DA LWAYS

SPECIFICAno

FOR

SCH FE BE G CO PLERS & D W GEA

OR

ELEC RIC ULTIPLE UNIT RO LING STOCK

FOR

CALCUTTA & BO Y S BURBA SERVICE

BROADG UGE

1676 mm

SP CIFICA ION 0.61- B - 36/ ev.68-1

( Eeo S CTED OVE BER 2004)

ISSUED BY

RESEARCH DESIG S & STA DARDS ORGANISATIONINISTRY OF RAILWAYS

AI< AGAR,Leo -2260

Specification No. 61-B-36/Rev. 68/1

INDIAN RAILWAYSSPECIFICATION FOR SCHARFENBERG COUPLERS AND DRAW GEAR

FORAC I DC EMU STOCK FOR CALCUTTA & BOMBAY SUBURBAN

SERVICESBROAD GAUGE

1 SCOPE:

i) This specification covers the design. manufacture and supply ofScharfenberg Couplers and Draw Gear for 4-car AC or 3-car DCEMU Stock.

ii) The coupling and draw gear arrangement at the outer ends ofeach 4-car/3--car unils shall be SUItable for filbng ofScharfenberg Automatic Coupler that meet the requ~emenls

given ,n Appendix 'A'. These end couplers shall be sunable forcoupling with AC I DC Locomotives provided with screwcoupling & side buffers either by using special Transition Gear(Adopter) or by removing the automatic head and replacing bypot and draw screw.

iii) All intermediate couplers in the 4-car l3-car units shall be of thesemi-permanent type.

iv) The Contractor shall develop a design based on soundengineenng practice and submit general arrangement andwor1<ing drawings and all technical data to concerned railwayorganization or Coach builders and to ROSa I Lucknow forapproval before commencing manufacture.

v) This specification IS Intended to indude everything requisite tothe manufacture of the coupler. notwlthstanding that everythingreqUIred may not be mentioned herein.

2. GENERAL DESIGN FEATURES:

I) The fiXIng of coupler to underlrame shall be by bolts I welding.The IODng arrangement and underframe cutaways shall beIdenhcal for all couplers (end and ,ntermediate).

II) The draft gear housing shan be capable of taking either rubberspnngs or nng springs, and identical spnng packs shall be usedfor both end and intermedIate couplers

IIi) The draft I buffing spnngs shall be of natural or synthehc rubber,avaIlable in India.

iv) The attachment of the draw hook to the draft gear shall bedesigned so that it can be conveniently replaced by automaticScharfenberg heads, without alteration 10 any other part of thecoupler or draft gear.

v) The location of the pivot pin centre line of couplers shall notexceed 707 mm from headstock face, and should preferably bethe same for both end and intermediate couplers.

vi) The distance between the headstocks of adjacent coaches shallbe 800 mm when semi-permanent couplers are fitted, and notless than 964 mm for the end couplers when fitted withautomatic heads.

vii) The semi-permanent couplers shall be provided witharrangement for coupling of brake pipes. If required provisionshould also be made for coupling of electrical cables for which76 electrical contacts should be catered for.

viii) The Air Brake connections shall tuttil the requirements given inAppendix 'B'.

3. MAIN REQUIREMENTS:

i) The couplers shall have a rated draft capacity of not less than34 tonnes and buff capacity not less than 800 mkg. The strokeof Buffing Gear shall be restricted to 75 mm and the SillPressure shalt not exceed 50.000 kg. under buffing impacts of800 mkg intensity.

ii) The couplers shall allow coupled coaches to negotiate curves ofradius 152.4 metres and shall be capable of passage in eitherdirection over standard 1 in BY:! turnouts, and shall functionsatisfactorily with a 75 mm difference in headstock heights ofadjacent coaches.

iii) The couplers shall be tight lock, and shall not develop slack inselVice.

4. TESTS:

The coupler assembly excluding the rubber draft gear shall withstandtensile loads of 70 to.mes and compressive loads of 100 tonnes withoutany permanent deformation and tensile or compressive loads of 150tonnes without fracture.

5. CONTRACTORS' RESPONSIBILITY:

The Contractor shall assist the coach builders in the fitting, testing andcommissioning of these couplers, and shall be responsible for their

satIsfactory worKing, and for any failure due to defective tfesign ormaterials for a period of two years from date of their placement inservice He shall replace, free of cos~ all parts damaged or founddefechve dunng the period of guarantee

The Contractor shall be responsible for the execution of the contractslnctly In accordance WIth the lanns of thIS speClficalJon and theStandard Conditions of Contract as may be applICable

6 INSTRUCTIONAL MANUALS:

The Contractor han supply repair manuals, onslnJclional booklets andspare parts lisl for these couplers.

7 CONTRACT DRAWINGS:

The Iisl of contract drawlClgs for ScIIarfenberg couplers and theirassemblies 's given on Appendix 'C'

*****

APPENDIX 'A' TO SPECIFICATIONNo. 61 - B - 361Rev. 68-1

ADDITIONAL REQUIREMENTS FOR FITMENT OF AUTOMATICSCHARFENBERG COUPlER HEADS

1 The automatic head when fllted shall be generally toScharfenberg Org. 40.6n(O).

2 Automatic coupling heads shall provide for automaticcoupling of brake pipes and have provision for subsequentfitting of automatic electrical contacts.

3. The automatic heads shall be capable of uncoupling throughhand operated lever. This lever shall Qrve a visual indicationof the coupler position and may be set in the open, neutral orclosed position. The lever shall be easily accessible foroperation and shall allow for frtting of pneumallC release fromdrive(s cab at a later date.

4 AutomatIC coupling shall take place satisfactorily whencoaches are brought together at speeds between 1 kmlh and15 kmlh.

5. The gathering range shall be 75 mm. Vertically on eMer Sideand 264 mm horizontally on either side of centre line of thecoupler.

6. It should be possible to couple Scharfenberg automaticheads with standard IRS draw hookS through a transitiongear adaptor Schaku automatic I IRS draw hook whichshould be obtainable on demand.

APPENDIX 'B' TO SPECIFICATIONNo. 61- B - 36/Rev. 68-1

NOTES ON BRAKE REQUIREMENTS FOR AUTOMATIC COUPLERS(WITH AIR CONNECTIONS)

a) Brake pipe connection to be 1" 8.S.P. - wooong pressure 4.922 kglcm2.

b} MalO reservoir connection to be %" B S P - wooong pressure 7 031 kg/enr.

c) Brake pipe 10 be dosed onty at uncoupled ends.

d) Main reservoir pipe to be closed only at uncoupled ends

e) In the event of an unwanted uncoupling between coach the brake pipeconnection on both halves of the traWl must be vented to the atmosphere ThemalO reservoir shoukt preferabty (but not essentialty) seal on both halves of thetrain under these circumstances.

f} Provision must be made on the coup~ adjaCeOt to the Driving Cabs of thecontrol trailers and the motor coach for a comection (112" Of 3/8' 8.S.P.) to thebrake pipe pressure switch.. This connection must be taken from the brake pipecontained wrthin the coupler. Thus the pressure SWttch at both ends of the trainWill be sUbjected to the atmospheric pressure but at all Intermediate points downthe train Will be subjected to brake pipe pressure

g) As there will be relative movement between the coupler and the main frame.flexible hose connections will be required for the brake pipe, the main reservoirpipe and (where fiUed) the pressure swrtch pipe.

APPENDIX 'C' TO SPECIFICATIONNo. 61- B - 36/Rev. 68-1

LIST OF DRAWINGS FOR SCHARFENBERG COUPLERSAND THEIR ASSEMBLIES

1- Semi-permanent Intermediate Coupfer End 'A' 40.586 (0) '-'

a) Rubber Draft Gear 40.586.06 (2) '-

b) Bearing Bracket 40.586.07 (3)

2. Semi-permanent Intermediate Coupler End 'B' 40.587 (0) \

a) Rubber Draft Gear 40.586.06 (2)

b) Bearing Bracket 40.586.07 (3)

3. Fully Automatic CouDler 40.672 (0)

a) Automatic Coupler Head 40.663 (1)

~ Coupler Head 40.640.01 (1)

ii) Air Pipe coupling for majo air reservoir Pipe 40.370.04 (1)

iii) Air Pipe Coupling with valve for brake pipe 40.663.03 (2)assembly

Iv) Stem with Spring Sleeve 40.371.02 (3)

b) Draw & Buff Gear 40.588 (0)5

I) Rubber Draft Gear 40.586.06 (2) '"

ii) Bearing Bracket with support 40.588.07 (2) v

iii) Centering carrier 40.1000.10 (2)