Enhanced Draw Gear & Screw Couplings Upgrade
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Questions and Answers

What is the length of the new part head stock pressing that should be used for replacement?

  • 750 mm
  • 760 mm
  • 740 mm
  • 746 mm (correct)

    • What is the maximum permitted wear for the buffer spindle body?

  • 3 mm
  • 10 mm
  • 15 mm
  • 5 mm (correct)

    • Which of the following distances pertains to the earlier design of head stocks from the center of the buffer?

  • 86.5 ± 0.2 mm vertically
  • 60.3 ± 0.2 mm horizontally
  • 60.3 ± 0.2 mm vertically (correct)
  • 85.5 ± 0.2 mm horizontally

    • How many hex head bolts should be placed to secure the assembly of the buffer?

    <p>4 nos.</p> Signup and view all the answers

    What should be checked for bulging or corrosion before replacing components?

    <p>The destruction tube</p> Signup and view all the answers

    What is the maximum load test for draw bars manufactured from St. 60-61?

    <p>39.5 t</p> Signup and view all the answers

    What type of equipment is used to test draw bars for surface cracks?

    <p>Magna-glow equipment</p> Signup and view all the answers

    What is the suggested 'no go' gauge limit for the 45 mm diameter hole in draft yoke?

    <p>48 mm flat</p> Signup and view all the answers

    How much wear is acceptable on the seating of the draw bar?

    <p>4 mm</p> Signup and view all the answers

    What type of key should be checked for bending and wear?

    <p>Draft key</p> Signup and view all the answers

    When should stress relieving not be done according to the specifications?

    <p>For draw hooks manufactured from St. 60-61</p> Signup and view all the answers

    What is the diameter of the bush that has a suggested 'no go' gauge limit?

    <p>32 mm</p> Signup and view all the answers

    What is the wear limit for the bent link at the location of 47 mm?

    <p>2 mm</p> Signup and view all the answers

    At what diameter does a draw gear pin need to be replaced if it is worn more than the specified limit?

    <p>31 mm</p> Signup and view all the answers

    What is the suggested 'no-go gauge' for the worn out locating pins?

    <p>19 mm</p> Signup and view all the answers

    Which component's wear limit is specified as 6 mm?

    <p>Wearing piece</p> Signup and view all the answers

    If a 'U' gap on each arm of a bent link has a suggested no-go gauge of 85 mm, what is the wear limit?

    <p>3 mm</p> Signup and view all the answers

    What is the replacement recommendation for pins that are found damaged, bent, or worn?

    <p>Replace as necessary</p> Signup and view all the answers

    What is the suggested no-go gauge for a draw hook pin measuring 60 mm?

    <p>58 mm</p> Signup and view all the answers

    What diameter is specified for the cotter hole?

    <p>2 mm</p> Signup and view all the answers

    What is the wear limit for the knuckle component?

    <p>4 mm</p> Signup and view all the answers

    What main modification was made to the buffer casing to reduce stress levels?

    <p>Increased size of base and location of fixing holes</p> Signup and view all the answers

    What is the recommended periodicity for inspection and maintenance of the buffers?

    <p>Every POH</p> Signup and view all the answers

    What is the suggested wear limit for the buffer casing body wall thickness?

    <p>5.5 mm</p> Signup and view all the answers

    Which tool is mentioned for measuring the thickness of the buffer casing?

    <p>Micrometer</p> Signup and view all the answers

    Which document details the design specifications of the revised buffer casings?

    <p>RDSO SK 94043 and SK 94044</p> Signup and view all the answers

    For which actions should record keeping be maintained during maintenance?

    <p>All relevant activities including defects and repairs</p> Signup and view all the answers

    What is the diameter limit for the fixing hole on the base of the buffer casing?

    <p>26 mm</p> Signup and view all the answers

    What is the maximum acceptable wear measurement for the buffer plunger according to the reference drawings?

    <p>2 mm</p> Signup and view all the answers

    What is the correct first step in the dismantling process of the buffer assembly?

    <p>Take out the split pin</p> Signup and view all the answers

    What should be done with the split pins during the assembly of the recoil spring?

    <p>Insert and open the split pins to 90 degrees.</p> Signup and view all the answers

    What does the casing design conform to in terms of specifications?

    <p>IRS-M 10</p> Signup and view all the answers

    What is the correct projection range for the shoulder on the draw hook from the head stock?

    <p>92 mm – 120 mm</p> Signup and view all the answers

    What should be checked for proper condition during maintenance?

    <p>The draw gear, screw couplings, and draft key condition.</p> Signup and view all the answers

    What type of grease is recommended for lubricating the screw portion of the coupling?

    <p>Graphite grease or used roller bearing grease</p> Signup and view all the answers

    What should be done with unused screw couplings on the suspension hook?

    <p>Replace them</p> Signup and view all the answers

    What is the purpose of the wear plate fitted during reclamation?

    <p>To prevent rotation of the buffer spindle</p> Signup and view all the answers

    Which of these components should be procured from RDSO approved sources?

    <p>Rubber buffer pads</p> Signup and view all the answers

    What type of assembly should the new buffer be according to the specifications?

    <p>To SK 98145 specifications</p> Signup and view all the answers

    What is a crucial check after cleaning accumulated dirt during maintenance?

    <p>Inspect for proper condition of draft key and cotters.</p> Signup and view all the answers

    What should an integral face plate be provided for?

    <p>To prevent welding of the centre plug.</p> Signup and view all the answers

    What is the vertical distance from the center of the buffer to the hole's location in the current design of head stocks?

    <p>85.5 ± 0.2 mm</p> Signup and view all the answers

    What feature of the rubber buffer pad pack must be measured during maintenance?

    <p>Free height</p> Signup and view all the answers

    In the assembly of the buffer, what is the required action for the hex head bolts?

    <p>Insert split pins</p> Signup and view all the answers

    What is the purpose of depositing weld metal in elongated holes of the buffer spindle body?

    <p>To improve structural integrity</p> Signup and view all the answers

    What is the horizontal distance from the center of the buffer for the earlier head stock designs?

    <p>174.5 ± 0.2 mm</p> Signup and view all the answers

    What is the primary reason for upgrading the material of draw gear and screw coupling components to IS:5517 -93 Grade 35 Mn6M03?

    <p>To increase the breaking load</p> Signup and view all the answers

    Which statement accurately reflects the requirements for stress relieving in draw gear and screw couplings manufactured from IS 5517 steel?

    <p>Stress relieving should be avoided to maintain tensile properties</p> Signup and view all the answers

    What is the maximum capacity of the proof load testing machines required for these draw gear and screw coupling components?

    <p>150t</p> Signup and view all the answers

    What is the effect of repeated stress relieving on draw gear and screw couplings made from Stc. 60.61 VSM10661 steel?

    <p>Adversely affects the tensile properties</p> Signup and view all the answers

    When was the material for draw gear and screw couplings updated to enhance their load capabilities?

    <p>1998</p> Signup and view all the answers

    Which specifications apply to draw gear and screw coupling components introduced after the material upgrade?

    <p>C -9509 and C -9505</p> Signup and view all the answers

    What is the proof load capacity for draw gear and screw coupling components made from upgraded IS:5517 -93 materials?

    <p>75t</p> Signup and view all the answers

    What is the maximum load test for draw bars manufactured from steel to IS:5517?

    <p>60 t</p> Signup and view all the answers

    Which method is used for inspecting draw bars for surface cracks?

    <p>Magna-glow equipment</p> Signup and view all the answers

    According to the specifications, what wear limit for a draw hook's seating must be checked?

    <p>4 mm</p> Signup and view all the answers

    For a draft key, what specific condition should be checked during inspection?

    <p>Bending and wear</p> Signup and view all the answers

    What is the maximum specified wear limit for the 32 mm diameter bush?

    <p>1 mm</p> Signup and view all the answers

    In what manner should a worn 45 mm diameter hole be repaired if needed?

    <p>Welding and drilling to nominal size</p> Signup and view all the answers

    What is the suggested 'no-go' gauge limit for the draft yoke's 45 mm hole?

    <p>48 mm flat</p> Signup and view all the answers

    What minimum distance must be maintained between the inner edges of two holes on a component?

    <p>$171 + 0.5 - 0$ mm</p> Signup and view all the answers

    During a load test, what is the required condition of the draw bars after the test?

    <p>No permanent deformation allowed</p> Signup and view all the answers

    What is the suggested gauge for checking wear on the draw bar seating?

    <p>5 mm adjustable projection</p> Signup and view all the answers

    What is the maximum acceptable wear limit for the shank of a draft key?

    <p>3 mm</p> Signup and view all the answers

    Which component's threads should not be stress relieved according to the specifications?

    <p>Draft keys manufactured from IS:5517</p> Signup and view all the answers

    When renewing draft keys, what should be done to the contact area?

    <p>Round off the edges</p> Signup and view all the answers

    What should be used to check the thread profile of the components?

    <p>A snap gauge</p> Signup and view all the answers

    What is the size limit for rubber draft pads before they must be replaced?

    <p>Below 186 mm</p> Signup and view all the answers

    What modification was made to the buffer casing to enhance its capability?

    <p>Increase in size of base and fixing holes</p> Signup and view all the answers

    What should be done if castle nuts show signs of damage?

    <p>Replace them</p> Signup and view all the answers

    What type of draft key is specifically mentioned for stress relieving procedures?

    <p>Stc. 60-61 steel draft key</p> Signup and view all the answers

    What is the recommended periodicity for inspecting and maintaining buffers?

    <p>Every POH</p> Signup and view all the answers

    What is the suggested maximum wear limit for the buffer casing body wall thickness?

    <p>5.5 mm</p> Signup and view all the answers

    How often should rubber draft pads be changed?

    <p>Every alternate POH</p> Signup and view all the answers

    Which specific aspect of the buffer assembly is critical for maintaining structural integrity?

    <p>Correct positioning of fixing holes</p> Signup and view all the answers

    What is the gauge limit for the slot width on draft keys?

    <p>38 mm</p> Signup and view all the answers

    What should be documented when buffers are removed during maintenance?

    <p>Defects, repairs, and the coach details</p> Signup and view all the answers

    What diameter is recommended for the fixing hole in the buffer casing base?

    <p>28 mm</p> Signup and view all the answers

    What action is the first step in dismantling the buffer assembly?

    <p>Taking out the split pin and unscrewing the nuts</p> Signup and view all the answers

    What is the purpose of record keeping in the maintenance of buffers?

    <p>To maintain a history of usage and repairs</p> Signup and view all the answers

    How much is the suggested wear limit for the buffer plunger according to reference drawings?

    <p>2 mm</p> Signup and view all the answers

    What document contains details of the revised buffer casing designs?

    <p>Maintenance Manual</p> Signup and view all the answers

    Study Notes

    Enhanced Draw Gear & Screw Couplings

    • Enhanced draw gear and screw coupling components were previously made from Stc. 60.61 VSM10661 steel, designed for a proof load of 60 tonnes (both) and a breaking load of 108 tonnes and 112 tonnes respectively.
    • In 1998, the material was upgraded to IS:5517-93 Grade 35 Mn6M03, increasing the proof load to 75 tonnes (both) and the breaking load to 130 tonnes (both).
    • Specifications C-9509 and C-9505 apply to these upgraded draw gear and screw couplings.
    • Dimensions remain the same as the previous design.
    • Hot working/welding reclamation of these components (except the draft yoke) is prohibited due to poor weldability and inadequate infrastructure.
    • Proof load testing machines need a capacity of at least 100 tonnes (or 150 tonnes). Load increases gradually to the prescribed level, then held for 2 minutes before release.
    • Permanent set is measured by checking the component's dimensions before and after load application.
    • The material in the draw gear and screw coupling must be hardened and tempered.
    • Stress relieving should not routinely be done on screw couplings or draw gear manufactured from IS 5517 steel..
    • Stress relieving during maintenance can negatively impact tensile properties.

    Guidelines

    • Components (except the draft yoke) are heat-treated to achieve their load-bearing capacity.
    • Heating above 550°C is prohibited for these components.
    • Latest specified material is used for screw couplings.

    Draw Gear Maintenance

    • Pre-inspection: Visually inspect all components for dimensional distortions, surface defects (cracks, dents, pitting). Mark any components failing inspection for rejection. Pay close attention to yoke and draw gear pins for any signs of movement, breakage, or bending.
    • Dismantling: Remove draft keys, draw hooks, screw couplings and related parts.
    • Dismantle the draw hook beam and draft yoke if necessary.
    • Cleaning: Thoroughly clean all components using appropriate methods (e.g., Bosch tanks, hot water jets) to check for surface defects prior to inspection.

    Inspection & Maintenance in POH

    • Periodicity: Inspection is conducted every periodic overhaul (POH).
    • Record Keeping: Detailed records are kept of all inspection stages, including the coach from which components were removed, the nature of any repairs, and the coach onto which the serviced item was fitted. Reasons for rejection and the required repairs should be clearly stated.
    • Load Testing: Load testing of newly procured draw gear components is required before fitting.
    • Crack Detection: Crack detection is critical.
    • Records of each inspection stage must be documented, linking them with the specific coach. Also, clearly include reasons for rejection or repairs.

    Table 9.1, 9.2, 9.3; Wear Limits & Suggested Gauges (Tables)

    • Tables detail wear limits and corresponding suggested gauges for various components (Draw Gear, Draft Keys, etc.) and specific locations on these parts.

    Screw Coupling Maintenance

    • Rivets on screw couplings and straight links are cut off.
    • Screw and straight links are removed when necessary.
    • Components are inspected for wear, including distortion and cracks

    Buffer Maintenance

    • Description and Guidelines: Enhanced buffer capacity (1030 kg.m) complying with IRS-M 10 standards, is fitted on BG mainline coaches.
    • Drawings and Components: Table 9.8 provides the drawings and details of various buffer components.

    Inspection

    • Record keeping for the condition and history of each buffer system.
    • Dismantling: Removing the buffer assembly for inspection.
    • Cleaning: Cleaning all components to allow for defect identification.
    • Inspection: Visually inspecting all components for cracks as well as assessing locations for wear. Details of wear limits appear in various tables.

    Mounting of Buffers

    • Mounting Procedure: Detailed procedure for mounting the buffer on the coach, including headstock inspection and bolt placement.
    • Maintenance: Inspection for any slackness in the system, and maintaining consistent tightness in buffer bolts. Inspection for the existence of cracks and wear.

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    Related Documents

    Draw & Buffing Gear Maintenance Manual PDF

    Description

    This quiz focuses on the specifications and upgrades of enhanced draw gear and screw coupling components. It covers material differences, proof and breaking load capacities, and testing guidelines. Participants will gain knowledge about steel grades and their applications in industrial settings.

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