automatic scharfenberg coupler 010.616 user manual

User Manual - Automatic Scharfenberg Coupler 010.616

Version 1

User Manual

Table of Contents

Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Table of Contents Table of Contents

1 Introduction ...................................... .......................................................................................... 13

1.1 Copyright ...................................................................................................................................... 13

1.2 Usage notes for this manual ........................................................................................................ 13

1.3 Selection of staff .......................................................................................................................... 14

1.4 Revision index .............................................................................................................................. 14

1.5 Approval table .............................................................................................................................. 14

2 Safety ............................................ .............................................................................................. 15

3 Product description ............................... .................................................................................... 17

3.1 Technical data .............................................................................................................................. 17

3.2 Overview drawing ........................................................................................................................ 17

3.3 Intended use ................................................................................................................................ 18

3.3.1 Potential misuse ........................................................................................................................... 18

3.3.2 Use in case of restricted readiness for operation ........................................................................ 19

3.4 General product description ......................................................................................................... 19

3.5 Description of components .......................................................................................................... 23

3.5.1 Coupler head ............................................................................................................................... 23

3.5.2 Uncouple device .......................................................................................................................... 26

3.5.3 Air pipe connection for brake pipe (BP) ....................................................................................... 27

3.5.4 Air pipe connection for main reservoir pipe and uncouple pipe ................................................... 29

3.5.5 Electric head operating gear ........................................................................................................ 31

3.5.6 Coupler shank .............................................................................................................................. 33

3.5.7 Bearing bracket ............................................................................................................................ 35

3.5.8 Electric head ................................................................................................................................ 35

3.5.9 Centring device and support ........................................................................................................ 38

3.5.10 Uncouple pipe .............................................................................................................................. 40

3.5.11 Pipe adapter ................................................................................................................................. 41

3.5.12 Pneumatic unit of the coupler head ............................................................................................. 42

3.5.13 Electrical unit at the coupler head ................................................................................................ 49

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3.5.14 Muff coupling ............................................................................................................................... 51

3.5.15 Earthing system ........................................................................................................................... 52

4 Operation ......................................... .......................................................................................... 53

4.1 Automatic coupling ...................................................................................................................... 53

4.2 Coupling without connecting the electric heads .......................................................................... 57

4.3 Coupling - on tight curves ........................................................................................................... 61

4.4 Automatic uncoupling .................................................................................................................. 61

4.5 Manual uncoupling ...................................................................................................................... 63

5 Light maintenance ................................. .................................................................................... 69

5.1 Materials ...................................................................................................................................... 71

5.2 Repair position ............................................................................................................................ 71

5.3 Maintenance schedule - light maintenance ................................................................................. 75

5.3.1 Light maintenance ML1 ............................................................................................................... 75




5.3.5 Heavy maintenance OH 1 and OH 2 ........................................................................................... 81

5.4 Rough cleaning ........................................................................................................................... 81

5.5 Visual inspection ......................................................................................................................... 82

5.6 Lubrication ................................................................................................................................... 83

5.7 Check the coupler lock for smooth operation .............................................................................. 89

5.8 Measure and correct the coupler lock backlash .......................................................................... 89

5.9 Check and adjust the projection of the electric head .................................................................. 94

5.10 Adjust the inclination and centre position .................................................................................... 95

5.11 Replace the gasket in the air pipe connection ............................................................................ 98

5.12 Check screw connections with a defined torque ......................................................................... 99

5.13 Repair the paint coating .............................................................................................................. 99

6 Heavy maintenance ................................. ................................................................................ 101

6.1 Standard tools ........................................................................................................................... 102

6.2 Materials .................................................................................................................................... 103

6.3 Preparations .............................................................................................................................. 104

6.4 Maintenance schedule - heavy maintenance ............................................................................ 104

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6.5 Disassembling the coupler into its components ........................................................................ 104

6.5.1 Remove the earthing system ..................................................................................................... 104

6.5.2 Remove the electrical unit of the coupler head ......................................................................... 105

6.5.3 Remove the pneumatic unit of the coupler head ....................................................................... 107

6.5.4 Remove the uncouple pipe ........................................................................................................ 108

6.5.5 Remove the electric head .......................................................................................................... 109

6.5.6 Remove electric head operating gear ........................................................................................ 109

6.5.7 Remove the air pipe connection for the brake pipe ................................................................... 111

6.5.8 Remove the air pipe connection for the main reservoir pipe and the uncouple pipe ................ 114

6.5.9 Remove the centring device and support .................................................................................. 115

6.5.10 Remove the muff coupling ......................................................................................................... 116

6.5.11 Remove the coupler head .......................................................................................................... 116

6.5.12 Remove the uncouple cylinder .................................................................................................. 117

6.5.13 Remove the coupler shank ........................................................................................................ 117

6.5.14 Remove the bearing bracket ...................................................................................................... 117

6.6 Disassembling, overhauling and assembling the individual components .................................. 118

6.6.1 Coupler head ............................................................................................................................. 118

6.6.2 Uncouple cylinder ...................................................................................................................... 127

6.6.3 Air pipe connection for brake pipe ............................................................................................. 130

6.6.4 Air pipe connection for main reservoir pipe and uncouple pipe ................................................. 133

6.6.5 Electric head operating gear ...................................................................................................... 135

6.6.6 Coupler shank ............................................................................................................................ 140

6.6.7 Bearing bracket .......................................................................................................................... 142

6.6.8 Electric head - replacement of male / female contacts .............................................................. 144

6.6.9 Electric head - replacement of snap-in terminal studs ............................................................... 145

6.6.10 Electric head .............................................................................................................................. 146

6.6.11 Centring device and support ...................................................................................................... 155

6.6.12 Pneumatic unit of the coupler head ........................................................................................... 159

6.6.13 Electrical unit of the coupler head .............................................................................................. 161

6.6.14 Muff coupling .............................................................................................................................. 163

6.6.15 Earthing system ......................................................................................................................... 164

6.7 Assemble the coupler ................................................................................................................ 165

6.7.1 Install the bearing bracket .......................................................................................................... 165

6.7.2 Install the coupler shank ............................................................................................................ 166

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6.7.3 Install the centring device and support...................................................................................... 166

6.7.4 Mount the coupler head ............................................................................................................ 167

6.7.5 Install the uncouple cylinder ...................................................................................................... 167

6.7.6 Mount the air pipe connection for the main reservoir pipe and the uncouple pipe ................... 167

6.7.7 Install the uncouple pipe ........................................................................................................... 169

6.7.8 Install the air pipe connection for the brake pipe ...................................................................... 171

6.7.9 Install the electric head operating gear ..................................................................................... 174

6.7.10 Install the electric head.............................................................................................................. 175

6.7.11 Assemble the muff coupling - horizontal configuration ............................................................. 175

6.7.12 Install the pneumatic unit of the coupler head .......................................................................... 179

6.7.13 Install the electrical unit of the coupler head ............................................................................. 181

6.7.14 Install the earthing system ........................................................................................................ 183

6.8 Final maintenance steps ........................................................................................................... 185

7 Mounting and removal .............................. .............................................................................. 187

7.1 Mounting and commissioning .................................................................................................... 187

7.2 Removal and decommissioning ................................................................................................ 191

8 Transportation, storage and disposal .............. ..................................................................... 193

8.1 Transportation ........................................................................................................................... 193

8.2 Storage ...................................................................................................................................... 193

8.3 Disposal ..................................................................................................................................... 193

9 Troubleshooting ................................... ................................................................................... 195

9.1 Target group .............................................................................................................................. 195

9.2 Safety ........................................................................................................................................ 195

9.3 Coupling fails ............................................................................................................................. 195

9.3.1 Mechanical coupling fails .......................................................................................................... 195

9.3.2 Failure when coupling electric heads ........................................................................................ 196

9.4 Uncoupling fails ......................................................................................................................... 198

9.4.1 Automatic mechanical uncoupling fails ..................................................................................... 198

9.4.2 Electrical uncoupling fails .......................................................................................................... 199

9.4.3 Manual uncoupling fails ............................................................................................................. 200

9.5 Electrical signals are disturbed ................................................................................................. 200

9.5.1 No or poor power transmission ................................................................................................. 200

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9.5.2 Damage to cables ...................................................................................................................... 201

9.6 Earthing system ......................................................................................................................... 201

9.7 Air pipe connection fails ............................................................................................................. 201

9.7.1 Pressure drop when coupled ..................................................................................................... 201

9.7.2 Pressure drop when uncoupled ................................................................................................. 202

9.7.3 Air brakes in vehicle cannot be released ................................................................................... 202

9.8 Coupler is in wrong position ....................................................................................................... 203

9.8.1 Coupler head is misaligned ....................................................................................................... 203

9.8.2 Coupler is misaligned................................................................................................................. 203

9.9 Unusual noise during operation ................................................................................................. 203

9.9.1 Clattering/knocking noise ........................................................................................................... 203

9.9.2 Unusual hard load changes ....................................................................................................... 203

9.10 Oil leaks ..................................................................................................................................... 203

10 SCHAKU standards .................................. ............................................................................... 205

10.1 Paint specification ...................................................................................................................... 205

10.1.1 General requirements (SCHAKU standard K000) ..................................................................... 205

10.1.2 Paint structure (SCHAKU-Norm K150) ...................................................................................... 206

10.2 Sealing and securing of screw connections (SCHAKU standard A023) ................................... 207

10.3 Replacing METALOPLAST bushes (SCHAKU standard Z006) ................................................ 208

10.4 Mount the One4 front plate (SCHAKU standard Z044) ............................................................. 209

11 Parts catalogue ................................... ..................................................................................... 211

11.1 Structure of the parts list ............................................................................................................ 211

11.2 Scharfenberg coupler 010.616 ''10.02'' ...................................................................................... 212

11.2.1 Coupler head 1.010.600.01 ....................................................................................................... 213

11.2.1.1 Coupler head casing 2.010.424.01.01 ''11.01'' .......................................................................... 215

11.2.1.2 Coupling link with bushes 4.010.164.01.08 ''10.03'' .................................................................. 216

11.2.1.3 Stem guide 2.010.139.01.06 ''10.06'' ......................................................................................... 216

11.2.1.4 Spring bearing 3.020.007.01.09 ''10.06'' .................................................................................... 217

11.2.2 Uncouple cylinder 3.STD.001.02 ''10.01'' .................................................................................. 218

11.2.3 Air pipe connection 3.STD.002.03 ''10.03'' ................................................................................ 219

11.2.4 Air pipe connection STD.001.04 ''11.01'' ................................................................................... 220

11.2.5 Electric head operating gear 010.572.05 ''10.01'' ...................................................................... 221

11.2.5.1 Cylinder 2.035.051.05.01 ''11.01'' .............................................................................................. 223

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11.2.6 Coupler shank 010.616.06 ........................................................................................................ 224

11.2.6.1 Coupler shank 010.600.06 ''10.01'' ........................................................................................... 224

11.2.7 Bearing bracket 010.616.07 ...................................................................................................... 226

11.2.7.1 Bearing bracket 4.050.117.07.01 .............................................................................................. 227

11.2.8 Electric head 08.009.060-Z1 ..................................................................................................... 228

11.2.9 Centring device 010.616.10 ...................................................................................................... 230

11.2.9.1 Stem 3.010.191.07.01 ''10.01'' .................................................................................................. 232

11.2.9.2 Support 3.136.001.10.01 ''11.05'' .............................................................................................. 232

11.2.9.3 Bearing bracket with bush 3.136.001.10.02 ''10.01'' ................................................................. 233

11.2.10 Uncouple pipe 2.STD.002.12 ''11.01'' ....................................................................................... 233

11.2.11 Air piping 010.616.13 ''10.01'' ................................................................................................... 234

11.2.12 Pneumatic unit 1.010.572.15 .................................................................................................... 235

11.2.13 Electrical unit 010.572.18 ''10.02'' ............................................................................................. 237

11.2.14 Muff coupling 010.109.36 ''10.05'' ............................................................................................. 238

11.2.15 Earthing system 010.616.43 ..................................................................................................... 239

11.3 Special tools and test equipment .............................................................................................. 240

11.4 Materials .................................................................................................................................... 242

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Figures

Fig. 1-1 "Front", "Rear", "Right" and "Left" ................................................................................................ 14

Fig. 3-1 Automatic Scharfenberg Coupler 010.616................................................................................... 18

Fig. 3-2 Theoretical gathering range ......................................................................................................... 22

Fig. 3-3 Coupler head type 10 - simplified drawing .................................................................................. 23

Fig. 3-4 Uncoupled / ready-to-couple position - simplified drawing .......................................................... 24

Fig. 3-5 Coupled position - simplified drawing .......................................................................................... 25

Fig. 3-6 Uncoupled position - simplified drawing ...................................................................................... 25

Fig. 3-7 Uncouple cylinder STD.001.02 .................................................................................................... 26

Fig. 3-8 Air pipe connection BP - simplified drawing................................................................................. 27

Fig. 3-9 Air pipe connection BP, coupled position .................................................................................... 28

Fig. 3-10 Air pipe connection BP, coupler rupture ...................................................................................... 28

Fig. 3-11 Air pipe connection for MRP and UP - simplified drawing ........................................................... 29

Fig. 3-12 Electric head operating gear 010.572.05 ..................................................................................... 31

Fig. 3-13 Coupler shank 010.600.06 ........................................................................................................... 33

Fig. 3-14 Combined force-displacement curve for all energy absorbing elements ..................................... 34

Fig. 3-15 Bearing bracket 010.616.07 ......................................................................................................... 35

Fig. 3-16 Electric head 08.009.060-Z1 ........................................................................................................ 36

Fig. 3-17 Centring device with support - simplified drawing ....................................................................... 38

Fig. 3-18 Uncouple pipe STD.002.12 .......................................................................................................... 40

Fig. 3-19 Air piping 010.616.13 ................................................................................................................... 41

Fig. 3-20 Pneumatic unit 010.572.15 .......................................................................................................... 42

Fig. 3-21 Vent of uncouple pipe .................................................................................................................. 44

Fig. 3-22 Pneumatic diagram P221.4 Ready-to-couple position ................................................................ 45

Fig. 3-23 Pneumatic diagram P221.4 Coupled position ............................................................................. 47

Fig. 3-24 Pneumatic diagram P221.4 Uncoupled position .......................................................................... 48

Fig. 3-25 Electrical unit 010.572.18 ............................................................................................................ 49

Fig. 3-26 Wiring diagram ............................................................................................................................. 50

Fig. 3-27 Muff coupling - simplified drawing ................................................................................................ 51

Fig. 3-28 Earthing system 010.616.43 ........................................................................................................ 52

Fig. 4-1 Stopcock ...................................................................................................................................... 54



Fig. 4-4 Stopcock ...................................................................................................................................... 58




Fig. 4-8 Stopcock ...................................................................................................................................... 64

Fig. 4-9 Hexagon head on operating gear - simplified drawing ................................................................ 65

Fig. 4-10 Manual uncoupling - simplified drawing ....................................................................................... 66

Fig. 4-11 Holder of handle at coupler head - simplified drawing ................................................................. 67


Fig. 5-1 Stopcock ...................................................................................................................................... 73

Fig. 5-2 Hexagon head on operating gear - simplified drawing ................................................................ 73

Fig. 5-3 Putting the coupler lock in the coupled position .......................................................................... 74

Fig. 5-4 Lubrication points of the coupler head - simplified drawing ......................................................... 84

Fig. 5-5 Lubricating nipple at the central pivot - simplified drawing .......................................................... 85

Fig. 5-6 Lubrication points of the coupler shank - simplified drawing ....................................................... 86

Fig. 5-7 Lubricating nipple at the bearing bracket - simplified drawing ..................................................... 87

Fig. 5-8 Lubrication points of the electric head - principle drawing ........................................................... 87

Fig. 5-9 Lubrication points at centring device ........................................................................................... 88

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Fig. 5-10 Muff coupling ............................................................................................................................... 88

Fig. 5-11 Coupler lock backlash gauge ...................................................................................................... 90

Fig. 5-12 Measuring the coupler lock backlash - overview of parts ........................................................... 91

Fig. 5-13 Positioning the coupler lock backlash gauge .............................................................................. 91

Fig. 5-14 Reading the coupler lock backlash gauge .................................................................................. 92

Fig. 5-15 Reading the Vernier scale (0.5 mm in example) ......................................................................... 92

Fig. 5-16 Gauge for measuring the projection of the electric head (x=min, y=max) .................................. 94

Fig. 5-17 Adjust the projection of the electric head .................................................................................... 95

Fig. 5-18 Adjust the inclination of the coupler ............................................................................................ 97

Fig. 5-19 Centring the coupler .................................................................................................................... 97

Fig. 5-20 Gasket and socket - simplified drawing....................................................................................... 98

Fig. 6-1 Connection of the earth wire - simplified drawing ..................................................................... 105

Fig. 6-2 Electrical unit 010.572.18 .......................................................................................................... 106

Fig. 6-3 Pneumatic unit 010.572.15 ....................................................................................................... 107

Fig. 6-4 Uncouple pipe STD.002.12 ....................................................................................................... 109

Fig. 6-5 Electric head operating gear 010.572.05 .................................................................................. 110

Fig. 6-6 Remove the stop spring ............................................................................................................ 112

Fig. 6-7 Use socket wrench .................................................................................................................... 112

Fig. 6-8 Air pipe connection for BP ......................................................................................................... 113

Fig. 6-9 Remove the stop spring ............................................................................................................ 114

Fig. 6-10 Use socket wrench .................................................................................................................... 115

Fig. 6-11 Centring device ......................................................................................................................... 116

Fig. 6-12 Bearing bracket 010.616.07 ...................................................................................................... 118

Fig. 6-13 Coupler lock, stem guide and spring bearing in the coupler head ............................................ 120

Fig. 6-14 Coupler lock .............................................................................................................................. 121

Fig. 6-15 Ratchet linked to hooked plate .................................................................................................. 121

Fig. 6-16 Lubricating nipples with dust protection caps ........................................................................... 122

Fig. 6-17 Coupler head 010.600.01 .......................................................................................................... 124

Fig. 6-18 Coupler lock, stem guide and spring bearing in the coupler head ............................................ 125

Fig. 6-19 Ratchet linked to hooked plate .................................................................................................. 125

Fig. 6-20 Coupler lock .............................................................................................................................. 126

Fig. 6-21 Uncouple cylinder STD.001.02 ................................................................................................. 128

Fig. 6-22 Air pipe connection BP - simplified drawing .............................................................................. 132

Fig. 6-23 Air pipe connection for MRP and UP STD.001.04 .................................................................... 134

Fig. 6-24 Cylinder 2.035.051.05.01 [variant A] ......................................................................................... 136

Fig. 6-25 Electric head operating gear 010.572.05 .................................................................................. 138

Fig. 6-26 Coupler shank 010.600.06 ........................................................................................................ 141


Fig. 6-28 Replacement of contacts - simplified drawing ........................................................................... 144

Fig. 6-29 Removing snap-in terminal studs - simplified drawing .............................................................. 145

Fig. 6-30 Pliers.......................................................................................................................................... 146

Fig. 6-31 Fixture of the protecting lid ........................................................................................................ 147

Fig. 6-32 Fixture of the contact block - simplified drawing ....................................................................... 148

Fig. 6-33 Fixture of the contact block - simplified drawing ....................................................................... 150

Fig. 6-34 Fixture of the protecting lid ........................................................................................................ 150

Fig. 6-35 Contact block overview 08.009.060-Z1 ..................................................................................... 151

Fig. 6-36 Wiring diagram 08.009.060-Z1 - part 1 of 3 .............................................................................. 152



Fig. 6-39 Centring device and support 010.616.10 .................................................................................. 156

Fig. 6-40 Stem .......................................................................................................................................... 158

Fig. 6-41 Pneumatic unit 010.572.15 ....................................................................................................... 160


Fig. 6-43 Muff coupling 2.010.109.36 ....................................................................................................... 163


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Fig. 6-45 Centring device .......................................................................................................................... 166

Fig. 6-46 Use socket wrench ..................................................................................................................... 168

Fig. 6-47 Install the stop spring ................................................................................................................. 169

Fig. 6-48 Uncouple pipe STD.002.12 ........................................................................................................ 170

Fig. 6-49 Air pipe connection for BP ......................................................................................................... 171

Fig. 6-50 Use socket wrench ..................................................................................................................... 172

Fig. 6-51 Install the stop spring ................................................................................................................. 173

Fig. 6-52 Electric head operating gear 010.572.05 ................................................................................... 174

Fig. 6-53 Muff coupling - simplified drawing .............................................................................................. 176

Fig. 6-54 Pneumatic unit 010.572.15 ........................................................................................................ 179


Fig. 6-56 Wiring diagram ........................................................................................................................... 182

Fig. 6-57 Earthing system 010.616.43 ...................................................................................................... 183

Fig. 6-58 Connection of the earth wire - simplified drawing ...................................................................... 184

Fig. 7-1 Hole configuration - view of the mounting surface of the product ............................................. 188

Fig. 10-1 Position of the parting line ......................................................................................................... 208

Fig. 11-1 Scharfenberg coupler 010.616 ''10.02'' ...................................................................................... 212

Fig. 11-2 Coupler head 1.010.600.01 ....................................................................................................... 213

Fig. 11-3 Coupler head casing 2.010.424.01.01 ''11.01'' .......................................................................... 215

Fig. 11-4 Coupling link with bushes 4.010.164.01.08 ''10.03'' .................................................................. 216

Fig. 11-5 Stem guide 2.010.139.01.06 ''10.06'' ......................................................................................... 216

Fig. 11-6 Spring bearing 3.020.007.01.09 ''10.06'' .................................................................................... 217

Fig. 11-7 Uncouple cylinder 3.STD.001.02 ''10.01'' .................................................................................. 218

Fig. 11-8 Air pipe connection 3.STD.002.03 ''10.03'' ................................................................................ 219

Fig. 11-9 Air pipe connection STD.001.04 ''11.01'' ................................................................................... 220

Fig. 11-10 Electric head operating gear 010.572.05 ''10.01'' ...................................................................... 221

Fig. 11-11 Cylinder 2.035.051.05.01 ''11.01'' .............................................................................................. 223

Fig. 11-12 Coupler shank 010.616.06 ......................................................................................................... 224

Fig. 11-13 Coupler shank 010.600.06 ''10.01'' ............................................................................................ 224

Fig. 11-14 Spring casing 2.010.600.06.01 .................................................................................................. 225

Fig. 11-15 Bearing bracket 010.616.07 ....................................................................................................... 226

Fig. 11-16 Bearing bracket 4.050.117.07.01 ............................................................................................... 227

Fig. 11-17 Electric head 08.009.060-Z1 ...................................................................................................... 228

Fig. 11-18 Centring device 010.616.10 ....................................................................................................... 230

Fig. 11-19 Stem 3.010.191.07.01 ''10.01'' ................................................................................................... 232

Fig. 11-20 Support 3.136.001.10.01 ''11.05'' .............................................................................................. 232

Fig. 11-21 Bearing bracket with bush 3.136.001.10.02 ''10.01'' ................................................................. 233

Fig. 11-22 Uncouple pipe 2.STD.002.12 ''11.01'' ........................................................................................ 233

Fig. 11-23 Air piping 010.616.13 ''10.01'' .................................................................................................... 234

Fig. 11-24 Pneumatic unit 1.010.572.15 ..................................................................................................... 235

Fig. 11-25 Electrical unit 010.572.18 ''10.02'' .............................................................................................. 237

Fig. 11-26 Muff coupling 010.109.36 ''10.05'' .............................................................................................. 238

Fig. 11-27 Earthing system 010.616.43 ...................................................................................................... 239

Fig. 11-28 Coupler lock backlash gauge ..................................................................................................... 240

Fig. 11-29 Mounting drift for gluing bushes into coupling link. .................................................................... 240

Fig. 11-30 Socket wrench for mouth piece ................................................................................................. 241

Fig. 11-31 Drift............................................................................................................................................. 241

Fig. 11-32 Gauge for measuring the projection of the electric head ........................................................... 242

Fig. 11-33 Pliers for snap-in terminal studs ................................................................................................ 242

Fig. 11-34 Tool for removal of snap-in terminal studs................................................................................. 242

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Tables

Tab. 3-1 Technical data 010.616 ............................................................................................................... 17

Tab. 5-1 Maintenance and overhaul levels ................................................................................................ 75

Tab. 6-1 Maintenance and overhaul levels .............................................................................................. 104

Tab. 10-1 Minimum cure time for METALOPLAST bushes ....................................................................... 209

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Introduction


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1 Introduction Introduction

The objective of this manual is to provide you with theoretical and practical knowledge on the product. Prior product knowledge is not required. However, it is strongly recommended to attend a hands-on training offered by Voith Turbo Scharfenberg.

Manual structure This manual consists of the following chapters: � Introduction: Usage notes for this manual � Safety: Structure of the safety messages and definition of the risk levels � Product description: Technical data, overview drawing, intended use, description of the

product and its components � Operation: Instructions for the correct operation of the product � Light maintenance: Maintenance and repair which can be performed without requiring a

workshop. � Heavy maintenance: Maintenance and repair at the removed product � Mounting and removal: Mounting and Removal including commissioning and decommission-

ing � Transportation, storage and disposal: Handling of the product before and after its use � Troubleshooting: Diagnosis and remedy of defects � SCHAKU standards: Operational standards of Voith Turbo Scharfenberg � Parts catalogue: Information required for the identification and ordering of spare parts

1.1 Copyright Copyright

All rights reserved for this technical document, also in the event of patent grant or utility model registration. No part of this document may be reproduced, disclosed to third parties or otherwise misused without prior written permission.

Trademarks Scharfenberg®, Scharfenbergkupplung®, SCHAKU®, Couplomatic®, GALEA®, OctiConn®, One4®

(China: 全固®), QuatConn®, RadiConn® and TwinStroke® are registered trademarks of Voith Turbo Scharfenberg GmbH & Co. KG.

Trademarks of third-party products are written in CAPS and are subject to trademark rights of the respective owner.

Copyright© Voith Turbo Scharfenberg GmbH & Co. KG. All rights reserved.

Domicile Voith Turbo Scharfenberg GmbH & Co. KG

Gottfried-Linke-Straße 205

D-38239 Salzgitter

1.2 Usage notes for this manual Usage notes for this manual

Product designation The designation of the product is given in the header of each page. This designation includes the drawing number of the product.

Active header Each page identifies the chapter and section you are currently reading.

User Manual

Introduction

Selection of staff Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Issue The manual version is shown in the marginal note on each page.

Simplification of drawings Illustrations explaining a working principle (e.g. coupler lock positions, lubrication schedule, etc.) are usually simplified and may slightly differ from the actual product. This is indicated by the words "simplified drawing" appended to the caption.

Superfluous details have been removed from all drawings. Auxiliary lines that do not belong to the illustrated part but facilitate orientation are displayed in grey.

The simplification of drawings is aimed at improving their understandability.

If the unit of measurement is missing, all measures are given in millimetres [mm]. Other units of measurement are identified expressly.

"Front", "Rear", "Right" and "Left" „Front“ refers to the direction away from the vehicle along the vehicle's longitudinal axis.

Accordingly, "Rear" refers to the opposite direction.

For Scharfenberg couplers, the designations "male cone side" and "female cone side" are used.

Fig. 1-1 "Front", "Rear", "Right" and "Left"

1 Longitudinal vehicle axis 4 Right (male cone side)

2 Rear 5 Left (female cone side)

3 Front

1.3 Selection of staff Selection of staff

Only reliable and qualified staff is allowed to work on Voith Turbo Scharfenberg products.

Responsibilities have to be strictly arranged. Untrained staff must be supervised.

Works on the electrical equipment of the product may only be carried out by, or under guidance and supervision by, a qualified electrician in compliance with the relevant electrical safety regu-lations.

1.4 Revision index Revision index

Version 1.

1.5 Approval table Approval table

Department Date Reviewed by Design Dept. PM 3.1 2012-10-25 Reviewed by RAMS Dept. PM 3.3 2012-10-30 Released by Documen tation Dept.

PS 2.1 2012-10-24

Prepared by PS 2.1 2012-10-24

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2 Safety Safety

In order to prevent faulty product handling, the descriptions are provided with safety messages. Safety messages are always situated above the step they refer to.

Indirect hazards The safety instructions refer to hazards which are directly associated with the product. Indirect hazards emanating from the vehicle are subject to the responsibility of the vehicle manufacturer and cannot be described by Voith Turbo Scharfenberg.

Furthermore, the manual only describes hazards which may occur within the scope of intended use [chap.3.3 � page 18] .

Safety message structure

CAUTIONCAUTIONCAUTIONCAUTION Designation of the hazard.Designation of the hazard.Designation of the hazard.Designation of the hazard. Short description of the hazard. � When does this hazard occur (only used exceptionally).

� What is to be done in order to avert the hazard. � What is to be done when being exposed to the hazard (only used exceptionally).

Basically, all safety messages of this manual are structured in a similar manner:

Safety symbols The following safety symbols are used in this manual:

DANGEDANGEDANGEDANGERRRR TopTopTopTop----level hazardlevel hazardlevel hazardlevel hazard DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

DANGERDANGERDANGERDANGER TopTopTopTop----level electrical hazardlevel electrical hazardlevel electrical hazardlevel electrical hazard DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGWARNINGWARNINGWARNING MediumMediumMediumMedium----level hazardlevel hazardlevel hazardlevel hazard WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONCAUTIONCAUTIONCAUTION LowLowLowLow----level hazardlevel hazardlevel hazardlevel hazard

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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CAUTIONCAUTIONCAUTIONCAUTION Risk of damage to material.Risk of damage to material.Risk of damage to material.Risk of damage to material. CAUTION, used without the safety symbol, indicates a hazardous situation which, if not avoided, could result in material damage.

NOTICENOTICENOTICENOTICE Useful tip.Useful tip.Useful tip.Useful tip. This note provides additional information that aims to facilitate the proper use of the product.

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Product description


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3 Product description Product description

This chapter describes the product. It contains the technical data, defines the intended use and describes the design, function, and working principle of the product and its components.

Target group This chapter is addressed to readers wishing to learn more about the basics and components of the product. Technical qualification is not required to understand this chapter.

3.1 Technical data Technical data

This section contains the essential technical data of the product. Compressive strength (Rp0.2)

1500 kN

Tensile strength (Rp0.2) 1000 kN Length Pivot to coupler face 1430 ±5 mm Total weight approx. 610 kg Collapsible tube Stroke On buff approx. 400 mm Maximum load On buff 850 kN ±10 % Friction spring Stroke On draft approx. 23 mm Release load On draft 80 ± 25 kN Maximum load On draft approx. 600 kN Energy absorption draft/buff 7,8 kJ ± 10 % buffer Stroke On buff approx. 143 mm Maximum load On buff 800 kN ± 10 % Energy absorption On buff 93 kJ ± 10 % Electric head Female contacts Ag 9 pcs. Female contacts Au 15 pcs. Male contacts Ag 9 pcs. Male contacts Au 15 pcs. Heaters Electric head 110 V, 25 W Themostat Switching threshold, on approx. 4 °C Switching threshold, off approx. 14 °C Slewing range horizontal ±25° Vertical ±6° Centring device Return-to-centre angle ±10° Minimum operating pressure

0.6MPa

Minimum coupling speed 0.6 km/h Paint in accordance with painting specification [chap.10.1 �

page 205] KCG

Tab. 3-1 Technical data 010.616

3.2 Overview drawing Overview drawing

This section provides an overview (Fig. 3-1) of the product indicating the most important dimen-sions.

User Manual

Product description

Intended use Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Fig. 3-1 Automatic Scharfenberg Coupler 010.616

1 Coupler head 7 Bearing bracket 18 Electrical unit

2 Uncouple cylinder 8 Electric head 36 Muff coupling

3 Air pipe connection 10 Centring device 43 Earthing system

4 Air pipe connection 12 Uncouple pipe 50 Dummy plug

5 Electric head operating gear 13 Air piping 6 Coupler shank 15 Pneumatic unit

3.3 Intended use Intended use

This section defines the intended use and describes examples of potential misuse.

The product is exclusively intended for the usage scenarios described in the chapter Operation [chap.4 � page 53] .

The product is designed to be mounted to rail vehicles. It may only be mounted to the vehicles meeting the warranted qualities of Voith Turbo Scharfenberg and in accordance with the speci-fied arrangement within the train set. When in doubt, please contact Voith Turbo Scharfenberg.

The product is a coupler of the central buffer coupler type.

Prior to commissioning the product, the following requirements have to be complied with:

� The product is completely installed in accordance with the instructions given in this manual [chap.7.1 � page 187] and in the vehicle manufacturer's documentation.

� The instructions given in the section Mounting and Commissioning [chap.7.1 � page 187] must be complied with.

� The product is centred and inclined according to the instructions of this manual [chap. � page 95] .

� All maintenance tasks described in this manual have been performed.

3.3.1 Potential misuse This section describes examples of potential misuse, which are not be deemed exhaustive. The following applications are prohibited:

Product modifications:

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� Permanent or temporary installation of additional loads, subassemblies, objects or functional units, unless such action is warranted by the conditions of use specified in the contract

� Use of other spare parts than the Voith original parts given in the spare parts list of this manual

� Removal of components without replacement � Mounting, leaning, supporting or applying additional loads or devices during operation and

when the vehicle is stationary (in the workshop), unless specified in the contract � Permanent or temporary installation of additional weight or objects at the collapsible tube

and its stroke area

Potential misuse:

� Coupling with couplers of a different type � Coupling with electric heads of a different type � Lifting the vehicle by means of the product � Pulling or pushing the vehicle, other vehicles or loads when uncoupled � Operation of the product beyond the contractually agreed operating conditions

3.3.2 Use in case of restricted readiness for opera tion If the product has lost its operationally safe condition, the operation of the products is only pos-sible with reservations.

The operationally safe condition is limited when

� the supply with power, signals or technical media or their transmission has been switched off or fails

� the automatic control fails partially or completely or is deactivated � an energy absorption element is damaged � components are deformed or broken � the product is no longer safely attached to the vehicle � the unrestricted mobility of the product is obstructed

Only towing is permitted after the product has lost its operationally safe condition. Towing is only permitted if the following prerequisites are complied with:

� The brake system of the towing vehicle must be in a fully functional condition. � The joints and articulation points of all involved couplers/articulations must be freely mova-

ble. � Extreme caution must be exercised when automatically coupling an automatic coupler with

a damaged energy absorption element.

When in doubt, please contact Voith Turbo Scharfenberg.

3.4 General product description General product description

This section describes the design, function, and working principle of the product.

Design The product consists of several modular components. The individual components are illustrated in the overview drawing ( [chap.3.2 � page 17] ).

� Coupler head � Uncouple cylinder � Air pipe connection for brake pipe (BP) � Air pipe connection for main reservoir pipe (MRP) and uncouple pipe (UP) � Electric head operating gear � Coupler shank � Bearing bracket � Electric head � Centring device and support

User Manual

Product description

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� Pipe adapter � Pneumatic unit of the coupler head � Electrical unit of the coupler head � Muff coupling � Earthing system

Function The functions can be classified according to the different operating modes.

The following functions are available for coupling and uncoupling operations:

� Approaching vehicles couple automatically � Vehicles couple automatically within the gathering range even with lateral or vertical offset

of the couplers � Electric heads couple automatically as soon as the vehicles are mechanically coupled � Electric heads uncouple automatically as the vehicles uncouple mechanically � The electric heads can also be coupled and uncoupled manually � As soon as the vehicles couple, the air pipes connect � When the uncoupled vehicles separate, the air pipes of the BP are disconnected at the

same time. The operating pressure remains stable. � Coupled vehicles can be uncoupled by remote control from the vehicle � Coupled vehicles can also be uncoupled manually � The coupler lock is immediately ready-to-couple as soon as the uncoupled vehicles have

separated

The following functions are available for multiple-unit operation:

� Mechanical connection in buff and draft directions � Gimballed movement between the vehicles of the train set is supported � Energy absorption elements cushion impacts between the vehicles � a coupler rupture causes a pressure drop which can be used to initiate emergency braking

For uncoupled couplers, the following functions are available:

� Permanent centring function

Further functions of the coupler are:

� Electric/electronic signal generation � The pneumatic unit can be switched on and off manually � The inclination of the coupler can be adjusted by means of the supporting spring

Tensile and compressive loads are transmitted inside the coupler via the following components:

� Coupler head with coupler lock for transmission of tensile loads and coupler face for trans-mission of compressive loads

� Muff coupling between coupler head and coupler shank � Coupler shank � Bearing bracket with pivot

During multiple unit operation, the energy absorption elements improve the travelling comfort and protect passengers, freight and vehicle from injuries or damage.

The following components are energy absorption elements:

� The spherical bearing in the coupler shank has a low cushioning effect � the regenerative buffer and the friction spring in the coupler shank absorb impacts � The rear-mounted collapsible tube cushions impacts destructively and protects the vehicle

from damage

Working principle Coupling:

As the vehicles approach, the coupler heads align, mate and automatically establish a rigid and reliable mechanical connection between the couplers.

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Simultaneously, the air pipe connections meet and connect the air pipes of the coupled vehicles.

At the same time the electric heads move forwards and couple automatically.

Uncoupling:

The coupler can be uncoupled through remote control from the vehicle.

The automatic uncouple device unlocks the coupler locks.

When the vehicles have separated, the couplers are again ready to couple.

The electric heads are uncoupled automatically, then they are retracted.

As soon as the vehicles separate, the air pipes are disconnected.

The coupler can be uncoupled manually.

Gimballed movement:

The articulation points enable gimballed movement of the coupled vehicles.

Energy absorption:

The energy absorption elements of the coupler are adapted to the specific requirements of the vehicle and to the respective position in the train configuration.

Gathering range The range within which automatic coupling is possible is referred to as the gathering range (Fig. 3-2). Automatic coupling is possible as long as the centre (M) of the counter coupler is situated within the hatched area.

The gathering range is determined theoretically and applies under idealised conditions. The most important conditions are:

� straight track � couplers exactly aligned [chap. � page 95] with the vehicle (front faces are parallel to each

other) � minimum coupling speed

As conditions change, results may differ.

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Product description

General product description Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Fig. 3-2 Theoretical gathering range

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Description of components

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3.5 Description of components Description of components

This section describes the design, function, and working principle of the individual components.

3.5.1 Coupler head This section describes the design, function, and working principle of the coupler head (Fig. 3-3).

Fig. 3-3 Coupler head type 10 - simplified drawing

a Male cone 2 Coupling link 6 Tension spring

b Female cone 3 Coupling link pin 7 Spring bearing

c Coupler face 4 Hooked plate 8 Stem guide

1 Coupler head casing 5 Central pivot 9 Ratchet

Design The main component of the coupler head is the coupler head casing (Fig. 3-3/1). The coupler lock is located inside of the coupler head casing.

The coupler head casing has a special profile at the front side. The profile consists of male (Fig. 3-3/a) and female (Fig. 3-3/b) cones. The male and female cones are surrounded by a wide, plane coupler front face (Fig. 3-3/c).

This profile is provided by a detachable front plate. The front plate is fixed to the front of the coupler head casing.

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Product description

Description of components Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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The coupler face is equipped with a guiding horn. The lower edge of the front plate has a lateral extension.

The coupler lock is a rotating lock. It consists of the coupling link (Fig. 3-3/2), hooked plate (Fig. 3-3/4), central pivot (Fig. 3-3/5) and tension springs (Fig. 3-3/6).

The catch consists of the spring bearing (Fig. 3-3/7), stem guide (Fig. 3-3/8) with compression spring and ratchet (Fig. 3-3/9).

Function The coupler head mechanically connects two vehicles by means of the coupler lock .

The male cone (Fig. 3-3/a) and the female cone (Fig. 3-3/b) of the profile act as sliding and cen-tring surfaces. The gathering range in terms of the vertical, horizontal and angular offset de-pends on the profile.

The guiding horn and the lateral extension significantly increase the gathering range.

In the coupled position, tension springs (Fig. 3-3/6) hold the coupler locks at the stops of the hooked plates (Fig. 3-3/4) and thus keep them locked in place.

The characteristics of the coupler head type are defined by a detachable front plate. It can be detached. This detachability makes the coupler lock easy to maintain.

The coupler locks transmit draft loads, the coupler faces (Fig. 3-3/c) buff loads.

The catch holds the coupler lock in the ready-to-couple position.

Working principle Automatic coupling is possible under the following conditions:

� the catch keeps the coupler lock in the ready-to-couple position � The couplers meet at a minimum speed (see [chap.3.1 � page 17] )

When mating, the coupler heads are centred and slide into each other.

These are the three possible positions of the coupler lock:

� Ready-to-couple position � Coupled position � Uncoupled position

Ready-to-couple position (Fig. 3-4) The coupling link web (Fig. 3-3/2) is close to the edge of the male cone (a). The ratchet (9) locks the hooked plate (4). The ratchet projects out of the side opening of the coupler head casing (1) and is engaged with the catch of the stem guide (8). The tension springs (6) are loaded.

Fig. 3-4 Uncoupled / ready-to-couple position - simplified drawing

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Coupled position (Fig. 3-5) During coupling the couplers' male cones (Fig. 3-3/a) slide into the female cones (b) of the mat-ing coupler. By doing so, they push back the stem guide (8). The stems unlock the ratchets (9). This releases the coupler locks, allowing them to be rotated by the tension springs (6) until the hooked plate (4) hits its stop at the coupler head casing (1). The coupling links (2) in the female cones interlock with the hooked plate recesses. The coupled position is established now, and both coupler locks are engaged with each other.

Fig. 3-5 Coupled position - simplified drawing

The coupling links and the hooked plates form a parallelogram.

The coupler locks are only subjected to tensile loads uniformly distributed onto both coupling links within the parallelogram. The forces are balanced. Accidental unlocking of the coupler locks is impossible. Normal wear does not affect the safety of the coupler lock.

Uncoupled position (Fig. 3-6) In order to uncouple the coupler heads, the uncouple device turns both coupler locks against the force of the tension springs (Fig. 3-3/6) until the coupling links (2) are released from the hooked plate recesses (4). The ratchets (9) engage with the stem guide (8) and keep the cou-pler locks in this position. The uncoupled position is reached.

Fig. 3-6 Uncoupled position - simplified drawing

As the vehicles move apart, the spring loaded stem and the catch move forward and release the ratchet. The hooked plates are rotated by the tension springs, push the coupling links to the edge of the male cones (a) and pull the ratchets into the coupler head casings (1) until they en-gage with the catch. The tension springs are loaded. The coupler lock is again ready to couple.

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3.5.2 Uncouple device This section describes the design, function, and working principle of the uncouple device (Fig. 3-7).

Fig. 3-7 Uncouple cylinder STD.001.02

1 Cylinder casing 6 Compression spring 12 Hexagon bolt

2 Cylinder cover 8 O-ring 14 Countersunk screw

3 Piston 9 O-ring

Design The uncouple device consists of a pneumatic uncouple cylinder and the manual uncouple de-vice.

The uncouple cylinder is located in the coupler head casing. Its piston rod rests against the hooked plate.

The manual uncouple device is part of the coupler head. An uncouple lever is rigidly mounted to the central pivot.

Function The uncouple device rotates the coupler lock from the coupled position to the uncoupled posi-tion.

Working principle The coupler locks can be uncoupled automatically or manually.

Automatic uncoupling can performed from both vehicles. The piston rod of the uncouple cylinder extends and makes the coupler lock turn.

Simultaneously, the same happens in the counter coupler.

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3.5.3 Air pipe connection for brake pipe (BP) This section describes the design, function, and working principle of the BP air pipe connection (Fig. 3-8).

Fig. 3-8 Air pipe connection BP - simplified drawing

2 Gasket 5 Valve casing 7 Valve insert

3 Socket 6 Compression spring 9 actuation

4 Rubber tube

Design The air pipe connection BP is located in the centre of the upper part of the coupler face.

It consists of mouth piece and valve.

The pipe adapter is located at the rear side.

The mouth piece protrudes from the coupler face. The mouth piece consists of a socket (Fig. 3-8/3) and a gasket (2). The socket (3) is spring mounted and captively secured against falling out of its bore.

The valve is located behind the front plate. It is fixed on the coupler head casing. It consists of the valve casing (5), the valve tappet (7) and the trigger (9).

Function and working principle The position of the valve depends on the position of the coupler lock. In the ready-to-couple po-sition the valve is closed.

When coupling, both mouth pieces are pressed tightly against each other (Fig. 3-9). At the same time the central pivot turns into the coupled position and opens the valve.

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Fig. 3-9 Air pipe connection BP, coupled position

13 Coupler face

In the event of a coupler rupture (Fig. 3-10), the position of the coupler lock does not change - the valve remains open and the BP is depressurised. The pressure drop results in automatic emergency braking.

Fig. 3-10 Air pipe connection BP, coupler rupture

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3.5.4 Air pipe connection for main reservoir pipe a nd uncouple pipe This section describes the design, function, and working principle of the air pipe connections MRP and UP.

Fig. 3-11 Air pipe connection for MRP and UP - simplified drawing

1 Valve tappet 3 Mouth piece (gasket + socket) 5 Spring cage

2 Rubber tube 4 Valve plate

Design The air pipe connection MRP and UP is located in the centre of the lower part of the coupler face. It consists of a mouth piece (MRP), a rubber tube (UP) and the common valve.

The mouth piece (Fig. 3-11/3) and the rubber tube (2) project over the coupler face. The mouth piece consists of a socket and a gasket. The socket is spring mounted and captively secured against falling out of its bore.

The rubber tube is situated in a spring cage (5) that is captively secured in the valve casing to protect it from falling out.

The valve is located at the rear side of the coupler face. The valve consists of valve casing and valve tappet.

Function and working principle When uncoupled, the MRP valve is closed.

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When coupling, the valve tappets of both air pipe connections are pressed against each other and open the air pipes. Simultaneously, both mouth pieces (3) are pressed tightly against each other.

The air pipe connection for the uncouple pipe only conducts air during the uncoupling operation.

When coupling, the rubber tubes (2) of both air pipe connections are pressed tightly against each other.

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3.5.5 Electric head operating gear This section describes the design, function, and working principle of the electric head operating gear (Fig. 3-12).

Fig. 3-12 Electric head operating gear 010.572.05

1 Shaft 15 Pin 30 Spring type straight pin

2 Fork 16 Hexagon bolt 33 Spring type straight pin

3 Rod 17 Hexagon bolt 34 Spring type straight pin

4 Guiding rod 18 Locking screw 36 Spring type straight pin

5 Lever 19 Locking screw 37 Split pin

6 Arm 20 Locking screw 39 Bush

7 Pin 22 Washer 40 Friction bearing

8 Spacer 24 Parallel pin 41 Friction bearing

9 Support 25 Hexagon nut 42 Compression spring

10 Handle holder 26 Hexagon nut 50 Support bracket

11 Sleeve 27 Hexagon nut 70 Cylinder

14 Pin 28 Lock washer

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Design The electric head operating gear is situated on the coupler head. The electric head operating gear consists of guiding elements and a pneumatic cylinder.

The guiding element is rigidly fixed to the coupler head casing and consists of control lever and guiding rods. The control lever engages laterally with the lid of the electric head.

Function The electric head operating gear permits automatic and manual coupling and uncoupling of the electric heads.

The casing is moved forwards and backwards on the guiding rods.

During this motion the control lever opens and closes the lid of the electric head automatically.

The pneumatic cylinder is fed with compressed air of the main reservoir pipe MRP.

Working principle The compressed air is redirected depending on the position of the coupler lock.

When coupling mechanically, the coupler lock turns in the coupled position. This redirects the compressed air such that the pneumatic cylinder pushes the electric head forwards.

The lid of the electric head opens, the electric heads mate, align and are pressed against each other with a preset force.

Even if the electric head operating gear is deactivated, the coupler can be coupled mechanically and pneumatically. The electric head remains retracted.

When uncoupling, the coupler lock turns to the uncoupled position. This redirects the com-pressed air such that the penumatic cylinder retracts the electric head.

While the electric head reverses, the lid is forced to close.

If the pneumatic system fails, the electric heads can be separated manually.

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3.5.6 Coupler shank This section describes the design, function, and working principle of the coupler shank (Fig. 3-13).

Fig. 3-13 Coupler shank 010.600.06

1 Intermediate piece 12 Anti-rotation lock 22 Gas-hydraulic buffer

2 Threaded ring 15 Guide ring 34 Hexagon bolt

3 Washer 16 Guide ring 35 Locking screw

4 Bush 18 Wiper 36 Plug

11 Flat key 20 Friction spring 60 Spring casing

Design The coupler shank consists of the following parts:

� Friction spring � buffer

The front end of the coupler shank has a collar.

The rear end of the coupler shank is provided with an eye and houses a spherical bearing.

Function The coupler shank connects coupler head and bearing bracket.

The coupler shank has a supporting function and forms the force flow line within the train set.

The collar permits attachment to the adjacent component by means of a muff coupling [chap.3.5.14 � page 51] .

In the train set, the drawgear protects the coupler and the vehicle from damage caused by loads exceeding the normal operating load. Impacts are cushioned by absorbing the impact energy. Every energy absorption element is installed with a defined pre-stress. Characteristic values are release load, stroke, end load and energy absorption (see Technical Data [chap.3.1 � page 17] ). The following energy absorption elements are installed:

� The buffer and the friction spring cushion buff loads in a regenerative manner

The spherical bearing permits gimballed movement between the vehicles.

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Working principle Within the train set, both draft and buff loads are transmitted along the force flow line.

The energy absorption element cushions extraordinary impacts. An impact which exceeds the maximum load of the energy absorption element is transmitted without further cushioning.

The regenerative buffer converts impact energy into compressive and friction energy: it contains preloaded gaseous and hydraulic media. The preload force ensures a defined response of the buffer. In the event of a heavy impact, the impact energy is reduced and partially stored by over-flowing and compressing the media. After the impact, the coupler shank returns to its initial posi-tion due to the stored spring energy.

The friction spring converts energy into friction energy: in a package of spring washers big and small rings are arranged alternately and pre-stressed with a defined force. The pre-load force ensures a defined response of the friction spring. In case of high loads the spring washers slide into each other, the outer spring washers are expanded, the inner compressed. The wedge-shaped edges of the rings produce very high friction energy. Due to the friction energy the im-pact energy is reduced and energy is stored due to the deformation of the spring washers. After the impact, the spring washers return to their initial position due to the stored spring energy and the coupler shank is ready to operate again.

Force-displacement curve of the total energy absorption of the product (Fig. 3-14):

Fig. 3-14 Combined force-displacement curve for all energy absorbing elements

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3.5.7 Bearing bracket This section describes the design, function, and working principle of the bearing bracket (Fig. 3-15).

Fig. 3-15 Bearing bracket 010.616.07

2 Pin 6 Base plate 33 Retaining ring

3 Anti-friction disc 21 Thrust plate 34 Lubricating nipple

4 Drift 30 Lock washer 35 Dust protection cap

5 Collapsible tube 31 Hexagon bolt 50 Bearing bracket

Design The bearing bracket consists of the bearing bracket, a pivot and a base plate with rear-mounted collapsible tube.

The front side of the bearing bracket is provided with two parallel legs. The two legs accommo-date the pivot which is inserted vertically. The rear is shaped cylindrically and seats together with the drift in the collapsible tube.

The collapsible tube is mounted between bearing bracket and base plate and protrudes to the vehicle underframe.

Function and working principle The bearing bracket connects the coupler shank and the vehicle underframe. It transmits draft and buff loads without producing any cushioning effect.

The pivot connects the bearing bracket with the coupler shank and permits horizontal slewing of the coupler.

The rear mounted collapsible tube absorbs impact loads exceeding the regenerative energy ab-sorption capacity of the coupler. In this case, the bearing bracket is pressed into the collapsible tube.

The collapsible tube converts impact energy into friction and deformation energy: a pre-stressed drift is mounted in it. The pre-stress ensures a homogenous flow of forces during operation. Heavy impacts press the drift into the collapsible tube which is widened. The impact energy is converted into friction and deformation energy.

After the impact, the stroke persists as backlash in the coupler shank, the product can no long-er be used. The installation of a new collapsible tube is required to operate the product again.

3.5.8 Electric head This section describes the design, function, and working principle of the electric head (Fig. 3-16).

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Fig. 3-16 Electric head 08.009.060-Z1

Design The electric head is situated on the coupler head and consists of a casing with lid, contact block and cover. It forms one mechanical unit with the electric head operating gear [chap.3.5.5 � page 31] .

The casing has a rectangular cross-section. The outer side pointing towards the coupler head is provided with guiding elements, the front side features centring devices. The bottom is provided with a drainage.

The front side of the casing is tightly closed by the contact block. To the front, it is surrounded by a gasket. The contact block is provided with bores. The bores hold the terminal studs. The contacts are screwed into the front ends of the terminal studs.

The rear side of the casing is tightly closed by a cover panel. The cover panel accommodates the cable glands and the connection to the operating gear.

The pivot-mounted lid is fixed to the front of the casing. The lid can be pivoted.

Function The electric head permits simultaneous connection and disconnection of the electric contacts of two mechanically coupled vehicles.

The contacts are replaced from the front. The terminal studs mechanically fix the contacts in the contact block and are connected to the electric cables. Cable glands ensure that the cables are guided through the lid in a waterproof and strain-relieved way.

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The drive link is the mechanical interface between the electric head and the electric head oper-ating gear [chap.3.5.5 � page 31] .

In uncoupled position, the lid protects the contacts from dust, water and mechanical damage and prevents inadvertent contact.

The sealing frames of two coupled electric heads seal up the contact area and thus protect the contacts from dust, water, mechanical damage and inadvertent contact.

Working principle During the coupling operation, the electric heads are moved forward.

The centring elements of the opposed casings mate and align the casings. Thus, the contacts meet precisely and the sealing frames are pressed against each other. When uncoupling, the contacts of the electric head are separated.

During coupling and uncoupling, the lids are opened and closed automatically.

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3.5.9 Centring device and support This section describes the design, function, and working principle of the centring device and support.

Design The centring device is screwed to the bearing bracket of coupler. It consists of support (Fig. 3-17/2), cam disc (6), supporting spring (50) and an own bearing bracket (57).

The forked levers of the support (2) enclose the coupler shank. The supporting spring is situated between the forked levers. A spring holder (8) is situated on each side of the coupler.

The spring holders (8) contain Belleville springs and a stem. The stem rests at the cam disc (6).

The cam disc (6) is fixed at the bearing bracket (57). It is provided with two peripheral recesses. These are exactly matched to the position of the spring holders (8).

Fig. 3-17 Centring device with support - simplified drawing

2 Support bracket 31 Hexagon bolt

6 Cam disc 39 Lock washer

7 Sliding plate 50 Supporting spring

8 Spring holder with stem 57 Bearing bracket

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Function The centring device exerts a defined spring force to keep the uncoupled coupler in line with the longitudinal vehicle axis and re-centres the coupler within a defined return-to-centre angle (see [chap.3.1 � page 17] ). Lateral movement is cushioned.

Working principle The spring force of the Belleville springs presses the stems into the recesses of the cam disc. The stems and the recesses centre themselves and hold the coupler in the centre position. Transversal loads at the coupler will be compensated up to a certain force.

In the case of stronger transversal loads, the coupler makes the support turn. The stems move out of the recesses of the cam disc and are pressed into the cylinders.

If the coupler is swung out of the return-to-centre angle, the stems are outside their recesses and cannot counteract, the coupler swings out freely.

Tight curves, transitions or S-curves, e.g. in the workshop, may cause a mismatch of gathering ranges between two couplers. Automatic coupling is only possible if both couplers are manually swivelled towards each other.

Manual handling of the coupler requires great physical effort and involves a high danger of inju-ry. Within the return-to-centre angle the high preload prevents swivelling and keeps the coupler in its position. After the coupler has been swung out beyond the repositioning angle, it can be easily moved further. Risk of injury consists in the following situations:

� Presence of persons in the danger area between moving cars � Outside the return-to-centre angle, the couplers can collide with each other and swing out in

an uncontrolled manner � If the return-to-centre angle is exceeded marginally, the movement of the cars can cause

the couplers to move into the return-to-centre angle and then swing back abruptly to their mid-position before the cars can be coupled safely

The chapter "Operation" describes this case in detail.

Centring of the coupler The position of the cam disc at the bearing bracket determines the direction of the longitudinal axis of the coupler. Slotted holes in the cam plate permit to fix the position at the bearing brack-et (refer to Centre coupler).

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3.5.10 Uncouple pipe This section describes design and function of the uncouple pipe (Fig. 3-18).

Fig. 3-18 Uncouple pipe STD.002.12

1 Adapter 12 Swivel fitting 16 Hose

11 Gasket 13 TE fitting

Design The uncouple pipe consists of an adapter and piping, if any.

The adapter connects to the uncouple cylinder and projects downwards through the coupler head casing.

Function and working principle The uncouple pipe connects the uncouple cylinder in the coupler head casing with the air pipe connection.

The uncoupling pipe transmits the uncouple impulse and only conveys compressed air during the uncouple operation.

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3.5.11 Pipe adapter This section describes the design and function of the pipe adapters (Fig. 3-19).

Fig. 3-19 Air piping 010.616.13

9 Socket 10 Pipe adapter 12 Pipe adapter

Design The pipe adapter is attached to the rear side of the air pipe connection. The pipe adapter is a shaped piece of pipe. It is equipped with a flange on one side and with a thread on the other side.

Function The pipe adapter extends the air pipe connection to the rear side of the coupler head.

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3.5.12 Pneumatic unit of the coupler head This section describes the design, function, and working principle of the pneumatic unit at the coupler head (Fig. 3-20).

Fig. 3-20 Pneumatic unit 010.572.15

1 Support bracket 16 Swivel fitting 55 Lock washer

2 Label 20 Male stud connector 56 Lock washer

10 5/2-way valve 30 3-way ball valve 80 Hose

11 Venting cap 35 Strainer 82 Hose

12 Silencer 50 Hexagon bolt 84 Hose

15 Double nipple 51 Socket head cap screw

Design The pneumatic unit of the coupler head is connected to the air pipe connection MRP. It mainly consists of:

� Stopcock for electric head operating gear � Strainer � 5/2 way valve for the electric head operating gear � Hoses and fittings

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Function Depending on the position of the coupler lock, the pneumatic unit of the coupler head controls the following components:

� The electric head operating gear [chap.3.5.5 � page 31]

The pneumatic unit can be switched on and off with the stopcock.

Working principle The pneumatic unit can assume the following positions, which correspond to the coupler lock [chap.3.5.1 � page 23] positions:

� Ready-to-couple position � Coupled position � Uncoupled position

The pneumatic diagram shows the working principle.

In ready-to-couple position, the pneumatic unit controls the following situation:

� The 5/2-way valve directs the compressed air into the part of the pneumatic cylinder that holds the electric head in the retracted position.

� The BP air pipe connection is sealed, maintaining the BP pressurised. � The MRP air pipe connection is sealed, maintaining the MRP pressurised. � The uncouple pipe is depressurised.

When coupling automatically, the coupler lock turns in the coupled position.

The pneumatic unit establishes the following condition:

� The coupler lock actuates the 5/2 way valve. � The 5/2-way valve directs compressed air into the part of the pneumatic cylinder that moves

the electric head to and holds it in the forward position. � Both MRP air pipe connections are engaged and the valve tappets are open. � The compressed air flowing through the MRP is allowed to pass through. � Both MRP air pipe connections are connected to each other and the valve tappets are

opened. � The compressed air existing in the MRP is allowed to pass through. � Both air pipe connections UP are connected via the coupler faces, but remain de-aerated.

When uncoupling automatically, the uncouple device is actuated.

The uncouple cylinder turns the coupler lock into the uncoupled position.

The pneumatic unit generates the following situation:

� The coupler lock actuates the 5/2 way valve. � The 5/2-way valve directs the compressed air into the part of the pneumatic cylinder that re-

tracts the electric head and holds it in its rear position. � Both MRP air pipe connections are engaged and the valve tappets are open. � The air pipe connections UP are connected at the coupler face and conduct compressed air.

When the vehicles are separated, the ready-to-couple position of the coupler locks is automati-cally restored.

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Safety note

WARNINGWARNINGWARNINGWARNING Accidental uncoupling caused by aiAccidental uncoupling caused by aiAccidental uncoupling caused by aiAccidental uncoupling caused by air seepager seepager seepager seepage Air can penetrate into the uncouple pipe via the uncouple valve (supplied by the vehi-cle manufacturer). The gradual pressure build-up may cause an undesired actuation of the uncouple cylinder. � Fit the uncouple valve with a throttled ventilation.

When coupled, possible leakage in one of the uncouple valves (Fig. 3-21/1) may cause a grad-ual pressure buildup in the uncouple pipe (3). This may result in a pressurisation of the uncou-ple cylinder and an unintended releasing of the coupler lock.

Thus, the uncouple valve should be fitted with a venting pipe (2) which is throttled to Ø 1 mm. This prevents the pressure buildup in the pipe, while at the same time ensuring safe uncoupling.

Fig. 3-21 Vent of uncouple pipe

A Coupling side 3 Uncouple pipe

B Vehicle side 4 Main reservoir pipe (MRP)

1 Uncouple valve 5 Stop valve MRP

2 Vent pipe with throttle, ø 1 mm

Pneumatic diagram Fig. 3-22 illustrates the pneumatic diagram P221.4 - ready-to-couple position.

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Fig. 3-22 Pneumatic diagram P221.4 Ready-to-couple position

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I Coupler head VIII Uncouple cylinder

II Coupler lock IX Uncouple pipe

III Cam X Main reservoir pipe

IV Electric head XI Stopcock of main reservoir pipe

V Pneumatic cylinder XII Uncouple valve

VI 5/2 way valve for electric head control XIII Throttle (Ø 1 mm)

VII Stopcock for electric head operating gear XIV Brake pipe

Fig. 3-23 illustrates the pneumatic diagram P221.4 - coupled position.

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Fig. 3-23 Pneumatic diagram P221.4 Coupled position

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Fig. 3-24 illustrates the pneumatic diagram P221.4 - uncoupled position before separation.

Fig. 3-24 Pneumatic diagram P221.4 Uncoupled position

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3.5.13 Electrical unit at the coupler head This section describes the design, function, and working principle of the electrical unit at the coupler head (Fig. 3-25).

Fig. 3-25 Electrical unit 010.572.18

5 Position switch 14 Elbow 20 End-sleeve for wires

10 Socket head cap screw 15 Curved connector 21 End-sleeve for wires

11 Lock washer 16 Hexagon nut 60 Sealing label

Design The electrical unit consists of:

� Heaters in the electric head casing � Position switch at central pivot � Cables and fasteners

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NOTICENOTICENOTICENOTICE Operating elements in the vehicleOperating elements in the vehicleOperating elements in the vehicleOperating elements in the vehicle Some operating and switching elements are delivered and installed by the vehicle manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

Function The heaters in the electric head casing prevent condensation of water and icing. This reduces the risk of short-circuits and contact breakage.

The position switch at the central pivot detects the position of the coupler lock. The respective signal is utilised for coupler control and for the indication in the vehicle.

Working principle The position switch at the central pivot is triggered by the rotation of the central pivot. As the central pivot reaches a predefined angle, the position switch is operated and signals the position of the coupler lock to the train control system.

Fig. 3-26/ illustrates how to connect the position switch that monitors the central pivot.

Fig. 3-26 Wiring diagram

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3.5.14 Muff coupling This section describes the design and function of the muff coupling connection (Fig. 3-27).

Fig. 3-27 Muff coupling - simplified drawing

Design The muff coupling consists of two muffs with screw connections. The muffs are placed around the collars of the components to be connected and then screwed together.

Muff couplings can be installed horizontally, vertically, or in inclined position. Muff couplings in-tended for horizontal or inclined installation have a drain hole in the lower muff.

Function The muff coupling is a clamped connection. The components to be joined are rigidly clamped together by the screws of the muff coupling. The screw connection is not situated in the flow of force of the coupler and is easily detachable.

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3.5.15 Earthing system This section describes the design and function of the earthing system (Fig. 3-28).

Fig. 3-28 Earthing system 010.616.43

2 Socket head cap screw 10 Washer 17 Earth wire

3 Clamp 14 Earth wire 18 Earth wire

5 Hexagon bolt 15 Earth wire 20 Earth label

7 Lock washer 16 Earth wire 30 Protection plug

Design The earthing system consists of copper wires connected to earth sockets.

Function and working principle The earthing system bridges non-conductive parts and coatings between the components.

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4 Operation Operation

This chapter describes the operation of the coupler.

NOTICENOTICENOTICENOTICE Operating elements in the vehicleOperating elements in the vehicleOperating elements in the vehicleOperating elements in the vehicle Some operating and switching elements are delivered and installed by the vehicle manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

Target group This chapter is addressed to qualified technical staff, in particular to the staff of the operator, that has to move the vehicle from the driver's cab or to couple or uncouple manually.

The target group has to be familiar with the basic principles of the product. A training by Voith Turbo Scharfenberg is highly recommended.

4.1 Automatic coupling Automatic coupling

This section describes automatic coupling.

Tools and Materials None.

Preparations

DANGERDANGERDANGERDANGER Electric shockElectric shockElectric shockElectric shock Danger to life when touching live parts. � The coupler has live parts.

� Cut off power. Safeguard the electrical circuits against unintentional restoration of power.

DANGERDANGERDANGERDANGER Risk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tension

The coupling link is subject to tensile load and may jump out abruptly from the coupler head male cone as the coupler lock is released. � Keep a safety distance of at least 10 cm from the male cone.

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury.

The electric head lids are automatically opened and closed. � Keep a sufficient distance to the lids.

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WARNINGWARNINGWARNINGWARNING Risk of accidental train separationRisk of accidental train separationRisk of accidental train separationRisk of accidental train separation Foreign matter may impede proper coupling. � Remove all foreign matter from the female cones of both coupler heads.

WARNINGWARNINGWARNINGWARNING Restricted readiness for operationRestricted readiness for operationRestricted readiness for operationRestricted readiness for operation If the product's readiness for operation is restricted, the relevant operating instructions of the vehicle operator must be complied with. � See also [chap.3.3.2 � page 19] .

NOTICENOTICENOTICENOTICE Operation of oOperation of oOperation of oOperation of opposite couplerpposite couplerpposite couplerpposite coupler For the opposite coupler specifications might differ. � Also follow the instructions in the user manual for the opposite coupler.

Check the ready-to-couple position The following specifications also apply for the opposite coupler. However, details might differ.

1) Check coupler face for impurities, if required: � Put coupler in repair position [chap.5.2 � page 71] � Remove foreign matter from the female and male cones of both coupler heads. � Clean coupler faces � Cancel repair position [chap.5.2 � page 71] .

2) Open the stopcock (Fig. 4-1) on both couplers to activate the electric head operating gears. � the electric head operating gear is switched on now

Fig. 4-1 Stopcock

A open

B Closed

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3) Power off the electric head.

4) Check coupler lock for ready-to-couple position.

The "ready-to-couple" position (Fig. 4-2) can be recognised as follows:

� the coupling link is retracted in the male cone, � the ratchet protrudes from the side (female cone side) of the coupler head casing


NOTICENOTICENOTICENOTICE Not in readyNot in readyNot in readyNot in ready----totototo----couple positioncouple positioncouple positioncouple position

If the coupler locks are not in their ready-to-couple position: � Actuate the manual uncoupling device.

5) Check the electric heads for ready-to couple position.

The electric heads show the "ready-to-couple" position if the following features apply for both couplers:

� The electric head is in the retracted position � The lid of the electric head is closed � The "electrically coupled" indication in the vehicle (car-builder's scope of delivery) is off

Coupling

WARNINGWARNINGWARNINGWARNING Risk of inRisk of inRisk of inRisk of injury.jury.jury.jury. If the couplers meet diagonally or outside of the gathering range, they rebound and swivel out abruptly. � Align couplers for coupling. � When coupling keep a safety distance of at least one meter.

1) Stop vehicles to be coupled at a distance of approx. one meter from one another.

2) Slowly approach the vehicles (at least 0.6 kph). � The couplers couple without manual assistance. � At the same time, the vehicles are also coupled electrically. � At the same time, the vehicles are also coupled pneumatically.

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DANGERDANGERDANGERDANGER Electric shockElectric shockElectric shockElectric shock A gap between the electric heads after coupling is presents a hazard for electric shock and crushing. � Keep a sufficient safety distance to the gap. � Uncouple completely and couple again.

3) Power on the electric head.

Check the coupled position The following specifications also apply for the opposite coupler. However, details might differ.

1) Check the coupler lock for coupled position (Fig. 4-3).

The coupled position of the coupler can be recognised as follows:

� the coupler coupler faces are close together. � The ratchet is situated inside the coupler head


2) Verify the coupled position of the electric heads.

The electric heads are in the coupled position if the following features apply for both couplers:

� the electric head casings are pressed against one another � the lid of the electric head is completely open � the "electrically coupled" indication in the vehicle (car-builder's scope of delivery) is on

NOTICENOTICENOTICENOTICE Coupling failsCoupling failsCoupling failsCoupling fails When coupling fails: � Separate vehicles and couple again.

Final steps

1) Check if the air pipe connections are air-tight (no hiss).

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4.2 Coupling without connecting the electric heads Coupling without connecting the electric heads

This section describes coupling without coupling the electric heads.

If the electric lines must not be coupled for operating reasons (e.g. for towing), the electric head operating gear can be switched off manually such that the couplers are only coupled mechani-cally.


Preparations

DANGERDANGERDANGERDANGER Electric shocElectric shocElectric shocElectric shockkkk Danger to life when touching live parts. � The coupler has live parts.


DANGERDANGERDANGERDANGER Risk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tension The coupling link is subject to tensile load and may jump out abruptly from the coupler head male cone as the coupler lock is released. � Keep a safety distance of at least 10 cm from the male cone.

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. The electric head lids are automatically opened and closed. � Keep a sufficient distance to the lids.

WARNINGWARNINGWARNINGWARNING Risk of accidental train separationRisk of accidental train separationRisk of accidental train separationRisk of accidental train separation

Foreign matter may impede proper coupling. � Remove all foreign matter from the female cones of both coupler heads.

WARNINGWARNINGWARNINGWARNING Restricted readiness for operationRestricted readiness for operationRestricted readiness for operationRestricted readiness for operation If the product's readiness for operation is restricted, the relevant operating instructions

of the vehicle operator must be complied with. � See also [chap.3.3.2 � page 19] .

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NOTICENOTICENOTICENOTICE Operation of opposite couplerOperation of opposite couplerOperation of opposite couplerOperation of opposite coupler For the opposite coupler specifications might differ. � Also follow the instructions in the user manual for the opposite coupler.

Check the ready-to-couple position The following specifications also apply for the opposite coupler. However, details might differ.

1) Check coupler face for impurities, if required: � Put coupler in repair position [chap.5.2 � page 71] � Remove foreign matter from the female and male cones of both coupler heads. � Clean coupler faces � Cancel repair position [chap.5.2 � page 71] .

2) Open the stopcock (Fig. 4-4) on both couplers to activate the electric head operating gears. � the electric head operating gear is switched on now

Fig. 4-4 Stopcock

A open

B Closed


4) Check coupler lock for ready-to-couple position.

The "ready-to-couple" position (Fig. 4-5) can be recognised as follows:

� the coupling link is retracted in the male cone, � the ratchet protrudes from the side (female cone side) of the coupler head casing

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NOTICENOTICENOTICENOTICE Not in readyNot in readyNot in readyNot in ready----totototo----couple positioncouple positioncouple positioncouple position If the coupler locks are not in their ready-to-couple position: � Actuate the manual uncoupling device.

Coupling

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. If the couplers meet diagonally or outside of the gathering range, they rebound and swivel out abruptly. � Align couplers for coupling. � When coupling keep a safety distance of at least one meter.

1) Stop vehicles to be coupled at a distance of approx. one meter from one another.

2) Slowly approach the vehicles (at least 0.6 kph). � The couplers couple without manual assistance. � At the same time, the vehicles are also coupled pneumatically. � The electric head remains retracted with closed lids.

Check the coupled position

1) Check the coupler lock for coupled position (Fig. 4-6).

The coupled position of the coupler can be recognised as follows:

� the coupler coupler faces are close together. � The ratchet is situated inside the coupler head

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NOTICENOTICENOTICENOTICE Coupling failsCoupling failsCoupling failsCoupling fails When coupling fails: � Separate vehicles and couple again.

Final steps

1) Check if the air pipe connections are air-tight (no hiss).

2) Secure stopcock against accidental opening. � The stop cock must be closed to keep the electric heads retracted.

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury.

When opening the stopcock, the electric head may abruptly jump forward. It depends on the position of electric head and coupler lock. � Stay away from the hazard area. � Then open stopcock.

NOTICENOTICENOTICENOTICE Coupling failsCoupling failsCoupling failsCoupling fails If the electric heads are to be coupled afterwards: � Open stopcocks of both couplers.

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4.3 Coupling - on tight curves Coupling - on tight curves

Tight curves, transitions or S-curves, e.g. in the workshop, may cause a mismatch of gathering ranges between two couplers. Automatic coupling is only possible if both couplers are manually swivelled towards each other.

Manual handling of the coupler requires great physical effort and involves a high danger of inju-ry. Within the return-to-centre angle the high preload prevents swivelling and keeps the coupler in its position. After the coupler has been swung out beyond the repositioning angle, it can be easily moved further. Risk of injury consists in the following situations:

� Presence of persons in the danger area between moving cars � Outside the return-to-centre angle, the couplers can collide with each other and swing out in

an uncontrolled manner � If the return-to-centre angle is exceeded marginally, the movement of the cars can cause

the couplers to move into the return-to-centre angle and then swing back abruptly to their mid-position before the cars can be coupled safely

1) To enable automatic coupling, move the vehicles to a straight track.

4.4 Automatic uncoupling Automatic uncoupling

This section describes automatic uncoupling.


Preparations

NOTICENOTICENOTICENOTICE Operating elemOperating elemOperating elemOperating elements in the vehicleents in the vehicleents in the vehicleents in the vehicle

Some operating and switching elements are delivered and installed by the vehicle manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

NOTICENOTICENOTICENOTICE Operation of opposite couplerOperation of opposite couplerOperation of opposite couplerOperation of opposite coupler

For the opposite coupler specifications might differ. � Also follow the instructions in the user manual for the opposite coupler.

NOTICENOTICENOTICENOTICE Uncouple without tensile loadUncouple without tensile loadUncouple without tensile loadUncouple without tensile load For uncoupling the couplers have to be free from tensile loads. � Avoid tensile loads when uncoupling. � Reduce unavoidable tensile loads to below 50 kN.


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Uncoupling

1) Press the uncouple button in the vehicle according to the instructions of the vehicle manu-facturer.

� The coupler is now in the uncoupled position.

Check the uncoupled position The following specifications also apply for the opposite coupler. However, details might differ.

1) Check the coupler lock for uncoupled position (Fig. 4-7).

Check the coupler lock for uncoupled position and make sure:

� the ratchet protrudes from the side of the coupler head


2) Checking the uncoupled position of the electric head.


� the electric head casings are separated � the electric head is in retracted position � The lid of the electric head is closed � the "electrically coupled" indication in the vehicle (car-builder's scope of delivery) is off

Separate the vehicles

1) Move the vehicles apart.

When separating the vehicle, the following takes place:

� The coupler locks rotate into the ready-to-couple position. � the air pipe connection closes the brake pipe � The uncoupled coupler is centred in the longitudinal vehicle axis


Final steps None.

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4.5 Manual uncoupling Manual uncoupling

The coupler can be uncoupled manually.

Tools and Materials � Various standard tools � Cranked ring wrench or ratchet SW 21 for manual operation of the electric head

Preparations

DANGERDANGERDANGERDANGER Electric shockElectric shockElectric shockElectric shock

Danger to life when touching live parts. � The coupler has live parts.


WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. Couplers subjected to tensile load may jump forward or to the side when uncoupling manually. � Keep the maximum safety distance during uncoupling; wherever possible, uncou-

ple the couplers from the inside of the curve.

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. The electric head lids are automatically opened and closed. � Keep a sufficient distance to the lids.

CAUTIONCAUTIONCAUTIONCAUTION Electric heads may get damaged.Electric heads may get damaged.Electric heads may get damaged.Electric heads may get damaged. Uncoupling the electric heads from one vehicle only may damage the electric heads. � Be sure to retract the electric heads on both vehicles.

NOTICENOTICENOTICENOTICE Uncouple without tensile loadUncouple without tensile loadUncouple without tensile loadUncouple without tensile load For uncoupling the couplers have to be free from tensile loads. � Avoid tensile loads when uncoupling. � Reduce unavoidable tensile loads to below 50 kN.

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NOTICENOTICENOTICENOTICE Separating the vehiclesSeparating the vehiclesSeparating the vehiclesSeparating the vehicles � Do not separate the vehicles before having finished the manual uncoupling proce-

dure, otherwise you will need to put both couplers separately into the uncoupled position.

� Apply the brakes of the vehicles.

1) Power off the couplers according to the vehicle manufacturer's instructions and prevent un-intentional reconnection of the power supply.

2) Close the stopcock (Fig. 4-8) on both couplers. � The electric head operating gear is deactivated.

Fig. 4-8 Stopcock

A open

B Closed

Manual uncoupling of the electric heads

1) Place a ring wrench on the hexagon head of the operating gear (Fig. 4-9).

2) Rotate the ring wrench. � The electric head must reach the rear limit stop � The lid closes automatically

3) Remove the ring wrench.

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Fig. 4-9 Hexagon head on operating gear - simplified drawing

4) Use the same procedure to retract the electric head of the opposite coupler.

Manual uncoupling of the couplers

NOTICENOTICENOTICENOTICE Assistance during uncoupAssistance during uncoupAssistance during uncoupAssistance during uncouplinglinglingling Uncoupling is easier when a second person simultaneously uncouples the opposite coupler.

CAUTIONCAUTIONCAUTIONCAUTION Risk of damage to uncouple rope.Risk of damage to uncouple rope.Risk of damage to uncouple rope.Risk of damage to uncouple rope. The uncouple rope may break when it is pulled too hard. � Pull the uncouple rope until the coupler locks have been disengaged (clicking

sound).

1) Pull the uncouple rope until the coupler locks have been disengaged (clicking sound).

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Fig. 4-10 Manual uncoupling - simplified drawing

1 Central pivot 3 Uncouple rope with handle

2 uncouple lever in uncoupled position

CAUTIONCAUTIONCAUTIONCAUTION Risk of damage to coupler.Risk of damage to coupler.Risk of damage to coupler.Risk of damage to coupler. The handle of the uncouple rope may dangle down and damage hoses and cables during operation if not hooked back into its holder properly. � Hook handle into holder after use.

2) Hook handle of uncouple rope properly into corresponding holder (Fig. 4-11).

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Fig. 4-11 Holder of handle at coupler head - simplified drawing

1 Handle 2 Uncouple rope

Check the uncoupled position The following specifications also apply for the opposite coupler. However, details might differ.

1) Check the coupler lock for uncoupled position (Fig. 4-12).

Check the coupler lock for uncoupled position and make sure:

� the ratchet protrudes from the side of the coupler head


2) Checking the uncoupled position of the electric head.


� the electric head casings are separated � the electric head is in retracted position � The lid of the electric head is closed � the "electrically coupled" indication in the vehicle (car-builder's scope of delivery) is off

Separate the vehicles

1) Move the vehicles apart.

When separating the vehicle, the following takes place:

� The coupler locks rotate into the ready-to-couple position.

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� the air pipe connection closes the brake pipe � The uncoupled coupler is centred in the longitudinal vehicle axis


Final steps

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. When opening the stopcock, the electric head may abruptly jump forward. It depends

on the position of electric head and coupler lock. � Stay away from the hazard area. � Then open stopcock.

1) Open the stopcock (Fig. 4-8) on both couplers. � The electric heads are again ready to be coupled automatically.

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5 Light maintenance Light maintenance

This chapter describes the required light maintenance tasks.

Definition Light maintenance includes tasks which can be performed directly at the vehicle. A workshop is not required.

In contrast, heavy maintenance can only be performed in a workshop.

Structure of this chapter This chapter includes the preparations as well as the required light maintenance tasks.

The maintenance tasks are listed in the Maintenance schedule - light maintenance [chap.5.3 � page 75] .

Target group This chapter is addressed to qualified technical staff specialised in mechanical engineering (for mechanical and pneumatic components) and electrical engineering (for electrical components).

The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain mainte-nance tasks.

Replacement of parts In most cases a visual check for corrosion, wear and damage is sufficient to decide whether parts must be replaced or not.

CAUTIONCAUTIONCAUTIONCAUTION Replacement of fastenersReplacement of fastenersReplacement of fastenersReplacement of fasteners Whenever parts or components are disassembled or removed, fasteners such as screws, nuts, washers, retaining rings, spiral rings and spring type straight pins have

to be replaced. � Replace all fasteners after loosening. � When refitting parts, use new fasteners as specified in the Parts catalog.

Gaskets and rubber tubes have to be replaced after removal and disassembly of a component at the latest.

Recommended torque for new bolted joints For bolted joints the following remarks apply.

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CAUTIONCAUTIONCAUTIONCAUTION Recommended torque for bolted jointsRecommended torque for bolted jointsRecommended torque for bolted jointsRecommended torque for bolted joints The recommended torque for screw connections applies to threads with a coefficient of friction µtotal=0.08 on all surfaces involved. That is to say: � The contact surfaces for screw head, washer and/or nut are only primed as

stated in the paint specification. � The contact surfaces and the threads are treated with RIVOLTA GWF.

� If another lubricant is used, the torque must be corrected accordingly.

CAUTIONCAUTIONCAUTIONCAUTION Recommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: � The contact surfaces for screw head, washer and/or nut are only primed. � The contact surfaces are clean, dry and free of grease. � RIVOLTA GWF is applied to the threads only.


Specific agreements will be explicitly mentioned, where applicable.

The hash (#) indicates that the respective item is to be tightened to a special torque.

Check the torques of existing bolted joints For existing bolted joints tightened to a defined torque, a special test procedure [chap.5.12 � page 99] is to be applied.

The following note is added at the respective spot of the instructions:

NOTICENOTICENOTICENOTICE Checking the recommended torqueChecking the recommended torqueChecking the recommended torqueChecking the recommended torque � Please respect the test procedure [chap.5.12 � page 99] for bolted joints

tightened to a defined torque.

Loosening of screw connections that are secured wit h threadlocker Screws, bolts, threaded pins etc. which are secured with acrylate glue must be heated cautious-ly before being loosened. The threadlocker gets pasty and the screw can be removed.

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Materials

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5.1 Materials Materials

NOTICENOTICENOTICENOTICE Materials as specifiedMaterials as specifiedMaterials as specifiedMaterials as specified The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any conse-quential damage.

Rough cleaning � Cleaning spray WEICON S (rough cleaning of all surfaces) � Cleaner LOCTITE 7063 (cleaning / degreasing for further treatment) � Ethyl alcohol (cleaning of valve casings)

Corrosion Protection � Anti-corrosive ZINGA (corrosion protection for coupler face, female cone and male cone of

coupler head - coating must not be thicker than 30 µm to prevent adverse effects on proper coupling functionality)

� Grease AUTOL TOP 2000 or grease spray AUTOL TOP 2000 (corrosion protection for all bearings, pivot points and sliding surfaces. Also if applicable: stem guide contact surface; piston rod contact surface; contact surfaces of cams for valves and limit switches; contact surfaces of lateral stops; visible surfaces of regenerating buffers; cylinder inside and piston rod of pneumatic cylinders; muff coupling collars)

� Penetrating oil RIVOLTA T.R.S. Plus (immediate measure for cleaning and re-greasing of corroded articulation points and parts subject to seizing; e.g. levers of electric head operat-ing gear, lid guides in electric head casing, bushes in protecting lid of electric head)

� Anti-seize RIVOLTA GWF (Corrosion protection for contact surfaces of screw heads and nuts as well as threads of all screws and bolts; exception: on muff couplings, only screw threads are to be treated, contact surfaces for screws and nuts must remain untreated)

Electric head � Artificial resin paint (repairing coating of electric head casing) � French chalk powder (flexibility of the contact block sealing frame, prevention of abrasion

and adhesion)

Paint � Paint according to Painting specification [chap.10.1 � page 205] � Contrasting colour for control elements 2-component PUR acrylic top coat, Flame red, RAL

3000, H05.975956 � Contrasting colour for earthing sockets Anti-sabotage lacquer, Rape yellow, RAL 1021,

H05.975955

5.2 Repair position Repair position

The coupler must be in repair position whenever maintenance and repair activities are carried out. This position is identical to the coupled position of the coupler lock.

Tools and Materials � Rod (e.g. hammer shank) � Cranked ring wrench or ratchet SW 21 for manual operation of the electric head

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Preparations




Danger to life when touching electric contacts. � Live wires are connected by the electric heads.


DANGERDANGERDANGERDANGER Risk of injury from sprRisk of injury from sprRisk of injury from sprRisk of injury from spring tensioning tensioning tensioning tension The coupling link is subject to tensile load and may jump out abruptly from the coupler head male cone as the coupler lock is released. � Keep a safety distance of at least 10 cm from the male cone.

WARNINGWARNINGWARNINGWARNING Danger of crushingDanger of crushingDanger of crushingDanger of crushing Pneumatically controlled components may be activated. � Prior to conducting any maintenance activities, switch the pneumatic system off

and depressurise air pipes and other pneumatic parts. Safeguard the electrical circuits against unintentional restoration of power.

1) Power off the coupler.

2) Switch off the compressed air supply and vent air pipes of the coupler.

3) Close the stopcock (Fig. 5-1).

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Fig. 5-1 Stopcock

A open

B Closed

Manual uncoupling of the electric heads

1) Place a ring wrench on the hexagon head of the operating gear (Fig. 5-2).

2) Rotate the ring wrench. � The electric head must reach the rear limit stop � The lid closes automatically

3) Remove the ring wrench.

Fig. 5-2 Hexagon head on operating gear - simplified drawing

4) Use the same procedure to retract the electric head of the opposite coupler.

Put the coupler lock in the coupled position

1) Place rod (Fig. 5-3/3) at the end of the ratchet (6).

2) Slightly tap on rod (3) to push ratchet (6) out of the catch.

As an alternative:

3) Insert rod (3) into the female cone such that it rests on the contact surface.

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4) Firmly tap on rod (3) to push ratchet (6) out of the catch.

The coupled position of the coupler lock can be verified as follows:

� Coupling link protrudes from male cone � Ratchet is retracted in coupler head casing � Hooked plate rests at stop in coupler head

Fig. 5-3 Putting the coupler lock in the coupled position

1 Male cone 4 Coupling links jumps out of male cone A Ready-to-couple position

2 Female cone

5 Hooked plate at stop B Coupled position

3 Rod 6 Ratchet retracted in coupler head

Put coupler in ready-to-couple position

1) Operate the automatic or manual uncouple device ( [chap.4.5 � page 63] ).

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Maintenance schedule - light maintenance

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5.3 Maintenance schedule - light maintenance Maintenance schedule - light maintenance

The maintenance schedule serves as an overview and quick reference to the maintenance tasks which are to be performed within the scope of light maintenance.

These brief descriptions do not substitute the full descriptions referred to.

The maintenance intervals are recommended values. They have to be reduced in case of ad-verse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing.

Maintenance level Time interval Maintenance level 1 (ML1) Monthly Maintenance level 2 (ML2) Every 3 months Maintenance level 3 (ML3) Annually Maintenance level 4 (ML4) Every 2 years Overhaul 1 (OH1) Every 6 years Overhaul 2 (OH2) Every 12 years Tab. 5-1 Maintenance and overhaul levels

5.3.1 Light maintenance ML1 The following tasks are to be performed within the scope of maintenance level 1:

Preparations � Put the coupler in the repair position [chap.5.2 � page 71]

Entire coupler � Rough cleaning [chap.5.4 � page 81] of the product � Visual inspection [chap.5.5 � page 82] for damage

Coupler head � Check the coupler lock for smooth operation [chap.5.7 � page 89] � Lubricate the central pivot using the grease nipples [chap.5.6 � page 83] � Grease the coupler lock with grease spray AUTOL TOP 2000 according to the lubrication

schedule [chap.5.6 � page 83] � Check if springs are broken, replace if necessary

Air pipe connection � Clean the socket and the gasket with grease free rag

Electric head operating gear � Clean the guiding rods with a grease-free rag

Coupler shank � Check the buffer for oil or grease leaks. If oil or grease leaks are found, return the coupler

shank to the manufacturer for overhaul

Bearing bracket � Perform a resonance test in order to check the collapsible tube for tight seat, replace if nec-

essary

Electric head � Clean contacts, contact block and centring elements with a lint-free dry rag � Clean sealing frame with a damp cloth, wipe dry and dust with French chalk powder; if nec-

essary, clean contacts once again

User Manual

Light maintenance

Maintenance schedule - light maintenance Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Muff coupling � Check whether the bores of the lower muff are filled with grease, re-grease if necessary

(horizontal muffs)



Entire coupler � Rough cleaning [chap.5.4 � page 81] of the product � Visual inspection [chap.5.5 � page 82] for damage


schedule [chap.5.6 � page 83] � Check if springs are broken, replace if necessary � Repair the anti-corrosive coating of coupler face, male and female cones with ZINGA ac-

cording to the Lubrication schedule [chap.5.6 � page 83]


Electric head operating gear � Clean the guiding rods with a grease-free rag � Extend the piston rod, clean and grease withAUTOL TOP 2000


shank to the manufacturer for overhaul


essary

Electric head � Grease or spray the lid guides and bearings with AUTOL TOP 2000. � Clean contacts, contact block and centring elements with a lint-free dry rag � Clean sealing frame with a damp cloth, wipe dry and dust with French chalk powder; if nec-

essary, clean contacts once again


(horizontal muffs)



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Entire coupler � Rough cleaning [chap.5.4 � page 81] of the product � Visual inspection [chap.5.5 � page 82] for damage � Repair damage to paint coating [chap.5.13 � page 99] (corrosion protection)

NOTICENOTICENOTICENOTICE New supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to set A new supporting spring will set faster at the beginning of its service life. Therefore,

after having installed a new supporting spring, the inclination of the coupler must be checked every 3 months. After the first year the intervals of the maintenance plan apply. � Check the inclination of the coupler, adjust if necessary � Slew the coupler horizontally and vertically (for slewing range refer to Technical data

[chap.3.1 � page 17] ) � Check the hoses for porosity, replace if necessary � Check all pneumatic parts for air tightness by applying soapy water with a brush.


schedule [chap.5.6 � page 83] � Check if springs are broken, replace if necessary � Measure the coupler lock backlash [chap.5.8 � page 89]

.If the admissible backlash is exceeded, disassemble the coupler head [chap.6.6.1 � page 118] and replace the bushes in the coupler head casing. Check the parts for wear, re-place the entire coupler lock if necessary

� Open the drain holes with a stiff wire � Repair the anti-corrosive coating of coupler face, male and female cones with ZINGA ac-



Electric head operating gear � Clean the guiding rods with a grease-free rag � Extend the piston rod, clean and grease withAUTOL TOP 2000 � Check if compression springs are broken, replace if necessary � Measure the electric head projection [chap.5.9 � page 94] and readjust if necessary


shank to the manufacturer for overhaul � Grease [chap.5.6 � page 83] visible sliding surfaces of the buffer with AUTOL TOP 2000.


essary � Remove the protection caps from the lubricating nipples � Use a grease gun to inject lubricant AUTOL TOP 2000. � Refit the protection caps

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Electric head � Clean the inner and outer side of the lid with a lint-free dry rag � Check the lid for damage. Replace the lid if damage is found. � Check the tension spring of the lid for damage. Replace the tension spring if damage is

found. � Check earth wires for damage. If damaged, replace earth wire. � Check the anti-corrosive paint of the casing. Repair anti-corrosive paint, if necessary. � Clean or open drain hole. � Grease or spray the lid guides and bearings with AUTOL TOP 2000. � Clean contacts, contact block and centring elements with a lint-free dry rag � Clean sealing frame with a damp cloth, wipe dry and dust with French chalk powder; if nec-

essary, clean contacts once again � Check the male and female contacts for wear (noticeable surface damage). If worn, replace

male/female contacts.

Centring device and support



� Check fastening screws for tight seat by means of a torque wrench. Recommended torque: refer to Removing centring device and support [chap.6.7.3 � page 166]

� Check adjusting screws with torque wrench for tight seat. Recommended torque: refer to Adjusting inclination and centre position

� Clean and open vent. � Remove the protection caps from the lubricating nipples � Use a grease gun to lubricate with AUTOL TOP 2000 � Refit the protection caps

Electrical unit � Check all screws for tight seat � Clean the switching elements of the position switch(es) with a grease-free rag.

Pneumatic unit � Manual operation of the 5/2-way valve � Clean the sieves at the valve ports with oil-free compressed air � Clean 5/2-way valve using ethyl alcohol and compressed air � Check the hoses for tight seat � Clean sieves of strainers


(horizontal muffs)



� Check [chap.5.12 � page 99] fastening screws for tight seat by means of a torque wrench. Recommended torque: refer to section Installing the muff coupling [chap. � page 175] .

� Open the drain holes

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Earthing system � Check the earth wires for damage, replace if necessary. � Check all fasteners for tight seat and intact colour marking; if necessary, replace the fasten-

ers and apply a new colour marking.



Entire coupler � Rough cleaning [chap.5.4 � page 81] of the product � Visual inspection [chap.5.5 � page 82] for damage � Repair damage to paint coating [chap.5.13 � page 99] (corrosion protection)

NOTICENOTICENOTICENOTICE New supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to set

A new supporting spring will set faster at the beginning of its service life. Therefore, after having installed a new supporting spring, the inclination of the coupler must be checked every 3 months. After the first year the intervals of the maintenance plan apply. � Check the inclination of the coupler, adjust if necessary � Slew the coupler horizontally and vertically (for slewing range refer to Technical data

[chap.3.1 � page 17] ) � Check the hoses for porosity, replace if necessary � Check all pneumatic parts for air tightness by applying soapy water with a brush.


schedule [chap.5.6 � page 83] � Check if springs are broken, replace if necessary � Measure the coupler lock backlash [chap.5.8 � page 89]

.If the admissible backlash is exceeded, disassemble the coupler head [chap.6.6.1 � page 118] and replace the bushes in the coupler head casing. Check the parts for wear, re-place the entire coupler lock if necessary

� Open the drain holes with a stiff wire � Repair the anti-corrosive coating of coupler face, male and female cones with ZINGA ac-


Air pipe connection � Clean the socket and the gasket with grease free rag � Replace [chap. � page 98] the gasket in the socket

Electric head operating gear � Clean the guiding rods with a grease-free rag � Extend the piston rod, clean and grease withAUTOL TOP 2000 � Check if compression springs are broken, replace if necessary � Measure the electric head projection [chap.5.9 � page 94] and readjust if necessary

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shank to the manufacturer for overhaul � Grease [chap.5.6 � page 83] visible sliding surfaces of the buffer with AUTOL TOP 2000.


essary � Remove the protection caps from the lubricating nipples � Use a grease gun to inject lubricant AUTOL TOP 2000. � Refit the protection caps

Electric head � Clean the inner and outer side of the lid with a lint-free dry rag � Check the lid for damage. Replace the lid if damage is found. � Check the tension spring of the lid for damage. Replace the tension spring if damage is

found. � Check earth wires for damage. If damaged, replace earth wire. � Check the anti-corrosive paint of the casing. Repair anti-corrosive paint, if necessary. � Clean or open drain hole. � Grease or spray the lid guides and bearings with AUTOL TOP 2000. � Clean contacts, contact block and centring elements with a lint-free dry rag � Clean sealing frame with a damp cloth, wipe dry and dust with French chalk powder; if nec-

essary, clean contacts once again � Check the male and female contacts for wear (noticeable surface damage). If worn, replace

male/female contacts.

Electrical unit � Check all screws for tight seat � Clean the switching elements of the position switch(es) with a grease-free rag.

Pneumatic unit � Manual operation of the 5/2-way valve � Clean the sieves at the valve ports with oil-free compressed air � Check the hoses for tight seat � Clean sieves of strainers


(horizontal muffs)



� Check [chap.5.12 � page 99] fastening screws for tight seat by means of a torque wrench. Recommended torque: refer to section Installing the muff coupling [chap. � page 175] .

� Open the drain holes

Earthing system � Check the earth wires for damage, replace if necessary. � Check all fasteners for tight seat and intact colour marking; if necessary, replace the fasten-

ers and apply a new colour marking.

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Rough cleaning

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5.3.5 Heavy maintenance OH 1 and OH 2 Heavy maintenance (overhaul) includes tasks which have to be performed in a well-equipped workshop at regular intervals.

The entire product must be removed [chap.7 � page 187] from the vehicle for heavy maintenance.

� Remove product according to the instructions in chapter Mounting and removal [chap.7 � page 187]

� Overhaul the product in the workshop according to the instructions given in the chapter Heavy maintenance [chap.6 � page 101]

5.4 Rough cleaning Rough cleaning

Rough cleaning removes persistent dirt and enables the visual inspection. [chap.5.5 � page 82]

Tools and Materials � Splash guards for electric components � Dry cleaning brush � Oil-free rags � Cleaner (spray) WEICON S

Preparations

CAUTIONCAUTIONCAUTIONCAUTION Surfaces of components may be damaged.Surfaces of components may be damaged.Surfaces of components may be damaged.Surfaces of components may be damaged. Zinc and yellow chromate coated surfaces may get damaged by wrong cleaners. � Do not use concentrated cleaners containing alkali, phosphoric acid, hydrochloric

acid or benzene.

1) Put the coupler in the repair position [chap.5.2 � page 71] .

2) Cover electric components using suitable splash guards to prevent the ingress of splash wa-ter.

Rough cleaning of the product

1) Remove coarse dirt with a dry cloth.

2) Wipe the product with a damp cloth.

3) To remove persistent dirt, spray surfaces with cleaner, allow the cleaner to act for some time and wipe off with a rag; repeat the procedure if necessary.

User Manual

Light maintenance

Visual inspection Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Clean electric head

DANGERDANGERDANGERDANGER Risk of short circuit due to moistureRisk of short circuit due to moistureRisk of short circuit due to moistureRisk of short circuit due to moisture Cleaning the electric head with water may cause the ingress of water into the contact compartment and the space between the contacts. This may cause a short circuit! � Be sure to cover the electric head while performing the rough cleaning of the cou-

pler. � Keep the contact area dry and watertight � Keep the drain holes open. � Clean the following parts one after another using a dry cloth (e.g. microfibre or

cotton) and a brush: casing, centring elements, inside and outside of the protect-ing lid (if any), contact block, contacts and sealing frame.

NOTICENOTICENOTICENOTICE Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity. The black oxide layer that builds up over time is conductive and does not need to be removed. � Do not sandpaper or file contact tips!

1) Clean the inner and outer side of the protecting lid with a dry rag.

2) Clean the electric head casing and the centring pins/bushes with a dry rag.

3) Clean the contacts and the contact block with a dry, clean and lint-free rag or cleaning brush.

4) Clean the gasket with a damp cloth, then wipe dry.

Final steps None.

5.5 Visual inspection Visual inspection

The visual inspection serves to detect visible damage to the product.

Tools and Materials � Light source (such as a flashlight)

Preparations None.

Visual inspection

1) Thoroughly check the entire product for visible damage. � If the product is visibly damaged:

2) Repair the product.

3) Electric head check the contacts and the contact block for visible damages and wear.

Final steps None.

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Lubrication

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5.6 Lubrication Lubrication

This section describes the lubrication points which can be accessed without removing the cou-pler from the vehicle. The couplers have to be separated.

Tools and Materials � Small, flat brush with stiff bristles � Grease AUTOL TOP 2000 � Grease spray AUTOL TOP 2000 � Anti-corrosive for coupler face ZINGA � Rubber care product French chalk powder

Preparations

CAUTIONCAUTIONCAUTIONCAUTION Sliding surfaces may get damaged.Sliding surfaces may get damaged.Sliding surfaces may get damaged.Sliding surfaces may get damaged. Dirt on the sliding surfaces may damage these surfaces. � First of all, remove the dirt from all sliding surfaces, for example by using brushes

and rags. � Having done this, grease the sliding surfaces.

CAUTIONCAUTIONCAUTIONCAUTION Corrosion of the coupler faceCorrosion of the coupler faceCorrosion of the coupler faceCorrosion of the coupler face Anti-corrosive coating may get damaged during coupling. � Repair the anti-corrosive coating during maintenance. � Make sure the coating is not thicker than allowed (max. 30 µm) to ensure perfect

coupling functionality.

CAUTIONCAUTIONCAUTIONCAUTION Risk of lubrication breakdown.Risk of lubrication breakdown.Risk of lubrication breakdown.Risk of lubrication breakdown. Different saponification characteristics of greases may impair proper lubrication. � Do not mix different types of grease. � Remove old grease before re-greasing.

CAUTIONCAUTIONCAUTIONCAUTION Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged. Grease may etch rubber parts or impair their elasticity. � Keep rubber parts free from grease.


2) Clean [chap.5.4 � page 81] the parts to be greased.

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Lubrication Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Lubrication points of the coupler head (Fig. 5-4)

Fig. 5-4 Lubrication points of the coupler head - simplified drawing

Item Lubrication point Lubricant 1Guiding surfaces in male cone and female

cone ZINGA

2Coupler face ZINGA 3Coupling link web AUTOL TOP 2000 4Central pivot AUTOL TOP 2000 5Rear side of hooked plate AUTOL TOP 2000 6Rear side of hooked plate AUTOL TOP 2000 7Contact surface of stem guide AUTOL TOP 2000 8Rear side of ratchet AUTOL TOP 2000 9Spring bearing AUTOL TOP 2000

10Drain holes open

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Lubrication

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Grease the central pivot (Fig. 5-5)

1) Remove the protection cap from the lubricating nipple (1).

2) Use a grease gun to inject lubricant AUTOL TOP 2000.

3) Refit the protection cap.

Fig. 5-5 Lubricating nipple at the central pivot - simplified drawing

Item Lubrication point Lubricant 1lubricating nipple AUTOL TOP 2000

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Lubrication points of the coupler shank The shank is greased at the sliding surfaces of regenerative buffer (Fig. 5-6/1). After - and only when - the coupler shank has been removed, it is possible to grease muff coupling collar (2) and the inside and centring surface (3) of the coupler shank.

Fig. 5-6 Lubrication points of the coupler shank - simplified drawing

Item Lubrication point Lubricant 1Sliding surface of the regenerative buffer AUTOL TOP 2000 2Muff coupling collar AUTOL TOP 2000 3Inside and centring surface of the coupler

shank Primer, as an alternative AUTOL TOP 2000

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Lubrication

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Lubricating nipples at bearing bracket � Grease the bearing bracket

- Remove the protection cap from the lubricating nipple (Fig. 5-7/1) - Use a grease gun to inject lubricant AUTOL TOP 2000. - Refit the protection cap.

Fig. 5-7 Lubricating nipple at the bearing bracket - simplified drawing

ItemLubrication point Lubricant 1lubricating nipple AUTOL TOP 2000

Lubrication points of the electric head

Fig. 5-8 Lubrication points of the electric head - principle drawing

Item Lubrication point Lubricant 1Lid guides ApplyAUTOL TOP 2000 2Lid bearing Spray with AUTOL TOP 2000 3Male contacts remain dry 3Female contacts remain dry 4Sealing frame ApplyFrench chalk powder

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Lubrication points at centring device and support

Fig. 5-9 Lubrication points at centring device

ItemLubrication point Lubricant 1 lubricating nipple Grease AUTOL TOP 2000

Lubrication points of the muff coupling (Fig. 5-10)

Fig. 5-10 Muff coupling

ItemLubrication point Lubricant 1Close cavity between screws and muff

bores AUTOL TOP 2000

Final steps None.

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Check the coupler lock for smooth operation

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5.7 Check the coupler lock for smooth operation Check the coupler lock for smooth operation

The coupler lock has to turn smoothly in order to ensure perfect coupling and uncoupling.

Tools and Materials � Grease spray AUTOL TOP 2000

Preparations

DANGERDANGERDANGERDANGER Risk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tensionRisk of injury from spring tension The coupling link is subject to tensile load and may jump out abruptly from the coupler head male cone as the coupler lock is released. � Keep a safety distance of at least 10 cm from the male cone.

For this check, a second person is required for assistance.


Check the coupler lock for smooth operation

1) Push back the ratchet and hold it in this position.

2) Uncouple coupler lock manually [chap.4.5 � page 63] several times.

� The coupler lock must return to its limit stop position without jamming.

Re-grease the coupler lock If the coupler lock does not turn smoothly:

1) Re-grease sliding surfaces with AUTOL TOP 2000.

2) Check if the coupler lock turns smoothly.

� If the coupler lock still fails to turn readily, remove the coupler lock [chap.6.6.1 � page 118] und check it for wear.

Final steps

1) Cancel repair position.

5.8 Measure and correct the coupler lock backlash Measuring and correcting the coupler lock backlash

The total coupler lock backlash is the clearance between the coupler faces of two coupled cou-pler heads when subjected to tensile load. The total coupler lock backlash is the sum of the coupler lock backlashes of both coupler heads. The coupler lock backlash gauge allows to sep-arately measure the backlash of a single coupler head.

The coupler lock backlash gauge presents a coupler head with a coupler lock of 0 mm. The coupler lock backlash is thus the coupler lock backlash of one coupler head in relation to the coupler lock backlash gauge.

Excessive coupler lock backlash leads to increased wear and reduced passenger comfort and may even affect the operational reliability of the coupler over time.

In addition, the contacts of the electric head do not meet exactly which may result in poor cur-rent and signal transmission.

Thus, every coupler head has an admissible coupler lock backlash.

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Light maintenance

Measuring and correcting the coupler lock backlash Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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If the coupler lock backlash is too small, there may be a risk of coupling failures, e.g. due to soil-ing and ice. Therefore, it is important to keep the coupler faces clean and to apply only a thin coating of the anticorrosive paint.

Tools and Materials � Coupler lock backlash gauge (Fig. 5-11) � Rag � compressed air

Fig. 5-11 Coupler lock backlash gauge

1 Body 4 Coupling link

2 Hooked plate 5 Pin

3 Torque wrench

Preparations


NOTICENOTICENOTICENOTICE Cleaning the coupler faceCleaning the coupler faceCleaning the coupler faceCleaning the coupler face The coupler face must be clean to obtain correct results. However, the anti-corrosive coating must remain intact.

2) Thoroughly clean coupler face (Fig. 5-12/11), male cone (13), female cone (10) and the hooked plate recess (15).

3) Remove protection plates (8) from magnets (7) of coupler lock backlash gauge.

4) Remove coupling link pin (5) from hooked plate (4) of the coupler lock backlash gauge, re-move coupling link (6).

5) Set torque wrench (3) to 200 Ncm.

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Measuring and correcting the coupler lock backlash

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Fig. 5-12 Measuring the coupler lock backlash - overview of parts

1 Coupler lock backlash gauge 7 Magnet 13 Male cone

2 Recess of hooked plate 8 Protection plate 14 Coupler head

3 Torque wrench 9 Rod 15 Recess of hooked plate

4 Hooked plate of gauge 10 Female cone 16 Ratchet

5 Coupling link pin 11 Coupler face 17 Hooked plate

6 Coupling link of gauge 12 Coupling link 18 Coupler lock release

Fig. 5-13 Positioning the coupler lock backlash gauge

19 Uncouple device

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Measuring and correcting the coupler lock backlash Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Fig. 5-14 Reading the coupler lock backlash gauge

20 Measurement position

Measure the coupler lock backlash

1) Place torque wrench (Fig. 5-12/3) on the coupler lock backlash gauge .

2) Place the coupler lock backlash gauge on coupler head (Fig. 5-13).

3) Hinge coupling links (6, 12) into hooked plates (2, 15).

4) Turn the torque wrench until the coupling link pin can be inserted (if necessary, have a se-cond person operate the manual uncouple device to rotate the coupler lock).

5) Turn the torque wrench clockwise and apply tensile load to the coupler lock backlash gauge until the wrench starts idling.

6) Check the measurement position (Fig. 5-14/20). � The coupler lock backlash gauge must lie flat on the coupler face.

7) Read the value indicated on the Vernier scale. Example: Fig. 5-15.

Fig. 5-15 Reading the Vernier scale (0.5 mm in example)

The admissible backlash of the coupler lock is 1.8 mm.

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Measuring and correcting the coupler lock backlash

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Correct the coupler lock backlash

NOTICENOTICENOTICENOTICE Only replace the entire coupler lockOnly replace the entire coupler lockOnly replace the entire coupler lockOnly replace the entire coupler lock Should the coupler lock clearance still be too large after replacing the bushes, replace the coupler lock [chap.3.5.1 � page 23] completely. � Only replace the entire coupler lock as a complete unit.

Only if the admissible coupler lock backlash is exceeded:

1) Disassemble the coupler head [chap.6.6.1 � page 118] .

2) Replace the bushes in the coupler head casing.

3) Check the coupler lock for damage and wear and replace the entire coupler lock if neces-sary.

4) Assemble the coupler head.

5) Measure the coupler lock backlash again.

Final steps

1) Remove the coupler lock backlash gauge.

2) Place protective plates onto the magnets.

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Checking and adjusting the projection of the electric head


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5.9 Check and adjust the projection of the electric head Checking and adjusting the projection of the electric head

The projection of the electric head has to be observed so that the electric heads are coupled in a watertight way and the contacts are pressed tightly against each other.

The projection of the electric head is the distance between the coupler face and the front edge of the electric head casing. If the front edge of the electric head casing projects beyond the plane of the coupler face, projection is a positive value (+); conversely, if it is behind the plane of the coupler face, projection is negative (-).

Since the electric head and the coupler head must not be parallel due to bearing clearance, several points have to be checked.

According to drawing [chap.6.6.5 � page 135] the projection of the electric head has to be be-tween the following limit dimensions:

� minimum permissible rear limit dimension "X" (1 mm) and � maximum permissible front limit dimension "Y"(3 mm).

Tools and Materials � Cranked ring wrench SW 21 for manual operation of electric head � Fig. 5-16/Gauge for measuring the projection of the electric head

Fig. 5-16 Gauge for measuring the projection of the electric head (x=min, y=max)

Preparations


2) Clean the front plate of the coupler head.

3) Manually move the electric head [chap. � page 73] forwards.

4) When the lid is closed, open it manually.

Check the projection of the electric head The electric head projection is measured by means of a dedicated gauge (Fig. 5-11). The front edge of the electric head casing may be located between the rear limit dimension "x" (1 mm) and the front limit dimension "y" (3 mm).

1) Place the gauge against the coupler face with the "x" side recess resting on the electric head casing. � The projection is correct when either a slight gap exists between the gauge and the cou-

pler face or the gauge just touches the face of the electric head casing.

2) Reverse the gauge so that the "y" side recess rests on the face of the electric head casing. � The projection is correct when the gauge is level with the coupler face.

If the front edge of the electric head casing is located behind the rear limit dimension "x" or pro-jects by more than the front limit dimension "y", the electric head projection has to be adjusted [chap. � page 95] as follows.

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Adjust the inclination and centre position

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Adjust the projection � The coupler must be moved to its rear end position by hand (Fig. 5-2).

1) Loosen counter nut (Fig. 5-17/1).

2) Turn hexagon nut (2) in order to increase or decrease electric head projection.

3) Manually move the electric head to its forward position until the lid is completely open.

4) Check projection and readjust if necessary.

5) Once the adjustment has been completed successfully, tighten hexagon nut (2). Recommended torque: 43 Nm.

6) Lock hexagon nut (2) by tightening second hexagon nut (1).

Fig. 5-17 Adjust the projection of the electric head

1 Lock nut 2 Hexagon nut

Final steps

1) Manually retract [chap. � page 73] the electric head.

2) Put the coupler lock in the ready-to-couple position [chap. � page 53] .

5.10 Adjust the inclination and centre position Adjust the inclination and centre position

The coupler must be aligned with the longitudinal axis of the vehicle.

The supporting spring may yield when permanently subjected to load. Yielding may lead to a vertical misalignment (sagging) of the uncoupled coupler. This reduces the coupler's gathering range. The inclination of the coupler must therefore be checked at regular intervals.

� Smallest angle of inclination: -0.5° � Largest angle of inclination: ±0°

User Manual

Light maintenance

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NOTICENOTICENOTICENOTICE New supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to setNew supporting springs tends to set A new supporting spring will set faster at the beginning of its service life. Therefore, after having installed a new supporting spring, the inclination of the coupler must be checked every 3 months. After the first year the intervals of the maintenance plan

apply.

Tools and Materials � Various standard tools � Digital spirit level

Preparations

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failureRisk of coupler failureRisk of coupler failureRisk of coupler failure

The adjustment procedure may provide inadequate results. � Be sure to adjust the coupler only after it has been mounted completely.

None.

The centring device and support assembly allows to adjust the coupler both vertically and hori-zontally.

Tools and Materials � Standard tools � Digital spirit level

Preparations

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failureRisk of coupler failureRisk of coupler failureRisk of coupler failure The adjustment procedure may provide inadequate results. � Be sure to adjust the coupler only after it has been mounted completely.

The uncoupled coupler must be aligned with the longitudinal axis of the vehicle. This ensures a maximum gathering range of the coupler head and a maximum slewing range.

Adjust the inclination

1) Loosen all four hexagon nuts (Fig. 5-18/3, 4) at the hexagon head screws (2).

2) Turn both hexagon head screws (2) in order to adjust the inclination of the coupler.

3) Align the coupler along the longitudinal axis of the vehicle.

4) Tighten hexagon nuts (3, 4). Torque: 350 Nm

5) Check inclination and centre position of coupler, readjust if necessary.

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Fig. 5-18 Adjust the inclination of the coupler

1 Supporting spring 4 Hexagon nut

2 Hexagon head screw 6 Support

3 Hexagon nut

Centre the coupler

1) Loosen locking screws (Fig. 5-19/1) of the cam disc (2).

2) Align the coupler along the longitudinal axis of the vehicle.

3) Tighten locking screws (1) at the cam disc (2). Torque: 130 Nm

4) Check centre position of coupler, readjust if necessary.

5) Adjust the inclination.

Fig. 5-19 Centring the coupler

1 Locking screws 2 Cam disc

User Manual

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Final steps

CAUTIONCAUTIONCAUTIONCAUTION AntiAntiAntiAnti----corrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mounting After mounting, the anti-corrosive paint of screws, nuts and seat-engaging surfaces is damaged. Priming only is no sufficient corrosion protection. Immediately upon conclu-sion of the mounting procedure, the damaged surface must be fully repainted in ac-cordance with the Paint specification [chap.10.1 � page 205] . � Repaint the screw connections.

1) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint [chap.5.13 � page 99] such surfaces in accordance with the Paint specification [chap.10.1 � page 205] .

2) Paint over the joint gaps.

5.11 Replace the gasket in the air pipe connection Replacing the gasket in the air pipe connection

The gasket has to be replaced at regular intervals according to the Maintenance schedule [chap.5.3 � page 75] .


Preparations


Replace gasket

1) Remove gasket (Fig. 5-20/A) from groove of socket (B).

2) Clean socket.

3) Insert new gasket (A) into groove of socket (B).

Fig. 5-20 Gasket and socket - simplified drawing

Final steps

1) Put the coupler in the ready-to-couple position [chap. � page 23] .

This cancels the repair position [chap.5.2 � page 71] .

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Check screw connections with a defined torque

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5.12 Check screw connections with a defined torque Check screw connections with a defined torque

This section describes how to check screw connections tightened to a defined torque for tight seat.

Tools and Materials � Torque spanner

Preparations None.

Check torque

1) The recommended torque is given in the instructions.

2) Adjust ratchet to 90% of the recommended torque.

3) Apply torque to respective bolted joint.

If the bolted joint has loosened:

4) Remove and dispose of screws.

5) Tighten screws to recommended torque.

Final steps None.

5.13 Repair the paint coating Repairing the paint coating

This section describes how to repair damaged paint coating of the product. This activity is based on the paint specification [chap.10.1 � page 205] . The painting specification includes

� the general requirements as per Schaku standard K000 and � the paint structure and colour as per Schaku standard KCG

Tools and Materials � Abrasive � Paint brush � Cleaner LOCTITE 7063 � Primer, top coat and hardener according to the Paint specification [chap.10.1 � page 205]

Preparations

1) Roughly clean [chap.5.4 � page 81] the spot to be repaired.

2) Remove residual paint with emery paper.

3) Degrease the area to be repaired with cleaner.

User Manual

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Repair the paint coating

NOTICENOTICENOTICENOTICE Respect drying timesRespect drying timesRespect drying timesRespect drying times � Be sure to observe the following drying times:

� At room temperature (20 °C): 12 - 24 h � In warm air (60 - 80 °C): 45 - 120 min � IR/NIR drying: 30 - 60 min

1) Apply a thin layer of primer and allow to dry.

2) Apply a thin layer of top coat and allow to dry.

CAUTIONCAUTIONCAUTIONCAUTION AntiAntiAntiAnti----corrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mounting

After mounting, the anti-corrosive paint of screws, nuts and seat-engaging surfaces is damaged. Priming only is no sufficient corrosion protection. Immediately upon conclu-sion of the mounting procedure, the damaged surface must be fully repainted in ac-cordance with the Paint specification [chap.10.1 � page 205] . � Repaint the screw connections.

3) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1 � page 205] .

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6 Heavy maintenance Heavy maintenance

This chapter describes the required heavy maintenance tasks.

Definition Heavy maintenance (overhaul) includes tasks which have to be performed in a well-equipped workshop at regular intervals.

The entire product must be removed [chap.7 � page 187] from the vehicle for heavy mainte-nance.

The instructions also apply for repair works.

In contrast, light maintenance can be performed directly at the vehicle and does not require vis-iting a workshop.

Structure of this chapter This chapter includes the preparations as well as the required heavy maintenance tasks.

The instructions given in this chapter are subdivided as follows:

� Disassembling the product into its components. � Disassembling, overhauling and assembling the individual components. � Reassembling the overhauled product.



Replacement of parts In most cases a visual check for corrosion, wear and damage is sufficient to decide whether parts must be replaced or not.

CAUTIONCAUTIONCAUTIONCAUTION Replacement of fastenersReplacement of fastenersReplacement of fastenersReplacement of fasteners Whenever parts or components are disassembled or removed, fasteners such as screws, nuts, washers, retaining rings, spiral rings and spring type straight pins have

to be replaced. � Replace all fasteners after loosening. � When refitting parts, use new fasteners as specified in the Parts catalog.

Gaskets and rubber tubes have to be replaced after removal and disassembly of a component at the latest.

Recommended torque for new bolted joints For bolted joints the following remarks apply.

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CAUTIONCAUTIONCAUTIONCAUTION Recommended torqueRecommended torqueRecommended torqueRecommended torque for the screw connections of the muff couplingsfor the screw connections of the muff couplingsfor the screw connections of the muff couplingsfor the screw connections of the muff couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: � The contact surfaces for screw head, washer and/or nut are only primed. � The contact surfaces are clean, dry and free of grease. � RIVOLTA GWF is applied to the threads only.


Specific agreements will be explicitly mentioned, where applicable.

The hash (#) indicates that the respective item is to be tightened to a special torque.

Check the torques of existing bolted joints For existing bolted joints tightened to a defined torque, a special test procedure [chap.5.12 � page 99] is to be applied.

The following note is added at the respective spot of the instructions:

NOTICENOTICENOTICENOTICE Checking tChecking tChecking tChecking the recommended torquehe recommended torquehe recommended torquehe recommended torque � Please respect the test procedure [chap.5.12 � page 99] for bolted joints


Loosening of screw connections that are secured wit h threadlocker Screws, bolts, threaded pins etc. which are secured with acrylate glue must be heated cautious-ly before being loosened. The threadlocker gets pasty and the screw can be removed.

6.1 Standard tools Standard tools

The following standard tools are required for maintenance:

� Set of slotted screwdrivers � Set of open-end wrenches � Set of socket wrenches � Set of ring wrenches � Set of Allen wrenches � Set of split pin drivers � Fitter's hammer (1000 g) � Chisel � Adjustable torque wrench according to ISO 6789

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Materials

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� Tools for bush removal � Pliers for mounting and removing retaining rings � Continuity tester � Oil-free compressed air � Clean rags � Brushes � Paint brush � Electric torch � Spirit level � Seam gauge � Abrasive

Any special tools and materials required for maintenance are identified at the beginning of the respective section.

The lifting and transportation of bulky components during heavy maintenance requires suitable cranes, lifting straps and trestles. The use of chains is prohibited, in order to prevent damage to the product.


NOTICENOTICENOTICENOTICE Materials as specifiedMaterials as specifiedMaterials as specifiedMaterials as specified

The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any conse-quential damage.

Rough cleaning � Cleaning spray WEICON S (rough cleaning of all surfaces) � Cleaner LOCTITE 7063 (cleaning / degreasing for further treatment) � Mixture of glycerol and ethyl alcohol (1:10) (removal of encrustations on rubber parts) � Ethyl alcohol (cleaning of valve casings)

Corrosion Protection � Anti-corrosive ZINGA (corrosion protection for coupler face, female cone and male cone of

coupler head - coating must not be thicker than 30 µm to prevent adverse effects on proper coupling functionality)

� Grease AUTOL TOP 2000 or grease spray AUTOL TOP 2000 (corrosion protection for all bearings, pivot points and sliding surfaces. Also if applicable: stem guide contact surface; piston rod contact surface; contact surfaces of cams for valves and limit switches; contact surfaces of lateral stops; visible surfaces of regenerating buffers; cylinder inside and piston rod of pneumatic cylinders; muff coupling collars)

� Penetrating oil RIVOLTA T.R.S. Plus (immediate measure for cleaning and re-greasing of corroded articulation points and parts subject to seizing; e.g. levers of electric head operat-ing gear, lid guides in electric head casing, bushes in protecting lid of electric head)

� Anti-seize RIVOLTA GWF (Corrosion protection for contact surfaces of screw heads and nuts as well as threads of all screws and bolts; exception: on muff couplings, only screw threads are to be treated, contact surfaces for screws and nuts must remain untreated)

Electric head � Artificial resin paint (repairing coating of electric head casing) � French chalk powder (flexibility of the contact block sealing frame, prevention of abrasion

and adhesion)

User Manual

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H05.975955

6.3 Preparations Preparations

This section describes how to prepare the coupler for Heavy maintenance.


2) Remove the coupler from the vehicle [chap.7.2 � page 191] , lay it down and support it us-ing suitable aids.

6.4 Maintenance schedule - heavy maintenance Maintenance schedule - heavy maintenance

The maintenance intervals are recommended values. They have to be reduced in case of ad-verse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing.

Maintenance level Time interval Maintenance level 1 (ML1) Monthly Maintenance level 2 (ML2) Every 3 months Maintenance level 3 (ML3) Annually Maintenance level 4 (ML4) Every 2 years Overhaul 1 (OH1) Every 6 years Overhaul 2 (OH2) Every 12 years Tab. 6-1 Maintenance and overhaul levels

6.5 Disassembling the coupler into its components Disassembling the coupler into its components

This section describes how to disassemble the coupler into its individual components.

6.5.1 Remove the earthing system The section describes how to remove the earthing system.

Tools and Materials � Various standard tools

Preparations None.

Remove the earthing system

1) Remove hexagon head screw (Fig. 6-1/2) from earth socket (5).

2) Remove lock washer (3) and washer (4).

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Disassembling the coupler into its components

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Fig. 6-1 Connection of the earth wire - simplified drawing

1 Cable lug 3 Lock washer 5 Earth socket

2 Hexagon bolt 4 Washer

Final steps None.

6.5.2 Remove the electrical unit of the coupler hea d This section describes how to remove the electrical unit of the coupler head (Fig. 6-2).


Preparations

1) Make sure that the components of the electrical unit are accessible.

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Remove the position switch

1) Remove the screws securing the cover of the position switch.

2) Remove the cover.

3) Loosen the wire ends.

4) Loosen the cable gland.

5) Cautiously pull the cable out.

6) Remove the socket head cap screws from the position switch and the coupler head cas-ing/holder.

7) Remove the position switch.

8) If necessary, loosen the cable clamps and ties and remove the cables.

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Final steps None.

6.5.3 Remove the pneumatic unit of the coupler head This section describes how to remove the pneumatic unit of the coupler head (Fig. 6-3).


Preparations None.








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Remove the hoses

1) Loosen the union nuts and remove the hoses.

Remove the stopcock

1) Remove fastening screws from support and coupler head casing.

2) Take off support including stopcock.

Remove the strainer

1) Screw strainer and double nipple off main reservoir pipe MRP.

Remove the 5/2-way valve

1) Remove fastening screws from 5/2-way valve and coupler head casing or support.

2) Remove the 5/2-way valve.

Final steps None.

6.5.4 Remove the uncouple pipe This section describes how to remove the uncouple pipe.


Preparations None.

Remove the uncouple pipe

1) Loosen union nuts of swivel fitting (Fig. 6-4/12) on rear side of air pipe connection.

2) Loosen union nuts of screw fitting (13).

3) Remove hose (16).

4) Remove adapter (1) from the cylinder casing.

5) Remove gasket (11).

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Final steps None.

6.5.5 Remove the electric head The electric head forms one mechanical unit with the electric head operating gear. The instruc-tions for removal of the electric head operating gear [chap.6.5.6 � page 109] also describe how to remove the electric head.

6.5.6 Remove electric head operating gear This section describes how to remove the electric head operating gear and the electric head.


Preparations

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. Tension springs may bounce off abruptly during mounting or removal. � Be sure to always install or remove tension springs in unloaded condition.

1) Check the electric head for current transmission, if required,

2) Cautiously remove tension springs from lid of electric head (Fig. 6-31).

3) Support the electric head.

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Remove the electric head

1) Loosen hexagon nuts (Fig. 6-5/27) and remove lock washers (28).

2) Remove hexagon head screws (17) from support (9) and control arm (6).

3) Remove arm (6).

4) Separate rear side of electric head casing and rod (3) of electric head operating gear.

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5) Remove spring type straight pins (30).

6) Pull guiding rods (4) to the front out of electric head and casing.

7) Remove electric head and lay it down without squeezing the cables.

Remove the electric head operating gear

1) Remove hexagon head screws (Fig. 6-5/16) from support (9), sleeves (11) and coupler head casing.

2) Remove locking screws (18) from support (50) and coupler head casing.

3) Remove the operating levers.

4) Remove the locking screws (Fig. 6-5/55) and the holder (75).

5) If any, remove the spring type straight pins (35).

6) Remove the locking screws (50) and the entire support (70).

7) If any, remove the spring type straight pins (37).

Final steps None.

6.5.7 Remove the air pipe connection for the brake pipe This section describes how to remove the air pipe connection for the brake pipe (BP) and its pipe adapter.

Tools and Materials � Various standard tools � Socket wrench for mouth piece mounting

Preparations

1) Separate all air pipes and air pipe connections.

Remove the pipe adapter The pipe adapter is removed only when the air pipe connection is disassembled.

Remove mouth piece

1) Using a screwdriver, push (A) stop spring (Fig. 6-6/1) and move (f) the spring until it engag-es with the recess in the mount. � Only the nose (4) of the stop spring remains visible.

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Fig. 6-6 Remove the stop spring

1 Stop spring 3 Mouth piece A Push

2 Coupler face 4 Spring nose e Locked position

f Unlocked position

2) Place socket wrench (Fig. 6-7/7) onto mouth piece (6).

3) Push in mouth piece (6) and turn until noses of socket are visible in the openings of the front plate or engage.

4) Remove mouth piece (6) to the front side from mounting bore.

5) Remove rubber tube (5) and compression spring (4) from mounting bore.

6) Remove the stop spring from the mounting bore.

Fig. 6-7 Use socket wrench

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1 Stop spring 4 Compression spring 7 Socket wrench

2 Socket 5 Rubber tube A Push

3 Gasket 6 Mouth piece B Turn

Remove the air pipe connection for BP

1) Remove both socket head cap screws (Fig. 6-8/38, 40) from valve casing (26).

2) Remove valve casing (26) together with the pipe adapter from the cam that is fitted to the central pivot.

3) Remove spacer bushes (Fig. 6-8/4) from the coupler head casing.

Fig. 6-8 Air pipe connection for BP

1 Cam disc pin 8 gasket 30 Compression spring

2 Sleeve 11 Socket 34 Socket head cap screw

3 Bush 13 Rubber tube 38 Socket head cap screw

4 Spacer bush 14 gasket 40 Socket head cap screw

5 Valve plate 17 Compression spring 46 Lock washer

6 Rubber ring 23 Stop spring 48 Lock washer

7 gasket 26 Valve casing

Final steps None.

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6.5.8 Remove the air pipe connection for the main r eservoir pipe and the un-couple pipe

This section describes how to remove the air pipe connection for main reservoir pipe (MRP) and the uncouple pipe (UP) together with the pipe adapter.


Preparations

1) Separate all air pipes and air pipe connections.

Remove the pipe adapter The pipe adapter is removed only when the air pipe connection is disassembled.

Remove mouth piece

1) Using a screwdriver, push (A) stop spring (Fig. 6-9/1) and move (f) the spring until it engag-es with the recess in the mount. � Only the nose (4) of the stop spring remains visible.

Fig. 6-9 Remove the stop spring

1 Stop spring 3 Mouth piece A Push

2 Coupler face 4 Spring nose e Locked position

f Unlocked position

2) Place socket wrench (Fig. 6-10/7) onto mouth piece (6).

3) Push in mouth piece (6) and turn until noses of socket are visible in the openings of the front plate or engage.

4) Remove mouth piece (6) to the front side from mounting bore.

5) Remove rubber tube (5) and compression spring (4) from mounting bore.

6) Remove the stop spring from the mounting bore.

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Remove the air pipe connection MRP

1) Remove socket head cap screws from coupler face and valve casing.

2) Remove valve casing.

Final steps None.

6.5.9 Remove the centring device and support This section describes how to remove the centring device and support.


Preparations

1) Secure centring device and support against falling down.

Remove centring device and support

1) Remove hexagon head screws (Fig. 6-11/1).

2) Remove centring device with support (3) and supporting spring (2) from bearing bracket of coupler.

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Fig. 6-11 Centring device

1 Hexagon bolt 3 Support 2 Supporting spring

Final steps None.

6.5.10 Remove the muff coupling This section describes how to remove the muff coupling.


Preparations

1) Support subassemblies on either side of the muff coupling.

Remove muffs

1) Block hexagon head screws, loosen hexagon nuts and remove together with lock washers.

2) Loosen muffs by tapping them with a cushioned hammer (place piece of wood underneath).

Final steps None.

6.5.11 Remove the coupler head The section describes how to remove the coupler head.


Preparations

1) Remove any parts attached to the coupler head.

2) Support the coupler head.

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Remove the coupler head

1) Remove the muff coupling.

Final steps

1) Place the coupler head on a suitable surface.

6.5.12 Remove the uncouple cylinder The uncouple cylinder is located in the coupler head casing. The uncouple cylinder is removed when dismantling the coupler head [chap.6.6.1 � page 118] .

6.5.13 Remove the coupler shank This section describes how to remove the coupler shank.


Preparations

DANGERDANGERDANGERDANGER Danger of explosionDanger of explosionDanger of explosionDanger of explosion The buffer contains highly compressed media. External sources of heat or undefined impacts may lead to an uncontrolled pressure increase damaging gaskets and mate-rial. An explosion of the buffer or leaking substances may cause lethal injuries. � Protect the buffer and the connected components from heat. � Prevent the buffer from knocks, impacts and falling down.

1) Remove any parts attached to the coupler shank.

2) Support the coupler shank and the rubber cushion drawgear or bearing bracket.

Remove the coupler shank � The coupler shank is connected to the bearing bracket by means of a pivot. The pivot is part

of the bearing bracket.

1) Remove the bearing bracket [chap.6.5.14 � page 117] .

Final steps

1) Place the coupler shank and the bearing bracket on a suitable surface.

6.5.14 Remove the bearing bracket This section describes how to remove the bearing bracket.


Preparations

1) Remove any parts attached to the coupler shank.

2) Support the coupler shank and the bearing bracket.

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Remove the bearing bracket

1) Remove retaining ring (Fig. 6-12/33).

2) Pull pivot (2) upwards and remove it from bearing bracket (50) and from the spherical bear-ing of the coupler shank.

3) Remove bearing bracket (50) carefully from the coupler shank and lay it down.






Final steps None.

6.6 Disassembling, overhauling and assembling the i ndividual components Disassembling, overhauling and assembling the individual components

This section describes how to disassemble the components, which parts to replace and how to overhaul and to reassemble the components.

6.6.1 Coupler head This section describes how to disassemble, overhaul and assemble the coupler head.

Tools and Materials � Hook for tension springs � Hot air gun or solvent Dichloromethane � Sharp knife or triangle scraper � Mounting drift for METALOPLAST bushes � Adhesive KL65 and hardener � Cleaner LOCTITE 7063 � Anti-corrosive ZINGA � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

Preparations None.

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Remove the front plate

1) Remove the screws securing the front plate to the coupler head casing.

2) Remove the front plate.

Unhook the tension springs


1) Unhook the tension springs using the mounting hook.

Remove the uncouple rope

1) Remove the rope clip from the uncouple rope and separate the uncouple rope from the cou-pler head casing.

2) Remove the spring type straight pin securing the uncouple rope to the handle.

3) Remove the spring type straight pin from the rope pulley pin.

4) Pull the rope pulley pin out of the uncouple lever.

5) Remove the rope guide from the rope pulley.

Removing parts attached to the central pivot

CAUTIONCAUTIONCAUTIONCAUTION Risk of injury.Risk of injury.Risk of injury.Risk of injury.

A central pivot inserted from the bottom may fall down when parts mounted to its up-per end are removed. � Protect the central pivot from falling down.

1) Protect the central pivot from falling down.

2) Remove the screws at the top and/or bottom end of the central pivot.

3) Remove the disc and/or uncouple lever.

4) Remove the central pivot.

5) Drive out the spring type straight pins and strip the cam off the central pivot.

6) Remove other parts (if any) attached to the central pivot.

Remove the coupler lock

1) Fig. 6-13/Remove stem guide (B) by loosening screws (A).

2) Remove spring bearing (E) by loosening screws (A).

3) Central pivot (C) has already been removed.

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Fig. 6-13 Coupler lock, stem guide and spring bearing in the coupler head

A Bolts D Coupler lock

B Stem guide E Spring bearing

C Central pivot

Remove and disassemble the coupler lock

1) Insert entire coupling link (Fig. 6-14/C) into the male cone of the coupler head casing. At the same time rotate hooked plate (D).

2) Fold the coupler lock such that coupling link (C) is close to hooked plate (D).

3) Remove the coupler lock from the coupler head casing.

4) Remove retaining ring (A) from bottom of coupling link pin (B).

5) Pull coupling link pin (B) out of hooked plate (D).

6) Separate coupling link (C) and hooked plate (D).

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Fig. 6-14 Coupler lock

A Retaining ring C Coupling link

B Coupling link pin D Hooked plate

7) Remove parallel pin (Fig. 6-15/B).

8) Remove ratchet (A) from hooked plate (C).

Fig. 6-15 Ratchet linked to hooked plate

A Ratchet B Parallel pin C Hooked plate

Remove the uncouple cylinder

1) Support the uncouple cylinder.

2) Remove the screws at the outside of the coupler head casing.

3) Remove the uncouple cylinder from the coupler head casing.

4) Overhaul [chap.6.6.2 � page 127] the uncouple cylinder.

Replacement parts - overhaul 1 � Fasteners

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� Worn parts � All springs � If applicable: friction bearing in coupler head casing � Bushes in coupling link (refer to SCHAKU standard Z006 [chap.10.3 � page 208] ) � Central pivot bushes in coupler head casing

- Remove the bushes using a suitable mounting drift. - Clean the bores. - Carefully drive in new bushes into the central pivot bores using a suitable mounting drift.

� Bush in ratchet � Stem guide � Spring bearing � Uncouple rope � Pulley for uncouple rope � lubricating nipple

- Remove the dust protection caps from lubricating nipples (1/Fig. 6-16). - Remove lubricating nipples (1). - Screw in new lubricating nipples (1). - Mount new dust protection caps.

Fig. 6-16 Lubricating nipples with dust protection caps

1 lubricating nipple

Replacement parts - overhaul 2 � All parts to be replaced during overhaul 1 � Ratchet

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Overhaule the coupler head

NOTICENOTICENOTICENOTICE Certain components must be kept free from greaseCertain components must be kept free from greaseCertain components must be kept free from greaseCertain components must be kept free from grease Do not grease tension springs, front side and tooth of ratchet.

1) Clean the following parts and check them for wear. � Coupling link (bore for pin, web) � Hooked plate (centre bore, recess) � Central pivot (shank) � Coupling link pin (shank) � Ratchet (tooth)

2) Check stem guide and spring bearing for smooth operation, grease with AUTOL TOP 2000 if necessary.

3) Repair the paint coating.

4) Grease the coupler head components in accordance with the lubrication schedule ( [chap.5.6 � page 83] ).

5) Apply RIVOLTA GWF to the contact surfaces for screw heads and nuts as well as to the threads of screws and bolts.

6) Open the drain holes with a stiff wire

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NOTICENOTICENOTICENOTICE Only install a new or overhauled uncouple cylinder!Only install a new or overhauled uncouple cylinder!Only install a new or overhauled uncouple cylinder!Only install a new or overhauled uncouple cylinder! Be sure to only install a new or overhauled and tested uncouple cylinder. � First, replace or overhaul the uncouple cylinder, then assemble the coupler head.

[chap.6.6.2 � page 127]

Fig. 6-17 Coupler head 010.600.01

1 Central pivot 20 Tension spring 33 Socket head cap screw

2 Ratchet 21 Pin 40 Locking screw

3 Bush 24 Parallel pin 50 Coupler head casing

4 Cam 25 Spring type straight pin 51 Front plate

5 Coupling link pin 26 Spring type straight pin 52 Hooked plate

6 Rope pulley 27 Spring type straight pin 53 Coupling link with bushes

7 Uncouple lever 28 Spring type straight pin 54 Stem guide

8 Handle 29 Retaining ring 55 Spring bearing

9 Spring holder 30 Lubricating nipple 56 Uncouple rope

10 Metal sheet 31 Dust protection cap 11 Rope guide 32 Locking screw

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Install the uncouple cylinder

1) Position the uncouple cylinder in the coupler head casing, ensuring that the bores of the un-couple cylinder and coupler head casing are aligned.

2) Screw the fastening screws in from the outside and tighten. � Recommended torque: 32 Nm.

Assemble and install the locking mechanism

1) Fix spring bearing (Fig. 6-18/E) in the coupler head casing using screws (A) - torque: 90 Nm.

2) Fix stem guide (B) in the coupler head casing using screws (A) - torque: 90 Nm.

Fig. 6-18 Coupler lock, stem guide and spring bearing in the coupler head

A Bolts D Coupler lock

B Stem guide E Spring bearing

C Central pivot

3) Connect new ratchet (Fig. 6-19/A) and hooked plate (C).

4) Drive in parallel pin (B).

Fig. 6-19 Ratchet linked to hooked plate

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A Ratchet B Parallel pin C Hooked plate

5) Join coupling link (Fig. 6-20/C) and hooked plate (D) such that their bores are aligned.

6) Insert coupling link pin (B) into the bores.

7) Mount spiral ring or retaining ring (A) to the bottom of coupling link pin (B).

8) Fold coupler lock and insert it into coupler head casing until centre bore of hooked plate (D) is aligned with central pivot bores of coupler head casing.

9) Rotate the coupler lock until the ratchet can be pulled out through the lateral coupler head opening and coupling link (C) can be pulled out through the male cone opening.

Fig. 6-20 Coupler lock

A Retaining ring C Coupling link

B Coupling link pin D Hooked plate

Assemble and install the central pivot and attached parts

1) Slide the cam over the central pivot, ensuring that the large portion of the cam points away from the parallel key groove of the central pivot.

2) Fix the cam using new spring type straight pins.

3) Insert the central pivot into the bores of the coupler head casing and hooked plate.

4) Mount other accessory parts to the central pivot.

5) Position the disc or uncouple lever at the central pivot.

If the parts catalogue [chap.11 � page 211] specifies the use of microencapsulated screws (marked with"MK"):

6) Insert and tighten the screws. Recommended torque: 49 Nm.

If INBUS-RIPP screws are specified in the parts catalogue [chap.11 � page 211] :

7) Insert and tighten the screws. Recommended torque: 85 Nm.

If other screws are specified in the parts catalogue [chap.11 � page 211] :

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8) Treat the screws with activator LOCTITE 7649 and threadlocker LOCTITE 243 prior to tight-ening; if necessary, place lock washers underneath. Recommended torque for M10 screws: 48 Nm.

Mount the uncouple rope

1) Insert the new uncouple rope into the eye in the coupler head casing, make a loop and fix the loop with a rope clip.

2) Fix the other end of the uncouple rope to the handle and secure with a spring type straight pin.

3) Place the uncouple rope into the groove of the rope pulley and slip the rope guide over the pulley.

4) Insert the rope pulley pin through rope guide, rope pulley and free end of the uncouple lever and secure with a spring type straight pin.

Install the tension springs


1) Mount the tension springs using the mounting hook.

Install the front plate

1) Prepare the front plate according to SCHAKU standard Z044 [chap.10.4 � page 209] .

2) Position the front plate and press it firmly against the coupler head.

3) Insert the screws and tighten uniformly. Recommended torque: 130 Nm.

Final steps

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.

Insufficient or excessive coupler lock backlash may cause malfunctions. � Prior to putting the coupler into service, verify that the admissible coupler lock

backlash is complied with.

1) Measure the coupler lock backlash [chap.5.8 � page 89] .

2) Check the coupler lock for smooth operation.

6.6.2 Uncouple cylinder This section describes how to disassemble, overhaul and assemble the uncouple cylinder.

Tools and Materials � Various standard tools � Water-filled container, soapy water � Compressed air (1 MPa = 10 bar) � Pipe seal LOCTITE 572 � Grease AUTOL TOP 2000

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� Anti-seize RIVOLTA GWF

Preparations None.

Disassemble uncouple cylinder

1) Remove countersunk screws (Fig. 6-21/14) from cylinder cover (2).

2) Remove cylinder cover (2) from cylinder casing (1).

3) Remove piston (3) and compression spring (6) from cylinder casing (1).

4) Remove O-ring (8) from the groove in piston (3).

5) Remove O-ring (9) from the groove in cover (2).

Replacement parts - overhaul 1 � Fasteners � Worn parts � O-rings � Compression spring

Replacement parts - overhaul 2 � All parts to be replaced during overhaul 1

Overhaul the uncouple cylinder

1) Clean individual parts, check for wear and replace worn parts.


3) Grease o-rings, inside of cylinder casing and piston rod with AUTOL TOP 2000.


Fig. 6-21 Uncouple cylinder STD.001.02

1 Cylinder casing 6 Compression spring 12 Hexagon bolt

2 Cylinder cover 8 O-ring 14 Countersunk screw

3 Piston 9 O-ring

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Assemble the uncouple cylinder

NOTICENOTICENOTICENOTICE Observe proper mounting position of cylinder cover!Observe proper mounting position of cylinder cover!Observe proper mounting position of cylinder cover!Observe proper mounting position of cylinder cover! The air supply port must point downwards when installed correctly.

1) Insert O-ring (Fig. 6-21/8) into the plate of piston (3).

2) Insert compression spring (6) into cylinder casing (1).

3) Insert the rod of piston (3) into cylinder casing (1) and push in carefully without damaging O-ring (8).

4) Insert O-ring (9) into the groove of the cylinder cover (2).

5) Place cylinder cover (2) onto cylinder casing (1).

6) Position cylinder cover (2) with the air supply port pointing downwards and press on care-fully.

7) Screw on countersunk screws (14) and tighten. Recommended torque: 13 Nm.

Check the uncouple cylinder for leak tightness

DANGERDANGERDANGERDANGER Risk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated components Compressed air is applied to the piston rod of the pneumatic cylinder thus it may ex-tend abruptly. � Leave sufficient space around the pneumatic cylinder.

WARNINGWARNINGWARNINGWARNING Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure. Leaking parts may lead to failure. � Prior to operation of the coupler, check pneumatic components for leaks.

1) Connect a suitable testing device with pressure gauge and 10 bar (1 MPa) compressed-air supply to the connector of the cylinder casing.

2) Place the entire uncouple cylinder into a water-filled container.

If bubbles appear at the cover seal:

3) Remove the uncouple cylinder and depressurise.

4) Carefully retighten the screws securing the cylinder cover in crosswise order.

5) Check again for tightness.

If no bubbles appear:

6) Switch off the compressed air supply. � The pressure must not drop by more than 0.1 bar = 0.01 MPa in 5 minutes.

7) Remove the testing device.

8) Open the drain hole.

If the uncouple cylinder leaks or a pressure drop is detected:

9) Replace the uncouple cylinder.

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Final steps None.

6.6.3 Air pipe connection for brake pipe This section describes how to disassemble, overhaul and assemble the air pipe connection for the brake pipe (BP).

Tools and Materials � Various standard tools � Socket wrench for mouth piece mounting � Socket wrench for bush mounting � Spare part kit ''mouth piece for BP / MRP'' � Cleaner Ethyl alcohol � Anti-seize RIVOLTA GWF � Grease AUTOL TOP 2000 � Compressed air (1 MPa = 10 bar) � Soap solution

Preparations None.

Remove the pipe adapter

NOTICENOTICENOTICENOTICE Dropping partsDropping partsDropping partsDropping parts When removing the pipe adapter, small parts located inside the air pipe connection

may loosen and drop down. � Be sure to take suitable measures to collect such parts.

1) Remove the screw connection at the flange of the pipe adapter.

Disassemble the air pipe connection for BP

DANGERDANGERDANGERDANGER Risk of injury.Risk of injury.Risk of injury.Risk of injury. The cam disc pin is spring-loaded. When the cam disc is unscrewed, the cam disc pin will jump into the valve casing. � Hold the cam disc pin using suitable means.

1) Secure cam disc pin (1) using suitable auxiliaries (piece of wood).

2) Remove gasket (8) from valve casing (26).

3) Unscrew valve plate (5) from cam disc pin (1).

4) Remove rubber ring (6) from valve plate (5).

5) Remove cam disc pin (1) and compression spring (17) from valve casing (26).

6) Slide sleeve (2) off cam disc pin (1).

7) Unscrew bush (3) from valve casing (26) using the socket wrench for bush mounting.

8) Remove gasket (7) from bush (3).

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Replacement parts - overhaul 1 � Worn parts � Parts of spare parts kit "mouth piece for BP / MRP": socket, rubber tube, gasket, stop spring

and compression spring. � Rubber ring (6), gaskets (7, 8), compression spring (17) � Socket head cap screws (38, 40) and lock washers (48) � Socket head cap screws (34) and lock washers (46) � Spacer bushes (4) � Sleeve (2)


Additionally:

� Cam disc pin (1) � Bush (3)

Overhaul the air pipe connection for BP


1) Clean parts with Ethyl alcohol and check for wear.



Assemble the air pipe connection for BP

1) Mount gasket (Fig. 6-22/7) onto bush (3).

2) Grease the thread of bush (3) with RIVOLTA GWF.

3) Insert bush (3) into valve casing (26) using the socket wrench for bush mounting.

4) Grease the inside of bush (3) with AUTOL TOP 2000.

5) Slide sleeve (2) onto cam disc pin (1).

6) Insert compression spring (17) and cam disc pin (1) into bush (3).

7) Insert new rubber ring (6) into the groove of valve plate (5).

8) Grease the thread of valve plate (5) with RIVOLTA GWF.

9) Screw valve plate (5) into the shank of cam disc pin (1).

10) Insert gasket (8) into the flange of valve casing (26).

11) Grease the head of cam disc pin (1) with AUTOL TOP 2000.

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Fig. 6-22 Air pipe connection BP - simplified drawing








Install the pipe adapter

1) Hold gasket and small parts of air pipe connection.

2) Position flange of pipe adapter at the air pipe connection and fix it via the screw connection. Recommended torque: 13 Nm.

Final steps None.

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6.6.4 Air pipe connection for main reservoir pipe a nd uncouple pipe This section describes how to disassemble, overhaul and assemble the air pipe connection for the main reservoir pipe (MRP) and the uncouple pipe (UP).

Tools and Materials � Various standard tools � Socket wrench for mouth piece mounting � Spare part kit "mouth piece for BP/MRP" � Spare part kit "mouth piece for UP" � Cleaner Ethyl alcohol � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF � Cleaner LOCTITE 7063 � Activator LOCTITE 7649 � Thread sealant LOCTITE 572 � Compressed air (1 MPa = 10 bar) � Soap solution

Preparations None.

Remove the pipe adapter

NOTICENOTICENOTICENOTICE Dropping partsDropping partsDropping partsDropping parts When removing the pipe adapter, small parts located inside the air pipe connection may loosen and drop down. � Be sure to take suitable measures to collect such parts.

1) Remove the screw connection at the flange of the pipe adapter.

Disassemble the air pipe connection for MRP and UP

1) Remove valve spring (Fig. 6-23/31) and O-ring (36).

2) Remove valve tappet (8) from valve casing (22).

3) Remove rubber ring (1) from the groove in valve tappet (8).

4) Remove hairpin clip (Fig. 6-23/10) from lateral bores of valve casing (22).

5) Remove cage (28) and rubber tube (13) from valve casing (22).

6) Remove seal (15) from valve casing (22).

Replacement parts - overhaul 1 � Fasteners � Worn parts � For MRP: parts of spare part kit "mouth piece for BP / MRP": socket (3), rubber tube (4),

gasket (5), stop spring (16) and compression spring (17). � For UP: parts of the spare part kit "mouth piece for UP": hairpin clip (10), rubber tube (13),

seal (15) and cage (28). � Rubber ring (1) � Valve spring (31)

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� O-ring (36)

Replacement parts - overhaul 2 � All parts to be replaced during overhaul 1 � Valve tappet (8)

Overhaul the air pipe connection


1) Clean parts with Ethyl alcohol and check for wear.

2) Clean the thread of the air supply port with LOCTITE 7063.

3) If necessary, activate the thread with LOCTITE 7649.

4) Protect the thread against the ingress of dirt and operator contact.



Fig. 6-23 Air pipe connection for MRP and UP STD.001.04

1 Rubber ring 15 Seal 40 Socket head cap screw

3 Socket 16 Stop spring 41 Socket head cap screw

4 Rubber tube 17 Compression spring 44 Hexagon nut

5 Gasket 22 Valve casing 47 Lock washer

8 Valve tappet 28 Cage 48 Lock washer

10 Hairpin clip 31 Valve spring 13 Rubber tube 36 O-ring

Assemble the air pipe connection for MRP and UP

1) Insert the gasket (Fig. 6-23/15) into the lower seat of the valve casing (22).

2) Insert the rubber tube (13) into the cage (28).

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3) Insert the cage (28) into the lower seat of the valve casing (22).

4) Secure the cage (28) with the stop spring (10).

5) Insert rubber ring (Fig. 6-23/1) into groove of valve tappet (8).

6) Slightly grease shank of valve tappet (8) and the upper seat of the valve casing (22) with grease AUTOL TOP 2000.

7) Insert valve tappet (8) from rear side into valve casing (22).

8) Place valve spring (31) onto the short end of valve tappet (8) and secure in place.

9) Insert O-ring (36) into the groove of valve casing (22) and secure in place.

Install the pipe adapter

1) Hold gasket and small parts of air pipe connection.

2) Position flange of pipe adapter at the air pipe connection and fix it via the screw connection. Recommended torque: 13 Nm.

Final steps None.

6.6.5 Electric head operating gear This section describes how to disassemble, overhaul and assemble the electric head operating gear (Fig. 6-25).

Tools and Materials � Various standard tools � Reference gauge for electric head projection � Hot air gun � Cleaner LOCTITE 7063 � Activator LOCTITE 7649 � Thread sealant, medium strength LOCTITE 572 (for threaded pipe adapters up to 1/4") � Thread sealant, high strength LOCTITE 586 (for threaded pipe adapters larger than 1/4") � Threadlocker LOCTITE 243 � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

Preparations None.

Disassemble the operating gear

1) Support cylinder (Fig. 6-24/70).

2) Remove hexagon nut (25) from the front end of the pneumatic cylinder and remove washer (22).

3) Remove pin (15) from support (9) and cylinder (70).

4) Remove split pin (37) from pin (14) at the rear side of cylinder (70).

5) Remove pin (14) from lever (5) and from the piston rod of cylinder (70).

6) Place cylinder (70) on a suitable surface.

7) Remove spring type straight pins (33, 34) from shaft (1) and lever (5).

8) Remove lever (5).

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9) Remove spring type straight pins (33, 34) from shaft (1) and fork (2).

10) Remove shaft (1) from support (50) and fork (2).

WARNINGWARNINGWARNINGWARNING Risk of injury.Risk of injury.Risk of injury.Risk of injury. The component is spring-loaded and may abruptly jump forwards. � Secure the part or the spring with a suitable device. � Carefully remove the part. � Carefully relieve spring.

11) Carefully remove both hexagon nuts (26) from rod (3). � This releases compression spring (42).

12) Remove spacer (8) and compression spring (42) from rod (3).

13) Remove rod (3) from pin (7).

14) Remove pin (7) from fork (2).

Disassemble the pneumatic cylinder

1) Remove hexagon head screws (Fig. 6-24/9) from cylinder cover (2).

2) Remove cylinder cover (2) and piston (1) from cylinder casing (3).

3) Only when worn out, remove bush (4) from piston (1).

4) Remove O-rings (5, 7, 8) and wiper (6).

Fig. 6-24 Cylinder 2.035.051.05.01 [variant A]

1 Piston 5 O-ring 9 Hexagon bolt

2 Cylinder cover 6 Wiper 10 Lock washer

3 Cylinder casing 7 O-ring 4 Bush 8 O-ring

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Replacement parts - overhaul 1 � Fasteners � Worn parts � Compression springs (if applicable) � Bushes � Friction bearing � Parts of the pneumatic cylinder:

- O-rings, U-rings (if applicable) - Wiper - Double cup seal (if applicable) - Compression springs (if applicable)


Overhaul the electric head operating gear

NOTICENOTICENOTICENOTICE Guiding rods and guiding bushes must be kept free from grease.Guiding rods and guiding bushes must be kept free from grease.Guiding rods and guiding bushes must be kept free from grease.Guiding rods and guiding bushes must be kept free from grease.

Guiding rods and guiding bushes must be grease-free.

1) Clean parts and check them for wear.


3) Clean the cylinder covers and the compressed-air ports of the cylinder casings with LOC-TITE 7063 cleaner.

4) Grease O- and U-rings, wipers, inside of cylinder casing and piston rod with AUTOL TOP 2000.


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Assemble the pneumatic cylinder

1) Press bush (Fig. 6-24/4) into piston (1).

2) Insert wiper (6) and O-Ring (8) into the grooves of cylinder cover (2).

3) Insert O-ring (7) into the groove of piston (1).

4) Carefully insert piston (1) into cylinder casing (3) without damaging O-ring (7).

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5) Insert O-ring (5) into the groove of cylinder casing (3).

6) Slip cylinder cover (2) over piston rod (1) and turn pneumatic connector into cylinder casing direction.

7) Fix cylinder cover (2) with lock washers (9) and hexagon head screws (10).

Check the pneumatic cylinder for tightness

DANGERDANGERDANGERDANGER Risk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated componentsRisk of injury resulting from pneumatically operated components Compressed air is applied to the piston rod of the pneumatic cylinder thus it may ex-tend abruptly. � Leave sufficient space around the pneumatic cylinder.

WARNINGWARNINGWARNINGWARNING Risk of cRisk of cRisk of cRisk of coupler failure.oupler failure.oupler failure.oupler failure. Leaking parts may lead to failure. � Prior to operation of the coupler, check pneumatic components for leaks.

1) Connect a suitable testing device with pressure gauge and 10 bar (1 MPa) compressed-air supply to one of the two air supply ports.

2) Seal the second air supply port against the ingress of water by suitable means, e.g. duct tape.

3) Place the entire pneumatic cylinder into a water-filled container.

4) Check for formation of air bubbles.

If bubbles appear at the cover seal:

5) Depressurise pneumatic cylinder.

6) Carefully retighten the screws securing the cylinder cover in crosswise order.

7) Check again for tightness.

If bubbles are detected at the other air supply port:

8) Remove, depressurise and disassemble the pneumatic cylinder, replace the O-ring, re-assemble the cylinder and check again for tightness.

If no bubbles appear:

9) Switch off the compressed air supply. � The pressure must not drop by more than 0.1 bar = 0.01 MPa in 5 minutes.

10) Remove the testing device.

11) Check the other air supply port.

If the pneumatic cylinder leaks or a pressure drop is detected:

12) Replace the pneumatic cylinder.

Assemble the operating gear

1) Slide compression spring (Fig. 6-25/42) and spacer (8) onto rod (3).

2) Insert pin (7) and new friction bearings (41) into fork (2).

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3) Slide the threaded end of rod (3) into the bore of pin (7) and screw on hexagon nuts (26).

4) Insert shaft (1) through lever (5), support (50) and fork (2) and secure with spring type straight pins (33, 34).

5) Join the piston rod of cylinder (70) to lever (5) by inserting pin (14) and secure pin (14) using split pin (37).

6) Fasten the front end of cylinder (70) to support (50) by inserting pin (15); place washer (22) onto pin (15) and tighten the hexagon nut. Recommended torque: 43 +7.5 Nm.

Final steps None.

6.6.6 Coupler shank This section describes how to disassemble, overhaul and assemble the coupler shank (Fig. 6-26).

Tools and Materials � Standard tools � Cleaner LOCTITE 7063 � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

Preparations

1) Support the components separately if necessary.

DANGERDANGERDANGERDANGER Danger of explosionDanger of explosionDanger of explosionDanger of explosion The buffer contains highly compressed media. External sources of heat or undefined impacts may lead to an uncontrolled pressure increase damaging gaskets and mate-

rial. An explosion of the buffer or leaking substances may cause lethal injuries. � Protect the buffer and the connected components from heat. � Prevent the buffer from knocks, impacts and falling down.

Remove the buffer and the friction spring

NOTICENOTICENOTICENOTICE This work requires special training, tools and a powerful press. We strongly recommend: � Return the complete coupler shank to the manufacturer for overhaul.

1) Return the complete coupler shank to the manufacturer.

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Remove the spherical bearing

NOTICENOTICENOTICENOTICE This work requires special training, tools and a powerful press. We strongly recommend: � Return the complete coupler shank to the manufacturer for overhaul.

1) Return the complete coupler shank to the manufacturer.

Replacement parts - overhaul 1 � Fasteners � Worn parts � Anti-rotation lock � Spherical bearing (to be replaced by manufacturer)


Overhaul the coupler shank

1) Clean the parts and check them for wear.



3) Grease inner surface of spherical bearing with AUTOL TOP 2000.

4) Grease visible sliding surfaces of buffer with AUTOL TOP 2000.

5) Grease the collar with AUTOL TOP 2000 lubricant.



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1 Intermediate piece 12 Anti-rotation lock 22 Gas-hydraulic buffer

2 Threaded ring 15 Guide ring 34 Hexagon bolt

3 Washer 16 Guide ring 35 Locking screw

4 Bush 18 Wiper 36 Plug

11 Flat key 20 Friction spring 60 Spring casing

Install buffer and friction spring Not applicable

Install the spherical bearing Not applicable

Final steps

1) Grease the collar with AUTOL TOP 2000.

6.6.7 Bearing bracket This section describes how to overhaul the bearing bracket (Fig. 6-27).

During disassembly of the coupler, the bearing bracket is removed and disassembled (except the collapsible tube). The overhauled bearing bracket is reassembled [chap.6.7.1 � page 165] when mounting it to the coupler.

Replacing the collapsible tube requires special training, tools and a powerful press. This work should be carried out by the manufacturer.

Tools and Materials � Various standard tools � Hot air gun or solvent Dichloromethane � Sharp knife or triangle scraper � Mounting drift for METALOPLAST bushes � Adhesive KL65 and hardener � Cleaner LOCTITE 7063 � Grease AUTOL TOP 2000

Preparations None.

Disassemble the bearing bracket

NOTICENOTICENOTICENOTICE This work requires special training, tools and a powerful press. We strongly recommend: � Return the complete bearing bracket assembly to the manufacturer for overhaul.

1) Return bearing bracket to manufacturer.

Replacement parts - overhaul 1 � Fasteners � Worn or damaged parts � Anti-friction discs � Bushes � lubricating nipple � Sliding plates

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Overhaul the bearing bracket


2) Replace bushes as per SCHAKU standard Z006 [chap.10.3 � page 208] .



4) Grease the pivot, contact surfaces of anti-friction discs, sliding surfaces and guiding surfac-es with grease AUTOL TOP 2000.






Assemble the bearing bracket Not applicable.

Final steps None.

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6.6.8 Electric head - replacement of male / female contacts This section describes how to replace male / female contacts.

Tools and Materials � Hexagon wrench size 6, recommended torque: 2 Nm � Installation aid lubricant HELLERINE (or vaseline)

Preparations

1) Put the coupler in the repair position.

2) Open or remove [chap. � page 147] the protecting lid.

Replace contact

1) Screw off contact (Fig. 6-28/2) using hexagon wrench (5).

2) Slightly grease new O-ring (3) with lubricating oil.

3) Place O-ring (3) onto new contact (2) from the rear side.

4) Screw in contact (2) using hexagon wrench (5). Recommended torque depending on wrench size: refer to tools and materials.

Fig. 6-28 Replacement of contacts - simplified drawing

1 Terminal stud 4 Contact block

2 Contact 5 Hexagon wrench

3 O-ring

Final steps

1) Check the contact for proper function.

2) Close or re-install lid.

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6.6.9 Electric head - replacement of snap-in termin al studs This section describes how to replace terminal studs.

Tools and Materials � Dismounting tool for snap-in terminal studs � Pliers for installation of snap-in terminal studs � Hot air gun

Preparations

1) Remove contact [chap. � page 143] .

2) Remove the contact block [chap. � page 147] .

Removal of terminal studs

1) Insert the tip of dismounting tool (Fig. 6-29/1) from the front side into the threaded bore of terminal stud (3).

2) Remove terminal stud (3) from contact block (2) by slightly tapping it out towards the rear side.

3) Loosen the wire connected to the terminal stud.

Fig. 6-29 Removing snap-in terminal studs - simplified drawing

1 Dismounting tool 2 Contact block 3 Snap-in terminal stud

Installation of terminal studs

NOTICENOTICENOTICENOTICE Connecting the wire to the terminal studConnecting the wire to the terminal studConnecting the wire to the terminal studConnecting the wire to the terminal stud � First connect the wire to the terminal stud, then install the terminal stud in the con-

tact block.

1) Check the wire insulation for visible damage, apply heat-shrink tubing if necessary.

2) Connect the wire to the terminal stud.

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CAUTIONCAUTIONCAUTIONCAUTION Insulation of electric lines may be damaged.Insulation of electric lines may be damaged.Insulation of electric lines may be damaged.Insulation of electric lines may be damaged. Insulation of wire may be damaged by scorching. � Apply hot air to heat-shrink tubing only.

3) Place the heat-shrink tubing over the naked wire and heat-shrink using a hot air gun.

4) Hold the terminal stud with the Fig. 6-30/mounting pliers.

5) Insert the snap-in head of terminal stud (3) from the rear side into the bore of contact block (2) until it snaps in place.

6) Check terminal stud (3) for tight seat. � The terminal stud must be free to float in its seat.

Fig. 6-30 Pliers

Final steps

1) Install [chap. � page 149] the contact block.

2) Install [chap. � page 143] the contact.

6.6.10 Electric head This section describes how to disassemble, overhaul and assemble the electric head.

CAUTIONCAUTIONCAUTIONCAUTION Warranty voidWarranty voidWarranty voidWarranty void The electric head boxes are sealed for safety reasons. � Any opening of the box by non-authorised staff within the guarantee period leads

to warranty void. Voith excludes any liability for non-authorised opening of the box.

Tools and Materials � Various standard tools � Tools for replacing the contacts [chap. � page 143] � Tools for replacing the terminal studs [chap. � page 144] � continuity checker � Leather rag or grease free linen rag � Oil-free compressed air � Grease AUTOL TOP 2000 � Sealant TEROSTAT-MS930 � French chalk powder

Preparations None.

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Remove the protecting lid

1) Remove the earth wire between lid (Fig. 6-31/1) and casing (2).

2) Remove tension spring (3).

3) Hold the protecting lid.

4) Remove socket head cap screws (5) securing both lid bearings (4), then remove the lid bearings and washers (6).

5) Remove the lid.

Fig. 6-31 Fixture of the protecting lid

1 Lid 4 Lid bearing

2 Casing 5 Socket head cap screw

3 Tension spring 6 Washer

Remove the contact block

1) Remove socket head cap screws (Fig. 6-32/3) from contact block (2).

2) Remove washers (4).

3) Carefully pull contact block (2) about 10 cm out of the casing.

4) Remove gasket (1).

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Fig. 6-32 Fixture of the contact block - simplified drawing

1 Gasket 3 Socket head cap screw 2 Contact block 4 Washer

Replace the electric head heaters

CAUTIONCAUTIONCAUTIONCAUTION Warranty voidWarranty voidWarranty voidWarranty void The electric head boxes are sealed for safety reasons. � Any opening of the box by non-authorised staff within the guarantee period leads

to warranty void. Voith excludes any liability for non-authorised opening of the box.

1) Open the rear cover of the electric head casing.

2) Disconnect the wires from the heater elements.

3) Remove the heaters with a suitable tool (scraper), and remove residues of adhesive.

4) Clean the surface with cleaner WEICON S.

5) Glue in new heater elements.

6) Connect the wires.

7) Treat the contact surfaces of cover and casing with sealant TEROSTAT-MS 930 and refit the cover to the rear side of the electric head casing.

Replacement parts - overhaul 1 � Tension spring(s) � Lid bearing � Fasteners � Worn parts � Earth wires � Full face gasket � Gasket

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Clean electric head

DANGERDANGERDANGERDANGER RisRisRisRisk of short circuit due to moisturek of short circuit due to moisturek of short circuit due to moisturek of short circuit due to moisture

Cleaning the electric head with water may cause the ingress of water into the contact compartment and the space between the contacts. This may cause a short circuit! � Be sure to cover the electric head while performing the rough cleaning of the cou-

pler. � Keep the contact area dry and watertight � Keep the drain holes open. � Clean the following parts one after another using a dry cloth (e.g. microfibre or

cotton) and a brush: casing, centring elements, inside and outside of the protect-ing lid (if any), contact block, contacts and sealing frame.

NOTICENOTICENOTICENOTICE Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity.Oxide layer on contacts conducts electricity. The black oxide layer that builds up over time is conductive and does not need to be

removed. � Do not sandpaper or file contact tips!

1) Clean the inner and outer side of the protecting lid with a dry rag.

2) Clean the electric head casing and the centring pins/bushes with a dry rag.

3) Clean the contacts and the contact block with a dry, clean and lint-free rag or cleaning brush.

4) Clean the gasket with a damp cloth, then wipe dry.

After cleaning

1) Grease moving parts and articulation points with AUTOL TOP 2000.

NOTICENOTICENOTICENOTICE Do not paint sliding surfaces and rubber framesDo not paint sliding surfaces and rubber framesDo not paint sliding surfaces and rubber framesDo not paint sliding surfaces and rubber frames Sliding surfaces and rubber frames must not get into contact with paint.

2) Check the coating for damage, if necessary repair with weather-proof 2-component polyure-thane varnish. � The paint serves as insulation.

Install the contact block

1) Mount gasket (Fig. 6-33/1).

2) Insert contact block (2) from the front side into the casing.

3) Fix contact block (2) with washers (4) and socket head cap screws (3).

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Fig. 6-33 Fixture of the contact block - simplified drawing

1 Gasket 3 Socket head cap screw 2 Contact block 4 Washer

Install the protecting lid

1) Treat socket head cap screws (Fig. 6-34/5) with LOCTITE 243.

2) Place lid (1) on casing (2) such that the bearing bores are aligned.

3) Insert new lid bearings (4) into the bores of the protecting lid and fasten the lid using wash-ers (6) and socket head cap screws (5).

4) Install the earth wire between lid and casing.

5) Mount new tension spring (3).

Fig. 6-34 Fixture of the protecting lid

1 Lid 4 Lid bearing

2 Casing 5 Socket head cap screw

3 Tension spring 6 Washer

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Final steps None.

Electric head diagrams Fig. 6-35 shows the contact block overview according to electric head diagram 08.009.060-Z1.

Fig. 6-35 Contact block overview 08.009.060-Z1

Fig. 6-36 shows the wiring diagram according to electric head diagram 08.009.60-Z1, part 1 of 3.

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Fig. 6-36 Wiring diagram 08.009.060-Z1 - part 1 of 3


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6.6.11 Centring device and support This section describes how to disassemble, overhaul and assemble the centring device and support assembly.

Tools and Materials � Standard tools � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

Preparations None.

Disassemble the support subassembly

1) Remove spring type straight pin (Fig. 6-39/21).

2) Pull pivot (5) downwards out of bearing bracket (57).

3) Separate support (56) from bearing bracket (57).

4) Remove the bushes from the bearing bracket using the device for bush removal.

5) Remove anti-friction discs (15).

6) Loosen locking screws (35) and remove support (2).

7) Remove socket head cap screws (24) and sliding plates (7).

8) Loosen hexagon nuts (28) on both sides.

9) Carefully remove hexagon head screws (32) from support (56).

10) Remove hexagon head screws (32) and hexagon nuts (28).

11) Remove supporting spring (50) with guide sheet (3) and flat (1).

12) Remove hexagon head screws (30) and lock washers (40).

13) Remove supporting spring (50).

14) Loosen socket head cap screws (24).

15) Remove plates (4).

16) Remove spring type straight pins (22).

17) Remove guide sheet (3) and washer (9).

18) Remove flat (1) from supporting spring (50).

Disassemble the centring device

1) Uniformly loosen socket head cap screws (Fig. 6-39/23) and relieve Belleville springs (42).

2) Remove socket head cap screws (23) and lock washers (41).

3) Remove spring holder (8) with stem (55), washer (12) and Belleville springs (42).

4) Remove locking screws (38).

5) Remove cam disc (6).

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Fig. 6-39 Centring device and support 010.616.10

1 Flat 16 Lubricating nipple 32 Hexagon bolt

2 Support bracket 17 Dust protection cap 35 Locking screw

3 Guiding plate 19 Protection plug 38 Locking screw

4 Plate 20 Plug 39 Lock washer

5 Pin 21 Spring type straight pin 40 Lock washer

6 Cam disc 22 Spring type straight pin 41 Lock washer

7 Sliding plate 23 Socket head cap screw 42 Plate spring

8 Spring holder 24 Socket head cap screw 50 Supporting spring

9 Washer 28 Hexagon nut 55 Stem

10 Metal sheet 30 Hexagon bolt 56 Support

15 Anti-friction disc 31 Hexagon bolt 57 Bearing bracket with bush

Parts to be replaced - centring device Replace the following parts of the centring device:

Replacement parts - overhaul 1 � Worn parts

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� Bushes � Stem with roller (55) � Cam disc (6) � Plates (4) � Sliding plates (7)


Parts to be replaced - support Replace the following parts of the support:

Replacement parts - overhaul 1 � Worn parts � Damaged parts

Replacement parts - overhaul 2 � All parts to be replaced during overhaul 1 � Supporting spring (50)

Overhaul the centring device



3) Grease pin (5) with AUTOL TOP 2000.

4) Grease all sliding surfaces and the inside of support (56) with AUTOL TOP 2000.


Assemble the support subassembly

1) Place supporting spring (Fig. 6-39/50) onto flat (1).

2) Insert hexagon head screws (30) with lock washers (40) through flat (1) and supporting spring (50). Recommended torque: 36 Nm.

3) Insert hexagon head screws (32) through flat (1) and hexagon nuts (28) into support (56).

4) Hand-tighten hexagon nuts (28).

5) Final adjustment [chap. � page 95] takes place after assembly of the complete coupler.

6) Place washer (9) onto supporting spring (50).

7) Place guide sheet (3) on washer (9) and fix with spring type straight pins (22).

8) Treat socket head cap screws (24) with threadlocker LOCTITE 243.

9) Fix plates (4) on guide sheet (3) with socket head cap screws (24). Recommended torque: 3 Nm.

10) Fix sliding plates (7) and plates (10) with socket head cap screws (24) to supports (2). Recommended torque: 3 Nm.

11) Fix support (2) with locking screws (35) to support (56). Recommended torque: 130 Nm.

Assemble the bearing bracket and support

1) Press new bushes into the central bore of bearing bracket (Fig. 6-39/57).

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2) Slightly grease cam disc (6) with AUTOL TOP 2000.

3) Place anti-friction discs (15) onto cam disc (6) and bearing bracket (57).

4) Place cam disc (6) onto support (56).

5) Insert support (56) with cam disc (6) into bearing bracket (57).

6) Insert pin (5) into centre bore of cam disc (6) and bearing bracket (57).

7) Drive in spring type straight pin (21).

8) Mount cam disc (6) with lock washers (38) to bearing bracket (57). Recommended torque: 100 Nm.

9) Use Flame red marking paint to mark the centred position on the bearing bracket.

Assemble the stem

1) Press bush (Fig. 6-40/10) into roller (7) and slightly grease the inside with AUTOL TOP 2000.

2) Insert roller (7) into stem (1) and align the bores.

3) Insert pin (5) into stem (1) and align the bores.

4) Insert pin (5) into stem (1) and roller (7).

5) Insert retaining ring (14), the gap has to point upwards.

6) Mount sleeve (3).

Fig. 6-40 Stem

1 Stem 7 Roller

2 Rod 10 Bush

3 Sleeve 14 Retaining ring

5 Pin

Assemble the spring holder

1) Insert stems (Fig. 6-39/55) through the bushes of support (56) into recesses of cam disc (6).

2) Slide Belleville springs (42) in pairs onto stems (55).

3) Fix spring holder (8) with socket head cap screws (23) and lock washers (41) to support (56) and stress the Belleville springs (42). Tighten the screws crosswise. Recommended torque: 12.5 Nm.

Final steps None.

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6.6.12 Pneumatic unit of the coupler head This section describes how to overhaul the pneumatic unit of the coupler head (Fig. 6-41).

Tools and Materials � Anti-seize RIVOLTA GWF � Thread sealant LOCTITE 572 or LOCTITE 586

Preparations None.

Disassemble the pneumatic unit The elements of the pneumatic unit of the coupler head have already been removed [chap.6.5.3 � page 107] individually during disassembly of the product. Further disassembly is not needed.

1) Remove fittings if necessary.

Replacement parts - overhaul 1 � Worn parts � Hoses � Double nipple, connectors (male connectors), fittings (swivel fittings), if any. � Hose clamps including fixation screws, cable ties, if any � 5/2 way valves � Strainer, if applicable only sieve


Overhaul the parts of the pneumatic unit

1) Replace all parts identified as replacement parts.


3) Replace the sieves of the strainers if necessary.

4) Treat screw connections according to SCHAKU standard A023 [chap.10.2 � page 207] .


Assemble the pneumatic unit The components included in the pneumatic unit of the coupler head are to be reassembled [chap.6.7.12 � page 179] individually.

1) Screw in fittings according to Fig. 6-41.

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Final steps None.

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6.6.13 Electrical unit of the coupler head This section describes how to overhaul the electrical unit of the coupler head.

Tools and Materials � High voltage tester � Ohmmeter

Preparations None.

Disassemble the electrical unit of the coupler head The components of the electrical unit of the coupler head have already been removed [chap.6.5.2 � page 105] one by one during the disassembly of the product. Further disassem-bly is not needed.





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Replacement parts - overhaul 1 � Worn parts � Mechanically operated switches

Replacement parts - overhaul 2 � All parts to be replaced during overhaul 1 plus: � Electric lines � Cable glands

Overhaul the electrical unit of the coupler head


2) Clean the switching elements of the position switch(es).

3) Check the position switch for proper function and the plunger for ease of movement.

4) Check the insulation of the electric lines and cable glands for damage.


Assemble the electrical unit of the coupler head The electrical unit of the coupler head is assembled when reassembling the product.

Final steps None.

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6.6.14 Muff coupling This section describes how to overhaul the muff coupling.

Tools and Materials � Various standard tools � Brush with stiff bristles � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF � Stiff wire

Preparations None.

Fig. 6-43 illustrates the muff coupling.

Fig. 6-43 Muff coupling 2.010.109.36

1 Muff 4 Hexagon bolt 6 Lock washer

2 Muff 5 Hexagon nut

Disassemble the muff coupling Not applicable.

Replacement parts - overhaul 1 � Screws � Lock washers � Nuts


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Overhaul the muff coupling

NOTICENOTICENOTICENOTICE Inner surfaces of muffs remain unInner surfaces of muffs remain unInner surfaces of muffs remain unInner surfaces of muffs remain unpaintedpaintedpaintedpainted Inner surfaces of muffs must be primed only.

1) Clean the muffs.

2) Degrease the inside of the muffs with cleaner LOCTITE 7063.

3) Check the muffs for damage, replace muffs with cracks even outside of the maintenance in-tervals.


5) Grease inside of muffs with AUTOL TOP 2000.

6) Treat the screw threads with anti-seize RIVOLTA GWF.

7) Open the drain hole with a stiff wire.

Assemble the muff coupling Not applicable.

Final steps None.

6.6.15 Earthing system This section describes how to overhaul the earthing system.

Tools and Materials � Anti-seize RIVOLTA GWF � Cleaner LOCTITE 7063 � Emery cloth

Preparations None.

Disassemble the earthing system Not applicable.

Replacement parts - overhaul 1 � Earth wires � Earth label � Hexagon head screws, lock washers and washers


Overhaul the earthing system

1) Clean the earthing symbol, replace missing symbols

2) Clean the earthing sockets.


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Assemble the earthing system Not applicable.

Final steps None.

6.7 Assemble the coupler Assembling the coupler

This section describes how to assemble the coupler.

6.7.1 Install the bearing bracket This section describes how to connect the bearing bracket to the coupler shank.

Tools and Materials � Grease AUTOL TOP 2000

Preparations

1) Support the coupler shank and bearing bracket using suitable aids.






Connect the bearing bracket to the coupler shank

1) Place lower anti-friction disc (Fig. 6-44/3) onto lower leg of bearing bracket (50).

2) Place upper anti-friction disc (3) onto the eye of the coupler shank.

3) Insert the coupler shank horizontally into bearing bracket (50) without damaging anti-friction discs (3).

4) Grease pivot (2) with AUTOL TOP 2000.

5) Insert pin (2) from above into the bores of the bearing bracket and the spherical bearing of the coupler shank and secure the pin with retaining ring (33).

Final steps None.

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6.7.2 Install the coupler shank This section describes how to install the coupler shank.


Preparations None.

Install the coupler shank � The coupler shank is connected to the bearing bracket by means of a pivot. The pivot is part

of the bearing bracket.

1) Install the bearing bracket [chap.6.7.1 � page 165] .

Final steps None.

6.7.3 Install the centring device and support This section describes how to install the centring device and support.

Tools and materials � Standard tools � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

Preparations None.

Install the centring device and support

1) Place centring device and support on the bearing bracket of the coupler.

2) Mount the centring device and support assembly to the coupler bearing bracket using lock washers and hexagon head screws (Fig. 6-45/1). Recommended torque: 300 Nm.

Fig. 6-45 Centring device

1 Hexagon bolt 3 Support

2 Supporting spring

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Final steps None.

6.7.4 Mount the coupler head This section describes how to mount the coupler head.


Preparations None.

Mount the coupler head

1) Install [chap.6.7.11 � page 175] the coupler head by means of a horizontal muff coupling.

Final steps None.

6.7.5 Install the uncouple cylinder The uncouple cylinder has already been installed into the coupler head [chap. � page 125] .

6.7.6 Mount the air pipe connection for the main re servoir pipe and the uncou-ple pipe

This section describes how to install the air pipe connection for main reservoir pipe (MRP) and the uncouple pipe (UP) together with the pipe adapter.


Preparations None.

Install the air pipe connection MRP and UP

1) Insert valve casing from the rear side into the bore of the coupler head front plate.

2) Connect front plate and valve casing using socket head cap screws.

3) Secure with hexagon head screws. Recommended torque: 35 Nm.

Mount the mouth piece

1) From the front, insert rubber tube (Fig. 6-46/5) and compression spring (4) into the bore of the front plate.

2) Position mouth piece (6) and hold it.

3) Place box spanner (7) onto mouth piece (6) and snap recess into groove of muff (2). � socket wrench (7), groove and noses of socket (2) must be aligned.

4) Turn socket (2) such that its noses are aligned with the recesses in the bore.

5) Push socket (2) into the bore (A) and turn approx. 90 degrees counter-clockwise (B). � The noses of socket (2) are now locked in place behind the mounting bore.

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6) Take socket wrench (7) off.





Secure mouth piece

1) Insert stop spring (Fig. 6-47/1) into the upper mounting bore (8) (a, b) until the parallel leg (5) stops (c).

2) Press stop spring (1) together (d) and push nose (3) into bore (8) until the catch (4) engages (e). � Nose (3) must be completely visible inside recess (8) as shown in Figure 3.

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Fig. 6-47 Install the stop spring

1 Stop spring 5 Parallel leg of spring a insert

2 Back of spring 6 S-shaped end b Intermediate position

3 Nose 7 Screwdriver c Stop

4 Tooth 8 Upper recess d Push together

e Installed position

Final steps

1) Connect all relevant air pipes and air pipe connections.

6.7.7 Install the uncouple pipe This section describes how to install the uncouple pipe (Fig. 6-48).

Tools and Materials � Thread sealant LOCTITE 572

Preparations None.

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Install the uncouple pipe

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure. Air pipes may leak after mounting. � Insufficient or excessive tightening of union nuts may lead to leakage or damage

of the nuts, and thus to coupler failure. � Check the air pipe adapters for leakage using soapy water. Bubbles indicate leak-

ing fittings which must be retightened. Stop tightening union nuts when the connection is tight.

NOTICENOTICENOTICENOTICE Screw fittings are treated with thread sealantScrew fittings are treated with thread sealantScrew fittings are treated with thread sealantScrew fittings are treated with thread sealant All threaded male sockets of pipe adapters, bite type fittings, cable glands and

threaded adapters are to be sealed with thread sealant. � Threaded pipe adapters up to 1/4” with LOCTITE 572 � Threaded pipe adapters larger than 1/4” with LOCTITE 586




1) Screw adapter (Fig. 6-48/1) with new gasket (11) into threaded bore of cylinder casing.

2) Connect fitting (13) to adapter (1) and hose (16) of the uncouple pipe. Screw on union nuts by hand, apply a mark and tighten union nuts by another approx. 1 1/2 turns. (Observe the mark previously made).

3) Connect hose (16) with swivelling screw fitting (12) to the rear side of the air pipe connec-tion.

Final steps None.

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6.7.8 Install the air pipe connection for the brake pipe This section describes how to install the air pipe connection for the brake pipe (BP) and its pipe adapter.


Preparations None.

Install the air pipe connection for BP

1) Place spacer bushes (4) onto the threaded bores of the coupler head casing and secure with appropriate means.

2) Align valve casing (26) with the front plate and the central pivot.

3) Slightly push in cam plate pin (1) if necessary.

4) Slide valve casing (26) onto the central pivot.

5) Align the bores with the threaded bores of the coupler head casing.

6) Insert socket head cap screws (38, 40) and lock washers (48) and tighten down. Recommended torque: 60 Nm.

Fig. 6-49 Air pipe connection for BP

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Install the mouth piece

1) From the front, insert rubber tube (Fig. 6-50/5) and compression spring (4) into the bore of the front plate.

2) Position mouth piece (6) and hold it.

3) Place box spanner (7) onto mouth piece (6).

4) Turn socket (2) until noses of socket (2) are in front of openings in front plate.

5) Push socket (2) into the bore (A) and turn approx. 90 degrees (B).

6) Take socket wrench (7) off.





Secure the mouth piece

1) Insert stop spring (Fig. 6-51/1) into the upper mounting bore (8) (a, b) until the parallel leg (5) stops (c).

2) Press stop spring (1) together (d) and push nose (3) into bore (8) until the catch (4) engages (e). � Nose (3) must be completely visible inside recess (8) as shown in Figure 3.

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Fig. 6-51 Install the stop spring

1 Stop spring 5 Parallel leg of spring a insert

2 Back of spring 6 S-shaped end b Intermediate position

3 Nose 7 Screwdriver c Stop

4 Tooth 8 Upper recess d Push together

e Installed position

Final steps

1) Connect all relevant air pipes and air pipe connections.

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6.7.9 Install the electric head operating gear This section describes how to install the electric head operating gear and the electric head.

Tools and Materials � Standard tools

Preparations None.

Install the electric head operating gear











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1) Mount pre-assembled support (Fig. 6-52/50) with spring type straight pins (36) and four locking screws (18) to the coupler head casing. Recommended torque: 330 Nm.

2) Mount support (9) with hexagon head screws (16), washers (28) and sleeves (11) to the coupler head casing. Recommended torque: 61 Nm.

Install the electric head

1) Fasten arm (Fig. 6-52/6) with hexagon head screws (17), lock washers (28) and hexagon nuts (27) to support (9). Torque: 130 Nm.

2) Insert new parallel pin (24) into control arm (6).

3) Position the electric head at the coupler head casing, making sure that the guide bushes of the electric head casing are aligned with the bores of support (9).

4) Slide guiding rods (4) from the front side through the guide bushes of the electric head and the friction bearings (40) in support (9) and secure the rods with spring type straight pins (30).

5) Connect the rear side of the electric head casing with rod (3).

Final steps


1) Refit the tension springs.

2) Install [chap. � page 183] the earth wires.

3) Connect the cables to the electrical unit [chap.6.7.13 � page 181] .

4) Measure and adjust the projection [chap.5.9 � page 94] of the electric head.

6.7.10 Install the electric head The electric head forms one mechanical unit with the electric head operating gear. The instruc-tions for mounting the electric head operating gear [chap.6.7.9 � page 174] also describe how to install the electric head.

6.7.11 Assemble the muff coupling - horizontal conf iguration This section describes how to assemble the horizontal muff coupling.

Tools and Materials � Various standard tools � Adjustable torque wrench � Hammer and piece of wood as cushion, or plastic hammer � Cleaner LOCTITE 7063 � Primer and top coat according to the Paint specification [chap.10.1 � page 205] KCG � Grease AUTOL TOP 2000 � Anti-seize RIVOLTA GWF

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Preparations

CAUTIONCAUTIONCAUTIONCAUTION Recommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: � The contact surfaces for screw head, washer and/or nut are only primed. � The contact surfaces are clean, dry and free of grease. � RIVOLTA GWF is applied to the threads only.


1) Grease the collars and contact surfaces of the components to be joined with grease AUTOL TOP 2000.

Fig. 6-53 Muff coupling - simplified drawing

1 Upper muff 10 Thread - treat with RIVOLTA GWF

2 Lower muff 11 Seat-engaging surfaces for screws and nuts - degrease with cleaner

3 Hexagon bolt 12 Inner side of muffs - degrease with cleaner - prime only

4 Hexagon nut 13 Cavity - fill with AUTOL TOP 2000

5 Lock washer 14 Drain hole - keep open

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Install the muff coupling

CAUTIONCAUTIONCAUTIONCAUTION Muff coupling may corrode.Muff coupling may corrode.Muff coupling may corrode.Muff coupling may corrode. At the clamping surfaces, standing water may overcome the corrosion protection and cause corrosion. � Always mount the muff containing the drain hole on the bottom side. � Mount the muff coupling horizontally with precision.

� The drain hole is located in the centre of the muff and only represents the lowest point when mounted exactly horizontally.

CAUTIONCAUTIONCAUTIONCAUTION Risk of oRisk of oRisk of oRisk of overstressing of hexagon head screwsverstressing of hexagon head screwsverstressing of hexagon head screwsverstressing of hexagon head screws Repeated re-tightening of screw connections to recommended torque may overstress screws. � Carefully follow the specified procedure. � If you are not sure which step of the procedure to take next, or if the current condi-

tion of the muff coupling cannot be clearly identified: � Remove the muff coupling once again. � Replace the lock washers. � Repeat the specified procedure.

CAUTIONCAUTIONCAUTIONCAUTION Risk of overstressing of hexagon head screwsRisk of overstressing of hexagon head screwsRisk of overstressing of hexagon head screwsRisk of overstressing of hexagon head screws When the muffs are not parallel to each other, the contact surfaces for screw heads and hexagon nuts will tilt. This results in unilateral overload. � During every step you carry out, be sure to verify that both muffs are parallel to

each other. � If the muffs are not parallel to each other:

� Replace the lock washers. � Repeat mounting.

1) Support the components using suitable aids.

2) Place the collars of the components to be joined against each other and align the collars.

3) Insert hexagon head screws (Fig. 6-53/1) into the bores of the upper muff (3).

4) Treat the threads of hexagon head screws (1) with anti-seize RIVOLTA GWF.

5) Place upper muff (3) onto the collars, adjust the muff horizontally and lightly tap with a hammer to ensure proper fit on the collars.

6) Mount lower muff (6).

7) Mount hexagon nuts (9) with lock washers (8) and align lower muff (6) such that it is parallel to upper muff (3).

8) Tighten hexagon nuts (9) crosswise, ensuring that the muffs remain parallel to each other. Recommended torque: 300 Nm.

If one or more of the hexagon nuts have to be turned by more than 3 degrees to obtain the rec-ommended torque:

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9) Repeat the previous step.

If the recommended torque has been obtained within a 3-degree angle of rotation for all hexa-gon nuts:

10) Verify the parallel position of the muffs.

If the muffs are not parallel to each other:

11) Remove the muff coupling, replace the lock washers and mount the muff coupling again.

Final steps

1) Fill the cavity between hexagon head screws (1) and the bores of lower muff (6) with grease AUTOL TOP 2000 in order to prevent corrosion.

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6.7.12 Install the pneumatic unit of the coupler he ad This section describes how to mount the pneumatic unit of the coupler head (Fig. 6-54).

Tools and Materials � Anti-seize RIVOLTA GWF � Thread sealant LOCTITE 572 or LOCTITE 586

Preparations

1) Treat screw connections according to SCHAKU standard A023 [chap.10.2 � page 207] .








Install the stopcock

1) Mount support (including stopcock) on coupler head casing using lock washers and socket head cap screws.

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� Recommended torque: 12.5 Nm.

Install the strainer

1) Screw strainer and double nipple into MRP (main reservoir pipe).

Install the 5/2-way valve

1) Position 5/2 way valve at coupler head.

2) Mount 5/2-way valve to coupler head casing or support using fastening screws. � Recommended torque: 6 Nm.

Install the hoses

1) Place hoses according to drawing and mount with union nuts.

Final steps None.

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6.7.13 Install the electrical unit of the coupler h ead This section describes how to install the electrical unit of the coupler head ( [chap. � page 181] ).

Tools and Materials � Standard tools

Preparations None.





Mount the position switch

1) Treat the threads and seat-engaging surfaces of the locking screws with RIVOLTA GWF.

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2) Fasten the position switch on the coupler head casing using lock washers and socket head cap screws.

3) Remove the screws securing the cover of the position switch.

4) Remove the cover.

5) Loosen the cable gland and cautiously insert the cables.

6) Fit the wires with end-sleeves and connect in accordance with the Wiring diagram [chap. � page 182] .

7) Fasten the cable gland to the position switch using a reducer if necessary.

8) Refit the cover to the position switch and secure with screws.

Fig. 6-56/ illustrates how to connect the position switch that monitors the central pivot.

Fig. 6-56 Wiring diagram

Final steps None.

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6.7.14 Install the earthing system This section describes how to install the earth wires.

Fig. 6-57 shows the earthing system:


2 Socket head cap screw 10 Washer 17 Earth wire

3 Clamp 14 Earth wire 18 Earth wire

5 Hexagon bolt 15 Earth wire 20 Earth label

7 Lock washer 16 Earth wire 30 Protection plug

Tools and Materials � Ohmmeter � Earthing symbol according to DIN EN 60417 (IEC 60417), symbol 5019 � Cleaner LOCTITE 7063 � Anti-sabotage lacquer, Rape yellow, RAL 1021 and paint brush � Terminal grease

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Preparations

NOTICENOTICENOTICENOTICE Earthing pointsEarthing pointsEarthing pointsEarthing points All earthing points have to be marked with an earthing label according to IEC 60417.

1) Thoroughly clean the bonding surface with cleaner.

2) Apply the earthing symbol.

3) Clean the earthing sockets (5).

Install the earthing system

1) Fasten cable lug (Fig. 6-58/1) with hexagon head screw (2), lock washer (3) and washer (4) to earthing socket (5). � Recommended torque:

for screws M6 - 6.5 Nm for screws M8 - 15 Nm for screws M10 - 31 Nm for screws M12 - 53 Nm

2) Degrease hexagon head screw (2), lock washer (3), cable lug (1), washer (4) and earthing socket (5) and mark them by applying a continuous stroke of Rape yellow paint.

3) Seal hexagon head screw (2), cable lug (1), lock washer (3), washer (4) and earthing socket (5) with terminal grease.

Fig. 6-58 Connection of the earth wire - simplified drawing

1 Cable lug 3 Lock washer 5 Earth socket

2 Hexagon bolt 4 Washer

Final steps

NOTICENOTICENOTICENOTICE Checking the eartChecking the eartChecking the eartChecking the earthing systemhing systemhing systemhing system

Proper function of the earthing system must be verified by a qualified electrician.

1) Check the earthing system in accordance with EN 50153, section 6.4.

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6.8 Final maintenance steps Final maintenance steps

1) Check the earthing sockets [chap. � page 183] for proper colour marking and corrosion protection, repair if necessary.

CAUTIONCAUTIONCAUTIONCAUTION AntiAntiAntiAnti----corcorcorcorrosive paint is damaged after mountingrosive paint is damaged after mountingrosive paint is damaged after mountingrosive paint is damaged after mounting

After mounting, the anti-corrosive paint of screws, nuts and seat-engaging surfaces is damaged. Priming only is no sufficient corrosion protection. Immediately upon conclu-sion of the mounting procedure, the damaged surface must be fully repainted in ac-cordance with the Paint specification [chap.10.1 � page 205] . � Repaint the screw connections.

2) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1 � page 205] .

3) Check the contrasting colour of the operator controls for damage; if necessary, repaint with contrast paint [chap. � page 104] 2-component PUR acrylic top coat, Flame red, RAL 3000, H05.975956.


5) Paint unused joining and contact surfaces as well as threaded holes.

6) Seal threaded through-holes at the top side by applying plastic plugs.

7) Seal blind holes with sealant SIKAFLEX 221 grey.

Upon completion of the heavy maintenance activities, the product can be refitted to the vehicle as described in Mounting and commissioning [chap.7.1 � page 187] .

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7 Mounting and removal Mounting and removal

This chapter describes the mounting of the product to the vehicle as well as its commissioning, decommissioning and removal from the vehicle.



7.1 Mounting and commissioning Mounting and commissioning

This section describes how to mount the product to the vehicle and how to put it into service.

Tools and Materials � Standard tools � Crane and lifting straps � Trestles � Ohmmeter � Compressed air (1 MPa = 10 bar) � Soap solution

Preparations




NOTICENOTICENOTICENOTICE Instructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturer Fasteners are provided by the vehicle manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

NOTICENOTICENOTICENOTICE InstruInstruInstruInstructions of the vehicle manufacturerctions of the vehicle manufacturerctions of the vehicle manufacturerctions of the vehicle manufacturer

Connection of the cables to the vehicle is the responsibility of the vehicle manufactur-er. � Respect the corresponding instructions of the vehicle manufacturer.

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CAUTIONCAUTIONCAUTIONCAUTION Inaccurate mounting dimensions may cause loss of Inaccurate mounting dimensions may cause loss of Inaccurate mounting dimensions may cause loss of Inaccurate mounting dimensions may cause loss of functionfunctionfunctionfunction The proper functionality of the product relies on its precise mounting. The anchoring plate must be perfectly aligned with the longitudinal, horizontal and vertical axes of the vehicle and must be prepared in accordance with the hole configuration. � Check the anchoring plate for perfect alignment with the longitudinal, horizontal

and vertical axes of the vehicle. � Make sure the holes in the anchoring plate correspond to the hole configuration.

� The anchoring plate of the vehicle must be plane and rectangularly aligned to the under-frame both vertically and horizontally.

1) Check the anchoring plate for levelness and rectangularity in accordance with ISO 2768-H, adjust if necessary.

2) Make sure there is sufficient space behind the anchoring plate.

3) Make sure the holes in the anchoring plate correspond to the hole configuration (Fig. 7-1).

Fig. 7-1 Hole configuration - view of the mounting surface of the product

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Mount the coupler

CAUTIONCAUTIONCAUTIONCAUTION The electric head and the cables may be damaged when mounting the couplerThe electric head and the cables may be damaged when mounting the couplerThe electric head and the cables may be damaged when mounting the couplerThe electric head and the cables may be damaged when mounting the coupler The cables of the electric head are directly connected to the vehicle. The electric head can only be mounted to the coupler after the coupler has been mounted to the vehicle. � First mount the coupler without the electric head to the vehicle. � Then mount the electric head to the coupler.

NOTICENOTICENOTICENOTICE Instructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturer The fasteners for mounting the product to the vehicle are provided by the vehicle

manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

1) Align the coupler on the anchoring plate.

2) Fasten the coupler according to the instructions of the vehicle manufacturer.

3) Route the cables such that they are not stretched or kinked and do not impede the free hori-zontal and vertical movement of the coupler, even when the coupler reaches its maximum swivelling angles. Make sure that the minimum bending radius is complied with (also refer to vehicle manufacturer's documentation). The minimum bending radius is:

� For freely suspended cables: 10 x outside diameter � For fixed cables: six times the outer diameter

4) Mount electric head [chap.6.7.10 � page 175] to the coupler.

DANGERDANGERDANGERDANGER Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure. Damaged or loose electrical components may lead to failure. � Prior to operation, check electrical components and cables for proper insulation

and power transmission.

5) Check the electrical components and cables for proper insulation and power transmission.

6) Route the air pipes such that they are not stretched or kinked and permit free horizontal and vertical movement of the coupler, even when it reaches its maximum swivelling angle (also refer to vehicle manufacturer's documentation).

7) Mount the air pipes according to the instructions of the vehicle manufacturer.

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CAUTIONCAUTIONCAUTIONCAUTION Risk oRisk oRisk oRisk of coupler failure.f coupler failure.f coupler failure.f coupler failure. Air pipes may leak after mounting. � Insufficient or excessive tightening of union nuts may lead to leakage or damage

of the nuts, and thus to coupler failure. � Check the air pipe adapters for leakage using soapy water. Bubbles indicate leak-

ing fittings which must be retightened. Stop tightening union nuts when the connection is tight.

8) Check the screw connections and fittings of the air pipes for leakage by applying soapy wa-ter, and retighten if necessary. Test pressure: 10 bar = 1 MPa. Maximum acceptable pres-sure drop: 0.1 bar in 5 minutes.

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failureRisk of coupler failureRisk of coupler failureRisk of coupler failure The adjustment procedure may provide inadequate results. � Be sure to adjust the coupler only after it has been mounted completely.

9) Adjust the inclination of the coupler.

10) Mount the earthing system to the vehicle [chap. � page 183] , also observing the vehicle manufacturer's instructions.

NOTICENOTICENOTICENOTICE Checking the earthing systemChecking the earthing systemChecking the earthing systemChecking the earthing system Proper function of the earthing system must be verified by a qualified electrician.

11) Check the earthing system in accordance with EN 50153, section 6.4.

CAUTIONCAUTIONCAUTIONCAUTION Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure. Prior to putting the coupler into service, check the coupler lock for smooth operation. � Release the coupler lock, then operate the manual uncouple device several times.

12) Check the coupler lock for smooth operation [chap.5.7 � page 89] .

Final steps


Commissioning Observe the preparatory activities described under Coupling [chap.4.1 � page 53] if the cou-pler is to be coupled afterwards.

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7.2 Removal and decommissioning Removal and decommissioning

This section describes how to remove the product from the vehicle and how to put it out of ser-vice.

Tools and Materials � Standard tools � Crane and lifting straps � Trestles

Preparations


2) Remove the air pipes between the coupler and the vehicle in accordance with the vehicle manufacturer's instructions.

CAUTIONCAUTIONCAUTIONCAUTION The electric head and the cables may be damaged when removingThe electric head and the cables may be damaged when removingThe electric head and the cables may be damaged when removingThe electric head and the cables may be damaged when removing the coupler.the coupler.the coupler.the coupler.

The cables of the electric head are directly connected to the vehicle. The entire cou-pler can only be removed from the vehicle when cables to the vehicle have been dis-connected. � First disconnect the cables between the electric head and the vehicle. � In a second step remove the coupler from the vehicle.

3) Disconnect the cables from the vehicle in accordance with the vehicle manufacturer's in-structions.

4) Remove the earthing system from the vehicle in accordance with the vehicle manufacturer's instructions.

5) Support the product.

Remove the coupler

NOTICENOTICENOTICENOTICE Instructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturerInstructions of the vehicle manufacturer The fasteners for mounting the product to the vehicle are provided by the vehicle manufacturer. � Respect the corresponding instructions of the vehicle manufacturer.

1) Remove the coupler from the vehicle according to the instructions of the vehicle manufac-turer.

Decommissioning No special measures required.

Final steps None.

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8 Transportation, storage and disposal Transportation, storage and disposal

This chapter describes how to prepare the product for transportation and storage and how to dispose of it.

Target group This chapter is addressed to logistics personnel working with and handling the product. Previ-ous knowledge of the product is not required.

The product must be in a secure condition to enable safe handling.

In particular, as a prerequisite the coupler has to be put in the repair position by technical staff.

8.1 Transportation Transportation

The completely assembled product is shipped on pallets or in boxes. Make sure it is tied up properly to avoid shipping damage.

8.2 Storage Storage

The product should be stored indoors, palletised and protected from exposure to direct sunlight. Prior to storage, corrosion has to be removed and the anticorrosive coating has to be applied again (refer to section Lubrication [chap.5.6 � page 83] ). Articulation points, sliding surfaces, etc. must be sufficiently greased in order to ensure perfect operation.

8.3 Disposal Disposal

In case of free-of-charge return delivery to the manufacturer, the product will be disposed of at no cost.

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9 Troubleshooting Troubleshooting

This chapter provides helpful information for the detection and correction of problems occurring during operation. The troubleshooting activities are to be performed in a logical order that allows to properly identify the source of the fault. The possible problems are indicated in the chapter headings.

Prior to troubleshooting, a thorough visual inspection of the product has to be performed in or-der to find out if the fault has been caused by loose connections or damaged components.

Troubleshooting is structured such that those faults which are the easiest to detect are men-tioned first. The troubleshooting tables list only the most probable faults and their possible causes. It is also possible that several faults occur at the same time.

If the fault cannot be classified immediately, start your troubleshooting activities with the me-chanical coupling problems as these are the easiest to detect.

These brief descriptions do not substitute the full descriptions referred to.

9.1 Target group Target group

This chapter is addressed to qualified technical staff in charge of operating the vehicle from the driver's cab or performing manual coupling and uncoupling operations.

Troubleshooting should be performed exclusively by experienced and qualified staff to make sure all faulty operations are identified and evaluated correctly and appropriate measures are taken. The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain troubleshooting activities.

9.2 Safety Safety

In order to prevent injuries, the coupler must be in its repair position [chap.5.2 � page 71] while troubleshooting activities are performed.

9.3 Coupling fails Coupling fails

Coupling problems may have the following reasons:

� Mechanical coupling problems may originate from a failure of the coupler lock or be due to faults occurring in other mechanical components of the couplers involved in the coupling procedure.

� Pneumatic coupling problems may be due to failure of the air pipe connection(s), individual pneumatic components, compressed-air supply or coupler control system of the vehicle.

� Electrical coupling problems may arise from a failure of the electric head, electric head op-erating gear, individual electrical components or the coupler control system of the vehicle.

If the main reason is hard to find, start your search with the possible mechanical reasons. These are easy to detect or to exclude.

9.3.1 Mechanical coupling fails Coupler faces heavily soiled

� Separate vehicles � Clean coupler faces [chap.5.4 � page 81] � Couple again [chap.4 � page 53] Foreign matter in male or female c one

� Remove foreign matter with compressed air � Couple again [chap.4 � page 53]

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Insufficient, to o old, wrong or soiled grease

� Clean coupler lock [chap.5.4 � page 81] � Grease coupler lock [chap. � page 84] (especially recess of hooked plate and coupling link

web) Coupler lock not in ready -to-couple position

� Actuate uncouple device [chap. � page 62] � Separate vehicles � Couple again [chap.4 � page 53] Coupling speed too low

� Separate vehicles � The maximum coupling speed must be defined by the vehicle manufacturer to ensure the

maximum loads the coupler can tolerate are not exceeded. � Couple again at a minimum speed of 0.6 km/h [chap.4 � page 53] Coupler lock is damaged

� Have damage repaired in workshop.

9.3.2 Failure when coupling electric heads



Gap between electric heads Improper adjustment of electric head projection

� Check the projection of the electric head [chap.5.9 � page 94] Contact block is skewed in casing

� Adjust contact block Centring pin is bent or broken

� Replace centring pin Centring bush is soiled

� Clean centring bush with compressed air Centring bush worn out

� Replace centring bush

Lid of electric head does not open Lid is dented

� Remove dents in lid � Replace lid [chap. � page 147] Lid bearing is tight due to buildup of dirt

� Clean lid bearing with compressed air [chap. � page 149] � Grease with penetrating oil � Replace lid bearing Guiding element is soiled

� Clean guiding element � Grease guiding element

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Control lever is bent

� Straighten control lever � Replace control lever Lid spring is broken

� Replace lid spring

Electric head fails to move forward, stops before r eching its end position, or moves sluggishly Stopcock is closed

� Open stopcock Position sw itch is damaged

� Readjust position switch [chap. � page 181] if possible � Replace damaged position switch Operating levers are soiled

� Clean operating levers Operating levers are tight, damaged or bent

� Grease operating levers with grease spray AUTOL TOP 2000 � Straighten operating levers � Replace damaged parts Compression spring in operating levers is broken

� Replace compression spring Guiding rods are soiled

� Clean guiding rods with a dry rag (do not grease!) Insufficient air pressure

� Increase pressure in pneumatic system to 0.6MPa Piston in pneumatic cylinder jams

� Check guiding element in cylinder cover � Clean piston rod and grease with AUTOL TOP 2000 Pneumatic cylinder is not tight

� Have pneumatic cylinder replaced in workshop 5/2-way valve is damaged

� Check 5/2-way valve � Clean externally � Clean with compressed air � Replace the 5/2-way valve Screw fittings leak

� Seal threads of male stud connectors with thread sealant � Carefully re-tighten screw fittings � Check for leakage by applying soapy water Hoses are porous/damaged

� Replace porous hose(s) Strainer is clogged

� Clean strainer (wire sieve) with petroleum, brush or oil-free compressed air

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9.4 Uncoupling fails Uncoupling fails

Uncoupling might fail for the following reasons:

� Mechanical coupling problems may originate from a failure of the coupler lock or be due to faults occurring in other mechanical components of the couplers involved in the coupling procedure.

� Pneumatic coupling problems may be due to failure of the air pipe connection(s), individual pneumatic components, compressed-air supply or coupler control system of the vehicle.

� Electrical coupling problems may arise from a failure of the electric head, electric head op-erating gear, individual electrical components or the coupler control system of the vehicle.

If the main reason is hard to find, start your search with the possible mechanical reasons. These are easy to detect or to exclude.

9.4.1 Automatic mechanical uncoupling fails

Excessive tensile force The vehicles to be separated exert too high tensile forces on coupler locks and thus prevent them from turning

� Relieve couplers � Release brakes of vehicle

Parts of uncouple pipe are damaged Hoses to uncouple cylinder are not tight

� Replace porous hose Screw fittings or seals leak

� Carefully re-tighten screw fittings � Replace seal � Check for leakage by applying soapy water � As an immediate measure seal the thread of the male stud connectors with thread sealant

LOCTITE 572 Gasket in cage is damaged

� Replace gasket Rubber tube is damaged

� Replace rubber tube Faulty operation of uncouple valve

� Press uncouple button once again and keep depressed for longer period of time Coupler lock is tight

� Manual uncoupling � Check coupler lock for damage � Grease coupler lock (hooked plate recess and coupling link web)

Pneumatic system failure Compressed -air supply is switched off

� Open stopcock Insufficient pressure in main reservoir pipe

� Check pneumatic system � Increase pressure in main reservoir pipe � Under normal conditions of operation, the pressure supplied must be at 0.6MPa

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Hoses to uncouple cylinder are not tight

� Tighten union nut of pipe adapter � Check for leakage by applying soapy water � As an immediate measure seal thread with sealant

Coupler is damaged Coupler lock is damaged

� Have damage repaired in workshop Uncouple cylinder is damaged

� Have damage repaired in workshop

Coupler is not sufficiently greased Insufficient, too old, wrong or soiled grease

� Manual uncoupling � Clean coupler lock � Grease (especially recess of hooked plate and coupling link web) [chap. � page 84]

9.4.2 Electrical uncoupling fails




Lid of electric head does not close Lid is dented

� Remove dents in lid � Replace lid [chap. � page 147] Lid bearing is tight due to buildup of dirt

� Clean lid bearing with compressed air [chap. � page 149] � Grease with penetrating oil � Replace lid bearing Guiding element is soiled

� Clean guiding element Control lever is bent

� Straighten control lever � Replace control lever Lid spring is broken

� Replace lid spring Lid guides are soiled or damaged

� Clean lid guides � Check lid guides for damage � Grease lid guides with grease spray AUTOL TOP 2000 � Replace damaged parts

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9.4.3 Manual uncoupling fails Vehicles to be se parated exert too high tensile forces on coupler lo cks and thus prevent them from turning

� Relieve coupler

9.5 Electrical signals are disturbed Electrical signals are disturbed

9.5.1 No or poor power transmission




Contact tips are soiled

� Clean contact tip � Remove persistent dirt with dry rag Wires are broken

� Check wires for continuity � Replace cable if necessary Contact tips are damp, causing electric arcing upon disconnection

� Dry contact tips � Replace contact tips if severely damaged Contact damaged due to worn centring elements

� Replace contact Female contact jams as bush is damaged

� Replace female contact Male contact is damaged

� Replace male contact

Short circuit Contacts and contact block are soiled

� Clean contacts and contact block with dry rag or compressed air Contacts and contact block are damp

� Carefully remove humidity with hot air Leakage current due to condensation

� Carefully remove humidity with hot air Water ingress in casing

� Check rubber frame of electric head for cracks � Replace rubber frame

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9.5.2 Damage to cables

DANGERDANGERDANGERDANGER Electric shocElectric shocElectric shocElectric shockkkk Danger to life when touching live parts. � The coupler has live parts.


Bending radius of cables is too small

� Increase bending radius (for moving cables at least 10 x cable diameter, for fixed cabled at least 6 x cable diameter)

Improper cable suspension, cable routing on vehicle is too tight

� Check cable suspension and cable routing � Remove kinks (if any) Insulation of terminal studs is damaged

� Open electric head casing � Check terminal studs � Mount heat-shrink tubing if necessary

9.6 Earthing system Earthing system

Coupler parts conduct electric current

� Check screws of earthing system for tight seat, tighten if necessary � Check earthing system for corrosion and clean if necessary; replace corroded screws and

washers � Check the earth wires for damage, replace if necessary

9.7 Air pipe connection fails Air pipe connection fails

Failures affecting the air pipe connection are usually indicated by a pressure drop. In a quiet environment the affected spots can be identified by a hissing noise, but this is impossible during train operation. A better way is to apply soapy water to the hoses to be checked. Bubbles indi-cate spots which are not tight.

9.7.1 Pressure drop when coupled

Parts of BP are damaged Mouth piece gasket is damaged


� Replace rubber tube Compression spring in mouth piece is broken

� Uncouple the vehicles � Remove mouth piece � Replace compression spring Hose conn ections leak

� Check hose connections, if necessary, tighten. � Check hose connections, replace if necessary.

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Parts of the MRP are damaged Mouth piece gasket is damaged


� Replace rubber tube Compression spring in mou th piece is broken

� Uncouple the vehicles � Remove mouth piece � Replace compression spring Hose connections leak

� Check hose stud, if necessary, replace. � Check hose connections, if necessary, tighten. � Check hose connections, replace if necessary. Hose to vehicle leaks

� Replace hose

9.7.2 Pressure drop when uncoupled

Parts of BP are damaged Gasket is damaged

� Replace gasket Air pipe connection is not tight

� Re-tighten screw connections � As immediate measure seal thread with thread sealant Pipe adapter is damaged, flange is bent

� Remove pipe adapter � Straighten flange � Replace pipe adapter if necessary

Parts of the MRP are damaged Gasket is damaged

� Replace gasket Air pipe connection is not tight

� Re-tighten screw connections � As immediate measure seal thread with thread sealant Pipe adapter is damaged, flange is bent

� Remove pipe adapter � Straighten flange � Replace pipe adapter if necessary Hose to vehicle leaks

� Replace hose

9.7.3 Air brakes in vehicle cannot be released Compression spring of air p ipe connection is broken

� Uncouple the vehicles � Remove mouth piece � Replace compression spring

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Troubleshooting


Coupler is in wrong position

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9.8 Coupler is in wrong position Coupler is in wrong position

Incorrect inclination of coupler

� Adjust inclination of coupler

9.8.1 Coupler head is misaligned Muff coupling has come loose

� Replace the screw connections Screws are corroded, nuts have come loose

� Replace the screw connections

9.8.2 Coupler is misaligned Muff coupling has come loose

� Replace the screw connections Screws are torn off

� Replace the screw connections

9.9 Unusual noise during operation Unusual noise during operation

9.9.1 Clattering/knocking noise Spherical bearing is damaged

� Next time in workshop, remove coupler shank and return to manufacturer for overhaul Longi tudinal backlash of coupler shank

� Drive vehicle to workshop in emergency mode [chap.3.3.2 � page 19] � Remove coupler shank and return to manufacturer for overhaul Buffer is damaged

� Drive vehicle to workshop in emergency mode [chap.3.3.2 � page 19] � Remove coupler shank and return to manufacturer for overhaul Muff coupling is loose

� Drive vehicle to workshop in emergency mode [chap.3.3.2 � page 19] � Replace all fastening screws, check collars and muffs for damage and mount muff coupling

[chap. � page 175] again

9.9.2 Unusual hard load changes Buffer is damaged

� Drive vehicle to workshop in emergency mode [chap.3.3.2 � page 19] � Remove coupler shank and return to manufacturer for overhaul

9.10 Oil leaks Oil leaks

Buffer is damaged

� Remove the coupler shank � Return coupler shank to manufacturer for repair

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SCHAKU standards


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10 SCHAKU standards SCHAKU standards

This section covers the product relevant SCHAKU standards. SCHAKU standards are in-house standards, work instructions or specifications which are applied internally by Voith Turbo Scharfenberg. The SCHAKU standards referred to in this section must be taken into account when working with Voith Turbo Scharfenberg products.

10.1 Paint specification Paint specification

This section describes how to paint steel parts.

The product is to be painted in accordance with the SCHAKU paint specification KCG.

10.1.1 General requirements (SCHAKU standard K000) This section explains how to repair the paint coat according to SCHAKU-Norm K000 and points out general requirements to be met while carrying out the repair work. The information given in the section "paint structure" further below and/or in specific instructions may differ from what is outlined below, have specification character and is to be applied preferably.

Not to be painted Keep the following parts and surfaces free from any coating:

� Sealing and sliding surfaces � Rubber parts, plastic caps and plastic hoods � Stainless steel screws for fastening of earth wires � Hoses � Cables � Electric head

Paint allowed here The following parts and surfaces may be painted:

� Stainless steel screws � Position switch � Casing of the air pipe connection � Uncouple cylinder � All brass or bronze parts of the pneumatic unit

To be primed only The following parts must be primed only:

� Rear side of bearing bracket / base plate (film thickness min. 15 µm, max. 40 µm) � Seat engaging surfaces of screws and contact surfaces of coupler components � Non-visible coupler parts (inner surfaces of hollow parts) � Surfaces of the muffs and muff collars to be joined.

Electro-plated surfaces Anti-corrosion coatings on electroplated screws may be damaged by tools. Subsequent to mounting such screws must be manually coated with protective varnish to K150. Tolerances for dry film thickness:

� Minimum dry film thickness: 60 µm � Maximum dry film thickness: 200 µm

Tools and Materials � Air blow gun � Clean paint brushes

User Manual

SCHAKU standards

Paint specification Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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� Abrasive � Alkaline cleaners � Organic solvents � Detergent (de-ionised water) � Drying aids (clean, lint-free rags; dry, oil-free compressed air) � Masking material � Primer, top coat and hardener according to SCHAKU standard KCG � Sealing compound SIKAFLEX 221 grey, TSK.979637

Cleaning The following cleaning procedures are admissible:

� Cleaning with suitable, e.g. alkaline, cleaners followed by rinsing with de-ionised water � Degreasing with organic solvents, and if necessary, additional sanding of the surfaces, fol-

lowed by washing and rinsing

Preparations

1) Surface impurities like wax, grease, oil, coolant, release agent, hand perspiration etc. are to be removed with suitable solvents or cleaners.

2) Rinse, then dry surface.

3) Roughen and clean the surface if necessary.

4) Prime surface within 4 hours.

For stainless steel, the following instructions apply according to the data sheet DB TL 918 301,1989 for small areas:

5) De-grease.

6) Sanding with abrasive paper/pads.

7) Clean.

For aluminium, the following instructions apply according to the data sheet DB TL 918 301,1989 for small areas:

8) De-greasing with organic solvents.

9) Sanding with abrasive paper/pads.

10) Cleaning with organic solvents.

Paint

1) Mix and apply paint in accordance with the manufacturer's instructions.

2) Seal threaded through-holes on the top side by inserting appropriate plugs (see parts cata-logue).

3) Seal blind holes with sealant SIKAFLEX 221 grey.

10.1.2 Paint structure (SCHAKU-Norm K150) This section describes the paint structure in accordance with SCHAKU standard K150 with the colour specified in SCHAKU standard KCG.

Paint structure � Paint ready for use � Non-visible coupler parts have to be primed once � Visible coupler parts have to be primed once and painted once with top coat

User Manual

SCHAKU standards


Sealing and securing of screw connections (SCHAKU standard A023)

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The final film thickness of primer and top coat is 220 µm

The tolerance for the overall dry film thickness is +30 µm or 30 % maximum. Special requirements take precedence.

NOTICENOTICENOTICENOTICE Respect drying Respect drying Respect drying Respect drying timestimestimestimes � Be sure to observe the following drying times:

� At room temperature (20 °C): 12 - 24 h � In warm air (60 - 80 °C): 45 - 120 min � IR/NIR drying: 30 - 60 min

Primer 2-component epoxy metal primer, water dilutable

Light ivory to colour scale RAL 1015; H05.975761

With epoxy hardener, water dilutable; H05.975760

mixing ratio (weight proportion) 2:1

Dry film thickness 80 µm

Top coat 2-component epoxy top coat, water dilutable

Colour Jet black RAL 9005; H05.975763

With epoxy hardener, water dilutable; H05.975759

mixing ratio (weight proportion) 1.7:1

Dry film thickness 140 µm

10.2 Sealing and securing of screw connections (SCH AKU standard A023) Sealing and securing of screw connections (SCHAKU standard A023)

This standard defines how to lock screw connections.

Procedure All threaded male sockets of pipe adapters, bite type fittings, cable glands and threaded adapt-ers are to be secured with threadlocker:

� Threaded pipe adapters up to 1/4”: LOCTITE 572 � Threaded pipe adapters larger than 1/4”: LOCTITE 586

Zinc and yellow chromate coated parts Consider a longer cure time of approx. 24h when treating zinc and yellow chromate coated parts.

Stainless steel parts If stainless steel or nickel plated parts are used, an activator must be applied to stimulate the passive material by copper ions which makes the adhesive cure.

Special requirements Special agreements or other dedicated specifications shall take precedence.

User Manual

SCHAKU standards

Replacing METALOPLAST bushes (SCHAKU standard Z006)


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10.3 Replacing METALOPLAST bushes (SCHAKU standard Z006) Replacing METALOPLAST bushes (SCHAKU standard Z006)

These instructions specify how to replace METALOPLAST bushes.

NOTICENOTICENOTICENOTICE KL 65KL 65KL 65KL 65 KL 65 is a cold-setting, slightly flexible two-component epoxy resin adhesive. KL 65 can be used at temperatures between -60 °C and +140 °C.

In its original packaging and at temperatures between +18 °C and +25 °C, KL 65 can be stored for up to 1 year.

Tools and Materials � Mounting drift (size corresponding to inside diameter of the bush) � Hot air gun � Spatula � Triangular scraper � Solvent (dichloromethane) � Cleaner LOCTITE 7063 � Adhesive KL 65 and hardener KL 65

Preparations

1) Dip the part into a methylene chloride bath and allow to react for approx. 30 minutes, or heat the part to max. 180 °C using a hot air gun.

Remove the bushes

1) Remove the bush using a triangle scraper.

Bond the bushes

1) Clean the bonding surfaces (bore and bush) with cleaner LOCTITE 7063 and allow to react for approx. 5 minutes.

2) Wipe the surfaces dry using a lint-free rag.

3) Mix adhesive and hardener at a ratio of 100:40. � Quantity to be applied: 0.3 – 0.6 g (ml).

4) Apply the adhesive evenly on the bonding surfaces (bore, outside and collar of plastic foil) using a putty knife. � Film thickness: 0.1 - 0.15 mm.

5) Roll the METALOPLAST foil into the shape of a bush and insert it into the bore. � The parting line of the bush must be perpendicular to the flow of force.

Fig. 10-1 Position of the parting line

User Manual

SCHAKU standards


Mount the One4 front plate (SCHAKU standard Z044)

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6) Fix the bush using the appropriate mounting drift.

7) Allow the adhesive to cure. At 5 °C 72 hours At 23 °C 8 hours At 40 °C 2 hours At 100 °C 10 minutes Tab. 10-1 Minimum cure time for METALOPLAST bushes

NOTICENOTICENOTICENOTICE Optimum strength resultsOptimum strength resultsOptimum strength resultsOptimum strength results

Optimum strength results are achieved at temperatures ranging from 40 °C to 100 °C.

10.4 Mount the One4 front plate (SCHAKU standard Z0 44) Mount the One4 front plate (SCHAKU standard Z044)

These instructions apply to couplers with or without front plate heaters.

1) Fill grooves in the rear side of the front plate completely (void-free) with Anti-Seize "HIGH-TECH" anti-seize agent and smooth surfaces.

2) Apply a thin layer of Anti-Seize "HIGH-TECH" anti-seize to the joining area on the coupler front plate. Film thickness 50 µm.

3) Install front plate.

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11 Parts catalogue Parts catalogue

The parts catalogue lists all parts of the product broken down to screw level. Glued parts are on-ly listed if they are available as spare parts. Parts of an inseparable unit are not listed.

11.1 Structure of the parts list Structure of the parts list

Item Item number. Non-illustrated parts are marked with "n.i." not illustrated.

Designation Designation of the item or subassembly.

Spare part kit elements are marked with footnotes.

DrwNo/Code (drawing number) SCHAKU drawing number for SCHAKU parts or standard reference for standardised parts and further information, if necessary.

ID No. Number to be quoted when ordering parts.

Q (Quantity) Items per assembly

Hash (#) The hash (#) indicates that the respective item is to be tightened to a special torque.

User Manual

Parts catalogue

Structure of the parts list Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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11.2 Scharfenberg coupler 010.616 ''10.02''

Fig. 11-1 Scharfenberg coupler 010.616 ''10.02''

Item Designation DrwNo/Code ID No. Q

- Scharfenberg coupler 010.616 ''10.02'' 231.002841 10 9 D CG 1

1 Coupler head 1.010.600.01 230.025169 10 0 1

2 Uncouple cylinder 3.STD.001.02 ''10.01'' TSK.998617 10 0 1

3 Air pipe connection 3.STD.002.03 ''10.03'' TSK.998975 10 0 1

4 Air pipe connection STD.001.04 ''11.01'' TSK.998529 11 0 1

5 Electric head operating gear 010.572.05 ''10.01'' 230.020641 10 0 1

6 Coupler shank 010.616.06 230.025445 10 0 1

7 Bearing bracket 010.616.07 230.024874 10 0 1

8 Electric head 08.009.060-Z1 230.025044 10 9 1

10 Centring device 010.616.10 230.024875 10 0 1

12 Uncouple pipe 2.STD.002.12 ''11.01'' 230.003136 11 0 1

13 Air piping 010.616.13 ''10.01'' 230.025393 10 0 1

15 Pneumatic unit 1.010.572.15 230.020633 10 0 1

18 Electrical unit 010.572.18 ''10.02'' 230.020690 10 0 1

36 Muff coupling 010.109.36 ''10.05'' TSK.127978 10 0 1

43 Earthing system 010.616.43 230.024876 10 0 1

50 Dummy plug - TSK.976747 10 0 1

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Structure of the parts list

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11.2.1 Coupler head 1.010.600.01

Fig. 11-2 Coupler head 1.010.600.01


1 Central pivot 2.010.159.01.00.06 ''10.04'' TSK.952346 10 9 1

2 Ratchet 3.000.088.01.00.05 ''10.10'' TSK.114247 10 6 1

3 Bush 4.000.088.01.00.15 ''10.02'' TSK.171893 10 0 1

4 Cam 4.010.186.01.00.13 ''10.03'' TSK.977048 10 0 1

5 Coupling link pin 4.000.088.01.00.17 ''10.18'' TSK.111378 10 9 1

6 Rope pulley 4.025.000.01.00.18 ''10.04'' TSK.175557 10 0 1

7 Uncouple lever 3.010.198.01.00.01 ''10.04'' TSK.968213 10 0 1

8 Handle 3.025.200.01.00.07 ''10.03'' TSK.219365 10 0 1

9 Spring holder 3.SK0.5886.01.00.01 ''10.01'' TSK.998479 11 0 1

10 Metal sheet 4.136.011.01.00.05 ''10.01'' TSK.998798 10 0 1

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11 Rope guide 4.025.000.01.00.17 ''10.09'' TSK.112043 10 6 1

20 Tension spring 3.SK0.6307 230.008813 10 0 2

21 Pin 4.010.164.12.00.09 ''10.04'' TSK.953188 10 9 1

24 Parallel pin ISO 2338 4h8x28 St A4P TSK.157221 10 0 1

25 Spring type straight pin ISO 8752 4x26 A TSK.310825 10 0 1

26 Spring type straight pin ISO 8752 5x45 St GEOMET 321-B Plus H01.164075 1



29 Retaining ring DNS-30-S02 TSK.967996 10 0 1

30 Lubricating nipple DIN 71412 A-M8x1 5.8 A3F TSK.171971 10 0 2

31 Dust protection cap - TSK.254325 10 0 2

32 Locking screw INBUS RIPP W251.12 M10x25 100 GEOMET 321 B PLUS VL TSK.961006 11 9 6

33 Socket head cap screw ISO 4762 M10x25-MK 8.8 A3 Cr(VI) free TSK.232269 10 0 4

40 Locking screw

VERBUS RIPP W158.12 M12x25 100 GEOMET 321 B PLUS VL TSK.963619 11 0 6

50 Coupler head casing 2.010.424.01.01 ''11.01'' 230.002784 11 0 1

51 Front plate 2.010.600.01.10 230.025168 10 0 1

52 Hooked plate 3.010.164.01.06 ''11.00'' TSK.956628 11 0 1

53 Coupling link with bushes 4.010.164.01.08 ''10.03'' TSK.956620 10 0 1

54 Stem guide 2.010.139.01.06 ''10.06'' TSK.225621 10 0 1

55 Spring bearing 3.020.007.01.09 ''10.06'' TSK.225702 10 0 1

56 Uncouple rope 4.SK0.4718.14 ''10.10'' type 102 / L=1010 TSK.997495 11 0 1

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11.2.1.1 Coupler head casing 2.010.424.01.01 ''11.0 1''

Fig. 11-3 Coupler head casing 2.010.424.01.01 ''11.01''


1 Bush 4.010.348.01.01.01 ''12.00'' TSK.988345 12 0 2

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11.2.1.2 Coupling link with bushes 4.010.164.01.08 ''10.03''

Fig. 11-4 Coupling link with bushes 4.010.164.01.08 ''10.03''


2 Bush 4.010.118.01.00.05 ''10.02'' TSK.953942 10 0 2

11.2.1.3 Stem guide 2.010.139.01.06 ''10.06''

Fig. 11-5 Stem guide 2.010.139.01.06 ''10.06''


1 Stem guide 3.010.139.01.00.09 ''10.04'' TSK.236462 10 6 1

3 Castle nut DIN 979 M12 A2-70 TSK.960690 10 0 1

4 Compression spring DIN 2098 4x20x105 SH TSK.184788 10 0 1

5 Spring type straight pin ISO 8752 3,5x18 A TSK.960696 10 0 1

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6 Washer ISO 7089 12 A2 200HV TSK.101122 10 0 1

8 Friction bearing - TSK.227684 10 0 1

10 Stem 4.010.139.01.00.13 ''10.03'' TSK.965645 10 6 1

11.2.1.4 Spring bearing 3.020.007.01.09 ''10.06''

Fig. 11-6 Spring bearing 3.020.007.01.09 ''10.06''


1 Spring bearing 4.010.203.01.00.02 ''10.03'' TSK.970239 10 0 1

2 Stem 4.020.007.01.00.20 ''10.05'' TSK.225690 10 9 1


4 Compression spring - TSK.226752 10 0 1

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11.2.2 Uncouple cylinder 3.STD.001.02 ''10.01''

Fig. 11-7 Uncouple cylinder 3.STD.001.02 ''10.01''


1 Cylinder casing 010.203.02.00.01 ''10.04'' TSK.968798 10 0 1

2 Cylinder cover 3.STD.001.02.00.01 TSK.998588 10 0 1

3 Piston 3.010.203.02.00.03 ''10.04'' TSK.968724 10 0 1


8 O-ring - TSK.186429 10 0 1

9 O-ring - TSK.971827 10 0 1

12 Hexagon bolt ISO 4017 M12x25 A2-70 TSK.151972 10 0 3

14 Countersunk screw DIN 7991 M8x20 A2-70 TSK.129849 10 0 4

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11.2.3 Air pipe connection 3.STD.002.03 ''10.03''

Fig. 11-8 Air pipe connection 3.STD.002.03 ''10.03''


1 Cam disc pin 4.SK0.5881 ''10.03'' TSK.997820 10 0 1

2 Sleeve 4.000.088.03.00.04 ''10.03'' TSK.171907 10 0 1

3 Bush 4.000.088.03.00.05 ''10.05'' TSK.171908 10 0 1

4 Spacer bush 4.SK0.5886.03.00.01 TSK.998969 11 0 2

5 Valve plate 3.000.088.03.00.07 ''10.12'' TSK.171911 10 0 1

6 Rubber ring 4.000.088.03.00.08 ''10.02'' TSK.171912 10 0 1

7 Gasket 4.000.088.03.00.09 ''10.06'' TSK.171914 10 0 1

8 Gasket 3.000.088.03.00.10 ''10.07'' TSK.171903 10 0 1

11 Socket ¹) 3.000.088.03.00.13 ''10.06'' TSK.171904 10 0 1

13 Rubber tube ¹) 4.000.088.03.00.15 ''10.04'' TSK.171905 10 0 1

14 Gasket ¹) 3.000.088.03.00.16 ''10.12'' TSK.171906 10 0 1

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17 Compression spring 3.000.651.03.00.06 ''10.03'' TSK.174614 10 0 1

23 Stop spring ¹) 4.010.000.03.00.15 ''10.02'' TSK.960011 10 0 1

26 Valve casing 2.STD.001.03.00.01 ''11.00'' TSK.999038 11 0 1

30 Compression spring ¹) 3.025.000.04.00.02 ''10.09'' TSK.175639 10 0 1

34 Socket head cap screw DIN 6912 M8x20 A2-70 TSK.101456 10 0 4

38 Socket head cap screw ISO 4762 M12x45 A2-70 TSK.283992 10 0 1


46 Lock washer VS8 TSK.951194 10 0 4


¹) Spare part kit ''mouth piece for BP / MRP'' 9.SER.003.10.001 TSK.979966 10 0 1

11.2.4 Air pipe connection STD.001.04 ''11.01''

Fig. 11-9 Air pipe connection STD.001.04 ''11.01''


1 Rubber ring 4.000.088.03.00.08 ''10.02'' TSK.171912 10 0 1

3 Socket ¹) 3.000.088.03.00.13 ''10.06'' TSK.171904 10 0 1

4 Rubber tube ¹) 4.000.088.03.00.15 ''10.04'' TSK.171905 10 0 1

5 Gasket ¹) 3.000.088.03.00.16 ''10.12'' TSK.171906 10 0 1

8 Valve tappet 3.000.088.04.00.08 ''10.12'' TSK.171924 10 0 1

10 Hairpin clip ²) 4.000.088.04.00.14 ''10.04'' TSK.171937 10 0 1

13 Rubber tube ²) 4.000.152.04.00.11 ''10.04'' TSK.171962 10 0 1

15 Seal ²) 4.000.355.04.00.11 ''10.03'' TSK.172062 10 0 1

16 Stop spring ¹) 4.010.000.03.00.15 ''10.02'' TSK.960011 10 0 1

17 Compression spring ¹) 3.025.000.04.00.02 ''10.09'' TSK.175639 10 0 1

22 Valve casing 3.035.102.04.00.01 ''10.03'' TSK.972824 10 0 1

28 Cage ²) 3.G04.175 ''10.03'' TSK.959089 11 6 1

31 Valve spring 3.000.088.04.00.10 ''10.02'' TSK.185024 10 0 1

36 O-ring - TSK.186452 10 0 1


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41 Socket head cap screw DIN 6912 M10x90 8.8 A3 Cr(VI) free TSK.114134 10 0 2

44 Hexagon nut DIN 934 M10 8 A3 Cr(VI) free TSK.113407 10 0 2



¹) Spare part kit ''mouth piece for BP / MRP'' 9.SER.003.10.001 TSK.979966 10 0 1

²) Spare parts kit "mouth piece for UP“ 9.SER.003.11.002 TSK.993061 10 0 1

11.2.5 Electric head operating gear 010.572.05 ''10 .01''

Fig. 11-10 Electric head operating gear 010.572.05 ''10.01''


1 Shaft 3.010.572.05.00.01 230.020638 10 0 1

2 Fork 3.010.480.05.00.02 ''10.02'' 230.009154 10 0 1

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3 Rod 4.010.480.05.00.03 ''10.01'' 230.009157 10 0 1

4 Guiding rod 4.010.524.05.00.03 230.015302 10 0 2

5 Lever 3.010.203.05.00.01 ''10.02'' TSK.970363 11 0 1

6 Arm 4.010.524.05.00.01 230.015227 10 0 1

7 Pin 4.030.043.05.00.02 ''10.04'' TSK.964359 10 0 1

8 Spacer 4.330.090.05.00.02 ''10.03'' TSK.972973 10 0 1

9 Support 1.010.572.05.00.02 230.020639 10 0 1

10 Handle holder 3.010.408.05.00.03 ''10.03'' 230.001888 10 0 1

11 Sleeve 4.010.524.05.00.02 230.015257 11 0 2

14 Pin ISO 2341 B-12h11x50x46 X5CrNi18-10 TSK.105419 10 0 1

15 Pin DIN 1445 18h11x45x70 X17CrNi16-2+QT800 TSK.986080 10 9 1

16 Hexagon bolt DIN 931 M12x90 8.8 A3 Cr(VI)-free TSK.108111 10 0 2

17 Hexagon bolt DIN 931 M12x55 8.8 A3 Cr(VI)-free TSK.108100 10 0 2

18 Locking screw


19 Locking screw


20 Locking screw

VERBUS RIPP W158.12-M8x12 100 GEOMET 321 B PLUS VL TSK.965194 11 9 2


24 Parallel pin ISO 8734 10m6x28 St GEOM-ET 321 B PLUS VL H01.164067 1

25 Hexagon nut ISO 7040 M12 A2-70 TSK.298805 10 0 1

26 Hexagon nut DIN 934 M12 A2-70 TSK.100940 10 0 2

27 Hexagon nut DIN 934 M12 8 A3 Cr(VI) free TSK.113409 10 9 2






37 Split pin ISO 1234 3.2x25 A2 TSK.114315 10 0 1

39 Bush 4.035.051.05.00.41 ''10.02'' TSK.182450 10 0 1




50 Support bracket 2.010.480.05.01 ''10.02'' 230.009158 10 0 1

70 Cylinder 2.035.051.05.01 ''11.01'' TSK.128917 11 0 1

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11.2.5.1 Cylinder 2.035.051.05.01 ''11.01''

Fig. 11-11 Cylinder 2.035.051.05.01 ''11.01''


1 Piston 3.035.051.05.00.23 ''10.07'' TSK.128918 10 9 1

2 Cylinder cover 2.035.034.05.00.25 ''10.05'' TSK.181175 10 0 1

3 Cylinder casing 2.035.051.05.00.01 ''10.03'' TSK.182443 10 0 1

4 Bush 4.035.051.05.00.24 ''10.02'' TSK.182447 10 0 1

5 O-ring - TSK.186453 10 0 1

6 Wiper - TSK.186406 10 0 1

7 O-ring - TSK.186393 10 0 1

8 O-ring - TSK.186365 10 0 1



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11.2.6 Coupler shank 010.616.06



1 Friction bearing - 230.001461 10 0 2

10 Coupler shank 010.600.06 ''10.01'' 230.022772 10 0 1

11.2.6.1 Coupler shank 010.600.06 ''10.01''

Fig. 11-13 Coupler shank 010.600.06 ''10.01''


1 Intermediate piece 010.600.06.00.01 230.022774 10 9 1

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2 Threaded ring 3.136.001.06.00.02 ''11.02'' 230.001429 11 9 1

3 Washer 3.136.001.06.00.03 ''11.00'' 230.001421 11 0 1

4 Bush 4.035.200.06.00.02 230.003619 10 0 1

11 Flat key 4.330.057.06.00.01 ''10.02'' TSK.957721 10 0 2

12 Anti-rotation lock 3.010.486.06.00.03 230.010138 11 0 1

15 Guide ring - 230.001427 10 0 1

16 Guide ring - TSK.999727 10 0 1

18 Wiper - 230.001426 11 0 1

20 Friction spring - 230.001419 10 9 1

22 Gas-hydraulic buffer - 230.022773 10 9 1


35 Locking screw

VERBUS RIPP W158.12-M8x20 100 GEOMET 321 B PLUS VL TSK.968777 11 0 2

36 Plug - TSK.956912 10 0 6

60 Spring casing 2.010.600.06.01 230.024922 10 0 1

Spring casing 2.010.600.06.01

Fig. 11-14 Spring casing 2.010.600.06.01


10 Spherical bearing - TSK.962591 11 9 1

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11.2.7 Bearing bracket 010.616.07



2 Pin 4.136.001.07.00.03 ''10.02'' 230.001262 10 9 1

3 Anti-friction disc 4.136.001.07.00.06 230.001508 10 0 2

4 Drift 010.454.07.00.02 ''11.01'' 230.006043 11 9 1

5 Collapsible tube VR7.0850.07.07.400 ''10.01'' 230.024988 10 9 1

6 Base plate 2.010.408.07.00.01 ''11.01'' 230.001719 11 9 1

21 Thrust plate 2.010.408.07.01 ''10.01'' 230.001725 10 0 1


31 Hexagon bolt ISO 4014 M20x100 8.8 A3 Cr(VI)-free TSK.108160 10 9 18

33 Retaining ring DNS-70-S02 TSK.977003 10 0 1

34 Lubricating nipple DIN 71412 A M10x1 5.8 A3F TSK.110110 10 0 1


50 Bearing bracket 4.050.117.07.01 230.010402 10 0 1

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11.2.7.1 Bearing bracket 4.050.117.07.01

Fig. 11-16 Bearing bracket 4.050.117.07.01


2 Bush 4.010.454.02.01.07 ''10.02'' 230.006193 10 0 2

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11.2.8 Electric head 08.009.060-Z1

Fig. 11-17 Electric head 08.009.060-Z1

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1 Casing, complete 08.008.201-01 230.012292 10 0 1

304 Friction bearing 15x17x20mm 230.010409 10 0 4

2 Label 08.000.280-02 230.017577 10 0 1

3 Name plate 08.000.280-03 230.008554 10 0 1

4 Earth label 165.998 008.EZ TSK.259276 10 0 5

6 Rubber strip 08.053.020-39 TSK.996078 10 0 1

7 Centring pin 08.008.203-39 230.008264 10 0 1

8 Centring bush 08.008.203-38 230.009561 10 0 1

10 Contact block 08.009.059-SKT F-114249-00 1

15 Rubber frame 08.008.201-59 230.001909 10 0 1

16 Earth strand 165.990 120.EZ-3 TSK.981220 10 0 1

30 Protecting lid, complete 08.008.201-03 230.001906 10 0 1

5 Label 08. TSK.959243 10 0 2

31 Lid bearing 08.008.203-81 230.002913 10 0 2

32 Socket head cap screw M 8x 16 TSK.999814 10 0 2


34 Tension spring 230.001907 10 0 1

35 Earth wire 165.990.132.EZ-3 TSK.958337 10 0 1

36 Bolt for tension spring fixture 08.008.203-54 230.009434 10 0 1

37 Bolt for tension spring fixture 08.008.203-54 230.009562 10 0 1

38 Socket set screw M 8x 10 230.000752 10 0 2

50 Hexagon bolt M 6x 8 230.007312 10 0 3

52 Hexagon protecting cap M6 TSK.187729 10 0 3



56 Hexagon bolt M 6x 10 TSK.958102 10 0 2

57 Washer A6.4 TSK.958127 10 0 1

70 Rear cover, complete 08.009.059-05 F-114253-21 1

71 Drive link 1 08.008.201-37 230.016817 10 0 1

72 Drive link 2 08.008.201-38 230.016818 10 0 1

73 Socket head cap screw M 6x 16 230.008546 10 0 2

74 Capstan screw M 6x 16 TSK.975934 10 0 2

75 Socket head cap screw M 6x 45 230.008550 10 0 8


77 Drive pin 08.008.201-70 230.016797 10 0 1

90 Hexagon nut M 20x 1.5 230.015661 10 0 2

99 Slotted spring type straight pin stainless 4 X 6 F-048267-00 2

170 Cable 01 08.009.060-11 F-114581-00 1

702 Terminal stud M04SQ006, silver plated 08.000.328 B 230.009563 10 0 9

708 Terminal stud M04SQ006 gold-plated 08.000.328 A 230.015016 10 0 15

1606 Series connector 2,5- 6,0Qmm 230.019543 10 0 2

171 Cable 08.009.060-25 F-114583-00 1

700 Terminal stud M04SQ001.5, silver plated 08.000.326 B 230.000755 10 0 9

706 Terminal stud M04SQ001.5 gold-plated 08.000.326 A 230.017876 10 0 10

707 Terminal stud M04SQ002.5 gold-plated 08.000.327 A 230.012294 10 0 5

172 Cable A 08.009.060-26 F-114582-00 1

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198 Heater element 25W / 110V L:210+ 08.007.010-60 TSK.998750 10 0 2

204 Male contact K08, silver plated 08.000.320-01 (4) 230.001623 10 0 9

205 Female contact K08, silver plated 08.000.402-00 230.001622 10 0 9

206 Male contact K08 gold-plated 08.000.320-01 (4) 230.001624 10 0 15

207 Female contact K08 gold plated 08.000.402-00 230.001620 10 0 15

804 O-ring 5.0 x 2.0 230.004437 10 0 48

2148 Thermostat 250VAC 16A / 24VDC 165.991 001 230.014767 10 0 1

11.2.9 Centring device 010.616.10

Fig. 11-18 Centring device 010.616.10

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1 Flat 3.136.001.10.00.01 ''10.01'' 230.001500 10 0 1

2 Support bracket 010.616.10.00.01 ''10.01'' 230.025437 10 0 2

3 Guiding plate 3.136.001.10.00.03 ''10.02'' 230.001502 10 0 1

4 Plate 4.136.001.10.00.04 230.001507 10 0 2

5 Pin 4.136.001.10.00.05 ''10.01'' 230.001514 10 9 1

6 Cam disc 3.136.001.10.00.06 ''11.02'' 230.001523 11 0 1

7 Sliding plate 4.050.051.02.01.07 ''11.00'' TSK.994307 11 0 2

8 Spring holder 4.010.191.07.00.02 ''10.03'' TSK.963685 10 6 2

9 Washer 3.330.193.07.00.01 ''10.04'' TSK.940903 10 0 1

10 Metal sheet 4.136.001.10.00.07 ''11.00'' 230.002943 11 0 2

15 Anti-friction disc - TSK.990155 10 0 2

16 Lubricating nipple DIN 71412 A M10x1 5.8 A3F TSK.110110 10 0 1


19 Protection plug - TSK.115467 10 0 2

20 Plug - TSK.956912 10 0 2





28 Hexagon nut ISO 4035 M24 05 A3 Cr(VI)-free TSK.239414 10 9 4

30 Hexagon bolt DIN 933 M10x35 8.8 A3 Cr(VI) free TSK.108370 10 0 4



35 Locking screw


38 Locking screw INBUS RIPP W251.12 M10x25 100 GEOMET 321 B PLUS VL TSK.961006 11 9 3




42 Plate spring - TSK.952775 10 0 50

50 Supporting spring 3.136.001.10.03 ''11.01'' 230.001526 11 9 1

55 Stem 3.010.191.07.01 ''10.01'' TSK.966751 10 0 2

56 Support 3.136.001.10.01 ''11.05'' 230.001499 11 0 1

57 Bearing bracket with bush 3.136.001.10.02 ''10.01'' 230.001436 10 0 1

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11.2.9.1 Stem 3.010.191.07.01 ''10.01''

Fig. 11-19 Stem 3.010.191.07.01 ''10.01''


1 Stem 3.010.191.07.00.03 ''10.02'' TSK.966573 10 6 1

2 Rod 4.010.191.07.00.04 ''10.04'' TSK.966719 10 6 1

3 Sleeve 4.010.191.07.00.05 ''10.01'' TSK.966767 10 0 1

5 Pin 4.030.027.10.00.02 ''10.07'' TSK.953088 10 9 1

7 Roller 4.035.061.07.00.09 ''10.03'' TSK.955390 10 9 1

10 Bush - TSK.955396 10 0 1

14 Retaining ring - TSK.186937 10 0 1

11.2.9.2 Support 3.136.001.10.01 ''11.05''

Fig. 11-20 Support 3.136.001.10.01 ''11.05''


3 Bush 4.010.191.07.00.07 ''10.01'' TSK.966724 10 0 2

5 Threaded insert DIN 8140 A-M24x36 X5CrNi18-10 TSK.967111 10 0 2

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11.2.9.3 Bearing bracket with bush 3.136.001.10.02 ''10.01''

Fig. 11-21 Bearing bracket with bush 3.136.001.10.02 ''10.01''


2 Bush 4.136.001.02.02.10 230.001435 10 0 2

11.2.10 Uncouple pipe 2.STD.002.12 ''11.01''

Fig. 11-22 Uncouple pipe 2.STD.002.12 ''11.01''


1 Adapter 4.035.051.04.00.04 ''10.07'' TSK.128993 10 0 1

11 Gasket DIN 7603 A-14x18 copper TSK.103222 10 0 1

12 Swivel fitting - TSK.104662 10 0 1

13 TE fitting DIN 2353 NL-10-R1/4KEG brass TSK.953270 10 0 1

16 Hose S45.12.32 ''10.12'' type 101 / A=340 230.003130 10 0 1

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11.2.11 Air piping 010.616.13 ''10.01''

Fig. 11-23 Air piping 010.616.13 ''10.01''


5 Socket 010.616.13.00.01 230.025569 10 0 2

10 Pipe adapter 3.010.537.13.01 ''10.01'' 230.016712 10 0 1

12 Pipe adapter 2.010.600.13.01 230.025289 10 0 1

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11.2.12 Pneumatic unit 1.010.572.15

Fig. 11-24 Pneumatic unit 1.010.572.15


1 Support bracket 3.010.546.15.00.02 230.020464 10 0 1

2 Label 4.010.238.05.00.04 ''10.01'' TSK.973044 10 0 1

10 5/2-way valve - TSK.184658 10 0 1

11 Venting cap 4.010.444.15.00.01 ''10.01'' 230.010074 10 0 1

12 Silencer - TSK.958229 10 0 2

15 Double nipple - TSK.187640 10 0 1

16 Swivel fitting - TSK.104659 10 0 7

20 Male stud connector - TSK.998444 10 0 1

30 3-way ball valve - TSK.953683 11 0 1

35 Strainer ³) - TSK.184943 10 0 1





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80 Hose 2.S44.11.31 ''10.22'' type 145 / A=175 230.020122 10 0 1

82 Hose 2.S44.11.31 ''10.22'' type 102 / A=320 TSK.986603 10 0 1

84 Hose 2.S44.11.31 ''10.22'' type 134 / A=400 230.001995 10 0 2

³) Spare part kit "strainer" - 230.008289 10 0 1

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11.2.13 Electrical unit 010.572.18 ''10.02''

Fig. 11-25 Electrical unit 010.572.18 ''10.02''


5 Position switch - TSK.987493 10 0 1



14 Elbow - 230.020692 10 0 1

15 Curved connector - TSK.991272 10 0 1

16 Hexagon nut - TSK.982041 10 0 1

20 End-sleeve for wires DIN 46228 E-1,5-8 E-Cu tin plated TSK.240169 10 0 2

21 End-sleeve for wires DIN 46228 E-2.5-8 E-Cu elec-tronically tin plated TSK.240170 10 0 1

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60 Sealing label 40-SK-5143-4(4) TSK.975539 10 0 0.05

11.2.14 Muff coupling 010.109.36 ''10.05''

Fig. 11-26 Muff coupling 010.109.36 ''10.05''


1 Muff 1.010.077.36.00.01 ''10.08'' TSK.136985 10 9 1

2 Muff 1.010.077.36.00.02 ''10.08'' TSK.136943 10 9 1

4 Hexagon bolt ISO 4014 M20x160 8.8 A3 Cr(VI) free TSK.110786 10 9 4

5 Hexagon nut ISO 4032 M20 8 A3 Cr(VI)-free TSK.113417 10 9 4


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11.2.15 Earthing system 010.616.43




3 Clamp DIN 3016-1 D1-13x20 W4 chromed TSK.982154 10 0 1

5 Hexagon bolt DIN 933 M10x16 A2-70 TSK.101023 10 0 9



14 Earth wire 4.E10.050.030.030.00 ''11.08'' type 101 - 50mm²x200 TSK.987763 10 0 1




18 Earth wire 4.E10.050.030.431.00 ''10.01'' type 103 - 50mm²x720 230.000550 10 0 1

20 Earth label 4.SK0.5143.00.00.03 ''10.01'' TSK.971719 10 0 8

30 Protection plug - TSK.115467 10 0 3

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11.3 Special tools and test equipment Special tools and test equipment

The following special tools are required for maintenance:

Coupler head � Coupler lock backlash gauge (230.011604, Fig. 11-28)

Fig. 11-28 Coupler lock backlash gauge

� Mounting drift Ø38, 40-SK-5608(4) (TSK.985705, Fig. 11-29)

Fig. 11-29 Mounting drift for gluing bushes into coupling link.

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Air pipe connection � Socket wrench for mouth piece (TSK.153175, Fig. 11-30)

Fig. 11-30 Socket wrench for mouth piece

Bearing bracket � Double-sided drift Ø70 4.SK0.6345 (230.009897, Fig. 11-31)

Fig. 11-31 Drift

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Materials Voith Turbo Scharfenberg GmbH & Co. KG | Automatic Scharfenberg Coupler Type 10 010.616

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Electric head � Gauge for measuring electric head projection (x = 1 mm; y = 3 mm) (230.013262, Fig. 11-32)

Fig. 11-32 Gauge for measuring the projection of the electric head

� Set of socket wrenches (SW 6 to SW 13) for replacing contact tips (230.015457) including Torque wrenches for torques up to 2 Nm (230.020664) Torque wrenches for torques between 2 Nm and 10 Nm (230.015534) Hexagon drive extension (SKW.990255)

Without illustration

� Mounting pliers for snap-in terminal studs (230.002452, Fig. 11-33)

Fig. 11-33 Pliers for snap-in terminal studs

� Tool for removal of snap-in terminal studs (230.002450, Fig. 11-34)

Fig. 11-34 Tool for removal of snap-in terminal studs


NOTICENOTICENOTICENOTICE Materials as specifiedMaterials as specifiedMaterials as specifiedMaterials as specified The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any conse-quential damage.

The following materials are required for maintenance:

Lubricants � Grease AUTOL TOP 2000 (TSK.289470) � Grease spray AUTOL TOP 2000 (TSK.985083) � Penetrating oil RIVOLTA T.R.S. Plus (TSK.261929) � Anti-corrosive agent ZINGA (H05.975953) � Installation aid lubricant HELLERINE (TSK.297803) � Terminal grease (H05.976020)

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Anti-seize � Anti-seize RIVOLTA GWF (TSK.348880) � Anti-seize Anti-Seize "HIGH-TECH" (H05.975429)

Cleaners � CleanerLOCTITE 7063 (TSK.977974) � Cleaner (spray) WEICON S (TSK.353917)

Activator � Activator LOCTITE 7649 (for stainless steel materials) (TSK.978862)

Threadlocker � Threadlocker, medium strength LOCTITE 243 (TSK.978135) � Threadlocker, high strength LOCTITE 270 (TSK.979436)

Thread sealant � Thread sealant, medium strength LOCTITE 572 (TSK.977856) � Sealing compound, high strength LOCTITE 586 (TSK.978141)

Sealants and adhesives � Sealing compound SIKAFLEX 221 grey (TSK.979637) � Special adhesive for METALOPLAST bushes, incl. hardener KL65 (TSK.254347)



H05.975955

automatic scharfenberg coupler 010.616 user manual

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