Periodic Overhauling of FIAT High Speed Railway Bogie in the Workshop--Part II

Activities in D1 Schedule: Every Trip/Weekly Monthly Schedule/D2 30 days ± 3 days
a) Activities in Trip Schedule.
b) Visual inspection of coupler head for damage.
c) Inspection of knuckle for damage
d) Checking of coupler operating mechanism for damage/ loose bolts etc.
e) Greasing of glide rod of coupler operating mechanism (once in 3 months)
f) Checking of telltale recess, for ensuring proper coupling.
g) Inspection of coupler carrier/supporting device and its springs for cracks and breakage.
h) Inspection of loose / broken / missing nuts and bolts (M-16) of coupler pin support plate and draft gear support plate.

Activities in D2 Schedule
a) Visual check for external damage, condition of wear plate on shank. Replace wear plate if necessary.
b) Check height 187.5 mm both sides near the bolts. Tighten the M16 nut to set specified height.
c) Apply grease on wear plate.
d) Check condition of wear plate. Replace wear plate if necessary
e) Visual check for external damage, loose bolts etc.
f) Apply grease on the slide and slide rods

• Six Monthly Schedule/D3 : 180 days ± 15 days
a) Coat bare steel areas of coupler head body and knuckle with Molykote D321R (or equivalent) dry spray. CAUTION: Do not spray on the knuckle locking surface and internal parts like lock etc.
b) Check gap between coupler head and knuckle with Jaw gap gauge (NO-GO). If wear out is not acceptable replace knuckle etc., as advised in the maintenance manual.
c) Check by profile gauge (GO).
d) Conduct anti-creep check
e) Examine condition of buff plate. Apply grease if necessary
f) Check wear on slide, slide rods and bearings. Replace if wear is excessive.

• ( Shop Schedule I) /SS-I : 18 Month±30 days/6 Lakhs Kms earned whichever is earlier
a) Inspection of coupler assembly by gauges: -
b) Checking of knuckle contour by contour maintenance gauge.
c) Checking of free slack in the contour by contour condemning limit gauge.
d) Checking of distortion of aligning wing pocket and guard arm by aligning wing limit gauge and guard arm distortion gauge.
e) Checking of vertical height of aligning wing pocket and guard arm by vertical height aligning wing pocket and guard arm gauge.
f) Wear of aligning wing pocket and guard arm to be checked by vertical height condemning limit aligning wing pocket and guard arm gauge.
g) Checking of knuckle nose wear and stretch limit by knuckle nose wear and stretch limit gauge.
h) Inspection of anti-creep protection
i) Measurement of coupler height 1105 mm from rail level- Reference point – Vertical centre of knuckle or centre of shank
j) Checking of proper locking
k) Cleaning of CBCs
l) Checking of functional operation of coupler
m) Checking of operation of coupler operating mechanism

• Shop Schedule II / SS-II : 3 Years/12 Lakhs Kms earned whichever is earlier
• Shop Schedule III /SS-III :6Years/24 Lakhs Kms earned whichever is earlier
a) All parts of CBC and allied accessories to be dismantled and overhauled as per OEM’s manual.
b) Visual inspection be made for cracks, damages, distortions etc.
c) Checking wear of toggle, lock lift lever etc.
d) Checking of wear of coupler shank wear plate
e) Checking for wear of lock of knuckle, pivot pin of knuckle and knuckle support pin.
f) Damage of draft gear rubber pads and its checking for pre-compression value.
g) Final assembly and checking of functional operation of coupler.