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G-80
INSPECTION AND MAINTENANCE OF
CENTRE BUFFER COUPLERS
( FOR WORKSHOP STAFF )
Issued by
RESEARCH AND DESIGNS AND STANDARDS
ORGANISATION LUCKNOW
CONTENTS
Scope
Classification Procedure
REPAIR PROCEDURES
1.2.2.l Parts cast in Grade B steel must not be reconditioned but may be reused see
1.2.1.1
1.2.3 "Scrap" is defined as any component not meeting the requirements of this
specification.
1.2.4 All Railway Workshops produoing coupler components must follow the correct
foundry practice.
2.4 Part mast be clean and free of dirt, paint, rust and scale which will interfere with
gauging and inspection.
2.5 Part must be visually inspected for cracks, fractures, sections broken out, worn
surfaces, distortion, surface upset and service notches.
2.6 Each part must meet requirements of the gauges listed to Tables I, II, III, IV &
V.
3.1.8 Reconditioned part must meet all of the requirements of this specification or
must be scrapped.
3.2 Coupler .
3.2.1 Coupler Body
3.2.1.1 Only those coupler bodies are acceptable as reconditioned which meet the
requirements of gauges listed in table 1 and must operate properly to perform
the functions of lockset, anticreep, full knuckle throw and free lock drop as per
Appendix B).
3.2.1.2 Shank Wear Plate
3.2.1.2.1 If the coupler shank originally provided with a shank wear plate on the bottom
wall has become worn from contact with striker casting, it must be restored by
application of a new wear plate.
3.2.1.2.2 New wear plate must be applied in accordance with Drg. No. SK-62724 item 10.
No weld splatter permitted on plate bearing surfaces.
3.2.1.2.2.1 A preheat may be used at the discretion of applier to ensure crack-free welds.
3.2.1.2.2.2 Heat treatment must not be performed after application of shank wear plate.
3.2.1.3 Markings
3.2.1.3.1 Coupler body must be legibly stamped as shown in fig.4.
3.2.1.3.2 Couplers having spherical surfaces of shank butt restored require additional
legible 12mm minimum steel stamped marking. "RG" (restored and gauge) on
topside of the coupler shank forward of pin hole as shown in Fig5.
3.2.1.4 Shank Alignment
3.2.1.4.1 Coupler shank must not be out of alignment with the head in excess of 9 mm
either vertically or laterally.
3.2.2 Knuckle
3.2.2.1 Knuckles should meet the requirements of gauges listed in Table II.
3.2.3 Lock
3.2.3.1 Lock must meet the requirements of gauges listed in Table III
3.2.3.2 Recoditioned lock must be identified by single star and the code of the Railway
Workshop punched at the location prescribed in fig.4..
3.2.4 Thrower - No reconditioning permitted.
3.2.5 Locklift Assembly - No reconditioning permitted,
3.2.6 Knuckle Pivot Pin
3.2.6.1 After straightening and heat treatment pin must be free of cracks, fractures,
sections broken out and service notches.
3.3.2 Front of yoke pin hole to butt inside surface length must be as follows with
measurements made as indicated in Fig .3.
4.2.2.1 Grade C steel castings are normalised and tempered / quenched and tempered
and marked HT.
4.2.2.2 Grade E steel castings are quenched and tempered and markad HTE.
4.2.3 Processing
4.2.3.3.1 Heat castings in the furnace so that the castings entire volume attains a
temperature of 900C and hold at this temperature for minimum of thirty
minutes.
4.2.3.3.2 Remove castings from furnace and allow to cool in still air to under 4270C; or to
cold,
4.2.3.3.3 Furnace heat to 538C and hold at this temperature for a minimum of two hours.
A higher temperature may be necessary to obtain a Brinell hardness of 179 to
241. The castings may be re-normalised and tempered if they are too soft and re-
tampered if they are too hard.
4.2.3.3.4 Cool in still air,
4.2.3.4 Quenched & Tampered Grade C Steel
4.2.3.4.1 Heat castings in the furnace so that the castings entire volume attains a
temperature of 9000 C and hold at this temperature for a minimum of thirty
minutes.
4.2.3.4.2 Remove castings from furnace and in less than one minute submerge them
completely in moving or agitated, water of 65C maximum at start of the
quench. Hold castings under water until cooled below 204C.
4.2.3.4.3 Remove castings from water and as soon as possible start to furnace heat them
to 663C, Hold the castings at this temperature for a minimum of two hours. A
higher temperature may be necessary to attain a Brinell Hardness of 179 to 241.
The castings must be re-quenched and tempered if they are too soft and re-
tempered if they are too hard.
4.2.3.4.4 All castings shall be tempered as soon as necessary to prevent cracking, but in
no case shall the time between quenching and tempering exceed eight hours.
4.2.3.4.5 Cool casting in still shop air.
4.2.3.5 Quenched & Tempered Grade E Steel.
4.2.3.5.1 Heat castings in the furnace so that the castings entire volume attains a
temperature of 900C and hold at this temperature for a minimum of thirty
minutes.
4.2.3.5.2 Reaove castings from furnace and in less than one minute submerge them
completely in moving, or agitated, water of 65C maximum at start of the
quench. Hold casting under water until cooled below 204C.
4.2.3.5.3 Remove castings from water and as soon as possible furnace heat them to
571C. Hold the castings at this temperature for a minimum of two hours, A
higher temperature may be necespary to attain a Brinell Hardness of 241 - 311.
The castings must be re-quenched and tempered if it is too soft and re-tempered
if it is too hard.
4.2.3.5.4 All castings shall be tempered as soon as necessary to prevent cracking but in no
case shall the time between quenching and tempering exceed eight hours.
4.2.3.5.5 Cool castings in still shop air.
4.2.4 Hardness
4.2.4.1 Tempering tenperatures listed in paragraph 4.2.3.3.3, 4.2.3.4.3 and 4.2.3.5.3
may have to be varied slightly to attain the desired ranges for casting Brinell
Hardnesses, as listed belov:
4.2.4.2 Forged or rolled parts shall also be processed in accordance with 4.2.3.4 or
4.2.3.5 and must be within the Brinell Hardness range specified in 5.0 of Repair
Procedure.
4.2.4.3 Hardness measurements will be made in the locations shown on Fig.5. The
surface at these locations will be properly prepared with removal of all
decarburised metal to permit accurate determination of hardness.
4.2.4.4 Number of Hardness Tests
4.2.4.4.1 When components of heat treated lot are of one manufacturer, hardness
determination will be made on ten percent of the components. When treatment
lot is less than twenty (20) components, a minimum of two(2) components will
be tested for hardness.
4.2.5 It is to be expected that heat treating temperatures may vary plus or minus 10c
from those specified during any given holding time cycle.
4.2.6 Furnace temperature for heat treatment shall be controlled by pyrometers having
associated recording equipment which produce time temperature record charts.
Pyrometer shall be calibrated atleast once every three months. Log sheet will
contain information from the record charts showing the type of products heat
treated. Record of pyrometer calibration and log sheets will be available for
examination for one year.
4.3 Finish
4.3.1 Surface discontinuities resulting from weld repairs or service upset or service
notches must be contoured to the surroundings surfaces by grinding.
4.3.2 All components must be cleaned sufficiently for proper inspection, reclamation
and operation. Coupler must not be sand or shot blasted when assembled.
4.3.3 Component must be free from cracks, fractures, sections broken out, service
notches in those critical areas shown shaded in Figures 6, 7 & 8.
4.3.4 All surface area discontinuities which are detected outside the critical areas
defined in Figures 6, 7 & 8.which exceed one-half of the section thickness in
length and are less than ten percent of the section thickness in depth shall be
removed by blending with the surrounding surfaces. Discontinuities greater in
depth than ten percent of the section thickness and those located in gauged
surfaces shall be removed and weld repaired in accordance with section 4.1...
5.1.1 Restoration of coupler head portion of coupler body including the application of
bushings to knuckle pivot pin holes is prohibited with the following exceptions:
5.1.1.1 Top and bottom pin protector bosses as shovn in Figure 9 to be repaired if the
crack does not extend into pivot lug.
Weld in the pin hole must be blended to the worn contour of the hole. Failure to
meet the minimun thicknes requirements of gauges No. WD-84073-S-8-RC,
Fig.14 and WD-84073-S-5-RC, Fig.15 will scrap coupler body. Heat treatment
for this weld repair is required in accordance with 4.1..
5.1.4.2 Coupler Guard Arm Distortion - Coupler body with distorted guard arm may be
restored either in a press or under light blows of a hammer, after heating the
guard arm. Care must be exercised to prevent heating the guard arm far enough
into the head to cause distortion of the opening in front face of the coupler. A
suggested set-up for correcting lateral distortion is illustrated in Fig.10. The
guard arm should be heated to 816 to 870 degrees C and the force applied to the
forward portion of the guard arm through a heavy steel plate formed to the outer
contour of the guard arm. After straightening, a careful examination must be
made to be certain that no cracks have developed as a result of this operation. If
cracks do occur they must be evaluated and repaired in accordance with 5.1.1
and 4.1.After straightening, the coupler body must be heat treated in accordance
with 4,2. Guard arm distortion gauge to Drg. No. WD-84073-S-l-RC, shown in
Fig .11 must be used in checking coupler body contour after straightening.
5.1.4.3 Guard arm and front face cracks Coupler Head- Coupler head with cracks in
guard arm or front face, may be weld repaired in accordance with 4.1.provided
any cracks do not extend through the full thickness of the front face. The coupler
body must be heat treated in accordance with 4,2.
5.1.5 Shank Wear Plate
5.1.5.1 Scrap coupler body if shank thickness is less than the following :
5.1.5.2 Coupler body having a shank length less than the minimun, allowed by gauges
to Drg.No. WD-84073-S-22-RC or WD-84073-S-26-RC, Fig .12 can be restored
by welding external surfaces of spherical butt to requirements of the applicable
gauges noted in Table I.
5.1.5.3 Shank butt height may be restored by welding top surface only per Fig .20.
5.1.5.4 Identify restored and gauged spherical shank butt per 3.2.1.3.2 and Fig.5.
5.1.5.5 Restored coupler body must be heat treated in accordance with 4,2
5.1.6 Bent Shank - Coupler Body with shank bent in excess of 9 mm in any direction
and out of alignment with the coupler head may be reclaimed by heating to a
temperature of 816 to 871 degrees C and straightened under a press. Care must
be exercised to bring the shank into proper alignment with the head within the 9
mm limits. After straightening, the coupler body must be carefully examined to
make certain that no cracks have developed from this operation. Cracks must be
evaluated and repaired in accordance with 5.1.2, 5.1.3 and 4.1.. The coupler
body must then be heat treated in accordance with 4,2.
5.2 Knuckle
5.2.1 Restoration for wear of the knuckle is permitted only in the following areas :
5.2.1.1 Lock engagement surface.
5.2.1.2 Hub, bottom only.
5.2.1.3 Pulling lug. Top and Bottom.
5.2.1.4. Pin Protectors, top and bottom
5.2.2 Repair of cracks or sections broken out at any location is prohibited.
5.2.3 Worn surfaces listed in 5.2.l may be restored by welding per Figures 26 & 27
and heat treating in accordance with 4.1.. and 4,2.The application of any plate
on the knuckle is prohibited.
5.2.4 Restored surfaces must meet the requirements of 3.2.2.
5.3 Lock.
5.3.1 Restoration for wear of the lock is permitted only on the knuckle engagement
surf ace. The entire repaired area must be restored flush with surrounding
surfaces.
5.3.2 Repair of cracks or sections broken out at any location is prohibited.
5.3.3 Worn surfaces may be restored by welding and heat treating in accordance with
4.1.. and 4,2The application of any plate on the lock is prohibited.
5.3.4 Restored surfaces must meet the requirements of 3.2.3.
5.4 Knuckle Pivot Pin
5.4.1 Bent pin suitable for reconditioning must be heated to a temperature of 816 to
871 degrees C. It must be straightened and allowed to cool in still air. After
straightening it must be reheated to the same temperature range as the first
heating and then quenched in oil for a period of three minutes and cooled in still
air. The temperature of the quenching oil bath shall be maintained within a
range of 38 to 66 degrees C.
5.4.2 Straightened pin must meet the requirements of 3.2.6.
5.5 Coupler Yoke.
5.5.1 Repairs for all yokes
5.5.1.1 Welding of cracks not exceeding 25 mm long x 3 mm deep is permitted in
critical areas of Fig.6. Yoke with cracks exceeding either of these dimensions in
critical areas must be scrapped.
5.5.1.2 No limitations on size of cracks repaired in non critica1 areas. Repairs of cracks
completely through a section is prohibited.
5.5.2 All upset areas must be repaired in accordance with 3.1.5.
5.5.3 All repairs made by welding and heat treating must be in accordance with 4.1..
and 4,2and must meet requirements of 3.3.
5.5.4 Yoke Head
5.5.4.1 If the dimension as measured in Fig.3 exceeds 794 mm restoration is prohibited
and the yoke must be scrapped.
5.5.4.2 Yoke pin hole may be restored to meet the overall length dimensions listed in
3.3.2.
5.5.4.3 Restoration of holes must be performed by welding and heat treating in
accordance with 4.1.. and 4,2
5.5.4.4 After heat treatment, the hole diameter must be restored to 92 mm by machining
or bushing per Fig.3A and located per 3.3.2.
5.5.4.5 Yoke worn from contact with coupler shank may be resotred by welding.
5.5.4.6 Yoke worn on the outise of the head may be restored by welding.
5.5.4.7 Yoke worn on the top and bottom outside of the head from striker contact may
be restored by welding when the yoke head width is not less than 203 mm. Yoke
must be scrapped when yoke head width is less than 203 mm.
5.6 Draft Gear Follovar (Applicable to Y-46 follover only)
5.6.1 Repair of crack or sections broken out at any location is prohibited.
5.6.2 Followers with indentations exceeding 3 mm in depth on the coupler or draft
gear surface must not be restored and must be scrapped.
5.6.3 Follower
5.6.3.1 No straightening is permitted.
5.6.3.2 Restoration by welding if indentations not exceeding 3 mm depth on the draft
gear bearing surface is permitted. Restoration of coupler bearing surface is
prohibited. Depth measurement is to be made after upset area is ground flush to
surrounding surfaces. Repaired surface must be dressed to blend with
surrounding areas.
5.6.3.3 Restoration welding and subsequent treatment must be in accordance with 4.1..
and 4,2
APPENDIX A
INDEX OF TABLES
TABLE - I
HEAD 11 WD-84073-S-1-RC
13 WD-84073-S-3-RC
16 WD-84073-S-3-RC
15 WD-84073-S-5-RC
14 WD-84073-S-6-RC & WD-84073-S-8-RC
17 Gauge No. 1 & Gauge No. 2
SHANK 19 WD-84073-S-21-RC
20 WD-84073-S-25-RC
21 WD-84073-S-17-RC
12 WD-84073-S-22-RC & WD-84073-S-26-RC
31 WD-84073-S-23-RC
32 WD-84073-S-24-RC
TABLE - II
TABLE - III
TABLE - IV
TABLE V
1.1 Enter knuckle thrower A, through front of coupler head and into knuckle thrower
trunnion hole, until it lies flat on floor of coupler head (Fig. 1.1)
1.2 Apply rotary lock lift assembly X, Y & Z on shaft F (Fig. 1.2).
1.3 Lift toggle L and rotate lock-lift assembly X-Y-Z towards front so that toggle Z enters
into lock hole. Next enter lock B through front of coupler head and place toggle arm
slot in lock B over trunnion of toggle G (Fig.1.3).
1.4 Then lower lock into position into lock hole (Fig l.4).
1.5 Hold lock B back in coupler head while raising it with locklift assembly X-Y-Z until
lock enters upper lock chamber. (Fig. 1.5).
1.6 Continue to raise lock B to the top-most position and hold. Then rotate knuckle
thrower A to the extreme left position and hold until lock is released to lock set
position as shown in Fig l.6. Next, insert knuckle E between the top and bottom
pulling lugs,
1.7 Rotate knuckle B inwardly to closed position, allow the lock B to drop into locked
position (Fig.1.7).
1.8 Next fit knuckle pivot pin H and secure by welded washer J (Fig.1.8),
1.9 It must be ensured that during assembly and in service none of the coupler
components are either painted or lubricated. After assembly operate the
coupler a few times to ensure free movement of components.
INSPECTION AND MAINTENANCE OF CLEVIS AND CLEVIS PIN
AND SCREW COUPLING
1. Clevis
1.1 Clevis shall not be built up by weldling. If worn more than 3 mn, it shall be
condemned.
2. Clevis pin
2.1 Pins having steps or cracks or which have a diameter less than 37 mm at any point
shall be condemned. Bent pins may be reclaimed by heating, then straightened and
allowed to cool in still air. Finally the pins shall be heat-treated to get hardness value
of 250-305 BHN.
3. Screw coupling
3.1 The reclamation practice for screw coupling shall be as per Indian Railway
Maintenance Manual for wagons issued by Railway Board.
1 WD -84073 -S-l-RC
2 WD -84073-S-3-RC
3 WD -84073-S-5-RC
4 WD -84073-S-6-RC
5 WD -84073-S-8-RC
6 WD -84073-S-17-RC
7 WD -84073-S-21-RC
8 WD -84073-S-22-RC
9 WD -84073-S-23-RC
10 WD -84073-S-24-RC
11 WD -84073-S-25-RC
12 WD -84073-S-26-RC
13 WD -84073-S-47-RC
14 WD -84073-S-59-RC
15 WD -84073-S-71-RC
16 WD -84073-S-96-RC
17 Gauge No. 1
18 Gauge No. 2
19 Gauge No. 3
20 Gauge No. 9
21 Gauge No. 10
22 Gauge No. 11
23 Gauge No. 12