Scharfenberg Semipermanent Coupler Half 010.617 User Manual.pdf

User Manual - Scharfenberg Semipermanent Coupler Half 010.617

Version 1

User Manual Table of Contents Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

Table of Contents Tableof Contents

G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

1

Introduction .................................................................. .................................................................................................................................. ................................................................ 9

1.1

Copyright...................................................................................................................................... ........................................................................................................................................ .. 9

1.2

Usage notes n otes for f or this manual ........................................................................................................ .......................................................................................................... .. 9

1.3

Selection of staff ........................................................................ .......................................................................................................................... ..................................................10

1.4

Revision index .................................................................................................................. .............................................................................................................................. ............ 10

1.5

Approval table .................................................................................................................. .............................................................................................................................. ............ 10

2

Safety ............................................................................ .......................................................................................................................................... ..............................................................11

3

Product description ...................................................................................................................13

3.1

Technical data .............................................................................................................................. ..............................................................................................................................13

3.2

Overview drawing ...................................................................... ........................................................................................................................ ..................................................13

3.3

Intended use .................................................................. ................................................................................................................................ ..............................................................14

3.3.1

Potential misuse ........................................................................................................................... ...........................................................................................................................15

3.3.2

Use in case of restricted readiness for operation ........................................................................ ........................................................................ 15

3.4

General product description .................................................................... ......................................................................................................... .....................................15

3.5

Description of components ..........................................................................................................17

3.5.1

Air pipe connection .................................................................... ...................................................................................................................... ..................................................17

3.5.2

Coupler shank .............................................................................................................................. ..............................................................................................................................18

3.5.3

Bearing bracket ............................................................................................................................ ............................................................................................................................20

3.5.4

Support .......................................................................... ........................................................................................................................................ ..............................................................21

3.5.5

Muff coupling ....................................................................................................... ................................................................................................................................ ......................... 22

3.5.6

Earthing system ...........................................................................................................................23

4

Operation ...................................................................... .................................................................................................................................... .............................................................. 25

4.1

Coupling ......................................................................... ....................................................................................................................................... ..............................................................25

4.2

Uncoupling ..................................................................... ................................................................................................................................... ..............................................................29

5

Light maintenance ................................................................... ..................................................................................................................... ..................................................31

5.1

Materials ........................................................................ ...................................................................................................................................... ..............................................................33

5.2

Maintenance schedule sche dule - light maintenance ..................................................................... ................................................................................. ............ 33

3


5.2.1

Light maintenance ML1 ............................................................................. ............................................................................................................... .................................. 33

5.2.2


5.2.3


5.2.4


5.2.5

Heavy maintenance OH 1 and OH 2...................................................................... ........................................................................................... ..................... 35

5.3

Rough cleaning c leaning .................................................................................................................. ........................................................................................................................... ......... 35

5.4

Visual inspection ......................................................................................................................... ......................................................................................................................... 36

5.5

Lubrication ................................................................................................................................... ................................................................................................................................... 36

5.6

Resonance test of the collapsible tube ....................................................................................... 39

5.7

Replace the gasket in the air pipe connection ............................................................................ ............................................................................ 39

5.8

Check screw connections co nnections with a defined torque ................................................................ ......................................................................... ......... 40

5.9

Repair the paint coating .............................................................................................................. 40

6

Heavy maintenance .......................................................................................................... ................................................................................................................... ......... 43

6.1

Standard tools ............................................................................................................................. ............................................................................................................................. 44

6.2

Materials ...................................................................................................................................... ...................................................................................................................................... 45

6.3

Preparations ................................................................................................................................ ................................................................................................................................ 45

6.4

Maintenance schedule sche dule - heavy maintenance m aintenance ..................................................................... .............................................................................. ......... 46

6.5

Disassembling the coupler into i nto its components ................................................................. .......................................................................... ......... 46

6.5.1

Remove the earthing system .................................................................... ...................................................................................................... .................................. 46

6.5.2

Remove the air pipe connection conne ction ................................................................ .................................................................................................. .................................. 47

6.5.3

Remove the coupler c oupler shank ....................................................................... ......................................................................................................... .................................. 48

6.5.4

Remove the bearing bracket .............................................................................................. ....................................................................................................... ......... 48

6.6

Disassembling, overhauling and assembling the individual components ................................... 50

6.6.1

Air pipe connection ........................................................................ ...................................................................................................................... .............................................. 50

6.6.2

Coupler shank ............................................................................................................................. ............................................................................................................................. 50

6.6.3

Bearing bracket ........................................................................................................................... ........................................................................................................................... 53

6.6.4

Muff coupling ...................................................................................................................... ............................................................................................................................... ......... 56

6.6.5

Earthing system ................................................................ ........................................................................................................................... ........................................................... 57

6.7

Assembling the coupler .......................................................................................... ............................................................................................................... ..................... 58

6.7.1

Install the bearing bracket ........................................................................................................... ........................................................................................................... 58

6.7.2

Install the coupler c oupler shank ........................................................................... ............................................................................................................. .................................. 59

6.7.3

Install the air pipe connection co nnection .................................................................... ...................................................................................................... .................................. 60

6.7.4

Assemble the muff coupling - vertical configuration .................................................................... 61

6.7.5

Install the earthing e arthing system ........................................................................ .......................................................................................................... .................................. 64

4




6.8

Final maintenance steps .............................................................................................................. ..............................................................................................................66

7

Mounting and removal...................................................................................... removal............................................................................................................... ......................... 67

7.1

Mounting and commissioning ......................................................................................................67

7.2

Removal and decommissioning ................................................................................................... ...................................................................................................71

8

Transportation, storage and disposal .....................................................................................73

8.1

Transportation ................................................................ .............................................................................................................................. ..............................................................73

8.2

Storage .......................................................................... ........................................................................................................................................ ..............................................................73

8.3

Disposal ......................................................................... ....................................................................................................................................... .............................................................. 73

9

Troubleshooting ....................................................................... ......................................................................................................................... ..................................................75

9.1

Target group .................................................................. ................................................................................................................................ ..............................................................75

9.2

Earthing system ...........................................................................................................................75

9.3

Air pipe connection fails ...................................................................................... ............................................................................................................... ......................... 75

9.3.1

Pressure drop when coupled ....................................................................................................... .......................................................................................................75

9.4

Coupler is in wrong position .................................................................... ......................................................................................................... .....................................75

9.4.1

Coupler is misaligned.............................................................................. misaligned................................................................................................................... .....................................76

9.5

Unusual noise during operation ................................................................................................... ...................................................................................................76

9.5.1

Clattering/knocking noise ............................................................................................................. .............................................................................................................76

10

SCHAKU standards ................................................................. ................................................................................................................... ..................................................77

10.1

Paint specification ............................................................................................... ........................................................................................................................ ......................... 77

10.1.1

General requirements requ irements (SCHAKU standard K000) ....................................................................... .......................................................................77

10.1.2

Paint structure (SCHAKU-Norm K150) ............................................................................ ........................................................................................ ............ 78

10.2

Sealing and securing of screw connections (SCHAKU standard A023) ..................................... 79

11

Parts catalogue ........................................................................ .......................................................................................................................... ..................................................81

11.1

Structure of the parts list ......................................................................... .............................................................................................................. .....................................81

11.2

Scharfenberg semipermanent coupler half 010.617 ....................................................................82

11.2.1

Air pipe connection 010.617.04 ................................................................................................... ................................................................................................... 83

11.2.2

Coupler shank 010.617.06 ''10.01'' .............................................................................................. ..............................................................................................84

11.2.2.1

Lock nut 3.050.023.06.03 3.050.023.06.0 3 ''10.03'' '' 10.03'' ...............................................................................................85

11.2.3

Bearing bracket 1.010.409.07 ''11.02'' ............................................................................. ......................................................................................... ............ 86

11.2.3.1

Bearing bracket 3.010.409.07.01 ''10.04'' ........................................................................ .................................................................................... ............ 87

11.2.4

Support 010.617.14 ................................................................... ..................................................................................................................... ..................................................88

5


11.2.5

Muff coupling half 3.010.131.36 ''10.05'' ..................................................................................... ..................................................................................... 89

11.2.6

Earthing system 010.617.43 ....................................................................................................... ....................................................................................................... 90

11.3

Special tools and test equipment ................................................................................................ ................................................................................................ 90

11.4

Materials ...................................................................................................................................... ...................................................................................................................................... 91


6

User Manual Figures Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

Figures Fig. 1-1 Fig. 3-1 Fig. 3-2 Fig. 3-3 Fig. 3-4 Fig. 3-5 Fig. 3-6 Fig. 3-7 Fig. 3-8 Fig. 4-1 Fig. 5-1 Fig. 5-2 Fig. 5-3 Fig. 6-1 Fig. 6-2 Fig. 6-3 Fig. 6-4 Fig. 6-5 Fig. 6-6 Fig. 6-7 Fig. 6-8 Fig. 6-9 Fig. 6-10 Fig. 6-11 Fig. 6-12 Fig. 6-13 Fig. 7-1 Fig. 7-2 Fig. 11-1 Fig. 11-2 Fig. 11-3 Fig. 11-4 Fig. 11-5 Fig. 11-6 Fig. 11-7 Fig. 11-8 Fig. 11-9 G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

"Front", "Rear", "Right" and a nd "Left" .................................................................................... ................................................................................................ ............ 10 Scharfenberg semipermanent coupler half 010.617 ....................................................................14 Air pipe connection 010.617.04 ................................................................................................... ................................................................................................... 17 Coupler shank 010.617.06 ...................................................................... ........................................................................................................... .....................................18 Force-displacement curve c urve of the collapsible tube .......................................................................19 Bearing bracket 010.409.07 .................................................................... ......................................................................................................... .....................................20 Support 010.617.14 ................................................................... ..................................................................................................................... ..................................................21 Muff coupling - simplified drawing ....................................................................... ................................................................................................ ......................... 22 Earthing system 010.617.43 ........................................................................................................ ........................................................................................................23 Muff coupling - simplified drawing ....................................................................... ................................................................................................ ......................... 26 Lubrication points of the coupler shank - simplified drawing ....................................................... .......................................................37 Lubricating nipple at the bearing bracket br acket - simplified drawing .....................................................38 Muff coupling ....................................................................................................... ................................................................................................................................ ......................... 38 Connection of the earth wire - simplified drawing ........................................................................46 Air pipe connection 010.617.04 ................................................................................................... ................................................................................................... 47 Bearing bracket 010.409.07 .................................................................... ......................................................................................................... .....................................49 Centring element - simplified drawing ................................................................. .......................................................................................... ......................... 51 Coupler shank 010.617.06 ...................................................................... ........................................................................................................... .....................................52 Centring element - simplified drawing ................................................................. .......................................................................................... ......................... 53 Bearing bracket 010.409.07 .................................................................... ......................................................................................................... .....................................55 Bearing bracket 010.409.07 .................................................................... ......................................................................................................... .....................................58 Correct installation position of the air pipe connections .............................................................. 60 Air pipe connection 010.617.04 ................................................................................................... ................................................................................................... 61 Muff coupling - simplified drawing ....................................................................... ................................................................................................ ......................... 62 Earthing system 010.617.43 ........................................................................................................ ........................................................................................................64 Connection of the earth wire - simplified drawing ........................................................................65 Hole configuration - view of the mounting surface of the product pr oduct ...............................................68 Scharfenberg semipermanent coupler half 010.617 ....................................................................69 Scharfenberg semipermanent coupler half 010.617 ....................................................................82 Air pipe connection 010.617.04 ................................................................................................... ................................................................................................... 83 Coupler shank 010.617.06 ''10.01'' .............................................................................................. ..............................................................................................84 Lock nut 3.050.023.06.03 3.050.023.06.0 3 ''10.03'' '' 10.03'' ...............................................................................................85 Bearing bracket 1.010.409.07 ''11.02'' ............................................................................. ......................................................................................... ............ 86 Bearing bracket 3.010.409.07.01 ''10.04'' ........................................................................ .................................................................................... ............ 87 Support 010.617.14 ................................................................... ..................................................................................................................... ..................................................88 Muff coupling half h alf 3.010.131.36 ''10.05'' .......................................................................... ...................................................................................... ............ 89 Earthing system 010.617.43 ........................................................................................................ ........................................................................................................90

Tables Tab. 3-1 Tab. 5-1 Tab. 6-1

Technical data 010.617........................................................................... 010.617................................................................................................................ .....................................13 Maintenance and overhaul levels ................................................................................................ ................................................................................................33 Maintenance and overhaul levels ................................................................................................ ................................................................................................46

7

User Manual Introduction Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

1 Introduction

Introduction The objective of this manual is to provide you with theoretical and practical knowledge on the product. Prior product knowledge is not required. However, it is strongly recommended to attend a hands-on training offered by Voith Turbo Scharfenberg. Manual structure This manual consists of the following chapters:  Introduction: Usage Usage notes for this manual  Safety: Structure Structure of the safety messages and definition of the risk levels Product description: Technical Technical data, overview drawing, intended use, description of the  product and its components  Operation: Instructions Instructions for the correct operation of the product Light maintenance: Maintenance Maintenance and repair which can be performed without requiring a  workshop.  Heavy maintenance: Maintenance Maintenance and repair at the removed product Mounting and removal: Mounting Mounting and Removal including commissioning and decommission ing  Transportation, storage and disposal: Handling Handling of the product before and after its use Troubleshooting: Diagnosis Diagnosis and remedy of defects   SCHAKU standards: Operational Operational standards of Voith Turbo Scharfenberg  Parts catalogue: Information Information required for the identification and ordering of spare parts

1.1 Copyright

Copyright All rights reserved for this technical document, also in the event of patent grant or utility model registration. No part of this document may be reproduced, disclosed to third parties or otherwise misused without prior written permission. Trademarks ®

®

®

®

®

®

®

Scharfenberg , Scharfenbergkupplung , SCHAKU , Couplomatic , GALEA , OctiConn , One4 ®

®

®

®

(China: 全固 ), QuatConn , RadiConn and TwinStroke are registered trademarks of Voith Turbo Scharfenberg GmbH & Co. KG. Trademarks of third-party products are written in CAPS and are subject to trademark rights of the respective owner. ©

Copyright Voith Turbo Scharfenberg GmbH & Co. KG. All rights reserved. Domicile Voith Turbo Scharfenberg GmbH & Co. KG


Gottfried-Linke-Straße 205 D-38239 Salzgitter

1.2

Usagenotesfor thismanual

Usage notes for this manual Product designation The designation of the product is given in the header of each page. This designation includes the drawing number of the product. Active header Each page identifies the chapter and section you are currently reading.

9

User Manual Introduction Selection of staff

Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

Issue The manual version is shown in the marginal note on each page. Simplification of drawings Illustrations explaining a working principle (e.g. coupler lock positions, lubrication schedule, etc.) are usually simplified and may slightly differ from the actual product. This is indicated by the words "simplified drawing" appended to the caption. Superfluous details have been removed from all drawings. Auxiliary lines that do not belong to the illustrated part but facilitate orientation are displayed in grey. The simplification of drawings is aimed at improving their understandability. If the unit of measurement is missing, all measures are given in millimetres [mm]. Other units of measurement are identified expressly. "Front", "Rear", "Right" and "Left" „Front“ refers to the direction away from the vehicle along the vehicle's longitudinal axis. Accordingly, "Rear" refers to the opposite direction. For Scharfenberg couplers, the designations "male cone side" and "female cone side" are used.

Fig. 1-1

"Front", "Rear", "Right" and "Left"

1 Longitudinal vehicle axis

4 Right (male cone side)

2 Rear

5 Left (female cone side)

3 Front

1.3 Selectionof staff

Selection of staff Only reliable and qualified staff is allowed to work on Voith Turbo Scharfenberg products. Responsibilities have to be strictly arranged. Untrained staff must be supervised.

1.4 Revisionindex

Revision index Version 1.

1.5 Approvaltable

Approval table Reviewed by Design Dept. Reviewed by RAMS Dept. Released by Documentation Dept. Prepared by

10

Department PM 3.1 PM 3.3 PS 2.1

Date 2012-10-25 2012-10-30 2012-10-24

PS 2.1

2012-10-26


User Manual Safety Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

2 Safety

Safety In order to prevent faulty product handling, the descriptions are provided with safety messages. Safety messages are always situated above the step they refer to. Indirect hazards The safety instructions refer to hazards which are directly associated with the product. Indirect hazards emanating from the vehicle are subject to the responsibility of the vehicle manufacturer and cannot be described by Voith Turbo Scharfenberg. Furthermore, the manual only describes hazards which may occur within the scope of intended use [chap.3.3  page 14] . Safety message structure

CAUTION Designation of the hazard. Short description of the hazard.  When does this hazard occur (only used exceptionally). 

What is is to be done in order to avert the hazard.  What is to be done when being exposed to the hazard (only used exceptionally).

Basically, all safety messages of this manual are structured in a similar manner: Safety symbols The following safety symbols are used in this manual:

DANGER TopTop-level -level hazard DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING MediumMedium-level -level hazard WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

LowLow-level -level hazard CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION Risk of damage to material. CAUTION, used without the safety symbol, indicates a hazardous situation which, if not avoided, could result in material damage.

11

User Manual Safety Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

NOTICE Useful tip. This note provides additional information that aims to facilitate the proper use of the product.


12

User Manual Product description Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

3

Productdescription

Product description This chapter describes the product. It contains the technical data, defines the intended use and describes the design, function, and working principle of the product and its components. Target group This chapter is addressed to readers wishing to learn more about the basics and components of the product. Technical qualification is not required to understand this chapter.

3.1 Technicaldata

Technical data This section contains the essential technical data of the product.

Compressive strength (Rp0.2) Tensile strength (Rp0.2) Length Total weight Collapsible tube

1500 kN

Pivot to coupler face

Tab. 3-1

Stroke On buff Maximum load On buff horizontal Vertical in accordance with painting specification [chap.10.1  page 77] Technical data 010.617

3.2

Overview drawing

Slewing range Paint

Overviewdrawing

1000 kN 1215 ± 5 mm 220 kg Approx. 250 mm 750 kN + 15 % ± 36° ± 6° KCG

This section provides an overview (Fig. 3-1) of the product indicating the most important dimensions.


13

User Manual Product description Intended use


Fig. 3-1

Scharfenberg semipermanent coupler half 010.617 4 Air pipe connection

3.3 Intendeduse

14 Support bracket

60 Hexagon bolt

6 Coupler shank

36 Muff coupling half

61 Hexagon nut

7 Bearing bracket

43 Earthing system

Intended use This section defines the intended use and describes examples of potential misuse. The product is exclusively intended for the usage scenarios described in the chapter Operation [chap.4  page 25] . The product is designed to be mounted to rail vehicles. It may only be mounted to the vehicles meeting the warranted qualities of Voith Turbo Scharfenberg and in accordance with the specified arrangement within the train set. When in doubt, please contact Voith Turbo Scharfenberg. The product is a coupler of the central buffer coupler type. Prior to commissioning the product, the following requirements have to be complied with:

14



  

3.3.1

General product description

The product is completely installed in accordance with the instructions given in this manual [chap.7.1  page 67] and in the vehicle manufacturer's documentation. The instructions given in the section Mounting and Commissioning [chap.7.1  page 67] must be complied with. All maintenance tasks described described in this manual have been performed.

Potential misuse This section describes examples of potential misuse, which are not be deemed exhaustive. The following applications are prohibited: Product modifications:     

Permanent or temporary installation of additional loads, subassemblies, objects or functional units, unless such action is warranted by the conditions of use specified in the contract Use of other spare parts than the Voith original parts given in the spare parts list of this manual Removal of components without replacement Mounting, leaning, leaning, supporting or applying additional loads or or devices during operation and when the vehicle is stationary (in the workshop), unless specified in the contract Permanent or temporary installation of additional weight weight or objects at the collapsible tube and its stroke area

Potential misuse:    

3.3.2

Coupling with couplers of a different type Lifting the vehicle by means of the product Pulling or pushing the vehicle, other vehicles or loads when uncoupled Operation of the product beyond the contractually agreed operating conditions

Use in case of restricted readiness for operation If the product has lost its operationally safe condition, the operation of the products is only possible with reservations. The operationally safe condition is limited when    

an energy absorption element is damaged components are deformed or broken the product is no longer safely attached to the vehicle the unrestricted mobility of the product is obstructed

Only towing is permitted after the product has lost its operationally safe condition. Towing is only permitted if the following prerequisites are complied with:  

The brake system of the towing vehicle vehicle must be in a fully functional condition. The joints joints and a articulation rticulation points of all involved couplers/articulations must be freely movable.

When in doubt, please contact Voith Turbo Scharfenberg. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

3.4

Generalproductdescription

General product description This section describes the design, function, and working principle of the product. Design The product consists of several modular components. The individual components are illustrated in the overview drawing ( [chap.3.2  page 13] ).    

Air pipe connection Coupler shank Bearing bracket Muff coupling

15

User Manual Product description General product description




Earthing system

Function The functions can be classified according to the different operating modes. The following functions are available for coupling and uncoupling operations:   

Centring when the vehicles approach Manual coupling and uncoupling by means of a muff coupling coupling Coupling of air pipe connections

The following functions are available for multiple-unit operation:  

Reliable mechanical connection in buff and draft directions Operationally limited gimballed movement between the vehicles

Further functions of the coupler are: Tensile and compressive loads are transmitted inside the coupler via the following components: Muff coupling between the couplers Coupler shank   Bearing bracket with pivot and screw connection to the vehicle During multiple unit operation, the energy absorption elements improve the travelling comfort and protect passengers, freight and vehicle from injuries or damage. 

The following components are energy absorption elements:  

The spherical spherical bearing bearing in the coupler shank has a low cushioning cushioning effect The collapsible collapsible tube in in the coupler shank shank cushions impacts destructively and protects the vehicle from damage

Working principle Coupling: After approaching two vehicles, the semipermanent coupler halves are coupled manually. Thus, a rigid connection of two semipermanent coupler halves is established. Simultaneously, the air pipe connections meet and connect the air pipes of the coupled vehicles. Uncoupling: The semipermanent coupler halves are uncoupled manually. As soon as the vehicles separate, the air pipes are disconnected. Gimballed movement: The articulation points enable gimballed movement of the coupled vehicles. Energy absorption: The energy absorption elements of the coupler are adapted to the specific requirements of the vehicle and to the respective position in the train configuration.


16


3.5

Descriptionof c omponents

Description of components

Description of components This section describes the design, function, and working principle of the individual components.

3.5.1

Air pipe connection This section describes the design, function, and working principle of the air pipe connection (Fig. 3-2).

Fig. 3-2

Air pipe connection 010.617.04

1 Air pipe connection

2 Gasket

7 Nut

C Centring sleeve

Design The air pipe connection consists of a pipe with a gasket. The air pipe connection is mounted parallel to the coupler shank. The gasket is located in the coupler face. Function The air pipe connection connects the air pipes of the coupled vehicles. Working principle During the coupling operation, the rubber gaskets are pressed against each other and form a reliable and tight connection.


17

User Manual Product description Description of components

3.5.2


Coupler shank This section describes the design, function, and working principle of the coupler shank (Fig. 3-3).

Fig. 3-3

Coupler shank 010.617.06 1 Collapsible tube

4 SCHAKU name plate

21 Intermediate piece

2 Drift

10 Spring type straight pin

22 Centring element

3 Guide pin

20 Drawbar

23 Lock nut

Design The coupler shank consists of the following parts:  

Centring element Collapsible tube

The front end of the coupler shank has a collar. The rear end of the coupler shank is provided with an eye and houses a spherical bearing. Function The coupler shank has a supporting function and forms the force flow line within the train set. The collar permits to connect the counter coupler by means of a muff coupling [chap.3.5.5  page 22] . In the train set, the drawgear protects the coupler and the vehicle from damage caused by loads exceeding the normal operating load. Impacts are cushioned by absorbing the impact energy.

18




Every energy absorption element is installed with a defined pre-stress. Characteristic values are release load, stroke, end load and energy absorption (see Technical Data [chap.3.1  page 13] ). The following energy absorption elements are installed:  The collapsible tube cushions excessive impacts in a destructive way The spherical bearing permits gimballed movement between the vehicles. Working principle Within the train set, both draft and buff loads are transmitted along the force flow line. The energy absorption element cushions extraordinary impacts. An impact which exceeds the maximum load of the energy absorption element is transmitted without further cushioning. The collapsible tube converts impact energy into friction and deformation energy: a pre-stressed drift is mounted in it. The pre-stress ensures a homogenous flow of forces during operation. Heavy impacts press the drift into the collapsible tube which is widened. The impact energy is converted into friction and deformation energy. The energy absorption increases proportionally with the stroke. After the impact, the stroke persists as backlash in the coupler shank, the product can no longer be used. The installation of a new collapsible tube is required to operate the product again. Force-displacement curve of collapsible tube:Fig. 3-4


Fig. 3-4

Force-displacement curve of the collapsible tube

19


3.5.3


Bearing bracket This section describes the design, function, and working principle of the bearing bracket (Fig. 35).

Fig. 3-5

Bearing bracket 010.409.07

5 Anti-friction disc

13 Drift

40 Bearing bracket

8 Pin

22 Lock nut

41 Supporting spring

9 Adjusting ring

23 Hexagon bolt

12 Lubricating nipple

24 Hexagon nut

Design The bearing bracket consists of the actual bearing bracket and a pivot. The bearing bracket has an even mounting surface and mounting bores. The front side of the bearing bracket is provided with two legs which are arranged on top of each other. The two legs accommodate the pivot which is inserted vertically. Function and working principle The bearing bracket connects the coupler shank and the vehicle underframe. It transmits draft and buff loads without producing any cushioning effect. The pivot connects the bearing bracket with the coupler shank and permits horizontal slewing of the coupler.

20



3.5.4


Support This section describes the design and function of the air pipe support bracket (Fig. 3-6).

Fig. 3-6

Support 010.617.14 1 Support bracket

10 Locking screw


Design The support is mounted to the coupler shank. Function The support carries the air pipe connections.


21


3.5.5


Muff coupling This section describes the design and function of the muff coupling connection (Fig. 3-7).

Fig. 3-7

Muff coupling - simplified drawing

Design The muff coupling consists of two muffs with screw connections. The muffs are placed around the collars of the components to be connected and then screwed together. Muff couplings can be installed horizontally, vertically, or in inclined position. Muff couplings intended for horizontal or inclined installation have a drain hole in the lower muff. Function The muff coupling is a clamped connection. The components to be joined are rigidly clamped together by the screws of the muff coupling. The screw connection is not situated in the flow of force of the coupler and is easily detachable.


22


3.5.6


Earthing system This section describes the design and function of the earthing system (Fig. 3-8).

Fig. 3-8

Earthing system 010.617.43 1 Hexagon bolt

4 Washer

11 Earth wire

2 Hexagon bolt

5 Earth label

12 Earth wire

3 Lock washer

10 Earth wire

Design The earthing system consists of copper wires connected to earth sockets. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

Function and working principle The earthing system bridges non-conductive parts and coatings between the components.

23

User Manual Operation Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

4 Operation

Operation This chapter describes the operation of the coupler. Target group This chapter is addressed to qualified technical staff, in particular to the staff of the operator, that has to move the vehicle from the driver's cab or to couple or uncouple manually. The target group has to be familiar with the basic principles of the product. A training by Voith Turbo Scharfenberg is highly recommended.

4.1 Coupling

Coupling This section describes how to connect the semipermanent coupler halves. Tools and Materials  Various standard tools Adjustable torque wrench   Hammer and piece of wood as cushion, or plastic hammer  Cleaner LOCTITE 7063 Primer and and top coat according to the Paint specification [chap.10.1  page 77] KCG   Grease AUTOL TOP 2000  Anti-seize RIVOLTA GWF Preparations

CAUTION Couplers may get damaged. If the semipermanent coupler halves do not match, they may get damaged. 

Before approaching the vehicles, make sure the semipermanent coupler halves are compatible with each other.

CAUTION Recommended torque for the screw connections of the muff muff couplings couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say:  The contact surfaces for screw screw head, washer and/or nut are only primed.  The contact surfaces are clean, dry and free of grease.  RIVOLTA GWF is applied to the threads only. 

If another another lubricant is used, the torque must be corrected accordingly.


25

User Manual Operation Coupling


CAUTION Replacement of fasteners Whenever parts or components are disassembled or removed, fasteners such as screws, nuts, washers, retaining rings, spiral rings and spring type straight pins have to be replaced.  

Replace all fasteners after loosening. When refitting parts, use new fasteners as specified in the Parts catalog.

1) If necessary, remove the muffs from the collar of the the coupler shank. 2) Check the semipermanent coupler halves for visible damage. 3) Clean the collars and muffs. 4) Grease the collars and contact surfaces of both semipermanent coupler halves with AUTOL TOP 2000.

Fig. 4-1


1 Right muff 2 Left muff 3 Hexagon bolt

4 Hexagon nut 5 Lock washer

10 Thread - treat with RIVOLTA GWF 11 Seat-engaging surfaces for screws and nuts - degrease with cleaner 12 Inner side of muffs - degrease with cleaner - prime only 13 Cavity - fill with AUTOL TOP 2000 15 Muff coupling collar - grease with AUTOL TOP 2000

Coupling

CAUTION Cables and hoses may chafe. Hoses and cables may chafe at horizontal muff couplings. 

26

Mount this muff coupling vertically.



Coupling

CAUTION Risk of overstressing of hexagon head screws Repeated re-tightening of screw connections to recommended torque may overstress screws.  

Carefully follow the specified procedure. If you are not sure which step of the procedure to take next, or if the current condition of the muff coupling cannot be clearly identified: the muff coupling once again.  Remove the  Replace the lock washers. washers.  Repeat the specified procedure.

CAUTION Risk of overstressing of hexagon head screws When the muffs are not parallel to each other, the contact surfaces for screw heads and hexagon nuts will tilt. This results in unilateral overload. 



During every step you carry out, be sure to verify that both muffs are parallel to each other. If the muffs are not parallel to each other: other:  Replace the lock washers. washers.  Repeat mounting.

1) Bring the two coupler halves into a line. line. 2) Slowly approach the vehicles and place the collars against each other. 3) Insert hexagon head screws (Fig. 4-1/1) into the bores of the muff (3). 4) Treat the threads of hexagon head screws (1) with anti-seize RIVOLTA GWF. 5)

Place right muff (3) on the collars, adjust vertically and fit on the collars by lightly tapping with a hammer.

6) Place left muff (6) on the collars. 7) Manually mount hexagon nuts (9) with lock washers washers (8) and align left left muff (6) such that that it is parallel to right muff (3). 8) Tighten hexagon nuts (9) crosswise, ensuring that the muffs remain parallel to each other. other. Recommended torque: 300 Nm. If one or more of the hexagon nuts have to be turned by more than 3 degrees to obtain the recommended torque: G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

9) Repeat the previous step. If the recommended torque has been obtained within a 3-degree angle of rotation for all hexagon nuts: 10) Verify the parallel position of the muffs. If the muffs are not parallel to each other: 11) Remove the muff coupling, replace the lock washers and mount the muff coupling again.

27

User Manual Operation Coupling


Final steps

CAUTION Anticorrosive paint is damaged after mounting Anti--corrosive After mounting, the anti-corrosive paint of screws, nuts and seat-engaging surfaces is damaged. Priming only is no sufficient corrosion protection. Immediately upon conclusion of the mounting procedure, the damaged surface must be fully repainted in accordance with the Paint specification [chap.10.1  page 77] . 

Repaint the screw connections.

1) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1  page 77] . 2) Fill cavity between hexagon head screws (1) and muff bores (3, 6) with grease AUTOL TOP 2000 in order to prevent corrosion. 3) Check if the air air pipes are air-tight (no hiss). 4) Refit [chap.  page 64] the earth wire between between the semipermanent coupler halves.


28


4.2 Uncoupling

Uncoupling

Uncoupling This section describes how to separate the semipermanent coupler halves. For safety reasons, all screw connections must be replaced when they have been disassembled or loosened. Tools and Materials Standard tools  Preparations 1) Remove the earth wire between the semipermanent coupler halves.

WARNING Risk of injury. Semipermanent coupler halves will abruptly lower during uncoupling.  

Support both semipermanent coupler halves. Keep sufficient safety distance.

2) Support the couplers. Uncoupling 1) Remove the hexagon nuts and lock washers. washers. 2) Remove the hexagon head screws from both muffs. 3) Loosen the muffs by tapping them with a cushioned hammer. 4) Separate the vehicles. Final steps 1) Replace the screw connections. 2) If desired, loosely loosely fix the the muffs to the free collar collar of the coupler shank.


29

User Manual Light maintenance Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

5

Lightmaintenance

Light maintenance This chapter describes the required light maintenance tasks. Definition Light maintenance includes tasks which can be performed directly at the vehicle. A workshop is not required. In contrast, heavy maintenance can only be performed in a workshop. Structure of this chapter This chapter includes the preparations as well as the required light maintenance tasks. The maintenance tasks are listed in the Maintenance schedule - light maintenance [chap.5.2  page 33] . Target group This chapter is addressed to qualified technical staff specialised in mechanical engineering (for mechanical and pneumatic components). The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain maintenance tasks. Replacement of parts In most cases a visual check for corrosion, wear and damage is sufficient to decide whether parts must be replaced or not.

CAUTION Replacement of fasteners Whenever parts or components are disassembled or removed, fasteners such as screws, nuts, washers, retaining rings, spiral rings and spring type straight pins have to be replaced.  


Gaskets and rubber tubes have to be replaced after removal and disassembly of a component at the latest. Recommended torque for new bolted joints G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

For bolted joints the following remarks apply.

31


CAUTION Recommended torque for bolted joints The recommended torque for screw connections applies to threads with a coefficient of friction µtotal=0.08 on all surfaces involved. That is to say:  The contact surfaces for screw head, washer and/or nut are only primed as

stated in the paint specification. with RIVOLTA GWF.  The contact surfaces and the threads are treated with If another another lubricant is used, the torque must be corrected accordingly. 

CAUTION Recommended torque for the screw connections of the muff muff couplings couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: screw head, washer and/or nut are only primed.  The contact surfaces for screw  The contact surfaces are clean, dry and free of grease.  RIVOLTA GWF is applied to the threads only. 


Specific agreements will be explicitly mentioned, where applicable. The hash (#) indicates that the respective item is to be tightened to a special torque. Check the torques of existing bolted joints For existing bolted joints tightened to a defined torque, a special test procedure [chap.5.8  page 40] is to be applied. The following note is added at the respective spot of the instructions:

NOTICE Checking the recommended torque 

Please respect the test procedure [chap.5.8  page 40] for bolted joints tightened to a defined torque.

Loosening of screw connections that are secured with threadlocker Screws, bolts, threaded pins etc. which are secured with acrylate glue must be heated cautiously before being loosened. The threadlocker gets pasty and the screw can be removed.


32


5.1 Materials

Materials

Materials

NOTICE Materials as specified The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any consequential damage. Rough cleaning Cleaning spray WEICON S (rough cleaning of all surfaces)   Cleaner LOCTITE 7063 (cleaning / degreasing for further treatment) Corrosion Protection Anti-corrosive ZINGA (corrosion protection for centring elements and coupler face - thick ness of coating must not exceed 30 µm)  Grease AUTOL TOP 2000 or grease spray AUTOL TOP 2000 (corrosion protection for all bearings, pivot points and sliding surfaces. Furthermore, if any: visible surfaces of regenerative buffers; muff coupling collars)  Anti-seize RIVOLTA GWF GWF (Corrosion protection for contact surfaces of screw heads and and nuts as well as threads of all screws and bolts; exception: on muff couplings, only screw threads are to be treated, contact surfaces for screws and nuts must remain untreated) Paint Paint according to Painting specification [chap.10.1  page 77]   Contrasting colour for earthing sockets Anti-sabotage lacquer, Rape yellow, yellow, RAL 1021, H05.975955

5.2

Maintenanceschedule- lightmaintenance

Maintenance schedule - light maintenance The maintenance schedule serves as an overview and quick reference to the maintenance tasks which are to be performed within the scope of light maintenance. These brief descriptions do not substitute the full descriptions referred to. The maintenance intervals are recommended values. They have to be reduced in case of adverse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing.


Maintenance level Maintenance level 1 (ML1) Not applicable Maintenance level 2 (ML2) Every 3 months Maintenance level 3 (ML3) Annually Maintenance level 4 (ML4) Not applicable Overhaul 1 (OH1) Every 6 years Overhaul 2 (OH2) Every 12 years Tab. 5-1 Maintenance and overhaul levels

5.2.1

Time interval

Light maintenance ML1 This maintenance level is not applicable.

5.2.2

Light maintenance ML2 The following tasks are to be performed within the scope of maintenance level 2:

33

User Manual Light maintenance Maintenance schedule - light maintenance


Preparations None. Entire coupler  Rough cleaning [chap.5.3  page 35] of the product Visual inspection [chap.5.4  page 36] for damage  Air pipe connection Only when the semipermanent coupler halves are separated: 

Clean the gasket with oil free compressed air or a grease-free grease-free rag

Coupler shank Perform a resonance test [chap.5.6  page 39] in order to check the collapsible tube for  tight seat, replace if necessary Muff coupling Check if muff bores are filled with with grease, re-grease if necessary (vertical muffs) 

5.2.3

Light maintenance ML3 The following tasks are to be performed within the scope of maintenance level 3: Preparations None. Entire coupler Rough cleaning [chap.5.3  page 35] of the product  Visual inspection [chap.5.4  page 36] for damage   Repair damage to paint coating [chap.5.9  page 40] (corrosion protection) Only when the semipermanent coupler halves are separated: 

Slew the coupler horizontally and vertically vertically (for slewing range refer to Technical data [chap.3.1  page 13] )

Air pipe connection Only when the semipermanent coupler halves are separated: 

Clean the gasket with oil free compressed air or a grease-free grease-free rag

Coupler shank Perform a resonance test [chap.5.6  page 39] in order to check the collapsible tube for  tight seat, replace if necessary Only when the semipermanent coupler halves are separated: 

Grease [chap.  page 37] muff coupling collar of semipermanent coupler half

Bearing bracket


 

34

Please respect the test procedure [chap.5.8  page 40] for bolted joints tightened to a defined torque. Check fastening screws for tight seat by means of a torque wrench. Recommended torque: refer to Mounting and commissioning [chap.7.1  page 67] . Remove the protection caps from the lubricating nipples



 

Rough cleaning

Use a grease gun to inject lubricant AUTOL TOP 2000. Refit the protection caps

Muff coupling  Check if muff bores are filled with with grease, re-grease if necessary (vertical muffs)




Please respect the test procedure [chap.5.8  page 40] for bolted joints tightened to a defined torque. Check [chap.5.8  page 40] fastening screws for tight seat by means of of a torque wrench. Recommended torque: refer to section Installing the muff coupling [chap.  page 61] .

Earthing system Check the earth wires for damage, replace if necessary.  Check all fasteners for tight seat and intact colour marking; if necessary, replace the fasten ers and apply a new colour marking.

5.2.4

Light maintenance ML4 This maintenance level is not applicable.

5.2.5

Heavy maintenance OH 1 and OH 2 Heavy maintenance (overhaul) includes tasks which have to be performed in a well-equipped workshop at regular intervals. The entire product must be removed [chap.7  page 67] maintenance.  

5.3 Roughcleaning

from the vehicle for heavy

Remove product according according to the instructions in in chapter Mounting and removal [chap.7  page 67] Overhaul the product in the the workshop according to the instructions given in the chapter Heavy maintenance [chap.6  page 43]

Rough cleaning Rough cleaning removes persistent dirt and enables the visual inspection. [chap.5.4  page 36] Tools and Materials Oil-free rags  Cleaner (spray) WEICON S  Preparations


CAUTION Surfaces of components may be damaged. Zinc and yellow chromate coated surfaces may get damaged by wrong cleaners. 

Do not use concentrated cleaners containing alkali, phosphoric acid, hydrochloric acid or benzene.

None.

35

User Manual Light maintenance Visual inspection


Rough cleaning of the product 1) Remove coarse dirt with with a dry cloth. 2) Wipe the the product with with a damp cloth. 3) To remove persistent dirt, spray surfaces with cleaner, allow the cleaner to act for some time and wipe off with a rag; repeat the procedure if necessary. Final steps None.

5.4 Visualinspection

Visual inspection The visual inspection serves to detect visible damage to the product. Tools and Materials  Light source (such as a flashlight) Preparations None. Visual inspection 1) Thoroughly check the entire product for visible damage. visibly damaged:  If the product is visibly 2) Repair the product. Final steps None.

5.5 Lubrication

Lubrication This section describes the lubrication points which can be accessed without removing the coupler from the vehicle. The couplers have to be separated. Tools and Materials Small, flat brush with stiff bristles   Grease AUTOL TOP 2000  Grease spray AUTOL TOP 2000 Anti-corrosive for coupler face ZINGA  Preparations

CAUTION Sliding surfaces may get damaged. Dirt on the sliding surfaces may damage these surfaces. 



36

First of all, all, remove the the dirt from all all sliding surfaces, for example by using brushes and rags. Having done this, grease the sliding sliding surfaces.



Lubrication

CAUTION Risk of lubrication breakdown. Different saponification characteristics of greases may impair proper lubrication. 

Do not mix different different types of grease.  Remove old grease before re-greasing.

CAUTION Rubber parts may get damaged. Grease may etch rubber parts or impair their elasticity. 

Keep rubber parts free from grease.

1) Clean [chap.5.3  page 35] the parts to be greased. Lubrication points of the coupler shank Only when the semipermanent coupler halves are separated, they are to be greased at the following points (Fig. 5-1):

Fig. 5-1


Lubrication points of the coupler shank - simplified drawing

Item Lubrication point 1Muff coupling collar 2Centring elements

Lubricant AUTOL TOP 2000 ZINGA

Lubricating nipples at bearing bracket Greasing the bearing bracket  - Remove the protection cap from the lubricating nipple (Fig. 5-2/1) - Use a grease gun to inject lubricant AUTOL TOP 2000. - Refit the protection cap.

37

User Manual Light maintenance Lubrication


Fig. 5-2

Lubricating nipple at the bearing bracket - simplified drawing

ItemLubrication point 1lubricating nipple

Lubricant AUTOL TOP 2000

Lubrication points of the muff coupling (Fig. 5-3)

Fig. 5-3

Muff coupling

ItemLubrication point 1Close cavity between screws and muff bores

Final steps None.

38

Lubricant AUTOL TOP 2000



5.6

Resonancetestof thecollapsible tube

Resonance test of the collapsible tube

Resonance test of the collapsible tube This section describes how to check the collapsible tube for tight seat.

NOTICE Resonance test of the collapsible tube By means of a resonance test, you can check whether the collapsible tube is sufficiently pre-stressed and firmly seated. We highly recommend training by our service personnel. Tools and Materials Various standard tools  Hammer  Preparations None. Conduct a resonance test 1) Give the collapsible tube of the coupler shank a gentle tap with a hammer and listen to the sound.  If you hear a sharp metallic sound: the collapsible tube is sufficiently pre-stressed and firmly seated.  If you hear a dull sound: replace collapsible tube [chap.  page 51] . Final steps None.

5.7

Replac gasketin theair pipeconnection

Replace the gasket in the air pipe connection The gasket has to be replaced at regular intervals according to the Maintenance schedule [chap.5.2  page 33] . This requires that the coupler halves be separated. Tools and Materials None. Preparations None.


Replace the gasket 1) Remove the gasket from the the groove. 2) Clean the groove. 3) Insert the n new ew gasket gasket into into the groove. Final steps None.

39

User Manual Light maintenance Check screw connections with a defined torque

5.8

Checkscrewconnections witha definedtorque


Check screw connections with a defined torque This section describes how to check screw connections tightened to a defined torque for tight seat. Tools and Materials  Torque spanner Preparations None. Check the torque 1) The recommended torque is given in in the instructions. 2) Adjust ratchet to 90% of the recommended torque. 3) Apply torque to respective bolted bolted joint. If the bolted joint has loosened: 4) Remove and dispose of screws. 5) Tighten screws to recommended torque. Final steps None.

5.9

Repairingthepaint coating

Repair the paint coating This section describes how to repair damaged paint coating of the product. This activity is based on the paint specification [chap.10.1  page 77] . The painting specification includes  

the general requirements as per Schaku standard K000 and the paint structure and colour as per Schaku standard KCG

Tools and Materials Abrasive   Paint brush  Cleaner LOCTITE 7063 Primer, top top coat and hardener according to the Paint specification [chap.10.1  page 77]  Preparations 1) Roughly clean [chap.5.3  page 35] the spot to be repaired. 2) Remove residual paint with emery paper. 3) Degrease the area to be repaired with cleaner. Repair the paint coating

NOTICE Respect drying times 

Be sure to observe the following drying times:  At room temperatur tem perature e (20 °C): 12 - 24 h (6 0 - 80 °C): 45 - 120 min  In warm air (60  IR/NIR drying: 30 - 60 min

1) Apply a thin layer of primer and allow to dry.

40



Repairing the paint coating

2) Apply a thin layer of top coat and allow to dry.



3) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1  page 77] .


41

User Manual Heavy maintenance Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

6

Heavymaintenance

Heavy maintenance maintenan ce This chapter describes the required heavy maintenance tasks. Definition Heavy maintenance (overhaul) includes tasks which have to be performed in a well-equipped workshop at regular intervals. The entire product must be removed [chap.7  page 67] from the vehicle for heavy maintenance. The instructions also apply for repair works. In contrast, light maintenance can be performed directly at the vehicle and does not require visiting a workshop. Structure of this chapter This chapter includes the preparations as well as the required heavy maintenance tasks. The instructions given in this chapter are subdivided as follows:   

Disassembling the product into its components. Disassembling, overhauling and assembling the individual components. Reassembling the overhauled product.

Target group This chapter is addressed to qualified technical staff specialised in mechanical engineering (for mechanical and pneumatic components). The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain maintenance tasks. Replacement of parts In most cases a visual check for corrosion, wear and damage is sufficient to decide whether parts must be replaced or not.

CAUTION Replacement of fasteners Whenever parts or components are disassembled or removed, fasteners such as screws, nuts, washers, retaining rings, spiral rings and spring type straight pins have to be replaced.   G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©


Gaskets and rubber tubes have to be replaced after removal and disassembly of a component at the latest. Recommended torque for new bolted joints For bolted joints the following remarks apply.

43

User Manual Heavy maintenance Standard tools




CAUTION Recommended torque for the screw connections of the muff muff couplings couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: screw head, washer and/or nut are only primed.  The contact surfaces for screw  The contact surfaces are clean, dry and free of grease.  RIVOLTA GWF is applied to the threads only. 


Specific agreements will be explicitly mentioned, where applicable. The hash (#) indicates that the respective item is to be tightened to a special torque. Check the torques of existing bolted joints For existing bolted joints tightened to a defined torque, a special test procedure [chap.5.8  page 40] is to be applied. The following note is added at the respective spot of the instructions:


Please respect the test procedure [chap.5.8  page 40] for bolted joints tightened to a defined torque.

Loosening of screw connections that are secured with threadlocker Screws, bolts, threaded pins etc. which are secured with acrylate glue must be heated cautiously before being loosened. The threadlocker gets pasty and the screw can be removed.

6.1 Standardtools

Standard tools The following standard tools are required for maintenance:         

44

Set of slotted screwdrivers Set of open-end wrenches Set of socket wrenches Set of ring wrenches Set of Allen wrenches Set of split pin drivers Fitter's hammer (1000 g) Chisel Adjustable torque wrench according to ISO 6789



         

Materials

Tools for bush removal Pliers for mounting and removing retaining rings Oil-free compressed air Clean rags Brushes Paint brush Electric torch Spirit level Seam gauge Abrasive

Any special tools and materials required for maintenance are identified at the beginning of the respective section. The lifting and transportation of bulky components during heavy maintenance requires suitable cranes, lifting straps and trestles. The use of chains is prohibited, in order to prevent damage to the product.

6.2 Materials

Materials

NOTICE Materials as specified The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any consequential damage. Rough cleaning Cleaning spray WEICON S (rough cleaning of all surfaces)   Cleaner LOCTITE 7063 (cleaning / degreasing for further treatment) Mixture of glycerol glycerol and ethyl alcohol (1:10) (removal of encrustations on rubber parts)  Corrosion Protection  Anti-corrosive ZINGA (corrosion protection for centring elements and coupler face - thickness of coating must not exceed 30 µm) Grease AUTOL TOP 2000 or grease spray AUTOL TOP 2000 (corrosion protection for all  bearings, pivot points and sliding surfaces. Furthermore, if any: visible surfaces of regenerative buffers; muff coupling collars) Anti-seize RIVOLTA GWF GWF (Corrosion protection for contact surfaces of screw heads and and  nuts as well as threads of all screws and bolts; exception: on muff couplings, only screw threads are to be treated, contact surfaces for screws and nuts must remain untreated)


Paint  Paint according to Painting specification [chap.10.1  page 77]  Contrasting colour for earthing sockets Anti-sabotage lacquer, Rape yellow, yellow, RAL 1021, H05.975955

6.3 Preparations

Preparations This section describes how to prepare the coupler for Heavy maintenance. 1) Uncouple the vehicles [chap.4  page 25] . 2) Remove the coupler from the vehicle [chap.7.2  page 71] , lay it down and support it using suitable aids.

45

User Manual Heavy maintenance Maintenance schedule - heavy maintenance

6.4

Maintenanceschedule- heavy maintenance


Maintenance schedule - heavy maintenance The maintenance intervals are recommended values. They have to be reduced in case of adverse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing. Maintenance level Maintenance level 1 (ML1) Not applicable Maintenance level 2 (ML2) Every 3 months Maintenance level 3 (ML3) Annually Maintenance level 4 (ML4) Not applicable Overhaul 1 (OH1) Every 6 years Overhaul 2 (OH2) Every 12 years Tab. 6-1 Maintenance and overhaul levels

6.5

Disassemblingthecoupler intoitscomponents

Time interval

Disassembling the coupler into its components This section describes how to disassemble the coupler into its individual components.

6.5.1

Remove the earthing system The section describes how to remove the earthing system. Tools and Materials  Various standard tools Preparations None. Remove the earthing system 1) Remove hexagon head screw (Fig. 6-1/2) from earth socket (5). 2) Remove lock washer (3) and washer (4).

Fig. 6-1 1 Cable lug

3 Lock washer

2 Hexagon bolt

4 Washer

Final steps None.

46

Connection of the earth wire - simplified drawing 5 Earth socket



6.5.2

Disassembling the coupler into its components

Remove the air pipe connection This section describes how to remove the air pipe connection. Tools and Materials  Various standard tools Preparations 1) Separate the air pipe pipe from the air pipe connection. Remove the air pipe connection 1) Remove hexagon nut (7, Fig. 6-2). 2) Pull air pipe connection (1) out of its guiding bore.

Fig. 6-2



2 Gasket

7 Nut

C Centring sleeve

Final steps None.


47

User Manual Heavy maintenance Disassembling the coupler into its components

6.5.3


Remove the coupler shank This section describes how to remove the coupler shank. Tools and Materials None. Preparations 1) Remove any parts attached to the coupler shank. 2) Support the coupler shank and the rubber cushion drawgear or bearing bracket. Remove the coupler shank  The coupler shank is connected to the bearing bracket by means of a pivot. The pivot is part

of the bearing bracket. 1) Remove the bearing bracket [chap.6.5.4  page 48] . Final steps 1) Place the coupler coupler shank and the bearing bracket on a suitable surface.

6.5.4

Remove the bearing bracket This section describes how to remove the bearing bracket. Tools and Materials Various standard tools  Preparations 1) Remove any parts attached to the coupler shank. 2) Support the coupler shank and the bearing bracket. Disassemble and remove the supporting spring 1) Loosen hexagon nuts (Fig. 6-3/24). 2) Remove hexagon head screw (23). 3) Pull supporting spring (41) out of pivot (8). Disassemble and remove the bearing bracket 1) Remove spring type straight pin (Fig. 6-3/22) at the bottom of the pivot (8). 2) Remove set collar (9). 3) Pull pivot (8) upwards and remove it from bearing bracket (40) and from the spherical bearing of the coupler shank. 4) Remove bearing bracket bracket (40) carefully from the coupler shank and lay it down.

48



Fig. 6-3

Disassembling the coupler into its components



13 Drift

40 Bearing bracket

8 Pin

22 Lock nut


9 Adjusting ring

23 Hexagon bolt


24 Hexagon nut

Final steps None.


49

User Manual Heavy maintenance Disassembling, overhauling and assembling the individual components

6.6

Disassembling, overhaulingandassemblingthe individualcomponents


Disassembling, overhauling and assembling the individual components This section describes how to disassemble the components, which parts to replace and how to overhaul and to reassemble the components.

6.6.1

Air pipe connection This section describes how to disassemble, overhaul and assemble the air pipe connection. Tools and Materials  Grease AUTOL TOP 2000  Anti-seize RIVOLTA GWF Preparations None. Disassemble the air pipe connection Not applicable. Replacement parts - overhaul 1 Worn parts   gasket Replacement parts - overhaul 2 All parts to be replaced during overhaul 1  Overhaul the air pipe connection 1) Clean the parts and check them for wear. 2) Repair the paint coating. 3) Apply RIVOLTA GWF to the the contact surfaces for screw heads and nuts as well as to the threads of screws and bolts. Assemble the air pipe connection Not applicable. Final steps None.

6.6.2

Coupler shank This section describes how to overhaul the coupler shank (Fig. 6-5). Tools and Materials  Standard tools Cleaner LOCTITE 7063  Grease AUTOL TOP 2000   Anti-seize RIVOLTA GWF Preparations 1) Support the components separately if necessary.

50



Disassembling, overhauling and assembling the individual components

Remove the centring elements Only if the centring element is damaged: 1) Remove spring type straight pin (Fig. 6-4/10) from centring centring element (1) and from the collar. 2) Remove centring element (1) from the collar of the coupler shank.

Fig. 6-4

Centring element - simplified drawing

1 Centring element

2 Centring pin


Remove the collapsible tube

NOTICE This work requires special training, tools and a powerful press. We strongly recommend: 

Return the complete coupler shank to the manufacturer for overhaul.

1) Return the complete coupler shank to the the manufacturer. Remove the spherical bearing

NOTICE This work requires special training, tools and a powerful press. We strongly recommend: 

Return the complete coupler shank to the manufacturer for overhaul.

1) Return the complete coupler shank to the the manufacturer. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

Replacement parts - overhaul 1  Fasteners Worn parts  Centring element (if damaged)   Spherical bearing (to be replaced by manufacturer) Replacement parts - overhaul 2 All parts to be replaced during overhaul 1 

51



Overhaul the coupler shank 1) Clean the parts and check them for wear. 2) Repair the paint coating.



3) Grease inner surface of spherical bearing with AUTOL TOP 2000. 4) Grease the centring elements according to the lubrication schedule [chap.5.5  page 36] 5) Grease the collar with AUTOL TOP 2000 lubricant. 6) Apply RIVOLTA GWF to the the contact surfaces for screw heads and nuts as well as to the threads of screws and bolts.

Fig. 6-5

Coupler shank 010.617.06 1 Collapsible tube

52

4 SCHAKU name plate

21 Intermediate piece

2 Drift


22 Centring element

3 Guide pin

20 Drawbar

23 Lock nut




Mount the collapsible tube Not applicable. Install the spherical bearing Not applicable Mount the centring elements 1) Insert centring element element (Fig. 6-6/1) into the collar collar of the coupler shank and align. 2) Secure centring element (1) using using spring type straight pins (10).

Fig. 6-6

Centring element - simplified drawing

1 Centring element

2 Centring pin


Final steps 1) Grease the collar with with AUTOL TOP 2000. 2) Grease the centring element with grease ZINGA.

6.6.3

Bearing bracket This section describes how to overhaul the bearing bracket (Fig. 6-7). The bearing bracket is removed [chap.6.5.4  page 48] and dismantled when disassembling the coupler. The overhauled bearing bracket is reassembled [chap.6.7.1  page 58] when mounting it to the coupler.


Tools and Materials  Various standard tools Cleaner LOCTITE 7063   Grease AUTOL TOP 2000 Preparations None. Disassemble the bearing bracket Not applicable. Replacement parts - overhaul 1 Fasteners 

53


    


Worn or damaged parts Anti-friction discs Bushes lubricating nipple Adjusting ring

Replacement parts - overhaul 2  All parts to be replaced during overhaul 1 Overhaul the bearing bracket 1) Clean the parts and check them for wear. 2) Replace bushes. 3) Repair the paint coating.



4) Grease the pivot, pivot, contact surfaces of anti-friction discs, sliding surfaces and guiding surfaces with grease AUTOL TOP 2000. 5) Apply RIVOLTA GWF to the the contact surfaces for screw heads and nuts as well as to the threads of screws and bolts.


54


Fig. 6-7




13 Drift

40 Bearing bracket

8 Pin

22 Lock nut


9 Adjusting ring

23 Hexagon bolt


24 Hexagon nut

Assemble the bearing bracket Not applicable. Final steps G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

None.

55


6.6.4


Muff coupling This section describes how to overhaul the muff coupling. Tools and Materials Various standard tools   Brush with stiff bristles  Grease AUTOL TOP 2000 Anti-seize RIVOLTA GWF   Stiff wire Preparations None. Disassemble the muff coupling Not applicable. Replacement parts - overhaul 1  Screws Lock washers   Nuts Replacement parts - overhaul 2 All parts to be replaced during overhaul 1  Overhaul the muff coupling

NOTICE Inner surfaces of muffs remain unpainted Inner surfaces of muffs must be primed only. 1) Clean the muffs. 2) Degrease the inside of the muffs with cleaner LOCTITE 7063. 3) Check the muffs for damage, replace muffs with cracks even outside of the maintenance intervals. 4) Repair the paint coating. 5) Grease inside inside of muffs with AUTOL TOP 2000. 6) Treat the screw threads with anti-seize RIVOLTA GWF. Assemble the muff coupling Not applicable. Final steps None.

56



6.6.5


Earthing system This section describes how to overhaul the earthing system. Tools and Materials  Anti-seize RIVOLTA GWF  Cleaner LOCTITE 7063 Emery cloth  Preparations None. Disassemble the earthing system Not applicable. Replacement parts - overhaul 1  Earth wires  Earth label Hexagon head screws, lock washers and washers  Replacement parts - overhaul 2  All parts to be replaced during overhaul 1 Overhaul the earthing system 1) Clean the earthing symbol, replace missing symbols 2) Clean the earthing sockets. 3) Apply RIVOLTA GWF to the the contact surfaces for screw heads and nuts as well as to the threads of screws and bolts. Assemble the earthing system Not applicable. Final steps None.


57

User Manual Heavy maintenance Assembling the coupler

6.7

Assemblingthecoupler


Assembling the coupler This section describes how to assemble the coupler.

6.7.1

Install the bearing bracket This section describes how to connect the bearing bracket to the coupler shank. Tools and Materials Grease AUTOL TOP 2000  Preparations 1) Support the coupler shank and bearing bracket using suitable aids.

Fig. 6-8



13 Drift

40 Bearing bracket

8 Pin

22 Lock nut


9 Adjusting ring

23 Hexagon bolt


24 Hexagon nut

Connect the bearing bracket to the coupler shank 1) Place lower anti-friction disc (Fig. 6-8/5) onto lower leg of bearing bracket (40).

58



Assembling the coupler

2) Place upper anti-friction disc (5) onto the eye of the coupler shank. shank. 3) Insert the coupler coupler shank horizontally into bearing bracket (40) without damaging anti-friction discs (5). 4) Grease pivot (8) with with AUTOL TOP 2000. 5) Insert pivot (8) from above into the bores of the bearing bracket and spherical bearing. 6) Mount adjusting ring (9) and secure with spring type straight pin (22). Mount the supporting spring 1) Slide supporting spring (41) onto pivot (8). 2) Mount supporting spring (41) with hexagon head screws (23) and hexagon nuts (24) on the coupler shank. Connect the bearing bracket to the coupler shank 1) Place lower anti-friction disc (3) onto lower leg of bearing bracket (50). 2) Place upper anti-friction disc (3) onto the eye of the coupler shank. shank. 3) Insert the coupler coupler shank horizontally into bearing bracket (50) without damaging anti-friction discs (3). 4) Grease pivot (2) with with AUTOL TOP 2000. 5) Insert pin (2) from above above into the bores of the bearing bracket and the spherical bearing of the coupler shank and secure the pin with retaining ring (33). Final steps None.

6.7.2

Install the coupler shank This section describes how to install the coupler shank. Tools and Materials  Various standard tools Preparations None. Install the coupler shank  The coupler shank is connected to the bearing bracket by means of a pivot. The pivot pivot is part

of the bearing bracket. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

1) Install the bearing bracket [chap.6.7.1  page 58] . Final steps None.

59


6.7.3


Install the air pipe connection This section describes how to install the air pipe connection. Tools and Materials None. Preparations None. Install the air pipe connection Fig. 6-9 shows the installation position of the air pipe connections.

Fig. 6-9

Correct installation position of the air pipe connections

R Upper air pipe connection: centring sleeve right* * front view according t o definition [chap.1.2  page 10]

1)

L

Lower air pipe connection: centring sleeve left*

Insert air pipe connection (1, Fig. 6-10) from the front side into its guiding bore.

2) Block air pipe connection (1) and fix hexagon nut (7) at the rear side.

60



Fig. 6-10




2 Gasket

7 Nut

C Centring sleeve

Final steps None.

6.7.4

Assemble the muff coupling - vertical configuration This section describes how to assemble the vertical muff coupling. Tools and Materials  Various standard tools Adjustable torque wrench  Hammer and piece of wood as cushion, or plastic hammer   Cleaner LOCTITE 7063 Primer and and top coat according to the Paint specification [chap.10.1  page 77] KCG  Grease AUTOL TOP 2000   Anti-seize RIVOLTA GWF Preparations

CAUTION Recommended torque for the screw connections of tthe he muff couplings The recommended torque for the screw connections of the muff couplings applies to a coefficient of friction on the threads of µtotal=0.08). That is to say: G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

 The contact surfaces for screw screw head, washer and/or nut are only primed.  The contact surfaces are clean, dry and free of grease.  RIVOLTA GWF is applied to the threads only. 


1) Grease the collars and contact surfaces of the components to be joined with grease grease AUTOL TOP 2000.

61



Fig. 6-11


1 Right muff 2 Left muff 3 Hexagon bolt

4 Hexagon nut 5 Lock washer

10 Thread - treat with RIVOLTA GWF 11 Seat-engaging surfaces for screws and nuts - degrease with cleaner 12 Inner side of muffs - degrease with cleaner - prime only 13 Cavity - fill with AUTOL TOP 2000 15 Muff coupling collar - grease with AUTOL TOP 2000

Install the muff coupling

CAUTION Cables and hoses may chafe. Hoses and cables may chafe at horizontal muff couplings. 

Mount this muff coupling vertically.

CAUTION Risk of overstressing of hexagon head screws Repeated re-tightening of screw connections to recommended torque may overstress screws.  

62

Carefully follow the specified procedure. If you are not sure which step of the procedure to take next, or if the current condition of the muff coupling cannot be clearly identified:  Remove the the muff coupling once again. washers.  Replace the lock washers.  Repeat the specified procedure.




CAUTION Risk of overstressing of of hexagon head screws When the muffs are not parallel to each other, the contact surfaces for screw heads and hexagon nuts will tilt. This results in unilateral overload. 



During every step you carry out, be sure to verify that both muffs are parallel to each other. If the muffs are not parallel to each other: other: washers.  Replace the lock washers.  Repeat mounting.

1) Support the components using using suitable aids. 2) Place the collars of of the components to be joined against each other other and align the collars. 3) Insert hexagon head screws (Fig. 6-11/1) into the bores bores of the muff (3). 4) Treat the threads of hexagon head screws (1) with anti-seize RIVOLTA GWF. 5)

Place right muff (3) on the collars, adjust vertically and fit on the collars by lightly tapping with a hammer.

6) Place left muff (6) on the collars. 7) Manually mount hexagon nuts (9) with lock washers washers (8) and align left left muff (6) such that that it is parallel to right muff (3). 8) Tighten hexagon nuts (9) crosswise, ensuring that the muffs remain parallel to each other. other. Recommended torque: 300 Nm. If one or more of the hexagon nuts have to be turned by more than 3 degrees to obtain the recommended torque: 9) Repeat the previous step. If the recommended torque has been obtained within a 3-degree angle of rotation for all hexagon nuts: 10) Verify the parallel position of the muffs. If the muffs are not parallel to each other: 11) Remove the muff coupling, replace the lock washers and mount the muff coupling again. Final steps 1) Fill cavity between hexagon head screws (1) and muff bores (3, 6) with grease AUTOL TOP 2000 in order to prevent corrosion. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

63


6.7.5


Install the earthing system This section describes how to install the earth wires. Fig. 6-12 shows the earthing system:

Fig. 6-12

Earthing system 010.617.43

1 Hexagon bolt

4 Washer

11 Earth wire

2 Hexagon bolt

5 Earth label

12 Earth wire

3 Lock washer

10 Earth wire

Tools and Materials Ohmmeter   Earthing symbol according to DIN EN 60417 (IEC 60417), symbol 5019  Cleaner LOCTITE 7063 Anti-sabotage lacquer, Rape yellow, RAL 1021 and paint brush   Terminal grease

64




Preparations

NOTICE Earthing points All earthing points have to be marked with an earthing label according to IEC 60417. 1) Thoroughly clean the bonding surface with with cleaner. 2) Apply the earthing symbol. 3) Clean the earthing sockets (5). Install the earthing system 1) Fasten cable lug lug (Fig. 6-13/1) with hexagon head screw (2), lock washer (3) and washer (4) to earthing socket (5).  Recommended torque: for screws M6 - 6.5 Nm for screws M8 - 15 Nm for screws M10 - 31 Nm for screws M12 - 53 Nm 2) Degrease hexagon head screw (2), lock lock washer (3), cable lug (1), washer (4) and and earthing socket (5) and mark them by applying a continuous stroke of Rape yellow paint. 3) Seal hexagon head screw (2), cable lug (1), lock lock washer (3), washer (4) and earthing socket (5) with terminal grease.

Fig. 6-13


Connection of the earth wire - simplified drawing

1 Cable lug

3 Lock washer

2 Hexagon bolt

4 Washer

5 Earth socket

Final steps

NOTICE Checking the earthing system Proper function of the earthing system must be verified by a qualified electrician. 1) Check the earthing system in accordance with EN 50153, section 6.4.

65

User Manual Heavy maintenance Final maintenance steps

6.8

Finalmaintenancesteps


Final maintenance steps 1) Check the earthing sockets [chap.  page 64] for proper colour marking and corrosion protection, repair if necessary.



2) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1  page 77] . 3) Paint over the joint gaps. 4) Paint unused joining and contact surfaces as well as threaded holes. 5) Seal threaded through-holes at the top side by applying plastic plugs. 6) Seal blind holes with with sealant SIKAFLEX 221 grey. Upon completion of the heavy maintenance activities, the product can be refitted to the vehicle as described in Mounting and commissioning [chap.7.1  page 67] .


66

User Manual Mounting and removal Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

7

Mountingandremoval

Mounting and removal This chapter describes the mounting of the product to the vehicle as well as its commissioning, decommissioning and removal from the vehicle. Target group This chapter is addressed to qualified technical staff specialised in mechanical engineering (for mechanical and pneumatic components). The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain maintenance tasks.

7.1

Mountingandcommissioning

Mounting and commissioning This section describes how to mount the product to the vehicle and how to put it into service. Tools and Materials  Standard tools  Crane and lifting straps Trestles   Ohmmeter  Compressed air (1 MPa = 10 bar) Soap solution   Anti-seize RIVOLTA GWF  Paint according to Painting specification [chap.10.1  page 77] Contrasting colour for earthing sockets Anti-sabotage lacquer, Rape yellow, yellow, RAL 1021,  H05.975955 Preparations

CAUTION Recommended torque for bolted bolted joints The recommended torque for screw connections applies to threads with a coefficient of friction µtotal=0.08 on all surfaces involved. That is to say:  The contact surfaces for screw head, washer and/or nut are only primed as



67

User Manual Mounting and removal Mounting and commissioning


CAUTION Inaccurate mounting dimensions may cause loss of function The proper functionality of the product relies on its precise mounting. The anchoring plate must be perfectly aligned with the longitudinal, horizontal and vertical axes of the vehicle and must be prepared in accordance with the hole configuration. 



Check the anchoring plate for perfect alignment with the longitudinal, horizontal and vertical axes of the vehicle. Make sure the holes in the anchoring plate correspond to the hole configuration.

 The anchoring plate of the vehicle must be plane and rectangularly aligned to the under-

frame both vertically and horizontally. 1) Check the anchoring plate for levelness and rectangularity in accordance with ISO 2768-H, adjust if necessary. 2) Make sure there is sufficient space behind the anchoring plate. 3) Make sure the the holes in in the anchoring plate correspond to the hole configuration (Fig. 7-1).

Fig. 7-1

Hole configuration - view of the mounting surface of the product

Mount the coupler 1) Align the coupler on the anchoring plate.

68



Mounting and commissioning




Fig. 7-2

Scharfenberg semipermanent coupler half 010.617 4 Air pipe connection

14 Support bracket

60 Hexagon bolt

6 Coupler shank

36 Muff coupling half

61 Hexagon nut

7 Bearing bracket

43 Earthing system

2) Treat the threads and seat-engaging surfaces of the fastening fastening screws to the vehicle with with RIVOLTA GWF.

69

User Manual Mounting and removal Mounting and commissioning


3) Insert the screws screws through the coupler and the anchoring plate (refer to overview drawing). drawing). 4) Apply the nuts nuts and lock washers (if any) and tighten firmly. Recommended torque for M36: 1700 Nm. 5) Route the air pipes such that they are not stretched or kinked and permit free horizontal and vertical movement of the coupler, even when it reaches its maximum swivelling angle (also refer to vehicle manufacturer's documentation). 6) Mount the air pipes according to the instructions of the vehicle manufacturer.

CAUTION Risk of coupler failure. Air pipes may leak after mounting.  Insufficient or excessive tightening of union nuts may lead to leakage or damage 

of the nuts, and thus to coupler failure. Check the air pipe adapters for leakage leakage using soapy water. Bubbles indicate leaking fittings which must be retightened. Stop tightening union nuts when the connection is tight.

7) Check the screw connections and fittings of the air pipes for leakage by applying soapy water, and retighten if necessary. Test pressure: 10 bar = 1 MPa. Maximum acceptable pressure drop: 0.1 bar in 5 minutes. 8) Mount the earthing system to the vehicle [chap.  page 64] , also observing the vehicle manufacturer's instructions.

NOTICE Checking the earthing system Proper function of the earthing system must be verified by a qualified electrician. 9) Check the earthing system in accordance with EN 50153, section 6.4. Final steps



1) Degrease all screw heads, nuts, washers, projecting threads, and seat-engaging surfaces, then prime and repaint such surfaces in accordance with the painting specification [chap.10.1  page 77] . 2) Paint over the joint gaps. Commissioning Observe the preparatory activities described under Coupling [chap.4.1  page 25] if the coupler is to be coupled afterwards.

70



7.2

Removalanddecommissioning

Removal and decommissioning

Removal and decommissioning This section describes how to remove the product from the vehicle and how to put it out of service. Tools and Materials  Standard tools Crane and lifting straps  Trestles  Preparations 1) Remove the air pipes between the coupler and the vehicle in in accordance with the vehicle manufacturer's instructions. 2) Remove the earthing system from the vehicle in accordance with with the vehicle vehicle manufacturer's instructions. 3) Support the product. Remove the coupler 1) Unscrew the screw connection. 2) Carefully remove the coupler from the anchoring anchoring plate. Decommissioning No special measures required. Final steps None.


71

User Manual Transportation, storage and disposal Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

8

Transportation, storageanddisposal

Transportation, storage and disposal This chapter describes how to prepare the product for transportation and storage and how to dispose of it. Target group This chapter is addressed to logistics personnel working with and handling the product. Previous knowledge of the product is not required. The product must be in a secure condition to enable safe handling.

8.1 Transportation

Transportation The completely assembled product is shipped on pallets or in boxes. Make sure it is tied up properly to avoid shipping damage.

8.2 Storage

Storage The product should be stored indoors, palletised and protected from exposure to direct sunlight. Prior to storage, corrosion has to be removed and the anticorrosive coating has to be applied again (refer to section Lubrication [chap.5.5  page 36] ). Articulation points, sliding surfaces, etc. must be sufficiently greased in order to ensure perfect operation.

8.3 Disposal

Disposal In case of free-of-charge return delivery to the manufacturer, the product will be disposed of at no cost.


73

User Manual Troubleshooting Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

9

Troubleshooting

Troubleshooting This chapter provides helpful information for the detection and correction of problems occurring during operation. The troubleshooting activities are to be performed in a logical order that allows to properly identify the source of the fault. The possible problems are indicated in the chapter headings. Prior to troubleshooting, a thorough visual inspection of the product has to be performed in order to find out if the fault has been caused by loose connections or damaged components. Troubleshooting is structured such that those faults which are the easiest to detect are mentioned first. The troubleshooting tables list only the most probable faults and their possible causes. It is also possible that several faults occur at the same time. If the fault cannot be classified immediately, start your troubleshooting activities with the mechanical coupling problems as these are the easiest to detect. These brief descriptions do not substitute the full descriptions referred to.

9.1 Targetgroup

Target group This chapter is addressed to qualified technical staff in charge of operating the vehicle from the driver's cab or performing manual coupling and uncoupling operations. Troubleshooting should be performed exclusively by experienced and qualified staff to make sure all faulty operations are identified and evaluated correctly and appropriate measures are taken. The target group has to be familiar with the basic principles of the product. Participation in a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certain troubleshooting activities.

9.2 Earthingsystem

Earthing system Coupler parts conduct electric current  



9.3

Air pipeconnectionfails

Check screws screws of earthing system system for tight seat, tighten if necessary Check earthing system for corrosion and clean if necessary; replace corroded screws and washers Check the earth wires wires for damage, replace if necessary

Air pipe connection fails Failures affecting the air pipe connection are usually indicated by a pressure drop. In a quiet environment the affected spots can be identified by a hissing noise, but this is impossible during train operation. A better way is to apply soapy water to the hoses to be checked. Bubbles indicate spots which are not tight.

9.3.1 G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

Pressure drop when coupled Parts of air pipe connection are damaged Gasket is damaged 

Replace gasket

Hose to vehicle leaks 

9.4

Coupler isi nwrongposition

Replace hose

Coupler is in wrong position Not applicable.

75

User Manual Troubleshooting Unusual noise during operation

9.4.1


Coupler is misaligned Muff coupling has come loose 

Replace the screw connections

Screws are torn off 

Replace the screw connections

9.5

Unusual noise during operation

9.5.1

Clattering/knocking noise

Unusualnoiseduring operation

Collapsible tube has collapsed   

Drive vehicle to workshop workshop in emergency mode [chap.3.3.2  page 15] Remove coupler shank Replace the collapsible tube

Spherical bearing is damaged 

Next time in workshop, remove coupler shank and return to manufacturer for overhaul overhaul

Muff coupling is loose  

Drive vehicle to workshop workshop in emergency mode [chap.3.3.2  page 15] Replace all fastening screws, check collars and muffs for damage and mount muff coupling [chap.  page 61] again


76

User Manual SCHAKU standards Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

10 SCHAKUstandards

SCHAKU standards This section covers the product relevant SCHAKU standards. SCHAKU standards are in-house standards, work instructions or specifications which are applied internally by Voith Turbo Scharfenberg. The SCHAKU standards referred to in this section must be taken into account when working with Voith Turbo Scharfenberg products.

10.1 Paintspecification

Paint specification This section describes how to paint steel parts. The product is to be painted in accordance with the SCHAKU paint specification KCG.

10.1.1

General requirements (SCHAKU standard K000) This section explains how to repair the paint coat according to SCHAKU-Norm K000 and points out general requirements to be met while carrying out the repair work. The information given in the section "paint structure" further below and/or in specific instructions may differ from what is outlined below, have specification character and is to be applied preferably. Not to be painted Keep the following parts and surfaces free from any coating:   

Sealing and sliding surfaces Rubber parts, plastic caps and plastic hoods Stainless steel screws for fastening of earth wires

Paint allowed here The following parts and surfaces may be painted:  

Stainless steel screws Casing of the air pipe connection

To be primed only The following parts must be primed only:    

Rear side side of bearing bracket / base plate (film thickness min. 15 µm, max. 40 µm) Seat engaging surfaces of screws and contact surfaces of coupler components Non-visible coupler parts (inner surfaces of hollow parts) Surfaces of the muffs and and muff collars to be joined.

Electro-plated surfaces Anti-corrosion coatings on electroplated screws may be damaged by tools. Subsequent to mounting such screws must be manually coated with protective varnish to K150. Tolerances for dry film thickness: G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

 

Minimum dry film thickness: 60 µm Maximum dry film thickness: 200 µm

Tools and Materials  Air blow gun  Clean paint brushes Abrasive   Alkaline cleaners  Organic solvents Detergent (de-ionised water)   Drying aids (clean, lint-free rags; dry, oil-free compressed air)  Masking material

77

User Manual SCHAKU standards Paint specification

 


Primer, top coat and hardener according to SCHAKU standard KCG Sealing compound SIKAFLEX 221 grey, TSK.979637

Cleaning The following cleaning procedures are admissible:  

Cleaning with suitable, e.g. alkaline, cleaners followed by rinsing with with de-ionised de-ionised water Degreasing with organic solvents, and if necessary, additional sanding of the surfaces, followed by washing and rinsing

Preparations 1) Surface impurities like like wax, grease, oil, coolant, release agent, hand perspiration etc. are to be removed with suitable solvents or cleaners. 2) Rinse, then dry surface. 3) Roughen and clean clean the surface if necessary. 4) Prime surface within 4 hours. For stainless steel, the following DB TL 918 301,1989 for small areas:

instructions

apply

according

to

the

data

sheet

5) De-grease. 6) Sanding with abrasive paper/pads. 7) Clean. For aluminium, the following instructions apply according to the data sheet DB TL 918 301,1989 for small areas: 8) De-greasing with organic solvents. 9) Sanding with abrasive paper/pads. 10) Cleaning with organic solvents. Paint 1) Mix and apply paint in accordance with the manufacturer's instructions. 2) Seal threaded through-holes on the top side by inserting appropriate plugs (see parts catalogue). 3) Seal blind holes with with sealant SIKAFLEX 221 grey.

10.1.2

Paint structure (SCHAKU-Norm K150) This section describes the paint structure in accordance with SCHAKU standard K150 with the colour specified in SCHAKU standard KCG. Paint structure Paint ready for use  Non-visible coupler parts have to be primed once   Visible coupler parts have to be primed once and painted once with top coat The final film thickness of primer and top coat is 220 µm The tolerance for the overall dry dr y film thickness is +30 µm or 30 % maximum. m aximum. Special requirements take precedence.

78


User Manual SCHAKU standards Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

Sealing and securing of screw connections (SCHAKU standard A023)

NOTICE Respect drying times 

Be sure to observe the following drying times: tem perature e (20 °C): 12 - 24 h  At room temperatur  In warm air (60 (6 0 - 80 °C): 45 - 120 min  IR/NIR drying: 30 - 60 min

Primer 2-component epoxy metal primer, water dilutable Light ivory to colour scale RAL 1015; H05.975761 With epoxy hardener, water dilutable; H05.975760 mixing ratio (weight proportion) 2:1 Dry film thickness 80 µm Top coat 2-component epoxy top coat, water dilutable Colour Jet black RAL 9005; H05.975763 With epoxy hardener, water dilutable; H05.975759 mixing ratio (weight proportion) 1.7:1 Dry film thickness 140 µm

10.2

Sealingandsecuring of screwconnections(SCHAKU standardA023)

Sealing and securing of screw connections (SCHAKU standard A023) This standard defines how to lock screw connections. Procedure All threaded male sockets of pipe adapters, bite type fittings, cable glands and threaded adapters are to be secured with threadlocker:  

Threaded pipe adapters up to 1/4”: LOCTITE 572 Threaded pipe adapters larger than 1/4”: LOCTITE 586

Zinc and yellow chromate coated parts Consider a longer cure time of approx. 24h when treating zinc and yellow chromate coated parts. Stainless steel parts If stainless steel or nickel plated parts are used, an activator must be applied to stimulate the passive material by copper ions which makes the adhesive cure. G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

Special requirements Special agreements or other dedicated specifications shall take precedence.

79

User Manual Parts catalogue Voith Turbo Scharfenberg GmbH & Co. KG | Scharfenberg Semipermanent Coupler Half 010.617

11 Partscatalogue

Parts catalogue catalog ue The parts catalogue lists all parts of the product broken down to screw level. Glued parts are only listed if they are available as spare parts. Parts of an inseparable unit are not listed.

11.1 Structureof theparts list

Structure of the parts list Item Item number. Non-illustrated parts are marked with "n.i." not illustrated. Designation Designation of the item or subassembly. Spare part kit elements are marked with footnotes. DrwNo/Code (drawing number) SCHAKU drawing number for SCHAKU parts or standard reference for standardised parts and further information, if necessary. ID No. Number to be quoted when ordering parts. Q (Quantity) Items per assembly Hash (#) The hash (#) indicates that the respective item is to be tightened to a special torque.


81

User Manual Parts catalogue Structure of the parts list

11.2


Scharfenberg semipermanent coupler half 010.617

Fig. 11-1

Scharfenberg semipermanent coupler half 010.617

Item

Designation

DrwNo/Code

-

Scharfenberg semipermanent coupler half

010.617

ID No. Q 231.002986 10 9 D CG 1

4

Air pipe connection

010.617.04

230.025310 10 0

2

6

Coupler shank

010.617.06 ''10.01''

230.024951 10 0

1

7

Bearing bracket

1.010.409.07 ''11.02''

TSK.993863 11 0

1

14

Support

010.617.14

230.025286 10 0

1

36

Muff coupling half

3.010.131.36 ''10.05''

TSK.127975 10 0

1

43

Earthing system

230.024961 10 0

1

60

Hexagon bolt

010.617.43 ISO 4014 M36x240 8.8 A3 Cr(VI)-free

TSK.982085 10 9

4

61

Hexagon nut

ISO 7040 M36 8 A3 Cr(VI)-free TSK.298892 10 9

4 G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

82


11.2.1

Structure of the parts list


Fig. 11-2


Item

Designation

DrwNo/Code

ID No.

Q

1

Air pipe connection

010.617.04.00.01

230.025309 10 0

1

2

Gasket

3.000.088.03.00.16 ''10.12''

TSK.171906 10 0

1

7

Nut

DIN 80705 M45x2 14H A3P

TSK.952853 10 0

1


83


11.2.2


Coupler shank 010.617.06 ''10.01''

Fig. 11-3

Coupler shank 010.617.06 ''10.01''

Item

Designation

DrwNo/Code

ID No.

Q

1

Collapsible tube

VR3.0750.15.00.250 ''10.02''

230.024952 10 9

1

2

Drift

4.010.108.06.00.01 ''11.01''

TSK.125559 11 9

1

3

Guide pin

4.010.380.06.00.03 ''10.01''

TSK.997700 11 0

1

4

SCHAKU name plate

TSK.183954 10 0

1

10

Spring type straight pin

4.SK0.3025 ''10.08'' ISO 8752 10x22 St GEOMET 321-B Plus

H01.164072

4

20

Drawbar

010.617.06.01 ''10.01''

230.024953 10 0

1

21

Intermediate piece

010.617.06.05

230.024959 10 0

1

22

Centring element

3.050.023.06.00.01 ''10.02''

TSK.978467 10 0

1

23

Lock nut

3.050.023.06.03 ''10.03''

TSK.978847 10 0

1

84



11.2.2.1


Lock nut 3.050.023.06.03 ''10.03''

Fig. 11-4

Lock nut 3.050.023.06.03 ''10.03''

Item

Designation

DrwNo/Code

ID No.

Q

1

Nut

3.050.023.06.00.12 ''11.01''

TSK.978769 12 9

1

2

Locking bolt

4.050.023.06.00.13 ''10.02''

TSK.978848 10 0

1

5


ISO 8752 4x28 A

TSK.264408 10 0

1

8

Thrust piece

-

TSK.955474 10 0

2


85


11.2.3


Bearing bracket 1.010.409.07 ''11.02''

Fig. 11-5

Bearing bracket 1.010.409.07 ''11.02''

Item

Designation

DrwNo/Code

ID No.

Q

5

Anti-friction disc

4.010.199.07.00.04 ''10.02''

TSK.969854 10 0

4

8

Pin

3.050.053.07.00.01 ''10.03''

TSK.993835 10 9

1

9

Adjusting ring

3.050.053.07.00.02 ''12.00''

230.011080 12 0

1

12

Lubricating nipple

DIN 71412 A-M8x1 5.8 A3F

TSK.171971 10 0

2

13

Dust protection cap

2

22


23

Hexagon bolt

TSK.254325 10 0 ISO 8752 10x100 St GEOMET 321-B Plus H01.164043 ISO 4017 M24x160 8.8 A3 Cr(VI)-free TSK.955497 10 0

2

24

Hexagon nut

ISO 4032 M24 8 A3P

TSK.113419 10 9

4

40

Bearing bracket

3.010.409.07.01 ''10.04''

TSK.993862 10 0

1

41

Supporting spring

1.010.298.07.01 ''10.03''

TSK.982947 10 0

1

86

1



11.2.3.1


Bearing bracket 3.010.409.07.01 ''10.04''

Fig. 11-6

Bearing bracket 3.010.409.07.01 ''10.04''

Item

Designation

DrwNo/Code

ID No.

Q

7

Bush

4.010.409.01.01.07 ''10.02''

TSK.993860 10 0

1

8

Bush

4.135.004.07.00.06

TSK.995290 10 0

1


87


11.2.4


Support 010.617.14

Fig. 11-7

Support 010.617.14

Item

Designation

DrwNo/Code

ID No.

Q

1

Support

230.025285 10 0

1

10

Locking screw

TSK.960443 10 0

4

25


010.617.14.00.01 VERBUS RIPP W158.12 M12x40 100 GEOMET 321 B PLUS VL ISO 8752 10x36 St GEOMET 321-B Plus

H01.164111

2


88


11.2.5


Muff coupling half 3.010.131.36 ''10.05''

Fig. 11-8

Muff coupling half 3.010.131.36 ''10.05''

Item

Designation

DrwNo/Code

ID No.

Q

1

Muff

TSK.136985 10 9

1

4

Hexagon bolt

1.010.077.36.00.01 ''10.08'' ISO 4014 M20x160 8.8 A3 Cr(VI) free

TSK.110786 10 9

2

5

Hexagon nut

ISO 4032 M20 8 A3 Cr(VI)-free TSK.113417 10 9

2

6

Lock washer

VS20

2

TSK.960439 11 0


89

User Manual Parts catalogue Special tools and test equipment

11.2.6



Fig. 11-9


Item

Designation

DrwNo/Code

ID No.

Q

1

Hexagon bolt

DIN 933 M10x16 A2-70

TSK.101023 10 0

4

2

Hexagon bolt

DIN 933 M10x20 A2-70

TSK.101024 10 0

2

3

Lock washer

VS10

TSK.951338 10 0

6

4

Washer

ISO 7089 10 A2 200HV

TSK.101119 10 0

6

5

Earth label

TSK.971719 10 0

5

10

Earth wire

TSK.987955 10 0

2

11

Earth wire

230.001926 10 0

1

12

Earth wire

4.SK0.5143.00.00.03 ''10.01'' 4.E10.050.030.030.00 ''11.08'' type 107 - 50mm²x500 4.E10.050.030.030.00 ''11.08'' type 122 - 50mm²x850 4.E10.050.030.030.00 ''11.08'' type 123 - 50mm²x540

230.002545 10 0

1

11.3

Specialtools andtest equipment

Special tools and test equipment None.

90



11.4 Materials

Materials

Materials

NOTICE Materials as specified The descriptions of this manual imply the use of the indicated materials. If any other materials are used, Voith Turbo Scharfenberg cannot be held liable for any consequential damage. The following materials are required for maintenance: Lubricants Grease AUTOL TOP 2000 (TSK.289470)   Grease spray AUTOL TOP 2000 (TSK.985083)  Penetrating oil RIVOLTA T.R.S. Plus (TSK.261929) Terminal grease (H05.976020)  Anti-seize  Anti-seize RIVOLTA GWF (TSK.348880) Cleaners  CleanerLOCTITE 7063 (TSK.977974)  Cleaner (spray) WEICON S (TSK.353917) Activator Activator LOCTITE 7649 (for stainless steel materials) (TSK.978862)  Threadlocker Threadlocker, medium strength LOCTITE 243 (TSK.978135)   Threadlocker, high strength LOCTITE 270 (TSK.979436) Thread sealant Thread sealant, medium strength LOCTITE 572 (TSK.977856)  Sealing compound, high strength LOCTITE 586 (TSK.978141)  Sealants and adhesives Sealing compound SIKAFLEX 221 grey (TSK.979637)  Paint  Paint according to Painting specification [chap.10.1  page 77] Contrasting colour for earthing sockets Anti-sabotage lacquer, Rape yellow, yellow, RAL 1021,  H05.975955 G K . o C & H b m G g r e b n e f r a h c S o 1 b r n 6 u o 2 T i s h r 0 t i e 1 - o V 2 V 1 7 2 1 0 1 6 . 2 0 0 k s 2 1 t 0 v ©

91

Scharfenberg Semipermanent Coupler Half 010.617 User Manual.pdf

Recommend Documents