40-SK-2551-1. b) Check dia. 47mm and 135mm with the help of bore gauge. Note:- Since Fork Eye sub assembly is load bearing component it should be replaced after 10 years of service irrespective of its condition 2. Cup Sleeve (Upper and Lower) to drg. no. SK-767, Ref. drg. no [13-128-15(3)] and drg. SK-757, Ref. drg. no [40-586-06-01(4)] The cup sleeves are to be checked with the help of profile master gauge of drg. 40-SK-2551-01 as explained in drawings and if found within limit , same can be used otherwise condemn the cup sleeve whichever is defective or worn out excessively. 3. Sub-assy. Front Plate to drg. SK-758, Ref. drg. no [40-586-06-02(4)] The external tube diameter 138 mm is to be checked by means of the limit snap gauge to drg. 40-SK-2551-5, and the diameter 22H 11 in the shackle is to be checked by the aid of the limit snap gauge to drg. 40-SK-2551- 6(4). 4. Sub-assy. Rear Plate to drg. SK-781, Ref. drg. no [40-586-06-03(4)] The inner diameter 30 mm of the guide is to be checked by means of the limit gauge 40-SK2551-7. 5. Sub-assy. Yoke to drg. SK-833, Ref. drg. no [40-586-06-04(2)] a) The internal diameter 138 mm and 47 mm are to be checked by means of the limit gauge to drg. 40-SK-2551-8. If limit gauge passes, condemn the yoke. b) The internal distance 249.5 inside which front plate, rear plate and rubber spring plates along with separating plate is fitted should be checked. If wear is more than 252 mm do not use the yoke sub assy. Note:- Since Yoke sub assembly is load bearing component and working under strainious condition and absorbs shocks during tensile and compressive load it should be replaced after 9-10 years of service irrespective of its condition 6. Articulation bearing to drg. SK-770, Ref. drg. no [40-SK-1960(3)] The diameter 80 mm is to be checked by means of the limit gauge to 40-SK-2551-9(4). The slack between inner ring and outer ring should not be more than 0.6 mm. Check this slack with the help of filler gauge. 7. Rubber spring to drg. SK-343, Ref. drg. no [40-SK-1837(1)] consisting of 6 rubber springs, 7 steel plate and 1 each front and rear plate. Length of the unstressed spring should not go below 256.8 mm. The rubber material is to be checked visually for its perfect condition. eg:- no breakage, cracks chip off of rubber. In case length of the under stressed spring goes below 256.8mm, same should be maintained by replacing the old rubber spring plate with new one.

8. Sub-assy. Bearing Bracket to drg. SK-753, Ref. drg. no 40-588-07(2, Ferrozell Bush (upper) to drg. SK-797, Ref. drg. no [40-524-07-3(4)] and bush (lower) to drg. SK-197, Ref. drg. no [ 40-524-07-4(4)]. The internal diameter 80 mm is to be checked by means of limit gauge to drg. 40-SK-2551-10(4). There should not be any visible cracks or damage. The upper and lower bushes should be replaced during the every P.O.H. 9. Sub-assy. Carrier to drg. SK-802, Ref. drg. no [40-524-07-03(4)] and Leaf Spring Complete to Ref. drg. no 40-524-07-06(3) The hole dia 32 mm is to be checked by means of limit gauge to drg. 40 SK-2551-11. If limit gauge passes, condemn the carrier sub assy. Note:- Since the Leaf Springs are load bearing component to avoid fatigue it should be replaced after 5-6 years of service irrespective of its condition. 10. Slide Plate to drg. SK-800, Ref. drg. no [40-524-07-4(4)] The thickness of 10 mm hylam sheet is to be checked by means of a vernier caliper. In case of wear exceeding 3 mm, the slide plate has to be replaced. Slide plate should be replaced during the every POH. 11. Bearing Bolt to drg. SK-341, Ref. drg. no [40-586-07-03(4)] The external diameter 80 mm is to be checked by means of the limit and snap gauge to drg. 40-SK-2551-12 Note:- Since the Bearing Bolt is a major are load bearing component it should be replaced after 5-6 years of service irrespective of its condition. 12. Leaf Spring Complete. drg. SK-312, Ref. drg. no [40-5241-07-06(3)] In case of wear of more than 2 mm on the top leaf it has to be replaced. Note:- Since the Leaf Spring is a load bearing component to avoid fatigue it should be replaced after 5-6 years of service irrespective of its condition 13. Sub-assy. Forked head to drg. SK-821, Ref. drg. no [40-1000-10-D1(4)] The hole dia 22 mm is to be checked by means of limit gauge to drg. 40- SK-2551-6. 14. Sub-assy. Pair of Cup sleeves to drg. no. SK-787, Ref. drg. no [40-317- 13-1(3)] The pair of cup sleeves is to be checked by means of profile master gauge to drg. 40-SK-2551-01 as explained in the drawing. In case the profile of any one of cupsleeve is not correct, same should be replaced with new one. 15. Allen Screw SK-336 1. Check the Allen Screws with NO GO gauge SK 338.if no-gauge is not passing use the allen screw. 2. The check should be done at least 3-4 different places on the shank Note:- Since the Allen Screw is a major load bearing component it should be replaced after 5-6 years of service irrespective of its condition. 16. Bolt SK 765,Ref. drg. no [ 40.586.06.3(4)] The external diameter of the bolt is to be checked by means of snap gauge to drg. no. 40-SK-2551-1(4)

17. Rubber spring plate SK-343, Ref. drg. no [40.SK.1837(1)] The thickness of rubber spring plate should be checked using the snap gauge (40.SK.2551.13) at least 2-3 places on both sides of plate. Note:- Since it absorbs load during compression and tension it should be replaced after alternate POH or after working more than 3 years of service OVERHAULING AND MAINTENANCE PROCEDURES DURING P.O.H Escorts-Semi-permanent Couplers fitted on EMU / DMU / MEMU stock of the Indian Railways are working under sever strenuous conditions. Since these couplers are one of the stress bearing components of the EMU stock, it is very essential to carryout necessary preventive periodic repairs and overhauling at regular intervals. Though these couplers are rigid and are designed for taking a compressive and tensile load of 100 tons and 70 tons respectively, due to their operation in extreme load conditions in India it is recommended to overhaul these as given below to ensure a trouble free service. This overhauling and maintenance schedule is based on actual field experience under Indian conditions, as these couplers are now running with the Indian Railways for the last 40-50 years. Couplers are to be opened for the major overhauling. 1) After every 18 months of service or during every POH. 2) In case of physical damage or accidents. At the time of POH of the coach the couplers should be stripped open and individual stress bearing components should be checked with their respective condemning gauges (as explained in the respective chapter) after cleaning these parts. The rubber parts of the air pipe coupler (MR & BP) must be replaced as and when opened irrespective of their condition. Polymide bush of the rear plate should also be replaced at the time of POH of the coach. Replacement of polymide bush is essential to protect excessive wear on the yoke welded assembly and allen screws M42x300 of the draw & buff gear. The procedure of replacement of polymide bush as given in the procedure for replacement of polymide bush, INSPECTION AND REPLACEMENT OF COMPONENTS 1. Bearing bracket with support drg. no. SK-753 , Ref. drg. no [40-588-07(2)]. Main stress bearing and the load transmitting components of this sub-assy. are 1. Bearing bolt 2. Ferrozell bushes 3. Leaf spring complete 4. Carrier sub-assy 5. Bearing bracket sub-assy. 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 . 2. Inspection and replacement of components of draw and buff gear drawing no. SK-752, Ref. drg. no [40-586-06(2)]. Draw and Buff gear is the major sub-assy., which absorbs shocks during application of tensile and compressive loads. The rubber spring plates and steel plates work, as a shock absorber. The major stress bearing components of these sub-assy. are a) Pair of cup sleeves b) Rubber spring plates c) Allen screw M42x300 d) Articulation bearing sub-assy. e) Yoke sub-assy. f) Polymide bush

g) Fork eye (sub-assembly) The rubber draft gear i.e. rubber plates and steel 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 which should not be less than 216.8 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 M42x300 are under load at the time of tension and are prone to wear against the rubbing action by the steel plates. They should be replaced if found excessively worn-out on shank dia. Articulation, bearing (inner and outer race) must always be under lubrication since there is a direct metal-to-metal contact in between them. Absence of proper lubrication may form rust and hence cause jamming of the articulation bearing. Every time the coupler is opened the gap between inner race and the ball should be checked by a filler gauge. If the gap is more than 0.6 mm the articulation bearing must be replaced by new one. It is always recommended to replace inner race and the ball in pairs. Replacement of the yoke is to be carried out on condition basis. But in any case the yokes 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 penetrate test etc. 3. Inspection & replacement of components of MR & BP Air pipe coupling drg. nos. (SK-198 (same for End A & B With change in elbow position) For all types of air pipe couplings, rubber sealing rings and rubber tubes must be replaced as and when the couplers are stripped irrespective of their condition. The springs should be checked for their strength and any rust formation. They should be replaced, if found defective or rusted or in case physically damaged. Other components should be replaced on condition basis as and when found broken or worn out excessively. 4. Components of centering device drg. no. SK-756, Ref. drg. no [40- 1000.10(2)] should be replaced on condition basis except all the compression springs. The springs which are always under compressive & tensile loads must be checked for their strength and should be replaced if they cross the condemning limits. 5. Components of Intermediate tube sub-assy of semi-permanent coupler end A and end B should be replaced on condition basis. Use of hammer to open the adjustable cup sleeves is to be avoided as far as possible. After complete overhauling of the couplers, a coat of black Enamel paint should be applied all over to protect the main body from rusting. Grease must be applied on all the moving parts. Date of overhaul should be punched / stamped on the coupler intermediate tube to maintain the overhauling records.

After overhauling the couplers they should be stocked in a clean & dry place till the time of fitment on the coaches. PROCEDURE FOR REPLACEMENT OF POLYMIDE BUSH Place the new polymide bush in a container containing any light lubricating oil. Boil water in a bigger container placing the container with lubricating oil and polymide bush inside the bigger container. Keep it for approx. 20 minutes till the polymide bush becomes soft. Now, slide the polymide bush on the steel tube of the rear plate and allow it to cool for some time. Fitting of polymide bush in cold condition by any means is not recommended as the cracks will develop internally which may curtail the life of the polymide bush. SPRING CONDEMNING CRITERIA OF CENTERING DEVICE SK-756 [40.1000.10(2)] Springs are to be condemned on condition basis. Springs with corrosion and pitting are to be rejected. Spring are to be checked for serviceability as per the table give below Spring Part No. SK-762, Ref. drg. no[13-088.03-14(4)] Length (L) [mm] 29.5 mm(comp.) Load (min) kg at L 10 Free length (min) [mm] 61

SK-809, Ref. drg. no [40-3000.10-1(4)] SK-808, Ref. drg. no[40-3000.10-2(4)] LIST OF FIXTURES AND GAUGES Description i. Fixture for pressing the Articulation bearing ii. Assembly fixture for Draw & Buff gear iii. Fixture for centering device. iv. Condemning gauges for Allen Screw Cup Sleeve Pair of cup sleeves Bolt Bolt Front plate S.A. (dia 138d) Front plate & forked head (dia 22h11) Rear Plate SA (dia 30H11) Yoke S.A. Articulation bearing Bush (dia 80 B9) [Ferrozal) Carrier S.A. & Leaf spring Bearing bolt

351 351

60 38

510 510

Drawing No. RCF 599 RCF 600, 601 RCF 602 SK. 338 40.SK.2551.01 40.SK.2251.02 40.SK.2551.1 40.SK.2551.5 40.SK.2551.6 40.SK.2551.7 40.SK.2551.8 40.SK.2551.9 40.SK.2551.10 40.SK.2551.11 40.SK.2551.12

FIXTURE FOR PRESSING ARTICULATION BEARING METHOD OF USING THE FIXTURE FOR PRESSING THE ARTICULATION 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). 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 press to 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. BEARING 1. Press the Fork Eye in which the Articulation Bearing is to be pressed on the set of adjustment bolts.

3. Place the clamped assembly as per (1) above on the yoke and with the help of press; start introducing it smoothly into the yoke. 4. The lower clamp touches the yoke, and then slides up gradually and ultimately comes 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 by 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. 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. METHOD OF USING THE ASSEMBLY FIXTURE FOR CENTERING DEVICE 1. Place the Tee Head Bolt on the Guide Pin ensure that the center of the Bolt is on the center 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 and 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 Centering Pin and tighten the nut on Bolt. 5. Release the pressure and then remove the assembly. PART LIST OF ESCORTS SEMI PERMANENT COUPLER & RECOMMENDED PERCENTAGE HOLDING FOR POH LIST OF DEVICES, FIXTURES AND STANDARD TOOLS REQUIRED FOR OVERHAULING OF SEMI-PERMANENT COUPLER SPANNERS 11-13 mm, 18-19 mm, 22-24 mm,30-32 mm,34-36 mm HAMMER Approx. 1 kg. SCREW DRIVER HAND PRESS BENCH-VICE ALLEN KEYS 6 mm, 32 mm Fixtures 1. Fixture for pressing the draw & buff gear 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)

CHECK SHEET FOR SUB ASSEMBLIES & COMPONENTS OF SEMI PERMANENT COUPLER S.No Description Drawing No Inspection Gauge No Instructions

1 2

Bolt Cup Sleeve (upper and lower)

40.586.06.03(4) SK 765 13.128.15 (03) SK 767 & 40.586.06.01(4) 40.586.06.02 (4) SK-758

40.SK.2551.1 (4) SK-757 40.SK.2551.01

Reject the bolt if gauge passes dia 30. Check the profile of cup sleeves by applying the paint on the counter as shown in the drawing 40.SK.2551.01. If the paint is touching more than the place reject the cup sleeve.

Front plate (sub-assy)

40.SK.2551.5 (4) 40.SK.2551.6 (4)

a) Check straightness of the front plate if found bent reject it. b) Reject the plate if gauge passes dia 138. c) If gauge passed dia 37.5, 138 & 22. d) Check the condition of threads. If found worn out reject the plate.

4 5

Rear plate (sub-assy) Yoke (sub-assy)

40.586.06.03 (4) SK-781 40.586.06.4 (4)

40.SK.2551.7 (4) 40.SK.2551.8 (3)

a) Check the straightness of the plate, if found bent reject it. b) If gauge passes dia 30 reject it. a) Check the internal dia if gauge passes dia 138 and 47 reject it the gauge. b) If the internal distance 249.5 increases to 252 reject it the yoke.

Rubber Spring Plate consists of 6 rubber spring and 7 steel plate.

40.SK.1837 (1) SK343 SK-242

RCF 601

a) The length of the unstressed spring should not go below 216.8 mm. In case the distance found less replace the 1 or 2 rubber spring plate. b) Check the condition of the rubber, if found deformed reject it.

Bearing bracket (subassy). Ferrozell bush (upper) Ferrozel bush (lower)

40.58.07 (3) 40.588.07.03 40.SK.2551.10(4) (4) SK-797 40.524.07.4 (4) SK-790 -do - do -

Check the internal dia 80 with the gauge and reject the component, if gauge passes.

Carrier (sub-assy) a) Leaf Spring complete

40.52407.03(4) SK312

40.SK.2551.11

Check the internal dia 32 if gauge passes

reject the component. b)

802 (40.524.07.06(3) SK- - do -

Check the area where leaf spring touches the slide plate, if the thickness of plate found to be worn out more than 2 mm reject the leaf spring.

Slide Plate

40.524.07.4(4) SK-800 -

The thickness of 10 mm hylam sheet is to be checked by means of vernier caliper. In case wear exceed more than 3 mm reject the

slide plate. 10 Bearing bolt 40.586.07.03(3) SK-341 40.SK.2551.12(4) a) Check the external dia 80 if gauge passes reject the bolt. b) Check the greasing passage after removing the grease nipple. If passage are clogged clean the same using the wire rod and kerosene. c) Check the condition of nipple if found defective replace it. d) Check the condition of threads and shank if found deformed reject the bearing bolt. 11 Allen screw 42x300 40.586.06. (2) SK-336 SK.338 a) Check the condition of shank and threads if found deformed or damage reject the screw. b) If gauge passes dia 42 reject the screw. 12 Articulation bearing 40.SK.1960 (3) SK- 770 40.SK.2551.9 (4) a) Check the condition of ball and outer race if any abnormality or cracks noticed reject the bearing. b) If gauge passes dia 80 reject the bearing. 13 Pair of cup sleeve 40.317.17.1.(3) SK-787 40.SK.2551 (2) Check the profile of cup sleeves by applying the paint on the counter as shown in the drawing 40.SK.2551.01. If the paint is touching more than the place reject the cup sleeve. 14 Fork head of centering device 40.1000.10.01(4) SK821 40.SK.2551.6(4) If gauge passes dia 22, replace the bush.

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