No.

48-BD-08
(Supersedes 48-BD-02)

INDIAN RAILWAYS
SCHEDULE OF TECHNICAL RQUIREMENT
No. 48-BD-08

FOR

HIGH TENSILE CENTRE BUFFER COUPLER

FOR
B.G. WAGONS

Issued by
RESEARCH DESIGNS & STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
LUCKNOW-226011

May , 2008 Price Rs. 5200/-

1
 INDEX
SL DESCRIPTION PAGE
No. NO.
1. LIST OF DRAWINGS. 3
2. SUMMARY OF CHANGES MADE IN 48-BD-08 (From 48-BD-02 with 3
Amendment No. 1 & 2)
3. SCHEDULE OF TECHNICAL REQUIREMENTS FOR HIGH TENSILE 4
CENTRE BUFFER COUPLER FOR BG WAGONS
0 FOREWORD 4
1 SCOPE 4
2 GENERAL REQUIREMENTS 5
3 PARTICULAR REQUIREMENTS 6
4 DRAFT GEARS 8
5 DRAWINGS 8
4. REQUIREMENTS FOR ACCEPTANCE OF COUPLER AND ITS 9
COMPONENTS FOR BG WAGONS ON INDIAN RAILWAYS
1 SCOPE 9
2 GENERAL REQUIREMENT 9
3 MATERIAL AND MANUFACTURE OF STEEL CASTINGS 10
4 COMPONENTS PERFORMANCE AND TEST REQUIREMENTS 17
5 REQUIREMENT FOR KNUCKLE PIN AND YOKE PIN 24
6 REQUIREMENT FOR OTHER COMPONENTS MANUFACTURED 25
BY STEEL CASTINGS
7 GUARANTEE 25
8 PURCHASE INSPECTION 26
9 RECORD OF INTERNAL ACCEPTANCE TESTS 28
5. ANNEXURE – 1 MANUFACTURERS CODE 29
6. APPENDIX-A --GAUGES TO ENSURE INTERCHANGEABILITY OF 30
COUPLER AND ITS PARTS
7. APPENDIX-B -- RDSO PROCEDURE FOR INSPECTION OF FOUNDRIES 31-33
8. APPENDIX-C -- STANDARD REFERENCE PHOTOGRAPHS FOR CASTING 34-40
SOLIDITY
9. FIGURES 1 TO 10
FIG-1 LOCATION OF BRINELL HARDNESS READINGS 41
FIG-2 HEAT TREATMENT REQUIREMENTS AFTER WELD REPAIR 42
FIG-3 & LOCATION OF PERMANENT SET MEASUREMENTS FOR 43
4 COUPLER BODIES, KNUCKLES & YOKE
FIG-5 INTERNAL SOLIDITY SECTION CUT LOCATIONS 44
FIG-6 & AREAS TO BE EVALUATED FOR DISCONTINUITY LEVELS 45-46
7
FIG-8 COUPLER INSPECTION OPERATING ROD 47
FIG-9 INSPECTION ZONES FOR CRITICAL AREAS 48
FIG-10 INSPECTION ZONES 49
10. ANNEXURE – 2 LOCATION FOR THE TEST SPECIMEN OF 50-52
COMPONENTS.

2
 LIST OF DRAWINGS
S. Drawing No. Alt. No. as on Description
No. February, 2008
1. WD-81010-S-03 Alt. No. 8 Arrangement of High Tensile Centre Buffer Coupler
(Non-Transition)
2. SK-62724 Alt. No. 20 Details for Transition and Non-transition CBC.
3. WD-87004-S-1 Alt. No. 8 Markings on Knuckle.
4. WD-87056-S-1 Alt. No. 4 Striker Casting wear plate
5. WA/BD-4460 Alt. No. 5 Striker casting
6. WA/BD-4462 Alt. No. 3 Yoke Pin Support.

Summary of changes made in 48-BD-08 (from 48-BD-02 with Amendment No.1 & 2)
Page 2 S. No. 6 ‘And its’ added before parts
S. No. 10 ‘Annexure – 2 Location for the test specimen for components’
added
Page 4 Clause 1.1 ‘for BG Wagons’ added after components
Clause 1.2 ‘for BG Wagons’ added after coupler
Page 7 Clause 3.3.2 ‘from Page 9 to 28’ deleted after Railways
Clause 3.3.2 (e) ‘Hole’ changed to ‘lever hook’
Page 8 Clause 3.7 (ii) ‘and’ added after components
Page 9 Clause 2.1 ‘All’ deleted before manufacturer’s
Clause 2.2.1 ‘Fifty’ in words added before (50)
Clause 2.5 (a) ‘and’ added after time
Page 10 Clause 2.5 (b) ‘3.0, 4.0,to 5.0 and 6.0’ changed to ‘3.0 to 6.0’
Page 11 Clause 3.1.1 Chemical composition revised as per Amendment No. 2
Clause 3.1.3 Para revised as per Amendment No. 2, with slight modification
Clause 3.2.1 Second Row of Table removed
In third & fourth Row carbon percent revised as per amendment
No. 2
Page 12 Clause 3.2.3 ‘Designation’ changed to ‘standard’
Clause 3.3.1 Chromium, Nickel & Molybdenum added
(2) `and of other intentional alloying elements’ deleted
Clause 3.4.1 ‘Designation’ changed to ‘standard’
Page 14 Clause 3.4.3.3.2 New para added as per Amendment No. 1
Clause 3.4.3.4 Extent of Radiographic inspection fixed at 5% for all inspection.
Page 23 Clause 4.9.3 ‘Repaired or’ deleted
Page 24 Clause 4.9.13 ‘during QAP’ deleted
Page 25 Clause 6.2 ‘Guarantee’ deleted
Page 26 Clause 7.0 ‘48 months’ changed to ‘54 months’ and ’36 months’ changed to
‘42 months’
Page 28 Clause 9.0 New Clause added
Page 29 Annexure – I (1) ‘Name in short’ changed to ‘code’ (2) Manufacturer’s code
revised & list updated
Page 30 Appendix A ‘and its‘ added before parts
Appendix A Drg.No.’WD-00041-S-01’ added
Page 44 Fig 5 Dimension ‘143‘ change to ‘67’ as per AAR specification, in
coupler shank

3
 SCHEDULE OF TECHNICAL REQUIREMENTS FOR
HIGH TENSILE CENTRE BUFFER COUPLER FOR BG WAGONS

0. FOREWORD

0.1 This specification is intended to cover the technical provisions relating to

Material, construction and tests and does not include all the necessary
provisions of the contract.

0.2 This Specification is issued under the fixed number 48-BD-08. The number
after BD indicates year of revision.

0.3 This revision supersedes all previous revisions.

0.4 This specification draws reference to the following specifications: -

(i) AAR M 118, M 201, M 205 & M 211.

(ii) AAR S 172 Section B Part- II & AAR S 137 Section B.

(iii) IS: 1875, 2004, 3885, 5517, 817 & 1181.

(iv) ASTM A 255, A 370, B 208, E 446 and E 604.

(v) IRS R-6.

0.5 Whenever there is a conflict among the stipulations in the present specification,
drawings or any of the relevant specifications, the most stringent requirement
will apply.

1 SCOPE

1.1 This specification covers the particular requirements for the supply of High
Tensile Centre Buffer Coupler and its components for B.G. Wagons.

1.2 The Tenderer shall submit his offer for High Tensile Centre Buffer Coupler
for B.G. Wagons consisting of the following Items:

S No. Name of Part Nos / Coupler

1. Coupler Body with Shank wear Plate 1
2. Knuckle 1
3. Lock 1
4. Knuckle thrower 1
5. Top Lock lift hole cap 1
6. Knuckle Pin with Washer 1
7. Rotary bottom operated articulated lock lift 1
assembly
8. Coupler Yoke 1

4
 S No. Name of Part Nos / Coupler
9. Yoke Pin 1
10. Yoke pin support with wear plate 1
11. Striker Casting with wear plate 1

2 GENERAL REQUIREMENTS

2.1 The manufacturer shall set aside one set of gauges for exclusive use of
Inspecting authorities. The accuracy of gauges shall be checked by Inspecting
authorities before the commencement of manufacture. Recalibration shall
subsequently be made at the frequency stipulated in internal Quality
Assurance Programme. Gauge drawings in original, shall also be made
available for checking the tolerances of these gauges.

2.2 All components of coupler shall be interchangeable. Manufacture and

inspection shall be carried out as per “REQUIREMENTS FOR ACCEPTANCE
OF COUPLER AND ITS COMPONENTS FOR BG WAGONS ON INDIAN
RAILWAYS” and as per other clauses of this specification.

2.3 Any deviation from inspection in respect of test details shall be worked to with
prior concurrence of the purchaser.

2.4 The manufacturer shall provide labour, appliances and other details necessary
for the inspection of the coupler and its components in accordance with this
specification at his own cost.

2.5 In case the offer does not correspond to this specification in any respect, the
tenderer shall submit a DEVIATION STATEMENT. This statement shall give
the deviations clause wise with technical reasons for the same. Change in
drawings, if any, shall be explained and accompanied by three copies of
revised drawings. In case the tenderer does not require any deviation from this
specification, a NIL DEVIATION certificate shall be submitted.

2.6 MARKING

2.6.1 All coupler components should have clear and legible manufacturers' name in
short code and batch No. etc., which shall remain legible through out the entire
service period. The letter size and height of the raised letter shall be as
specified in relevant RDSO drawing.

The coupler components found having illegible marking at the time of fitment
in Railway Workshops, Maintenance depot or on Wagon Builders premises
shall be treated as rejected and shall be replaced by the manufacturers free of
cost. The cost of transportation shall be borne by the manufacturer.

2.6.2 The manufacturer code shall be provided as per table shown at Annexure-I.

5
2.7 GAUGES:

The manufacturer shall have the capacity to manufacture and supply the
gauges required for inspection and maintenance of Coupler and its
components. The manufacturer should supply these gauges to Zonal Railways
against the requirement of zonal railways.

2.8 Manufacturer shall supply Installation and Maintenance Manuals for proper
installation and maintenance of coupler to RDSO. The number of manuals to
be supplied shall be 25 per contract and shall be free of cost. The manual shall
contain following information:

i) Principal of operation and important design features.

ii) Illustration explaining the working and maintenance practices.

iii) Details of attention required during overhauling.

iv) Special tools, capacity and specification.

v) List of spares along with the specification and part no. etc.

2.9 FIELD PERFORMANCE:

The supplier shall regularly collect data and samples of previous supply from
field to assess the actual life obtained, nature of defects occurring in the
service and should take necessary corrective action to improve quality. Half-
early report should be submitted to RDSO on data, samples collected and
action taken.

2.10 TRAINING OF RAILWAY STAFF:

The manufacturer shall also provide training to sufficient number of Railway

Maintenance Supervisors / staff in consultation with purchaser, free of cost at
his own premises or in Railway Workshops.

3 PARTICULAR REQUIREMENTS

3.1 GENERAL ARRANGEMENT

3.1.1 General arrangement of the coupler shall be to RDSO Drg. No. WD-81010-S-
03, latest alteration.

3.2 MATERIAL

3.2.1 The material of High Tensile Centre Buffer Coupler components shall be as
indicated in RDSO Drg. No. SK-62724 latest alteration and this specification.

6
3.3 COUPLER

3.3.1 Coupler body and shank wear plate shall be to Drg. No. SK-62724 (Item 1 &
Item 10 respectively), latest alteration. Shank wear plate shall be welded to
the coupler shank as shown in the drawing.

3.3.2 Coupler components shall be in accordance with ‘REQUIREMENTS FOR

ACCEPTANCE OF COUPLER AND ITS COMPONENTS FOR BG WAGONS ON
INDIAN RAILWAYS’ of this STR and shall meet the stipulations given below:

a) Knuckle shall be to Drg. No. SK-62724 (Item 2), latest alteration.

b) Lock shall be to Drg. No. SK-62724 (Item 8), latest alteration.

c) Knuckle thrower shall be to Drg. No. SK-62724 (Item 9), latest

alteration.

d) Knuckle pivot pin with securing arrangement shall be to Drg. No. SK-
62724 (Item 4), latest alteration.

e) Articulated Lock lift assembly consisting of Toggle, Universal Lock lift

lever Connector and Lock lift lever hook shall be to Drg No. SK-62724
(Item 5, 6 & 7 respectively), latest alteration.

f) Top lift hole Cap shall be to Drg No. Sk-62724 (Item 11), latest
alteration.

3.4 COUPLER, YOKE, YOKE PIN AND YOKE PIN SUPPORT

3.4.1 Coupler Yoke shall be to Drg. No. SK-62724 (Item 3) latest alteration.

3.4.2 Yoke pin shall be to Drg. No. SK-62724 (Item 12), latest alteration.

3.4.3 Yoke pin support shall be to Drg. No. WA/BD-4462 latest alteration. Yoke pin
support shall be supplied complete with wear plate welded as shown in
drawing.

3.5 STRIKER CASTING

3.5.1 Striker casting and Striker Casting Wear plate shall be to Drg. No. WA/BD-
4460 and WD-87056-S-01 respectively, latest alteration. Striker casting shall
be supplied complete with wear plate bolted and tack welded as shown in
drawing.

3.6 MAINTENACE SPARES

3.6.1 Tenderer shall make recommendations suggesting scale of spares to be

provided for holding each 100 couplers for a period of six years. ‘Price
proposal for these spares shall also be submitted with the offer separately.

7
3.6.2 The Coupler Manufacturer shall supply all the spare parts required for
maintenance of couplers supplied by them for use on Indian Railways against
specific requirements of railways. In case of failure, their registration is liable
to be cancelled.

3.7 The supplier shall supply following items free of cost to Railways:

(i) Two nos. of cut models per contract.

(ii) 25 sets of colored wall charts per contract explaining working of center
buffer coupler, components and details of maintenance requirements.

4 DRAFT GEARS

4.1 The coupler shall be suitable for fitment on freight stock along with Draft gear
and its follower to Indian Railway’s Schedule of Technical Requirement
No. 49-BD-02 latest revision.

5 DRAWINGS

Drawing referred to in this schedule of requirement may be collected

separately from RDSO, Lucknow on payment.

*******************

8
 REQUIREMENTS FOR ACCEPTANCE OF COUPLER AND ITS COMPONENTS
FOR BG WAGONS OF INDIAN RAILWAYS

1 SCOPE

1.1 This specification covers purchase and acceptance requirements for coupler,
its components and coupler Yoke used on Indian Railways. Material
requirements for coupler body, knuckle, coupler lock and coupler yoke must
meet various requirements of AAR specifications M-201 and M-205, if not
stated in this specification.

2 GENERAL REQUIREMENTS

2.1 Manufacturer’s foundries, material and boundary dimensions of the coupler

and its components must be approved by RDSO. The basis for such approval
shall be satisfactory compliance with the provision of AAR specifications M-
201, M-205, M-211 and this specification.

2.2 All manufacturers seeking registration for supply of couplers, must submit an
application to RDSO on proforma to be procured for this purpose. The
application must include, interalia, proof that the foundry satisfies the
requirements for category “A” foundries specified and updated by the Bureau
of Indian Standards / RDSO from time to time. Registration will be subjected
to the foundry being able to produce prototype couplers / components referred
to here in para 2.2.1.

2.2.1 Five (5) numbers of coupler and components shall be selected and tested as
per the requirement of this specification including tests to be carried out
during manufacturing process by Inspecting Authorities from a lot of not less
than fifty (50) couplers.

2.3 Manufacturers will not be permitted to sublet any steel castings. Re-
registration will be required for any change in manufacturing process, place
and material of coupler and its components.

2.4 Application shall be submitted in three copies in accordance with the

prescribed proforma and be accompanied by three copies of the drawings,
full information with respect to grade of material with well documented internal
Quality Assurance Programme and the name of foundry or foundries that
will produce the items.

2.5 The internal QUALITY ASSURANCE PROGRAMME (QAP) must also cover
the following.

(a) Gauging scheme to ensure dimensional accuracy of the components.

System to ensure that gauges are recalibrated from time to time and
are accurate.

(b) Stagewise manufacturing quality checks/test of coupler

components and their frequency.

9
 These tests and checks must be in conformity to all the requirements
covered in para 3.0 to 6.0.
If frequency of tests/checks is not specified, the manufacturer shall
decide it and clearly indicate in QAP.

(c) System to ensure use of correct raw material.

(d) Stagewise details of heat treatment and control checks to ensure

proper heat treatment. The heat treatment should meet the
requirement of para 3.6.

(e) Proper system to ensure quality of component manufactured other

than casting. Proper tests/inspection procedures in conformity with the
requirement of this specification for such components shall be
developed and maintained. If these components are being purchased
from sub-let vendors, the coupler manufacturer shall have facilities
and system for their testing and inspection.

(f) System for disposal of defective components identified during various

stages of manufacture and implementation of QAP, so that such
components are not mixed up with lot being offered for inspection.

(g) List of testing and inspection facilities with their calibration status.

2.5.1 The manufacturer shall keep the records of Internal Quality Programme
properly for future references/investigations. The manufacturer shall present
these records as and when asked by the Purchaser / Inspecting official or
RDSO Lucknow.

2.5.2 It should be possible from the QAP records to identify the manufacturing
details/tests of components with Serial Number marked on the components
from QAP records. There must be relation between Serial Number marked on
the components with heat number, batch number, date of manufacture and
various test results.

2.5.3 In addition to above clause of para 2.5 the manufacturer shall submit QAP as
per the guidelines indicated for preparation of QAP in RDSO Document No.
IL:03:2000 with latest revision. The complete QAP shall be got periodically re-
approved from RDSO, as and when it becomes due.

3 MATERIAL AND MANUFACTURE OF STEEL CASTINGS

3.1 Chemical Composition and Tests.

3.1.1 Chemical Composition

The steel analysis shall not exceed the following:

10
 Grade E Grade B
Carbon percent 0.28 - 0.33 0.32 (Max)
Manganese percent 0.8 – 1.10 0.90 (Max.)
Phosphorus, maximum percent 0.03 0.03
Sulphur, maximum percent 0.03 0.03
Silicon percent 0.40 –0.60 0.60 (Max.)
Chromium, percent 0.50 – 0.80 ----
Nickel, percent 0.50 – 0.60 ----
Molybdenum, percent 0.15 – 0.25 ----

3.1.2 GRADE B STEEL

For each reduction of 0.01 percent of carbon below the maximum specified,
an increase of 0.04 percent manganese above the maximum specified will
be permitted to a maximum of 1.2 percent.

The content of elements other than those specified above shall be selected
by manufacturer to obtain the physical properties specified in this
specification.

3.1.3 The chemical composition as given in clause 3.1.1 shall be specified by the
manufacturer in the QAP and checked at the time of adding the alloying
elements at melting stage as well as at the time of chemical analysis of
specimen / sample for verification of chemical properties. Records for each
heat lot shall be maintained for 100% traceability. The manufacturer shall
ensure that all physical properties, as specified in this specification, are
achieved by using proper heat treatment process.

3.2 HARDENABILITY

3.2.1 Composition of Grade E steel, except for coupler locks, shall produce in the
standard jominy test the minimum hardness at 11 mm from the quench end
for the carbon composition as follows, based on the initial composition :

Carbon percent Minimum Hardness, RC

0.28 to 0.30 33
0.31 to 0.33 35

3.2.2 FREQUENCY OF TESTING

The manufacturer shall carry out jominy tests on the following frequency:

a) On every heat till ten (10) consecutive heats gives satisfactory test
results.

b) On satisfactory Jominy test results for ten (10) consecutive heats at

least one test every month.

c) On unsatisfactory Jominy test results during monthly tests, tests on

11
 every heat till ten (10) consecutive satisfactory tests.

3.2.3 HARDENABILITY CALCULATIONS

The ideal critical Diameter (D1) shall be calculated for each heat of quenched
and tempered steel in accordance with ASTM Standard A 255 latest revision,
Appendix III. The calculated dia. shall be indicated in test records and QAP.

3.3 CHEMICAL ANALYSIS

3.3.1 LADLE ANALYSIS

The manufacturer shall carry out test of samples taken during the initial 25
percent of the castings poured from each ladle to determine the percentage
of carbon, manganese, phosphorous, sulphur, silicon chromium, nickel &
molybdenum. The results of analysis shall be reported to Inspecting Authority
and shall conform to the requirements of para 3.1.1 If drillings are used, they
must be taken at least 6.5 mm beneath the surface of the test ingot.

3.3.2 END OF HEAT ANALYSIS

A sample found with last acceptable castings of each heat must be used by
manufacturer to determine the percentage of manganese. The results of this
analysis must be reported to Inspecting Authority and shall conform to the
requirements of para 3.1.1. If drillings are used, they must be taken at least
6.5 mm beneath the surface of the test ingot.

3.3.3 TEST LUGS

For all castings at least two and not more than four test lugs shall be cast.
The location of test lugs shall be such that when removed, they shall indicate
steel castings have been subjected to heat treatment. The standard test lug
shall be 25mm in height by 25 mm in width and 13 mm or 16 mm in thickness
where it joins with castings.

If in the opinion of the inspector, a casting, if not heat treated, will be heat-
treated.

3.4 MECHANICAL PROPERTIES AND TESTS

Each melt shall be tested for mechanical properties after heat treatment. The
coupons from each melt shall be heat treated with castings of the same grade,
in the same manner as the casting they represent.

3.4.1 TENSILE TEST SPECIMEN COUPONS

The coupons shall either be cast attached to the castings or the gating
system or produced from keel blocks and prepared in accordance with
ASTM Standard A 370, latest revision.

12
3.4.1.1 TENSION TEST

3.4.1.1.1 Test shall be conducted in accordance with standard Methods and

Definition for mechanical testing of steel products, ASTM standard A 370,
latest revision, using 13mm round, 51mm gauge length specimens as
illustrated in that specification. Specimens are to be removed from
coupons produce as per para 3.4.1 and shall meet the following
requirements:

Grade E Grade B
Tensile strength N/sq. mm. (Minimum) 827.473 482.652
Yield strength N/sq. mm. (Minimum) 689.643 261.927
Elongation in 51mm (minimum %) 14 24
Reduction in area % 30 36

3.4.1.1.2 One specimen per heat for each grade of steel shall be tested. If test
specimen shows a defect during machining or exhibits flaws before or
after testing, it should be discarded and another specimen substituted.

3.4.1.1.3 Specimens from castings shall be at least 80% of' tensile and yield
strengths required by clause 3.4.1.1.1".

3.4.2 IMPACT TEST

3.4.2.1 The manufacturer shall carry out test to determine impact properties by
Standard Charpy-V-Notch type “A” specimen prepared as shown in
ASTM Standard A 370. Specimen to be removed from coupons prepared
as per para 3.4.1. A test consists of determining the average energy
absorbed from three-impact specimen from the same heat. The results
should meet the following minimum requirements at the following
temperatures.

Cast steel Temp. Deg.C Energy Kg.m.

Grade E - 40 2.77
Grade B -7 2.07

3.4.2.2 The manufacture shall test specimen and record results including
chemistry of that heat, excluding flawed specimen. Frequency of such
test shall be one heat per week per grade of steel during pouring of the
last 25 percent of the heat. Specimen to be removed from coupons as
per para 3.4.1 and test shall be conducted in accordance with standard
Methods and Definitions of ASTM Standard A 370, latest revision.

3.4.3 HARDNESS

3.4.3.1 The cast steel components must meet the following Brinell hardness
range:

13
 Grade BHN Range
Grade E steel castings (except knuckle) 241-311
Grade E, Knuckles 261-291
Grade B, castings 137-208

3.4.3.2 Testing shall be done on a surface that has been ground to remove
decarburization in accordance with ASTM A 370. The hardness shall be
checked on the location as shown in Fig-1. Hardness of the components
not shown in figure shall be checked at suitable location.

3.4.3.3 ACCEPTANCE LEVEL OF CASTING DEFECTS

3.4.3.3.1 2% of the castings shall be subjected to destruction to examine the

presence of casting defects. Defects such as blow holes, slag inclusions,
shrinkage, etc. are not acceptable. Porosity to a level of 2% of the cross
section may be considered acceptable.

3.4.3.3.2 Knuckle, Coupler Body and Yoke shall be subjected to destructive test.
The location for the test shall be as per Annexure-II (Sheet-1 , 2 , & 3).

3.4.3.4 ACCEPTANCE STANDARD FOR RADIOGRAPHIC EXAMINATION

Radiographic examination shall be conducted on Knuckle, Coupler Body &

Yoke to the extent of 5% of the casting produced and level of acceptance
shall be as per ASTM E 446 Level-II. The location for Radiographic test
shall be as per Annexure-II (Sheet-1 , 2 , & 3).

3.5 FRACTURE TOUGHNESS

Fracture Toughness test shall be conducted on specimens from castings in

accordance with either ASTM E604 or E208 except that Nil –Ductility
Transition Temperature (NDTT) shall be -57º C or lower for grade E.

3.6 HEAT TREATMENT

3.6.1 After pouring castings shall be allowed to cool to a temperature below

500° C prior to heat treatment, at a rate that will not be injurious to the
castings.

3.6.2 Grade E steel castings shall be furnished quenched and tempered. Grade B
steel castings shall be furnished normalized or normalized and tempered.

3.6.3 Normalized steel castings shall be processed in the following order:

3.6.3.1 Heat to a proper uniform temperature above the transformation range and
hold for the proper time to achieve complete austenization and to refine
the grain structure.

3.6.3.2 Withdraw from the furnace & cool in still air until temperature is below

14
 350° C

3.6.4 Normalized and tempered steel castings shall be processed in the

following order:

3.6.4.1 Heat to the proper uniform temperature above the transformation range
and hold for the proper time to achieve complete austenization and to
refine the grain structure.

3.6.4.2 Withdraw from the furnace and cool in still air until casting in their entirety
are at least 50° C below tempering temperature.

3.6.4.3 Temper by reheating to the proper uniform temperature below the

transformation range, but not less than 300° C and hold for the required
time. Remove from the furnace and allow to cool at any desired rate.

3.6.5 QUENCHED AND TEMPERED STEEL CASTINGS SHALL BE

PROCESSED IN THE FOLLOWING ORDER:

3.6.5.1 Heat to the proper uniform temperature above the transformation range
and hold for the proper time to achieve complete austenization and to
refine the grain structure.

3.6.5.2 Withdraw from furnace while castings are above the transformation range,
subject to rapid cooling by suitable liquid medium to a temperature
substantially below the transformation range.

3.6.5.3 Temper by reheating to proper uniform temperature below the

transformation range, but not less than 400° C, Hold for the required time,
remove from the furnace and allow to cool at any desired rate. All castings
prone to cracking after quenching shall be tempered as soon as
necessary to prevent cracking, but in no case shall the time between
quenching and tempering exceed eight hours.

3.6.6 All the stages of heat treatment with various temperature ranges of
processes shall be clearly brought out in QAP. Inspecting Authority may
examine it with actual heat treatment process being followed as and when
required.

3.6.7 MICROSTRUCTURE

3.6.7.1 With a view to ensure the homogeneity of the steel and the quality of heat
treatment, it is essential to examine the microstructure of the knuckles at
the time of acceptance inspection.

3.6.7.2 The samples should be taken from the actual castings produced and not
from the separately cast test bars. Microstructure achieved shall be fine
tempered martensite.

15
3.7 WELD REPAIR OF DEFECTS IN CASTING

3.7.1 The entire defect must be removed prior to weld repair. The area to be
welded must have the sides contoured to provide for the application of a
sound weld. Maximum depth of repaired area must allow at least 3.2mm
sound metal remaining between the bottom of the weld groove and the
opposite side of the casting wall in areas where welding cannot be
accomplished from both sides of the casting wall. Where a defect
continues through the casting wall and both sides of the wall are
accessible for welding, the casting shall be welded from both sides using a
double 'V' or a "U" contour weld. Where a defect continues through the
casting and is inaccessible from both sides and unless prohibited by
specific component specification (para 3.8 of this specification), defect
may be weld repaired by using a copper backup plate provided the
surface is smooth and clean.

3.7.2 Welders shall be qualified and use procedures under the welder
qualification procedure contained in IS: 817 and IS: 1181 latest revision, or
equivalent in the position welding is to be performed.

3.7.3 Defects may be repaired by using a metal-electrode arc welding process,

which will result in sound weld deposit having, in the heat-treated
condition, minimum mechanical properties equal to the requirements for
the parent metal. Welding may be performed in either the non-heat treated
or heat treated condition. Post weld heat treatment requirements are
outlined in para 3.8 of this specification.

3.7.4 Grade B or E castings shall not be welded while the temperature of the
casting is below 4.5° C. Localized pre-heating is acceptable.

3.7.5 FOR WELDING GRADE B STEEL CASTINGS

If shielded metal arc process is used, the electrode shall be a low

hydrogen coated type, AWS/ASTM Class E7015, E7016, E7018, E8015,
E8016, E8018 or equivalent, approved by M & C Directorate of RDSO.

3.7.6 FOR WELDING GRADE E STEEL CASTINGS.

The welding materials used for the repair of defects in Grade E steel
castings shall be AWS/ASTM Class electrode E12015, E12016, E12018,
E13015, E13016, E13018 or equivalent approved by M & C Directorate of
RDSO.

3.8 WELDING ON COUPLERS, KNUCKLES AND YOKES:

3.8.1 Any welding in shaded areas as defined in Fig-2 will be considered

structural repair and must be in accordance with Paragraph 3.8.2. Welds
outside the critical area must be in accordance with the requirements of
para 3.7 of this specification.

16
3.8.2 The defect area to be welded must be prepared by contouring sides for a
sound weld with a minimum 6mm weld relief at the root.

3.8.3 Maximum depth of repaired area must not exceed 25 mm with a minimum
of 3.2 mm sound metal between edge of repair weld and the nearest
casting wall.

3.8.4 After weld repair, a casting shall be heat treated as required by Fig-2 using
the applicable process of para 3.6 of this specification.

4 COMPONENTS PERFORMANCE AND TEST REQUIREMENTS

4.1 The purpose of the below listed test requirements is to qualify and monitor
the manufacturing process. Results obtained form 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 RDSO Lucknow shall be notified and given a schedule for
corrective action to be completed. Retests are permitted.

4.2 CASTING INTEGRITY

4.2.1 Manufacturer's Internal Process Specification and Quality Assurance

Programme control casting integrity. As a periodic check, a laboratory static
test will be conducted on one (1) specimen of every 5,000 couplers,
knuckles and yokes being produced or once every three (3) or six months
according to the following tabulation, whichever occurs first. If production is
less than 1,000 in the frequency period, no test is required for that period.
However, in any case, at least one (1) test is required per year. The
specimen shall represent current production practices.

Component Frequency Period

Coupler Body 6 months
Knuckle 3 months
Yoke 6 months
Lock 3 months

4.2.1.1 Following ten (10) successful consecutive laboratory static tests, the
manufacturer may reduce frequency of testing to one (1) laboratory static
test per year. If a test fails for other than a flawed specimen, the
manufacturer will be required to re-estabish the base ten (10) successful
tests before going to reduced frequency of testing.

4.2.2 PROOF TESTS

4.2.2.1 Coupler bodies and knuckles must meet permanent set and ultimate
strength requirements shown in paragraph 4.2.2.1.3. The dimensions
shown in Fig-3 shall be used for determining permanent set and result
shall be recorded. Special test knuckles for testing coupler bodies shall

17
 have a load capacity in excess of 408 tonnes.

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
the " 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.

4.2.2.1.3 STATIC TENSION TEST REQUIREMENTS:

Maximum Permanent Set - mm

Grade E Steel
At 181.5 t At 317.5 t Minimum Ultimate
* Knuckle 0.76 - 295 t.
Coupler body - 0.76 408 t.

*Based on testing with dummy knuckle fixture.

4.2.2.2 PROOF TEST OF YOKE

4.2.2.2.1 METHOD OF TESTING

The method of testing coupler yokes and measuring permanent set is

shown in Fig-4. The support and loading of the yokes for these tests shall
be equivalent to service application.

In making deflection measurements, the measuring instruments shall be

set at zero, after a load of 9 tonnes has been applied and released to
datum load of 2.27 tonnes.

The minimum ultimate load shall be considered the load at which

distortion shall not exceed 6 mm over all, measured vertically or laterally.

4.2.2.2.2 TEST REQUIREMENT

The maximum permanent set, measured from the point of load

application to the point of support, and the minimum ultimate load, shall
be as shown below:

Maximum permanent set - - - mm

Material of Yoke At 340.20 t. Minimum Ultimate

Grade E steel 0.76 408 t.

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 (6) months thereafter by

18
 sectioning three (3) specimens listed in Paragraph 4.2.1. Each specimen
shall be from a different heat. However, if the production is less than 1,000
during this frequency period, no test is required. In any case, one (1) test
is required per year. After two (2) years of successful sectioning results,
the manufacturer may reduce the frequency of sectioning to one (1)
casting each year. 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 two (2) years of successful tests
before going to the reduced frequency of testing.

4.2.3.2 Castings are to be sectioned in accordance with Fig-5.

4.2.3.3 Areas to be rated for discontinuity severity level are illustrated in Fig-6 and
Fig-7.

4.2.3.4 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 C, of this specification 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:

Sectional area Maximum severity Levels

Component Type A B C D E F
Coupler Head 3 5 4 4 4 2
Knuckle 4 4 2 - - -
Coupler Shank 3 4 4 4 - -
Yoke 2 4 4 4 - -

4.3 PERIODIC PRODUCTION TESTS

4.3.1 At least every two (2) months, one (1) coupler and one (1) 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.
Coupler and yoke in each grade of steel produced, shall be tested at least
once per year. After two (2) years of successful testing, the manufacturer
may reduce the frequency of testing to one (1) coupler and one (1) 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 - Para 3.5

Impact Properties - Para 3.4.2
Tensile Properties - Para 3.4.1.1

19
 Chemistry - Para 3.3
Hardness - Para 3.4.3

4.4 COUPLER OPERATION

4.4.1 Assembled couplers must be free of any foreign material that will
prevent proper operations described in Paragraph 4.4.1.1 through
Paragraph 4.4.1.5. A coupler inspection operating rod is illustrated in Fig-
8.

4.4.1.1 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.

4.4.1.2 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.

4.4.1.3 The coupler lock must automatically drop to the locked position when the
knuckle is closed as described in Paragraph 4.4.1.2. The coupler knuckle
is locked shut when the lock drops to seat on or within 6mm of the knuckle
tail lock shelf.

4.4.1.4 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 function of knuckle closure and lock drop as described in
Paragraph 4.4.1.2 and 4.4.1.3.

4.4.1.5 Coupler must provide anti-creep protection to prevent accidental unlocking

as specified in Section B, Part II, of AAR Standard S-172, Paragraph
4.2.8.

4.4.2 Couplers furnished complete must be fitted with knuckles of the same
grade of steel as the coupler body. Couplers must be fitted with grade E
locks. The assembled coupler must operate as described in Section 4.4.

4.5 CASTING FINISH

4.5.1 Riser pads and gate stubs shall not project more than 6mm above the
surrounding surface at any location. Where interference would exist in the
operation or application or where serviceability would be affected, the riser
pads and gate stubs shall be contoured to surrounding areas.

4.5.2 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. Couplers must not be sand or

20
 shot blasted when completely assembled.

4.5.3 The castings shall not be painted or covered with any substance that will
hide defects. However, manufacturer's and/or purchaser's paint
identification marks are acceptable.

4.6 LUBRICATION

4.6.1 Only dry lubricant shall be applied to the coupler head or the coupler head
fittings. This lubricant may be applied using water, alcohol, or other non-
petroleum based carrier.

4.7 MARKINGS

4.7.1 All coupler / components shall have legible markings, as specified in

RDSO Drawing No.SK - 62724 (latest alteration). Knuckle shall have the
markings "for manufacturer’s name, serial number, month & year of
manufacture etc. as shown in RDSO Drg. No.WD - 87004-S-l (latest
alteration)

4.7.2 As already mentioned in clause 2.6 of Page 5, the manufacturer shall

ensure that marking details are legible and are of good quality which shall
remain legible through out the entire service life of coupler and its
components. The marking shall be done at the casting stage itself so that
the marking shall remain legible during entire service life of the
components. The manufacturer will not be permitted to provide
manufacturer's code and marking by electric arc welding in case these are
not visible at casting stage.

4.7.3 Grade E steel castings shall be identified by raised letter HTEA.

4.8 PAINTING

4.8.1 Only exposed surfaces of Coupler and Yoke shall be painted with Black
quick drying paint in accordance with IRS R 6. Paint must not be applied
to the inside of the Coupler or internal fittings. Painting shall be done after
the completion of inspection on Coupler & Yoke of acceptable casting lot.

4.9 GENERAL REQUIREMENT FOR CASTING ACCEPTANCE

This section defines and classifies casting defects and is to be used for
visual inspection and gauging of coupler bodies, knuckles, locks, and
Yokes by the manufacturer before offering for Purchase Inspection.

4.9.1 WALL THICKNESS

Wall thickness tolerances except where controlled by gauges or RDSO's

drawings, are:

21
 6 mm up to, not including 11mm wall, + 3 mm - 0.8 mm
11 mm up to, not including 19mm wall, + 3 mm - 2.4 mm
19 mm up to, not including 32mm wall, + 3 mm - 3 mm
32 mm and over, + 4.8 mm - 4 mm

If grinding makes walls thinner then minus limits above, castings must be
restored by welding to within tolerances specified in paragraph 4.9.1.

4.9.1.1 In local areas dictated by individual manufacturing practices, padding or

additional metal thickness is done for casting solidity. This practice is not
violation of the plus tolerance of the metal section.

4.9.2 SURFACE ACCEPTANCE LEVEL

The minimum acceptable surface conditions for the defects described below
shall govern. Acceptable surfaces shall be defined utilizing Steel Castings
Research and Trade Association (SCRATA) Comparators for the Definition
of Surface Quality of Steel Castings (1981). The listed defect classification
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.

4.9.2.1 Surface conditions evaluated with SCRATA comparators:

Critical Area Fig-9 Non Critical Area Fig-9

A Surface Roughness A3 A3
B Surface Inclusion B2 B4
C Gas Porosity C2 C3
D Laps D1 D4
E Scabs E2 E2
F Chaplets F2 F4
G Thermal Dressing G2 G3
H Mechanical Dressing H3 H4
J Welds J2 J3

Surface conditions B and C are acceptable if the depth of the defect does
not exceed ten (10) percent of the section thickness at critical areas and
twenty- five (25) percent of the section thickness in non-critical areas.

4.9.2.2 Surface conditions not evaluated with SCRATA comparators.

4.9.2.2.1 Offsets greater than ten (10) percent of the casting wall thickness are not
permitted. (Offsets: An offset is an abrupt, unintentional change in the
casting surface.)

4.9.2.2.2 Cracks, hot tears, cold shuts, and weld cracks , which are visually
apparent, are not permitted.

4.9.2.2.3 Zone 1 areas must be prepared in accordance with Fig-10.

22
4.9.3 ILLEGIBLE MARKINGS

Illegible markings are markings that do not conform to Paragraph 4.7 and
Coupler components with illegible markings shall be rejected.

4.9.4 EVIDENCE OF IMPROPER HEAT TREATMENT

Evidence of Improper Heat Treatment as shown from manufacturer's

records shall not be accepted. Heat treatment lugs may be used by
Inspecting Authority to assist in the determination of improper heat
treatment.

4.9.5 IMPROPER WELD REPAIR

Following weld defects shall not be acceptable.

4.9.5.1 Any crack in a repair weld.

4.9.5.2 Weld more than 1.5 mm below surrounding surface in shaded areas of
Fig-9. Minimum wall thickness must be maintained.

4.9.5.3 Slag inclusion or incomplete fusion in shaded areas as well as outside the
shaded areas of Figure- 9.

4.9.5.4 Arc strike in shaded areas of Fig-9.

4.9.5.5 Weld below surrounding surface to depth greater than ten (10) percent of
wall thickness. Minimum wall thickness must be maintained.

4.9.6 IMPROPER APPLICATION OF WEAR PLATES

4.9.6.1 Application of wear plates not performed in accordance with standard S-

137 shall not be acceptable.

4.9.7 IMPROPER CLEANING

4.9.7.1 Cleaning not meeting the conditions of paragraph 4.5.2 shall not be
acceptable.

4.9.8 MECHANICAL AND THERMAL DRESSING

Stress Risers (including chisel marks, handling notches and gouges in

excess of 1.5 mm deep) shall not be acceptable.

4.9.8.1 Any notches caused by flame cut, grinding, or chisel; cut, etc. in shaded
areas of Fig-9 shall not be acceptable.

4.9.8.2 Any notches caused by flame cut, grinding, or chisel cut etc. greater than
ten (10) percent of wall thickness outside the shaded areas of Fig-9 shall

23
 not be acceptable.

4.9.9 IMPROPER LUBRICANTS

Lubrication not conforming to Paragraph 4.6 shall not be acceptable.

4.9.10 RISER AND GATE PROJECTION

Riser pads and gate stubs projecting more than 6mm above surrounding
surface at any location shall not be acceptable. Where interference would
exist in the operation or application or where the serviceability would be
affected, the riser pads and gate stubs shall be contoured to the
surrounding surfaces.

4.9.11 SHARP OR JAGGED EDGES

Sharp or jagged edges that could be injurious to workers shall not be

acceptable.

4.9.12 ACCEPTANCE CRITERIA

Before offering for the inspection, the manufacturer shall examine all steel
castings for the defect listed in Paragraph 4.9 and defective castings shall
be repaired or replaced. Detailed record of inspection shall be maintained.

4.9.13 WEIGHT VARIATION:

Variation in weight of coupler body, yoke and other components, viz.

knuckle, lock, rotary parts, shall not vary more than FIVE percent above or
THREE percent below what has been determined as the average weight,
ascertained from the actual weight of 20 nos. of each of the coupler
components verified for each dimensional accuracy in presence of
Inspecting Authority in the beginning of the contract.

Those coupler components, which do not fall within the prescribed limits of
weight variation, shall be rejected by manufacturer.

5 REQUIREMENT FOR KNUCKLE PIN AND YOKE PIN

5.1 MATERIAL

Steel 42 Cr4Mo2 to IS: 5517-1993or steel having minimum yield strength of

61 kgf / Sq.mm shall be used for the manufacture of knuckle pin. Steel class
5 to IS: 1875 -93 or steel having minimum yield strength of 43 kgf / Sq.mm
shall be used for manufacture of yoke pin.

5.2 HEAT TREATMENT

The pins shall be heat treated if required, to meet the requirements
specified in Para 5.3

24
5.3 MECHANICAL PROPERTIES REQUIREMENTS

5.3.1 KNUCKLE PIN

5.3.1.1 The material shall have minimum yield strength of 61 Kgf / Sq.mm

5.3.1.2 Hardness value shall be within the range of 229 to 428 BHN. Two or more
hardness determinations shall be made at locations approximately midway
between the center and end of the pin on opposite sides from each other.
Hardness shall also be taken at centre of the diameter of, the pin at mid
length. Hardness shall be taken after a sufficient amount of decarburization
has been done from the surface.

5.3.2 YOKE PIN

5.3.2.1 The material shall have minimum yield strength of 43 kgf / Sq.mm.

5.3.2.2 Hardness shall be within the range of 262 to 302 BHN. Two or more
determinations shall be made on cylindrical surface at location
approximately at the centre and 25 mm from each end of the pin.

5.4 GAUGING

All-important dimensions of the pin as shown in RDSO Drawings shall be

within the limits when gauged.

5.5 FINISH

The finished pin shall be straight, have a smooth surface and be free of
scale. It shall not be painted. There should not be any injurious defects on
surface of the pin.

5.6 MARKING

Manufacturer name & year of manufacture shall be stamped on the head of

each knuckle pin and on the end of Yoke pin.

6 REQUIREMENT FOR OTHER COMPONENTS MANUFACTURED BY

STEEL CASTINGS

6.1 The components shall be manufactured and tested as per the requirement of
respective component specification given in component drawings.
Dimensions shall be checked as per their drawings.

6.2 Surface finish requirement shall be as per the standards specified in

drawings / Specifications.

7 GUARANTEE

The coupler supplied shall be accompanied by a guarantee for a period of

25
 54 months from the date of supply or 42 months from the date of fitment,
whichever is earlier.

8 PURCHASE INSPECTION

8.1 The Inspecting Authority 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 which concerns the manufacture of the ordered material. The
inspector shall comply with all applicable safety rules and local regulations.
The manufacturer shall afford the inspector, free of charge, all reasonable
facilities and necessary assistance to satisfy the Inspector that the material is
being furnished In accordance with this specification. Tests and inspection
shall be made prior to dispatch at the place of manufacture to ensure that
provisions of this specification are being met. Any additional tests must be
negotiated prior to placement of order. All inspections shall be conducted
while not interfering with manufacturing operations.

8.1.1 Manufacturer shall set aside one set of gauges for the exclusive use of
inspector. All the drawings in original shall also be made available for
checking the tolerances of these gauges.

8.1.2 The cost of all tests and inspection shall be borne by the manufacturer.

8.2 The purchase inspection shall be carried out as follows:-

8.2.1 The Inspecting Authority shall first check the records of the manufacturer to
ensure that the steel casting offered for inspection have been manufactured
strictly to the requirement of this specification and QAP of the manufacturer in
the manufacturer's premises. It shall also be examined and ensured that
QAP of manufacturer meets the requirement of Para 2.5 of this specification.

8.2.2 It shall be verified from the records that the following as tested/examined
during manufacture meets the requirements of this specification. Serial No.
marked on components shall be used to identify the records.

1. Chemical composition
2. Mechanical properties
3. Fracture toughness
4. Hardness tests
5. Impact test
6. General requirements of casting acceptance
7. Interchangeability of components and dimensional accuracy.
8. All requirements of components other than steel castings
9. Coupler operation.

8.2.3 Inspecting Authority should also do at least one ON PROCESS inspection

for small quantity purchase order and at least two process inspection per
month for large quantity purchase order during manufacture of casting for
the followings:-

26
 1. Chemical composition
2. Mechanical properties
3. Impact test.
4. Hardness test
5. General requirement of casting acceptance.
6. Requirements of components manufactured other than steel castings.

Records of these inspection shall be verified at the time of inspection

against para 8.2.2.

8.2.4 After having been satisfied about offered inspection lot that the
components are strictly manufactured to all the requirement of this
specification, the Inspecting Authority shall carry out the inspection as
per procedure given bellow:-

8.2.4.1 The manufacturer shall submit test results of Coupler/Coupler

component offered for inspection with Heat No., Batch No. marking details
and internal test details to Inspecting Authority. From a lot of 200 Couplers
or a part there-of, following inspection shall be done.

a) Five (5) percent Coupler shall be dismantled and each casting shall be
checked for the following:-

(1) Gauging of all components with calibrated gauges.

(2) General requirement of casting acceptance.
(3) Marking.
(4) Weight variations.

On identification of a single defect on any of the components, the

whole lot shall be rejected. However the manufacturer can re-offer the
lot after carrying out internal inspection for identification of all defective
components. Such defective component can be repaired or replaced
by the manufacturer. In the re-offered lot Ten (10) percent coupler
shall be checked for the above requirement and whole lot shall be
rejected if a single defect is identified in the re-offered lot.

b) Components other than steel castings shall be checked as per

requirement of this specification for the followings.

(a) Dimensional accuracy

(b) Surface finish requirements
(c) Hardness testing

Note:- The frequency for hardness test shall be 1 per 100 Nos.

The dismantled components, if meet the requirement of the paragraph

8.2.4.1 (a) and (b), shall be assembled arbitrarily and following shall be
checked.

27
 (1) Interchangeability of components
(2) Easy assembly of components
(3) Coupler operation

8.2.4.2 The lot shall be rejected on failure of coupler or coupler components on

any of the above requirements. However, the manufacturer can re-offer
the lot, after carrying out internal inspection and replacement or repair of
all defective components.

8.2.4.3 In re-offered lot, double sample will be drawn and all requirements of
paragraph 8.2.4.1 (a) and 8.2.4.1 (b) above shall be checked.

8.2.4.4 One coupler body, knuckle and yoke from the remaining lot shall be
selected at random and tested for proof test requirements and other
casting shall be tested for hardness. On failure of proof test and / or
hardness requirements, the whole lot shall be rejected. However the
manufacturer can re-offer the lot after removing all the defective
components manufactured in that particular heat and batch in which failed
component was cast.

8.2.4.5 In re-offered lot double the sample shall be tested for proof and hardness
test provided re-offered lot meets the requirement of paragraph 8.2.4.1 (a)
and (b).

8.2.4.6 There should not be any failure in re-offered lot.

8.2.4.7 The coupler components with illegible marking shall be identified and
rejected from the lot.

8.2.4.8 On completion of inspection and acceptance by inspection authority, the

coupler shall be painted as per paragraph 4.8 of this specification , before
inspector’s approval stamping & dispatch to consignee.

8.2.4.9 The components used for hardness/proof test etc. from the lot during
purchase inspection shall be replaced free of cost by manufacturer.

9 RECORD OF INTERNAL ACCEPTANCE TESTS

The manufacturer will maintain a list of all internal acceptance tests being
carried out by him at various stages of manufacturing of the product. Proper
record of such internal acceptance tests shall be maintained by him and also
included in the QAP. At the time of inspection of the product, these records
shall be put up to the Inspecting Authority for scrutiny and countersign.

**************

28
 ANNEXURE-I

SPECIFICATION No. 48-BD-08

MANUFACTURERS CODE

S.No. MANUFACTURER’S NAME CODE

1. Burn Standard Co. Ltd., Howrah BS
2. BESCO. Ltd., Kolkata. BESCO
3. Bhilai Engineering Co. Ltd., Bhilai BECO
4. Hindustan Engineering & Industries Ltd., Kolkata HEI
5. Orient Steel Industries Ltd., Kolkata. OSIL
6. Titagarh Industries Ltd., Kolkata TITA
7. Texmaco Ltd., Kolkata. TEX
8. Datre Corporation. Ltd., 24 parganas, Kolkata DATRE
9. Raneka Industries Ltd., Pithampur, Dhar, M.P. RIL
10. Braithwaite & Co. Ltd., Hooghly. BWT
11. Jupiter Alloys & Steel (India) Ltd., Kolkata JASIL
12. Frontier Alloy & Steel Ltd., Kanpur FAS
13. Titagarh Wagon Ltd., Heavy Engineering., Hooghly. TWL
14. Siena Engineering Pvt. Ltd., Pithampur, Dhar, M.P. SN
15. Brand Alloys Ltd., Hooghly. BAL
16. East India Steel Pvt. Ltd., Rourkela. EIS
17. Rine Engineering Pvt. Ltd., Solan H.P. RN
18. Atul Engineering Udyog, Agra. AEU
19. A.D. Electro Steel Co. Pvt. Ltd., Howrah ADE
20. Asansol Steel Castings (P) Ltd., Asansol. ASCPL
21. Jagdamba Liquified Steels Ltd., Roorkee JLS

Note:
1. Manufacturer not named above shall put his code, as approved by RDSO.

2. Marking Scheme for Batch Sl. No., manufacturer code shall be as per relevant
drawing of each component.

29
 APPENDIX- A

GAUGES TO ENSURE INTERCHANGEABILITY OF COUPLER AND ITS PARTS

GAUGE NO. DESCRIPTION

COUPLER WD-84073-S-1-RC 10A Contour Gauge
HEAD WD-84073-S-2-RC Bottom Anticreep-Vertical Location
WD-84073-S-3-RC Bottom Anticreep-Horizontal Location
WD-84073-S-4-RC Top Anticreep-Vertical location
WD-84073-S-5-RC Pivot Lug
WD-84073-S-6-RC Pin Protector
WD-84073-S-7-RC Pulling Lug Gauge - Knuckle side
WD-84073-S-8-RC Pivot Pin
WD-84073-S-9-RC Lock Chamber
WD-84073-S-10-RC Lock Hole
WD-84073-S-11-RC Rotary Lug
WD-84073-S-12-RC Shank End Pin Hole
COUPLER WD-84073-S-41-RC Knuckle Bottom Pulling Lug
PARTS WD-84073-S-42-RC Knuckle Movable Point
WD-84073-S-43-RC Knuckle Hub
WD-84073-S-44-RC Knuckle Tail Height
WD-84073-S-45-RC Knuckle Top Pulling Lug
WD-84073-S-46-RC Knuckle Tail Shelf
WD-84073-S-47-RC Knuckle Pin Hole
WD-84073-S-48-RC Knuckle Length
WD-00041-S-01 Gauges for Knuckle
WD-84073-S-56-RC Lock Contour Guard-Arm Side
WD-84073-S-57-RC Lock Contour - Knuckle Side
WD-84073-S-58-RC Lock Toggle
WD-84073-S-59-RC Lock Parallel and thickness
WD-84073-S-60-RC Lock Slot
WD-84073-S-61-RC Lock Toggle Arm Width-Go & No Go
WD-84073-S-66-RC Knuckle Thrower Contour
WD-84073-S-67-RC Knuckle Thrower Trunion
WD-84073-S-76-RC Lock Lift Assembly
WD-84073-S-77-RC Composite Gauge for Connector
WD-84073-S-78-RC Composite Gauge for Hook
WD-84073-S-79-RC Composite Gauge for Toggle
WD-84073-S-96-RC Knuckle pivot Pin Dia. & Length GO&NO GO
COUPLER WD-84073-S-15-RC Shank Height
SHANK WD-84073-S-17-RC Shank Butt Width
WD-84073-S-18-RC Pin Hole Shank Vail Thickness
WD-84073-S-19-RC Butt Rear Wall Thickness
WD-84073-S-20-RC Pivot Pin Hole
WD-84073-S-21-RC Shank Height with Wear Plate
WD-84073-S-22-RC Shank Length (Non-Transition)
WD-84073-S-23-RC Shank Butt End Contour
WD-84073-S-24-RC Spherical Butt and Pin Hole
WD-84073-S-25-RC Shank Butt Height

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 APPENDIX-B

RDSO PROCEDURE FOR THE INSPECTION OF FOUNDRIES

The RDSO inspection programme is designed to qualify and evaluate each foundry
and manufacturer's capability of producing castings to RDSO specification. This
programme is directed towards 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 followings:

1. Entire plant operation, with emphasis on procedure that affect quality and
uniformity of product.

2. Confirmation of values in certification test reports by following data gathering

and storage throughout the foundry process.

3. Inspection of production and quality control equipment and facilities to determine

ability to meet production requirements.

4. Interviews of supervisors with respect to procedures and methods used in

production.

5. A review of the results of inspection with plant management and advise if any
deficiencies are noted.

The following areas will be evaluated by the RDSO inspector:

A. procedure

1. Moulding Operations

a) Check pattern facilities and procedures for assuring proper pattern size
control.

b) Check sand conditioning and test procedures.

c) Evaluate core-making facilities.

d) Observe core-setting procedures. Proper quality control procedures

must be in effect to assure cores are set properly. Care must be taken
to avoid core shifts during movement and pouring.

2. Melting Practices

a) Chemical Control of raw material.

b) Temperature control on melting material.

c) Proper time and quantity control over additions.

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3. Pouring Practices

a) Time records on pouring.

b) Temperature record during pouring.

c) Proper chemical and physical tests on representative castings.

d) Positive method of determining last casting.

4. Cleaning Room Operations

a) Cleaning equipment should be adequate to provide clean casting for

proper inspection.

b) Observe welding operations to assure quality workmanship. Welding

equipment must be well maintained and evidence of periodic checking
for correct Amperage and Voltage readings. Welding rods and wires
must be properly identified and stored according to RDSO Standards.

c) Workmanship of grinding operations should be evaluated.

d) Facilities for performing welding according to temperature requirements

of RDSO specification 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 minor.

e) Inspection should be made of facilities and procedures for installing

wear plates and other fixtures to castings.

5. Heat Treating Practices

a) Proper temperature control of furnace with adequate recording

capabilities.

b) Furnaces should be adequate to assure uniform temperature

throughout.

c) Proper records must be kept co positively identity castings which

have received heat treatment.

d) Quench tanks must have circulating capability with facility to assure

proper temperature of coolant. Tanks should be kept clean and free of
scrap material which is likely to impair operation.

6. Casting Quality

a) A random casting should be selected from the inspection area and run
through the sample room. Object of this should be to evaluate over all
quality of the finished casting. Pattern quality, core setting, and

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 dimensional control should be evaluated.

b) Availability and accuracy of gauges should be determined and

calibration system for gauges should be evaluated.

c) All physical test apparatus should be inspected for general operating

condition and calibration. All equipments requiring calibration should
have current certification.

B. ORGANISATION POLICY WITH RESPECT TO

1. Proper separation between production responsibility and quality control

responsibility.

2. Procedure for resolving controversy between operations and quality

control on non-conforming items.

3. Disposition of non-conforming items.

4. Knowledge of supervisory personnel with regard to Quality Assurance

requirements.

C. PERSONNEL

1. Procedure for qualifying workmen for particular Jobs. Training provided for
new employees.

2. Procedure for qualifying supervisors and methods of training and determining

performance.

3. Determine if there are proper welding procedures and competent expertise in

plant to perform welding tests and solve welding problems. Determine
how and when welders are qualified.

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 APPENDIX-C

STANDARD REFERENCE PHOTOGRAPHS FOR CASTING SOLIDITY

1.0 SCOPE

1.1 The reference photographs illustrates various types and degrees of

shrinkage occuring in coupler, knuckle and yoke sections. They are full scale
and provide the following:-

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

severity level.

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

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

2.0 PREFACE

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

2.2 Radiographic evaluation of shrinkage is based on the greatest severity found

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

3. EVALUATION

3.1 Severity level is established by determining which photograph of

discontinuities most closely resembles the discontinuities present in the
sectional area being investigated as illustrated in the attached photographs.

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