Scharfenberg Semipermanent Coupler Half 010.617 User Manual.pdf

8/17/2019 Scharfenberg Semipermanent Coupler Half 010.617 User Manual.pdf

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User Manual - Scharfenberg Semiperma-nent Coupler Half 010.617

Version 1





User Manual

Table of Contents

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

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Table of ContentsTableof Contents

1 Introduction .................................................................................................................................. 9

1.1 Copyright ........................................................................................................................................ 9

1.2 Usage notes for 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 - light maintenance ................................................................................. 33



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




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

5.3 Rough cleaning ........................................................................................................................... 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 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 - heavy maintenance .............................................................................. 46

6.5

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

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

6.5.2 Remove the air pipe connection .................................................................................................. 47

6.5.3 Remove the coupler 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 shank ............................................................................................................. 59

6.7.3 Install the air pipe connection ...................................................................................................... 60

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

6.7.5

Install the earthing system .......................................................................................................... 64



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

7

Mounting and 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................................................................................................................... 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 (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 ''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



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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



User Manual

Figures


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FiguresFig. 1-1 "Front", "Rear", "Right" and "Left" ................................................................................................ 10

Fig. 3-1


Fig. 3-2 Air pipe connection 010.617.04 ................................................................................................... 17

Fig. 3-3 Coupler shank 010.617.06 ........................................................................................................... 18

Fig. 3-4

Force-displacement curve of the collapsible tube ....................................................................... 19

Fig. 3-5 Bearing bracket 010.409.07 ......................................................................................................... 20

Fig. 3-6 Support 010.617.14 ..................................................................................................................... 21

Fig. 3-7

Muff coupling - simplified drawing ................................................................................................ 22

Fig. 3-8 Earthing system 010.617.43 ........................................................................................................ 23

Fig. 4-1 Muff coupling - simplified drawing ................................................................................................ 26

Fig. 5-1

Lubrication points of the coupler shank - simplified drawing ....................................................... 37

Fig. 5-2 Lubricating nipple at the bearing bracket - simplified drawing ..................................................... 38

Fig. 5-3 Muff coupling ................................................................................................................................ 38

Fig. 6-1

Connection of the earth wire - simplified drawing ........................................................................ 46



Fig. 6-4

Centring element - simplified drawing .......................................................................................... 51

Fig. 6-5 Coupler shank 010.617.06 ........................................................................................................... 52

Fig. 6-6 Centring element - simplified drawing .......................................................................................... 53

Fig. 6-7

Bearing bracket 010.409.07 ......................................................................................................... 55


Fig. 6-9

Correct installation position of the air pipe connections .............................................................. 60

Fig. 6-10

Air pipe connection 010.617.04 ................................................................................................... 61

Fig. 6-11

Muff coupling - simplified drawing ................................................................................................ 62

Fig. 6-12

Earthing system 010.617.43 ........................................................................................................ 64

Fig. 6-13

Connection of the earth wire - simplified drawing ........................................................................ 65

Fig. 7-1 Hole configuration - view of the mounting surface of the product ............................................... 68

Fig. 7-2


Fig. 11-1



Fig. 11-3

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

Fig. 11-4

Lock nut 3.050.023.06.03 ''10.03'' ............................................................................................... 85

Fig. 11-5 Bearing bracket 1.010.409.07 ''11.02'' ......................................................................................... 86

Fig. 11-6

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

Fig. 11-7

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

Fig. 11-8 Muff coupling half 3.010.131.36 ''10.05'' ...................................................................................... 89

Fig. 11-9

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

Tables

Tab. 3-1 Technical data 010.617................................................................................................................ 13

Tab. 5-1 Maintenance and overhaul levels ................................................................................................ 33

Tab. 6-1

Maintenance and overhaul levels ................................................................................................ 46





User Manual

Introduction


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1 IntroductionIntroduction

The objective of this manual is to provide you with theoretical and practical knowledge on theproduct. Prior product knowledge is not required. However, it is strongly recommended to attenda hands-on training offered by Voith Turbo Scharfenberg.

Manual structure

This manual consists of the following chapters:

Introduction: Usage notes for this manual Safety: Structure of the safety messages and definition of the risk levels Product description: Technical data, overview drawing, intended use, description of the

product and its components Operation: Instructions for the correct operation of the product Light maintenance: Maintenance and repair which can be performed without requiring a

workshop. Heavy maintenance: Maintenance and repair at the removed product Mounting and removal: Mounting and Removal including commissioning and decommission-

ing Transportation, storage and disposal: Handling of the product before and after its use Troubleshooting: Diagnosis and remedy of defects SCHAKU standards: Operational standards of Voith Turbo Scharfenberg Parts catalogue: Information required for the identification and ordering of spare parts

1.1 CopyrightCopyright

All rights reserved for this technical document, also in the event of patent grant or utility modelregistration. 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 ofthe 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 Usage notes for this manualUsagenotesfor thismanual

Product designation

The designation of the product is given in the header of each page. This designation includesthe drawing number of the product.

Active header

Each page identifies the chapter and section you are currently reading.



User Manual

Introduction

Selection of staff Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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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 thewords "simplified drawing" appended to the caption.

Superfluous details have been removed from all drawings. Auxiliary lines that do not belong tothe 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 ofmeasurement 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 Selection of staffSelectionof 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 Revision indexRevisionindex

Version 1.

1.5 Approval tableApprovaltable

Department Date Reviewed by Design Dept. PM 3.1 2012-10-25Reviewed by RAMS Dept. PM 3.3 2012-10-30Released by DocumentationDept.

PS 2.1 2012-10-24

Prepared by PS 2.1 2012-10-26



User Manual

Safety


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2 SafetySafety

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. Indirecthazards emanating from the vehicle are subject to the responsibility of the vehicle manufacturerand cannot be described by Voith Turbo Scharfenberg.

Furthermore, the manual only describes hazards which may occur within the scope of intendeduse [chap.3.3 page 14] .

Safety message structure

CAUTIONCAUTIONCAUTIONCAUTION

Designation of the hazard.Designation of the hazard.Designation of the hazard.Designation of the hazard.

Short description of the hazard.

When does this hazard occur (only used exceptionally).

What 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:

DANGERDANGERDANGERDANGERTopTopTopTop----level hazardlevel hazardlevel hazardlevel hazard

DANGER indicates a hazardous situation which, if not avoided, will result in death or

serious injury.

WARNINGWARNINGWARNINGWARNING

MediumMediumMediumMedium----level hazardlevel hazardlevel hazardlevel hazard

WARNING indicates a hazardous situation which, if not avoided, could result in death

or serious injury.


LowLowLowLow----level hazardlevel hazardlevel hazardlevel hazard

CAUTION indicates a hazardous situation which, if not avoided, could result in minor

or moderate injury.


Risk of damage to material.Risk of damage to material.Risk of damage to material.Risk of damage to material.

CAUTION, used without the safety symbol, indicates a hazardous situation which, if

not avoided, could result in material damage.



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Safety


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NOTICENOTICENOTICENOTICE

Useful tip.Useful tip.Useful tip.Useful tip.

This note provides additional information that aims to facilitate the proper use of the

product.



User Manual

Product description


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3 Product descriptionProductdescription

This chapter describes the product. It contains the technical data, defines the intended use anddescribes 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 ofthe product. Technical qualification is not required to understand this chapter.

3.1 Technical dataTechnicaldata

This section contains the essential technical data of the product.

Compressive strength(Rp0.2)

1500 kN

Tensile strength (Rp0.2) 1000 kN

Length Pivot to coupler face 1215 ± 5 mmTotal weight 220 kg

Collapsible tube Stroke On buff Approx. 250 mmMaximum load On buff 750 kN + 15 %

Slewing range horizontal ± 36°

Vertical ± 6°

Paint in accordance with painting specification [chap.10.1 page 77]

KCG

Tab. 3-1 Technical data 010.617

3.2 Overview drawingOverviewdrawing

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

sions.



User Manual

Product description

Intended use Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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Fig. 3-1 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

3.3 Intended useIntendeduse

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 vehiclesmeeting the warranted qualities of Voith Turbo Scharfenberg and in accordance with the speci-fied 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:



User Manual

Product description


General product description

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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 in this manual have been performed.

3.3.1 Potential misuse

This section describes examples of potential misuse, which are not be deemed exhaustive. Thefollowing applications are prohibited:

Product modifications:

Permanent or temporary installation of additional loads, subassemblies, objects or functionalunits, 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 thismanual

Removal of components without replacement Mounting, leaning, supporting or applying additional loads 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 or objects at the collapsible tube

and its stroke area

Potential misuse:

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

3.3.2 Use in case of restricted readiness for operation

If the product has lost its operationally safe condition, the operation of the products is only pos-sible 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 onlypermitted if the following prerequisites are complied with:

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

ble.

When in doubt, please contact Voith Turbo Scharfenberg.

3.4 General product descriptionGeneralproductdescription

This section describes the design, function, and working principle of the product.

Design

The product consists of several modular components. The individual components are illustratedin the overview drawing ( [chap.3.2 page 13] ).

Air pipe connection Coupler shank Bearing bracket

Muff coupling



User Manual

Product description

General product description Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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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 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 comfortand protect passengers, freight and vehicle from injuries or damage.

The following components are energy absorption elements:

The spherical bearing in the coupler shank has a low cushioning effect The collapsible tube in the coupler 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 thevehicle and to the respective position in the train configuration.



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Product description


Description of components

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3.5 Description of componentsDescriptionof c omponents

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 thecoupler 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 areliable and tight connection.



User Manual

Product description

Description of components Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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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

DesignThe 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 loadsexceeding the normal operating load. Impacts are cushioned by absorbing the impact energy.



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Product description



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Every energy absorption element is installed with a defined pre-stress. Characteristic values arerelease 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 themaximum load of the energy absorption element is transmitted without further cushioning.

The collapsible tube converts impact energy into friction and deformation energy: a pre-stresseddrift 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 isconverted 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 long-er 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



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3.5.3 Bearing bracket

This section describes the design, function, and working principle of the bearing bracket (Fig. 3-5).

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 thebearing 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 draftand buff loads without producing any cushioning effect.

The pivot connects the bearing bracket with the coupler shank and permits horizontal slewing ofthe coupler.



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Product description



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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 25 Spring type straight pin

Design

The support is mounted to the coupler shank.

Function

The support carries the air pipe connections.



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Product description


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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 aroundthe collars of the components to be connected and then screwed together.

Muff couplings can be installed horizontally, vertically, or in inclined position. Muff couplings in-tended 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 clampedtogether by the screws of the muff coupling. The screw connection is not situated in the flow offorce of the coupler and is easily detachable.



User Manual

Product description



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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.

Function and working principle

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





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Operation


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4 OperationOperation

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 VoithTurbo Scharfenberg is highly recommended.

4.1 CouplingCoupling

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 top coat according to the Paint specification [chap.10.1 page 77] KCG Grease AUTOL TOP 2000 Anti-seize RIVOLTA GWF

Preparations


Couplers may get damaged.Couplers may get damaged.Couplers may get damaged.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 halvesare compatible with each other.


Recommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the muff couplingsRecommended torque for the screw connections of the 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:

The contact surfaces for 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 lubricant is used, the torque must be corrected accordingly.



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Operation

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

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Replacement of fastenersReplacement of fastenersReplacement of fastenersReplacement 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 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 AUTOLTOP 2000.


1 Right muff 10 Thread- treat with RIVOLTA GWF

2 Left muff 11 Seat-engaging surfaces for screws and nuts- degrease with cleaner

3 Hexagon bolt 12 Inner side of muffs

- degrease with cleaner- prime only

4 Hexagon nut 13 Cavity- fill with AUTOL TOP 2000

5 Lock washer 15 Muff coupling collar- grease with AUTOL TOP 2000

Coupling


Cables and hoses mayCables and hoses mayCables and hoses mayCables and hoses may chafe.chafe.chafe.chafe.

Hoses and cables may chafe at horizontal muff couplings.

Mount this muff coupling vertically.



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Operation


Coupling

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Risk of overstressing of hexagon head screwsRisk of overstressing of hexagon head screwsRisk of overstressing of hexagon head screwsRisk 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 condi-tion of the muff coupling cannot be clearly identified:

Remove the muff coupling once again. Replace the lock washers. Repeat the specified procedure.



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 toeach other.

If the muffs are not parallel to each other:

Replace the lock washers. Repeat mounting.

1) Bring the two coupler halves into a 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 tappingwith a hammer.

6) Place left muff (6) on the collars.

7) Manually mount hexagon nuts (9) with lock washers (8) and align left muff (6) such that it isparallel to right muff (3).

8) Tighten hexagon nuts (9) crosswise, ensuring that the muffs remain parallel to each 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 rec-ommended torque:

9) Repeat the previous step.

If the recommended torque has been obtained within a 3-degree angle of rotation for all hexa-gon nuts:

10) Verify the parallel position of the muffs.


11) Remove the muff coupling, replace the lock washers and mount the muff coupling again.



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Operation

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Final steps


AntiAntiAntiAnti----corrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mountingcorrosive paint is damaged after mounting

After mounting, the anti-corrosive paint of screws, nuts and seat-engaging surfaces is

damaged. Priming only is no sufficient corrosion protection. Immediately upon conclu-

sion of the mounting procedure, the damaged surface must be fully repainted in ac-

cordance 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 TOP2000 in order to prevent corrosion.

3) Check if the air pipes are air-tight (no hiss).

4) Refit [chap. page 64] the earth wire between the semipermanent coupler halves.



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Operation


Uncoupling

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4.2 UncouplingUncoupling

This section describes how to separate the semipermanent coupler halves.

For safety reasons, all screw connections must be replaced when they have been disassembledor loosened.

Tools and Materials Standard tools

Preparations

1) Remove the earth wire between the semipermanent coupler halves.

WARNINGWARNINGWARNINGWARNING

Risk of injury.Risk of injury.Risk of injury.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.

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 fix the muffs to the free collar of the coupler shank.





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Light maintenance


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5 Light maintenanceLightmaintenance

This chapter describes the required light maintenance tasks.

Definition

Light maintenance includes tasks which can be performed directly at the vehicle. A workshop isnot 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 groupThis chapter is addressed to qualified technical staff specialised in mechanical engineering (formechanical and pneumatic components).

The target group has to be familiar with the basic principles of the product. Participation in atraining by Voith Turbo Scharfenberg is highly recommended and mandatory for certain mainte-nance tasks.

Replacement of parts

In most cases a visual check for corrosion, wear and damage is sufficient to decide whetherparts must be replaced or not.





to be replaced.



Gaskets and rubber tubes have to be replaced after removal and disassembly of a componentat the latest.

Recommended torque for new bolted joints

For bolted joints the following remarks apply.



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Recommended torque for bolted jointsRecommended torque for bolted jointsRecommended torque for bolted jointsRecommended 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 asstated in the paint specification.

The contact surfaces and the threads are treated with RIVOLTA GWF.






The contact surfaces for 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.


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:


Checking the recommended torqueChecking the recommended torqueChecking the recommended torqueChecking the recommended torque

Please respect the test procedure [chap.5.8 page 40] for bolted joints tightenedto 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 cautious-ly before being loosened. The threadlocker gets pasty and the screw can be removed.



User Manual

Light maintenance


Materials

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5.1 MaterialsMaterials

NOTICENOTICENOTICENOTICEMaterials as specifiedMaterials as specifiedMaterials as specifiedMaterials 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 conse-

quential 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 regenera-tive buffers; muff coupling collars)

Anti-seize RIVOLTA GWF (Corrosion protection for contact surfaces of screw heads andnuts as well as threads of all screws and bolts; exception: on muff couplings, only screwthreads 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, RAL 1021,

H05.975955

5.2 Maintenance schedule - light maintenanceMaintenanceschedule- lightmaintenance

The maintenance schedule serves as an overview and quick reference to the maintenancetasks 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 ad-verse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing.

Maintenance level Time interval Maintenance level 1 (ML1) Not applicableMaintenance level 2 (ML2) Every 3 monthsMaintenance level 3 (ML3) Annually

Maintenance level 4 (ML4) Not applicableOverhaul 1 (OH1) Every 6 yearsOverhaul 2 (OH2) Every 12 yearsTab. 5-1 Maintenance and overhaul levels

5.2.1 Light maintenance ML1

This maintenance level is not applicable.


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



User Manual

Light maintenance

Maintenance schedule - light maintenance Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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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 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 grease, re-grease if necessary (vertical muffs)


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)


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

Air pipe connection


Clean the gasket with oil free compressed air or a 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 necessaryOnly when the semipermanent coupler halves are separated:

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

Bearing bracket




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



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Rough cleaning

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

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




Check [chap.5.8 page 40] fastening screws for tight seat by means 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.


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-equippedworkshop at regular intervals.

The entire product must be removed [chap.7 page 67] from the vehicle for heavy

maintenance. Remove product according to the instructions in chapter Mounting and removal [chap.7

page 67] Overhaul the product in the workshop according to the instructions given in the chapter

Heavy maintenance [chap.6 page 43]

5.3 Rough cleaningRoughcleaning

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


Surfaces of components may be damaged.Surfaces of components may be damaged.Surfaces of components may be damaged.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, hydrochloricacid or benzene.

None.



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Light maintenance

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Rough cleaning of the product

1) Remove coarse dirt with a dry cloth.

2) Wipe the product with a damp cloth.

3) To remove persistent dirt, spray surfaces with cleaner, allow the cleaner to act for sometime and wipe off with a rag; repeat the procedure if necessary.

Final steps

None.

5.4 Visual inspectionVisualinspection

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. If the product is visibly damaged:

2) Repair the product.

Final steps

None.

5.5 LubricationLubrication

This section describes the lubrication points which can be accessed without removing the cou-pler 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


Sliding surfaces may get damaged.Sliding surfaces may get damaged.Sliding surfaces may get damaged.Sliding surfaces may get damaged.

Dirt on the sliding surfaces may damage these surfaces.

First of all, remove the dirt from all sliding surfaces, for example by using brushesand rags.

Having done this, grease the sliding surfaces.



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Lubrication

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Risk of lubrication breakdown.Risk of lubrication breakdown.Risk of lubrication breakdown.Risk of lubrication breakdown.

Different saponification characteristics of greases may impair proper lubrication.

Do not mix different types of grease.

Remove old grease before re-greasing.


Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.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 fol-lowing points (Fig. 5-1):

Fig. 5-1 Lubrication points of the coupler shank - simplified drawing

Item Lubrication point Lubricant

1Muff coupling collar AUTOL TOP 20002Centring elements 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.



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Light maintenance

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Fig. 5-2 Lubricating nipple at the bearing bracket - simplified drawing

ItemLubrication point Lubricant1lubricating nipple AUTOL TOP 2000

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

Fig. 5-3 Muff coupling

ItemLubrication point Lubricant1Close cavity between screws and muff

boresAUTOL TOP 2000

Final steps

None.



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Light maintenance


Resonance test of the collapsible tube

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5.6 Resonance test of the collapsible tubeResonancetestof thecollapsible tube

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


Resonance test of the collapsible tubeResonance test of the collapsible tubeResonance test of the collapsible tubeResonance test of the collapsible tube

By means of a resonance test, you can check whether the collapsible tube is suffi-

ciently 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 thesound. 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 Replace the gasket in the air pipe connectionReplac gasketin theair pipeconnection

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 groove.

2) Clean the groove.

3) Insert the new gasket into the groove.

Final steps

None.



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Light maintenance

Check screw connections with a defined torque Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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5.8 Check screw connections with a defined torqueCheckscrewconnections witha definedtorque

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 the instructions.

2) Adjust ratchet to 90% of the recommended torque.

3) Apply torque to respective 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 Repair the paint coatingRepairingthepaint 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 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


Respect drying timesRespect drying timesRespect drying timesRespect drying times

Be sure to observe the following drying times:

At room temperature (20 °C): 12 - 24 h In warm air (60 - 80 °C): 45 - 120 min IR/NIR drying: 30 - 60 min

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



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













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Heavy maintenance


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6 Heavy maintenanceHeavy maintenance

This chapter describes the required heavy maintenance tasks.

Definition

Heavy maintenance (overhaul) includes tasks which have to be performed in a well-equippedworkshop at regular intervals.

The entire product must be removed [chap.7 page 67] from the vehicle for heavy mainte-nance.

The instructions also apply for repair works.

In contrast, light maintenance can be performed directly at the vehicle and does not require vis-iting 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 (formechanical and pneumatic components).


Replacement of parts

In most cases a visual check for corrosion, wear and damage is sufficient to decide whetherparts must be replaced or not.





to be replaced.



Gaskets and rubber tubes have to be replaced after removal and disassembly of a componentat the latest.

Recommended torque for new bolted joints

For bolted joints the following remarks apply.



User Manual

Heavy maintenance

Standard tools Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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The contact surfaces for 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.


Specific agreements will be explicitly mentioned, where applicable.


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:




Loosening of screw connections that are secured with threadlocker

Screws, bolts, threaded pins etc. which are secured with acrylate glue must be heated cautious-ly before being loosened. The threadlocker gets pasty and the screw can be removed.

6.1 Standard toolsStandardtools

The following standard tools are required for maintenance:

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



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Heavy maintenance


Materials

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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 therespective section.

The lifting and transportation of bulky components during heavy maintenance requires suitablecranes, lifting straps and trestles. The use of chains is prohibited, in order to prevent damage tothe product.



Materials as specifiedMaterials as specifiedMaterials as specifiedMaterials as specified



quential damage.

Rough cleaning Cleaning spray WEICON S (rough cleaning of all surfaces) Cleaner LOCTITE 7063 (cleaning / degreasing for further treatment) Mixture of 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 - 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 regenera-tive buffers; muff coupling collars)

Anti-seize RIVOLTA GWF (Corrosion protection for contact surfaces of screw heads andnuts 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, RAL 1021,

H05.975955

6.3 PreparationsPreparations

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.



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Heavy maintenance

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6.4 Maintenance schedule - heavy maintenanceMaintenanceschedule- heavy maintenance

The maintenance intervals are recommended values. They have to be reduced in case of ad-

verse operating conditions (e.g. in winter). This applies in particular to cleaning and greasing.Maintenance level Time interval

Maintenance level 1 (ML1) Not applicableMaintenance level 2 (ML2) Every 3 monthsMaintenance level 3 (ML3) AnnuallyMaintenance level 4 (ML4) Not applicableOverhaul 1 (OH1) Every 6 yearsOverhaul 2 (OH2) Every 12 yearsTab. 6-1 Maintenance and overhaul levels

6.5 Disassembling the coupler into its componentsDisassemblingthecoupler intoitscomponents

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 Connection of the earth wire - simplified drawing

1 Cable lug 3 Lock washer 5 Earth socket

2 Hexagon bolt 4 Washer

Final steps

None.



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6.5.2 Remove the air pipe connection

This section describes how to remove the air pipe connection.


Preparations

1) Separate the air 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.




Final steps

None.





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Final steps

None.



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6.6 Disassembling, overhauling and assembling the individual componentsDisassembling, overhaulingandassemblingthe individualcomponents

This section describes how to disassemble the components, which parts to replace and how tooverhaul 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 contact surfaces for screw heads and nuts as well as to thethreads 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.



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Remove the centring elements

Only if the centring element is damaged:

1) Remove spring type straight pin (Fig. 6-4/10) from 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 10 Spring type straight pin

Remove the collapsible tube


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 manufacturer.

Remove the spherical bearing


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 manufacturer.

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




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Overhaul the coupler shank




Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.



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.


Fig. 6-5 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



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Mount the collapsible tube

Not applicable.

Install the spherical bearing

Not applicable

Mount the centring elements

1) Insert centring element (Fig. 6-6/1) into the collar of the coupler shank and align.

2) Secure centring element (1) using spring type straight pins (10).

Fig. 6-6 Centring element - simplified drawing

1 Centring element 2 Centring pin 10 Spring type straight pin

Final steps

1) Grease the collar 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 disassemblingthe coupler. The overhauled bearing bracket is reassembled [chap.6.7.1 page 58] whenmounting 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



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


Overhaul the bearing bracket


2) Replace bushes.


CAUTIONCAUTIONCAUTIONCAUTIONRubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.Rubber parts may get damaged.



4) Grease the pivot, contact surfaces of anti-friction discs, sliding surfaces and guiding surfac-es with grease AUTOL TOP 2000.




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Assemble the bearing bracket

Not applicable.

Final steps

None.



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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 couplingNot applicable.

Replacement parts - overhaul 1 Screws Lock washers Nuts


Overhaul the muff coupling

NOTICENOTICENOTICENOTICEInner surfaces of muffs remain unpaintedInner surfaces of muffs remain unpaintedInner surfaces of muffs remain unpaintedInner 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 in-tervals.


5) Grease 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.



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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


Overhaul the earthing system

1) Clean the earthing symbol, replace missing symbols

2) Clean the earthing sockets.


Assemble the earthing system

Not applicable.

Final steps

None.



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6.7 Assembling the couplerAssemblingthecoupler

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.






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).



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2) Place upper anti-friction disc (5) onto the eye of the coupler shank.

3) Insert the coupler shank horizontally into bearing bracket (40) without damaging anti-friction

discs (5).

4) Grease pivot (8) 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 thecoupler shank.

Connect the bearing bracket to the coupler shank1) 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.

3) Insert the coupler shank horizontally into bearing bracket (50) without damaging anti-frictiondiscs (3).

4) Grease pivot (2) with AUTOL TOP 2000.

5) Insert pin (2) from above into the bores of the bearing bracket and the spherical bearing ofthe 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.


Preparations

None.

Install the coupler shank

The coupler shank is connected to the bearing bracket by means of a pivot. The pivot is partof the bearing bracket.

1) Install the bearing bracket [chap.6.7.1 page 58] .

Final steps

None.



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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* L Lower air pipe connection: centring sleeve left** front view according to definition [chap.1.2 page 10]

1) 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.



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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 top coat according to the Paint specification [chap.10.1 page 77] KCG Grease AUTOL TOP 2000 Anti-seize RIVOLTA GWF

Preparations


Recommended torque for the screw connections of tRecommended torque for the screw connections of tRecommended torque for the screw connections of tRecommended torque for the screw connections of the muff couplingshe muff couplingshe muff couplingshe muff couplings



The contact surfaces for 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 AUTOLTOP 2000.



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1 Right muff 10 Thread- treat with RIVOLTA GWF

2 Left muff 11 Seat-engaging surfaces for screws and nuts- degrease with cleaner

3 Hexagon bolt 12 Inner side of muffs- degrease with cleaner- prime only

4 Hexagon nut 13 Cavity- fill with AUTOL TOP 2000

5 Lock washer 15 Muff coupling collar- grease with AUTOL TOP 2000

Install the muff coupling


Cables and hoses may chafe.Cables and hoses may chafe.Cables and hoses may chafe.Cables and hoses may chafe.

Hoses and cables may chafe at horizontal muff couplings.

Mount this muff coupling vertically.



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 condi-tion of the muff coupling cannot be clearly identified:

Remove the muff coupling once again. Replace the lock washers. Repeat the specified procedure.



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Risk of overstressing of Risk of overstressing of Risk of overstressing of Risk of overstressing of hexagon head screwshexagon head screwshexagon head screwshexagon 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 toeach other.


Replace the lock washers. Repeat mounting.

1) Support the components using suitable aids.

2) Place the collars of the components to be joined against each other and align the collars.

3) Insert hexagon head screws (Fig. 6-11/1) 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 tappingwith a hammer.

6) Place left muff (6) on the collars.

7) Manually mount hexagon nuts (9) with lock washers (8) and align left muff (6) such that it isparallel to right muff (3).

8) Tighten hexagon nuts (9) crosswise, ensuring that the muffs remain parallel to each 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 rec-ommended torque:

9) Repeat the previous step.

If the recommended torque has been obtained within a 3-degree angle of rotation for all hexa-gon nuts:

10) Verify the parallel position of the muffs.


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.



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6.7.5 Install the earthing system

This section describes how to install the earth wires.

Fig. 6-12 shows the earthing system:


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



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Preparations


Earthing pointsEarthing pointsEarthing pointsEarthing points

All earthing points have to be marked with an earthing label according to IEC 60417.

1) Thoroughly clean the bonding surface with cleaner.

2) Apply the earthing symbol.

3) Clean the earthing sockets (5).

Install the earthing system

1) Fasten cable 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 Nmfor screws M8 - 15 Nmfor screws M10 - 31 Nmfor screws M12 - 53 Nm

2) Degrease hexagon head screw (2), lock washer (3), cable lug (1), washer (4) and earthingsocket (5) and mark them by applying a continuous stroke of Rape yellow paint.

3) Seal hexagon head screw (2), cable lug (1), 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 5 Earth socket

2 Hexagon bolt 4 Washer

Final steps


Checking the earthing systemChecking the earthing systemChecking the earthing systemChecking 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.



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6.8 Final maintenance stepsFinalmaintenancesteps

1) Check the earthing sockets [chap. page 64] for proper colour marking and corrosion pro-

tection, repair if necessary.









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 sealant SIKAFLEX 221 grey.

Upon completion of the heavy maintenance activities, the product can be refitted to the vehicleas described in Mounting and commissioning [chap.7.1 page 67] .



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7 Mounting and removalMountingandremoval

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 (formechanical and pneumatic components).


7.1 Mounting and commissioningMountingandcommissioning

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, RAL 1021,

H05.975955

Preparations


Recommended torque for boRecommended torque for boRecommended torque for boRecommended torque for bolted jointslted jointslted jointslted joints








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Inaccurate mounting dimensions may cause loss of functionInaccurate mounting dimensions may cause loss of functionInaccurate mounting dimensions may cause loss of functionInaccurate 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, horizontaland 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 holes 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.



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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 screws to the vehicle withRIVOLTA GWF.



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3) Insert the screws through the coupler and the anchoring plate (refer to overview drawing).

4) Apply the 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 andvertical movement of the coupler, even when it reaches its maximum swivelling angle (alsorefer to vehicle manufacturer's documentation).

6) Mount the air pipes according to the instructions of the vehicle manufacturer.


Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.Risk of coupler failure.

Air pipes may leak after mounting.

Insufficient or excessive tightening of union nuts may lead to leakage or damageof the nuts, and thus to coupler failure.

Check the air pipe adapters for leakage using soapy water. Bubbles indicate leak-ing fittings which must be retightened. Stop tightening union nuts when theconnection is tight.

7) Check the screw connections and fittings of the air pipes for leakage by applying soapy wa-ter, and retighten if necessary. Test pressure: 10 bar = 1 MPa. Maximum acceptable pres-sure drop: 0.1 bar in 5 minutes.

8) Mount the earthing system to the vehicle [chap. page 64] , also observing the vehiclemanufacturer's instructions.


Checking the earthing systemChecking the earthing systemChecking the earthing systemChecking the earthing systemProper 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









2) Paint over the joint gaps.

Commissioning

Observe the preparatory activities described under Coupling [chap.4.1 page 25] if the cou-

pler is to be coupled afterwards.



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7.2 Removal and decommissioningRemovalanddecommissioning

This section describes how to remove the product from the vehicle and how to put it out of ser-

vice.

Tools and Materials Standard tools Crane and lifting straps Trestles

Preparations

1) Remove the air pipes between the coupler and the vehicle in accordance with the vehiclemanufacturer's instructions.

2) Remove the earthing system from the vehicle in accordance with the vehicle manufacturer'sinstructions.

3) Support the product.

Remove the coupler

1) Unscrew the screw connection.

2) Carefully remove the coupler from the anchoring plate.

Decommissioning

No special measures required.

Final steps

None.





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8 Transportation, storage and disposalTransportation, storageanddisposal

This chapter describes how to prepare the product for transportation and storage and how todispose of it.

Target group

This chapter is addressed to logistics personnel working with and handling the product. Previ-ous knowledge of the product is not required.

The product must be in a secure condition to enable safe handling.

8.1 TransportationTransportation

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

8.2 StorageStorage

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 appliedagain (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 DisposalDisposal

In case of free-of-charge return delivery to the manufacturer, the product will be disposed of atno cost.





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9 TroubleshootingTroubleshooting

This chapter provides helpful information for the detection and correction of problems occurringduring operation. The troubleshooting activities are to be performed in a logical order that allowsto properly identify the source of the fault. The possible problems are indicated in the chapterheadings.

Prior to troubleshooting, a thorough visual inspection of the product has to be performed in or-der 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 men-tioned first. The troubleshooting tables list only the most probable faults and their possiblecauses. 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 me-chanical coupling problems as these are the easiest to detect.

These brief descriptions do not substitute the full descriptions referred to.

9.1 Target groupTargetgroup

This chapter is addressed to qualified technical staff in charge of operating the vehicle from thedriver's cab or performing manual coupling and uncoupling operations.

Troubleshooting should be performed exclusively by experienced and qualified staff to makesure all faulty operations are identified and evaluated correctly and appropriate measures aretaken. The target group has to be familiar with the basic principles of the product. Participationin a training by Voith Turbo Scharfenberg is highly recommended and mandatory for certaintroubleshooting activities.

9.2 Earthing systemEarthingsystem

Coupler parts conduct electric current

Check screws of earthing system for tight seat, tighten if necessary

Check earthing system for corrosion and clean if necessary; replace corroded screws andwashers

Check the earth wires for damage, replace if necessary

9.3 Air pipe connection failsAir pipeconnectionfails

Failures affecting the air pipe connection are usually indicated by a pressure drop. In a quietenvironment the affected spots can be identified by a hissing noise, but this is impossible duringtrain operation. A better way is to apply soapy water to the hoses to be checked. Bubbles indi-cate spots which are not tight.

9.3.1 Pressure drop when coupled

Parts of air pipe connection are damagedGasket is damaged

Replace gasket

Hose to vehicle leaks

Replace hose

9.4 Coupler is in wrong positionCoupler isi nwrongposition

Not applicable.



User Manual

Troubleshooting

Unusual noise during operation Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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9.4.1 Coupler is misalignedMuff coupling has come loose

Replace the screw connectionsScrews are torn off

Replace the screw connections

9.5 Unusual noise during operationUnusualnoiseduring operation

9.5.1 Clattering/knocking noiseCollapsible tube has collapsed

Drive vehicle to 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

Muff coupling is loose

Drive vehicle to 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



User Manual

SCHAKU standards


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10 SCHAKU standardsSCHAKUstandards

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

10.1 Paint specificationPaintspecification

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 inthe section "paint structure" further below and/or in specific instructions may differ from what isoutlined 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 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 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 fordry film thickness:

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



User Manual

SCHAKU standards

Paint specification Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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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 de-ionised water Degreasing with organic solvents, and if necessary, additional sanding of the surfaces, fol-

lowed by washing and rinsing

Preparations

1) Surface impurities like wax, grease, oil, coolant, release agent, hand perspiration etc. are tobe removed with suitable solvents or cleaners.

2) Rinse, then dry surface.

3) Roughen and clean the surface if necessary.4) Prime surface within 4 hours.

For stainless steel, the following instructions apply according to the data sheetDB TL 918 301,1989 for small areas:

5) De-grease.

6) Sanding with abrasive paper/pads.

7) Clean.

For aluminium, the following instructions apply according to the data sheet DB TL 918 301,1989for 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 cata-logue).

3) Seal blind holes 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 thecolour 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 film thickness is +30 µm or 30 % maximum. Specialrequirements take precedence.



User Manual

SCHAKU standards


Sealing and securing of screw connections (SCHAKUstandard A023)

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Respect drying timesRespect drying timesRespect drying timesRespect drying times Be sure to observe the following drying times:

At room temperature (20 °C): 12 - 24 h In warm air (60 - 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 Sealing and securing of screw connections (SCHAKU standard A023)Sealingandsecuring of screwconnections(SCHAKU standardA023)

This standard defines how to lock screw connections.

Procedure

All threaded male sockets of pipe adapters, bite type fittings, cable glands and threaded adapt-ers 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 thepassive material by copper ions which makes the adhesive cure.

Special requirements

Special agreements or other dedicated specifications shall take precedence.





User Manual

Parts catalogue


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11 Parts cataloguePartscatalogue

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

11.1 Structure of the parts listStructureof theparts 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 andfurther information, if necessary.

ID No.

Number to be quoted when ordering parts.

Q (Quantity)

Items per assembly

Hash (#)




User Manual

Parts catalogue

Structure of the parts list Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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11.2 Scharfenberg semipermanent coupler half 010.617


Item Designation DrwNo/Code ID No. Q

- Scharfenberg semipermanent coupler half 010.617231.002986 10 9 DCG 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 010.617.43 230.024961 10 0 1

60 Hexagon bolt

ISO 4014 M36x240 8.8 A3

Cr(VI)-free TSK.982085 10 9 461 Hexagon nut ISO 7040 M36 8 A3 Cr(VI)-free TSK.298892 10 9 4



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Parts catalogue


Structure of the parts list

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11.2.1 Air pipe connection 010.617.04



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



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11.2.2 Coupler shank 010.617.06 ''10.01''

Fig. 11-3 Coupler shank 010.617.06 ''10.01''


1 Collapsible tube VR3.0750.15.00.250 ''10.02'' 230.024952 10 9 12 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 4.SK0.3025 ''10.08'' TSK.183954 10 0 1

10 Spring type straight pinISO 8752 10x22 St GEOMET321-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



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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''


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 15 Spring type straight pin ISO 8752 4x28 A TSK.264408 10 0 1

8 Thrust piece - TSK.955474 10 0 2



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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. Q5 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 - TSK.254325 10 0 2


23 Hexagon boltISO 4017 M24x160 8.8 A3Cr(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



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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''


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



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11.2.4 Support 010.617.14

Fig. 11-7 Support 010.617.14


1 Support 010.617.14.00.01 230.025285 10 0 1

10 Locking screw

VERBUS RIPP W158.12M12x40 100 GEOMET 321 BPLUS VL TSK.960443 10 0 4




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11.2.5 Muff coupling half 3.010.131.36 ''10.05''

Fig. 11-8 Muff coupling half 3.010.131.36 ''10.05''


1 Muff 1.010.077.36.00.01 ''10.08'' TSK.136985 10 9 1

4 Hexagon boltISO 4014 M20x160 8.8 A3Cr(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 TSK.960439 11 0 2



User Manual

Parts catalogue

Special tools and test equipment Voith Turbo Scharfenberg GmbH & Co. KG | ScharfenbergSemipermanent Coupler Half 010.617

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11.2.6 Earthing system 010.617.43



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 4.SK0.5143.00.00.03 ''10.01'' TSK.971719 10 0 5

10 Earth wire4.E10.050.030.030.00 ''11.08''type 107 - 50mm²x500 TSK.987955 10 0 2

11 Earth wire4.E10.050.030.030.00 ''11.08''type 122 - 50mm²x850 230.001926 10 0 1

12 Earth wire4.E10.050.030.030.00 ''11.08''type 123 - 50mm²x540 230.002545 10 0 1

11.3 Special tools and test equipmentSpecialtools andtest equipment

None.



User Manual

Parts catalogue


Materials

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NOTICENOTICENOTICENOTICEMaterials as specifiedMaterials as specifiedMaterials as specifiedMaterials as specified



quential 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, RAL 1021,H05.975955



Documents

Scharfenberg Semipermanent Coupler Half 010.617 User Manual.pdf