PRESCRIBED MAINTENANCE: CBC LHB VS CBC WAGON

LHB COACH CBC INSTRUCTIONS WAGON CBC INSTRUCTIONS

ASSEMBLY
COMPONENT PREVENTIVE MAINTENANCE INSTRUCTIONS AS AS PER OPERATION AND MAINTENANCE MANUAL WAGON COUPLER MAINTENANCE INSTRUCTIONS
PER LHB COACH MAINTENANCE MANUAL FAIVELEY

KNUCKLE -Inspect knuckle pin bearing bosses and pulling face for The maintenance of the coupler head in general is Contour Gauge is used for checking of wear in the
cracks or broken sections or bent shank. If any damage described in the AAR manual “Standard for Periodic guard arm and knuckle face of CBC. All wagons coming
is found, replace knuckle. Inspection and Maintenance of Passenger Coaches for ROH or POH are checked by this “not go” gauge
-The Contour maintenance gauge is used to inspect APTA M-002-98” CHECKING OF STRETCHED KNUCKLE
for correctness of contour. If the gauge does not seat - Inspection of automatic coupler head (every 3 Application of Knuckle stretch and Nose wear gauge.
against the front face of the coupler, there is excessivemonth) includes the following: To check if Knuckle is stretched
wear to the front face of the coupler or a stretched - Visually examine the coupler head. CHECKING THE KNUCKLE NOSE WEAR
knuckle. Remove and inspect the knuckle, using the - Coat bare steel areas of coupler head body and Apply Knuckle stretch and Nose wear gauge to check
Knuckle Nose Wear gauge. knuckle with Molykote D321R (or equivalent) dry Excessive knuckle nose wear
-The Contour condemning limit gauge no. 34100-1 is lubricant spray. CHECKING THE KNUCKLE LOCKING FACE
used to inspect limit of contour slack (limit has been set
CAUTION: Under no circumstances spray lubricate Apply the gauge no. 5. Excessive wear at locking face of
at 3/8 inch). The gauge must not pass between the front the lock, lock lift lever or knuckle locking faces as the Knuckle.
face of the coupler head and the pulling face of the this will allow the lock to be "squeezed" upwards and
knuckle. If the gauge does pass, remove the knuckle may lead to uncoupling!
and inspect once more for wear. If the knuckle is worn, In addition to the 3 month activities carry out the
replace knuckle. While the knuckle is out of the following every 1 year:
coupler, inspect the knuckle pivot pin and pivot pin - Jaw gap gauge test
hole for excessive wear. If the knuckle pivot pin is - Knuckle profile gauge check
worn, replace knuckle pivot pin. If the knuckle pivot Check for free slack in the contour of the coupler
pin and pivot pin hole are in acceptable condition, the using the “Inspector Contour Gauge - II”
lock could be worn and should be replaced. Also, the 228943W14.
front face of the coupler could have excessive wear and - If the coupler contour exceeds limit of the gauge, it
should be replaced if found worn out. indicates that knuckle may need replacement.
-Knuckle Nose Wear and Stretch Limit: IF KNCKLE - Check with “Condemning limit gauge 228965W14
DOESN’T PASS THIS GAUGE, replace the knuckle. (old no. D228009- 100), if the gap exceeds limit of
-To inspect lock on knuckle tail shelf, make sure the the gauge, the knuckle shall be replaced.
coupler lock is seated not more then 1/8 inch. above the - If this replacement does not bring the coupler into
knuckle tail shelf,(preferably seated on the shelf. See limits, the lock may be replaced.
“S” in figure). If adjustment is necessary metal should - If this replacement does not bring the coupler into
be removed from guard arm (non tapered) side of lock limits, the coupler body must be replaced.
by grinding preferably by machining. The amount of
metal to be removed is 1/8 inch the distance the lock is
to be lowered.

LOCK The lock must drop freely to the locked position when CHECKING OF LOCK WEAR
& the knuckle is fully closed. There is a combined wear of lock at knuckle contacting
LOCK LIFT surface & engagement surface with coupler body. LOCK
ASSEMBLY WEAR GAUGE is used to check wear of lock at
knuckle.
KNUCKLE 1.Inspect for bent or broken uncoupling mechanism. If
THROWER uncoupling mechanism is broken, replace.
 2.Check for proper operating rod eye clearance as
follows: a. Close and lock the coupler and knuckle. b.
Ensure coupler is centered in the carrier. c. Measure
clearance between the rod eye and lock lift lever. d.
Proper clearance should be 1/8 inch to ¼ inch.
3.If operating rod eye clearance is not correct, heat the
coupler-operating rod to “cherry red” color and adjust
with 2 pipe wrenches.
4. Check socket cap screw for free movement, if not
break free and lubricate.
5. Check square tubing for smooth sliding from side to
side, if not lubricate.
KNUCKLE PIN Inspect knuckle pin. Ensure cotter pin is secure in the CHECKING OF KNUCKLE PIN HOLE
pivot pin. If worn more than 25%, replace pivot pin and Pin hole is checked by this gauge for wear limit
cotter pin. (Compare pin thickness to thinnest part of
wear for an estimate.) The pivot pin‟s original diameter
is 1-5/8 inches. CHECKING OF KNUCKLE PIN PROTECTION
Knuckle pin hole protection limit is checked with the
help of this gauge to avoid breakage .
SUPPORT PIN Inspect support pin (6). Ensure cotter pin (7) is secure
in support pin. Original diameter of the support pin is
5/8 inch, if worn more than 25% replace support pin
and/or cotter pin. (Compare pin thickness to thinnest
part of wear for estimate).
SHANK WEAR Check coupler shank wear plate for wear. If shank wear Procedure for building up the wear on coupler CHECKING OF SHANK HEIGHT WITH WEAR
PLATE plate is worn more than 3/16 inch, the coupler should shank PLATE GAUGE
be replaced; The coupler shank is welded with a wear plate in the Shank wear gauge: wear in the plate is checked with this
Check the thickness of wear plate. If needed, remove supporting area, made of manganese steel. This plate gauge
the wear plate from the support beam and add a new is the contact area of the coupler shank to the coupler
plate to the beam by welding support device. In case of wear, the worn plate can be
removed and substituted by a new one. Welding
procedure commonly adopted in the railway industry
for wear plate replacement is also recommended for
this application.
COUPLER Inspect the coupler body sidewall and pin bearing CHECKING OF SHANK LENGTH
HEAD BODY Shank length is checked by a gauge
bosses for cracks, broken sections or bent shank. If any
damage is found, replace the coupler. CHECKING OF SHANK HEIGHT WITH WEAR PLATE GAUGE
Shank height with wear plate gauge

ANTI CREEP Anti–creep protection is the front of overlap between - Anti creep check
TEST the toggle and the anti–creep shoulder on couplers. Determine anti-creep protection and ensure it
Perform following steps to inspect for proper complies with specifications.
anti–creep protection:
1.inspection for anti–creep protection is made through
the front of the coupler.
 2.With the coupler in the locked position insert a pry
bar through the front of the coupler between the
knuckle tail shelf and lock, forcing the lock upward.
3.Forcing the lock upward as far as it will go engages
the top of the toggle with the bottom of the knuckle tail
shelf
4.Insert a pry bar between the leg of the lock and the
front of the lock hole. Pull toward the front of the
coupler to force the lock leg rearward.
5.If the front edge of the toggle is 1/8” or more forward
of the rear corner of the knuckle tail shelf the anti-creep
is unacceptable; replace lock lift assembly
6.If an actual measurement is desired, inscribe a line on
top of the toggle along the rear face of the knuckle tail
shelf. Measure at point “C”, the measurement must not
be less than 3/8”.
TELLTALE Check that the telltale recess is not obstructed. If found
RECESS obstructed, look for defective uncoupling mechanism or
broken lock. Replace damaged parts as necessary.
GUARD ARM -The aligning wing limit gauge is used to inspect for CHECKING OF GUARD ARM EXPANSION
& excessive distortion of guard arm of the coupler head. Contour Gauge is used for checking of wear in guard arm
COUPLER The gauge must seat against the front face of the and knuckle face of CBC. All wagons coming for ROH
WING
coupler head and the pivot lug and clear at all points or POH are checked by this “not go” gauge
around the interlocking lug guard arm face and lateral CHECKING OF GUARD ARM DISTORTION
aligning surface. If the gauge does not seat or clear at If guard arm distortion is more than 4.8 mm, it should be
the proper locations, there is excessive wear to the front closed into normal
face and pivot lug or distortion to the guard arm or
interlocking lug. Remove and replace the coupler.
-The vertical height aligning wing pocket and guard arm
gauge AND vertical height condemning limit aligning
wing wear and Guard arm gauge are used to inspect
for excessive distortion and vertical height of Aligning Wing
and/or Guard Arm of the coupler head. The gauge must pass
(slide into) the wing pocket and over the guard arm. If the
gauge does not pass, there is vertical distortion to the wing
pocket and/or guard arm. Remove and replace the coupler.

DRAFT GEAR REFERENCE: RDSO DRAFT_GENERAL Maintenance of draft gear has to be done together with A.Excessive slack in draft gears is not permitted and this
OVERHAULING OF BALANCED DRAFT the inspection of the whole coupler. should be either reduced or eliminated. The maximum
The following actions are needed: permissible free slack in the draft gear is 25 mm(1") after
GEARS(REVERTED-CORRECTED) - Visually examine the draft gear (every 3 month)
which, it shall be removed and reclaimed or condemned.
● Complete Overhauling of the draft gear should be - Check the Miner spring column during the main
overhaul (6 to 8 years) for mechanical damage and The free slack can be determined by first sledging the
done at SS-III schedule in six yearly basis. coupler back solid and then measuring the clearance
pre-load value.
- Replace spring column in case of mechanical damage between the coupler horn and the striker face. N
or change in preload value. B.Visual examination of the rubber pads & coil springs
when the draft gear is in place in the wagon can be

RUBBER PADS
● Elastomeric pads: Check for damage,
excess wear & preset so that it has loosen
the pre-compression value of 20-35 kN at
assembled height OR there is play in their
mounted area.
● Preload testing: For testing the
pre-compression/preload value, put
the BDG on same fixture before
dismounting. New pads are
recommended as BDG will be open
next 6 years’ basis.
● Scragging: If new pads are not
scragged earlier at supplier end then
Balanced Draft Gear assembly should
be given 75% of its functional
stroke/travel during assembling
three-four times in fixture on Hydraulic
press.
○
COMPONENTS
● Check for any wear, crack and damage
(generally not occurred) replace by new one
if found damaged by visually and NDT
(Ultrasonic testing-ASTM-A388 &Die
penetrating test-ASTM E165)
misleading and the draft gears shall therefore be
inspected at every POH of the wagon, irrespective of the
amount of free slack existing
Inspection of Rubber padsI.Reject pads which show
tears, large material chunks, large bond failures, or
extreme wear into the steel plate edges.
II.Pads are gauged and must not be less than 2 1/8” (54
mm) as measured by a gap gauge at the middle of each
side.
III.Bent (but not broken or cracked) steel plates are
acceptable as these will straighten during assembly.
IV.Creases and folds are normal and are acceptable for
reconditioned gears.
V.VISUAL INSPECTION OF RUBBER PADSi.Full
bonding to each of the metal is required. ii.Top and
bottom surfaces of plates must be free of elastomer films
or drops. iii.Inspection sprues must be 3.18 mm or 1/8"
min. below the steel plate surface. iv.Pad must be free
from cracks. v.Parting line flash should not exceed
0.78mm or 1/16". vi.Elastomeric material should be free
from foreign material i.e., trapped air etc. vii.Check for
proper markings.
INSPECTION OF COMPONENTS
SHOES: The shoe, which has to be reused must be free
from the following defects. No concave wear on any
friction surface No cracks or spalls No wear more than
0.8 mm or 1/32" on any friction surface II. WEDGE: The
wedges which have to be re-used must be free from the
following defects.
No crack or spall of the carburized case on the friction
faces or the top of the wedge. No wear more than 0.8 mm
or 1/32" on the friction surface. No indication of broken
or any cracks on any of the locking lugs. III. HOUSING
OR CYLINDERS: The inside friction bore walls must be
worn symmetrical and the wall thickness must not be less
than 20.6 mm or 13/16" There must not be any bottom
ridging in the bore.
SUPPORTING Maintenance of the supporting device
DEVICE Maintenance of supporting device has to be done
together with the inspection of the whole coupler. The
following actions are needed:
- Visually examine the supporting device (every 3
month)
- Check the compression springs during the main
overhaul (6 to 8 years)
- Check the thickness of wear plate. If needed remove
the wear plate from the support beam and add a new
plate to the beam by tack welding
- Replace the compression springs in case of
mechanical damage and loss of preload.
MANUAL Maintenance of manual uncoupling device has to be
UNCOUPLING done together with the inspection of the whole
DEVICE coupler. The following actions are needed:
- Visually examine the manual uncoupling device and
add grease on slide rods (every 3 month)
- Check the wear of the uncoupling rods during the
annual inspection (every year)
- Check the wear of the uncoupling rods and the
bearings during the main overhaul (6 to 8 years)
- Replace the uncoupling rods in case of excessive
wear
INSTALLED Operate the coupler operating mechanism to ensure the ● it is important to check when the coupler
ASSEMBLY/M knuckle (1) opens when the coupler-operating rod is operating mechanism is operated to fully open
ECHANISM raised to the top position; the knuckle, and the knuckle is slowly closed,
CHECK the lock drops freely and the mechanism
Clean dirt/ grime from coupler assembly; Inspect to
ensure that the train lines or other attachments do not returns to fully locked position.
interfere with coupler during operation. If piping or ● Only dry lubricant shall be applied to the
brackets are bent and out of alignment, straighten or coupler head or the coupler head fittings.
replace. ● When in the transition Centre Buffer Coupler,
the knuckle does not move freely, grind the top
face of "top pulling lug" and "lock face" of
knuckle in position.
● Inspection of couplers, whilst fitted to wagons,
should be made to ensure proper coupling any
position which it can assume during train
operation.