File No.

RDSO-MW0CD(CPLR)/3/2020-O/o PED/SW/RDSO 3660

I/69246/2024
Hkkjr ljdkj &jsy ea=ky; Government of India - Ministry of Railways
vuql/a kku vfHkdYi vkSj ekud laxBu Research Designs & Standards Organisation
y[kuÅ & 226011 Lucknow – 226011
EPBX (0522) 2451200 DID (0522) 2450115
FAX (0522) 2458500 DID (0522) 2465310

No. MW/CPL/BG/HT Date: 11.12.2024

1. Atul Engineering Udyog, NUNHAI, Agra – 282006.

2. Frontier Alloy Steels Limited KM 25/5 & 6 Kalpi Road, Rania Kanpur Dehat-209304, Uttar Pradesh,
India.
3. Jupiter Wagons Ltd., Shahgunj, Chinsurah, Distt.- Hooghly-712104, West Bengal.
4. Jai Multi Engg. Co.Bhagwanpura, Barwala Road, Teh. Derabassi, Mohali140507,Punjab.
5. Texmaco Rail & Engineering Ltd., Steel Foundry Division, Belgharia,North 24 Parga nas, Kolkat–
700056.
6. M/s TITAGARH RAIL SYSTEMS LIMITED-KOLKATA,( Both Unit) 756 Anandapur, E.M Bypass
Kolkata,West Bengal - 700107, India.
7. Bhilai Engineering Corporation Ltd., Hathkhoj Village, Industrial Area, Bhilai-490026, Dist-Durg (C.G.)-
490026.
8. Hindustan Engineering & Industries Ltd., Bamunari Plant, NH-2, Delhi Road, Bamunari, Dist-Hoogly,
Pin-712250, West Bengal, India.
9. Kharagpur Metal Reforming Industries Pvt. Ltd. Koushallya, P.O. Kharagpur, Dist. Paschim Midnapur ,
PIN-721301 (W.B.).
10. Shree Kedar Metal Foundries, Shree Kedar Metal Foundries Gate No. 49, Near Industrial Estate,
Palus, Dist-Sangli Maharashtra-416310.
11. Siena Engineering Pvt. Ltd. Plot No. 18A-22 and S-3/3, Sector-III, Sagore Kutti Road, Pithampur, Distt.
Dhar-454775 (M.P.).
12. NF Forgings Pvt. Ltd. Sankrail Industrial Park,N H-6 Bombay Road, Dhulagarh, Sankrail Howrah-
711302.
13. Oriental Foundry Pvt. Ltd., Survey No. 442 & 455/P-23, Village Chopadava, Tal Bhachau, Dist-Kutoh,
Gujarat-370165.
14. M/s JEKAY WAGONS LIMITED-KOLKATA P.O. Mugma, P.S. Nirsa, Distt: Dhanbad, Jharkhand-
828204.
15. Raneka Industries Ltd., Plot No. 15,16,17 Sector-3 (Sagore), Pithampur, Dist- Dhar (M.P.), Pin-454775.
16. Frontier Alloy Steels Ltd. Jamni Wala Road, Badri Nagar, Paonta Sahib, Dist. Sirmaur 173025, H. P.
(India).
17. Rine Engineering Pvt Ltd,73A, B&C,HPSIDC Indl. Area, Baddi, Dist.- Solan (H.P.)-173205.
18. N.K. Iron Industries, C-3, Foundry Nagar, Hathras Road Agra,Uttar Pradesh - 282006, India.
19. Hi-Tech Investment Castings Pvt. Ltd, 204, GIDC.II, Distt. Bhavnagar Sihor-364240 (Gujarat) India.
20. Lal Baba industrial Corporation Pvt. Ltd., 78, Lalbabu Shire Road, Belur, Howrah-711202 (W.B.).
21. Nikoo Precision Cast Pvt. Ltd., Survey No. 44/2, Rajkot-Gondal National Highway 27, Near Toll Plaza,
Village Bharudi (Gondal), Dist: Rajkot-360311, Gujarat (India).
22. Vikas Hitech Castings, Sankrail Industrial Park, N.H.-6, Bhagabatipur, P.O.- Chaturbhujkati , Sankrail,
Howrah-711302.
23. Sati Auto Components Pvt. Ltd. M12 Large Sector, Adityapur, Industrial Area Gamharia, ,Dist –
Jamshedpur-832108.
24. Thirumala Precicasts Pvt. Ltd, Gat no. 115/1A At. Post Ulegaon Taluka South Solapur-413224 (MH).
25. Industrial forge and engineering company limited-Jamshedpur, A 21P- A 25P, Phase VI, Adityapur
Industrial Area, Gamharia, Jamshedpur,Jharkhand – 832108.
26. Burn standard co. ltd.-Kolkata, 22-B, Raja Santosh Road, , Kolkata, West Bengal, PinCode- 700027,
India .
27. M/s ELECTRO MAGNETIC INDUSTRIES-VADODARA, PLOT NO. 1 G.I.D.C ESTATE,POR
RAMANGAMDI, POR VADODARA,Gujarat - 391243, India.

Page 1 of 2
 File No.RDSO-MW0CD(CPLR)/3/2020-O/o PED/SW/RDSO 3661
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28. M/s RAUSHEENA UDYOG LIMITED-GUWAHATI, Chaygaon Industrial Growth Centre, Village-
Chatabari, P.O.- Birpara, Kamrup,Assam - 781123, India.
29. M/s IRON FORT ENGINEERING LLP-HOOGHLY, Joykrishnapur, Dharapara, Chanditala, Begampur,
Hooghly ,West Bengal - 712306, India.
30. M/s NEETU YOSHI PRIVATE LIMITED-HARIDWAR, khasra no.255 and 256, village fakkarhedi, tehsil
Bhagwanpur, Haridwar, Uttarakhand, 247661 khasra no.255 and 256, village fakkarhedi, tehsil
Bhagwanpur, Haridwar, Uttarakhand, 247661.
31. M/S Aglow Engineers And Fabricators Private Limited-Howrah Howrah Amta Road Salap
Howrah,West Bengal – 711409
32. M/S Anand Sales Corporation-Kolkata Nand Sales Corporation, Bhandardah, Domjur, Howrah
Howrah,West Bengal – 711411
33. M/S Annapurna Engineering Works-Howrah 88/1 Deshpran Sasmal Road Howrah,West Bengal -
711101,
34. M/S Comet Technocom Pvt. Ltd. Block-2, 2nd Floor,Lemon Fresh 29/1, Kalabagan Lane, Howrah
Howrah,West Bengal - 711104,
35. M/S Devvrat Industrial Corporation-Kolkata 53/1/3 Hazra Road 3rd Floor Kolkata,West Bengal -
700019,
36. M/S Engineering Trade Centre [I] Pvt. Ltd.-Howrah 249/H,Gt Road,Liluah Howrah,West Bengal -
711204,
37. M/S Frontier Springs Limited-Kanpur Dehat Km 25/4 Kalpi Road Rania Kanpur Dehat-209304 Km 25/4
Kalpi Road Rania Kanpur Dehat-209304 Kanpur,Uttar Pradesh – 209304.
38. M/S Melbrow Engineering Works Pvt. Ltd.-Kolkata 113 Park Street Poddar Point Kolkata,West Bengal
- 700016,
39. M/S Cosmic Engineers-Howrah 16 Rameswar Malia 1st Bye Lane Howrah,West Bengal – 711101
40. M/S Eastern Engineering Industries-Howrah 40 E Road Belgachia Howrah,West Bengal - 711105,
41. M/S Engineering Trade Centre [I] Pvt. Ltd.-Howrah 249/H,Gt Road,Liluah Howrah,West Bengal –
711204
42. M/S India Tools Crafts Pvt Ltd-Kolkata 2nd Floor , Eastern Building,19 R.N. Mukherjee Road, Kolkata
Kolkata,West Bengal - 700001,
43. M/S A.D.Electro Steel Co.Pvt.Ltd-Kolkata Baltikuri, Surkimill,Kalitala Howrah Kolkata,West Bengal –
711113
44. M/S Dekon India-Howrah 9/1 Agrasain Street Liluah Howrah,West Bengal - 711204,
45. M/S Asansol Steel Castings Private Limited-Howrah 29/1, Kalabagan Lane, Block-2, Lemon Fresh,
2nd Floor, Howrah Howrah,West Bengal - 711104

Sub:- Regarding submission of revised QAP of CBC assembly and its components and clause wise / para
wise compliance of RDSO specification no. WD-70-BD-10 (Rev.04).

Ref:- RDSO specification No. WD-70-BD-10 (Rev.03) of CBC Assembly and its components.

Wagon directorate has revised RDSO specification no. WD-70-BD-10 (Rev.04) Since November 2024. In
consequence to above, here it is being advised to submit revised QAP and updated clause wise / para wise
compliances of RDSO specification no. WD-70-BD-10 (Rev.04) to this office at earliest. In failure to this a
necessary action may be initiated as per para 4.2.1.1 of ISO document No: QO-D-8.1-11 with latest revision.

(Arvind Kumar)
Director/Wagon
For Director General/Wagon

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 3612
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R
ED/SW/RDSO
No. WD-70-BD-10 (Rev.-4)

INDIAN RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENT

No. WD-70-BD-10 (Rev. 4)

FOR

UPGRADED HIGH TENSILE CENTRE BUFFER COUPLER

FOR
FREIGHT STOCK

Issued by

RESEARCH DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS
LUCKNOW-226011

November, 2024
 No. WD-70-BD-10 (Rev.4) 3613
3394612/2024/O/o ED/SW/RDSO
SCHEDULE OF TECHNICAL REQUIREMENTS FOR UPGRADED
HIGH TENSILE CENTRE BUFFER COUPLER FOR FREIGHT STOCK

0. PREAMBLE

Train parting due to breakage of CBC coupler components continues to be an area of

concern for Indian Railways. Quality of CBC components has direct bearing on online failures
and premature replacement of components during different maintenance schedules. This
specification with latest alteration is an attempt to improve reliability of this critical sub-
assembly of freight stock. This document covers works done for improving performance of
CBC coupler, material specification, process of manufacturing, inspection, testing, gauging
etc.

0.1 CBC of Indian Railways is based on the AAR specification. In 1960 few manufacturers
acquired TOT of Grade-B castings from North American Manufacturers. For operating longer
trains, the material of CBC was first upgraded to “C‟ and then to “E” Grade. For indigenous
development and multi sourcing, RDSO issued the drawings of CBC and gauges for CBC in
1980. However, the coupler and knuckle failures continued unabated.

0.2 During that period, following major problems were encountered in the manufacturing of the
Grade-E couplers:
 Difference in chemical composition between the imported Grade- E coupler and the
indigenous coupler. The AAR specification did not specify the alloying elements which
were being used in the imported coupler as analyzed in RDSO report No. 6375.
 Non achievement of physical properties mentioned in the specification issued by RDSO,
especially with respect to impact strength at -40°C. Most of the couplers were failing in
the impact test.
 Improper heat treatment.
 Casting defects.
 Poor dimensional control and surface finish.

0.3 To improve the indigenous couplers, RDSO constituted a Technology Development Group,
comprising of representatives of Wagon, QA and M&C directorates of RDSO along with
representatives of Industry to improve the coupler and it’s specification. Three meetings of
the Technology Development Group were held on 08.08.2006, 10.10.2007 and 26.06.2009.
Additionally these issues were also discussed in a meeting of RDSO and coupler
manufacturers held on 19.03.2007. Following decisions were taken in the meeting of the
Technology Development Group:
 To revise the chemical composition and inclusion of alloying elements by use of Nickel,
Chromium and Molybdenum.
 Manufacturers were asked to switchover from green sand moulding method to no-bake
moulding method by March 2008. Only one firm reported that they had switched over to
completely mechanized PLC controlled high pressure moulding line with automatic sand
plant equipped with sand cooling system and the consistency of the coupler
manufactured by this process was considerably better.

0.4 Despite various initiatives taken by RDSO, there was tardy progress in quality improvement
of coupler by various manufacturers as reflected by failures and the results of quality audits
conducted, and Indian Railway had to take recourse to import of couplers from AAR
approved sources for the new breed of high-capacity wagons, viz, BOXNHL and BCNHL. For
this purpose, RDSO specification No. WD-66-BD-06 was issued.

0.5 Since import of couplers was not a long-term solution, RDSO was assigned the Task of
developing a new specification as a long-term import substitute for the coupler. Following
approach was taken:
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 No. WD-70-BD-10 (Rev.4) 3614
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 Detailed investigation of failed couplers in RDSO. A detailed investigation into
couplers failures reported to RDSO was undertaken and the investigations revealed
that in addition to shrinkage and blow holes, the physical properties of the
specification have not been met in the failed couplers.
 Two failed couplers were sent to National Metallurgical Laboratory (NML) for detailed
investigations. As per the detailed investigations carried out, the failures were
attributed to improper steel chemistry and presence of casting defects such as
blowholes, porosity, slag inclusions, shrinkage cavities and lower impact energy.
NML concluded that factors such as moisture in moulding sand, improper ramming of
the moulding sand, insufficient venting, improper degassing of the molten metal can
give rise to blowholes and porosity in the casting. They further stated that shrinkage
cavities could be attributed to incorrect gate design, insufficient metal in the riser to
compensate for contraction and interrupted metal pouring in the mould. They have
also concluded that incorrect microstructure is due to improper heat treatment.
 Two imported couplers to AAR specification were also tested in detail at
National Metallurgical Laboratory to ensure adherence to specification.
 The RDSO drawings were checked and it was found that couplers manufactured to
these drawings and gauged as per RDSO gauges would ensure interchangeability.
 In view of the consistency offered by the no-bake process and high pressure
moulding, as decided by the Technology Development Group, RDSO got prototype
manufactured through these processes. These couplers were manufactured to the
chemical composition with alloying elements as stipulated in RDSO Specification No.
48-BD-02 and heat treated. The couplers manufactured by these processes had
high dimensional accuracy.
 The prototype couplers were tested at National Metallurgical Laboratory, and it
exceeded all parameters of physical properties in the AAR specification. The impact
strength at -40°C was significantly higher than the AAR specification. Tests for all
physical properties were conducted on samples prepared from casting.

0.6 This specification has been pre-validated through these studies to ensure that couplers
manufactured against said specification matches up to the international standards and
indigenous manufacturing capability is developed.

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 No. WD-70-BD-10 (Rev.4) 3615
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1.0 FOREWORD

1.1 This specification is intended to cover the technical provisions relating to raw material,
manufacturing process, tests and inspection for couplers, and infrastructure for
producing such upgraded couplers and does not include all the necessary provisions of
the contract.

1.2 This Specification is issued under the fixed number WD-70-BD-10. The number after
BD indicates year of issue.

1.3 This specification draws reference to the following specifications: -

(i) AAR M-118, M-201, M-205, M-211
(ii) AAR S-172 Section B Part- II & AAR S-137 Section B.
(iii) IS: 1875, 2004, 3885, 5517, 817 & 1181.
(iv) ASTM A-255, A-370, E-208, E-446 and E-604.
(v) ASTM A-668.

2.0 SCOPE
This specification covers the supply and acceptance requirements for Upgraded High
Tensile Centre Buffer Coupler and its components, outlines the process of
manufacturing and lays down the infrastructural requirements for manufacturing of
coupler and its components. Material requirements for coupler body, knuckle, lock and
yoke must meet various requirements of AAR specifications M-201 and M-205 in
addition to requirements mentioned in this specification.
2.1 CBC will consist of cast and forged components. Cast components are either of Grade-B
or Grade-E. The details are given in the Table-I. The coupler component; Lock, if
manufactured though forging process shall be manufactured with material grade Class L
(LH) (Normalized, quenched, and tempered) and chemical composition X4 of ASTM A-
668/A-668M-2a. Rotary bottom operated articulated lock lift assembly (Toggle,
Connector and Hook) and Knuckle thrower; if manufactured through forging process
shall be of material grade Class 2 of IS: 1875 or IS:2004.
TABLE- 1
SN Name of Part Cast/Forged Nos./ Coupler
1 Coupler Body with Shank wear Plate Cast Grade-E 1
2 Knuckle Cast Grade-E 1
3 Lock Cast Grade-E /Forged 1
4 Knuckle thrower Cast Grade-B /Forged 1
5 Knuckle Pin with Anti-theft cotter pin Forged/Rolled 1
6 Rotary bottom operated Cast Grade-B/Forged 1
articulated lock lift assembly
7 Yoke Cast Grade-E 1
8 Yoke Pin Forged/Rolled 1
9 Yoke pin support with wear plate Cast Grade B / Forged 1
10 Striker casting with wear plate Cast Grade B 1
11 Back Stop Cast Steel/Forging 2

Status of vendor and quantity restriction indicated against each registered vendor in the
UVAM (Unified Vendor Approval Module) portal for coupler and its components shall be
applicable for supply to Zonal Railways and Wagon Builders.

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 No. WD-70-BD-10 (Rev.4) 3616
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3.0 GENERAL REQUIREMENTS
3.1 Coupler Drawings
a) General arrangement of the coupler shall be to RDSO Drg. No. WD-81010-S-03,
latest alteration.
b) Coupler body and shank wear plate shall be to Drg. No. SK-62724 (Item 1 & Item
10 respectively), latest alteration. Shank wear plate shall be welded to the coupler
shank as shown in the drawing. The Coupler body must be manufactured as per
applicable requirements of this specification.
c) Knuckle shall be to t h e Drg. No. SK-62724 (Item 2), latest alteration. The
knuckle must be manufactured as per applicable requirements of this specification.
d) Lock shall be to Drg. No. SK-62724 (Item 8), latest alteration. The lock must be
manufactured by lost wax/investment or forging process.
e) Knuckle thrower shall be to Drg. No. SK-62724 (Item 9), latest alteration. The
knuckle thrower must be manufactured by a lost wax/investment or forging
process.
f) Knuckle pivot pin with securing arrangement shall be to Drg. No. SK-62724 (Item
4), latest alteration.
g) Articulated Lock lift assembly consisting of Toggle, Universal Lock lift lever
connector and Lock lift lever hook shall be to Drg No. SK-62724 (Item 5, 6 & 7
respectively), latest alteration. The knuckle lock lift assembly must be
manufactured by a lost wax/investment or forging process.
h) Yoke shall be to Drg. No. SK-62724 (Item 3) latest alteration. The Yoke must be
manufactured as per applicable requirements of this specification.
i) Yoke pin shall be to Drg. No. SK-62724 (Item 12), latest alteration. Yoke pin shall
be manufactured through forging or from rolled bars.
j) Yoke pin support shall be to Drg. No. WA/BD-4462 latest alteration. Yoke pin
support shall be supplied complete with wear plate welded as shown in drawing.
k) Striker casting and Striker Casting Wear plate shall be to Drg. No. WA/BD-4460
and WD-87056-S-01 respectively, latest alteration. Striker casting shall be
supplied complete with wear plate bolted and tack welded as shown in drawing.
l) Back Stop shall be to Drg. No. W/BD-699, latest alteration.
3.2 Draft Gear and Yoke
The coupler shall be suitable for fitment on freight stock along with Draft gear and its
follower to Indian Railways Schedule of Technical Requirement No. WD-71-BD-15
(Latest Rev.) & No.49-BD-08 (Latest Rev.) and Drawing No. 81010-S-03 Alt 7 or
latest.
3.3 Gauges
3.3.1 The CBC and all the coupler components shall be gauged with RDSO approved gauges
manufactured as per RDSO Drawings of gauges given in Annexure-I. The manufacturer
must possess at least 04 full sets of gauges for following purpose:
I. Master gauges.
II. One set exclusively preserved for inspecting authorities.
III. 02 sets for production/internal inspection.
NB: 02 sets of gauges are prescribed for production/internal inspection so as during
calibration/replacement, availability of all gauges is ensured for production/internal
inspection. Master gauges shall be used for calibration of rest 03 sets of gauges at
prescribed periodicity or after every 2000 pieces supplied whichever is earlier for which
the manufacturer shall have a well-equipped facility or from OEM/authorized agency
with prior approval from DG/Wagon/RDSO. Periodicity of calibration shall be specified
by OEM of these gauges and a record to this effect shall be maintained by the
manufacturer. Master gauges shall be got calibrated only from OEM/authorized agency
Page 5 of 48
 No. WD-70-BD-10 (Rev.4) 3617
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at frequency prescribed for calibration of such master gauges. Manufacturers can also
use their in house calibration facility for master gauges only with prior approval of
DG/Wagon/RDSO.
3.3.2 The gauges shall be colour coded with suitable colour to distinguish them from the
uncalibrated gauges. The colour of the calibrated gauges used in the month shall be
prominently displayed and updated by the standards section.
3.3.3 The drawings referred to in this schedule of requirements are available on
RDSO/IREPS/UVAM website for download as per extant instructions.
3.4 Interchangeability
3.4.1 All couplers and coupler components shall be interchangeable. Interchangability of
manufactured coupler components will be audited twice a year by wagon dte. or by
nominated QA(Mechanical) unit by DG/Wagon/RDSO. RDSO shall audit the
manufacturing process and shall check 20 couplers at random with the gauges defined
in clause 3.3. This is not withstanding the regular inspection being done by the
manufacturer.
3.4.2 The manufacturer shall provide labour, appliances and other details necessary for the
inspection of the coupler and its components in accordance with this specification at his
own cost.
3.5 Marking
3.4.1 All coupler components should have clear and legible manufacturer’s name in short
code and batch No. etc., which shall remain legible throughout the full-service period as
specified in RDSO Drawing No.SK-62724 (latest alteration). Knuckle shall have the
markings "for manufacturer’s name in short code, serial number, month & year of
manufacture etc. as shown in RDSO Drg. No. WD 87004-S-l (latest alteration).
3.5.2 The letter size and height of the raised letters shall be as specified in relevant RDSO
drawing. The marking shall be done at the casting stage itself. The manufacturer will not
be permitted to provide manufacturer's code and marking by electric arc welding in case
these are not visible at casting stage. Coupler body, Knuckle, Yoke and Lock shall also
be identified by raised letter UHTE whether made by casting or forging.
3.5.3 The coupler components found having illegible marking at the time of fitment in Railway
Workshops, Maintenance depot or on Wagon Builders premises shall be treated as
rejected and shall be replaced by the manufacturers free of cost. The cost of
transportation shall be borne by the manufacturer. Marking particulars of all coupler
components shall be maintained by Wagon Builder/Workshops/Depot as per
Annuxure– A.
3.6 Maintenance Spares
The Coupler manufacturer shall supply all the spare parts required for maintenance of
couplers supplied by them for use on Indian Railways against specific requirements of
Railways. In case of failure, their registration is liable to be cancelled.
4.0 PARTICULAR REQUIREMENTS
4.1 REQUIREMENT FOR KNUCKLE PIN AND YOKE PIN
4.1.1 MATERIAL
Manufacturer will ensure use of suitable material for manufacturing of knucle pin.
Proposed material and its actual mechanical properties shall be part of QAP. meeting
mechanical properties given in para 4.2.1.1.
Steel class 5 to IS: 1875 93 shall be used for manufacturing of yoke pin.
4.1.2 HEAT TREATMENT
The pins shall be heat treated to meet the requirements specified in Para 4.2

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 No. WD-70-BD-10 (Rev.4) 3618
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4.2 MECHANICAL PROPERTIES REQUIREMENTS
4.2.1 KNUCKLE PIN
4.2.1.1 The minimum requirement for knuckle pin is as follows:
Tensile Strength Yield Strength Elongation Reduction in
Area
Kgf/mm2 Kgf/mm2 % %
98.42 63.27 15 38

4.2.1.2 Hardness value shall be within the range of 277 to 332 BHN. Two or more hardness
determinations shall be made at locations approximately midway on diametrically
opposite sides from each other on the cylindrical surface. Hardness shall also be taken
on the center at both ends of the pin. Hardness shall be taken after decarburization by
surface grinding up to a minimum depth of 0.20 mm.
4.2.2 YOKE PIN
4.2.2.1 The material shall have following minimum requirements:
Tensile Strength Yield Strength Elongation Reduction in Area
Kgf/mm2 Kgf/mm2 % %
95 53 18.5 44.8
4.2.3 Hardness shall be within the range of 262 to 302 BHN. Two or more hardness
determinations shall be made on cylindrical surface at location approximately at the
center and 25 mm from each end of the Yoke Pin. These locations should be diametrically
opposite. Hardness shall also be taken on the center at both ends of the pin.
4.2.4 BACK STOP
The material shall have following minimum requirements:
For Casting (Gr 230-450 IS:1030-1998):
Tensile Strength Yield Strength Elongation Reduction in Area
(Min.) (Min.) (Min.) (Min.)
2
Kgf/mm Kgf/mm2 % %
46 23.5 22 31
For Forging (IS 1875-93 Class-3A)
Tensile Strength Yield Strength Elongation Reduction in Area
(Min.) (Min.) (Min.) (Min.)
Kgf/mm2 Kgf/mm2 % %
55.06 28.5 20 -
4.3 GAUGING
All-important dimensions of the Knuckle/Yoke Pin as shown in RDSO Drawings shall be
within the limits when gauged.
4.4 FINISH
The finished Knuckle/Yoke Pin shall be straight, free from scale and have surface finish of
Ra 3.2 µm or better. Surface finish shall be checked using contact type/non-contact type
roughness testor. Surface shall also be free from any visible defect. Pin shall not be
painted.
4.5 MARKING
Manufacturer name in short code & year of manufacture shall be stamped on the head of
each knuckle Pin and on the both ends of Yoke Pin.

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 No. WD-70-BD-10 (Rev.4) 3619
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4.6 REQUIREMENT FOR COMPONENTS MANUFACTURED BY STEEL
CASTINGS/FORGING
4.6.1 The casting/forging components shall be manufactured and tested as per the requirement
of respective component specification given in component drawings. Dimensions shall be
checked as per their respective drawings
4.6.2 Surface finish requirement shall be as per the standards specified in
drawings/specifications.
5.0 MANUFACTURE
5.1 Material
The material of Upgraded High Tensile Centre Buffer Coupler components shall be as
indicated in RDSO Drg. No. SK-62724 latest alteration and in the specification.
5.2 Process of Steel Making
5.2.1 All steel melting and refinement must be performed with the use of an Electric Arc
Furnace. Any other process of steel melting may also be employed provided it’s capability
of consistently attaining the required chemistry of castings is established to the RDSO
specification.
5.2.2 Ladle Analysis
The ladle analysis of steel when carried out by spectrometer to determine the
percentage of Carbon, Manganese, Phosphorous, Sulphur, Silicon Chromium, Nickel &
Molybdenum shall conform to the requirements as mentioned in Table 2.
Table -2

Casting Components As per

As per IS:1875-93
Element (%) ASTM 668
Grade E Grade B (Class-2/3)
(Grade-X4)
Carbon 0.28 - 0.33 0.32 (Max) 0.45 (Max.) 0.15 - 0.25(for class 2)
0.30-0.40 (for class 3A)
Manganese 0.60 – 0.90 0.90 (Max.) 1.10 (Max.) 0.60 – 0.90
Phosphorus (max.) 0.03 0.03 0.025 0.04
Sulphur (max.) 0.03 0.03 0.025 0.04
Silicon 0.40 –0.60 0.60 (Max.) 0.35 (Max.) 0.15 - 0.35
Chromium 0.50 – 0.80 ---- 1.10 (Max.) -
Aluminum 0.02 – 0.05 - -
Nickel 0.50 – 0.60 ---- - -
Molybdenum 0.15 – 0.25 ---- 0.25 (Max.) -
5.3 Manufacturing Process
5.3.1 Raw Material
Raw material, scrap and ferro-alloys used for the manufacturing of steel castings/forging
shall be analysed in advance and only those conforming to the QAP shall be used. Care
should be taken to ensure that the scrap selected is free from rust, grease, oil and other
prohibited contaminants.
5.3.2 Methoding
i Casting solidification software must be available with the firm to evaluate
castings for potential defects and to qualify the casting for production.
ii Standardized running, gating and risering system design including use of chills and
chaplets shall be developed with the help of casting solidification software and only
such system be employed for regular production of castings. Complete methoding
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system shall be part of approved QAP of the firm.
iii Casting solidity must be verified with the aid of casting solidification software to
achieve proper internal solidity standards. These standards are measured by means
of porosity percentage values. These porosity percentage values must not exceed
the maximum severity levels of a particular sectional area as given in Para 7.2.5.
5.4 Moulding
Moulding shall be carried out by employing either of the following process given below:
i High Pressure Moulding Line with Intensive Mixture for Green sand mould with
Automatic Moisture Control and addition of Binder in fixed rates
or
ii Articulated Mixer (continuous type) with fume extraction facility & Compaction Table
for No-Bake System.
For High Pressure Moulding Line, mould hardness shall be minimum 85 and the same
should be uniform at all the surfaces (Within 85 to 90 at the entire surface including
verticals), and for No – Bake System, scratch hardness of mould shall be minimum 60
and same should be uniform at all the surfaces, so as to get good dimensional accuracy
in castings.
5.4.2 Core making
 All cores shall be produced only by No-Bake process for which continuous mixer
with compaction table/batch mixer shall be available.

 Only single piece core shall have to be used for manufacturing of coupler body and
yoke.

 Mechanized and automated core making using core shooters shall be followed for
dimensional and quality control.

 Any deviation will require prior approval from DG/Wagon/RDSO.

5.4.3 Melting
A sufficient carbon boil must be accomplished with a 20 point carbon reduction. Double
slag process for proper removal of Sulphur and Phosphorus shall be followed. Argon
purging may be carried out to ensure freedom from harmful gases. Ladle pre-heating at
600 to 700°C shall be carried out. Temperature checking in Furnace and in Ladle by
Immersion Pyrometer shall be done before pouring in Mould.
5.4.4 Pouring
During pouring in mould, temperature checking by Laser Beam Type/Infrared
Pyrometer shall be done. After pouring castings shall be allowed to cool to a
temperature below 300°C, at a rate that will not be injurious to the castings. Moulding
boxes shall be opened to extract the castings after they have cooled down sufficiently to
room temperature.
5.4.5 Fettling
Risers, runners and ingates shall be removed from the castings. Use of knock-off risers
shall be preferred for improving the surface condition of the castings. All castings shall
thereafter be properly cleaned, dressed and shot blasted to ensure freedom from
surface imperfections, loosely adherent sand, scale etc.

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5.4.6 Heat-treatment
All castings shall be heat treated after fettling. Grade-E steel castings shall be furnished
normalised, quenched and tempered. Grade-B steel castings shall be furnished
normalized and tempered. Suitable heat treatment furnaces shall be employed and
must be capable of maintaining an even heat distribution within +/- 10°C throughout.
Verification must be established by performing a minimum of eight zone survey on
monthly basis and record on the same shall be maintained by the manufacturer. For
optimum heat flow only 70-80% of total volumetric capacity of heat treatment furnace
shall be used. Stacking diagram for coupler assembely and its components for heat
treatment shall be part of approved QAP of the manufacturer.

5.3.8.1 Normalized and tempered steel castings shall be processed in the following order:
Heat to the proper uniform temperature above the transformation range (890-920ºC) and
hold for the adequate time (1 Hr + 1Hr for each 25 mm section thickness) to achieve
complete austenization and to refine the grain structure.
Withdraw from the furnace and cool in still air until casting in its entirety is below 300
ºC. Temper by reheating to the required and uniform temperature below the
transformation range, but not less than 400ºC and hold for the required time (1 Hr + 1Hr
for each 25 mm section thickness). Remove the castings from the furnace and allow it
to cool to room temp.
5.3.8.2 Normalised, Quenched and tempered steel castings shall be processed in the
following manner:
Heating shall be done in the Furnace with Automatic Charging Arrangement and facility
to quench within 60 seconds. Castings shall be heated to the required uniform
temperature above the transformation range (890ºC - 920ºC) and held for the adequate
time (1Hr + 1Hr for each 25 mm section thickness) to achieve complete austenization and
to refine the grain structure.
Withdraw from the furnace and cool in still air until casting in their entirety are below
500 ºC.
Castings shall be reheated to required uniform temperature above the transformation
range (880ºC - 900ºC) and held for the adequate time (1Hr + 1Hr for each 25 mm section
thickness) to achieve complete austenization and to obtain the finer grain structure.
Withdraw from furnace while castings are above the transformation range, subject to
rapid cooling (quenching) in suitable liquid medium in a quench tank to a temperature
substantially below the transformation range. Quenching Tank should have volumetric
capacity of more than 10 times of charge with Cooling Tower system along with highly
agitated liquid medium mechanical arrangement from bottom of the tank. Rise in the
temperature of the quench tank after quenching shall not be more than 10ºC.
Tempering should be done within one hour of quenching. Tempering is to be done in the
Furnace equipped with Hot Air Circulation System at the top for better heat transfer from
Hot Air to casting.
Temper by reheating to required uniform temperature above the transformation range
(590ºC -620ºC) and held for the adequate time (1Hr + 1Hr for each 25 mm section
thickness). Hold for the required time, remove from the furnace and allow to cool to room
temperature

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5.3.8.3 All the stages of heat treatment with various temperature ranges of processes shall be
clearly brought out in QAP. Inspecting Authority shall examine it with actual heat
treatment process being followed during quality audit.
5.3.8.4 Heat-Treatment Documentation
The manufacturer is required to develop and document heat-treating standards that
describe the processes, process control procedures, and record keeping requirements.
These documents are to be presented and reviewed as part of the Vendor Registration
Process, inspections & audits and are intended to ensure that products are properly heat
treated. Furnace temperatures for heat treatment shall be controlled by pyrometers
having associated recording equipment that produce time-temperature record charts that
are identified by date and furnace number. A log sheet for each load of castings heat
treated (batch) should show all information pertinent to each heat-treat load including the
following:
• Type of casting
• Prescribed heat treatment
• Serial numbers and the heat numbers of the castings
• Actual time of heat treatment.
Pyrometers shall be calibrated every 3 months. Records of time-temperature charts,
furnace log sheets, and pyrometer calibrations will be preserved for 6 years and made
available to the purchaser/authorized personnel of Indian Railways upon request.
6.0 TEST SAMPLES
Test samples shall be prepared from the castings (coupler, yoke and knuckle) or from
test coupons. An integrally cast test coupon needs to be physically continuous with the
casting while gated test coupon( only for investment casting) would be separated from
the casting by the gated system. Both methods would ensure that the casting and the test
coupon were casted using the same molten metal. Further, for Coupler body, Knuckle
and Yoke; two lugs shall be integrally cast. The location of test lugs shall be such that
when removed, they shall indicate that condition of heat treatment on particular steel
castings. The standard test lug shall be 25 mm in height by 25 mm in width and 13 mm or
16 mm in thickness where it joins with castings. Test lug shall not be used for preparation
of test sample for checking mechanical properties. The samples from the casting, test
coupon as well as test lugs must meet the properties of this specification. Manufacturer
will submit drawings to RDSO regarding location of test lug on castings, similarly size of
test coupon and casting method i.e. integral with casting or through separate gating
system( only for investment casting) shall also be specified in the QAP.
6.1 Test coupons
The coupons shall either be cast attached to the castings or the gating system and
prepared in accordance with ASTM Standard A-370, latest revision. Coupons cast with
coupler should be integral part and the same shall be removed only after the inspecting
authority has inspected and passed the lot. For investment casting components, test
sample shall be prepared from the test coupon or from the casting. For forging/
components test sample shall be prepared from the product itself.
7.0 TESTING
7.1 Chemical Composition
The product analysis shall be carried out from the test sample (test lug or test coupon or
sample prepared from the product) taken from finished component by spectrometer.
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Table-5

Cast Temp. Energy (Minimum) Energy (Minimum)

Steel ( ºC ) ( If Test is performed on sample (If sample prepared from
prepared from Test Coupon ) Castings)
(80% of Test Coupon values)
Grade –E -40 3.50 kg.m (34.3 J) 2.8 kg.m (27.5 J)
Grade –B -7 2.07 kg.m (20.3 J) 1.7 kg.m (16.7 J)
7.2.3 Hardness
The heat treated cast steel components must meet the following Brinell hardness range as
specified in Table-6 (i):
Table-6 (i)
Grade Hardness(BHN)
Grade-E steel castings (except knuckle) 241-311
Grade-E, Knuckles 241-291
Grade-B, castings 137-208

As Quenched Hardness:
Quenching operation should be performed after fettling and shot blasting operations. The
cast steel components after quenching must meet the following Brinell hardness range as
specified in Table-6(ii):
Table-6(ii)
Grade Hardness(BHN)
Grade-E steel castings Minimum 429

Testing shall be done on a surface (that has been ground to remove decarburization) as
well as in the core on the sectioned castings in accordance with ASTM A-370.The hardness
shall be checked on the location as shown in Fig-1. Hardness of the components not shown
in figure shall be checked at suitable location.
7.2.4 Nil Ductility Test
Fracture Toughness/Nil Ductility Test shall be conducted on test sample prepared from
finished product in accordance with either ASTM E604 or E208. Only in case of Lock, test
sample can be prepared from test coupon for casting or forged test sample. The test
specimen shall withstand the test without showing any sign of distress. For Grade-E or
equivalent forged grade material( Coupler body, Yoke, Knuckle and Lock) Nil –Ductility
Transition Temperature (NDTT) shall be -57°C or lower.
7.2.5 Destructive Testing
Destructive test shall be carried out on the actual casting during prototype inspection as well
as during purchase inspection.
One casting per 200 shall be subjected to destruction to examine the presence of casting
defects. Defects such as blow holes, slag inclusions, shrinkage, etc. are not acceptable.
Porosity to a level of 2% of the cross section may be considered acceptable.
Castings are to be sectioned in accordance with Fig-2. Areas to be rated for discontinuity
severity level are illustrated in Fig-3 and Fig-4. Casting areas for evaluation shall be rated as
to level of severity by comparing them with "Standard Reference Photographs for Casting
Solidity, included as Annexure-III of this specification and results shall be recorded. The
rated level of severity for each section must not exceed those listed in the following table-7:
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Table-7
Sectional area-Maximum severity Levels
Component Type A B C D E F
Coupler Head 3 5 4 4 4 2
Knuckle 4 4 2 - - -
Coupler Shank 3 4 4 4 - -
7.3 Non-Destructive Testing
7.3.1 Acceptance Standard For Radiographic Examination
Radiographic examination shall be conducted on Knuckle, Coupler Body & Yoke to the
extant as specified in para no.7.6 & 8.3 (as applicable) on the castings produced and level
of acceptance shall be as per ASTM E-446 Level-II. The location for Radiographic test
shall be as per Annexure-II (Sheet-1, 2, & 3). Radiographic testing facility shall be
available with the manufacturer i.e. testing to be in-house. The procedure of radiography is
given in Annexure-II.
7.3.2 Magentic Partical Test:
Magnetic Particle Test shall be conducted on Knuckle, Coupler Body & Yoke to the
extant as specified in para no.7.6 & 8.3 (as applicable) on the castings produced.
Procedure for Magnetic Particle Testing and critical location for testing shall be as per
Annexure-III. Magnetic Particle Testing facility shall be available with the manufacturer
i.e. testing to be in-house. The “continuous” MPT method is used in conjunction with dry
powder magnetic particle application at the specified critical areas of CBC components.
This inspection method covers the Alternating Current (AC) yoke technique using dry
powder magnetic particle application at the specified critical areas. Manufacturer can also
use any alternative methods of MPT with prior approval from DG/Wagon/RDSO. Approved
procedure for MPT shall be part of approved QAP.
7.4 Metallographic Test
With a view to ensure the homogeneity of the steel and the quality of heat treatment, it is
essential to examine the microstructure of the knuckles at the time of prototype and
purchase inspections. The samples should be taken from the lugs attached to actual
castings produced and not from the separately cast test bars/test coupons.
Microstructure achieved shall be uniform fine tempered martensite.
7.5 Static Test
Manufacturers must maintain Internal Process Specification and Quality Assurance
Program to control casting integrity. As a periodic check, a laboratory static test will be
conducted on one (1) specimen of every 5,000 coupler bodies, knuckles and yokes being
produced or once every three (3) or six (6 ) months according to the following tabulation,
whichever occurs first. If production is less than 1,000 in the frequency period, no test is
required for that period. However, in any case, at least one (1) test is required per year.
The specimen shall represent current production practices.
Table-8
Component Frequency Period
Coupler Body 6 months
Knuckle 3 months
Yoke 6 months
Static tests shall also be conducted at time of Prototype inspection.

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Proof Test of Coupler Body and Knuckle:
Method of Testing:
Coupler bodies and knuckles must meet permanent set and ultimate strength
requirements shown in Table-9. The dimensions shown in Fig-5 shall be used for
determining permanent set and result shall be recorded. Special test knuckles for testing
coupler bodies shall have Minimum Ultimate Breaking Load capacity in excess of 408
tonnes. When testing coupler bodies, if test knuckle breaks before required loading is
attained, the test shall be terminated and the applied load recorded as the “maximum
applied load”. "Test machines shall have a minimum capacity to meet specified loads and
shall be calibrated to ASTM standards.
Static Tension Test Requirements:
Table-9
Component Grade E Steel
Maximum Permanent Set – in mm Minimum Ultimate Breaking force
At 181.5 t At 317.5 t in ton
* Knuckle 0.76 - 295 t
Coupler body - 0.76 408 t
*Based on testing with dummy knuckle fixture.
Proof Test of Yoke:
Method of Testing:
The method of testing yokes and measuring permanent set is shown in Fig-6. The support
and loading of the yokes for these tests shall be equivalent to service application. In
making deflection measurements, the measuring instruments shall be set at zero, after a
load of 9 tonnes has been applied and released to datum load of 2.27 tonnes. The
minimum ultimate load shall be considered the load at which distortion shall not exceed 6
mm over all, measured vertically or laterally.
Test Requirement
The maximum permanent set, measured from the point of load application to the point of
support, and the minimum ultimate load, shall be as shown below:
Table-10
Maximum permanent set - in Minimum Ultimate breaking force in
mm ton
Material of Yoke
At 340.2 t. 408 t
Grade-E steel 0.76 mm -
7.6 Type and Number of Tests
The quality control organization of the manufacturer should carry out tests as given below.
Records must be maintained for the tests carried out.
S.N. Parameters Test to be Sampling Reference Test
done on plan specification
1. Visual & Operational Check CBC 10% of the offered Para: 8.2 & RDSO Drgs
Components lot or min. 10 8.4
2. Dimensional CBC 10% of the offered lot Para:3.3 RDSO Drgs
Components or min. 10

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 No. WD-70-BD-10 (Rev.4) 3628
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The purchase inspection shall be carried out as follows:-
The Inspecting Authority shall first check the records of the manufacturer to ensure that the
item offered for inspection have been manufactured strictly to the requirement of this
specification and QAP of the manufacturer in the manufacturer's premises.
• A heat is defined as the total quantity of the castings produced in one melt
and heat treated together i.e castings having same chemical composition.
Since marking particulars on casting are created at the time of casting itself.
Therefore, It will be mandatory to heat treat items of one melt together to avoid
any traceability related issue arising due to items poured together but not heat
treatment simultaneously.
• One batch consists of castings having same chemical composition and
undergoing same heat treatment in the heat treatment furnace. One batch can
have more than one heat.
• A lot is defined as the total no. of castings offered for inspection and this may
include several heats/batches.
Inspecting Authority should also do at least one inspection of any of the following
manufacturing process during every purchase inspection or one per month whichever is
earlier:-
1. Chemical composition.
2. Mechanical properties.
3. Impact test.
4. Hardness test.
5. General requirement of casting acceptance.
6. Requirements of components manufactured other than steel castings.
Record of these inspections shall be maintained and it should be ensured that each process
get covered in cyclic manner.
After having been satisfied about offered inspection lot that the components are strictly
manufactured to all the requirement of this specification, the Inspecting Authority shall carry
out the inspection as per procedure given bellow:-
The manufacturer shall submit test results of Coupler/Coupler component offered for
inspection with Heat No., Batch No. marking details and internal test details to Inspecting
Authority. From a lot of 200 Couplers or a part there-of, following inspection shall be done.
(a) Ten percent (10%) or Minmumm 10 Coupler/Coupler component shall be dismantled
and each casting shall be checked for the following:-
a) Gauging of all components with calibrated gauges.
b) General requirement of casting acceptance.
c) Marking.
d) Weight variations.
On identification of a single defect on any of the components, the whole lot shall be rejected.
However the manufacturer can re-offer the lot after carrying out internal inspection for
identification of all defective components. Such defective component can be replaced by the
manufacturer.
In the re-offered lot Twenty percent (20%) Coupler/ Coupler components shall be checked for
the above requirement and whole lot shall be rejected if a single defect is identified in the
re-offered lot.
(b) Components other than steel castings shall be checked as per requirement of this
specification for the followings.
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 No. WD-70-BD-10 (Rev.4) 3629
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a) Dimensional accuracy.
b) Surface finish requirements.
c) Hardness testing.
The dismantled components, if meet the requirements of the paragraph (a) and (b) above
shall be assembled randomly and following shall be checked.
a) Interchangeability of components.
b) Easy assembly of components.
c) Proper Coupler operation.
8.2 COUPLER OPERATION
Assembled couplers must be free of any foreign material that will prevent proper operations
described in this Paragraph. A coupler inspection operating rod is illustrated in Fig-7.
 The knuckle must rotate to the open position by a continuous rotary force
applied by hand through the inspection operating rod from the rod handle.
 The knuckle must rotate to fully closed position to permit drop of the lock to the
locked position by a continuous steady force applied by hand on the knuckle nose.
 The lock must automatically drop to the locked position when the knuckle is closed.
The knuckle is locked shut when the lock drops to knuckle tail shelf or gap between
lock and knuckle tail shelf is 6 mm or less.
 Lock set test shall be conducted in the following manner:
 Force shall be applied through the inspection operating rod to raise the lock
above the knuckle tail.
 The rod shall be eased back and released, the lock must rest on the forward top
edge of the knuckle thrower lock leg.
 The knuckle then must be free to rotate fully open by hand through force
applied on the inside face of the knuckle nose.
 Knuckle shall be closed, lock must automatically drop to the locked position.
Coupler must provide anti-creep protection to prevent accidental unlocking as specified in
Section B, Part II, of AAR Standard S-172, Paragraph 4.2.8. Couplers furnished complete must
be fitted with knuckles of the same grade of steel as the coupler body. Couplers must be fitted
with Grade-E or equivalent forged locks. The assembled coupler must operate as described in the
Section B.
The lot shall be rejected on failure of coupler or coupler components on any of the above
requirements. However, the manufacturer can re-offer the lot, after carrying out internal inspection
and replacement or repair of all defective components. In re-offered lot, double sample will be
drawn and all the above mentioned requirements (of Para 8.1 and 8.2) shall be checked.
8.3 In addition to the tests mentioned in para 8.1 and 8.2 the inspecting official will conduct tests
as under :

S.N Parameters Test to be Sampling Reference Test

done on plan specification
1 Mechanical
Properties Test one per Heat Para: 7.2 ASTM A-370
 Tensile strength Coupon/CBC
 YS component
 Elongation
 RA

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2  Proof Static CBC As per Table-8 Para:7.5 Para:7.5
tension test Component One per lot
 Proof static
test of yoke
3 Chemical composition Lug/test One per heat Table: 2 IS-228
coupon
4 Microstructure Lug/test One per heat Para: 7.4 IS-7739
coupon
5 Hardness CBC 10% of the lot or min Table: 6(i) IS-1500
component 10 numbers (in case of
knuckle records for 100%
intranal checking to be
verified also)
6 Destructive test CBC One per lot Para:7.2.5 Para:7.2.5
Component
7 Impact Test Three per heat Para:7.2.2 ASTM A-370
Coupon/CBC
component
8 Nil ductility CBC One per heat Para:7.2.4 ASTM E-604
components or E-208
9 Weight variation CBC 10% of the lot or min 10 Para:8.6 Para 14 of
components numbers (in case of knuckle AAR M-201
records for 100% intranal
checking to be verified also)
10 Radiographic test CBC 5% of the lot Para:7.3.1 Annexure-II
components
11 Magnetic Partical Test CBC 5% of the offered lot Para:7.3.2 Annexure-III
Components
NB: Care should be taken that normally samples being subjected to Radiographic test are different from those
being tested through MPT.

i. On failure of sample in any of the above tests, the whole lot shall be rejected.
However the manufacturer can re-offer the lot after removing all the defective
components manufactured in that particular heat in which failed component was
cast.
ii. In the re-offered lot double the sample shall be tested provided re-offered lot meets
the requirements of Para 8.1 and 8.2. There should not be any failure in re-offered
lot.
iii. The coupler components with illegible marking shall be identified and rejected from
the lot.
iv. On completion of inspection and acceptance by inspection authority, the coupler
shall be painted as per paragraph 8.9 of this specification, before inspector’s
approval stamping & dispatch to consignee.
v. The components used for tests etc. from the lot during purchase inspection shall be
replaced free of cost by manufacturer.
8.4 Casting Surface Finish
Riser pads and gate stubs shall not project more than 6 mm above the surrounding
surface at any location. Where interference would exist in the operation or application or
where serviceability would be affected, the riser pads and gate stubs shall be contoured
to surrounding areas.
Castings shall be blasted sufficiently clean to permit thorough, visual Inspection. Prior to
shipment, castings shall be free of dirt, rust, or loose material that would affect operation.
Couplers must not be sand or shot blasted when completely assembled.
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8.4.1 Surface Finish Acceptance Level
AAR specification No.M-215 for coupling system, specify that steel casting must comply
with all applicable provisions of specification No.M-201 & M-211 including the surface
finish and solidity requirements of specification No.M-211. Under the para 13.2 of AAR
specification No.M-211 on “Coupler & yokes, AAR approved – purchase & acceptance”,
surface acceptance level have been stipulated for coupler components. Further, under the
ASTM A-802-19 “Standard practice for steel casting, surface acceptance standards, visual
examination”, acceptance criteria for surface inspection of steel casting by visual
examination have been provided. Following these guidelines casting surface finish is
stipulated as under.
The minimum acceptable surface conditions for the defects described below shall
govern. Acceptable surfaces shall be defined utilizing Steel Castings Research and
Trade Association (SCRATA) Comparators for the Definition of Surface Quality of Steel
Castings (1981). The listed defect classification does not apply to inaccessible areas.
Surface defects described herein do not preclude the requirements of proper gauge
application as defined elsewhere in this specification.
Surface conditions evaluated with SCRATA comparators:
Critical Area (Fig-8) Non Critical Area (Fig-8)
A Surface Roughness A3 A3
B Surface Inclusion B2 B4
C Gas Porosity C2 C3
D Laps D1 D4
E Scabs E2 E2
F Chaplets F2 F4
G Thermal Dressing G2 G3
H Mechanical Dressing H3 H4
J Welds J2 J3
Surface conditions not evaluated with SCRATA comparators. Offsets greater than ten
percent (10%) of the casting wall thickness are not permitted. (Offsets: An offset is an
abrupt, unintentional change in the casting surface.) Cracks, hot tears, cold shuts, and
weld cracks, which are visually apparent, are not permitted Zone 1 areas must be
prepared in accordance with Fig 9.
8.5 Wall Thickness
Wall thickness tolerances except where controlled by gauges or RDSO's drawings, are:
6 mm up to, not including 11mm wall, + 3 mm - 0.8 mm
11 mm up to, not including 19mm wall, + 3 mm - 2.4 mm
19 mm up to, not including 32mm wall, + 3 mm - 3 mm
32 mm and over, + 4.8 mm - 4 mm
8.6 Weight Variation:
Variation in weight of coupler body, yoke and other components, viz. knuckle, lock,
rotary parts, shall not vary more than FIVE percent ( 5%) above or THREE percent
(3%) below of that indicated in drawing no. SK-62724 latest alteration. Those coupler
components, which do not fall within the prescribed limits of weight variation, shall be
rejected by manufacturer.
8.7 Illegible Markings
Illegible markings are markings that do not conform to paragraph 3.5 and coupler
components with illegible markings shall be rejected.
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8.8 Lubrication & Painting
Only dry lubricant shall be applied to the coupler head or the coupler head fittings. This
lubricant may be applied using water, alcohol, or other non-petroleum based carrier.
Painting.
Only exposed surfaces of Coupler and Yoke shall be painted with Black quick drying
paint after inspection. Painting scheme and paint to be used shall be part of the approved
QAP. Paint must not be applied to the inside of the Coupler or internal fittings. Painting
shall be done after the completion of inspection on Coupler & Yoke of acceptable casting
lot.
Any deviation in lubrication or painting is permitted only with prior approval of
DG/Wagon/RDSO.

9.0 GUARANTEE
The coupler supplied shall be accompanied by a guarantee for a period of 72 months from
the date of supply or 60 months from the date of fitment, whichever is earlier.
10.0 RECORD OF INTERNAL ACCEPTANCE TESTS:
The manufacturer will maintain a list of all internal acceptance tests being carried out by
him at various stages of manufacturing of the product. Proper record of such internal
acceptance tests shall be maintained by him and also included in the QAP. At the time of
inspection of the product, these records shall be put up to the Inspecting Authority for
scrutiny and countersign.
The manufacturer shall maintain records for a minimum period of six(6) years of all
weights, mechanical test reports, chemical test reports and heat treatment records
applicable to the purchased castings. These records shall be made available to the
purchaser upon request. The manufacturer shall also maintain records for a minimum of
six(6) years that provide traceability from the serial number of individual castings, where
applicable to the records stated above.
11.0 MINIMUM FOUNDRY INFRASTRUCTURE REQUIREMENTS
11.1 A foundry producing coupler castings should have the capacity to produce at least 5000
couplers and coupler components per year.
11.2 To ensure dimensional and feature control, the castings shall be produced by one of the
following moulding processes mentioned in Clause 5.3.3 of this specification for which the
necessary infrastructure should be available.
11.3 The foundry must have the ability to conduct all the tests mentioned in this specification.
11.4 Chemically bonded no bake sands out of a articulated continuous mixer with PLC control
shall be used to produce casting cores for which necessary infrastructure should be
available.
11.5 Melting furnace capacity should be a minimum of 5 MT utilizing electric arc.
11.6 Heat treating furnaces should be capable of holding at least 3 MT of castings and reaching
and maintaining temperatures of 950 deg C. Furnaces should have automatic temperature
control and be capable of operating as low as 500 deg C and fitted with an automatic digital
recorder.
11.7 Other equipment to meet the requirements of this specification should be available.
11.8 The foundry shall hold a valid Quality Assurance Certification as per AAR M1003 or ISO
9001.

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 No. WD-70-BD-10 (Rev.4) 3633
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12.0 PROCESS FOR THE QUALIFICATION, APPROVAL AND VENDOR PROGRESSION
OF A CASTING FOUNDRY FOR THE MANUFACTURE OF RAILROAD COUPLERS.
12.1 For consideration of foundry approval to produce couplers, yokes, knuckles, and coupler
components, the manufacturer must have the minimum infrastructure listed in Clause 11
of this specification. Thereafter the manufacturer shall submit a vendor approval
application to RDSO containing the following information:-
 A description of the facilities processes and capabilities, along with detailed
information on quality control procedures.
 A list of all components to be produced at the facility.
12.2 Along with the application, the vendor will request RDSO for an inspection only after
fulfilling the following requirements.
 Their infrastructure is compliant with this specification and they meet the eligibility
requirements.
 They will be in a position to manufacture 25 couplers and its components during the
visit of RDSO audit team.
12.3 INSPECTION OF MANUFACTURING FACILITY AND PROCESSES:
RDSO shall send a team for carrying out an audit of the manufacturing facilities and the
quality assurance system to verify if the manufacturer is capable of manufacturing couplers
to this specification. To facilitate the audit, 25 couplers and its components will be
manufactured. Other extant guidelines for registration of vendor as per relevant ISO apex
document of RDSO shall be applicable. The inspection procedure shall also include a
review of the following items:
 Plant operation and procedures, including confirmation of certification tests, production
and quality equipment inspection, employee interviews and finished product defect
levels.
 Process control plans, including critical inputs, outputs and specification limits, sample
size and frequency, control method and reaction plan.
 Critical processes, including practices for pattern and core boxes, core making,
moulding, melting, pouring, cleaning, heat treating and casting quality.
 Organization, verifying separation between production and quality control responsibility,
resolution mechanism for non-conforming product and controlled disposition of non-
conforming product.
 Personnel, verifying procedures for qualifying employees, training of new employees
and existence of competent expertise.
12.4 TYPE TEST:
First article inspection of the couplers and its components for dimensional control as per
gauges will be carried out. Two samples (Coupler body, Yoke and Knuckle) will be picked
up by RDSO team and sent to National Metallurgical Laboratory (NML) for type testing.
RDSO at its discretion may send the samples to another laboratory as well. The test
charges will be borne by the manufacturer.
12.4.1 If any of the couplers and its components of offered 25 couplers and its components fails
during any of the Type test, manufacturer will be required to manufacture 50 couplers and
its components for re-testing. No component of failed lot shall be part of these 50 couplers
and its components. If any component failes in re-offered lot, vendor registration case shall
be closed.

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 No. WD-70-BD-10 (Rev.4) 3634
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12.5 After successful conduct of capacity-cum-capability assessment as per extant guidelines
given in relevant ISO apex document and after successful type test as per Clause 12.4,
RDSO will grant an approval for manufacture & supply as a developmental source. The
developmental source will be placed in the List of RDSO registered Vendors for
Developmental Orders available on UVAM portal with following restriction on supply.
i. Maximum permitted quantity-5000 Nos. complete coupler sets and 5000 Nos. of Grad-
E castings i.e. coupler body, knuckle and yoke. Other coupler components can be
supplied without any restriction on quantity.
ii. The ceiling limit of supply beyond 5000 Nos. on complete coupler set and 5000 Nos. of
Grade-E castings i.e. coupler body, knuckle and yoke shall be withdrawn when the
following conditions are fullfilled:
 500 couplers assembly have completed at-least one year of satisfactory service.
 Satisfactory type tests on two coupler body and two knuckles which have completed
one year of service similar to other stipulations of para 12.4.
 Samples picked up from the field must meet the physical and chemical properties of
the specification. If first sample of two coupler body and knuckle fail for physical and
chemical properties, the firm will be required to submit an explanation for the same.
Based on rationality of the explanation, second sample of two coupler body and two
knuckle will be picked up from field and shall be subjected to re-test. In case the
second sample also fails during re-testing, the firm shall be delisted from the vendor
directory.
 No unresolved non conformances or pending warranty cases as on date of
application of manufacturer for removal of ceiling limit. The manufacturer should
also have infrastructure and processes to meet the following requirements.
I. Use of single piece core for coupler body & yoke.
II. Casting component non-destructive testing requirements as per AAR M-220.
12.6 Non conformances shall be reported to RDSO and the manufacturer, identifying the failed
material or service provided by the manufacturer. The initiator of non-conformance reports
may include the wagon builder or owner or Indian Railways. The non-conformance report
shall identify the product, a description of the non-conformance and disposition of the
product. The manufacturer shall respond to the report within 30 days, identifying the root
cause and corrective action plan to address the non-conformance. A follow up plan shall
also be included to ensure that the corrective action is effective and permanent. Inadequate
or ineffective response to non-conformance will initiate a process of decertification at the
discretion of RDSO.
12.7 Post removal of ceiling limit manufacturer will be treated as Developmental vendor. Further
upgradation from Developmental to Approved vendor shall be done as per the extant
RDSO’s ISO procedure.
12.8 The manufacturer seeking approval for manufacture & supply of complete assembly of
Upgraded High Tensile Centre Buffer Coupler should have in-house manufacturing facility
for minimum five major components i.e. Coupler Body, Knuckle, Yoke, Striker Casting and
Yoke Pin Support Plate.
12.9 The manufacturer having status as an Approved vendor for complete assembly of
Upgraded High Tensile Centre Buffer Coupler will be permitted to use full quantity of in-
house manufactured sub components for supply of complete assembly even if the
manufacturer is registered as a vendor with Developmental status for the sub items of
complete assembly of Upgraded High Tensile Centre Buffer Coupler.

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 No. WD-70-BD-10 (Rev.4) 3635
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13. MINIMUM INFRASTRUCTURE REQUIREMENTS FOR INVESMENT CASTING:
(Manufacturing facility for coupler components i.e. Lock, Knuckle Thrower, Toggle,
Connector and Hook).
 One Wax melting machine & Wax Mixing Machine, should be available for wax
melting and mixing.
 Centralized wax filling facilities should be available for feeding to wax injection
press.
 Sufficient Die should be available for pattern making.
 Runner Riser press should be available for making riser and runner in the pattern.
 Wax Injection Press should be available or making wax pattern.
 At least one Hot Plate should be available
 Extruder press for breaking different sizes of solid wax.
 Jar Mill for making slurry.
 At least one Slurry Tank should be available.
 Rain fall sander should be available for shell moulding.
 Facility and space for drying moulds.
 De-waxing facilities should be available.
 Fluidizes sand bed.
 Dust Collector.
 One Auto clave should be available for de-waxing.
 One Electric /Induction Furnace of 300 kgs (Min.) should be available for meting
purpose.
 One Shell Baking Furness should be available.
 Sufficient nos of Vibrating Knockout, Grinding Machines should be available.
 One Wax Boiler should be available for melting of return wax
 One Centrifuge with tank should be available for screening of return wax.
 One Steam Boiler is essential for de-waxing of mould.
 Digital pyrometer/ Immersion pyrometer are required for taking melting & pouring
temperature of molten metal.
 Minimum one number oil-fired/gas-fired/induction furnace for heating of components
up to 1000ºC. The furnaces should be provided with automatic temperature
controllers and recorders and temperature-time graph recording facilities. Zone wise
tempreture variation shall be within ±10ºC. The furnace shall have facility for
controlling the internal atmosphere to avoid undesirable scaling and
decarburisation.
 One Oil/Water quenching tank with necessary heat exchanger and continuous
circulation of oil facilities should be available. The quenching tank should be
provided with automatic temperature recorder.
 One forced air circulation, electric or oil-fired/gas-fired tempering furnace of
adequate capacity having automatic temperature controllers and recorder.
 The manufacturer must have the facility to conduct all the tests mentioned in this
specification.
14. MINIMUM FORGING INFRASTRUCTURE REQUIREMENTS
 Covered area with adequate space for storage of raw materials e.g. billets, round
corner squares, rounds, etc.
 One band saw/billet shearing machine shall be available.
 Two hammers with minimum capacity of 3.5 MT or double acting pneumatic
hammer / forging press of equivalent capacity along with at least two trimming
press.
 Two compressors of 75 cfm minimum capacity each shall be installed, in addition to
blower of minimum 5 HP.
 One number of oil-fired/gas-fired/induction furnace shall be available with hydraulic/
mechanical operated for heating cut pieces of billets/RCS/rounds etc shall be
available. The temperature range of these furnaces should be up to 1200ºC and
Page 24 of 48
 No. WD-70-BD-10 (Rev.4) 3636
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should be provided with automatic temperature controllers. The controller should be
calibrated once every six month. The desired temperature shall be achieved within
an accuracy of ±10ºC.
 One number of oil-fired/gas-fired/induction furnace for heating of components up to
1000ºC. The furnaces should be provided with automatic temperature controllers
and recorders and temperature-time graph recording facilities. Zone wise
tempreture variation shall be within ±10ºC. The furnace shall have facility for
controlling the internal atmosphere to avoid undesirable scaling and
decarburisation.
 One Oil/Water quenching tank with necessary heat exchanger and continuous
circulation of oil facilities should be available. The quenching tank should be
provided with automatic temperature recorder.
 One forced air circulation, electric or oil-fired/gas-fired tempering furnace of
adequate capacity having automatic temperature controllers and recorders.
 One Normalising furnace of adequate capacity having automatic temperature
controllers and recorders.
 One shot blasting machine with table dia of at least 3 ft. The shot blasting machine
shall have in-built facility of sieving undersize shots.
 A die shop having adequate die sinking facilities comprising of spark erosion
machines etc.
 Adequate machining facilities comprising of vertical milling machine/radial drilling
machines/horizontal lathes with tapping arrangements etc. of suitable capacities
and standard makes required for preparation of die blocks and machining of forged
components.
 Adequate numbers of hand grinders required for removal of fins & burrs. Prior to
release of dies for production, it should be ensured that the dies are checked
dimensionally in all respects including its mounting or the forging hammer/press.
The firm must list out the method of checking the dies i.e. either on plaster of Paris
blocks of on auto-cad arrangement. Proper records of die inspection/checking
showing the date of checking, important dimensions and contours must be
maintained. Any ill effect of dies or forged components or their mismatching with
forging hammers/press must be recorded. The remedial measures taken should
also be documented.
 BHN testing machine with necessary standard test pieces. The hardness-testing
machine shall have capacity to apply 3000 kgs load on one test specimen.
 The manufacturer must have the facility to conduct all the tests mentioned in this
specification.
15. AUTHORITY TO MAKE DEVIATIONS/RELAXATIONS FROM THIS SPECIFICATION
Normally there should be no deviation from this specification. Adhoc relaxations/
deviations often lead to dilution of technology and limits the quality and performance of the
indigenous manufacture. A well-structured regime shall be followed put in place to
administer any deviation/modifications in this specification after its finalization. Similar
practice is also followed by AAR in respect of their coupler specifications.
15.1 Deviations to this specification shall be examined by the following Coupler Standards
Committee comprising the following functionaries of Indian Railways and RDSO:
15.1.1 Executive Director Standards, Wagon, RDSO as convener.
15.1.2 Executive Director Standards, Carriage, RDSO.
15.1.3 One SAG officer from Railways to be nominated by the Railway Board
deviations/Modifications may be moved by manufacturers, users or by RDSO design
directorates. The Coupler Standards Committee shall submit its recommendations to the
Railway Board for approval before incorporating/permitting the same.
*******
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 No. WD-70-BD-10 (Rev.4) 3637
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Annexure – A

Table for Marking Particular by the Wagon Builder/POH workshop

SN Wagon Name of PO/ Contract IC/DM Make Casting Month/ Whether Sign.
builder/ CBC No. and Date No. and No. Year marking is
POH Component Date compliant
shop/ toclause no
Depot 3.5 of spec.
and relevant
drawing
(Yes/No)

Page 26 of 48
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 No. WD-70-BD-10 (Rev.4) 3639
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Procedure for Radiography

Procedure:

1. Radiograph shall be taken in open space.

2. Gamma Radiography shall be used for radiography.

3. Source of radiography shall be put into the pin Holes.

4. Put the Radiography film outside the pin Holes as shown in photograph.

5. Appropriate penetrameter shall be keep over the radiography film.

6. Sensitivity of radiography shall be set 2% of the thickness of the castings.

7. Radiography shall be taken for area of Knuckle, Coupler Body and Yoke shown in the
photographs.

Acceptance Standard:

Acceptance Standard shall be as per ASTM E-446 (Reference Radiographs for steel casting
upto 2 in. (51 mm) in thickness), Volume-II.

(i) Sensitivity of radiography shall be 2% of the thickness of casting.

(ii) Defects like Gas Porosity, Sand & Slag inclusion and Shrinkage upto Level-II shall
be accepted.
(iii) Defects like Hot Tear, Crack, Insert, and Mottling shall not be permitted.

Page 28 of 48
 No. WD-70-BD-10 (Rev.4) 3640
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Annexure- III
Procedure for Magnetic Partical Test

1. Woking principal
The MPT inspection monitors iron particles concentration at areas of flux leakage, which may
be caused due to surface crack, hot tear, void, etc., or a non-relevant indication such as
geometry change, scale, rust, etc.

2. Required Equipment For Inspection

i. Electromagnetic AC yoke—used for inducing electro-magnetism into the coupler
components to be inspected.
ii. Dry powder magnetic particles (average 80 µm or finer iron oxide powder) —
used during magnetic particle inspection.
iii. White non-aqueous spray developer - used to create high contrast between the
Dry powder magnetic particles and the inspection surface, unless the Dry
powder magnetic particles being used itself provides sufficient level of contrast
to identify defects.
iv. Magnetic particle field indicator (Pie gauge) shall be used for checking proper

IMPLEMENTED 07/2020
magnetization of coupler components being inspected.
v. Light source (ambient or produced) that provides a minimum intensity of 538
Lux at the inspection surface.
vi. Cloth for cleaning of the inspection surface.
vii. Cleaner shall be applied on surface being checked. It should also be free
from any paint etc.
viii. Industrial grade Ruler/Tape to measure size of crack.

3. Qualification Required for MPT

Personnel performing magnetic particle inspection on Coupler components should
be certified at least Level-II to Indian Society for Non-Destructive Testing (ISNT) in
accordance to IS:13805/American Society for Non-Destructive Testing (ASNT).
An ISNT/ASNT Level-III professional should approve the training and training
programs, which shall cover the necessary requirements for magnetic particle
testing and its application to Coupler components.

4. MPT Documentation
The facilities conducting MPI shall maintain inspection records of tests conducted and for a
minimum of 6 years to cover warranty period of CBC and its components.

5. Coupler Components Inspection Requirements

I. Prior to performing MPT, visually inspect all visible parts of the Coupler Body, knuckle
and Yoke.
II. Any Coupler Body, knuckle and Yoke found with visible cracks of more than 6.35 mm
length shall be discarded without any requirement of MPT.
III. For Coupler Body, knuckle and Yoke discovered without visible cracks or with cracks up
to 6.35 mm long, MPT shall be carried out in following manner:
IV. Perform MPT inspection on the critical area as mentioned in Figure 8 & 9.

Page 29 of 48
 No. WD-70-BD-10 (Rev.4) 3641
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V. On a daily basis, the MPT yoke shall be verified to have an AC lifting power of 4.5 kg
minimum at the maximum pole spacing used. A record to this effect shall be
maintained by the coupler manufacturer.
VI. Clean the critical area of the coupler component, shown in Figure 8 & 9, to be free of
extraneous rust, scale, flux, grease, oil, paint or any material that may interfere with
the inspection. If using liquid or oil-based cleaner, ensure the coupler components is
completely dry before applying magnetic particles. A recently sand- or shot-blasted
surface is acceptable for inspection
VII. Perform a second visual inspection of the Coupler components and follow steps II
above.
VIII. Spray a light coat of developer onto critical area of the coupler components. Dry
powder magnetic particles having adequate colour contrast with base surface can be
used without developer also.
IX. Set the yoke current to AC and use a Pie gauge to verify magnetic field strength and
direction. Conduct the verification at the beginning of each inspection, starting with the
first article of inspection
X. With the yoke energized, apply the dry magnetic particles with a bulb applicator or
powder blower in such a manner that a light, uniform, dust-like coating settles on the
critical area.
XI. Examine the critical area of coupler component for any accumulations of magnetic
powder at flux leakage areas caused due to possible defects.
XII. Repeat the test on Coupler components in the horizontal position and the vertical
position as per attached photographs.
XIII. Clean the inspection area of the coupler component to remove magnetic particle dust
and excess developer.

XIV. MPT shall be done only at critical location specified in Figure no. 8 & 9 and proper
record shall be maintained as per given format. Inclusion/exclusion of any critical
area shall be done only with prior approval from RDSO.

6. Criteria for rejection

Coupler components shall be free from cracks of length more than 6.35 mm. Coupler
components must be free of
• surface cracks,
• surface discontinuities (hot tears, inclusions, porosity) with width, length, or
depth dimensions greater than 3.18 mm,
• a grouping of five or more pin holes within a 6.45 cm 2 area and 4.8 mm or
greater deep,
• individual pin holes greater than 1.6 mm in diameter and greater than 4.8mm.
deep.

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LOCATION OF SECTIONING

d 01 SZ"56 3UtB
18 01 N0I1Y00I

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fl0l1% N0 ’Ott 7Y1tf3S
9 X 8St X 0t8 0

Page 29 of 46 Page 31 of 48
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9t‖t+f 0 9t'0t

LOCATION OF
SECTIONING

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ANNEXURE 3 OF 3

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Annexure-III

STANDARD REFERENCE PHOTOGRAPHS FOR CASTING SOLIDITY

1.0 SCOPE

1.1 The reference photographs illustrates various types and degrees of shrinkage
occuring in coupler, knuckle and yoke sections. They are full scale photographs and
provide the following:-

1.1.1 A guide enabling recognition of shrinkage and its differentiation as to severity

level.

1.1.2 Serve as standard for evaluating minimum acceptability as specified for the product.

1.2 The reference photographs show graded shrinkage in six levels of increasing
severity.

2.0 PREFACE

2.1 The reference photographs were prepared from actual production castings, which
were first radiographed. The radiographs were evaluated and rated as to shrinkage
severity level by comparison with the standard reference radiographs in ASTM E-
446 72. A saw cut was made through the rated shrinkage area of the casting at 90
degrees to the plane of radiograph. The casting section was then ground smooth
and sand blasted to delineate shrinkage for photographs. The exposed shrinkage
in section were then ranked visually according to severity and divided into levels
corresponding to those found in ASTM E446.

2.2 Radiographic evaluation of shrinkage is based on the greatest severity found in any
127mm x 178mm area of the section being examined. In a similar manner,
evaluation of saw cut sections is predicated on the greatest shrinkage severity
encountered in a 127mm length of the casting section. The difference and the
judgment of an individual in determining the severity level of the radiographs
combine to produce a possible variation in the severity level rating of the
reference photographs that can amount to one level above or below the ASTM
E446 reference radiograph rating.

3.0 EVALUATION

3.1 Severity level is established by determining which photograph of discontinuities most

closely resembles the discontinuities present in the sectional area being investigated
as illustrated in the attached photographs.
 [Type the document title] No. WD-70-BD-10
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No. WD-70-BD-10 (Rev.4)
SHRINKAGE OF VISUAL SEYERITY-1

SHRINKAGE OF VISUAL
SEVERITY- 2

No. WD-70-BD-10 (Rev.4)

SHRINKAGEOFYISUALSEYERITY-1
 3647
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No. WD-70-BD-10 (Rev.4)

SHRINKAGE OF VISUAL
SEVERITY-3

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 3649
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SHRINKAGE OF VISUAL SEYERITY-4

SHRINKAGE OF VISUAL

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SHRINKAGE OF VISUAL SEYERITY-5

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SHRINKAGE OF VISUAL SEYERITY-6

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 No. WD-70-BD-10 (Rev.4) 3652
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LOCATION FOR BRINELL HARDNESS READINGS

PIN HOLE

ing face

Knuckle

NOTE:

Figure No. 1

Page 41 of 48
 3653
No. WD-70-BD-10 (Rev.4)
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INTERNAL SOLIDITY SECTION CUT LOCATIONS

Coupler Head

Figure -2

Page 42 of 48
 3654
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No. WD-70-BD-10 (Rev.4)

ONTINUITY LEYELS
AREAS TO BE EYALUATED FOR DISC

SECTION E- E

NOTE: SECTION CUT AREAS TO BE

RATED FOR SOLIDITY ARE
UNSHADED.

Figure -3

Page 43 of 48
 3655
3394612/2024/O/o ED/SW/RDSO No. WD-70-BD-10 (Rev.4)

AREAS TO BE E'. VALUA TED FOR DISCONTINUITY LEYELS

0ECT!ON C-C

KNUCKLE

SECTION D- D SECTION 0 -0

SECTION OF CUT AREAS TO BE

EVALUATED FOR SOLIDITY ARE
UNSHADED

YOKE
Figure-4

Page 44 of 48
 3656
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LOCATION OF PERMANENT SET

MEASUREMENTS FOR
COUPLER BODY, KNUCKLE & YOKE

Figure-5

S UPPORT_

Figure -6

Page 45 of 48
 3657
No. WD-70-BD-10 (Rev.4)
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25 DIA.
ROD

COUPLER INSPECTION
OPERATING ROD

Figure - 7

Page 46 of 48
 3658
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INSPECTION ZONES FOR CRITICAL AREAS

tsOTE. CRITIcAL• AREAS ARE SNO6N CR08SMTCHE0

Figure - 8

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 3659
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ZONE 1
INSPECTION ZONES No. WD-70-BD-10 (Rev.4)

SECTIOH E- E

OP & BOT1 OM SU tF AC £ S 25

SECT ION D-D

ZONE 1

Figure- 9
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