TMG E1291
SWITCH ROLLERS
Version 1.1
Issued October 2012
Owner:
Chief Engineer, Signals and Control Systems
Approved
by:
Warwick Allison
Chief Engineer
Signals and Control Systems
Authorised
by:
Paul Szacsvay
Principal Engineer
Signal Research & Development
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
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Engineering Manual
Engineering Manual
Signals
RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
Document control
Version
1.0
1.1
Date
01/12/2009
11/10/2012
Summary of change
First issue.
TMA 400 format applied. Sect 1.1 amended to remove the
requirement to lubricate slide plates where switch rollers
are fitted.
Summary of changes from previous version
Summary of change
© RailCorp
Issued October 2012
Section
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Switch Rollers
TMG E1291
Contents
ABOUT THIS STANDARD ......................................................................................................................4
1
General .....................................................................................................................................4
1.1
Purpose .....................................................................................................................................4
1.2
Application of Switch Rollers.....................................................................................................4
1.3
Types of Switch Roller ..............................................................................................................4
1.4
Description ................................................................................................................................5
1.4.1
The Schreck-Mieves (Teksol) Roller for Assymetric Switches ..................................5
1.4.2
Schreck-Mieves (Teksol) Roller for 60kg full height Switches...................................5
1.4.3
The Schreck-Mieves (Teksol) Roller for 53kg switches ............................................6
1.4.4
The CDP In-plate Roller For Assymetric Switches ....................................................7
1.4.5
The RotorRail Roller Type Ric 294 for 60kg Full Height Switches ............................9
2
Installation .............................................................................................................................10
2.1
Schrek-Mieves (Teksol) Switch Rollers ..................................................................................10
2.2
2.1.1
Assymetric Switches................................................................................................10
2.1.2
Full Height Switches 53kg or 60kg Switches...........................................................13
CDP Switch Rollers.................................................................................................................17
2.2.1
Assymetric Switches – New Turnouts .....................................................................17
2.2.2
Assymetric Switches - Retrofit.................................................................................18
2.3
Special Inspection For CDP Rollers One Month after Turnout Commissioning or
Roller Installation – New Turnouts and Retrofit ......................................................................19
2.4
RotorRail Switch RollersRotorail switch rollers are suitable for full height
switches only and are currently supplied for 60kg turnouts. ...................................................20
3
Maintenance ..........................................................................................................................20
3.1
Schrek-Mieves EKOS (Teksol) Assymetric Switches .............................................................20
3.1.1
Schrek-Mieves EKOS (Teksol) Convential Switches ..............................................21
3.2
CDP In-plate Type...................................................................................................................22
3.3
RotorRail Type RIC 294 ..........................................................................................................23
4
Manufacturers Drawings ......................................................................................................24
GENERAL INFORMATION ....................................................................................................................25
INSTALLATION PREPARATIONS.........................................................................................................26
GENERAL INFORMATION ....................................................................................................................31
INSTALLATION PREPARATIONS.........................................................................................................32
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
ABOUT THIS STANDARD
This manual describes the installation and maintenance of switch rollers on 53kg and
60kg conventional and 60kg tangential turnouts.
1
General
1.1
Purpose
Where switch rollers are used it is generally no longer necessary to regularly lubricate
slide plates. However, the slide plates must first be coated with Rocol or similar to
prevent formation of rust on the plates. The rollers lift the switch 1 – 4mm above the slide
plate surface as the switch moves between the open and the closed positions so that
there is no contact between the switch and plate while the switch is moving.
Note: Where Teksol type rollers are used and switch loading is still evident on the A chair,
then it shall be necessary to lubricate the A chairs using approved lubricant.
In the open position the switch is held clear of the plates but in the closed position the
rollers must be adjusted so that the wheel load from passing trains is carried by the slide
plates and not the roller assembly.
As there is no longer friction between plates and switch, the forces required to move the
switch are lower reducing the load on the switch operating mechanism.
The roller bearings on all the types described in this document are sealed and require no
lubrication
1.2
Application of Switch Rollers
Switch rollers - can be fitted to 60kg tangential turnouts with asymmetric (half height)
switches, 60kg turnouts with full height switches and 53kg turnouts.
Rollers for asymmetric switches can either be fitted into the bay between sleepers or built
into the switch chair plates.
Rollers for 60kg full height switches can be fitted into the bay between sleepers or on to
the existing 60Kg switch chair slide plate.
For 53Kg switches the rollers are fitted into the bay between sleepers
All types of rollers can be retrofitted to existing turnouts but this may require changes to
the switch chair plates depending on which type of roller is used.
1.3
Types of Switch Roller
There are currently three approved types of switch roller being used in NSW. These are:
The Schreck-Mieves type manufactured by Schreck-Mieves GmbH in Germany and
supplied in Australia by Teksol International Pty Ltd.
The CDP in plate type manufactured by Peddinghaus Group in Germany and supplied
with new turnouts by VAE Australia and Pacific Rail Engineering and supplied by CDP
Australia for retrofit application.
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Switch Rollers
TMG E1291
The RotorRail on plate type switch roller, which is manufactured in the UK by Vortok
International and distributed in Australia by Pandrol Australia for retrofit applications.
1.4
Description
1.4.1
The Schreck-Mieves (Teksol) Roller for Assymetric Switches
This roller consists of one or two rollers mounted in a cast box that is pivoted on a frame
that clamps to the foot of the stockrail. Roller height and switch clearance above plates is
adjusted by a spring-loaded bolt.
As the wheel passes over the switch, the bellville washer spring is further compressed
until the switch bears on the slide plates. Full wheel loads are therefore taken on the slide
plates, not on the roller assembly.
Figure 1 Schreck-Mieves EKOS Switch Rollers for Asymmetric Switches
1.4.2
Schreck-Mieves (Teksol) Roller for 60kg full height Switches
This roller consists of one or two rollers mounted in a cast box that is pivoted on a frame
which is in turn mounted to a fabricated steel fame. This hooks over the foot of the
stockrail in the six foot and is attached to the sleepers or beams in the four foot.
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Switch Rollers
TMG E1291
Figure 2 V200 Switch Roller Conventional Switch
Figure 3 Z200 Switch Roller Conventional Switch
Figure 4 Brackets Conventional Switch
1.4.3
The Schreck-Mieves (Teksol) Roller for 53kg switches
This assembly has three or four rollers to compensate for the narrow foot on the 53kg
switch.
Otherwise, it is similar to, but not interchangeable with, the 60 kg assembly.
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Switch Rollers
TMG E1291
Figure 5 53kg Conventional 4 Roller Unit
Figure 6 53kg Conventional 3 Roller Unit
1.4.4
The CDP In-plate Roller For Assymetric Switches
Three CDP assemblies are used in Railcorp. Two of these roller types are currently in
use but are no longer manufactured. These are the ZHV3 which consists of two rollers
mounted in a rocker that is bolted to the special switch chair plate, the other the ZHV2
consists of two rollers mounted in a rocker and one fixed roller, also mounted to the
special switch chair plate. The third and currently supplied CDP in-plate roller type RV2
has no rocker but has two fixed rollers mounted on the roller carriage which is bolted to
the special switch chair plate and is used through the turnout.
The special switch chair plate is common to all three CDP type rollers described above
and is made so that the closed switch can bear on a slide plate on one half of the chair
plate while the other half of the plate is recessed to accept the switch rollers.
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Switch Rollers
TMG E1291
Figure 7 CDP Roller Assembly ZHV3
This assembly is used where the switch movement is
less than 60 mm
Figure 8 CDP Switch Roller Assembly ZHV2
This assembly is used towards the tip of the switch
where movement is up to 150 mm
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Switch Rollers
TMG E1291
Figure 9 CDP Switch Roller Assembly RV2
This assembly is used throughout the switch
1.4.5
The RotorRail Roller Type Ric 294 for 60kg Full Height Switches
The RotoRail roller is a retro-fit switch roller assembly for full height 60kg switches that
fits on to existing slide plates.
The rollers are cantilevered over the side of the baseplate structure, taking support from
it. The RotorRail units are supplied with shims to ensure a snug fit on the standard base­
plates and allow for minor width variances. The existing screw-spikes are used to fix the
units to the baseplates.
Figure 10 RotorRail Roller Type Ric 294 Heal End
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Switch Rollers
TMG E1291
Figure 11 RotorRail Roller Type Ric 294 Toe End
2
Installation
2.1
Schrek-Mieves (Teksol) Switch Rollers
2.1.1
Assymetric Switches
Select the sleeper bays into which the rollers are to be placed. Recommended locations
are given in Table 1. However these locations may need to be varied by one bay in either
direction to suit individual turnouts.
Table 1
Roller Locations
Turnout Type
Roller Type
Beam Nos
Signalling Terminology
190
3 and 4
10 and 11
B and C
I and J
V200
Z200
250
3 and 4
11 and 12
B and C
J and K
V200
Z200
300
3 and 4
11 and 12
B and C
J and K
V200
Z200
500
3 and 4
10 and 11
17 and 18
B and C
I and J
P and Q
V200
V200
Z200
800
4 and 5
14 and 15
25 and 26
C and D
M and N
V200
V200
Z200
1200
5 and 6
D and E
V200
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Switch Rollers
TMG E1291
15 and 16
24 and 25
33 and 34
N and O
V200
Z200
Z200
a)
Close one switch.
b)
Start with the roller closest to the tip of the switch.
c)
Remove the cover (7) from the adjusting nut.
d)
Remove the camp plate (4), washer (3) and nut (2).
e)
Slacken off the locknut (5).
f)
Slacken the adjusting nut (6) until the assembly will slide under the switch and
engage with the foot of the stockrail.
If a minimum clearance of 2 mm
cannot be obtained the V200 roller
assembly must be replaced by a
Z200 assembly
V200 Roller Assembly
Z200 Roller Assembly
Note different roller positions for Z200-1-S54 and Z200-2-S54
g)
© RailCorp
Issued October 2012
Fit the clamp plate, nut and washer and tighten. Ensure that the assembly is
properly seated on the foot of the rail.
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Switch Rollers
h)
TMG E1291
Tighten the adjusting nut until the switch is 1 mm clear of the slide plate next to
the roller toward the tip of the switch.
Preferred position –
washer slightly
outside sleeve
The adjusting nut must
not be tightened past the
point where the washer is
flush with the end of the
sleeve
Figure 12 Maximum Spring Tension Adjustment
CAUTION
Adjustment beyond the maximum position shown will result in roller
damage
i)
Check that the tip of the switch is not more than 1 mm clear of the first slide
plate. Adjust the roller if necessary.
j)
Repeat steps 3 to 7 with the other roller(s) on that switch.
k)
Tighten the adjusting nut until the switch is 2 - 3 mm clear of the slide plates
either side of the roller(s).
l)
Check the clearance between switch and slide plates between the rollers and
for 4 or 5 chairs toward the heel. Clearance should be 1mm or more between
rollers and should taper off to zero after about 5 or 6 chairs towards the heel.
m)
Repeat steps 1 to 11 for the opposite switch.
n)
Operate the switches over and back four to five times.
o)
Check the clearance between the foot of the switch and slide plates and adjust
if necessary.
p)
Tighten locknuts on all assemblies.
q)
Refit covers to all assemblies.
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Switch Rollers
2.1.2
TMG E1291
Full Height Switches 53kg or 60kg Switches
Figure 13 53kg Full Height Switches
Figure 14 60kg Full Height Switches
Select the sleeper bays into which the rollers are to be placed. Recommended locations
are given in Table 2.1. However these locations may need to be varied by one bay in
either direction to suit individual turnouts.
The area on the timber adjacent to the slide chair should be in reasonable condition so
that the bracket can rest on this ledge properly.
Maximum bay width 370 mm, minimum bay width 285 mm.
a)
© RailCorp
Issued October 2012
Close one switch.
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Switch Rollers
TMG E1291
b)
Start with the roller closest to the tip of the switch.
c)
Remove sufficient ballast from underneath the rail so that the switchroller and
the brackets can sit properly on the sleeper. Also ensure that the timber is
cleaned of built up grease and dirt in the area where it supports the bracket.
d)
Attach the brackets loosely to the EKOS with the bolts provided. It is preferred
to fit the lock nuts at this time. Position 1 and 4 on the attached sketch. If fitting
to concrete sleepers, place approx. 4 washers in between EKOS and bracket to
compensate for the pad under the slide chair.
e)
Hook in the EKOS on the outside of the stockrail. Ensure that the EKOS is
hooked in firmly and the brackets sit tightly against the sleeper (2+5) Use a
hammer or clamps to hold the EKOS in position while you tighten the bolts and
locknuts (1+4) and drill the holes (3+6).
f)
Remove the cover (20) from the adjusting nut.
g)
Slacken off the locknut (19).
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Switch Rollers
TMG E1291
If a minimum clearance of 2 mm cannot be
obtained the V200 roller assembly must be
replaced by a Z200 assembly
Figure 15 V200 Roller Assembly
Figure 16 Z200 Roller Assembly
h)
© RailCorp
Issued October 2012
Tighten the adjusting nut until the switch is 1 mm clear of the slide plate next to
the roller toward the tip of the switch.
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Switch Rollers
TMG E1291
Preferred position –
washer
slightly
outside sleeve
The adjusting nut must
not be tightened past the
point where the washer is
flush with the end of the
sleeve
Figure 17 Maximum Spring Tension Adjustment
CAUTION
Adjustment beyond the maximum position shown will result in roller
damage
i)
Check that the tip of the switch is not more than 1 mm clear of the first slide
plate. Adjust the roller if necessary.
j)
Repeat steps 3 to 5 with the other roller(s) on that switch.
k)
Tighten the adjusting nut until the switch is 2 - 3 mm clear of the slide plates
either side of the roller(s).
l)
Check the clearance between switch and slide plates, between the rollers and
for 4 or 5 chairs toward the heel. Clearance should be 1mm or more between
rollers and should taper off to zero after about 5 or 6 chairs towards the heel.
m)
Repeat steps 1 to 11 for the opposite switch.
n)
Operate the switches over and back four to five times.
o)
Check the clearance between the foot of the switch and slide plates and adjust
if necessary.
p)
Tighten locknuts on all assemblies.
q)
Refit covers to all assemblies.
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Switch Rollers
TMG E1291
2.2
CDP Switch Rollers
2.2.1
Assymetric Switches – New Turnouts
CAUTION
With new turnouts where the RV2 switch roller plate assemblies are
supplied installed in the turnout, ensure that rollers are positioned so that
all rollers on the assemblies are clear of and not carrying the weight of the
closed switch before any rail vehicle is permitted to run over the turnout.
When reinstalling or adjusting ZHV2 and ZHV3 switch rollers ensure that
rollers are positioned such that the outer roller on the rocker is clear of the
foot of the closed switch before any rail vehicle is permitted to run over the
turnout.
CAUTION
Ballasting, tamping and lining of the turnout must be completed
and
The switch operating mechanism must be installed, adjusted and operating
(at least by emergency hand throw lever or crank).
Before switch rollers are adjusted
Note
Note: Since the switch rollers may not be effective while the operating mechanism is
being set up, a minimal amount of a light lubricating oil (SAE 20 –30) may be used on the
slide plates to assist operation during set up. Ensure that no oil is allowed into the roller
assemblies.
Set Up Adjustment
r)
Close one switch.
s)
Remove the protective cap from the roller assembly.
t)
For the RV2 roller ensure that the roller carriage assembly is installed with the
“A” stamping towards the stock rail.
u)
Allow the switch to lay in the position it is driven to by the operating mechanism.
If the switch is lying slightly off the stockrail back towards the heel do not force it
closed with a switch clip.
v)
Adjust each of the roller assemblies along that switch so that the foot of the
switch is 1 – 1.5mm clear of the outer roller in the rocker assembly for the ZHV2
and ZHV3 or the roller nearest the switch for the RV2.
w)
Tighten the two roller carriage hold down bolts (torque = 75Nm)
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Switch Rollers
2.2.2
TMG E1291
x)
Open the switch.
y)
Check that the clearance between the foot of the switch and the slide plates is 2
to 3 mm.
z)
If the clearance is less than 1 mm on any slide plate, insert 1mm shims between
the roller carriage and the switch chair plate on the roller assemblies closest to
the slide plate with minimal clearance. (Clearance between switch and slide
plate may vary along the turnout depending on whether the turnout has a
slightly convex or slightly concave vertical curve).
aa)
Do not shim more than 6mm.
bb)
After shimming close the switch and re-adjust the roller assembly position so
that the outer roller in the rocker for the ZHV2 and ZHV3 or the roller nearest
the switch for the RV2 is 1 to 1.5 mm clear of the foot of the switch.
cc)
Tighten the two roller carriage hold bolts (Torque – 75Nm)
dd)
Repeat these operations for the opposite switch.
Assymetric Switches - Retrofit
These rollers are located on the beams, not in the bays.
Determine which beams rollers are to be placed as shown on table 2.2
Table 2
Roller Locations
Turnout Type
Roller Type
Beam Nos
Signalling Terminology
190
3
10
B
I
RV2 / ZHV3
RV2 / ZHV3
250
3
11
B
J
RV2 / ZHV3
RV2 / ZHV3
300
3
11
B
J
RV2 / ZHV3
RV2 / ZHV3
500
3
10
17
B
I
P
RV2 / ZHV3
RV2 / ZHV3
RV2 / ZHV2
800
4
14
25
C
M
RV2 / ZHV3
RV2 / ZHV3
RV2 / ZHV2
1200
5
15
24
33
D
N
RV2 / ZHV3
RV2 / ZHV3
RV2 / ZHV2
RV2 / ZHV2
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Switch Rollers
TMG E1291
Roller location may need to be varied one beam either side of that recommended above
to obtain optimum results for a particular turnout. For 800 and 1200 metre turnouts, an
additional roller may be required if there is a vertical curve in the turnout.
ee)
Remove the existing switch chair plates on those beams.
ff)
Remove the roller assemblies from the new switch chair plates.
gg)
Place and fix the new switch chair plates onto the beams (sleepers).
hh)
Close one switch – use the operating mechanism, not a point clip.
ii)
Refit the roller carriage assemblies to the switch chair plates ensuring that for
the RV2 type the “A” stamping on the carriage is towards the stock rail.
jj)
Adjust the roller assemblies so that the foot of the switch is 1 to 1.5mm clear of
the outer roller in the rocker assembly for the ZHV2 and ZHV3 or the roller
nearest the switch for the RV2.
kk)
Tighten the two roller carriage hold down bolts (Torque = 75 Nm)
ll)
Open the switch.
mm) Check that the clearance between the foot of the switch and the slide plates is 2
mm to 3 mm.
2.3
nn)
If the clearance is less than 1 mm on any slide plate, insert 1mm shims between
the roller carriage and the switch chair plate on the roller assemblies closest to
the slide plate with minimal clearance. (Clearance between switch and slide
plate may vary along the turnout depending on whether the turnout has a
slightly convex or slightly concave vertical curve.).
oo)
Do not shim more than 6mm.
pp)
After shimming close the switch and re-adjust the roller assembly position so
that the outer roller in the rocker for the ZHV2 and ZHV3 or the roller nearest
the switch for the RV2 is 1 to 1.5 mm clear of the foot of the closed switch.
qq)
Tighten the two roller carriage hold down bolts (Torque = 75Nm).
rr)
Repeat for the opposite switch.
Special Inspection For CDP Rollers One Month after Turnout
Commissioning or Roller Installation – New Turnouts and
Retrofit
a)
With switches open, check the clearance between each slide plate and the foot
of the switch. On new turnouts in particular, this clearance is likely to have
changed. Add or remove shims as required to maintain clearance between 1
and 4 mm. Note that the clearance should not exceed 3mm on the slide plate to
which the rollers are fitted. If it does, the rollers on that chair will be ineffective
and load will be transferred to the assemblies on either side.
b)
With switches closed, check the clearance (adjust if height has been changed)
between the foot of the switch and the outer roller in the rocker assembly for
the ZHV2 and ZHV3 type or the nearest roller to the switch on the RV2 type. It
is likely that, towards the back of the switch, this clearance will have increased.
If the clearance exceeds 2mm, adjust the roller assembly.
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Switch Rollers
c)
2.4
TMG E1291
Check that the bolts holding the roller carriage to the slide chairs are tightened
to the specified torque.
RotorRail Switch RollersRotorail switch rollers are suitable for
full height switches only and are currently supplied for 60kg
turnouts.
It is not imperative that the sets of Rotorail rollers are positioned exactly on the bearers
as described below as all switches differ in their wear and set up.
If the switch blade is hogged at these positions and not in contact with the
slide chair then they should be located on a more appropriate adjacent
chair. Need to confirm bearer spacings or remove table
d)
The first of the RotorRail units should be mounted on bearer No 2(B) or as near
to the toe of the switch as possible.
e)
The second RotorRail units should be mounted 5 bearers back on bearer No
7(G) or where the slide chair carries the most load or shows the highest degree
of wear.
f)
For longer switches, extra pairs of RotorRails maybe positioned along the
length from the toe towards the heal of the switch at 5 bearer intervals.
g)
Note: The second subsequent pairs of switch rollers are not necessarily
required to be fitted to the same bearer.
h)
Remove the screw spikes and clean off any excess grease from the base plate
using a scrapper and a degreasing rag.
i)
Fit the switch roller to base plate with its full shim kit.
j)
Assess the fit on the baseplate and shim to achieve a tight fit. It is essential to
achieve a tight fit to prevent the unit from bending under the weight of the switch
k)
Slide the unit towards the rail until rollers touch the
switch blade, then back it off 3-5mm.
l)
Position the locking plate over the holes in the baseplate
and align the serrations with those on the side of the
switch rollers.
m)
Replace the bolts through the locking plate and tighten
to the correct torque.
3
Maintenance
3.1
Schrek-Mieves
Switches
EKOS
(Teksol)
Assymetric
Clean away any build up of oil, grease or grime from around the rollers.
Examine rollers for flat spots indicating that the roller is binding or seized. If flat spots are
found, replace entire roller assembly and return the defective part to the depot for
servicing or replacement.
Check that the roller assembly is securely clamped to the stockrail.
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Switch Rollers
TMG E1291
Check that the clearances between switch and rail plates are correct. 0.5 to 1 mm for first
two to three plates near the tip of the switch increasing to 2 to 3 mm for other plates.
Check that the minimum clearance between the outer roller and the closed switch on the
V200 roller assembly is maintained.
Figure 18 EKOS V200 Switch Roller Minimum Clearance
Note: Switches may be clear of the chair plates by more than the dimensions quoted
above due to variations in the level through the turnout.
If the switch is 5 mm or more clear of the plates on either side of a roller but is rubbing on
plates further along the turnout, it may be necessary to vary the roller location until the
deficiencies in level through the turnout have been corrected.
Do not attempt to adjust the roller higher to further lift the switch. This will result in the
adjusting spring taking full wheel load when a train passes over the turnout and fracture
of the roller assembly.
3.1.1
Schrek-Mieves EKOS (Teksol) Convential Switches
Clean away any build up of oil, grease or grime from around the rollers.
Examine rollers for flat spots indicating that the roller is binding or seized. If flat spots are
found, replace entire roller assembly and return the defective part to the depot for
servicing or replacement.
Check that the roller assembly is securely clamped to the stockrail.
Check that the clearances between switch and rail plates are correct. 0.5 to 1 mm for first
two to three plates near the tip of the switch increasing to 2 to 3 mm for other plates.
Check that the minimum clearance between the outer roller and the closed switch on the
V200 roller assembly is maintained.
Figure 19 EKOS V200 Switch Roller Minimum Clearance
Note: Switches may be clear of the chair plates by more than the dimensions quoted
above due to variations in the level through the turnout.
© RailCorp
Issued October 2012
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Page 21 of 35
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
If the switch is 5 mm or more clear of the plates on either side of a roller but is rubbing on
plates further along the turnout, it may be necessary to vary the roller location until the
deficiencies in level through the turnout have been corrected.
Do not attempt to adjust the roller higher to further lift the switch. This will result in the
adjusting spring taking full wheel load when a train passes over the turnout and fracture
of the roller assembly.
Check that the roller bracket is securely attached to the bearer and clamped to the
stockrail.
Check switch roller is securely attached to switch roller bracket.
3.2
CDP In-plate Type
Clean away any build up of oil, grease or grime from
around rollers.
Examine rollers for flat spots indicating that the roller is
binding or seized. If flat spots are found, replace entire
roller assembly and return the defective part to the
depot for servicing.
Check that the roller assembly is securely bolted to the
chair plate.
Check the minimum clearance between the foot of the
closed switch and the outer roller in the rocker. This
should be 1 to 2 mm.
A 1.6mm lock/detection gauge placed between the roller and foot of the switch indicates
sufficient clearance provided that the switch is resting on the chair plate when closed. For
each millimetre the switch is off the chair plate 1 mm must be added to the clearance
between the foot of the switch and roller.
Check the clearance between the foot of the open switch and the slide chair. This should
be between 1 mm and 4 mm (3 mm max on chairs fitted with rollers with no shims).
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
Figure 20 CDP Switch Roller Minimum Clearance
Note: Switches may be clear of the chair plates by more than the dimensions quoted
above due to variations in the level through the turnout.
If the switch is more than 3 mm clear of the plates on either side of a roller, but is rubbing
on plates further along the turnout, it may be necessary to shim the roller until the
deficiencies in level through the turnout have been corrected. Total shim thickness should
not exceed 5 mm.
Examine mounting plate to ensure that it is not hogging and in contact with switch due to
insufficient shimming
Ensure that clearances to the closed switch are maintained.
3.3
RotorRail Type RIC 294
No greasing of the rollers is necessary.
Ensure that the rollers remain 3mm to 5mm from the switch-blades. If switch is adjusted
the roller may require adjustment.
Examine rollers for flat spots indicating that the roller is binding or seized. If flat spots are
found, replace entire roller assembly and return the defective part to the depot for
servicing.
Check screw spikes for tightness.
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Issued October 2012
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Page 23 of 35
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RailCorp Engineering Manual — Signals
Switch Rollers
4
TMG E1291
Manufacturers Drawings
© RailCorp
Issued October 2012
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Page 24 of 35
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
GENERAL INFORMATION
Identification
EKOS® “STANDARD” | Installation instructions | State 11/2002
Purpose of the document
These installation instructions are an “on location guide”. They describe the installation of
the Tongue Roller System EKOS® under normal conditions and in well-positioned
switches. For additional more detailed information please refer to the other valid
documentation or contact Schreck-Mieves GmbH directly.
Other valid documentation
Please keep all the documentation you received on purchasing or on delivery of the
Tongue Roller System EKOS® safely.
Other valid documentation could be: product descriptions, technical drawings, planning
documentation, delivery notes and the arrangement map.
All rights reserved
Nothing from these installation instructions is to be copied or reproduced in any way
shape or form without the prior written consent of Schreck-Mieves GmbH.
Exclusion of liability
Schreck-Mieves is explicitly excluded from any liability in the event that the installation
instructions or the other valid documentation have not been observed, or the specific
country's safety regulations have not been adhered to.
Any questions?
Schreck-Mieves GmbH Krückenweg 113 D-44225 Dortmund
phone: +49 (0) 2 31. 71 08-0 fax: +49(0)231.711588 e-mail:
[email protected]
Obligations of the operator
The operator of the track system must ensure that:
• the respective country's regulations regarding working on the track are observed
• installation and maintenance work is only carried out by qualified and familiarized
personnel
• the track stretches or switches are only secured by trained safety personnel
• the personnel must be able to spot any danger and act individually to avert any
such danger
© RailCorp
Issued October 2012
UNCONTROLLED WHEN PRINTED
Page 25 of 35
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
Danger during installation
When installing the Tongue Roller System care must be taken to ensure that no parts of
the body come between the stock rail and the tongue. Otherwise there is a danger that
these parts of the body could be jammed when switching over the switch which could be
life threatening!
INSTALLATION PREPARATIONS
The first steps
a)
Check the correctness and completeness of the delivery
b)
Check the Tongue Roller System to ensure it is an orderly state
c)
Get safety personnel to secure the relevant stretch of track
d)
Use the arrangement map to determine the installation position in the switch
e)
Ensure the following tools are at hand for the installation of Tongue Roller
System:
–
–
–
–
–
–
© RailCorp
Issued October 2012
template and metal ruler
spatula and wire brush
open-ended / ring spanner, SW 30
torque wrench, SW 30, adjustable to 270 Nm
Ballast fork
Hammer
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RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
V 200 Z 200
© RailCorp
Issued October 2012
UNCONTROLLED WHEN PRINTED
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Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 28 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 29 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 30 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
GENERAL INFORMATION
Identification
EKOS® “LEVEL TONGUE” | Installation instructions | State 11/2002
Purpose of the document
These installation instructions are an “on location guide”. They describe the installation of
the Tongue Roller System EKOS® under normal conditions and in well-positioned
switches.
For additional more detailed information please refer to the other valid documentation or
contact Schreck-Mieves GmbH directly.
Other valid documentation
Please keep all the documentation you received on purchasing or on delivery of the
Tongue Roller System EKOS® safely.
Other valid documentation could be: product descriptions, technical drawings,
planning documentation, delivery notes and the arrangement map.
All rights reserved
Nothing from these installation instructions is to be copied or reproduced in any way
shape or form without the prior written consent of Schreck-Mieves GmbH.
Exclusion of liability
Schreck-Mieves is explicitly excluded from any liability in the event that the installation
instructions or the other valid documentation have not been observed, or the specific
country's safety regulations have not been adhered to.
Any questions?
Schreck-Mieves GmbH
Krückenweg 113
D-44225 Dortmund
phone: +49 (0) 2 31. 71 08-0
fax: +49(0)231.711588
e-mail: [email protected]
© RailCorp
Issued October 2012
UNCONTROLLED WHEN PRINTED
Page 31 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
TMG E1291
Obligations of the operator
The operator of the track system must ensure that:
• the respective country's regulations regarding working on the trac k are observed
• installation and maintenance work is only carried out by qualified and familiarized
personnel
• the track stretches or switches are only secured by trained safety personnel
• the personnel must be able to spot any danger and act individually to avert any
such danger
When installing the Tongue Roller System care must be taken to ensure that no parts of
the body come between the stock rail and the tongue. Otherwise there is a danger that
these parts of the body could be jammed when switching over the switch which could be
life threatening!
INSTALLATION PREPARATIONS
The first steps
a)
Check the correctness and completeness of the delivery
b)
Check the Tongue Roller System to ensure it is an orderly state
c)
Get safety personnel to secure the relevant stretch of track
d)
Use the arrangement map to determine the installation position in the switch
e)
Ensure the following tools are at hand for the installation of Tongue Roller
System:
– template and met al ruler
– spatula and wire brush
– open-ended / ring spanner , SW 30
– open-ended / ring spanner , SW 24
– Ballast fork
– Hammer
– Drilling equipment (timber 10 + 11 mm / concrete 18 mm)
© RailCorp
Issued October 2012
UNCONTROLLED WHEN PRINTED
Page 32 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 33 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 34 of 35
Version 1.1
RailCorp Engineering Manual — Signals
Switch Rollers
© RailCorp
Issued October 2012
TMG E1291
UNCONTROLLED WHEN PRINTED
Page 35 of 35
Version 1.1