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G 80. inspection and maintenance of centre buffer couplers ( for workshop staff )

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G 80. inspection and maintenance of centre buffer couplers ( for workshop staff )

  1. 1. No.G-80INSPECTION AND MAINTENANCE OF CENTRE BUFFER COUPLERS ( FOR WORKSHOP STAFF ) Issued byRESEARCH AND DESIGNS AND STANDARDS ORGANISATION LUCKNOW
  2. 2. CONTENTS 1. Maintenance Manual for Coupler. Scope Classification Procedure Reconditioned Acceptance Requiremets for Reuse INSTRUCTIONS FOR RECONDITIONING REPAIR PROCEDURES 2. Inspection and Maintenance of Draft Gears (A) HR-40-I & MF-400-I-IR (B) High Capacity Draft Gears, MK.50 & RF-361. 3. Inspection and Maintenance of Clevis, Clevis pin and Screw Coupling. 4. Inspection and Maintenance of Striker Casting and Striker Casting Wear Plate. 5. List of Gauge Drawings
  3. 3. MAINTENANCE MANUAL FOR COUPLER ( FOR WORKSHOP)1.0 SCOPE1.1 This specification covers requirements for reconditioned couplers and their parts, coupler yoke, draft gear followers, yoke pin and other parts used in coupler and yoke freight wagon application.1.2 For purposes of this specifications the folloving definitions and control will apply .1.2.1.1 Parts cast in Grade B steel shall be procured in accordance with para 4.2.3.11.2.2 "Reconditioned" is defined as any component that has been rebuilt and / or heat treated in accordance with this specification.1.2.2.l Parts cast in Grade B steel must not be reconditioned but may be reused see 1.2.1.11.2.3 "Scrap" is defined as any component not meeting the requirements of this specification.1.2.4 All Railway Workshops produoing coupler components must follow the correct foundry practice.2.0 CLASSIFICATION PROCEDURE2.1 Part with service crack in area shown in Fig.1 must be scrapped.2.2 The results of inspection and gauging will determine if part or assembly may bereconditioned or must be scrapped.2.3 All parts except coupler locklift asseably must be disasseabled for inspection. Locklift assembly must be inspected.2.4 Part mast be clean and free of dirt, paint, rust and scale which will interfere with gauging and inspection.2.5 Part must be visually inspected for cracks, fractures, sections broken out, worn surfaces, distortion, surface upset and service notches.2.6 Each part must meet requirements of the gauges listed to Tables I, II, III, IV & V.2.7 Gauges shall be manufactured either in Railway Workshop or gauge manufacturers as per RDSO drawings.3.0 Reconditioned Acceptance Requiremets for Reuse.3.1 General
  4. 4. 3.1.1 Part must be evaluated in accordance with procedure in 2.0.3.1.2 Part or assembly must not be painted.3.1.3 Part or assembly must not be lubricated.3.1.4 Part or assembly must be free of cracks fractures, sections broken out and service notches, except as permited by this specification, see 4.3.1 and 4.3.4.3.1.5 Surface upset must be ground and blended to the surrounding sarfaces. This ground area must be free of cracks.3.1.6 Process procedure must be in accordance with 4.0 including the specified hardness requirements.3.1.7 The part or assembly classified as reconditioned must be identified by single star and the code of the Railway workshop punched at the location prescribed in fig.4.3.1.8 Reconditioned part must meet all of the requirements of this specification or must be scrapped.3.2 Coupler .3.2.1 Coupler Body3.2.1.1 Only those coupler bodies are acceptable as reconditioned which meet the requirements of gauges listed in table 1 and must operate properly to perform the functions of lockset, anticreep, full knuckle throw and free lock drop as per Appendix B).3.2.1.2 Shank Wear Plate3.2.1.2.1 If the coupler shank originally provided with a shank wear plate on the bottom wall has become worn from contact with striker casting, it must be restored by application of a new wear plate.3.2.1.2.2 New wear plate must be applied in accordance with Drg. No. SK-62724 item 10. No weld splatter permitted on plate bearing surfaces.3.2.1.2.2.1 A preheat may be used at the discretion of applier to ensure crack-free welds.3.2.1.2.2.2 Heat treatment must not be performed after application of shank wear plate.3.2.1.3 Markings3.2.1.3.1 Coupler body must be legibly stamped as shown in fig.4.3.2.1.3.2 Couplers having spherical surfaces of shank butt restored require additional legible 12mm minimum steel stamped marking. "RG" (restored and gauge) on topside of the coupler shank forward of pin hole as shown in Fig5.
  5. 5. 3.2.1.4 Shank Alignment3.2.1.4.1 Coupler shank must not be out of alignment with the head in excess of 9 mm either vertically or laterally.3.2.2 Knuckle3.2.2.1 Knuckles should meet the requirements of gauges listed in Table II.3.2.3 Lock3.2.3.1 Lock must meet the requirements of gauges listed in Table III3.2.3.2 Recoditioned lock must be identified by single star and the code of the Railway Workshop punched at the location prescribed in fig.4..3.2.4 Thrower - No reconditioning permitted.3.2.5 Locklift Assembly - No reconditioning permitted,3.2.6 Knuckle Pivot Pin3.2.6.1 After straightening and heat treatment pin must be free of cracks, fractures, sections broken out and service notches.3.2.6.2 Must meet the requirements of gauges listed in Table IV.3.2.7 Coupler, Assembled Coupler.3.2.7.1 Must meet the requirements of coupler, assembled complete as specified in 3.2.7.1.1.3.2.7.1.1 Coupler must operate properly to perform the functions of lockset. anticreep, full knuckle throw and free lock drop as per Appendix B.3.2.7.1.2 A coupler made up of Reconditioned and new parts is classified as Reconditioned and must meet the requirements of 3.2.1.2 and gauges listed in Table I for assembled coupler.3.3 Coupler Yoke3.3.1 Part or assembly must be free of cracks fractures, sections broken out and service notches.3.3.2 Front of yoke pin hole to butt inside surface length must be as follows with measurements made as indicated in Fig .3. Length (Min.) 786 mm Length (Max.) 787.5 mm3.3.3 Yoke must be legibly stamped as shown in fig.4.
  6. 6. 3.4 Draft Gear Follower.3.4.1 Draft gear follower must meet the requirements of gauges listed in TableV3.4.2 Must be free of the conditions described in 3.1.4.3.4.3 Service induced indentations upto 1 mm are acceptable.3.4.4 Draft gear follower must be legibly stamped as shown in fig.4.3.4.5 Yoke Pin3.4.5.1 No reconditioning permitted.4.0 INSTRUCTIONS FOR RECONDITIONING4.1 Weld Repair and Straightening4.1.1 Repairs of components may be made by welding using qualified welders and procedures in IS Specification IS:7318 Part I latest revisions in the down-hand position.4.1.2 The entire defect must be removed prior to weld repair.4.1.3 Casting may be uniformly or locally, preheated to a temperature between 1500 C and 320°C to ensure crackfree welds.4.1.4 Repair welding shall be performed vith low hydrogen coated elctrodes or by gas shielded welding process. Weld deposits shall provide properties equivalent to the properties of finished castings.4.1.5 Heat treatment required after weld repair or straightening.4.1.5.1 Normalised and tempered castings that have been straightened must be normalised and tempered in accordance with 4.2.3.3 to meet hardness requirements of 4.2.4.1.4.1.5.3 Quenched and tempered castings that have been weld repaired or straightened must be quenched and tempered as per 4.2.3.4 to meet hardness requirements of 4.2.4.1.4.2 Heat Treatment4.2.1 After heating for repair prior to heat treatment components shall be allowed to cool to a temperature below 5380C at a rate that will not be injurious to the castings.4.2.2 Material Grade Identification.4.2.2.1 Grade C steel castings are normalised and tempered / quenched and tempered and marked HT.
  7. 7. 4.2.2.2 Grade E steel castings are quenched and tempered and markad HTE.4.2.3 Processing Components must be processed in accordance with existing material grade identification and repair per 4.1.5.4.2.3.1 Normalising When specified, such heat treatment must be done in a close furnace at a temperature between 871 and 913 degrees C held for thirty minutes. Furnace temperature for heat-treating must be effectively regulated by the use of pyrometers. The material then must be allowed to cool in still air, protected from air drafts and the weather.4.2.3.2 Normalising and tempering of steel parts marked HTE is prohibited.4.2.3.3 Normalised & Tempered Grade C Steel4.2.3.3.1 Heat castings in the furnace so that the castings entire volume attains a temperature of 900°C and hold at this temperature for minimum of thirty minutes.4.2.3.3.2 Remove castings from furnace and allow to cool in still air to under 4270C; or to cold,4.2.3.3.3 Furnace heat to 538°C and hold at this temperature for a minimum of two hours. A higher temperature may be necessary to obtain a Brinell hardness of 179 to 241. The castings may be re-normalised and tempered if they are too soft and re- tampered if they are too hard.4.2.3.3.4 Cool in still air,4.2.3.4 Quenched & Tampered Grade C Steel4.2.3.4.1 Heat castings in the furnace so that the castings entire volume attains a temperature of 9000 C and hold at this temperature for a minimum of thirty minutes.4.2.3.4.2 Remove castings from furnace and in less than one minute submerge them completely in moving or agitated, water of 65°C maximum at start of the quench. Hold castings under water until cooled below 204°C.4.2.3.4.3 Remove castings from water and as soon as possible start to furnace heat them to 663°C, Hold the castings at this temperature for a minimum of two hours. A higher temperature may be necessary to attain a Brinell Hardness of 179 to 241. The castings must be re-quenched and tempered if they are too soft and re- tempered if they are too hard.
  8. 8. 4.2.3.4.4 All castings shall be tempered as soon as necessary to prevent cracking, but in no case shall the time between quenching and tempering exceed eight hours.4.2.3.4.5 Cool casting in still shop air.4.2.3.5 Quenched & Tempered Grade E Steel.4.2.3.5.1 Heat castings in the furnace so that the castings entire volume attains a temperature of 900°C and hold at this temperature for a minimum of thirty minutes.4.2.3.5.2 Reaove castings from furnace and in less than one minute submerge them completely in moving, or agitated, water of 65°C maximum at start of the quench. Hold casting under water until cooled below 204°C.4.2.3.5.3 Remove castings from water and as soon as possible furnace heat them to 571°C. Hold the castings at this temperature for a minimum of two hours, A higher temperature may be necespary to attain a Brinell Hardness of 241 - 311. The castings must be re-quenched and tempered if it is too soft and re-tempered if it is too hard.4.2.3.5.4 All castings shall be tempered as soon as necessary to prevent cracking but in no case shall the time between quenching and tempering exceed eight hours.4.2.3.5.5 Cool castings in still shop air.4.2.4 Hardness4.2.4.1 Tempering tenperatures listed in paragraph 4.2.3.3.3, 4.2.3.4.3 and 4.2.3.5.3 may have to be varied slightly to attain the desired ranges for casting Brinell Hardnesses, as listed belov: Coupler Bodies/ Yokes Knuckle Normalised Grade B Value not specified. Not applicable. N &T Grade C 179 to 241 BHN 179 to 229 BHN Q & T Grade C 179 to 241 BHN 199 to 229 BHN Q & T Grade E 241 to 311 BHN 261 to 291 BHN4.2.4.2 Forged or rolled parts shall also be processed in accordance with 4.2.3.4 or 4.2.3.5 and must be within the Brinell Hardness range specified in 5.0 of Repair Procedure.4.2.4.3 Hardness measurements will be made in the locations shown on Fig.5. The surface at these locations will be properly prepared with removal of all decarburised metal to permit accurate determination of hardness.
  9. 9. 4.2.4.4 Number of Hardness Tests4.2.4.4.1 When components of heat treated lot are of one manufacturer, hardness determination will be made on ten percent of the components. When treatment lot is less than twenty (20) components, a minimum of two(2) components will be tested for hardness.4.2.5 It is to be expected that heat treating temperatures may vary plus or minus 10°c from those specified during any given holding time cycle.4.2.6 Furnace temperature for heat treatment shall be controlled by pyrometers having associated recording equipment which produce time temperature record charts. Pyrometer shall be calibrated atleast once every three months. Log sheet will contain information from the record charts showing the type of products heat treated. Record of pyrometer calibration and log sheets will be available for examination for one year.4.3 Finish4.3.1 Surface discontinuities resulting from weld repairs or service upset or service notches must be contoured to the surroundings surfaces by grinding.4.3.2 All components must be cleaned sufficiently for proper inspection, reclamation and operation. Coupler must not be sand or shot blasted when assembled.4.3.3 Component must be free from cracks, fractures, sections broken out, service notches in those critical areas shown shaded in Figures 6, 7 & 8.4.3.4 All surface area discontinuities which are detected outside the critical areas defined in Figures 6, 7 & 8.which exceed one-half of the section thickness in length and are less than ten percent of the section thickness in depth shall be removed by blending with the surrounding surfaces. Discontinuities greater in depth than ten percent of the section thickness and those located in gauged surfaces shall be removed and weld repaired in accordance with section 4.1...5.0 REPAIR PROCEDURES5.1 Coupler Body5.1.1 Restoration of coupler head portion of coupler body including the application of bushings to knuckle pivot pin holes is prohibited with the following exceptions:5.1.1.1 Top and bottom pin protector bosses as shovn in Figure 9 to be repaired if the crack does not extend into pivot lug.5.1.1.2 Guard Arm-Head5.1.1.3 Knuckle side wall head.
  10. 10. 5.1.1.4 Guard arm and front face crack repairs not extending through the full thickness of the wall of head.5.1.1.5 Anticreep ledge of head as per Figure 16.5.1.2 Restoration of shank is prohibited if the following condition exists:5.1.2.1 Wear on bottom of shank exceeds 9 mm depth as measured in Fig. 2.5.1.3 Restoration of yoke pin hole on shank is prohibited if any of the following conditions exist:5.1.3.1 Crack exceeding 35 mm in length in the shaded area of shank pin hole as shown in Fig. 7.5.1.3.2 Wear on bottom of shank exceeds 9 mm as measured in Fig. 2.5.1.3.3 Any buckling in shank walls.5.1.3.4 Repairs required in shaded area of Fig.l.5.1.4 Coupler Head Repair5.1.4.1 Top and bottom pin protectors with cracks or sections broken out may be weld repaired in the zones shovn in Figure 9. If the failure extends beyond the permissible repair zones, the coupler body must be scrapped. Weld repair must be in accordance with 5.1. The weld must be ground to the outside requirements of gauge no. WD 84073-S-6-RC. Weld in the pin hole must be blended to the worn contour of the hole. Failure to meet the minimun thicknes requirements of gauges No. WD-84073-S-8-RC, Fig.14 and WD-84073-S-5-RC, Fig.15 will scrap coupler body. Heat treatment for this weld repair is required in accordance with 4.1..5.1.4.2 Coupler Guard Arm Distortion - Coupler body with distorted guard arm may be restored either in a press or under light blows of a hammer, after heating the guard arm. Care must be exercised to prevent heating the guard arm far enough into the head to cause distortion of the opening in front face of the coupler. A suggested set-up for correcting lateral distortion is illustrated in Fig.10. The guard arm should be heated to 816 to 870 degrees C and the force applied to the forward portion of the guard arm through a heavy steel plate formed to the outer contour of the guard arm. After straightening, a careful examination must be made to be certain that no cracks have developed as a result of this operation. If cracks do occur they must be evaluated and repaired in accordance with 5.1.1 and 4.1.After straightening, the coupler body must be heat treated in accordance with 4,2. Guard arm distortion gauge to Drg. No. WD-84073-S-l-RC, shown in Fig .11 must be used in checking coupler body contour after straightening.
  11. 11. 5.1.4.3 Guard arm and front face cracks Coupler Head- Coupler head with cracks in guard arm or front face, may be weld repaired in accordance with 4.1.provided any cracks do not extend through the full thickness of the front face. The coupler body must be heat treated in accordance with 4,2.5.1.5 Shank Wear Plate5.1.5.1 Scrap coupler body if shank thickness is less than the following :5.1.5.2 Coupler body having a shank length less than the minimun, allowed by gauges to Drg.No. WD-84073-S-22-RC or WD-84073-S-26-RC, Fig .12 can be restored by welding external surfaces of spherical butt to requirements of the applicable gauges noted in Table I.5.1.5.3 Shank butt height may be restored by welding top surface only per Fig .20.5.1.5.4 Identify restored and gauged spherical shank butt per 3.2.1.3.2 and Fig.5.5.1.5.5 Restored coupler body must be heat treated in accordance with 4,25.1.6 Bent Shank - Coupler Body with shank bent in excess of 9 mm in any direction and out of alignment with the coupler head may be reclaimed by heating to a temperature of 816 to 871 degrees C and straightened under a press. Care must be exercised to bring the shank into proper alignment with the head within the 9 mm limits. After straightening, the coupler body must be carefully examined to make certain that no cracks have developed from this operation. Cracks must be evaluated and repaired in accordance with 5.1.2, 5.1.3 and 4.1.. The coupler body must then be heat treated in accordance with 4,2.5.2 Knuckle5.2.1 Restoration for wear of the knuckle is permitted only in the following areas :5.2.1.1 Lock engagement surface.5.2.1.2 Hub, bottom only.5.2.1.3 Pulling lug. Top and Bottom.5.2.1.4. Pin Protectors, top and bottom5.2.2 Repair of cracks or sections broken out at any location is prohibited.5.2.3 Worn surfaces listed in 5.2.l may be restored by welding per Figures 26 & 27 and heat treating in accordance with 4.1.. and 4,2.The application of any plate on the knuckle is prohibited.5.2.4 Restored surfaces must meet the requirements of 3.2.2.5.3 Lock.5.3.1 Restoration for wear of the lock is permitted only on the knuckle engagement surf ace. The entire repaired area must be restored flush with surrounding surfaces.5.3.2 Repair of cracks or sections broken out at any location is prohibited.5.3.3 Worn surfaces may be restored by welding and heat treating in accordance with 4.1.. and 4,2The application of any plate on the lock is prohibited.
  12. 12. 5.3.4 Restored surfaces must meet the requirements of 3.2.3.5.4 Knuckle Pivot Pin5.4.1 Bent pin suitable for reconditioning must be heated to a temperature of 816 to 871 degrees C. It must be straightened and allowed to cool in still air. After straightening it must be reheated to the same temperature range as the first heating and then quenched in oil for a period of three minutes and cooled in still air. The temperature of the quenching oil bath shall be maintained within a range of 38 to 66 degrees C.5.4.2 Straightened pin must meet the requirements of 3.2.6.5.5 Coupler Yoke.5.5.1 Repairs for all yokes5.5.1.1 Welding of cracks not exceeding 25 mm long x 3 mm deep is permitted in critical areas of Fig.6. Yoke with cracks exceeding either of these dimensions in critical areas must be scrapped.5.5.1.2 No limitations on size of cracks repaired in non critica1 areas. Repairs of cracks completely through a section is prohibited.5.5.2 All upset areas must be repaired in accordance with 3.1.5.5.5.3 All repairs made by welding and heat treating must be in accordance with 4.1.. and 4,2and must meet requirements of 3.3.5.5.4 Yoke Head5.5.4.1 If the dimension as measured in Fig.3 exceeds 794 mm restoration is prohibited and the yoke must be scrapped.5.5.4.2 Yoke pin hole may be restored to meet the overall length dimensions listed in 3.3.2.5.5.4.3 Restoration of holes must be performed by welding and heat treating in accordance with 4.1.. and 4,25.5.4.4 After heat treatment, the hole diameter must be restored to 92 mm by machining or bushing per Fig.3A and located per 3.3.2.5.5.4.5 Yoke worn from contact with coupler shank may be resotred by welding.5.5.4.6 Yoke worn on the outise of the head may be restored by welding.5.5.4.7 Yoke worn on the top and bottom outside of the head from striker contact may be restored by welding when the yoke head width is not less than 203 mm. Yoke must be scrapped when yoke head width is less than 203 mm.5.6 Draft Gear Follovar (Applicable to Y-46 follover only)5.6.1 Repair of crack or sections broken out at any location is prohibited.5.6.2 Followers with indentations exceeding 3 mm in depth on the coupler or draft gear surface must not be restored and must be scrapped.5.6.3 Follower5.6.3.1 No straightening is permitted.
  13. 13. 5.6.3.2 Restoration by welding if indentations not exceeding 3 mm depth on the draft gear bearing surface is permitted. Restoration of coupler bearing surface is prohibited. Depth measurement is to be made after upset area is ground flush to surrounding surfaces. Repaired surface must be dressed to blend with surrounding areas.5.6.3.3 Restoration welding and subsequent treatment must be in accordance with 4.1.. and 4,2
  14. 14. APPENDIX A INDEX OF TABLESTable No. Title I Coupler Body Reconditioned Acceptance. II Knuckle Reconditioned Acceptance. III Lock Reconditioned Acceptance. IV Knuckle Pivot Pin Reconditioned Acceptance Requirements. V Draft Gear Follower Reconditioned Acceptance. TABLE - I Coupler Body - Reconditioned acceptance Drg. No. SK-62724 (Item 1 & 18) and WD-85036-S-01 (Item-1) .Description Fig No. Gauge No. HEAD 11 WD-84073-S-1-RC 13 WD-84073-S-3-RC 16 WD-84073-S-3-RC 15 WD-84073-S-5-RC 14 WD-84073-S-6-RC & WD-84073-S-8-RC 17 Gauge No. 1 & Gauge No. 2 SHANK 19 WD-84073-S-21-RC 20 WD-84073-S-25-RC 21 WD-84073-S-17-RC 12 WD-84073-S-22-RC & WD-84073-S-26-RC 31 WD-84073-S-23-RC 32 WD-84073-S-24-RC
  15. 15. TABLE - II Knuckle - Reconditioned acceptance Drg. No. SK-62724 (Item 2) and W-85036-S-01 (Item 2). Fig No. Gauge No. 26 10 26 11 26 12 23 3 27 9 24 WD-84073-S-47-RC TABLE - III Lock - Reconditioned acceptance Drg. No. SK-62724 (Item 8) and W-85036-S-01 (Item 4). Fig No. Gauge No. 25 WD-84073-S-59-RC TABLE - IV Knuckle pivot pin - Reconditioned acceptance Drg. No. SK-62724 (Item 4) Reconditioned acceptance requirements Fig No. Gauge No. 28 WD-84073-S-96-RC TABLE V Draft Gear Follower- Reconditioned acceptance AAR Catalogue No. Y 46 HTE - Applicable to HT CBC only,Fig No. Gauge No.30 WD-84073-S-71-RC.(Item - 7)
  16. 16. APPNDIX B COUPLER OPERATION For testing of assembled coupler for correct operation, it must be free of any foreignmaterial that will prevent proper operating functions described in the following. Aninspection operating rod, for use in operating assembled couplers is illustrated in fig. I B. Ifcoupler fails to properly operate, or does not have proper anti-creep protection, parts may beinterchanged to meet specification requirements, or check parts to assure proper finishing ofrepaired areas. Only the lubricant may be applied to head or fittings.1. Coupler knuckle must throw to the open position by a continuous rotary force applied by hand through the opening rod from rod handle.2. Coupler knuckle must rotate to the fully closed position to permit drop of the lock to the locked position by a continuous steady force applied by hand on the knuckle nose.3. Coupler lock must automatically drop to the locked position when the knuckle is closed as described in part 2. Coupler knuckle is locked shut when the lock drops to seat on, or to within 6 mm of seating on the knuckle tail lock shelf.4. Coupler is put on locked when the knuckle is restrained from opening while force is applied through the operating rod to raise the lock above the knuckle tail. When the rod is eased back and released, the lock must rest on the forward top edge of the knuckle thrower lock leg. The knuckle than / must be free to rotate open by hand force applied on inside face of the knuckle nose. Coupler then must perform the functions of knuckle closure and lock drop as described in parts 2 and 3.5. Coupler must provide anti-creep protection to prevent accidental unlocking. Inspect as specified below.Coupler Toggle Anti-creep Inspection Raise the lock with a pry bar under the lock fulcrum while forcing the lock tail rearward with a screwdriver (or similar tool) as shown in Pig.2B. If lock can be raised to allow opening of the knuckle on two consecutive attempts, this anti-creep is defective and the coupler assembly is not acceptableBottom Rotary Anti-creeps Inspection To assure anti-creep protection against longitudinal impact,(1) pull articulated rotary lock-lift assembly linkage forward and(2) attempt to lift this linkage. See Fig. 3B. If the anti-creep prong does not contact under the front face to prevent raising of the lock while maintaining forward pressure on the linkage, the anti-creep is defective and the coupler assembly is not acceptable
  17. 17. Trade Company with (Initials or Trade Company with (Initials ormark Trade Name) mark Trade Name) BS Burn Standard Co. 10-C, MI Mukand Iron & Steel Works Hunger Ford Street, Ltd., Lal Bahadur Shastri Calcutta-700017. Marg Kurla, Bombay-400070 BH Bhartia Electric Steel Co. OS Orient Steel Industries Ltd., Poonam, 7th Floor, 5/2, 2,Brabourne Road, Calcutta- Russel Street, Calcutta- 700001 700016. BE Beco Steel castings Pvt. Ltd SR Sri Rang a Industries, Post Industrial Area, Post Box Box No. 2041, Athinalayain No. 8, Bhilai-490001. Road, Ganpathy Post. Coimbatore-64l0 08. CI Central India Machinery TS Titagarh Steel Ltd., 137, Mfg. Co. Ltd., Agra Loop Biplabhai Rashbeharl Bose Road, Birlanagar, Gwalior- Road, Calcutta-700001 474004. HD Hindustan Dev. Corpn. Ltd., TE Texmaco Ltd., Belgharia, Modi Building, 27. Sir 24 Parganas Calcutta-56. R.N.Mukherjee Road, Calcutta-7 00001. HS Himmat Steel Foundry Ltd., AM Anup Malleables Ltd., G.T. College Road, Karbala East, Road, Near Kendra Dak Raipur (M.P.) . Bungalow, Dhanbad-828109. HI Hindustan Iron & Steel Co, 8, Rajendra Deb Road, Calcutta-700007.
  18. 18. APPENDIX C STEEL CASTINGS RECLAIMATION INSPECTION CRITERIA1. The W/S Inspecting Officer should verify coupler and yoke reclamation is being performed in accordance with this specification.2. Initial Inspection of castings - Check gauging techniques, visual, and/or magnetic particle Inspection procedures. Reclamation shop should have a good understanding of critical and non-critical casting areas and how these relate to repair procedures.3. Removal of Casting Defects - Observe arc-air oxy-acetylene scraping methods for complete removal of defects before weld repair.4. Weld Repair of Defects - Verify that low Hydrogen welding electrodes, designated for the appropriate type of material, are used exclusively for repairs. Welders should be tested and qualified in the positions welding is to be performed. Weld repairs must be free of any cracks.5. Heat Treating of Castings after Welding - Components shall be heat treated after welding in conformance to this Specifications. Furnaces should be adequate to assure uniform temperature throughout. Temperature controls and recording equipment should be in proper working order. Furnace calibration equipment should be observed. Quenching Tanks must have circulating capability and equipment to transfer parts from furnace to quench tank should be in good condition. Reclaimer should have thorough knowledge of heat treatment principles and types of heat treatment required depending on casting type,6. Finishing - Observe finish grinding of casting to insure surface discontinuities resulting from weld repair are contoured to the surrounding surfaces.7. Ascertain that gauges required by the applicable specification are present and used properly.8. Quality Control - Discuss additional quality control steps taken by the reclaiming party to insure proper workmanship. These may include;A. Periodic Brinell Hardness Testing of reclaimed castings to insure proper heat treatment.B. Magnaflux Inspection of finished castings.C. Metallurgical analysis (microstructure, Charpy V-notch tests) by metallurgical engineer on property or hired as consultant.D. Failure Analysis programme. The Reclaimer should be aware of the pathology of casting failures.
  19. 19. INSPECTION AND MAINTENANCE OF DRAFT GEAR (A) HR-40-I AND MF-400-1-IR:1. Description - Cardwell Westinghouse HR-40-I Draft Gear.1.1 The essential parts of the Cardwell Westinghouse HR-40-I draft gear are shown in fig. 1.11, Its average weight without yoke is 179 kg.2. Description - National Rubber Type MF 400-I-IR2.1 The essential parts of the National Rubber type MF 400-I-IR draft gear are shown in Fig.2.11 below. The average weight without yoke is 132 Kg,3. INSPECTION - Draft Gears3.1 The draft gears shall be inspected at every POH of the wagon, irrespective of the amount of free slack existing,4. Removal of Coupler and Draft Gear from Wagon.4.1 Remove yoke pin support by conventional methods. Then remove the yoke pin, if necessary by inserting two chisels where the front follower bears hard against the striker casting at the draft lugs.4.2 The coupler is now loose and can be pulled out. Care must be taken to avoid personal injury as the coupler weighs over 200 kg and its head is heavier than the shanks4.3 The coupler can then be completely dis-assembled by following the reverse of the procedure for assembly of coupler as detailed in Appendix 1.4.4 Remove the yoke support plate by conventional methods. When the gear is loose in the wagon pocket, the gear and yoke assembly must be supported by jacks or other means to avoid personal injury,4.5 To remove the gear and yoke assembly when the gear is tight in the wagon pocket, first apply cross-key A, Fig. 4.5, through front of yoke and position in yoke pin hole. Then apply screw B in cross-key A and turn until contact is made with front follower of draft gear. With wrench C, turn screw with aid of a piece of 38mm pipe until gear is loose in the wagon pocket. Remove wrench and lower the gear and yoke assembly on supports from the wagon pocket. (Details of screw given in Appendix 2).4.6 To remove the draft gear from the yoke, compress the gear by means of screw (Appendix 2) sufficiently and insert two pre-shortoners as done during assembly. Then release the screw and remove the draft gear.5. Draft Gear Reclamation Practices (Cardwell Westinghouse),5.1 Housing Building up of wear on housing up to a maximum of 3 mm in depth on either side is permitted, housing having excessive wear or cracks shall be condemned,5.2 Integral Follower5.2.1 Building up of wear to a depth of 3 mm is permitted.
  20. 20. 5.3 Rubber Pads5.3.1 Rubber pads should not be reused. Assembly of draft gear pads should be done as detailed in section 7 & 8,5.4 Wagon Pocket Prior to the re-application of the draft gear to the wagon. Measure the pocket and if greater than 629mm the same is built upto 625.5 +0mm/-1.55 mm by welding steel shims to back stops. To avoid unequal loading, the pocket shall be kept square within 1.5mm.6. Draft Gear Reclamation Practices (National Type MF 400-1-IR)6.1 Followers6.1.1 Building up of wear to a depth of 3 mm is permitted.6.2 Front Compensating Unit6.2.1 The front compensating rubber pads are to be replaced with a new set.6.2.2 When the front compensating pads are broken or otherwise damaged and found tight in the intermediate follower, it can be pressed out by using a 13 mm steel pusher plate 203 x 178. (The width is required to bear on all 7-rubber pad steel inserts and still clear the followers). The intermediate follower must be blocked up to a height (230 mm or more) that will allow the front compensating pads to clear. Retaining tabs on both end pads must be straightened prior to pressing out the unit.6.3 Rear Cushioning Unit6.3.1 The rear-cushioning unit of rubber pads shall be replaced by new pads.6.4 Wagon Pocket6.4.1 Prior to re-application of the draft gear to the wagon pocket. Measure pocket and if greater than 629mm,the same is built upto 625.5 +0/-1.25 mm by welding steel shims to back stops. To avoid unequal loading, the pocket shall be kept square within 1.5 mm.7. Assembly of Draft Gear - Cardwell Westinghouse7.1 Clean draft gear housing of all burrs, insert the rubber draft gear spring first and then the spacer plate between each of two rubber draft gear springs, 11 numbers of rubber draft gear springs and 10 numbers of spacer plates are required for housing.7.2 Place plunger on rubber pack and apply pressure either hydraulically or with screw jack in order to insert locking lugs on both sides of housing. Then insert two locking pins between the housing and lugs of the locking lugs,7.3 Place integral follower on plunger and tack weld the integral follower with plunger on all four sides of vee grooves provided.7.4 The draft gear may be upto 632 mm length but is pre-shortened to 619 mm using 13 mm Pre-shorteners (pre-shorteners should be of commercial grade Aluminum) to facilitate insertion into yoke pocket. For insertion of pre-shorteners compress pack
  21. 21. hydraulically (60 tonnes) and insert pre-shorteners on both sides in the gap between locking lugs and housing,8. Assembly of National Rubber Type MF 400-I-IR Draft Gear8.1 First assemble front unit by inserting and positioning front follower into intermediate follower,8.2 Next insert rubber unit into retaining clamp making sure that all end pad retaining tabs have been straightened out fig. 8.2 shows fixture for assembly of front compensating rubber pads).8.3 By using a press or other suitable means, compress pads sufficiently to allow clamping bolts to be tightened (force about 7 tonnes).8.4 After applying retaining clamp, place the protruding side of rubber unit in the opening of intermediate follower, making sure that front follower is in place,8.5 Position 13 mm thick steel pusher plate 139 x 171 on top of rubber unit, such that it bears on all seven rubber pad steel inserts but still clears the sides of retaining clamp. Then press front rubber unit into intermediate follower, which requires a force of approximately 1 tonne. After pressing when the unit is in position bend the retaining ring tabs into recesses on follower, by hammer.8.6 Next, assemble rear unit by placing rear rubber unit on rear follower Then insert retaining bolts and place front unit on rear unit. Compress complete assembly to 632mm and fit to retaining units until snug and than tack weld (force about 60 tonne).8.7 Pre-shorten complete draft pack for fitting into yoke and wagon pocket by further compressing pack to 619 mm by means of press fit pre-shortening blocks (force about 60 tonnes). B. HIGH CAPACITY DRAFT GEARS CARDWELL MARK 50 AND MINERS RF-36l1. Cardwell Mark 501.1 The reclamation practice for Cardwell Mark 50 draft gear is as per instructions circulated by M/s. Bhartia.2. Miners RF-3612.1 The reclamation practice for Miners RF-361 draft gear is as per instructions circulated by Burns and Standards.
  22. 22. APPINDIX 11. Assembly of Coupler1.1 Enter knuckle thrower A, through front of coupler head and into knuckle thrower trunnion hole, until it lies flat on floor of coupler head (Fig. 1.1)1.2 Apply rotary lock lift assembly X, Y & Z on shaft F (Fig. 1.2).1.3 Lift toggle L and rotate lock-lift assembly X-Y-Z towards front so that toggle Z enters into lock hole. Next enter lock B through front of coupler head and place toggle arm slot in lock B over trunnion of toggle G (Fig.1.3).1.4 Then lower lock into position into lock hole (Fig l.4).1.5 Hold lock B back in coupler head while raising it with locklift assembly X-Y-Z until lock enters upper lock chamber. (Fig. 1.5).1.6 Continue to raise lock B to the top-most position and hold. Then rotate knuckle thrower A to the extreme left position and hold until lock is released to lock set position as shown in Fig l.6. Next, insert knuckle E between the top and bottom pulling lugs,1.7 Rotate knuckle B inwardly to closed position, allow the lock B to drop into locked position (Fig.1.7).1.8 Next fit knuckle pivot pin H and secure by welded washer J (Fig.1.8),1.9 It must be ensured that during assembly and in service none of the coupler components are either painted or lubricated. After assembly operate the coupler a few times to ensure free movement of components.
  23. 23. INSPECTION AND MAINTENANCE OF CLEVIS AND CLEVIS PIN AND SCREW COUPLING1. Clevis1.1 Clevis shall not be built up by weldling. If worn more than 3 mn, it shall be condemned.2. Clevis pin2.1 Pins having steps or cracks or which have a diameter less than 37 mm at any point shall be condemned. Bent pins may be reclaimed by heating, then straightened and allowed to cool in still air. Finally the pins shall be heat-treated to get hardness value of 250-305 BHN.3. Screw coupling3.1 The reclamation practice for screw coupling shall be as per Indian RailwayMaintenance Manual for wagons issued by Railway Board. INSPECTION AND MAINTENANCE OF STRIKER CASTING AND STRIKE CASTING WEAR PLATE1. Striker Casting1.1 If Striker Casting front lug is worn by 5mm, striker casting shall be replaced.2. Striker Casting Wear Plate2.1 Striker Casting wear plate shall be replaced at every POH. Details of striker casting wear plate and its securing arrangement are shown in Appendix I.
  24. 24. LIST OF DRAWINGS1 WD -84073 -S-l-RC2 WD -84073-S-3-RC3 WD -84073-S-5-RC4 WD -84073-S-6-RC5 WD -84073-S-8-RC6 WD -84073-S-17-RC7 WD -84073-S-21-RC8 WD -84073-S-22-RC9 WD -84073-S-23-RC10 WD -84073-S-24-RC11 WD -84073-S-25-RC12 WD -84073-S-26-RC13 WD -84073-S-47-RC14 WD -84073-S-59-RC15 WD -84073-S-71-RC16 WD -84073-S-96-RC17 Gauge No. 118 Gauge No. 219 Gauge No. 320 Gauge No. 921 Gauge No. 1022 Gauge No. 1123 Gauge No. 12

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