OPERATION & SPARE PARTS MANUAL

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Imogene Franklin
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1 P a g e 1 OPERATION & SPARE PARTS MANUAL BACKDRIVE ALIGNMENT KIT (0111/110006) ISSUE 2 JULY 2015 Any alterations or modifications to this equipment or the use of after-market spare parts, without the express written agreement of Direct Track Solutions Limited, may invalidate the warranty.

P a g e 2 Contents Letter Ref Description of Page Page No Front Page 2 A General Description Of Backdrive Alignment Kit 3 B Technical Data 4 C Operations

2 P a g e 2 Contents Letter Ref Description of Page Page No Front Page 2 A General Description Of Backdrive Alignment Kit 3 B Technical Data 4 C Operations Procedure 5 to 8 D Maintenance 9 E Spare Parts 10 F Assembly 11 Amendments Change Number Pages Amended Date Author Issue 1 First Issue July 2015 A. Gilbert

3 P a g e 3 A GENERAL DESCRIPTION The Backdrive Alignment Kit has been produced to meet the Network Rail requirement for setting up mechanical backdrives. Rigid but lightweight, the Crank Location Gauges used for setting the crank parallel to the rail (whilst in mid position) are produced from pultruded ISO resin bars and hard anodised aluminium components. The resin bar is naturally non-conductive which allows this product to be used in 3 rd rail areas. Nylon, stainless steel and hard anodised aluminium, are used for the Crank and Sleeve Gauge. This is used to check that the crank plate and sleeves are located in the correct position as required by Network Rail specification. The step gauges, produced from mild steel & hardened are designed to set the distance between the switch rail and stock rail at each stretcher bar. All step gauges are provided in a foam lined carry case. The lost motion gauges are designed to set the excess motion at each drive rod allowing a smooth transition throughout the switch. This component is manufactured from mild steel and has a hardened finish.

4 P a g e 4 B TECHNICAL DATA Item Description Data Information 1 Crank Location Gauge Full/Shallow Depth 2 Crank Location Gauge (UIC54) Shallow Depth 3 Carrying strap for Crank Location Gauges 50 x 50 x 3.2mm ISO Resin Hollow Bar Hard Anodised Angle Section Zinc Plated main body Pin ABS End Caps 50 x 50 x 3.2mm ISO Resin Hollow Bar Hard Anodised Angle Section Zinc Plated Pins ABS End Caps Woven fabric strap with Steel buckles Interchangeable pins to suit full and shallow depth layouts. Insulated - for use in third rail areas Datum pegs set 14mm down from the head of the rail to avoid field flow interference Offset to accommodate front crank +18mm (6 foot) and -18mm (4 foot) from the rail in which the crank plate is mounted. Insulated - for use in third rail areas Datum pegs set 14mm down from the head of the rail to avoid field flow interference Keeps gauges together for carrying to and from site 4 Step Gauges (9 pairs) Mild Steel Hardened Case depth 0.35mm/0.45mm 56/60 HRC 5 Lost Motion Gauges Mild Steel Hardened Case depth 0.35mm/0.45mm 56/60 HRC Designed to suit the switch and stock rail machining Various dimensions to suit all flat bottom switch openings Flat, machined gauge profiled to locate over connection rods 6 Crank and Sleeve Gauge Nylon Machined Components Stainless steel & hard anodised aluminium components 7 Carry Case for Step and Lost Motion Gauges 4 fixed measuring positions along the head of the bar with 3 mm spring plunger for locating correct position 3 elongated dowel pins on main boss locating position to avoid split pin and grease nipple interference Hard anodised aluminium telescopic arm with 4 positions for locating the sleeves Full and shallow depth compatible with simple 26mm slide at rail end ABS Plastic with Foam Insert Simple to carry to and from site

P a g e 5 C OPERATIONS PROCEDURE PLEASE NOTE THIS IS ONLY A GUIDE FOR USE. YOU MUST FOLLOW NETWORK RAILS SPECIFIED PROCEDURE FOR SETTING UP BACKDRIVES.

5 P a g e 5 C OPERATIONS PROCEDURE PLEASE NOTE THIS IS ONLY A GUIDE FOR USE. YOU MUST FOLLOW NETWORK RAILS SPECIFIED PROCEDURE FOR SETTING UP BACKDRIVES. Step Gauges: These are intended to sit between the switch and stock rail both sides at each stretcher bar position, once the measurements for the openings have been taken using the back to back gauge in conjunction with the TEF3239 document. Method of use: Once switch openings are established, half the dimension and select the relevant size of step gauge to suit the switch (e.g. CV, DV, EV etc.) Example: If the opening is 108mm, use 54mm step gauge. Set point machine to manual and manually operate switch over to mid position At each stretcher bar location starting at No. 1, locate step gauges right side and left between the switch and stock rails then adjust stretcher bar to suit Once locked in position, continue method throughout switch at each stretcher bar location Above picture (1.1) shows step gauge located between switch rail and stock rail at first stretcher bar location. Ensure the nib points in to the four foot on each side as these are designed to follow the 1:4 angle on the head of both switch and stock rail. Each of the individual gauges are identified with the opening measurement and stretcher bar location 1 st, 2 nd, 3 rd etc. Drawing (1.2) shows where each measurement IS identified for ease of use when on track side, simply take the measurement from the relevant TEF3239 document and apply throughout the switch.

6 P a g e 6 BACKDRIVE ALIGNMENT KIT METHOD OF USE CONTINUED. Crank Plate/Sleeve Alignment Gauge: This gauge is not only designed to set the distance of the crank base plate from field face of rail, but it is also to set the sleeve slides on the crank assembly. These dimensions are crucial as if the measurement is out, this can cause extra strain on the point machine/clamp lock. Testing at York training school has proven that back drives which have not been aligned with this method could be draining the drive machine by up to and in excess of 100 bar. Set up correctly, the gauges can reduce the pressure between Bar. Method of use: Place main slide body location pegs (x3) on crank base assembly boss There is sufficient clearance to avoid grease nipple and also the gauge rotates 360 degrees so will not come in to contact with the split cotter pin. Slide the location bar out until the datum pegs are positioned to the field face side of the stock rail ensuring BOTH of the datum points are in contact with the rail (this is set a minimum of 14mm down from head of rail to avoid field flow) Adjust crank plate to suit once again ensuring datum pegs are always in contact with rail. Once the plate is in position, remove headed pin from sleeve and locate the telescopic pin to the position required for the sleeve location and back 5/8 set screws off to enable sleeve to locate in correct position. Repeat above sequence at each crank position. As you can see from image (1.3) the gauge is located on field face of rail and then to centre of main boss on the crank assembly. This is the most accurate way of gauging the correct dimension as per the standard requirements. The slide which is resting on the switch rail gives you the option of use for full depth or shallow depth as there is a 26mm difference in the height of the slide plates. Simply slide this to your required position and rest on the head of the rail. 1.3

3 other gauges are universal and will suit full or shallow depth switches. The crank gauges are designed to locate the crank arm 90 degrees to the rail whilst the switch is set in mid position.

7 P a g e 7 BACKDRIVE ALIGNMENT KIT METHOD OF USE CONTINUED. Crank Gauges (90 degrees) x 4: UIC 54 Shallow Depth Only x 1 to set the first crank assembly only, 90 degrees to the rail taking in to account the +18mm (6 foot) and 18mm (four foot) offset dimension. 3 other gauges are universal and will suit full or shallow depth switches. The crank gauges are designed to locate the crank arm 90 degrees to the rail whilst the switch is set in mid position. This can be achieved in the four foot or six foot. Method of use: Disconnect channel rodding from the adjustable side of the assembly. Back off fixed connection rods from stretcher bars (front, middle and rear) Select relevant gauge from kit and fit the appropriate location pin (full or shallow depth) Locate pin in available hole on crank assembly ENSURING HOLE IS FREE FROM CONTAMINATION. The crank is then swung to enable the datum pegs to locate on the field face side of the rail and leave in position. Repeat above process and ensure all gauges remain in position with datum pegs in place at all times. Once satisfied all gauges are in place, adjust the adjustable connection rod as required and reassemble the channel rodding ensuring the gauges remain in place. Leave fixed connection rods loose on the stretcher bar and follow next process to set excess motion.

8 P a g e 8 Above shows a four foot EVS switch set with crank gauges. Note you can only take the measurement from the side with the crank plate fixed. This is crucial as the measurement differs dramatically so it will affect the backdrive alignment. BACKDRIVE ALIGNMENT KIT METHOD OF USE CONTINUED. Lost motion gauges (x4): The lost motion gauges are designed to gauge any excess motion at mid and rear position dependant on switch size. Method of use: Place gauges at middle and rear position as required either side of the drive lug over the connection rod and sleeve nut. Adjust the sleeve nuts in to suit required measurements. Tighten back nuts either side and remove gauges. NOTE: ON 3 CRANK SUPPLEMENTARY DRIVES THE MID CRANK LOST MOTION MAY REQUIRE ADJUSTMENT TO ACHIEVE OPTIMUM SETUP. THIS MAY RESULT IN LOST MOTION BEING REDUCED The above drawings (1.6 & 1.7) show the drive lugs where the gauges must be placed on either side. (1.8) shows the lost motion gauge. This will be identified on back face. NETWORK RAIL ADVISE THE USE OF THE P8 GAUGE WHEN ALIGNMENT IS FINISHED TO CHECK FOR FLANGE BACK CONTACT

9 P a g e 9 D MAINTENANCE The Backdrive Alignment Kit consists of various precision measuring tools in which have been designed to be used within the railway environment. Extra care should be taken not to damage the gauge when in use, transportation and storage. Excessive force on critical components may lead to inaccuracy in use. It is advised the Backdrive Alignment Kit should be inspected on a regular basis for any visual signs of damage or wear. Any components which show signs of damage, should be considered for replacement to maintain the positional accuracy of the gauge(s) BACKDRIVE ALIGNMENT KIT METHOD OF CLEANING. Crank Gauge UIC 54 and 113lb Method of cleaning: Once used, wipe down yellow bar with a cloth to remove any rain, dirt or grease. Clean off any grease, water etc. on locating pin and give a light spray of fin lube or other lubricating spray to ensure longevity of this item. Step Gauges: Method of cleaning: Once used, wipe off with a cloth and pair back together. Place back in tool box provided following the drawing in the lid. Lost Motion Gauges: Method of cleaning: Once used, wipe off with a cloth and pair back together. Place back in tool box provided. Crank Plate and Sleeve Alignment Gauge: Method of cleaning: Once used wipe down with a cloth and ensure telescopic sleeve gauge is located in its home position and lock off with pin provided. Clean location area around pin and pegs. MISUSE OF TOOLING CAN LEAD TO AN INACCURACY IN GAUGE MEASUREMENT! ENSURE TO FOLLOW THE ABOVE INSTRUCTIONS TO AVOID ANY ISSUES WITH THE GAUGE.

P a g e 10 E SPARE PARTS In the event that spare part is needed, see our table below to match the part

NETWORK RAIL CAT NO DESCRIPTION PICTURE 0111/110982 0111/110983 0111/110984 0111/110985 0111/110986

GAUGE (PAIR) STRETCHER BAR 2 DTS-15-0019 STEP GAUGE (PAIR) STRETCHER BAR 2 DTS-15-0020 STEP GAUGE

STRETCHER BAR 3 DTS-15-0023 STEP GAUGE (PAIR) STRETCHER BAR 4 DTS-15-0024 STEP GAUGE (PAIR) STRETCHER

10 P a g e 10 E SPARE PARTS In the event that spare part is needed, see our table below to match the part required. NETWORK RAIL CAT NO DESCRIPTION PICTURE 0111/ / / / / / / / / STEP GAUGE (PAIR) STRETCHER BAR 1 DTS STEP GAUGE (PAIR) STRETCHER BAR 2 DTS STEP GAUGE (PAIR) STRETCHER BAR 2 DTS STEP GAUGE (PAIR) STRETCHER BAR 2 DTS STEP GAUGE (PAIR) STRETCHER BAR 3 DTS STEP GAUGE (PAIR) STRETCHER BAR 3 DTS STEP GAUGE (PAIR) STRETCHER BAR 4 DTS STEP GAUGE (PAIR) STRETCHER BAR 5 DTS STEP GAUGE (PAIR) STRETCHER BAR 6 DTS / LOST MOTION GAUGE 7.5MM 0111/ CRANK LOCATION GAUGE (UIC54) SHALLOW DEPTH PIN 0111/ CRANK LOCATION GAUGE FULL DEPTH PIN

P a g e 11 F ASSEMBLY To change from Shallow Depth to Full Depth

11 P a g e 11 F ASSEMBLY To change from Shallow Depth to Full Depth please follow the below instructions:- Unscrew location pin from main body pin (Figure 1.9) 1.9 Ensure the thread is in good condition free from any contaminants on it. Visually check the O Ring is still in place then move to next step Screw full depth pin back on up to the O Ring where it will feel slightly tight, twist once more and pin should be in place and ready for use. Ensure this is only tightened by hand as the use of tools will damage the gauge. 1.12

Backdrive Installation, Set-up & Faults new standard.

Backdrive Installation, Set-up & Faults new standard. A backdrive is only used on vertical switches at type C switch and above or on inclined switches type D and above. It is primarily used to assist the