PART-III

S. No.

Part-III

Description Reference Date of issue 1. Maintenance schedule of coaching CBC. MC/BLB/CBC 30.10.2006 2. Interchangeable component of Semi

Permanent Couplers. MC/EMU/CBC 06.01.2009

3. Use of single piece design of bearing bolts for semi permanent coupler.

MC/EMU/CBC 23.06.2009

4. Maintenance instruction and manual of Crash Buffers and operating instructions & Check points of CBC.

MC/Crashworthiness 23.12.2020

5. Check list for investing train parting cases in passenger coaching stock.

MC/BLB/CBC 26.07.2010

6. Gauge for checking difference in height of coupler of SLR/LHB generator van and knuckle of Locomotive.

MC/BLB/CBC 26.07.2010

7. Guidelines for operation of CBC equipped coaches.

MC/BLB/CBC 31.07.2010

8. Use of modified vertical restrictor in CBC equipped power car and SLR

MC/BLB/CBC 10.09.2010

9. Drawing of key for locking of manual uncoupling device of H type tight lock CBC for coaches.

MC/BLB/CBC 19.11.2010

10. Introduction of double decker train over IR –announced by Hon’ble MR in railway budget 2011

MC/CB/AC/DD 08.06.2011

11. Checking of crack in shank of FTIL make AAR ‘H’ type Centre Buffer Coupler of main line coaches.

MC/BLB/CBC 30.09.2011

001 FAX 91-0522·245850091-0522-2450679

(IT""( :~.~Telegram 'RAILMANAK'

Lucknow

?:'&rtiRI Tele . 2451200 (PBX)

2450115{DID)

'L{PJf w<liT' - 'tR~J~~ .lfi7~ 'fl'l'O"l

~ - 226011Government of India - Ministry of Railway~

Research Designs & Standards OrganisationLucknow • 226 011

~ : 30.10.2006

lj'<.U ~. U~ fum;:;fr c:fif.:m, ~- 400 001.

2, 'i~ ~c:rit I-iTU~ ~t1, ~rlT ~ 700 001

3. ~ BU. <l~1 m~. ~ ~~ - 110 001.

4, 7,'tmur~, tTIqi' ~. 9 - 600 003,

5, ·,:'fiilul l1Ul ~c:lil. ~c:l f.1c:rr<P1, fum::c:~ - 500 071.

6 ?,fulJ] t¥ ~Ril. ~ ~'q. mlc:!WTfll - 700 043,

7 ~~.• fl~i!lg'l! - 273 012.

8, ~~~ ~. 4k1lqltl,~ - 781 011.

g q~ rc{il. ""1m. '~~ ~ 400 020.

10. lfCI"l1Ul~. ~ - 844 101.

11. t¥~ tfriJ,~ tcR ~. ~ (fll~(ffi. 'tl;:;;::~'Ii!l~Ij'l!I. ~. \'l"ttm - 751 016,

12. \1'"ffR l1Ul ~c:rir, ~rr ~ ,~RI~Ii1I~ - 211 001.

13. \mR qfillll ~RiI. ~ - 302 006.

14. ?1$'ur qft~ ~. ~ - 580 023.

15. rrftw1l'lt'-ll ~c:rir, ~B1Jx - 482 001

16. r:-fiilvT ~ llRl ~. 3fR '$~ ""''I'I~'''''''''''"l, RlC"iI'l!ilj'l! - 495 004.

17. ~Tj"'?M Ch-'ru Q'j~, 9 - 600 038.

18 B ~ rft;:r({\, ~. <nt['<'~ - 144 602.

Sub: Maintenance schedule of coaching CSC.Ref: CMI No. RDSO/2006/CG/CMI-01 dated 16.10.2006 circulated vi,;"

this office letter of even no. dated 17.10.2006.

There was slight misalignment and some errors in references in the tablesrelated to CSC Schedules on pages 4 to 6 of the above-referred CMI. Thecorrected pages are enclosed. The same may please be replaced in the copysent earlier. The inconvenience caused is regretted.

1 'I'Tl!<f;r~ f.'Rm; U1&l> ,oftFe.R'I/<litflM. mo <ffij 'Ci~ I2. irm:l 'ifl,$.~.~" il~ (fi[l'G8Cffi. ~ ~ll:1lfll·;;:I. ~ m<ffI ':l. 7501,~ - 560 075

Rcf.:CGW 0001 Date of Issue: 16.10.2006 eMI NO.(Red) Page no. I of X RDSO/2006/CG/CM I . 01

Re\'ision No. Nil.

INDIAN RAILWAYS

I,

I Control/ing OfficerI ,';igo<tlure: ~~.. ~c~ign<1lj=- __.J1\J..l~J~

SCHEU OLE OF INSPECTION AND MAINTENANCE

OF

TIGHTLOCK "H' TYPE CENTRE BUFFER COUPLERS

FITIEDON

INDIAN RAILWAYS PASSENGER COACHES

S.No. Month I Year of Revision I Page No. Reason forIssue Amendment Amendmen!..__.~

1. October 2006 0 NA First Issue ,J

ISSUED BYRESEARCH DESIGNS AND STANDARDS ORGANIZATION

MANAK NAGAR, LUCKNOW • 226011

.,,

Rcf.:CGW 0001(Rev.])

Date of Issue: 16.10.2006Page no. 4 01'8 (corrected)

eMI NO. ---'1RDS012006fCGfCM I - 01 ,Revision No. Nil.

3, Maintenance Schedule and Action

Action I Check Sheet ReferenceescSchedule-I APTA ASF !FAIVELEY

Rp·M- ,,002·98 ,,

------- -_.---'

a) Visual inspection of coupler Para Para 3.3 1Par8 ~~_____Jhead for damage 5.3

b) Visual inspection of knuckle for Para 3.3.1 Refer para Idamaae 3.3"1 of I\SFc) Checking of coupler operating Para 3.3.3 Para 5.4mechanism for damage, loosebolts etc.

d) Greasing of glide rod of Para 3.3.3 Para 5,dcoupler operating mechanism ($) -----_.-e) Checking of telltale recess for Para 33.2 Para 4 2 Iensuring proper coupling. clause 3 & i ,,

4 i I-,-_... I

f) Inspection of coupler Para 3.3.21 Para 5 ;: ~ ""l,carrier/supporting device and its Clause 1 & I,sDrinas for cracks and breakaae 2 Ig) Inspection of loose I broken / ~~lmissing nuts and bolts (M-16) ofcoupler pin support plate and ,draft oear suoDort plate

.~ .,. -i

5_1

I" "I

I" -1I)": !

I

esc a) All items of Schedule-ISchedule -II

- -b) Inspection of couplerassemblv bv qauqes: - ---_. -_.i) Checking of knuckle contour Gauge Gauge no ! F.'l"il,by contour maintenance gauge no. 31000 Para i@ 31000 3.3.7

Para 4.2ii) Checking of free slack in the Gauge Gauge no Paracontour by contour condemning no. 34100-1limit gauge. @ 34100-1 Para 3.3.9

Para4.5.1and4.5.2 _..J. _____

Rcf.:CGW 0001(l~ev.J)

Date of Issue: 16.10.2006I'agc IHI. 5 of 8 (corrccrt'd)

CMINO. --I

RIJSOI2006lCGIC~1I- 1/ 1Revision No. f\'i1.

Para5.5.2

iii) Checking of distortion of Gaugealigning wing pocket and guard no.arm by aligning wing limit 32600gauge@ and guard arm Para 4.3distortion gauge@.

Gauge no.32600 Para3.3.4 andGauge no. I36527-2 or36527-3 and IIpara 3.3.12

fc-===.,--~-c-====h==--1~e-=:==-=-=-+",,=-....jiv) Checking of vertical height of Gauge Gauge no. P-3ra Ialigning wing pocket and guard no. 34101-4 5.5.3arm by vertical height aligning 34101-4 Para 3.35wing pocket and guard arm Para 4.3gauge.@

Para55.4

no.v) Wear of aligning wing pocket Gauge Gaugeand guard arm to be checked by no. 44250-5vertical height condemning limit 44250-5 Para 3.3.6 I'

aligning wing pocket and guard Para 4.4 :'arm qauqe .@" ' J

I-"Vi~)~C~h"ec~k"i~ng""-o"'f"k"'nc-u"c;:-klC:e--=n"o"'se'-+-;G;-a:::u"'g"'e:--+rGC:aC-u"g"e--"n"o~ -p-ar8' -- I

wear and stretch limit by no. 34100-2A Para I 5.5 : i

knuckle nose wear and stretch 34100- 3.3.8 ilimit gauge @ 2A Para

4.5.3c) Inspection of anti-creepprotection

Para 33.11 Para 5.1

Para3.3.13and 5.2.1

Para 5.5

Vertical

d) Measurement of couplerheight 1105 mm from rail level -

e) Checking of proper locking

Reference pointcentre of knuckle

Ref ;J3rCi I,331},1

I,,,d .. 2 . t01 .~~",f I

I IPara 3310 -rRclpaia I

I 3.3.10 ofASF &5.5 of

I-;;-====== -+.==_b_=-:;-;=-+.A"'P,.;T,;__f) Cleaning of CBCs Para 6 Para 3.3.1.1 Ref Para

3.3.1 1 ofASF and I

para fi 'J: r

APT;, 'I-g:::)"C"h"'e"c"'k"'in"'g--o"'f----;f"'u"'ncCCtCCioc-n"'a"'lt-,P"a"'ra:-;;3-+"Pc-a-ra~2~.1-&;;-c2;-.-;;2+, ~P'--:ar<i 4'-- _.:operation of coupler i I

j

r;;R-et;-',:-;('C:C"".,,,,.,-,0"'0;C;0'"'1----r;;n-'C-"-'-:')-:I-ss-u-c-:-;\76-.1"0C".2"0"0"6-T"":'C""M"'C"N"07.""'.----·~I

(I{l'\'.~) 1',lgC no. 6 of 8 (corrected) RDS0I2006/CC/Ci\'1I ·01Revision No. Nil. I

h) Checking of operation of Para 3.3.3 Para 5.4coupler operating mechanism

_._-,i) Modification of locking screw I,,as per ROSO's drawing no. CG- I 1

K6036 I______J

Faiveley

'-'=;----,----;;-7-"""-=;--.,-;-=-.,--.,-----,------;;--.,.--.,-.,--:-=--------,CSC Action I Check Sheet ReferenceSchedule- APTA ASFIII RP·M-

002-98a) All items of Schedule-I & II

Paras 3.8&5

Ref para IPara 5.25.2 ofFaivelev i i

'---1Para Para 3 I61.12 J

Para 6.1

f) Checking of excessive wear of Para 5.5lock of knuckle, pivot pin of knuckleand knuckle support pin

b) All parts of esc and alliedaccessories to be dismantled asper removal procedure and to becleaned and overhauled asdescribed in attached MaintenanceManual.

g) Damage of draft gear rubberpads and its checking for pre­compression valueh) Final assembly be made as perorocedure

iI1

1 If-C).,-.,-V.,-is-u-a""l-iC-n-s-pe-c-:t.,-io-n-cbC"e-m-ac-dc--e---;-fo-r+----~C=la-u-sC"e--;5+'"Re-f---i

cracks, damage, distortions etc. of para I Clause 5 I6.1.1.1 I of para I

6.1.1.1 of IASF ---I

~d-;)c--C""hc--e-c""k.,-in-g-w-e-a-r-o""f7to-g-g7Ie-.""lo-C7k""l-;ift+------+-,PC"a-ra--+"'R"'ef;-para Ilever etc. 6.1.1.1 6.1.1.1 of 1

ASF !~e')""C""hLec-c:;k"'inLg=-0:;fC--C-w7e::a::r--=oTf-c::o'u"p"-le::r+'P""aLr"a-:5'."2-l-c='ac-u"s"e--;6'-!-.';::Rc'e'i-~ .-- -I

shank wear plate. ~f. Para I (',~ausl'; __~~ I,).3.1 101 Dell", •

1

3:;1 'Jf 'ASF and IPara 5.2 (of APTA I

Para Ref I6.1.1.1 6.111 0l

I ASF

Ih·f,;CGW 000 I Date of Issue: 16.10.2006 CMI NO.(Iled) Page no. 2 of 8 IlDSO/2006/CG/CMI - 01

Revision No. Nil.

CONTENTS

S.NO. DESCRIPTION PAGENO.

1. SCOPE 32. MAINTENANCE FREQUENCY 33. MAINTENANCE SCHEDULE AND ACTION 44. NOTES 7

Ref.:CCW 0001 Dalc of Issue: 16.10.2006 CMf NO.(1{('\' ..3 ) I):age nn. 3 of 8 RDSOl2006/CGICM I • 0 I

Revision No. Nil.

SCHEUDLE OF INSPECTION AND MAINTENANCE OF TIGHTLOCK 'H' TYPE CSCsFITTED ON INDIAN RAILWAYS PASSENGER COACHES

1. Scope

This document deals with the maintenance aspects of CSGs fitted on passenger coaches ofIndian Railways, These GSGs are procured as per ROSa specification G~KOOg (Rev.1). Thedetailed design is of the manufacturer only.

Since these couplers are manufactured as per patented drawings of APTA and themanufacturers. the details of maintenance procedure to be followed should be as per themaintenance manuals provided by the manufacturers and APTA, attached as Annexures A. S &C.

Following documents are enclosed as Annexures A. S & C.

Annexure 'A' ~Majntenance Manual of Faiveley Transport India ltd. (previously SASWASCO)

Annexure 'S' ~MaintenanceManual of ASF/Keystone/USA.Annexure 'C' -APTA- Recommended practice for inspection and maintenance of type H

tight lock couplers - APTA RP- M·002-ga. Rp·M·004-ga.

2. Schedule And Maintenance Frequency

The schedule and set of activities to be followed depending on the state of GSC and coachshould be as follows: ~

SI. Position of CSC Freauencv As er UsaaeNo. Coupler Schedule LHS Coach ICF Rajdhani/ ICF Mail!

Shatabdi # EXDress01. Coupled (in rake I Each trip Each trip Each trip

formation)02. Uncoupled (Single II 18 months * IOH "C"

coach) Schedule03. Dismounted from III 6 years 6 years 6 years

coach anddisassembled

# For future reference when CBCs are introduced in ICF Rajdhani! Shatabdi rakes

18 months is the frequency of Shop Schedule I as per Railway Soard's letter no,95/M(C)/141/(LHS) PI. Dated 22.a.2006.

Rcf.,CGW 0001 nate of Issue; 16 .10.2006 eMf NO.(Rev.J) P:lge 110. 4 of 8 RDSO/2006/CG/CM I - U1

Revision No. Nil.

3. Maintenance Schedule and Action

Action I Check Sheet ReferenceCBCSchedule-I APTA ASF FAIVELEY

RP·M·002·98

a) Visual inspection of coupler Para Para 3.3.1 Para 5.1head for damaae 5.3b) Visual inspection of knuckle for Para 3.3.1 Para 5.4damaaec) Checking of coupler operating Para 3.3.3 Para 5.4mechanism for damage, loosebolts etc.

d) Greasing of glide rod of Para 3.3.3 Para 5.4coupler aperatinQ mechanism ($)e) Checking of telltale recess for Para 3.3.2 Para 4.2ensuring proper coupling. clause 3 &

4f) Inspection of coupler Para 3.3.2 Para 5.3carrier/supporting device and its Clause 1 &sprinqs for cracks and breakaq€ 2 --g) Inspection of loose I broken Imissing nuts and bolts (M-16) ofcoupler pin support plate anddraft aear sUDDart Dlate

CBC a) All items of Schedule-ISchedule -II b) Inspection of coupler

assembly by Qauqes: -i) Checking of knuckle contour Gauge no. 31000 Para 4.2

I ~ contour maintenance gauge

ii) Checking of free slack in the Gauge Gauge no. Para 5.1contour by contour condemning no. 31000 Paralimit gauge. @ 34100-1 3.3.7

Para4.5.1and4.5.2

iii) Checking of distortion of Gauge Gauge no. Para 5.1aligning wing pocket and guard no. 34100-1arm by aligning wing limit 32600 Para 3.3.9gauge@ and guard arm Para 4.3distortion gauge@.

Rcf.:CGW 0001(I{l'\'.~)

Date of Issue: 16.10.2006Page no. 5 of 8

CMINO. IRDSO/2006/CGtCMI -III I

I{evision No. Nil. i

iv) Checking of vertical height of Gauge Gauge no. Paraaligning wing pocket and guard no. 32600 Para 5.5.2arm by vertical height aligning 34101-4 3.3.4 andwing pocket and guard arm Para 4.3 Gauge no.gauge.@ 36527-2 or

36527-3 andoara 3.3.12

v) Wear of aligning wing pocket Gauge Gauge no. Paraand guard arm to be checked by no. 34101-4 5.5.3 andvertical height condemning limit 44250-5 Para 3.3.5 5.5.4aligning wing pocket and guard Para 4.4arm oauoe .@vi) Checking of knuckle nose Gauge Gauge no. Refwear and stretch limit by no. 44250-5 Gaugeknuckle nose wear and stretch 34100- Para 3.3.6 no.limit gauge @ 2A Para 44250-5

4.5.3 Para3.3.6 ofASF

c) Inspection of anti-creep Gauge no. Paraprotection 34100-2A Para 5.51

3.3.8d) Measurement of coupler Para 3.3.11 Para 5 1height 1105 mm from rail level -

Reference point - Verticalcentre of knuckle

e) Checking of proper locking Para 5.5 Para3.3.13 Ref paraand 5.2.1 3.313

and 1.2.1of ASF

f) Cleaning of CSCs Para 6 Para 3.3.10 Ref para I

3.3.10 ofASF &5.5 ofAPTA

glChecking of functional Para 3 Para 3.3.1.1 Ref Paraoperation of coupler 3.3.1.1 of

ASF andpara 6 ofAPTA

hi Checking of operation of Para 2.2 Para 4coupler operating mechanism

J

Ret'.:CCW 0001 Date of Issue: 16.10.200(, CMt NO.(Red) Page no. 6 of 8 R()SOIl006/CG/CMI - 01

Revision No. Nil.

i) Modification of locking screw Para 3.3.3 Para 5.4as per ROSO's drawing no. CG-K6036

CBCSchedule­III

Action I Check SheetAPTARP-M­002·98

a) All items of Schedule-I & II

ReferenceASF Faiveley

b) All parts of CBC and alliedaccessories to be dismantled asper removal procedure and to becleaned and overhauled asdescribed in attached MaintenanceManual.

c) Visual inspection be made forcracks, damage, distortions etc.

d) Checking wear of toggle. lock liftlever etc.

e) Checking of wear of coupler Para 5.2shank wear plate.

f) Checking of excessive wear of Para 5,5lock of knuckle, pivot pin of knuckleand knuckle support ping) Damage of draft gear rubberpads and its checking for pre­compression valueh) Final assembly be made as perprocedurei) Checking of functional operation Para 3.5of couDler

Para 6.1

Clause 5of para6.1.11

Para6.1.1.1

Clause 6of Para3.3.1

Para6.1.1.1

Ref para5.2 ofFaivelevPara6.1.1.2Para 2.1

Paras 3.8&5

RefClause 5of para6.1.1.1 ofASFRef para6.1.1.1 ofASFRefClause 6of para3.3.1 ofASF andPara 5.2of APTARef6.11.1 ofASFPara 5.2

Para 3

Para 4

1~('f.:CGW 11001(Rn.3)

Note:

Dall' of Issue: 16 .10.2006Page no. 7 of 8

CM) NO. IRHSOl20061CGICMl - III iRevision No. Nil. :

1. At! the above-mentioned actions are common for all makes of GBGs. Wherever detailsare given in the manufacturers' or APTA manual, references have been given. Absenceof reference to relevant para of manufacturers or APTA's manual does no\ mean that theactivity is not required for the concerned make of GBG.

2.

3.

i)ii)iii)iv)v)VI)

4.

5.

($) Once in 3 months or earlier if needed.

@ The following gauges are shop-issue-size gauges and not condemning gauges:

Contour maintenance gaugeContour condemn'lng limit gauge.Aligning wing limit gaugeVertical height aligning wing pocket and guard arm gaugeKnuckle nose wear and stretch limit gaugeVertical height condemning limit aligning wing pocket and guard arm gauge.

The gauges should only be procured from the suppliers of complete CSC assemblies,

As given in para 8.2 of APTA RP-M-004-98, no painting should be done on any part orthe assembly after overhaul except where specifically advised by ROSO.

6. Only dry lubrication as per paras 4.2 and 8.3 of RP-M-004-98 should be done inSchedule III.

7. Reconditioning procedure of coupler should be followed as per Para 5 of APTA - RP-M­004 98. As mentioned in APTA - RP-M-004-98 Para 2.3. knuckles. locks. knucklethrowers, knuckle pivot pins, rotary lock life assemblies and coupler pivot pins shOUld notbe reconditioned.

8. Following instructions to be followed for welding and heat treatment processes duringreconditioning of couplers. {Reference: paras 4.1 and 4.2 of G-80 (inspection andmaintenance instructions for center buffer couplers used in freight cars) issued byROSO}.

8.1 Weld repair and straightening

8.1.1 Repairs of components may be made by welding using qualified welders andprocedures as per IS specification IS: 7318 (Part I) latest revision, in the down handposition.

8.1.2 All defects must be removed prior to weld repair.

8.1.3 Casting may be uniformly or locally preheated to a temperature between 150 deg. Cand 320 deg. C to ensure crack free welds. Under no condition welding beperformed when casting temperature is below 150 deg. C or above 320 deg. C.

••

"

. '.

Rcf.:CGW 00111 Dale of Issue: 16.10.2006 CMINO.(Rev.J) Page no. 8 of 8 RIlSO/2006/CG/CMI - 01

Revision No. Nil.

8.1.4 Repair welding shall be performed with low hydrogen, coated electrodes or by gasshielded welding process. Weld deposits shall provide properties equivalent to theproperties of finished castings.

8.1.5 Heat treatment is required after weld repair or straightening.

8.2 Heat Treatment

8.2.1 After heating for straightening prior to heat treatment, components shall be allowedto cool to a temperature below 538 deg. C at a rate that will not be injurious to thecastings.

8.2.2 Heal castings in the furnace so that the castings' entire body attains a temperature of900 deg C and keep at this temperature for a minimum of 20 minutes.

8.2.3 Remove castings from furnace and in less than 1 minute, submerge them completelyin moving or agitated water of 65 deg. C max. at start of the quenching. Holdcastings under water until cooled below 204 deg C.

8.2.4 Remove castings from water and as soon as possible heat them to 571 deg. C. Holdthe casting at this temperature for a minimum of 2 hrs. A higher temperaturA may benecessary to attain a Brinell hardness of 241-311. The casting must be re-quenchedand tempered if it is too soft and re-tempered, if it is too hard.

)

•

8.2.5 All castings shall necessarily be tempered as soon as possible to prevent cracking,but in no case shall the time between quenching and tempering exceed 8 hrs.

8.2.6 Cool the castings in still shop air.

8.3 Finish

8.3.1 Surface discontinuities resulting from weld repairs or service upset or servicenotches must be contoured and matched to the surrounding surfaces bygrinding.

8.3.2 All components must be cleaned sufficiently for proper inspection,rectamation and operation. Coupler must not be sand or shot blasted whenassembled .

8.3.3 Component must be free from cracks, fractures, sections broken out, servicenotches in the critical areas.

W V S I FAY. 91-0522-';4;.J500 % ~~~ 'TnTT-n-*4 't 91-0522-;&0670

+$\ q e ~ m af%xm Jk ZmK mc aT7 :~~ & WZRS - 226011 Telcgranl : 'RAILMANAK', Govsrnrnenl of India - Ministry of Railways 'iY

Lucknow &h%~/ ?e!e

I Y . z ~ . ~ 1::);: Research Designs B Standards : 2451 200 (PeX) Lucknow - 226 011 -

24401 15 (DID)

MCIEMUICBC ,$%LA( 1'%773 :06.01.09

T- T, 5- - - F + 4

ar rkm (nRm,Rya T& .i) : 1. % 4 ~ & . & % W 8 Z % P 3 , ~ - 4 0 0 0 0 1 .

5 3 q a f 5 2, @ w, d;vm &, d?GFi - 700 001.

3. m3 m, & m, 7 6 R.* - I10 001~

4 &?l && T d ZWI , - BCO 003. 5 T b l Ti4 kd h - d q , - 500 071.

6 dpr? $ $?i?T ~lT??3 -$h, 3?;lisihlfl - 700 043~

7. phi? w, 'lkT3~ - 273 012.

.1:"- 8. k R , I , I 701 011

0 {rflqrr .h+4, ~ c I ~ I s , 2 ~ s -~ 4 0 3 om, 1 0 ' $ q T kh, L* - 844 7 G : .

11 @ ?&4 $&, $&! ??67 w ? , 5-*, -1, a@-?, &RIl - 751 016

12 rr;m 9 4 M, &ii h ,q.?mr;: - 217 coi. 13. W? t6&, - 30% 006. 1 *I T k P l ?*, cm - 580 02s $5. J iks 9 ~ 4 S d , m q 3 - 482 OK

16. &I 11:) TA w, X7;1\7 2 3 1 % ~ iljl~lrcffl7, kfRv - 495 W4. 17. 3&<6i &il ~?kfi, i > ~ $ - 500 038

l a . h ?h w., $Tv, 37?W - 144 602

Sub . Interchanyeablc components of semi permanent couplers . . I( ,! c'' Ref: (i )L?y CME~NL2lliqr:l SCK letter l o . M.44. WS.Coach Alter Insln.Spec.350 dated 04.8.2008 !-L..-- .---

(ii) CEE(RS)/CR leuer no.L.531.P.SI.A dated 01.9.2008 1 I :.!~ (iii) AEMEIGenl.ltiqrs.lSCR letter no. M.44.WS.Coach Altcrlnstn.Spec.330'dated 23.9.08 8.06.1 1.08

4 . , 1 > 5 ./liX With the lr?tlers referred above the issues raised about interchangeability of different sub assemblies

of Schaku semi-permanent couolers. Please refer this office letter dated 27.04.2007 of ever) no. earlier issued& \Vestern Railway (copy enclosed) in lhis regard.

. . -7 00

. . , ( \ I . . . " --I P- a3

DA -As above (3m;;T ?am) 0 , .- .;,,\ : ,>:\\?,;: .>,;f i / .q!,>,4) 1: <,I,

CODY:

(i ) Dy. CMEIWSIHqrs officeiRail NilayamlSecundrabadi SCR (ii) CEE(RS)ICEEI HQ olficelParcel Rldg. 2°6 flooriMumbai CSTjCR (iii) AEMEIGenl.lHqrs.1 Rail Nilayam,Secundrabadi SCR - 3 , 6. --t

(m w

&%?TI FAX

T1T3;

Telegram

?8i+/ Tele

: 91-0522-2458500

91-0522-2450679

:** m : 'RAILMANAK',

Lucknow : 2451200 (PBX)

24501 15 (DID)

mTm5r-krn a 7 t h m -+ m +Im V353 - 226011

Government of India - Ministry of Railways Research Designs 8 Standards

Lucknow - 226 011

9ur %, ~ e d ? ? # k 7 *- 400 001.

$ m. $ZI???l Fh'. &GIiRll - 700 001. . m%, mm. *m - 110 001.

+I id, wd m:, -+=I$ - GOO 003.

dbl a4 m. hl m. h f Z ? F J R - 500 071.

Z f h $ w. TI& *. &GIiRll - 700 043.

k&. ThZIy - 273 012.

3ifrln m. m, - 781 011.

& %. *, @ - 400 020.

$ W w, W%J? - 844 101.

$ TEh -%. *& k? d. &, m, m, &h - 751 016.

m mw. *jT& .mrmK- 211 001.

3Ei? * *, - 302 006.

Z f h * m. - 580 023.

d$W T4 w. q- 482 001. &PI $ 9ur Wr, 3m $ w f h &, f k q - 495 004.

F%W $Z@. - GOO 038 -h ;h w. m, -?TI - 144 602

Sub : Use of single piece design of bearing bolts for semi permanent coupler ~ a \ & , ~ e f : M h WSF, Kolkata note no. WSFIPSIRCF1177 dated 09,032009

I I

m In view of repeated cases of failures of welded bearing bolts it is advised to sto&

the use welded bearing bolts and to use only the single piece design and arrange t g replace the existing welded bearing bolt to single piece design.

It is also advised to segregate the two-piece design bearing bolts and dispose suitably to prevent mixing with single piece. -

h / F a x : 91-0522-2458500 lgnaFim7-hm m : '~~ qfim;rmiTsftrmd.ra;r Telegram : 'RAILMANAK', Lucknow FMF5 - 226 01 1 -/Tele : 2451200(PBX) Government of India - Min~stty of Railways

2450567 (DID) Research Designs & Standards Organisation Lucknow - 226 01 1

h

No. MCICBIACIDD

-/m Dated: 08.06.201 1

Sub: Introduction of double decker trains over IR -Announcement made by Hon'ble MR in the Railway Budget 201 1.

Ref: i) Railway Board's letter no. 2006/CEDO/SR/8 dt. 05.09.2006 ii) This office letter no. MCICBIACIDD dated 04.01 . I0

In compliance to Hon'ble MR's announcement of introducing double decker train in JP-Delhi and ADI-Mumbai route while presenting Railway Budget of 2011, AC Double Decker coaches presently under manufacture at Rail coach factory, Kapurthala are expected to be ready to put in service by the end of this year. The coaches have higher height and may require removal of infringements on existing fix structures to enable their operation.

A) Issues related with infringements wi th fixed structure except platform -

This issue can be resolved in following two ways.

Option I

Indian Railways SOD Rev 2004 Chapter I Para 8(ii) stipulates following dimensions of fixed structure (Except Platform) -

03

(a) From 305mm above rail level to 1065 mm - 1905 mm lncreaslng to 23&m (b) From 1065 mm above rail level to 3355 mm 2380 mm --I (c) From 3355 mm above rail level to 4420 mm - 2360 mm decreasing to 2 1 8 r n m

The clause is applicable for new works or alteration of existing works. The flxed structures altered as per this dimensions will provide adequate clearance not only to the proposed AC Double Decker coach but also to future coaches of higher height.

Option II

Railways on the basis of loading gauge or kinematic envelope of higher height Garibrath and AC Double Decker Coach have been requested vide letter at reference ii) above to remove infringements on existing structures to enable operation of Garibrath (of higher height) and AC Double Decker trains: Th_eextentfvv~~~?eededforrremovaIIIo~ inf!ngementis%~ected to be less in this option. A write-up on how to ensure the requisite clearance along with RDSO Sketch No CG-11040 is enclosed.

B) Issues related with infringements with platform - The body of double decker coach extends below platform level. It is important to ensure that platform coping distance from centre line of the track is maintained as per provision in Indian Railways SOD Rev 2004 Chapter II Para 3(ii). It specifies following dimensions-

(a) Horizontal distance from centerline of the track to face of passenger1 goods platform coping

Maximum - 1680 mm Minimum - 1670 mm

(b) Horizontal distance from centerline of the track to face of any platform wall.

Maximum - 1905 mm Minimum - 1675 mm

(c) New platform walls should be built to maximum dimensions and the coping corbelled out to 1675 mm.

All the above dimensions are specified for straight platforms. Curve platforms require extra clearance. A guideline for provision of extra clearance is provided in annexure-l of IR SOD Rev 2004. Extra clearance shown in Annexure-l of SOD is only for guidance and it is required to be worked out on the basis of actual super elevation provided on the curved platform line.

AC Double Decker train is being introduced for the first time in Howrah-Dhanbad section. During the trial in Howrah-Dhanbad section, it was found that platform coping distance from centerline of the track were not maintained as per the SOD and ER had to undertake massive work of modifying platform coping.

In view of this, Railways are advised to ensure removal of infringement as specified above well in advance for timely introduction of AC Double Decker Train. Also. Railways are requested to provide following information on inside curved platform between the proposed route of JP-Delhi and ADI-Mumbai section. co, .

Cr, Station Name

(A)

Any Permanent Speed Restriction. If yes, speed in kmph

Platform

1. 2.

Degree of Curve

Cant E l h t i o n -i erg r-B

rn

The data is required for inside curved platform only and it will be used for analysis of clearance between coach body and platform coping.

Apart from conducting regular COCR in the section, RDSO may conduct trials for platform clearance once written confirmation of maintaining platform coping distance from centerline of the track is received from Railways.

Encl.: As above. p (Anand Swaroop) Director Carriage

For Director General (Carriage)

"U Copy to: i) EDMEICoaching, Railway Board, New Delhi.

ii) CMEs of NR, NWR and WR Railways. iii) ED/Trap-I, RDSO, Lucknow.

/

Clearance Car

A clearance car is a type of rail car for maintenance of way service. It's purpose is to check the clearances around the tracks and ensure that trains conforming to the loading gauge or kinematic envelope will not encounter any obstruction.

A simple clearance car may consist of an outline of the system loading gauge1 Kinematic envelop attached to a coach or a wagon, which could be towed along the route to ensure the clearances were still sufficient.

Modern clearance car uses lasers for measurement of three dimensional position of fixed structure. It is understood that personnel of Engineering Department of Railways have been trained in the past (Year 2006-07) for laser based measurement of three dimensional position of fixed structure.

A simple clearance car consists of a wooden outline.

RDSO has made a drawing of kinematic envelop (Drawing No - CG-11040) of Proposed AC Double Decker Coach. &

-e r; Railways were requested to remove infringements on existing structuresto enable operat ioh

of AC Double Decker trains vide ED/Track/RDS07s letter no: ~ ~ 1 ~ ~ ~ 1 3 I ~ o a c h e s dateflO 08.06.07 and the same was reiterated vide RDSO letter no MCICBIACIDD 04.01.10. Th? kinematic envelop shown in the new drawing is within that of advised earlier.

The profile of wooden outline has been made in such a way that when clearly passed on straight line in quasi static condition, the minimum side (excluding platform) and overhead clearance required for running AC Double Decker trains is ensured. The wooden outline when placed longitudinally in middle of a rolling stock having bogie centre distance between 14785mm and 14900rnm (LHBIICF), will approximately take care of requirement of extra clearance as per provision in SOD on inside curve. Similarly, the wooden outline when

- ~ - -~ placed-Iongitudinallyattheend~ofICF c o a c h ~ v v i l l ~ ~ x i m a t e l y take care of requirement of

extra clearance on outside curve. AC Double Decker coach (length equal to that of LHB coach) though longer than ICF coach has same requirement of extra clearance on outside curve. +--f'

(Anand Swaroop) Director ICarriagelRDSO

F Or TRACK \

NOTE: - -~ , 1. POSITION OF A - 2000 W o l MOVE R A I L LEVEL FROM CENTRE L INE OF THE TRACK. CX3 2. TliE KINEMATIC PROFILE I S SYMMETRIC PROM TliE MIOOLE. d 3. KINEMATIC ENMLOPE INCLUDES BOTH THE SHEOEO AREAS. 4. I T MAY NOT BE POSSIBLE 1 0 INCLUDE UPPER SHEDED PAEA FOR CHECKING

INFRINGEMENTS UNDER L I V E CONOUCTOR OF OHE. 5. THE MAXIMUM HEIOHT OF LOWER SHEOEO AREA HA3 BEEN KEPT 4500 nn FROM

R A I L LEVEL. SSUMING 4800 mn MlNlWJM HEIQHT OF CONOUCTOR OF OHE ON0 APPROXIMATELY 300 #.MINIMUM CLEIIRPNCE REOUIRED. I N CASE THE M l M l W M HEIGHT OF CONDUCTOR IS LOYER THW 4800 mn THE SHEOEO RREA IS ~ E E D E O TO BE MODIFIED ACCORDINOLY.