descriptive & maintenance manual for high tensile

SANROK ENTERPRISES

DESCRIPTIVE & MAINTENANCE MANUAL

DMM/AAR-H/PASSENGER/001 REV:-00 VER:-01 DATE OF ISSUE:-18/12/2014

SANROK ENTERPRISES - All Rights Reserved. Any unauthorised printing and publishing will be treated as an offence. Is to be used by the person or group intended at all times

of 62

DESCRIPTIVE & MAINTENANCE MANUAL FOR HIGH TENSILE TIGHTLOCK CENTRE BUFFER COUPLER

AAR-H TYPE HEAD WITH BALANCED DRAFT GEAR FOR FITMENT ON BROAD GAUGE (BG)PASSENGER

COACHES OF INDIAN RAILWAYS As Per RDSO Specification No. RDSO/2011/CG-03 Rev. 01

SANROK DRAWING NO-1.183.00.001C

SANROK ENTERPRISES FARIDABAD

Head Office : E-14, Greater Kailash Enclave-1, New Delhi-110048 Telefax :- +91-11-41731413,

Works/Unit-1: FF-11, SCO-35, Distt. Shopping Centre, Sector -16 Market, Faridabad-121002 (Haryana) Tel: 0129-4071553,4179075, Fax: 0129-4071554

Unit-II : Behind Bharat DharamKanta , Krishna Colony, Ground Floor, Opp. Plot No. 81, Sec-25 Ballabgarh, Faridabad, Haryana, Tel: 0129-4315197

E-mail:[email protected], [email protected], [email protected]

www.sanrok.in

mailto:[email protected]



http://www.sanrok.in/

SANROK ENTERPRISES




of 62

Descriptive & Maintenance Manual Revision Details:

Rev. No. Revision Details Date Approved By Signature

SANROK ENTERPRISES




of 62

Disclaimer

This manual is the property of SANROK ENTERPRISES who claim proprietary rights in the material

disposed. It is issued in confidence for information only and may not be copied or used for

manufacture without specific written permission from SANROK ENTERPRISES.

SANROK ENTERPRISES reserves the right to modify details not effecting strength or application as

may be necessary to facilitate manufacture, ease maintenance or design.

All care has been taken to put the accurate information in this manual, however if any error or

omission is noticed by the user, we would be happy if it is brought to our notice through postal mail

or E- mail.

SANROK ENTERPRISES




of 62

Table of Contents

S.NO Contents Page No. 1 Introduction ofSanrokAAR-H Passenger Coupler 6

1.1 General 6

1.2 AAR-H Passenger Coupler with Balanced Draft Gear Introduction 6

2 AAR-H Passenger Coupler with Balanced Draft Gear Specification 7

3 General Maintenance Process 7

3.1 Cleaning 7

3.2 Touch-Up Painting 7

3.3 Fasteners 8

3.3.1 Tightening Torques 8

3.3.2 Dos and Don’ts For Fasteners 9

3.4 General Safety Precautions 10

4 General Construction Details 11

4.1 High Tensile Tight Lock Centre Buffer Coupler with Balanced Draft Gear

11

4.2 AAR-H Coupler Head Assembly 12

4.3 Balanced Draft Gear Assembly 13

4.4 Vertical Supporting Assembly 14

4.5 Manual Uncoupling Device 15

4.6 Front Support Plate and Rear Support Plate 16

5 Check List for Maintenance Of Coupler 17-19

6 Coupler Head Assembly & Accessories Mounting & Dismounting 20

6.1 Mounting of the Balanced Draft Gear 20

6.2 Mounting of the Coupler Head Assembly 21

6.3 Mounting of the Vertical Support Assembly 22

6.4 Mounting of the Manual Uncoupling Device 23

6.5 Final check of Coupler Installation 24

6.6 Dismounting of Coupler from BG Passenger Coaches 25

6.6.1 Dismounting of Coupler Head Assembly 25-27

7 Coupling and Uncoupling Procedure 27

7.1 General Information 27

7.2 Coupling Procedure 27-28

7.3 Uncoupling Procedure 29

8 Maintenance of the Coupler 30

8.1 Maintenance of Coupler Head 30

8.2 Anti-Creep Check 30-33

8.3 Maintenance and Repair of the Coupler Head 34

8.3.1 Coupler Wing Limit Inspection 35

8.3.2 Vertical Height Aligning Wing Pocket and Guard ARM Gauge 36

SANROK ENTERPRISES




of 62

8.3.3 Vertical Height Condemning Limit Aligning Wing Pocket and Guard ARM Gauge

37

8.3.4 Contour Maintenance Gauge 38

8.3.5 Knuckle Nose Wear and Stretch Limit Gauge 39

8.3.6 Contour Condemning Limit Gauge 40

8.4 Maintenance of the Vertical Support Assembly 41

8.5 Maintenance of the Manual Uncoupling Device 41

8.6 Maintenance of the Balanced Draft Gear Assembly 41

8.7 Maintenance of the Front & Rear Support Plate 41

9 Overhauling & Reconditioning Criteria of the Components of AAR-H Passenger Coupler

42-43

9.1 Spring Condemning Criteria 44

9.2 Reconditioning Procedure of AAR ‘H’ Type Centre Buffer Coupler Head Assembly

44

9.3 Procedure to Increase Coupler Height (Buffer Height) 45

10 Welding Repair Procedure 46

11 Detailed Part List 47

11.1 Detailed Part List for AAR ‘H’ Type Head Passenger Coupler 47

11.2 Detailed Part List for Balanced Draft Gear 48

11.3 Detailed Part List for Vertical Support Assembly 49

11.4 Detailed Part List for Manual Uncoupling Device Assembly 50

11.5 Detailed Part List for Front Support Plate 51

11.6 Detailed Part List for Rear Support Plate 52

12 List of Drawings 53-60

Pages for Note Preparation 61-62

SANROK ENTERPRISES




of 62

1. Introduction:- 1.1 General :-

This document describes the scope of maintenance and service that is necessary in order to maintain the performance and reliability of the AAR-H Type Coupler with Balanced Draft Gear and its accessories. The following schedules and procedures must be properly accomplished for equipment warranty conditions to apply. This scheduled maintenance shall also assist in maintaining product performance over an extended period of time.

1.2 AAR-H Coupler Head with Balanced Draft Gear Introduction:-

SANROK AAR-‘H’ Type High Tensile Tight Lock Centre Buffer Coupler with Balanced Draft Gear is for use on Broad Gauge Passenger Coaches of Indian Railways and conforms to RDSO specification No. RDSO/2011/CG-03 Rev.01. These couplers are used to couple two adjacent Coaches or a Coach to a Locomotive. A coach is fitted with one AAR-H Centre Buffer Coupler at each end. Sanrok AAR-H Passenger Coupler has the provision to couple with AAR-H &E Type Couplers. When a Coach is connected to the Coupler of the Locomotive orCoachit allows the coaches to move and accommodate track curvature and buffer height changes while all the time remaining in coupled condition. The coupling action is automatic; however there is an uncoupling arrangement provided to uncouple the couplersmanually. The AAR ‘H’ Type Coupler Head is provided with Aligning Wings, located at either side of the coupler head. These wings serve to align the couplers into correct relation with other during the coupling operation and maintain this unit relation when couplers are coupled. When completely coupled the knuckles and the front face of the engaging coupler are securely locked and all the Buffing loads are transferred to the Shank of the coupler. When the adjacent coupler is coupled the aligning wings are interlocked in such a manner thatprevents vertical movement of the couplers with respect to each other. This feature ensures the ANTI CLIMBING of the coaches on each other in case of an accident. SANROK couplers with AAR ‘H’ type head can be coupled with similar couplers of other makes and also couplers with E type head as the head profile follows the APTA SS-M-002-98-S -168.

SANROK ENTERPRISES




of 62

2. AAR-H Coupler with Balanced Draft Gear Specifications:- S.No Description Detail

01 Coupling Length from the pivot point , mm 1030±5

02 Strength of Coupler Head and Balanced Draft Gear (Tensile), Tonnes

150

03 Strength of Coupler Head and Balanced Draft Gear (Compression), Tonnes

200

04 Bending Strength of Coupler Head, Tonnes 50

05 Horizontal Swing , (o) 18

06 Vertical Swing (o) 3-5

07 Vertical gathering range , mm 90

08 Horizontal gathering range , mm 110

09 Casting material AAR-M 201 Gr ‘E’

3. General Maintenance Process:-

3.1 Cleaning:-

Make sure that the Coupler, Balanced Draft Gear, Connecting Pin, Vertical Support

Assembly and Manual Uncoupling Device is thoroughly cleaned and free from any

foreign matter before sending the Coaches for service.

It is important that the Coupler, Balanced Draft Gear, Connecting Pin, Vertical Support

Assembly and Manual Uncoupling Device are kept clean from dirt &foreign matter in

order to reduce the risk for operational malfunctions.

3.2 Touch-up Painting:-

Damaged painted areas on the Coupler Head Assembly, Balanced Draft Gear, Front

Support Plate, Rear Support Plate, Vertical Support Assembly and Manual Uncoupling

Device assembly must be repainted to prevent further deterioration. The damaged part

is painted with following during manufacturing:

Primer

Primer: Universal Primer (Red Oxide)

Top Coat

Top coat: Black Enamel

Technical data and specifications for primer and top coat according to paint supplier’s

data sheet

NOTE! Always read and follow instructions on warning label on cans.

Damages that may have occurred during assembly or in traffic should be retouched.

NOTE! Balanced Draft Gear Pads, Separating Plates, Springs, Threads, Coupler Head

Front Face, Knuckle, Lock, Rotary Lock Lift Assy., outer dia. Of Knuckle Pin, Connecting

Pin and grounding connections shall not be painted.

The following surfaces are only painted with primer:-

Inside of socket joints

Flanges for socket joints

SANROK ENTERPRISES




of 62

3.3 Fasteners:-

When assembling/mounting parts on AAR-H Coupler Head Assy., Balanced Draft Gear

And their Accessories always use new fasteners, such as screws, nuts, washers, securing

plates etc. Make sure and confirm with the Parts List – that all fasteners are of the same

dimension and quality as specified in Part List of this Manual. Tighten screws to correct

torque (if not specified, follow the screw suppliers recommendations). Recommended

tightening torques are listed below. At least 4 full threads shall remain clear between the

bearing surface of the nut and unthreaded part of the shank (This means that at least 4

threads shall extend into the members being joined by the bolt).

3.3.1 Tightening Torques:-

In the table below the tightening torques (± 5%) for lubricated fasteners are listed.

Always lubricate with Molykote 1000 or equivalent, Loctite should be applied. These

tightening torques applied for all fasteners unless otherwise specified within the

instructions.

Bolt Size (Metric)

Pitch (mm)

Tightening Torque (Nm)

Grade 4.6 Grade 6.8 Grade 8.8 Grade 10.9 Grade 12.9

M3 0.5 0.51 1.01 1.35 1.90 2.27

M4 0.7 0.95 1.91 2.54 3.57 4.29

M5 0.8 2.28 4.56 6.09 8.56 10.3

M6 1.0 3.92 7.85 10.5 14.7 17.7

M8 1.25 9.48 18.9 25.3 35.5 42.7

M10 1.5 19.1 38.1 50.9 71.5 86.8

M12 1.75 32.6 65.1 86.9 122 146

M14 2.0 51.9 104 139 195 234

M16 2.0 79.9 160 213 299 359

M18 2.5 110 220 293 413 495

M20 2.5 156 312 416 585 702

M22 2.5 211 422 563 792 950

M24 3.0 270 539 719 1010 1213

M27 3.0 398 795 1060 1490 1789

M30 3.5 540 1080 1440 2025 2430

TABLE-1

SANROK ENTERPRISES




of 62

3.3.2 Dos and Don’ts for Fasteners:-

DOs:-

Do make sure that there is proper storage arrangement for the bolts, nuts and

washers away from moisture, rain, dust, dirt and sunlight.

Do clean and lubricate the bolt and nut threads if these are dirty.

Do ensure that the nut moves freely on the bolt threads.

Do use only calibrated torque wrench (Calibrated within last 1 year).

Do proper checking of the bolts after initial tightening and after second stage

tightening.

Do check the tightening procedure if bolt breaks during tightening operation. It

obviously means that the bolts are being over-tightened.

Do provide small welding tack after final tightening and inspection to damage the

threads to prevent the bolt from being opened where threat of sabotage/ theft is

apprehended.

DON’Ts:-

Don’t use rusted, damaged and dirty bolts.

Don’t hammer the bolts to damage the threads.

Don’t overheat the bolt while making welding tack as the bolt might get damaged.

Don’t use Direct Tension Indicators which have not been calibrated.

SANROK ENTERPRISES




of 62

3.4 General Safety Precautions:-

WARNING: The use of solvents as cleaning agents and the use of lubricants can involve health and/or safety hazards. The manufacturers of the solvents and lubricants should be contacted for safety data. The recommended precautions and procedures of the manufacturers should be followed.

CAUTION: When using an air jet do not direct it toward another person. Improper use of air jet could result in bodily injury.

CAUTION: Personal eye protection must be worn when undertaking work. This is especially important during disassembly of the buffer as loose parts and springs may fly out.

It is always recommended to use the genuine spare parts available from SANROK ENTERPRISES, FARIDABAD, to ensure best life and performance of the AAR-H Type Centre Buffer Passenger Coupler.

The Coupler and its accessories are heavy and care should be exercised while

handling, by using designated material handling equipment to avoid injury to self.

SANROK ENTERPRISES




of 62

4. General Construction Detail:-

4.1 High Tensile Tight Lock Centre Buffer Coupler with Balanced Draft Gear:- Coupler arrangement on the coaches is according to drawing attached in this manual at

clause 12.0. It consists of 6(six) major parts:-

a. Coupler Head Assembly to Sanrok Drawing No-1ED-1013

b. Balanced Draft Gear Assembly to Sanrok Drawing No-1ED-1014

c. Vertical Support Assembly to Sanrok Drawing No-1ED-1015

d. Manual Uncoupling Device to Sanrok Drawing No-1ED-1017

e. Front Support Plate to Sanrok Drawing No-1ED-1018

f. Rear Support Plate to Sanrok Drawing No-1ED-1019

Fig.1 Assembled View of AAR-H Passenger Coupler

SANROK ENTERPRISES




of 62

4.2 AAR-H Coupler Head Assembly:-

Coupler head is a standard AAR “H” type tight lock centre buffer coupler head with an

uncoupling device that can be operated from outside the track when connected to the

manual uncoupling device which is also part of the Couplersupply. Coupler parts are

manufactured out of high strength steel casting to AAR-M 201 Gr-E. Parts like Rotary

lock lift, Knuckle Thrower, knuckle, Toggle, lock, are assembled in the coupler head to

enable coupling and uncoupling. The contour of the coupler head is to APTA SS-M-002-

98 S-166 & 168.

Fig.2 AAR-H Coupler Head Assembly

SANROK ENTERPRISES




of 62

4.3 Balanced Draft Gear Assembly:-

The Balanced Draft Gear is a universal device for energy absorption in both draw and

buff mode during coupling and service.

Balanced Draft Gear Major Load Bearing parts are made of High Tensile material, and

have two sets of Polymer springs fitted in series inside the housing. This arrangement

provides balanced preloads within the housing. It is suitable to be fitted into UIC pocket

of 510 mm. The housing is fastened into the pocket with the help of the wedge

arrangement, which virtually makes the housing an integral part of the under frame.

This unique feature allows only the spring column assembly to compress during buffing

loads, thus allowing a smooth longitudinal ride.

The Fork Head is provided with a wear plate to avoid wear of the under frame during

buff& draw movement of the fork assembly of the draft gear. The stroke in tensile

(draw) mode is limited to 58mm while that in compression (buff) mode is 80mm.

Fig.3 Balanced Draft Gear Assembly

SANROK ENTERPRISES




of 62

4.4 Vertical Support Device Assembly:-

The Vertical Support assembly is to maintain position of Coupler Head from Rail Level.

The support device comprises of four preloaded compression springs. This device is

mounted to the Coach structure. The coupler head shank rests on top of the wear plate

of Vertical support device and this device supports the coupler weight. It allows the

Coupler to maintain the standard buffer height of 1105 mm and also negotiate the

vertical angular swing of 5 to 7 0..The Base Assembly of the Vertical Support Device

assembly is mounted on the end wall thru M20 bolts. The Housing houses 4(four) helical

coil springs placed in parallel. This allows the desired deflection during service. The rest

plate is fitted with a wear plate, to avoid access wear on the coupler shank and the rest

plate.

Fig.4Vertical Support Device Assembly

SANROK ENTERPRISES




of 62

4.5 Manual Uncoupling Device:- Manual uncoupling device consists of 3(three) main parts as shown in figure below. a. Rotary Bar with Handle b. Uncoupling bar c. Locking device

Uncoupling Bar assembled into the rotary bar with handle and forms manual uncoupling device. The manual uncoupling device is mounted on the end wall of coach connecting the uncoupling mechanism on coupler head through the Uncoupling Bar with handle. Rotary Bar is lifted and then rotated in the clockwise direction for uncoupling. After coupling, locking piece should be tightened with special key to prevent unauthorized uncoupling after formation of rake.

Fig.5 Manual Uncoupling Device

SANROK ENTERPRISES




of 62

4.6 Front Support Plate and Rear Support Plate:- Front support and Rear support platesare fastened to the under frame after mounting the draft gear in the UIC pocket of coach. Front support plate has a hole for inserting the central pin. A locking plate is fitted by sliding in between the central pin and Front support plate to prevent central pin from falling off. This arrangement facilitates fitment and removal of coupler head without removing the Front support plate. It is very important to use only M16 bolts with grade 10.9 for fastening the mounting plates. Torque should be: 180-200 Nm. This torque is also to be checked during periodic inspection.

Fig.6Front Support Plate

Fig.7Rear support plate

SANROK ENTERPRISES




of 62

5. CHECK LIST FOR MAINTENANCE OF COUPLER:-

S.No. Description During Journey

2nd and 5 months

1 year 2 years 3 years 6 years Remarks

1 Tight Lock Coupler Head

1.1 Check Tell Tale Recess

Please see point no. 7.2 of this manual fig 16.

1.2 Check wear of Wear Plate

1.3 Check crack in Knuckle, Coupler Head, Lock, Rotary Lock Lift, Toggle and Knuckle Thrower

1.4 Anti-Creep Test

Please see point no. 8.2 of this manual.

1.5 Maintenance and repair of Coupler Head (check with Maintenance Gauges (please see point no. 8.3 of this manual)

Please see point no. 8.3 of this manual.

1.6 Apply grease on Wear Plate

1.7 Apply dry lubricant

1.8 Check Knuckle Pin and Support Pin (for Knuckle Pin) for Wear, Crack and Damage

2. Balanced Draft Gear Assembly

2.1 Check Elastomeric Pads

2.2 Check Crack in Front Fork, Rear Plate, Separating Plates and Draft Gear Housing

SANROK ENTERPRISES




of 62

2.3 Check Wear of Front Wear Plate (for Front Fork) and Support Plate( for Middle Plate of Housing)

2.4 Check Fasteners Torque

Please see point no. 3.3.1 of this manual.

3. Vertical Support Assembly

3.1 Check Springs for damage, preload and crack

3.2 Check wear of Wear Plate



3.4 Apply Grease on Wear Plate

4. Manual Uncoupling Device

4.1 Check for bend, crack and damage of Uncoupling Bar and Rotary Bar with Handle



4.3 Check Support and Mounting Brackets for crack and damage

4.4 Apply Grease on Uncoupling Bar and Rotary Bar with Handle

SANROK ENTERPRISES




of 62

4.5 Check Locking Piece Assy. for locking operation.

5. Front carrier plate

5.1 Check for Bend, Crack and Damage of plate



6. Rear carrier plate

6.1 Check for Bend, Crack and Damage plate



SANROK ENTERPRISES




of 62

6. COUPLER MOUNTING & DISMOUNTING PROCEDURES:- The Coupler parts delivered are ready for mounting to the vehicle under frame. Mounting procedure/sequence to be followed for installation of Coupler on the vehicle described below. For lifting Coupler parts a special hydraulic lifting bench is to be used.

6.1 Mounting of Balanced Draft Gear Assembly :- Apply adequate grease on all bearing surfaces of Draft Gear and in the Draft Gear

pocket before mounting the Draft Gear.

The Draft Gear is to be lifted from underneath the car into the Draft Gear pocket by means of special hydraulic lifting bench.

Insert Balanced Draft Gear in coach pocket of 510mm by keeping Balanced Draft Gear’swear plates facing bottom side and holding the wedge assembly with housing by hand. After inserting the Balanced Draft Gear in the pocket, tighten the special bolt of wedge block at the back of balanced draft gear at the torque of 340Nm to make them sit tight between the front and rear stopper plates. (Ensure tightening torque).

The Rear Support Plate is fastened using 10(Ten) Hex bolts M16 – Grade 10.9.

Use of Loctite as a thread locking agent is recommended.

Fig.8

Note: - * Parts shown are only for representation/Explanation purpose and are not in Sanrok Enterprises Scope

SANROK ENTERPRISES




of 62

6.2 Mounting of Coupler Head Assembly:- The coupler head has to be inserted into the draft gear from front end of BG passenger

coaches to connect the coupler head linkage to the draft gear by means of the connecting pin as shown in fig.9.

After inserting Coupler Head Assembly, secure the Connecting Pin with the help of Front Support Plate.

Front Support Plate is secured by 6(Six) M16 Hex bolt/Nut.

Fig.9 `

SANROK ENTERPRISES




of 62

6.3 Mounting of the Supporting Device:- Holding the coupler head in lifted position (above horizontal), the supporting device is

to be mounted below the coupler head shank before letting the coupler head to rest on the supporting device.

The supporting device is then fastened using four bolts M20 – Grade 10.9.

Use of Loctite as thread locking agent is recommended.

Apply grease on the wear plate of supporting device.

Fig.10

SANROK ENTERPRISES




of 62

6.4 Mounting of the Manual Uncoupling Device:- To complete the coupler mounting, manual uncoupling device has to be fitted.

Mounting brackets are to be fastened/welded on the Coach structure.

Support Brackets Two Type has to be fastened to these mounting brackets by means of M16 Bolts/Nut.

Uncoupling Bar has to be connected to the coupler head Rotary Lock Lift, before fastening the device to Support bracket.

Use of Loctite and tightening with adequate torque (for M16, 180-200 Nm and for M12, 60-80 Nm) is recommended and this torque is also to be checked during periodic inspection.

Check Uncoupling operation by lifting and turning handle of the device clockwise.

After coupling, locking piece should be tightened with special key to prevent unauthorized uncoupling after formation of rake.

Fig.11

SANROK ENTERPRISES




of 62

6.5 Final check of Coupler installation:- After completion of coupler installation the following functional checks are to be executed:

Proper fastening and securing of all bolt connections to recommended torque.

Free movement of the coupler head in horizontal and vertical direction.(See Fig.12 Below)

Free movement of the Rotary Bar with Handle of the manual uncoupling device.

Coupling and uncoupling operation. (Described in Point6)

Fig.12

SANROK ENTERPRISES




of 62

6.6 Dismounting of Coupler from BG Passenger Coaches:- 6.6.1 Dismounting Coupler Head Assembly:-

Remove Uncoupling Bar and Rotary Bar with Handle from the rotary lock lift device of coupler head and support brackets fitted on Coach.(As shown in fig.13)

Dismount Vertical Support Assembly from coach.

Dismount Front Support Plate andConnecting Pin as shown in fig.14

Remove the Connecting pin.

Fig.13

SANROK ENTERPRISES




of 62

Fig.14

Fig.15

SANROK ENTERPRISES




of 62

Remove Coupler Head Assy. from draft Gear. (Support Coupler Head Assy. with the help of overhang crane or Fork Lift during dismantling of coupler head assembly from draft gear.

Do not let coupler head assembly and Balanced Draft Gear fall from height in any case, this may cause damage the parts of coupler head assembly and Balanced Draft Gear.

7. COUPLING AND UNCOUPLING PROCEDURE:- 7.1 General Information:-

During coupling and uncoupling, care should be taken that no person stands between the vehicles. Coupling is automatic. For uncoupling - unlock, lift and rotate manually the handle of manual uncoupling device in a clockwise direction.

7.2 Coupling Procedure:-

The coupling procedure is described as follows: The handle of Manual Uncoupling Assy. must be in the bottom position to couple the

coupler.

Bring the vehicles near to each other at a slow speed (approx. 2-3 km/h) and stop the vehicles at approximately 1 meter distance of each other.

Check alignment and position of coupler centre. Couplers must be within the gathering range as given in Clause No 2 of this manual.

Check position of tell-tale device for proper coupling (location of the tell-tale is shown inFig16 below). When properly locked, the tell-tale recess in the lock lift assembly is visible below the coupler. If the tell-tale recess is visible with mated couplers, the couplers are properly locked

Fig.16

Make sure, that the handle of manual uncoupling device is locked after coupling.

SANROK ENTERPRISES




of 62

NOTE:- Coupling cannot be done when both the knuckles are closed.

Coupling can only be done when, Two Knuckles are in open condition or One knuckle in open condition and other one in closed condition or vice versa

Fig.17

Fig.18

Fig.19

After coupling, reverse the power to pull (snatch) the vehicles apart. This is a typical pull test to reconfirm a positive coupling.

SANROK ENTERPRISES




of 62

7.3 Uncoupling Procedure:- For uncoupling use the manual uncoupling device provided, Rotary Bar with Handle of

this device is accessible from the trackside.

Unlock the handle by untightening the locking screw with the special key.

Lift and turn the handle in clockwise direction and pull the coach apart. Lifting the handle disengage the Coupler Lock that actuates Knuckle Thrower to pivot the Knuckle to the open position.

Note:- Before uncoupling make sure that the couplers are not subjected to any load and the

Rotary Bar is free to Rotate.

SANROK ENTERPRISES




of 62

8. MAINTENANCE OF THE COUPLER:- The coupler needs overhauling at an interval 6 years of service. 8.1 Maintenance of the Coupler Head:-

The maintenance of the coupler head in general is described in the AAR manual “Standard for Periodic Inspection and Maintenance of Passenger Coaches APTA M-002-98”

CAUTION: Under no circumstances lubricate the lock, lock lift lever or knuckle locking faces as this will allow the lock to be “squeezed” upwards and may lead to uncoupling! 8.2 Anti-creep check:-

Determine anti-creep protection and ensure it complies with specifications.

Step 1: Inspection for anti-creep protection is made through the front of the coupler. To have effective protection „A‟ is to be 1/8” or more.

Fig.20 Step-1

SANROK ENTERPRISES




of 62

Step 2: With the coupler in the locked position insert a pry bar through the front of the coupler between the knuckle tail shelf and lock, forcing lock upward as in fig.3.

Fig.21Step-2

Step 3: Forcing the lock upward as far as it will go engages the top of the toggle with the bottom of the knuckle tail shelf.

Fig.22Step-3

SANROK ENTERPRISES




of 62

Step 4: with the lock held up by the pry bar and the toggle engaged with the knuckle tail shelf, insert a flat bar or screw driver between the leg of lock and front of lock hole. Pull toward the front of coupler, to force lock leg rearward.

Fig.23Step-4

Step 5: If the front edge of the toggle is 1/8” or more forward of the rear corner of

the knuckle tail shelf the anti-creep protection is unsatisfactory, and should be corrected by substituting a new lock lift assembly.

Fig.24Step-5

SANROK ENTERPRISES




of 62

Step 6: If actual measurement is desired, inscribe a line on top of toggle along the rear face of the knuckle tail shelf and measure at point “C”, the measurement must not be less than 3/8”.

Fig.25Step-6

SANROK ENTERPRISES




of 62

8.3 Maintenance and repair of the Coupler Head:- In addition to the above, the following recommended maintenance gauges are to be used during regular inspection, maintenance and repair.

S. No Gauge No

Gauge Detail Gauge ID

01 31000 Contour Maintenance gauge 071906-36

02 32600 Aligning Wing Limit gauge 091410-64

03 34101-4 Guard Arm 092210-60

04 44250-5 Vertical height Aligning Wing Pocket and Guard Arm gauge

092210-61

05 34100-1 AAR Contour Condemning limit Gauge 091410-53

06 34100-2A Knuckle Nose Wear and Stretch limit Gauge

031806-68

Fig.26

SANROK ENTERPRISES




of 62

8.3.1 Coupler Wing Limit Inspection:- The aligning wing limit gauge No. 32600 is used to inspect for excessive distortion of aligning and /or guard arm of the coupler head as shown in fig below. The gauge must seat against the front face of the coupler head and the pivot lug. If the gauge does not seat or clear at the proper locations, there is excessive wear to the front face and pivot lug.

Fig.27

SANROK ENTERPRISES




of 62

8.3.2 Vertical Height Aligning Wing Pocket and Guard Arm Gauge:- The vertical height aligning wing pocket and guard arm Gauge No-34101-4 is used to inspect for excessive distortion and vertical height of aligning wing and/or guard arm of the coupler head, as shown below. The gauge must pass (slide into) the wing pocket and over the guard arm. If the gauge does not pass (slide into), there is vertical distortion to the wing pocket and/or guard arm.

Fig.28

SANROK ENTERPRISES




of 62

8.3.3 Vertical Height Condemning Limit Aligning Wing Pocket and Guard ARM Gauge:-

The vertical height condemning limit aligning wing pocket and guard arm gauge No. 44250-5, as shown below is used to check for wear of aligning wing and guard arm. The gauge must not pass into the wing pocket or over the guard arm. If the gauge does not pass, there is excessive wear to the interlocking surfaces of the wing pocket and/or guard arm.

Fig.29

SANROK ENTERPRISES




of 62

8.3.4 Contour Maintenance Gauge:-

The contour maintenance gauge 31000 is used to inspect for correctness of contour as shown below. The gauge must pass through the contour with the knuckle fully closed and locked, with the gauge seated against the front face of the coupler head. If the gauge does not seat against the front face of the coupler, there is an excessive wear to the front face of the coupler or a stretched knuckle. Remove and inspect the knuckle, using the Knuckle Nose Wear and stretch Limit Gauge No. 34100-2A.

Fig.30

SANROK ENTERPRISES




of 62

8.3.5 Knuckle Nose Wear and Stretch Limit Gauge:- The knuckle Nose Wear and Stretch Limit Gauge no. 34100-2A is shown in fig. below. Verify that the points A, B and C of the gauge seat on the knuckle and point D does not touch or clear more than ¼”. If the points do not touch or clear properly, replace the knuckle.

Fig.31

SANROK ENTERPRISES




of 62

8.3.6 Contour Condemning Limit Gauge:- The Contour Condemning Limit Gauge no. 34100-1 is used to inspect limit of contour slack (Limit has been set at 3/8”). Refer fig. below. To inspect the limit of contour slack, close the knuckle and then pull slack of knuckle out toward you. The gauge must not pass between the front face of the coupler head and the pulling face of the knuckle. If the gauge does pass, remove the knuckle and inspect once more for wear. If the knuckle is worn, replace knuckle. While the knuckle is out of the coupler, inspect the knuckle pivot pin and pivot pin hole for excessive wear. If the knuckle pivot pin is worn, replace knuckle pivot pin. If the knuckle, pivot pin and pivot pin hole are in acceptable condition, the lock could be worn and should be replaced. Also, the front face of the coupler could have excessive wear and should be replaced if found.

Fig.32

SANROK ENTERPRISES




of 62

8.4 Maintenance of the Vertical Support Assembly:- Maintenance of supporting device has to be done together with the inspection of the whole coupler. The following actions are needed:

Visually examine the supporting device (every 2 months).

Check the compression springs during the main overhaul (6 years).

Check the thickness of wear plate, if it is worn out by 3mm replace it by new one (Thickness of wear plate in new condition 5 +1mm).

Replace the compression springs in case of mechanical damage and loss of preload.

8.5 Maintenance of the Manual Uncoupling Device:- Maintenance of manual uncoupling device has to be done together with the inspection of the whole coupler. The following actions are needed:

Visually examine the manual uncoupling device and apply grease on uncoupling Bar and Rotary Bar with Handle (every 2 month). Check the function of the uncoupling device by rotatingthe handle in clockwise direction.

Check the wear of the uncoupling bar sliding area during the annual inspection (every year).

8.6 Maintenance of the Balanced Draft Gear Assembly:- Maintenance of Balanced Draft Gear has to be done together with the inspection of the whole coupler. The following actions are needed:

Visually Examine the Draft Gear (Every- 3 months).

Check all parts for cracks and damage.

Apply grease on appropriate locations.

Check Elastomeric pads during main overhaul (6 years) for mechanical damage and pre load.

8.7 Maintenance of Front and Rear Support Plates:- Maintenance of Front & Rear Support Plate has to be done together with the inspection of the whole coupler. The following actions are needed:

Visually examine the plates for any crack, damage (every-2 months)

Check the torque of fasteners.

Apply grease on appropriate locations.

SANROK ENTERPRISES




of 62

9. OVERHAULING AND RECONDITIONING CRITERIA OF THE COMPONENTS OF PASSENGER COUPLER:-

S.No Description Criteria for Determining the Condition Instrument/ Fixture / Gauge Required

A Coupler Head Assy.

01 Coupler Head& Knuckle

Check for wear, Crack and Damage, Replace by new one if found damaged.

Visually

NDT (Ultrasonic testing, Die penetrant test etc.)

02 Check Knuckle Wear Check with Condemning limit gauge (please see point No. 8.3.5of this manual.

Knuckle Nose Wear & Stretch Limit Gauge-34100-2 & 34100-1

03 Check Coupler Head Profile

Check with aligning limit gauge (Please see point no.8.3 of this manual)

Aligning wing limit gauge No. 32600

04 Check Coupler Head guard arm cone and pocket

Check with vertical height aligning wing pocket guard arm gauge. (Please see point No.8.3 of this manual)

Vertical Height Aligning wing pocket and Guard Arm Gauge No. 34101-4& 44250-5

05 Check Knuckle & Coupler Contour

Check Knuckle and Coupler Contour as specified in point No. 8.3 of this manual

Contour Maintenance Gauge No. 31000-1

06 Split Pins and Washers

If found damaged then replace by new one

Visually

07 Support Pin (for Knuckle Pivot Pin) and Knuckle Pivot Pin

To be replaced if any bend, damage and wear is observed.

Visually


08 Check Rotary Lock lift and Toggle

Check with Anti creep testas mention in point no. 8.2 of this manual, replace if it did not pass the test Check for wear, crack and damage, replace by new one if found damaged.

Visually


09 Check Wear Plate Check the thickness of wear plate, if it is worn out by 3mm replace it by new one (Thickness of wear plate in new condition 5 +1mm).

Vernier Calliper

10 Check Lock If any damage or crack is observed, replace by new one.

Visually


110 Check Knuckle Thrower

Check for function, wear, damage or crack, if not working correctly or found damaged replaced by new one.

Visually


SANROK ENTERPRISES




of 62

12 Articulated Spheroelastic Rubber Bearing

Check forcrack and damage, replace by new one if found damaged.

Visually

B Balanced Draft Gear

01 Check Front Fork and Housing

Check for wear, crack and damage, replace by new one if found damaged.

Visually


02 Check Elastomeric Pads

Check for damage

Check preload

Check compression (Buff) and tensile (Draw) stroke

250 T Hydraulic 4 Pillar Vertical/Horizontal with 1.5 m daylight.

Mounting Fixture

C Manual Uncoupling Device

01 Uncoupling Bar and Rotary Bar with Handle


Visually


02 Mounting and Support Brackets


Visually


03 Locking Piece Must be fully functional, if any bend, damage is observedreplaces it by new one.

Visually

D Vertical Support Assy.

01 Check Wear Plate Check the thickness of wear plate, if it is worn outreplaced by new one

Vernier Calliper

02 Check Compression Springs (3 Nos.)

Check for damage, rust and preload. replace by new one if found damaged

Universal Test Machine

03 Base Assy. and Rest Plate Assy.


Visually

E Rear Support Plate Check for wear, crack and damage, replace by new one if found damaged.

Visually


F FrontSupport Plate Check for wear, crack and damage, replace by new one if found damaged.

Visually


G Mounting Fasteners If found damaged replace by new one Visually


Table-2

SANROK ENTERPRISES




of 62

9.1 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 Drawing No. Assembled Length (L) mm Load (min) kg at L Free Length (min) mm

1ED-1165 123 (comp.) 236 170

Table-3

9.2 Reconditioning Procedure of AAR ‘H’ Type Centre Buffer Coupler Head Assembly

The following procedures should be adopted while carrying out the Coupler Head

Reconditioning:-

1 Disassemble the Coupler Head Assembly from Coach as specified in point 6.6 of

this manual.

2 Mount the coupler head Assembly on a Station/Workbench, which can take load

of 600 Kg Min.

3 Mount the coupler head assembly in such a way that the knuckle faces you and it

must be to your left hand side.

4 Clean all parts with Air and Emery Paper and ensure that parts are free from dirt,

paint, rust and scale which may interfere with gauging and inspection.

5 Check coupler head assembly for cracks, fractures, worn out surfaces, distortion

and service notches.

Use Die Penetrant Test and Magnetic Particle Inspection to inspect Coupler

Head Assembly for cracks.

6 Check the thickness of wear plate, if wear is more than 3mm replace the wear

plate. Follow welding procedure mentioned in point 10 of this manual to weld

wear plate.

7 Coupler with shank bent may be reconditioned provided:-

No cracks have developed as a result of bending

Measure amount of bend by using flat scale, and this should not exceed 1”

per feet of shank length.

8 Straightening of bent shank can be done by heating region of the bend at a

temperature between 816°C to 871°C.

9 After straightening carefully examine the coupler head to make sure that no crack

has developed from repair.

10 After reconditioning check the coupler head assembly with AAR-H Gauges as

mentioned in point 8.3 of this manual.

SANROK ENTERPRISES




of 62

9.3 Procedure to Increase Coupler Height (Buffer Height):-

I. Before readjusting the Coupler Head height the head of the Coupler should be

supported by using a Jack, Trolley or Overhang Crane.

II. Coupler should be raised to the required height with the help of jack or over

hang crane.

III. Clean the dirt/smudge from the wear plate of coupler head and Vertical

Support Assy.

IV. Measure the gap between wear plates.

V. Select a combination of shims which equal the gap measured.

VI. Weld the shims on the wear plate. Follow welding procedure on point No.10 of

this manual.

VII. Untighten The Allen Bolts of Vertical Support Assembly and lift the spring

upwards with the help of pry bar.

VIII. Lower the Coupler Head Assy. so that Coupler shank sits on Vertical Support

Assy.

IX. Tighten the Allen bolts of the Vertical Support Assembly.

SANROK ENTERPRISES




of 62

10. Welding Repair Procedure:-

Welders shall be qualified and use procedures under the welder qualification procedure

contained in ASTM A488, Latest Revision or equivalent, in the position welding is to be

performed. Welder must wear following safety instruments during welding:

I. Welding Apron

II. Nose Mask

III. Welding Gloves

IV. Safety Shoes

V. Welding Shield

The entire defect must be removed prior to weld repair.

The area to be welded must have the sides contoured to provide for the application of a

sound weld.

Maximum depth of repaired area must be at least 1/8” sound metal remaining between the

bottom of the weld groove and the opposite side of the casting wall in areas where welding

cannot be accomplished from both sides of the casting wall.

Where a defect continues through the casting wall and both sides of the wall are accessible

for welding, the casting shall be welded from both sides using a double “V” or a “U” contour

weld.

Where defect continues through the casting and is not visible from both sides and unless

prohibited by specific component specification, defect may be weld repaired by using a

copper backup plate provided the surface is smooth and clean.

Defects may be repaired by using a metal-electrode arc welding process which will result in

sound weld deposit having, in the heat treated condition, minimum mechanical properties

equal to the requirements for the parent metal. Post weld heat treatment requirements are

outlined in the product specification for the component involved.

Castings shall not be welded while the temperature of the casting is below 4.4°C. Localized

pre-heating is acceptable.

The welding material used for the repair of defects in grade E steel castings shall be

AWS/ASTM Class electrode E12015, E12016, E12018, E13015, E13016, E13018 or equivalent.

Preheated the electrode in the oven for 1 hr at 350 °C. Hold the baked electrodes at 100 °C

before welding.

Pre heat the wear plate (Coupler head assy. And vertical support assy.) to a temperature of

400°C-450°C before welding.

Ensure that the surface area where welding is required must be free from dust, grease, oil

and any foreign particles.

Post weld treatment: After welding, remove the spatters and slag, before subjecting to stress relieving. Heat the

welded region locally by flame torch to 600 – 650 °C & allow the body to cool to room

temperature by slow cooling by covering the heated surface zone with ceramic wool.

SANROK ENTERPRISES




of 62

11 Detailed Part List

11.1 Detailed Part List for AAR-H Type Head Passenger Coupler Head:-

Fig.33

Item No. Part Name Drawing No. No. Off

01 AAR-H Coupler Main Body 1ED-1065 01

02 Knuckle 1ED-1067 01

03 Lock 1ED-1069 01

04 Toggle 1ED-1076 01

05 Rotary Lock Lift 1ED-1074 01

06 Knuckle Thrower 1ED-1071 01

07 Wear Plate 1ED-1166 01

08 Rotary Lock Pin 1ED-1149 01

09 Main Pin for Knuckle 1ED-1079 01

10 Articulated Spheroelastic Rubber Bearing 1ED-1023 01

11 Support Pin for Main Pin for Knuckle 1ED-1080 01

12 Split Pin for Main Pin Knuckle Ø7x60 IS:549 01

13 Split Pin Support Pin Ø5x40 IS:549 01

14 Connecting Pin 1ED-1016 01

Table-5

SANROK ENTERPRISES




of 62

11.2 Detailed Part List for Balanced Draft Gear:-

Fig.34


01 FRONT FORK Complete 1ED-1045 01

02 Housing Complete 1ED-1050 01

03 TPE Spring Pad ------------- 07

04 Separating Plate 1ED-1042 07

05 Rear Plate 1ED-1058 01

06 Main Bolt 1ED-1041 01

07 Main Nut 1ED-1059 02

08 Wedge Assy. 1ED-1054 02

09 Hex Head Bolt M20 X 55 Din 933 01

10 Plain Washer Din 1441 01

11 Locking Washer M20 1ED-1147 01

12 Front Wear Plate 1ED-1127 01

13 Hex Socket Head Cap Screw M10 X 25 IS:2269 04

14 Support Plate For Middle Plate Housing 1ED-1167 01

15 Hex Socket Head Cap Screw M12 X 30 IS:2269 02

Table-6

SANROK ENTERPRISES




of 62

11.3 Detailed Part List for Vertical Support Assembly:-

Fig.35


01 Base Assy. 1ED-1108 01

02 Rest Plate Assy. 1ED-1110 01

03 Compression Spring 1ED-1165 04

04 Nylock Nut M20 IS:1364 Part-1 02

05 Allen Bolt M20X130 Gr. 10.9 IS:1364 Part-1 02

06 Conical washer 1ED-1124 02

07 Flat Washer 1ED-1125 02

08 Spring Washer DIN127 02

Table-7

SANROK ENTERPRISES




of 62

11.4 Detailed Part List for Manual Uncoupling Device Assembly:-

Fig.36


01 Support Bracket Inner 1ED-1138 1

02 Support Bracket Outer 1ED-1137 1

03 Rotary Bar With Handle 1ED-1133 1

04 Uncoupling Bar Sub Assy. 1ED-1132 1

05 Locking Piece Sub Assy. 1ED-1134 1

06 Mounting Bracket Inner 1ED-1128 1

07 Mounting Bracket Outer 1ED-1129 1

08 Allen Screw M10 X 20 M10X20 4

09 Hex Head Bolt M16 X 55 M16X40 4

10 Hex Nut M16 M16 4

11 Spring Washer M16 4

12 Hex Socket Head Cap Screw M8 X 30 M8X40 4

Table-8

SANROK ENTERPRISES




of 62

11.5 Detailed Part List for Front Support Plate:-

Fig.37


01 Front Support Plate 1ED-1018 01

02 Hex Head Bolt Gr. 10.9 M16 X 45 IS:1364 Part 1 02

03 Hex Castle Nut M16 IS:1364 Part 1 02

04 Split Pin 5 X 40 IS:549 02


06 Spring Washer M16 IS:1364 Part 1 06

07 Hex Nut M16 IS:1364 Part 1 06

Table-9

SANROK ENTERPRISES




of 62

11.6 Detailed Part List for Rear Support Plate:-

Fig.38


01 Rear Support Plate 1ED-1019 01


03 Spring Washer M16 IS:1364 Part 1 10

04 Hex Nut M16 IS:1364 Part 1 10

Table-10

SANROK ENTERPRISES




of 62

12. LIST OF DRAWINGS:

AAR-H COUPLER WITH BALANCED DRAFT GEAR FOR FITMENT ON BG PASSENGER COACH:

Fig.39

SANROK ENTERPRISES




of 62

AAR-H COUPLER HEAD ASSEMBLY:

Fig.40

SANROK ENTERPRISES




of 62

BALANCED DRAFT GEAR:

Fig.41

SANROK ENTERPRISES




of 62

VERTICAL SUPPORT ASSEMBLY:

Fig.42

SANROK ENTERPRISES




of 62

MANUAL UNCOUPLING ARRANGEMENT:

Fig.43

SANROK ENTERPRISES




of 62

FRONTSUPPORT PLATE:

Fig.44

SANROK ENTERPRISES




of 62

REAR SUPPORT PLATE:

Fig.45

SANROK ENTERPRISES




of 62

CONNECTING PIN:

Fig.46

SANROK ENTERPRISES




of 62

NOTES

descriptive & maintenance manual for high tensile

Documents