eMf 990I(Rev-2)

INDIAN RAILWAYS
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MAINTENANCE INSTRUCTIONS

For

ENHANCED DR.AW GEAR & SCREW COUPLINGS

Of

BG MAINLINE COACHES

(February-2004)

Resear~b Designs & Standards Organisation

, Lucknow 226 011
.' CMI 990 I (Rev 2)

A. Description & Guidelines

The instructions contained in this technical pamphlet apply to inspection & maintenance
in workshops & depots of Enhanced Capacity Draw Gear and Screw Couplings fitted on
reF type BG mainline coaches.

Description

Enhanced draw gear and screw coupling components were earlier manufactured from
Stc. 60.61 VSM10661 steel. The draw gear & screw couplings are designed for a proof
load of601 (both) and a breaking load of 108t & 112 t respectively.

In 1998,the material for the draw gear and screw coupling components has been
upgraded to IS5517-93 Grade 35 Mn6M03 to enhance the proofload to 701 (both) and a
hreaking load of 130 t (both). This was fimher enhanced to 75t(both) for proof load
testing instead of 701 (both) and accordingly spec.C-9505 and 9509 has been revised.
Specifications C-9509 and C - 9505 apply to these draw gear and screw coupling
respectively. The dimensions of these draw gear & screw couplings are the same as
earlier.

e evant drawmgs are !lIven he Iow:

RI
VSM10661 lS:5517-93
Stc.60-61 Gr.35Mn6M03
General Arrangement SK-79061 SK-99003
Draw Rook SK-79062 SK-99004
Draft Yoke SK-79 146 [CF Drg.-T-2-1-012
Draft Kev SK-79064 SK-99006
Draw bar and castle nut SK-79063 SK-99007
Rubber spring SK-KJ004 Specn. C-950 I(Rev.3)
Screw couolin. assly. SK-79067 SK-99001
Details of screw couplin,g SK-79068 SK-99002

Guidelines

The components, except draft yoke, are specially heat treated to achieve the load bearing
capacity. Hence these components should not be heated above 550°C. The latest
specified material for screw coupling and draw gear is 35 Mn6M03 to IS 5517-1993.
The material is required to be in hardened and tempered condition to achieve high tensile
and yield strength. Stress relieving during maintenance acts as tempering treatment and
there will be adverse effect on tensile propenies when every time stress relieving is done.
For screw couplings and draw gear manufactured from steel to IS:5517 the practice of
stress relieving in workshops should be dispensed with.

Due to poor weldability of these steels as weU as inadequate infrastructure in Railway

workshops for pre-& post-weld heat treatment, reclamation of these components (except
draft yoke) by hot working/welding is prohibited.

Page 20[8
 CMl9901 (Rev 2)

The poof load testing machines should have a capacity of applying loads upto a
maximum of lOOt • 1501. The load should be increased on the component gradually.
When the prescribed load is achieved, hold it for 2 minutes before gradually releasing the
load and checking for permanent set.

Measure permanent set by checking the distance across 2 marks on the components, as
far apart as possible, before and after application of load. 1t is preferable to have direct
indication of pennanent set, for higher productivity.

B. Inspedion & Maintenance in pon

Periodicity: Every POR.

Record-keeping : lnspeetion records should be kept for each inspection stage, relating
them to "the coach from which stripped & also the coach on which fitted after
maintenance. Reasons for rejection & repairs should be clearly mentioned.

Load testing and crack detection should be eamed out even on newly procured draw gear
components before fitting them on the coaches.

Draw Gear Maintenance

Ref Drawing: RDSO SK·79061 & SK·99003
Pre-inspection
Inspect all components visually for dimensional distortion and surface defects such as
crack, dent marks, pitting etc. Mark components failing in this check for rejection,

Special attention should be paid to the condition of the yoke & draw gear pins for signs
of creep motion. loose or bent/cracked pins. Elongated or worn out yoke holes should be
marked for repairs. Any welding cracks or distortion in the yoke should also be checked
visually.

Dismantling
Take out the draft key from the draw bars and the draw hook after straightening & pulling
out the draft key cotters.

Remove the draw hook along with the screw coupling.

Detach the screw coupling assembly from the draw hook by cutting off the snap head
rivet and removing the pin from the collar.

Remove the split pins and the castle nuts form the draw bar rear ends.

Remove the spring end plates, draft pads and parting plates and pull out both the draw
bars. .

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 eMI 990 I (Rev 2)

Dismantle the draw book heam by un-bolting it from the underframe.

Remove the draft yoke, if required in pre-inspection, by pulling out the draw gear pins,
using a puller.

Clean the components by any suitable metbod (Bosch tanks, hot water jets etc.) before
inspecting them for cracks, distortions, corrosion or wear. The detailed instructions for
inspection & repair of individual components are given below:-

Draw hook
Ref. Drg. ROSO SK- 79062 & 99004

Remove the scale, rust, work hardened layers and surface cracks, if any> by light
grinding/filing. Take care so that no grinding cracks or sharp edges are generated which
could act as stress raisers. Use dye-penetant test for checking surface cracks in case of
doubts.

Inspect the draw hook for deformations & cracks. The neck" its pin hole, and the slot are
vulnerable locations. Draw hooks worn beyond the maximum permissible wear laid
down in the table below should be scrapped: -
Location of wear Wear limit Suggested NO GO gauge
Root of hook near point of contract 13mm Profile gauge with IS mm
with beot Iiok adjustable oroiection
62 mm dia Din hole 3mm 65 mm flat
Bottom side of shank 56 mm height 15 mm 41 mm snaD
Draft kev slot 059 mm) 13mm 173 mm flat
38 mm width 2mm 40 mm flat
Hook opening 48 mm 5mm 46 mm GO
53 mm NO GO Dlug

Stress relieve the draw hooks manufactured from steel to 51. 60-61. Stress relieving
should not be done for draw hooks manufactured from steel to IS 5517.

Load Test draw hooks (Stc. 60-61) at 60 t and those oflS:5517 Gr. 35Mn6M03 at 75 t
respectively. There should be no permanent set after release of load.

Draw Bar
Ref. Drawings: ROSO SK- 79063 & SK- 99007

Check the draw bar for dimensional distortions and damaged threads. Also check for
wear on teo
hfill Owtnll Iocattons: ~
Location of wear Wear limit Suggested NO GO gauge
155mm draft key slot 9mm 164 nun snaD
39 mm shank bodv 3mm 36 mm snaD
Slot width 38 min 2mm 40 mm flat
Threads M39x3 I mm Thread profile

Page 40f8
 eMI 9901 (Rev 2)

Reject draw bars failing these standards. In acceptable draw bars, clean tbe threads and
ease them. Round offthe roots of threads at the slot.

Check the castle nuts for damaged threads, worn nut faces and threads visually. Replace
castle nuts if so,

Stress relieve the draw bars manufactured from steel to St 60-61. Stress relieving should
not be done for draw bars manufactured from steel to IS :5517

Test all draw bars by magna-glow equipment for surface cracks.

Load test draw bar (Stc. 60.61) at 39.5 t and those of (IS 5517 Gr. 35Mn6M03) at 601.
There should not be any permanent deformation.

Draft key

Ref Drawing: ROSa SK 79064 & SK- 99006

Check draft key for bending and for wear as given below:-

Location of wear Wear limit Sua.ested NO GO aau.e

Draw bar seating 139 nun 4mm Profile gauge witb 5 mm
adjustable projection
Draw hook seating 139 nun 4mm Profile gauge with 5 mm
adjustable projection
Thickness 36 mm 4mm 32 mmsnap.
Cotter hole 14 mm dia 2mm 16 mm olu!!.

Renew worn, misshaped draft keys. In acceptable draft keys, round off the contact area
with the draw bars & draw hook to remove ridges, pitting, etc. if any.

Stress relieve the draft key manufactured from steel to St,60-61. Stress relieving should
not be done for draft key manufactured from steel to IS: 5517

Rubber draft pads

Ref Drg. ROSa SK-K3004 & Spec. C-9501 (Rev.3)

Tbe rubber pads sbould invariably be changed as a set every alternate POH's. The sets
should not be formed from supplies from different supplies. Furthermore, the pads
should be checked every POR for bulging, pelishing or having got set to a length below
193 mm. Replace tbe pads (as a set) iffound defective.
\
Draft Yoke
Ref ICF Drawing No.ICFrr-2-1-0\2
Carry out detailed inspection, after removal and cleaning, for welding cracks, distortions
and wear as given in the table below:

Page 5 0/8
 eMf 990 I (Rev 2)

Component Wear location Wear limit Suggested NO GO gauges

Draft voke 45 mm dia hole 3mm 48 mm flat
Bush 32mm dia hole lmm 33mm flat

Rebuild the 45 mm dia hole by welding and drilling to the nominal .size, if",r,~~uired.
Ensure that the mmimum distance between the mner edges of the 2 holes IS 171 . mm.

Replace corroded, cracked or worn bushes.

Draw gear pin

Ref. Drawing: ICF/SK-2-I-016
Replace pins, found damaged, bent or worn more than 1 mrn anywhere on the nominal
diameter (31 mm).

Draw hook beam (Ref. ICF Drg. No. T-2-1-602 and RDSO SK-99034)
Check the following locations for wear:-

Wear location Wear limit Suggested NO GO gauge

Wearin~ piece 6mm snao gauge 12 mm thick.
Locating pins 25mm dia 6mm 19 mm snap

The wearing piece on the draw hook beam should be replaced ifwom or cracked.

The locating pins provided to restrict side-ways movement of the draw hook, should be
replaced if deficient, cracked or worn.

Screw coupling Maintenance

Ref. Drawings:SK-79067 & SK-99001 (Assembly)
SK-79068 & SK-99002 (Details)

Cut off rivets at both ends of screw and also rivets on trunnion for straight links and
remove screw and straight links.

Inspect the components for distortion, cracks or wear exceeding the limits below. In case
of doubt, dye-penetrant tests, may be used for confirming the presence/absence of cracks.

Component Wear location Wear limit Suggested NO GO

gauee
Straight link 61 mm dia hole 2mm 63 mm flat
Straight link 47 mm dia hole 2mm 49 mm flat
Bent link 42 mm dia stem 3mm 39 mm snaD
Bent link. -47 mm dia hole 2mm 49 mm flat
Bent link -78 mm 'U' gap 3 mm on each arm 77 mm to go 85 mm
NO GO gauge
Pin on draw hook 60 mm dia 2mm 58 mm flat
Screw 55 x 6.35 mm 1 mm K thread profile

Page 60f8
 CM! 990 I (Rev 2)

klthread I gauge
Trunnion LHIRH Thread I rnm K thread profile
Knuckle 55.635x6.35 gauge
Klthread
Trunnion LWRH 76 rnm thickness 4rnm 72 rnm snap
Knuckle
Trunnion LHIRH 46 rnm dia pin 2rnm 44 mm snap
Knuckle

Replace the worn out components. Replace both the trunnions if required. Remove
ridges, rust, notches etc. by grinding.

Stress relieve the screw couplings manufactured from steel to 8t 60-61.

Stress relieving should not be done for screw couplings manufactured from steel to
IS:55J7

Assemble the screw coupling as shown in SK-79067 & 99001.

Load test the screw coupling assemhly under proof load of 60 t (Stc. 60-61) and 75t
(IS:5517) respectively. There should not be any pennanent set.

Re-Filment OfDraw Gear On Coach

".
Ref Drawing: ROSa SK-7906l & SK-99003

Lubricate the wearing surfaces in the screw couplings, draw hooks and draw bars with
graphite grease or used Roller Bearing grease.

Place the draft yoke and secure it with draw gear pins. Place lock pins and splits pins in
the bracket and secure lock pin with split pin. Do not re-use split pins,

Position the draw hook beam on head stock and secure it with bolts and nuts as shown in
ICF/SK T-2-1-602.

Assemble the screw coupling with draw hook by inserting pin and rivet the pin.

Position the draw bars in the draft yoke and insert draw hook. Insert the draft Key in
draw bars and draw hook. Fit cotters in the draft key and bend them. Do not re-use
cotters.

Place a rubher draft pad pack (consisting of? pads) to STR No. C-9501 (Rev.3),4 nos of
3.15 rnm thick parting plates and 1 no. of 16 rnm thick spring end plate on each draw bar.
Thc free height of ruhher springs & parting plates should he 208 mm.

Tighten the castle nuts using a spanner to achieve a pre-compression of 193 nun length of
pack. This should he checked by a gauge.

Page 70f8
"
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eMI 9901 (Rev 2)

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•
Insert the split pins through the castle nuts and draw bars and open the spht pins to 90
degrees. Use new split pins always.

Ensure that the projection of the shoulder on the draw hook from the head stock is within
92 mm -120 mm.

C. Maintenance In Depots

Periodicity of inspection: as specified in BG Coach Maintenance Manual.

Periodicity of maintenance: as specified in BG Coach Maintenance Manual.

Check for proper condition of the draw gear and screw couplings, after cleaning the
accumulated dirt. Pay special attention to displaced draft key & it's cotters, draw bars
and condition of draft pads.

~ Lubricate the screw portion of the coupling and the area around the draw hook pin with
graphite grease or used roller bearing grease.

Always replace unused screw coupling on the suspension hook.

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