·..,.r . -~---,

---.;

No II G-,76 Sf}'T FY.Bm 1987

.. ~ .

INSPECTIOltim> MAI~nNANCE OF ;,~.

CENTRE BUFFER COuPLERS (FOR

LINE STkFF).

OOOr}00019~

L ••

I~ fued. by RESBA!\CB DESIGNS AND SIA":D.u~ .. n~ C;,G:;.1HSA'flO'N

LUCKNO~.

". . )

GENERAL .lRRANG£'l-tSN't OF Crl'TR& BUFFER COUPLER (TMJ~Sl'£IOU) l ~

::!... lot t.r1 1.oe ill f'\ _-~ 11.

6:eap.

,. elm' pia..

8. IrunUoIl e-.::rh oo~u~ • . 9. 8 '-rl ku C aJ5 U n&.

::1.0. ~ok.. pi n.

i 11. '10k. p1n IQl)por\

1.L Shank Y4al' ptat ...

13. ~ttiker .rCt.s't.1~ ..,e~r plate . ..- .

... -

. -. -' ... - ..

0000000191\ .~

• •

\~ 1. Coupler Body'Wi thshank.

2. Knuckle.

3. Kn'l~l(le pivot pin ... ith .... sher

4. Rot ~y lockli! t as sembly.

5. Cap.

6. Striker Casting. \

7. Yoke pin.

8. Yoke pin support.

9. Shank ~ear"plate.

1 o. fIr 1 k E'~ C as t1 ng 'Wear p 1 at e

1 . 3 -7 ;

I

.. __ ._.-----'--

\

\ \ ~

00000001/15

The purpOse of thos. inst.ructions 18 to ass1a\ the Tre1n Exa..rdn&rs/Slok Line staff to detect all1 corr$c\ ltDii>ro~&r oordi t.10rul 1tt101rlng the complete coupler, cou.pl.r parts and co~l~r operat1~ rn&chardem.

~JW.ELJ~B~XAMl1irUQFJ.lL~

\Ic'Mn 1ns~ect1on of a co~ler and the op era.ting . m&cbanism 1e ma1e, the t'o11oYi t€ 1 tems 8hould be checked t-

1. QR.!U:.A\t.n&~

The optrat1. t€ rod ab:>u1d rot be bent and should be proP&l'17 beld in th' bea.r1n& piece prorld&a on the u/rrame.

2 •. ~~~~chard§m

The coupler operating mechanism should open the knuckle when the handle 1B raised and rotated. to the top p<iBt--t1on.

Tbe lockllust drop freely to the locked pasi ti on 'When the knucklels closed 1>10 .. 1)' •. Tbe locked posi tien is indicated by the toggle ~h1eb should be clearly v1sible belo~ the coupler head.

4. ~(!S" ..angbt

Burru height eboul4 be cb&cked in accorda~. ~ tb Rule 2.13.7 or eonterence Ilules Part III (Reproduced in APpendix 1).

5. ,Pefie! entID ama.g iM,t;:rciS slyely )lQrn CQmDQnen\~

The i'ollo'Wing 1 t.ems shall be cbecked for cracks/par ts broken orr/mls,1n& 1-

- Coupler body - Trans1 t10n Sere .. Cotlpl1Dt - Knuckle pin - St.r1ker casting - :toke pin support

Tbe tollovlng items shall be checked for exces~1ve "ear 1-

- Knuckle - E tr1ker cast1 ng 'Wear plate - Coupler shank 'Wear plate.'

Note s - Lim ts of "ear are tabulated in Appendix 9 • ••• • 12

·'~O . / ~. .

0000000196

- a -

~l)..tL~A_~~JJt)u·r sI~A_JL1~ ~U.N~.lli...Mji

.~t 1 sic~ line,ind dlJrinG itOii, the rollo'-log should be che~ked J.nd rest::Hed :-

'10 deteL'::1ine the affact1v~l18SS of the ant1--\.:rz~p prot-:cti.~n,""":1.nsert a bar bet''':oJtJn the l·)ck ';ind kl1uckla t ·.tt 1 shdlf and. pry the lock IIp\Ii::ird 3.nd at the S::i!:ltJ ti;:1e force the lock leg rear\liard by inserting a scre'«dr1ver bltst'lrlG&Q the lock leg and the tr'Ont of tM look tole I:JJ shovni, in !PPGn.dJ.x 2, 11lure 1 and 2.

;.

It thlt lock. Gan be ra1.s&d. bl this method Gno~h to pf3l.'mi t open1os of the knuckl •• the coupler has in.~U!f1c1.€tnt ant1-areap prot&ct1on. CorrGOtion of 1Q3u1r1Q1~n~ anti.-creap proteoctloQ should be made bl replac1n& (1) the lockUtt assembl1't

I (11) thA look» or (111) tba knuckle. UsuaUy, . l'splacOOlentof thG locklltt assembly 18 sufficient

but 1n some eases fu.rther benefit 18 obtained bJ . r.newll. of lock ard/o'f knookle. It renewal of these parts do ea no~ corroo\ the condi tioD, the tault il probably due to vorn anti-creep pl'otectlon or "ear of tb,(1J ;:e~ vall of the bottom lock1101. in the couple.f h~ad and the coupler bodl should be rene'tled.

(2) ~J_llL .. S~.ll~lklA

Coupl€11'8 ~th distance between nose. ot knuckle andfLuard arm exoeedir:c. 136 mm as measured by the Qauge No.,1 ahovn 1n lppendlx 31 must haVQ the deteoti"e pu~ 01' parts 1'8ne .. 64 to br103 tbeeoltplsr within req,uireQ, gauge of 130 na. as measured '01 Gauge 1'002, abo"l'). i'!t, Appendix 3B. If the coupler 18 out ot . gaugea tb~ ~~)d$ must not b. rene\iad unless the

4 ~·vil.cat1on of r&co~l tloned 01' ne'4 knuckle, lock and knucklo p~,vot pl0., any or al.!l 'tdll not bring 1t \d.tb1n th@ ~:&<!u1r~d gauge ot 130 Cl.t1'h

(3) ~USL~;b -LnA Host W§§l \

Knuckle! shall be checked tor'stretch and nosa vemr bJ U81~ ~al'1e No c 3o Knuckles exceedin,g tb~ ,aug~ 11m! t$! s.ha..L. be condemned. Details ot gaug~ and :1 tsapp1J.,'c~f.',t1on ~~ sho\fo. 1n Appendix 3C, figures 19 2 &. ~e ' ...

(4) ~JXfJlat~

Sha.nk t;~.fM' plti,t® Olm couple~ must ll' replaced it the ""a,r ~llat~ 1; ,*>l:tl mot. than 5 mzle. Detail. of' "ear platA us abo"n, iii .!pp~nd1x 4o

.... 5 .... 0000000197

- 3 -

Striker casting 'gear plate spould be replaced i! 'Worn !flOre than 6 mrn. Details of \lear plate and its eecur1ng arrangement are sho\ln lnAppend~x 5.

•

(~ §A~~~~t~i~

Exoesslve Slack in the Draft Gear should be reduced or ellndnated. The amount of tree slack oan b~ determi ned br tirs t el&d.gi ng the coupler back solid and then measuring the clearanoe bet~een ·the eo~ler horn s.OO strIker tace. Next, br inserting a long bar bet\;isen the born and striker te.ce, pry the oOUp ler out as tar aB pos ~1ble .and ega! n . measure the space bet\J6en the horn and tbestri ker. The diffe.rence b8t~eQn tbese two measurOOlsnts 19 the amount or free slack present. The ma.rlmum permissible free !lack in the drs.ft gear is 25mm. PictorIal representation is given in AppendIx 6.

(7) Art1cJUAt~d ~ck:ur~ AsSembly

The effectivenes s or Articulated wckUft As sembly smuld be checked. It is a device which prevents accidental Separations due to combi nation or vertical and longl tud1 nal shock upon the coupler. See Appendix 7.

The Articulated wckll.ft Lever is permitted to -free sle.ck" due to 1 ts hinged construction, thus when end shocks occur, the lever .8w1~s fOnlaN and the pro3ection provided at its outer end engages the under slde of the lo"er tront face of the coupler bead. Thi s engagement is in effect an lidded ant1-creep and serves to prevent rotation of the lever and release or the regular ant1-creep •. Wi tb this .engagement, Upward

'bounce of the lock is stopped and accIdental unlocking of the coupler is prevented.

(8) l22uplet smelJi!.igg Mecban1sm

The operating ,.mechanismu-sed wi tb the Articulated Ro tary Co upler is gener,i1.i-i)rj o!; ;tMe one-piece standard deSign as shown 1n Appendix SA.

The bear- ng piece of the uncoupU ng gear Shall be provided vi \.!l safety strap if not all"eady provided. Fltment of the safety strap shall be as sho"n in A-'pend1% BB.

. . 0 Q 0.0.0 Uo.l. 9. .. 8. .....

cbs

- 4 -».

(1) In e.ddit1on to the checks listed above, items 8OO .. n against Coupler Examination in Yard should elso be covered.

(11) tim! ts or 'Weal' for CBC compo·nents are tabled in Appendix 9 •

.... -.-.-

0000000199

7 I~~ lOD,·)[JU[JO

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~~J~~~m-»j;A.~AlQ-.llnY.-t.~l~.!3J.N.~_l.ll. x If..x )~ !(..."(X

.... ..

"2~13.7 Bu.i'f&r beights in Broed Ga.uge and Hetre Gauge e tock flhall be td. thin t.hG l1m1 ts SOO\itl balo .... ,-

.Empty !() aaetl

Broad Gauge 1105 tn.lU 1030 mm ro~.imum m1 nimum

Metre Gauge 585mm '535 rom. In ax11!1 um m1n1.mum

Note I To !!lake up the buffer heights to ms.rltnu:m perro1ss~le limits due to reduced d18!!leter of "heels a packing piece of' req.u1red des1l}\ ~ t)ize may be interIX>sed bet\deen axle box crovn and spring buckle (See' Plates 31 and 32).

xxx

OOO~000200

,.

~orTi.;' ',i'D

w u ex: 0 u.. 0:: • 4. t

cD , , . >- • ex: Cl.

0001100020r ftG·UR·t 1";-" ._ ................................ : ..

q.

Appan6.1x ·31

. ,' ..

. . ---(-1------ .----~-_+_..:_;f"__.-~--- --"-..

~ .

2.7 ..

The coupler contour is f'ejctuble ""hen tbe g.ugt un ~ p~s.sed vertically througb abe contour in po~ition .bo\~n &. with points eA" &:. 'B'

contacling ,u~ arm.

Tolerances UDles3 otberwise '~C1ntd ± 0.05 ~""'. Angles ± 2 minutes

,'" ,., j8> •

r " ,n , .. '''0 ,.J 1'~11.~' • ( f .• ... j ''/

OGonn00202.

hppeild1x 3 B

-~--~.--.~----

The coupler cootour is rejecuble when the gauge un be pU$~ vertically through the contour in positio~ ,ho .... '"Q a:. with points "Au &. "Rn contacting guud ann,

indicates complc\.C head needs reconditioning.

OOOOC00203 "'o,...r./r,",(q. 1r10

tic" 'U'

II I

"T'1 -,Q .C ::tJ f'T1 . I

.-.

r9+2So SJt. \ 92·'

MATER\AL'~- 5 "THICK l""OOL SyttL P\.Ai F'fNSHc.D S~AC:':'S H~ENf .

-.. c:: . ) 0

, \.._-

c-C:" 0

~I J I ~I ~I I

~ 1I1

__ I I i I I i I I

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~I ~.3? I 'f~'-~ iT

<:3'"1 ,1l ~/ '

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I~')~J ; -(;.35./1 44 ol,...,J .-r- -' -r f- £; -; i cO' I J ~t

I' .~ G'.3~~ t& 1 ~ ~t T . ~ "~s I

I V'1 1.1, r r- ,:~- . I .0 eo ,~"1 ) ~ 1'1") . H\J"·r / I • ' \);1 .', / 'N~ ~ :J, N : ~ v J '

I 0/. ~'7 ~"'))V; --I" .\.iI' Nt I ,/ I ~. i J 11." CO ~ =---.J.. ---'''- .-1._

I . l ~ l 1 ! -'-_._- .-. - I ! ! f 4'riJ ~~2~~. 25-~ __ .. ___ . _____ ,~_o':.$\ ... _.84-14 ______ ~~4~.3b..J

o I , I

o L 303-2. i! o --.-.-..... _" .. -- ~ ! g ________ . __ . _________ .______ ~ 9_2 _ . _. _ .... _ _ .. ~

g ----~~'. ".) CGAUGE ~.3 . s: KNUCr~LE STRt:~- ~NOSE WEAR

~,

~ -0 rr1 Z o -X I

W (')

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c:: /)

a r---; , ~

'--r-.. , .... 0

0' a o a

,0 a C> r·.~

a en

I

J I

I '-__ ".1 I ,

KNUCKLE S TRETC~i GAUGE ----------------------------------

I , J ,

I I ( , I.

>1 V V 1

rri Z 0 1

, ·x ~ ()I

. c...-: . ; Q '---. ... -. , -L

, .. H

KNUCKLE NOSI:. WORN LIMIT POINT IN'MUST NOT PASS WITH POINl"S 0, P, R IN CONTc:.CT.

P

R ----------------------------------~ I

(' WOQN J\\ //-\

KNUC K L E. ' ~,,~ _/

\\ NEW .-J "'--- ( . '<NUCKLE , \ .

~.~.--.-----~

Kf\JUCK LE NOSE WEAR GAl)GE

l>1 -0 VI rn 21 o Xl (.,.) I

("') I

2.1 0

\.JJ -__ z -'

--- -~

A PPENQtX-4-

I

t

----------- - -- ------- ----M,b..T£.Rl,b..L - IS: 3885 "'l.1 G1'. 4 - --. ""

HARDNESS .. 3~·O - 400 BHN. \ - --0"" 0 rJ \ l"" 'l' 0 l~ 'J~ J~));_

15 0000000207

\ \

\ S'R\KE~ CAST\NG ~

APVt.ND\~ 5

/-- S1R\KER CASTING / WE~R PLf...1E

/

~ - M \2. BOl1, SO lO'~~ W\TH NUl eo SPRING WAS\-\Ek.

SECUR\NG ARRP-.NGEMEt'{l OF SHI\NK WEP-.R PL~,E

6·5 S -

S T R \ K ERe A 511 N G V\ EAR P L fl:l t ------- ,---

M/~llRIAL - ,s: 3885 Pt. 1 GY.4

HARDNESS -:!>OO-340 BHN I'

0000000208

c-------BAR - ..... ,

...-.---.,.

------ ---.. --"---~--... --- , ..

..... t . \ . I •

.. ' ..., t

.-, . \ - . '\ I

25~ ..t-,

•

.~'

I

lOC. __ ~~~~~~---r~T IU.ll(O 'UOHTL'"

WAIN AteT ,- t'-U' TILL .... OSlll~

10 [~C;AC( lUG

.Appendix 7

•

tfOItWll'O'1110t& -\ Of 0"["1'1~ "00 _'

~Wll '051110" 0' 0'llU1.te, "00

POSITION I. POSITION 2. ' POSITION !. POStTIOIiC WITH ~lU111IIW IlOO I,.Uit{ AI '01.1 oel'l • UVl" ~U$ T~. ,O't.~o AUX11IA"Y AIIC11-C"U·" • AUl[ILlUY Attlt.C"[(P [~[D .... IW·I.* U'&.I[W[.'.

POlll'C)te 0' PA'-TI .11M 0' ['U,1.1ItQ

ItOO "OlATED TO "H,EASt Alil"­tMf' ,IUO" TO ItEGULA" UN • Loelute, 0,£"&110.,..

fUNCTIONAL PRINCIPLES OF' A~1ICUlA1EO ROTARV LOCkL1FT ASSEMBLY.

0000000210

Appendix SA .~ . .....-.-

~F·· .. =t=,. ·1~·-· -'-'=fl-~l?--.. ! 1:0

• .! I: ill \iT _. ~.~--.~__ Jll 'ltla" . t~ .~. ~~1".. l. ~ ..

. ~0 . --=---:-:::.~. ~ ~~--~""--.-----~--­:j:-~---- --.-

r o /

i. Bracketo

a. Opera tin~f handle.

fer

l ...........

0000C00211"

..-.. ~ I . . ,

3

~ppendix S9 p--

. ~s)'.e lH1CK--\

1. B~.r 'Br.eket. R. CoQl>ler .lbd. a. ~a.rlDl Pioc" 4. saret.x ~t:r~.

Fllr1EN'l' OF SlFBTY sr RAP

0000000212

APPendix 9

--------- --,.;..:.._-----------------_ .. ,- --, -----._" .

S. NO. Description Limits for replacement Gauge No. ~ __ -_-~M~-----~--------_ .. _-.. '----~----~ . _____ # ___ ~ __ ----~ _____ _ , ' . '

10 Y.nuckle nose wae!' limi t gmige £1.5 mm MaJe c 3

20 shaT1k wear plate (\>,hen ne'" (5 mm thick).

I

3. Knllckla pin ('Nhcn ne'« 41.28mrn)

4. Clevis pin (when new 38 mm.) ,

50 strikex~ casting wear plate (When new 8 mm thick).

.. o .... o-e-

. "Sf' ~ 1 .- U :.: i} '._\ 0

1 mm

38 mrn.

36 rom.

2mm

000000011'3