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RDSO C-7602: 12/92 Head Stock Repair: 12/10 IRS Specifications Bogie & U/ Gear: EMU Corrosion Repair: EMU Wheel Failure analysis LHB Wheel shelling Steel Rubber Components Schaku Coupler

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Schaku Coupler

Originally designed by M/s Scharfenburgkupplung, GmbH, Germany, Semi-Permanent Couplers are used on the EMU stock of IndianRailways. It consists of following main components;

Sl Component Drawing No ReferenceDrawing No

1 Draw and buff gear SK-752 40.586.06 (2)

2 Bearing bracket withsupport

SK-753 40.588.07(2)

3 Centering device SK-756 40.1000.10(2)

4 Air pipe couplings formain air reservoir pipeand brake pipe

SK-198 [for semi-permanent couplerEnd ‘A’ and End ‘B

5 Intermediate tube SK-754 40.586.01.01(2)

6 Adjustable cup sleeve SK-755 40.317.13(2)

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

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sleeve joint. During the process of manual coupling the air pipeconnections between the two coaches are also establishedautomatically. The pivoted joints between the coupler and the coaches isdesigned and constructed in such a way that even in case of maximumdifference in level, the coaches are capable of negotiating all track curvesand of passing through points of change of gradient occurring duringservice. 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 andtensile load of 70 tons.

2. The dynamic absorption capacity of the rubber draft gear of these couplersis 800 m-kg.

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

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

5. Due to high draft capacity incorporated in semi-permanent couplers, itallows 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 extentthe 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 transverseforces acting on the wheel flanges are kept minimum .This reduces thewear of the wheel flanges and minimizes the chances of derailment.

8. As the coupling links of semi-permanent couplers form a parallelogramwith equilibrium of forces, unintentional disengagement of coaches due toshocks is rendered impossible.

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

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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)]

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Adjustable Cup SleeveAir Pipe Couplingarticulation BearingBearing Bracket with supportCentering Devicecentering DevviceCheck SheetCoupler PhotosDraw & Buff GearFork EyeFront Plate Sub AssemblyIntermediate Tube SubAssemblyLeaf Spring Sub AssemblyLubricationPreventive MaintenanceRear Plate Sub AssemblyRubber Spring PlateSemi-permanent coupler End‘A”Trager Carrier Sub AssemblyYoke Sub Assembly

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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 byturning 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 withoutexpensive 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 theopposite 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).. Theelbows R3/4” and R1” have been provided for establishing permanent connection with the pneumatic pipe lines.

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WeldingWheel

Cast Vs ForgedCast Wheel = 120 KmPHFatigue crack initiationIRS-R-19 of 1993 (Part II)LHB Wheel shellingPreInspection: WheelRail Wheel InteractionRail Wheel Interaction:TunoutsRail Wheel TribilogyRCF:Rolling Contact FatigueResidual Stress in CastWheelsWheel DefectWheel Failure analysisWheel GrazingWheel 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 protectingthe 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 connectionto 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 articulationbearing (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) , therubber 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 astwisting 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 referattached 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 keepthe 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 bearingin 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 spotsare 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 anduncoupling. 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 verticalplane. 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 ensuremaintain 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 everyside 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 springcasing (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 aspring 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, thehexagonal 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 intermediatetube, 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 Description of the Component Type / Brand of Lubricants Periodicity of Lubrication Lubrication spots 1 Adjustable cup sleeve Servogem (RR-3) 6 months I

2 Hole in Centering Carrier - do - 6 months II

3 Bush on Rear Plate - do - POH III

4 Bearing bolt and Articulation Bearing Molykote paste POH & every 6 months in car sheds IV

5 Leaf Spring Servogem (RR-3) 6 months V

6 Front pin of Centering Carrier - do - 6 months VI

7 Spindle of Adjustable cup sleeve- do - 6 months VII

8 Bolt of Adjustable cup sleeve - do - 6 months VIII

9 Pin 31.8 C11 x 200 x 180 (which holds the leaf spring) -do- POH

10 Threaded portion of carrier sub-assy. -do- POH

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 ifany 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 LowerCup 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 pairof 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 abnormalsame should be attended by replacing the cup sleeve.

4 Bearing bracketwith support

a) Check the condition of split pins fitted on the carrier sub-assy. to hold the leaf spring. If split pin found deformed ormissing 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.

5 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.

6 Greasing ofArticulation 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 usedotherwise 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 todrg. 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-SK-2551-7.

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 than252 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 itshould 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). Theslack 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 unstressedspring 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 caselength 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) todrg. 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 andlower 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 LeafSprings 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 loadbearing 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 shouldbe 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 cup-sleeve is not correct, same should be replaced with new one.

15. Allen Screw SK-3361. 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 5-6years 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 absorbsload 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.HEscorts-Semi-permanent Couplers fitted on EMU / DMU / MEMU stock of the Indian Railways are working under sever strenuous conditions. Since these couplersare 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 extremeload 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 onactual 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 condemninggauges (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 openedirrespective 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 toprotect 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 inthe 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 bushes3. Leaf spring complete4. Carrier sub-assy5. 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 removedby 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 steelplates work, as a shock absorber. The major stress bearing components of these sub-assy. are –a) Pair of cup sleevesb) Rubber spring platesc) Allen screw M42x300d) 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 pairof 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 wearagainst 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 causejamming 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 ismore 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 ofthe 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 havedeveloped 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 alltypes of air pipe couplings, rubber sealing rings and rubber tubes must be replaced as and when the couplers are stripped irrespective of their condition. Thesprings should be checked for their strength and any rust formation. They should be replaced, if found defective or rusted or in case physically damaged. Othercomponents 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 openthe 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 allover 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 BUSHPlace 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 polymidebush 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 plateand 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 curtailthe 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 tablegive below –

Spring Part No. Length (L) [mm] Load (min) kg at L Free length (min) [mm]SK-762, Ref. drg. no[13-088.03-14(4)] 29.5 mm(comp.) 10 61

SK-809, Ref. drg. no [40-3000.10-1(4)] 351 60 510SK-808, Ref. drg. no[40-3000.10-2(4)] 351 38 510

LIST OF FIXTURES AND GAUGES

Description Drawing No.i. Fixture for pressing the Articulation bearing RCF 599ii. Assembly fixture for Draw & Buff gear RCF 600, 601iii. Fixture for centering device. RCF 602iv. Condemning gauges for Allen Screw SK. 338Cup Sleeve 40.SK.2551.01 Pair of cup sleeves Bolt 40.SK.2251.02 Bolt 40.SK.2551.1Front plate S.A. (dia 138d) 40.SK.2551.5Front plate & forked head (dia 22h11) 40.SK.2551.6Rear Plate SA (dia 30H11) 40.SK.2551.7Yoke S.A. 40.SK.2551.8Articulation bearing 40.SK.2551.9 Bush (dia 80 B9) [Ferrozal) 40.SK.2551.10Carrier S.A. & Leaf spring 40.SK.2551.11Bearing bolt 40.SK.2551.12

FIXTURE FOR PRESSING ARTICULATION BEARINGMETHOD OF USING THE FIXTURE FOR PRESSING THE ARTICULATION BEARING1. 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).

ASSEMBLY FIXTURE FOR DRAW & BUFF GEAR PROCEDURE1. 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 andpress 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 90º 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 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 DEVICE1. 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 COUPLERSPANNERS 11-13 mm, 18-19 mm, 22-24 mm,30-32 mm,34-36 mmHAMMER Approx. 1 kg.SCREW DRIVERHAND PRESSBENCH-VICEALLEN KEYS 6 mm, 32 mm

Fixtures1. Fixture for pressing the draw & buff gear sub-assy. into the yoke : RCF 6002. GO gauge for draw & buff gear sub-assy. : RCF 6013. Fixture for assembly of centering device & Spring holder : RCF 6024. 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 Bolt 40.586.06.03(4) SK 765 40.SK.2551.1 (4) Reject the bolt if gauge passes dia 30.

2 Cup Sleeve (upper andlower)

13.128.15 (03) SK 767 &40.586.06.01(4)

SK-757 40.SK.2551.01 Check the profile of cup sleeves by applying the paint on the counteras shown in the drawing 40.SK.2551.01. If the paint is touchingmore than the place reject the cup sleeve.

3 Front plate (sub-assy) 40.586.06.02 (4) SK-758 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 Rear plate (sub-assy) 40.586.06.03 (4) SK-781 40.SK.2551.7 (4) a) Check the straightness of the plate, if found bent reject it. b) Ifgauge passes dia 30 reject it.

5 Yoke (sub-assy) 40.586.06.4 (4) 40.SK.2551.8 (3) a) Check the internal dia if gauge passes dia 138 and 47 reject it thegauge. b) If the internal distance 249.5 increases to 252 reject it theyoke.

6 Rubber Spring Plateconsists of 6 rubberspring and 7 steel plate.

40.SK.1837 (1) SK-343 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.

7 Bearing bracket (sub-assy). Ferrozell bush (upper) Ferrozel bush (lower)

40.58.07 (3) 40.588.07.03(4)SK-797 - 40.524.07.4 (4)SK-790

40.SK.2551.10(4)-do - - do -

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

8 Carrier (sub-assy) a) Leaf Spring complete

40.52407.03(4) SK-802 (40.524.07.06(3) SK-312

40.SK.2551.11- do -

Check the internal dia 32 if gauge passes reject the component. b)Check the area where leaf spring touches the slide plate, if thethickness of plate found to be worn out more than 2 mm reject theleaf spring.

9 Slide Plate 40.524.07.4(4) SK-800 - The thickness of 10 mm hylam sheet is to be checked by meansof 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. Ifpassage are clogged clean the same using the wire rod andkerosene. c) Check the condition of nipple if found defective replace it.d) Check the condition of threads and shank if found deformed rejectthe bearing bolt.

11 Allen screw 42x300 40.586.06. (2) SK-336 SK.338 a) Check the condition of shank and threads if found deformedor 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 abnormalityor 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 thecounter as shown in the drawing 40.SK.2551.01. If the paint istouching more than the place reject the cup sleeve.

14 Fork head of centeringdevice

40.1000.10.01(4) SK-821

40.SK.2551.6(4) If gauge passes dia 22, replace the bush.

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