Draw and Buffing Gear in Railways
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Questions and Answers

What should be done if the guard arm distortion exceeds 4.8 mm?

  • It should undergo minor adjustments.
  • It should be left as is.
  • It should be replaced immediately.
  • It should be closed into normal. (correct)

When checking the knuckle, what should happen at point D when A, B, and C are in contact?

  • D should not be checked.
  • D must touch as well.
  • D must have a visible gap. (correct)
  • D must be bent slightly.

If the gauge no. 3 indicates contact at points A and either B or C, what action should be taken?

  • Adjust the guard arm.
  • Renew the coupler body. (correct)
  • Lubricate the coupler.
  • Reset the gauge and recheck.

What condition of the knuckle necessitates its renewal?

<p>If D touches when A, B, and C are in contact. (B)</p> Signup and view all the answers

During the inspection of knuckle nose wear, what is the indication that requires renewing the knuckle?

<p>If E passes when F and G are in contact. (D)</p> Signup and view all the answers

Why is it important for point E not to pass during knuckle nose wear inspection?

<p>It ensures the knuckle is functioning well. (A)</p> Signup and view all the answers

What type of gauge is used for checking the guard arm distortion?

<p>Gauge no. 3 (D)</p> Signup and view all the answers

Which company is listed as a manufacturer of BESCO in the high capacity draft gear section?

<p>Burn Standard Co. Ltd. (C)</p> Signup and view all the answers

What is the location of Titagarh Wagon Ltd. according to the provided information?

<p>113, Park Street, Calcutta-700 016 (B)</p> Signup and view all the answers

Which item is associated with Annpurna Engg. Works based on the content?

<p>Top Lock Lift Hole Cap (B)</p> Signup and view all the answers

Which of the following companies is linked to the Miner design type?

<p>Texmaco Rail and Engineering Ltd. (A), Frontier Alloys Steel Ltd. (B)</p> Signup and view all the answers

Identify the specification that includes the knuckle pin with washer.

<p>SPEC-48-BD-08 (B)</p> Signup and view all the answers

What is the yield strength of the knuckle in a standard coupler?

<p>132 tonnes (D)</p> Signup and view all the answers

How much higher is the draft capacity of a high tensile coupler compared to a standard coupler?

<p>36% (D)</p> Signup and view all the answers

Which high capacity draft gear has the highest weight capacity?

<p>MK-50 (D)</p> Signup and view all the answers

What is the performance efficiency of the RF-361 draft gear?

<p>79.6% (B)</p> Signup and view all the answers

What type of draft gears are currently fitted on new freight stocks?

<p>RF-361, MK-50, and MINER SL-76 (B)</p> Signup and view all the answers

What is the pre-compression force applied to the RF-361 draft gear?

<p>Rubber pads (B)</p> Signup and view all the answers

Which of the following is NOT identified as a high capacity draft gear currently in service?

<p>HR-40-I (D)</p> Signup and view all the answers

What is the travel capacity of the MK-50 draft gear?

<p>81.5 mm (A)</p> Signup and view all the answers

What type of material is used in the RF-361 draft gear assembly?

<p>Rubber (C)</p> Signup and view all the answers

What is the maximum allowable wear on any friction surface?

<p>0.8 mm or 1/32&quot; (C)</p> Signup and view all the answers

Which defect is NOT permissible on the wedges intended for reuse?

<p>Indentations deeper than 0.5 mm (C)</p> Signup and view all the answers

What condition must the inside friction bore walls satisfy?

<p>Must have a wall thickness of at least 20.6 mm (D)</p> Signup and view all the answers

Which of the following statements about the housing is true?

<p>There must be no bottom ridging in the bore. (D)</p> Signup and view all the answers

What is required for the parts before re-assembly?

<p>They must be free of oil, grease, and moisture. (D)</p> Signup and view all the answers

What process is recommended for cleaning wedges and shoes before assembly?

<p>Shot-peening (D)</p> Signup and view all the answers

What is indicated about the profile gauges used for housing?

<p>Gauges No. 27706 and 27200 must be used. (C)</p> Signup and view all the answers

During assembly, where should the assembly ring be placed?

<p>Over the housing (A)</p> Signup and view all the answers

What should be avoided on the wedge and shoe parts?

<p>Sharp edges (D)</p> Signup and view all the answers

What does a concavity of more than 0.8 mm in the bore indicate?

<p>The bore must be replaced. (D)</p> Signup and view all the answers

What is the maximum allowable parting line flash for rubber pads?

<p>0.78 mm (A)</p> Signup and view all the answers

Which of the following is NOT a requirement for rubber pads during static testing?

<p>Must be skewed after the load is released (A)</p> Signup and view all the answers

What condition should elastomeric material meet before acceptance?

<p>It should be free from foreign material (B)</p> Signup and view all the answers

Which dimension must the outside profile of the internal follower meet as a minimum?

<p>11.25&quot; x 7&quot; (D)</p> Signup and view all the answers

During the visual inspection of forged items, which of the following is NOT a common check?

<p>Identifying color uniformity (B)</p> Signup and view all the answers

What must the pads exhibit after a load is released during testing?

<p>Return to minimum free height (C)</p> Signup and view all the answers

Which of the following is a requirement for the top and bottom surfaces of plates?

<p>Must be free of elastomer films (D)</p> Signup and view all the answers

What is the maximum allowable deviation for the base's flatness across the diagonals?

<p>1/16” (1.6mm) (B)</p> Signup and view all the answers

Which of the following inspections is required for rubber pads during visual checks?

<p>Visual inspection of all pads (A)</p> Signup and view all the answers

What is the minimum depth for inspection sprues below the steel plate surface?

<p>3.18 mm (A)</p> Signup and view all the answers

What is indicated when the plate clearance reduces to zero in the draft gear?

<p>The draft gear will start wearing on the housing. (C)</p> Signup and view all the answers

What is the recommended press force required to dismantle the Mark-50 draft gear?

<p>40 tonnes (A)</p> Signup and view all the answers

Which gauge is used as a No-Go Gauge to check the minimum housing wall thickness?

<p>Gauge No.BE-92/62-6 (A)</p> Signup and view all the answers

What happens if parts of the draft gear start wearing on the housing?

<p>Considerable damage occurs, making reconditioning impossible. (A)</p> Signup and view all the answers

Which type of gauge is used to check the movable plate area?

<p>Go, No-Go Gauge (D)</p> Signup and view all the answers

Which of the following components is NOT part of the RF-361 draft gear?

<p>Clutch housing (B)</p> Signup and view all the answers

What gauge is used for checking the flatness of the housing in RF-361 draft gear?

<p>Gauge 27257 (A)</p> Signup and view all the answers

When is complete reconditioning of RF-361 draft gear necessary?

<p>If there is a cracked weld at the rear wall (B)</p> Signup and view all the answers

Which gauge is used as a pre-shortened assembled gauge for final inspection?

<p>Gauge 27207 (C)</p> Signup and view all the answers

What indicates a loose clutch in the RF-361 draft gear?

<p>Defective rubber springs package (C)</p> Signup and view all the answers

Which gauge is specifically designed for measuring the wedge in the RF-361 draft gear?

<p>Gauge 27216 (A)</p> Signup and view all the answers

What is a common indication of poor welding practice in the RF-361 draft gear?

<p>Fatigue cracks on welds (B)</p> Signup and view all the answers

What is the weight capacity of the RF-361 high capacity draft gear?

<p>138.0 kg (D)</p> Signup and view all the answers

Which draft gear type has the highest performance efficiency?

<p>MK-50 (D)</p> Signup and view all the answers

What is the yield strength of the knuckle in a high tensile coupler?

<p>180t (C)</p> Signup and view all the answers

During which period were bogie wagons manufactured that were originally fitted with HR-40-I draft gears?

<p>1984-85 (C)</p> Signup and view all the answers

How much higher is the draft capacity of the high tensile coupler compared to the standard coupler in percentage?

<p>36% (D)</p> Signup and view all the answers

Which type of draft gear has a travel capacity of 67.8 mm?

<p>RF-361 (B)</p> Signup and view all the answers

What is the reaction force of the MK-50 draft gear?

<p>269.0 tonnes (A)</p> Signup and view all the answers

What action is mandated for standard draft gears in relation to high capacity draft gears?

<p>They are to be replaced with high capacity draft gears. (D)</p> Signup and view all the answers

Which is NOT one of the high capacity draft gears currently in service?

<p>HR-40-I (D)</p> Signup and view all the answers

What is the minimum wall thickness that the housing must meet at its bottom?

<p>11.9 mm (C)</p> Signup and view all the answers

Which method of cutting is mentioned as potentially creating an explosive mixture if not properly ventilated?

<p>Flame cutting (D)</p> Signup and view all the answers

What should be the measured thickness of rubber pads according to the gap gauge?

<p>2 1/8 inches (D)</p> Signup and view all the answers

What is a permissible condition for steel plates according to the inspection guidelines?

<p>Bent but not broken or cracked (A)</p> Signup and view all the answers

What is the maximum force that the hydraulic ram must be capable of resisting?

<p>10 tons (B)</p> Signup and view all the answers

During complete reconditioning, what should be done with the wedges and shoes?

<p>They must be removed (D)</p> Signup and view all the answers

What is the maximum thickness cut required when cutting the rear wall plate?

<p>1 1/4 inches (B)</p> Signup and view all the answers

What should be done if the rubber pads show large material chunks?

<p>They must be rejected (B)</p> Signup and view all the answers

What happens to the internal spring force when the wedge is cleared from the housing lug?

<p>It is released (A)</p> Signup and view all the answers

What must be locked about ¼ inch longer than the housing length to facilitate rear plate separation?

<p>The hydraulic ram (B)</p> Signup and view all the answers

What is the purpose of pre-shortening the RF-361 draft gear?

<p>To facilitate installation into the yoke and draft pocket (D)</p> Signup and view all the answers

What is the maximum internal spring force for a normally released Mark 50 draft gear?

<p>10,000 kg (A)</p> Signup and view all the answers

When inspecting draft gear at the ROH depot, what appears in a normally released condition?

<p>The housing is against the rear lugs (B)</p> Signup and view all the answers

What must be done to the draft gear approximately during its removal from the wagon pocket?

<p>Compress it by 6.35 mm (1/4') (B)</p> Signup and view all the answers

What is the required action for the external surfaces of the draft gear after pre-shortening?

<p>They are to be painted with black or blue paint (A)</p> Signup and view all the answers

What might indicate a normal fully released draft gear even if a slight gap is present?

<p>An enlarged draft gear pocket is present (D)</p> Signup and view all the answers

Which tool is used to check the pre-shortened length of the RF-361 draft gear?

<p>Gauge 27207 (D)</p> Signup and view all the answers

What is the initial condition of a draft gear when installed into a wagon pocket?

<p>It has ample initial spring load for a tight fit (B)</p> Signup and view all the answers

Which option is correct regarding the operation of the pre-shortening block?

<p>It applies a load to compress the gear (A)</p> Signup and view all the answers

In terms of maintenance protocols, what is a critical aspect when inspecting draft gear condition?

<p>Determine if the draft gear is in a normal released or stuck condition (D)</p> Signup and view all the answers

Flashcards

Guard Arm Distortion Checking

Using gauge No. 3 to check if guard arm is distorted. If points B or C touch while A is in contact, the coupler body needs replacing.

Guard Arm Distortion Limit

If guard arm distortion exceeds 4.8mm, it must be corrected to the original shape.

Stretched Knuckle Checking

Using gauge No. 4, check for stretched knuckles. Points A, B, and C should touch, and there should be a gap at point D.

Knuckle Stretch Renewing

If gap "D" closes during knuckle inspection, the knuckle needs replacing due to stretching.

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Knuckle Nose Wear Checking

Using gauge No. 4, check knuckle nose wear. Points E, F, and G contact, but point E must not pass through.

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Knuckle Nose Excessive Wear Renewing

If point E passes through during knuckle nose wear inspection, the knuckle needs replacing, due to excessive wear.

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Contour Gauge No. 3

Inspection gauge used to check for guard arm distortion after repair of outgoing wagons in a CBC unit. It's a "go/no-go" type gauge used in assembled condition.

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High Tensile Coupler

A coupler with higher yield strength than standard couplers.

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Draft Capacity

The maximum force a coupler can withstand during pulling.

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High Capacity Draft Gears

Draft gears designed for increased pulling force.

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RF-361 Draft Gear

A high capacity draft gear, self-contained and assembled with pre-compressed rubber.

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MK-50 Draft Gear

Another type of high-capacity draft gear.

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Coupler Body Grades

Different strength levels of coupler bodies (Gr.B, Gr.E).

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Knuckle

Part of the coupler that connects to other wagons.

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Yield Strength (Knuckle)

The maximum stress a coupler knuckle can bear without yielding.

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Standard CBC Couplers

A standard type of coupler for wagons; same dimensions as high tensile couplers.

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Alliance II Coupler Components

Parts of the Alliance II Coupler, a crucial component in railway wagons.

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High Capacity Draft Gear Specs

Technical specifications for strong railway wagon pulling mechanisms.

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Top Lock Lift Hole Cap

A secure cap for a specific hole used in lift systems for train wagons.

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Knuckle Pin with Washer

A connecting part of a railway wagon, a pin with a washer.

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Wagon Maintenance Manual - Chapter 8

A specific section detailing the maintenance procedures for the draw and buffing mechanisms on railway cars.

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Friction surface wear limit

Wear on friction surfaces must not exceed 0.8 mm (1/32 inch).

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Wedge defects

Wedges must be free from cracks, spalls, or excessive wear on the carburized case and locking lugs.

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Housing bore wear

Friction bore walls must be symmetrical and at least 20.6mm (13/16 inch) thick.

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Bottom ridging

Friction bores must not have any bottom ridging.

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Bore taper concavity

Bore taper must be smooth; concavity must not exceed 0.8mm (1/32 inch).

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Housing defects

Housing must be free from cracks, bulges, and pass specific gauges (27706, 27200, 27257).

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Assembly cleanliness

All parts must be free of oil, grease, and moisture for proper assembly.

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Shot-peening purpose

Wedges and shoes are shot-peened to remove rust, dirt, and create a better visual examination

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Sharp edges prohibition

Parts must not have sharp edges to prevent cutting and gouging.

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Assembly procedure

The assembly ring is placed first; then shoes,wedge, and assembly block are carefully put into position.

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Reconditioned Gear Creases

Acceptable imperfections in the form of creases and folds on reconditioned gears.

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Rubber Pad Bonding

Rubber pads must bond completely to the metal plates.

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Pad Surface Inspection

Rubber pad surfaces must be free from films, drops, and elastomer issues.

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Inspection Sprues Size

Inspection sprues must be at least 3.18 mm (1/8") below the steel plate surface.

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Pad Crack Inspection

Rubber pads must not contain cracks.

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Parting Line Flash Limit

Parting line flash on the pads should not exceed 0.78 mm (1/16").

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Foreign Material Check

Rubber pads must be free from foreign material like trapped air.

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Static Test Squeeze Height

Squeeze rubber pads to a height of 37 mm for bond failure, chunk, crack, and bubble inspection.

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Internal Follower Dimensions

Outside profile dimensions must be at least 11 1/4" x 7" (286mm x 178mm).

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Base Flatness Tolerance

Base of the follower must be flat within 1/16" (1.6mm) across diagonals.

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RF-361 Draft Gear Components

The RF-361 draft gear is composed of housing, wedge, shoes, bore inserts, top follower, rubber pads, and rear wall plate.

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RF-361 Housing Gauges

Gauges like 27200 Profile, 27706, and 27257 Flatness gauge are for inspecting the housing.

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RF-361 Shoe Gauges

Gauges 27253, 27254, 27298, and 27716 measure shoe dimensions.

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RF-361 Wedge Gauges

Wedge gauges (27215, 27216, 27266, and 27267) are used to inspect wedge dimensions.

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RF-361 Final Inspection Gauges

Final inspection uses gauges 27207 (pre-shortened assembled) and 27739 (box gauge).

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RF-361 Draft Gear Reconditioning

Reconditioning involves replacing the rear wall plate if the clutch is loose, housing is damaged, or weld is cracked, otherwise only clutch components are replaced.

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Loose Clutch Cause RF-361

A loose clutch in RF-361 draft gear may indicate defective rubber springs package or excessive wear on friction surfaces in the cylinder bore.

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High Tensile Coupler

A coupler with higher strength compared to standard couplers.

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Draft capacity

Maximum force a coupler can manage when pulling.

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High Capacity Draft Gear

Draft gears made to withstand greater pulling forces.

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RF-361 Draft Gear

A self-contained draft gear made with pre-compressed rubber.

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MK-50 Draft Gear

Another type of high-capacity draft gear.

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Coupler Body Grades

Different strength ratings for coupler bodies.

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Knuckle (Coupler)

The connecting part of a coupler.

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Yield Strength (Knuckle)

Maximum stress a knuckle can hold without permanent deformation.

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Standard CBC Couplers

A common type of coupler, having similar dimensions to high-tensile couplers.

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Mark-50 Draft Gear Inspection

Regular inspection of the Mark-50 draft gear is needed when the wagon is in the shop, being repaired, or draft gears are removed.

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Plate Clearance

The space between movable and stationary plates, indicating friction surface wear.

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Draft Gear Ineffectiveness

When the plate clearance reduces to zero, the draft gear loses its ability to cushion.

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Housing Gauges (Initial Inspection)

Gauges like BE-91/62-2 (minimum housing length), BE-91/62-1 (maximum housing clearance), BE-92/62-6 (minimum housing thickness) are used to assess housing suitability.

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Wedge Shoe Removal

Removing the wedge shoe is a step in disassembling the Mark-50 draft gear.

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Gear Reconditioning

A process to restore a gear to its original working condition, often necessary due to loose clutches or broken welds.

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Rear Wall Plate Removal

The rear wall plate must be removed from the gear housing for complete dis-assembly.

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Hydraulic Press Use

A hydraulic press is used to separate the rear wall from the housing, exerting a 10-ton force.

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Cutting Method

Rear wall plate cutting can involve abrasive cut-off wheel, sawing, or flame cutting, with proper ventilation.

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Rubber Pads Inspection

Inspect rubber pads for any tears, large chunks, or severe wear; check minimum size.

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Housing Wall Thickness

Housing wall thickness at the bottom must meet minimum specifications (11.9mm and 19.8mm).

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Pad Minimum Size

Rubber pads must be at least 2 1/8 inches measured at the middle of each side.

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Bent Steel Plates

Bent steel plates on rubber pads are acceptable if not broken or cracked, as they will straighten during assembly.

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Component Removal

Release the hydraulic ram to free the gear. Remove the rubber pads and internal follower from the housing.

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Housing Inspection

Inspect the housing for cracks, bulges and wall thickness, ensuring it meets minimum specifications.

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Pre-shortening RF-361 Draft Gear

Reducing the length of the assembled RF-361 draft gear before installation to ensure proper fit in the yoke and draft pocket.

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Pre-shortening Block

A specific block (Drawing no. 25658) used to compress the RF-361 gear during pre-shortening process.

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Pre-shortened Length Check

Verifying the reduced length of the RF-361 gear after compression using gauge 27207.

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Draft Gear Painting

Applying black or blue paint to the external surfaces of the pre-shortened draft gear.

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Normal Released Draft Gear

A draft gear in a working position, with the follower plate against front lugs, housing against the rear lugs, and friction clutch components in their neutral position.

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Draft Gear Inspection

Inspecting the draft gear when wagons enter the repair depot (ROH) to check its condition.

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Draft Gear Removal Compression

Compressing the draft gear approximately 6.35 mm (1/4 inch) when removing it from the wagon pocket.

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Draft Gear Stuck Condition

A condition where the draft gear is not in the normal released position, hindering its proper function.

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RF-361 Draft Gear Components

A complete draft gear with housing, wedge, shoes, inserts, followers, rubber pads, and rear plate.

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Draft Gear Inspection Gap

Small gaps may exist at either front or rear draft lugs during a normal full release of the unit, in larger draft gear pockets.

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Study Notes

Draw and Buffing Gear

  • Two main arrangements used on Broad Gauge wagons:
    • Older arrangement: screw coupling with side buffers
    • Conventional arrangement: Centre Buffer Coupler (CBC) transmitting draft and buffing loads
  • Older arrangement uses screw coupling, draw hook, and draw hook springs for draft load, and side buffers for buffing force
  • Conventional screw coupling (WA/BD-125) working load: 22.5 tonnes
  • Centre Buffer Coupler (CBC) adopted for BOX, BOXN and other new design wagons, higher capacity than older design
  • Knuckle type CBCs have working strength of 120 tonnes
  • Alliance-II coupler working strength: 54 tonnes
  • CBC has a transition version, with screw coupling and side buffers, allowing coupling with screw-coupled wagons
  • Conventional draw and buffing gear is phased out, details not included in this manual
  • Current use focuses on high-capacity CBC and draft gear (2002 manual for maintenance)
  • Indian Railways uses AAR type centre buffer couplers (E-type head, F-type shank) on BG freight stock.
  • AAR coupler draft capacity depends on knuckle strength (weakest link)
  • Material AAR M-201 Grade C and E yield strengths: 132t and 180t, respectively
  • Advantages of AAR Centre Buffer Coupler:
    • Coupler and buffing gear located at center of wagon
    • Identical at both ends, wagon direction immaterial
    • Automatic coupling action
    • Possible coupling with screw coupling via transition arrangement

Parts of Centre Buffer Coupler Assembly

  • Coupler body, Knuckle, Knuckle pivot pin, Lock, Knuckle thrower, Toggle, Universal lock lift lever connector, Lock lift lever hook, Lock lift rivet, etc.
  • Parts of non-transition coupler interchangeable with transition type coupler, except for striker casting/wear plate and coupler body/shank (longer in transition version).

Inspection of CBC

  • Coupler and operating mechanism inspection:
    • Check coupler operation through complete cycle (knuckle throw, lock set, lock-to-lock, locking)
    • Check for shank bending
    • Check shank wear plates, and replace if worn through
    • Check shank wear (if no wear plates), and weld if wear approaches 6.5mm
    • Inspect operating mechanism for free movement of parts
  • Inspect coupler head and fittings for cracks/damage. Use dry lubricants (water, alcohol, non-petroleum based carrier)
  • Only lubricate exposed surfaces of coupler and yoke.

Inspection of Draft Gears

  • Excessive slack in draft gears not permissible (25mm maximum)

Removal of Coupler and Draft Gear

  • Method for removing coupler and draft gear from wagons varies based on whether its loose in pocket or tight
  • Use conventional methods to remove parts like the yoke pin support plate and yoke pin

CBC Measuring Gauges and Their Applications

  • Gauges used for checking wear in guard arm, knuckle (face of CBC) for various issues.
  • Check guard arm expansion; renew knuckle components or lock if gauge passed
  • Check guard arm distortion; renew coupler body if gauge doesn't fit
  • Check stretched/worn knuckle; renew knuckle if gauge touches other parts
  • Check knuckle nose wear; renew knuckle if wear exceeds limit
  • Check knuckle lock-face wear; renew knuckle if gauge passes
  • Inspect anti-creep edge of bottom lifter; If gap, replace bottom lifter
  • Inspect anti-creep lug of rotary lever; renew rotary lever if gauge not properly fitting

High Tensile Coupler and High Capacity Draft Gear

  • Replaced grade C type coupler with grade E (high tensile) to reduce maintenance for heavy haul freight trains
  • A comparison of materials and strengths for grade C and E couplers is provided
  • Standard and high tensile CBCs are identical in dimension but high tensile couplers have higher capacity
  • Improved high-capacity draft gears (MK-50, RF-361, Miner SL-76) for increased capacity
  • Different models for freight and locomotive use

RF-361 Draft Gear

  • Fully enclosed, self-contained unit with pre-compressed rubber pads

List of Gauges for RF-361 Draft Gear

  • Providing a list of gauges for checking

Maintenance

  • Different inspection points and procedures for the various parts.
  • Complete reconditioning if required, including replacing rear wall plates if necessary or clutch components (shoes & wedges), or cracked weldings (of housing)

Dismantling Procedure

  • Procedures for removing components from draft gears (including shoes, wedges, and other related components)
  • Inspection of different parts (shoes, wedges, housing) procedures for various conditions

Welding of Rear Plate

  • Procedures for welding the rear wall plate to the draft gear housing

Static Test

  • Inspection of rubber pads, visual verification of parts for damage.

Removal of Stuck Draft Gear

  • Steps to remove stuck draft gears, suitable methods for loosening draft gears from wagon pockets/handles
  • Important step by step procedures

Summary of Action Plan

  • Actions to reduce train partings, including inspection, improvement, and replacement of components (especially knuckles, locks, and operating handles) and improving maintenance standards for CBC and draft gear are outlined.

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Description

This quiz covers the arrangements of draw and buffing gear used in Broad Gauge wagons, focusing on the transition from older screw coupling methods to the modern Centre Buffer Coupler (CBC). It highlights the specifications and working strengths of different coupling types and emphasizes the current practices in Indian Railways. Test your knowledge on these essential components of railway engineering!

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