Maintenance Practices & Manual For POH of Schaku Couplers: 2019-20 8/1.0 October 2019

i
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
शाकू कप्ऱर के लऱए अनुरऺण

प्रेक्टिस एवम ऩी ओ एच मेनुअऱ
Maintenance Practices &
Manual for POH of Schaku Couplers
कैमिे क/एम/प्रोज/2019-20/एमऩी8/1.0
अटिूबर 2019
CAMTECH/M/PROJ/2019-20/MP8/1.0
October 2019
Maharajpur, Gwalior (M.P.) - 474005

ii
शाकू कप्ऱर के लऱए अनुरऺण

प्रेक्टिस एवम ऩी ओ एच मेनुअऱ
Maintenance Practices &
Manual for POH of Schaku Couplers
कैमिे क/एम/प्रोज/2019-20/एमऩी8/1.0
अटिूबर 2019
CAMTECH/M/PROJ/2019-20/MP8/1.0
October 2019
i
FOREWORD
Semi-Permanent Coupler (Schaku Coupler) play an important role in running of
DEMU/EMU. The failure of Semi-Permanent Coupler (Schaku Coupler has a great
impact on the reliability of the DEMU/EMU. This Manual has been prepared for
Supervisors and artisan staff of DEMU/EMU sheds and workshops who are involved
in the maintenance of Semi-Permanent Coupler (Schaku Coupler). This Manual not
only cover maintenance of Semi-Permanent Coupler (Schaku Coupler) but care has
been taken to explain basic things including its storage and handling. All
information of components has been covered in this Manual. The book is also
useful for newly appointed artisan. With these important features, I am sure that
the handbook will give necessary help to the concerned staff to ensure problem
free service of the Schaku Coupler.
CAMTECH is continuously making efforts in documentation and up-

gradation of information on advanced maintenance practices. This document
contains a Maintenance practices, types of Schaku Coupler and their salient
features etc. being used on Indian Railways.
I am confident that the information given in this Maintenance manual will

help field staff of Mechanical department in improving their knowledge as well as
in correct and efficient maintenance of Schaku Coupler in their Sheds/Workshops.
CAMTECH Lucknow Jitendra Singh

Date: 30.10.2019 Principal Executive Director
ii
PREFACE
The importance of Schaku Couplers cannot be denied in the efficient
operation of DEMU/EMU in railways. On Indian Railways Schaku Couplers have
replaced conventional at a large number of Diesel car Shed and workshops due to
their wide applications and safety reasons. In the current scenario, Schaku Couplers
of different approved manufacturers have been installed in Indian Railways.
To refresh the knowledge of staff involved in maintenance of Schaku

Couplers, CAMTECH has prepared this maintenance Manual which consists of
Maintenance aspects of different approved manufacturers. This manual is also
consist of description of components and their availably to ensure the reliability
and availability to achieve the correct maintenance of Schaku Couplers.
We are sincerely thankful to Officers and supervisors of North Central

Railway, West Central Railway, Central railway and Western Railway and all the
manufactures of Schaku Couplers who helped us in preparing this manual.
Since technological upgradation and learning is a continuous process, you

may feel the need for some addition/modification in this question bank. If so,
please give your comments on email address dirmech@gmail.com or write to us at
Indian Railways Centre for Advanced Maintenance Technology, In front of Adityaz
Hotel, Airport Road, Maharajpur, Gwalior (M.P.) 474005.
CAMTECH Gwalior Manoj Kumar

Date: 30.10.2019. Joint Director (Mechanical)
iii
Contents
Section Sub- Section Pages

Description
Foreword i
Preface ii
Contents iii
Correction Slip iv
Disclaimer & Our objective v
CAMTECH Publications vi
1 - Introduction 1
2 - Type of Coupler 1
3 Salient features of Semi-Permanent Coupler 1
3.1 Escorts 1
3.2 Sanrok 2
3.3 Westing House 2
3.4 Blue Bird 3
Main Parts of Semi-Permanent Coupler 4
4.0
4.1 Main Sub Assemblies of Semi-Permanent Coupler 4
4.1.1 Coupler – End ‘A’ 4
4.1.2 Coupler- End ‘B’ 5
4.2 Features of Semi-Permanent Coupler 6
4.3 Description & Functional Features of Sub Assemblies 6
4.3.1 Bearing Bracket (Used both in End ‘A’ & End ‘B’) 6
4.3.2 Draw and buffing gear (Used both in End ‘A’ & End ‘B’
7
4.3.3 Intermediate Tube (Used both in End ‘A’ & End ‘B’)
8
4.3.4 Air Pipe Coupling (Used both in End ’A’ & End ‘B’)
9
4.3.5 Centering Device (Used only in End ‘B’)
9
4.3.6 Adjustable Cup Sleeve (Used only in End ’A’)
10
4.3.7 Center Adjustment Device (Used both in End ‘A’ & End ‘B’)
4.4 Maintenance Schedules
11
4.4.1 Trip schedule to “C” schedule 12
4.5 Periodically Overhauling 12
4.5.1 Overhauling Procedures 12
4.5.2 Polyamide bushes 12
4.5.3 Bearing Bracket with Support 12
4.5.4 Draw and Buffer gear 12
4.5.5 Lower & upper Cup-sleeves 13
4.5.6 Spring sleeves 13
4.5.7 Intermediate tube sub assembly 13
4.5.8 Painting & Assembly 13
Inspection and Replacement of Components and Sub assemblies 13
5.0
5.1 Inspection and replacement of components of Main Bracket / Bearing 13
Bracket with support drg. No 2ED-181-1001 {SCHAKU DRG. NO. 40-
iv
588.07(2)}
5.2 Inspection and replacement of components of Draft Gear / Draw and 14
Buff Gear drawing No. 2ED-181-1011 {SCHAKU DRG. NO. 40-586.06(2)}
Fixtures and method of use
5.2.1 Fixtures and Method of Using 14
5.2.1.1 Fixture for pressing Articulation Bearing (Fixture Drawing No. SE-F- 14
134)
5.2.1.2 Procedure for assembly of Draft Gear/ Draw & Buff Gear 16
5.2.1.3 Method of using the fixture for Draft Gear / Draw & Buff Gear sub 23
assy.
5.3 Inspection and replacement of components of Centering Device drg. 23
No 2ED-181-1006 { SCHAKU Drg. No. 40-1000.10(2)}
5.3.1 Method of using the assembly fixture for Centering Device (Fixture 23
Drawing No. SE-F-135)
5.4 Inspection and replacement of components of Intermediate Tube Drg. 24
No 2ED-181-1004 {SCHAKU 40-586.01:01(2)}.
5.4.1 Device for removal of bearing bolt (Fixture Drawing No. SE-F-140) 24
- Lubrication Scheme
6.0 27
7.0 Spring Condemning Criteria
27
8.0 Tools and Gauges for Maintenance
8.1
27
For Depot
8.2 27
For Workshop
28
9.0 Tools, Fixtures and Gauges & method of using gauges
9.1 28
Pressing Method of using the Fixture and the Articulation Bearing
9.2 Assembly Fixture For Draw & Buff Gear
9.3 28
Method of Using the Fixture for Draw & Buff gear Sub-assy.
9.4 28
Method of Using the Assembly Fixture for Centering Device
- 38
10.0 Part List & Recommended percentage of Holding for POH 39
-
11.0 Rejectable defects 41
v
सुधार ऩर्चियों को जारी करना
ISSUE OF CORRECTION SLIPS
इस प्रश्न फैंक के लरए बविष्म भें जायी की जाने िारी सुधाय ऩर्चिमों के क्रभाॊक इस प्रकाय से यहें ग:े
The correction slips to be issued in future for this question bank will be numbered as follows:
केमिे क/एम/प्रोज/2019-20/एमऩी 8/1.0 # XX दि .................
CAMTECH/M/PROJ/2019-20/MP8/1.0# XX date .......
जहाॊ “XX” सम्फॊर्धत सधु ाय ऩची की क्रभ सॊख्मा है (01 से शरू ु होकय)
Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).
सुधार ऩचीयाॉ जारी की गयीॊ
CORRECTION SLIPS ISSUED
सुधाय ऩची की क्रभ जायी कयने सॊशोर्धत ऩष्ृ ठ क्रभाॊक टिप्ऩणिमाॉ Remarks
सॊख्मा की तायीख एिॊ भद सॊख्मा
Sr. No. of Date of Page no. and Item No.

Correction issue modified
Slip
vi
डिस्कटऱेमर
मह स्ऩष्ि ककमा जाता है कक इस हस्तऩस्ु स्तका भें दी गमी जानकायी, ये रिे फोर्ि प्रकाशनों तथा आय र्ी एस
ओ प्रकाशनों के ककसी बी ितिभान आरेखों को विस्थावऩत नहीॊ कयतीॊ है | मह दस्तािेज िैधाननक नहीॊ है
ियन इसभें टदए गए ननदे श केिर भागि दशिन हे तु हैं | मटद ककसी बफन्द ु ऩय वियोधाबास दृष्िीगोचय होता
है , तफ ये रिे फोर्ि प्रकाशनों, आय र्ी एस ओ भागिदशिन अथिा जोनर ये रिे के ननदे शों का ऩारन कयें |
DISCLAIMER
It is clarified that the information given in this handbook does not supersede any
existing provisions laid down in the Railway Board and RDSO publications. This
document is not statuary and instructions given are for the purpose of guidance
only. If at any point contradiction is observed, then Railway Board/RDSO guidelines
may be referred or prevalent Zonal Railways instructions may be followed.
----------------------------------------------------------------------------------------------------
हमारा उद्िे श्य
अनयु ऺि प्रौद्मोर्गकी औय कामिप्रिारी का उन्नमन कयना तथा उत्ऩादकता औय ये रिे की ऩरयसम्ऩवि एिॊ
जनशस्तत के ननष्ऩादन भें सध
ु ाय कयना स्जससे अॊतवििषमों भें विश्िसनीमता , उऩमोर्गता औय दऺता प्राप्त
की जा सके |
OUR OBJECTIVE
To upgrade Maintenance Technologies and Methodologies and achieve
improvement in Productivity and Performance of all Railway assets and manpower
which inter-alia would cover Reliability, Availability and Utilisation.
मटद आऩ इस सन्दबि भें कोई विचाय औय सझ
ु ाि दे ना चाहते हैं तो कृऩमा हभें इस ऩते ऩय लरखें :
सॊऩकि सत्र
ू : सॊमत
ु त ननदे शक (माॊबत्रक)
ऩत्राचाय का ऩता : बायतीम ये र उच्च अनयु ऺि प्रौद्मोर्गकी केंद्र,
भहायाजऩयु , ग्िालरमय (भ. प्र.) वऩन कोर् 474020
िे रीपोन : 0751-2470890
पैतस : 0751-2470841
ई-भेर : dirmech@gmail.com
If you have any suggestion & any specific comments, please write to us:
Contact person : Joint Director (Mechanical)
Postal Address : Centre for Advanced Maintenance Technology, Maharajpur,
Gwalior (M.P.) Pin Code – 474 020
Phone : 0751 - 2470890
Fax : 0751 – 2470841
Email : dirmechh@gmail.com
vii
कैमिे क प्रकाशन CAMTECH Publications

CAMTECH is continuing its efforts in the documentation and up-gradation of information on maintenance
practices of Signalling & Telecom assets. Over the years a large number of publications on Signalling &
Telecom subjects have been prepared in the form of handbooks, pocket books, pamphlets and video films.
These publications have been uploaded on the internet as well as railnet.
For downloading these publications
On Internet:
Visit www.rdso.indianrailways.gov.in
Go to Directorates → CAMTECH → OtherImportant Links→ Publications for download → Mechanical
Engineering
Or http://www.rdso.indianrailways.gov.in/view_section.jsp?lang=0&id=0,2,17,5025
On Railnet:
Visit RDSO website at 10.100.2.19
Go to Directorates → CAMTECH → Publications → Mechanical Engineering
Or http://10.100.2.19/camtech/Publications/CAMTECH%20Publications%20Online/CAMTECHMain.htm
A limited number of publications in hard copy are also available in CAMTECH library which can be got
issued by deputing staff with official letter from controllong officer. The letter should be addressed to Joint
Director (Mechanical), CAMTECH, Gwalior.
For any further information regarding publications please contact:
Joint Director (Mechanical) – 0751-2470890 (O)(BSNL)

SSE/Mechanical - 8989473656
Or
Email at dirmech@gmail.com
Or
FAX to 0751-2470841 (BSNL)
Or
Write at
Joint Director (Mechanical)
Indian Railways Centre for Advanced Maintenance Technology,
In front of Hotel Adityaz, Airport Road, Maharajpur,
Gwalior (M.P.) 474005
CAMTECH/M/PROJ/19-20/MP8 1
Maintenance Practices and manual of SCHAKU Coupler

1.0 Introduction
Semi Permanent Coupler:- DEMU/EMU stock are provided with the Semi
Permanent Couplers manufactured by Messers Scharfenburg Kupplung, GmbH,
Germany (short formed as “SCHAKU”). When two coaches are coupled by Semi
Permanent Couplers, one coach is fitted with “Semi Permanent Coupler – End ‘A’
& the other one is fitted with “Semi Permanent Coupler–End ‘B’.
Semi Permanent Coupler is designed to ensure a permanent connection of

railcars which in traffic form a unit and therefore need not be separated unless in
an emergency or in the workshop.
The Drawbar / Intermediate Tube are connected by means of an Adjustable muff

coupling/Pair of Cup Sleeve set. The set can be detached easily thus allowing
quick separation of the cars for repair.
The Drawbar / Intermediate Tube are provided with a centring hole and a
centring pin which help to align the drawbars
When being connected and protect the shank of the Drawbars / Intermediate
Tube against twisting. Besides the main mechanical connection, the Semi
Permanent Coupler also ensures the safe connection of the main air reservoir
pipes.
Semi Permanent Coupler is based on the Generic Semi Permanent Couplers being
used on the EMU stock of the Indian Railways currently.
Semi Permanent Coupler is fully interchangeable with the Semi Permanent

Coupler of current suppliers.
2.0 Type of Coupler : Following make semi-permanent couplers are being used
in Indian Railways.
1. Escorts make
2. Wasting house
3.Blue bird
4. Sanrok
3.0 Salient feature : Salient features of above make couplers are as below-
3.1 Escorts make :
1. Compressed load 100 tons and tensile load 70 tons
2. Dynamic absorption capacity of the rubber draft gear of these

couplers is 800 m-kg.
3. Due to rigid connection of this coupler there exists negligible play
between them in coupling position and hence no appreciable wear
and tear during train operation.
Maintenance Practices and manual of SCHAKU Coupler October 2019

4. Due to rigid and stress transmitting mechanical connection between

the coaches by fitting semi-permanent couplers, protection to
the coach and the load against undue impacts is secured.
5. Due to high capacity incorporated in semi-permanent couplers, it
allows coaches to buffer at high speeds (from 3 km/hr to 15 km/hr)
without any damage to the coach and the load.
6. Interlocking arrangement of these couplers prevents to some extent

the mounting or telescoping of the coaches when involved in
accidents.
7. As the fulcrum of these couplers is located far in the rear of the

coach, coupler side displacements in curves and consequently the
transverse forces acting on the wheel flange are kept minimum. This
reduces the wear of the wheel flange and minimizes the chances of
derailment.
8. As the coupling links of semi-permanent couplers from a

parallelogram with equilibrium of forces, unintentional
disengagement of coaches due to shocks is rendered impossible.
9. The design and construction of the pivoted joint between these

couplers and coach permits vertical deflection of ±75 mm and
horizontal deflection of 284 mm or 13º on either side and as a
consequence enables the coaches to couple up at all track curves
and also on points of change of gradient even at maximum height
difference between the two coaches.
3.2 Sanrok :
S.N Description Specification Detail

Value
1. Coupling Length from pivot ------ 1107 mm
point mm
2. Static strength in Buff Mode 100 Tonne 120 Tonne
3. Static strength in Draw Mode 70 Tonne 100 Tonne
4. Ultimate or Fracture strength 150 Tonne 150 Tonne
5. Stroke of the Draw Gear mm 75 max 56
6. Horizontal Swing (o) -- 15
7. Vertical Swing (o) ---- 5-7
8. Energy absorption capacity 800 mkg 900 mkg
dynamic
9. Height from top the rail mm ---- 1035
10. End Force – Sill load 50,000 kg 500 kN +10/-5 kN
11. Coach to Coach interconnection ------ Thru adjustable muff
coupling
3.3 Westing House
1. Semi –permanent couplers are used to couple coaching stock of Electric Multiple
Units which are at present, operating with Central, Western, Eastern, South
Eastern, Southern Railways in India.

2. These couplers are designed for taking a maximum comprehensive load 100 tons
and maximum tensile load of 70 tons.
3. Due to rigid connection of these Couplers, there exists negligible play between
them in coupled position and hence no appreciable wear and tear during the train
operation.
4. Due to rigid and stress transmitting mechanical connection between the coaches
fitted with “SCHAKU” Couplers, protection to the coach and the load being carried,
against undue impacts is secured.
5. The energy absorption capacity of the rubber-draft gear of the Semi-Permanent
Coupler is 800 M-kg
6. Due to draft capacity incorporated in the WSF-SCHAKU” Semi- Permanent
Couplers, it allows the coaches to buff at higher speeds (3 km/hr to 15 km/hr)
before being coupled, without causing any damage to the coach and the load
being carried.
7. The interlocking arrangement of these couplers prevent to some extent the dis-
mounting or telescoping of the coaches when involved in accidents.
8. As the fulcrum of these coupler is located far inside the rear of the coach coupler
side displacement in curved track causes minimum transverse forces acting on the
wheel flange of de-railment.
9. The design and construction of the pivoted joint between these couplers and
coach permits vertical deflection of ±75 mm and horizontal deflection of 284 mm
or 13º on either side and as a consequence enables the coaches to couple up at all
track curves and also on points of change of gradient even at maximum height
difference between the two coaches.
10. Coupling is done manually by operating one ‘Adjustable Cup sleeve’on straight or
curved tracks, gradients with specified height difference ensuring simultaneous
coupling of main reservoir pipes (MR) and brake pipes (BP).
3.4 Blue Bird
1. The fixing of coupler to underframe shall be by bolts /welding. The fixing
arrangements and underframe cut away shall be identical for all couplers
(end and intermediate).
2. The draft gear housing shall be capable of taking either rubber springs or
ring springs, and identical spring packs shall be used for both end and
intermediate couplers.
3. The draft/buffing springs shall be of natural or synthetic rubber, available in
India.
4. The attachment of the draw hook to the draft gear shall be designed so that
it can be conveniently replaced automatic Scharfenbarg heads, without
alteration to any other part of the coupler of draft gear.
5. The location of pivot pin centre line of couplers shall not exceed 707 mm
from Headstock face, and should preferably be the same for both end and
intermediate couplers.

6. The distance between the Headstocks of adjacent coaches shall be 800 mm

when Semi-permanent couplers are fitted, and not less than 964 mm for
the end couplers when fitted with automatic heads.
7. The semi-permanent couplers shall be provided with arrangement for
coupling of brake pipes. If required provision should also be made for
coupling of electrical cables for which 76 electrical contacts should be
catered for.
4.0 Main Parts
4.1 MAIN SUB ASSEMBLIES OF SEMI PERMANENT COUPLER

4.1.1 Coupler – End ‘A’ consist of: -
Bearing Bracket with Support – Sub Assembly
Draw and Buffer Gear – Sub Assembly.
Intermediate Tube – Sub Assembly.
Air Pipe Coupling – Sub Assembly.
Center Adjustment Device – Sub Assembly.
Adjustable Cup sleeve – Sub Assembly

4.1.2 Coupler- End ‘B’ consist of: -

Bearing Bracket with Support – Sub Assembly.
Draw and Buffer Gear – Sub Assembly.
Intermediate Tube – Sub Assembly.

Air Pipe Coupling – Sub Assembly.
Center Adjustment Device – Sub Assembly.

Centering Device – Sub Assembly.

4.2 FEATURES OF SEMI- PERMANENT COUPLERS
 This coupler is designed for taking a maximum tensile load of 70 tons.
Due to rigid connection of these Couplers, there exist negligible play between them in
 coupled position and hence no appreciable wear and tear during the train operation.

The absorption capacity of the rubber draft gear of the Semi Permanent Couplers is 800
 
M-kg.
The design and construction of the pivot joint between these Couplers and coaches is
achieved by using the “Articulation Bearing” and permits a total deflection of ± 75 mm
and horizontal deflection of 284 mm or 13 on either side. This enables the coaches to
couple up easily at all track curves and also on points of changing gradient even at the
maximum height difference between two coaches.
4.3 DESCRIPTION & FUNCTIONAL FEATURES OF SUB ASSEMBLIES
4.3.1 Bearing Bracket (Used both in End ‘A’ & End ‘B’)
It is the part of the semi permanent Coupler which is fixed onto the end part of the
coach. This sub-assembly is basically fabricated and machined to house two Ferro zell
bushes with concentric vertical axes and connected to the Articulation Bearing of the
draw and buffer gear sub-assembly by means of one bearing bolt. One leaf spring holding
device which is mounted on this bolt by thread engagement. These leaf springs held
together tightly helps to support the overhung portion of the Draw and buffer gear from
under side.
FIG. 1: BEARING BRACKET WITH SUPPORT

Nomenclature of fig. 1
Description Ref.No. Description Ref.No.
Bush 3 Pin 32 d 9 x 200 x 180 17
Bush 4 Unmachined Disc 33 18
Disc Thrust Piece 5 Split Pin 8 x 50 19
Slide Plate 6 Fan Disc V10, 5 20
Plate 7 Spring Washer A8 21
Plate Disc 8 Bearing Bolt (Sub Assly.) 22
Hex. Hd Screw A M30 x 90 10 Bearing bracket (sub Assly.) 24
Hex. Hd Screw A M8 x 15 11 Carrier (Sub Assly.) 32
Csk Hd Screw M10 x 30 12 Fastening (Sub Assly.) 47
Hex. Nut M30 13 Leaf Spring Comp. (Sub Assly.) 52
Split Pin 3/8” dia x 5-1/2” 15 Block (Sub Assly.) 58
Grease Nipple A10 16
4.3.2 Draw and buffing gear (Used both in End ‘A’ & End ‘B’
This part of the semi permanent Coupler accommodates the rubber spring (Perforated
steel plate with rubber moulded on it) and steel plate held alternatively to provide an
energy absorption capacity of about 80M- Kg and a draft capacity of 34 tonnes.
FIG. 2 DRAW AND BUFFING GEAR

DESCRIPTION REF.NO DESCRIPTION REF.NO
Bolt 5 Socket Head Screw M42 x 300 16
Bush 6 Split Pin 10 x 70 17
Upper Part of the Cup Sleeve 7 Clamping Pin 5 x 40 18
Spencer Moulton Rubber Pivoting Bearing – Const’n.
Springs 8 Type-A 19
Spencer Mild Steel lates3/16” 9 Lower Part of Cup Sleeve 22
Hex. Head Screw M16 x 180 11 Front Plate (Sub Assly.) 26
Hex. Nut M16 12 Rear Plate (Sub Assly.) 33
Spring Washer A16 13 Yoke (Sub Assly.) 38
Clamping Pin 8 x 80 14 Eye (Sub Assly.) 44
It comprises of a fabricated yoke which houses the said Rubber springs, plates, one front
plate and one rear plate, a fork eye which houses the “Articulation Bearing”. This fork
eye is mounted on the yoke by means of two Socket head screws, which also keep the
Rubber-spring and plate in position. There is a pin with a polyamide bush, which keeps
the fork eye in central axis of the yoke. During the train operation the rubber spring
along with plates are subjected to compression only in both the cases when the coupler
is under tensile load or compressive load. The draw and buffer gear is connected to
bearing bracket in one side and rigidly to the intermediate tube on the other side.
4.3.3 Intermediate Tube (Used both in End ‘A’ & End ‘B’)
The intermediate tube is fabricated by welding two forged rings on both side of a
seamless (heavy) tube piece. Then subsequent stress relieving and machining is done on
it. Intermediate tube being rigidly connected to the draw and buffer gear assembly,
become one single solid stock extending from the pivot center (i.e. articulation bearing)
up to its other free end.
FIG. 3 INTERMEDIATE TUBE ASSLY.

DESCRIPTION REF.NO. DESCRIPTION REF.NO.
Tube 1 Spring Sleeve 10 x 20 10
Ring 2 Lug 5
Plate 3
4.3.4 Air Pipe Coupling (Used both in End ’A’ & End ‘B’)
This is bracket type fabricated structure which houses two male thread mountings for
main reservoir pipe and brake pipe and two conical rubber washers fitted inside hex.
head sockets which form the coupling face. When both the Semi Permanent Couplers
(End ’A’
End ‘B’) are manually coupled. These rubber washers projected outwards coupled
simultaneously to ensure leak proof air passages for MR& BP.
FIG. 4 AIR PIPE COUPLING
4.3.5 Centering Device (Used only in End ‘B’)
This is machined from a circular disc type forging with guide pins welded in it. It forms
the coupling face of the Intermediate tube (End ’B’).

FIG . 5 CENTERING DEVICE
4.3.6 Adjustable Cup Sleeve (Used only in End ’A’)
This subassembly is mounted on the outer part of the Intermediate tube of Semi-
permanent Coupler (End ’A’). This comprises of two-semi circular sleeve with tapered slot
inside. These sleeves are adjusted and bought in position by means of a spindle with both
left hand and right hand thread formed on it. Closing of these two sleeves grips firmly
two outer ends of Intermediate Tubes of Semi-permanent Couplers (End ’A’ & End ‘B’)
thus forming one rigid connection. The exact centering is done by two guide pins welded
onto the centering devices, one housed in the Adjustable Cup sleeve and another fitted
at the end of Intermediate Tube (End ’B’).
FIG. 6ADJUSTABLE CUP SLEEVE

4.3.7 Center Adjustment Device (Used both in End ‘A’ & End ‘B’)
This consists of two concentric helical compression springs housed in a barrel with clevis
end fitting to facilitate mounting onto the underside of the frame. This combination of
springs fitted with a push rod always exert are storing force to keep the coupler end in
central position which often gets moved sidewise due to relative lateral displacement of
two compartments during the train operation.
FIG. 7 CENTER ADJUSTMENT DEVICE
DESCRIPTION REF.NO.
Compression Spring 1
Compression Spring 2
Disc Spring 4
M24 x Hex. Nut 6
Hook Spring Nut 7
Bolt, B22, h11 x 65 x 58.5 8
M23 washer 9
Split Pin 5 x36 10
Plug (Sub Assly.) Complete Comprising 12
Eye 30
Spring Casing (Sub Assly.) Comp. Comprising 16
Spring Casing (Sub Assly.) Comp. Comprising 21
Fork Head 25
Clamping Screw 29

4.4 MAINTENANCE SCHEDULES
Following maintenance schedules are carry out in the DEMU car shed and workshop.
4.4.1 Trip schedule to “C” schedule
Check slackness by coupler play inspection gauge between two couplers, which should not
 more than 4 mm.
Check slackness by coupler play inspection gauge in individual coupler, which should not
more than 2 mm.
Visually check for physical damage/ missing components and replace them.
4.5 PERIODICALLY OVERHAULING
4.5.1 Overhauling Procedure
The Semi-Permanent Couplers are to be dismounted for the major overhauling
In every POH schedule.

In case of physical damage, deformation or accidents.
The overhauling process involves:
Dismount the coupler from the DEMU car.

Completely dismantle the coupler and clean all components.
Check all individual stress bearing components with their respective condemning
 gauges.
The rubber parts of the air-pipe coupling (MR & BP) must be replaced irrespective of their
conditions.
4.5.2 Polyamide bushes

Polyamide bushes of the rear plate should also be replaced at the time of the POH of the
coach. Replacement of polyamide bush is essential to protect excessive wear on the yoke
assembly and socket head screws of draw and buffer gear. The new bush should be
softened by heating it for 20 minutes in boiling water in a specially designed bath shown
in fig. 11. It is done when the new one is kept in a container, which receives heat from
boiling water for about 20 minutes. Then it becomes easier to slide the polyamide bush it
should not be fitted by hammering in cold condition.
4.5.3 Bearing Bracket with Support

Inspection and replacement of components of Bearing Bracket with Support involves
checking of cracks, damaged shapes etc. found on Bearing bolt, Bearing bracket &
Ferrozell bushes.

Bearing bolt should be checked for its wear by the condemning gauge. The grease
passages should be cleansed properly clogged grease should be removed by Kerosene/
steel rods also easy grease flow through all passages it to be removed.

4.5.4 Draw and Buffer gear
The rubber spring and steel plate combination should be checked for: -

Total height of 7 steel plates + rubber spring + front plate + rear plate = Minimum 256.8
 mm in unstressed condition.
Energy absorption capacity to be compared with the graph, plotted by the standard one
 as given in SCHAKU Drg. No. 40-586.06(2).
External condition and appearance of the rubber springs are to be checked for aging and
should be replaced by new one if found not satisfactory.

4.5.5 Lower & upper Cup-sleeves
The pair of lower & upper Cup-sleeves should be checked by the condemning gauges.
These Cup-sleeves along with socket head screws are to be replaced by new ones if found
excessively worn out. Lubrication of Articulation bearing is to be ensured. The gap
between the inner race and the ball should not exceed 0.3 mm. In case this gap is bigger
one new articulation bearing is to be fitted. NDT and Die- penetration test on yoke
structure should be carried out and if found with any cracks etc. it is to be replaced by
new yoke.
4.5.6 Spring sleeves

The spring sleeves used in all the sub assemblies are to be checked for proper shape and
appearance. They should be replaced if not found in satisfactory condition.
4.5.7 Intermediate tube sub assembly

Component of Intermediate tube sub assembly of Semi Permanent Coupler (End ‘A’ &
End ‘B’) should be replaced if found not satisfactory to withstand the service conditions.
Welded joints should be checked for cracks etc. by NDT & Die-penetration test. Use of
hammer to open Adjustable Cup- sleeves is to be avoided as far as possible.
4.5.8 Painting & Assembly

After complete overhauling of the Semi-Permanent Coupler. One coat of black Enamel
should be applied all over to protect the main body from rusting. Grease must be applied
to all moving parts. Date of overhaul should be punched/ stamped on the Intermediate
tube to maintain the overhauling records.
After complete overhauling, the Semi-Permanent Coupler should be assembled again and
kept in a clean & dry place till the time of fitment on the coaches.
5.0 Inspection and Replacement of Components and Sub assemblies

5.1 Inspection and replacement of components of Main Bracket / Bearing
Bracket with support drg. No 2ED-181-1001 {SCHAKU DRG. NO. 40-
588.07(2)}.
Bearing bolt should be checked for its wear by the condemning gauge. The
grease passage should be absolutely clear. Clogged grease should be
removed by kerosene/steel rods. Also ensure that the grease when applied
through the grease nipple flows easily.

5.2 Inspection and replacement of components of Draft Gear / Draw and Buff
Gear drawing No. 2ED-181-1011 {SCHAKU DRG. NO. 40-586.06(2)}
The rubber plates are required to be opened out of the yoke during POH and
checked for:
a) Total height of 7 steel plates + 6 rubber spring plates + front plate + rear
plate which should not be less than 256.8 mm
b) External condition of rubber spring plates. In case of any deformation or

ageing effect is found in any of the plates it must be replaced by a new one.
The pair of lower & upper cup sleeves should be checked by the
condemning gauge. Allen screws M42 X 300 are under load at the time of
tension and are prone to wear against the rubbing action by the steel plates.
Allen Bolt should be checked by the condemning gauge and replaced if
found worn-out.
Polyamide bush of rear plate sub assembly should be replaced at time of

POH of the coach. Replacement of Polyamide Bush is essential to protect
excessive wear on the Yoke sub assembly and Allen Screw M42X300 of the
draw and buff gear sub assembly.
5.2.1 Fixtures and Method of Using
5.2.1.1 Fixture for pressing Articulation Bearing (Fixture Drawing No. SE-F-134)
Method of using fixture for pressing the articulation bearing
a) Hold the mandrel into the press ram
b) Keep the fork eye on to the resting fixture and make it horizontal
c) Keep the articulation bearing on the fork eye hole
d) Guide the mandrel into the inner ring of articulation bearing and press it
Replacement of yoke is to be carried out on conditional basis but in case the

yoke must be checked by NDT for internal fatigue stresses/cracks which
might have developed during running period and are not visible to the
naked eye. NDT may include Ultrasonic testing, die penetrant test etc.


Assembly fixture for Draft Gear / Draw and Buff Gear (Fixture Drawing No.SE-F-
137 & SE-F-138)
5.2.1.2 Procedure for assembly of Draft Gear/ Draw & Buff Gear
a) Assemble the six spring rubber plates and seven steel plates on two clamps
drg. No SE-G-138 with two pins drawings in the two holes in plates and
press them with the help of a press to a height of 247.3 mm and lock them
by tightening the nuts of the clamps (use Drg. SE-G-136 For checking
dimension 247.3mm)
b) Place yoke in the frame (drg. SE-G-137 Sheet 1) at 90° to normal position
along with front and rear plates
c) Place the clamped assembly as per 1 above on the yoke & with the help of
press, start introducing it smoothly into the yoke.
d) The lower clamp touches the yoke, and then slides up gradually and
ultimately comes out with upper clamp.
e) Ensure proper alignment of holes in the plates & yoke and remove the pins.

f) Assemble the yoke with the fork eye by introducing Allen screws. Tighten
Allen screws.
g) The plates should not be loose in the yoke. If so dismantle & reassemble the
parts with new plates.






5.2.1.3 Method of using the fixture for Draft Gear / Draw & Buff Gear sub assy.
a) Keep the buffer plates into the holding clamps and inserts the two pins inside.
b) Press the buffer plates and tighten up the nuts
c) Keep the resting blocks on to the press.
d) Keep the yoke on to it.
e) Keep the top block on to the yoke.
f) Now keep the draw & buff gear partial sub-assembly into it and press it
5.3 Inspection and replacement of components of Centering Device drg. No

2ED-181-1006 { SCHAKU Drg. No. 40-1000.10(2)}
Components of Centering Device drg. No 2ED-181-1006 should be replaced on

conditional basis except all the compression springs. The springs which are
always under compressive and tensile loads must be checked for their
strength and should be replaced if they cross the condemning limits as
given in spring condemning criteria.
5.3.1Method of using the assembly fixture for Centering Device (Fixture Drawing No.
SE-F-135)
a) Pass the bolt through the spring pot and compression spring (inner & outer)
b) Put the spring plate and tighten up the lock nut
c) Place the complete sub assembly on to the fixture
d) Compress the compression springs with the help of the fixture up to the
stop and tighten up the lock nut.
e) Remove the compressed sub assembly from the fixture for final assembly in
to the spring casing.

5.4 Inspection and replacement of components of Intermediate Tube Drg. No

2ED-181-1004 {SCHAKU 40-586.01:01(2)}.
Components of intermediate tube sub assembly should be replaced on

conditional basis.
Use of hammer to open adjustable cup sleeve is to be avoided as far as possible.
5.4.1 Device for removal of bearing bolt (Fixture Drawing No. SE-F-140)
In the event the removal of bearing bolt 2ED-181-1093 (SCHAKU DRG. 40-
586.07-03(3)) is found to be difficult due to jamming (lack of lubrication) a
special fixture can be used to remove the bearing bolt. The fixture is located
underneath bearing bolt on a platform of 600-700 mm height kept on the
shop floor between the rails of the track. The spindle is moved in upward
direction by turning the handle, and the bolt is pushed out. If the pushing
force exerted to the bolt by this method is not sufficient to remove the bolt,
use of hydraulic jack is suggested.
After complete overhauling of the coupler, a coat of black enamel should be

applied all over to protect the coupler parts from rusting. Grease must be
applied on all moving parts. Date of overhaul should be punched / stamped
on the intermediate tube to maintain the overhauling records.

SPECIAL TOOLS & FIXTURES
FIG. 8 SCISSORS TYPE HYDRAULIC LIFTING PLATFORM

FIG. 9 HYDRAULICALLY POWERED PRESS
FIG. 9 FIXTURE FOR DISMANTLING & ASSEMBLY OF MAIN

SOCKET HEAD CAP SCREW OF DRAFT GEAR
FIG.10 BATH FOR SOFTENING OF POLYMIDE BUSH

6.0 Lubrication Scheme
S NO Part Name Periodicity Type of Lubricant
01 Bush Polyamide POH Servo GP grease 2 or HP GP Gerase
or equivalant
02 Bearing Bolt 6 months --------do------
03 Leaf Springs 6 months --------do------
04 Articulation Bearing At the time of POH of the Molykote (Mos2) paste, make OKS
coach or equivalent
7.0 SPRING CONDEMNING CRITERIA:

Springs are to be condemned on condition basis. Springs with corrosion and
pitting are to be rejected. Springs are to be checked for serviceability as per
the table given below:
Spring Similar Schaku Length (L) Load (min) Free Length (min)
Drawing No. Drawing No. mm kg at L mm
2ED-181-1069 AB-784/13-088.03- 29.5 (comp.) 10 61

14(4)
2ED-181-1115 40-3000.10-1(3) 351 60 510
2ED-181-1116 40-3000.10-2(3) 351 38 510
8.0 Tools and Gauges for Maintenance
8.1 For Depots
S.No. Description Drawuing No.
1. Fixture for pressing the Articulation bearing RCF 599

2. Assembly fixture for Draw & Buff gear RCF 600,601
3. Fixture for centering device RCF 602
4. Condemning gauges for -
1. Allen Screw SK 338
2. Cup Sleeve 40.SK.2551.01
3. Pair of cup sleeves 40.2251.02
4. Bolt 40.SK.2551.1
5. Front plate S.A (dia 138d) 40.SK.2551.5
6. Front plate & forked head (dia 22h11) 40.SK.2551.6

7. Rear plate SA (dia 30H11) 40.2551.7

8. Yoke S.A 40.SK.2551.8
9. Articulation bearing 40.SK.2551.9
10. Bush (dia 80 B9) [Ferrozal] 40.SK.2551.10
11. Carrier S.A. & Leaf spring 40.SK.2551.11
12. Bearing bolt 40.SK.2551.12
8.2 For Workshops

List of Devices, Fixtures and Standard Tools required for Overhauling of Semi-Permanent
Coupler
Standard Tooling
Spanners : 1. 11-13 mm
2. 18-19 mm
3. 22-24 mm
4.30-32 mm
5. 34-36 mm
Hammer : Approx. 1 kg
Screw Driver 6 mm, 32 mm
Hand Press 6 mm, 32 mm
Bench Vice 6 mm, 32 mm
Allen Keys 6 mm, 32 mm
Fixture
1. Fixture for pressing the draw & buff gear v sub –assy. Into the yoke : RCF 600.
2. GO gauge for draw & buff gear sub-assy : RCF 601
3. Fixture for assembly of centering device & spring holder : RCF 602
4. Fixture for articulation bearing RCF 599 ( for pressing in fork eye)Description of
9.0 Tools, Fixtures and Gauges & method of using gauges
9.1 Pressing Method of using the Fixture and the Articulation Bearing
1. Press the fork eye in which the Articulation Bearing is to be pressed on the set of
adjustment bolts.
2. Position the spring loaded locater in the bore of fork eye.
3. Adjust the adjustment bolts to achieve a free movement of locater within the
bore of fork eye.
4. Place the articulation Bearing on the collar of locater as in figure.
5. Press the articulation Bearing with the help of pressing mandrel.
6. The spring loaded locater will automatically slide down
7. Ensure that Articulation Bearing has fully engaged and in position (observe the
collar)


9.2 Assembly Fixture For Draw & Buff Gear :
Procedure :
1. Assemble the six rubber springs and seven steel plates on two clamps drg. No.
RCF-600 (sheet 4) with two pins drg. No. RCF -600 in the two holes in plates and
press them with the help of a height of 207.3 mm and lock them by tightening the
nuts of the clamps (use RCF-601) for checking dim. 207.3 mm).
2. Place yoke in the frame (RCF – 600) at 90° to normal position along with front and
rear plates.
3. Place the clamped assembly as per (1) above on the yoke and with the help of
press; start introducing it smoothly into yoke.
4. The lower clamp touches the yoke, and then slides up gradually and
ultimatelycomes out with upper clamp.
5. Ensure proper alignment of holes in the plates & yoke and remove the pins.
6. Assemble the yoke with the fork eye the introducing allen screws. Tighten allen
screws.
7. The plates should not be loose in the yoke. If so dismantle and reassemble the
parts with new plates.
9.3 Method of Using the Fixture for Draw & Buff gear Sub-assy.
1. Keep the buffer plates into the holding clamps and insert the two pins inside.
2. Press the buffer plates and tighten up the nuts.
3. Keep the resting block on to the press.
4. Keep the yoke on to it.
5. Keep the top block on to the yoke.
6. Now keep the draw & buff gear partial sub-assy. Into it and press it.








9.4 Method of Using the Assembly Fixture for Centering Device
1. Place the Tee Head Bolt on the Guide Pin ensure that the centre of the Bolt is on
the centre of the Guide Pin.
2. Insert the spring pot and spring on the Tee Head Bolt.
3. Place the spring plate on the Tee Head Bolt, slightly press it insert it inside the
fixture and then place Centering pin on the upper side of Tee Head bolt.
4. Apply pressure in the cylinder due to which the Tee Head Bolt will move upward
then, then remove the centring pin and tighten the nut on bolt.
5. Release the pressure and then remove the assembly.

10.0 Part List & Recommended percentage of Holding for POH
S.No. Description Ref Drawing No. Recommended %

holding for
POH
A. Semi Permanent Coupler End ‘A’ 40-586-(O) 5
a. Draw & Buff Gear 40.586-06(2) 10
Bolt 40.586-06-3(4) 25
Bush (Polymide) 40.586-06-4(40 100
Cup Sleeve Upper Part 13-128-15 (30 25
Rubber Sp. Plate 40-SK-1837(1) A 80
Steel Plate 3/16” 40-SK-1837(1) B 25
Hex Hd. Screw M16x180 40.586-0692) Pt. 15 25
Hex. Nut M16 40.586-06(2) Pt.12 25
Hex. Nut Spring washer A16 40-586-06(2) Pt. 13 25
Spring dowel pin 8x80 40-586-06920 Pt. 14 100
Allen Screw M42x300 40.586-06(2) Pt.16 25
Split pin 40.586-06(2) Pt. 17 100
Spring Dowel Pin 5x40 40.586-06(2) Pt. 18 100
Articulation Bearing (sub-assy.) 40-SK-1960(3) 50
Seal 40-SK-1960-3(3) 100
Cup Sleeve Lower (Sub-assy 40-SK-1960-01(4) 25
Front Plate (sub-assy) 40-586-06-02(4) 10
Rear Plate (Sub-assy) 40-SK-06-02(4)) 10
Yoke (Sub-assy) 40-586-06-04(2) 10
Fork Eye (Sub-assy) 40-586-06-0592) 35
Name plate SK-147 10
Disc for bearing Bkt/Taper washer 40-524-07-0594) 10
Yoke (Sub-assy) 40-586-06-04(2) 10
Fork Eye (Sub-assy.) 40-586-06-05(2) 35
Name plate SK 147 10
Self tapping screws 4x5/18” long 25
Bush SK 331 50
b Intermediate Tube (Assy.) 40-586-01-01(2) 10
Spring dowel Sleeve 10x20 40-586-01-01(2) Pt.1 100
c Air pipe coupling SK-198 25
Angle plate (welded) SK-199 10
Rubber tube 13-088-03-15940 100
Spring 13-088-03-14(4) 30
Sleeve 13-088-03-1394) 25
Sealing ring 13-088-03-16(4) 100
Spring pot SK-365 20
Washer SK-366 20
Hex Nut R1” DIN 431 20
Elbow R1”x3/4” 20
Elbow R1”x1’ DIN 1569 20
Hex Hd. Screw M12x25 SK-198 Pt.10 25
Spring washer B 12 SK-198 Pt.11 25
Spring dowel sleeve 8x25 SK-198Pt. 12 25
d Adjustable cup sleeve 40-317-13(2) 10
Pin of cup sleeves 40-317-17-1(3) 10

Spindle 40-317-17-2(3) 50
Tube 40-317-17-3(5) 10
Winged nut 40-317-13-8(4) 100
Handle 40-317-13-9(4) 100
Split Pin 1/8”x3/4” 40-317-13(2) Pt. 6 50
Pin 10h11x75x67 40-317-13(2) Pt.7 25
Guide Pin 14h11x120 40-317-13(2) Pt. 8 100
Spring Dowel Sleeve 10x60 40-317-13(2) Pt. 9 100
Spring Dowell Sleeve 5x32 40-317-13(2) Pt. 10 100
Spring Dowel sleeve 5x32 40-317-13(2) Pt. 11 25
Adjustable ring B-30 40-317-13(2) Pt. 12 25
Centering Carrier (Sub-assy.) 40-317-13-01(4)
Split Pin 10x90 40-317-13(2) Pt. 14 100
e Bearing Bracket with support 40-588-07(2) 10
Bush (Upper) 40-524-07-3(4) 100
Bush (lower) 40-524-07-4(4) 100
Disc for bearing Bkt/taper washer 40-524-07-5(4) 25
Trust Piece 40-524-07-6(4) 20
Slide Plate 40-524-07-7(4) 100
Plate 40-524-07-8(4) 20
Disc 40-588-07-8(4) 20
Hex Hd Screw AM 30x90 40-588-07(2) Pt.14 25
Hex Hd Screw M8x20 440-588-07(2) Pt.23 50
Counter sunk Hd. Screw AM10x45 40-588-07(2) Pt.24 100
Hex Nut M30 40-588-07(2) Pt.15 25
Split Pin 3/8”x5 “1/2 40-588-07(2) Pt.16 100
Grease Nipple A10 40-588-07(2) Pt.17 100
Pin 31.8C11x200x180 40-588-07(2) Pt.18 25
Washer 33 mm 40-588-07(2) Pt.19 25
Bearing Bolt 40-588-07-03(3) 30
Bearing Bracket (Sub-assy) 40-586-07-01920 10
Trigger carrier 9sub-assy) 40-524-07-03(4) 40
Holder support (Sub-assy.)_ 40-524-07-04(4) 10
Leaf Spring 9sub-assy0 40-524-07-06(4) 40
B Semi Permanent Coupler End ‘B” 40-587-(0) 5
Draw & Buff Gear 40-586-06(2) 10
Intermediate tube 9Assy) 40-586-01-01(2) 10
Centering carrier sub-assy End ‘B’ 40.318.13(40)
Spring Dowel sleeve 10x20 40-586-01(2) Pt. I 100
C Centering Device 40.1000.10(20
Compression Spring 40.3000.10.1
Compression Spring 40.3000.10.2
Tee head bolt 40.3000.10.4
Spring plate 40.3000.10.5
Locking Piece Sub-assy 40.3000.10.01(4)
Spring pot 40.3000.10.03(4)
Spring casing sub-assy 40.3000.10.03(4)
Fork head 40.1000.10.01(4)

Washer 23
Split pin dia 6x35
Hex. Nut M24
Spring ring dia 104
Bolt 22h 11x65x58.5
11.0 Rejectable defects
Overhauling and Reconditioning Criteria of the Components of Semi-Permanent Coupler:-
S.No. Description Drg. No. Similar SCHAKu Criteria for Fixture / Gauge
Drg. No. Determining the Required
Condition
1. Tragger/ Carrier 2ED-181-1200 40-524.07:03(4) Hole dia 32mm is to be Limit Gauge to
(Sub Assembly) Checked Condemn the Drg. No.
component if the SE-G-117
gauge passes through.
2. Holder Support 2ED-181-1102 40-524.07:04(4) Visible Cracks or Visual
(Sub Assy.) damage
3. Bush Upper 2ED-181-1091 40-524.07-3(4) Internal Diameter 80 Limit Gauge to
+0.200 / +0.274mm is Drg. No.
to SE-G-118
be Checked. Condemn
Bush if gauge passes
through it. There
should
not be any visible crack
or damage.
4. Bush Lower 2ED-181-1089 40-524.07-4(4) Internal Diameter 80 Limit Gauge to
+0.200 / +0.274mm is Drg. No.
to SE-G-118
be Checked. Condemn
Bush if gauge passes
through it. There
should
not be any visible crack
or damage.
5. Disc Upper/ 2ED-181-1087 40-524.07-5(4) Visible Cracks or Visual
Taper Disc damage
6. Thrust Piece 2ED-181-1095 40-524.07-6(4) Visible Cracks or Visual
damage
7. Slide Plate 2ED-181-1246 40-524.07-7(4) Plate Thickness of Vernier calliper
(Ferrozal) 10mm
is to be Checked.
Replaced if wear
exceeding 3mm.
8. Plate 2ED-181-1216 40-524.07-8(4) Visible Cracks or Visual
damage
9. Leaf Spring 2ED-181-1106 40-524.07.06(3) If wear of more than Vernier Calliper
Complete (Sub 2mm on the top leaf it
Assy.) has to be replaced
10. Bearing Bracket/ 2ED-181-1088 40-586.07:01(2) Internal Fatigue NDT (Ultrasonic
Main Bracket stresses testing, Die
/ Cracks. penetrant test
etc.)

11. Bearing Bolt 2ED-181-1093 40-586.07:03(3) External diameter Ø80 Snap gauge to
mm is to be checked. drg. No.
Condemn Bolt if it SE-G-119
passes through the
gauge.
12. Disc Lower/Flat 2ED-181-1086 40-588.07-3(4) Visible Cracks or Visual
Disc damage
13. Plate 2ED-181-1105 AB/742 Visible Cracks or Visual
damage
14. Pin (31.8c11x200) DIN 1433 40-588.07(2) Prt. External diameter Snap Gauge to
18 Ø31.8 drg. No.
c11 mm is to be SE-G-120
checked. Condemn Pin
if
gauge passes through
15. Cup Sleeve Lower 2ED-181-1153 40-586.06:01(4) External diameter Profile Gauge to
(Sub Assy.) Ø31.8 drg. No.
c11 mm is to be SE-G-121
checked. Condemn Pin
if
gauge passes through
16. Front Plate (Sub 2ED-181-1156 40-586.06:02(4) External diameter of Limit Snap Gauge
Assy.) tube 138mm and to Drg. No. SE-G-
diameter 22H11 of 122
bush Limit gauge to
is to be checked. Drg. No. SE-G-132
Condemn Front Plate
Sub. Assy. If gauge
passes over it.And
Check
for Straightness of
Plates, Visible Cracks or
damage.
17. Rear Plate (Sub 2ED-181-1157 2ED-181-1157 Inner Diameter Limit Snap Gauge
Assy.) Ø30mm to Drg. No. SE-G-
of guide tube is to be 123
checked. Condemn
Rear Plate Sub. Assy. If
gauge
passes over it.
And Check for
Straightness of Plates,
Visible Cracks/damage
18. Bush Polymide 2ED-181-1182 40-586.06-4(4) Check the exsesive --------------------
wear
and for Visible Crack or
Damage
19. Yoke (Sub assy.) 2ED-181-1183 40-586.06:04(2) Internal diameter Limit gauge to
Ø138mm and Ø47 mm drg. No.
are to be checked. SE-G-124
Condemn Yoke if the NDT (Ultrasonic
Gauge Passes Through testing, Die
it.Internal Fatigue penetrant test
stresses / Cracks. etc.)

20. Fork Eye with 2ED-181-1383 2-SK.399 ------------------ -----------

Bolt
(Sub Assy.)
21. Fork Eye 2ED-181-1168 40-586.06:05(2) Internal Fatigue NDT (Ultrasonic
stresses testing, Die
/ Cracks. penetrant test
etc.)
22. Bolt 2ED-181-1181 40-586.06-3(4) Outer Diameter Snap Gauge to
Ø30mm drg. No.
d11 is to be checked. SE-G-126
Condemn bolt if gauge
passes over bolt
23. Cup Sleeve Upper 2ED-181-1149 40-624.06-4(3) Check the Profile & for Profile Gauge to
Visible Crack/damage drg. No. SE-G-121
24. Rubber Spring 2ED-181-1245 40-SK-1837(1) Length of unstressed Vernier Calliper
Plate spring should not go
below 256.8 mm.
Check for Straightness
of
Plates, Visible Cracks or
damage.
25. Steel Plate 2ED-181-1250 40-SK 1837(1) Visible Cracks or Visual
Damage
26. Articulation 2ED-181-1151 40-SK 1960(3) Diameter 80mm is to Limit Gauge to
Bearing be checked and slack Drg. No. SE-G-
between inner and 127 & Filler
outer ring should be Gauge
more than 0.3mm.
Condemn the Inner
Ring if the gauge
passes through it.
27. Allen Screw / 2ED-181-1189 40-586.06(2) Prt. Outer Diameter of Snap Gauge to
Bolt (M42X300) 16 shank & Thread. drg. No.SE-G-
Condemn the Screw if 128
gauge passes over the
shank or threads
28. Sealing ring 2ED-181-1071 13-088.03-16(4) Visible Cracks or --------------------
Damage
29. Sleeve 2ED-181-1069 AB-785/13- Visible Cracks or Visual
088.03- Damage
13(4)
30. Spring 2ED-181-1069 AB-784/13- Condemning limits -----------------
088.03- as given in spring
14(4) condemning criteria.
31. Rubber Tube 2ED-181-1070 AB-782/13- Check for damage, ---------------------
088.03- ageing and apperance
15(4)
32. Spring Pot 2ED-181-1065 AB/781 Visible Cracks or Visual
Damage
33. Angle Plate 2ED-181-1062 40-587.04:01(2) Visible Cracks or Visual
Damage
34. Support Washer 2ED-181-1066 AB/783 Visible Cracks or Visual
Damage
35. Hex. Nut R1” DIN 431 40-587.04(3) Prt. Visible Cracks or Visual
5 Damage
36. Elbow R DIN 1569 40-587.04(3) Prt. Visible Cracks or Visual

1”X3/4” 9 Damage
37. DIN 1569 40-587.04(3) Prt. 40-587.04(3) Prt. 8 Visual
Elbow R 1” X 1” 8
38. Pair of Cup 2ED-181-1074 40-317.13-1(3) Visible Cracks or Visual
Sleeve Damage
39. Spindle 2ED-181-1080 40-317.13-1(3) Visible Cracks or Visual
Damage
40. Tube 2ED-181-1081 40-317.13-3(5) Visible Cracks or Visual
Damage
41. Winged Nut 2ED-181-1082 40-317.13-8(4) Check for Thread, Thread Plug
Visible Cracks or Gauge /Visual
Damage
42. Handle 2ED-181-1083 40-317.13-9(4) Visible Cracks or Visual
Damage
43. Guide Pin DIN 1433 IA 71153/40- Visible Cracks or Visual
14h11x120 317.13(2) Prt.8 Damage
44. Adjusting Nut 2ED-181-1198 IA 71154/40- Visible Cracks or Visual
B-30 317.13(2)Prt.12 Damage
45. Centering 2ED-181-1076 40-317.13:01(4) Visible Cracks or Visual
Carrier End –A Damage
(Sub Assy.)
46. Intermediate 2ED-181-1058 ------------------ Internal Fatigue NDT (Ultrasonic
Tube/Draw Bar stresses / Cracks. testing, Die
penetrant test
etc.)
47. Eye 2ED-181-1060 AB-735/40- Visible Cracks or Visual
586.01:01(2) Damage
Prt.5
48. Centering 2ED-182-1132 40-318.13-1(3) Visible Cracks or Visual
Carrier End-B / Damage
Centering
Device Carrier
49. Centering Pin 2ED-181-1079 40-281.01-6(4) Visible Cracks or Visual
Damage
50. Compression 2ED-181-1115 40-3000.10-1(3) Condemning limits -------------
Spring as given in spring
condemning criteria.
51. Compression 2ED-181-1116 40-3000.10-2(3) Condemning limits ------------------
Spring as given in spring
condemning criteria
52. Tee Head Bolt 2ED-181-1117 40-1000.10-5(4) Visible Cracks or Visual
Damage
53. Spring Plate 2ED-181-1118 40-3000.10-5(4) Visible Cracks or Visual
Damage
54. Locking Piece 2ED-181-1120 40-3000.10:01(4) Visible Cracks or Visual
(Sub Assy.) Damage
55. Spring Pot (Sub 2ED-181-1124 40-3000.10:02(4) Visible Cracks or Visual
Assy.) Damage
56. Spring Casing 2ED-181-1130 40-3000.10:03(4) Visible Cracks or Visual
(Sub Assy.) Damage

57. Fork Head (Sub 2ED-181-1204 40-1000.10-6(3) Visible Cracks or Visual

Assy.) Damage.Internal Limit Gauge to
Diameter 22 H11 mm Drg. No. SE-G-
is to be Checked. 132
Condemn Forked
Head if gauge passes
through it.
58. Washer 23 mm DIN 1441 40-1000.10(2) Visible Cracks or Visual
Prt.9 Damage
59. Bolt 22h11x65 DIN 1435 40-1000.10(2) Visible Cracks or Visual
Prt. Damage
8



Maintenance Practices & Manual For POH of Schaku Couplers: 2019-20 8/1.0 October 2019

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i

शाकू कप्ऱर के लऱए अनुरऺण

Maharajpur, Gwalior (M.P.) - 474005

शाकू कप्ऱर के लऱए अनुरऺण

CAMTECH is continuously making efforts in documentation and up-

I am confident that the information given in this Maintenance manual will

CAMTECH Lucknow Jitendra Singh

To refresh the knowledge of staff involved in maintenance of Schaku

We are sincerely thankful to Officers and supervisors of North Central

Since technological upgradation and learning is a continuous process, you

CAMTECH Gwalior Manoj Kumar

Section Sub- Section Pages

सुधार ऩर्चियों को जारी करना

ISSUE OF CORRECTION SLIPS

केमिे क/एम/प्रोज/2019-20/एमऩी 8/1.0 # XX दि .................

CAMTECH/M/PROJ/2019-20/MP8/1.0# XX date .......

सुधार ऩचीयाॉ जारी की गयीॊ

CORRECTION SLIPS ISSUED

Sr. No. of Date of Page no. and Item No.

कैमिे क प्रकाशन CAMTECH Publications

For downloading these publications

For any further information regarding publications please contact:

Joint Director (Mechanical) – 0751-2470890 (O)(BSNL)

FAX to 0751-2470841 (BSNL)

Maintenance Practices and manual of SCHAKU Coupler

Semi Permanent Coupler is designed to ensure a permanent connection of

The Drawbar / Intermediate Tube are connected by means of an Adjustable muff

Semi Permanent Coupler is fully interchangeable with the Semi Permanent

3.1 Escorts make :

1. Compressed load 100 tons and tensile load 70 tons

2. Dynamic absorption capacity of the rubber draft gear of these

Maintenance Practices and manual of SCHAKU Coupler October 2019

4. Due to rigid and stress transmitting mechanical connection between

6. Interlocking arrangement of these couplers prevents to some extent

7. As the fulcrum of these couplers is located far in the rear of the

8. As the coupling links of semi-permanent couplers from a

9. The design and construction of the pivoted joint between these

S.N Description Specification Detail

3.3 Westing House

Maintenance Practices and manual of SCHAKU Coupler October 2019

Maintenance Practices and manual of SCHAKU Coupler October 2019

6. The distance between the Headstocks of adjacent coaches shall be 800 mm

4.0 Main Parts

4.1 MAIN SUB ASSEMBLIES OF SEMI PERMANENT COUPLER

Maintenance Practices and manual of SCHAKU Coupler October 2019

4.1.2 Coupler- End ‘B’ consist of: -

Intermediate Tube – Sub Assembly.

Center Adjustment Device – Sub Assembly.

Maintenance Practices and manual of SCHAKU Coupler October 2019

4.2 FEATURES OF SEMI- PERMANENT COUPLERS

 This coupler is designed for taking a maximum tensile load of 70 tons.

Maintenance Practices and manual of SCHAKU Coupler October 2019

4.3 DESCRIPTION & FUNCTIONAL FEATURES OF SUB ASSEMBLIES

FIG. 1: BEARING BRACKET WITH SUPPORT

Maintenance Practices and manual of SCHAKU Coupler October 2019

Description Ref.No. Description Ref.No.

Bush 3 Pin 32 d 9 x 200 x 180 17

Bush 4 Unmachined Disc 33 18

Disc Thrust Piece 5 Split Pin 8 x 50 19

Slide Plate 6 Fan Disc V10, 5 20

Plate 7 Spring Washer A8 21

Plate Disc 8 Bearing Bolt (Sub Assly.) 22