Escorts BDG Rdso 2011 Cg-03 (Rev 3)

OPERATION AND MAINTENANCE MANUAL
HIGH TENSILE TIGHT LOCK CENTRE BUFFER COUPLER WITH

HEAD AND BALANCED DRAFT GEAR FOR
FITMENT ON BG PASSENGER COACHES
Doc. No. RED-RD-CS-11-OM-01
Customer Spec. No. RDSO/2011/CG-03 (Rev 3)
Document Revision History

Rev. Date Changes and reasons Prepared Reviewed Approved
for change by by by
00 27/08/2021 Initial Release Dinesh Kumar Amit Kumar Siva Karthik
Maintenance Procedure
01 09/03/2022 Biswajit Bose Prabhat Soni Satish Kumar I
Updated
Para no. 6.5.1;6.5.2;6.5.3
02 15/06/2022 Biswajit Bose Prabhat Soni Satish Kumar I
Thickness Changed
AAR-H TYPE CBC AND BDG. Rev.02
Doc. No. RED-RD-CS-11-OM-01 Date-15/06/2022
CUSTOMER SPEC. NO. RDSO/2011/CG-03 Rev.03
TABLE OF CONTENTS
1 INTRODUCTION.......................................................................................................7
2 PRINCIPAL DESIGN FEATURES OF ESCORTS MAKE AAR-H TYPE CBCS. .......................8
3 DETAILED DESCRIPTION ..........................................................................................9
AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY (DRAWING NO. 1C101060021) ........... 9
BALANCED DRAFT GEAR (DRAWING NO. 1C101060004) ................................................. 10
VERTICAL SUPPORT ASSEMBLY (DRAWING NO. 1C101060031) .................................... 11
MANUAL UNCOUPLING DEVICE ASSEMBLY (DRAWING NO. 1C101060026).................. 12
4 COUPLER INSTALLATION .......................................................................................13
COUPLER INSTALLATION ON COACH................................................................................ 13
CHECK POINTS AFTER INSTALLATION ON COACH.......................................................... 13
5 COUPLING AND UNCOUPLING PROCEDURE ...........................................................18
GENERAL............................................................................................................................... 18
COUPLING PROCEDURE ..................................................................................................... 18
UNCOUPLING PROCEDURE................................................................................................ 18
6 MAINTENANCE PROCEDURE FOR AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY,
VERTICAL SUPPORT ASSEMBLY, MANUAL UNCOUPLING DEVICE ASSEMBLY &
BALANCED DRAFT GEAR........................................................................................19
AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY............................................................. 19
VERTICAL SUPPORT ASSEMBLY........................................................................................ 24
MANUAL UNCOUPLING DEVICE ASSEMBLY ..................................................................... 25
BALANCED DRAFT GEAR .................................................................................................... 26
FRONT AND REAR CARRIER PLATE................................................................................... 28
MAIN PIN ................................................................................................................................ 31
7 USE OF VARIOUS GAUGES & OVERHAUL PROCEDURE ............................................32
ALIGNING WING LIMIT GAUGE NO. 32600. ......................................................................... 32
VERTICAL HEIGHT ALIGNING WING POCKET AND GUARD ARM GAUGE NO. 34101-4. 33
VERTICAL HEIGHT CONDEMNING LIMIT ALIGNING WING POCKET AND GUARD ARM
GAUGE NO. 44250-5............................................................................................................. 34
CONTOUR MAINTENANCE GAUGE NO. 31000. ................................................................. 35
KNUCKLE NOSE WEAR AND STRETCH LIMIT GAUGE NO. 34100-2A .............................. 36
CONTOUR CONDEMNING GAUGE 34100-1..................................................................... 37
ANTI-CREEP PROTECTION ................................................................................................. 38
OVERHAUL PROCEDURE .................................................................................................... 41
TROUBLE SHOOTING........................................................................................................... 51
8 LIST OF SPARE PARTS ASSEMBLY WISE ..................................................................52
SPARE PARTS FOR INSTALLATION OF BALANCED DRAFT GEAR & A.A.R TYPE-"H"
TIGHT LOCK COUPLER (1C101060011) ............................................................................. 52
PARE PARTS FOR AAR-H TIGHT LOCK COUPLER HEAD ASSY. (1C101060021)............ 53
SPARE PARTS FOR VERTICAL SUPPORT ASSY. (1C101060031) .................................... 54
SPARE PARTS OF DRAFT GEAR ASSY. (1C101060004).................................................... 55
SPARE PARTS OF MANUAL UNCOUPLING DEVICE ASSY. (1C101060026) .................... 56
SPARE PARTS OF FRONT CARRIER PLATE (1C101060013) ............................................ 57
SPARE PARTS OF REAR CARRIER PLATE (1C101060017)............................................... 58
9 LIST OF SPARE PARTS, GAUGES AND SPECIAL TOOLS..............................................59
INSTALLATION DRAWING FOR BALANCED DRAFT GEAR & A.A.R TYPE-"H"
TIGHTLOCK COUPLER (1C101060011) .............................................................................. 59
AAR TYPE 'H' TIGHT LOCK COUPLER HEAD ASSY. (1C101060021) ................................ 59
VERTICAL SUPPORT ASSY. (1C101060031) ...................................................................... 60
BALANCED DRAFT GEAR (1C101060004) .......................................................................... 60
MANUAL UNCOUPLING DEVICE ASSY. (1C101060026) .................................................... 60
Confidential document, Unauthorized circulation is strictly prohibited Format No. : FM:R&D:021/02/05.03.2020
Page 2
Classification | ESCORTS-CONFIDENTIAL
LIST OF CHANGED ITEMS FROM AAR-H REV01 TO REV03.............................................. 61

SET OF APTA GAUGES ........................................................................................................ 62
INSPECTION, REPAIR, MAINTENANCE, RECONDITIONING TOOLS & FIXTURES
REQUIREMENT FOR AAR-H TYPE TIGHT LOCK COUPLER............................................. 62
10 REMARKS..............................................................................................................63
11 ANNEXURE A.........................................................................................................64
12 ANNEXURE B.........................................................................................................65
13 ANNEXURE C.........................................................................................................66

Page 3
TABLE OF FIGURES
Figure 1: AAR-H Tight Lock Coupler Head Assembly ..................................................................... 9
Figure 2: Balanced Draft Gear ...................................................................................................... 10
Figure 3: Vertical Support Assembly ............................................................................................. 11
Figure 4: Rotary Bar with Handle .................................................................................................. 12
Figure 5: Un-Coupling Bar ............................................................................................................ 12
Figure 6: Installation Drawing for BDG & AAR Type H Tight Lock Couplers ................................. 14
Figure 7: Check for Coupler Locking............................................................................................. 15
Figure 8: Tell-tale Recess ............................................................................................................. 16
Figure 9: Keyway Slot Locking...................................................................................................... 17
Figure 10: Coupling / Un coupling mechanism .............................................................................. 18
............................................................................................ 21
............................................................................................ 22
Figure 13: Tilting of Coupler Head assembly ................................................................................ 22
Figure 14: Damaged Vertical Support Assembly ........................................................................... 23
Figure 15: Detection hole for Main Pin in Front Carrier Plate ........................................................ 29
Figure 16: Heavy rusting of Front Carrier Plate ............................................................................. 29
Figure 17: Wear Zone in Front Carrier Plate ................................................................................. 29
Figure 18: Tilting of Coupler Head Assembly ................................................................................ 30
Figure 19: Damaged vertical support assembly ............................................................................ 30
Figure 20: Gap between Front Fork and Axial Stiffener Plate ....................................................... 31
Figure 21: Procedure for Checking Aligning Wing Limit Gauge No.-32600 ................................... 32
Figure 22: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No. 34101-4 .................. 33
Figure 23: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No. 44250-5 .................. 34

Page 4
Figure 24: Contour Maintenance Gauge no. 31000 ...................................................................... 35
Figure 25: Procedure for Checking Knuckle Nose Wear and Stretch Limit Gauge no. 34100-2A.. 36
Figure 26: Procedure for Checking Wear on Knuckle Nose with Counter Maintenance Gauge No.
34100-1 .................................................................................................................................. 37
Figure 27: Anti-Creep Protection .................................................................................................. 38
Figure 28: Minimum Overlap......................................................................................................... 38
Figure 29: Minimum Overlap Test Step 1...................................................................................... 39
............................... 41
............................... 41
Figure 35: Section View of Coupler Shank.................................................................................... 42
Figure 36: Procedure for Checking Aligning Wing Limit ................................................................ 43
Figure 37: Aligning Wing Limit Gauge No-32600 .......................................................................... 44
Figure 38: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No-34101-4 ................... 44
Figure 39: Contour Condemning Limit Gauge no. 34100-1 ........................................................... 45
Figure 40: Knuckle Nose Wear and Stretch Limit Gauge No.-34100-2A ....................................... 45
Figure 41: Contour Maintenance Gauge No.-31000 ..................................................................... 46
Figure 42: Installation of Coupler Head in coach........................................................................... 47
Figure 43: Dismantling of Balanced Draft Gear ............................................................................. 50
Figure 44: Exploded & Assembly view for Balanced Draft Gear & A.A.R Type-"H" Tight-Lock
Coupler .................................................................................................................................. 52
Figure 45: Exploded & Assembly view of AAR-H Tight Lock Coupler Head Assy. ........................ 53
Figure 46: Exploded & Assembly view of Vertical Support Assy. .................................................. 54

Page 5
Figure 47: Assembled view of Balanced Draft Gear...................................................................... 55
Figure 48: Exploded & Assembly view of Manual Uncoupling Device Assy. ................................. 56
Figure 49: Exploded & Assembly view of Front Carrier Plate ........................................................ 57
Figure 50: Exploded & Assembly view of Front Carrier Plate ........................................................ 58

Page 6
1 INTRODUCTION
Escorts make AAR-H Type High Tensile Tight Lock Center Buffer Couplers (also known as AAR-H type
CBCs) are for BG passenger coaches of Indian Railways. Escorts is introducing the new AAR-H Coupler
Rev03 which fully complies with the latest RDSO s specification RDSO/2011/CG-03 (Rev-03). The serial
number is mentioned on the Coupler Name Plate and the series starts, from 1001 R3 where R3 indicates
Rev03 serve to differentiate AAR H Rev 03 Coupler from AAR H Rev01 Coupler.
As per latest RDSO s specification RDSO/2011/CG-03 (Rev-03), the upgraded design of AAR-H Coupler
Rev03 resulted in change of some items from existing AAR-H Coupler. The list of changed items with
drawing number are listed in section 9.6. In case spare is required for Rev01 and it falls under the
changed item list, then corresponding drawing number to be used while ordering.
The AAR-H type Coupler is for coupling two adjacent coaches/Locomotives to facilitate the formation of
train. A coach shall have one Coupler at each end. When coupled, it allows the coaches to move and
accommodate track curvature and differences in vertical height, while remaining in coupled condition
at all the times.
Engagement of one Coupler with another Coupler is automatic. However, unlocking is to be done
manually. It is equipped with manual Uncoupling Device to unlock the Coupler from outside the track.
The AAR-H type Tight Lock Coupler is provided with aligning wing pocket, located at the left side and
guard arm on the right when facing the Coupler Head. This aligning wing pocket and guard arm serve to
keep the Couplers in correct position with respect to each other during the coupling operation and
maintain this connection during service. This kind of connection prevents vertical moment of Couplers
with respect to each other. When completely coupled, the Knuckles and front faces of engaging Couplers
are securely locked and all Buffing loads are carried through the shank of the Coupler.

Page 7
2 PRINCIPAL DESIGN FEATURES OF ESCORTS MAKE AAR-H TYPE CBCs.

The principal design features of the AAR-H type CBCs are described below
1. Escorts make Coupler, couples type Couplers of any make.
2. Ensures more positive engagement even when coupling at lower speeds.
3. Increased safety in the event of derailment due to vertical Interlocking provided when two
Couplers are coupled together.
4. Reduction of Slack in the Coupler contour.
5. Low preload than that of the conventional Draft Gear. Draw & Buff forces are balanced in
Balanced Draft Gear to improve ride comfort.
6. Imported High quality and reliable Elastomeric Pads have been used to improve ride comfort.
7. Silent Block in the Coupler body adds to ride comfort and reduced jerks.
8. Improved vertical support for improved coupling ability.
9. Improved bolt design on vertical support for longer life.
10. Easy to replace the Main Pin.
11. Balanced Draft Gear is provided with Wedge Blocks for easy replacement during IOH & POH.
12. The tertiary pin arrangement will provide extra safety against the unintended turning of manual
Uncoupling Device and unlocking of Knuckle.

Page 8
3 DETAILED DESCRIPTION
The AAR-H Couplers consists of the following main sub-assemblies:
AAR-H Tight Lock Coupler Head Assembly (1C101060021)
Balanced Draft Gear (1C101060004)
Vertical Support Assembly (1C101060031)
Manual Uncoupling Device Assembly (1C101060026)
AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY (DRAWING NO. 1C101060021)

The Coupler Head is a standard AAR-H Tight Lock Coupler Head and is manufactured out of high strength
steel casting to M201 Grade E as per AAR M201. The Contour of the Coupler Head is to APTA SS-M-002-
98 (Standard S-166 & S-168). The Draw Bar is an integral part of the Head Body and is fitted with Silent
Block for connection with the Balanced Draft Gear as shown in Figure 1. Other parts of this assembly
are Knuckle, Lock, Knuckle Thrower, Rotary Lock Lift Assembly, Knuckle Pin, Chain with Handle &
Supporting Pin.
Figure 1: AAR-H Tight Lock Coupler Head Assembly

Page 9
BALANCED DRAFT GEAR (DRAWING NO. 1C101060004)

The Balanced Draft Gear is energy absorption device which absorbs energy during coupling and service.
It is a double acting Draft Gear, which absorbs energy in both draw (pull mode) and Buff (push or
compression mode). The Draft Gear has been designed to fit in the UIC coach pocket, measuring
510mm as shown in Figure 2.
The Elastomer Pads have low spring rates at low travel and significantly higher rates at higher travel.
Specially designed Wedge Block keep the Draft Gear tight in the pocket, once tightened with 350 Nm
torque. The Wedge Block s also help in dismantling the Draft Gear easily from the underframe pocket.
Figure 2: Balanced Draft Gear

Page 10
VERTICAL SUPPORT ASSEMBLY (DRAWING NO. 1C101060031)

The Vertical Support Assembly as shown in Figure 3 is used to maintain position of Coupler Head from
rail level. It is fitted on coach with mounting bolts 4 Nos. M20 X 50, 10.9 grade & Special Washer SK-
730 and plays an important role in adjusting height form rail level, which is 1090 +15/-5 mm.
Also it allows Coupler Head for Vertical Swing within 5° to 7°.
Figure 3: Vertical Support Assembly

Page 11
MANUAL UNCOUPLING DEVICE ASSEMBLY (DRAWING NO. 1C101060026)

Manual Uncoupling Device consists of two main parts as shown in Figure 4 & Figure 5.
1. Rotary Bar with Handle.
2. Uncoupling Bar.
An uncoupling bar fits into the Rotary Bar with Handle and forms Manual Uncoupling Device. This
device helps to uncouple the engaged Tight Lock Coupler from outside the track.
Also, a Unique Locking Piece is provided to prevent unauthorized person from operating the
Uncoupling Device. This will help in improving security, and it should be tightened with special key
after formation of rake.
The inner and outer Mounting Brackets are fitted on the coach with 4 Nos. M12 X 50 Hex. Head. Bolt
Grade 10.9, B12 Spring Washer and M12 Nylock Nut.
Figure 4: Rotary Bar with Handle
Figure 5: Un-Coupling Bar

Page 12
4 COUPLER INSTALLATION
Escorts High Tensile AAR-H Coupler with CBC Rev03 for passenger coaches of Indian Railways are
according to the requirement of IR specification which are described in technical specification of
RDSO/2011/CG-03 (Rev-3).
The general installation arrangement of Coupler with Balanced Draft Gear on coaches are as per Drawing
No 1C101060011, which is shown in Figure 6.
COUPLER INSTALLATION ON COACH
1. First place Balanced Draft Gear inside 510mm pocket by keeping Wear Plates facing bottom side
and holding the Wedge Key assembly with housing by hand. After inserting the Balanced Draft
Gear in the pocket, tighten the special bolt of Wedge Block at the back of Balanced Draft Gear to
a torque of 350 Nm to make it sit tight between the front and rear stopper plates. (Ensure
tightening torque).
2. Then AAR-H Coupler is attached to Balanced Draft Gear with a Main Pin, which passes through
Silent Block and pin hole in Draft Gear. After inserting the Main Pin, Front & Rear Carrier Plates
are mounted on coach frame with mounting bolts at torque of 240 Nm. (Ensure tightening
torque).
3. After installing AAR-H Coupler and Balanced Draft Gear, Vertical Support Assembly is installed.
Vertical Support Assembly is fitted to coach frame by Mounting Bolts. Tighten these bolts to
tightening torque of 540 Nm. The position of Vertical Support Assembly is such that it maintains
height of Coupler Head to 1090 +15/-5 mm from rail level. (Check for tightening torque & Coupler
height).
4. Finally fit Manual Uncoupling Device on both ends of coach where Mounting Brackets are
provided. When two Couplers are coupled, they are ensured to be in locked condition if tell- tale
recess is clear as shown in Figure 7 & Figure 8.
CHECK POINTS AFTER INSTALLATION ON COACH

The Coupler must be checked to make sure they are properly locked by tell-tale vision. (Ref. Figure 7,
8 & 9).

Page 13
Figure 6: Installation Drawing for BDG & AAR Type H Tight Lock Couplers

Page 14
CHECK FOR COUPLER LOCKING
Figure 7: Check for Coupler Locking

Page 15
Figure 8: Tell-tale Recess
Caution!
Only when tell-tale recess is clear the Couplers should be considered

as mated.
Bright yellow mark will be visible in closed condition as shown.

Page 16
Figure 9: Keyway Slot Locking
Caution!
Only when tell-tale recess is visible, Rotary Bar must rest into
slot of Inner Support Bracket and locked by Locking Screw.
After full tightening, the Locking Screw must protrude outside
(Dim. L) by 43.0 46.0 mm.

Page 17
5 COUPLING AND UNCOUPLING PROCEDURE

GENERAL
Coupling is the method of joining two coaches with the help of AAR-H Type CBCs fitted at each end of
the coach. Similarly, to separate two coaches the CBCs are uncoupled with the help of Uncoupling
Device attached with Coupler Head.
COUPLING PROCEDURE
CLOSING THE COUPLER
The Handle of the uncoupling mechanism must be in the bottom position (Position . The Couplers
will be automatically locked when pushed on the face of the Knuckle, causing it to pivot until the face
of the Knuckle is parallel to the shell of the coach.
MATING THE COUPLERS WITH H TYPE COUPLER

Coupler of one coach shall be opened with the help of uncoupling mechanism and the other Coupler
may be in open/closed condition. The vehicles are then moved closer together. As the Couplers come
into contact, the Knuckle of the open Coupler will pivot and engages with the other Coupler. In fully
engaged Coupler, mating could be confirmed by (1) clear tell-tale recess, (2) sound of lock drop.
MATING THE COUPLERS WITH E TYPE COUPLER

The operat Coupler does not have aligning
Couplers shall be restricted through use
of restrictor arrangement by Indian Railways.
UNCOUPLING PROCEDURE
The Handle of the manual uncoupling mechanism must be rotated from bottom position ( A)
to the top most position ( B ) as shown in Figure 10. This rotation mechanism will disengage
the Coupler lock and actuates the Knuckle thrower to pivot the Knuckle to the open position.
Figure 10: Coupling / Un coupling mechanism

Page 18
6 MAINTENANCE PROCEDURE FOR AAR-H TIGHT LOCK COUPLER HEAD

ASSEMBLY, VERTICAL SUPPORT ASSEMBLY, MANUAL UNCOUPLING DEVICE
ASSEMBLY & BALANCED DRAFT GEAR
The table below gives the list of maintenance tasks to be followed
AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY
Examination Per Every 6 18 36 54 72
Weekly
/ Inspection Maintenance task Month Months Months Months Months Months Remedy
(D1)
Type (D2) (D3) (SS-I/1) (SS-II) (SS-I/2) (SS-III)
Visually check Coupler Head
Refer to Section 7.8.1
for any damage
Visually check for tell-tale
Refer Figure 8
recess in coupled condition
Visually check for any
Replace if found
damage of the Knuckle.
damaged.
(Item No.2 in Figure 45)
Split Pin for Main Pin for
Knuckle missing or New Split Pin to be
damaged. placed.
Support Pin for Main Pin for

Knuckle missing or New Support Pin to be
damaged. placed.
Ensure that the Tertiary Pin
Replace the Tertiary
is properly seated in the slot
Pin if found damaged
and is not damaged
Split Pin for Support Pin New Split Pin for
missing /or damaged Support Pin to be
(Item No.12 in Figure 45) placed.
Replace the Silent
Check for Silent Block Refer Refer Refer
Block, if found
Damage as per Visual note note note
damaged
Verification Process 1 6.1.1.a 6.1.1.b 6.1.1.c
Refer Section 6.1.2
Un-mount the Coupler

Check for Silent Block Refer Refer Refer from coach and replace
Damage as per Visual note note note the Silent Block if
Verification Process 2 6.1.1.a 6.1.1.b 6.1.1.c found damaged
Refer Section 6.1.3

Page 19
Aligning wing limit

Refer Section 7.1
gauge No. 32600
Vertical height
aligning wing pocket
Refer Section 7.2
and guard arm
gauge No. 34101-4
Inspect with Gauges
Vertical height
condemning limit
aligning wing pocket Refer Section 7.3
and guard arm
gauge No. 44250-5
Contour
maintenance gauge Refer Section 7.4
No. 31000
Knuckle nose wear
and stretch limiting Refer Section 7.5
gauge No. 34100-2A
Contour condemning
Refer Section 7.6
gauge No. 34100-1
Refer Section 7.7
Anti-Creep (Daily check to be
Mechanism done only if the
Coupler in open
condition)
Height of Coupler Refer Section
from the rail level 7.8.3 & 7.8.4
Replace if the gap
Worn out main pin
between the hole
of Knuckle (Item
and the pin is
No.6 of Figure 45)
more than 2 mm
Disassemble and
clean the parts.
Ensure no grease Use graphite
and paint used powder in dry
Other Inspections
between the Coupler condition or with

moving parts alcohol or non-
petroleum-based
carriers.
In case of any
Perform DPT or MPI crack, discard the
after dismantling to component and
detect any cracks. replace it with a
new one.
Must Change Items:
Replace Item no.
2,5,6,7,8,9, 10, 11 &
12 as shown in Figure
45
Replacement of rest
of the items to be
condition based
determined by the
DPT/MPI or any
damage.

Page 20
Check if the
Replace the Wear
thickness of Wear
Plate if its
Plate (Item No.9 of
thickness is less
Figure 45) is not less
than or equal to 3
than or equal to 3
mm.
mm.
NOTES:
a) Un-mount the Coupler at SS-II stage and check the Silent Block condition. In case of
any cracks or failure in rubber bonding, replace the Silent Block.
b) Following guidelines to be followed;
1. If the Silent Block was not replaced at SS-II stage then un-mount the Coupler from the coach
and check the Silent Block condition for any cracks or failure of rubber bonding. Replace the
Silent Block, if found damaged.
2. If the Silent Block has been replaced at SS-II stage then it has to be visually inspected for any
cracks or failure in rubber bonding at SS-I/2 stage without un-mounting from the coach;
c) It is mandatory to replace the Silent Block after 72 months from the date of
commissioning, irrespective of the condition of Silent Block.
SILENT BLOCK Visual Verification Process 1:

Step 1: Check if any part of Silent B
in Fig.11
Figure 11:

Page 21
Step 2: In case any part of Silent Block assy. (Rubber or Inner Sleeve) is visible as
shown in Fig. 12, take out the Coupler and replace the Silent Block at the earliest.
Figure 12:
SILENT BLOCK VISUAL VERIFICATION PROCESS 2

Step 1: Check if there is tilting of Coupler Head assembly as shown in Fig. 13
Figure 13: Tilting of Coupler Head assembly
Step 2: In case tilting is there, check if there is any damage in Vertical Support Assembly or if
the springs of Vertical Support Assembly have permanent set as shown in Fig. 14.

Page 22
Figure 14: Damaged Vertical Support Assembly
Step 3: In case of any damage in Vertical Support Assembly, replace the same and again check
if there is tilting of Coupler Head Assembly.
Step 4: If the tilting still persists, then un-mount the Coupler assembly and check for the
damage of Silent Block. Replace the Silent Block at the earliest, if it is found in damaged
condition.

Page 23
VERTICAL SUPPORT ASSEMBLY

Weekly
(D1)
Visually check Vertical
Replace if found
Support Assembly for any
damaged
damage
Verify in case of coupled Replace the Wear

Couplers if the shanks of Plates of either shank
the Couplers are in contact or Vertical Support
with respective Vertical Assy. as per the Section
Support Assemblies. 7.8.3 & 7.8.4
Ensure that wheel wear /
broken bolster / broken or
equalizer springs are Replace the Vertical
repaired before Support Assy. if found
inspection. broken.
Verify if the springs have Replace the spring set.

permanent set, indicated Dimension H (distance
by the Rest plate assy. between wear plate
(Item No.2 in Figure 46) and Base Plate) is
resting on the Base Assy. acceptable between
(Item No. 1 in Figure 46) 185 mm to 189 mm.
Check for any damage of

Allen Bolt, by measuring Replace If found
the gap b/w the coils of damaged.
Spring
Check for any damage in Replace If found

Castle Nut & Split Pin. damaged or missing.
Perform DPT or MPI after

dismantling to detect any In case of any crack,
cracks in Base Assy and discard the component
Rest Plate Assy (Item No. 1 and replace it with a
and 2 as shown in Figure new one.
46)
Must Change Items:
Replace item no. 3, 4, 5, 6,
7, 8, 9 & 10 as shown in
Figure 46.
Replace Item 8 & 9 as
shown in Figure 44.
Replacement of rest of the

items to be condition
based determined by the
DPT/MPI or any damage.
Check if the thickness of
Replace the Wear Plate
Wear Plate (Item No.10 of
if its thickness is less
Figure 46) is not less than
than or equal to 3 mm.
or equal to 3 mm.

Page 24
MANUAL UNCOUPLING DEVICE ASSEMBLY

Weekly
(D1)
Visually check for any Replace if found

damaged / bent parts damaged
Ensure the Lock is secure Replace the Lock if

and the Rotary Bar found damaged and
Handle (Item No.3 of make sure that the
Figure 48 ) is seated in Uncoupling Rod is
the rectangular slot of seated in the slot of
the outer support the Support Bracket
bracket (Item No.2 of Outer and securely
Figure 48) locked.
Must Change Items:

Replace Item No. 2, 3, 4,
5, 8 & 9 as shown in
Figure. 48
Replace Item 10, 11 & 12
as shown in Figure. 44
Replacement of rest of
the items to be condition
Ensure that the gap Follow the steps

between Locking Bolt mentioned in
and Rotary Bar Handle is to reduce
not more than 2mm. the gap.
With Locking Screw of

the Locking Piece of the If such visual
Uncoupling Device obstruction is noticed
completely tightened in the Tell-Tale recess,
(Refer Figure9) , there then Rotary Bar with
Handle (Item No.3),
should not be any visual
Support Bracket Outer
obstruction of the Tell- (Item No. 2) and
Tale recess during the Locking Piece sub-assy
manual rotational (Item No. 5) to be
movement of the replaced with new
Uncoupling Handle. one.

Page 25
BALANCED DRAFT GEAR

Weekly
(D1)
Visually check for any Replace if found

damaged / bent parts damaged
Inspect the Elastomeric

Pads
or deformation
2. Rough damages or
cracks deeper than 2 mm Replace as described
on the exterior surface 7.8.9
3. The installed height of
each pad with respect to
the height of the adjacent
pads do not vary by more
than ±2 mm to ensure
correct pre-load is
maintained
Replace as described
Bent Intermediate Plate 7.8.9
Ensure tightening
Check loosening of Wedge torque of 350 Nm. If
Sub Assy (Item No.12 of tightening not possible,
Figure 47) then replace wedge sub
assy.
In case of any crack,

Perform DPT or MPI after
discard the component
dismantling to detect any
and replace it with a
cracks
new one.
Must Change Items:

Replace Item No. 1, 4, 6, 8,
10, 11, 12, 14, 16, 17 & 18
as shown in Figure 47.
Replacement of rest of the

items to be condition

Page 26
1. Replace the front fork

in case the depression
is more than 5 mm.
1. The localized depression
upto 5mm is acceptable in
a. The distance
Front Fork at the interface
between wedges of
with Coupler Shank.
main body shank is
During inspection, check
Wear Limit Inspection
acceptable up to 155
following points:
mm. To make up the
worn out portion of the
a. Distance between
wedge, weld repair is
wedges of Main Body
possible as per
Shank.
ANNEXURE A.
b. Condition of Silent
Block.
b. If Silent Block found
c. Vertical Support
damaged then replace.
assembly height to be
checked and any variation
c. In case of any damage
to be noted.
in Vertical Support
Assy, then follow as per
section 6.2
Note: Moderate rust on the Discs and the Guiding Rod is acceptable. The Elastomeric Pads along with
Bushes to be replaced after 6 years. For Balanced Draft Gears only pads in the same condition should
be used on both sides. Please keep in mind that after a reassembly the spring stacks need at least one
full functional stroke for proper performance.

Page 27
FRONT AND REAR CARRIER PLATE

Examination / Per Every 6 18 36 54 72
Weekly
Inspection Maintenance task Month Months Months Months Months Months Remedy
(D1)
VISUAL VERIFICATION
PROCESS 1
Visual inspection for
Refer Section 6.5.1
excessive rusting on
Front Carrier Plate as
shown in Section 6.5.1.
VISUAL VERIFICATION
PROCESS 2
Visual inspection for
Refer Section 6.5.2
tilting of Coupler
assembly as shown in
Section 6.5.2.
VISUAL VERIFICATION
PROCESS 3
Visual inspection of Gap
Refer Section 6.5.3
between Front Fork and
Front Carrier Plate as
shown in Section 6.5.3
Check if the Main Pin is
visible from the
Replace the Axial
detection hole provided
Stiffener Plate if Main
at the bottom of Axial
Pin is visible
Stiffener Plate Refer
Figure 15
Perform DPT or MPI
after dismantling to
detect any cracks
new one.
Must Change Items:

Replace Item No. 1 of
fig. 49 & 50 and item
No. 2 of fig. 49
Replacement of
fastener items (as
shown in Figure 49 &
50) to be done in case of
any breakage or
damage upon visual
examination.

Page 28
Figure 15: Detection hole for Main Pin in Front Carrier Plate
FRONT AND REAR CARRIER PLATE-Visual Verification Process 1 :

Step 1: Check if there is excessive rusting on Front Carrier Plate as shown in Fig. 16
Figure 16: Heavy rusting of Front Carrier Plate
Step 2: In case of excessive rusting, un-mount the Front Carrier Plate and check its
condition. Replace the Axial Stiffener Plate if its thickness is reduced to 4 mm from
10 mm at the wear zone.
Wear Zone
Figure 17: Wear Zone in Front Carrier Plate

Page 29
FRONT AND REAR CARRIER PLATE Visual Verification Process 2 :

Step 1: Check if there is tilting of Coupler Head assembly as shown in Fig. 18
Horizontal Axis
Figure 18: Tilting of Coupler Head Assembly
Step 2: In case tilting is there, check if there is any damage in Vertical Support
Assembly or if the springs of Vertical Support Assembly have permanent set as
shown in Fig. 19.
Figure 19: Damaged vertical support assembly

Step 3: In case of any damage in Vertical Support Assembly, replace the same and
again check if there is tilting of Coupler Head assembly.
Step 4: If the tilting still persists, then un-mount the Front Carrier Plate and check
its condition. Replace the Axial Stiffener Plate if its thickness is reduced to 4 mm
from 10 mm at the wear zone.

Page 30
FRONT AND REAR CARRIER PLATE Visual Verification Process 3 :

Step 1: Check the gap between Front Fork and Axial Stiffener Plate.
Front Fork
Gap b/w Front Fork &

Axial Stiffener Plate
Axial Stiffener Plate
Figure 20: Gap between Front Fork and Axial Stiffener Plate
Step 2: If the gap is zero at the location shown in Fig. 20, then un-mount the Front
Carrier Plate and check its condition. Replace the Axial Stiffener Plate if its
thickness is reduced to 4 mm from 10 mm at the wear zone.
MAIN PIN

Weekly
(D1)

Perform DPT or MPI
after dismantling to
detect any cracks
new one.
Main pin is a Must

change item at SS-
III schedule.

Page 31
7 USE OF VARIOUS GAUGES & OVERHAUL PROCEDURE

ALIGNING WING LIMIT GAUGE NO. 32600.
USAGE
The gauge must seat against the front face of the Coupler Head and must clear all the points around
the Interlocking lug guard arm face & lateral aligning surface. The gauge is to be used in a manner as
shown in Figure 21. Gauge not sitting / clearing its proper location is an indication of excessive wear
or distortion. In this condition the Coupler Head must be replaced.
Figure 21: Procedure for Checking Aligning Wing Limit Gauge No.-32600

Page 32
VERTICAL HEIGHT ALIGNING WING POCKET AND GUARD ARM GAUGE NO. 34101-4.
USAGE
The gauge is used to inspect for excessive distortion of vertical height of aligning wing and guard arm
of the AAR-H Coupler Head. The gauge is to be used in a manner as shown in the Figure 22. This gauge
must slide in the wing pocket and over the guard arm, otherwise it is an indication of vertical
distortion. In such an event, the Coupler Head must be replaced.
Figure 22: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No. 34101-4

Page 33
VERTICAL HEIGHT CONDEMNING LIMIT ALIGNING WING POCKET AND GUARD ARM GAUGE
NO. 44250-5.
USAGE
This gauge is used to check for wear of aligning wing and guard arm. This gauge does not check the
distortion of the Coupler Head. This gauge is to be used in a manner as shown in the Figure 23. This
gauge must not pass into the wing pocket or over the guard arm, otherwise it is an indication of
excessive wear of the Interlocking surfaces of the wing pocket and/or guard arm. In this event the
Coupler body must be replaced.
Figure 23: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No. 44250-5

Page 34
CONTOUR MAINTENANCE GAUGE NO. 31000.

USAGE
This gauge is used to inspect the correctness of the contour. This gauge should be used in a manner
as shown in the Figure 24. This gauge must pass through the contour with the Knuckle fully close and
locked, with the gauge seated against the front face of the Coupler Head. Gauge not sitting against
the front face of the Coupler is an indication of excessive wear on the front face of the Coupler or
stretched Knuckle in which event the Knuckle must be removed from the Coupler Head and checked
for wear and stretch by using Knuckle nose wear and stretch limit gauge no. 34100-2A shown in
Figure 25.
Figure 24: Contour Maintenance Gauge no. 31000

Page 35
KNUCKLE NOSE WEAR AND STRETCH LIMIT GAUGE NO. 34100-2A

USAGE
This gauge is used to check for excessive wear on the nose of the Knuckle and for any stretch. This
gauge should be used in a manner as shown in the Figure 25. It should be verified that point D must
then the Knuckle must be replaced.
Figure 25: Procedure for Checking Knuckle Nose Wear and Stretch Limit Gauge no. 34100-2A

Page 36
CONTOUR CONDEMNING GAUGE 34100-1

USAGE
This gauge is used to check/inspect the contour Slack of the Coupler. This gauge must be used in a
manner as shown in the Figure 26. This gauge must not pass between the front face of the Coupler
Head and the pulling face of the Knuckle.
If the gauge passes, then Knuckle should be removed and replaced with new Knuckle. If the
substitution does not bring the Coupler within the limits of gauge No.-34100-1, then lock should be
replaced with new Lock. If the contour is still not maintained within the limits of gauge no. 34100-1,
then Coupler body should be replaced.
Figure 26: Procedure for Checking Wear on Knuckle Nose with Counter Maintenance Gauge No. 34100-1

Page 37
ANTI-CREEP PROTECTION
To check the amount of effective anti-creep protection in a Tight Lock Coupler, insert a small flat bar
or chisel between the Lock and Knuckle tail shelf and ply lock upwards. At the same time force Lock
leg rearward by inserting a similar bar from beneath the Coupler between the Lock leg and the front
of the Lock hole. (Refer the Photographs in the Figure 27 to 32 below).
The amount of Anti-Creep Protection can be determined by inspection from the front of the Coupler.
Figure 27: Anti-Creep Protection
If actual measurement is desired a line is scribed on the top of the Toggle along the rear face of the
Knuckle tail shelf and the measurement is taken from the line of front edge of the Toggle and parallel
to its side.
Figure 28: Minimum Overlap

Page 38
Caution!
Do not hammer any part of the Rotary Lock Lift assembly; this may cause
permanent distortion to the assembly. In case of a stuck Lock, gently mallet
it from the bottom to set it free.
STEP 1
Insert the pry bar between the

Lock and Knuckle tail shelf and lift
the Lock as high as possible, so
that Toggle hits the bottom of the
Knuckle tail shelf.
Figure 29: Minimum Overlap Test Step 1
STEP 2
With the Lock held up by the bar and the

Toggle engaged with the Knuckle tail shelf,
insert a flat bar or screw driver between the
leg of Lock and the front of the Lock hole. Pull
towards the front of Coupler which pushes
Toggle backwards.

Page 39
STEP 3
With the Lock held up by the

bar, and the Toggle is pushed
backwards, the Anti-Creep is
determined.
STEP 4
For the Anti-Creep to work, the distance

between the rear of the Knuckle tail shelf
and the front edge of the Toggle, should be
.

Page 40
OVERHAUL PROCEDURE
COUPLER HEAD ASSEMBLY
The following procedure describes the Coupler disassembly, testing/checking & assembly.
1. Insert a hydraulic trolley below Coupler Head and pump until it lifts Coupler Head slightly as
shown in Figure 33. This function may also be performed with the help of an Overhead crane
by hanging it on to the overhead crane with the help of chains as shown in Figure 34.
2. Overhead crane lifting chains should be tied with Coupler shank near Vertical Support
assembly towards front of Coupler Head as shown in Figure 34.
Figure 33: Tight Lock Coupler using hydraulic trolley
Figure 34: e Tight Lock Coupler using overHead crane

Page 41
3. Loosen 6 Nos. Nuts (M16) of the Front Carrier Plate and remove the Front Carrier Plate.
4. Take a M16 x 2 bolt (approx. length 300 mm, 10.9 grade) & tighten it in Main Pin centre hole
taping.
5. Pull the bolt downward by hand, moving the Coupler Head to & fro, up and down by
overhead crane.
6. If unable to pull the Main Pin by hand, then a suitable puller may be used.
7. After pulling the Main Pin out, pull the Coupler Head out of coach under frame by moving
the trolley outside or by moving the crane.
8. AAR H Coupler is a bulky & complex shaped product; therefore, it should be handled with
great care.
9. Use minimum 1 ton lifting capacity crane or hydraulic trolley.
10. Unload Coupler Head at a suitable place.
11. Place the Coupler Head assembly on a workbench, which can handle a weight of at least
500kg. Care should be taken while handling the Coupler Head as it is heavy and should be
handled by using appropriate handling tools.
12. Orient the Head so as the Knuckle faces you and is to your left.
13. All parts of the assembly must be clean and free of dirt, paint, rust and scale, which may
interfere with gauging and inspection.
14. Visually check the Coupler Head for cracks, fractures, sections broken out, worn surfaces,
distortion, and surface upset and service notches.
15. Weld repair on machined surfaces is prohibited.
16. The thickness of all Wear Plates used shall be nominally 6mm. The material of Wear Plate
shall be spring steel. Coupler shanks Wear Plates that are loose, missing, worn-out more than
3mm must be replaced by welding a new Wear Plate. Intermittent welding to be done along
the longitudinal edges only. No welding permitted across shank at either end of the plate.
The welding materials used in Grade E steel castings shall be to AWS/ASTM E12015, E12016,
E12018, E13015, E13016, E13018 or equivalent.
Figure 35: Section View of Coupler Shank

Page 42
17. Coupler with shanks bent may be reconditioned provided:
No cracks have developed as a result of bending.

Amount of bend measured by using flat scale does not exceed one inch per foot
of shank length, measured from front face to pivot point of shank.
Top wall is not buckled.
18. Straightening operation on bent shank can be done by heating locally the bend at a
temperature between 816°C to 871°C. The heat should be applied on the side toward the
bent concave side.
19. After straightening operation, a careful examination should be made to make certain that no
crack has resulted from this operation. And using flat scale check alignment of shank. In all
cases where shanks have been heated to straighten, the coupler body shall be heat-
treated as per AAR Specification M-212.
Caution!
The Coupler Head and its components are heavy and should be handled
correctly using proper material handling equipment.
20. Coupler with distorted aligning wing pocket may be restored to normal by locally heating the
distorted area and straightening under a press or by other suitable means. The amount of
heat necessary may vary according to the degree of distortion, but in most cases,
temperature is kept between 8160C to 8710 C. The competed work shall then be checked and
must meet the requirements of gauge No. 32600 as shown in the Figure 36 & Figure 37.
Figure 36: Procedure for Checking Aligning Wing Limit

Page 43
Figure 37: Aligning Wing Limit Gauge No-32600
21. Couplers with cracks in the aligning wing pocket may be reconditioned by welding, in
accordance with the specification M-212, provided such crack or cracks do not extend into
the Coupler Head proper and the Coupler body is then heat treated in accordance with
section 5.2 of AAR-M212. In case the wing pocket is broken off, the Coupler shall not be
reconditioned.
22. Couplers with cracks in the guard arm may be reconditioned by welding, in accordance with
the specification M-212, provided such crack or cracks do not extend into the Coupler Head
proper and the Coupler body is then heat treated in accordance with section 5.2 of AAR-
M212. In case the wing pocket is broken off, the Coupler shall not be reconditioned. If cracks
are found at any other location, the Coupler shall be replaced. Further the Coupler shall be
checked with the gauge 34101-4 as shown in Figure 38 below.
Figure 38: Vertical Height Aligning Wing Pocket and Guard Arm Gauge No-34101-4

Page 44
23. Check the Coupler Head assembly parts first by using Gauge No.-34100-1, if it does not pass
then Knuckle is ok & if it passes then Knuckle should be removed and replaced with new
Knuckle. If the substitution does not bring the Coupler within the limits of gauge No.-34100-
1, then Lock should be replaced with new Lock. If the contour is still not maintained within
the limits of gauge no. 34100-1, then Coupler body should be replaced.
Figure 39: Contour Condemning Limit Gauge no. 34100-1
Figure 40: Knuckle Nose Wear and Stretch Limit Gauge No.-34100-2A

Page 45
24. The Knuckle shall be checked with nose wear and stretch limit gauge No. 34100-2A as shown
in the Figure 40. If the limits of this gauge are reached, indicating wear, then Knuckle shall
be scrapped. Also, ensure to check the Knuckle as per the Gauge No. 31000 for correctness
of the contour and if it does not pass then parts are to be replaced or ground suitable as per
APTA SS-M-002-98 clause 5.5.1 and clause 5.5.2.
Figure 41: Contour Maintenance Gauge No.-31000
25. Surface upset must be ground and blended to the surrounding surfaces. This ground area
must be free from cracks.
26. The following parts of Coupler Head assembly must NOT be reconditioned if any defects
found.
Coupler Knuckles and Locks;
Knuckle thrower;
Rotary Lock Lift assembly;
Connecting pins;

Page 46
INSTALLATION OF COUPLER HEAD IN COACH.

1. Put the Coupler Head on trolley or hang it with crane by tying it with chains as shown in
Figure 42.
2. Insert Coupler shank in coach pocket over Vertical Support Assembly.
3. Insert Main Pin through Balanced Draft Gear hole by keeping the holes of Balanced Draft
Gear & Coupler Silent Block inline.
4. Take Front Carrier Plate and tighten it with new Nylock Nuts.
5. Only dry graphite powder 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.
Figure 42: Installation of Coupler Head in coach
Caution!
Do not Paint or lubricate any component of the Coupler Head. This can
result in faulty operation and undesired uncoupling.

Page 47
PROCEDURE TO INCREASE COUPLER HEIGHT (BUFFER HEIGHT).

1. Before an attempt is made to readjust the Coupler height the Head of the Coupler should be
amply supported by using a jack or a trolley.
2. The jack should be raised to bring Coupler to the required height.
3. All the dirt/smudge should be wiped from the Coupler shank wear plate and Vertical Support
Assembly Wear Plate.
4. Measure the gap between the Coupler Shank Wear Plate and Vertical Support Wear Plate.
5. Measure the thickness of both the Wear Plates. The original thickness of the Wear Plates is
6 mm. Wear Plates which have reduced to 3 mm or less should be replaced by removing the
Coupler Head and Vertical Support Assembly
6. Select a combination of shims, which closely equals the gap measured.
7. Weld the shims on the wear plate.
8. Loosen the bolts of Vertical Support Assembly and using a pry handle ply the Vertical Support
Assembly upwards.
9. Lower the trolley so that the Coupler shank sits on the Vertical Support Assembly.
10. Tighten the bolts of the Vertical Support Assembly.
PROCEDURE TO DECREASE THE COUPLER HEIGHT.

1. Determine the distance that the Coupler should be lowered.
2. Loosen the bolts of the Vertical Support Assembly.
3. Inspect the wear on the Wear Plate of the shank of the Coupler Head.
4. Inspect the wear on the Wear Plate of Vertical Support Assembly.
5. Pry the Vertical Support Assembly.
6. Remove tack welds and remove shims as required.
7. Re-tighten bolts of Vertical Support Assembly.
8. Release the trolley.
9. Re-inspect the Coupler height.
MAIN PIN FOR KNUCKLE REPLACEMENT.

1. Using a support, the weight of the Knuckle should be supported.
2. The Split Pin of the Main Pin for Knuckle should be opened and removed.
3. Open and remove the Split Pin for Support Pin for Knuckle
4. Lower the Main Pin for Knuckle through the pin hole of the Coupler Head and Knuckle.
5. Insert a new Main Pin for Knuckle through the same hole. While doing so care must be taken
that the Main Pin for Knuckle is inserted from the bottom of the Coupler with the Split Pin
hole visible above the top of the Coupler Head.

Page 48
6. Insert new Split Pin and spread its legs to fix.

7. Install new Support Pin for Knuckle and secure it also by pulling new Split Pin and spreading
its legs.
Caution!
When the Main Pin for Knuckle is removed, the Knuckle is free to rotate.
Any movement of the Knuckle at this point can let the Knuckle fall and
cause manual injury. Extreme caution should be exercised at this point
of time.
REPLACEMENT OF KNUCKLE.
1. Before trying to replace the Knuckle verify that the Knuckle is closed and locked.
2. Using a support / jack support the weight of the Knuckle from the front of the Coupler Head.
3. Remove the Main Pin for Knuckle as described earlier.
4. Lift the Lock by using the Manual Uncoupling arrangement.
5. Slowly slide the Knuckle away from the Coupler Head.
6. Place the new Knuckle and re-install the Main Pin for Knuckle as described earlier.
PROCEDURE TO REPLACE SILENT BLOCK

1. Place the Coupler Head Assembly over the special base, on the hydraulic press. Place the
removing Fixture AARH-015 over the silent block. Apply hydraulic force over the fixture,
this will allow the Silent Block to slowly come out of the bore in the Coupler Head.
2. Apply the same procedure to insert the Silent Block in the shank of the Coupler Head using
the Fixture AARH-014.
REMOVAL OF COUPLER AND BALANCED DRAFT GEAR FROM COACH

1. Hang the Coupler Head to an overhead crane.
2. Remove the Front Carrier Plate by untightening M16 Nut and bolts
3. Remove the Main Pin from between Coupler Head and Balance Draft Gear.
4. Remove the Coupler Head Assembly.
5. Place a hydraulic trolley under the Front Fork of the Balance Draft Gear.
6. Un-tighten M16 bolt and Nut then remove the Wedge Lock for Rear Carrier Plate.
7. Remove the Rear Carrier Plate.
8. Loosen the Wedge-Key assembly and remove.
9. The Balanced Draft Gear rests on the hydraulic trolley, lower down the hydraulic trolley and
remove the Balanced Draft Gear.

Page 49
DISMANTLING OF BALANCED DRAFT GEAR

1. Place the Balanced Draft Gear on the hydraulic press with suitable fixtures.
2. Press the Rear Stopper Plate of the Balanced Draft Gear attached with fixture with Hydraulic
Press. Refer Figure 43 and Fixtures - AARH-012 & NCRF-142.
3. Open the M20 bolt and remove the plain washer and lock washer.
4. Untighten the Round Nut and remove the Rear Stopper Plate along with the Round Nut.
5. Remove the Elastomeric Pads and Bush for Intermediate Plate (Rev 03).
6. Remove the H type housing with an overhead crane.
7. Remove the Elastomeric Pads and Intermediate Plate.
8. Remove the Main bolt from the Front Fork.
9. Clean all the parts of any dirt, grease / oil. If cleaning is required, surfactant containing
detergents are permissible at temperatures up to 50° C. It is necessary to rinse afterwards
with clear water. The use of short time steam cleaning could be accepted also. Long term
exposure to steam will damage the spring pads.
10. Visually check all the parts.
11. Replace the damage parts.
12. Assemble the Balanced Draft Gear in the same way as dismantled. Ensure to tighten the Nut
over the main bolt completely till the last thread so that the bolt and Nut surfaces align. This
will ensure that the Draft Gear is preloaded suitably for the assembly. Finally lock washer to
be assembled with plain washer and bolt as provided.
Figure 43: Dismantling of Balanced Draft Gear

INSPECTION FOR PROPER FITMENT OF BALANCED DRAFT GEAR
In case of Balanced Draft Gear, ensure that wedge locks are tightened properly with Rear Carrier
Plate M16 bolts. Also, ensure tightening of special bolt of Wedge Block at torque of 350Nm.
Page 50
TROUBLE SHOOTING
The following table given the description of typical trouble shooting procedures to be followed for the
Couplers.
Effect Cause Test Remedy
Defective
Ensure the Rotary Bar is
Manual Visually check the position of
seated at the bottom of the
Uncoupling Manual Uncoupling Lever.
rectangular slot provided.
Mechanism.
Clean and adjust various
Check free movement of
components of Uncoupling
Uncoupling Handle.
Tell-tale recess Handle and Brackets.
obstructed. Manually check Rotary Lock
Clean Rotary Lock Lift
Lift Lever assembly for free
Assembly and Toggle.
movement.
Check lock up/down

Lock not seated Clean Lock by anti-rusting
movement and Knuckle
properly spray and re-use.
rotation; it should be free.
Vertical Support Check for any sign of Replace the Vertical

Assembly spring collapsed or broken Vertical Support Assembly springs
Coupling or Allen bolt Support Assembly springs and bolts if required or
height damaged. and bolts. adjust spring height.
disturbed from Remove the Coupler main
rail level. Silent Block body and visually check for
Replace the silent block.
damaged any bonding or rubber crack
failure in silent block.
Damage, bent or Rotary Bar rectangular

loose Mounting section must seat on slot
Manual
Brackets, provided in Outer Support
Uncoupling Visually check all
Support Bracket and locking Screw
Device Lever components.
Brackets, Rotary should easily be tightened
not in position
Bar or in full for desired
Uncoupling bar. functioning of the device.

Page 51
8 LIST OF SPARE PARTS ASSEMBLY WISE

SPARE PARTS FOR INSTALLATION OF BALANCED DRAFT GEAR & A.A.R TYPE-"H" TIGHT
LOCK COUPLER (1C101060011)
Figure 44: Exploded & Assembly view for Balanced Draft Gear & A.A.R Type-"H" Tight-Lock Coupler
Sl. No. Description Drg. No. Sl. No. Description Drg. No.
BALANCED DRAFT GEAR
HEX HEAD BOLT
1 FOR AAR-H TYPE TIGHT 1C101060004 10 DIN 931/ IS:1364
M12X50 GR.10.9
LOCK COUPLER REV 03
FRONT CARRIER PLATE HEX NYLOCK NUT
2 1C101060013 11 DIN 985
ASSY (REV. 03) M12 GR.8.0
REAR CARRIER PLATE (REV
3 1C101060017 12 SPRING WASHER B12 DIN 127
03)
MANUAL UNCOUPLING DIN 125A/
4 1C101060026 13 PLAIN WASHER M16
DEVICE ASSY (REV. 03) IS:2016
AAR-H TIGHT LOCK
HEX HEAD BOLT
5 COUPLER HEAD ASSY (REV. 1C101060021 14 DIN 931/ IS:1364
M16X60 GR.10.9
03)
VERTICAL SUPPORT ASSY HEX NYLOCK NUT
6 1C101060031 15 DIN 982
(REV. 03) M16 GR.8.0
7 MAIN PIN (REV 03) 1C101060019 16 WASHER (BOTTOM) SK-1537
HEX HEAD SCREW HEX HEAD BOLT
8 DIN933/ IS:1364 17 DIN 931/ IS:1364
M20X50 GR.10.9 M16X65 GR.10.9
9 WASHER M20 SK-730

Page 52
PARE PARTS FOR AAR-H TIGHT LOCK COUPLER HEAD ASSY. (1C101060021)
Figure 45: Exploded & Assembly view of AAR-H Tight Lock Coupler Head Assy.
SUPPORT PIN FOR MAIN
1 MAIN BODY 1C101060027 7 1C101060033
PIN KNUCKLE (REV 03)
SILENT BLOCK FOR AAR-
2 KNUCKLE SK-611 8 1C101060069
H COUPLER (REV 03)
WEAR PLATE FOR MAIN
3 LOCK SK-612 9 SK-711
BODY
KNUCKLE
4 SK-1560 10 CHAIN WITH HANDLE 1C101060036
THROWER
ROTARY LOCK
5 1C101060037 11 SPLIT PIN 8 x 90 IS:549 / DIN 94
LIFT ASSY.
MAIN PIN FOR
6 KNUCKLE (REV 1C101060068 12 SPLIT PIN 5 x 40 IS:549 / Eq.
03)

Page 53
SPARE PARTS FOR VERTICAL SUPPORT ASSY. (1C101060031)
Figure 46: Exploded & Assembly view of Vertical Support Assy.
BASE ASSEMBLY
1 1C101060038 6 CONICAL WASHER SK-729
(REV03)
2 REST PLATE ASSY. 1C103020003 7 WASHER (TOP) SK-1536
COMPRESSION HEX. CASTLE NUT IS:2232 / DIN
3 SK-722 8
SPRING (M16 x 2) GR.8.0 935
4 WASHER (BOTTOM) SK-1537 9 SPLIT PIN 5 x 40 IS:549 / Eq.
5 ALLEN BOLT SK-1535 10 WEAR PLATE SK-723

Page 54
SPARE PARTS OF DRAFT GEAR ASSY. (1C101060004)
Figure 47: Assembled view of Balanced Draft Gear
WEDGE LOCK FOR
1 FRONT FORK (REV 03) 1C101060001 11 SK-1652
BDG
FRONT WEAR PLATE (REV WEDGE KEY SUB
2 1C101060009 12 SK-1608
03) ASSY.
HEX. CSK SCREW
3 MAIN BOLT (REV 03) 1C101060002 13* IS:6761
(M10x30) GR.12.9
4 ELASTOMERIC PAD 1C101050018 14 LOCK WASHER SK-1547
5* INTERMEDIATE PLATE 1C101050021 15 ROUND NUT SK-1551
BUSH FOR INTERMEDIATE HEX BOLT M20X40
6* 1C101060008 16 IS 1363
PLATE (REV 03) GR.10.9
PLAIN WASHER ID-22,
7 H-TYPE HOUSING (REV 03) 1C101060003 17 IS:2016
OD-37,THICK-3.15MM
CIRCLIP INTERNAL IS:3075
8 BUSH SK-1546A 18*
NORMAL 95x3 PART-2
REAR STOPPER PLATE SUPPORT PLATE FOR
9 1C101060007 19 SK 1623
(REV 03) H- HOUSING
BUSH FOR MAIN BOLT
10* 1C101060005
(REV 03)
Notification!
* Marked items not shown in figure.

Page 55
SPARE PARTS OF MANUAL UNCOUPLING DEVICE ASSY. (1C101060026)
Figure 48: Exploded & Assembly view of Manual Uncoupling Device Assy.
SUPPORT BRACKET MOUNTING BRACKET

1 SK-554 7 SK-562
(INNER) (OUTER)
SUPPORT BRACKET ALLEN SCREW (M10X20) IS:2269
2 SK-555 8
(OUTER) GR.12.9 / Eq.
ROTARY BAR WITH
1C10106006 HEX. HEAD BOLT IS:1364
3 HANDLE SUB ASSEMBLY 9
7 (M16X45) GR.8.8 / Eq.
(REV 03)
UNCOUPLING BAR SUB 1C10106006 HEX. NYLOCK NUT (M16)
4 10 DIN 982
ASSY (REV 03) 6 GR.8.0
DIN-
LOCKING PIECE SUB
5 SK-716 11 PLAIN WASHER (M16) 125A /
ASSY.
IS:2016
MOUNTING BRACKET
6 SK-561 12 SPRING WASHER (B10) DIN 127
(INNER)

Page 56
SPARE PARTS OF FRONT CARRIER PLATE (1C101060013)
Figure 49: Exploded & Assembly view of Front Carrier Plate
SL. DESCRIPTION DRG. NO. SL. DESCRIPTION DRG. NO.

NO. NO.
1 FRONT CARRIER 1C101060014 5 PLAIN WASHER DIN 125 A /
PLATE - WELDED (M16) IS:2016
2 AXIAL STIFFENER 1C101060073 6 HEX HEAD BOLT DIN 931 /
PLATE MAIN (REV 03) (M16 X 60, GR. 10.9) IS:1364
3 HEX. CASTLE NUT DIN 935 / 7 SPLIT PIN - Ø5 x 40 IS:549 / EQ.
(M16x2, Gr. 8.0) IS:2232
4 HEX NYLOCK NUT DIN 982 8 HEX HEAD BOLT ISO:4017 /
(M16x2, Gr. 8.0) (M16 X 45, GR. 8.8) EQ.

Page 57
SPARE PARTS OF REAR CARRIER PLATE (1C101060017)
Figure 50: Exploded & Assembly view of Front Carrier Plate
SL.
DESCRIPTION DRG. NO.
NO.
1 REAR CARRIER PLATE 1C101060017
2 HEX. NYLOCK NUT (M16, Gr. 8.0) DIN 982
3 HEX HEAD BOLT (M16 X 60, Gr. 10.9) DIN 931 / IS:1364
4 PLAIN WASHER (M16) DIN 125A / IS:2016
5 HEX HEAD BOLT (M16 X 65, Gr. 10.9) DIN 931 / IS:1364

Page 58
9 LIST OF SPARE PARTS, GAUGES AND SPECIAL TOOLS

Recommended spare parts quantity for AAR-H Coupler Rev03 to be maintained for holding 500 Couplers
for a period of 10 years are listed below.
INSTALLATION DRAWING FOR BALANCED DRAFT GEAR & A.A.R TYPE-"H" TIGHTLOCK
COUPLER (1C101060011)
Escorts
SL. No. Part Description Quantity
Part number
BALANCED DRAFT GEAR FOR AAR-H TYPE TIGHT
1 1C101060004 10
LOCK COUPLER REV 03
2 FRONT CARRIER PLATE ASSY (REV. 03) 1C101060013 50
3 REAR CARRIER PLATE (REV 03) 1C101060017 25
4 MANUAL UNCOUPLING DEVICE ASSY (REV. 03) 1C101060026 50
AAR-H TIGHT LOCK COUPLER HEAD ASSY (REV.
5 1C101060021 10
03)
6 VERTICAL SUPPORT ASSY (REV. 03) 1C101060031 50
7 MAIN PIN (REV 03) 1C101060019 500
8 HEX HEAD SCREW M20X50 GR.10.9 DIN933/ IS:1364 2000
9 WASHER M20 SK-730 2000
DIN 931/
10 HEX HEAD BOLT M12X50 GR.10.9 2000
IS:1364
11 HEX NYLOCK NUT M12 GR.8.0 DIN 985 2000
12 SPRING WASHER B12 DIN 127 2000
DIN 125A/
13 PLAIN WASHER M16 1000
IS:2016
DIN 931/
IS:1364
15 HEX NYLOCK NUT M16 GR.8.0 DIN 982 1000
16 WASHER (BOTTOM) SK-1537 1000
DIN 931/
IS:1364
AAR TYPE 'H' TIGHT LOCK COUPLER HEAD ASSY. (1C101060021)
Escorts
Part number
1 MAIN BODY 1C101060027 25
2 KNUCKLE SK-611 500
3 LOCK SK-612 100
4 KNUCKLE THROWER SK-1560 100
5 ROTARY LOCK LIFT ASSY. 1C101060037 500
6 MAIN PIN FOR KNUCKLE (REV 03) 1C101060068 500
7 SUPPORT PIN FOR MAIN PIN KNUCKLE (REV 03) 1C101060033 500
8 SILENT BLOCK FOR AAR-H COUPLER (REV 03) 1C101060069 500
9 WEAR PLATE FOR MAIN BODY SK-711 500

Page 59
10 CHAIN WITH HANDLE 1C101060036 100

11 SPLIT PIN 8 x 90 IS:549 / DIN 94 500
12 SPLIT PIN 5 x 40 IS:549 / Eq. 500
VERTICAL SUPPORT ASSY. (1C101060031)

Escorts
Part number
1 BASE ASSEMBLY (REV03) 1C101060038 100
2 REST PLATE ASSY. 1C103020003 250
3 COMPRESSION SPRING SK-722 2000
4 WASHER (BOTTOM) SK-1537 1000
5 ALLEN BOLT SK-1535 1000
6 CONICAL WASHER SK-729 1000
7 WASHER (TOP) SK-1536 1000
IS:2232 / DIN
8 HEX. CASTLE NUT (M16 x 2) GR.8.0 1000
935
9 SPLIT PIN 5 x 40 IS:549 / Eq. 1000
10 WEAR PLATE SK-723 500
BALANCED DRAFT GEAR (1C101060004)
SL. Escorts
Part Description Quantity
No. Part number
1 FRONT FORK (REV 03) 1C101060001 50
2 FRONT WEAR PLATE (REV 03) 1C101060009 100
3 MAIN BOLT (REV 03) 1C101060002 25
4 ELASTOMERIC PAD 1C101050018 1500
5 INTERMEDIATE PLATE 1C101050021 100
6 BUSH FOR INTERMEDIATE PLATE (REV 03) 1C101060008 1500
7 H-TYPE HOUSING (REV 03) 1C101060003 25
8 BUSH SK-1546A 1000
9 REAR STOPPER PLATE (REV 03) 1C101060007 25
10 BUSH FOR MAIN BOLT (REV 03) 1C101060005 500
11 WEDGE LOCK FOR BDG SK-1652 1000
12 WEDGE KEY SUB ASSY. SK-1608 1000
13 HEX. CSK SCREW (M10x30) GR.12.9 IS:6761 200
14 LOCK WASHER SK-1547 500
15 ROUND NUT SK-1551 25
16 HEX BOLT M20X40 GR.10.9 IS 1363 500
17 PLAIN WASHER ID-22, OD-37,THICK-3.15MM IS:2016 500
18 CIRCLIP INTERNAL NORMAL 95x3 IS:3075 PART-2 500
19 SUPPORT PLATE FOR H- HOUSING SK 1623 100
MANUAL UNCOUPLING DEVICE ASSY. (1C101060026)
Escorts
Part number
1 SUPPORT BRACKET (INNER) SK-554 150
2 SUPPORT BRACKET (OUTER) SK-555 500
ROTARY BAR WITH HANDLE SUB ASSEMBLY
3 1C101060067 500
(REV 03)
Page 60
4 UNCOUPLING BAR SUB ASSY (REV 03) 1C101060066 150

5 LOCKING PIECE SUB ASSY. SK-716 500
6 MOUNTING BRACKET (INNER) SK-561 150
7 MOUNTING BRACKET (OUTER) SK-562 150
8 ALLEN SCREW (M10X20) GR.12.9 IS:2269 / Eq. 1000
9 HEX. HEAD BOLT (M16X45) GR.8.8 IS:1364 / Eq. 2000
10 HEX. NYLOCK NUT (M16) GR.8.0 DIN 982 2000
DIN-125A /
11 PLAIN WASHER (M16) 2000
IS:2016
12 SPRING WASHER (B10) DIN 127 1000
LIST OF CHANGED ITEMS FROM AAR-H REV01 TO REV03.
In case spare is required for Rev01 and it falls under the changed item list, then corresponding drawing
number to be used while ordering. The list of changed items with drawing number are below.
AAR-H Coupler Rev01 AAR-H Coupler Rev03
S. No. Description of
Drawing No. Description of Component
Component Drawing No.
AAR-H TIGHT LOCK COUPLER AAR TYPE 'H' TIGHT LOCK COUPLER
1 SK-463 1C101060021
HEAD ASSEMBLY HEAD ASSY. (REV 03)
BALANCED DRAFT GEAR FOR AAR-H
2 BALANACED DRAFT GEAR SK-1550 1C101060004
TYPE TIGHT LOCK COUPLER - REV 03
VERTICAL SUPPORTING
3 SK-465 VERTICAL SUPPORT ASSY. (REV 03) 1C101060031
ASSEMBLY
MANUAL UNCOUPLING MANUAL UNCOUPLING DEVICE ASSY
4 SK-466 1C101060026
DEVICE (REV. 03)
5 FRONT CARRIER PLATE SK-476 FRONT CARRIER PLATE ASSY (REV. 03) 1C101060013
6 REAR CARRIER PLATE SK-1548 REAR CARRIER PLATE (REV 03) 1C101060017
7 MAIN PIN DG-01-13 MAIN PIN (REV 03) 1C101060019
8 MAIN BODY SK-610 MAIN BODY 1C101060027
9 ROTARY LOCK LIFTER SK-1656 ROTARY LOCK LIFT ASSY. 1C101060037
10 MAIN PIN FOR KNUCKLE SK 575 MAIN PIN FOR KNUCKLE (REV 03) 1C101060068
SUPPORT PIN FOR MAIN PIN SUPPORT PIN FOR MAIN PIN KNUCKLE
11 SK 576 1C101060033
KNUCKLE (REV 03)
SILENT BLOCK FOR AAR-H SILENT BLOCK FOR AAR-H COUPLER
12 SK-1532 1C101060069
COUPLER (REV 03)
13 - - CHAIN WITH HANDLE 1C101060036
14 BASE ASSEMBLY SK-506 BASE ASSEMBLY (REV03) 1C101060038
15 REST PLATE ASSY SK-508 REST PLATE ASSY. 1C103020003
16 FRONT FORK SK-1539 FRONT FORK (REV 03) 1C101060001
17 FRONT WEAR PLATE SK-618 FRONT WEAR PLATE (REV 03) 1C101060009
18 MAIN BOLT SK-1540 MAIN BOLT (REV 03) 1C101060002
19 ELASTOMER PAD SK 1552 ELASTOMERIC PAD 1C101050018
20 INTERMEDIATE PLATE SK 1549 INTERMEDIATE PLATE 1C101050021
BUSH FOR INTERMEDIATE BUSH FOR INTERMEDIATE PLATE (REV
21 SK 1577 1C101060008
PLATE 03)
22 H-TYPE HOUSING SK-1543 H-TYPE HOUSING (REV 03) 1C101060003
23 REAR STOPPER PLATE SK-1579 REAR STOPPER PLATE (REV 03) 1C101060007
24 BUSH SK-1546B BUSH FOR MAIN BOLT (REV 03) 1C101060005

Page 61
ROTARY BAR WITH HANDLE ROTARY BAR WITH HANDLE SUB

25 SK-560 1C101060067
SUB ASSEMBLY ASSEMBLY (REV 03)
26 UNCOUPLING BAR SUB ASSY SK-732 UNCOUPLING BAR SUB ASSY (REV 03) 1C101060066
SET OF APTA GAUGES

Set of APTA Gauges consist of all six gauges required for inspection of new Coupler Head assembly,
acceptable wear limit in operation and in repair & maintenance detailed below).
APTA Gauge Escorts
SL. No. Description
Part No. Part No.
1 Contour maintenance gauge (Profile gauge) 31000 SK-1643
2 Aligning wing limit gauge 32600 SK-1642
3 Knuckle nose wear and stretch limit gauge 34100-2A SK-1641

4 Contour Slack/condemning limit gauge 34100-1 SK-1640
Vertical height aligning wing pocket and guard
5 34101-4 SK-1639
arm gauge (GO GAUGE)
Vertical height condemning limit aligning wing
6 44250-5 SK-1638
pocket & guard arm gauge (NO GO GAUGE)
INSPECTION, REPAIR, MAINTENANCE, RECONDITIONING TOOLS & FIXTURES

REQUIREMENT FOR AAR-H TYPE TIGHT LOCK COUPLER
SL. No. Description of testing equipment & fixtures
1. Coupler Head assembly & testing equipment

Draft Gear assembly/disassembly fixture with hydraulic press of 70-ton capacity. Refer
2.
Fixture Drawing No. AARH-012 & NCRF-142.
3. Coupler handling trolley for Silent Block pressing on 70-ton press
Fixture for pressing & removing of silent block. Refer Fixture Drawing No. AARH-014 &
4.
AARH-015.
5. Vertical Support Assembly fixture for mounting on 25-ton press
6. Pressing/assembly/disassembly fixture for Draft Gear
7. Hydraulic trolley cum lifter (scissor type)
8. Pneumatic torque wrench (600 Newton Meter)
9. Balanced Draft Gear pads conditioning fixture
10 Over Head crane 5-ton capacity with complete set up

Page 62
10 REMARKS
1. W.r.t Sr. No.1 of clause 9.8 testing equipment, the assembly & testing equipment can be used in
assembling, reconditioning & inspection of Couplers.
2. Sr. No.2, machine can be used to assemble, disassemble of Draft Gear/Balanced Draft Gear.
3. The welding materials to be used in Grade E steel castings shall be to AWS/ASTM E12015, E12016,
E12018, E13015, E13016, E13018 or equivalent.

Page 63
11 ANNEXURE A
Coupler Main body wedge wear Weld repair work instructions
S. No. Procedure Images
Place the Coupler Main Body Rear Carrier Plate on a flat surface so that
1
there is easy access of welding electrode for welding.
Weld build up to be done uniformly layer by layer covering all the wear
2
area.
After each welding layer, chipping to be done with the help of chipping hammer so that no gap is
3
left.
Weld build up in the wear area to be done slightly above the original
4
wedge height.
5 After Welding, leave the Coupler main body for 24 hours to cool in normal air to room temperature.
Remove the excess weld from the wear area by grinding to make it
similar to new wedge. The desired height of 160 max. can be
6 maintained.
Also ensure while grinding, the height of repaired wedges should be at
same level.
7 Always wear gloves and safety goggles during welding.

8 Paint the repaired area with black color (RAL 9005).
9 Electrode Size : 4mm to be used
Electrode type : AWS/ASTM Class electrode E12015, E12016, E12018, E13015, E13016, E13018, or
10
equivalent to be used

Page 64
12 ANNEXURE B
In the table below, the tightening torques (±5%) for various fasteners used in Coupler Assembly are listed.
These tightening torques are applicable for all fasteners of same size, unless otherwise mentioned in the
installation drawings or instructions.
Sr. No. Dimension Tightening Torque (Nm)

1 M8 29
2 M10 59
3 M12 100
4 M16 240
5 M20 540

Page 65
13 ANNEXURE C
Steps to reduce gap between Locking Bolt and Rotary Bar Handle in Manual Uncoupling Device.

Page 66
NOTES

Page 67

Page 68
Plot No. 114-115, Sector 24, Faridabad-121005 (India)
Head Office & works Mumbai Branch Chennai Branch Kolkata Branch
Plot no.114 & 115, Sector 24, Times Square, Unit no.2, M- South West Wing,
Faridabad-121 005 A-Wing, 3rd floor, 3rd Avenue, 9th
Haryana, (India) Andheri Kurla Road, Anna Nagar East, 1, Shakespeare Sarani,
Email: rail.service@escorts.co.in Sakinaka, Chennai-600 102 Kolkata- 700 071
Web. Mumbai- 400 059 Tamil Nadu, India E-mail:
www.escortsgroup.com/railway- Maharashtra, India E-mail: kolkata@escorts.co.in
equipment-division E-mail: chennai@escorts.co.in Tel: 91-33-22825191
Tel: 91-129-2516382, 6608 mumbai@escorts.co.in Tel: 91-44-26287729 Fax: 91-33-22814518
Fax: 91-129-2232148 Tel: 91-22-24218159 Fax: 91-44-26287341

Escorts BDG Rdso 2011 Cg-03 (Rev 3)

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OPERATION AND MAINTENANCE MANUAL

HIGH TENSILE TIGHT LOCK CENTRE BUFFER COUPLER WITH

Document Revision History

LIST OF CHANGED ITEMS FROM AAR-H REV01 TO REV03.............................................. 61

Confidential document, Unauthorized circulation is strictly prohibited Format No. : FM:R&D:021/02/05.03.2020

Figure 2: Balanced Draft Gear ...................................................................................................... 10

Figure 3: Vertical Support Assembly ............................................................................................. 11

Figure 4: Rotary Bar with Handle .................................................................................................. 12

Figure 5: Un-Coupling Bar ............................................................................................................ 12

Figure 7: Check for Coupler Locking............................................................................................. 15

Figure 8: Tell-tale Recess ............................................................................................................. 16

Figure 9: Keyway Slot Locking...................................................................................................... 17

Figure 10: Coupling / Un coupling mechanism .............................................................................. 18

Figure 13: Tilting of Coupler Head assembly ................................................................................ 22

Figure 14: Damaged Vertical Support Assembly ........................................................................... 23

Figure 16: Heavy rusting of Front Carrier Plate ............................................................................. 29

Figure 17: Wear Zone in Front Carrier Plate ................................................................................. 29

Figure 18: Tilting of Coupler Head Assembly ................................................................................ 30

Figure 19: Damaged vertical support assembly ............................................................................ 30

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Figure 24: Contour Maintenance Gauge no. 31000 ...................................................................... 35

Figure 27: Anti-Creep Protection .................................................................................................. 38

Figure 28: Minimum Overlap......................................................................................................... 38

Figure 29: Minimum Overlap Test Step 1...................................................................................... 39

Figure 30: Minimum Overlap Test Step 2...................................................................................... 39

Figure 31: Minimum Overlap Test Step 3...................................................................................... 40

Figure 32: Minimum Overlap Test Step 4...................................................................................... 40

Figure 35: Section View of Coupler Shank.................................................................................... 42

Figure 36: Procedure for Checking Aligning Wing Limit ................................................................ 43

Figure 37: Aligning Wing Limit Gauge No-32600 .......................................................................... 44

Figure 39: Contour Condemning Limit Gauge no. 34100-1 ........................................................... 45

Figure 41: Contour Maintenance Gauge No.-31000 ..................................................................... 46

Figure 42: Installation of Coupler Head in coach........................................................................... 47

Figure 43: Dismantling of Balanced Draft Gear ............................................................................. 50

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Figure 47: Assembled view of Balanced Draft Gear...................................................................... 55

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2 PRINCIPAL DESIGN FEATURES OF ESCORTS MAKE AAR-H TYPE CBCs.

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AAR-H TIGHT LOCK COUPLER HEAD ASSEMBLY (DRAWING NO. 1C101060021)

Figure 1: AAR-H Tight Lock Coupler Head Assembly

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BALANCED DRAFT GEAR (DRAWING NO. 1C101060004)

Figure 2: Balanced Draft Gear

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VERTICAL SUPPORT ASSEMBLY (DRAWING NO. 1C101060031)

Figure 3: Vertical Support Assembly

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MANUAL UNCOUPLING DEVICE ASSEMBLY (DRAWING NO. 1C101060026)

Figure 4: Rotary Bar with Handle

Figure 5: Un-Coupling Bar

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CHECK POINTS AFTER INSTALLATION ON COACH

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CHECK FOR COUPLER LOCKING

Figure 7: Check for Coupler Locking

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Figure 8: Tell-tale Recess

Only when tell-tale recess is clear the Couplers should be considered

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Figure 9: Keyway Slot Locking