AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components i COUPLERS AND YOKES, AAR APPROVED - PURCHASE AND ACCEPTANCE Specification M-211 Adopted: 1972; Revised: 2000, 2003 1.0 SCOPE These specifications cover purchase and acceptance requirements for AAR-approved drawbars, couplers and their parts, coupler yokes, and steel gear followers used for freight service in inter change. Coupler bodies, knuckles, coupler locks, cast draft gear followers, and coupler yokes must meet the requirements of AAR Specification M-201, unless stated otherwise herein. 2.0 APPROVAL REQUIREMENTS 2.1 Approval of Manufacturer 2.1.1 All manufacturers, foundries, material, and designs must be approved by the AAR. The basis for such approval shall be satisfactory compliance with this specification as well as with the provisions of AAR Specifications M-201, M-205 (for yokes), and M-1003. 2.1.2 To obtain AAR approval, manufacturers must submit an application to the Association of American Railroads, as outlined in Appendix B. All foundries producing castings for that manu- facturer must be individually approved. Foundries that have not been previously approved will require an inspection by an AAR representative. This application must include a statement that the requestor will defray the total inspection expense and be accompanied by a draft in the amount estimated as required to defray all costs to include transportation and five days on site. Any AAR costs in excess of this amount will be paid to the AAR. In order to remain on the approved list, the manufac- turer must be certified under the provisions of Specification M-1003. 2.1.3. An AAR representative shall have free entry at all times to all parts of the manufacturer's work that concerns the manufacture, test, and inspection of materials for use in interchange ser- vice. The AAR representative shall comply with all applicable safety rules and local regulations. The access is for the purpose of providing assurance that industry standards are being main- tained. The manufacturer shall afford the AAR representative all reasonable facilities to ensure that materials are being furnished in accordance with the specifications. 2.1.3.1 A meeting shall be held at the end of the inspection activity to allow discussion of findings that likely will be presented in a written report. 2.1.3.2. A final written inspection report will be developed and handled in accordance with Appendix K, Procedures for Handling of Foundry Approval. 2.1.4. Inspections of all manufacturers must be conducted once every 2 years. Whenever possible, Specification M-211 inspections will be coordinated with Specification M-1003 audits. Inspections will include, but not be limited to, the requirements of Appendix H. The cost of the inspection will be borne by the manufacturer. 2.1.5 Manufacturers will be advised of inspection findings. If after review of the final report a manufacturer is considered not qualified for initial AAR approval or continued approval, the man- ufacturer may request a reinspection at the manufacturer's expense. 2.2 Component Design Approval 2.2.1 When required, all designs of components must be submitted to the AAR for approval. 2.2.2 Any design submitted for approval may be approved by waiver of official design tests, if applicable. B16 008AAR Manual of Standards and Recommended Practices an Couplers and Freight Car Draft Components Ma 2.2.3 Approval of a design applies to the manufacturer for whom it is approved. This approval will also cover the same design produced by another approved manufacturer upon notice to the AAR. 224 Only approved designs shall be eligible to be identified by stamped or cast “AAR” identifica- tion. 22.5 Application or notification shalll be submitted in eight copies in accordance with Appendices B, C, and D and be accompanied by copies of drawings and full information with respect to grade of material from which it is cast and the name of the foundry or foundries that will produce the item. 2.2.6 Static design approval tests shall be conducted on yokes and coupler shelves. 2.2.6.1 Yokes must meet the design test requirements of Specification M-205. 2.2.6.2 Each manufacturer must provide test verification that coupler shelves will support a ver- tical load of 200,000 Ib with couplers in buff position. The Standard F coupler bottom shelf is a long-standing AAR configuration and does not require design qualification. 2.2.7 Coupler Fatigue Evaluation 2.2.7.1 Any coupler manufacturer whose design differs from that of the AAR standard couplers shall have fatigue strength calculations submitted. The AAR will consider requests for waiver of this requirement in cases of minor changes not affecting fatigue life. As an alternate to fatigue cal- culations, fatigue test data on the actual product may be used. 2.2.7.2 Fatigue calculations shall be made using Miner's Rule and the coupler force spectrum of. AAR Specification M-1001 in the Manual of Standards and Recommended Practices, Section C, Chapter 7. If fatigue product tests are used, the load spectrum shall be equivalent to that of AAR Specification M-1001, Chapter 7, or as approved by the AAR. 2.3 Certification 2.3.1, Initial Certification For initial certification of each manufacturing facility or new product, each foundry shall certify to the AAR its capability to meet the requirements of this specification for all designs to be produced. In addition, each foundry shall furnish to the AAR results from the first two sets of periodie tests as defined in paragraph 4.2 of this specification and results of tests required by Specification M-201 for the same heats. Information to be furnished on form as shown in report of Metallurgical Testing per AARAppendix J. 2.3.2 A manufacturer's certification may be made as the basis of acceptance if requested by the purchaser. The certification shall include a statement that the material has been manufactured, sampled, tested, and inspected in accordance with, and meets the requirements of, all applicable provisions of these specifications. Each certification furnished shall be signed by the manufacturer or an authorized agent. 3.0 MATERIAL REQUIREMENTS 3.1. The purpose of the Fracture Toughness and Impact Properties testing is to qualify and moni- tor the material properties, Results obtained from a flawed specimen shall be discarded and another specimen shall be selected. Failure of an individual test should not be considered indica- tive of the material. Each failure shall be investigated and corrective action taken as determined by the manufacturer, If corrective action is not completed within four weeks, the AAR shall be noti- fied and given a schedule for corrective action to be completed. Retests are permitted. 3.2 Grade E steel castings, as defined in Specification M-201, shall be quenched and tempered and shall conform to the following requirements. sve BAITAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components wan 3.2.1 Tensile Properties The steel shall meet the following minimum requirements: 3.2.1.1 Specimens from keel blocks shall meet requirements of AAR Specification M-201, para- graph 7.2, 8.2.1.2 Specimens from castings shall have at least 80% of the tensile and yield strengths required by AAR Specification M-201, paragraph 7.2. Use format of Appendix J. .2 Fracture Toughness Fracture Toughness tests shall be conducted on specimens from castings in accordance with either ASTM E604 or ASTM E208 except that the Nil-Ductility Transition Temperature (NDTT) shalll be ~70 °F or lower for Grade E. 3.2.3 Impact Properties ‘The steel shall meet the following minimum requirements: 3.2.3.1 Specimens from Keel Blocks Charpy value at~40 °F Grade E 20 fib 3.2.8.2 Tests shalll be conducted in accordance with ASTM A370 using Charpy “V" notch type specimens. 3.2.4 Hardness Hardness of Grade E castings shall meet the requirements of AAR Specification M-201, paragraph 7.4 except for knuckles, which shall be as follows: Knuckles Grade E 241-281 BHN See Fig. A.18 for locations for taking hardness readings. 4.0 TEST REQUIREMENTS 4.1 The purpose of the below listed test requirements is to qualify and monitor the manufactur- ing process, Results obtained from a flawed specimen shall be discarded and another specimen shall be selected. Failure of an individual test should not be considered indicative of any product. Each failure shall be investigated and corrective action taken as determined by the manufacturer. If corrective action is not completed within four weeks, the AAR shall be notified and given a schedule for corrective action to be completed. Retests are permitted. Bs. 240sAAR Manual of Standards and Recommended Practices on Couplers and Freight Car Draft Components 4.2 Casting Integrity 4.2.1 Manufacturers must maintain internal process specifications and a quality assurance pro- gram to control casting integrity. As a periodic check, a laboratory statie test will be conducted on one specimen of every 5,000 E and 5,000 F interlocking couplers, knuckles, and yokes representing current designs being produced or once every three or six months according to the following tabu- lation, whichever occurs first. If production in any design group is less than 1,000 in the frequency period, no test is required for that period. However, in any case, at least one test is required per year for each design group produced. The specimens shall represent current production practices. Design Group Frequency Period E60, E67 ~~ S months: E68 6 months £69 6 months F70 3 months F73, F79 6 months ‘40, Y41, SY40, YS93 3 months yas, v49 6 months 50, F5t 3 months 4.2.1.1 Following 10 successful consecutive laboratory static tests by the design group, the manu- facturer may reduce the frequency of testing to one laboratory static test per year per design group. If a test fails for other than a flawed specimen, the manufacturer will be required to rees- tablish the base 10 successful tests before going to the reduced frequency of testing. 4.22 Proof Tests 4.2.2.1 Coupler bodies and knuckles must meet permanent xet and ultimate strength require- ments shown in paragraph 4.2.2.1.3. The dimensions shown in Fi A.13 shall be used for deter- mining permanent set and results shall be recorded. Speci! text knuckles for testing coupler bodies shall have a load capacity in excess of 900,000 Ib. 4.2.2.1.1 When testing coupler bodies, if test knuckle breaks before required loading is attained, the test shall be terminated and the load recorded as “maximum applied load.” 4.2.2.1.2 Test machines shall have a minimum capacity to meet specified loads and be calibrated to ASTM standards, 42.2.1.3. Static Tension Test Requirements ‘Maximum Permanent Set (in.) Grade E Steel 400,000 tb 700,000 ——_Minimum Uttimate “Knuckle 03 = 50,000 fo Body - 03 $900,000 1b *Based on testing with dummy knuckle fixture 4.2.22 Yokes ‘Test values for coupler yokes, Specification M-205, shall apply: 4.2.3 Internal Solidity 4.2.3.1 Capability of meeting internal solidity requirements shall be established at the beginning of production and every six months thereafter by sectioning three specimens from each design group listed in paragraph 4.2.1, Each specimen shall be from a different heat. However, if any design group production is less than 1,000 during this frequency period, no test is required. In any case, at least one test is required per year for each design group. After 2 years of successful section- 0s B-19AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components on ing results, the manufacturer may reduce the frequency of sectioning to one casting each year per design group. Castings will also be sectioned whenever significant changes are made in foundry practices. If a test fails, the manufacturer will be required to re-establish the base of 2 years of suc- cessful tests before going to the reduced frequency of testing. 4.2.3.2 Castings are to be sectioned in accordance with Fig. A.14 or Fig. A.15. 4.2.3.3. Areas to be rated for discontinuity severity level illustrated in Fig. A.16 and Fig. A.17. 42.3.4 Casting areas for evaluation shall be rated as to level of severity by comparing them with “Standard Reference Photographs for Casting Solidity” included as Appendix I, and results shall be recorded. 4.2.3.5. The rated level of severity for each section must not exceed those listed in the following table: Maximum Severity Levels ‘Component Type ~ ‘Sectional Area CSAC‘ a“! OU Ul ao E Coupler Head 3 5 4 a q = E Coupler Shank 4 4 . 2 = - = E Knuckle 4 4 2 S = = Yoke 2 4 4 4 = - = F Coupler Head 3 5 4 4 4 2 3 F Coupler Shank 3 4 4 4 = = = F Knuckle 4 4 2 = = - ~ F Yoke 2 4 4 4 S = - 4.3 Periodic Production Tests At least every two months, one coupler and one yoke, with their respective test coupons, or keel block specimens in each grade of steel produced during that period, regardless of design, shall be sectioned and the following tests shall be performed on specimens from these castings and coupons or keel block specimens. If desired, a foundry may alternate couplers and yokes, month by month, to maintain a continuing record. Each design group of couplers and yokes, as defined in paragraph 4.2.1, in each grade of steel produced, shall be tested at least once per year. After 2 years of suc- cessful testing, the manufacturer may reduce the frequency of testing to one coupler and one yoke tested per year, in each grade of steel produced, from a randomly selected design group. Properties to be tested are as follows: Fracture Toughness paragraph 3.2.2 Impact Properties, paragraph 323 Tensile Properties paragraph 3.2.1 Check Analysis (Chemistry) Specification Specification M-201, paragraph 6.4 Hardness paragraph 3.24 B-20 10sAAR Manual of Standards and Recommended Practices , Couplers and Freight Car Draft Components 5.0 WELD REPAIR Weld repair must be in accordance with AAR Specification M-201 and the following subpara- graphs. 5.1 Welding on Couplers, Knuckles, and Yokes 5.1.1 Any welding in shaded areas, as defined in Fig. A.11, will be considered structural repair and must be in accordance with paragraph 5.1.2. Welds outside the critical area must be in accor- dance with the requirements of AAR Specification M-201. 5.1.2 The defect area to be welded must be prepared by contouring the sides for a sound weld with a minimum 1/4-in.-wide relief at the root. 5.1.8 The maximum depth of the repaired area must not exceed 1 in. with a minimum of 1/8 in. sound metal between the edge of the repaired weld and the nearest casting wall. 5.2 After welding repairs are made, a casting shall be heat treated as required by Fig. A.11, using the applicable process of Specification M-201. 6.0 WROUGHT STEEL PARTS 6.1 Knuckle Pivot Pin Refer to Specification M-118, 62. Draft Gear Follower Refer to Standard $-119. 63 Coupler and Yoke Connecting Pin Refer to Specification M-118. 64 Draft Key Refer to Standard S-121. 7.0 CASTING WEIGHTS 7.1 Minimum casting weights are listed in Fig. A.1 8.0 GAUGING 8.1 Couplers and parts, yokes, and draft gear followers shall meet the requirements of the gauges and/or tolerances listed in Figs. A.2, A.3, A.4, A.5, A.6, A.7, and A.8. Yokes and draft gear followers must also comply with the standards listed below: S-119 Followers S-141 Y40 Type Yokes $-142 ¥4t Type Yokes -143 SY40 Type Yokes $-149 45 Type Yokes $-151 Y49 Type Yokes 8.2. A casting shall be reheat treated if it is out of gauge tolerance and requires heating in excess of the tempering temperature to bring it within the gauge limits. 8.3 Gauges Numbers 24319, 24323, 24325, 34618, 34620, and 34622 are to be certified with a master knuckle at least once a year. 0s BiAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components a 9.0 COUPLER OPERATION 9.1 Assembled couplers must be free of any foreign material that will prevent proper operations described in paragraph 9.1.1 through paragraph 9.1.5. A coupler inspection operating rod is illus- trated in Fig. A.12. 9.1.1 The coupler knuckle must rotate to the open position by a continuous rotary force applied by hand through the inspection operating rod from the rod handle. 9.1.2 The coupler 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. 9.1.3 The coupler lock must automatically drop to the locked position when the knuckle is closed as described in paragraph 9.1.2. The coupler knuckle is locked shut when the lock drops to seat on or within 1/4 in. of the knuckle tail lock shelf. 9.1.4 The coupler is put on lock set when the knuckle is restrained from opening while force is applied through the inspection operating rod while trying to raise the lock above the knuckle tail. When the rod is 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 open by hand force applied on the inside face of the knuckle nose, The coupler then must perform the functions of knuckle closure and lock drop as described in paragraph 9.1.2 and paragraph 9.1.3. 9.1.5 The coupler must provide anticreep protection to prevent accidental unlocking. 9.2 AAR standard couplers furnished complete must be fitted with AAR standard or alternate standard knuckles of the same grade of steel as the coupler bods. Couplers must be fitted with grade E locks. The assembled coupler must operate as described in paragraph 9.0, AAR alternate standard couplers furnished complete must be fitted with AAR alternate standard knuckles ES0BE. 10.0 CASTING FINISH 10.1 sr pads and gate stubs shall not project more than 1/4 in_ above the surrounding surface at any location. Where interference would exist in the operation or apphcation or where service ability would be affected, the riser pads and gate stubs shall be contoured to surrounding areas. 10.2 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. Cou- plers must not be sand- or shot-blasted when completely assembled 10.3 The castings shall not be painted or covered with any substances that will hide defects. However, manufacturer's and/or purchaser's paint identification marks are acceptable. 11.0 LUBRICATION 11.1. Only dry lubricant shall be applied to the coupler head or the coupler head fit lubricant may be applied using a water, alcohol, or other nonpetrolcum based carrier. 12.0 MARKINGS 12.1 All yokes, couplers, and parts shall have legible markings as specified in Figs. A.9 and A.10. Only castings manufactured in accordance with the provisions of this specification are eligible to be identified by a standard AAR catalog number. AAR standard catalog numbers are shown in this section. For purposes of this specification, legible markings shall mean markings of such a charae- ter that by observing the marks it is possible to accurately deduce their intended meaning. ings. This 12.2. When cither the catalog number or cast date markings are illegible, the manufacturer must apply these markings to each casting in a workmanship manner by electric arc welding using a maximum 1/8-in.-diameter electrode. Subsequent heat treatment is not required for pencil weld- ing of markings in noncritieal areas, as defined in Fig. A.10. BeAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components 12.8 No proprietary numbers will be used when comparable AAR standard catalog numbers are available, 12.4 Grade E castings shall be identified with the raised letter “E” cast as the last character of the AAR catalog number. 13.0 CRITERIA FOR CASTING ACCEPTANCE This section defines and classifies casting defects and will be used for visual inspection and gaug- ing of coupler bodies, knuckles, locks, yokes, and cast draft gear followers. 13.1. Wall Thickness 13.1.1 Wall thickness tolerances, except where controlled by gauges or AAR standard drawings, are as follows 4114" up to, not including 7/16" wall +18" 1132" 76" up to, not including 3/4" wal +18" 382" 3/4" up to, not including 11/4" wall +118" 118° 1118" and over +316 5132" If grinding makes walls thinner than minus limits above, castings must be restored by welding to within tolerances specified, 18.1.2 In local areas dictated by individual manufacturing practices, padding or additional metal thickness is done for casting solidity. This practice is not a violation of the plus tolerance of the metal section, 13.2 Surface Acceptance Level 13.2.1 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. The listed defect classifications do not apply to inaccessible areas. Surface defects described herein do not preclude the requirements of proper gauge application as defined elsewhere in this specification 13.2.1.1 Surface conditions evaluated with SCRATA comparators: Critical Area Fig. AA Non-Critical Area Fig. A.1t |) Surface Roughness 3 a3 8) Surface inclusions 82 Bs C) Gas Porosity c2 3 D) Laps ot 4 E) Scabs £2 £2 F) Chaplets F2 Fa ) Thermal Dressing G2 6 H) Mechanical Dressing H3 Ha J) Welds 2 B 13.2.1.1.1 Surface conditions B and C are acceptable if the depth of defect does not exceed 10% of the section thickness at critical areas and 25% of the section thickness in noneritical areas. 13.2.2 The following surface conditions are not evaluated with SCRATA comparators: 13.2.2.1 Offsets: An offset is an abrupt, unintentional change in a casting surface. 13.2.2.1.1 Offsets greater than 10% of the casting wall thickness shall not be accepted, 13.2.2.2 Cracks, hot tears, cold shuts, and weld cracks that are visually apparent are not permit- ted. v0 B23AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components 13.2.2.3 Zone 1 areas must be prepared in accordance with Fig. A.11. 13.2.3. Critical defect: A defect as defined in paragraph 13.5.2 and in the shaded areas as shown in Fig. AL. 18.2.4 Major defect: A defect as defined in paragraph 13.5.3 for shaded areas and paragraph 13.5.2 outside the shaded areas, as shown in Fig. A.11. 13.2.5 Minor discrepancy: A defect as defined in paragraph 13.2.1 outside the shaded areas shown in Fig. A.11, 13.3. Hlegible Markings Illegible markings are markings that do not conform to paragraph 12.1 18.3.1. Major defect: An illegible marking consisting of loss of heat identification, catalog numb manufacturer's trademark, or cast date. 18.3.2. Minor discrepancy: Illegible marking not listed in paragraph 13.3.1 13.4 Evidence of Improper Heat Treatment Critical defect: Evidence of improper heat treatment as shown from manufacturer's records. At the purchaser's option, heat treatment lugs may be used to assist in the determination of improper heat treatment, 13.5 Improper Weld Repair 13.5.1 Weld repair shall be performed in accordance with paragraph 5.0. 13.5.2. Critical Defects 13.5.2.1 Any crack in a repair weld 13.5.2.2. Weld more than 1/16 in. below surrounding surface in shaded areas of Fig. A.11. Minimum wall thickness must be maintained. 13.5.2.3. Slag inclusion or incomplete fusion in shaded areas of Fig. A.11. 13.5.2.4 Are strike in shaded areas of Fig. A.11. 13.5.3 Major Defects 18.5.3.1 Weld below surrounding surface to depth greater than 10% of wall thickness. Minimum wall thickness must be maintained. 13.5.3.2. Slag inclusion or incomplete fusion outside of shaded areas of Fig. A.11 13.5.3.3. Are strike outside the shaded areas of Fig. A.11 13.6 Improper Cleaning Major defect: Failure to meet the conditions of paragraph 10.2 13.7. Misapplication of Assembly Parts Major defect: Misapplication of assembly parts is a major defect. Knuckles and locks applied to couplers must be in accordance with paragraph 9.2. This manual covers selection of other parts in Standards $-102, S-103, S-105 through S-112, S-114, S-115, S-154, S-155, S-163, S-164, S-165, $-170, and 8-172. B24 senAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mut 13.8 Mechanical and Thermal Dressing 13.8.1 Stress risers (including chisel marks, handling notches, and gouges in excess of 1/16 in. deep). 13.8.2 Critical defect: Any notches caused by flame cut, grinding, or chisel cut, etc., in shaded areas of Fig. A.11. 13.8.3 Major defect: Any notches caused by flame cut, grinding, or chisel cut, etc., greater than 10% of wall thickness outside of shaded areas of Fig. A.11. 13.9 Improper Lubricants Major defect: Lubrication not conforming to paragraph 11.0. 13.10. Riser and Gate Projection Major defect: Riser pads and gate stubs projecting more than 1/4 in. above surrounding surface at any location. Where interference would exist in the operation or application or where the service- ability would be affected, the riser pads and gate stubs shall be contoured to the surrounding sur- faces. 13.11 Sharp or Jagged Edges Critical defect: Sharp or jagged edges that could be injurious to workers. 13.12 Casting Weights 13.12.1 Major defect: Failure of coupler bodies, yokes, knuckles, and assembled couplers to meet the minimum weights shown in Fig. A.1 13.13 Failure to Meet Gauging Requirements 13.18.1 Defect categories are shown in Figs. A.2, A.3, A4, A.5, A.6, A.7, and AS, 14.0 PURCHASERS INSPECTION 14.1 The purchaser's inspector shall have free access at all times, while performing the work on the contract of the purchaser, to all parts of the manufacturer's works that concern the manufac- ture of the ordered material. The purchaser's inspector shall comply with all applicable safety rules and local regulations. The manufacturer shall afford the inspector, free of charge, all reason- able facilities and necessary assistance to satisfy the inspector that the material is being furnished in accordance with these specifications. Tests and inspections shall be made prior to shipment at the place of manufacture to ensure that provisions of this specification are being met. Any addi- tional tests must be negotiated prior to placement of the order. All inspections shall be conducted while not interfering with manufacturing operations. 14.2 Method of Inspection 14.2.1 At the option of the purchaser, the inspections may be performed on 100% of the castings in an order, a portion of an order, or on an acceptance sampling basis. The purchaser and manufac turer shall mutually afford each other a reasonable time period to schedule and perform the desired inspection. 14.2.2 The purchaser may also waive the inspection based on previous satisfactory performance by the manufacturer. Such waiver does not relieve the manufacturer from meeting all require- ments of applicable specifications. 14.3 Inspection Lot An inspection lot shall consist of all castings or assemblies of one kind or description submitted by the manufacturer at one time for acceptance. The inspection lot may represent the whole order or a part of the order.AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components han 14.4 Classification of Defects and Discrepancies 144.1 Critical defect: A critical defect is a defect that is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or relying upon the products or is likely to result in structural failures, or is likely to prevent performance of a major end usage item, such as a freight car or locomotive. Specific defects are shown in paragraph 13.0 and in Figs. A2, A.3, A4, A5, A6, A, and AS. 14.4.2 Major defect: A major defect is a defect other than a critical defect that materially reduces the usability of the product for its intended purpose. Specific defects are shown in paragraph 13.0 and in Figs. A.2, A.3, Ad, 5, A6, A.7, and AS. 14.4.3 Minor discrepancy: A minor discrepancy is a condition that is not likely to materially reduce the usability of the product for its intended purpose or is a departure from established stan- dards having little bearing on the effective use or operation of the unit. Specific discrepancies are shown in paragraph 13.0 and in Figs. A.2,A.3,A.4,A.5,A.6,A.7, and A8. 14.5 Acceptance Criteria for 100 Percent Inspection 14.5.1 Inspected units: All units presented for shipment may be inspected for the defects and dis- crepancies listed in paragraph 13.0. 14.5.2 Acceptable units: All units inspected must be free of defects and discrepancies listed in paragraph 13.0. Defective units shall either be replaced or repaired prior to shipment. 14.6 Acceptance Criteria for Sampling Inspection 14.6.1 Sampling inspection criteria may be as defined by the purchaser. 14.6.2 The purchaser may make tests to govern the acceptance and rejection of the material in purchaser's laboratory or elsewhere. Such tests shall be made at the expense of the purchaser. 14.6.3 Any unit that is found to have critical defects, subsequent to the inspection at the foundry or elsewhere, will be rejected and the manufacturer immediately notified. No alteration to the part may be made without agreement between the purchaser and the manufacturer. 15.0 SUPPLEMENTAL REQUIREMENTS 15.1 Scope Supplementary requirements shall be applied only when specified by the purchaser. Details of the supplementary requirements shalll be agreed upon by the manufacturer and purchaser. The speci- fied tests shall be performed by the manufacturer prior to shipment of the castings. 15.2, Magnetic Particle Inspection 15.2.1 Castings made in accordance with these specifications may be subject to magnetic particle inspection as specified in the inquiry, contract, or order and when mutually agreed upon by the manufacturer and the purchaser. 15.2.2 For magnetic particle inspection, the number of pieces made from the same pattern to be inspected and standards of acceptability shall be agreed upon by the manufacturer and purchaser, except that only shaded areas of Fig. A.11 shall be inspected and then only for linear defects. Mag: netic particle inspection shall be in accordance with ASTM Method E-709. 15.3. Supplemental Gauges When so specified in the inquiry, contract, or order and when mutually agreed upon by the manu- facturer and the purchaser, castings made in accordance with this specification may be subject to gauging in addition to gauges and tolerances listed in the specification. The form and nature of the gauges is to be negotiated between the purchaser and manufacturer. B26 v0Mau AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A APPENDIX A REFERENCED FIGURES AND TABLES E Couplers Minimum Weight (ib)* Catalog No. Coupler Body Complete Coupler E60DE, E60EE 328 434 EG7CE, E67DE 349 459 SBESODE, SBEGEE 336 446 SBEG7CE, SBE67DE 361 ai ‘SEGODE, SEB0EE 355 465 SE67CE, SEG7DE 380 490 Coupler Knuckle ESOAE, ESOARE, ESOBE 7 EJF Couplers Minimum Weight ib)" Catalog No, ~~ Coupler Body Complete Coupler EG8CE, E68DE 4a 537 E69BE, ES9CE, 544 654 SBEBECE, SBESBDE 439 549 ‘SBESOBE, SBEGCE 556 666 SE68CE, SE68DE 458 568 SE6QBE, SE69CE 575 685 SC ipler Knuckle — ESOAE, ESOARE, ES0BE 7 F Interlocking couplers Minimum Weight (b)" Catalog No. Coupler Body Complete Coupler FTODE 369 485 FTSBE 588 704 FTSDE am 587 SFTODE 383 499 SFTODE 485 601 Coupler Knuckle — FSIAE at Coupler yokes Catalog No. Minimum Weight (by YAOAE, SYAOAE = 196 YatAE 22 YASAE 203 YaQAE 264 “Note: Normal weighis are 3% more than weights shown, ‘Minimum weights for couplers and yokes Paragraphs 7.1, 13.12.1 Fig. AA B27AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIN:A Mau E, SE, AND SBE COUPLERS S/sa/|s 6 |2/2 ‘Type E Coupler Head a —_ os Gauge No. 24306 Inspector's Contour (Go Gauge Only) x 24140-1" ‘Top Anticreep Vertical Location x 24140-2 Bottom Anticreep Vertical Location x 24919 Bottom Anticreep Horizontal Location x 14513 Pivot Lug x 14414 Pin Protector—Used with Gauge 15037 x 24283 Pulling Lug—Used with Gauge 15037 BS 24283-7A, Lock Walt Spacer—Used with Gauges 24283 and 15037, x 15037 Pivot Pin x 15037-18 Pivot Pin Hole x agit Lock Chamber x 24312 Lock Hole x 241403 Rotary Lug x 24136-3" Top Locklift Hole x 5108-14, Pin Protector (applied along longitudinal centerline of pin hole) x “For top operating couplers only ‘Type E, SE and SBE Coupler Parts Gauge No. 24319 Knuckle Movable Point x 14220 Knuckle Hub x 14437 Knuckle Tail Height x 24323 Knuckle Top Pulling Lug x 24325 Knuckle Bottom Pulling Lug x 24142 Knuckle Tall Shel x 241382 Lock Toggle Hole x 24138.1" Lock Shot x 24134 Lock Contour—Guard Arm Side x 24135 ‘Lock Contour—Knuckle Side x (24138-3 Upper Lock Thickness x 144914 Lower Lock Thickness x 241328 Knuckle Thrower x 13242-2 Knuckle Thrower Trunion x 35359 Articulated Rotary Locklift Assembly x 31710418 Knuckle Pivot Pin x “For top operating lock only Classification of gauges to ensure interchangeability of coupler parts Paragraphs 8.1, 13.13.1,, 144.1, 1442, 14.43 Fig. A2 B28AAR Manual of Standards and Recommended Pract Couplers and Freight Car Draft Components Mant APPENDIX A E, SE, AND SBE COUPLERS S/s/5 5 |2 | Type E60D, E60E, SEGDD, SEGE and SBE60D, SBEGOE Coupler Shanks Gauge No. 20843-1 Keysiot—Minimum x 20843-2 Keyslot—Maximum x 1971 Keyslot—Location x 3510418 Height—Maximum x ‘Type E67C, E67D, SE67C, SEB7D and SBEG7C, SBE67D Coupler Shanks Gauge No. 43389-2 Keysio—Mirimum x 20843-2 Keyslot—Maximum x 1971 Keysto—Location x 3510410, Height—Maximum |x Classification of gauges to ensure interchangeabilty of coupler parts (Continued) Paragraphs 8.1, 1313.1, 144.1, 144.2, 1443, Fig. A2 (Continued) E/F COUPLERS £/3/s 6 || EF Coupler Head and Parts ‘Same as E Coupler Head and Parts Type E68C, E6ED, SEGEC, SE6BD and SBEGEC, SBEG8D Coupler Shanks Gauge No. 34638-1 Shank Height x 3469-2 Butt Height x 34639-68 Butt Shoulders Wieth x 3469-88, Butt Pin Hole Side Wall Thickness x 49637-24 Minimum Shank Butt Thickness x 4976314 Maximum Shank Butt Thickness x 3464248 Shank Butt Spherical Surface x 497634 ‘Aignment Shoulder x 9763.3, ‘Spherical But Height x Type E698, E69C, SBEGSB and SBEBSC Coupler Shanks ~ Gauge No. 34638-2 Butt Height x 3469-88 Butt Pin Hole Side Wall Thickness x 49637-28 Minimum Shank Butt Thickness x 49763-14 Maximum Shank Butt Thickness x 3642-18 Shank Butt Spherical Surface x 497633 Spherical Butt Height x Classification of gauges to ensure interchangeabilty of coupler parts Paragraphs 6.1 1313.1, 184.1, 1442, 16.43 Fig. A3 m9 B29AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A. matt F AND SF INTERLOCKING COUPLERS. 2/5/8 § |2/2 Type F Coupler Head Gauge No. 34630 Inspector's Contour (Go Gauge Only) x 14513 Pivot Lug x 34604 Pulling Lug—Used with Gauge 15037 x asi Lock Wall Spacer—Used with Gauges 34604 and 15037 x 15037 Pivot Pin x 15037-14 Pin Hole x 34607 Pin Protector—Used with Gauge 15037 x 34610 Lock Chamber x eit Upper Lock Hole x 4613 Lower Look Hole x 37551 ‘Thrower Hole—Used with Gauge 34812-2 x 613-4 Rotor Hole x 241363" Top Lockift Hole x meat" Top Operating Anticreep Ledge x 51008-14 Pin Protector (applied along longitudinal enteriine of pinhole) = || X. “Only or top operating F couplers “Type F Coupler Parts ens TI Gauge No. 14220 Knuckle Hub x 34616 Kuckle Tal Wieth x 34617 Knuckle Tail Height x 34618 Knuckle Movable Point Contour x 34620 Knuckle Top Puling Lug x 34622 Knuckle Bottom Puling Lug x 34625 Lock Contout-Guard Arm Side x mez Lock Contour-Knuckle Side lex 6294 Lock Thickness x 34628-2 Lock Toggle Hole x 34832, 34632-1 Thrower x BI710-14 Knuckle Pivot Pin x 34637-1 Rotor Shaft and Key x 41146 Rotary Lockift Assembly x 37594 Lock Slot x 34637-2" Rotor Shaft and Eye Rivet Hole x 3637-3" Rotor Eye Shaft Opening x 34837-4" Rotor Shaft End x *For double rotor Classification of gauges to ensure interchangeability of coupler parts Paragraphs 8.1,13.13.1., 144.1, 144.2, 1443 Fig. A4 B20AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components we APPENDIX A F AND SF INTERLOCKING COUPLERS 2)3/8 6 |2/|2 “Type F70D and SF70D Coupler Shanks + Gauge No. 3463941 Shank Height 34639-2 Butt Height x 3463068 Butt Shoulders Width x 34639-88, Butt Pin Hole Side Wall Thickness x 34642-2 Butt Contour x 9637-28 Minimum Shank Butt Thickness x 4976314 Maximum Shank Butt Thickness x 49637-3 Recess Verification Only x Type F738 Coupler Shanks Gauge No, 346392 Butt Height x 3463988 Butt Pin Hole Side Wall Thickness x 49637-24 Minimum Shank Butt Thickness ix 49763-14 Maximum Shank Butt Thickness x 346422" Butt Contour x 496373 Recess Verification Only x “Alignment shoulder check not applicable ‘Type F790 and SF78D Coupler Shanks Gauge No. 3463941 ‘Shank Height x 34639-2 Butt Height x 34639-64 Butt Shoulders Width x 4639-88 Butt Pin Hole Side Wall Thickness x 4963728 Minimum Shank Butt Thickness x 49763-418 Maximum Shank Butt Thickness x 346422 Butt Contour x 49637-3 Recess Verification Only x Classification of gauges to ensure interchangeabilty of coupler parts (Continued) Paragraphs 61, 1313.1. 144.1, 1444.2, 14.4.3 Fig. A4 (Continued) swe B31AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A @y gs + pt 082 8 g Cisa5_ G47 (1 FROM EDGE) S ‘A,B,C, and D Dimensions Yoke A 8 c D yao 34625 25.000 5.000 3.500 SY40 or YS93 4.625 25.000 5.000 3.000 vat 46.000 36.375 5.500 3.500 Note: For tolerance classification, see Fig. A7 Tolerances for ¥40, SY40 and Yt type yokes Paragraphs 8.1, 13.13.1, 14.4.1, 144.2, 14.4.3, Fig. AS B32 mosCORED HOLES MANUFACTURERS OPTION AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components set A,B, &C Dimensions Yoke A B 45 30-3132" 8718" vag 4211182" garter Note: For tolerance classification, see Fig, A.7 Tolerances for Y45 and Y49 type yokes Paragraphs 8.1, 13.13.1,, 14.4.1, 164.2, 144.3 Fig. AS B33 c 10318" 10.314" APPENDIX AAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A. Mani Tolerance Classification Remarks 1 Major All yokes, plus length 2 Major All yokes, minus length 3 Minor ‘SY40, YS93, Y40, ¥41 only inside length 4 Minor All yokes, outside height over pocket 5 Major All yokes, inside pocket height 6 Minor All yokes, strap thickness 7 Major ‘Al'yokes, outside butt height 8 Major SY40, ¥S93, Y40, ¥41 keysiot height. Y45, Y49 minus pin hole diameter 9 Major All yokes; front opening inside height 10 Minor ‘SY40, YS93, Y40, Y41 only; keysiot length "1 Minor SY40, YS93, Y40, Y41 only lus nose thickness 12 Minor ‘SY40, YS93, Y40, Y41 only; minus nose thickness 8 Minor All yokes, strap with 4 Major ‘Al yokes; font opening smallest inside wadth 5 Minor ‘All yokes; front opening largest inside wath 16 Minor All yokes; head front outside width 7 Minor ‘Y45, Ya9 only: plus pin hole diameter 18 Minor ‘Y45, ¥49 only: head width at strker gue 19 Minor ‘Y45, Y49 only: head outside height Yoke tolerances—yoke types Y40, SY40, YS93, Y41, YAS. Y49 Paragraphs 8.1, 13.13.1., 14.4.1, 144.2, 1443 Fig. AT B34 sosAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mau APPENDIX A DRAFT GEAR FOLLOWER FOR USE WITH RIGID SHANK E COUPLERS, / f Z| yp \ dy \ge * 738 & ge \ 5 \ | ~ \. \h | { = I | $9423 —__“} avert PVosrasruar ro vicscrons oncons TR J SRSSTET CATALOG NO. Y44AE, CAST STEEL FOLLOWER MATERIAL AND NARKINGS PER SPECIFICATION W211 CATALOG NO. Ya4A, ROLLED STEEL FOLLOWER MATERIAL. 1S C-1045 STEEL OR EQUIVALENT QUENCHED AND TEMPERED BHN 267.31 Tolerance Classification Remarks 1 Major Plus with 2 Minor Minus with 3 Minor Pius thickness 4 Major Minus thickness 5 Major Plus height 6 Minor Minus height 7 Minor Flatness “A" Dimension Follower Tolerance aang 8 13/16" + 3/16", -1116" YAGAE 9+ 0,-1 Tolerances for Y44AE & Y46AE followers Paragraphs 8.1, 1313.1, 144.1, 14.4.2, 14.43 Fig. AS mes B35AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A Meu sree Rais vespeg sourgen HO.» was st E coupler markings Paragraph 12.1; M-206 Paragraph 5.4 Fig. AS B36 neAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mau APPENDIX A “eos urns mwa Ima es Tana Locate HERE i nd SST RECESSED SERALNOF USED, esto aaen 4 CacaTION OF wBPRKNG M F coupler markings Paragraphs 12.1, 12.2; M-205 Paragraph 5.4 Fig. A.10 nae B37AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A, Mou Eee SECTION A \; Secon a Fp Bron ‘eeron 6-8 vew 8 ‘SECTION AA eT: | aTEAL AREAS AR OWN CSOT 258" {GRADE E STEEL CASTINGS ees JENCH & TEMPER SHADED AREA ou metas TEMPER NORSHADED AREA Inspection zones and post weld heat treat requirements for criti | areas Paragraphs 6.1.1, 5.2, 13.2.1.1, 13.223, 1323, 13.24, 13.25, 135.22, 13523, 135.24, 1353.2, 135.33, 138.2, 1383, 1522 Fig. Att B38AAR Manual of Standards and Recommended Practices sn Couplers and Freight Car Draft Components APPENDIX A it & EF COUPLER HEAD oon ne ‘GRADE E STEEL CASTINGS WEBS, | avenow a enren Ei05 m [NON-SHADED AREA aes Inspection zones and post weld heat treat requirements for critical areas Pergrephs 511,52, 13214, 18223, 1823.13.24, 1926 135.22, 12523, 13524, 135.32, 13533, 1982 13.83, 1522 Fig, A.11 (Continued) B39AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A Man (GRAGEE STEEL CASTINGS WTERLOCKNG COUPLER HEAD [wecos mw MELE IN ca ‘QUENCH & TEMPER wets w NON'SHADED AREA inspection zones and post weld heat treat requirements for critical areas Paagaphs 511,50 NT Boas 2S Ok BOS SoS BO2S ob Na a ED2, 135.33, 1382, 1383, 18.22 Fig. A.11 (Continued) B40 m8AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Meu APPENDIX A Coupler inspection operating rod Paragraph 8.1 Fig. AMZ nes B-4lAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX A Mann COUPLER HEAD F INTERLOCKING COUPLER HEAD Location of permanent set measurements for coupler bodies and knuckles Paragraph 4.2.2.1 Fig. AAS B42 manMeu AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX COUPLER HEADS ae “Lb on “Ub tS on & COUPLER SHANKS re | Soe REAR HOLE RADIUS—| RIGID SHANK « Tangent 10, PIN PROTECTOR Internal solidity section cut locations. Paragraph 4.2.3.2, Fig, A146 B43APPENDIX A, AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components ¢ A c a g ‘ : ‘THRU JUNCTION FILLETS WITHIN FILLETS fap a — I) lhe ot VERTICAL PIN TYPE YOKE 1 > THRU JUNCTION FILLETS WITHIN FILLETS () | € HORIZONTAL KEY TYPE YOKE Internal solidity section cut locations Paragraph 4.2.3.2 Fig. A15 B44 v0AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mau APPENDIX A, ene at ve = stern Ee Sarin er cin shawn ELCOUPLER HEAD NOTE: SECiIONCUTAREAS TORE RATED FOR SOLO ARE UNSHADED Areas to be evaluated for discontinuity levels Paragraph 4.2.3.3 Fig. A.16 08 BsAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components AeenDux a oT NOTE: SecmiOn cur anens 10 86 ct secrion Guy ATEAS TO j cd ee | | a] 7 | AX | = . “) ert u c ; . sel section 6-8 —_| I \ cess) YORE with WoRIZONTAL KEY YOKE miTH VERTICAL PIN ‘Areas to be evaluated for discontinuity levels, Paragraph 4.23.3 Fig. AAT B46 109AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Matt APPENDIX A PIN HOLE € Le Cl oY b 1 aN Lock Keone E/F & F Body —Fiat side ' YOKE NOTE: Hardness reacing required at Follower {wo locatone on coupiers & yokes ‘Be indeated by 6, Location for Brinell hardness readings Paragraph 3.2.4 Fig. 18 rao B-a7AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX 8 em APPENDIX B INSTRUCTIONS REGARDING APPLICATION FOR: STATUS AS AN APPROVED MANUFACTURER, (SEE PARAGRAPH 2.2.5 AND APPENDICES G AND J FOR FURTHER INFORMATION) 1.0 APPLICATION 1.1 The manufacturer must submit eight copies of the application for approved status (shown in Appendix D) to the AAR. 1.2. The application must be accompanied by a description or brochures that describe facilities and manufacturing processes, including detailed information on quality control procedures. If more than one facility is involved, each must be fully described as a separate entity and applied for on an individual basis. 1.3. The application must be accompanied by a draft in the amount estimated to defray inspection costs, including transportation and five days at each foundry site. The application must state that the applicant will pay the AAR for all costs that exceed the draft amount. 1.4 The application must list all couplers, coupler parts, coupler yokes. and draft gear followers that the manufacturer will produce. This will include AAR-catalog-numbered standards and pro- prietary items. The manufacturer will indicate which proprietary items are being submitted for AAR approval. 2.0 LIST OF APPROVED MANUFACTURERS ‘The AAR will publish quarterly a list of approved manufacturers and their approved facilities if more than one is involved. In the event that a manufacturer is deleted from this list for cause, reapplication for approval will be required. Bas voAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mau APPENDIX C APPENDIX C APPROVAL REQUIREMENTS FOR SPECIAL DESIGN COUPLERS, COUPLER PARTS, YOKES, AND DRAFT GEAR FOLLOWERS (SEE PARAGRAPH 2.2.5 AND APPENDIX L PARAGRAPH 1.0 FOR FURTHER INFORMATION) 1.0 SCOPE 1.1 Special and proprietary designs that deviate from AAR-catalog- numbered items and will be used in interchange or common carrier service by agreement will be identified with the initials “AAR” either stamped or cast in raised letters and will require separate approval by the AAR. 2.0 APPROVAL APPLICATION CONTENT 2.1 Description of the Special Features Use Appendix D format. For couplers, identify features from Appendices E and F. For knuckles, identify features from Appendix G. 2.1.1 Funetion 2.1.2 Component design type to which feature is applicable 2.1.3, Owner, builder, or designer who developed. 2.1.4 Railroad(s), car owner(s), or manufacturer(s) requesting special design. 2.1.5 Car type for which special design is to be furnished on original application. 2.1.6 Replacement(s) (What Can Be Applied). Design deviations are to be listed if not inter- changeable with an AAR standard. 2.1.7 Include statement that the item will be manufactured, sampled, tested, inspected in accor- dance with, and will be equal to or exceed the requirements of applicable specifications. If the material deviates from AAR specifications, then mechanical, chemical, and hardenability test reports must accompany the application. A certification must be included that contains a state- ment that the component is compatible with AAR requirements and that the design complies with AAR operational and DOT safety requirements. 8 Specifications for reconditioning the special design, if different from applicable AAR specifi- cations, must be provided to each purchaser upon request. 3.0 DOCUMENTATION REQUIREMENTS Right drawings listing material, heat treatment, and complete dimensioning must accompany the application. a0 B49AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX D Matt APPENDIX D APPLICATION FOR APPROVAL OF SPECIAL DESIGN COUPLER, PART, YOKE, OR DRAFT GEAR FOLLOWER (SEE PARAGRAPH 2.2.5, APPENDIX C PARAGRAPH 2.1, AND APPENDIX L PARAGRAPH 1.0 FOR FURTHER INFORMATION) File No. To: AAR c/o Chief—Technical Standards ‘Transportation Technology Center, Inc. P.O. Box 11130 55500 DOT Road Pueblo, CO 81001 By: (Manufacturer) Requested By: (Railroad, Car Owner) Car Type and Service: (if known) ___ Initial Quantity: Part Type Name____ Code No, ____ Manufacturer's Former Part No(s) Manufacturer's Drawing No. Partial AAR LD. No.______X__X_ Material complies with Specification(s): Design complies with AAR and DOT safety requirements and AAR operational requirements. Same as AAR Standard Cat.No.____, exeept__ Reason for deviation from AAR Standard Catalog Number: _ By_______________Date. AAR Action: By Date___ : Copies with drawings to the AAR (8 copies) B50 na03APPENDIX E AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX E DESIGN FEATURES FOR AAR-APPROVED SPECIAL COUPLER BODIES sroiseo wou? (SEE APPENDIX C PARAGRAPH 2.1 FOR FURTHER INFORMATION) carsaes of BSIAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX E Man ‘THIS PAGE LEFT BLANK INTENTIONALLY B-s2 v0AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mau APPENDIX F APPENDIX F AAR CODE FOR DESIGNATING DESIGN FEATURES SIX-DIGIT AAR IDENTIFICATION NO. FOR COUPLER BODIES (SEVEN DIGITS FOR COUPLERS WITHOUT SHANK WEAR PLATES) SCDIGIT AAR IDENTIFICATION NO. FOR COUPLER BODIES ‘SEVEN DIGITS FOR COUPLERS WTA DESIGN REVISIONS | tLe ——_ NO = AAA APA NUMBER ASCENT DONDT SE LETTERS Sec” a ata 22 es ne ae Ee | to4od ScSt aD NER 100" Wo. one THE REVISED BODY aT THE COARENT DESIGN oho, 1¢ 16 C008 NO. FH Lee POO OG] ineoty bi snoSoBY MATEMAL BeCoUES TIS vos BS3AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components CODE SPACE NUMBERS (SEE APPENDIX C PARAGRAPH 2.1 FOR FURTHER INFORMATION) SRE | esowenow | Fes Nee | Mugs | Gop | at | em |e | anon «per Es vert ee et ee] ear, e oe : Hootie tet _+ avon : eee ee eae es | enna | stene | Sao. | coma [S| ee pa eee et a oo ee : 7 : : a ete ett Se et eta BS4 voAAR Manual of Standards and Recommended Prat Couplers and Freight Car Draft Components ‘cates? CORTES CODE SPACE NUMBERS (CONTINUED) (SEE APPENDIX C PARAGRAPH 2.1 FOR FURTHER INFORMATION) ae] om, ee] CES [ee] RE [ER] eee Pe] ane ag eel cmeee a aml Germ [er] core, [S8] carn [| ORE s eae Pre | ae se] pam a t ae forse errs] tms [eran 7 | re feet | — ere SOF a 7} nee aed a 2 eam senses BSSAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX G Mant APPENDIX G FOUR DIGIT IDENTIFICATION CODE FOR SPECIAL COUPLER KNUCKLES CODE SPACE NUMBER (SEE APPENDIX C PARAGRAPH 2.1 FOR FURTHER INFORMATION) 1 T 2 3 4 certe |“HeA0" | NUMBER | CORNG | NUMBER Sonroun ever | CASTSTEEL © [twee | 8 | cone | 1 | _maRStaNoARO(ioa | —0 CRADED MITT F Type F 9 ‘SOLID 2 ~ “VACANT — GRADE E M211 a 3 ‘AAR ALT. STANDARD s SPECIAL FOUR DIGIT CODE wwe £8 3 cove Space NO. 1 —TYPE COUPLER HEAD STANDARD CORING AAR ALT. STANDARD GRADE E STEEL - B-S6 voAAR Manual of Standards and Recommended Practices ea Couplers and Freight Car Draft Components poenowe n APPENDIX H AAR PROCEDURE FOR THE INSPECTION OF FOUNDRIES (SEE PARAGRAPH 2.1.4 AND APPENDICES A AND J FOR FURTHER INFORMATION) 1.0 INTRODUCTION ‘The AAR inspection program is designed to qualify and evaluate each foundry’s and manufac- turer's capability of producing castings to AAR specifications. This program is directed toward establishing a minimum acceptable level of performance and capability with respect to experience, procedures, ability, and equipment to produce castings of the required quality. Each foundry inspection will include the following: 1.1 Entire plant operation, with emphasis on procedures that affect quality and uniformity of product. 1.2 Confirmation of values in certification test reports by following data gathering and storage throughout the foundry process. 1.8 Inspection of production and quality control equipment and facilities to determine ability to meet production requirements. 1.4. Interviews of supervisors with respect to procedures and methods used in production. 1.5 A review of the results of inspection with plant management and advise if any deficiencies are noted. 2.0 EVALUATION AREAS ‘The following areas will be evaluated by the AAR representative 1, Procedures 2.1.1 Molding Operations 21.1.1 Check pattern facilities and procedures for ensuring proper pattern size control. 21.1.2 Check sand conditioning and test procedures, 21.1.8 Evaluate core making facilities. 2.1.14 Observe core setting procedures. Proper quality control prxedures must be in effect to ensure cores are set properly. Care must be taken to avoid cure shifts during movement and pour- ing. 21.2 Melting Practices 2.1.2.1 Chemical control of raw material 2.1.2.2. Temperature control on melting material. 2.1.2.3 Proper time and quantity control over additions. 2.1.3 Pouring Practices 2.1.3.1 Time records on pouring. 2 3.2 Temperature record during pouring. 2.1.3.3, Proper chemical and physical tests on representative 2.1.3.4 Positive method of determining last casting. sans B-S7AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX H Mant 2.1.4 Cleaning Room Operations 2.1.4.1 Cleaning equipment should be adequate to provide clean casting for proper inspection. 2.1.4.2 Observe welding operations to ensure quality workmanship. Welding equipment must be well maintained and show evidence of periodic checking for correct amperage and voltage read- ings. Welding rods and wire must be properly identified and stored according to American Welding Society (AWS) standards. 2.1.4.3 Workmanship of grinding operations should be evaluated. 2.1.4.4 Facilities for performing welding according to temperature requirements of AAR specifi- cations should be available. It is desirable that all weld repairs be made in the green condition prior to heat treat. If proper foundry practices are enforced, weld repair requirements will be 2.1.5 Heat Treating Practices 2.1.5.1 Furnaces must have proper temperature control and adequate recording capabilities. 2.1.5.2. Furnaces should be adequate to ensure uniform temperature throughout. 2.1.5.3 Proper records must be kept to positively identify castings that have received heat treat- ment. 2.1.5.4 Quench tanks must have circulating capability with facility to ensure proper temperature of coolant. Tanks should be kept clean and free of scrap material likely to impair operation. 2.1.6 Casting Quality 2.1.6.1 A random casting should be selected from the inspection area and run through the sample room. The object of this should be to evaluate overall quality of the finished casting. Pattern qual- ity, core setting, and dimensional control should be evaluated. 2.1.6.2 Availability and accuracy of gauges should be determined and a calibration system for gauges should be evaluated. 2.1.6.3 All physical test apparatus should be inspected for general operating condition and cali- bration. All equipment requiring calibration should have current certification. 22 Organization Policy (with Respect to the Following) 2.2.1 Proper separation between production responsibility and quality control responsibility. 2.2.2 Procedure for resolving controversy between operations and quality control on nonconform- ing items. 2.2.3 Disposition of nonconforming items, 2.2.4 Knowledge of supervisory personnel with regard to quality assurance requirements. 2.3. Personnel 2.3.1 Verify that procedures exist for qualifying workmen for particular jobs. Training provided for new employees. 23.2 Verify that procedures exist for qualifying supervisors and methods of training and for determining performance. 2.3.3. Determine if there are proper welding procedures and competent expertise in the plant to perform welding tests and solve welding problems. Determine how and when welders are quali- fied. B-58 sunsAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mont APPENDIX APPENDIX I STANDARD REFERENCE PHOTOGRAPHS FOR CASTING SOLIDITY (SEE PARAGRAPH 4.2.3.4 FOR FURTHER INFORMATION) 1.0 SCOPE 1.1 The reference photographs illustrate various types and degrees of shrinkage occurring in cou- pler, knuckle, and yoke sections. They are full scale and provide the following: 1.1.1 Serve as a guide for enabling recognition of shrinkage and its differentiation as to severity level. 1.1.2. Serve as standards 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 that were first radiographed. The radiographs were evaluated and rated as to shrinkage severity level by compar- ison with the standard reference radiographs in ASTM E446-72. A saw cut was made through the rated shrinkage area of the casting at 90° to the plane of the radiograph. The casting section was then ground smooth and sand blasted to delineate shrinkage for photographs. The exposed shrink- age in sections was then ranked visually according to severity and divided into levels correspond- ing to those found in ASTM E446. 2.2 Radiographic evaluation of shrinkage is based on the greatest severity found in any 5 in. x 7 in, area of the section being examined. In a similar manner, evaluation of saw cut sec- tions is predicated on the greatest shrinkage severity encountered in a 5-in. length of the casting section. This 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 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 following photographs. sve B59AAR Manual of Standards and Recommended Practices — Couplers and Freight Car Draft Components sean ‘SHRINKAGE OF VISUAL SEVERITY 1 Fig. 4 B-60 reAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components : APPENDIX ‘SHRINKAGE OF VISUAL SEVERITY 2 Fig. 12 0s B61APPENDIX 1 AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components ‘SHRINKAGE OF VISUAL SEVERITY 3 Fig. 13 B62AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mant APPENDIX ‘SHRINKAGE OF VISUAL SEVERITY 4 Fig, 4 03 B63AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components APPENDIX t Matt te SHRINKAGE OF VISUAL SEVERITY 5 Fig. LS vie & B64 oyAAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components Mou APPENDIX SHRINKAGE OF VISUAL SEVERITY 6 Fig. 16 10s B65AAR Manual of Standards and Recommended Practices Couplers and Freight Car Draft Components on APPENDIX J sssocnd Busou 0 psn 99 ou pres LD Kuo UOZsULO} 9 PasoNGa BED BAL « ‘aye 1woye007 ‘huedwog, ‘Aq ponwang usa | wn we | ERS | Men | ose | oxone loss]v0 [oo [seu[ zc] a vwaa- [ww | wen [ ERS TS | over | coor lors] v0 [x0 [seu] ze] 9 ‘ounahy | sary | Nn zene | wa | ad [ax] a]om[w[o[m[w]_]S]e]s | 2] me] ow eai~Fiion| Amy | sxnipin |vondeon | voenmou | aise | mm (4/8/1212 (2/4 [18128 8] S| a2 | at (Gane una Sa WONYHOAR Tn BES] SgRRY OID (aa ua SEKTORY TOMER SNENIDEES ONISYO 40 SISKWNY YN woe * ce | coves | coooo: oss] 10 [0 [sen] ze] a vn use | are z ro) ors] 10 [0 [seu] zx] 9 © acy | _ Nie Son | cove yee | me ale lmielololy|_lsle ls el 2] eo | ov “BqUrN sun | Aaveuo | ssaupien | vonetuor | uononpou | aisuan | pm [s(x lei sleiel%i%{e]% 1%) %| was | eon Sore (ee aaa SEL WONMHDSM Gas Besa] SST WOME ‘eit uRUOR) SATY WOMTO ‘SNBMNOIES 1951 NOINOD 40 SISATWNY (Ga TTA 49 ISA SUNVIE TIV) soday SIL, £q posaAo, portag (Ges GNV 18'S SHAVUDVUVd TIS) ‘UV dd ONILSAL TVOIUNTIVIAW 40 LYOdaa £ XIGNAddV B-66AAR Manual of Standards and Recommended Practices Couplers and Freight Car Dra f soon ‘ouplers and Freight Car Draft Components aprewoun k APPENDIX K PROCEDURES FOR HANDLING OF FOUNDRY APPROVAL (SEE PARAGRAPH 2.1.3.2 AND APPENDICES C AND H FOR FURTHER INFORMATION) 1.0 Upon completion of inspection, the AAR representative will forward a copy of the inspection report to the AAR. If the representative recommends approval of the facility without exception, the AAR will forward the inspection report to the appropriate committee for approval. If discrepancies are noted in the representative's report, the AAR office will advise the proponent of the discrepancies, request that corrective action be taken within 30 days, and require that the proponent inform the AAR in writing of these actions within the same 30-day period. At the end of the 30-day period, the inspection report and any correspondence received from the proponent will be forwarded to the appropriate committee to provide their approval/disapproval/comments. 2.0 The application must be accompanied by a description or brochures that describe facilities and manufacturing processes, including detailed information on quality control procedures. If more than one foundry is involved, each must be fully described as a separate entity and applied for on an individual basis. 3.0 The application will be accompanied by a draft in the amount estimated to defray inspection costs, including transportation and five days at each foundry site. The application must state that the applicant will reimburse the AAR for all costs that exceed the amount of the draft. 4.0 The application will list all couplers and their parts, coupler yokes, and draft gear followers that the manufacturer will make initial production. This will include AAR-catalog-numbered standards and proprietary items. Manufacturer will indicate which proprietary items manufacturer will submit for AAR approval. 5.0 A foundry inspection report is to be sent to the AAR office. If the report contains noted deficiencies, the applicant will be advised of deficiencies and will be requested to respond regarding corrective actions within 30 days. The committee will not receive the report until response is received regarding deficiencies. Upon receipt of response, the response and the report will be distributed to the appropriate committee to provide their approval/disapproval/comments. 6.0 Upon approval of the committee, the applicant will be advised of conditional approval and added to the AAR circular listing conditionally approved foundries. 7.0 If an application cannot be satisfactorily approved by mail, the AAR staff will docket for consideration by the committee at the next meeting. A manufacturer's representative will be invited to explain, if necessary. 8.0. The following appropriate specification references shall be adhered to: M201 M205 Matt 9.0 The AAR will publish quarterly a list of approved manufacturers and their approved foundries if more than one is involved. In the event that a manufacturer is deleted from this list, for cause, reapplication for approval will be required. pans B67AAR Manual of Standards and Recommended Practices os Couplers and Freight Car Draft Components APPENDIX L Mati APPENDIX L PROCEDURES FOR HANDLING SPECIAL COUPLER BODY APPLICATION 1.0. Application for approval will be received at the AAR office in accordance with Specification M-211, Appendices B and C. 2.0 AAR office will acknowledge receipt and will forward the application(s) to the appropriate committee to provide their approval/disapproval/comments via Form 101. 3.0 Upon approval, the AAR staff will advise the proponent of approval. 4.0 If an application cannot be approved by mail, the AAR staff will docket for committee consideration at the next meeting, and the applicant is so notified. The applicant is invited to attend and present the case, if necessary. B68 10