MSRP-S 10

10/2010
Association of American Railroads

SAFETY AND OPERATIONS
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION S
CASTING DETAILS
Issue of 2010
Effective October 2010
Compiled under the direction of the Committees responsible for the subjects shown herein.
Published by
The Association of American Railroads

425 Third Street, SW., Washington, D.C. 20024
© Copyright Association of American Railroads
Printed in U.S.A.
10/2010
Copyright © 2010 by the Association of American Railroads (AAR)

Safety and Operations
425 Third Street SW.
Washington, D.C. 20024
All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this publica-
tion be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of
rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the pur-
chaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise
made available to multiple users through any electronic distribution media including but not limited to a local area net-
work or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and
its authorized distributor(s) without written permission from the AAR.
AAR Manual of Standards and Recommended Practices
Casting Details
ORDERING INFORMATION
Copies of the various sections of this manual can be obtained as follows:
ORDERS FOR Publications Department

PUBLICATIONS Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: pubs@aar.com
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
TTCI Web page: http://www.aar.com
Online ordering: http://www.aarpublications.com/
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations’ Technical Services are available in
LETTER hardcopy or electronic format (online access via AAR’s Web page at www.aarcirculars.aar.org). Circulars
SUBSCRIPTIONS are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification
of rules and standards revisions, industry early warning and maintenance advisories, and other
information related to mechanical rules and standards. Subscriptions are valid for one year.
For ordering information, contact the following:
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
Email: pubs@aar.com
AAR Web page: http://www.aar.org
TTCI Web page: http://www.aar.com
MSRP-A1 The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and
INDEX recommended practices. It is available online at http://www.aar.com/aar_standards-publications.htm This
easy-to-access document is a convenient way to quickly identify in which manual a specific document
resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been
updated via Circular Letter.
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Technical Committee Coordinator
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: castings@aar.com
Phone: 719-584-7101
Fax: 719-585-1895
10/2010 S–i
Casting Details
THIS PAGE LEFT BLANK INTENTIONALLY
S–ii 10/2010
Casting Details
TO THE USER
Section S, Part I—”Casting Details,” Manual of Standards and Recommended Practices, Associa-
tion of American Railroads (AAR), covers casting and coupling system requirements of the Mechan-
ical Division of the Association of American Railroads.
USER’S GUIDE
Section S contains all of the specifications that relate to the design and casting of side frames, bol-
sters, couplers, and yokes. This manual also contains information on gauging and rebuilding these
components. It consists of the following:
• Preface: A listing of the subjects covered in the individual volumes making up this man-
ual. This preface is part of each section.
• Table of Contents in Alphabetical Sequence: A generalized subject listing that indi-
cates applicable specifications, standards, and recommended practices.
• Specifications, Standards, and Recommended Practices: The body of this volume
deals specifically with castings details.
RELATED SECTIONS
Section S, “Casting Details,” should be used in conjunction with Section S, Part II, “Trucks and
Truck Details,” and Section S, Part III, “Coupler and Yoke Details.” Other sections containing per-
tinent information are as follows:
• Section B—Couplers and Freight Car Draft Components
• Section C—Car Construction
• Section E—Brakes and Brake Equipment
• Section G—Wheels and Axles
• Section H—Journal Bearings and Lubrication
RESPONSIBILITY
The coverage of Section S, “Casting Details,” is the responsibility of the Coupling System and Truck
Castings Committee (CSTCC).
10/2010 S–iii
Casting Details
PREFACE
The Manual of Standards and Recommended Practices of the Safety and Operations Department,
Association of American Railroads, is issued by authority of the Management Committee of the Di-
vision and includes all regularly adopted specifications, standards, and recommended practices of
the Association of American Railroads.
The manual is composed of the following sections:
• Section AS—Administrative Supplement serves as a suplement to all MSRP sections (this
is available as a free download at http://www.aar.com/aar_standards-publications.htm)
• Section A—Table of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/aar_standards-publica-
tions.htm)
• Section B—Couplers and Freight Car Draft Components (100 Series)
• Section C—Car Construction—Fundamentals and Details (200 and 2000 Series)
• Section C, Part II—Design, Fabrication, and Construction of Freight Cars, M-1001
• Section C, Part III—Specifications for Tank Cars, M-1002
• Section D—Trucks and Truck Details (300 and 3000 Series)
• Section E—Brakes and Brake Equipment (300, 400, and 4000 Series)
• Section E, Part II—Electronically Controlled Brake Systems
• Section F—Sensors
• Section G—Wheels and Axles (600 Series)
• Section G, Part II—Wheel and Axle (Shop) Manual (600 Series)
• Section H—Journal Bearings and Lubrication (700 Series)
• Section H, Part II—Roller Bearing (Shop) Manual (700 Series)
• Section H, Part III—Lubrication (Shop) Manual (700 Series)
• Section I—Intermodal Equipment Manual
• Section J—Specification for Quality Assurance, M-1003
• Section K—Railway Electronics (5700 Series)
• Section K, Part II—Railway Electronics (5800 Series)
• Section K, Part III—Railway Electronics (5900 Series)
• Section L—Lettering and Marking of Cars (900 Series)
• Section M—Locomotives and Locomotive Interchange Equipment
• Section N—Multi-Level Manual
• Section S—Casting Details
• Section S, Part II—Truck Details and Casting Codes
• Section S, Part III—Coupler and Yoke Details
Specifications are designated with an “M” prefix (e.g., M-900). Standards are prefixed “S” (e.g.,
S-900). Recommended Practices carry the prefix “RP”( e.g., RP-900).
S–iv 10/2010
10/2010 Casting Details
TABLE OF CONTENTS—ALPHABETICAL
Subject Standard Page

Blooms, Billets, and Slabs—Alloy Steel M-131 S[M-131]29
Bolster Design Loads M-203A S[M-203A]77
Casting Component NonDestructive Testing Requirements M-220 S[M-220]347
Castings, Steel M-201 S[M-201]41
Foundry and Product Approval Requirements for the Manufacture of M-211 S[M-211]141
Couplers, Coupler Yokes, Knuckles, Follower Blocks, and Coupler
Parts
Couplers and Yokes, Secondhand—Classification and Reconditioning M-212 S[M-212]201
Procedure
Coupling Systems M-215 S[M-215]337
Forgings, Alloy Steel M-127 S[M-127]21
Forgings, Carbon Steel M-126 S[M-126]11
Forgings, Carbon Steel Blooms, Billets, and Slabs M-105 S[M-105]1
Knuckles, Types E and F—Fatigue Test M-216 S[M-216]343
Side Frame and Bolsters, AAR Approved—Purchase and Acceptance M-210 S[M-210]87
Side Frames and Bolsters, Used and Reconditioned—Classification and M-214 S[M-214]307
Repair Procedure
Span Bolsters M-975 S[M-975]353
Truck Bolsters, Cast or Structural—Design and Testing M-202 S[M-202]51
Truck Frames, Fabricated Steel M-213 S[M-213]297
Truck Side Frames, Cast Steel—Design and Testing M-203 S[M-203]65
Yoke, Coupler—Test Requirements M-205 S[M-205]83
10/2010 S–v
TABLE OF CONTENTS—NUMERICAL
Standard Subject Page

M-105 Forgings, Carbon Steel Blooms, Billets, and Slabs S[M-105]1
M-126 Forgings, Carbon Steel S[M-126]11
M-127 Forgings, Alloy Steel S[M-127]21
M-131 Blooms, Billets, and Slabs—Alloy Steel S[M-131]29
M-201 Castings, Steel S[M-201]41
M-202 Truck Bolsters, Cast or Structural—Design and Testing S[M-202]51
M-203 Truck Side Frames, Cast Steel—Design and Testing S[M-203]65
M-203A Bolster Design Loads S[M-203A]77
M-205 Yoke, Coupler—Test Requirements S[M-205]83
M-210 Side Frame and Bolsters, AAR Approved—Purchase and Acceptance S[M-210]87
M-211 Foundry and Product Approval Requirements for the Manufacture of S[M-211]141
Couplers, Coupler Yokes, Knuckles, Follower Blocks, and Coupler
Parts
M-212 Couplers and Yokes, Secondhand—Classification and Reconditioning S[M-212]201
Procedure
M-213 Truck Frames, Fabricated Steel S[M-213]297
M-214 Side Frames and Bolsters, Used and Reconditioned—Classification and S[M-214]307
Repair Procedure
M-215 Coupling Systems S[M-215]337
M-216 Knuckles, Types E and F—Fatigue Test S[M-216]343
M-220 Casting Component NonDestructive Testing Requirements S[M-220]347
M-975 Span Bolsters S[M-975]353
S–vi 10/2010
M-105
FORGINGS, CARBON STEEL BLOOMS, BILLETS, AND SLABS
Specification
M-105
Adopted: 1905; Last Revised: 1964

1.0 SCOPE
1.1 This specification covers carbon steel semifinished rolled or forged blooms, billets, and slabs
for reforging.
1.2 Blooms, billets, and slabs are semifinished steel products, hot rolled or forged from ingots to
approximate cross-sectional dimensions. Blooms and billets may be square, round, or rectangular
in section; slabs are rectangular. The following size distinctions are in general use:
• Blooms—cross-sectional area greater than 36 in.2
• Billets—maximum cross-sectional area 36 in.2 ; minimum cross-sectional area, 16 in.2
• Slabs —minimum thickness, 1 1⁄2 in.; width, more than twice the thickness; and generally a
cross-sectional area of not less than 16 in.2
1.3 Supplementary requirements S1 to S17 of an optional nature are provided. They shall apply
only when specified by the purchaser. Details of these supplementary requirements shall be
agreed upon by the manufacturer and the purchaser.
2.0 MANUFACTURE
2.1 Process
The steel shall be made by any of the following processes: open hearth, electric-furnace, or basic
oxygen.
2.2 Discard
A sufficient discard shall be made from each ingot to secure freedom from piping and undue segre-
gation.
2.3 Reduction from Ingot
Unless otherwise specified, the material shall be made from ingots having at least two times the
cross-sectional area of the material.
10/2010 S [M-105] 1
Casting Details
M-105
3.0 CHEMICAL REQUIREMENTS

3.1 Chemical Composition
3.1.1 The steel when ordered to standard analysis in sizes not exceeding 200 in.2 in cross-sec-
tional area shall conform to the requirements as to chemical composition prescribed in Table 3.1
for the respective grades.
Note: Data in Table 3.1 are applicable to standard semifinished steel products in sizes not exceed-
ing a 200 in.2 cross-sectional area and are subject to permissible variations for check analysis (see
Table 3.4).
Table 3.1 Ladle chemical ranges and limits for carbon steels of forging qualitya/
AISI Carbon Manganese Phosphorusb/ Sulphur SAE
Number (%) (%) (maximum %) (maximum %) Number
C1010 0.08 to 0.13 0.30 to 0.60 0.040 0.050 1010
C1015 0.13 to 0.18 0.30 to 0.60 0.040 0.050 1015
C1016 0.13 to 0.18 0.60 to 0.90 0.040 0.050 1016
C1020 0.18 to 0.23 0.30 to 0.60 0.040 0.050 1020
C1022 0.18 to 0.23 0.70 to 1.00 0.040 0.050 1022
C1025 0.22 to 0.28 0.30 to 0.60 0.040 0.050 1025
C1026 0.22 to 0.28 0.60 to 0.90 0.040 0.050 1026
C1029 0.25 to 0.31 0.60 to 0.90 0.040 0.050 —
C1030 0.28 to 0.34 0.60 to 0.90 0.040 0.050 1030
C1035 0.32 to 0.38 0.60 to 0.90 0.040 0.050 1035
C1040 0.37 to 0.44 0.60 to 0.90 0.040 0.050 1040
C1042 0.40 to 0.47 0.60 to 0.90 0.040 0.050 1042
C1045 0.43 to 0.50 0.60 to 0.90 0.040 0.050 1045
C1050 0.48 to 0.55 0.60 to 0.90 0.040 0.050 1050
C1055 0.50 to 0.60 0.60 to 0.90 0.040 0.050 1055
a/ Other AISI or SAE grades may be used under this specification upon agreement between the
manufacturer and the purchaser.
b/ The steel when ordered to other than standard analysis in sizes not exceeding 200 in.2 in
cross-sectional area shall conform to the requirements as to chemical ranges and limits pre-
scribed in Table 3.2.
Note: Silicon, if specified, should conform to standard limitations as follows:

AISI Number Silicon (%)
Up to C1015, excl. 0.10 maximum
C1015 to C1025, incl. 0.10 maximum or
0.10 to 0.20, or
Over C1025 0.15 to 0.30 or
0.10 to 0.20, or
Acid open-hearth steel 0.15 to 0.30
0.35 maximum
S [M-105] 2 10/2010
Casting Details
M-105
3.1.2 The steel when ordered to other than standard analysis in sizes not exceeding 200 in.2 in a
cross-sectional area shall conform to the requirements as to chemical ranges and limits prescribed
inTable 3.2.
Note: Data in Table 3.2 are applicable to other than standard semifinished steel products in sizes
not exceeding 200 in.2 in a cross-sectional area and are subject to permissible variations for check
analysis (see Table 3.4).
Table 3.2 Ladle chemical ranges and limits for basic and acid open-hearth steels
1 2 3 4
Chemical Ranges and Limits (%)
When Maximum of
Range Maximum Limit
Element Specified Element Is...
Carbona/ To 0.10, incl. 0.10
Over 0.10 to 0.25, incl. 0.06
Over 0.25 to 0.40, incl. 0.07
Over 0.40 to 0.55, incl. 0.08
Over 0.55 to 0.80, incl. 0.11
Over 0.80 0.14
Manganese To 0.40, incl. 0.40
Over 0.40 to 0.50, incl. 0.25
Over 0.50 to 1.15, incl. 0.30
Over 1.15 to 1.65 0.35
Phosphorusb/ Basic open-hearth steel:
To 0.05, incl. 0.04
Over 0.05 to 0.08, incl. 0.03
Over 0.08 to 0.13, incl. 0.05
Acid open hearth steel:
To 0.05, incl. 0.05
Over 0.05 to 0.07, incl. 0.04
Over 0.07 to 0.15, incl. 0.06
Sulphurc/ Basic open-hearth steel:
To 0.05, incl. 0.05
Over 0.05 to 0.07, incl. 0.04
Over 0.07 to 0.15, incl. 0.06
Acid open-hearth steel:
To 0.05 incl. 0.05
Silicon When silicon is required, the following ranges and limits are commonly used for
basic open-hearth steels: 0.10 max., 0.07 to 0.15, 0.10 to 0.20, 0.15 to 0.30.
Copper Minimum of 0.20 is standard for copper steel.
a/ The carbon ranges shown in column 3 apply when the specified maximum
limit for manganese does not exceed 1.00%. When the maximum manganese
limit exceeds 1.00%, add 0.01 to the carbon ranges.
b/ Phosphorized steel is not subject to check analysis for phosphorus.
c/ The sulphur ranges shown apply to basic open-hearth steels. Acid
open-hearth steel is not furnished sulphurized. Sulphurized steel is not sub-
ject to check analysis for sulfur.
10/2010 S [M-105] 3
Casting Details
M-105
3.1.3 The steel when ordered in sizes exceeding 200 in.2 in a cross-sectional area shall conform to
the chemical ranges and limits prescribed in Table 3.3 for the composition required.
Note: Data in Table 3.3 are applicable to semifinished steel products in sizes exceeding 200 in.2 in
a cross-sectional area and are subject to permissible variations for check analysis (see Table 3.4).
Table 3.3 Ladle chemical ranges and limits for basic and acid open-hearth steels
When Maximum of Range or Maximum
Element Specified Element Is... Limit
Carbon To 0.25, incl. .0.09
Over 0.25 to 0.40, incl. 0.10
Over 0.40 to 0.55, incl. 0.11
Over 0.55 to 0.80, incl. 0.14
Over 0.80 to 0.95, incl. 0.17
Over 0.95 to 1.35, incl. 0.19
Manganese To 0.50, incl. 0.25
Over 0.50 to 1.15, incl. 0.30
Over 1.15 to 1.65 0.35
Phosphorus Basic open-hearth steel 0.040 max.
Acid open-hearth steel 0.050 max.
Sulphur Basic open-hearth steel 0.050 max.
Acid open-hearth steel 0.050 max.
Silicon To 0.35, incl. 0.15
Note: Acid open-hearth semifinished steel is normally furnished with a silicon range of 0.20% to
0.35%.
Table 3.4 Permissible variations for check analysis of basic and acid open-hearth steels
Variation, Over the Maximum Limit or Under the Minimum Limit (%)
Over Over Over Over
To 100 to 200 to 400 to 800 to
Limit, or Maximum of Specified 100 in.2, 200 in.2, 400 in.2, 800 in.2, 1600 in.2, Over
Element Range (%) incl. incl. incl. incl. incl. 1600 in.2
Carbon Over 0.25, incl. 0.02 0.03 0.03 0.04 0.05 0.06
Over 0.25 to 0.55, incl. 0.03 0.04 0.04 0.05 0.06 0.07
Over 0.55 0.04 0.05 0.05 0.06 0.07 0.08
Manganese To 0.90, incl. 0.03 0.04 0.05 0.06 0.07 0.08
Over 0.90 to 1.65, incl. 0.06 0.06 0.06 0.07 0.08 0.09
Phosphorus Over maximum only, to 0.05, incl. 0.008 0.008 0.01 0.01 0.015 0.015
Sulphur Over maximum only, to 0.05, incl. 0.008 0.01 0.01 0.01 0.015 0.015
Silicon To 0.35, incl. 0.02 0.02 0.03 0.04 0.04 0.05
Copper Under minimum only 0.02 0.03
S [M-105] 4 10/2010
Casting Details
M-105
3.2 Ladle Analysis

An analysis of each heat of steel shall be made by the manufacturer to determine the percentages
of the elements specified in Tables 3.1, 3.2, and 3.3. This analysis shall be made from a test ingot
taken during the pouring of the heat. The chemical composition thus determined shall be reported
to the purchaser or his representative and shall conform to the requirements specified in
paragraph 3.1.
3.3 Check Analysis
3.3.1 Analysis may be made by the purchaser from material representing each heat or lot. The
chemical composition thus determined shall not vary from the ranges or limits specified in
Tables 3.1, 3.2, and 3.3 by more than the amounts specified in Table 3.4, but the several determi-
nations of any element in a heat may not vary both above and below the specified range.
3.3.2 To indicate adequately the composition of a heat or lot, samples shall be selected to repre-
sent the heat as fairly as possible, from a minimum number of pieces as follows:
Lots Number of Pieces
15 ton or less 4
Over 15 ton 6
3.3.3 If the number of pieces from a heat is less than the number of samples specified in
paragraph 3.3.2, one sample shall be taken from each piece.
3.3.4 Samples for analysis shall be taken at a point on a diagonal midway between the cross-sec-
tional center and the corners of the piece by drilling parallel to the axis. In cases where it is not
practical to drill parallel to the axis, the piece shall be drilled on the side, but samples shall not be
taken until they represent the portion midway between the cross-sectional center and the corner.
3.3.5 The approximate diameter of the drill used shall be as follows:
Area of Cross-Section Approximate Drill
to Be Sampled (in.2) Diameter (in.)
16 and under 1⁄2
Over 16 1
4.0 WORKMANSHIP AND FINISH

4.1 Finish and Soundness
4.1.1 The material shall be free from injurious imperfections.
4.1.2 Material shall be furnished in condition to withstand for an indefinite time exposure to all
climatic conditions without developing any external or internal cracks. The method of cooling or of
treatment before shipment shall be optional with the manufacturer, but manufacturer shall be
responsible (in the same manner as for defects disclosed after delivery) for cracks that may develop
before material is subjected to reheating. When any other specific treatment or conditioning of
material is specified by the purchaser, the manufacturer shall be responsible only for carrying out
the specific operations.
4.1.3 When authorized by the purchaser, conditioning, cutting, or parting of material may be
done by scarfing or flame cutting when methods involving preheating and temperature control
necessary to avoid any damage to flame-cut material are employed.
10/2010 S [M-105] 5
Casting Details
M-105
4.2 Surface Conditioning

4.2.1 Material may be conditioned to remove injurious surface defects, provided the depth of con-
ditioning does not exceed 1⁄16 in. for each inch of dimension concerned, up to a maximum depth of
3⁄4 in., and provided that the width of the conditioning is at least four times its greatest depth;
except that in the case of slabs where the width is at least twice the thickness, the depth of condi-
tioning on the wide surfaces may exceed this allowance by 50%, up to a maximum depth of 3⁄4 in.
The maximum depth of conditioning on two parallel sides at opposite locations shall not exceed
one and one-half times the maximum allowed for one side.
4.2.2 In special cases, particularly where it is necessary on large material and is not injurious,
greater depth of conditioning may be permitted by special agreement between the manufacturer
and the purchaser.
4.3 Permissible Variations in Weight
The permissible variation from the specified or theoretical weight of blooms, billets, and slabs
shall be ±5% for individual pieces or for lots of less than a carload. For carload lots, the permissible
variation shall be ±2.5% of the total weight of the lot.
5.0 MARKING
The heat number shall be marked or stamped on a side near the end or on the end when practica-
ble. When the material is bundled, the heat number shall be marked on a tag attached to the bun-
dle.
6.0 INSPECTION AND REJECTION
6.1 Inspection
6.1.1 The inspector representing the purchaser shall have free entry, at all times while the work
on the contract of the purchaser is being performed, to all parts of the manufacturer’s works that
concern the manufacture of the material ordered. The manufacturer shall afford the inspector, free
of charge, all reasonable facilities and necessary assistance to satisfy the inspector that the mate-
rial is being furnished in accordance with these specifications. Tests and inspection shall be made
at place of manufacture prior to shipment unless otherwise specified.
6.1.2 The purchaser may make tests to cover the acceptance or rejection of the material in pur-
chaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.
6.2 Rejection
6.2.1 Material represented by samples that fail to conform to the requirements of these specifica-
tions will be rejected.
6.2.2 Material that shows injurious defects subsequent to its original inspection and acceptance
at the manufacturer’s works or elsewhere will be rejected, and the manufacturer shall be notified.
6.3 Rehearing
Samples tested in accordance with these specifications that represent rejected material shall be
held for a period of 14 days from date of the test report. In case of dissatisfaction with the results of
the tests, the manufacturer may make claim for a rehearing within that time.
S [M-105] 6 10/2010
Casting Details
M-105
7.0 SUPPLEMENTARY REQUIREMENTS

One or more of the following supplementary requirements shall apply only when specified by the
purchaser in the inquiry, contract, and order. Details of these supplementary requirements shall
be agreed upon by the manufacturer and the purchaser.
S1 Specified Process The purchaser may specify that the steel shall be made in the basic open-hearth, acid
open-hearth, or electric furnace. When electric-furnace steel is specified, the steel shall
conform to the requirements as to chemical ranges and limits prescribed in Table 7.1
subject to permissible variations in check analyses shown in Table 7.2.
S2 Discard The purchaser may specify any definite amount of discard other than as provided in
paragraph 2.2.
S3 Specified Maximum The purchaser may specify maximum amounts of incidental alloying elements.
Incidental Alloying
Elements
S4 Restricted Chemistry The purchaser may specify a more restricted range (higher mimimum or lower
maximum) or a more restricted limit, for one or more elements, than the standards
provided in Tables 3.1, 3.2, 3.3, and 7.1.
S5 Restricted Check The purchaser may specify more restrictive check analysis requirements for one or
Analysis more elements than provided in Tables 3.4 and 7.2.
S6 Guaranteed 1. When specified, the purchaser or representative may select one top-cut billet,
Segregation Tests bloom, or slab from which to make check analyses to represent each heat. Two
sets of drillings shall be taken from the top face of this piece at points on the same
diagonal of the piece. The drillings shall be taken with a 5⁄8 in. drill parallel to the
axis of the ingot as cast. The distance from the center of the piece to the drilling
points shall be, respectively, 15% and 80% of the length of the half diagonal of the
piece.
2. From the drillings taken at the 80% point, a complete analysis may be made. The
chemical composition thus determined shall conform to the requirements specified.
3. From the drillings at the 15% point, a carbon determination may be made. The
difference between the carbon content of the drillings from the 15% point and that
of the drillings from the 80% point, expressed as a percentage of the latter, shall not
exceed the following values:
Carbon Content
Thickness (in.)
Difference (%)
15 and under 15
Over 15 20
4. If, in any heat, the drillings taken in accordance with paragraph 1 above do not
conform to the requirements prescribed in paragraph 3 above, additional drillings
may be taken in a similar manner after making a further top discard from the
material from each ingot of at least 10% of the original weight. The results of this
analysis shall conform to the requirements prescribed in paragraph 3 above;
otherwise, the heat represented shall be rejected.
10/2010 S [M-105] 7
Casting Details
M-105
Note: Data in Table 7.1 are subject to variations for check analysis (see Table 3.4).
Table 7.1 Ladle chemical ranges and limits for electric-furnace steels other than standard
When Maximum of Range
Element Specified Element Is... (Electric-Furnace Steels)
Carbon To 0.25 0.05a/ 0.08b/
Over 0.25 to 0.40 0.06 a/ 0.09b/
Over 0.40 to 0.55 0.07a/ 0.09b/
Over 0.55 to 0.70 0.09a/ 0.11b/
Over 0.70 to 0.95 0.11a/ 0.14b/
Over 0.95 to 1.35 0.14a/ 0.17b/
Manganese To 0.45, 0.15
Over 0.45 to 0.80 0.20
Over 0.80 to 1.15 0.25
Over 1.15 to 1.65 0.30
Phosphorus 0.025 max.
Sulphur To 0.060 0.02
Over 0.060 to 0.100 0.04
Over 0.100 to 0.140 0.05
Silicon To 0.15 0.08
Over 0.15 to 0.20 0.10
Over 0.20 to 0.35 0.15
Over 0.35 to 0.60 0.20
a/ These ranges for carbon apply to steel not exceed-
ing 200 in.2 in a cross-sectional area, or 18 in. in
width, or 10,000 lb in weight per piece.
b/ These ranges for carbon apply to steel exceeding
200 in.2 in a cross-sectional area, or 18 in. in
width, or 10,000 lb in weight per piece.
Table 7.2 Permissible variations for check analysis of electric-furnace steels

Variation, Over the Maximum Limit or
Under the Minimum Limit (%)
Limit, or Maximum of Specified To 100 in.2, Over 100 to Over 200 to Over 400 to
Element Range (%) incl. 200 in.2, incl. 400 in.2, incl. 800 in.2, incl.
Carbon To 0.30, incl. 0.01 0.02 0.03 0.04
Over 0.30 to 0.75, incl. 0.02 0.03 0.04 0.05
Over 0.75 0.03 0.04 0.05 0.06
Manganese To 0.90, incl. 0.03 0.04 0.05 0.06
Over 0.90 to 1.65, incl. 0.04 0.05 0.06 0.07
Phosphorus Over maximum only 0.004 0.01 0.01 0.01
Sulphur To 0.060, incl. 0.005 0.01 0.01 0.01
Silicon To 0.35, incl. 0.02 0.02 0.03 0.04
Over 0.35 to 0.60 0.03 0.06 0.06 0.07
S [M-105] 8 10/2010
Casting Details
M-105
S7 Guaranteed Heat When heat-treatment requirements are specified, all phases of testing procedure shall
Treatment be subject to agreement between the manufacturer and the purchaser. These involve
size of material to be tested; location of test bar; the size, shape, and method of
preparing test specimens; temperature and time of treatment; agitation of quenching
medium; and similar requirements. The minimum and maximum limits of a specified
hardness range shall be consistent with the hardness obtainable in the full range of the
specified chemical limits.
S8 Nonmetallic Inclusion When nonmetallic inclusion requirements are specified, the samples for testing shall
Requirements be taken on a longitudinal plane midway between the center and surface of the
material. The samples shall be hardened before being polished to avoid polishing pits;
and the area to be examined shall be agreed upon. The rating of the inclusion count
shall be based upon the average length of the inclusions, the longest inclusion, and the
general background. Any standards agreed upon shall be based upon a magnification
of 100×. Reference may be made to the “Recommended Practice for Determination of
the Inclusion Content of Steel” (ASTM Designation: E45).
S9 Macroetch Tests The purchaser may specify macroetch tests. This test consists of deep etching a
representative section in hot acid. The location, number, and interpretation of tests
should be determined by the manufacturer and the purchaser before the steel is
produced. Reference may be made to the “Tentative Method of Macroetch Testing”
(ASTM Designation: A317).
S10 Magnetic Particle 1. Magnetic particle inspection consists of suitably magnetizing the material and
Testing applying a prepared magnetic powder that adheres to the lines of flux leakage. On
properly magnetized material, flux leakage develops along surface or subsurface
non-uniformities.
2. The magnetic particle test was developed for, and used primarily on, fully machined
or ground surfaces of finished parts.
3. The method of magnetic particle inspection varies with the degree of
magnetization; the methods of conducting the inspection, including such conditions
as relative location of surfaces tested, method and sequence of magnetizing and
applying the powder; amperage; and the interpretation of indications.
4. There shall be definite agreement between the manufacturer and the purchaser
regarding methods of conducting magnetic particle tests or methods of inspection
and the interpretation of the results. Reference may be made to the “Standard
Methods for Magnetic Particle Testing and Inspection of Heavy Forgings” (ASTM
Designation: A275).
S11 Grain Size 1. Except as qualified in paragraph 2 below, carburized austenitic grain size may be
specified as coarse or fine; to be determined in accordance with the “Standard
Classification of Austenite Grain Size in Steels” (ASTM Designation: E19). The
steel shall be designated as coarse-grain when the grain structure falls within the
limits depicted in photographs Nos. 1 to 5, inclusive, ASTM Grain Size Charts E19,
and fine-grain when the grain structure falls within photographs Nos. 5 to 8,
inclusive. The grain structure shall be considered satisfactory if 70% is within the
specified grain size limits.
2. Due to certain manufacturing conditions, the grain size distinctions prescribed in
paragraph 1 above cannot be adhered to in blooms larger than 100 in.2 in
cross-sectional area nor in slabs larger than 20 in. × 5 in. For these larger sizes,
grain size requirements shall be negotiated between the purchaser and producers
10/2010 S [M-105] 9
Casting Details
M-105
S12 Fracture Tests When specified, the soundness and homogeneity of the material may be judged by a
transverse fracture test. When making the test, a central area equivalent to at least
10% of the total area of the end of the piece shall be fractured. Before processing, there
shall be definite agreement between the manufacturer and the purchaser regarding
methods of conducting the test and interpretation of results.
S13 Surface Preparation The purchaser may specify, for purposes of making possible closer inspection, that the
material shall be pickled in acid, or sand- or shot-blasted, or prepared by any other
agreed-upon method.
S14 Controlled Cooling When the purchaser desires closer control of cooling than provided in paragraph 4.1.2,
purchaser may specify, when agreed upon, either
• a maximum controlled rate of cooling after hot-working;
• annealing, normalizing, or normalizing and tempering; or a maximum hardness.
S15 Surface Conditioning In case the maximum permitted depth for removal of surface defects as stated in
paragraph 4.2 is excessive for the purchaser’s requirements, purchaser may specify
either scarfing, grinding, or chipping to a maximum depth agreed upon.
S16 Marking and The purchaser may specify marking other than that required in paragraph 5.0.
Identification
S17 Ultrasonic Testing When agreed upon by the manufacturer and purchaser, ultrasonic testing may be
specified. There shall be definite agreement between the manufacturer and the
purchaser regarding methods of conducting ultrasonic tests and the interpretation of
results.
S [M-105] 10 10/2010
M-126
FORGINGS, CARBON STEEL
Specification
M-126

1.0 SCOPE
This specification covers eight grades of carbon steel forgings, other than axles, as follows:
• Grade A—Untreated. This grade is primarily used for drop forgings and parts of minor
importance and those that are to be case hardened.
• Grade B—Untreated. This grade is used for a general group of miscellaneous ordinary
forgings where heat treatment is not deemed necessary.
• Grade C—Annealed, normalized, or normalized and tempered
• Grade D—Annealed, normalized, or normalized and tempered
• Grade E—Normalized and tempered
• Grade F— Double-normalized and tempered
• Grade G—Quenched and tempered
• Grade H—Normalized, quenched, and tempered
Grades E, F, G and H forgings are used in heavy duty service on locomotives, cars, and other equip-
ment.
Note: Heat-treated and untreated axles are covered in the AAR Manual of Standards and Recom-
mended Practices, Section G, Specification M-101.
2.0 MANUFACTURE
2.1 Process
The steel shall be made by any of the following processes: Open-hearth, electric furnace, or basic
oxygen.
2.2 Discard
A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segre-
gation.
2.3 Forging Practice
The forgings may be made direct from the ingot or from billets, the total reduction from ingot to
forging being not less than 3 to 1, unless otherwise specified.
2.4 Prolongation for Test
2.4.1 For test purposes, prolongations shall be attached to at least 5% of the forgings in each size
classification in each heat and in each heat-treating lot.
2.4.2 Forgings may be used for test procurement if forgings with prolongations are not available
or have been expended.
2.5 Boring
2.5.1 Boring, when required, shall be performed before normalizing, in the case of normalized
and tempered forgings; and before quenching, in the case of quenched and tempered forgings. In
the case of normalized, quenched, and tempered forgings, boring when required shall be performed
either before normalizing or before quenching.
10/2010 S [M-126] 11
Casting Details
M-126
2.5.2 For quenched and tempered forgings, it is recommended, but not mandatory, that all forg-
ings over 7 in. in diameter be bored. No solid forging over 10 in. in diameter, and no forging over
8 in. in wall thickness shall be liquid quenched.
2.5.3 In bored forgings, the diameter of the hole shall be a matter of agreement between the man-
ufacturer and the purchaser.
2.6 Cooling and Heating
2.6.1 When hot blooms are to be cooled, they shall be subject to contact with water or air drafts
and allowed to cool uniformly. They shall not be subject to contact with water or air drafts.
2.6.2 Blooms overheating shall be reheated for forging in a manner that will prevent internal
bursts
2.6.3 Forgings shall be control cooled to below the critical range after forging and in a manner
that will prevent internal cracks that may result from too rapid cooling.
2.6.4 Forgings (Grades C through H) that are heat treated directly from forging are subject to the
following conditions:
2.6.4.1 They shall be cooled below the transformation temperature or to approximately 1,000 °F
before any reheating operation; and
2.6.4.2 They must not be permitted to cool below 500 °F without slow cooling as defined in
paragraph 2.6.3.
Note: As the temperature of the forgings approaches the minimum or 500 °F, a supplemental heat
source may be necessary to ensure an effective cooling cycle.
2.6.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of
paragraphs 2.6.1, 2.6.3, and 2.6.4.2 may be omitted, but forging blooms must then be pile cooled.
2.7 Heat Treatment
Heat treatment may be performed in either batch-type furnaces or continuous furnaces.
2.7.1 Forgings
Forgings for heat treatment shall be reheated gradually and uniformly to the proper temperature
to refine the grain and held at this temperature for a sufficient time to effect the desired change.
2.7.2 Annealing
After heating to a suitable temperature, the forgings shall be allowed to cool slowly and uniformly.
A furnace charge thus treated is termed an annealing charge.
2.7.3 Normalizing
After heating to a suitable temperature, the forgings shall be withdrawn from the furnace and
allowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge.
Cooling may be accelerated by increased air circulation, which must be controlled to provide rea-
sonably uniform cooling.
2.7.4 Double Normalizing
The procedure shall consist of two separate heat treatments. The second treatment shall be per-
formed at a lower temperature than the first treatment. A furnace charge thus treated is termed a
double normalizing charge. Cooling may be accelerated by increased air circulation, which must be
controlled to provide reasonably uniform cooling.
2.7.5 Quenching
After heating to a suitable temperature, the forgings shall be quenched in a suitable medium
under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge.
S [M-126] 12 10/2010
Casting Details
M-126
2.7.6 Tempering
Forgings shall be reheated gradually to, and held at, a suitable temperature below the critical
range and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is
termed a tempering charge.
2.8 Straightening
Straightening required by forgings furnished without machining shall be done at a temperature
not lower than 950 °F and in such a manner as to leave the surface free from injurious scars.
Straightening performed at temperatures lower than 950 °F shall be performed prior to machining
and shall be followed by proper stress relieving or applicable heat treatment.
The steel shall conform to the requirements as to chemical composition prescribed in Table 3.1.
Table 3.1 Chemical composition of steel
Chemical Composition (%)
Grades Grades
Element Grade A Grade B C, D, and E Grade F G and H
Carbon 0.15 max 0.15 to 0.25 0.40 to 0.55 0.45 to 0.59
Manganese 0.30 to 0.60 0.30 to 0.60 0.60 to 0.90 0.60 to 0.90 0.60 to 0.90
Phosphorus (maximum) 0.045 0.045 0.045 0.045 0.045
Sulfur (maximum) 0.050 0.050 0.050 0.050 0.050
Silicon (minimum) 0.15 0.15 0.15
3.2 Ladle Analysis

of carbon and the elements specified in paragraph 3.1. The chemical composition thus determined
shall be reported to the purchaser or his representative and shall conform to the requirements
specified in paragraph 3.1.
3.3 Check Analysis
An analysis may be made by the purchaser from a forging representing each heat. The chemical
composition thus determined shall conform to the requirements of paragraph 3.1, subject to toler-
ances shown in Table 3.2. Samples for analysis may be taken from the forging or from a full-sized
prolongation, at any point midway between the center and surface when solid, or midway between
the inner and outer surfaces of the wall when bored. If drillings are taken, they shall be obtained
using a 5⁄8 in. drill, or turnings may be taken from the test specimen.
Table 3.2 Permissible variations for check analysis
Permissible Variations, Over the Maximum Limit or Under the Minimum Limit (%)
Element 100 in.2 and undera/ Over 100 to 400 in.2, inclusivea/
Carbon (Grades A and B only) 0.02 0.04
Manganese 0.03 0.05
Phosphorus 0.008 0.010
Sulfur 0.008 0.010
Silicon 0.02 0.02
a/ Determine by cross-section from which drillings are taken.
10/2010 S [M-126] 13
Casting Details
M-126
4.0 PHYSICAL REQUIREMENTS

4.1 Tension Tests
4.1.1 The forgings shall conform to the requirements prescribed in Table 4.1.
Table 4.1 Tensile requirements for carbon steel forgings
Size (in.)
Solid Diameter Bored Wall Tensile Elongation Reduction
or Thickness Thickness Strength, Yield Point, in in.2, of Area,
Not Not Minimum Minimum Minimum Minimum
Grade Over Over Over Over (psi) (psi) (%) (%)
C 8 75,000 37,500 20 33
Annealed, normalized, or 8 14 75,000 37,500 19 31
normalized and tempereda/
D 8 80,000 40,000 22 35
Annealed, noramlized, or 8 14 80,000 40,000 21 33
normalized and Tempereda/
E 8 85,000 44,000 25 40
Normalized and tempered 8 14 83,000 43,000 23 37
F 8 8 4 88,000 50,000 22 37
Double normalized and tempered 12 12 4 6 86,000 48,000 21 35
14 84,000 46,000 20 33
G 4 2 90,000 55,000 20 39
Quenched and tempered 4 7 2 31⁄2 85,000 50,000b/ 20 39
7 10 31⁄2 5 85,000 50,000b/ 19 37
5 8 82,500 48,000b/ 19 36
H 7 115,000 75,000b/ 16 35
Normalized, Quenched, 7 10 4 105,000 65,000b/ 18 35
and Tempered 4 8 100,000 60,000b/ 18 35
a/ Alternative treatments specified are optional with the manufacturer.
b/ See paragraph 4.1.5.
4.1.2 The classification of forgings shall be determined by the specified diameter or thickness of
solid forgings disregarding large ends and collars or by the specified wall thickness of bored forg-
ings that are heat treated after rough boring.
4.1.3 The diameter of the test prolongation of forgings shall be the specified diameter of thickness
of the forging disregarding large ends and collars.
4.1.4 The yield point prescribed in Table 4.1 for Grades C, D, E, and F forgings may be deter-
mined by the drop of the beam or halt of the gauge of the testing machine, or by the use of dividers.
Where a definite yield point net is exhibited, the yield point method defined in paragraph 4.1.5
shall be used.
4.1.5 The yield point prescribed in Table 4.1 for Grades G and H forgings shall be determined by
a strain gauge or extensometer reading to 0.0002 in. Yield point may be defined as the stress at
0.6% total strain under load or as the stress at 0.2% offset. The method described in “Standard
Methods and Definitions for Mechanical Testing of Steel Products” (ASTM A370) shall be followed.
After the yield point has been passed, the extensometer may then be removed and the test contin-
ued to determine the tensile strength.
4.1.6 Tests of forgings shall be made only after final heat treatment.
S [M-126] 14 10/2010
Casting Details
M-126
4.2 Tension Test Specimens

4.2.1 Tension test specimens shall be taken from the test prolongation or a forging in accordance
with the provisions of paragraph 2.4.
4.2.2 Unless otherwise specified, the axis of the specimen shall be located at any point midway
between the center and surface of the solid forgings or full-sized prolongation, or at any point mid-
way between the inner and outer surface of wall of bored forgings, and shall be parallel to the axis
of the forging in the direction in which the metal is most drawn out.
4.2.3 Tension test specimens shall conform to dimensions shown in Fig. 4.1.
NOTE: THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE ENDS MAY BE OF ANY
SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL BE AXIAL.
Fig. 4.1 Standard round tension test specimen with 2-in. gauge length
4.3 Microscopic Test (Grades D, E, F, G, and H)
4.3.1 A specimen representing each size classification of each heat of each heat-treatment lot
shall be taken for microscopic tests from the tension test specimen. This section for microscopic
test shall be cut from the large undistorted portion of the test tension specimen in such a way as
will give a face transverse to the axis of the forging.
4.3.2 The face shall be polished practically free from scratches and shall be so etched as to clearly
define the microstructure. The specimen shall be examined under a magnification of 100 diame-
ters.
4.3.3 The whole of this section shall show uniform, well broken up, fine-grained structure, and
shall conform to the requirements illustrated in the photomicrographs, Figs. 4.2, 4.3, and 4.4.
10/2010 S [M-126] 15
Casting Details
M-126
Fine-Grained Uniform Structure—Desired (×100) Maximum-Grained Structure—Acceptable (×100)
Fig. 4.2 Microscopic test—Grades D and E
Fine-Grained Uniform Structure—Desired (×100) Maximum-Grained Structure—Acceptable (×100)
Fig. 4.3 Microscopic test—Grade F

S [M-126] 16 10/2010
Casting Details
M-126
Oil-Quenched—Desired (×100) Water-Quenched—Desired (×100)
Fig. 4.4 Desired microstructure for the referenced quench method

4.4 Number of Tests
4.4.1 Unless otherwise specified by the purchaser, mechanical tests shall be made from
heat-treated forgings as follows:
4.4.1.1 Where batch-type heat-treating furnaces are used, one test shall be made from each size
classification shown in Table 4.1 represented in each heat in each annealing or normalizing
charge; or from each size classification in each heat in each normalizing or quenching charge rep-
resented in each tempering charge.
4.4.1.2 Where continuous heat-treating furnaces are used, one test shall be made from each
grade from each size classification shown in Table 4.1 represented by each heat. The pieces repre-
sented by each test shall be designated a heat-treatment lot and each lot shall not contain more
than 70 pieces from one heat.
4.4.2 If any test specimen fails because of mechanical condition of the testing apparatus, it may
be discarded and another specimen taken.
4.4.3 For Grades D, E, F, G, and H forgings, one microscopic test shall be made in accordance with
paragraph 4.3 from each size classification represented in each heat in each heat-treatment lot.
4.5 Retests
4.5.1 If the results of the mechanical tests of any test lot do not conform to the requirements spec-
ified because a flaw developed in the test specimen during testing, a retest shall be allowed if the
defect is not caused by ruptures, cracks, or flakes in the steel.
4.5.2 In the case of Grade C, D, E, F, G, and H forgings, if the results of the mechanical tests of
any lot do not conform to the requirements specified, the manufacturer may re-treat such lot, but
not more than three additional times, and retests shall be made in accordance with paragraph 4.1,
according to the requirements for the class of forgings involved.
10/2010 S [M-126] 17
Casting Details
M-126

5.1 Workmanship
The forgings shall conform to the sizes and shapes specified by the purchaser.
5.2 Finish
The forgings shall be free from injurious defects and shall have a workmanlike finish.
6.0 MARKING
6.1 Identification marks shall be legibly stamped on each forging and on each test specimen. The
purchaser may indicate the location of such identification marks.
6.2 After the material has been inspected, the inspector shall stamp each accepted forging with
the inspector’s private mark.
7.1 Inspection
of charge, all reasonable facilities and necessary assistance to satisfy inspector that the material is
being furnished in accordance with these specifications. Tests and inspection shall be made at
place of manufacture prior to shipment unless otherwise specified.
7.2 Rejection
at the manufacturer’s works, or elsewhere, will be rejected, and the manufacturer shall be notified.
7.3 Rehearing
7.4 Certification
At the purchaser’s request, a certification may be made the basis of acceptance of the material.
This shall consist of a copy of the manufacturer’s test report that the material has been sampled,
tested, and inspected in accordance with the provisions of the specification. Each certification so
furnished shall be signed by an authorized agent of the supplier or manufacturer.
S [M-126] 18 10/2010
Casting Details
M-126

The following supplementary requirements shall apply only when specified by the purchaser.
Details shall be agreed upon by the manufacturer and the purchaser.
S1 Carbon Determination In addition to the complete analysis specified in paragraph 3.3 for Grades C, D, E, F,
G, and H forgings, a carbon determination may be made by the purchaser on drillings
taken with a 5§8 in. drill from the center of the forging or full-sized prolongation to
determine by the variation in carbon the amount of segregation. This determination
shall show the carbon content to be within 12% of the amount found at any point
midway between the center and surface. This requirement does not apply to bored
forgings.
S2 Residual Alloy Content The purchaser may specify that the residual alloying elements in the steel shall not
exceed 0.25% nickel, 0.15% chromium, or 0.06% molybdenum.
S3 Rough Machining The purchaser may specify a preliminary rough machining prior to the heat-treating
operation.
S4 Macroscopic Tests The prolongation from the largest forging in each heat shall be sawed normal to the
axis of the forging and shall then be split longitudinally. The transverse and the
longitudinal face shall be etched for macroscopic examination.
S5 Mechanical Tests The purchaser may specify mechanical tests of Grades A and B forgings. If mechanical
property tests do not conform to the requirements agreed upon, the manufacturer may
anneal or normalize the lot involved, but not more than three times.
10/2010 S [M-126] 19
Casting Details
M-126
S [M-126] 20 10/2010
M-127
FORGINGS, ALLOY STEEL
Specification
M-127

1.0 SCOPE
This specification covers six grades of alloy steel forgings, as follows:
• Grades A, B, and C—Normalized and tempered

• Grades D, E, and F—Normalized, quenched and tempered
2.0 MANUFACTURE
2.1 Process
The steel shall be made by any of the following processes: Open-hearth, electric furnace, or basic
oxygen.
2.2 Discard
A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segre-
gation.
2.3 Forging Practice
The forgings may be made direct from the ingot or from billets, the total reduction from ingot to
forging being not less than 3 to 1, unless otherwise specified.
2.4 Prolongation for Test
2.4.1 For test purposes, unless otherwise specified, prolongations shall be left attached to approx-
imately 20% of the various forgings in each size classification in each heat and in each heat-treat-
ing charge.
2.4.2 The manufacturer may elect to submit a forging for test. By mutual agreement, test speci-
mens may be taken from the forgings with a hollow drill.
2.5 Boring
2.5.1 Boring, when required, shall be performed before normalizing in the case of normalized and
tempered forgings. In the case of normalized, quenched, and tempered forgings, boring, when
required, shall be performed either before normalizing or before quenching.
2.5.2 For quenched and tempered forgings, it is recommended, but not mandatory, that all forg-
ings over 7 in. in diameter be bored. No solid forging over 10 in. in diameter, and no forging over
8 in. in wall thickness shall be liquid quenched.
2.5.3 In bored forgings, the diameter of the hole shall be a matter of agreement between the man-
ufacturer and purchaser.
2.6 Cooling
2.6.1 Blooms for forgings shall be allowed to cool uniformly and shall not be permitted to come in
contact with water or drafts of air.
2.6.2 The cooling of forgings after the forging operation shall be controlled in accordance with
approved methods.
10/2010 S [M-127] 21
Casting Details
M-127
2.7 Heat Treatment

2.7.1 Forgings to be heat treated shall be allowed to cool below the critical range, in accordance
with the provisions of paragraph 2.6.2.
2.7.2 Forgings
Forgings for heat treatment shall be reheated gradually and evenly to the proper temperature to
refine the grain and held at this temperature for a sufficient time to effect the desired change.
2.7.3 Normalizing
For normalizing, the forgings shall be held at the proper temperature and then withdrawn from
the furnace and allowed to cool in still air. A furnace charge thus treated is termed a normalizing
charge.
2.7.4 Quenching
Forgings to be quenched shall be held at the proper temperature and then quenched in a suitable
medium under substantially uniform conditions. A furnace charge thus treated is termed a
quenching charge.
2.7.5 Tempering
Forgings shall be tempered after quenching or after normalizing. Forgings for tempering shall be
reheated gradually to, and held at, the proper temperature below the critical range and shall then
be allowed to cool under suitable conditions. A furnace charge thus treated is termed a tempering
charge.
2.7.6 Straightening
Any straightening required by forgings furnished without machining shall be done at a tempera-
ture not lower than 950 °F and in such a manner as to leave the surface free from injurious scars.
Any straightening done at temperatures lower than 950 °F on forgings requiring machining shall
be performed prior to machining and shall be followed by the applicable heat treatment or by
proper stress relieving.
3.1.1 The steel shall conform to the following requirements as to chemical composition:
Phosphorus, maximum 0.045%
Sulfur, maximum 0.050%
3.1.2 The limits for elements other than phosphorus and sulfur in the composition of alloy steel
shall be agreed upon by the manufacturer and the purchaser.
3.2 Ladle Analysis
3.2.1 An analysis of each heat of steel shall be made by the manufacturer to determine the per-
centages of carbon, manganese, phosphorus, sulfur, and silicon; also the alloying elements agreed
upon in accordance with paragraph 3.1.2.
3.2.2 The chemical composition thus determined shall be reported to the purchaser or pur-
chaser’s representative and shall conform to the requirements specified in paragraph 3.1.
S [M-127] 22 10/2010
Casting Details
M-127
3.3 Check Analysis

An analysis may be made by the purchaser from a forging representing each heat. The chemical
composition thus determined shall conform to the requirements of paragraph 3.1, subject to toler-
ances shown in Table 3.1. Samples for analysis may be taken from the forging or from a full-sized
prolongation, at any point midway between the center and surface when solid, or midway between
the inner and outer surfaces of the wall when bored. If drillings are taken, they shall be obtained
using a 5⁄8 in. drill, or turnings may be taken from the test specimen.
Table 3.1 Permissible variations for check analysis
Permissible Variations, Over the Maximum Limit (%)
Element 100 in.2 and under Over 100 to 400 in.2, inclusive
Phosphorus 0.008 0.010
Sulfur 0.008 0.010
4.0 PHYSICAL REQUIREMENTS

4.1 Tension Tests
4.1.1 The forgings shall conform to the requirements as to tensile properties prescribed in
Table 4.1.
Table 4.1 Tensile requirements for carbon steel forgings
Size (in.)
Solid Diameter Bored Wall Tensile Elongation Reduction
or Thickness Thickness Strength, Yield Point, in in.2, of Area,
Not Not Minimum Minimum Minimum Minimum
Grade Over Over Over Over (psi) (psi) (%) (%)
A 8 4 80,000 55,000 28 60
8 20 4 8 80,000 55,000 28 55
B 5 21⁄2 90,000 60,000 24 48
5 9 2 ⁄2
1 41⁄2 90,000 60,000 22 44
9 13 4 ⁄2
1 61⁄2 90,000 58,000 21 43
13 20 6 ⁄2
1 8 88,000 56,000 20 40
C 5 21⁄2 95,000 72,000 23 55
5 9 2 ⁄2
1 41⁄2 95,000 70,000 22 53
9 13 4 ⁄2
1 61⁄2 93,000 67,000 22 50
13 20 61⁄2 8 91,000 65,000 21 48
D 7 31⁄2 95,000 70,000a/ 23 54
7 10 31⁄2 5 90,000 65,000a/ 20 50
5 8 85,000 60,000a/ 20 50
E 7 31⁄2 105,000 80,000a/ 20 50
7 10 31⁄2 5 100,000 75,000a/ 19 50
5 8 95,000 70,000 a/ 19 50
F 4 2 125,000 105,000a/ 16 50
4 7 2 31⁄2 115,000 95,000 a/ 16 45
7 10 3 ⁄2
1 5 110,000 85,000a/ 16 45
a/ See paragraph 4.1.5.
10/2010 S [M-127] 23
Casting Details
M-127
4.1.2 The classification of forgings shall be determined by the nominal or specified diameter or
thickness of solid forgings, disregarding large ends and collars, or by the nominal wall thickness of
bored forgings.
4.1.3 The nominal or specified outside diameter or thickness of the forgings, disregarding large
ends and collars, shall determine the size of the prolongation for test specimens.
4.1.4 The yield point prescribed in Table 4.1 for Grades A, B, and C forgings may be determined
by the drop of the beam or halt of the gauge of the testing machine; or by the use of dividers.
Where a definite yield point is not exhibited, the yield point method defined in paragraph 4.1.5
shall be used.
4.1.5 The yield point prescribed in Table 4.1 for Grades D, E, and F forgings shall be determined
by a strain gauge or extensometer reading to 0.0002 in. Yield point may be defined as the stress at
0.6% total strain under load or as the stress at 0.2% offset. The method described in “Standard
Method of Tension Testing of Metallic Materials” (ASTM E8) shall be followed. After the yield
point has been passed, the extensometer may then be removed and the test continued to determine
the tensile strength.
4.1.6 The yield point shall be determined at a speed of head not to exceed 1⁄16 in. per minute per
inch of gauge length. The tensile strength shall be determined at a speed of head not to exceed
3⁄4 in. per minute per inch of gauge length.
4.1.7 Tests of forgings shall be made only after final heat treatment.
4.2 Tension Test Specimens
4.2.1 Tension test specimens shall be taken from the test prolongation, or the manufacturer may
elect to furnish an extra forging for the purpose. When approved by the purchaser, the test speci-
men may be taken from forgings with a hollow drill.
4.2.2 Unless otherwise specified, the axis of the specimen shall be located at any point midway
between the center and surface of the solid forging or full-sized prolongation, or at any point mid-
way between the inner and outer surface of wall of bored forgings, and shall be parallel to the axis
of the forging in the direction in which the metal is most drawn out.
4.2.3 Tension test specimens shall conform to dimensions shown in Fig. 4.1.
NOTE: THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE ENDS MAY BE OF ANY
SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL BE AXIAL.
Fig. 4.1 Standard round tension test specimen with 2-in. gauge length
S [M-127] 24 10/2010
Casting Details
M-127
4.3 Microscopic Test

4.3.1 For Grades A, B, and C forgings, a specimen representing each size classification of each
heat of each heat-treatment lot shall be taken for microscopic tests from the tension test specimen.
These sections for microscopic tests shall be cut from the large undistorted portion of the test spec-
imen in such a way as will give one face normal and one face parallel to the axis of the specimen.
4.3.2 Both faces shall be polished practically free from scratches. The transverse face shall be so
etched as to clearly define the microstructure. The longitudinal face shall be left unetched. The
specimen shall be examined under a magnification of 100 diameters.
4.3.3 The whole of the transverse section shall show uniform, well broken up, fine-grained struc-
ture, and shall conform to the requirements illustrated in the photomicrographs, Figs. 4.2, 4.3, and
4.4.
4.3.4 For information only, the longitudinal unetched face will be examined for solid non-metallic
impurities and should show such impurities well scattered over the field.
Fine-Grained Uniform Structure—Desired) Maximum-Grained Structure—Acceptable
Fig. 4.2 Photomicrographs (×100) of Grade A normalized and tempered alloy-steel forgings
10/2010 S [M-127] 25
Casting Details
M-127
Fine-Grained Uniform Structure—Desired Maximum-Grained Structure—Acceptable
Fig. 4.3 Photomicrographs (×100) of Grade B normalized and tempered alloy-steel forgings
Fine-Grained Uniform Structure—Desired Maximum-Grained Structure—Acceptable
Fig. 4.4 Photomicrographs (×100) of Grade C normalized and tempered alloy-steel forgings
S [M-127] 26 10/2010
Casting Details
M-127
4.4 Number of Tests

4.4.1 Unless otherwise specified by the purchaser, tension tests shall be made as follows: One test
shall be made from each size classification shown in Table 4.1 in each heat in each normalizing or
quenching charge represented in each tempering charge.
4.4.2 If any test specimen fails because of mechanical reasons, it may be discarded and another
specimen taken.
4.4.3 For normalized and tempered forgings, one microscopic test shall be made in accordance
with paragraph 4.3 from each size classification represented in each heat in each heat-treatment
lot.
4.5 Retests
4.5.1 If the results of the physical tests of any test lot do not conform to the requirements speci-
fied because a flaw developed in the test specimen during testing, a retest shall be allowed if the
defect is not caused by ruptures, cracks, or flakes in the steel.
4.5.2 If the percentage of elongation of any test specimen is less than that specified in
paragraph 4.1, and any part of the fracture is more than 54 in. from the center of the gauge length,
as indicated by scribe scratches marked on the specimen before testing, a retest shall be allowed.
4.5.3 If the results of the physical tests of any lot do not conform to the requirements specified,
the manufacturer may retreat such lot, but not more than three additional times, and retests shall
be made in accordance with paragraph 4.1, according to the requirements for the grade of forgings
involved.
5.1 Workmanship
5.1.1 The forgings shall conform to the sizes and shapes specified by the purchaser.
5.1.2 When centered, centers shall conform to the design and dimensions of the purchaser’s
drawings, if so specified.
5.1.3 When forgings are drilled from both ends and the hole thus drilled is out of line, the diame-
ter of the hole may be increased by boring or reaming in order to take out the offset and secure a
workmanlike finish, but the diameter of the hole shall not be increased more than 1⁄8 in.
5.2 Finish
The forgings shall be free from injurious defects and shall have a workmanlike finish.
6.0 MARKING
6.1 The manufacturer’s and purchaser’s identification marks, specification number, steel, heat
number, forging number, and date, shall be legibly stamped on each forging as designated by the
purchaser, with letters and figures not less than 1⁄4 in. high. In case it is necessary to move the
above markings due to machining, permission shall first be obtained from the inspector in charge.
6.2 After the material has been inspected, the inspector shall stamp each accepted forging with
inspector’s private mark.
10/2010 S [M-127] 27
Casting Details
M-127

7.1 Inspection
being furnished in accordance with these specifications. Tests and inspection shall be made at the
place of manufacture prior to shipment, unless otherwise specified.
7.2 Rejection
at the manufacturer’s works, or elsewhere, will be rejected, and the manufacturer shall be notified.
7.3 Rehearing
The following supplementary requirements shall apply only when specified by the purchaser.
Details shall be agreed upon by the manufacturer and the purchaser.
S1 Rough Machining The purchaser may specify a preliminary rough machining prior to the heat-treating
operation.
S2 Residual Alloy Content The purchaser may specify that the residual alloying elements, not intentionally added,
shall not exceed 0.35% copper, 0.25% nickel, 0.20% chromium, and 0.06%
molybdenum.
S3 Macroscopic Tests The prolongation from the largest forging in each heat shall be sawed normal to the
axis of the forging and shall then be split longitudinally. The transverse and longitudinal
face shall be etched for macroscopic examination.
S4 Carbon Determination In addition to the analysis specified in paragraph 3.3, a carbon determination may be
made by the purchaser on drillings taken with a 5⁄8 in. drill from the center of the forging
or full-sized prolongation to determine by the variation in carbon the amount of
segregation. This determination shall show the carbon content to be within 12% of the
amount found at any point midway between the center and surface. This requirement
does not apply to bored forgings.
S5 Controlled Cooling The purchaser may specify a controlled cooling procedure.
Procedure
S [M-127] 28 10/2010
M-131
BLOOMS, BILLETS, AND SLABS—ALLOY STEEL
Specification
M-131
Adopted: 1953; Revised: 1964

1.0 SCOPE
1.1 This specification covers alloy steel semifinished rolled or forged blooms, billets, and slabs for
reforging.
1.2 Blooms, billets, and slabs are semifinished steel products, hot-rolled or forged from ingots to
approximate cross-sectional dimensions. Blooms and billets may be square, round, or rectangular
in section; slabs are rectangular. The following size distinctions are in general use:
Blooms Cross-sectional area greater than 36 in.2

Billets Maximum cross-sectional area 36 in.2; minimum cross-sectional area 16 in.2
Slabs Minimum thickness, 1 1⁄2 in.; width, more than twice the thickness;
generally a cross-sectional area of not less than 16 in.2
1.3 Supplementary requirements S1 to S17 of an optional nature are provided. They shall apply
only when specified by the purchaser. Details of these supplementary requirements shall be
agreed upon by the manufacturer and the purchaser.
2.0 MANUFACTURE
2.1 Process
The steel shall be made by any of the following processes: open-hearth, electric-furnace, or basic
oxygen.
2.2 Discard
A sufficient discard shall be made from each ingot to secure freedom from piping and undue segre-
gation.
2.3 Reduction from Ingot
Unless otherwise specified, the material shall be made from ingots having at least two times the
cross-sectional area of the material.
3.1.1 The steel when ordered to standard analysis shall conform to the requirements as to chemi-
cal composition prescribed in Table 3.1 for the respective grades.
Notes:
1. Data in Table 3.1 are applicable to standard semifinished steel products and are subject to per-
missible variations for check analysis (see Table 3.3).
2. The ranges and limits in this table apply only to material not exceeding 200 in.2 in a cross-sec-
tional area, or 18 in. in width, or 10,000 lb in weight per piece.
3. Small quantities of certain elements may be found in alloy steel that are not specified or re-
quired. These elements are to be considered as incidental and acceptable to the following max-
imum amounts: copper, 0.35%; nickel, 0.25%; chromium, 0.20%; molybdenum, 0.06%.
4. Other AISI or SAE grades may be used under this specification upon agreement between the
manufacturer and the purchaser.
10/2010 S [M-131] 29
Table 3.1 Chemical ranges and limits for open-hearth and electric-furnace alloy steels—standard semifinished steel products (page 1 of 2)
Chemical Composition Limits (%)
AISI Corresponding
Numbera/ Carbon Manganese Phosphorusb/ Sulfurb/ Silicon Nickel Chromium Molybdenum SAE Number
1320 0.18 to 0.23 1.60 to 1.90 0.040 0.040 0.20 to 0.35 1320
1330 0.28 to 0.33 1.60 to 1.90 0.040 0.040 0.20 to 0.35 1330
1340 0.38 to 0.43 1.60 to 1.90 0.040 0.040 0.20 to 0.35 1340
2317 0.15 to 0.20 0.40 to 0.60 0.040 0.040 0.20 to 0.35 3.25 to 3.75 2317
2330 0.28 to 0.33 0.60 to 0.80 0.040 0.040 0.20 to 0.35 3.25 to 3.75 2330
2335 0.33 to 0.38 0.60 to 0.80 0.040 0.040 0.20 to 0.35 3.25 to 3.75
2340 0.38 to 0.43 0.70 to 0.90 0.040 0.040 0.20 to 0.35 3.25 to 3.75 2340
2345 0.43 to 0.48 0.70 to 0.90 0.040 0.040 0.20 to 0.35 3.25 to 3.75 2345
E2512 0.09 to 0.14 0.45 to 0.60c/ 0.025 0.025 0.20 to 0.35 4.75 to 5.25 2512
2515 0.12 to 0.17 0.40 to 0.60 0.040 0.040 0.20 to 0.35 4.75 to 5.25 2515
E2517 0.15 to 0.20 0.45 to 0.60c/ 0.025 0.025 0.20 to 0.35 4.75 to 5.25 2517
3115 0.13 to 0.18 0.40 to 0.60 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.55 to 0.75 3115
3120 0.17 to 0.22 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.55 to 0.75 3120
3130 0.28 to 0.33 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.55 to 0.75 3130
3135 0.33 to 0.38 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.55 to 0.75 3135
3140 0.38 to 0.43 0.70 to 0.90 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.55 to 0.75 3140
3145 0.43 to 0.48 0.70 to 0.90 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.70 to 0.90 3145
3150 0.48 to 0.53 0.70 to 0.90 0.040 0.040 0.20 to 0.35 1.10 to 1.40 0.70 to 0.90 3150
S [M-131] 30
Casting Details
E3310 0.08 to 0.13 0.45 to 0.60c/ 0.025 0.025 0.20 to 0.35 3.25 to 3.75 1.40 to 1.75 3310
E3316 0.14 to 0.19 0.45 to 0.60c/ 0.025 0.025 0.20 to 0.35 3.25 to 3.75 1.40 to 1.75 3316
4023 0.20 to 0.25 0.70 to 0.90 0.040 0.040 0.20 to 0.35 0.20 to 0.30 4023
4032 0.30 to 0.35 0.70 to 0.90 0.040 0.040 0.20 to 0.35 0.20 to 0.30 4032
4053 0.50 to 0.56 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.20 to 0.30 4053
4130 0.28 to 0.33 0.40 to 0.60 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 to 0.25 4130
E4135 0.33 to 0.38 0.70 to 0.90 0.025 0.025 0.20 to 0.35 0.80 to 1.10 0.18 to 0.25
4140 0.38 to 0.43 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 to 0.25 4140
4142 0.40 to 0.45 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 to 0.25
4145 0.43 to 0.48 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 to 0.25 4145
4150 0.48 to 0.53 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 to 0.25 4150
4320 0.17 to 0.22 0.45 to 0.65 0.040 0.040 0.20 to 0.35 1.65 to 2.00 0.40 to 0.60 0.20 to 0.30 4320
4337 0.35 to 0.40 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.65 to 2.00 0.70 to 0.90 0.20 to 0.30
4340 0.38 to 0.43 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.65 to 0.35 0.70 to 0.90 0.20 to 0.30 4340
4620 0.17 to 0.22 0.45 to 0.65 0.040 0.040 0.20 to 0.35 1.65 to 2.00 0.20 to 0.30 4620
M-131
10/2010
Table 3.1 Chemical ranges and limits for open-hearth and electric-furnace alloy steels—standard semifinished steel products (page 2 of 2)
Chemical Composition Limits (%)
M-131
AISI Corresponding
10/2010
Numbera/ Carbon Manganese Phosphorusb/ Sulfurb/ Silicon Nickel Chromium Molybdenum SAE Number
4640 0.38 to 0.43 0.60 to 0.80 0.040 0.040 0.20 to 0.35 1.65 to 2.00 0.20 to 0.30 4640
TS4720 0.17 t0 0.22 0.50 to 0.70 0.040 0.040 0.20 to 0.35 0.90 to 1.20 0.35 to 0.55 0.15 to 0.25 TS4720
4820 0.18 to0 0.23 0.50 to 0.70 0.040 0.040 0.20 to 0.35 3.25 to 3.75 0.20 to 0.30 4820
5026 0.43 to 0.50 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.20 to 0.35 5046
5132 0.30 to 0.35 0.60 to 0.80 0.040 0.040 0.20 to 0.35 0.75 to 1.00 5132
5140 0.38 to 0.43 0.70 to 0.90 0.040 0.040 0.20 to 0.35 0.70 to 0.90 5140
5150 0.48 t0 0.53 0.70 to 0.90 0.040 0.040 0.20 to 0.35 0.70 to 0.90 5150
5160 0.55 to 0.65 0.75 to 1.00 0.040 0.040 0.20 to 0.35 0.70 to 0.90 5160
E50100 0.95 t0 1.10 0.25 to 0.45 0.025 0.025 0.20 to 0.35 0.40 to 0.60 50100
E51100 0.95 t0 1.10 0.25 to 0.45 0.025 0.025 0.20 to 0.35 0.90 to 1.15 51100
E52100 0.95 to 1.10 0.25 to 0.45 0.025 0.025 0.20 to 0.35 1.30 to 1.60 52100
Vanadium
6120 0.17 t0 0.22 0.040 0.040 0.20 to 0.35 0.70 to 0.90 0.10 min.
6145 0.43 to 0.48 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 min.
6150 0.48 to 0.53 0.040 0.040 0.20 to 0.35 0.80 to 1.10 0.15 min. 6150
Molybdenum
8620 0.18 to 0.23 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.15 to 0.25 8620
8630 0.28 to 0.33 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.15 to 0.25 8630
S [M-131] 31
Casting Details
8540 0.38 to 0.43 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.15 to 0.25 8640
8655 0.50 to 0.60 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.15 to 0.25 8655
8660 0.55 to 0.65 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.15 to 0.25 8660
8720 0.18 to 0.23 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.20 to 0.30 8720
8740 0.38 to 0.43 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.20 to 0.30 8740
8745 0.43 to 0.48 0.040 0.040 0.20 to 0.35 0.40 to 0.70 0.40 to 0.60 0.20 to 0.30 8745
E9310 0.08 to 0.13 0.025 0.025 0.20 to 0.35 3.00 to 0.35 1.00 to 1.40 0.08 to 0.15 9310
9440 0.38 to 0.43 0.040 0.040 0.20 to 0.35 0.30 to 0.60 0.30 to 0.50 0.08 to 0.15 9440
9840 0.38 to 0.43 0.040 0.040 0.20 to 0.35 0.85 to 1.15 0.70 to 0.90 0.20 to 0.30 9840
a/ Those steels with the letter “E” before the designation number are to be made in the electric furnace.
b/ For acid open-hearth steel, the maximum phosphorus and sulphur is 0.05%.
c/ For open-hearth steel, the manganese is 0.40% to 0.60%.
Casting Details
M-131
3.2 The steel when ordered to other than standard analysis shall conform to the requirements as
to chemical ranges and limits prescribed in Table 3.2.
Notes:
1. Boron steels can be expected to have 0.0005% minimum boron content.
2. Data in Table 3.2 are applicable to other than standard semifinished steel products and are sub-
ject to permissible variations for check analysis (see Table 3.3).
Table 3.2 Chemical ranges and limits for basic and acid open-hearth steels—other than
standard semifinished steel products
When Maximum of Open-Hearth Electric-Furnace Maximum
Element Specified Element Is... Steels Steels Limit
Carbon To 0.25, incl. 0.06 a/ 0.09b/ 0.05a/ 0.08 b/
Over 0.25 to 0.40, incl. 0.07 a/ 0.10b/ 0.06a/ 0.09b/

Over 0.40 to 0.55, incl. 0.08a/ 0.10b/ 0.07a/ 0.09b/
Over 0.55 to 0.70, incl. 0.10a/ 0.12b/ 0.09a/ 0.11b/
Over 0.70 to 0.95, inc. 0.12a/ 0.15b/ 0.11a/ 0.14b/
Over 0.95 to 1.35, incl. 0.15a/ 0.18b/ 0.14a/ 0.17b/
Manganese To 0.45, incl. 0.20 0.15
Over 0.45 to 0.80, incl. 0.25 0.20
Over 0.80 to 1.15, incl. 0.30 0.25
Over 1.15 to 1.65 0.35 0.30
Over 1.65 to 2.10, incl. 0.40 0.35
Phosphorus Basic open-hearth steel 0.04
Acid open hearth steel 0.05
Basic electric-furnace steel 0.03
Acid electric-furnace steel 0.05
Sulphur To 0.060, incl. 0.02 0.02
Over 0.060 to 0.100, incl. 0.04 0.04
Over 0.100 to 0.140, incl. 0.05 0.05
Basic open-hearth steel 0.04
Acid open hearth steel 0.05
Basic electric-furnace steel 0.03
Acid electric-furnace steel 0.05
Silicon To 0.15, incl. 0.08 0.08
Over 0.15 to 0.20, incl. 0.10 0.10
Over 0.20 to 0.35, incl. 0.15 0.15
Over 0.35 to 0.60, incl. 0.20 0.20
Over 0.60 to 1.00, incl. 0.30 0.30
Over 1.00 to 2.20, incl. 0.40 0.35
Acid steelsc/
S [M-131] 32 10/2010
Casting Details
M-131
Table 3.2 Chemical ranges and limits for basic and acid open-hearth steels—other than
standard semifinished steel products
When Maximum of Open-Hearth Electric-Furnace Maximum
Element Specified Element Is... Steels Steels Limit
Nickel To 0.50, incl. 0.20 0.20
Over 0.50 to 1.50, incl. 0.30 0.30
Over 1.50 to 2.00, incl. 0.35 0.35
Over 2.00 to 3.00, incl. 0.40 0.40
Over 3.00 to 5.30, incl. 0.50 0.50
Over 5.30 to 10.00, incl. 1.00 1.00
Chromium To 0.40, incl. 0.20 0.15
Over 0.40 to 0.80, incl. 0.25 0.20
Over 0.80 to 1.05, incl. 0.30 0.25
Over 1.05 to 1.25, incl. 0.35 0.30
Over 1.25 to 1.75, incl. 0.50 0.40
Over 1.75 to 3.99, incl. 0.60 0.50
Molybdenum To 0.10, incl. 0.05 0.05
Over 0.10 to 0.20, incl. 0.07 0.07
Over 0.20 to 0.40, incl. 0.10 0.10
Over 0.40 to 0.80, incl. 0.15 0.15
Over 0.80 to 1.15, incl. 0.20 0.20
Tungsten To 0.50, incl. 0.20 0.20
Over 0.50 to 1.00, incl. 0.30 0.30
Over 1.00 to 2.00, incl. 0.50 0.50
Over 2.00 to 4.00, incl. 0.60 0.60
Vanadium To 0.25, incl. 0.05 0.05
Over 0.25 to 0.50, incl. 0.10 0.10
a/ These ranges for carbon apply to steel not exceeding 200 in.2 in cross-sec-
tional area, or 18 in. in width, or 10,000 lb. in weight per piece.
b/ These ranges for carbon apply to steel exceeding 200 in.2 in cross-sectional
area, or 18 in. in width, or 10,000 lb. in weight per piece.
c/ Minimum silicon limit for acid open-hearth or acid electric-furnace alloy
steels is 0.15%.
10/2010 S [M-131] 33
Casting Details
M-131
Table 3.3 Standard variations for check analysis of open-hearth and electric-furnace steels
Variation Over Maximum Limit or Under Minimum Limit (%)
Limit or Maximum of Over 100 to Over 200 to Over 400 to
Element Specified range (%) To 100 in.2 200 in.2, inclusive 400 in.2, inclusive 800 in.2, inclusive
Carbon To 0.30, incl. 0.01 0.02 0.03 0.04
Over 0.30 to 0.75, incl. 0.02 0.03 0.04 0.05
Over 0.75 0.03 0.04 0.05 0.06
Manganese To 0.90, incl. 0.03 0.04 0.05 0.06
Over 0.90 to 2.10, incl. 0.04 0.05 0.06 0.07
Phosphorus Over maximum only 0.005 0.01 0.01 0.01
Sulphur To 0.060, incl. 0.005 0.01 0.01 0.01
Silicon To 0.35, incl. 0.02 0.02 0.03 0.04
Over 0.35 to 2.20, incl. 0.05 0.06 0.06 0.07
Nickel To 1.00, incl. 0.03 0.03 0.03 0.03
Over 1.00 to 2.00, incl. 0.05 0.05 0.05 0.05
Over 2.00 to 5.30, incl. 0.07 0.07 0.07 0.07
Over 5.30 to 10.00, incl. 0.10 0.10 0.10 0.10
Chromium To 0.90, incl. 0.03 0.04 0.04 0.05
Over 0.90 to 2.10, incl. 0.05 0.06 0.06 0.07
Over 2.10 to 3.99, incl. 0.10 0.10 0.12 0.14
Molybdenum To 0.20, incl. 0.01 0.01 0.02 0.03
Over 0.20 to 0.40, incl. 0.02 0.03 0.03 0.04
Over 0.40 to 1.15, incl. 0.03 0.04 0.05 0.06
Tungsten To 1.00, incl. 0.04 0.05 0.05 0.06
Over 1.00 to 4.00, incl. 0.08 0.09 0.10 0.12
Vanadium To 0.10, incl. 0.01 0.01 0.01 0.01
Over 0.10 to 0.25, incl. 0.02 0.02 0.02 0.02
Over 0.25 to 0.50, incl. 0.03 0.03 0.03 0.03
Minimum value specified,
check under minimum limit 0.01 0.01 0.01 0.01
4.0 LADLE ANALYSIS

of the elements specified in Tables 3.1 and 3.2. This analysis shall be made from a test ingot taken
during the pouring of the heat. The chemical composition thus determined shall be reported to the
purchaser or purchaser’s representative and shall conform to the requirements specified in
paragraph 3.1.
S [M-131] 34 10/2010
Casting Details
M-131
5.0 CHECK ANALYSIS

5.1 Analysis may be made by the purchaser from material representing each heat or lot. The
chemical composition thus determined shall not vary from the ranges or limits specified in
Tables 3.1 and 3.2 by more than the amounts specified in Table 3.3, but the several determinations
of any element in a heat may not vary both above and below the specified range.
5.2 To indicate adequately the composition of a heat or lot, samples selected to represent the heat
as fairly as possible shall be taken midway between center and outside of the material, from a min-
imum number of pieces as follows:
Lots Number of Pieces

5 ton or less . . . . . . . . . . . . . . . 3
Over 5 to 10 ton, incl. . . . . . . . . 4
Over 10 to 15 ton, incl. . . . . . . . 5
Over 15 ton . . . . . . . . . . . . . . . . 6
5.3 If the number of pieces from a heat is less than the number of samples specified in
paragraph 5.2, one sample shall be taken from each piece.
5.4 When chips are taken by drilling, the approximate diameter of the drill used shall be as fol-
lows:
Area of Cross-Section Approximate

to be Sampled (in.2) Drill Diameter (in.)
16 and under. . . . . . . . . . . . . . . 1⁄2
Over16 . . . . . . . . . . . . . . . . . . . 1

6.1 Finish and Soundness
6.1.1 The material shall be free from injurious imperfections.
6.1.2 Material shall be furnished in condition to withstand for an indefinite time exposure to all
climatic conditions without developing any external or internal cracks. The method of cooling or of
treatment before shipment shall be optional with the manufacturer, but manufacturer shall be
responsible (in the same manner as for defects disclosed after delivery) for cracks that may develop
before material is subjected to reheating. When any other specific treatment or conditioning of
material is specified by the purchaser, the manufacturer shall be responsible only for carrying out
those specific operations.
6.1.3 When authorized by the purchaser, conditioning, cutting, or parting of material may be
done by scarfing or flame cutting when methods involving preheating and temperature control
necessary to avoid any damage to flame-cut material are employed.
10/2010 S [M-131] 35
Casting Details
M-131
6.2 Surface Conditioning

6.2.1 Material may be conditioned to remove injurious surface defects provided the depth of con-
ditioning does not exceed 1⁄16 in. for each inch of dimension concerned, up to a maximum depth of
3⁄4 in., and provided that the width of the conditioning is at least four times its greatest depth;
except that in the case of slabs where the width is at least twice the thickness, the depth of condi-
tioning on the wide surfaces may exceed this allowance by 50%, up to a maximum depth of 3⁄4 in.
The maximum depth of conditioning on two parallel sides at opposite locations shall not exceed
one and one-half times the maximum allowed for one side.
6.2.2 In special cases, particularly where it is necessary on large material and is not injurious,
greater depth of conditioning may be permitted by special agreement between the manufacturer
and the purchaser.
6.3 Permissible Variations in Weight
The permissible variation from the specified or theoretical weight of blooms, billets, and slabs
shall be ±5% for individual pieces or for lots of less than a carload. For carload lots, the permissible
variation shall be ±2.5% of the total weight of the lot.
7.0 MARKING
The heat number shall be legibly stamped on each bloom, billet, or slab. For blooms and billets
4 in. × 4 in. and larger in section and in slabs, the heat number shall be marked or stamped on a
side near the end or on the end when practicable. Billets less than 4 in. × 4 in. in section or slabs of
a size not practicable to be marked or stamped individually shall, when loaded for shipment, be
properly separated and identified. When the material is bundled, the heat number shall be
marked on a tag attached to the bundle.
8.1 Inspection
being furnished in accordance with these specifications. Tests and inspection shall be made at
place of manufacture prior to shipment unless otherwise specified.
8.2 Rejection
8.2.1 Material represented by samples that fail to conform to the requirements of this specifica-
tion will be rejected.
at the manufacturer’s works, or elsewhere, will be rejected and the manufacturer shall be notified.
8.3 Rehearing
Samples tested in accordance with this specification that represent rejected material shall be held
for a period of 14 days from date of the test report. In case of dissatisfaction with the results of the
tests, the manufacturer may make claim for a rehearing within that time.
S [M-131] 36 10/2010
Casting Details
M-131

One or more of the following supplementary requirements shall apply only when specified by the
purchaser in the inquiry, contract, and order. Details of these supplementary requirements shall
be agreed upon by the manufacturer and the purchaser.
S1 Specified Process The purchaser may specify that the steel shall be made in the basic open-hearth, acid
open-hearth, or electric furnace.
S2 Discard The purchaser may specify any definite amount of discard other than as provided in
paragraph 2.2.
S3 Incidental Alloy Content The purchaser may specify maximum amounts of incidental alloying elements.
S4 Restricted Chemistry The purchaser may specify a more restricted range (higher minimum or lower
maximum) or a more restricted limit for one or more elements than the standards
provided in Tables 3.1 and 3.2.
S5 Restricted Check The purchaser may specify more restrictive check analysis requirements for one or
Analysis more elements than those provided in Table 3.3.
S6 Guaranteed 1. When specified, the purchaser or his representative may select one top-cut billet,
Segregation Tests bloom, or slab from which to make check analyses to represent each heat. Two
sets of drillings shall be taken from the top face of this piece at points on the same
diagonal of the piece. The drillings shall. be taken with a 5⁄8 in. drill parallel to the
axis of the ingot as cast. The distance from the center of the piece to the drilling
points shall be, respectively, 15% and 80% of the length of the half diagonal of the
piece.
2. From the drillings taken at the 80% point, a complete analysis may be made. The
chemical composition thus determined shall conform to the requirements specified.
3. From the drillings taken at the 15% point, a carbon determination may be made.
The difference between the carbon content of the drillings from the 15% point and
that of the drillings from the 80% point, expressed as a percentage of the latter,
shall not exceed the following values:
Carbon Content
Thickness (in.) Difference (%)
15 or under . . . . . . . . . . . . . . . . 15
Over15 . . . . . . . . . . . . . . . . . . . 20
4. If, in any heat, the drillings taken in accordance with paragraph 1 do not conform to
the requirements prescribed in paragraph 3, additional drillings may be taken in a
similar manner after making a further top discard from the material from each’ingot
of at least 10% of the original weight. The results of this analysis shall conform to
the requirements prescribed in paragraph 3; otherwise the heat represented shall
be rejected.
S7 Guaranteed Heat When heat-treatment requirements are specified, all phases of testing procedure shall
Treatment be subject to agreement between the manufacturer and the purchaser. These involve
size of material to be tested; location of test bar; the size, shape, and method of
preparing test specimens, temperature and time of treatment; agitation of quenching
medium; and similar requirements. The minimum and maximum limits of a specified
hardness range shall be consistent with the hardness obtainable in the full range of the
specified chemical limits.
10/2010 S [M-131] 37
Casting Details
M-131
S8 Nonmetallic Inclusion When nonmetallic inclusion requirements are specified, the samples for testing shall
Requirements be taken on a longitudinal plane midway between the center and surface of the
material. The samples shall be hardened before being polished to avoid polishing pits;
and the area to be examined shall be agreed upon. The rating of the inclusion count
shall be based upon the average length of the inclusions, the longest inclusion, and the
general background. Any standards agreed upon shall be based upon a magnification
of 100×. Reference may be made to the Recommended Practice of Determination of
the Inclusion Content of Steel (ASTM Designation: E 45).
S9 Macroetch Tests The purchaser may specify macroetch tests. This test consists of deep etching a
representative section in hot acid. The location, number, and interpretation of tests
should be determined by the manufacturer and the purchaser before the steel is
produced. Reference may be made to the Tentative Method of Macroetch Testing and
Inspection of Steel Forgings (ASTM Designation: A 317).
S10 Magnetic Particle 1. Magnetic particle inspection consists in suitably magnetizing the material and
Testing applying a prepared magnetic powder that adheres to it along the lines of flux
leakage. On properly magnetized material, flux leakage developes along surface
or subsurface non-uniformities.
2. The magnetic particle test was developed for, and used primarily on, fully machined
or ground surfaces of finished parts.
3. The method of magnetic particle inspection varies with
a. the degree of magnetization
b. the methods of conducting the inspection, including such conditions as relative
location of surfaces tested and method and sequence of magnetizing and applying
the powder
c. the amperage
d. the interpretation of indications
4. There shall be definite agreement between the manufacturer and the purchaser
regarding method of conducting magnetic particle tests or methods of inspection
and the interpretation of the results. Reference may be made to the Standard
Methods for Magnetic Particle Testing and Inspection of Heavy Forgings (ASTM
Designation: A 275).
S11 Grain Size 1. Except as qualified in paragraph 2 below, carburized austenitic grain size may be
specified as coarse or fine; to be determined in accordance with the Standard
Classification of Austenite Grain Size in Steels (ASTM Designation: E 19). The
steel shall be designated as coarse-grain when the grain structure falls within the
limits depicted in photographs Nos. 1 to 5, inclusive, ASTM Grain Size Charts E 19;
and fine-grain when the grain structure falls within photographs Nos. 5 to 8,
inclusive. The grain structure shall be considered satisfactory if 70% is within the
specified grain size limits.
2. Due to certain manufacturing conditions, the grain size distinctions prescribed in
paragraph 1 above cannot be adhered to in blooms larger than 100 in.2 in
cross-sectional area nor in slabs larger than 20 in.× 5 in. For those larger sizes,
grain size requirements shall be negotiated between the manufacturer and the
purchaser.
S12 Fracture Tests When specified, the soundness and homogeneity of the material may be judged by a
transverse fracture test. When making the test, a central area equivalent to at least
10% of the total area of the end of the piece must be fractured. Before processing,
there shall be definite agreement between the manufacturer and the purchaser
regarding methods of conducting the test and interpretation of results.
S [M-131] 38 10/2010
Casting Details
M-131
S13 Surface Preparation The purchaser may specify, for purposes of making possible closer inspection, that the
material shall be pickled in acid, sand-or shot-blasted, or prepared by any other
agreed-upon method.
S14 Controlled Cooling When the purchaser desires closer control of cooling than provided in paragraph 6.1.2,
he may specify, when agreed upon, either
• a maximum controlled rate of cooling after hot working;
• annealing, normalizing, or normalizing and tempering; or
• a maximum hardness.
S15 Conditioning In case the maximum permitted depth for removal of surface defects as stated in
paragraph 6.2 is excessive for the purchaser’s requirements, purchaser may specify
either grinding or chipping to a maximum depth agreed upon.
S16 Marking and T h e purchaser may specify marking other than that required in paragraph 7.0.
Identification
S17 Ultrasonic Testing When agreed upon by the manufacturer and purchaser, ultrasonic testing may be
specified. There shall be definite agreement between the manufacturer and the
purchaser regarding methods of conducting ultrasonic tests and the interpretation of
results.
10/2010 S [M-131] 39
Casting Details
M-131
S [M-131] 40 10/2010
M-201
CASTINGS, STEEL
Specification
M-201

1.0 SCOPE
This specification covers carbon and alloy steel castings for locomotive and car equipment and for
miscellaneous use graded as A, B, B+, C, D, and E. This specification provides for all castings
unless another AAR specification for a particular product provides for a variation.
2.0 BASIS OF PURCHASE
2.1 Grade A castings shall be furnished unannealed, annealed, or normalized unless otherwise
specified by the purchaser. Grades B and B+ castings shall be furnished normalized or normalized
and tempered. Grade C castings shall be furnished normalized and tempered or quenched and
tempered. Grades D and E castings shall be furnished quenched and tempered.
2.2 At the purchaser’s request, a certification will be made the basis of acceptance. The certifica-
tion shall include a statement that the material has been manufactured, sampled, tested, and
inspected in accordance with, and meets the requirements of, all applicable provisions of these
specifications. Each certification furnished shall be signed by an authorized agent of the supplier
or manufacturer. Where not specifically stated, it is to be understood that upon the request of the
purchaser records mentioned in this specification shall be made available for review by the pur-
chaser.
3.0 RECORDS
The manufacturer shall maintain records for a minimum of 3 years of all of the weights, mechani-
cal test reports, chemical test reports, and heat-treatment records required by this specifica-
tion—representing the purchased castings. These records will be made available to the purchaser
upon request. The manufacturer shall also maintain records for a minimum of 3 years that provide
traceability from the serial number of individual castings, where serial numbers are required, to
the records stated above.
MANUFACTURE
4.0 PROCESS
The steel may be made by one or more of the following processes: open hearth, electric furnace,
crucible, converter, or basic oxygen.
5.0 HEAT TREATMENT
Castings shall be cleaned sufficiently to respond to heat treatment. Internal cavities shall not be
blocked by molding material. They shall then be treated according to the following procedure
appropriate to the requirements of paragraph 2.0.
After pouring, castings shall be allowed to cool to a temperature below 1000 °F (538 °C) prior to
heat treatment at a rate that will not be injurious to the castings.
5.1 Full Annealing
The casting shall be heated to the proper temperature above the transformation range for the re-
quired time to achieve complete austenization and to refine the grain structure. The casting shall
then be allowed to cool slowly in the furnace. Unless otherwise required by the purchaser, the man-
ufacturer has the option of normalizing instead of full annealing, where full annealing is specified.
10/2010 S [M-201] 41
M-201
5.2 Normalized Steel Castings

Normalized steel castings shall be processed in the following order:
5.2.1 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.
5.2.2 Withdraw from the furnace and cool in still air until temperature is below 700 °F (371 °C).
5.2.3 At the manufacturer’s option, Grades B and B+ castings specified as normalized may
receive a subsequent tempering.
5.3 Normalized and Tempered Steel Castings
Normalized and tempered steel castings shall be processed in the following order:
5.3.2 Withdraw from the furnace and cool in still air until castings in their entirety are at least
100 °F (38 °C) below tempering temperature.
5.3.3 Temper by reheating to the proper uniform temperature below the transformation range,
but not less than 600 °F (316 °C) and hold for the required time. Remove from the furnace and
allow to cool at any desired rate.
5.4 Quenched and Tempered Steel Castings
Quenched and tempered steel castings shall be processed in the following order:
5.4.2 Withdraw from the furnace and while castings are above the transformation range, subject
to rapid cooling by suitable liquid medium to a temperature substantially below the transforma-
tion range.
5.4.3 Temper by reheating to the proper uniform temperature below the transformation range,
but not less than 800 °F (427 °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 tem-
pering exceed 8 hours.
5.5 Heat-Treatment Documentation
These provisions apply only to truck frames, bolsters, coupler bodies, yokes, draft gear housings,
cushion units, and draft sills. The manufacturer is required to develop and document heat-treating
standards that describe the processes, process control procedures, and record keeping require-
ments. These documents are to be presented and reviewed as part of the Foundry Approval process
and are intended to ensure that products are properly heat treated. Furnace temperatures for heat
treatment shall be controlled by pyrometers having associated recording equipment that produce
time-temperature record charts that are identified by date and furnace number. A log sheet for
each load of castings heat treated should show all information pertinent to each heat-treat load
including the following:
• type of product
• the prescribed heat treatment
• the serial numbers (if not available, the heat numbers) of the castings on the load
• the identification number of the test coupon or coupons charged with the load
• actual time of heat treatment
S [M-201] 42 10/2010
M-201
Alternate procedures will be considered, provided a detailed proposal is submitted in writing to

the AAR for approval. This submission must ensure that the intent of this specification is being
complied with. Pyrometers shall be calibrated every 3 months. Records of time-temperature
charts, furnace log sheets, and pyrometer calibrations will be maintained for 3 years and available
to the purchaser upon request.
5.6 Test Lugs
For all castings, at least two and not more than four test lugs shall be cast on all castings 150 lb
and over and on such castings less than 150 lb as required by the purchaser. The location of the
test lugs shall be such that when removed by a qualified inspector, the test lugs shall indicate if
the casting has been subjected to heat treatment. Manufacturers shall document inspector qualifi-
cations and test lug inspection procedures. If inspection of the test lug indicates that the casting
has not been heat treated, the casting will be heat treated. The standard test lug shall be 1 in. in
height, 1 in. in width, and 1⁄2 in. or 5⁄8 in. thick where it joins the casting.
6.0 CHEMICAL PROPERTIES AND TESTS
The steel analysis shall meet the following:
Grades A, B, and B+ Grades C, D, and E

Carbon, maximum percentage 0.32 0.32
Manganese, maximum percentage 0.90 1.85
Phosphorus, maximum percentage 0.04 0.04
Sulfur, maximum percentage 0.04 0.04
Silicon, maximum percentage 1.50 1.50
6.1.1 Grades A, B, and B+ Steel

For each reduction of 0.01% carbon below the maximum specified, an increase of 0.04% manganese
above the maximum specified will be permitted to a maximum of 1.2%.
6.1.2 The content of elements other than those designated in paragraph 6.1 shall be selected by
the manufacturer to obtain the physical properties specified. Each manufacturer shall establish
requirements for tramp elements that can have an adverse effect on impact properties or welding.
The requirements shall account for contribution of tramp elements to the carbon equivalency (CE)
of the finished casting. For Grades A, B, and B+, a CE equal to 0.72 maximum is allowable based
on the formula given below and the maximum values of C, Mn, and Si in paragraph 6.1. For
Grades C, D, and E, a CE equal to 0.88 maximum is allowable. Formulas, such as given below and
justified by the manufacturer, are to be used for calculating carbon equivalency. The actual values
of C, Mn, and Si, along with the values for tramp elements, are to be used when calculating the CE
of actual melts.
CE = C + Mn + Si- + Cr + Mo + V- + Ni + Cu-
------------------ ------------------------------ ------------------
6 5 15
10/2010 S [M-201] 43
M-201
6.2 Hardenability
6.2.1 Grades D and E Steel
Composition of steel, except for coupler locks, shall produce in the standard Jominy test the mini-
mum hardness at 7⁄16 in. from the quenched end for the carbon composition as follows, based on the
initial composition:
Percentage Carbon Minimum Hardness, Rc

up to .25 30
0.25 to 0.30 33
0.31 to 0.32 35
6.2.2 Frequency of Test

Following satisfactory Jominy test results for 10 consecutive heats, the manufacturer shall con-
duct one Jominy test at least once every month for Grades D and E steel.
6.2.3 Hardenability Calculations
The Ideal Critical Diameter (DI) shall be calculated for each heat of quenched and tempered steel
in accordance with ASTM Designation A255, latest revision, Appendix III. The calculated DI value
shall be shown as information on the report of mechanical and chemical tests as defined in
paragraph 3.0.
6.3 Chemical Analyses
6.3.1 Ladle Analysis
An analysis of test samples taken during the initial 25% of the castings poured from each ladle
must be made by the manufacturer to determine the percentage of carbon, manganese, phospho-
rus, sulfur, and silicon and of the intentional alloying elements. The result of this analysis shall be
reported to the purchaser or purchaser’s representative upon request and shall conform to the
requirements of paragraph 6.1. If drillings are used, they must be taken at least 1⁄4 in. beneath the
surface of the test ingot.
6.3.2 End of Heat Analysis
For each heat of steel, a sample representing the last metal going into, or taken after the pouring
of, the last acceptable casting must be used by the manufacturer to determine the percentage of
manganese. The results of this analysis shall be reported to the purchaser or purchaser’s represen-
tative upon request and shall conform to the requirements of paragraph 6.1. If drillings are used,
they must be taken at least 1⁄4 in. beneath the surface of the test ingot.
6.4 Check Analysis
An analysis may be made by the purchaser from the broken tension test specimen or from a cast-
ing of each heat. The chemical composition thus determined shall conform to the requirements
specified in paragraph 6.1. Drillings for analysis shall be taken not less than 1⁄4 in. beneath the
surface and shall be taken in such a manner as not to impair the usefulness of a casting.
S [M-201] 44 10/2010
M-201
7.0 MECHANICAL PROPERTIES AND TESTS

7.1 Tensile Test Specimen Coupons
7.1.1 At the manufacturer’s option, coupons shall be either cast attached to the casting or the gat-
ing system or produced from keel blocks and prepared in accordance with ASTM Designation
A370, latest revision.
7.1.2 The process used for the manufacture of keel blocks shall be representative of the manufac-
turer’s normal process methods.
7.1.3 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 cast-
ings they represent. Each heat treat furnace load shall include at least one test coupon of the same
grade of steel and have its mechanical properties determined and recorded. Batch process heat
treat furnace load is defined as all the castings in the heat-treat furnace of the same grade of steel.
Continuous process heat-treat furnace load is defined as all the castings of the same grade of steel
that pass a given location in the furnace during the period of one heat-treating cycle.
7.2 Tension Test
7.2.1 Test shall be conducted in accordance with Standard Methods and Definitions for Mechani-
cal Testing of Steel Products, ASTM Standard A370, latest revision, using l/2-in. round (13-mm)
2-in. (50-mm) gauge-length specimens as illustrated in that specification. Specimens are to be
removed from coupons produced per paragraph 7.1.1.
7.2.2 The steel used for the casting shall conform to the following minimum requirements.
Grade A
Grade Grade Grade Grade Grade
Annealed or B B+ C D E
Unannealed
Normalized
Tensile strength (ksi) 60 60 70 80 90 105 120
Yield point (ksi) 30 30 38 50 60 85 100
Elongation in 2 in. (percentage) 22 26 24 24 22 17 14
Reduction of area (percentage) 30 38 36 36 45 35 30
7.2.3 The manufacturer shall test specimens from melt heats and record results, excluding
flawed specimens. One specimen per heat for each grade of steel shall be tested. If a test specimen
shows a defect during machining or exhibits flaws before or after testing, it shall be discarded and
another specimen substituted. Specimens are to be removed from coupons produced per
paragraph 7.1.1. Results of testing must show compliance with the requirements of
paragraph 7.2.2 prior to shipment of finished castings.
7.2.4 If the percentage of elongation of any tension specimen is less than that specified, and any
part of the fracture is more than 3⁄4 in. from the center of the gauge length as indicated by the
gauge marks on the specimen before testing, a retest is allowed. Specimens are to be removed from
coupons produced per paragraph 7.1.1.
7.2.5 At the time of purchase, at only the purchaser’s option, specimens may be cut from castings
(excluding flawed specimens) and must have at least 80% of the tensile and yield properties estab-
lished in paragraph 7.2.2.
10/2010 S [M-201] 45
M-201
7.3 Impact Test

7.3.1 The steel impact properties may be determined by testing standard Charpy-V Notch Type A
specimens prepared as illustrated in Figure 11 in ASTM Standard A370. Specimens are to be
removed from coupons produced per paragraph 7.1.1. A test consists of determining the average
energy absorbed from three impact specimens from the same heat. The results shall meet the fol-
lowing minimum requirements at the stated temperature:
Cast Steel Temperature (°F) Energy (ft·lb)

Grades B and B+ +20 15
Grade C (NT) 0 15
Grade C (QT) –40 20
Grade D –40 20
Grade E –40 20
7.3.2 Impact tests shall be conducted in accordance with the Standard Methods and Definitions
for Mechanical Testing of Steel Products, ASTM Standard A370, latest revision.
7.3.3 The manufacturer shall test specimens from melt heats and record results, including chem-
istry of that heat, excluding flawed specimens. Frequency of these tests shall be one test per week
per grade of steel obtained during the pouring of the last 25% of the heat. Specimens are to be
removed from coupons produced per paragraph 7.1.1.
7.3.4 As a manufacturer’s alternative, impact properties may be determined by use of the
Dynamic Tear Test (ASTM E604) or the Nil Ductility Transition Test (ASTM E208). Specimens are
to be removed from coupons per paragraph 7.1.1.
7.3.4.1 The Dynamic Tear test shall consist of determining the average energy absorbed from
three specimens from the same heat that shall be a minimum of 50 ft·lb at the temperature speci-
fied in the table in paragraph 7.3.4.3.
7.3.4.2 The Nil Ductility test shall consist of testing two specimens at the temperature specified
in the table in paragraph 7.3.4.3. Both specimens shall exhibit “no-break” performance.
7.3.4.3 Dynamic Tear and Nil Ductility Test Temperature
Cast Steel Testing Temperature (°F)

Grades B and B+ +60
Grade C (NT) +60
Grade C (QT) –60
Grade D –60
Grade E –60
7.3.5 A check test may be made by the purchaser from a casting at purchaser’s expense. Results
of this testing shall conform to the minimum values specified in paragraph 7.3.4.
S [M-201] 46 10/2010
M-201
7.4 Hardness
7.4.1 Cast steel components, except as provided for in product specifications, must be within a
Brinell Hardness range as follows:
Material Grade Identification BHN Range

Grade A 108–160
Grades B and B+ 137–228
Grade C 179–241
Grade D 211–285
Grade E 241–311
7.4.2 Testing is to be done on a surface that has been ground to remove decaburization in accor-
dance with ASTM A370. This may be used as a process check as needed to supplement other test
results. A hardness test is to be performed on a furnace heat lot basis of either one casting or cou-
pon.
8.0 NUMBER OF TESTS, SMALL ORDERS
In case of small orders for castings weighing over 180 lb where the size of the order and the avail-
able pattern and foundry equipment are such that not more than five castings can be cast in one
heat, the physical properties, as required in paragraph 7.0, will be determined from an extra or
spare test coupon cast with and attached to some other casting of the same heat.
9.0 RE-HEAT TREATMENT
If the results of the physical test lot do not conform to the requirements specified, the manufac-
turer may re-heat treat such lot not more than twice, and retests shall be as specified in
paragraph 7.0.
WORKMANSHIP AND FINISH

10.0 WORKMANSHIP
All castings shall conform to the drawing tolerances furnished to the purchaser or to the dimen-
sions predicated by the pattern supplied by the purchaser, if no drawing has been provided.
11.0 FINISH
The castings shall be free from injurious defects, and shall be thoroughly cleaned when offered for
inspection.
12.0 WELD REPAIR OF DEFECTS
12.1 Weld Repair of Defects
Manufacturers are to have specific procedures for weld repairs to castings, including but not lim-
ited to restrictions to the amount of weld repair allowed for both critical and non-critical areas of
the castings. The requirements of this specification are also to be incorporated in the manufac-
turer’s procedures. 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 1⁄8 in. 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 defect continues through the casting and is inaccessible
from both sides and unless prohibited by specific component specification, defect may be weld
repaired by using a copper backup plate provided the surface is smooth and clean.
12.2 Welders, welding operators, and welding procedures shall be qualified in accordance with
AWS 15.1, Railroad Welding Specification, latest revision.
10/2010 S [M-201] 47
M-201
12.3 Defects may be repaired by using a metal-electrode arc welding process that 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 the product spec-
ification for the component involved.
12.4 Grade A, B, B+, C, D, or E castings shall not be welded while the temperature of the casting
is below 40 °F. Localized pre-heating to a minimum of 40 °F is acceptable. The temperature shall
not exceed 600 °F to avoid the possibility of warping.
12.5 For Welding Grade A Steel Castings
If a shielded metal arc process is used, the electrode shall be E6015, E6016, E6018, or equivalent.
12.6 For Welding Grades B and B+ Steel Castings
If a shielded metal arc process is used, the electrode shall be a low hydrogen coated type as follows:
• for Grade B—AWS/ASTM Class E7015, E7016, E7018, E8015, E8016, E8018, or equiva-
lent may be used
• for Grade B+—AWS/ASTM E8015, E8016, E8018, E9015, E9016, E9018, or equivalent
may be used
12.7 For Welding Grade C Steel Castings
If a shielded metal arc process is used, the electrode shall be a low hydrogen coated type,
AWS/ASTM Class E9015, E9016, E9018, or equivalent. At the option of the manufacturer, an elec-
trode of the AWS/ASTM Class E10015, E10016, E10018, or equivalent may be used for higher
mechanical properties after heat treatment.
12.8 For Welding Grade D Steel Castings
If a shielded metal arc process is used, the electrode shall be a low hydrogen coated type
AWS/ASTM E11015, E11016, E11018, or equivalent.
12.9 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, El3018, or equivalent.
13.0 MARKING
When marking requirements are not covered by individual product specification, the manufac-
turer’s identification mark, the pattern number and grade, and when specified, the purchaser’s ini-
tials shall be legibly cast on all castings.
14.0 VARIATION IN WEIGHT
When not covered by individual product specification, the normal weight shall have been previ-
ously agreed upon between the purchaser and the manufacturer. Castings may vary not more than
5% above or 3% below what has been determined as the normal weight for the castings.
S [M-201] 48 10/2010
Casting Details
M-201
INSPECTION AND REJECTION

15.0 INSPECTION
15.1 The inspector representing the purchaser shall have free entry, at all times while the work
being furnished in accordance with these specifications. Tests shall be made prior to shipment, and
inspection shall be made prior to shipment at the place of manufacture unless otherwise specified.
15.2 The purchaser may make tests to govern the acceptance or rejection of the material in pur-
15.3 Rejection
Material represented by samples that fail to conform to the requirements of these specifications or
to individual product specification will be rejected.
15.4 Material that, subsequent to test and inspection at the foundry or elsewhere and its accep-
tance, shows injurious defects, will be rejected and the manufacturer shall be notified.
15.5 AAR Representation
In addition to the purchaser’s representation, an AAR official representative shall have free entry
at all times to all parts of the manufacturer’s works that concern the manufacture, test, and
inspection of materials for use in interchange service. This access is for the purpose of providing
assurance that industry standards are being maintained. The manufacturer shall afford the AAR
representative all reasonable facilities to ensure that materials are being furnished in accordance
with these specifications.
10/2010 S [M-201] 49
Casting Details
M-201
S [M-201] 50 10/2010
M-202
TRUCK BOLSTERS, CAST OR STRUCTURAL—DESIGN AND TESTING
Specification
M-202

1.0 SCOPE
1.1 These specifications cover all truck bolsters for freight equipment. This excludes span bol-
sters, which are covered by Specification M-975, and 3-axle truck bolsters, which are covered by
Specification M-203A.
1.2 All designs of truck bolsters must be approved by the Coupling System and Truck Castings
Committee (CSTCC) before being placed in interchange freight service. The basis for approval is
provided by this specification.
1.3 Application for approval shall be addressed to the Chief—Technical Standards, Transporta-
tion Technology Center, Inc. The application shall be accompanied by copies of detail construction
drawings and full information with respect to composition of material and heat treatment
employed. The preferred method of transmission is electronic, submitted in either .tif or .pdf for-
mat to techstds@aar.com.
1.4 Approval will be based upon the results of dynamic and static tests. The CSTCC may recom-
mend approval of the design, material, and heat treatment with tests waived on the basis of previ-
ous satisfactory static and dynamic tests of similar designs, material, and heat treatment.
Waiver of tests should be requested only on the basis of a design previously approved as a result of
official dynamic and static tests. The waiver request should be accompanied by substantiating
data covering the new design and the design being used as a basis for such request when there are
differences not covered by Appendix A.
2.0 MATERIAL
Material shall be one of the following, as designated, and shall conform to the latest revision of the
appropriate specifications.
Cast Steel Specification M-201 and M-210, Grade B, B+, or C

Structural MSRP Section C-II, Specification M-1001, Chapter 3, Materials—Body Structure
3.0 DESIGN
3.1 All standard fundamental AAR requirements, in addition to those specifically mentioned
herein, shall govern.
3.2 The minimum basis for testing shall be the vertical load “P” as given in Table 3.1, obtained as
follows:
P = 2C-2000 (d-4)
C = Axle capacity
d = Journal diameter
10/2010 S [M-202] 51
M-202
Table 3.1 Minimum vertical test loads by GRL

Gross Rail Load of Two C P
Journal Size Truck Type 4-Wheel Trucks (lb) Axle Capacity (lb) Vertical Load (lb)
5 1⁄2 × 10 2D 177,000 42,000 81,000
6 × 11 2E 220,000 52,500 101,000
6 1⁄2 × 12 2F 263,000 63,000 121,000
286,000 68,750 132,500
6 1⁄2 × 9 2K 263,000 63,000 121,000
286,000 68,750 132,500
7 × 12 2G 315,000 76,000 146,000
3.3 Best practices for bolster designs shall be used. A documented design process utilizing best
practices shall be completed for each bolster design with documentation available for review by
purchaser upon request. Documentation shall be maintained by the manufacturer to demonstrate
that the design process is continually utilized to ensure adequate designs according to this specifi-
cation. Finite element techniques and solidification analysis are examples of best practices and
shall be performed by the manufacturer for each bolster design.
For the design, the vertical load, P, shall be taken as acting on the centerline of the bolster any-
where within 8 in. each side of the center of the bolster; also anywhere from the center of spring
support to a point 23 in. from the center of the bolster. The transverse load, equal to 0.25P, shall be
taken as acting on the neutral axis and shall be applied only at the center of the bolster.
4.0 STATIC TEST REQUIREMENTS
4.1 At least two specimens of each new design shall be tested in a suitable static testing machine
under the supervision of a representative of the CSTCC. The two specimens selected shall be good
average product.
4.2 Bolsters shall comply with the requirements of Table 4.1. The transverse and the vertical
tests shall be made separately. The vertical loads shall be applied separately, first at side bearing
and then at the center plate. The same specimen may be used for the transverse and the two verti-
cal loading tests.
4.3 Table 4.1 provides the minimum basis for computing test loads.
Table 4.1 Minimum computational load cases
Load in Pounds
Vertical
Transverse Grades B, B+, and C
Center Plate
Vertical Side Bearing
Load for zero setting of instruments 5000 5000 5000
Additional load for maximum deflection .95P 1.43P 1.43P
Load for maximum permanent set 1.9P 2.38P 2.85P
Minimum ultimate load ……. ……. 5.22P
S [M-202] 52 10/2010
M-202
4.4 Table 4.2 provides the minimum values from paragraph 4.3 to be used in actual testing:
Table 4.2 Minimum load cases for testing
6 1⁄2 × 12
5 1⁄2 × 10 6 × 11 and 7 × 12
6 1⁄2 × 9
Gross rail load of two 4-wheel trucks (lb) 177,000 220,000 263,000 286,000 315,000
P—vertical load 81,000 101,000 121,000 132,500 146,000
Load 0.95P (deflection) 82,000 101,000 120,000 130,900 143,000
Table 4.3 Limits specified for testing loads and conditions

Test Requirements (in.)
Grade B Grade B+ Grade C
.075 .100 .120 Maximum (transverse) deflection for a minimum load of . . . . . .95P
.025 .025 .025 Maximum (transverse) permanent set at a minimum load of . . 1.9P
.055 .063 .070 Maximum (side bearing) deflection for a minimum load of . . . . 1.43P
.025 .025 .025 Maximum (side bearing) permanent set at a minimum load of. 2.38P
.075 .091 .105 Maximum (center plate) deflection for a minimum load of . . . . 1.43P
.025 .025 .025 Maximum (center plate) permanent set at a minimum load of . 2.85P
Minimum ultimate load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22P
4.5 The deflection measuring instruments shall be located midway between supports of speci-
mens and shall set at zero under an initial load of 5000 lb. A load of 20,000 lb shall be applied and
then released to 5000 lb for the zero setting of instruments.
10/2010 S [M-202] 53
M-202
4.6 Loading Diagrams for Static Tests

Fig. 4.1 shows the method for transverse test loading and Fig. 4.2 shows the method for vertical
test loading of truck bolsters.
NOTE: SET-UP IS TYPICAL; VARIATIONS ARE PERMITTED IN DESIGN OF APPARATUS, ALSO

TO SUIT DESIGN OF BOLSTER, PROVIDED TEST RESULTS ARE NOT AFFECTED.
Fig. 4.1 Diagram of bolster test fixture for use in transverse loading
S [M-202] 54 10/2010
M-202
NOTE: SET-UP IS TYPICAL; VARIATIONS ARE PERMITTED IN DESIGN OF APPARATUS, ALSO

TO SUIT DESIGN OF BOLSTER, PROVIDED TEST RESULTS ARE NOT AFFECTED.
Fig. 4.2 Diagram of bolster test fixture for use in vertical loading
5.0 DYNAMIC TEST REQUIREMENTS
5.1 Dynamic test requirements were developed based on the AAR study reported in AAR Report
R-440, “Analysis of Road Service Environmental Data and Laboratory Fatigue Test Data for Devel-
opment of Recommended Bolster Fatigue Test Guidelines,” dated August, 1980.
For approval, a minimum of three bolsters shall be selected from a lot of twenty-five by a represen-
tative of the Committee. Fatigue tests shall be performed on such machines as shall be approved
by the CSTCC, with at least two tests under the supervision of a representative of that Committee
(and with the unsupervised test being reviewed by the same representative).
5.2 Load Positions
The bolster shall be positioned in a fixture where vertical loads can be applied as illustrated in
Fig. 5.1 at positions Z', G, Q, C, and Z. The load is reacted at positions S and S'. The loads applied
at positions Z' and Z are 25 in. on each side of the center pin (Q) position. The loads acting at these
positions shall be applied through a block bolted to the bolster that is representative of conven-
tional side bearings. The loads acting at positions G, Q, and C shall be applied through a simulated
standard AAR car body center plate with 3° chamfer. Positions S' and S are schematically shown at
the center of the bolster spring seat supports. These supports shall simulate the load reactions
normally offered by spring groups. A double rocker block support is a satisfactory simulation of
this type of support. Fig. 5.2 is a sketch of a typical loading arrangement.
10/2010 S [M-202] 55
M-202
G Q C
Z' Z
S' S
EQUIDISTANT EQUIDISTANT
L TO C
C L OF TRUCK COLUMNS
Fig. 5.1 Diagram of referenced bolster loading positions
LOADING TO LOADINGS TO
SIMULATED SIDE SIMULATED BODY
BEARING CENTER PLATE
2'-1" LOADING BEAM
EQUIDISTANT EQUIDISTANT
L TO C
C L OF TRUCK COLUMNS
SETUP IS TYPICAL, VARIATIONS ARE PERMITTED UPON
APPROVAL BY EQUIPMENT ENGINEERING COMMITTEE
Fig. 5.2 Sketch of a typical bolster loading arrangement

5.3 Description of Cyclic Loads
The fatigue test shall consist of the application of the following types of cyclic loads. The resultant
wave forms obtained from a computer-controlled hydraulic loading system are shown in Figs. 5.3
through 5.5.
5.3.1 Rock Load
A vertical load R (see Table 5.2) shall be moved alternately through positions Z', Z, Z', Z, etc. In
order to mechanically stabilize the loading means, an additional load may be applied on the center
plate at all times. This type of loading constitutes the first 25% of the total load cycles on each test
block (see Fig. 5.3).
5.3.2 Bounce Load
The bounce load shall be applied vertically to center plate areas only. This type of loading consti-
tutes the remaining 75% of the total load cycles of each test block.
S [M-202] 56 10/2010
M-202
5.3.2.1 Simulation
The application of the bounce loads shall follow a path according to the following load sequence of
Table 5.1 (see Fig. 5.4).
To complete this bounce load sequence, additional full center plate loadings shall be applied at
position Q, varying from B-2 to B-l magnitude. The number of loads at Q shall equal the total num-
ber of loads at positions C and G (see Fig. 5.5).
Table 5.1 Vertical bolster loading sequence
Load Position of Load
Magnitude Line of Action
B-2 G
B-1 G
B-2 G
B-2a/ Qa/
B-2 C
B-1 C
B-2 C
B-2a/ Qa/
B-2 G
a/ May be deleted, if desired
5.4 Load Magnitudes

The minimum magnitudes of the cyclic loads are given in Table 5.2.
Table 5.2 Minimum load cycle magnitudes vs GRL
Gross Wheel Load
Journal Two 4-Wheel Trucks B-1 B-2 R
Size (in.) (lb) (lb) (lb) (lb)
5 1⁄2 × 10 177,000 191,000 27,000 85,000
6 × 11 220,000 238,000 33,000 110,000
6 1⁄2 × 12 and 263,000 285,000 40,000 130,000
6 1⁄2 × 9 286,000 310,000 43,500 141,000
7 × 12 315,000 342,000 48,000 155,000
5.5 Cyclic Load Application

The fatigue test shall consist of applying each type of cyclic load in a fixed loading block sequence
with rock load cycles followed by bounce load cycles. A minimum of three bolsters shall be tested to
a minimum of 700,000 cycles per bolster.
A loading block sequence shall consist of 100,000 total cycles. Blocks shall be repeated to reach the
total number of 700,000 cycles. See Table 5.3 for the details of the 100,000-cycle loading block.
Table 5.3 Loading block
Loads Cycles
Rock load cycles (Z-Z') 25,000 Fig. 5.3
Bounce load cycles (center plate edge) (Load C-G). 37,500 Fig. 5.4
Bounce load cycles (uniform center plate center) (Load Q) 37,500 Fig. 5.5
Total Cycles 100,000
10/2010 S [M-202] 57
M-202
Z' G Q C Z
S' S
ROCK LOADING
R
LOAD
AT
Z
DWELL
LOAD
AT
Z'
O TIME
1 CYCLE 1 CYCLE
DWELL PERIOD FOR MOVEMENT OF LOADING BEAM
Fig. 5.3 Vertical edge “bounce” input into the side bearing location
S [M-202] 58 10/2010
M-202
Z' G Q C Z
S S
EDGE BOUNCE LOADING
B1
LOAD
AT
G
B2
O
LOAD
AT
Q
B2
O
B1
LOAD
AT
C
B2
O
TIME
1 CYCLE 1 CYCLE
Fig. 5.4 Vertical edge “bounce” input into the center bowl location
10/2010 S [M-202] 59
M-202
Z' G Q C Z
S'
S
CENTER BOUNCE LOADING
B1
LOAD
AT
Q
B2
O
TIME
1 CYCLE 1 CYCLE
Fig. 5.5 Vertical “bounce mode” input into the center bowl location
5.6 Test Requirements
Cyclic loads shall be applied until the bolster fails or until the proponent elects to stop the test.
Failure is defined as the occurrence of one or more of the following conditions:
• Inability of the bolster to support the B-l or R load.
• Separation of any segment of the bolster from the parent structure.
• Permanent deflection exceeding 1⁄4 in.
The test requirement is met if none of the three bolsters tested has failures as described above.
If cracks develop in any zone during testing, a record must be submitted of when they occurred in
the test sequence, their size, location (including designation for Zone 1, 2, or 3), orientation, and
propagation history for determining influence on structural integrity and development of crack
acceptance/rejection criteria.
5.7 Static Test
The manufacturer may, at the conclusion of the cyclic testing, apply a static load of the force shown
in B-l of Table 5.1 at position Q and hold for a short duration of time. This optional test is not part
of the acceptance requirement.
6.0 MARKING
6.1 All approved cast truck bolsters shall be legibly marked as follows:
6.1.1 All Designs
AAR identification number must be cast integral to the casting as follows:
Grade Steel Marking Example

B AAR-B (identification number) AAR-B 1400
B+ AAR-B+ (identification number) AAR-B+ 1402
C AAR-C (identification number) AAR-C 1401
S [M-202] 60 10/2010
M-202
6.1.2 The markings specified above, when properly applied by the manufacturer, will serve as a
positive means of certifying that the design has been approved.
6.2 Coded Designs
Apply a proper code number that fully identifies the design, including material and heat treat-
ment. The code number system is shown in the AAR Manual of Standards and Recommended
Practices, Section S, Part II, Standard S-392, which is the AAR code for designating design fea-
tures for side frames and truck bolsters having built-in snubbing devices and single shoe brakes.
6.3 All truck bolsters made of structural steel shall be legibly marked with the letters AAR-S, fol-
lowed by the identification number assigned (e.g., AAR-S-1402). This marking is in addition to
those required in Chapter 3 of MSRP Section C, Part II, Specification M-1001.
6.4 The markings specified in paragraphs 6.1 and 6.2 are in addition to those required by Specifi-
cation M-201 in this manual. Location of markings is specified in MSRP Section S, Part II, Stan-
dards S-312 and S-314.
6.5 The code number, when applicable, as well as the identification number shall be shown on the
manufacturer’s detail drawing.
6.6 The manufacturer is to include a serial number on the bolster based on the month and year in
which the bolster was manufactured. Location on the bolster is to be according to MSRP Section S,
Part II, Standard S-312.
7.0 TEST FACILITY AND OBSERVERS
7.1 Tests and testing must be performed at a facility approved by the CSTCC. An AAR represen-
tative approved by the CSTCC must witness tests and provide test data and certification to the
AAR that test procedures and results are fully in accordance with AAR requirements.
7.2 The applicant requesting approval of the bolster shall make all arrangements for these tests
in accordance with these requirements.
7.3 Following successful completion of official witnessed testing, a test report is to be submitted
to the Chief—Technical Standards, Transportation Technology Center, Inc. This report shall
include the following information on the test specimens:
• Metal thickness readings compared to drawing dimensionsa/
• Internal solidity levelsa/
• Chemistry
• Mechanical properties, including impact
• Grain sizea/
• Model No., serial No., cast date
• Weight
• Radiographsa/
a/ To be recorded for 1) turn of spring seat; and 2) bottom tension member
10/2010 S [M-202] 61
APPENDIX A M-202
APPENDIX A
REQUIREMENTS GOVERNING APPLICATIONS FOR APPROVAL OF
BOLSTER DESIGNS UNDER LATEST ISSUE
1.0 Approval under this specification applies only to the foundry from which the approved
bolsters are produced, and if a manufacturer desires that more than one foundry be approved,
each foundry must be approved independently. The procedure for obtaining and maintaining
foundry approval is contained in Specification M-210.
2.0 The Committee reserves the right to select truck bolsters from production for subsequent
tests at no cost to the manufacturer aside from furnishing the test specimens.
3.0 This appendix provides the guidelines used by the CSTCC to determine what constitutes a
change in bolster designs and whether new approvals are necessary or not.
3.1 All base designs not already approved shall be submitted to the Chief—Technical Standards,
Transportation Technology Center, Inc., for CSTCC approval or notification that official AAR tests
are required.
3.2 Approval of a design applies only to the foundry for which it is approved; it does not cover an
identical or similar design made by another foundry or the same design made of a different mate-
rial by the same foundry.
3.3 In the event a foundry fails to maintain an approved status, the designs and castings previ-
ously produced will retain their AAR approval and identification number.
3.4 In the event a significant change is made to the casting process, such as using light-weight
casting procedures or changes to the casting wall thicknesses, the manufacturer shall submit
designs affected to the Chief—Technical Standards, Transportation Technology Center, Inc., for
Committee approval or notification that official AAR tests are required.
4.0 When a base pattern design has been approved, such approval will also apply to any issues of
that pattern when any of the following changes are made:
• Style of end casting within spring seat area where no reduction is made in the strength of
critical sections.
• Style and location of dead lever bracket or omission of same.
• Addition or removal of integral friction or pocket-type side bearings or change in contour of
side bearing pad.
• Addition or removal of finish allowances in center plate.
• A reduction of 1⁄2 in. or less in the distance from the spring or support seat to the center
plate bearing surface.
• Any increase in the distance from the spring or support seat to the center plate bearing
surface.
• Change in diameter and rim height of conventional center plate bowl.
• Change in side bearing spacing, provided the centerline of the side bearing is located
within the region from the center of the spring support to a point 23 in. from the center of
the bolster.
• Addition or removal of retaining key slots in the side walls of the bolster for locking center
pins, providing that the top of the key is 3 in. below the center plate bearing surface and
that the top and bottom of the slots are formed by a radius.
• Addition or removal of construction required for application of miner-safety locking pin.
• Lowering the center plate surface 1⁄4 in. to allow for a center plate liner, providing that the
average metal thickness is maintained.
S [M-202] 62 10/2010
M-202 APPENDIX A
4.1 Patterns previously approved for Grade B may be approved for Grade B+ or Grade C, and pat-
terns previously approved for Grade B+ may be approved for Grade C if patterns are unchanged
and a new pattern number is assigned.
4.2 All changes to pattern numbers with an assigned AAR I.D. number that do not require AAR
approval must be forwarded to the AAR in the format shown in Appendix B.
5.0 TEST SPECIMENS
5.1 All test specimens presented for static and dynamic testing shall be produced by the manu-
facturer’s normal production methods as defined in Specification M-210, Appendix A, and be repre-
sentative of the manufacturer’s average commercial product. The test bolsters shall not be given
any special preparation that has not been given all truck bolsters in the course of regular produc-
tion. An advance I.D. number will be issued to allow production. Bolsters cannot be placed in reve-
nue service until AAR approval is granted. Records must be kept of all castings produced prior to
receipt of official AAR approval.
5.2 If the representative of the CSTCC rejects the test specimens due to apparent special prepa-
ration, he shall so inform the manufacturer. At the manufacturers’ request and expense, an inspec-
tion of similar products ready for shipment will be made by such representative or by the CSTCC
prior to testing to determine if the specimens presented for test are representative of the manufac-
turer’s regular production. The CSTCC shall make the final decision in case of appeal.
10/2010 S [M-202] 63
APPENDIX B M-202
APPENDIX B
FORMAT FOR SUBMITTING CHANGES TO
BASE DESIGN PATTERN NUMBERS
Date: ______________________________
Subject: Side Frame/Bolster Pattern Number Change
Chief—Technical Standards
55500 DOT Road
Pueblo, CO 81001
Email: techstds@aar.com
Dear Sir:
Please be advised of the following change to the pattern number of this side frame/bolster cited.
 Side Frame  Bolster
New Design
Pattern No. Applicable AAR I.D. No.a/
Drawing No.
Original Approved Design

Pattern No.
Drawing No.
a/ I.D. number assigned by manufacturer

based on original approved base design
AAR I.D. number as covered in
Specification M-202 or Specification M-203,
Appendix A.
Yours truly,
Company
S [M-202] 64 10/2010
M-203
TRUCK SIDE FRAMES, CAST STEEL—DESIGN AND TESTING
Specification
M-203

1.0 SCOPE
1.1 This specification covers all cast steel side frames for freight equipment.
1.2 All designs of truck side frames must be approved by the Coupling System and Truck Cast-
ings Committee (CSTCC) before being placed in interchange freight service. The basis for approval
is provided by this specification.
1.3 Application for approval shall be addressed to the Chief—Technical Standards, Transporta-
tion Technology Center, Inc. Application shall be accompanied by copies of detail construction
drawings and full information with respect to composition of material and heat treatment
employed. The preferred method of transmission is electronic submitted in either .tif or .pdf format
to techstds@aar.com.
1.4 Approval will be based upon the results of dynamic and static tests. The CSTCC may recom-
mend approval of the design, material, and heat treatment with tests waived on the basis of previ-
ous satisfactory static and dynamic tests of similar designs, material, and heat treatment.
Waiver of tests should only be requested on the basis of a design previously approved as a result of
official dynamic and static tests. The waiver request should be accompanied by substantiating
data covering the new design and the design being used as a basis for such request when there are
differences not covered by Appendix A.
2.0 MATERIAL
Material shall be of cast steel in accordance with the latest revisions of Specifications M-201 and
M-210, Grades B, B+, and C.
3.0 DESIGN
3.2 The minimum basis for testing shall be the axle capacity “C” as given in Table 3.1
Table 3.1 Minimum vertical test loads by GRL
Journal Size Truck Type Gross Rail Load (lb) C-Axle Capacity (lb)
5 1⁄2 × 10 2D 177,000 42,000
6 × 11 2E 220,000 52,500
263,000 63,000
6 1⁄2 × 12 2F
286,000 68,750
263,000 63,000
6 1⁄2 × 9 2K
286,000 68,750
7 × 12 2G 315,000 76,000
10/2010 S [M-203] 65
M-203
3.3 Best practices for side frame designs shall be used. A documented design process utilizing
best practices shall be completed for each side frame design with documentation available for
review by purchaser upon request. Documentation shall be maintained by the manufacturer to
demonstrate that the design process is continually utilized to ensure adequate designs according
to this specification. Finite element techniques and solidification analysis are examples of best
practices and shall be performed by the manufacturer for each side frame design.
For the design, the vertical load shall be taken as acting on the spring base (or its equivalent for
test) and shall be 1.5 “C.” The transverse load shall be taken as acting on the bolster guides, one
half on each guide on a line located above the nominal centerline through the two axles an amount
equal to the journal diameter of the axle less 1 1⁄2 in. and shall be 0.4 “C.”
4.0 STATIC TESTS
4.1 At least two specimens of each design shall be tested in a suitable static testing machine
under the supervision of a representative of the Coupling System and Truck Castings Committee.
The two specimens selected shall be good average product.
4.2 The side frames shall comply with static test requirements of Table 4.1. The transverse and
the vertical tests shall be made separately, but the same specimen may be used for both tests.
4.3 Table 4.1 provides the minimum basis for computing test loads.
Table 4.1 Minimum computational load cases
Load in Pounds
Grades B, B+, and C
Transverse Vertical
Load for zero setting of instruments 5000 lb 5000 lb
Additional load for maximum deflection 0.57C 2.14C
Load for maximum permanent set 1.14C 4.28C
Elastic limit, minimum 4.04C
Ultimate load 11.90C
4.4 Table 4.2 provides the minimum values from paragraph 4.3 to be used in actual testing:
Table 4.2 Minimum load cases for testing
6 1⁄2 × 12 7×9
and and
5 1⁄2 × 10 6 × 11 6 1⁄2 × 9 7 × 12
(lb) (lb) (lb) (lb)
C-axle capacity (lb) 42,000 52,500 63,000 68,750 76,000
Load 0.57C (deflection) 29,000 35,000 41,000 44,200 48,200
Load 1.14C (set) 48,000 60,000 72,000 78,400 86,400
Load 2.14C (deflection) 95,000 117,500 140,000 152,150 167,000
Load 4.28C (set) 180,000 225,000 270,000 294,250 324,000
Load 4.04C (elastic limit) 170,000 212,500 255,000 277,750 306,000
Load 11.90C (ultimate) 500,000 625,000 750,000 818,150 900,000
S [M-203] 66 10/2010
M-203
Table 4.3 Test requirements

Max. Transverse Max. Transverse Max. Transverse Max. Transverse
Deflection for a Deflection for a Deflection for a Deflection for a
Minimum Load of Minimum Load of Minimum Load of Minimum Load of
Wheel 0.57C (in.) 1.14C (in.) 2.14C (in.) 4.28C (in.)
Base Grade of Steel Grade of Steel Grade of Steel Grade of Steel
B B+ C B B+ C B B+ C B B+ C
5 ft 6 in. .070 .097 .120 .010 .010 .010 .040 .048 .055 .010 .010 .010
5 ft 8 in. .070 .097 .120 .010 .010 .010 .040 .048 .055 .010 .010 .010
5 ft 9 in. .072 .100 .124 .010 .010 .010 .041 .050 .057 .010 .010 .010
5 ft 10 in. .074 .103 .127 .011 .011 .011 .042 .051 .058 .011 .011 .011
5 ft 11 in. .076 .106 .131 .011 .011 .011 .044 .053 .060 .011 .011 .011
6 ft 0 in. .078 .109 .135 .011 .011 .011 .045 .054 .062 .011 .011 .011
6 ft 1 in. .081 .112 .138 .012 .012 .012 .046 .055 .063 .012 .012 .012
6 ft 2 in. .083 .115 .142 .012 .012 .012 .047 .057 .065 .012 .012 .012
6 ft 3 in. .085 .118 .146 .012 .012 .012 .049 .059 .067 .012 .012 .012
6 ft 4 in. .087 .121 .150 .013 .013 .013 .050 .060 .069 .013 .013 .013
4.5 The deflection measuring instruments shall be located midway between supports of the spec-
imen and shall be set at zero under an initial load of 5000 lb. In the vertical test only, a load of
20,000 lb shall be applied to the side frame and then released to 5000 lb for the zero setting of
instruments.
4.6 The elastic limit shall be determined by the Johnson Fifty Percent method. This may be
defined as the point on the stress strain diagram at which the rate of deformation is 50% greater
than the initial rate of deformation.
5.0 LOADING DIAGRAMS FOR STATIC TESTS
Fig. 5.1 shows the method for transverse test loading. Fig. 5.2 shows the method for vertical test
loading. Fig. 5.3 shows the location of knife edges in the vertical tests for various spring groupings.
10/2010 S [M-203] 67
M-203
Fig. 5.1 Transverse setup
NOTE: SET-UP IS TYPICAL, VARIATIONS ARE PERMITTED IN DESIGN OF APPARATUS, ALSO

TO SUIT DESIGN OF SIDE FRAME, PROVIDED TEST RESULTS ARE NOT AFFECTED.
Fig. 5.2 Vertical setup

S [M-203] 68 10/2010
M-203
NOTE: GROUPS SHOWN ABOVE ARE TYPICAL. FOR OTHER SPRING GROUPS,
LOADING IS TO BE EQUALIZED ACCORDING TO SPRING ARRANGEMENT.
Fig. 5.3 Location of knife edges in vertical tests

6.0 DYNAMIC TESTS
6.1 For approval, four representative side frames from a lot of twenty-five shall be submitted for
dynamic testing in accordance with paragraph 8.0 and with the requirements of this paragraph.
6.2 The dynamic test requirements are given in Table 6.1.
Table 6.1 Number of vertical cycles
Grade B Grade B+ Grade C
Minimum loading each specimen before first critical crack is recorded 50,000 75,000 75,000
Average loadings for specimens tested shall exceed 100,000 125,000 125,000
6.3 Definition of a Crack

A crack is any break in the parent metal that has definite direction and a minimum length of 1⁄4 in.
The crack must work under test when sprayed with mineral spirits or suitable fluid.
6.3.1 Definitions of a Failure
6.3.1.1 Any crack in a general transverse direction of a member that propagates in length during
the test. For official recognition, a transverse crack must be at least 1⁄4 in. in length and must show
1⁄4 in. additional progress transversely.
6.3.1.1.1 A transverse crack shall be recorded as critical at that number of loadings when it has
progressed 1⁄4 in. after initial recognition.
6.3.1.1.2 Any crack in a pedestal roof, including the relief radius.
6.3.1.2 Any crack in Zone 1 as shown in Fig. 8.2 of Specification M-210.
6.3.2 If cracks develop in any zone during testing, a record must be submitted of when they
occurred in the test sequence and their size, location, orientation, and propagation history.
10/2010 S [M-203] 69
M-203
6.4 Test specimens must have loads applied and cycled as shown in Table 6.2.
Table 6.2 Minimum load range (lb)
6 1⁄2 × 12 7×9
and and
Type Loading 5 1⁄2 × 10 6 × 11 6 1⁄2 × 9 7 × 12
Vertical 0 to 100,000 0 to 125,000 0 to 150,000 0 to 164,000 0 to 180,950
Transverse in and out 0 to 13,000 0 to 16,500 0 to 19,500 0 to 21,300 0 to 23,520
Center twist right and left 0 to 8,500 0 to 10,650 0 to 12,800 0 to 13,950 0 to 15,420
6.5 Manner of applying loads shall be as follows:

Vertical To be applied as a uniformly distributed load on the spring seat of the side frame.
To be applied to the edges of the columns in approximately the same location that the bolster contacts
Transverse the columns when the truck is at a static loaded condition. For each vertical loading, there shall be one
transverse loading alternating between inward and outward directions.
To be applied as a twisting moment in the center of the frame in a horizontal plane. For each two vertical
Center Twist loadings, there will be a center twist load alternating clockwise and counterclockwise. Loads shown are
applied to the end of a lever extending 39 in. from the centerline of the frame to the center of the track.
Note: The number of cycles shown in Table 6.1 refers to vertical loads. The transverse and twist
loads are additional and in the ratio shown above.
6.6 Fig. 6.1 is a sketch of a typical loading arrangement. Fig. 6.2 shows the resultant wave forms
obtained from a computer controlled hydraulic loading system.
Fig. 6.1 Method of applying vertical, twist, and transverse loads to side frames
S [M-203] 70 10/2010
M-203
2 CYCLES
SPECIFIED VERTICAL LOAD
0
DURING TEST, A MINIMUM OF 50 VERTICAL LOAD APPLICATIONS
PER MINUTE.
SPECIFIED TWIST LOAD
SPECIFIED TWIST LOAD
DURING TEST, A MINIMUM OF 50 TWIST LOAD APPLICATIONS

PER MINUTE.
SPECIFIED
TRANSVERSE
LOAD
SPECIFIED TRANSVERSE LOAD
DURING TEST, A MINIMUM OF 100 TRANSVERSE LOAD

APPLICATIONS PER MINUTE.
Fig. 6.2 Time histories of minimum input loads
10/2010 S [M-203] 71
M-203
7.0 MARKING
All approved cast side frames shall be legibly marked as follows:
7.1 All Designs
7.1.1 AAR identification number must be cast integral to the casting as follows:
Grade Steel Marking Example
B AAR-B (identification number) AAR-B 400
B+ AAR-B+ (identification number) AAR-B+ 402
C AAR-C (identification number) AAR-C 401
7.1.2 The markings specified above, when properly applied by the manufacturer, will serve as a
positive means of certifying that the design has been approved and, by reference to circular reports
and/or files of the CSTCC (and prior Committees holding the responsibility), the exact date of
approval can be ascertained.
7.2 Coded Designs
Practices, Section S, Part II, Standard S-392, which is the AAR code for designating design fea-
tures for side frames and truck bolsters having built-in snubbing devices and single shoe brakes.
7.3 The markings specified in paragraphs 7.1 and 7.2 are in addition to those required by Specifi-
cation M-201. Location of markings is specified in MSRP Section S, Part II, Standards S-312 and
S-314.
7.5 The manufacturer is to include a serial number on the side frame based on the month and
year in which the side frame was manufactured. Location on the side frame is to be according to
MSRP Section S, Part II, Standard S-314.
tative approved by the CSTCC must witness tests and provide test data and certification to the
8.2 The applicant requesting approval of the side frame shall make all arrangements for these
tests in accordance with these requirements.
S [M-203] 72 10/2010
M-203
8.3 Following successful completion of officially witnessed testing, a test report is to be submitted
to the Chief—Technical Standards, Transportation Technology Center, Inc. This report shall
include the following information on the test specimens:
• Metal thickness readings compared to drawing dimensionsa/
• Internal solidity levelsa/
• Chemistry
• Grain sizea/
• Model No., serial No., cast date
• Weight
• Radiographsa/
a/ To be recorded for 1) turn of spring seat; and 2) inner pedestal jaw
See Table 6.2 for load values.

See paragraph 6.5 for relationships between test load applications.
10/2010 S [M-203] 73
APPENDIX A M-203
APPENDIX A
REQUIREMENTS GOVERNING APPLICATIONS FOR APPROVAL OF
SIDE FRAME DESIGNS UNDER LATEST ISSUE
1.0 Approval under this specification applies only to the foundry from which the approved side
frames are produced, and if a manufacturer desires that more than one foundry be approved, each
foundry must be approved independently. The procedure for obtaining and maintaining foundry
approval is contained in Specification M-210.
2.0 The Committee reserves the right to select truck side frames from production for subsequent
static and dynamic tests at no cost to the manufacturer aside from furnishing the test specimens.
3.0 This appendix provides the criteria used by the CSTCC for obtaining and maintaining
approval of cast side frame designs.
3.1 All base pattern designs not already approved shall be submitted to the Chief—Technical
Standards, Transportation Technology Center, Inc., for Committee approval or notification that
official static and dynamic tests are required.
3.2 Approval of a design applies only to the foundry for whom it is approved; it does not cover an
identical or similar design made by another foundry or the same design made of a different mate-
rial by the same foundry.
3.3 In the event a foundry fails to maintain an approved status, the designs and castings previ-
ously produced will retain their AAR approval and identification number.
3.4 In the event a significant change is made to the casting process, such as using light-weight
casting procedures or changes to the casting wall thicknesses, the manufacture shall submit
designs affected to the Chief—Technical Standards, Transportation Technology Center, Inc., for
Committee approval or notification that official AAR tests are required.
4.0 When a base pattern design has been approved, such approval will also apply to any issues of
that pattern when any of the following changes are made:
• Addition or removal of pad for stamping truck number.
• Columns altered to make any of the following variations in the design family, provided
there is no increase in width of bolster opening at the bottom:
• Barber S-2 (family)
• Ride Control (family)
• Cushion-Ride (family)
• Change in design of pedestal roof for application of wear liner of up to ¼ in. thickness pro-
viding the design metal thickness of pedestal roof is maintained between side walls of com-
pression member.
• Patterns previously approved for Grade B may be approved for Grade B+ or Grade C, and
patterns previously approved for Grade B+ may be approved for Grade C, if patterns are
unchanged and new pattern number is assigned.
4.1 All changes to pattern numbers with an assigned AAR I.D. Numbers that do not require AAR
approval must be forwarded to the AAR in the format shown in Appendix B.
4.2 Tests may be waived when the following conversion of approved designs are made: conversion
from wide to narrow pedestal jaw if the construction of the tension and compression members is
kept identical.
S [M-203] 74 10/2010
M-203 APPENDIX A
5.0 TEST SPECIMENS

5.1 All test specimens presented for both static and dynamic testing shall be produced by the
manufacturer’s normal production methods as defined in Specification M-210, Appendix A and be
representative of the manufacturer’s average commercial product. The test bolsters shall not be
given any special preparation that has not been given all side frames in the course of regular pro-
duction. An advance I.D. number will be issued to allow production. Side frames cannot be placed
in revenue service until AAR approval is granted. Records must be kept of all castings produced
prior to receipt of official AAR approval.
5.2 If the representative of the CSTCC rejects the test specimens due to apparent special prepa-
ration, he shall so inform the manufacturer. At the manufacturer’s request and expense, an inspec-
tion of similar products ready for shipment will be made by such representative or by the
Committee prior to testing to determine if the specimens presented for test are representative of
the manufacturer’s regular production. The CSTCC shall make the final decision in case of appeal.
10/2010 S [M-203] 75
APPENDIX B M-203
APPENDIX B
FORMAT FOR SUBMITTING CHANGES TO
BASE DESIGN PATTERN NUMBERS
Date: ______________________________
Subject: Side Frame/Bolster Pattern Number Change
Chief—Technical Standards
55500 DOT Road
Pueblo, CO 81001
Email: techstds@aar.com
Dear Sir:
Please be advised of the following change to the pattern number of this side frame/bolster cited.
 Side Frame  Bolster
New Design
Pattern No. Applicable AAR I.D. No.a/
Drawing No.
Original Approved Design

Pattern No.
Drawing No.
a/ I.D. number assigned by manufacturer

based on original approved base design
AAR I.D. number as covered in
Specification M-202 or Specification M-203,
Appendix A.
Yours truly,
Company
S [M-203] 76 10/2010
M-203A
BOLSTER DESIGN LOADS
Specification
M-203A

1.0 SCOPE
1.1 This document became effective January 1, 1979.
1.2 This specification describes the design and test requirements for six-wheel truck bolsters and
side frame systems.
2.0 BOLSTER VERTICAL DESIGN LOADS
2.1 Paragraph 3.2 in Specification M-202 states that the minimum basis for designing and test-
ing four-wheel truck bolsters is the vertical load “P.” By considering the number of axles, the verti-
cal load “P1” for six-wheel truck bolsters can be obtained by direct proportion from the formula
given for calculating “P” for four-wheel truck bolsters. That is,
P = 2C – 2000 (d-4)
Therefore P1 = 3C – 3000 (d-4)
where C = capacity of one axle
and d = journal diameter (nominal)
2.2 For six-wheel truck bolster design purposes, the minimum numerical values of the vertical
loads shall be as follows:
(5 1⁄2 in. diameter journals) P1 = 3 × 42,000– 3000 (5 1⁄2 – 4) = 121,500
(6 in. diameter journals) P1 = 3 × 52,500– 3000 (6 – 4) = 151,500
(6 1⁄2 in. diameter journals) P1 = 3 × 63,000– 3000 (6 1⁄2 – 4) = 181,500
(7 in. diameter journals) P1 = 3 × 76,000– 3000 (7 – 4) = 219,000
2.3 The vertical load on the bolster shall be considered to be located at any point from the longitu-
dinal centerline of the bolster to the center plate rim. The load shall further be considered to be
located at any point between the center plate rim and the side bearing until such condition exists
that 100% of the load will be supported by the side bearing.
2.4 All bolster arms, supporting beams, or any other load-carrying member of the bolster shall be
analyzed using the maximum bending moment that could occur for any of the above-described con-
ditions.
3.0 BOLSTER TRANSVERSE DESIGN LOADS
3.1 The six-wheel truck bolster is subject to transverse loads in two directions:
• Longitudinal (or car) loads due to impacts, braking, etc.
• Transverse (or car) loads due to body sway, track curvature, etc.
It is not likely that these two conditions will occur simultaneously; therefore, they will be consid-
ered separately. For design purposes, the stresses will be combined individually with those calcu-
lated from the vertical load, and the condition of maximum stress will govern the design of the
member in question.
3.2 The bolster longitudinal (of car) load shall be 0.25 of the center plate load. This load is
resisted by the bolster arms and is reacted into the side frame system. The load shall be considered
to be equally distributed to all four bolster arms.
10/2010 S [M-203A] 77
M-203A
3.3 The bolster transverse (of car) design load shall be the same as the side frame transverse
design load. The minimum vertical load for one side frame is 3⁄4 (axle capacity). The minimum
transverse design load of the side frame is 0.4 of the vertical load; thus the minimum transverse
(of car) design load applied to each bolster arm is .3 (axle capacity) for the corresponding journal
size. That is,
0.75 (axle capacity) × 0.4 = 0.3 (axle capacity)
The combined vertical and transverse loads shall conform to Specification M-202, Table 4.1.
4.0 BOLSTER STATIC TEST REQUIREMENTS
4.1 Bolster Vertical Center Plate and Side Bearing Static Test Loads
To calculate the minimum vertical center plate and side bearing test loads, reference is made to
Specification M-202, Table 4.2. The deflection and set loads from Table 4.2 shall be used for the
six-wheel truck bolster.
Minimum Load (lb) Grades B and C

Vertical Side Bearing Vertical Center Plate
Load for zero setting of instruments 5,000 5,000
Additional load for maximum deflection 1.43P1 1.43P1
Load for maximum permanent set 2.38P1 2.85P1
Maximum ultimate load 5.22P1
The “P1” loads are those listed in the bolster vertical design section. The maximum deflection and
set values for the six-wheel truck bolster shall be as follows:
Minimum Load on Side Bearing

6-Wheel Truck Deflection at 1.43P1 (in.) Set at 2.38P1 (in.)
Wheel Base Grade B Grade C Grade B Grade C
6 ft 10 in. .066 .084 .030 .030
8 ft 6 in. .083 .106 .038 .038
8 ft 8 in. .084 .106 .038 .038
9 ft 0 in. .087 .110 .039 .039
10 ft 0 in. .094 .120 .043 .043
11 ft 0 in. .102 .130 .046 .046
Minimum Loads on Center Plate

6-Wheel Truck Deflection at 1.43P1 (in.) Set at 2.85P1 (in.)
6 ft 10 in. .090 .126 .030 .030
8 ft 6 in. .113 .158 .038 .038
8 ft 8 in. .114 .160 .038 .038
9 ft 0 in. .118 .165 .039 .039
10 ft 0 in. .128 .180 .043 .043
11 ft 0 in. .139 .195 .046 .046
S [M-203A] 78 10/2010
M-203A
4.2 Bolster Transverse Static Test Loads

The six-wheel truck bolster shall not be subject to transverse test requirements due to the size of
the casting and the degree of difficulty encountered in producing a satisfactory and safe test proce-
dure.
5.0 SIDE FRAME DESIGN AND TEST LOADS
5.1 Side Frame Design Loads
Paragraph 3.2 in Specification M-203 states that the minimum basis for designing and testing of
four-wheel truck side frames shall be the axle capacity “C.” This value is also the capacity of one
side frame of a four-wheel truck, since both the axle and the four-wheel truck side frame have two
journal bearings. Inasmuch as the six-wheel truck side frame is supported by 1 1⁄2 journal bearings,
its capacity “C1” can be obtained from the axle capacity “C” from the following relation:
1
1 --- C
2 - = 3--- C
C 1 = ----------
2 4
For design purposes, the minimum numerical values for C1 for the various journal sizes shall be as
follows:
(5 1⁄2 in. diameter journals) C1 = 42,000 × 3⁄4 – 31,500 lb

(6 in. diameter journals) C1 = 52,500 × 3⁄4 – 39,375 lb
(6 1⁄2 in. diameter journals) C1 = 63,000 × 3⁄4 – 47,250 lb
(7 in. diameter journals) C1 = 76,000 × 3⁄4 – 57,000 lb
The minimum vertical design load shall be 1.5 “C1.” The minimum transverse design load shall be
0.4 “C1” acting on the bolster guides.
5.2 Side Frame Static Test Loads and Deflection Requirements
The static test load requirements for the six-wheel truck side frames shall be as follows:
Minimum Load (lb) Grades B and C

Transverse Vertical
Load for zero setting of instruments 5,000 5,000
Additional load for maximum allowable deflection .57C1 2.14C1
Load for maximum allowable permanent set measured at the centerline of load 1.14C1 4.28C1
Elastic limit, minimum 4.04C1
Ultimate load, minimum 11.90C1
10/2010 S [M-203A] 79
M-203A
The “C1” values are those listed in the side frame design load section. The maximum deflection and
set values for the side frames for the various wheel base trucks shall be as follows:
Vertical
6-Wheel Truck Deflection at 1.14C1 (in.) Set at 4.28C1 (in.)
6 ft 10 in. .034 .043 .007 .007
8 ft 6 in. .040 .055 .010 .010
8 ft 8 in. .042 .058 .011 .011
9 ft 0 in. .047 .065 .012 .012
10 ft 0 in. .055 .079 .015 .015
11 ft 0 in. .062 .093 .017 .017
Transverse
6-Wheel Truck Deflection at .57C1 (in.) Set at 1.14C1 (in.)
6 ft 10 in. .058 .102 .007 .007
8 ft 6 in. .070 .120 .010 .010
8 ft 8 in. .074 .127 .011 .011
9 ft 0 in. .083 .142 .012 .012
10 ft 0 in. .097 .170 .015 .015
11 ft 0 in. .111 .198 .017 .017
5.3 Side Frame Fatigue Test Requirements

Approved or service-tested designs shall be exempted from fatigue tests. New truck side frame
designs that do not differ fundamentally from the basic Buckeye design shall be given conditional
approval until such time as proper test equipment is available and sufficient experimental testing
is accomplished to form the basis for establishing test criteria.
6.0 EQUALIZER DESIGN AND TEST LOADS
6.1 Equalizer Design Loads
The equalizer is a load-carrying member of the side frame system that carries one half of one axle
capacity. The minimum “C1” design loads for the equalizers shall be as follows:
5 1⁄2 in. diameter journals = 21,000 lb

6 in. diameter journals = 26,250 lb
6 1⁄2 in. diameter journals = 31,500 lb
7 in. diameter journals = 38,000 lb
The vertical design load for the equalizer shall be 1.5 “C1.” The transverse design load for the
equalizer shall be 0.4 “C1.”
S [M-203A] 80 10/2010
M-203A
6.2 Equalizer Static Test Loads and Deflection Requirements

The equalizer vertical test requirements shall be the same as the vertical test requirements for the
six-wheel truck side frame.
Minimum Load (lb)

Grades B and C
Vertical
Load for zero setting of instruments 5,000
Additional load for maximum allowable deflection 2.14C1
Load for maximum allowable permanent set measured at the centerline of load 4.28C1
Elastic limit, minimum 4.04C1
Ultimate load, minimum 11.90C1
The minimum “C1” values are those listed in the equalizer design load section. The maximum
deflection and set values for the equalizers shall be as follows:
Vertical
Equalizer Lengths Deflection at 2.14C1 (in.) Set at 4.28C1 (in.)
Between Load Centers Grade B and
(in.) Grade B Grade C Grade C
27 .026 .034 .0035
30 .027 .035 .0040
33 .027 .036 .0040
36 .028 .037 .0045
39 .029 .038 .0050
42 .030 .040 .0055
45 .031 .042 .0060
The equalizer shall not be subject to transverse test requirements due to the degree of difficulty in
obtaining a satisfactory test procedure.
6.3 Equalizer Fatigue Test Requirements
Approved or service-tested designs shall be exempted from fatigue tests. New equalizer designs
that do not differ fundamentally from the basic Buckeye design shall be given conditional approval
until such time as proper test equipment is available and sufficient experimental testing is accom-
plished to form the basis for establishing test criteria.
10/2010 S [M-203A] 81
Casting Details
M-203A
S [M-203A] 82 10/2010
10/2010
Casting Details
M-205
YOKE, COUPLER—TEST REQUIREMENTS
Specification
M-205
Adopted: 1926;
Advanced to Standard: 1932; Last Revised: 2003
1.0 SCOPE
1.1 This specification covers the test requirements for AAR-approved freight coupler yokes.
1.2 AAR standard and alternate standard coupler yokes that have been approved for use in inter-
change service are shown elsewhere in this manual.
1.3 Special yoke designs may be approved by application for approval to the AAR.
2.0 BASIS FOR APPROVAL
2.1 All designs and manufacturers of coupler yokes must be approved by the AAR before yokes
can be used in interchange service. The basis for such approval shall be satisfactory compliance
with this specification.
2.1.1 Any design submitted for approval may be approved by waiver of official design tests.
2.1.2 Initial approval of a design applies only to the manufacturer for whom it is approved. It
does not cover an identical or similar design produced by another manufacturer or the same design
made of a different material by the same manufacturer.
2.1.3 The AAR may approve a design that has been previously approved for one manufacturer for
another manufacturer without the test prescribed in paragraph 4.0 provided the manufacturer
seeking approval has “qualified” by having a satisfactory test record.
2.1.3.1 For a manufacturer to become “qualified,” manufacturer’s record must cover satisfactory
design tests, as prescribed in paragraph 4.0, of not less than three different designs of coupler
yokes. Two of the three designs must be AAR standard or alternate standard conventional draft
gear pocket yokes shown in this manual.
2.1.3.2 When a “qualified” yoke manufacturer has not submitted a yoke design for AAR-super-
vised tests for a period of 3 years, the AAR may request that a current production design be sub-
mitted for the tests required by this specification. These tests will be conducted at the
manufacturer’s expense.
2.1.3.3 A “qualified” manufacturer who has not conducted AAR-supervised tests for a period of
3 years must test the yoke submitted for approval. Application for approval shall be addressed to
the Association of American Railroads, who will refer the application to the appropriate commit-
tee.
2.2 When permission is granted applicant to test the yoke, applicant will be furnished an identifi-
cation number to be used for manufacture of the test specimens required in paragraph 4.1.2.
2.3 Approval will be based on the satisfactory results of the static tests specified in
paragraph 4.0.
2.4 The committee may approve the design, cast in a certain grade of material, on the basis of
previous satisfactory tests of similar design and material.
10/2010 S [M-205] 83
10/2010
Casting Details
M-205
3.0 DESIGN
3.1 AAR standard and alternate standard yoke designs are shown in this manual.
3.2 Special yoke designs are those that vary in dimensions or material from the AAR standard or
alternate standard designs shown in this manual. Special yoke designs must have a minimum
cross-section of 10 1⁄2 in.2 in tension and conform to load requirements of paragraph 4.3. As applica-
ble, the special yoke designs should conform to AAR standard or alternate standard designs shown
in this manual with respect to material, dimensions, and tolerances. These special yoke designs
will not be protected in interchange service.
4.0 TEST REQUIREMENTS
4.1 Three coupler yokes shall be subjected to static tension tests.
4.1.1 The selection of specimens for test and the tests shall be witnessed by an official AAR repre-
sentative unless a written waiver is given by the AAR.
4.1.2 Specimen yokes to be tested will be selected from a lot of not less than 50 yokes. The test
specimens selected shall be representative of production yokes prescribed in the drawings and
applicable specifications.
S [M-205] 84 10/2010
10/2010
Casting Details
M-205
4.2 Method of Testing

4.2.1 The method of testing the coupler and yokes measuring permanent set are shown in the
diagrams of Fig. 4.1. The support and loading of the yokes for these tests shall be equivalent to ser-
vice application.
DIMENSION FOR READINGS
SUPPORT
BLOCK
LOAD SUPPORT
DUMMY SHANK
TENSION TEST
HORIZONTAL KEY YOKES Y40 AND Y41 DESIGNS

FOR USE WTH RIGID SHANK E COUPLERS SUPPORT
BLOCK
LOAD SUPPORT
DUMMY SHANK
DIMENSION FOR READINGS TENSION TEST
VERTICAL PIN CONNECTION YOKES Y45 AND Y49 DESIGNS

FOR USE WTH F AND E/F COUPLERS
Fig. 4.1
4.2.2 In making deflection measurements, the measuring instruments shall be set at zero after a
load of 20,000 lb has been applied and released to a datum load of 5,000 lb.
4.2.3 The minimum ultimate load shall be considered the load at which the yoke is distorted to
an extent that would cause binding in the draft gear pocket specified for the yoke being tested. In
no case shall the distortion exceed 1⁄4-in. overall, measured vertically or laterally.
10/2010 S [M-205] 85
10/2010
Casting Details
M-205
4.3 Tension Tests

The maximum permanent set, measured from the point of load application to the point of support,
and the minimum ultimate load shall be as shown below.
Table 4.1
Maximum Permanent Minimum
Yoke for Use with
Set at 750,000 lb Ultimate
Type E, E/F, and F Couplers: Grade E 0.03 in. 900,000 lb
5.0 AAR IDENTIFICATION REQUIREMENTS

5.1 In the event that yokes fail to pass specification tests, the AAR representative will witness
the removal of the AAR identification number from the balance of the lot or group from which the
test specimens were selected.
5.2 When a yoke design cast in a certain grade material successfully passes the requirements of
these specifications, approval will be granted by the AAR to the manufacturer to produce this
design yoke in the material tested and will assign the official AAR identification number.
5.3 The manufacturers for whom these designs have been approved are shown in the list of
M-1003 approved facilities, prepared quarterly by the AAR.
5.4 Yoke Marking Requirements
Other yoke marking requirements are shown in AAR Specification M-211, Fig. A.9 and Fig. A.10.
S [M-205] 86 10/2010
M-210
SIDE FRAME AND BOLSTERS, AAR APPROVED—PURCHASE AND

ACCEPTANCE
Specification
M-210

1.0 SCOPE
This specification covers the purchase and acceptance requirements for AAR-approved four- and
six-wheel truck side frames and bolsters. AAR-approved truck side frame and bolster designs are
those that have been approved by the Coupling System and Truck Castings Committee in compli-
ance with the following design specifications:
• AAR Manual of Standards and Recommended Practices, Specification M-202, “Truck Bol-
sters, Cast or Structural—Design and Testing” (current version)
• AAR Manual of Standards and Recommended Practices, Specification M-203, “Truck Side
Frames, Cast Steel—Design and Testing” (current version)
• AAR Manual of Standards and Recommended Practices, Specification M-203A, “Bolster
Design Loads” (current version)
1.1 Basis of Purchase and Acceptance
1.1.1 Castings will comply with Specification M-201, “Castings, Steel,” unless otherwise provided
herein.
1.1.2 As per Specification M-201, at the purchaser’s request, records and a certification will be
made for the basis of acceptance. The certification shall include a statement that the material has
been manufactured, sampled, tested, and inspected in accordance with, and meets the require-
ments of, all applicable provisions of the specifications above and any other pertinent specifica-
tions or requirements. Each certification furnished shall be signed by an authorized agent of the
supplier or manufacturer.
1.1.3 Purchaser’s Representation
1.1.3.1 The inspector representing the purchaser shall have free entry at all times to the manu-
facturer’s works that concern the manufacture, test, and inspection of the material offered. The
manufacturer shall afford the inspector all reasonable facilities to assure the inspector that the
material is being furnished in accordance with these specifications.
1.1.3.2 All inspections shall be conducted so as not to interfere unnecessarily with manufacturing
operations.
1.2 Basis of Foundry Approval
1.2.1 All manufacturers, foundries, material, and designs for North American Interchange must
be approved by the AAR. The basis for such approval includes but is not limited to satisfactory
compliance with the provisions of MSRP Specifications M-201, M-202, and/or M-203, M-1003
(“Quality Assurance” in Section J), and this specification. If a cast component is discontinued, the
provisions of MSRP Administrative Supplement Standard S-060, must be followed.
1.2.2 All manufacturers desiring an “approved” status must submit an application to the
Chief—Technical Standards, Association of American Railroads. All foundries producing castings
for that manufacturer must be approved individually. Foundries that have not been previously
approved will require an inspection by an AAR representative. This application must include a
statement that the requestor will defray the total inspection expense and be accompanied by a
draft in the amount estimated as required to defray all costs to include transportation and 5 days
on site. Any costs in excess of this amount will be reimbursed to the AAR.
10/2010 S [M-210] 87
M-210
1.2.3 Inspections of all foundries will be conducted annually (at least once per year). All inspec-
tions will include, but not be limited to, the requirements of Appendix A. The cost of inspection will
be borne by the manufacturer. Any casting used for the annual inspection must be cast within 90
days of inspection, from a lot of no less than 25 pieces.
1.2.4 Manufacturer will be advised of inspection findings. If, after review of these findings, a
manufacturer is considered not qualified for AAR approval, manufacturer may request a reinspec-
tion at manufacturer’s expense.
1.2.5 A foundry that has met AAR inspection requirements and has subsequently met AAR
approval requirements on one or more different designs of side frame and/or bolsters shall be
approved.
1.2.5.1 Approval to produce side frames extends 3 years from the date of the last successful AAR
M-203 side frame approval test, provided that annual foundry inspections requirements have also
been met. If no new side frame design(s) are tested within a 3-year approval period, testing of an
existing AAR-approved design (cast within 90 days of test, from a lot of no less than 25 pieces) is
required to extend AAR approval. Testing of a new design resets the 3-year approval period.
1.2.5.2 Approval to produce bolsters extends 3 years from the date of the last successful AAR
M-202 bolster approval test, provided that annual foundry inspections requirements have also
been met. If no new bolster design(s) are tested within a 3-year approval period, testing of an exist-
ing AAR-approved design (cast within 90 days of submission for test, from a lot of no less than 25
pieces) is required to extend AAR approval. Testing of a new design resets the 3-year approval
period.
1.2.6 AAR Representation
1.2.6.1 An AAR official representative shall have free entry at all times to all parts of the manu-
facturer’s works that concern the manufacture, test, and inspection of materials for use in inter-
change service. This access is for the purpose of providing assurance that industry standards are
being maintained. The manufacturer shall afford the AAR representative all reasonable facilities
to assure the representative that materials are being furnished in accordance with these specifica-
tions.
1.2.6.2 The AAR reserves the right to require additional technical inspections, announced or
unannounced, and/or to employ third-party inspectors on a resident basis as deemed necessary by
the AAR and the Coupling System and Truck Castings Committee (CSTCC).
1.2.7 M-210 approval of a manufacturer or foundry may be removed for the following reasons:
1.2.7.1 For Cause. Consistent failure to maintain adequate quality control standards as evi-
denced by performance, inspections, or non-compliance with appropriate specifications.
1.2.7.2 Discontinued Production. A manufacturer or foundry discontinues production for
other than scheduled maintenance or other scheduled shutdowns.
1.2.7.3 Inspection Refusal. Refusal by a manufacturer to accept an inspection scheduled under
the provisions of this specification.
1.2.8 Applicants requesting certification or recertification in accordance with this specification
must meet the requirements of AAR Manual of Standards and Recommended Practices, Section J,
Specification M-1003, “Quality Assurance.” A list of approved casting manufacturers (foundries) is
maintained quarterly by the AAR Quality Assurance Committee.
S [M-210] 88 10/2010
M-210
2.0 CAST STEEL MANUFACTURE

2.1 Truck side frames and bolsters shall be made in Grades B, B+, or C (NT) steel per Specifica-
tion M-201.
2.2 The cast steel shall be made by open-hearth, electric furnace, basic oxygen, or any other pro-
cess approved on a case-by-case basis by the AAR Coupling System and Truck Castings Commit-
tee.
3.0 CHEMICAL PROPERTIES AND TESTS
Chemical composition, analysis, and frequency of testing are to comply with Specification M-201.
4.0 MECHANICAL PROPERTIES AND TESTS
4.1 Test Specimen Coupons
Test coupons will be in conformance with Specification M-201.
4.2 Impact Properties
Test coupons must meet impact properties as outlined in Specification M-201.
4.3 Internal Solidity
4.3.1 For new foundry approvals, the capability of a manufacturer’s casting process relative to
internal solidity shall be initially demonstrated by saw-cut sectioning two specimens from each
“design group” listed in paragraph 4.3.3. The two specimens shall be obtained from separate heats.
4.3.2 The saw-cut sectioning procedure is to be used as a process control tool to develop satisfac-
tory casting solidity. The intent is to provide a checking procedure to periodically monitor the cast-
ing process. As a process control procedure, one specimen of each design group will be sectioned
every 6 months. If the production in any bolster design group is less than 1,000 pieces or in any
truck frame design group is less than 2,000 pieces during this period, then no sectioning is
required for that group. However, at least one casting from each design group in production must
be sectioned each year and at any time a significant change to a critical process (as outlined in
Table A.1, items 1A through 1F) is made in foundry practice. It is recognized that any sampling
procedure cannot ensure that there will be no random internal discontinuities in any castings not
sectioned. Records shall be retained in accordance with paragraph 6.6 and in accordance with the
manufacturer’s M-1003 Quality Assurance Program.
4.3.3 For the purpose of this specification, “design groups” are defined as side frames or bolsters
produced with the same AAR identification number. Castings of Grades B and B+ material are
considered to be in the same design group.
4.3.4 Castings are to be sectioned in accordance with Figs. C.1 and C.2.
4.3.5 Areas to be rated for discontinuity severity levels are illustrated Figs. C.1 and C.2.
4.3.6 Casting areas for evaluation, excluding padding and risering, shall be rated for severity in
accordance with photographs in Appendix C. Reference photographs are full size and provide a
standard for evaluating minimum acceptability for the casting.
4.3.7 Internal discontinuities in excess of severity level I are not permitted in the cross-hatched
areas designated in Figs. C.1 and C.2. Cracks and/or hot tears are not permitted in any locations.
10/2010 S [M-210] 89
M-210
4.4 Hardness Testing

4.4.1 A hardness test will be performed on each casting to ensure it meets the specifications
defined in Specification M-201, paragraph 7.4. Castings that do not meet the requirement will not
be shipped.
4.4.2 For bolsters, hardness will be recorded at the location as shown in Fig. 4.1.
ALTERNATE LOCATIONS
Fig. 4.1 Bolster hardness test location

4.4.3 For side frames, hardness will be recorded at the location shown in Fig. 4.2. In the event
that a riser has been cast in the location noted for hardness testing on the side frame, do not per-
form the hardness test over the riser.
S [M-210] 90 10/2010
M-210
Fig. 4.2 Side frame hardness test location

4.4.4 The manufacturing process should document and track the hardness values to confirm com-
pliance with process controls. Manufacturer must take necessary actions if values fall outside min-
imum or maximum hardness range.
5.0 INSPECTION
5.1 Special Customer Requirements
The manufacturer may group castings in inspection lots per customer request.
5.2 Visual Inspection
5.2.1 Visual inspection shall be used to ensure that castings are free of imperfections that affect
strength as defined in paragraph 6.2.
5.2.2 All welds shall be visually inspected. Welds shall be accepted if they are in conformance
with AWS D15.1 “Visual Inspection of Completed Welds” and meet other requirements when spec-
ified elsewhere in that standard. Porosity must not exceed the limits of AWS D15.1 for Class 2
welds.
10/2010 S [M-210] 91
M-210
5.3 Gauging
5.3.1 Toleranced dimensions shall be within the limits of AAR standards and/or approved gauges.
5.3.1.1 Castings shall conform to the detailed construction drawings and be within manufactur-
ing variations for untoleranced dimensions.
Table 5.1 Typical and acceptable metal thickness variations
Metal Thickness Dimension Tolerance
1/4 in. up to, not including 7/16 in. +1/8 in., –1/32 in.
7/16 in. up to, not including 3/4 in. +1/8 in., –3/32 in.
3/4 in. up to, not including 1 1/4 in. +1/8 in., –1/8 in.
1 1/4 in. and greater +3/16 in., –5/32 in.
5.3.1.2 In local areas dictated by individual manufacturing practices, padding (or additional
metal thickness) is done for casting solidity. These practices are not considered to violate the plus
tolerance of metal section.
5.3.2 The manufacturer shall make available to the purchaser’s inspector for in-plant inspection
the approved gauges listed in Table 8.1 and shown with application instructions on Figs. 8.3 to
8.32 of this specification.
5.3.3 For those gauges not applied to 100% of castings produced, sampling techniques shall be
employed to confirm compliance with gauge requirements. For all gauges applied, sampling
records must be maintained in an auditable form to ensure suitability of gauging frequency in
accordance with production volume. An acceptable technique must be demonstrable to the AAR
inspector.
6.0 MANUFACTURER’S PROCESSES
6.1 Weld Repair
Written procedures shall be maintained for weld repairs and include the requirements listed in
paragraph 6.1.2. Manufacturers will have a demonstrable process to ensure compliance to this
procedure, including training programs and record keeping programs showing that line supervi-
sors and staff use due diligence to follow the prescribed practices.
6.1.1 Defects in castings may be repaired by welding. The defect must be removed prior to weld
repair. Defects that do not reduce metal thickness below allowable minimums, as defined in
paragraph 5.3.1, may be removed and blended with the surrounding surfaces. When defect
removal reduces metal thickness below allowable minimums, weld repair is required. 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 one side is
inaccessible, use of a copper, brass, or suitable weld backup tape is required. Grinding, chipping,
oxy-fuel washing, or air arc shall be used to remove defects, and appropriate inspection methods
(AWS D15.1) shall be used to ensure that the entire defect has been removed. Mechanical cleaning
must follow air arc defect removal to remove the carburized layer. Welding must be accomplished
in accordance with paragraph 6.1. Defect evacuation utilizing weld electrodes (often referred to as
“hot-rodding weld-defect-evacuation practice”) is prohibited.
6.1.1.1 Fabrication of a casting by welding is prohibited unless a welded design is approved by
the Coupling System and Truck Castings Committee.
6.1.1.2 The manufacturer will incorporate a marking system (or equivalent) to ensure that all
weld repairs are properly tracked through the entire weld repair and tempering process.
S [M-210] 92 10/2010
M-210
6.1.2 All welders shall be qualified under the welder qualification procedures contained the latest
revisions of ASTM A-488, AWS D15.1, Railroad Welding Specification, and the manufacturer’s
written procedures. Weld repair must be made in the position for which the welder is qualified in
all cases. Welding in the flat down hand position is preferred. Facilities performing weld repairs
under this specification shall be inspected and approved by the AAR.
6.1.3 A preheat must be used if required in the manufacturer’s written weld procedures. Under
no condition shall welding be performed when the casting temperature is below 40 °F. (4 °C). Local
preheat is permitted.
6.1.4 Repair Welding
6.1.4.1 Repair welding shall be performed with low hydrogen-coated elements, flux core wire, or
gas-shielded welding process. Weld deposits shall provide properties equivalent to those of the fin-
ished casting.
6.1.4.2 For stick arc welding, use the electrodes indicated for the applicable grade of steel, as fol-
lows:
Grade of Steel Electrode
B AWS/ASTM E7015, E7016, E7018, or equivalent
B+ AWS/ASTM E8015, E8016, E8018, E10018, or equivalent
C (castings) AWS/ASTM E9015, E9016, E9018, or equivalent
At manufacturer’s option, an electrode of AWS/ASTM Class E10015, E10016, E10018, or equiva-

lent may be used for higher mechanical properties after heat treatment.
6.1.4.3 Electrodes must be stored in accordance with AWS Specification D15.1, latest revision.
6.1.5 Process Requirements After Weld Repair
6.1.5.1 Good foundry practice dictates that all welding should be performed prior to heat treat-
ment.
6.1.5.1.1 In the event a casting needs to be weld-repaired after the required heat treatment (tem-
pering), it must be processed in accordance with the requirements of Figs. 8.1 and 8.2.
6.1.5.1.2 Written procedures for this process must be available for review upon request by pur-
chasers and AAR inspectors and auditors. All hardened attachments, such as bushings, liners,
wear plates, split wedge inserts, and fasteners, must be removed prior to reheat treatment.
6.1.5.2 Castings must be grit- or shot-blasted for cleaning after any heat treatment above the
critical temperature.
6.1.5.3 Castings may be subjected to appropriate nondestructive inspection methods to deter-
mine weld integrity.
6.1.5.4 Heat treatment of weld-repaired castings shall conform to applicable procedures con-
tained in Specification M-201, latest revision. Furnace tempering of the entire casting is required
after a Zone 1 weld repair on all grades of material (localized tempering is not allowable for repairs
in Zone 1).
10/2010 S [M-210] 93
M-210
6.2 Finishing
6.2.1 General Finishing Requirements for Side Frames and Bolsters
6.2.1.1 Cleaning equipment must provide clean castings for proper inspection.
6.2.1.2 Loose material (e.g., core rods, slag, core sand, shot) inside the casting must be removed.
6.2.1.3 Sharp or ragged edges that could be injurious to workers shall be removed.
6.2.1.4 Surface discontinuities resulting from the removal of gates and risers shall be contoured
to within 1⁄4 in. above or 3⁄8 in. below the surrounding surfaces as long as minimum wall thickness
is maintained, unless interference would be created to assembly, operation, application, or service-
ability.
6.2.1.5 Ribs and padding added to facilitate manufacture may or may not be removed. When
removed, the remaining material is to be blended to within 1⁄4 in. of the surrounding surfaces. Any
rib or pad that interferes with assembly, operation, application, or serviceability must be removed.
6.2.1.6 Parting line shifts greater than 1⁄8 in. are to be blended within 1⁄8 in. of the surrounding
area, as long as minimum wall thickness is maintained.
6.2.1.7 Surface conditions in noncritical areas, identified as Zones 2 and 3 in Figs. 8.1 and 8.2,
shall meet the following requirements:
6.2.1.7.1 All negative surface conditions (holes) with a surface area of 1⁄2 in. diameter and a depth
of more than 3⁄16 in. must be weld-repaired.
6.2.1.7.2 A grouping of five or more pin holes within a 1 in.2 area and 3⁄16 in. or greater in depth
must be weld-repaired.
6.2.1.7.3 Individual pin holes greater than 1⁄16 in. in diameter and greater than 3⁄16 in. deep must
be repaired.
6.2.1.7.4 Fused chaplets need not be removed.
6.2.1.7.5 Gouges exceeding 1⁄8 in. deep and greater than 1 in. long shall be blended or
repair-welded and blended. Minimum wall thickness must be maintained.
6.2.1.8 Surface conditions in critical areas, identified as Zone 1 in Fig. 8.1, shall meet the follow-
ing requirements.
SCRATA Reference Quality Levels for Critical Zones
Surface Roughness A3
Inclusions B4
Gas/Porosity C2
Wrinkles D3
Scabs E4
Chaplets F2
Thermal Dressing G2
Gouges H4
( ⁄8 in. max. depth)
1
Welds J3
S [M-210] 94 10/2010
M-210
6.2.1.9 Remove all fins on the exterior surface to within 1⁄8 in. of the surrounding surface. Remove
all interior fins that interfere with access for assembly purposes to within 1⁄4 in. of the surrounding
surfaces. Any fin that interferes with assembly, operation, application, or serviceability must be
removed.
6.2.1.10 Core shifts/mismatch in critical areas, identified as Zone 1 in Fig. 8.1, that exceed 1⁄8 in.
must be welded and/or blended. Minimum wall thickness must be maintained. For purposes of this
section, the ribs and side walls beneath the center plate are considered to be critical areas.
6.2.1.11 Welds are to have slag removed and on external surfaces be blended to within 1⁄8 in. of
the surrounding surfaces. Blending is not required on internal surfaces except in critical areas,
identified as Zone 1 in Figs. 8.1 and 8.2. Any weld or blending must not interfere with assembly,
operation, application, or serviceability of the casting.
6.2.1.12 A crack, hot tear, or surface shrinkage is a condition on the casting that was formed dur-
ing the manufacture or processing of the casting. These foundry-related defects must be removed
by either grinding or excavation and repair-welding. Minimum wall thickness must be main-
tained.
6.2.1.13 Arc strikes in Zones 1 and 2 locations (after heat treatment) are prohibited per
AWS D15.1 and shall be ground to sufficiently remove the heat affected zone or be treated as welds
and handled in accordance with paragraph 6.1.1 and Figs. 8.1 and 8.2.
6.2.2 Finishing of Bolster Features
6.2.2.1 Center plate surfaces shall conform to AAR Manual of Standards and Recommended
Practices, Section D, Standard S-305.
6.2.2.2 Application of center plate liners shall conform to MSRP Standards S-305, S-306, S-307,
and S-308.
6.2.2.3 Side bearing pads shall conform to MSRP Section D, Standards S-394 and S-3013.
6.2.2.4 Wedge Pockets
6.2.2.4.1 All fins, projections, and excess metal shall be removed from wedge pocket walls and
surfaces.
6.2.2.4.2 Wedge pocket slope surfaces shall meet the following SCRATA quality levels: A2, H2,
J2.
6.2.2.4.3 Negative slope surface conditions in excess of 1⁄8 in. in depth must be repair-welded to
meet the following SCRATA quality levels: A2, H2, J2.
6.2.2.4.4 Finished wedge pockets must comply with manufacturers’ gauge requirements for each
specific application.
6.2.2.5 Application of Wedge Pocket Wear Plates and Inserts
6.2.2.5.1 Wedge pocket wear plates and inserts must be seated firmly against mating surfaces
and be properly positioned before welding.
6.2.2.5.2 Welds must not protrude beyond the surface of the wear plates or inserts. Welds in holes
within the perimeter of the wear plates must be flush to 1⁄16 in. below the face of the plate.
6.2.2.5.3 Welds must be solid and free of cracks.
6.2.2.5.4 Wedge pockets, wear plates, and inserts must be free of any foreign material after weld-
ing.
6.2.2.5.5 A 1⁄32 in. × 1⁄2 in. feeler must not pass between casting surface and wear plate more than
3⁄4 in. from the nearest edge.
10/2010 S [M-210] 95
M-210
6.2.2.6 Dead Lever Fulcrum Bracket Mounting Surface

6.2.2.6.1 Area shall be free of surface discontinuities that would interfere with the application of
the dead lever fulcrum bracket.
6.2.2.6.2 Holes shall be free of positives or negatives that would interfere with proper seating of
the bracket and fastener.
6.2.2.7 Application of Dead Lever Fulcrum Bracket
6.2.2.7.1 The dead lever fulcrum bracket, when required, shall be attached with the specified fas-
teners with at least two threads extending beyond the nut.
6.2.2.7.2 Nuts, washers, and bolt heads must seat flat against the casting for at least a continu-
ous 210° of the circumference. A 1⁄32 in. × 1⁄2 in. feeler gauge must not go between the casting and
the fastener.
6.2.2.7.3 A 1⁄32 in. × 1 in. feeler gauge must not go between the casting and the bracket more than
1⁄4 in. deep.
6.2.3 Finishing of Side Frame Features

6.2.3.1 Application of Column Wear Plates
6.2.3.1.1 Wear plates must be seated and fastened in accordance with the manufacturer’s specifi-
cations.
6.2.3.1.2 A 1⁄32 in. × 1⁄2 in. feeler gauge must not go between the plate and casting more than 1⁄2 in.
deep.
6.2.3.1.3 Protrusions from bolts, retainers, or welds must not extend beyond the face of the wear
plate.
6.2.3.1.4 Nuts, washers, and collars must seat flat against the casting for at least 210° of the cir-
cumference, with no more than 60° continuous gap as checked with a 1⁄64 in. × 1⁄2 in. feeler gauge.
6.2.3.1.5 Bolts must have a minimum of two full threads extending beyond the nut.
Note: Note: For additional information, see AAR Manual of Standards and Recommended Practic-
es, Section D, Standard S-320 and Alternate Standard S-3003.
6.2.4 The manufacturer shall maintain an auditable scoring system to ensure compliance to fin-
ishing standards.
6.3 Marking
6.3.1 Side frames and bolsters shall have legible markings as indicated in MSRP, Section S, Part
II, Standards S-312 and S-314. AAR identification number must be cast integral to the castings.
6.3.1.1 When any of the required markings shown in MSRP Standards S-312 and S-314 are illeg-
ible, the manufacturer must apply these markings to each casting in a workmanlike manner by
electric arc welding using a maximum 1⁄8 in. diameter electrode. Subsequent heat treatment is not
required for pencil welding of markings in Zones 2 and 3, as defined in Figs. 8.1 and 8.2.
6.3.1.2 When the AAR identification number is illegible, the manufacturer must apply this mark-
ing using pencil welding as specified in paragraph 6.3.1.1. To ensure that the intent of
paragraph 6.3.1 and MSRP Standards S-312 and S-314 are satisfied, casting production, as indi-
cated by the cast date, must be subsequent to the date on which the AAR identification number
was granted.
6.3.2 Wheel base distance must be cast on adjacent to the marking buttons in 3⁄4 in. numbers.
S [M-210] 96 10/2010
M-210
6.3.3 After the material has been inspected and accepted, the inspector may stamp each casting
with a private mark.
6.4 Painting
Castings that have been accepted by the plant inspection department and/or purchaser shall be
given a protective coat of paint, if specified.
6.5 Shipment
6.5.1 Side frames shipped in pairs shall be mated in accordance with MSRP Section S, Part II,
Standard S-378, unless otherwise required within this specification.
6.5.2 Side frames shipped in pairs must have matching button counts unless approved by the
purchaser.
6.6 Records
6.6.1 All records required by this and related specifications shall be made available upon request.
6.6.2 Manufacturers producing and selling castings per this standard must maintain permanent
records containing the AAR identification number, date of manufacture, pattern and serial num-
bers, and distribution statistics that will be provided to the AAR quarterly in an electronic format
developed and agreed upon by the manufacturers. AAR’s agent will maintain the records in a con-
fidential file for 30 years.
7.0 LANGUAGE
7.1 Foundries using a native language other than English are responsible for the accurate com-
munication of all applicable AAR and customer requirements within the foundry.
7.2 Foundry practices and the final product must conform to the English language versions of
any applicable standards or specifications.
7.3 Critical records are defined as the standards, internal procedures, and forms necessary to
demonstrate compliance with MSRP Specifications M-210 and M-1003. Critical records must be
kept up to date with production and be maintained in English.
8.0 GAUGE DRAWINGS
Drawings for gauges listed in Table 8.1 are maintained by the Truck Manufacturer’s Engineers’
Committee. Copies of the drawings are available through the Truck Manufacturer’s Engineers’
Committee.
10/2010 S [M-210] 97
M-210
Grade C
Normalized or
Grade B and B+
Quenched and
Tempered
Welds in Zone 1 Furnace temper a/ Furnace temper b/
Welds in Zone 2 Two or more equal passes—no heat treat Temper
Welds in Zone 3 Heat treat optional Heat treat optional
a/ Zone 1 temper will be a furnace temper.
b/ Internal ribs under the bolster center bowl are considered Zone 1
locations.
FIGURE A
Fig. 8.1 EC 3042
S [M-210] 98 10/2010
M-210
Grade C
Normalized or
Grade B and B+
Quenched and
Tempered
Welds in Zone 1 Furnace temper a/ Furnace temper b/
Welds in Zone 2 Two or more equal passes—no heat treat Temper
Welds in Zone 3 Heat treat optional Heat treat optional
a/ Zone 1 temper will be a furnace temper.
b/ Internal ribs under the bolster center bowl are considered Zone 1
locations.
FIGURE B
Fig. 8.2 EC 3043
10/2010 S [M-210] 99
M-210
Table 8.1 AAR standard gauges for side frames and bolsters
The gauge application figures contained in this specification illustrate one possible design to meet the gauging requirement.
Alternate gauge construction may be used if the gauging method does not change.
Gauge Application
Gauge No. Gauge Description
Figure No.
Side Frames (5½ × 10, 6 × 11, 6½ × 9, 6½ × 12, and 7 × 12)
8.3 EC 1107–3 Application of wheel base gauge to side frames
8.4 EC 1107–2 Enlarged view of scale on wheel base gauge
8.5 EC 1107–1 Wheel base gauge for side frames
8.6 EC 1119 Warp gauge for side frames
8.7 EC 1120 Column “Go” gauge for side frames
8.8 EC 1121 Column “No-Go” gauge for side frames
8.9 EC 1136 Journal roof to spring seat height and alignment gauge for truck side frames
8.10 EC 2037–2 Unit-type brake beam guide bracket gauges for side frames
8.11 EC 1149 Unit guide bracket alignment gauge for truck side frame
8.12 EC 1083–2 Application of adapter clearance gauge to narrow pedestal side frame
8.13 EC 1084–2 Application of box gauge to narrow pedestal side frame
8.14 EC 1085–2 Application of no-pass gauge for thrust lug and pedestal jaw narrow pedestal side frames
8.15 EC 1086–2 Application of transverse roof flatness gauge for narrow pedestal side frames
8.16 EC 1087–2 Application of radius gauge for thrust lug and jaw face narrow pedestal side frames
8.17 EC 1088–2 Application of no-go gauge for thrust-lug width on narrow-pedestal side frames
8.18 EC 1089–2 Application of longitudinal roof flatness gauge for narrow pedestal side frames
8.19 EC 1090–2 Application of key slot gauge and journal roof to key slot gauge for pedestal side frames
8.20 EC 1091–2 Application of thrust lug height gauge for narrow pedestal side frames
Truck Bolsters (5½ × 10, 6 × 11, 6½ × 9, 6½ × 12, and 7 × 12)
8.21 EC 1109 As-cast center plate go gauge for truck bolster
8.22 EC 1126 Center plate go gauge for truck bolster center plate wear liners
8.23 EC 1110 As-cast center plate no-go gauge for truck bolster
8.24 EC 1127 Center plate no-go gauge for truck bolster vertical ring wear liners
8.25 EC 1112–2 Application of center pin hole diameter and depth gauge for truck bolster
8.26 EC 1159 Bolster side bearing pad gauge constant-contact type flatness application
8.27 EC 1114–2 Application of center plate to side bearing gauge for truck bolster
8.28 EC 1124 Spring seat twist gauge for truck bolsters
8.29 EC 1142–2 Application of spring seat to center plate gauge for truck bolster
8.30 EC 1115 Column go and no-go gauge for truck bolster
8.31 EC 1116 Column guide no-go gauge for truck bolster
8.32 EC 1108–2 Application of span and squareness gauge for truck bolster
S [M-210] 100 10/2010

M-210
Fig. 8.3 EC 1107–3

Application of wheel base gauge to side frames
10/2010 S [M-210] 101

M-210
Fig. 8.4 EC 1107–2

Enlarged view of scale on wheel base gauge
S [M-210] 102 10/2010

M-210
Fig. 8.5 EC 1107–1

Wheel base gauge for side frames
10/2010 S [M-210] 103

M-210
Fig. 8.6 EC 1119

Warp gauge for side frames
S [M-210] 104 10/2010

M-210
Fig. 8.7 EC 1120

Column “Go” gauge for side frames
10/2010 S [M-210] 105
M-210
Fig. 8.8 EC 1121

Column “No-Go” gauge for side frames
S [M-210] 106 10/2010

M-210
Fig. 8.9 EC 1136

Journal roof to spring seat height and alignment gauge for truck side frames
10/2010 S [M-210] 107

M-210
Fig. 8.10 EC 2037–2

Unit-type brake beam guide bracket gauges for side frames
S [M-210] 108 10/2010

M-210
Fig. 8.11 EC 1149

Unit guide bracket alignment gauge for truck side frame
10/2010 S [M-210] 109

M-210
Fig. 8.12 EC 1083–2

Application of adapter clearance gauge to narrow pedestal side frame
S [M-210] 110 10/2010

M-210
Fig. 8.13 EC 1084–2

Application of box gauge to narrow pedestal side frame
10/2010 S [M-210] 111

M-210
Fig. 8.14 EC 1085–2

Application of no-pass gauge for thrust lug and pedestal jaw narrow pedestal side frames
S [M-210] 112 10/2010

M-210
Fig. 8.15 EC 1086–2

Application of transverse roof flatness gauge for narrow pedestal side frames
10/2010 S [M-210] 113

M-210
Fig. 8.16 EC 1087–2

Application of radius gauge for thrust lug and jaw face narrow pedestal side frames
S [M-210] 114 10/2010

M-210
Fig. 8.17 EC 1088–2

Application of no-go gauge for thrust-lug width on narrow-pedestal side frames
10/2010 S [M-210] 115

M-210
Fig. 8.18 EC 1089–2

Application of longitudinal roof flatness gauge for narrow pedestal side frames
S [M-210] 116 10/2010

M-210
Fig. 8.19 EC 1090–2

Application of key slot gauge and journal roof to key slot gauge for pedestal side frames
10/2010 S [M-210] 117

M-210
Fig. 8.20 EC 1091–2

Application of thrust lug height gauge for narrow pedestal side frames
S [M-210] 118 10/2010

M-210
Fig. 8.21 EC 1109

As-cast center plate go gauge for truck bolster
10/2010 S [M-210] 119

M-210
Fig. 8.22 EC 1126

Center plate go gauge for truck bolster center plate wear liners
S [M-210] 120 10/2010

M-210
Fig. 8.23 EC 1110

As-cast center plate no-go gauge for truck bolster
10/2010 S [M-210] 121

M-210
Fig. 8.24 EC 1127

Center plate no-go gauge for truck bolster vertical ring wear liners
S [M-210] 122 10/2010

M-210
Fig. 8.25 EC 1112–2

Application of center pin hole diameter and depth gauge for truck bolster
10/2010 S [M-210] 123

M-210
Fig. 8.26 EC 1159

Bolster side bearing pad gauge constant-contact type flatness application
S [M-210] 124 10/2010

M-210
Fig. 8.27 EC 1114–2

Application of center plate to side bearing gauge for truck bolster
10/2010 S [M-210] 125

M-210
Fig. 8.28 EC 1124

Spring seat twist gauge for truck bolsters
S [M-210] 126 10/2010

M-210
Fig. 8.29 EC 1142–2

Application of spring seat to center plate gauge for truck bolster
10/2010 S [M-210] 127

M-210
Fig. 8.30 EC 1115

Column go and no-go gauge for truck bolster
S [M-210] 128 10/2010
M-210
Fig. 8.31 EC 1116

Column guide no-go gauge for truck bolster
10/2010 S [M-210] 129

M-210
Fig. 8.32 EC 1108–2

Application of span and squareness gauge for truck bolster
S [M-210] 130 10/2010

M-210 APPENDIX A
APPENDIX A
AAR PROCEDURE FOR THE INSPECTION OF FOUNDRIES
The AAR inspection program is designed to qualify and evaluate each foundry’s and manufacturer’s
capability of producing castings to AAR specifications. This program is directed toward establishing
a minimum acceptable level of performance and capability with respect to experience, procedures,
ability, and equipment to produce castings of the required quality. Each foundry will be evaluated
on the following requirements during an inspection of the facilities by the AAR inspector:
1. Observe entire plant operation, with emphasis on procedures that affect quality and uniformity
of product.
2. Confirm values of certification test reports by following data gathering and storage throughout
the foundry process.
3. Inspect production and quality control equipment and facilities to determine ability to meet pro-
duction requirements.
4. Interview supervisors and workers with respect to procedures and methods used in all aspects
of production.
5. Review finished product defect matrix and scoring.
6. Review results of inspection with plant management and advise of any deficiencies noted.
Process control plans shall be established to control the critical foundry processes. Process control
plans should be obtained and reviewed by the official AAR auditor/inspector prior to the actual au-
dit. These control plans shall include at a minimum:
• Process name / operation description
• Critical process inputs
• Process outputs
• Specification limits
• Evaluation technique
• Sample size / frequency
• Control method (control chart, report, etc.)
• Reaction plan
Note: Process change procedures shall be in place to ensure that processes are reverified using ap-
propriate techniques following changes. This is to ensure that any changes demonstrate that the
revised process continues to meet the specified process limits.
Critical Processes and their outputs are covered below and shall be reviewed by the inspector.
10/2010 S [M-210] 131

APPENDIX A M-210
Table A.1 Critical processes and their outputs (page 1 of 3)

1. Critical Processes
A. Pattern and Core Box Practices
i. Pattern and core box design, dimensions, and rigging control
ii. Pattern and core box maintenance control
B. Core Making Practices
i. Core making and finishing control
ii. Sand testing control
C. Molding Practices
i. Sand testing control
ii. Mold making and core setting control to avoid shifts and offsets during mold move-
ment and pouring
D. Melting Practices
i. Raw material control
ii. Chemistry control including tramp elements
iii. Heat and pouring temperature control
E. Pouring Practices
i. Casting pouring time control
ii. Pouring temperature control
iii. Control of manganese reversion testing on the last casting poured
iv. Control of chemistry
v. Chemical and physical tests on representative castings
vi. Positive method for determining last casting
F. Cleaning Room Operations
i. Cleaning equipment must provide clean castings for proper inspection.
ii. Observe welding operations to ensure quality workmanship and conformance to writ-
ten procedures defined in paragraph 6.1, “Weld Repair” (obtain foundry weld repair
procedures/process control plan prior to audit). Welding equipment must be well
maintained and show proof of periodic checking (at least annually) for correct amper-
age and voltage readings. Welding rods and wire must be properly identified and
stored according to AWS standards.
iii. Workmanship of grinding operations should be evaluated.
iv. Facilities for performing welding according to temperature requirements of AAR spec-
ifications should be available. It is desirable that all weld repairs be made in the green
condition prior to heat treating. If proper foundry practices are in force, weld repair
requirements will be minor.
v. Inspection should be made of facilities and procedures for installing wear plates and
other fixtures to castings.
S [M-210] 132 10/2010

M-210 APPENDIX A

G. Heat-Treating Practices
i. Proper temperature control on furnace with adequate recording capabilities must be
evident.
ii. Procedures should be in place to periodically verify (as defined in Specification M-201)
uniform temperature throughout furnaces.
iii. Proper records must be kept to positively identify castings that have received heat
treatment.
iv. Quench tanks must have circulating capability with facility to ensure proper temper-
ature of coolant. Tanks should be kept clean and free of scrap material likely to impair
operation.
H. Casting Quality
i. A random sample of castings should be selected from the inspection area and dimen-
sionally and visually inspected. The object of this should be to evaluate the overall
quality of the finished casting. Pattern quality, core setting, and dimensional control
should be evaluated.
ii. Availability and accuracy of gauges should be determined and the calibration system
for gauges should be evaluated.
iii. All physical test apparatus should be inspected for general operating condition and
calibrations. All equipment requiring calibration should have current certification.
iv. Records of internal solidity must be verified, as defined in paragraph 4.3 and
Appendix C.
2. Organization Policy
A. Proper separation between production responsibility and quality control responsibility.
B. Procedure for resolving controversy between operations and quality control on noncon-
forming items.
C. Disposition of non-conforming items.
D. Attitude of supervisory personnel with regard to quality assurance requirements.
3. Personnel
A. Procedures for qualifying workmen for particular jobs. Training provided for new employ-
ees.
B. Procedures for qualifying supervisors and methods of training and determining perfor-
mance.
C. Determine if there are proper welding procedures and competent expertise in the plant to
perform welding tests and solve welding problems. Determine how and when welders are
qualified.
4. Record Retention
A. Each foundry will retain records of foundry and casting approval.
B. Manufacturing and distribution records will be maintained as required in
paragraph 6.6.2.
10/2010 S [M-210] 133

APPENDIX A M-210

5. Language
A. Foundries using a native language other than English must provide a translator or tech-
nical expert to assist in the audit.
B. This translator or technical expert is responsible for demonstrating to the auditor that the
foundry understands and complies with all applicable AAR requirements. To do so, the
expert may be asked by the auditor to explain various foundry practices and critical re-
cords as related to these requirements (paragraph 7.0).
S [M-210] 134 10/2010

M-210 APPENDIX B
APPENDIX B
AAR CASTING TECHNICAL INSPECTOR QUALIFICATION GUIDELINES
1.0 The AAR inspection program is designed to evaluate and assess the ability of foundries
producing castings to AAR specifications. This appendix is intended to identify the requirements
for becoming an AAR-qualified Casting Technical Inspector and for performing inspections on
behalf of and authorized by the AAR on behalf of the AAR Casting Committee, hereinafter referred
to as the Committee, in accordance with the provisions of the applicable AAR Manual of
Standards and Recommended Practices.
2.0 Inspector candidates must apply to the AAR and include the following information to verify
compliance with the provisions herein:
2.1 Resume of work experience, formal education, and related training.
2.2 References who may be contacted, including past or present employer(s) and those who have
knowledge of the candidate’s capabilities.
2.3 Evidence of experience and/or training for the following core skills as it relates to the produc-
tion of steel castings:
• Steel making – melting
• Heat treating
• Chemical testing
• Mechanical testing
• Welding
• Nondestructive testing
• Metrology
3.0 In addition to the above, inspectors must be aware of the technical requirements in the
applicable AAR Manual of Standards and Recommended Practices.
4.0 The Committee shall review candidate applications. If the Committee approves the candidate
as an AAR Casting Technical Inspector, the AAR will execute the necessary contracts for
employment of services and confidentiality.
5.0 At the discretion of the Committee, the candidate may be required to attend inspections,
quality audits, and/or additional training once authorized as an AAR Casting Technical Inspector.
Attendance at audits may not be performed prior to entering into a confidentiality agreement with
the AAR.
6.0 The Committee may request a meeting/interview with the candidate inspector to obtain
additional information.
7.0 AAR Casting Technical Inspectors shall be certified as such for a period of 3 years. At the end
of this period, the inspector must be reevaluated for continued certification. The Committee
reserves the right to reconsider certification of approved AAR Casting Technical Inspectors. If
certification is reconsidered prior to the recertification period, the inspector will be advised in
writing of cause for this reconsideration and be permitted the opportunity to discuss the issue with
the Committee.
10/2010 S [M-210] 135

APPENDIX C M-210
APPENDIX C
INTERNAL SOLIDITY STANDARDS
1.0 INTERNAL SOLIDITY SECTION CUT LOCATIONS AND SECTIONAL AREAS FOR
ELEVATION
Fig. C.1 EC 2065

S [M-210] 136 10/2010
M-210 APPENDIX C
Fig. C.2 EC 2066

10/2010 S [M-210] 137
APPENDIX C M-210
2.0 SOLIDITY STANDARDS FOR SIDE FRAMES AND BOLSTERS—CLASS 1
Fig. C.3 3368-01-A
Fig. C.4 3368-01-0B
S [M-210] 138 10/2010

Casting Details
M-210 APPENDIX C
Fig. C.5 3368-02-A
Fig. C.6 3368-02-B
10/2010 S [M-210] 139

Casting Details
APPENDIX C M-210
Fig. C.7 3368-03-A
S [M-210] 140 10/2010

10/2010
Casting Details
M-211
FOUNDRY AND PRODUCT APPROVAL REQUIREMENTS FOR THE

MANUFACTURE OF COUPLERS, COUPLER YOKES, KNUCKLES,
FOLLOWER BLOCKS, AND COUPLER PARTS
Specification
M-211

Paragraph
or Appendix Topic Page
1.0 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]142
2.0 Basis of Foundry Approval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]142
3.0 Test Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]143
4.0 Product Design Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]146
5.0 Weld Repair and Thermal Dressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]147
6.0 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]149
7.0 Coupler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]150
8.0 Casting Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]150
9.0 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]150
10.0 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]151
11.0 Criteria for Casting Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]151
12.0 Purchasers Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]154
13.0 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]155
14.0 Language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]155
15.0 Gauge Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]155
Appendix A Referenced Figures and Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]157
Appendix B Foundry Approval Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]179
Appendix C Product Design Approval Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]180
Appendix D Application for Approval of Non-Standard Design Coupler, Part, Yoke, or Draft Gear Follower . S[M-211]182
Appendix E Design Features for AAR-Approved Special Coupler Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]183
Appendix F AAR Code for Designating Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]184
Appendix G Four-Digit Identification Code for Special Coupler Knuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]188
Appendix H Technical Inspection of Foundries—Requirements and Procedures . . . . . . . . . . . . . . . . . . . . . . S[M-211]189
Appendix I Standard Reference Photographs for Casting Solidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]193
Appendix J Report of Metallurgical Testing per AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-211]200
10/2010 S [M-211] 141

10/2010
Casting Details
M-211
1.0 SCOPE
1.1 This specification covers the following:
• Requirements for AAR-approved foundries that manufacture couplers, coupler yokes,
knuckles, follower blocks, and cast coupler parts for use in North American freight inter-
change service
• Requirements for couplers, coupler yokes, knuckles, follower blocks, and cast coupler parts
for use in North American freight interchange service
1.2 All designs and foundries shall be approved by the AAR before being used in interchange ser-
vice. The basis for approval shall be compliance with this specification.
2.0 BASIS OF FOUNDRY APPROVAL
2.1 Foundry approval shall include compliance with this specification as well as with the follow-
ing:
• AAR Manual of Standards and Recommended Practices (MSRP), Section S,
Specifications M-201, M-205 (for yokes), and M-220
• MSRP, Section J, Specification M-1003
• MSRP Section AS, Standard S-060
• AWS D15.1, Railroad Welding Specification for Cars and Locomotives.
2.2 Each facility that produces castings or conducts thermal dressing, welding, or heat-treatment
shall be approved.
2.3 Each foundry requires an initial technical inspection to achieve approval and an annual tech-
nical inspection to maintain that approval, as outlined in Appendix H.
2.4 Each foundry requires an initial QA inspection to achieve approval and an annual QA inspec-
tion to maintain that approval as described in MRSP Section J, Specification M-1003.
2.5 Each foundry requires design approval for one or more designs of couplers, coupler yokes, or
knuckles that the foundry manufactures. If a product and design group (defined in
paragraph 3.2.1) are discontinued, the provisions of MSRP Section AS, Standard S-060, shall be
followed.
2.6 A foundry that has met AAR technical, QA, and component design requirements on one or
more different designs of couplers, coupler yokes, or knuckles shall be approved to manufacture
any standard or alternate standard component in those design groups.
2.7 Quenched and tempered Grade E steel castings, as defined in Specification M-201, shall be
utilized for all couplers, knuckles, locks, coupler yokes, and follower blocks, unless specifically
approved under alternate AAR specification(s).
S [M-211] 142 10/2010

10/2010
Casting Details
M-211
2.8 List of Approved Foundries

2.8.1 The AAR publishes a list of approved foundries that satisfy the requirements of Specifica-
tion M-211.
2.8.2 Removal from the List of Approved Foundries
Specification M-211 approval of a foundry may be removed for the reasons listed below. In the
event that a foundry is deleted from this list, reapplication for approval is required.
• For Cause—Consistent failure to maintain adequate quality control standards as evi-
denced by performance, inspections, or noncompliance with specifications.
• Discontinued Production—A foundry discontinues production as described in MSRP
Section AS, Standard S-060 for reasons other than economic conditions or usage require-
ments.
• Inspection Refusal—Refusal by a foundry to accept an inspection scheduled under the
provisions of this specification.
This paragraph describes requirements for component and material testing.
Test records shall be kept and made available for inspection by the AAR representative during the
annual technical or QA audit or upon request by customers. Material properties shall be reported
using the format provided in Appendix J.
3.1 M-201 Test Requirements
3.1.1 M-201 material test requirements are summarized in Table 3.1.
Table 3.1 Summary—M-201 material tests
M-201 Property
(M-201 Paragraph) Test Measurement Sample Detail Testing Frequency
Tensile (7.2) Tensile Strength One sample from coupon Every heat
Yield Strength
Elongation
Reduction of Area
Chemistry (6.3.1) Ladle chemistry analysis during first Ladle sample
25% of pour
Chemistry, % Mn Ladle, coupon, or casting chemistry Sample taken at end of pour
(6.3.2) analysis
Hardness (7.4) Brinell Hardness Sample from coupon and a sample from
casting per Fig. A.18.
Impact Properties Charpy V Notch Type A Three specimens from coupon(s) made Once/week/grade
(7.3) (ASTM A370), or… at end 25% pour of one heat
Option 1: Dynamic Tear Test Sample from coupon
(ASTM E604), or…
Option 2: Nil Ductility Test Sample from coupon
(ASTM E208)
Hardenability (6.2) Jominy Test Sample from casting or coupon Once/month/grade
after 10 consecutive
heats have been
successfully tested
10/2010 S [M-211] 143

10/2010
Casting Details
M-211
3.2 Design Group, New Product, and New Foundry Test Requirements
Design group test requirements, summarized in Table 3.2, supplement those set forth in Specifica-
tion M-201 and are required for both acquiring and maintaining foundry approval. These tests are
also used for approval requirements for new products.
Table 3.2 Design group tests
Design Groups
or Product Test (M-211 Paragraph) Samples Frequency
Coupler and Impact Toughness One design group casting with Once per year per design
yokes Dynamic Tear Test (ASTM E604) or one group keel block. group, or…
Periodic Production Tests (3.2.3)
Nil Ductility Test (ASTM E208)

Impact Toughness For newly approved foundries,
Charpy V Notch Type A (ASTM A370) every 6 months per design
group until four consecutive
Tensile Properties
tests are successful, or…
(as described in M-201, including
Tensile Strength, Yield Strength,
For any new product, every 6
Elongation, and Reduction of Area)
months until four consecutive
Chemistry tests are successful. Products
Hardness from design groups that have
Coupler, yokes, Internal Solidity Test (3.2.4) One component per design not been produced for more
and knuckles group. (For new products, than 6 months must have a full
three like components, each series of tests to get back onto
from a different heat for the the once-per-year schedule.
initial test.)
Coupler, yokes, Static Tension Proof Tests (3.2.5 or One component per design
and knuckles 3.2.6) group. (Three yokes required
for new designs.)
New couplers Coupler Shelf Test (3.2.7) One component per design for Once for any new design.
only any change in shelf design.
3.2.1 Design Groups

Foundries shall organize products using the following five design groups for the purpose of manag-
ing tests required for foundry approval:
1. E and E/F couplers

2. F couplers
3. E yokes
4. F yokes
5. E and F knuckles
3.2.2 Test Schedule

For foundries with 2 or more years of successful design group tests, all tests are required once per
year per design group. Newly approved foundries shall conduct all tests for each design group
every 6 months until four consecutive tests are successful. New products are subject to a complete
series of tests every 6 months until four consecutive tests are successful. Products from design
groups that have not been produced for more than 6 months must have a full round of testing to
get back onto the once-per-year schedule.
S [M-211] 144 10/2010

10/2010
Casting Details
M-211
3.2.3 Periodic Production Tests

Periodic production test samples shall be taken from both the casting component and an accompa-
nying keel block from the same heat. Mechanical and chemical property tests shall be conducted
per Specification M-201. Tensile tests on castings shall include elongation and reduction in area,
with the understanding that these tests are for information purposes only.
3.2.4 Internal Solidity Test
3.2.4.1 Internal solidity requirements shall be established by sectioning one specimen from each
design group. At least one casting from each design group in production must be sectioned each
year and at any time a significant change occurs to a critical process. New products require an ini-
tial sectioning of three castings, each from a different heat.
3.2.4.2 Castings shall be sectioned in accordance with Fig. A.14 or Fig. A.15.
3.2.4.3 Areas to be rated for discontinuity severity level are illustrated in Figs. A.16 and A.17
3.2.4.4 Casting areas for evaluation shall be rated as to level of severity by comparing them with
“Standard Reference Photographs for Casting Solidity,” included as Appendix I.
3.2.4.5 The rated level of severity for each section shall not exceed those listed in Table 3.3.
Cracks and/or hot tears are not permitted in any visible surface location.
Table 3.3 Maximum severity levels
Sectional Area
Component Type
A B C D E F G
E coupler head 3 5 4 4 4 2 —
E coupler shank 4 4 — — — — —
E knuckle 4 4 2 — — — —
E yoke 2 4 4 4 — — —
F coupler head 3 5 4 4 4 2 3
F coupler shank 3 4 4 4 — — —
F knuckle 4 4 2 — — — —
F yoke 2 4 4 4 — — —
3.2.5 Static Tension Proof Tests—Coupler Bodies and Knuckles

3.2.5.1 Coupler bodies and knuckles shall meet permanent set and ultimate strength require-
ments shown in Table 3.4. The dimensions shown in Fig. A.13 shall be used to determine perma-
nent set.
3.2.5.2 Test machines shall be calibrated annually (with a 30-day grace period to allow for flexi-
bility in test scheduling) to national or industry recognized standards. Special test knuckles for
testing coupler bodies shall have a load capacity in excess of 900,000 lb.
3.2.5.3 When testing coupler bodies, if the test knuckle breaks before required loading is
attained, the test shall be terminated and the load recorded as “maximum applied load.” When
this occurs, additional tests shall be required until the required test load is achieved. The same
coupler body or a new coupler body shall be tested at the discretion of the manufacturer.
Table 3.4 Static tension proof test requirements for coupler bodies and knuckles
Permanent Set Test Minimum
Load (lb) Maximum Set (in.) Ultimate Load (lb)
Knuckle 400,000 .03 650,000
Coupler body 700,000 .03 900,000
10/2010 S [M-211] 145

10/2010
Casting Details
M-211
3.2.6 Static Tension Proof Tests—Yokes

Yokes shall meet the requirements of Specification M-205. For design group tests, one yoke shall
be statically tested and not three as called for in Specification M-205. For new designs of yokes,
three yokes shall be tested as described in Specification M-205.
3.2.7 Coupler Shelf Test
For any new design, a manufacturer shall provide test verification that coupler shelves will sup-
port a vertical load of 200,000 lb with couplers in buff position. The standard F coupler bottom
shelf is a long-standing AAR configuration and does not require design qualification.
3.3 Failure of Test Samples
3.3.1 M-201 and Periodic Production Tests
3.3.1.1 If M-201 or periodic production test results do not meet requirements as a result of a
flawed specimen, results obtained shall be discarded and another specimen shall be selected (fail-
ure of an individual test should not always be considered indicative of the material). If satisfactory
results cannot be accomplished, an investigation shall be performed to determine the extent of any
noncompliance (i.e., if it is confined to a casting, several castings, one heat, or if it extends beyond
this).
3.3.1.2 If the test results show that the product does not meet requirements, appropriate correc-
tive action shall be taken to prevent the production of additional deficient components. The AAR
shall be notified of systemic corrective actions needed to resolve the noncompliance and given a
schedule for implementation.
3.3.1.3 If corrective actions are taken on castings, subsequent test results shall show compliance
prior to shipment. The AAR and purchaser shall be notified of product that has shipped that may
not meet requirements.
3.3.2 Proof Tests and Internal Solidity Tests
3.3.2.1 If initial proof test or internal solidity tests do not meet requirements, the cause of non-
compliance shall be studied and an investigation shall be conducted to ensure that there is not a
systemic problem in the manufacturing process. A follow-up test shall be conducted to help ensure
that the noncompliance is not systemic.
3.3.2.2 If corrective actions are taken in the manufacturing process, subsequent test results shall
show compliance, and the AAR shall be notified of the changes and test results. In addition, the
frequency of design group tests, for products affected by these changes, must be reestablished by
testing every 6 months until four successful tests are completed.
4.0 PRODUCT DESIGN APPROVAL
Special designs that deviate from AAR-catalog-numbered items and that will be used in inter-
change shall be approved by the AAR. Only approved products shall be identified with the initials
“AAR” cast in raised letters.
4.1 Standard Designs
4.1.1 Only approved designs shall be eligible to be identified by an “AAR” designation.
4.1.2 AAR-approved designs accepted as industry standards are listed in Appendix A and include
E, E/F, and F couplers, E and F coupler yokes, E and F knuckles, and E and F follower blocks.
4.1.3 Casting shall have minimum casting weights as listed in Fig. A.1.
S [M-211] 146 10/2010

10/2010
Casting Details
M-211
4.2 Non-Standard Design Coupler Bodies, Yokes, and Knuckles

4.2.1 Application for approval of non-standard designs shall be submitted in accordance with
Appendix C.
4.2.2 Only after AAR approval shall non-standard designs be eligible for “AAR” designation.
4.2.3 Non-standard designs include proprietary designs that are not listed in Appendix A and are
approved under this specification or designs that have been approved under Specification M-215.
4.2.4 Approval of a design applies to the manufacturer for whom it is approved. This approval
may cover the same design produced by another approved manufacturer upon notice to and confir-
mation by the AAR.
4.2.5 Design Engineering Requirement
A design process utilizing best practices shall be completed for each coupler, yoke, and knuckle
design with documentation available for review by the AAR or purchaser upon request. Finite ele-
ment techniques and solidification analysis are examples of best practices. The AAR will consider
requests for waiver of this requirement in cases of minor changes not affecting the structural
design.
4.2.6 Fatigue Evaluation
4.2.6.1 Non-standard coupler, yoke, and knuckle designs shall have fatigue strength calculations
submitted. As an alternative to fatigue calculations, fatigue test data on the actual product may be
used. The AAR will consider requests for waiver of this requirement in cases of minor changes not
affecting fatigue life.
4.2.6.2 Fatigue calculations shall be made using Miner’s Rule and the coupler force spectrum of
AAR Specification M-1001 in the Manual of Standards and Recommended Practices, Section C,
Part II, Chapter 7. If fatigue product tests are used, the load spectrum shall be equivalent to that
of AAR Specification M-1001, Chapter 7, or as approved by the AAR. For yokes and knuckles, only
the draft component of the Chapter 7 load spectra shall be used.
5.0 WELD REPAIR AND THERMAL DRESSING
Facilities performing weld repairs shall be inspected and approved by the AAR. Welding shall be in
accordance with Specifications M-201 and M-211.
5.1 A written procedure shall be in place to identify and control castings that require weld repair
and/or thermal dressing after heat-treatment. Markings shall be utilized and include either paint
color code, color coded tags, or other suitable means that ensure that a component’s status is
clearly known throughout the finishing process.
5.2 Manufacturers shall have a demonstrable process to ensure compliance to written proce-
dures, including training programs and record-keeping programs.
5.3 Low-hydrogen SMAW electrodes shall be purchased in hermetically sealed containers or shall
be baked as prescribed by AWS D15.1, “Railroad Welding Specification for Cars and Locomotives.”
Immediately after opening a hermetically sealed container, electrodes shall either be used or
stored in an oven held at a temperature of at least 250 °F. Low-hydrogen electrodes shall be
re-baked no more than one time by the consumer. Electrodes that have been wet shall not be used.
5.4 Welding shall not be allowed when the surfaces to be welded are wet or exposed to rain, snow,
or high wind, or when the ambient temperature in the area to be welded is below 0 °F. These envi-
ronmental conditions do not alter or preclude the minimum preheat or interpass temperatures
required by the welding procedure (see paragraph 5.5.2).
10/2010 S [M-211] 147

10/2010
Casting Details
M-211
5.5 Procedure Qualification and Testing

5.5.1 Procedures for weld repair on castings manufactured to this specification shall be qualified
in accordance with the latest revision of AWS Specification D15.1, “Railroad Welding Specification
for Cars and Locomotives.”
5.5.2 Welding procedures shall include appropriate preheat temperatures as determined by
equivalent carbon content values and the material section thickness to be welded. Under no condi-
tion shall welding be performed when the casting temperature is below 40 °F. Procedure qualifica-
tion test coupons shall be subjected to the same heat-treatment before and after welding as are
applied to the casting.
5.5.3 Build-up welds shall be qualified using a complete joint penetration (CJP) groove weld test.
5.5.4 Procedures may be qualified using shielded-metal arc (SMAW), flux-core arc (FCAW), or
gas-metal arc (GMAW) welding processes. Weld material deposited shall provide properties equiv-
alent to the applicable grade of cast steel specified in Specification M-201.
5.5.5 The number of tests, type of specimens, range of thickness qualified, and position limita-
tions for weld repair on castings shall be the same as for CJP groove weld tests on plate specified
in AWS D15.1. For alternative qualification to the specified root, face, and/or side guided-bend
tests, three macroetch cross-sectional test specimens may be prepared when qualifying low ductil-
ity cast materials having greater than 90 ksi yield. The reduced section tension tests are still
required.
5.5.6 Essential variables: limitations shall be the same as those listed in AWS D15.1. A separate
qualification test shall be required if changes are made outside the limitations of essential vari-
ables.
5.6 Performance Qualification and Testing
5.6.1 Welders and welding operators performing weld repairs to castings manufactured to this
specification shall be qualified by testing prescribed by the latest revision of AWS D15.1, “Railroad
Welding Specification for Cars and Locomotives.”
5.6.2 Weld repair shall be made in the position for which the welder is qualified in all cases.
Welding in the flat (down-hand) position is preferred.
5.7 Repair
5.7.1 Welds in the non-shaded areas defined in Fig. A.11 shall be in accordance with the require-
ments of Fig. A.11 and the following:
• The entire defect shall be removed by machining, grinding, chipping, oxygen gouging,
air-carbon-arc gouging, or plasma-arc gouging.
• Where a defect does not propagate through the complete casting wall or thickness, the area
can be prepared by contouring the base metal for build-up welding.
• Where a defect penetrates through the casting wall or thickness, the area shall be
prepared for a complete joint penetration (CJP) weld. If both sides of the wall are
accessible for welding, the casting may be welded from both sides using a double “V” or “U”
groove joint contour weld per Specification M-201. If inaccessible for welding from the root
side, the casting may be weld repaired using a single “V” or “U” groove joint contour with
either fused backing (steel plate) or un-fused backing (copper, brass, or ceramic plate)
provided the root surface is smooth and clean.
S [M-211] 148 10/2010

10/2010
Casting Details
M-211
5.7.2 Welds in the shaded areas defined in Fig. A.11 shall be considered structural repair and
shall be in accordance with the requirements of Fig. A.11 and the following:
• Defects that penetrate completely through the wall or thickness cannot be repaired.
• For defects that do not penetrate completely through the wall, the entire defect shall be
removed (by methods listed in paragraph 5.7.1), and the area shall be prepared by contour-
ing the casting for build-up welding.
• Root face of the prepared cavity shall be a minimum 1/4 in. wide.
• "Maximum depth of a repair area shall not exceed 1 in. deep while maintaining a mini-
mum of 1/8 in. sound casting thickness at the base of the prepared cavity.
5.7.3 If welding repairs are performed after heat-treatment, the casting shall be reheat-treated
(by furnace method) as required by Fig. A.11.
5.8 Thermal Dressing
5.8.1 Best foundry practices include conducting thermal dressing before heat-treatment.
5.8.2 If thermal dressing is required after heat-treatment and is in the shaded areas of Fig. A.11,
the casting shall be heat-treated again.
5.8.3 If thermal dressing is required after heat-treatment and is in the non-shaded areas of
Fig. A.11, heat-treatment is optional.
5.9 Inspection
All welds shall be visually inspected. Welds shall be accepted if they are in conformance with AWS
D15.1, “Visual Inspection of Completed Welds” and meet other requirements when specified else-
where in that specification. Porosity shall not exceed the limits of AWS D15.1 for Class 2 welds.
6.0 GAUGING
6.1 Couplers, knuckles, coupler parts, yokes, and follower blocks shall meet the requirements of
the gauges and/or tolerances listed in Figs. A.2, A.3, A.4, A.5, A.6, A.7, and A.8. Yokes and draft
gear followers must also comply with the standards listed below:
S-141—Y40 Type Yokes

S-143—SY40 Type Yokes
6.2 A casting must be reheat-treated if it is brought into gauge tolerance by the method of heat-
ing the casting in excess of the tempering temperature.
6.3 All gauges shall be certified.
6.4 For those gauges not applied to 100% of castings produced, sampling techniques shall be
employed to confirm compliance with gauge requirements. For all gauges applied, sampling
records shall be maintained in an auditable form to ensure suitability of gauging frequency in
accordance with production volume. An acceptable technique must be demonstrable to the AAR
inspector.
6.5 Gauge Drawings
Drawings for gauges listed in Appendix A are maintained by the Mechanical Committee for Stan-
dard Coupler Manufacturers (MCSCM).
10/2010 S [M-211] 149

10/2010
Casting Details
M-211
7.0 COUPLER OPERATION

7.1 Assembled couplers must be free of any foreign material that will prevent proper operations
described in paragraph 7.1.1 through paragraph 7.1.5. A coupler inspection operating rod is illus-
trated in Fig. A.12.
7.1.1 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.
7.1.2 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.
7.1.3 The coupler lock must automatically drop to the locked position when the knuckle is closed
as described in paragraph 7.1.2. The coupler knuckle is locked shut when the lock drops to seat on
or within 1⁄4 in. of the knuckle tail lock shelf.
7.1.4 The coupler is put on lock set when the knuckle is restrained from opening while force is
applied through the inspection operating rod while trying to raise the lock above the knuckle tail.
When the rod is eased back and released, the lock must rest on the forward top edge of the knuckle
thrower lock leg. The knuckle then must be free to rotate open by hand force applied on the inside
face of the knuckle nose. The coupler then must perform the functions of knuckle closure and lock
drop as described in paragraph 7.1.2 and paragraph 7.1.3.
7.1.5 The coupler must provide anticreep protection to prevent accidental unlocking.
7.2 AAR standard couplers furnished complete must be fitted with AAR standard or alternate
standard knuckles of the same grade of steel as the coupler body. Couplers must be fitted with
grade E locks.
8.0 CASTING FINISH
8.1 Riser pads and gate stubs shall not project more than 1⁄4 in. above the surrounding surface at
any location. Where interference would exist in the operation or application or where serviceabil-
ity would be affected, the riser pads and gate stubs shall be contoured to surrounding areas.
8.2 Castings shall be blasted sufficiently clean to permit thorough visual inspection. Prior to
shipment, castings shall be free of dirt, rust, or loose material that would affect operation. Cou-
plers must not be sand- or shot-blasted when completely assembled.
8.3 The castings shall not be painted or covered with any substances that will hide defects. How-
ever, foundry and/or purchaser paint identification marks are acceptable.
9.0 LUBRICATION
Only dry lubricant shall be applied to the coupler head or the coupler head fittings. This lubricant
may be applied using a water, alcohol, or other nonpetroleum based carrier.
S [M-211] 150 10/2010

10/2010
Casting Details
M-211
10.0 MARKINGS
10.1 All yokes, couplers, and parts shall have legible markings as specified in Figs. A.9 and A.10.
Only castings manufactured in accordance with the provisions of this specification are eligible to
be identified by a standard AAR catalog number. AAR standard catalog numbers are shown in this
section. For purposes of this specification, legible markings shall mean markings of such a charac-
ter that by observing the marks it is possible to accurately deduce their intended meaning.
10.2 When required markings are illegible, the foundry must apply these markings to each cast-
ing in a workmanship manner by electric arc welding using a maximum 1/8-in.-diameter electrode.
Every effort shall be made to perform this pencil welding prior to heat-treatment.
10.3 Subsequent heat-treatment in accordance with paragraph 5.7.3 is not required for pencil
welding of any markings. However, if pencil welding is performed in critical areas, as defined in
Fig. A.10, the foundry must have in its written procedures a process to record this and to alert the
finishing area working these castings that such welding is being done so that such welding can be
performed prior to heat-treatment and the condition creating the pencil welding requirement
addressed.
10.4 No proprietary numbers shall be used when comparable AAR standard catalog numbers are
available.
10.5 Grade E castings shall be identified with the raised letter “E” cast as the last character of
the AAR catalog number.
11.0 CRITERIA FOR CASTING ACCEPTANCE
This section defines and classifies casting defects and shall be used for visual inspection and gaug-
ing of coupler bodies, knuckles, locks, yokes, and cast draft gear follower blocks.
11.1 Wall Thickness
11.1.1 Wall thickness tolerances, except where controlled by gauges or AAR standard drawings,
are as follows:
1/4" up to, not including 7/16" wall + 1/8" –1/32"

7/16" up to, not including 3/4" wall + 1/8" –3/32"
3/4" up to, not including 1 1/4" wall + 1/8" –1/8"
1 1/4" and over + 3/16" –5/32"
If grinding makes walls thinner than minus limits above, castings must be restored by welding to
within tolerances specified.
11.1.2 In local areas dictated by individual manufacturing practices, padding or additional metal
thickness is done for casting solidity. This practice is not a violation of the plus tolerance of the
metal section.
10/2010 S [M-211] 151

10/2010
Casting Details
M-211
11.2 Surface Acceptance Level

11.2.1 The minimum acceptable surface conditions for the defects described below shall govern.
Acceptable surfaces shall be defined utilizing Steel Castings Research and Trade Association
(SCRATA) Comparators for the Definition of Surface Quality of Steel Castings. The listed defect
classifications do not apply to inaccessible areas. Surface defects described herein do not preclude
the requirements of appropriate gauge application as defined elsewhere in this specification.
11.2.1.1 Surface conditions evaluated with SCRATA comparators:
Critical Area Fig. A.11 Non-Critical Area Fig. A.11
A) Surface Roughness A3 A3
B) Surface Inclusions 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
11.2.1.1.1 Surface conditions B and C are acceptable if the depth of defect does not exceed 10% of
the section thickness at critical areas and 25% of the section thickness in noncritical areas.
11.2.2 The following surface conditions are not evaluated with SCRATA comparators:
11.2.2.1 Offsets: An offset is an abrupt, unintentional change in a casting surface.
11.2.2.1.1 Offsets greater than 10% of the casting wall thickness shall not be accepted.
11.2.2.2 Cracks, hot tears, cold shuts, and weld cracks that are visually apparent or detected by
NDT per Specification M-220 are not permitted.
11.2.2.3 Shaded and non-shaded areas must be prepared in accordance with Fig. A.11.
11.2.3 Critical defect: A defect as defined in paragraph 11.5.2 and in the shaded areas as shown
in Fig. A.11.
11.2.4 Major defect: A defect as defined in paragraph 11.5.3 for shaded areas and
paragraph 11.5.2 outside the shaded areas, as shown in Fig. A.11.
11.2.5 Minor discrepancy: A defect as defined in paragraph 11.2.1 outside the shaded areas
shown in Fig. A.11.
11.3 Illegible Markings
Illegible markings are markings that do not conform to paragraph 10.1.
11.3.1 Major defect: An illegible marking consisting of loss of heat identification, catalog number,
manufacturer’s trademark, or cast date.
11.3.2 Minor discrepancy: Illegible marking not listed in paragraph 11.3.1.
11.4 Evidence of Improper Heat-Treatment
Critical defect: Evidence of improper heat-treatment as shown from foundry’s records. At the pur-
chaser’s option, heat-treatment lugs may be used to assist in the determination of improper
heat-treatment.
S [M-211] 152 10/2010

10/2010
Casting Details
M-211
11.5 Improper Weld Repair

11.5.1 Weld repair shall be performed in accordance with paragraph 5.0.
11.5.2 Critical Defects
11.5.2.1 Any crack in a repair weld.
11.5.2.2 Weld more than 1⁄16 in. below surrounding surface in shaded areas of Fig. A.11. Minimum
wall thickness must be maintained.
11.5.2.3 Slag inclusion or incomplete fusion in shaded areas of Fig. A.11.
11.5.2.4 Arc strike in shaded areas of Fig. A.11.
11.5.3 Major Defects
11.5.3.1 Weld below surrounding surface to depth greater than 10% of wall thickness. Minimum
wall thickness must be maintained.
11.5.3.2 Slag inclusion or incomplete fusion outside of shaded areas of Fig. A.11.
11.5.3.3 Arc strike outside the shaded areas of Fig. A.11.
11.6 Improper Cleaning
Major defect: Failure to meet the conditions of paragraph 8.2.
11.7 Misapplication of Assembly Parts
Major defect: Misapplication of assembly parts is a major defect. Knuckles and locks applied to
couplers must be in accordance with paragraph 7.2. This manual covers selection of other parts in
MSRP Section S, Part III, Standards S-102, S-103, S-105 through S-112, S-114, S-115, S-154,
S-155, S-163, S-164, S-165, S-170, and S-172.
11.8 Mechanical and Thermal Dressing
11.8.1 Stress risers (including chisel marks, handling notches, and gouges in excess of 1⁄16 in.
deep).
11.8.2 Critical defect: Any areas of overheating or notches caused by flame cut, grinding, or chisel
cut, etc., in shaded areas of Fig. A.11.
11.8.3 Major defect: Any areas of overheating or notches caused by flame cut, grinding, or chisel
cut, etc., greater than 10% of wall thickness outside of shaded areas of Fig. A.11.
11.9 Improper Lubricants
Major defect: Lubrication not conforming to paragraph 9.0.
11.10 Riser and Gate Projection
Major defect: Riser pads and gate stubs projecting more than 1⁄4 in. above surrounding surface at
any location. Where interference would exist in the operation or application or where the service-
ability would be affected, the riser pads and gate stubs shall be contoured to the surrounding sur-
faces.
11.11 Sharp or Jagged Edges
Critical defect: Sharp or jagged edges that could be injurious to workers.
11.12 Casting Weights
Major defect: Failure of coupler bodies, yokes, knuckles, and assembled couplers to meet the mini-
mum weights shown in Fig. A.1.
10/2010 S [M-211] 153

10/2010
Casting Details
M-211
11.13 Failure to Meet Gauging Requirements

Defect categories are shown in Figs. A.2, A.3, A.4, A.5, A.6, A.7, and A.8.
11.14 Scoring System
The foundry shall maintain an auditable scoring system to ensure compliance to finishing
standards.
12.0 PURCHASERS INSPECTION
12.1 The purchaser’s inspector shall have free access at all times, while performing the work on
the contract of the purchaser, to all parts of the foundry that concern the manufacture of the
ordered material. The purchaser’s inspector shall comply with all applicable safety rules and local
regulations. At the manufacturer’s discretion, proprietary information concerning a product or
process may be withheld if the customer is also a competitor. 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 these specifications. Tests and inspections
shall be made prior to shipment at the place of manufacture to ensure that provisions of this spec-
ification are being met. Any additional tests must be negotiated prior to placement of the order. All
inspections shall be conducted while not interfering with manufacturing operations.
12.2 Method of Inspection
12.2.1 At the option of the purchaser, the inspections may be performed on 100% of the castings
in an order, a portion of an order, or on an acceptance sampling basis. The purchaser and manufac-
turer shall mutually afford each other a reasonable time period to schedule and perform the
desired inspection.
12.2.2 The purchaser may also waive the inspection based on previous satisfactory performance
by the manufacturer. Such waiver does not relieve the manufacturer from meeting all require-
ments of applicable specifications.
12.3 Inspection Lot
An inspection lot shall consist of all castings or assemblies of one kind or description submitted by
the manufacturer at one time for acceptance. The inspection lot may represent the whole order or
a part of the order.
12.4 Classification of Defects and Discrepancies
12.4.1 Critical defect: A critical defect is a defect that is likely to result in hazardous or unsafe
conditions for individuals using, maintaining, or relying upon the products or is likely to result in
structural failures, or is likely to prevent performance of a major end usage item, such as a freight
car or locomotive. Specific defects are shown in paragraph 11.0 and in Figs. A.2, A.3, A.4, A.5, A.6,
A.7, and A.8.
12.4.2 Major defect: A major defect is a defect other than a critical defect that materially reduces
the usability of the product for its intended purpose. Specific defects are shown in paragraph 11.0
and in Figs. A.2, A.3, A.4, A.5, A.6, A.7, and A.8.
12.4.3 Minor discrepancy: A minor discrepancy is a condition that is not likely to materially
reduce the usability of the product for its intended purpose or is a departure from established stan-
dards having little bearing on the effective use or operation of the unit. Specific discrepancies are
shown in paragraph 11.0 and in Figs. A.2, A.3, A.4, A.5, A.6, A.7, and A.8.
12.5 Acceptance Criteria for 100% Inspection
12.5.1 Inspected units: All units presented for shipment may be inspected for the defects and dis-
crepancies listed in paragraph 11.0.
S [M-211] 154 10/2010

10/2010
Casting Details
M-211
12.5.2 Acceptable units: All units inspected must be free of defects and discrepancies listed in
paragraph 11.0. Defective units shall either be replaced or repaired prior to shipment.
12.6 Acceptance Criteria for Sampling Inspection
12.6.1 Sampling inspection criteria may be as defined by the purchaser.
12.6.2 The purchaser may make tests to govern the acceptance and rejection of the material in
purchaser’s laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.
12.6.3 Any unit that is found to have critical defects, subsequent to the inspection at the foundry
or elsewhere, shall be rejected and the manufacturer immediately notified. No alteration to the
part may be made without agreement between the purchaser and the manufacturer.
13.0 RECORDS
13.1 All records required by this and related specifications shall be made available upon request.
13.2 Manufacturers producing and selling coupler body, knuckle, and yoke castings per this
specification must maintain for 30 years records containing the AAR catalog number, date of
manufacture, pattern and serial numbers, and distribution statistics. These records shall be
provided to the AAR quarterly in an electronic, searchable format. AAR’s agent (agreed upon by
the manufacturers) shall maintain the records in a confidential file for 30 years.
14.0 LANGUAGE
14.1 Foundries using a native language other than English are responsible for the accurate
communication of all applicable AAR and customer requirements within the foundry. Foundries
also shall be responsible for accurate translation between employees and AAR representatives or
customer representatives.
14.2 Foundry practices and the final product must conform to the English language versions of
any applicable standards or specifications.
14.3 Critical documents are defined as the standards, internal procedures and/or work instruc-
tions, drawings, and forms necessary to demonstrate compliance with MSRP Specifications M-201
and M-211 and MSRP Section J, Specification M-1003. Critical documents must be kept up to date
with production and be maintained in English.
15.0 GAUGE DRAWINGS
Drawings for gauges listed in Appendix A are maintained by the Mechanical Committee for
Standard Coupler Manufacturers (MCSCM).
10/2010 S [M-211] 155

10/2010
Casting Details
M-211
16.0 SUPPLEMENTAL REQUIREMENTS

16.1 Scope
Supplementary requirements shall be applied only when specified by the purchaser. Details of the
supplementary requirements shall be agreed upon by the manufacturer and purchaser. The speci-
fied tests shall be performed by the manufacturer prior to shipment of the castings.
16.2 Magnetic Particle Inspection
16.2.1 Supplementary magnetic particle inspection requirements shall be in addition to the
requirements of Specification M-220.
16.2.2 Castings may be subject to magnetic particle inspection as specified in the inquiry,
contract, or order and when mutually agreed upon by the manufacturer and the purchaser.
16.2.3 For magnetic particle inspection, the number of pieces made from the same pattern to be
inspected and standards of acceptability shall be agreed upon by the manufacturer and purchaser,
except that only shaded areas of Fig. A.11 shall be inspected and then only for linear defects. Mag-
netic particle inspection shall be in accordance with ASTM Method E-709.
16.3 Supplemental Gauges
When so specified in the inquiry, contract, or order and when mutually agreed upon by the manu-
facturer and the purchaser, castings made in accordance with this specification may be subject to
gauging in addition to gauges and tolerances listed in the specification. The form and nature of the
gauges is to be negotiated between the purchaser and manufacturer.
S [M-211] 156 10/2010

10/2010
Casting Details
M-211 APPENDIX A
APPENDIX A
REFERENCED FIGURES AND TABLES
Minimum Weight (lb)*

Catalog No. Coupler Body Complete Coupler
E60DE, E60EE 324 434
E67CE, E67DE 349 459
SBE60DE, SBE60EE 336 446
SBE67CE, SBE67DE 361 471
SE60DE, SE60EE 355 465
SE67CE, SE67DE 380 490
Coupler Knuckle
E50AE, E50ARE, E50BE 77

E68CE, E68DE 427 537
E69BE, E69CE, 544 654
SBE68CE, SBE68DE 439 549
SBE69BE, SBE69CE 556 666
SE68CE, SE68DE 458 568
SE69BE, SE69CE 575 685
Coupler Knuckle
E50AE, E50ARE, E50BE 77

F70DE 369 485
F73BE 588 704
F79DE 471 587
SF70DE 383 499
SF79DE 485 601
Coupler Knuckle
F51AE 81
Catalog No. Minimum Weight (lb)*

Y40AE, SY40AE 196
Y41AE 242
Y45AE 203
Y49AE 264
*Note: Normal weights are 3% more than weights shown.
Minimum weights for couplers and yokes
Paragraph 11.12
Fig. A.1
10/2010 S [M-211] 157

10/2010
Casting Details
APPENDIX A M-211
Critical
Minor
Major
E, SE, AND SBE COUPLERS
Type E Coupler Head

Gauge No.
24306 Inspector’s Contour (Go Gauge Only) X
24140-1* Top Anticreep Vertical Location X
24140-2 Bottom Anticreep Vertical Location X
24919 Bottom Anticreep Horizontal Location X
14513 Pivot Lug X
14414 Pin Protector—Used with Gauge 15037 X
51840 Pulling Lug—Used with Gauge 15037 X
24283-7A Lock Wall Spacer—Used with Gauges 51840 and 15037 X
15037 Pivot Pin X
15037-1A Pivot Pin Hole X
24311 Lock Chamber X
24312 Lock Hole X
24140-3 Rotary Lug X
24136-3* Top Locklift Hole X
51008-1A Pin Protector (applied along longitudinal centerline of pin hole) X
*For top operating couplers only
Type E, SE and SBE Coupler Parts

Gauge No.
51832 Knuckle Movable Point X
14220 Knuckle Hub X
14437 Knuckle Tail Height X
51835 Knuckle Top Pulling Lug X
51836 Knuckle Bottom Pulling Lug X
51834 Knuckle Tail Width X
24138-2 Lock Toggle Hole X
24138-1** Lock Slot X
24134 Lock Contour—Guard Arm Side X
24135 Lock Contour—Knuckle Side X
24138-3 Upper Lock Thickness X
14491A Lower Lock Thickness X
24132B Knuckle Thrower X
13242-2 Knuckle Thrower Trunion X
35359 Articulated Rotary Locklift Assembly X
31710-1A Knuckle Pivot Pin X
**For top operating lock only
Classification of gauges to ensure interchangeability of coupler parts
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.2
S [M-211] 158 10/2010

10/2010
Casting Details
M-211 APPENDIX A
Critical
Minor
Major
E, SE, AND SBE COUPLERS
Type E60D, E60E, SE60D, SE60E and SBE60D, SBE60E Coupler Shanks
Gauge No.
20843-1 Keyslot—Minimum X
20843-2 Keyslot—Maximum X
1971 Keyslot—Location X
35104-1A Height—Maximum X
Type E67C, E67D, SE67C, SE67D and SBE67C, SBE67D Coupler Shanks
Gauge No.
43389-2 Keyslo—Minimum X
20843-2 Keyslot—Maximum X
1971 Keyslo—Location X
35104-1A Height—Maximum X
Classification of gauges to ensure interchangeability of coupler parts (Continued)
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.2 (Continued)
Critical
Minor
Major
E/F COUPLERS
E/F Coupler Head and Parts

Same as E Coupler Head and Parts
Type E68C, E68D, SE68C, SE68D and SBE68C, SBE68D Coupler Shanks
Gauge No.
34639-1 Shank Height X
34639-2 Butt Height X
34639-6A Butt Shoulders Width X
34639-8B Butt Pin Hole Side Wall Thickness X
49637-2A Minimum Shank Butt Thickness X
49763-1A Maximum Shank Butt Thickness X
34642-1A Shank Butt Spherical Surface X
49763-4 Alignment Shoulder X
49763-3 Spherical Butt Height X
Type E69B, E69C, SBE69B and SBE69C Coupler Shanks
Gauge No.
34642-1A Shank Butt Spherical Surface X
49763-3 Spherical Butt Height X
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.3
10/2010 S [M-211] 159

10/2010
Casting Details
APPENDIX A M-211
Critical
Minor
Major
F AND SF INTERLOCKING COUPLERS
Type F Coupler Head

Gauge No.
34630 Inspector’s Contour (Go Gauge Only) X
14513 Pivot Lug X
34604 Pulling Lug—Used with Gauge 15037 X
34614 Lock Wall Spacer—Used with Gauges 34604 and 15037 X
15037 Pivot Pin X
15037-1A Pin Hole X
34607 Pin Protector—Used with Gauge 15037 X
34610 Lock Chamber X
34611 Upper Lock Hole X
34613 Lower Lock Hole X
37551 Thrower Hole—Used with Gauge 34612-2 X
34613-1 Rotor Hole X
24136-3* Top Locklift Hole X
34614-1* Top Operating Anticreep Ledge X
51008-1A Pin Protector (applied along longitudinal centerline of pin hole) X
*Only for top operating F couplers
Type F Coupler Parts

Gauge No.
14220 Knuckle Hub X
34616 Knuckle Tail Width X
34617 Knuckle Tail Height X
34618 Knuckle Movable Point Contour X
34620 Knuckle Top Pulling Lug X
34622 Knuckle Bottom Pulling Lug X
34625 Lock Contour-Guard Arm Side X
34627 Lock Contour-Knuckle Side X
34629-1 Lock Thickness X
34629-2 Lock Toggle Hole X
34632, 34632-1 Thrower X
31710-1A Knuckle Pivot Pin X
34637-1 Rotor Shaft and Key X
41146 Rotary Locklift Assembly X
37594 Lock Slot X
34637-2* Rotor Shaft and Eye Rivet Hole X
34637-3* Rotor Eye Shaft Opening X
34637-4* Rotor Shaft End X
*For double rotor

Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.4
S [M-211] 160 10/2010

10/2010
Casting Details
M-211 APPENDIX A
Critical
Minor
Major
F AND SF INTERLOCKING COUPLERS
Type F70D and SF70D Coupler Shanks

Gauge No.
34642-2 Butt Contour X
49637-3 Recess Verification Only X
Type F73B Coupler Shanks

Gauge No.
34642-2* Butt Contour X
*Alignment shoulder check not applicable
Type F79D and SF79D Coupler Shanks

Gauge No.
34642-2 Butt Contour X
Classification of gauges to ensure interchangeability of coupler parts (Continued)
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
10/2010 S [M-211] 161

10/2010
Casting Details
APPENDIX A M-211
Yoke A B C D
Y40 34 5/8 in. 25 in. 5 in. 3 1/2 in.
SY40 or YS93 34 5/8 in. 25 in. 5 in. 3 in.
Y41 46 in. 36 3/8 in. 5 1/2 in. 3 1/2 in.
NOTES:
1. FOR TOLERANCE CLASSIFICATION, SEE FIG. A.7
2. DIMENSIONS TAKEN FROM MANUAL OF STANDARDS AND RECOMMENDED PRACTICES,
SECTION S-III, STANDARDS S-141, S-142, AND S-143.
Tolerances for Y40, SY40 and Y41 type yokes

Paragraphs 6.1, 11.0, 12.4.1, 12.4.2, 12.4.3
Fig. A.5
S [M-211] 162 10/2010

10/2010
Casting Details
M-211 APPENDIX A
Yoke A B C
Y45 30 31/32 in. 8 7/8 in. 10 3/8 in.
Y49 42 11/32 in. 9 9/16 in. 10 3/4 in.
NOTES:
1. FOR TOLERANCE CLASSIFICATION, SEE FIG. A.7
2. DIMENSIONS TAKEN FROM MANUAL OF STANDARDS AND RECOMMENDED
PRACTICES, SECTION S-III, STANDARDS S-149 AND S-151.
Tolerances for Y45 and Y49 type yokes

Paragraphs 6.1, 11.0, 12.4.1, 12.4.2, 12.4.3
Fig. A.6
10/2010 S [M-211] 163

10/2010
Casting Details
APPENDIX A M-211
Tolerance Classification Remarks

1 Major All yokes, plus length
2 Major All yokes, minus length
3 Minor SY40, YS93, Y40, Y41 only; inside length
4 Minor All yokes, outside height over pocket
5 Major All yokes, inside pocket height
6 Minor All yokes, strap thickness
7 Major All yokes, outside butt height
8 Major SY40, YS93, Y40, Y41 keyslot height, Y45, Y49 minus pin hole diameter
9 Major All yokes; front opening inside height
10 Minor SY40, YS93, Y40, Y41 only; keyslot length
11 Minor SY40, YS93, Y40, Y41 only; plus nose thickness
12 Minor SY40, YS93, Y40, Y41 only; minus nose thickness
13 Minor All yokes, strap width
14 Major All yokes; front opening smallest inside width
15 Minor All yokes; front opening largest inside width
16 Minor All yokes; head front outside width
17 Minor Y45, Y49 only; plus pin hole diameter
18 Minor Y45, Y49 only; head width at striker guide
19 Minor Y45, Y49 only; head outside height
Yoke tolerances—yoke types Y40, SY40, YS93, Y41, Y45, Y49
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.7
S [M-211] 164 10/2010

10/2010
Casting Details
M-211 APPENDIX A
CATALOG NO. Y44AE, CAST DRAFT GEAR FOLLOWER

FOR USE WITH RIGID SHANK F COUPLERS
ALL EDGES 1/16" MINIMUM RADIUS OR CHAMFER

1/8''
1''
q w
FLATNESS,
SEE NOTE 1
+t e
y r
NOTE:
1. MUST BE FLAT TO 1/16 ACROSS DIAGONALS. u
2. AS AN ALTERNATIVE, THE OPTIONAL GROOVES
MAY BE LOCATED AT THE SAME END.
OPTIONAL
INDENTATION
GROOVES (2)

q Major Plus width
w Minor Minus width
e Minor Plus thickness
r Major Minus thickness
t Major Plus height
y Minor Minus height
u Minor Flatness
Y44AE Follower
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
Fig. A.8
10/2010 S [M-211] 165
10/2010
Casting Details
APPENDIX A M-211
CATALOG NO. Y46AE, CAST DRAFT GEAR FOLLOWER

FOR USE WITH RIGID SHANK F COUPLERS
q w
+t e
–y r

q Major Plus width
w Minor Minus width
e Minor Plus thickness
r Major Minus thickness
t Major Plus height
y Minor Minus height
u Minor Flatness
Y46AE Follower
Paragraphs 6.1, 11.13, 12.4.1, 12.4.2, 12.4.3
S [M-211] 166 10/2010
10/2010
Casting Details
M-211 APPENDIX A
AAR & CATALOG NO.

MOLDERS MARK PATENT MARKINGS RAISED IN DEPRESSED
(IF USED) IF CAST
3 /8
CANADIAN MFG. 1/16" MAX. U.S. MFR. 1/32" MAX. AAR
"
1/2
IN 1/16" DEPRESSED PANEL 3/32" DEPRESSED PANEL
"
TOP OR ROTARY OPERATION ON ALL COUPLERS
1/2
PATD 3/8"
"
1972
3/8" 1974
6 1/2"
DATES DEPEND PATD MFRS TRADEMARK
1977
ON SILANK STYLE
3 1/2" 3/4"
1 3/8"
10 1/2" 3/8"
2 1/2"
MFR. INITIALS 3/4"

3/8"
ALTERNATE DATE CAST 3/4"
3/8"
2" MOLDERS MARK CATALOG NO. 1/2" MARKINGS RAISED IN DEPRESSED PANEL
6" (IF USED) ON CAST FOLLOWERS ONLY
CATALOG NO.
AAR
4 3/4"
AAR
3" E
3/4"
ALTERNATE LOCATION
3"
MFRS TRADEMARK NO MARKING
CANADIAN & U.S.
PATENT MARKINGS IDENTIFICATION
GROOVES
SERIAL NO. CAST ON MFRS TRADEMARK
BOTTOM OF GUARD ARM
OR ON GUARD ARM SHOE DATE CAST
OF LOCK CHAMBER DATE CAST
MFRS HEAT NO. STAMPED ON MFRS TRADEMARK
KNUCKLE SIDE OF SHANK
3/4"
1234
1/2" PATD
3/16" MFRS TRADEMARK

1991 1/4" RAISED IN
MFRS DEPRESSED
SERIAL NUMBER 1/8" PANEL
(IF USED) 1/2"
1/4"
CATALOG NO. DATE CAST ALTERNATE LOCATION

1/2" MFRS SERIAL NUMBER
MOLDERS MARK 3/8"
3/8" (IF USED)
(IF USED)
1/2"
3/4"
1/2"
1/2" 1234
3/16" 1/4" 1/2"
3/4"
3/8" MOLDERS MARK MFRS INITIALS HEAT NO. (IF USED) CATALOG NO.
(IF USED) & ALTERNATE LOCATION FOR
MFRS SERIAL NUMBER
PATTERN SERIAL NO. MFRS TRADEMARK (BOTH RECESSED)
ALL LOCK MARKINGS MAY BE DEPRESSED
OR RAISED IN DEPRESSED PANELS.
(OPPOSITE SIDE) MFRS INITIALS
MFRS TRADEMARK
DATE CAST
(OPPOSITE SIDE)
3/8"
RAISED IDENTIFICATION MARKS FOR
6" YOKES CAST IN GRADE E STEEL
MANUFACTURED AFTER 6-77
1/2"
CATALOG NO.
SERIAL NO. (CAST ONE) OR

HEAT NO. (STAMPED ON)
(OPPOSITE SIDE)
ONE MUST BE USED
NOTES: 1. ALL MARKINGS SHOWN TO BE RAISED UNLESS OTHERWISE SPECIFIED.
2. LOCATION AND USE OF HEAT TREAT LUGS ARE OPTIONAL WITH MANUFACTURER.
3. ALL INDICATED MARKING SIZES ARE MINIMUM.
4. LOCATION OF MARKINGS MAY BE VARIED WITHIN INDICATED AREAS TO SUIT MANUFACTURER PRACTICES.
E coupler markings
Paragraph 10.1; Specification M-205, paragraph 5.4
Fig. A.9
10/2010 S [M-211] 167
10/2010
Casting Details
APPENDIX A M-211
MFRS INITIALS
ALTERNATE DATE CAST

1"
AAR CATALOG NO. 3"

2
RAISED IN DEPRESSED 8
AAR
MOLDERS MARK PANEL IF CAST
(IF USED)
1"

4
CATALOG NO.
1"
MFRS TRADEMARK
3"
AAR
1"

4
3"

4
10 1" CANADIAN & U.S.
1"
2
PATENT MARKINGS
MFRS TRADEMARK MFRS TRADEMARK

DATE CAST MFRS TRADEMARK
1"
4
SERIAL NO. CAST ON
BOTTOM OF GUARD 5"

16
ARM OR KNUCKLE SIDE
OF LOCK HAMMER
MFRS HEAT NO. STAMPED ON PATENT MARKINGS 3"
8
KNUCKLE SIDE OF SHANK CATALOG NO.
FOR CANADA FOR U.S.
PATTERN SEAL NO. MOLDERS MARK
PATD PATD 1 8
3" (IF USED)
1234 3"

4 1979 1"
2
1"
1"
3 2 1"
6 2
2
AAR
3"

1" 4
2 2
MFRS TRADEMARK 3"

8
MFRS TRADEMARK
1"
CATALOG NO.
2
MFRS SERIAL NO. ALL LOCK MARKINGS MAY BE
MOLDERS MARK (IF USED) AAR DEPRESSED OR RAISED IN
(IF USED) DEPRESSED PANELS
3" 1"
8 2 RAISED IN
DEPRESSED PANEL
3"
4
1"

2
1234
MFRS TRADEMARK
MFRS HEAT NO. (IF USED) & ALTERNATE
DATE CAST LOCATION FOR MFRS SERIAL NO. (BOTH RECESSED) 1"
2 CATALOG NO.
SERIAL NO. (IF USED) CATALOG NO. RAISED
IN DEPRESSED PANEL
ALTERNATE LOCATION CATALOG NO. SPLIT BETWEEN TWO
AREASALTERNATE LOCATION IF
1 1"
1 1"

2

2
RAISED IN DEPRESSED PANEL SERIAL NO. IS NOT USED

AAR
NO
1"
2
MARKINGS HEAT NO. STAMPED ON
1"
(IF USED)
2
DATE CAST
MFRS TRADEMARK
OPPOSITE SIDE
OPPOSITE SIDE
SERIAL NO. CAST ON, OR CATALOG NO.
MFRS TRADE MARK HEAT NO. STAMPED ON
ONE MUST BE USED MFRS TRADEMARK
3 /8" RAISED IDENTIFICATION MARKS FOR DATE CAST
6" YOKES CAST IN GRADE E STEEL (OPPOSITE SIDE)
1" MANUFACTURED AFTER 6-77

2
1"
NOTES: 1. ALL MARKINGS SHOWN TO BE RAISED UNLESS OTHERWISE SPECIFIED.
NOTES: 2. LOCATION AND USE OF HEAT TREAT LUGS ARE OPTIONAL WITH THE MANUFACTURER.
NOTES: 3. ALL INDICATED MARKING SIZES ARE MINIMUM.
NOTES: 4. LOCATION OF MARKING MAY BE VARIED WITHIN INDICATED AREAS TO SUIT MANUFACTURERS PRACTICE.
F coupler markings
Paragraphs 10.1, 10.2; Specification M-205, paragraph 5.4
Fig. A.10
S [M-211] 168 10/2010
10/2010
Casting Details
M-211 APPENDIX A
GRADE STEEL CASTINGS

WELDS IN QUENCH & TEMPER
SHADED AREA
WELDS IN FURNACE TEMPER OR
NON-SHADED AREA QUENCH & TEMPER
Inspection zones and post-weld heat-treat requirements for critical areas

Paragraphs 5.7.1, 5.7.3, 11.2.1.1, 11.2.2.3, 11.2.3, 11.2.4, 11.2.5, 11.5.2.2, 11.5.2.3, 11.5.2.4, 11.5.3.2, 11.5.3.3, 11.8.2,
11.8.3, 16.2.3
Fig. A.11
10/2010 S [M-211] 169
10/2010
Casting Details
APPENDIX A M-211

SHADED AREA
E & E/F COUPLER HEAD

WITH SAFETY SHELF

Paragraphs 5.7.1, 5.7.3, 11.2.1.1, 11.2.2.3, 11.2.3, 11.2.4, 11.2.5, 11.5.2.2, 11.5.2.3, 11.5.2.4, 11.5.3.2, 11.5.3.3, 11.8.2,
11.8.3, 16.2.3
S [M-211] 170 10/2010
10/2010
Casting Details
M-211 APPENDIX A

SHADED AREA
F INTERLOCKING COUPLER HEAD

WITH SAFETY SHELF

Paragraphs 5.7.1, 5.7.3, 11.2.1.1, 11.2.2.3, 11.2.3, 11.2.4, 11.2.5, 11.5.2.2, 11.5.2.3, 11.5.2.4, 11.5.3.2, 11.5.3.3, 11.8.2,
11.8.3, 16.2.3
10/2010 S [M-211] 171
10/2010
Casting Details
APPENDIX A M-211
Coupler inspection operating rod

Paragraph 7.1
Fig. A.12
S [M-211] 172 10/2010

10/2010
Casting Details
M-211 APPENDIX A
KN UC KLE
BODY
E COUPLER HEAD
LE
KNUCK
BO D Y
F INTERLOCKING COUPLER HEAD
Location of permanent set measurements for coupler bodies and knuckles

Paragraph 3.2.5.1
Fig. A.13
10/2010 S [M-211] 173

10/2010
Casting Details
APPENDIX A M-211
COUPLER HEADS
B A B
A A A
1"
1"
HORN HORN
THRU PULLING LUGS LINE LINE
C D THRU
D PULLING
LC
C

LUGS
LC
SHANK

SHANK
C
45°
45°
45°
E F G F C
45°
E E
E
D
1"
D
1"
B B
3 1"
2 G 4"
F
TYPE E
F
TYPE F
COUPLER SHANKS
A
B A B
KEYSLOT CENTER LC
REAR HOLE RADIUS
2 5"
8
30°
1"
SHANK B
2 LC

C D C
30°
2 5"
8
B A D
A
RIGID SHANK
F TYPE 5 1"

4
KNUCKLE
PULLING LUGS
311"
16

B
C
C
BUFFING SHOULDER
THROWER PAD
TANGENT TO
PIN PROTECTOR
A A
B
2 5"
8
Internal solidity section cut locations

Paragraph 3.2.4.2
Fig. A.14
S [M-211] 174 10/2010

10/2010
Casting Details
M-211 APPENDIX A
C B A
BEHIND HEAD STRAPS

A
B
B
A
C B A
THRU JUNCTION FILLETS WITHIN FILLETS

C
B
A
D D
A
C B
VERTICAL PIN TYPE YOKE
B A
C
B A
D D
B A
C
B A
THRU JUNCTION FILLETS WITHIN FILLETS

C
B
A
A
B
C HORIZONTAL KEY TYPE YOKE
Internal solidity section cut locations

Paragraph 3.2.4.2
Fig. A.15
10/2010 S [M-211] 175

10/2010
Casting Details
APPENDIX A M-211
F TYPE SHANK, NO PIN BEARING BLOCK
NOTE: SECTION CUT AREAS TO BE RATED FOR SOLIDITY ARE UNSHADED.
Areas to be evaluated for discontinuity levels

Paragraph 3.2.4.3
Fig. A.16
S [M-211] 176 10/2010

10/2010
Casting Details
M-211 APPENDIX A
1" 1"
1" 1"
Areas to be evaluated for discontinuity levels

Paragraph 3.2.4.3
Fig. A.17
10/2010 S [M-211] 177

10/2010
Casting Details
APPENDIX A M-211
NOTE: For knuckles, hardness readings to

be taken on any of the three locations
indicated
Location for Brinell hardness readings

Table 3.1
Fig. A.18
S [M-211] 178 10/2010

10/2010
Casting Details
M-211 APPENDIX B
APPENDIX B
FOUNDRY APPROVAL APPLICATION REQUIREMENTS
(SEE PARAGRAPH 2.0 AND
APPENDIX H FOR FURTHER INFORMATION)
1.0 SCOPE
This appendix covers requirements necessary to obtain status as an approved foundry for manu-
facturing AAR standard and special design couplers, coupler yokes, knuckles, draft gear followers,
and cast coupler parts for use in North American interchange service.
To initiate the AAR approval process, manufacturers shall submit a foundry approval application
as outlined below.
2.0 APPLICATION CONTENT
2.1 The manufacturer must submit required information by e-mail to Chief—Technical Stan-
dards, Transportation Technology Center, Inc. at techstds@aar.com.
2.2 The application must be accompanied by a description (including brochures if available) of
manufacturing facilities, processes, and capabilities, including detailed information on quality con-
trol procedures.
2.3 The application must be accompanied by a draft in the amount estimated to defray technical
inspection costs, including transportation and five days at each foundry site. The application must
state that the applicant will pay the AAR for all costs that exceed the draft amount.
2.4 The application must list all couplers, coupler yokes, knuckles, draft gear followers and cou-
pler parts that the foundry will produce, including AAR-catalog-numbered standards and proprie-
tary items.
2.5 If more than one facility is involved, each must be fully described as a separate entity and
applied for on an individual basis.
10/2010 S [M-211] 179

10/2010
Casting Details
APPENDIX C M-211
APPENDIX C
PRODUCT DESIGN APPROVAL PROCEDURE
1.0 APPLICATION FOR APPROVAL
The initial approval process is intended to inform the AAR that a product is in development for the
purpose of obtaining its initial acceptance and approval to move forward with final designs and
limited production for testing.
1.1 The manufacturer shall submit an electronic copy of the application for approval (shown in
Appendix D) by email to Chief—Technical Standards, Transportation Technology Center, Inc., at
techstds@aar.com.
1.2 The AAR shall acknowledge receipt and shall forward the application to the appropriate AAR
committee for ballot on approval to proceed.
1.3 AAR staff shall advise the proponent of the AAR committee’s approval to proceed or disap-
proval. Disapproval shall include comments and recommendations on what steps to take. In some
cases, the AAR committee may request the applicant to attend a face-to-face meeting and present
the product.
2.0 REQUEST FOR CONDITIONAL APPROVAL (INITIAL ALLOTMENT)
2.1 This request is for the proponent to gain official approval when product development is com-
plete, all foundry and product tests have been successful, and the product is ready for production.
2.2 If approved by the AAR committee, the AAR shall provide an official letter granting condi-
tional approval and shall include an initial allotment of 1,000 units that must not be exceeded
without further approval from the AAR. If not approved, the AAR shall inform the proponent
regarding what steps to take.
2.3 Content of Request for Initial Allotment
The following items are required in the request for initial allotment:
• All items included in the initial application
• Design Engineering Report
• Fatigue Evaluation Report
• Test Results (M-211 Test Requirements for Castings and Material Properties)
• Other information the proponent deems necessary or has been requested by the AAR
3.0 REQUEST FOR INCREASE IN ALLOTMENT
3.1 Higher allotment levels shall be approved before a proponent increases the distribution of
components beyond the previously approved level. Allotments are typically approved at the follow-
ing levels, although the proponent may request different allotment levels if distribution and ser-
vice performance reports support the request.
• 1,000 (approved during request for initial allotment)
• 5,000
• 15,000
• 30,000 and every 20,000 thereafter until full approval is achieved
3.2 If approved by the AAR committee, the AAR shall provide an official letter granting the allot-
ment increase that again shall not be exceeded without further approval from the AAR. If not
approved, the AAR shall inform the proponent how to proceed.
S [M-211] 180 10/2010

10/2010
Casting Details
M-211 APPENDIX C
3.3 Content of Request for Increase in Allotment

Requests for allotment increases shall include distribution and service performance reports on the
products introduced in service up to the date of the request as defined in the Manual of Standards
and Recommended Practices, Section B, Standard S-101, “Field Service Experience—Reporting
Requirements.”
4.0 REQUEST FOR FULL UNCONDITIONAL APPROVAL
After a minimum of 2 full years of field service by the product and submittal of required distribu-
tion and service reports, the proponent may request full unconditional approval. Reports of fail-
ures or problems with the functionality of a component are cause for delay in full unconditional
approval as deemed necessary by the AAR committee.
10/2010 S [M-211] 181

10/2010
Casting Details
APPENDIX D M-211
APPENDIX D
APPLICATION FOR APPROVAL OF NON-STANDARD DESIGN COUPLER,
PART, YOKE, OR DRAFT GEAR FOLLOWER
File No. __________

To: AAR
c/o Chief—Technical Standards, Transportation Technology Center, Inc.
Email with drawings (with complete dimensioning) to techstds@aar.com
By: (Manufacturer)
Name and Location of Foundry:
Requested By: (Railroad, Car Owner, or Manufacturer)
Developed By: (Owner, Builder, or Designer)
Initial Car Type and Service to Be Furnished on:
Initial Quantity: 1,000
AAR Design Type:
Name ________________________________________________________________________________
Features Code No._____________________________________________________________________
(coupler features described in Appendices E and F, and knuckles features in Appendix G)
Manufacturer’s Former Part No.(s) _____________________________________________________
Manufacturer’s Drawing No. ___________________________________________________________
Partial AAR I.D. No. ___ ___ ___ _X_ _X_ ___ ___
Same as AAR Standard Catalog No. ____________________________________________________
...except (describe deviation) ___________________________________________________________
______________________________________________________________________________________
Replacement (also can be applied) ______________________________________________________
Design complies with AAR safety and operational requirements?  Yes  No
Design complies with DOT safety requirements?  Yes  No
Material complies with Specification M-201 Grade E?  Yes  No
Explanation if material is other than M-201 Grade E: ____________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Reconditioning complies with Specification M-212?  Yes  No
Explanation of special reconditioning requirements:______________________________________
______________________________________________________________________________________
______________________________________________________________________________________
By____________________________________ Date_____________________
For AAR Use Only

AAR I.D. No. ___ ___ ___ ___ ___ ___ ___
By____________________________________ Date_____________________
S [M-211] 182 10/2010
10/2010
Casting Details
M-211 APPENDIX E
APPENDIX E
DESIGN FEATURES FOR AAR-APPROVED SPECIAL COUPLER BODIES
(SEE APPENDIX D UNDER “AAR DESIGN TYPE FEATURES CODE” FOR FURTHER
INFORMATION)
10/2010 S [M-211] 183

10/2010
Casting Details
APPENDIX F M-211
APPENDIX F
AAR CODE FOR DESIGNATING DESIGN FEATURES
SIX-DIGIT AAR IDENTIFICATION NO. FOR COUPLER BODIES
(SEVEN DIGITS FOR COUPLERS WITH DESIGN REVISIONS)
E O O O O C
BODY MATERIAL*
HEAD TYPE C, D, E, Q OR S
E, F OR R
SERIAL NO. - AAR ALPHA NUMBERIC ASSIGNMENT
DO NOT USE LETTERS
BUTT DESIGN I, O, Q, X, OR Z
LETTER DESIGNATION
K - RIGID
F - F TYPE
S - SWIVEL OI TO 99
R - ROTARY DUMP AO TO A9
V - SPECIAL
YO TO Y9
OA TO 9A
SHANK LENGTH
9 RANGES OY TO 9Y
AA BA CA DA
AB BB CB
1LESS THAN 12'' AC
2EQUAL TO 12'' OR LESS THAN 18'' BC CC
3EQUAL TO 18'' OR LESS THAN 24''
4EQUAL TO 24'' OR LESS THAN 30'' AY
5EQUAL TO 30'' OR LESS THAN 36'' BY CY DY
954'' AND OVER
TYPICAL IDENTIFICATION REVISE SPECIAL COUPLER BODY NO. ONLY IF THE REVISED BODY
AAR IS NOT INTERCHANGEABLE WITH THE CURRENT DESIGN.
IDENT. NO. 14 DIGIT CODE NO.
*IF COUPLER HAS A DESIGN REVISION, SHOW REVISION
E F 5 0 1 C E F H 33 B 05 B 2 D O O C IN THE 6TH DIGIT, AND BODY MATERIAL BECOMES THE
7TH DIGIT.
C.
TS
. LO
BRA S
CKE
T
CKE
ERT
S
NT
ITY
ION
RE
F. V
BRA
ME
BIL
ELF
TU
CAT
AND
SUR
IGN
E
EA
AND
APA
SIZ
G SH
H
. LO
SS
NF
TH
GT
UGS
AR
C
TE
N
GS
.A
G
SIG
SIG
ON
EN
L
RIZ
WE
PE
PE
ININ
EN
PLA
O
ERIA
L
D LU
NK L
RIA
KL
LN
TY
TY
ATI
DE
DE
KL
. HO
NK
RETA
AR
TE
RIA
AN
AD
AD
ER
AN
TT
TT
*MAT
SHA
HEA
SHA
W.P
MA
WE
HE
HE
SH
BU
BU
OP
SH
SE
S [M-211] 184 10/2010

10/2010
Casting Details
M-211 APPENDIX F
10/2010 S [M-211] 185

10/2010
Casting Details
APPENDIX F M-211
CODE SPACE NUMBERS

1 2&3 4&5 6
HEAD TYPE BUTT DESIGN FEATURES SHANK LENGTH OPERATION CAPABILITY
CODE DESCRIPTION
CODE RIGID BUTT TO KEYSLOT BUTT HOLE CORED CODE LENGTH CODE
LTR. DESCRIPTION TYPES KEYSLOT SIZE SIZE BUTT NO. * LTR. DESCRIPTION
E TYPE E KA 4" 5 1/8" × 1 1/4" 2 1/8" WITH 01 14 1/2" B BOTTOM OPER ONLY
F TYPE F KB 4" 6 5/8" × 1 5/8" 2 1/8" WITH 02 15 5/8" C TOP OR BOTTOM OPER.
ROTARY KC 4" 6 5/8" × 2 1/8" 2 1/8" WITH 03 16 1/8" BOTTOM OPERATION &
R K
HEAD KD 4" 6 7/8" × 1 5/8" 2 1/8" WITH 04 16 1/2" INVERTED KNUCKLE PIN
KE 4" 6 7/8" × 1 5/8" 2 1/8" × 1 1/2" WITH 05 16 11/16" R BAIL TYPE OPER. ROD
KF 4" 6 7/8" × 1 5/8" W/OUT SOLID 06 16 3/4" T TOP OPERATION ONLY
KG 3" 8 1/4" × 1 5/8" 2 1/8" WITH 07 16 15/16" TOP OPERATION &
A
KH 3" 8 5/8" × 1 5/8" 2 1/8" WITH 08 17 3/16" INVERTED KNUCKLE PIN
KJ 4" 8 5/8" × 1 5/8" 2 1/8" WITH 09 17 1/4" BOTTOM OPERATION
D
KK 4" 8 5/8" × 1 5/8" W/OUT SOLID 10 17 1/2" TOP KNUCKLE PIN RET.
KL 4" 9 1/4" × 1 5/8" 2 1/8" WITH 11 18"
S CABLE OPERATION
KM 4" 9 1/4" × 1 5/8" W/OUT SOLID 12 18 1/2"
KN 4" 6 5/8" × 1 5/8" W/OUT SOLID 13 19 3/4"
KP 4" 5 1/4" × 2 1/8" 2 1/8" WITH 14 20 1/4"
KR 2 1/2" 5 1/8" × 2 1/8" 2 1/8" WITH 15 20 7/16"
KS 4" 8 3/8" × 1 5/8" 2 1/8" WITH 16 21 1/4"
KT 3" 7 3/4" × 1 5/8" 2 1/8" WITH 17 21 1/2"
KU 4" 5 1/8 × 1 3/8" 2 1/8" WITH 18 22"
KV 3" 7 3/4" × 1 5/8" W/OUT SOLID 19 22 1/4"
20 22 1/2"
21 23 1/4"
22 23 7/8"
23 24 3/4"
F BUTT TO PIN BRG. ALIGN TOP 24 25"
TYPES PIN HOLE BLK. TYP. SHLD. CONTOUR 25 26 11/16"
FA 3 3/8" WITHOUT WITH TAPERED 26 26 15/16"
FB 3 3/8" WITHOUT W/OUT TAPERED 27 27"
FC 3 15/32" WITHOUT WITH TAPERED 28 27 1/2"
FD 3 1/2" F65A WITH TAPERED 29 28"
FE 3 1/2" F65A W/OUT TAPERED 30 29"
FF 3 1/2" F65B WITH TAPERED 31 29 1/2"
FG 3 1/2" F65B W/OUT TAPERED 32 30"
FH 3 1/2" WITHOUT WITH FLAT 33 31"
FJ 3 1/2" WITHOUT W/OUT FLAT 34 33"
FK 3 1/2" WITHOUT WITH TAPERED 35 34"
FL 3 1/2" WITHOUT W/OUT TAPERED 36 38"
FM 3 1/2" NCD SPEC. WITH TAPERED 37 41"
38 48"
39 20"
40 24 1/4"
41 65 1/2"
42 53 3/4"
43 17 1/8"
ROTARY 44 24 7/8"
SHANK DESCRIPTION
45 50 1/2"
RA STYLE 1 46
RB STYLE 2 47
RC STYLE 3 48
RD 49
RE 50
SPL.
BUTT DESCRIPTION * LENGTH
HORN TO BUTT
VA BUCKEYE CROSSKEY F FOR RIGID TYPE.
VB HORN TO PIN CL
FOR PIN TYPE.
VC
VD
VE
SWIVEL SIDE
PIN SIZE NO. OF LOOPS LOOP SPACING LOOP RADIUS LOOP THK. KEYSLOT
TYPES WEAR PAD
SA 2 3/8" 2 3 11/16" 3 3/4" 1 5/8" WITH WITHOUT
SB 2 31/32" 2 2 3/8" 3 1/2" 2 5/8" WITHOUT WITHOUT
SC 2" 1 — 3" 9 1/8" WITHOUT WITHOUT
SD 3 1/2" 2 2 5/8" 4" 2 5/8" WITHOUT WITHOUT
SE 3 1/2" 1 — 4" 6 7/16" WITHOUT WITHOUT
SF 2 1/4" 2 2 1/2" 3" 2 3/4" WITHOUT WITHOUT
SG 3 1/2" 2 2 5/8" 4" 2 5/8" WITHOUT WITH
SH 2 3/8" 2 3 11/16" 3 3/4" 1 5/8" WITHOUT WITHOUT
SK 2 3/8" 2 1 7/8" 3 3/4" 2 3/8" WITHOUT WITHOUT
S [M-211] 186 10/2010

10/2010
Casting Details
M-211 APPENDIX F
CODE SPACE NUMBERS (CONTINUED)

7&8 9 10 11 12 13 14
SHK. WEAR SUR. VERT. WEAR PLATE HOR. SHANK LUGS & RETAINING
WEAR PLATE SIZE LOC. LOC. HEAD LUGS & BRACKETS BRACKETS SHELF COUPLER MATERIAL
.DIMENSION DIMENSION CODE HEAD LUG CODE SHANK LUG
CODE SIZE CODE CL DRAFT TO CODE HORN TO NO. OR STYLES & CODE CODE CAST STEEL
NO. STYLE
NO THK. × LG. LTR WEAR SUR NO. WEAR PLATE LTR. COMBINATIONS LTR. DESCRIPTION LTR. GRADE
00 W/OUT W.P. A 3" 0 WITHOUT W.P. 0 WITHOUT 0 WITHOUT B BOTTOM SHELF C GRADE C M-211
01 1/4" × 7" B 3 3/16" 1 0" -1" INC. 1 STYLE 1 1 STYLE 1 O WITHOUT SHELF D GRADE D M-201
02 1/4" × 8"* C 3 1/4" 2 OVER 1"-2" INC. 2 STYLE 2 2 STYLE 2 S TOP & BOTT. SHELF E GRADE E M-211
03 1/4" × 9" D 3 3/8" 3 OVER 2"-3" INC. 3 STYLE 3 3 STYLE 3 T TOP SHELF S SPECIAL
04 1/4" × 10"* E 3 7/16" 4 OVER 3"-4" INC. 4 STYLE 4
05 1/4" × 11"* F 3 1/2" 5 OVER 4"-5" INC. 5 STYLE 5
06 1/4" × 12" G 2 5/8" 6 OVER 5"-6" INC. 6 STYLE 6 STD. F COUPLER IS
07 1/4" × 13" 7 STYLE 7 CODED “B”
08 1/4" × 14" 8 STYLE 8
09 1/4" × 16" 9 STYLE 9 F COUPLER WITH TOP
10 1/4" × 17 1/2"* A COMBINATION 1-2 SHELF IS CODED “S”
11 3/8" × 18" B COMBINATION 1-3
12 1/4" × 19 1/2" C COMBINATION 1-4
13 1/4" × 22 1/2"* D COMBINATION 2-5
14 1/4" × 30" E COMBINATION 4-5
15 1/4" × 31" F COMBINATION 6-7
16 SPECIAL G COMBINATION 1-2-4
17 3/8" × 8" H COMBINATION 1-3-4
18 3/8" × 9 1/2" J COMBINATION 3-5
19 COMB. 17 &18 K COMBINATION 3-6-7
20 3/8" × 10"
21 1/2" × 8"
22 1/2" × 10"
23 COMB. 17 & 20
24 1/4" × 6 3/4"
*A.A.R. STANDARD
10/2010 S [M-211] 187

10/2010
Casting Details
APPENDIX G M-211
APPENDIX G
FOUR-DIGIT IDENTIFICATION CODE FOR SPECIAL COUPLER
KNUCKLES
CODE SPACE NUMBER
1 2 3 4
CODE COUPLER CODE NOSE CODE CODE
CONTOUR CAST STEEL
LETTER HEAD NUMBER CORING NUMBER LETTER
E Type E 8 CORED 1 AAR STANDARD (10A) D GRADE D M-201
F Type F 9 SOLID 2 VACANT E GRADE E M-211
3 AAR ALT. STANDARD S SPECIAL
FOUR DIGIT CODE

EXAMPLE E 8 3 E
CODE
SPACE
NO.
1 —TYPE COUPLER HEAD
2 —STANDARD CORING
3 —AAR ALT. STANDARD
4 —GRADE E STEEL
S [M-211] 188 10/2010

10/2010
Casting Details
M-211 APPENDIX H
APPENDIX H
TECHNICAL INSPECTION OF FOUNDRIES—REQUIREMENTS AND
PROCEDURES
1.0 SCOPE
The AAR inspection program is designed to determine if a foundry is qualified to produce castings
to AAR specifications. Observe entire plant operation, with emphasis on procedures that affect
quality and uniformity of product.
2.0 REQUIREMENTS
2.1 An AAR representative shall have entry at all times to areas of the foundry that involve the
manufacture, test, and inspection of products.
2.2 The AAR representative shall be free of conflict of interest and must comply with applicable
safety rules and local regulations.
2.3 The manufacturer shall afford the AAR representative all reasonable support needed to
determine if products are being produced in accordance with the specifications.
2.4 Inspections shall be conducted annually (at least once per year). The cost of inspection shall
be borne by the manufacturer.
2.5 Any castings used to meet annual inspection requirements must be cast within 90 days of
inspection from a lot of no less than 25 pieces.
2.6 Upon completion of the inspection and report, manufacturers shall be advised of inspection
findings.
2.6.1 If no deficiencies are noted during the inspection, the AAR representative shall immedi-
ately forward the inspection report to the AAR for approval ballot.
2.6.2 If deficiencies are noted during the inspection, the AAR representative shall advise the pro-
ponent of the discrepancies, request that corrective action be taken within 30 days, and require
that the proponent inform the representative in writing of these actions within the same 30-day
period. The AAR representative shall not forward the report to the AAR until a response is
received regarding deficiencies. Upon receipt of the response, the report shall be distributed to the
AAR for committee ballot.
2.6.3 If approved by AAR committee, the proponent shall be advised of approval status and added
to or continued on the AAR list of approved foundries.
2.6.4 If a foundry cannot be satisfactorily approved but is working on a solution that the AAR
considers will allow approval, that foundry may be granted a conditional approval if deemed
appropriate by the AAR.
2.6.5 If a foundry is considered not qualified for AAR approval, the foundry shall be omitted from
the approved foundry list. In this case, the manufacturer may request a re-inspection at manufac-
turer’s expense. In addition, the manufacturer may request an audience with the AAR for consid-
eration by the AAR committee at the next face-to-face meeting. A manufacturer’s representative
may be invited to discuss.
2.6.6 The AAR reserves the right to require additional inspections, announced or unannounced,
and/or to employ third-party inspectors on a resident basis as deemed necessary by the AAR.
10/2010 S [M-211] 189

10/2010
Casting Details
APPENDIX H M-211
3.0 PROCEDURE FOR THE INSPECTION OF FOUNDRIES

3.1 Observe entire plant operation, with emphasis on procedures that affect quality and unifor-
mity of product.
3.1.1 Confirm values of certification test reports by following data gathering and storage
throughout the foundry process.
3.1.2 Inspect production and quality control equipment and facilities to determine ability to meet
production requirements.
3.1.3 Interview supervisors and workers with respect to procedures and methods used in all
aspects of production.
3.1.4 Review finished product defect matrix and scoring.
3.1.5 Review results of inspection with plant management and advise if any deficiencies are
noted.
3.2 Process control plans shall be established to control the critical foundry processes. Process
control plans should be obtained and reviewed by the official AAR auditor/inspector prior to the
actual audit. These control plans shall include, at a minimum, the following:
• Process name/operation description
• Critical process inputs
• Process outputs
• Specification limits
• Evaluation technique
• Sample size/frequency
• Control method (control chart, report, etc.)
• Reaction plan
Note: Process change procedures shall be in place to ensure that product quality is reestablished
and maintained following any changes in foundry practices.
4.0 CRITICAL PROCESSES AND THEIR OUTPUTS
The following critical processes shall be reviewed by the AAR inspector:
4.1 Pattern and Core Box Practices
• Pattern and core box design
• Pattern and core box maintenance control
4.2 Core-Making Practices
• Core making and finishing control
• Sand testing control
4.3 Molding Practices
• Sand testing controls
• Mold making and core setting to avoid shifts and offsets during mold movement and
pouring
4.4 Melting Practices
• Raw material control; appropriate time and quantity of alloy additions
• Chemistry control including tramp elements
• Appropriate time and quantity control over additions.
S [M-211] 190 10/2010

10/2010
Casting Details
M-211 APPENDIX H
4.5 Pouring Practices

• Time records on pouring
• Temperature record during pouring
• Appropriate chemical and physical tests on representative castings
• Positive method of determining last casting
4.6 Cleaning Room Operations
• Cleaning equipment should be adequate to provide clean casting for proper inspection.
• Observe welding operations to ensure quality workmanship. Welding equipment must be
well maintained and show evidence of periodic checking for correct amperage and voltage
readings. Welding rods and wire must be correctly identified and stored according to Amer-
ican Welding Society (AWS) standards.
• Workmanship of grinding operations should be evaluated.
• Facilities for performing welding according to temperature requirements of AAR specifica-
tions should be available. It is desirable that all weld repairs be made in the green condi-
tion prior to heat-treat. If correct foundry practices are enforced, weld repair requirements
will be minor.
4.7 Heat-Treating Practices
• Furnaces must have appropriate temperature control and adequate recording capabilities.
• Furnaces should be adequate to ensure uniform temperature throughout.
• Appropriate records must be kept to positively identify castings that have received
heat-treatment.
• Quench tanks must have circulating capability with a facility to ensure correct tempera-
ture of coolant. Tanks should be kept clean and free of scrap material likely to impair oper-
ation.
4.8 Casting Quality
• A random sampling of castings casting should be selected from the inspection area and
dimensionally and visually inspected. The object of this should be to evaluate overall qual-
ity of the finished casting. Pattern quality, core setting, and dimensional control should be
evaluated.
• Availability and accuracy of gauges should be determined, and a calibration system for
gauges should be evaluated.
• All physical test apparatus should be inspected for general operating condition and cali-
bration. All equipment requiring calibration should have current certification.
• Records of internal solidity tests, defined in paragraph 3.2.4 and Appendix I, must be
verified.
• All testing required by paragraph 3.0 must be completed at defined intervals.
• Coupler assemblies must be operated and evaluated in accordance with paragraph 7.0.
5.0 ORGANIZATION POLICY (WITH RESPECT TO THE FOLLOWING)
• Verify appropriate separation between production responsibility and quality control
responsibility.
• Verify there is a procedure for resolving controversy between operations and quality con-
trol on nonconforming items.
• Disposition of nonconforming items shall be controlled.
• The attitude of supervisory personnel with regard to quality assurance requirements must
be positive and supportive.
10/2010 S [M-211] 191

10/2010
Casting Details
APPENDIX H M-211
6.0 PERSONNEL
• Verify that procedures exist for qualifying workmen for key process jobs. Training must be
provided for new employees.
• Verify that procedures exist for qualifying supervisors and methods of training and for
determining performance.
• Determine if there are appropriate welding procedures and competent expertise in the
plant to perform welding tests and solve welding problems. Determine how and when
welders are qualified.
7.0 RECORD RETENTION
• The AAR and each foundry shall retain records of foundry and casting approval for 30
years.
• Manufacturing and distribution records shall be maintained as required in
paragraph 13.2.
8.0 LANGUAGE
• Foundries using a native language other than English must provide a translator or
technical expert to assist in the audit.
• This translator or technical expert is responsible for demonstrating to the auditor that the
foundry understands and complies with all applicable AAR requirements. To do so, the
expert may be asked by the auditor to explain various foundry practices and critical
records as related to these requirements (paragraph 14.3).
S [M-211] 192 10/2010

Casting Details
M-211 APPENDIX I
APPENDIX I
STANDARD REFERENCE PHOTOGRAPHS FOR CASTING SOLIDITY
(SEE PARAGRAPH 3.2.4.4 FOR FURTHER INFORMATION)
1.0 SCOPE
1.1 The reference photographs illustrate various types and degrees of shrinkage occurring in cou-
pler, knuckle, and yoke sections. They are full scale and provide the following:
1.1.1 Serve as a guide for enabling recognition of shrinkage and its differentiation as to severity
level.
1.1.2 Serve as standards for evaluating minimum acceptability as specified for the product.
1.2 The reference photographs show graded shrinkage in six levels of increasing severity.
2.0 PREFACE
2.1 The reference photographs were prepared from actual production castings that were first
radiographed. The radiographs were evaluated and rated as to shrinkage severity level by compar-
ison with the standard reference radiographs in ASTM E446-72. A saw cut was made through the
rated shrinkage area of the casting at 90° to the plane of the radiograph. The casting section was
then ground smooth and sand blasted to delineate shrinkage for photographs. The exposed shrink-
age in sections was then ranked visually according to severity and divided into levels correspond-
ing to those found in ASTM E446.
2.2 Radiographic evaluation of shrinkage is based on the greatest severity found in any
5 in. × 7 in. area of the section being examined. In a similar manner, evaluation of saw cut sec-
tions is predicated on the greatest shrinkage severity encountered in a 5-in. length of the casting
section. This difference and the judgment of an individual in determining the severity level of the
radiographs combine to produce a possible variation in the severity level rating of the reference
photographs that can amount to one level above or below the ASTM E446 reference radiograph
rating.
3.0 EVALUATION
Severity level is established by determining which photograph of discontinuities most closely
resembles the discontinuities present in the sectional area being investigated as illustrated in the
following photographs.
10/2010 S [M-211] 193

Casting Details
APPENDIX I M-211
SHRINKAGE OF VISUAL SEVERITY 1

Fig. I.1
S [M-211] 194 10/2010

Casting Details
M-211 APPENDIX I

Fig. I.2
10/2010 S [M-211] 195

Casting Details
APPENDIX I M-211

Fig. I.3
S [M-211] 196 10/2010

Casting Details
M-211 APPENDIX I

Fig. I.4
10/2010 S [M-211] 197

Casting Details
APPENDIX I M-211

Fig. I.5
S [M-211] 198 10/2010

Casting Details
M-211 APPENDIX I

Fig. I.6
10/2010 S [M-211] 199

APPENDIX J
REPORT OF METALLURGICAL TESTING PER AAR
(SEE PARAGRAPH 3.0)
APPENDIX J
Period Covered by This Report: __________

(ALL BLANKS MUST BE FILLED)
ANALYSIS OF COUPON TEST SPECIMENS

CHEMICAL ANALYSIS (Maximum Values) CHEMICAL ANALYSIS (Record Only) MECHANICAL TEST (Minimum Values)
Catalog Heat Steel % % % % % % % % % % % % Yield Tensile Reduction Elongation Hardness Charpy NDTT
Number No. Grade C Mn S P Si CE Al Cu Cr Ni Mo B V psi psi of Area % % BHN ft-lb °F
Specified E .32 1.85 .04 .04 1.50 .88 100,000 120,000 30 14 241–311 20 min.
Value
ANALYSIS OF CASTING SPECIMENS

CHEMICAL ANALYSIS (Maximum Values) CHEMICAL ANALYSIS (Record Only) MECHANICAL TEST (Minimum Values)
S [M-211] 200
Casting Details
Reduction
Catalog Heat Steel % % % % % % % % % % % % Yield Tensile of Areaa/ Elongationa/ Hardness Charpya/
Fracture
Toughness
Pass (Y/N)?
Number No. Grade C Mn S P Si CE Al Cu Cr Ni Mo B V psi psi % % BHN ft-lb

Specified E .32 1.85 .04 .04 1.50 .88 80,000 96,000 Not Not 241–311 N/A
Value specified specified
a/ This data is requested for information only and should not be used for engineering purposes.
SUBMITTED BY COMPANY FOUNDRY LOCATION DATE
____________________________________ __________________________________ ___________________________________ __________________

M-211
10/2010
10/2010
Casting Details
M-212
COUPLERS AND YOKES, SECONDHAND—CLASSIFICATION AND

RECONDITIONING PROCEDURE
Specification
M-212

TABLE OF CONTENTS
Paragraph Subject Page No.
1.0 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]203
1.2 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]203
1.3 Facilities Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]203
2.0 Classification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]204
3.0 Secondhand Acceptance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]204
3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]204
3.2 Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.1 Coupler Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.2 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.3 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.4 Thrower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.5 Locklift Assembly and Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]205
3.2.6 Knuckle Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]206
3.2.7 Coupler, Assembled Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]206
3.3 Coupler Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]206
3.4 Draft Gear Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]207
3.5 Draft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]207
3.6 Connecting Pin, Catalog Number Y47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]207
4.0 Reconditioned Acceptance Requirements for Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]207
4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]207
4.2 Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]208
4.2.1 Coupler Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]208
4.2.1.5 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]208
4.2.2 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]208
4.2.3 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.2.4 Thrower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.2.5 Locklift Assembly and Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.2.6 Knuckle Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.2.7 Coupler, Assembled Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.3 Coupler Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]209
4.5 Reforged Draft Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]210
4.6 Connecting Pin, Catalog Number Y47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]210
5.0 Instructions for Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]210
10/2010 S [M-212] 201

10/2010
Casting Details
M-212
Paragraph Subject Page No.

5.1 Weld Repair and Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]210
5.2 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]211
5.2.2 Material Grade Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]211
5.2.3 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]211
5.2.3.2 Normalized and Tempered Grade C Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]211
5.2.3.3 Quenched and Tempered Grade C Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]212
5.2.3.4 Quenched and Tempered Grade E Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]212
5.2.4 Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]212
5.3 Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]213
5.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]213
6.0 Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]213
6.1 Coupler Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]213
6.1.4 Coupler Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]214
6.1.4.2 F Coupler Interlocking Surfaces Restoration. . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]215
6.2 Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]217
6.3 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]217
6.4 Knuckle Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]217
6.5 Coupler Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]218
6.5.2 Repairs for All Yokes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]218
6.5.5 Restoration of Yoke Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]218
6.5.6 Restoration of Yoke Keyslots (Y40, SY40, and Y41 Types) . . . . . . . . . . . . . . . . . . S[M-212]218
6.5.7 E/F and F Yoke Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]218
6.6.3 Type Y44 or Slab Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]219
6.6.4 Y46 Type Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]219
6.7 Draft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]219
6.8 Reconditioning of Solid Butt E/F and F Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]220
Appendix A Tables, Catalog Numbers, and Gauge Numbers for Secondhand and Reconditioned
Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]221
Appendix B Gauge Application Drawings—by Figure Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]227
Appendix C Gauge Application Drawings—Numerical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]230
Appendix D Coupler Operation and Procedure for Checking Anticreep Protection . . . . . . . . . . . . . . . . . S[M-212]285
Appendix E Manufacturer’s Trademark Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]290
Appendix F Application Instructions for Status as an Approved Reconditioning Facility . . . . . . . . . . . . . S[M-212]292
Appendix G Steel Castings Reclamation Plant Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]293
Appendix H Guidelines for Shop Certification Inspection Reclamation of Couplers, Yokes, and Related
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S[M-212]294
S [M-212] 202 10/2010

10/2010
Casting Details
M-212
COUPLERS AND YOKES, SECONDHAND—CLASSIFICATION AND

RECONDITIONING PROCEDURE
Specification
M-212
1.0 SCOPE
1.1 This specification covers requirements for former and current secondhand and reconditioned
AAR-approved couplers and their parts, coupler yokes, draft gear followers, draft keys and con-
necting pins, and other parts used in the coupler and yoke freight car applications as listed in AAR
Interchange Rules. It is the intent of this specification to provide detailed instructions for each
phase of the reclamation process in the order that the phases should be performed.
1.2 Definitions
The following definitions will apply:
Secondhand Any used component or assembly meeting the requirements of this

specification that can be used without reconditioning, except where
noted
Reconditioned Any component that has been rebuilt and/or heat-treated in
accordance with this specification
Scrap Any component prohibited by AAR interchange rules and parts not
meeting all requirements of this specification
New Any component not previously used, meeting the requirements of
AAR Specification M-211, that may be used in the assemblies
defined by this specification.
1.3 Facilities Approval
1.3.1 All facilities that recondition AAR-approved couplers and their parts, coupler yokes, draft
gear followers, and draft keys must be approved by the AAR. The basis for approval shall be satis-
factory compliance with the provisions of this specification. Periodic facility reinspection is
required every 3 years.
1.3.2 All reconditioning facilities desiring an “approved” status must submit an application to the
Association of American Railroads, as outlined in Appendix F. Each reconditioning facility must be
individually approved. Facilities that have not been previously approved will require an inspection
by an AAR representative. The application must include a statement that the requestor will defray
the total inspection expenses and be accompanied by a draft in the amount estimated as required
to defray all costs to include transportation and two days on site. Any costs in excess of this
amount will be paid to the AAR. In order to remain on the approved list, the manufacturer must be
certified under the provisions of AAR Manual of Standards and Recommended Practices, Section
J, Specification M-1003.
1.3.3 Upon attaining approved status, facilities will grant an AAR representative free entry at all
times to all parts of the facility. This access is for the purpose of providing assurance that industry
standards are being maintained. The facility shall afford the AAR representative all reasonable
facilities to ensure that materials are being furnished in accordance with these specifications.
1.3.4 Unless otherwise specified, general references to couplers shall include nonshelf- and
shelf-types.
10/2010 S [M-212] 203

10/2010
Casting Details
M-212
2.0 CLASSIFICATION PROCEDURE

2.1 Parts or assemblies listed in Table A.1 must not be classified for further service and must be
scrapped. Parts or assemblies listed in Table A.2 may be used for secondhand only.
2.2 Parts must be clean and free of dirt, paint, rust, and scale that will interfere with gauging
and inspection.
2.3 Parts must be visually inspected for cracks, fractures, missing sections, worn surfaces, distor-
tion, surface upset, and service notches. Parts with service cracks in areas shown in Fig. C.6,
Fig. C.7, Fig. C.8, Fig. C.9, and Fig. C.10 must be scrapped. For disposition of coupler bodies with
cracks, see paragraphs 2.8 and 2.9.
2.4 Parts to be classified, except coupler locklift assembly, must be disassembled for inspection.
Locklift assembly must be inspected.
2.5 Each part must meet requirements of the gauges of its classification listed in Tables A.3
through A.7 if secondhand or Tables A.8 through A.11 if reconditioned.
2.6 The results of inspecting and gauging will determine if parts or assemblies are suitable for
secondhand classification, reconditioning, or scrapping.
2.7 Proprietary parts or assemblies are suitable for secondhand or reconditioned classification
only after consulting with the manufacturer to determine conformance with intent of this specifi-
cation.
2.8 Coupler bodies are not acceptable for secondhand classification or reconditioning and must be
scrapped when the body has a crack that meets any of the following conditions:
2.8.1 Extends beyond the shaded areas labeled (AA) in Fig. C.12.
2.8.2 Extends 2 in. in length, or additive in length if more than one crack is present within a
panel 2 in. wide as indicated by the shaded areas labeled (BB) in Fig. C.13.
2.8.3 Extends beyond the radius area between the horn and the shank as indicated by the shaded
area labeled (CC) in Fig. C.14; or that extends 2 in. in length or additive in length if more than one
crack is present, within the radius area between the horn and shank as indicated by the shaded
areas labeled (CC) in Fig. C.14.
2.8.4 Located in unshaded areas of Figs. C.12, C.13, and C.14, including the coupler shelf, top or
bottom (not shown in Figs. C.12, C.13, and C.14).
2.9 Any crack or break in the shaded area for Figs. C.12, C.13, and C.14 will condemn the coupler
body. A crack is defined as any fracture without complete separation into parts, as illustrated in
Fig. C.15. Shrinkage tears and hot tears are defined as a defect with irregular, tagged edges along
the length of the defect, as illustrated in Fig. C.16. Shrinkage tears or hot tears in the unshaded
area of Figs. C.12, C.13, and C.14 will not significantly reduce the strength of the coupler and shall
not be considered cracks.
3.0 SECONDHAND ACCEPTANCE REQUIREMENTS
3.1 General
3.1.1 Parts must be evaluated in accordance with the procedure in paragraph 2.0.
3.1.2 Parts or assemblies must not be painted except for an identification spot color code, if used,
or as described in paragraph 3.1.6.
3.1.3 Parts or assemblies must not be lubricated except as permitted in paragraph 5.4.
S [M-212] 204 10/2010

10/2010
Casting Details
M-212
3.1.4 Parts or assemblies must be free of cracks, fractures, missing sections, defective weld, and
service notches except as permitted by paragraph 3.3.2. For disposition of coupler bodies with
cracks, see paragraphs 2.8 and 2.9.
3.1.5 Surface upset must be ground and blended to the surrounding surfaces. Gouges or notches
not exceeding 1⁄8 in. deep must be blended into surrounding surfaces by grinding. This ground area
must be free of cracks.
3.1.6 The secondhand part or assembly must have identification of the shop facility and its loca-
tion making this evaluation. The identification can be by paint stenciling or by attachable durable
tags.
3.2 Coupler
3.2.1 Coupler Body
3.2.1.1 Only the catalog number parts listed in Table A.3 are acceptable as secondhand. They
must meet the requirements of gauges listed in this table and must accept parts to operate prop-
erly in accordance with paragraph 3.2.7.2. Parts must be free of defects listed in paragraph 3.1.4.
3.2.1.2 Shank Wear Limits and Replacement of Wear Plates
3.2.1.2.1 A coupler not required to be equipped with shank wear plate as noted in Table A.3 must
not be worn more than 1⁄8 in. deep on the bottom shank wall from contact with the coupler carrier
as measured in Fig. C.1.
3.2.1.2.2 If a coupler design requires a shank wear plate, then a new wear plate must be applied
if the old wear plate is worn more than 1⁄16 in. Any new wear plates applied must be applied in
accordance with AAR Manual of Standards and Recommended Practices, Section S, Part III, Stan-
dard S-137, provided the shank is not worn. No weld splatter is permitted on a plate bearing sur-
face.
3.2.1.2.2.1 Under no conditions will welding be performed when the casting temperature is below
40 °F.
3.2.1.3 Type E, E/F, or F coupler shank must not be out of alignment with the head in excess of
3⁄8 in.
3.2.2 Knuckle
3.2.2.1 Only the catalog number parts listed in Table A.4 are acceptable as secondhand and must
meet the requirements of gauges listed in this table. Knuckles must be free of cracks, fractures,
missing sections, defective welds, and service notches. Visual and NDT inspections must be con-
ducted per Specification M-220.
3.2.2.2 Suffix “E” of the catalog number stamped or cast on top of the knuckle denotes grade E
steel.
3.2.3 Lock
3.2.3.1 Only the catalog number parts listed in Table A.5 are acceptable as secondhand and must
meet the requirements of gauges listed in this table. Locks must be free of conditions described in
paragraph 3.1.4.
3.2.4 Thrower
3.2.4.1 Thrower must be free of conditions described in paragraph 3.1.4.
3.2.5 Locklift Assembly and Rotor
3.2.5.1 Locklift assemblies and rotors are not acceptable as secondhand.
10/2010 S [M-212] 205

10/2010
Casting Details
M-212
3.2.6 Knuckle Pivot Pin

3.2.6.1 Knuckle pivot pin must be free of conditions described in paragraph 3.1.4.
3.2.6.1.1 Pins must be examined for minute cracks in or adjacent to bearing areas. If any cracks
are found, pin must be scrapped.
3.2.6.2 Pin must meet the requirements of gauges listed in Table A.6.
3.2.7 Coupler, Assembled Complete
3.2.7.1 Assembled coupler must be assembled with parts having catalog numbers as permitted in
this manual. Current listings of catalog numbers and parts permitted can be found in the Correct
Repair tables of the Field Manual of the AAR Interchange Rules, Rules 16, 17, and 18.
3.2.7.2 Coupler must operate properly to perform the functions of lockset, anticreep, full knuckle
throw, and free lock drop per Appendix D.
3.2.7.3 A coupler assembled with secondhand and new and/or reconditioned parts is classified as
secondhand and must meet the gauge requirements listed in Table A.3.
3.2.7.3.1 See Fig. C.31 for proper application of gauge 25623-1. If this NO-GO gauge passes as
shown, the assembly is unacceptable.
3.2.7.4 Shank wear or wear plate requirements are specified in paragraph 3.2.1.2.
3.2.7.5 Assembled coupler fitted for bottom operation must have top locklift hole cap, catalogue
number E2A, applied to top locklift hole if coupler does not have hole cast closed.
3.2.7.6 Each part of the assembly must meet the requirements of its classification:
New part AAR Specification M-211

Secondhand part AAR Specification M-212, paragraph 3.0
Reconditioned part AAR Specification M-212, paragraph 4.0
3.2.7.7 Assembled coupler must be equipped with a knuckle having the same grade of steel as the
coupler body.
3.3 Coupler Yoke
3.3.1 Only the catalog number parts listed in Table A.7 are acceptable as secondhand and must
meet the requirements.
3.3.2 Coupler yoke must be free of the conditions described in paragraph 3.1.4 except in type Y40
or Y41 yoke design. A crack in either or both sides at rear of keyslot is acceptable.
3.3.3 From the front of keyslot or connector pin hole to butt inside surface, the length must not be
more than that shown below, with measurements as indicated in Fig. C.2.
Yoke Type Length maximum

Y40 35 in.
SY 40, Y593 35 in.
Y41 46 3/8 in.
Y45 31 1/4 in.
Y49 42 5/8 in.
S [M-212] 206 10/2010

10/2010
Casting Details
M-212
3.4 Draft Gear Follower

3.4.1 Only the parts listed in Table A.8 are acceptable as secondhand and must meet the gauge
requirements of this table.
3.4.2 Draft gear follower must be free of conditions described in paragraph 3.1.4.
3.4.3 Service-induced indentations on either the coupler or draft gear bearing surface on E fol-
lower or the draft gear bearing surface on F or E/F follower must have upset metal dressed flush
with the surrounding surface. After dressing, the depth of any remaining indentations must not
exceed 1⁄8 in. Gauging must be performed after dressing. See AAR Manual of Standards and Rec-
ommended Practices, Section B, Standard S-119 for other slab-type follower requirements.
3.5 Draft Key
3.5.1 Draft key suitable for use as secondhand must not be worn more than 5⁄16 in. at any point,
nor have more than 1⁄16 in. bow in any direction. Thickness due to upset must not exceed 1 9⁄16 in.
3.5.2 Draft key must conform to the dimensions and hardness requirements shown in MSRP Sec-
tion B, Standard S-121, except for wear and distortion allowed in paragraph 3.5.1.
3.6 Connecting Pin, Catalog Number Y47
3.6.1 Connecting pin must be free of conditions described in paragraph 3.1.4 and must not be
altered to facilitate application.
3.6.2 Minimum diameter at any point must not be less than 3 3⁄8 in. for the Y47 pin.
3.6.3 Bend must not exceed 1⁄16 in. in total length.
4.0 RECONDITIONED ACCEPTANCE REQUIREMENTS FOR REUSE
4.1 General
4.1.1 Parts must be classified in accordance with the procedure in paragraph 2.0.
4.1.2 Parts or assemblies must not be painted except for identification color code spot, if used.
4.1.3 Parts or assemblies must not be lubricated except as permitted in paragraph 5.4.
4.1.4 Parts or assemblies must be free of cracks, fractures, missing sections, defective weld, and
service notches, except as permitted by paragraphs 4.3.2, 5.3.4, and 6.5.1. For disposition of cou-
pler bodies with cracks, see paragraphs 2.8 and 2.9.
4.1.5 Surface upset must be ground and blended to the surrounding surfaces. Gouges or notches
not exceeding 1⁄8 in. deep shall be blended into surrounding surfaces by grinding. This ground area
must be free of cracks.
4.1.6 Process procedure must be in accordance with paragraph 5.0 .
4.1.7 The reconditioned part or assembly must be marked with the facility identification code and
the reconditioning location.
4.1.8 The reconditioned part must meet all of the requirements of this classification or be
scrapped.
10/2010 S [M-212] 207

10/2010
Casting Details
M-212
4.2 Coupler
4.2.1 Coupler Body
4.2.1.1 Only the catalog number parts listed in Table A.9 are acceptable as reconditioned. They
must meet the gauge requirements listed in this table and must accept parts to operate properly in
accordance with paragraph 3.2.7.2. Coupler shanks with transverse cracks are not acceptable for
reconditioning and must be scrapped.
4.2.1.2 Shank Wear Limits and Replacement of Wear Plates
4.2.1.2.1 A coupler not equipped with shank wear plate as noted in Table A.9 must not be worn
more than 1⁄8 in. deep on the bottom shank wall from contact with the coupler carrier as measured
in Fig. C.1. If repaired, the entire wear area must be restored flush with surrounding surfaces. No
sharp corners are permitted. Transverse welding is prohibited.
4.2.1.2.2 If coupler design requires shank wear plate, then new wear plate must be applied in
accordance with AAR Manual of Standards and Recommended Practices, Section S, Part III, Stan-
dard S-137. No weld splatter is permitted on plate bearing surfaces.
4.2.1.2.2.1 Under no conditions will welding be performed when the casting temperature is below
40 °F.
4.2.1.2.2.2 Heat treating must not be performed after application of shank wear plate.
4.2.1.2.2.3 Before applying wear plate, the shank must be restored to a flat surface by grinding or
in accordance with paragraph 6.1.6.
4.2.1.3 Shank length restoration may be accomplished by the preferred method of electric weld-
ing on the entire surface of the shank butt, when permitted. An alternative method of welding a
steel plate on the shank butt is acceptable for rigid shanks only. The application of plates or weld
build-up to the coupler horn is prohibited. The restored surface on rigid shanks must be reason-
ably smooth and in a plane perpendicular to the shank coupler carrier bearing surface and parallel
within 1⁄8 in. of the rear keyslot wall. Overall shank length must meet the requirements of gauge
number 49355, Fig. C.33.
4.2.1.4 The entire width of the rear keyslot wall must be parallel within 1⁄8 in. to the front keyslot
wall and the radii must be 13⁄16 in. at the rear of the keyslot for rigid shanks.
4.2.1.5 Markings
4.2.1.5.1 The coupler body must be legibly marked in the location as shown in Fig. C.4.
4.2.1.5.2 Type E/F and F couplers having spherical surface of shank butt restored require addi-
tional legible 1⁄2-in.-minimum steel-stamped marking, “RG” (restored and gauged) on top side of
coupler shank forward of pin hole as shown on Fig. C.5.
4.2.1.5.3 Grade C couplers converted to grade E shall be identified with a 1⁄8-in.-thick steel plate
or a cast steel lettering plate tack welded onto the guard arm side of the horn. The steel plate shall
have “CE” stamped in 3⁄8-in. stencils or the lettering plate will have the letters “CE” cast in 1⁄2-in.
letters. The plate will be visible when looking at the AAR identification on the horizontal face of
the guard arm. The AAR reconditioned markings must be steel stamped on the knuckle side of the
horn for types E and E/F couplers and on the guard arm side of the horn for type F couplers.
4.2.1.6 Type E, E/F, or F coupler shanks must not be out of vertical or lateral alignment with the
head in excess of 3⁄8 in.
4.2.2 Knuckle
Reconditioning of knuckle is prohibited.
S [M-212] 208 10/2010

10/2010
Casting Details
M-212
4.2.3 Lock
4.2.3.1 Only Table A.10 catalog number parts are acceptable as reconditioned and must meet the
gauge requirements of this table.
4.2.3.2 Lock must be identified with a 3⁄8-in. steel stamp on the top surface next to the parting
line per Fig. C.4.
4.2.4 Thrower
No reconditioning permitted.
4.2.5 Locklift Assembly and Rotor
4.2.6 Knuckle Pivot Pin
4.2.7 Coupler, Assembled Complete
4.2.7.1 Assembled coupler must meet the requirements of paragraph 3.2.7.2.
4.2.7.2 A coupler assembled with reconditioned and new parts is classified as reconditioned and
must meet the gauge requirements listed in Table A.9.
4.3 Coupler Yoke
4.3.1 Only Table A.11 catalog numbers are acceptable as reconditioned and must meet the gauge
requirements of this table.
4.3.2 A coupler yoke must be free of the conditions described in paragraph 3.1.4 except in Y40 or
Y41 yoke head design. A crack in either or both sides at rear of keyslot is acceptable.
4.3.3 Front of keyslot or front of weld-restored connector pin hole or bushing to butt inside sur-
face, length must be as follows with measurements made as indicated in Table C.2.
Yoke Type Length Minimum Length Maximum
SY40, YS93 34 9/16 in. 34 3/4 in.
Y40 34 9/16 in. 34 3/4 in.
Y41 45 15/16 in. 46 1/8 in.
Y45 30 15/16 in. 31 in.
Y49 42 5/16 in. 42 3/8 in.
4.3.4 Keyslot top or bottom wall wear up to 1⁄16 in. is acceptable.

4.3.5 Yoke must be legibly marked in the location as shown in Table C.4.
4.3.6 Grade C yokes converted to grade E shall be identified with a 1⁄8-in.-thick plate or a
cast-steel lettering plate welded next to the reconditioned markings on the butt end. The plate
shall have “CE” stamped in 3⁄8-in. steel stencil, or the lettering plate will have the letters “CE” cast
in 1⁄2-in. letters. In addition, the yokes should also have the 3⁄8-in. raised identification marks on the
yoke straps to signify grade E steel. The raised identification marks must be welded on and ground
smooth on top prior to heat treatment.
10/2010 S [M-212] 209

10/2010
Casting Details
M-212

4.4.1 Only Table A.8 parts are acceptable as reconditioned and must meet the gauge require-
ments of this table.
4.4.2 Draft gear follower must be free of the conditions described in paragraph 4.1.4.
4.4.3 After removal of upset metal, service-induced indentations up to 1⁄16 in. are acceptable.
4.4.4 Draft gear follower must be legibly steel stamped as shown in Table C.4.
4.5 Reforged Draft Key
4.5.1 Reforged draft key must be free of the conditions described in paragraph 4.1.4.
4.5.2 Key must conform to the dimensions shown in Fig. C.28.
4.5.3 Total bow on the length under the head to end of key must not exceed 1⁄32 in. in any direc-
tion.
4.5.4 Key must meet the hardness requirements of MSRP Section B, Standard S-121 and be
marked in accordance with Standard S-121 and Fig. C.28.
4.5.5 Reconditioning by means other than reforging is prohibited.
4.6 Connecting Pin, Catalog Number Y47
No reconditioning is permitted.
5.0 INSTRUCTIONS FOR RECONDITIONING
5.1 Weld Repair and Straightening
5.1.1 Weld repairs of components may be made in the flat (downhand) position by welders quali-
fied under ASTM Designation A488 or AWSBD.1.1.
5.1.2 The entire defect must be removed prior to weld repair. Defects that extend through the
entire wall thickness shall scrap the casting.
5.1.3 Casting must be uniformly or locally preheated to ensure crack-free welds. Under no condi-
tion will welding be performed when the area to be weld-repaired is below 40 °F (4 °C). If local pre-
heating is performed, it shall be as specified in Specification M-201, paragraph 12.4.
5.1.4 Repair welding shall be performed with low-hydrogen-coated electrodes or by the
gas-shielded welding process. Weld deposits shall provide properties equivalent to finished cast-
ings. Electrodes E9015, E9016, and E9018 must be used for crack repairs of grade C quenched and
tempered castings. Electrodes E9015, E9016, or E9018 must be used for crack repairs in grade C
castings to be normalized. Electrodes E12015, E12016, or E12018 must be used in grade E cast-
ings for crack repairs.
5.1.5 Heat treatment is required after weld repair or straightening.
5.1.5.1 Normalized and tempered grade C steel castings that have been straightened must be
normalized and tempered in accordance with paragraph 5.2.3.2 to meet hardness requirements of
paragraph 5.2.4.1.
5.1.5.2 Normalized and tempered grade C steel castings that have only been weld-repaired must
be either normalized and tempered per paragraph 5.2.3.2 or quenched and tempered per
paragraph 5.2.3.3 to meet hardness requirements of paragraph 5.2.4.1.
5.1.5.3 Quenched and tempered castings that have been weld-repaired or straightened must be
quenched and tempered per paragraph 5.2.3.3 or paragraph 5.2.3.4 to meet hardness require-
ments of paragraph 5.2.4.1.
S [M-212] 210 10/2010

10/2010
Casting Details
M-212
5.1.6 Repair welding on and/or application by welding of coupler shelves is prohibited.

5.2 Heat Treatment
5.2.1 After heat straightening prior to heat treatment, components shall be cooled to a tempera-
ture below 1000 °F at a rate that will not damage the castings.
5.2.2 Material Grade Identification
5.2.2.1 Grade C steel castings produced prior to September 1, 1981, are either normalized and
tempered or quenched and tempered. The normalized and tempered castings are marked HT as a
part of the catalog number or as a separate marking. The quenched and tempered castings are
marked HT as a part of the catalog number and have the Q located adjacent to the catalog number.
Grade C castings produced after September 1, 1981, are manufactured quenched and tempered
and are identified with the letter “C” being the last letter of the catalog number that is cast in
raised letters, but may be reclaimed by either quenching and tempering or normalizing and tem-
pering.
5.2.2.2 Grade E steel castings are quenched and tempered. Grade E steel castings produced prior
to September 1, 1981, are marked HTE as a part of the catalog number or as a separate marking.
Grade E castings produced after September 1, 1981, are identified with the letter “E” being the
last letter of the catalog number that is cast in raised letters.
5.2.3 Processing
5.2.3.1 Castings must be segregated by grades of steel for furnace batches. Casting furnace load
batches must be arranged to ensure complete exposure equally throughout.
5.2.3.1.1 All grade E components shall be quenched and tempered.
5.2.3.1.2 All grade C components cast on or after September 1, 1981, must be quenched and tem-
pered.
5.2.3.1.3 Grade C components cast prior to September 1, 1981, and marked HTQ shall be
quenched and tempered except as listed below. These exceptions may be either normalized and
tempered or quenched and tempered:
M&T, Pittsburgh cast after 4/10/78

ASF, Alliance cast after 3/15/79
National, Melrose Park cast after 11/25/80
5.2.3.2 Normalized and Tempered Grade C Steel
5.2.3.2.1 Heat castings in a furnace to 1650 °F throughout the castings’ entire volume and hold at
this temperature for a minimum of 30 minutes. Castings should be heated at a rate not to exceed
500 °F per hour. Furnace temperature should not be above 800 °F when castings are charged into
furnace.
5.2.3.2.2 Remove castings from furnace and allow to cool in static air to under 800 °F or to cold.
5.2.3.2.3 Heat castings in a furnace to 1000 °F and hold at this temperature for a minimum of
2 hours. Furnace temperature should not be over 400 °F when castings are charged into furnace. A
higher temperature may be necessary to obtain a proper hardness specified in paragraph 5.2.4.1.
The castings must be renormalized and tempered if they are too soft and retempered if they are
too hard.
5.2.3.2.4 Cool in static shop air or proceed per paragraph 5.2.3.2.5.
5.2.3.2.5 Quenching immediately after tempering of quenched and tempered material is permit-
ted.
10/2010 S [M-212] 211

10/2010
Casting Details
M-212
5.2.3.3 Quenched and Tempered Grade C Steel

this temperature for a minimum of 30 minutes. Furnace temperature should not be above 800 °F
when castings are charged into furnace.
5.2.3.3.2 Remove castings from furnace and, in less than 1 minute, completely submerge them in
moving or agitated water that is maintained between 55 °F and 150 °F at start of the quench, with
a preferred range of 55 °F to 75 °F. Hold castings under water until cooled below 400 °F.
5.2.3.3.3 Remove castings from water and, as soon as possible, start to furnace heat them to
1225 °F. Hold the castings at this temperature for a minimum of 2 hours. A higher temperature
may be necessary to attain a proper hardness specified in paragraph 5.2.4.1. The castings must be
requenched and tempered if they are too soft and retempered if they are too hard.
5.2.3.3.4 All castings shall be tempered as soon as possible to prevent cracking, but in no case
shall the time between quenching and tempering exceed 8 hours.
5.2.3.3.5 Cool castings in static shop air or proceed per paragraph 5.2.3.3.6.
5.2.3.3.6 Quenching immediately after tempering of quenched and tempered material is permit-
ted.
5.2.3.4 Quenched and Tempered Grade E Steel
this temperature for a minimum of 30 minutes. Furnace temperature should not be above 800 °F
when castings are charged into furnace.
5.2.3.4.2 Remove castings from furnace and, in less than 1 min., completely submerge them in
moving or agitated water that is maintained between 55 °F and 150 °F at start of the quench, with
a preferred range of 55 °F to 75 °F. Hold castings under water until cooled below 400 °F.
5.2.3.4.3 Remove castings from water and, as soon as possible, furnace heat them to 1060 °F.
Hold the castings at this temperature for a minimum of 2 hours. A higher temperature may be
necessary to attain a proper hardness specified in paragraph 5.2.4.1. The castings must be
requenched and tempered if they are too soft and retempered if they are too hard.
5.2.3.4.4 All castings shall be tempered as soon as possible to prevent cracking, but in no case
shall the time between quenching and tempering exceed 8 hours.
5.2.3.4.5 Cool castings in static shop air or proceed per paragraph 5.2.3.3.6.
5.2.4 Hardness
5.2.4.1 Tempering temperatures listed in paragraphs 5.2.3.2.3, 5.2.3.3.3, and 5.2.3.4.3 may have
to be varied slightly to attain the desired ranges for casting Brinell hardnesses, as listed.
Coupler Bodies/Yokes
N and T Grade C 179 to 241 BHN
Q and T Grade C 179 to 241 BHN
Q and T Grade E 241 to 311 BHN
5.2.4.2 Hardness measurements will be made in the locations shown on Fig. C.5. The surface at
these locations will be properly prepared by removal of all decarburized metal to permit accurate
hardness determination.
S [M-212] 212 10/2010

10/2010
Casting Details
M-212
5.2.4.3 Number of Hardness Tests (Required for Coupler Bodies, Yokes, and Knuckles
Only)
5.2.4.3.1 When heat-treated lot components are of one manufacturer, hardness determinations
will be made on 10% of the components. When treatment lot is less than 20 components, a mini-
mum of 2 components will be tested for hardness.
5.2.4.3.2 When components of heat-treated lot are of more than one manufacturer, hardness
determinations will be made on 10% of the components of each manufacturer. When number of
components of each manufacturer is less than 20, a minimum of 2 components will be tested for
hardness.
5.2.5 Heat-treating temperatures may vary plus or minus 20 °F from those specified during any
given holding time cycle.
5.2.6 Furnace temperature for heat treatment shall be controlled by pyrometers having associ-
ated recording equipment that produce time-temperature record charts. Pyrometers shall be cali-
brated at least once every 3 months. Log sheets will contain record chart information showing the
product type heat-treated. Pyrometer calibration record and log sheets will be available for exami-
nation for 1 year.
5.3 Finish
5.3.1 Surface discontinuities resulting from weld repairs, service upset, or service notches must
be contoured to the surrounding surfaces by grinding.
5.3.2 All components must be sufficiently cleaned for proper inspection, reclamation, and opera-
tion. Coupler must not be sand- or shot-blasted when assembled.
5.3.3 Component must be free from cracks, fractures, missing sections, or service notches in those
critical areas shown shaded in Figs. C.6, C.7, C.8, C.9, C.10, and C.11. For disposition of coupler
bodies with cracks, see paragraphs 2.8 and 2.9.
5.3.4 All surface area discontinuities that have been detected outside the critical areas as defined
in Figs. C.6, C.7, C.8, C.9, C.10, and C.11 that exceed one-half of the section thickness in length
and are less than 10% of the section thickness in depth shall be removed by blending with the sur-
rounding surfaces. Discontinuities that are greater in depth than 10% of the section thickness and
those discontinuities located in gauged surfaces shall be removed and weld-repaired in accordance
with paragraph 5.1.
5.4 Lubrication
Only dry lubricant may be applied to the coupler head or to any of the fittings of the coupler head.
6.0 REPAIR PROCEDURES
6.1 Coupler Body
6.1.1 Restoration of the coupler head portion of the coupler body, including the application of
bushings to knuckle pivot pin holes, is prohibited with the following exceptions:
6.1.1.1 Interlocking surfaces—F head.
6.1.1.2 Guard arm—E and F head.
6.1.1.3 Knuckle side wall—E head.
6.1.1.4 Chain lug or angle cock bracket—E and F head.
6.1.1.5 Anti-creep ledge for E heads not passing gauge number 48496-1, Fig. C.29, may be
restored by welding to gauge number 48496-2, Fig. C.41.
10/2010 S [M-212] 213

10/2010
Casting Details
M-212
6.1.2 Rigid shank coupler restoration is prohibited if any of the following conditions exist:
6.1.2.1 Wear on bottom of shank exceeds 3⁄8-in. depth as measured in Fig. C.1.
6.1.2.2 Shank butt to keyslot length is less than 3 1⁄2 in.
6.1.2.3 Keyslot length fails to meet requirements of gauge number 49355, Fig. C.33.
6.1.2.4 Keyslot burned out.
6.1.2.5 Shank butt modified to accommodate Farlow attachment.
6.1.2.6 Transverse welding required forward of the keyslot rear wall.
6.1.3 E/F or F vertical pin shank restoration is prohibited if any of the following conditions exist:
6.1.3.1 Cracks in shaded area of Fig. C.7 or Fig. C.8. For disposition of coupler bodies with cracks,
see paragraphs 2.8 and 2.9.
6.1.3.2 Transverse welding required forward of pin hole.
6.1.3.3 Wear on bottom of shank exceeds 3⁄8-in. depth as measured in Fig. C.1.
6.1.3.4 Any buckling in shank walls.
6.1.3.5 Failure of solid butt design to meet requirements of gauge number 44250-8, Fig. C.71, at
center.
6.1.4 Coupler Head Repair
6.1.4.1 Top and bottom pin protectors with cracks or missing sections may be weld-repaired in
the zones shown in Fig. C.17, E and F heads, but only to repair broken section if the crack does not
extend greater than 3⁄8 in. into pivot lug per Fig. C.18. If the failure extends beyond permissible
repair zones, the coupler body must be scrapped. Weld repair must be in accordance with
paragraph 5.1. The weld must be ground to the outside contour requirements of gauge number
49362, Fig. C.18.
6.1.4.1.1 Weld in the pin hole must be blended to the remaining unrepaired hole contour, as
shown in Fig. C.17. Failure to meet the minimum thickness requirements of gauge numbers 49353
for type E couplers, Fig. C.30, and 49361, for type F couplers, Fig. C.30, will scrap coupler body.
Heat treatment for this weld repair is required in accordance with paragraph 5.2.
6.1.4.1.2 When gauge number 49354, Fig. C.32, enters between the pin protector bosses, the hor-
izontal surface of the bottom boss must be restored by welding and grinding to meet the require-
ments of gauge number 51236, Fig. C.34. The knuckle pin hole contour must be maintained as
explained in paragraph 6.1.4.1.1.
S [M-212] 214 10/2010

10/2010
Casting Details
M-212
6.1.4.2 F Coupler Interlocking Surfaces Restoration

6.1.4.2.1 Guard Arm and Interlocking Wing Pocket Distortion
6.1.4.2.1.1 Guard Arm Distortion—Coupler body with distorted guard arm may be restored
either in a press or under light hammer blows after heating the guard arm or the entire coupler
body. When using the hammer straightening method, care must be exercised in preventing beating
the guard arm far enough into the head to causing distortion of the opening in the coupler front
face. A suggested setup for correcting lateral distortion is illustrated in Fig. C.19. The guard arm
or the entire coupler body should be heated to 1500 °F to 1600 °F and the force applied to the for-
ward portion of the guard arm through a heavy steel plate formed to the outer guard arm contour.
In no case shall straightening be performed if coupler temperature is below 1200 °F. After
straightening, a careful examination must be made to be certain that no cracks have developed as
a result of this operation. If cracks do occur, they must be evaluated and repaired in accordance
with paragraphs 6.1.1 and 5.1. After straightening, the coupler body must be heat-treated in accor-
dance with paragraph 5.2. Guard arm distortion gauge numbers 44251-1A and 34101-5A, shown
in Fig. C.20, must be used in checking coupler body contour after straightening.
6.1.4.2.1.2 Interlocking Wing Pocket Distortion—Coupler body with distorted interlocking wing
pocket may be restored by locally heating the distorted area or the entire coupler body to 1500 °F
to 1600 °F and straightening under a press or by other suitable means. When using a hammer
straightening method, care must be exercised in confining the heat as much as possible to the
pocket area in order to prevent distortion of the coupler head during straightening. In no case shall
straightening be performed if coupler temperature is below 1200 °F. A careful examination should
be made to be certain that no cracks have developed as a result of this operation. If cracks do occur,
they must be evaluated and repaired in accordance with paragraphs 6.1.1 and 5.1. The coupler
body must then be heat-treated in accordance with paragraph 5.2. Reclamation gauge number
43062-1A, shown in Fig. C.21, must be used during the straightening operation.
6.1.4.2.1.3 The completed work must be inspected with interlocking wing pocket and guard arm
aligning surface reclamation gauge number 44247-1, Fig. C.22.
6.1.4.2.2 Interlocking Lug and Guard Arm Wear—Coupler body worn on the top and/or bottom
guard arm interlocking lug and interlocking surfaces may be restored by welding in accordance
with paragraph 5.1. The coupler must then be tempered in accordance with paragraph 5.2. Resto-
ration of the worn surface must be within the limits of gauge number 34101-4, shown in Fig. C.23.
Final checking of completed work must be made with interlocking wing pocket and guard arm
interlocking surfaces reclamation gauge number 44247-1, shown in Fig. C.22.
6.1.4.2.3 Safety Support Shelf—No reclamation of the safety support shelf is required, but if
peened, the surface must be dressed smooth. Restoration of the shelf contour is prohibited.
6.1.4.2.4 Auxiliary Interlocking Lug—Auxiliary interlocking lug restoration is not necessary
unless it interferes with application of guard arm reclamation gauge number 44251-1A, shown in
Fig. C.20. If straightening is required, the lug must be locally heated to 1500 °F to 1600 °F and
straightened under a press or by other suitable means. The coupler must then be heat-treated in
accordance with paragraph 5.2.
10/2010 S [M-212] 215

10/2010
Casting Details
M-212
6.1.4.3 E Coupler Guard Arm Distortion—Coupler body with distorted guard arm may be
restored either in a press or under light hammer blows after heating the guard arm or the entire
coupler body. When using the hammer straightening method, care must be exercised in preventing
heating the guard arm far enough into the head to cause distortion of the opening in coupler front
face. A suggested setup for correcting lateral distortion is illustrated in Fig. C.19. The guard arm,
or the entire coupler, should be heated to 1500 °F to 1600 °F and the force applied to the forward
portion of the guard arm through a heavy steel plate formed to the outer contour of the guard arm.
In no case shall straightening be performed if coupler temperature is below 1200 °F. After
straightening, a careful examination must be made to be certain that no cracks have developed as
a result of this operation. If cracks do occur they must be evaluated and repaired in accordance
with paragraphs 6.1.1 and 5.1. After straightening, the coupler body must be heat-treated in accor-
dance with paragraph 5.2. Guard arm distortion gauge number 25005-D, shown in Fig. C.24, must
be used in checking coupler body contour after straightening.
6.1.4.4 Guard Arm and Front Face Cracks E and F Coupler Heads—Coupler heads with cracks in
the guard arm or front face may be weld-repaired in accordance with paragraph 5.1. The coupler
body must then be heat-treated in accordance with paragraph 5.2. For disposition of coupler bodies
with cracks, see paragraphs 2.8 and 2.9.
6.1.4.5 Chain Lug and Angle Cock Bracket on E and F Heads—Cracked, broken, or missing lugs
or brackets may be repaired or replaced. Former AAR standard catalog numbers will have the
same location as current AAR standards.
6.1.5 Vertical Pin Shank Restoration E/F and F Couplers
6.1.5.1 Scrap coupler body if shank butt thickness is less than the following:
6.1.5.1.1 For solid butt design, failure to meet gauge number 44250-8, Fig. C.71, at center.
6.1.5.2 Restoration Procedure
6.1.5.2.1 Coupler body having a shank length less than the minimum allowed by gauge numbers
44248-2C or 44248-3B, Fig. C.25 and Fig. C.26, can be restored by welding external spherical butt
surfaces to requirements of the applicable gauges noted in Table A.9.
6.1.5.2.2 Solid butt coupler body design having a shank length less than the minimum allowed by
gauge numbers 44248-2C or 44248-3B, Fig. C.25 and Fig. C.26, and/or less than maximum butt
thickness allowed by gauge number 50051-3, Fig. C.37, can be restored by welding external spher-
ical shank butt surface and internal rear shank pin hole surface to requirements of the applicable
gauges noted in Table A.9.
6.1.5.3 Shank butt height may be restored by welding top surface only per Fig. C.46 or Fig. C.67.
Top recessed radii must meet requirements of gauge number 50052-2, Fig. C.68, after restoration.
6.1.5.4 Identify restored and gauged spherical shank butt per paragraph 4.2.1.5.2 and Fig. C.5.
6.1.5.5 Restored coupler body must be heat-treated in accordance with paragraph 5.1.5.
6.1.6 Shank Wear at Coupler Carrier E, E/F, and F Couplers—Coupler shank contact with car-
rier, less than 3⁄8-in. depth into the bottom wall as measured in Fig. C.1 may be restored by welding
in accordance with paragraph 5.1 and must be made smooth by grinding. Welding on plates to
restore wear into the bottom wall is prohibited. Transverse welding across the shank is prohibited.
After welding, the coupler body must be heat-treated in accordance with paragraph 5.2. A coupler
body worn in excess of 3⁄8 in. at this location must not be restored and must be scrapped.
S [M-212] 216 10/2010

10/2010
Casting Details
M-212
6.1.7 Bent Shank—E, E/F, and F Coupler—Coupler body shank bent out of alignment with the
coupler head in excess of 3⁄8 in. in any direction may be reclaimed by heating to 1500 °F to 1600 °F
and straightening under a press. In no case shall straightening be performed if coupler tempera-
ture is below 1200 °F. Care must be exercised in bringing the shank into proper alignment with
the head within the 3⁄8-in. limits. After straightening, the coupler body must be carefully examined
making certain that no cracks have developed from this operation. Cracks must be evaluated and
repaired in accordance with paragraphs 6.1.2 and 6.1.3 and paragraph 5.1. The coupler body must
then be heat-treated in accordance with paragraph 5.2.
6.1.8 Rigid Shank Restoration—The following steps are the only approved method for restoration
of coupler body, keyslot, and butt dimensions:
6.1.8.1 Apply gauge number 49355, Fig. C.33, to ensure keyslot length. If keyslot length fails to
meet requirements of this gauge, restoration is prohibited.
6.1.8.2 Weld-restore the rear of the keyslot in accordance with paragraph 5.1. Add the difference
between the actual length and the minimum lengths of 6 7⁄8 in. for E60 design and 8 5⁄8 in. for
E67 design.
6.1.8.3 Use machine tool or cone grinder to generate true 13⁄16-in. radius at the rear of keyslot for
the entire shank width. The machined surface must be parallel within 1⁄8 in. with the keyslot front.
This machining may be done after heat treatment. Break sharp corners after machining.
6.1.8.4 Restore shank butt square to top and bottom walls, parallel to keyslot front, and 4 in.,
+3⁄32 , –0 from keyslot rear, by one of the following methods:
6.1.8.4.1 The preferred method is by adding weld to shank butt on entire surface and grinding
smooth to squareness and parallel requirements.
6.1.8.4.2 An alternative method is to weld a plate on the shank butt. Butt, plate, and weld
requirements are as follows:
6.1.8.4.2.1 Plate must be A.I.S.I. C-1030, C-1045, or equivalent.
6.1.8.4.2.2 Plate size must be 4 3⁄4 in. × 5 3⁄4 in. × 1⁄4 in. minimum thickness.
6.1.8.4.2.3 Plate flatness before welding must be within 1⁄32 in.
6.1.8.4.2.4 Butt before welding plate must be flat within 1⁄32-in. concavity and no convexity.
6.1.8.4.2.5 Weld size must be 1⁄4-in. minimum and must extend around entire periphery of plate.
6.2 Knuckle
Repair of cracks or missing sections at any location is prohibited.
6.3 Lock
6.3.1 Lock restoration for wear is permitted only on the knuckle engagement surface indicated in
Fig. C.54. The entire repaired area must be restored flush with the surrounding surfaces.
6.3.2 Repair of cracks or missing sections at any location is prohibited.
6.3.3 Worn knuckle engagement surface may be restored by welding and heat treating in accor-
dance with paragraph 5.1 and paragraph 5.2. The application of any plates on the lock is prohib-
ited.
6.3.4 Restored surfaces must meet the requirements of paragraph 4.2.3.
6.4 Knuckle Pivot Pin
Knuckle pivot pin reconditioning is prohibited.
10/2010 S [M-212] 217

10/2010
Casting Details
M-212
6.5 Coupler Yoke

6.5.1 Repair of type Y40 or Y41 yoke head designs having a crack in either or both sides at rear of
keyslot is not required.
6.5.2 Repairs for All Yokes
6.5.2.1 Yokes with cracks shall not be weld-repaired except SY40, Y40, and Y41 type yokes with
cracks in rear keyslot wall.
6.5.2.2 Welding draft gear bearing surface of yoke to restore overall length dimensions of
paragraph 4.3.3 is prohibited.
6.5.3 All upset areas must be repaired in accordance with paragraph 4.1.5.
6.5.4 All welding and heat-treating repairs must be in accordance with Rules 4.3, 5.1, and 5.2.
6.5.5 Restoration of Yoke Straps
6.5.5.1 Wear of the strap thickness in excess of the requirements of the “B” end of either gauge
number 49373 and/or 49373-2, Fig. C.58, as applicable to those yokes shown in Table A.11 must
not be repaired and yoke must be scrapped.
6.5.5.2 Wear of the strap thickness not in excess of the requirements of paragraph 6.5.5.1 may be
weld- and heat-treat-repaired in accordance with paragraph 5.1 and paragraph 5.2. Weld surfaces
must be blended by grinding with the surrounding surfaces.
6.5.5.3 Weld repair of cracks in straps is prohibited.
6.5.6 Restoration of Yoke Keyslots (Y40, SY40, and Y41 Types)
6.5.6.1 Yokes with keyslots worn in excess of 3⁄8-in. depth at front top or bottom walls must be
scrapped.
6.5.6.2 Repair of service cracks is prohibited.
6.5.6.3 If dimension, as measured in Fig. C.2, is in excess of the following dimensions, restoration
is prohibited and yoke must be scrapped:
Type Y40—35 1⁄8 in.
Type Y41—46 1⁄2 in.
Type SY40—35 1⁄8 in.
6.5.6.4 Keyslot front wall may be restored by welding and machining to true 13⁄16-in. radius to
meet the overall length dimensions listed in paragraph 4.3.3.
6.5.6.5 Wear in keyslot less than 3⁄8 in. deep may be restored by welding. Restored area must be
blended by grinding with the surrounding surfaces.
6.5.7 E/F and F Yoke Head
6.5.7.1 If the dimension, as measured in Fig. C.2, exceeds the following dimensions, restoration is
prohibited and the yoke must be scrapped:
Type Y45—31 3⁄8 in.
Type Y49—42 3⁄4 in.
6.5.7.2 Connecting pin hole may be restored by welding or bushing to meet the overall length
dimensions listed in paragraph 4.3.3, providing it meets the requirements of gauges 44246-6,
Fig. C.61, and 44246-3, Fig. C.62.
S [M-212] 218 10/2010

10/2010
Casting Details
M-212
6.5.7.3 If hole restoration is done by welding and heat treating, it must be done in accordance
with paragraph 5.1 and paragraph 5.2 and diameter restored by machining to 3 5⁄8 in., or bushing
applied per Fig. C.3.
6.5.7.4 Yoke worn from contact with coupler shank may be restored by welding.
6.5.7.5 Yoke worn on the outside of the head from contact with the filler plate may be restored by
welding.
6.5.7.6 Yoke worn on the top and bottom outside of the head from striker contact may be restored
by welding when the yoke head is not less than 8 in. Yokes must be scrapped when yoke head
width is less than 8 in.
6.6.1 Repair of cracked or missing sections at any location is prohibited.
6.6.2 Followers with indentations exceeding 1⁄8 in. in depth on the coupler or draft gear surface
must not be restored and must be scrapped.
6.6.3 Type Y44 or Slab Follower
6.6.3.1 Bent follower may be straightened by hot pressing or forging. After straightening, a care-
ful visual examination must be made ensuring that no cracks have developed as a result of this
operation. If cracks do occur, the follower must be scrapped. Flatness to be gauged with gauge
number 34643-3, Fig. C.65.
6.6.3.2 Follower must meet requirements of paragraph 4.4.
6.6.3.3 Weld restoration of indentations not exceeding 1⁄8 in. in depth on the coupler or draft gear
bearing surfaces is permitted. Depth measurement is made after upset area is ground smooth to
surrounding surfaces. The repaired surfaces must be dressed to blend with the surrounding areas.
6.6.3.4 Follower must be heat-treated to the requirements of MSRP Section B, Standard S-119
and must be stamped in accordance with Standard S-119 and paragraph 4.1.7 of this specification.
6.6.4 Y46 Type Follower
6.6.4.1 No straightening is permitted.
6.6.4.2 Weld restoration of indentations not exceeding 1⁄8-in. depth on the draft gear bearing sur-
face is permitted. Coupler bearing surface restoration is prohibited. Depth measurement is made
after upset area is ground smooth to surrounding surfaces. Repaired surfaces must be dressed to
blend with surrounding areas.
6.6.4.3 Restoration welding and subsequent heat treatment must be in accordance with
paragraph 5.1 and paragraph 5.2.
6.6.5 Draft gears with integral followers; see information about “Reconditioning” in MSRP Sec-
tion B, Specification M-901B.
6.7 Draft Key
6.7.1 Draft key worn less than 3⁄8 in. at any point may be reforged in accordance with Fig. C.28.
6.7.2 Reforging of key worn more than 3⁄8 in. is prohibited and key must be scrapped.
6.7.3 Reforged draft key must be heat-treated to meet the hardness requirements of MSRP Sec-
tion B, Standard S-121.
6.7.4 Reforged key must be marked as shown in Standard S-121.
6.7.5 Welding on the draft key is prohibited.
10/2010 S [M-212] 219
10/2010
Casting Details
M-212
6.8 Reconditioning of Solid Butt E/F and F Couplers

6.8.1 Use gauge number 44250-8, Fig. C.71, to determine if coupler butt is too thin to be recondi-
tioned. If gauge number 44250-8 passes, scrap coupler body.
6.8.2 The coupler body must meet all other requirements of Specification M-212 for
reconditioning.
6.8.3 Use gauge number 50052-2, Fig. C.68 to check radius recess on outsides of pin holes top side
of shank on all couplers.
6.8.4 Use gauge number 50051-2, Fig. C.69 to check alignment shoulders on all couplers with
shoulders.
6.8.5 Use gauge number 44250-2A, Fig. C.46, to check the shoulders on certain F butt couplers at
the same time the top shape is checked.
6.8.6 Use gauge numbers 50051-3, Fig. C.37, and 49776-2A, Fig. C.49, and 50051-1, Fig. C.70, to
check the spherical surface of E/F and F couplers. Use gauge 50051-1 to check the pin hole for cor-
rect fit of the connecting pin.
S [M-212] 220 10/2010

10/2010
Casting Details
M-212 APPENDIX A
APPENDIX A
TABLES, CATALOG NUMBERS, AND GAUGE NUMBERS FOR
SECONDHAND AND RECONDITIONED ACCEPTANCE
Table A.1 Coupler body and parts, yokes, draft keys, and draft gear followers for freight cars, that are not acceptable
for classification and must be scrapped
Item AAR Catalog Numbers or Description
Coupler Bodies D60
E60, BE60, E60HT, CE60HT, BE60AHT, BE60BHT
E61, E61BC, E61HT, E61AHT, CE61AHT, BE61AHT, BE61BHT
E62, BE62HT, BE62
E63, BE63, E63HT, BE63HT, BE63AHT, E63AHT
E68AHT, BE68HT
E69HTE
All 5x5 shanks
All 5x7 shanks
F70BHT, F70HT, F70BHTE, CF70HT, CF70AHT
F71BHT, CF71HT, CF71AHT
F72BHT, CF72HT, CF72AHT
F73HT
F79BHT, F79BHTE, CF79HT, CF79AHT
Coupler Knuckles D Types
E50, E50HT with tail core hole
Any knuckle over 15 years of age from cast date
Any HTS knuckle is prohibited
Any knuckle without flag staff hole
Other Coupler Parts D coupler parts
E7 separate toggle
E8 lock lifter
E14, E14A rotary assemblies, single
E15, E15A rotary assemblies, double
E40 lock
Used E2 or E2A top lock lift hole caps
F8 single rotor
F9 double rotor
F10 double rotor eye
F65, F65A, F65B, F65BHT, F65BC, pin bearing block
Used F66 retaining springs
E40HTS locks
F41HTS locks
F45HTS locks
Paragraph 2.1
10/2010 S [M-212] 221

10/2010
Casting Details
APPENDIX A M-212
Table A.1 Coupler body and parts, yokes, draft keys, and draft gear followers for freight cars, that are not acceptable
for classification and must be scrapped (Continued)
Item AAR Catalog Numbers or Description
Yokes Riveted type
Keyless type
Vertical key type
Farlow
Y20
Y30HT, CY30HT, BY30HT
Y35 types
Y36 types
Y37, BY37, Y37HT, BY37HT, Y37AC
Y40, BY40, BY40HT, CY40HT, Y40HT
BY41
Y45, Y45HT, BY45, BY45HT
Draft Keys Those less than 6" × 1 1⁄2" nominal cross-section
Those previously reclaimed
Followers Slab followers less than 2 1⁄4" nominal thickness
Y-46
Y-48
Farlow type
Paragraph 2.1
Table A.2 Coupler body and parts acceptable for secondhand usage only
Item AAR Catalog Numbers
Coupler Bodies
Coupler Parts
Followers
Paragraph 2.1
S [M-212] 222 10/2010

10/2010
Casting Details
M-212 APPENDIX A
Table A.3 Coupler body—secondhand acceptance

CATALOG NUMBERS ACCEPTABLE FOR SECONDHAND CLASSIFICATION
E67BHT
E67BHTE E69AHT
E60CHT/CHTE E67BE E69AE
E60CC/DC E67BC/CC E68BHT/BHTE E69BE F70CHT
E60CE/DE/EE E67BE/CE/DE E68BC/BE E69CE F70CHTE
SBE60CC/DC SBE67BC/CC E68CE/DE SBE69AE F70CC/CE F79CHT
SBE60CE/DE SBE67BE/CE/DE SBE68BC/BE SBE69BE F70DE F79CHTE
SBE60EE SE67BHT SBE68CE/DE SBE69CE SF70CHT F73AHT F79CC/CE/DE
SE60CHT/CHTE SE67BHTE SE68BHT/BHTE SE69AE SF70CHTE F73AHTE SF79CHT
FIG. SE60CC/DC SE67BC/CC SE68BC/BE SE69BE SF70CC/CE F73AC SF79CHTE
GAUGE NO. NO. SE60CE/DE/EE SE67BE/CE/DE SE68CE/DE SE69CE SF70DE F73AE/BE SF79CC/CE/DE
25005-D C.24 X X X X — — —
48496-1 C.29 X X X X — — —
TYPE E
HEAD
49353 C.30 X X X X — — —
25623-11 C.31 X X X X — — —
49354 C.32 X X X X — — —
49355 C.33 X X — — — — —
GAUGE REQUIREMENTS
44248-2C C.25 — — — — X — —
SHANKS
44248-3B C.26 — — X X — X X
44250-6 C.71 — — X X X X X
49360 C.35 — — X X X X X
44251-1A, 34101-5A C.20 — — — — X X X
34101-4 C.23 — — — — X X X
44250-5 C.36 — — — — X X X
49361 C.30 — — — — X X X
TYPE F
HEAD
36527-3 C.39 — — — — X X X
or or
36527-2A C.38
49354 C.32 — — — — X X X
47120-21 C.40 — — — — X X X
NOTE:
1FOR COUPLERS ASSEMBLED COMPLETE.
Paragraphs 2.5, 3.2.1.1, 3.2.7.3, 3.2.1.2.1
Table A.4 Knuckle—secondhand acceptance

CATALOG NUMBERS ACCEPTABLE FOR
SECONDHAND CLASSIFICATION
E50AE
E50HTE
REQUIREMENTS
E50BE F51AE
GAUGE NO. FIG. NO. E50ARE F51HTE
GAUGE
24992-1 C.50 X —
44250-3 C.51 — X
49363 C.52 X X
49364-B C.53 X X
NOTE: Any of the above catalog numbers with an “X” suffix are also acceptable.
Paragraphs 2.5, 3.2.2.1
10/2010 S [M-212] 223

10/2010
Casting Details
APPENDIX A M-212
Table A.5 Lock—secondhand acceptance

CATALOG NUMBERS ACCEPTABLE FOR SECONDHAND
CLASSIFICATION
E42AE
E42HTE
REQUIREMENTS
E42HT
GAUGE
E40AE
GAUGE NO. FIG. NO. E40HT E40HTE F41HT F41AE F45AE
49365 C.54 X X — — —
49366 C.54 — — X X X
Table A.6 Knuckle pivot pin, catalog number C-10 gauges secondhand requirements acceptance
GAUGE NUMBER FIGURE NO.
REQUIREMENTS
49369 C.56
GAUGE
43556-1A C.27
Paragraphs 2.5, 3.2.6.2
Table A.7 Yokes—secondhand acceptance

CATALOG NUMBERS ACCEPTABLE FOR SECONDHAND
CLASSIFICATION
Y40AHT Y45HTE
Y40AHTE Y41AHT Y45AHT Y49HT
Y40AC Y41AHTE Y45AHTE Y49HTE
REQUIREMENTS
Y40AE Y41AC Y45AC Y49AC

GAUGE
GAUGE NO. FIG. NO. SY40AE Y41AE Y45AE Y49AE

49371 C.57 X X X X
49373 C.59 X X X X
49373-2 C.59 — — X X
“A” SIDE OF GAUGES 49373 AND 49373-2 PER INSTRUCTIONS IN Fig. C.59.
Paragraphs 2.5, 3.3.1
Table A.8 Draft gear follower—secondhand and reconditioned acceptance

CATALOG NUMBERS ACCEPTABLE FOR SECONDHAND OR
RECONDITIONED CLASSIFICATION
Y44 OR Y44A
REQUIREMENTS
SLAB OR
Y44HTE OR Y46HTE
GAUGE
GAUGE NO. FIG. NO. Y44AE CAST Y46AE

34643-3 C.65 X X
49376 C.66 — X
Paragraphs 2.5, 3.4.1, 4.4.1
S [M-212] 224 10/2010

10/2010
Casting Details
M-212 APPENDIX A
Table A.9 Coupler body—reconditioned acceptance

CATALOG NUMBERS ACCEPTABLE FOR RECONDITIONED CLASSIFICATION
E67BHT
E67BHTE E69AHT
E60CHT/CHTE E67BE E69AE
E60CC/DC E67BC/CC E68BHT/BHTE E69BE F70CHT
E60CE/DE/EE E67BE/CE/DE E68BC E69CE F70CHTE
SBE60CC/DC SBE67BC/CC E68BE/CE/DE SBE69AE F70CC/CE F79CHT
SBE60CE/DE SBE67BE/CE/DE SBE68BC/BE SBE69BE F70DE F79CHTE
SBE60EE SE67BHT SBE68CE/DE SBE69CE SF70CHT F73AHT F79CC/CE/DE
SE60CHT/CHTE SE67BHTE SE68BHT/BHTE SE69AE SF70CHTE F73AHTE SF79CHT
FIG. SE60CC/DC SE67BC/CC SE68BC/BE SE69BE SF70CC/CE F73AC SF79CHTE
GAUGE NO. NO. SE60CE/DE/EE SE67BE/CE/DE SE68CE/DE SE69CE SF70DE F73AE/BE SF79CC/CE/DE
25005-D C.24 X X X X — — —
48496-1, 48496-23 C.29 X X X X — — —
C.41
TYPE E
51236 C.34 X X X X — — —
HEAD
49353 C.30 X X X X — — —
49354 C.32 X X X X — — —
493625 C.18 X X X X — — —
283931 C.42 X X X X — — —
49775-4 C.43 X X — — — — —
49775-5 C.44 X X — — — — —
49355 C.33 X X — — — — —
49775-1 C.45 — — X — X — X
49775-6 C.45 — — — X — X —
49775-2 C.46 — — X X X X X
44250-2A4 C.46 — — — — X X X
SHANKS
50052-14 C.67 — — X X — — —
50052-24 C.68 — — — — X X X
49775-3 C.47 — — X — X — X
44248-2C C.25 — — — — X — —
44248-3B C.26 — — X X — — —
49776-2A2 C.49 — — X X X X X
50051-12 C.70 — — X X X X X
50051-22 C.69 — — X — X — X
50051-3 C.37 — — X X X X X
44251-1A and 34101-5A C.20 — — — — X X X
44250-5 C.36 — — — — X X X
49361 C.30 — — — — X X X
TYPE F
51236 C.34 — — — — X X X
HEAD
44247-1 C.22 — — — — X X X
44248-11 C.48 — — — — X X X
493625 C.18 — — — — X X X
47120-21 C.40 — — — — X X X
NOTES:
1FOR COUPLERS ASSEMBLED COMPLETE.
2FOR COUPLER BODY MARKED “RG” IN ACCORDANCE WITH PARAGRAPH 4.2.1.5.2 AND FIG. C.5.
348496-2 USED ONLY FOR RESTORED ANTI-CREEP LEDGE.
4USED ONLY FOR SHANK BUTT WITH TOP RESTORED.
5FOR WELD-REPAIRED PIN PROTECTOR ONLY.
Paragraphs 2.5, 4.2.1.1, 4.2.1.2.1, 4.2.7.2, 6.1.5.2.1, 6.1.5.2.2
10/2010 S [M-212] 225

10/2010
Casting Details
APPENDIX A M-212
Table A.10 Lock—reconditioned acceptance

CATALOG NUMBERS ACCEPTABLE FOR RECONDITIONED
CLASSIFICATION
E40HTE
E40AE
REQUIREMENTS
E42HTE F41HTE F45HT

GAUGE NO. FIG. NO E42AE F41AE F45AE
GAUGE
49365 C.54
X — —
49367 C.55
49366 C.54
— X X
49367-1 C.55
Paragraph 4.2.3.1
Table A.11 Yokes—reconditioned acceptance

CATALOG NUMBERS ACCEPTABLE FOR RECONDITIONED
CLASSIFICATION
Y40AC Y45AC
Y40AHT Y41AC Y45AE Y49AC
Y40AHTE Y41AHT Y45HTE Y49AE
Y40AE Y41AHTE Y45AHT Y49HT
GAUGE NO. FIG. NO. SY40AE Y41AE Y45AHTE Y49HTE
49371 C.57 X X X X
REQUIREMENTS
493721 C.58 X X X X
GAUGE
44246-2 C.60 — — X X
44246-3 C.62 — — X X
44246-4 C.63 — — X X
44246-63 C.61 — — X X
34647-5 C.64 — — X X
493732 C.58 X X X X
49373-22 C.58 — — X X
NOTES:
1PER TABLE INSTRUCTIONS IN FIG. C.58.
2ACCEPTANCE FOR RECONDITIONING, “B” SIDE OF GAUGE ONLY PER TABLE INSTRUCTIONS IN FIG. C.58.
3FOR BUSHED YOKES ONLY.
Paragraphs 2.5, 4.3.1, 6.5.5.1
S [M-212] 226 10/2010

10/2010
Casting Details
M-212 APPENDIX B
APPENDIX B
GAUGE APPLICATION DRAWINGS—BY FIGURE NUMBER
Fig. No. Title Reference Text or Table Page No.
C.1 Measurement on bottom of shank from Paragraphs 3.2.1.2.1, 4.2.1.2.1, 6.1.2.1, S[M-212]233
carrier contact 6.1.3.3 and 6.1.6
C.2 Measurement of yoke length Paragraphs 3.3.3, 4.3.3, 6.5.6.3 and 6.5.7.1 S[M-212]233
C.3 Pin hole bushing coupler yoke Paragraph 6.5.7.3 S[M-212]234
C.4 Reconditioned acceptance markings for Paragraphs 4.2.1.5.1, 4.2.3.2, 4.3.5, and S[M-212]235
coupler bodies, coupler parts, followers, and 4.4.4
yokes
C.5 Location for Brinell hardness reading and RG Paragraphs 4.2.1.5.2, 5.2.4.2, and 6.1.5.4 S[M-212]236
stamp for reconditioning couplers, yokes and
parts
C.6 Yoke inspection zones Paragraphs 2.3, 5.3.3, and 5.3.4 S[M-212]237
C.7 Coupler shank inspection zones—pin Paragraphs 2.3, 5.3.3, 5.3.4, 6.1.3.1 S[M-212]238
bearing block shank
C.8 Coupler shank inspection zones—solid butt Paragraphs 2.3, 5.3.3, 5.3.4, 6.1.3.1 S[M-212]238
shank
C.9 F coupler head inspection zones Paragraphs 2.3, 5.3.3, 5.3.4 S[M-212]239
C.10 E coupler head inspection zones Paragraphs 2.3, 5.3.3, 5.3.4 S[M-212]240
C.11 Knuckle head inspection zones Paragraphs 5.3.3 and 5.3.4 S[M-212]241
C.12 Knuckle side Paragraphs 2.8 and 2.9 S[M-212]242
C.13 Knuckle front Paragraphs 2.8 and 2.9 S[M-212]243
C.14 Knuckle top Paragraphs 2.8 and 2.9 S[M-212]244
C.15 Example of crack Paragraph 2.9 S[M-212]245
C.16 Example of shrinkage tear Paragraph 2.9 S[M-212]246
C.17 Pin protector bosses E, E/F and F coupler Paragraphs 6.1.4.1 and 6.1.4.1.1 S[M-212]247
heads
C.18 Gauge No. 49362 Paragraphs 6.1.4.1 and Table A.9 S[M-212]248
C.19 Suggested Setup for Straightening Types E, Paragraphs 6.1.4.2.1.1 and 6.1.4.3 S[M-212]249
E/F, and F Coupler Guard Arm
C.20 Gauges Nos. 44251-1A and 34101-5A Paragraphs 6.1.4.2.1.1, 6.1.4.2.4, and S[M-212]249
Tables A.3 and A.9
C.21 Gauge No. 43062-1A Paragraph 6.1.4.2.1.2 S[M-212]250
C.22 Gauge No. 44247-1 Paragraphs 6.1.4.2.1.3, 6.1.4.2.2, and S[M-212]250
Table A.9
C.23 Gauge No. 34101-4 Paragraph 6.1.4.2.2 and Table A.3 S[M-212]251
C.24 Gauge No. 25005-D Paragraph 6.1.4.3 and Tables A.3 and A.9 S[M-212]252
C.25 Gauge No. 44248-2C Paragraphs 6.1.5.2.1, 6.1.5.2.2, and S[M-212]253
Tables A.3 and A.9
C.26 Gauge No. 44248-3B Paragraphs 6.1.5.2.1, 6.1.5.2.2, and S[M-212]253
Tables A.3 and A.9
C.27 Gauge No. 43556-1A Table A.6 S[M-212]254
C.28 Reclaimed Draft Key and Markings Paragraphs 4.5.2, 4.5.4, 6.7.1 S[M-212]255
10/2010 S [M-212] 227

10/2010
Casting Details
APPENDIX B M-212
APPENDIX B (CONTINUED)
C.29 Gauge No. 48496-1 Paragraph 6.1.1.5,Tables A.3 and A.9 S[M-212]256
C.30 Gauge No. 49353, Type E and Gauge No. Paragraph 6.1.4.1.1,Tables A.3 and A.9 S[M-212]257
49361, Type F
C.31 Gauge No. 25623-1 Paragraph 3.2.7.3.1 and Table A.3 S[M-212]258
C.32 Gauge No. 49354 Paragraph 6.1.4.1.2 and Tables A.3 and A.9 S[M-212]258
C.33 Gauge No. 49355 Paragraphs 4.2.1.3, 6.1.2.3, 6.1.8.1, S[M-212]259
Tables A.3 and A.9
C.34 Gauge No. 51236 Paragraph 6.1.4.1.2 and Table A.9 S[M-212]260
C.35 Gauge No. 49360 Table A.3 S[M-212]261
C.36 Gauge No. 44250-5 Tables A.3 and A.9 S[M-212]261
C.37 Gauge No. 50051-3 Paragraphs 6.1.5.2.2, 6.8.6, and Table A.9 S[M-212]262
C.38 Gauge No. 36527-2A Table A.3 S[M-212]263
C.39 Gauge No. 36527-3 Table A.3 S[M-212]263
C.40 Gauge No. 47120-2 Tables A.3 and A.9 S[M-212]264
C.41 Gauge No. 48496-2 Paragraph 6.1.1.5 and Table A.9 S[M-212]265
C.45 Gauge Nos. 49775-1 and 49775-6 Table A.9 S[M-212]267
C.46 Gauge Nos. 44250-2A and 49775-2 Paragraphs 6.1.5.3, 6.8.5, and Table A.9 S[M-212]268
C.49 Gauge No. 49776-2A Paragraph 6.8.6 and Table A.9 S[M-212]270
C.51 Gauge No. 44250-3 Table A.4 and Table A.5 S[M-212]272
C.53 Gauge No. 49364-B Table A.4 S[M-212]273
C.54 Gauge Nos. 49365 and 49366 Table A.5 and Table A.10 S[M-212]274
C.55 Gauge Nos. 49367 and 49367-1 Table A.10 S[M-212]274
C.57 Gauge No. 49371 Table A.7 and Table A.11 S[M-212]275
C.58 Gauge Nos. 49372, 49373, and 49373-2 Paragraph 6.5.5.1 and Table A.11 S[M-212]276
C.59 Gauge Nos. 49373 and 49373-2 Table A.7 S[M-212]276
C.61 Gauge No. 44246-6 Paragraph 6.5.7.2, Table A.11 S[M-212]277
C.62 Gauge No. 44246-3 Paragraph 6.5.7.2, Table A.11 S[M-212]278
S [M-212] 228 10/2010

10/2010
Casting Details
M-212 APPENDIX B
APPENDIX B (CONTINUED)
C.68 Gauge No. 50052-2 Paragraphs 6.1.5.3, 6.8.3, and Table A.9 S[M-212]282
C.69 Gauge No. 50051-2 Paragraph 6.8.4 and Table A.9 S[M-212]282
C.70 Gauge No. 50051-1 Paragraph 6.8.6 and Table A.9 S[M-212]283
C.71 Gauge Nos. 44250-6 and 44250-8 Paragraphs 6.1.3.5, 6.1.5.1.1, 6.8.1, and S[M-212]284
Table A.3
10/2010 S [M-212] 229

10/2010
Casting Details
APPENDIX C M-212
APPENDIX C
GAUGE APPLICATION DRAWINGS—NUMERICAL
Gauge No. Fig. No. Description Reference Text or Table Page No.
Gauge No. 24992-1 C.50 Knuckle nose wear and stretch limit Table A.4 S[M-212]271
Gauge No. 25005-D C.24 E coupler guard arm distortion Paragraph 6.1.4.3 and S[M-212]252
Tables A.3 and A.9
Gauge No. 25623-1 C.31 E coupler, worn contour limit Paragraph 3.2.7.3.1 and S[M-212]258
Table A.3
Gauge No. 28393 C.42 E coupler, reconditioned contour limit Table A.9 S[M-212]265
Gauge No. 34101-4 C.23 F coupler, vertical height interlocking wing Paragraph 6.1.4.2.2 and S[M-212]251
pocket and guard arm, Go Table A.3
Gauge No. 34101-5A C.20 F coupler, guard arm distortion Paragraphs 6.1.4.2.1.1, S[M-212]249
6.1.4.2.4, and Tables A.3 and
A.9
Gauge No. 34643-3 C.65 Draft gear follower flatness Paragraph 6.6.3.1 and S[M-212]280
Table A.8
Gauge No. 34647-5 C.64 Vertical pin connection yoke, head width Table A.11 S[M-212]279
Gauge No. 36527-2A C.38
or Assembled F coupler knuckle closure limit Table A.3 S[M-212]263
Gauge No. 36527-3 C.39
Gauge No. 43062-1A C.21 F coupler, aligning wing reconditioning Paragraph 6.1.4.2.1.2 S[M-212]250
Gauge No. 43556-1A C.27 Coupler knuckle pin bend Table A.6 S[M-212]254
Gauge No. 44246-2 C.60 Vertical pin connection yoke, head opening Table A.11 S[M-212]277
Gauge No. 44246-3 C.62 Vertical pin connection yoke, head Paragraph 6.5.7.2, Table A.11 S[M-212]278
thickness, without bushing
Gauge No. 44246-4 C.63 Vertical pin connection yoke, inside Table A.11 S[M-212]279
contour
Gauge No. 44246-6 C.61 Vertical pin connection yoke, head Paragraph 6.5.7.2, Table A.11 S[M-212]277
thickness, with bushing
Gauge No. 44247-1 C.22 F coupler, interlocking wing pocket and Paragraphs 6.1.4.2.1.3, S[M-212]250
guard arm aligning surface 6.1.4.2.2, and Table A.9
Gauge No. 44248-1 C.48 F coupler, guard arm distortion and coupler Table A.9 S[M-212]269
contour wear limits
Gauge No. 44248-2C C.25 F coupler, minimum length, 22 1¤2-in. Paragraphs 6.1.5.2.1, S[M-212]253
normal length 6.1.5.2.2, and Tables A.3 and
A.9
Gauge No. 44248-3B C.26 F79, E68, F73, and E69 type couplers, Paragraphs 6.1.5.2.1, S[M-212]253
minimum shank lengths 6.1.5.2.2, and Tables A.3 and
A.9
Gauge No. 44250-2A C.46 Vertical pin connection coupler, butt shank Paragraphs 6.1.5.3, 6.8.5, and S[M-212]268
height and restoration Table A.9
Gauge No. 44250-3 C.51 F knuckle, nose wear stretch limit Table A.4 and Table A.5 S[M-212]272
Gauge No. 44250-5 C.36 F coupler, vertical height of interlocking Tables A.3 and A.9 S[M-212]261
wing pocket and guard arm, No Go
Gauge Nos. 44250-6 C.71 Vertical pin connection, coupler, butt Paragraphs 6.1.3.5, 6.1.5.1.1, S[M-212]284
and 44250-8 thickness 6.8.1, and Table A.3
S [M-212] 230 10/2010
10/2010
Casting Details
M-212 APPENDIX C
APPENDIX C (CONTINUED)
Gauge No. 44251-1A C.20 F coupler, guard arm distortion Paragraphs 6.1.4.2.1.1, S[M-212]249
6.1.4.2.4, and Tables A.3 and
A.9
Gauge No. 47120-2 C.40 F coupler contour Tables A.3 and A.9 S[M-212]264
Gauge No. 48496-1 C.29 E coupler body, anticreep, No Go Paragraph 6.1.1.5,Tables A.3 S[M-212]256
and A.9
Gauge No. 48496-2 C.41 E coupler body, anticreep, Go Paragraph 6.1.1.5 and S[M-212]265
Table A.9
Gauge No. 49353 C.30 Pin hole minimum thickness requirements Paragraph S[M-212]257
6.1.4.1.1,Tables A.3 and A.9
Gauge No. 49354 C.32 Coupler body, distance between pivot lugs Paragraph 6.1.4.1.2 and S[M-212]258
Tables A.3 and A.9
Gauge No. 49355 C.33 E60 and E67 type couplers, shank length Paragraphs 4.2.1.3, 6.1.2.3, S[M-212]259
key slot location and length 6.1.8.1, Tables A.3 and A.9
Gauge No. 49360 C.35 Vertical pin connection coupler, minimum Table A.3 S[M-212]261
butt height
Gauge No. 49361 C.30 Pin hole minimum thickness requirements Paragraph S[M-212]257
6.1.4.1.1,Tables A.3 and A.9
Gauge No. 49362 C.18 Coupler body, pin protector boss, outside Paragraphs 6.1.4.1 and S[M-212]248
contour Table A.9
Gauge No. 49363 C.52 Knuckle hub, height, acceptance for Table A.4 S[M-212]272
secondhand
Gauge No. 49364-B C.53 Knuckle, pin hole wear limits Table A.4 S[M-212]273
Gauge Nos. 49365 C.54 Lock thickness, concavity of knuckle Table A.5 and Table A.10 S[M-212]274
and 49366 engagement surface
Gauge Nos. 49367
C.55 E and F lock acceptance gauges Table A.10 S[M-212]274
and 49367-1
Gauge No. 49369 C.56 Knuckle pin wear limits Table A.6 S[M-212]275
Gauge No. 49371 C.57 Yoke, rear relief fillet Table A.7 and Table A.11 S[M-212]275
Gauge Nos. 49372, C.58
Yoke, strap wear limit for secondhand Paragraph 6.5.5.1 and
49373, and 49373-2 and S[M-212]276
acceptance and reconditioning Table A.11, Table A.7
C.59
Gauge No. 49376 C.66 Y46 type draft gear follower depth of Table A.8 S[M-212]280
spherical surface
Gauge No. 49775-1 C.45 Coupler shank height wear plate Table A.9 S[M-212]267
Gauge No. 49775-2 C.46 Vertical pin connection coupler, butt shank Paragraphs 6.1.5.3, 6.8.5, and S[M-212]268
height and restoration Table A.9
Gauge No. 49775-3 C.47 Vertical pin connection coupler with Table A.9 S[M-212]269
aligning shoulder butt width
Gauge No. 49775-4 C.43 E60- and E67-type couplers, key slot Table A.9 S[M-212]266
location
Gauge No. 49775-5 C.44 E60- and E67-type couplers, maximum Table A.9 S[M-212]266
shank height
10/2010 S [M-212] 231

10/2010
Casting Details
APPENDIX C M-212
APPENDIX C (CONTINUED)
Gauge No. 49775-6 C.45 Coupler shank height wear plate Table A.9 S[M-212]267
Gauge No. 49776-2A C.49 Vertical pin connection coupler, shank butt Paragraph 6.8.6 and Table A.9 S[M-212]270
spherical surface
Gauge No. 50051-1 C.70 Vertical pin connection coupler, restored Paragraph 6.8.6 and Table A.9 S[M-212]283
shank butt thickness
Gauge No. 50051-2 C.69 Vertical pin connection coupler, alignment Paragraph 6.8.4 and Table A.9 S[M-212]282
shoulder restoration
Gauge No. 50051-3 C.37 Vertical pin connection coupler, butt Paragraphs 6.1.5.2.2, 6.8.6, S[M-212]262
thickness restoration and Table A.9
Gauge No. 50052-1 C.67 Vertical pin connection coupler, butt shank Paragraph 6.1.5.3 and S[M-212]281
height restoration Table A.9
Gauge No. 50052-2 C.68 Vertical pin connection coupler, restored Paragraphs 6.1.5.3, 6.8.3, and S[M-212]282
shank butt recess Table A.9
Gauge No. 51236 C.34 Coupler pivot lug reconditioned Paragraph 6.1.4.1.2 and S[M-212]260
acceptance gauge Table A.9
S [M-212] 232 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Wear
Straight Edge Wear

Straight Edge Wear
Typical Rigid Shank Typical Vertical Pin Connection Shank

Couplers originally provided without wear plate
Measurement on bottom of shank from carrier contact

Paragraphs 3.2.1.2.1, 4.2.1.2.1, 6.1.2.1, 6.1.3.3 and 6.1.6
Fig. C.1
Straight Edge Against

Front of Keyslots Straight Edge Against
Front of Vertical Pin Holes
Yoke Length at Center
Yoke Length at Center
Typical Horizontal Key Yoke Typical Vertical Pin Connection Yoke
Measurement of yoke length

Paragraphs 3.3.3, 4.3.3, 6.5.6.3 and 6.5.7.1
Fig. C.2
10/2010 S [M-212] 233

10/2010
Casting Details
APPENDIX C M-212
1/16" X 30° CHAMFER

BOTH ENDS
OUTSIDE BORE HOLES 4.242"
DIA. +- .000"
.002"
, 125 RMS
FINISH. HOLES TO BE
IN LINE WITHIN 1/32".
BUSHING PRESSED FLUSH

TO OUTSIDE SURFACE
1/32" X 45° CHAMFER
BOTH ENDS
INSIDE
(BUSHINGS MUST MEET HARDNESS

REQUIREMENTS OF STANDARD S-100)
Pin hole bushing coupler yoke

Paragraph 6.5.7.3
Fig. C.3
S [M-212] 234 10/2010

10/2010
Casting Details
M-212 APPENDIX C
1"

4
Reconditioned acceptance markings for coupler bodies, coupler parts, followers, and yokes
Paragraphs 4.2.1.5.1, 4.2.3.2, 4.3.5, and 4.4.4
Fig. C.4
10/2010 S [M-212] 235

10/2010
Casting Details
APPENDIX C M-212
Flat side
Follower
Location for Brinell hardness reading and RG stamp

for reconditioning couplers, yokes and parts
Paragraphs 4.2.1.5.2, 5.2.4.2, and 6.1.5.4
Fig. C.5
S [M-212] 236 10/2010

10/2010
Casting Details
M-212 APPENDIX C
NOTE: Repair of Service Cracks in areas shown shaded are prohibited.
Yoke inspection zones

Paragraphs 2.3, 5.3.3, and 5.3.4
Fig. C.6
10/2010 S [M-212] 237

10/2010
Casting Details
APPENDIX C M-212
"B"
"C"
1"
"A" "A"
"C"
"B"
1"
SECTION "A - A"

NOTE: Repair of Service Cracks in areas shown shaded are prohibited.
Coupler shank inspection zones—pin bearing block shank

Paragraphs 2.3, 5.3.3, 5.3.4, 6.1.3.1
Fig. C.7
TOP & BOTTOM SURFACES

"B"
1" 1"
1"
"B"
"D" "D"
"A" 1"
1"
VIEW "B-B" SECTION "A-A"
"A" 1"
SECTION "D-D"
NOTE: Welding on coupler shelves is prohibited.
Coupler shank inspection zones—solid butt shank

Paragraphs 2.3, 5.3.3, 5.3.4, 6.1.3.1
Fig. C.8
S [M-212] 238 10/2010

10/2010
Casting Details
M-212 APPENDIX C
F coupler head inspection zones

Paragraphs 2.3, 5.3.3, 5.3.4
Fig. C.9
10/2010 S [M-212] 239

10/2010
Casting Details
APPENDIX C M-212
E coupler head inspection zones

Paragraphs 2.3, 5.3.3, 5.3.4
Fig. C.10
S [M-212] 240 10/2010

10/2010
Casting Details
M-212 APPENDIX C
3"
¾"
4"
4"
(AA)
(AA)
Knuckle head inspection zones

Paragraphs 5.3.3 and 5.3.4
Fig. C.11
10/2010 S [M-212] 241

10/2010
Casting Details
APPENDIX C M-212
Knuckle side
Paragraphs 2.8 and 2.9
Fig. C.12
S [M-212] 242 10/2010

10/2010
Casting Details
M-212 APPENDIX C
5½"
2"
(AA)
(AA) (BB)
(AA)
1"
1"
Knuckle front
Fig. C.13
10/2010 S [M-212] 243

10/2010
Casting Details
APPENDIX C M-212
(CC)
2"
Knuckle top
Fig. C.14
S [M-212] 244 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Example of crack
Paragraph 2.9
Fig. C.15
10/2010 S [M-212] 245

10/2010
Casting Details
APPENDIX C M-212
Example of shrinkage tear

Paragraph 2.9
Fig. C.16
S [M-212] 246 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Pin protector bosses E, E/F and F coupler heads

Paragraphs 6.1.4.1 and 6.1.4.1.1
Fig. C.17
10/2010 S [M-212] 247

10/2010
Casting Details
APPENDIX C M-212
A 1/32-in.-diameter feeler must not enter at any point

between curved surface and gage after welding
and finish grinding with surfaces seated as indicated
Gauge No. 49362

Coupler body, pin protector boss, outside contour
Paragraphs 6.1.4.1 and Table A.9
Fig. C.18
S [M-212] 248 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Suggested Setup for Straightening Types E, E/F, and F Coupler Guard Arm
Paragraphs 6.1.4.2.1.1 and 6.1.4.3
Fig. C.19
GAUGE APPLICATION
Gauges Nos. 44251-1A and 34101-5A

F coupler, guard arm distortion
Paragraphs 6.1.4.2.1.1, 6.1.4.2.4, and Tables A.3 and A.9
Fig. C.20
10/2010 S [M-212] 249

10/2010
Casting Details
APPENDIX C M-212
Gauge No. 43062-1A

F coupler, aligning wing reconditioning
Paragraph 6.1.4.2.1.2
Fig. C.21
Gauge No. 44247-1

F coupler, interlocking wing pocket and guard arm aligning surface
Paragraphs 6.1.4.2.1.3, 6.1.4.2.2, and Table A.9
Fig. C.22
S [M-212] 250 10/2010

10/2010
Casting Details
M-212 APPENDIX C
MUST PASS
MUST PASS
SIDE ELEVATION ELEVATIONKNUCKLE SIDE

GUARD ARM
Gauge No. 34101-4

F coupler, vertical height interlocking wing pocket and guard arm, Go
Paragraph 6.1.4.2.2 and Table A.3
Fig. C.23
10/2010 S [M-212] 251

10/2010
Casting Details
APPENDIX C M-212
FORCE
GAUGE
CONTACT
1 /4" MAX.
NOTE:
APPLY TO TOP AND BOTTOM PIVOT HOLES.
Gauge No. 25005-D

E coupler guard arm distortion
Paragraph 6.1.4.3 and Tables A.3 and A.9
Fig. C.24
S [M-212] 252 10/2010

10/2010
Casting Details
M-212 APPENDIX C
HORN LINE
SEAT
SEAT
NO
F70 TYPE
Gauge No. 44248-2C

F coupler, minimum length, 22 1⁄2-in. normal length
Paragraphs 6.1.5.2.1, 6.1.5.2.2, and Tables A.3 and A.9
Fig. C.25
HORN LINE
SEAT
E68 & F79 TYPES

SEAT
NO
E69 & F73 TYPES

SEAT
MUST NOT SEAT
Gauge No. 44248-3B

F79, E68, F73, and E69 type couplers, minimum shank lengths
Paragraphs 6.1.5.2.1, 6.1.5.2.2, and Tables A.3 and A.9
Fig. C.26
10/2010 S [M-212] 253

10/2010
Casting Details
APPENDIX C M-212
Coupler pin must seat at two points and

must rotate 360°
Gauge No. 43556-1A

Coupler knuckle pin bend
Table A.6
Fig. C.27
S [M-212] 254 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Reclaimed Draft Key and Markings

Paragraphs 4.5.2, 4.5.4, 6.7.1
Fig. C.28
10/2010 S [M-212] 255

10/2010
Casting Details
APPENDIX C M-212
Coupler is not acceptable for secondhand if either

end of no-go gauge number 48496-1 passes body
anticreep ledge and seats
Gauge No. 48496-1

E coupler body, anticreep, No Go
Paragraph 6.1.1.5,Tables A.3 and A.9
Fig. C.29
S [M-212] 256 10/2010

10/2010
Casting Details
M-212 APPENDIX C
MUST NOT ENTER

WITH PIN SEATED
AT REAR OF PIN HOLE
BUFFING
SHOULDER
Coupler is unsatisfactory if gauge piece

enters between hole and buffing surface
with pin seated at rear of pin hole, or if
pin protector NO-GO thickness seats.
Weld of buffing shoulder to restore
wear is prohibited.
APPLY GAUGE WITHIN 1/8" EITHER SIDE

Must not seat OF PIN HOLE LONGITUDINAL CENTERLINE ONLY.
PIN
PROTECTOR
Gauge No. 49353, Type E and

Gauge No. 49361, Type F
Pin hole minimum thickness requirements
Paragraph 6.1.4.1.1,Tables A.3 and A.9
Fig. C.30
10/2010 S [M-212] 257

10/2010
Casting Details
APPENDIX C M-212
The coupler is rejected if the gauge passes vertically through the contour in the position shown with points B and C contacting the guard
arm and with the knuckle held in pull position. The “A” position indicated on the gauge is not used for secondhand acceptance.
Gauge No. 25623-1

E coupler, worn contour limit
Fig. C.31
3/8-in. Steel
plate-hardened
rustproof "" surface
Gauge No. 49354

Coupler body, distance between pivot lugs
Paragraph 6.1.4.1.2 and Tables A.3 and A.9
Fig. C.32
S [M-212] 258 10/2010

10/2010
Casting Details
M-212 APPENDIX C
NOTE: FOR RECONDITIONED ACCEPTANCE, COUPLER MUST ALSO SATISFY

GAUGE NO. 49775-4, Fig. C.43.
Gauge No. 49355

E60 and E67 type couplers, shank length key slot location and length
Paragraphs 4.2.1.3, 6.1.2.3, 6.1.8.1, Tables A.3 and A.9
Fig. C.33
10/2010 S [M-212] 259

10/2010
Casting Details
APPENDIX C M-212
Gauge No. 51236

Coupler pivot lug reconditioned acceptance gauge
Fig. C.34
S [M-212] 260 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Gauge No. 49360

Vertical pin connection coupler, minimum butt height
Table A.3
Fig. C.35
Gauge No. 44250-5

F coupler, vertical height of interlocking wing pocket and guard arm, No Go
Tables A.3 and A.9
Fig. C.36
10/2010 S [M-212] 261

10/2010
Casting Details
APPENDIX C M-212
SEAT
BOTTOM
TOP OF F SHANK
CONTACT
TOP HALF
OF GAUGE
MEASURE OPENING THAT IS TOTAL MOUNT THAT COULD BE WELDED IN PIN

HOLE AND BUTT COMBINED. USE CARE THAT WELD IN PIN HOLE, WHEN
FINISHED, STILL ACCEPTS GAUGES 50051-1 (Fig. C.71) AND 50051-3.
TOP OF F SHANK
CONTACT
BOTTOM
BOTTOM HALF
OF GAUGE SEAT
Gauge No. 50051-3

Vertical pin connection coupler, butt thickness restoration
Paragraphs 6.1.5.2.2, 6.8.6, and Table A.9
Fig. C.37
S [M-212] 262 10/2010

10/2010
Casting Details
M-212 APPENDIX C
(For Guard Arm Distortion, Gauge 36527-3, shown below, may also be used)
Gauge No. 36527-2A

Assembled F coupler knuckle closure limit
Table A.3
Fig. C.38
Gauge No. 36527-3

Assembled F coupler guard arm distortion limit
Table A.3
Fig. C.39
10/2010 S [M-212] 263

10/2010
Casting Details
APPENDIX C M-212
MUST MUST
SEAT SEAT
A
B
Gauge No. 47120-2

F coupler contour
Tables A.3 and A.9
Fig. C.40
S [M-212] 264 10/2010

10/2010
Casting Details
M-212 APPENDIX C
GO
GAUGE NO.
48496-2
MUST SEAT
NOTE:
COUPLER WITH ANTICREEP LEDGE WORN TO ALLOW NO-GO GAUGE NO. 48496-1 TO PASS,
MAY BE RESTORED BY WELDING. RESTORED ANTI-CREEP LEDGE MUST BE DRESSED TO
ALLOW GO GAUGE NO. 48496-2 TO PASS AND SEAT.
Gauge No. 48496-2

E coupler body, anticreep, Go
Paragraph 6.1.1.5 and Table A.9
Fig. C.41
Gauge No. 28393

E coupler, reconditioned contour limit
Table A.9
Fig. C.42
10/2010 S [M-212] 265

10/2010
Casting Details
APPENDIX C M-212
49775-4
NO GO
GO
Gauge No. 49775-4

E60- and E67-type couplers, key slot location
Table A.9
Fig. C.43
RAISED MARKINGS
A
49775-5
GO
A SECTION A-A
NOTE:
GAUGE MUST GO FULL LENGTH OF SHANK EXCEPT MAY PASS AROUND
RAISED MARKINGS AT LOCATION SHOWN ABOVE.
Gauge No. 49775-5
E60- and E67-type couplers, maximum shank height
Table A.9
Fig. C.44
S [M-212] 266 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Gauge Nos. 49775-1 and 49775-6

Coupler shank height wear plate
Table A.9
Fig. C.45
10/2010 S [M-212] 267

10/2010
Casting Details
APPENDIX C M-212
USE GAUGE NO. 49775-2 IN

THIS ZONE ON BOTH SIDES.
49775-2
NO GO
GO
GAUGE NO. 49775-2
NOTE:
WORN F COUPLER SHANK BUTT NOT SATISFYING NO-GO PORTION OF GAUGE
NO. 49775-2 (A DIMENSION) MAY BE RESTORED BY WELDING TOP SURFACE ONLY AS
INDICATED BY SHADED AREA TO MEET REQUIREMENTS OF GAUGE 44250-2A WHEN
APPLIED AS SHOWN. AFTER WELDING, 1 /16" DIAMETER FEELER MUST NOT ENTER AT
ANY POINT.
TOP
GAUGE NO. 44250-2A
SEAT OR WITH UP TO
1 /16 INCH AT B OR C
A
MUST SEAT
B
44250-2A
C C
MUST SEAT
B
BOTH SURFACES
MUST SEAT
BUTT MUST SEAT EXCEPT FOR COUPLERS WITHOUT ALIGNMENT SHOULDERS. REAR SURFACE
OF GAUGE MUST BE KEPT PERPENDICULAR TO COUPLER CENTERLINE.
Gauge Nos. 44250-2A and 49775-2

Vertical pin connection coupler, butt shank height and restoration
Paragraphs 6.1.5.3, 6.8.5, and Table A.9
Fig. C.46
S [M-212] 268 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Gauge No. 49775-3

Vertical pin connection coupler with aligning shoulder butt width
Table A.9
Fig. C.47
MUST SEAT CHECKS GUARD ARM DISTORTION
MUST PASS
MUST
SEAT
MUST NOT PASS ENTIRELY THRU

CHECKS CONTOUR CONDEMING LIMITS
Gauge No. 44248-1

F coupler, guard arm distortion and coupler contour wear limits
Table A.9
Fig. C.48
10/2010 S [M-212] 269

10/2010
Casting Details
APPENDIX C M-212
ROTATE GAUGE TO COVER

FULL SPERICAL SURFACE
60° 60°
1"

32 MAX. CLEAR
MUST SEAT
MAY
HAVE
TAPER
Gauge No. 49776-2A

Vertical pin connection coupler, shank butt spherical surface
Paragraph 6.8.6 and Table A.9
Fig. C.49
S [M-212] 270 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Gauge No. 24992-1

Knuckle nose wear and stretch limit
Table A.4
Fig. C.50
10/2010 S [M-212] 271

10/2010
Casting Details
APPENDIX C M-212
Gauge No. 44250-3

F knuckle, nose wear stretch limit
Table A.4 and Table A.5
Fig. C.51
SECTION A-A
Gauge No. 49363

Knuckle hub, height, acceptance for secondhand
Table A.4
Fig. C.52
S [M-212] 272 10/2010

10/2010
Casting Details
M-212 APPENDIX C
NOTES:
1. ALLMARKINGS STAMPED ON.
2. BREAK ALL SHARP EDGES.
3. STEEL HARDENED.
4. "" SURFACES.
5. RUST PROOF.
Application Drawing
TRANSVERSE DIRECTION
SEC. A-A
GAUGE MUST NOT SEAT ON SHOULDER
WHEN APPLIED TO PIN HOLE TOP OR BOTTOM
IN EITHER THE LONGITUDINAL OR
TRANSVERSE DIRECTION
LONGITUDINAL DIRECTION
Gauge No. 49364-B

Knuckle, pin hole wear limits
Table A.4
Fig. C.53
10/2010 S [M-212] 273

10/2010
Casting Details
APPENDIX C M-212
GAUGE MUST NOT GO

FRONT OR REAR
49366 49365
NO GO SEAT NO GO
KNUCKLE ENGAGEMENT SEAT
NO SEAT NO SEAT SURFACE NO SEAT NO SEAT
TYPE F LOCK TYPE E LOCK

(TOP VIEW) (TOP VIEW)
NOTE: CONCAVITY CHECK REQUIRED ON KNUCKLE ENGAGEMENT SURFACE ONLY.

Gauge Nos. 49365 and 49366
Lock thickness, concavity of knuckle engagement surface
Fig. C.54
GAUGE NO. 49367-1 GAUGE NO. 49367
TYPE F LOCK TYPE E LOCK

(TOP VIEW) (TOP VIEW)
Gauge Nos. 49367 and 49367-1

E and F lock acceptance gauges
Table A.10
Fig. C.55
S [M-212] 274 10/2010
10/2010
Casting Details
M-212 APPENDIX C
NO GO
ROTATE MINIMUM 180º, MUST

NOT PASS AT ANY POINT
NO GO
ACROSS ENTIRE LENGTH
Gauge No. 49369

Knuckle pin wear limits
Table A.6
Fig. C.56
1 /2"
1 /4" DRILL MUST SEAT

GAUGE NO.
4 1 /2"
00
0.
APPLY GAUGE AS SHOWN AND CHECK FULL WIDTH OF BOTH

00
STRAPS. A 1 /16" X 1 /2" WIDE FEELER GAUGE MUST NOT GO

BETWEEN GAUGE AND STRAP EXCEPT IN AREA OF FILLET
RELIEF SHOWN ON AAR STANDARD S-139-78.
º
90

1 /2"
4 1 /2"
¼-in. Steel plate-hardened "" rustproof
Gauge No. 49371

Yoke, rear relief fillet
Fig. C.57
10/2010 S [M-212] 275

10/2010
Casting Details
APPENDIX C M-212
ZONE D 3"
MUST NOT SEAT

ZONE C
VERTICAL PIN CONNECTION TYPE
APPLY GAUGES TO BOTH STRAPS & BOTH SIDES FOR COMPLETE LENGTH OF INDICATED ZONE.
MUST NOT SEAT B

49372, 49373, & 49373-2
HORIZONTAL KEY CONNECTION TYPE
RECONDITIONED ACCEPTANCE IF GAUGE DOES NOT SEAT

YOKE TYPES GAUGE NO. SIDE ZONE
Y40, Y41, SY40 49372 B COMPLETE LENGTH
Y45, Y49 49372 A D
B C
CANNOT BE RECONDITIONED AND MUST BE SCRAPPED IF GAUGES SEAT
Y40, Y41, SY40 49373 B COMPLETE LENGTH
Y45, Y49 49373 B C
49373-2 B D
Gauge Nos. 49372, 49373, and 49373-2
Yoke, strap wear limit for secondhand acceptance and reconditioning
Fig. C.58
ZONE D 3"
A
MUST NOT SEAT B

ZONE C
VERTICAL PIN CONNECTION TYPE
49373 AND 49373-2
APPLY GAUGES TO BOTH STRAPS & BOTH SIDES FOR COMPLETE LENGTH OF INDICATED ZONE.
MUST NOT SEAT
HORIZONTAL KEY CONNECTION TYPE
SECONDHAND ACCEPTANCE IF GAUGES DO NOT SEAT

Y40, Y41, SY40 49373 A COMPLETE LENGTH
Y45, Y49 49373 A C
49373-2 A D
Gauge Nos. 49373 and 49373-2
Table A.7
Fig. C.59
S [M-212] 276 10/2010

10/2010
Casting Details
M-212 APPENDIX C
A B
GAUGE MUST PASS FROM B TO A

Gauge No. 44246-2
Vertical pin connection yoke, head opening
Table A.11
Fig. C.60

MUST NOT START
3 /16"
1 /2"
2"
2.094"
4 1 /2"
3 /16"

1 3 /16"
44246-6
1 /2"
3"
NO. 44246-6
RECONDITIONED ACCEPTANCE GAUGE YOKE HEAD THICKNESS FOR BUSHING
APPLICATION STEEL PLATEHARDENED RUST PROOF
APPLY AROUND ENTIRE EDGE

OF PIN HOLE BEFORE AND AFTER
BORING FOR BUSHING APPLICATION.
MUST NOT START
Gauge No. 44246-6

Vertical pin connection yoke, head thickness, with bushing
Paragraph 6.5.7.2, Table A.11
Fig. C.61
10/2010 S [M-212] 277

10/2010
Casting Details
APPENDIX C M-212

1 /8"
1"
MUST PASS
3 1 /2"
MUST PASS
2.406"
4 5 /8"
1 /8"

1 1 /8"
44246-3
4 1 /2" 1 /2"
NO. 44246-3
RECONDITIONED ACCEPTANCE GAUGE
YOKE HEAD THICKNESS
STEEL PLATEHARDENED
RUST PROOF
Gauge No. 44246-3

Vertical pin connection yoke, head
thickness, without bushing
Paragraph 6.5.7.2, Table A.11
Fig. C.62
S [M-212] 278 10/2010

10/2010
Casting Details
M-212 APPENDIX C
MUST SEAT
MUST
SEAT
MUST PASS
MUST
SEAT
MUST SEAT
Gauge No. 44246-4

Vertical pin connection yoke, inside contour
Table A.11
Fig. C.63
A A & B ZONES MUST BE GAUGED ON TOP & BOTTOM OF YOKE.

B
34647-5 GO
34647-5 GO
GAUGE NO. 34647-5

A B SECTION A-A SECTION B-B
SECTION A-A ZONE SECTION B-B ZONE
Gauge No. 34647-5

Vertical pin connection yoke, head width
Table A.11
Fig. C.64
10/2010 S [M-212] 279

10/2010
Casting Details
APPENDIX C M-212
34643-3
NO SEAT SEAT NO SEAT
SEAT
34643-3
SEAT SEAT
NOTE:
USED FOR Y-44, Y44A SLAB OR Y44AE,
Y44HTE CAST FOLLOWER (NOT ILLUSTRATED)
AND
USE DIAGONALLY FOR Y46HT OR Y46HTE, Y46AE CAST
FOLLOWERS (ILLUSTRATED)
Gauge No. 34643-3

Draft gear follower flatness
Fig. C.65
CLEARANCE
1 /8" MAXIMUM
MUST SEAT MUST SEAT
CONDEMNED IF CLEARANCE EXCEEDS 1 /8"
Gauge No. 49376

Y46 type draft gear follower depth of spherical surface
Table A.8
Fig. C.66
S [M-212] 280 10/2010

10/2010
Casting Details
M-212 APPENDIX C
WITH ALIGNMENT SHOULDER
NOTE: WORN E/F COUPLER SHANK BUTT NOT SATISFYING NO-GO PORTION OF
GAUGE NO. 49775-2 (A DIM.) MAY BE RESTORED BY WELDING TOP SURFACE
1/16 DIA. WIRE FEELER ONLY AS INDICATED BY SHADED AREA TO MEET REQUIREMENTS OF GAUGE 50052-1
NO GO WHEN APPLIED AS SHOWN. AFTER WELDING, 1/16 DIA. FEELER MUST NOT ENTER
AT ANY POINT.
A
SEAT
Gauge No. 50052-1

Vertical pin connection coupler, butt shank height restoration
Fig. C.67
10/2010 S [M-212] 281

10/2010
Casting Details
APPENDIX C M-212
USE ON TOP OF COUPLER

AT CENTER OF RECESSED RADIUS.
REFERENCE
3 7 /8"
MUST CONTACT
Gauge No. 50052-2

Vertical pin connection coupler, restored shank butt recess
Paragraphs 6.1.5.3, 6.8.3, and Table A.9
Fig. C.68
MUST CONTACT
A 1 /16 INCH FEELERNO-GOWITH GAUGE ROTATED ONE SIDE WITH

ALL CLEARANCE ON OPPOSITE SIDE.
APPLY FULL HEIGHT HOLDING GAUGE PERPENDICULAR TO SPHERICAL
SURFACE.
Gauge No. 50051-2

Vertical pin connection coupler, alignment shoulder restoration
Fig. C.69
S [M-212] 282 10/2010

10/2010
Casting Details
M-212 APPENDIX C
Gauge No. 50051-1

Vertical pin connection coupler, restored shank butt thickness
Fig. C.70
10/2010 S [M-212] 283

10/2010
Casting Details
APPENDIX C M-212
A MUST NOT PASS
GAUGE NO. USE “A”

44250-6 SECONDHAND ACCEPTANCE 3.125 in.
44250-8 CONDEMNING 2.750 in.
Gauge Nos. 44250-6 and 44250-8

Vertical pin connection, coupler, butt thickness
Paragraphs 6.1.3.5, 6.1.5.1.1, 6.8.1, and Table A.3
Fig. C.71
S [M-212] 284 10/2010

10/2010
Casting Details
M-212 APPENDIX D
APPENDIX D
COUPLER OPERATION AND PROCEDURE FOR CHECKING ANTICREEP
PROTECTION
(Paragraph 3.2.7.2)
1.0 COUPLER OPERATION
When testing assembled couplers for correct operation, they must be free of any foreign material
that will prevent operating functions described in the following. An inspection operating rod for
use in operating assembled couplers is illustrated in Fig. D.1. If coupler fails to properly operate or
does not have proper anticreep protection, parts may be interchanged to meet specification
requirements. Check parts to ensure that proper finishing or repaired areas meet specification
requirements. Only dry lubricants may be applied to head of fittings.
1.1 Coupler knuckle must throw to the open position by a continuous rotary force applied by
hand through the operating rod from rod handle.
1.2 Coupler knuckle must rotate to the 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.
1.3 Coupler lock must automatically drop to the locked position when the knuckle is closed as
described in paragraph 1.2 above. Coupler knuckle is locked shut when the lock drops to seat on,
or to within 1⁄4 in. of seating on the knuckle tail lock shelf.
1.4 Coupler is put on lockset when the knuckle is restrained from opening while force is applied
through the operating rod 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 inside face of the knuckle nose. Coupler
must then perform the functions of knuckle closure and lock drop described in paragraphs 1.2 and
1.3 above. Coupler must provide anticreep protection to prevent accidental unlocking.
E and F Coupler Toggle or Line Anti-Creep Inspection
Fig. D.1
10/2010 S [M-212] 285

10/2010
Casting Details
APPENDIX D M-212
2.0 CHECKING ANTI-CREEP PROTECTION

2.1 The anticreep features of a coupler are designed to prevent movement of parts in service that
would cause an unintentional uncoupling. The following figures outline procedures for checking
anticreep for bottom and top operated couplers.
CHECK CAP SECUREMENT
ANTI-CREEP PROJECTION
PRY BAR FORCE
SCREWDRIVER FORCE
NORMAL LOCKED POSITION
SECTIONAL VIEW THROUGH HEAD
Fig. D.2
2.1.1 To determine the effectiveness of the anticreep protection, insert a bar between the lock and
knuckle tail shelf and pry the lock upward. At the same time, force the lock leg rearward by insert-
ing a screwdriver between the lock leg and the front of the lock hole, as shown in Fig. D.2.
2.1.2 If the lock can be raised by this method enough to permit opening the knuckle, the coupler
has insufficient anticreep protection. You may correct insufficient anticreep protection by replac-
ing the following:
2.1.2.1 The locklift assembly
2.1.2.2 The lock
2.1.2.3 The knuckle
2.1.2.4 All of the above
2.1.3 Usually the replacement of the locklift assembly is sufficient. In some cases, further bene-
fits are obtained by renewal of the lock and/or knuckle. If renewal of these parts does not correct
the condition, the fault is probably due to worn anticreep protection or wear of the rear wall of the
bottom lock hole in the coupler head, and the coupler body must be renewed.
S [M-212] 286 10/2010

10/2010
Casting Details
M-212 APPENDIX D
2.2 Fig. D.3 outlines procedures for top-operated Type E couplers.
PRY BAR FORCE

TOP OPERATION
NORMAL LOCKED POSITION SCREWDRIVER
SECTIONAL VIEW THROUGH HEAD FORCE
Fig. D.3
2.2.1 The articulated locklift is permitted to “free swing” due to its hinged construction. When
end shocks occur, the lever swings forward and the projection provided at its outer end engages the
underside of the lower front face of the coupler head. This engagement is, in effect, an added anti-
creep and serves to prevent rotation of the lever and release of the regular anticreep. With this
engagement, upward bounce of the lock is stopped and accidental unlocking of the coupler is pre-
vented.
2.2.2 The provisions for repair of insufficient anticreep protection in Type E top operated cou-
plers are the same for bottom operated Type E couplers.
2.2.3 In addition to the anticreep protection described in Fig. D.3, it is essential that the anti-
creep features of the locklift be inspected and corrected when required as shown in Fig. D.4.
.
MAIN ANTI-CREEP
STILL IN POSITION
TO ENGAGE LUG
LOCK
RAISED
SLIGHTLY
AUXILIARY
ANTI-CREEP
AUXILIARY
ANTI-CREEP
NORMAL
POSITION NORMAL POSITION
OF LOCK OF OPERATING ROD
NORMAL POSITION
OF OPERATING ROD
POSITION 1. POSITION 2. POSITION 3.

POSITION WITH OPERATING ROD SAME AS POS. 1 EXCEPT POSITION OF PARTS WITH OPERATING
& LEVER PARTS THROWN FORWARD AUXILIARY ANTI-CREEP IN ROD ROTATED TO RELEASE ANTI-
AUXILIARY ANTI-CREEP ENGAGED. MINIMUM ENGAGEMENT. CREEP PRIOR TO REGULAR UN-
LOCKING OPERATION.
Fig. D.4
10/2010 S [M-212] 287

10/2010
Casting Details
APPENDIX D M-212
2.3 Inspection of Toggle Anticreep Protection

2.3.1 To determine the amount of anticreep protection, insert a pry bar or chisel between the lock
and the knuckle tail shelf, prying the lock upward. Force the lock leg rearward by inserting a
screwdriver or flat bar from beneath the coupler between the lock leg and the front of the lock hole.
Amount of toggle anticreep protection is determined by measuring the overlap of toggle and
knuckle lock shelf. The normal dimension “A” is 9⁄16 in. See Fig. D.5. Minimum allowable overlap is
1⁄4 in. If the overlap is less than 1⁄4 in., usually replacement of the locklift assembly is sufficient to
renew satisfactory anticreep protection, but in some cases further benefit is obtained by renewal of
the lock and/or knuckle. If renewal of these parts does not correct the condition, the fault is proba-
bly because of a worn area on the coupler head at the rear of the bottom lock hole. The coupler
body should be replaced.
.
"
9/16
NORMAL
KNUCKLE LOCK SHELF
KNUCKLE LOCK SHELF
F5 TOGGLE
MUST NOT BE LESS THAN 1/4"

TOP VIEW
SIDE VIEW /16"
9
NORMAL
F5 TOGGLE
Fig. D.5
2.4 Inspection of Lever Anticreep Protection

2.4.1 To inspect for lever anti-creep protection, see Fig. D.6.
COUPLER ANTICREEP
LEDGE
LOCK LEG
LEVER
ANTICREEP
SHOULDER
LEVER
LOCKLIFT
ASSEMBLY
LEVER AND ANTICREEP SURFACES WITH LEVER IN RAISED POSITION ANTICREEP

IN NORMAL POSITION SURFACES MUST ENGAGE TO PREVENT LEVER
ROTATION AND LOCK LIFTING
Fig. D.6
S [M-212] 288 10/2010

10/2010
Casting Details
M-212 APPENDIX D
2.4.2 Force the lever upward with the right hand and, using a pry bar inserted through the cou-
pler rotor eye, apply pressure with the left hand in the direction to unlock the coupler. Lifting the
lever will engage the anticreep surface as shown in Fig. D.6. If the lock raises or locklift assembly
operates to unlock the coupler, usually replacement of the locklift lever is sufficient corrective
action. In some cases further benefits are obtained by replacement of the rotor.
2.4.3 To ensure anticreep protection against longitudinal impact, pull E24 or E25 articulated
rotary locklift assembly linkage forward and attempt to lift this linkage. See Fig. D.7. If the anti-
creep prong does not contact under the front face to prevent raising of the lock while maintaining
forward pressure on the linkage, the anticreep is defective and the coupler assembly is not accept-
able. The lock should be moved around in the coupler head while making this test in order to
ensure positive anticreep protection at any lock location.
Fig. D.7
10/2010 S [M-212] 289

10/2010
Casting Details
APPENDIX E M-212
APPENDIX E
MANUFACTURER’S TRADEMARK IDENTIFICATION
Trademark Company (Initials or Trade Name) Trademark Company (Initials or Trade Name)
A Alliance Castings Company

Fundidora DeAceros Tepeyac, S.A.
(FATSA)
American Steel Foundries (ASF) McConway & Torley Corporation (M&T)

Granite City Kutztown, PA
American Steel Foundries (ASF) McConway & Torley Corporation (M&T)

Indiana Harbor Pittsburgh, PA
American Steel Foundries (ASF) Alliance National Castings Div., Cicero (National)
National Castings Div., Melrose Park

SM ASF-K de Mexico
(National)
National Castings Div., Mexico

Buckeye Steel Castings (Buckeye)
Sahagun, Heldago, Mexico
Canadian Steel Foundries (CSF) National Castings Div., Sharon (National)
Columbus Steel Castings Omaha Steel Castings Co. (Omaha)
Dominion Foundries & Steel, Ltd.

(DOFASCO) PD Qingdao Sansheshan Precision Casting
Co., China (Workhorse Rail)
Dresser Transportation Equipment

Sicerurgica Nacional, S.A. (Sidena)
(Gould)
Fundiciones de Hierro y Acero, S.A.

(FHASA)
S [M-212] 290 10/2010

10/2010
Casting Details
M-212 APPENDIX E
10/2010 S [M-212] 291

10/2010
Casting Details
APPENDIX F M-212
APPENDIX F
APPLICATION INSTRUCTIONS FOR STATUS AS AN
APPROVED RECONDITIONING FACILITY
(See paragraph 1.3.2 for further information)
1.0 APPLICATION
1.1 The reconditioner will submit eight copies of an application for an approved facility to the
AAR, Chief—Technical Standards, Transportation Technology Center, Inc., P.O. Box 11130, 55500
DOT Road, Pueblo, CO 81001.
1.2 The application must be accompanied by a description or brochures that describe facilities
and manufacturing processes, including detailed information on quality control procedures. If
more than one facility is involved, each must be fully described as a separate entity and applied for
on an individual basis.
1.3 The application will be accompanied by a draft in the amount estimated to defray inspection
costs, including transportation and five days at each reconditioning site. The application must
state that the applicant will pay the AAR for all costs that exceed the draft amount.
1.4 The application will list all couplers, coupler parts, coupler yokes, and draft gear followers
that the manufacturer will recondition.
2.0 LIST OF APPROVED MANUFACTURERS
A list of facilities (along with their identification marks) that are approved to recondition couplers
and yokes under the provisions of Specifications M-212 and M-1003 is available at
http://www.aar.com. In the event that a facility is deleted from this list for cause, reapplication for
approval will be required.
S [M-212] 292 10/2010

10/2010
Casting Details
M-212 APPENDIX G
APPENDIX G
STEEL CASTINGS RECLAMATION PLANT
INSPECTION CRITERIA
1.0 The reclamation plant inspector should verify that coupler and yoke reclamation is being
performed in accordance with AAR Specification M-212.
2.0 INITIAL INSPECTION OF CASTINGS
Check gauging techniques, visual, and/or magnetic particle inspection procedures. Reclamation
shop should have a good understanding of critical and noncritical casting areas and how these
relate to repair procedures.
3.0 REMOVAL OF CASTING DEFECTS
Observe arc-air or oxy-acetylene scarfing methods for complete removal of defects before weld
repair.
4.0 WELD REPAIR OF DEFECTS
Verify that AWS welding electrodes, designated for the appropriate type of material, are used
exclusively for repairs. Welders should be tested and qualified in the positions welding is to be per-
formed. Weld repairs must be free of any cracks.
5.0 HEAT TREATING OF CASTINGS AFTER WELDING
Components shall be heat-treated after welding in conformance to Specification M-212. Furnaces
should be adequately heated to ensure uniform temperature throughout. Temperature controls
and recording equipment should be in proper working order. Furnace calibration equipment
should be observed. Quenching tanks must have circulating capability and equipment transferring
parts from furnace to quench tank should be in good condition. Reclaimer should have thorough
knowledge of heat-treatment principles and types of heat treatment required depending on casting
type.
6.0 FINISHING
Observe finish castings grinding to ensure that surface discontinuities resulting from weld repair
are contoured to the surrounding surfaces.
7.0 Ascertain that required gauges by the applicable AAR specification are present and properly
used.
8.0 QUALITY CONTROL
Discuss additional quality control steps taken by the reclaiming party to ensure proper workman-
ship. These may include the following:
8.1 Periodic Brinell hardness testing of reclaimed castings to ensure proper heat treatment.
8.2 Magnaflux inspection of finished castings.
8.3 Metallurgical analysis (microstructure, Charpy V-notch tests) by metallurgical engineer on
property or hired as consultant.
8.4 Failure Analysis program. The reclaimer should be aware of the pathology of casting failures.
10/2010 S [M-212] 293

10/2010
Casting Details
APPENDIX H M-212
APPENDIX H
GUIDELINES FOR SHOP CERTIFICATION INSPECTION
RECLAMATION OF COUPLERS, YOKES, AND RELATED PARTS
Acceptable
Acceptable
M-212
Not
Description
Paragraph
I. PRELIMINARY INSPECTION AND FURNACE

1. Are couplers having condemning cracks scrapped? 2.3
2. Are required gauges available? Appx. H Supp
3. Are secondhand couplers separated? 2.0
4. Are couplers properly sorted for heat treatment? 5.2.3
5. Are couplers at proper temperature when straightened? 6.1.4.3
6. Are furnace controls operable and accurate? 5.2.6
7. Are yoke catalog numbers acceptable? Table A.11
8. Are yokes free of condemning cracks and wear? 3.3.2
II. WELDING
9. Are welders certified? 5.1.1
10. Are gauges available for shank length, squareness, and key size? Table A.9
11. Are welds of good quality and proper wire used? 5.1.4
12. Is welding done only in allowable locations? 6.0
13. Are couplers at correct temperature when welded? 3.2.1.2.2.1
14. Are all shank wear plates removed? 3.2.1.2.2
15. Is trimming and blending proper? 4.1.5
16. Is heat treatment performed after weld repair or straightening? 5.1.5
17. Are welds on shanks, butts, and keyway ground smooth? 5.3.1
III. HEAT TREATMENT
18. Has pyrometer been calibrated within 3 months? 5.2.6
19. Is recorded temperature within range and held for proper time? 5.2.3.2
20. Is date, quality, grade and manufacturer of coupler recorded on chart for each heat? 5.2.6
21. Is heat treatment performed before application of shank wear plate? 4.2.1.2.2.3
22. Are quenching and tempering requirements followed? 5.1.5.3
23. Are castings separated by grade for furnace batches? 5.2.3.1
24. Are yokes properly heat-treated? 5.2.3.2
IV. BRINELL TEST
25. Is record of Brinell test complete? 5.2.4.3
26. Are the required number of tests completed? 5.2.4.3
27. Is Brinell test made properly and in correct location? Fig. C.5
V. FINAL ASSEMBLY AND MARKING
28. Are reclamation marks in place and proper? Fig. C.4
29. Are shank wear plates properly applied? 4.2.1.2.2
30. Does assembled coupler properly operate? Appendix D
31. Are yokes properly stamped per Fig. C.4? Fig. C.4
Recommend Shop Approval Recommend Shop Disapproval
S [M-212] 294 10/2010

10/2010
Casting Details
M-212 APPENDIX H
Initial Inspection Reinspection
Routine Inspection Certification in Jeopardy
Reason for Disapproval: _________________________________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
Inspector(s) Signature: __________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Date: ___________________________________________________________________________________
10/2010 S [M-212] 295

10/2010
Casting Details
APPENDIX H M-212
APPENDIX H (SUPPLEMENT)
REQUIRED GAUGES
A facility must possess only those gauges for components it intends to recondition.
Gauge Yes No Gauge Yes No

COUPLER BODY SECONDHAND ACCEPTANCE
25005-D* 49360
48496-1* 44251-1A*
49353* 34101-5A*
25623-1 34101-4
49354* 44250-5*
49355* 43062-1A*
44248-2B* 49361*
44248-3A* 49354*
44250-6 36527-3 or 36527-2A
KNUCKLE SECONDHAND ACCEPTANCE
24992-1 49363
44250-3 49364B
KNUCKLE PIVOT PIN SECONDHAND ACCEPTANCE
49369 43556-1A
YOKES SECONDHAND ACCEPTANCE
44246-1 49373*
49371* 49373-2*
DRAFT GEAR FOLLOWER SECONDHAND and RECONDITIONED ACCEPTANCE
34643-3 49376
COUPLER BODY RECONDITIONED CLASSIFICATION
49496-2 49775-3
49362 48496-2
28393 49776-2A
49775-4 50051-1
49775-5 50051-2
49775-1 50051-3
49775-6 44247-1
49775-2 44248-1
44350-2A 43063-1
50052-1 43202-1
50052-2
YOKES RECONDITIONED ACCEPTANCE

49372 44246-4
44246-2 44246-6
44246-3 34647-5
*Indicates that gauge is also required for reconditioned acceptance.
S [M-212] 296 10/2010

M-213
TRUCK FRAMES, FABRICATED STEEL
Specification
M-213

1.0 SCOPE
1.1 This specification covers all one-piece fabricated steel truck frames for freight equipment
where side frames and bolsters are integrally joined as a single unit. (Individual fabricated side
frames and bolsters that are not physically joined and are intended to operate separately in the
truck should be designed and tested in accordance with Specifications M-202 and M-203).
1.2 All designs of truck frames must be approved by the Brake Systems Committee before being
placed in interchange freight service. The basis for approval is provided by these specifications.
1.3 Applications for approval shall be addressed to the Chief—Technical Standards, who will
refer same to the Brake Systems Committee. Five copies of the application shall be submitted and
shall be accompanied by copies of detail construction drawings and full information with respect to
composition of material and heat treatment employed.
1.4 Approval will be based upon the results of static and dynamic tests. Alternatively, the Com-
mittee may recommend approval of the design, material, and heat treatment on the basis of previ-
ous satisfactory static and dynamic tests of similar designs, material, and heat treatment. Waiver
of tests should be requested only on the basis of a design previously approved as a result of official
static and dynamic tests. A waiver request should be accompanied by substantiating data covering
the new design being used as a basis for such a request when there are differences not covered by
Specification M-203, Appendix A.
2.0 MATERIAL
2.1 Material shall be ASTM A-441, latest revision, that has been certified to exceed 15 ft·lb at
0 °F on the Charpy V-Notch Impact Test.
2.2 Structural steel other than the above may be used if approved by the Brake Systems Commit-
tee.
2.3 Welding of all parts shall be done with appropriate electrodes or process for the material
used. Procedure, workmanship, and qualification of welders shall be done in accordance with the
latest recommendations of the American Welding Society; the AAR Manual of Standards and Rec-
ommended Practices, Section C Part II, Specification M-1001, “Design, Fabrication, and Construc-
tion of Freight Cars”; and MSRP Section C Part III, Specification M-1002, “Specifications for Tank
Cars,” Appendix W.
3.0 DESIGN
3.2 The basis for calculations and testing shall be the vertical load P as given in Table 3.1.
Table 3.1 Vertical loads for design and testing of fabricated side frames
Size of Journal (in.) Type of Truck Axle Capacity (lb) P-Vertical Load (lb)
5 1⁄2 × 10 2D 42,000 81,000
6 × 11 2E 52,500 101,000
6 ⁄2 × 12
1 2F 63,000 121,000
7 × 12 2G 76,000 146,000
10/2010 S [M-213] 297
M-213
3.3 The vertical load, equal to P, shall be taken as acting on the centerline of the bolster any-
where within 8 in. each side of the bolster; also, on the center of the side bearing. On designs
where vertical loads are applied other than on center plates and side bearings, application shall be
taken at points in the load path between the car body and truck frame.
3.3.1 The longitudinal load, equal to 0.25 P, shall be taken as acting on the neutral axis (or, for
test, on a line 5 in. below the center plate bearing surface), and shall be applied only at the center
of the bolster.
3.3.2 The transverse load shall be taken as acting at the center plate equally distributed to the
pedestals on one side where the bearing adapter seats, and shall be 0.2P.
3.4 A stress analysis shall be performed using a finite element computer program. A static analy-
sis is to be performed using the loads as specified in paragraphs 3.2 and 3.3. The maximum verti-
cal, longitudinal, and transverse stresses in the designs shall not exceed 30% of the yield strength
of the steel when considered separately and 38% of the yield strength of the steel when considered
in combination. A submission for approval is to include a description of the computer program
model, including the following:
• description of the structural model
• model drawing
• assumptions used in the modeling of the structure
• boundary conditions used
• summary of the resulting stresses and deflections
3.5 A fatigue design analysis shall be made of the structure in accordance with the AAR Manual
of Standards and Recommended Practices, Section C, Part II, Specification M-1001, Chapter 7,
“Fatigue Design of New Freight Cars.” Applied loads for this analysis should be the road environ-
ment spectrum data contained in the guidelines, where applicable, or similar data obtained from
separate over-the-road tests. Assumed road environment data and supporting fatigue calculations
are to be provided.
3.6 No change in the design, materials, manufacturing procedures, or configuration of an
approved fabricated truck may be made without formal written approval of AAR.
4.1 At least two specimens of each new design shall be tested in a suitable static testing machine
under the supervision of a representative of the Brake Systems Committee. The two specimens
selected shall be a good average product.
4.2 The truck frames shall comply with the static test requirements of Specification M-202,
Table 4.2. The vertical, longitudinal, and transverse tests shall be made separately. The vertical
loads shall be applied first at the side bearing and then at the center plate. The same specimen
may be used for the longitudinal, transverse, and two vertical loading tests.
4.3 Table 4.1 lists the basis for computing test loads.
Table 4.1 Static tests
Vertical Vertical
Longitudinal Transverse
Side Bearing Center Plate
Load for zero setting of instruments 5000 5000 5000 5000
Additional load for maximum deflection .95P .30P 1.43P 1.43P
Load for maximum permanent set 1.9P .6P 2.38P 2.85P
Ultimate load minimum — — — 5.22P
S [M-213] 298 10/2010

M-213
4.4 The following are values from paragraph 4.3 as used in actual testing:
5 1⁄2 × 10 6 × 11 6 1⁄2 × 12 7 × 12
Load 0.3P (Deflection) 29,000 35,000 41,000 48,200
0.6P (Set) 48,000 60,000 72,000 86,400
0.95P (Deflection) 82,000 101,000 120,000 143,000
1.43P (Deflection) 120,000 149,000 177,500 212,000
1.9P (Set) 154,000 192,000 230,000 276,000
2.38P (Set) 192,000 240,000 287,500 345,000
2.85P (Set) 231,000 288,000 345,000 414,000
5.22P Ultimate 423,500 528,000 632,500 759,000
Test requirements
Wheelbase Maximum Deflection or Set
.075 in. maximum (longitudinal) deflection for a load of .95P
.025 in. maximum (longitudinal) permanent set for a load of 1.90P
5 ft 6 in. .070 in. maximum (transverse) deflection for a load of .3P
.001 in. maximum (transverse) permanent set for a load of .6P
5 ft 6 in. .080 in. maximum (side Bearing) deflection at center for a load of 1.43P
5 ft 8 in. .980 in. maximum (side bearing) deflection at center for a load of 1.43P
.025 in. maximum (side bearing) permanent set for a load of 2.85P
5 ft 6 in. .127 in. maximum (center plate) deflection for a load of 1.43P
.025 in. maximum (center plate) permanent set for a load of 2.85P
5.22P minimum ultimate load
4.5 Values for deflection and permanent set are based on AAR Grade B steel having minimum
yield strength of 38,000 psi and ultimate of 70,000 psi. If material of other strengths is used, max-
imum allowable deflections shown above must be multiplied by a correction factor F determined by
the following equation:
YS × E-
F = ------------------
912,000
where
YS = yield strength of material
E = percentage elongation in 2 in.
10/2010 S [M-213] 299
M-213
4.6 The deflection measuring instruments shall be located midway between supports of specimen
and shall be set at zero under an initial load of 5000 lb. In the vertical test only, a load of 20,000 lb
shall be applied to the center plate and then released to 5000 lb for the zero setting of instruments.
4.7 Strain gauges (rosettes) are to be applied at critical locations, as determined by the stress
analysis and strains recorded. Strains within the elastic range are to be converted to stresses. Tab-
ulation showing calculated stresses and test stresses is to be provided.
5.0 LOADING DIAGRAMS FOR STATIC AND DYNAMIC TESTS
5.1 Test loadings are to be applied as illustrated in the following figures:
Fig. 5.1 Lateral (transverse loading)

Fig. 5.2 Longitudinal loading at center plate (static)
Fig. 5.3 Vertical (static) loading
Fig. 5.4 Vertical loading on center plate and side bearings (dynamic)
Fig. 5.5 Twist (torsional) (dynamic) loading
LOADING BLOCK
LENGTH OF WHEELBASE
Fig. 5.1 Lateral (transverse loading)
S [M-213] 300 10/2010

M-213
LOADING
BLOCK
Fig. 5.2 Longitudinal loading at center plate (static)
EQUAL EQUAL
LOADING
Fig. 5.3 Vertical (static) loading

10/2010 S [M-213] 301
M-213
Z´
S
GQ
C Z
S
S
Fig. 5.4 Vertical loading on center plate and side bearings (dynamic)
T T
T
Fig. 5.5 Twist (torsional) (dynamic) loading
6.0 DYNAMIC TESTS
6.1 For approval, two representative truck frames shall be submitted for fatigue tests on such
machines as shall be approved by the Brake Systems Committee with such tests under supervi-
sion of a representative of that Committee.
6.2 Load Positions
6.2.1 The frame shall be positioned in a fixture where vertical loads can be applied as illustrated
in Fig. 5.4 at positions, Z1, G, Q, C, and Z. The load is reacted at the pedestals at positions S. The
loads applied at positions Z1 and Z are 25 in. on each side of the center pin (Q) position. The loads
acting at these positions shall be applied through a block bolted to the frame, which is representa-
tive of conventional side bearings. The loads acting at positions G, Q, and C shall be applied
through a simulated standard AAR car body center plate with 3° chamfer. Positions S are schemat-
ically shown at the center of the pedestal roofs and may be spherically crowned surfaces of approx-
imately 50-in. radius, and are all in the same plane for the vertical loading tests.
6.2.2 For the twist test, the frame shall be positioned in a fixture where vertical loads shall be
applied to two diagonal corners of the frame directly over the center of the pedestals and supported
at the remaining diagonal pedestals as shown in Fig. 5.5.
S [M-213] 302 10/2010

M-213
6.3 Description of Cyclic Loadings

The fatigue test shall consist of applications of the following types of cyclic loads:
6.3.1 Rock Load
A sinosoidal vertical load R shall be moved alternately through position Z1, Z, Z1, Z, etc. To
mechanically stabilize the loading means, an additional load may be applied on the center plate at
all times.
6.3.2 Bounce Load
The bounce load shall be applied vertically to center plate areas only. The application of the bounce
load shall follow a sinosoidal path according to the load sequence shown in Table 6.1 To complete
this bounce load sequence, additional full center plate loadings shall be applied at Position Q,
varying from B-2 to B-1 magnitude.
6.3.3 Simulation
The number of loads at Q shall equal the total number of loads at positions C and G.
Table 6.1 Bolster load sequence
Load Position of Load
Magnitude Line of Action
B-2 G
B-1 G
B-2 G
B-2a/ Qa/
B-2 C
B-1 C
B-2 C
B-2a/ Qa/
B-2 G etc.
a/ Optional
6.3.4 Twist Load

Equal loads shall be simultaneously applied to diagonal corners while opposite corners are sup-
ported at the pedestals and then released, continuing for the required number of cycles. To
mechanically stabilize the loading means and the frame, an additional vertical load may be
applied at the corners where loadings are applied.
10/2010 S [M-213] 303

M-213
6.4 Load Magnitudes

6.4.1 The magnitudes of the cyclic bounce and rock loads are given in Table 6.2.
Table 6.2 Minimum bounce and rock bolster loads
Size of Journal (in.) B-1 (lb) B-2 (lb) R (lb)
5 1⁄2 × 10 191,000 27,000 85,000
6 × 11 238,000 33,000 110,000
6 1⁄2 × 12 285,000 40,000 130,000
7 × 12 342,000 48,000 155,000
6.4.2 The magnitude of the twist load shall be sufficient to cause a twist in the frame of 3° simu-
lating one wheel dropping 3 in. below the rail elevation of the other three wheels.
If the frame rests on a spring suspension rather than directly on the journals, it will be necessary
to determine the load required from calibration of the springs and torsional stiffness of the frame.
Thus, the angle caused by the differential height of the springs added to the twist in the frame
must equal 3°. Calculation and calibration charts must be submitted from test results to verify the
procedure.
6.5 Cyclic Load Applications
The fatigue test shall consist of each type cyclic load listed in paragraph 6.3 and shall be done in
the quantity and order as listed in Table 6.3.
Table 6.3 Minimum cycle requirements
Loads Cycles
Rock load 175,000
Bounce load (center plate edge) 262,500
Bounce load (center plate center) 262,000
Twist load 500,000
Total cycles 1,200,000
6.6 Performance Requirement

6.6.1 Cyclic loads shall be applied until the truck frame fails or until the total cycles required in
Table 6.3 have been exceeded.
6.6.2 Failure is defined as the occurrence of one of the following conditions:
6.6.2.1 The inability of the frame to support the B-1 or R load.
6.6.2.2 Permanent deflection exceeding 3⁄8 in.
6.6.2.3 A critical crack—any break in the parent metal or weld that has definite direction and a
minimum length of 1⁄4 in. The crack must work under test when sprayed with mineral spirits or
suitable liquid. A crack is considered longitudinal and non-critical if it extends lengthwise of the
member in which it is located.
For official recognition, a transverse crack must be 1⁄4 in. in length and must show 1⁄4 in. additional
progress transversely. Also, a transverse crack shall be recorded as critical at that number of load-
ings when it has progressed 1⁄4 in. after initial recognition.
6.6.2.4 Any crack that, if discovered in service, would lead to condemnation of a truck frame for
service.
S [M-213] 304 10/2010

M-213
7.0 MARKING
7.1 All approved frames shall be legibly marked as follows:
7.1.1 Coded Designs
Practices, Section S, Part II, Standard S-392.
7.1.2 All Designs
Apply the identification number as follows:
STRUCTURAL STEEL—AAR S-0000
7.2 The markings specified above, when properly applied by the manufacturer, will serve as a
positive means of certifying that the design has been approved, and, by reference, the exact date of
approval can be ascertained.
7.3 The markings specified in paragraphs 7.1.1 and 7.1.2, in addition to those required by other
AAR specifications, are to be stamped on a builder’s badge plate that is riveted to the frame at a
neutral axis or other non-critical area. Each frame shall bear a serial number.
10/2010 S [M-213] 305

Casting Details
M-213
S [M-213] 306 10/2010

M-214
SIDE FRAMES AND BOLSTERS, USED AND

RECONDITIONED—CLASSIFICATION AND REPAIR PROCEDURE
Specification
M-214

1.0 SCOPE
1.1 These specifications cover the classification (inspection) and repair procedures for used and
reconditioned, AAR-approved, four-wheel truck side frames and bolsters. It is intended that these
procedures will be followed for all truck casting repair except running repair, which is covered by
the Field Manual of the AAR Interchange Rules, Rules 47 and 48.
Running repairs are interpreted to be those repairs performed on repair tracks to correct specific
defects for the safe operation of the car as differentiated from repair to restore service life into the
castings. Whenever castings are removed from the car for reconditioning, the work must be done
in full compliance with these specifications.
Alternate procedures will be considered provided a detailed proposal is submitted to the AAR for
approval.
1.1.1 AAR-approved truck side frame and bolster designs are those that have been approved by
the Equipment Engineering Committee in compliance with Specification M-203, “Truck Side
Frames, Cast Steel—Design and Testing,” and Specification M-202, “Truck Bolsters, Cast or Struc-
tural—Design and Testing.”
1.1.2 In addition, the requirements of the following AAR specifications must be satisfied:
• Specification M-201 “Castings, Steel”
• Specification M-210 “Side Frame and Bolsters, AAR Approved—Purchase and Acceptance”
• M-1003 “Specification for Quality Assurance”
Note: Relative to the former two specifications, the requirements of M-1003 take prece-
dence.
1.2 Definitions (page 1 of 2)
For purposes of this specification, the following definitions and control will apply.
Used Any side frame or bolster that has been in service.
Secondhand Any used component or assembly that meets the requirements of
paragraph 3.0 of this specification. A used component, once classified
as secondhand, may be placed in service without reconditioning.
Reconditioned Any component that meets the requirements of paragraph 4.0 of this
specification.
Scrap Any component prohibited by the Field Manual of the AAR Inter-
change Rules or that cannot be classified as per paragraphs 2.0, 3.0, or
4.0 of this specification.
New Any component not previously used.
Proprietary Those features of a side frame or bolster that are unique to a specific
truck design for which repair and maintenance requirements are pro-
vided by the truck designer.
Lateral direction A direction perpendicular to the track.
Longitudinal direction A direction parallel to the track.
Transverse Perpendicular to the long axis of the component.
10/2010 S [M-214] 307

M-214
1.2 Definitions (page 2 of 2)

Running repairs Those repairs performed on repair tracks to correct specific defects for
the safe operation of the car as differentiated from repair to restore
service life into the castings.
Crack Any fracture without complete separation into parts.
1.3 Facility Approval
1.3.1 General
All facilities that classify and/or recondition side frames and bolsters must be approved under the
provisions of this specification as outlined in subsequent paragraphs and will be subject to the pro-
visions contained therein. Such facilities will be considered as either “Classification” or “Recondi-
tioning” facilities.
1.3.2 Classification Facilities
1.3.2.1 Classification facilities must be capable of performing all functions and ensuring compli-
ance with the provisions listed in paragraphs 2.0 and 3.0 of this specification. An application must
be submitted in accordance with the provisions of Appendix A. Classification facilities will not be
subject to the inspection and certification requirements of AAR Manual of Standards and Recom-
mended Practices, Section J, Specification M-1003, “Specification for Quality Assurance.”
1.3.2.2 All welders must be qualified in accordance with AWS D15.1, latest revision.
1.3.3 Reconditioning Facilities
1.3.3.1 All facilities reconditioning AAR-approved side frames and bolsters must be approved by
the AAR Coupling System and Truck Castings Committee (CSTCC). The basis for approval shall
be satisfactory compliance with the provisions of this specification, including the provisions for
classification and, where applicable, for secondhand acceptance.
1.3.3.2 All facilities desiring an “approved” status must submit an application to the AAR Cou-
pling System and Truck Castings Committee (CSTCC), Association of American Railroads, as out-
lined in Appendix A.
1.3.3.3 Upon attaining approved status, facilities must grant an AAR representative free entry at
all times to all parts of the facility. This access is for the purpose of providing assurance that indus-
try standards are being maintained. The facility must afford the AAR representative all reason-
able facilities to ensure that materials are being furnished in accordance with this specification.
1.3.3.4 Inspections may be conducted biennially, and will include, but not be limited to, the
requirements of Appendix B of this specification. The cost of inspection will be borne by the facil-
ity.
1.3.3.5 The facility will be advised of inspection findings. If after review of these findings, a facil-
ity is considered not qualified for AAR approval, a reinspection and/or a reduction in the period of
approval may be required with the costs to be borne by the facility.
S [M-214] 308 10/2010

Casting Details
M-214
1.3.3.6 The AAR will publish at least annually a list of approved facilities. In the event a facility
is removed from the list, reapplication for approval will be required. Facilities may be removed
from this list for the following reasons:
1.3.3.6.1 For Cause
1.3.3.6.1.1 Consistent failure to maintain adequate quality control standards as evidenced by
inspections of castings in interchange service or non-compliance with appropriate specifications.
1.3.3.6.1.2 In the event a facility is removed from the approved list for cause, all material on
hand will be restricted from sale. The facility must provide the AAR with a listing of all completed
material on hand and the purchasers of all such material in the previous 6 months. The facility
must advise all purchasers who have received completed material that their approval has been
withdrawn.
1.3.3.6.2 Discontinued Production
A facility discontinues production for other than scheduled maintenance or other scheduled shut-
downs for a period exceeding 6 months.
1.3.3.6.3 Inspection Refusal
Refusal by a facility to accept an inspection scheduled under the provisions of this specification.
1.3.4 An inspection check list is provided in Appendix C and will serve as the basis for the inspec-
tion findings.
2.0 CLASSIFICATION PROCEDURE
2.1 All used side frames and bolsters removed from service must be classified before reapplying
to a car other than the one from which removed.
2.1.1 Side frames and bolsters must be removed from the truck for inspection and classification.
2.1.2 Parts must be clean and free of dirt, paint, rust, and scale that will interfere with gauging
and inspection.
2.1.3 Parts must be visually inspected for cracks, fractures, sections broken out, worn surfaces,
distortion, surface upset, and service notches.
2.2 Side frames and bolster castings over 30 years old, based on date cast, may be reconditioned,
but may be applied only with the permission of the car owner.
2.3 The following side frames and bolsters cannot be reconditioned:
2.3.1 Side frame and bolster patterns listed in Field Manual of the AAR Interchange Rules,
Rule 90 or Rule 47 must not be classified for further service and must be scrapped.
2.3.2 Parts with any crack, nick, gouge, or scrape in the unlined or uncrosshatched areas shown
in Fig. D.1 must be scrapped, except as follows:
2.3.2.1 Side frames with nicks, gouges, and scrapes of any size in spring seat support ribs, as
shown in Fig. D.1, or side frames with nicks, gouges, and scrapes not exceeding 1/8 in. depth and
not exceeding 6 in. in length lateral to the side frames, or not exceeding 20% of original thickness
and 3 in. in aggregate width with no limit on length longitudinal of the side frame.
2.3.2.2 Bolsters with nicks, gouges, and scrapes in the unlined and uncrosshatched areas that are
no more than 1/8 in. deep and that are either 1) transverse to long axis of bolster and no more than
6 in. long; or 2) parallel to long axis of bolster and of any length.
2.3.3 Parts not having pattern numbers, manufacturer’s marking, date cast, and either an AAR
identification number or code number.
10/2010 S [M-214] 309

Casting Details
M-214
2.3.4 Cast steel side frames and bolsters, repaired or reconditioned, that are fabricated by use of
components from other castings, plates, etc., except as permitted by AAR specifications.
2.3.5 Side frame with journal boxes designed for solid bearings any type.
2.3.6 Bolsters of 50-ton (5 1/2 × 10) or less capacity whose bowl depth is > 1 3/8 in. for nominal
1 1/8 in. bowl depth; or 70-ton (6 × 11) or greater capacity bolsters whose bowl depth is > 1 7/16 in.
for nominal bowl depth of 1 1/8 in.; 2 1/16 in. for nominal bowl depth of 1 3/4 in.; or 2 5/16 in. for
nominal bowl depth of 2 in. The measurement is taken from the top of the center plate rim to the
bearing surface, where this surface is the casting surface if no liner originally existed, or to the
liner surface if a horizontal liner originally existed. Care must be taken when measuring 16 in.
diameter center plate bowl depths because they have been furnished with original bowl depths of 1
1/8 in. and 1 3/4 in., with and without 1/4 in. horizontal liners, and with a bowl depth of 2 in., with
a 1/4 in. horizontal liner.
2.4 Each side frame and bolster must meet the appropriate functional dimensions of that design
and the appropriate gauges of Table D.1. Providing appropriate gauges shall be the responsibility
of the classifier. Tolerances must conform to Fig. D.6.
2.5 The results of inspection and gauging will determine if part is suitable for secondhand classi-
fication, may be reconditioned, or must be scrapped.
3.0 SECONDHAND ACCEPTANCE REQUIREMENTS
3.1 General
3.1.1 Part must be evaluated in accordance with procedure in paragraph 2.0.
3.1.2 Part must be free of cracks, fractures, sections broken out, and weld defects.
3.1.3 Identification of Classification Facilities
3.1.3.1 The part classified as secondhand must have identification paint stenciled on the casting
to indicate the classification facility’s report mark, date, and shop identification symbol arranged
in the following form:
Company marks: ABS
Shop identification symbol: AV
Date: 9-93
3.1.3.2 Paint-stenciled identification must be made in an area cleaned by grinding or other

means and must not be covered by subsequent painting of the component. Previous classification
or reconditioning markings must be removed.
3.2 Side Frames
3.2.1 Repair of secondhand side frames is limited to the following:
3.2.1.1 Application of side frame column friction wear plates per AAR Manual of Standards and
Recommended Practices, Section D, Standards S-320 or S-3003.
3.2.1.1.1 The face of the side frame column may be built up by welding if the column thickness is
5/16 in. or greater. One shim of mild steel or better, 1/8 in. to 3/16 in., may be used between the
hardened wear plate and the casting, and the use of hardened wear plates is allowed to restore the
column spacing. Hardened wear plates from 3/8 in. to 9/16 in. may be used. The length and width
of the shims must be the same as that of the wear plate. The combined thickness of the shim, if
used, and the wear plate must not exceed 9/16 in. Fig. D.7 defines the minimum final surface
requirement.
S [M-214] 310 10/2010

Casting Details
M-214
3.2.1.2 Roof of pedestal-type side frames may be repaired by any of the following:
3.2.1.2.1 Application of a wear liner in accordance with the requirements of AAR Manual of
Standards and Recommended Practices, Section S-II, Standard S-327 except that the EC-1157
gauge may be used in place of the EC-1090.
3.2.1.2.2 Application of proprietary pedestal roof liners approved by the AAR when applied in
accordance with manufacturer’s instructions.
OR
3.2.1.2.3 Restoration of pedestal roof by grinding or machining provided the remaining pad is not
less than flush with pedestal roof relief. The gauging requirements of MSRP Standard S-327 must
be met.
3.2.1.3 Brake beam wear plates.
3.2.1.4 Truck spring retainer modification.
3.2.1.5 Transverse nicks, scrapes, and gouges longer than 1 in. must be blended smooth with the
adjacent surfaces by grinding in a direction parallel to the long axis of the side frame.
3.2.1.6 When a side frame spring seat support rib is gouged, the gouge must be ground to a
blended contour. In extreme cases, the complete rib may be removed by grinding, if so desired.
However, the parent metal section must not be reduced more than 1/8 in.
3.2.2 Wear limits applicable to secondhand side frames are as follows:
3.2.2.1 Worn Column Guides
3.2.2.1.1 Side frame with column guides having 1/8 in. or less of lateral wear may be used as is. If
wear exceeds 1/8 in., the side frame must be restored to the functional dimensions contained in
AAR Manual of Standards and Recommended Practices, Section D-II. Column guides may be built
up if wear is 1/4 in. or less. Building up of worn column guides in Grade C material requires pre-
heat per paragraph 5.1.6 of this specification. Post-heat treatment is not required.
3.2.2.1.2 Side frames with column faces with total longitudinal wear between column faces of
1/4 in. or less need not be repaired. If wear exceeds 1/4 in., the side frame cannot be classified as
secondhand. (Longitudinal clearances are primarily a matter of wear of frame or bolster column
wear plates and bolster or frame column surfaces. See maintenance instructions from truck
designer.)
3.2.2.2 Side Frame Pedestal Wear
3.2.2.2.1 Side frame pedestal thrust lug longitudinal wear affecting the truck wheel base must be
gauged in accordance with AAR Manual of Standards and Recommended Practices, Section S-II,
Standard S-378. A side frame need not be repaired if its wheel base matches the buttons as origi-
nally manufactured. If the gauged wheel base does not match the buttons, the side frame cannot
be classified as secondhand. Side frame must have wheel base measured and nominal dimension
marked on side frame in accordance with AAR Standard S-378.
3.2.2.2.2 Side frames with pedestal thrust lug lateral wear less than a total of 1/8 in. need not be
repaired. If wear exceeds a total of 1/8 in., the side frame cannot be classified as secondhand and
must be reconditioned before reuse.
3.2.2.2.3 Side frames with pedestal roof wear < 1/16 in., gauged as shown in Fig. D.2 with the
EC-1200 gauge, need not be repaired. Side frames with pedestal roof wear ≥1/16 in., but < 3/16 in.,
as determined from the relief at each end of the roof pad, may be repaired in accordance with
paragraph 3.2.1.2. Side frames with pedestal roof wear > 3/16 in. cannot be repaired and must be
scrapped.
10/2010 S [M-214] 311

Casting Details
M-214
3.2.3 Side frames under visual inspection observed to be bent, twisted, or otherwise deformed
shall not be classified as secondhand.
3.2.4 Side frames classified as secondhand must have wheel base measured and the dimension in
inches (to the nearest whole inch) stamped in 3/8 in. or larger numerals adjacent to the side frame
matching buttons unless a number is already stamped or cast on.
3.3 Bolsters
3.3.1 Repair of secondhand bolsters is limited to the following:
3.3.1.1 Replacement of vertical or horizontal bolster center plate liners, metallic or non-metallic,
except when wear has occurred exceeding the limits specified in paragraph 3.3.2.2 on the vertical
and/or horizontal cast surfaces of the bolster center plate. If such wear has occurred, the bolster
cannot be classified as secondhand and must be reconditioned before reuse.
3.3.1.2 Application, in kind, of bolster friction pocket slope wear plates. This is a proprietary area
of the bolster and must be repaired in accordance with the truck designer’s or manufacturer’s
maintenance manual.
3.3.2 Wear limits applicable to secondhand bolsters are as follows:
3.3.2.1 Worn bolster gibs and lands, if applicable.
3.3.2.1.1 Bolsters with gibs having 1/8 in. or less of lateral wear as determined by the use of
gauge EC-1148, latest revision, as listed in Table D.1 and shown in Fig. D.5 or using gauges recom-
mended in the truck designer’s maintenance manual, need not be repaired. If wear exceeds 1/8 in.,
the bolster must be restored to the dimensions listed in Fig. D.5 or as provided in the truck
designer’s maintenance manual. Bolster gibs may be built up if wear is 1/2 in. or less. In addition
to the dimensions shown in the AAR Manual of Standards and Recommended Practices, Section D,
gibs on bolsters manufactured prior to January 17, 1987, may be restored to original dimensions,
which are provided in Fig. D.5 for the truck designs listed.
3.3.2.1.2 Bolsters with lands having 1/8 in. or less of longitudinal wear need not be repaired. If
wear exceeds 1/8 in., the bolster cannot be classified as secondhand and must be reconditioned
before reuse. Localized wear in the corners may exceed 1/8 in. providing it does not extend more
than 1 in. along the lands. (Longitudinal clearances are primarily a matter of wear of frame or bol-
ster column wear plates, friction shoes, and bolster or frame column surfaces. See maintenance
instructions from truck designer.)
3.3.2.2 Worn Bolster Center Bowls
3.3.2.2.1 A bolster need not be repaired if the diameter of the worn bolster bowl is ≤ 12 5/8 in. (for
12-in.-diameter bowl), or 14 5/8 in. (for 14-in.-diameter bowl), or 15 5/8 in. (for a 15-in.-diameter
bowl) or 16 5/8 in. (for 16-in.-diameter bowl). If these limits are exceeded, the bolster cannot be
classified as secondhand and must be reconditioned before reuse.
3.3.2.2.2 Bolsters of 50-ton (5 1/2 × 10) or less capacity need not be repaired if the depth of the
worn bolster bowl is < 1 9/32 in. for a nominal 1 1/8 in. bowl depth. Bolsters of 70-ton (6 × 11) or
greater capacity need not be repaired if the depth of the worn bolster bowl is 1 11/32 in. for a nom-
inal 1 1/8 in. bowl depth, 1 31/32 in. for a nominal 1 3/4 in. bowl depth, or 2 7/32 in. for a nominal
2 in. bowl depth. The measurement is taken from the top of the center plate rim to the bearing sur-
face, where this surface is the casting surface if no liner originally existed, or to the liner surface if
a horizontal liner originally existed. If these limits are exceeded, the bolster cannot be classified as
secondhand. Care must be taken when measuring 16-in.-diameter center plate bowl depths
because they have been furnished with original bowl depths of 1 1/8 in. and 1 3/4 in., with and
without 1/4 in. horizontal liners, and with a bowl depth of 2 in., with a 1/4 in. horizontal liner.
3.3.2.2.3 A bolster having cracked, broken, or missing vertical or horizontal liners shall not be
used as secondhand until replaced.
S [M-214] 312 10/2010
Casting Details
M-214
3.3.2.2.4 Oil retaining rings on bolster bowl must be removed.

3.3.3 Transverse nicks, scrapes, and gouges longer than 1 in. must be blended smooth with the
adjacent surfaces by grinding in a direction parallel to the long axis of the bolster.
3.3.4 Bolsters under visual inspection observed to be bent, twisted, or otherwise deformed shall
not be classified as secondhand.
3.4 Side frames and bolsters may be coasted with a light-bodied paint that will not prevent detec-
tion of flaws or cracks in ordinary inspection.
4.0 RECONDITIONED ACCEPTANCE REQUIREMENTS FOR REUSE
4.1 General
4.1.1 Part must be classified in accordance with procedure in paragraph 2.0.
4.1.2 Reconditioned side frames and truck bolsters must have accumulation of dirt, paint, rust,
and scale removed that will interfere with gauging and inspection.
4.1.3 Part must be free of cracks, fractures, sections broken out, and service notches, except as
permitted by this specification.
4.1.4 Surface upset (battered or rolled by wear) must be ground and blended to the surrounding
surfaces. This ground area must be free of cracks.
4.1.5 Reconditioning must be in accordance with paragraph 5.0, including the specified hardness
requirements.
4.1.6 Identification of Reconditioning Facilities
4.1.6.1 The part classified as reconditioned must have identification stamped on the casting
using at least 3/8 in. steel stencils to indicate reconditioning facility’s report mark, date, and shop
identification symbol arranged in the following form:
Company marks: ABS
Shop identification symbol: AV
Date: 9/90
4.1.6.2 Stamped identification must be made in an area smoothed by grinding or other means
before stamping, such area located on the side frame or bolster as shown in Fig. D.1 Previous
reconditioning stamp must be removed.
4.1.7 Reconditioned part must meet all of the requirements of this specification.
4.2 Side Frames
4.2.1 General Reconditioning Requirements
4.2.1.1 Repair is restricted to the lined and crosshatched areas shown in Fig. D.1 for side frames.
Appurtenances and proprietary features not shown in the outline must be repaired in compliance
with the designer’s maintenance manual.
4.2.1.2 Building up of worn surfaces in Grade B and Grade B+ material is permitted only in the
crosshatched area, provided the wear is 3/16 in. or less or, in the case of column guides, 1/4 in. or
less. Specific areas are addressed elsewhere in this specification or in designers’ maintenance
manuals and provide wear limits that are to be followed. Repair of cracks in Grade B and Grade
B+ material are permitted only in crosshatched areas, provided the cracks are not transverse to a
load-carrying member and are 1 in. or less in length. Heat treatment is not required.
10/2010 S [M-214] 313

Casting Details
M-214
4.2.1.3 Repair of cracks in Grade B and Grade B+ material is permitted in lined areas, provided
the cracks are not transverse to a load-carrying member and are 1 in. or less in length. Two or
more equal weld passes are required. Stress relief is not required.
4.2.1.4 Repair of cracks in Grade C material is permitted in crosshatched or lined areas, provided
the cracks are not transverse to a load-carrying member and are 1 in. or less in length. Preheat per
paragraph 5.1.6 is required. Stress relief per paragraph 6.1.5 of Specification M-210 is required.
4.2.1.5 Building up of worn surfaces in Grade C material is permitted only in the crosshatched
areas, provided the wear is 3/16 in. or less or, in the case of the column guides, 1/4 in. or less. Spe-
cific areas are addressed elsewhere in this specification or in the designers’ maintenance manuals
and provide wear limits that are to be followed. Preheat per paragraph 5.1.6 is required. Post-heat
treatment is not required.
4.2.1.6 No welding is permitted except in the crosshatched or lined area as shown in Fig. D.1.
4.2.1.7 Heat treating must not be performed after application of any wear plate or liner. Liners or
wear plates must be removed before heat treatment.
4.2.2 Application of Wear Plates
4.2.2.1 Existing side frame column friction plates meeting AAR Manual of Standards and Rec-
ommended Practices, Section D, Standards S-320 or S-3003, may be retained, provided spacing
between the wear plates is within the acceptable tolerances for reconditioned side frames and nei-
ther wear plate is worn more than 1/16 in. Application of new column wear plates is to be per AAR
Standards S-320 or S-3003. Weld-only applications are prohibited unless the design and procedure
are approved by the AAR for that particular applicant.
4.2.2.1.1 The face of the side frame column may be built up by welding if the column thickness is
5/16 in. or greater. One shim of mild steel or better, 1/8 in. to 3/16 in., may be used between the
hardened wear plate and the casting, and the use of hardened wear plates is allowed to restore the
column spacing. Hardened wear plates from 3/8 in. to 9/16 in. may be used. The length and width
of the shims must be the same as that of the wear plate. The combined thickness of the shim, if
used, and the wear plate must not exceed 9/16 in. Fig. D.7 defines the minimum final surface
requirement for mounting shims or wear plates.
4.2.2.2 Roof of pedestal-type side frames must be ground or machined smooth and must be
repaired by applying a wear liner as shown in AAR Manual of Standards and Recommended Prac-
tices, Section S-II, Standard S-327 (except that the EC-1157 gauge may be used in place of the
EC1090) if the wear vertically is > 1/16 in. and if either of the following conditions apply:
4.2.2.2.1 It replaces a similar worn liner previously applied on new or repaired pedestal roof.
OR
4.2.2.2.2 With no wear liner, the amount of wear vertically is 3/16 in. or less, as determined from
the relief of each end of the roof pad. For configuration and application procedure, refer to MSRP
Standard S-327.
4.2.2.2.3 If neither of these conditions apply, the side frame must be scrapped.
4.2.2.2.4 Proprietary pedestal roof liners approved by the AAR may be used when applied in
accordance with the manufacturer’s drawing.
S [M-214] 314 10/2010

Casting Details
M-214
4.2.3 Restoration of Worn Surfaces

4.2.3.1 Side frame column guides must be restored to the functional dimensions as shown in AAR
Manual of Standards and Recommended Practices, Section D-II. Nonfunctional details need not be
restored.
4.2.3.1.1 Lateral surfaces are to be restored to provide truck gib clearances per AAR Manual of
Standards and Recommended Practices, Section S-II, Standards S-301, S-302, and S-304.
4.2.3.1.2 Longitudinal clearances are primarily a matter of wear of frame or bolster column wear
plates and bolster or frame column surfaces. See maintenance instructions from truck designer.
4.2.3.1.3 Renewal of side frame friction pocket slopes either by weld or by application of slope
wear plates. This is a proprietary area of the side frame and must be reconditioned per designer’s
maintenance manual.
4.2.4 Side frame structural members under visual inspection observed to be bent, twisted or oth-
erwise deformed shall not be straightened or reconditioned.
4.2.5 Side frames reconditioned must have wheelbase measured and the dimensions in inches (to
the nearest whole inch) stamped in 3/8 in. numerals adjacent to the side frame matching buttons
unless a number is already stamped or cast on.
4.2.6 Thrust lug must be restored to dimensions shown in MSRP Section-II, Standard S-325.
4.2.7 Transverse nicks, scrapes, and gouges longer than 1 in. must be blended smooth with the
adjacent surfaces by grinding in a direction parallel to the long axis of the side frame.
4.2.8 When a side frame spring seat support rib is gouged, the gouge must be ground to a blended
contour. In extreme cases, the complete rib may be removed by grinding, if so desired. However,
the parent metal section must not be reduced more than 1/8 in.
4.2.9 To allow for removal of snow and ice, side frame brake beam guides may be modified in
accordance with guidelines established by the side frame manufacturer or by a procedure
approved by the Equipment Engineering Committee.
4.3 Bolsters
4.3.1 General Reconditioning Requirements
4.3.1.1 Repair is restricted to the lined and crosshatched areas shown in Fig. D.1 for bolsters.
Appurtenances or proprietary features not shown must be in compliance with designer’s mainte-
nance manuals.
4.3.1.2 Building up of worn surfaces in Grade B and Grade B+ material is permitted only in
crosshatched areas, provided the wear is 3/16 in. or less. Specific areas are addressed elsewhere in
this specification or in the designers’ maintenance manuals and provide wear limits that are to be
followed. Repair of cracks in Grade B and Grade B+ material is permitted only in crosshatched
areas, provided the cracks are not transverse to a load-carrying member and are 1 in. or less in
length. Friction pockets may be built up in accordance to the guidance provided by truck designers’
maintenance manuals. Bolster rim may be built up if thickness at base is 5/8 in. or greater as mea-
sured at the level of the horizontal casting surface. If the rim thickness is < 5/8 in., the rim must be
replaced by a method that will restore the original strength and contour. If the repair design
requires a hardened ring, that ring shall meet the requirements of the AAR Manual of Standards
and Recommended Practices, Section D, Standard S-305. Bolster gib may be built up if wear is 1/2
in. or less. Heat treatment is not required.
4.3.1.3 Repair of cracks in Grade B and Grade B+ material is permitted in lined areas, provided
cracks are not transverse to a load-carrying member and are 1 in. or less in length. Two or more
equal weld passes are required. Stress relief is not required.
10/2010 S [M-214] 315

Casting Details
M-214
4.3.1.4 Repair of cracks in Grade C material is permitted in crosshatched or lined areas, provided
the cracks are not transverse to a load-carrying member and are 1 in. or less in length. Preheat per
paragraph 5.1.6 is required. Stress relief per paragraph 6.1.5 of Specification M-210 is required.
4.3.1.5 Building up of worn surfaces in Grade C material is permitted only in cross-hatched
areas, provided the wear is 3/16 in. or less. Specific areas are addressed elsewhere in this specifica-
tion or in the designers’ maintenance manuals and provide wear limits that are to be followed.
Friction pockets may be built up if wear is 1/4 in. or less or as allowed by truck designers’ mainte-
nance manuals. Bolster rim may be built up if thickness at base is 5/8 in. or greater as measured
at the level of the horizontal casting surface. If the rim thickness is < 5/8 in., the rim must be
replaced by a method that will restore the original strength and contour. If the repair design
requires a hardened ring, that ring shall meet the requirements of MSRP Section D, Standard
S-305. Bolster gib may be built up if wear is 1/2 in. or less. Preheat per paragraph 5.1.6 is
required. Heat treatment is not required.
4.3.1.6 Side bearing attachment, if originally secured by welding, does not require heat treat-
ment of bolsters when rewelded unless it is Grade C material, which requires a minimum of 300 °F
local preheat in accordance with paragraph 5.1.6.
4.3.1.7 No welding is permitted except in the crosshatched or lined areas shown in Fig. D.1.
4.3.1.8 Heat treating must not be performed after application of any wear plate, liner, or side
bearing cage. Wear plates, liners, or side bearing cages must be removed before heat treatment.
4.3.1.9 Transverse nicks, scrapes, and gouges longer than 1 in. must be blended smooth with the
adjacent surfaces by grinding in a direction parallel to the long axis of the bolster.
4.3.2 Application of Wear Liners
4.3.2.1 Bolster center plate liners are to be replaced in kind unless authorized by owner. Applica-
tion is to be made per MSRP Section D, Standard S-305.
4.3.2.1.1 Bolsters of 50-ton (5 1/2 × 10) or less capacity originally furnished without center plate
horizontal liners and whose bowl depth is ≤ 1 3/8 in. for nominal 1 1/8 in. bowl depth; or bolsters of
70-ton (6 × 11) or greater capacity originally furnished without center plate horizontal liners and
whose bowl depth is ≤ 1 7/16 in. for nominal 1 1/8 in. bowl depth or ≤ 2 1/16 in. for nominal
1 3/4 in. bowl depth, must have the center bowl horizontal surface restored per MSRP Section D,
Standard S-305. The measurement is taken from the top of the center plate rim to the casting hor-
izontal bearing surface. A center plate horizontal liner must then be applied to provide the appro-
priate bowl depth.
4.3.2.1.2 The bowl depth for reconditioned bolsters of 50-ton (5 1/2 × 10) or less capacity must be
> 1 1/16 in., but < 1 9/32 in. The bowl depth for reconditioned bolsters of 70-ton (6 × 11) or greater
capacity must be > 1 1/16 in. but < 1 11/32 in. for a nominal bowl depth of 1 1/8 in.; > 1 11/16 in.
but < 1 31/32 in. for a nominal 1 3/4 in. bowl depth; and > 1 15/16 in. but < 2 7/32 in. for a nominal
2 in. bowl depth. The measurement is taken from the top of the center plate rim to bearing surface,
where this surface is the casting surface if no liner is to be applied, or to the liner surface if a hori-
zontal liner is applied.
4.3.2.1.3 Oil retainer rings on bolster bowl must be removed.
4.3.2.2 Renewal of bolster friction pocket slopes must be made either by weld or by application of
slope wear plates. This is a proprietary area of the bolster and must be reconditioned per
designer’s maintenance manual.
S [M-214] 316 10/2010

Casting Details
M-214
4.3.3 Restoration of Worn Surfaces

4.3.3.1 Bolster lands must be restored to the functional dimension as shown in MSRP Section
D-II. Nonfunctional details need not be restored. Bolster gibs must be restored in accordance with
the dimensions listed in Fig. D.5 or as provided in the truck designer’s maintenance manual. Bol-
sters manufactured prior to January 1, 1987, may be restored to original dimensions, which are
provided in Fig. D.5 for the truck designs listed, except that new cars must have bolsters restored
to the new standard. Bolsters for the listed designs that are manufactured after January 1, 1987,
must be maintained to the new standard. Bolster center bowl diameters must be restored to origi-
nal dimensions with tolerances allowed by Fig. D.6.
4.3.3.1.1 Gauging per EC-1148, latest revision, listed in Table D.1 and shown in Fig. D.5 or as
recommended in the truck designer’s maintenance manual, provides bolster gib restoration
requirements.
4.3.3.1.2 Longitudinal clearances are primarily a matter of wear of frame or bolster column wear
plates, friction shoes, and bolster or frame column surfaces. See maintenance instructions from the
truck designer.
4.3.3.1.3 Fig. D.3 shows the suggested method for application of new gibs, wear plates, and cast
integral horizontal lever support.
4.3.4 Bolster structural members that, under visual inspection, are observed to be bent, twisted,
or deformed shall not be straightened or reconditioned.
4.4 Painting
Side frames and bolsters may be coated with light-bodied paint that will not prevent detection of
flaws or cracks in ordinary inspection.
5.0 INSTRUCTION FOR RECONDITIONING
5.1 Welding
5.1.1 Repairs of components and building up of worn surfaces may be made by welding, using
procedures and welders qualified in accordance with the welder qualification procedures contained
in AWS D15.1, latest revision. The flat-down hand position is preferred, but other positions for
which the welder is qualified may be used.
5.1.2 Fabrication of a casting by welding is prohibited, except as permitted by AAR specifications.
5.1.3 The entire defect must be removed prior to weld repair.
5.1.4 Preparation
The edges of the piece to be welded must be prepared as shown in Fig. D.4a or Fig. D.4b. If both
sides of the fractured member can be worked upon, the fracture should be prepared as in Fig. D.4a.
When only one side of the fractured member is accessible, Fig. D.4b must be followed. The entire
crack must be removed by flame cutting or other suitable means so that no portion of the crack
remains. The surfaces upon which new material is to be deposited must be clean and reasonably
smooth.
10/2010 S [M-214] 317

Casting Details
M-214
5.1.5 Weld Contour

Completed welds should follow the contour shown in Fig. D.4c or Fig. D.4d. Heavy reinforcement is
neither necessary nor desirable. The weld should be so finished as not to produce a notch effect at
the junction of the weld with the parent material, and every precaution should be taken to avoid
abrupt changes in section thickness at the line of fusion.
5.1.6 Casting may be uniformly or locally preheated to ensure crack-free welds. Under no condi-
tion will welding be performed when the casting temperature is below 40 °F (4 °C). If local pre-
heating is done, the casting shall be preheated to a temperature of between 300 °F and 600 °F, and
the welding shall be accomplished while the area to be welded is maintained at a temperature
above 300 °F. The temperature of the casting shall not exceed 600 °F to avoid the possibility of
warping.
5.1.7 Welding shall be performed with low-hydrogen-coated electrodes or flux core wire or by
gas-shielded welding process. Weld deposits shall provide mechanical properties equivalent to the
properties of the finished casting. For stick-arc welding of Grade B and Grade B+ steel,
AWS/ASTM electrode E7015, E7016, E7018, or equivalent may be used; for stick-arc welding of
Grade B+ castings, AWS/ASTM electrode E8015, E8016, E8018, or equivalent may be used; for
stick-arc welding Grade C castings, AWS/ASTM E9015, E9016, or E9018, or equivalent may be
used for higher mechanical properties after heat treatment. Electrodes must be stored in accor-
dance with AWS Specification D15.1, latest revision.
5.1.7.1 Tempering, if required, shall be done as follows: Heat in a closed furnace to between
1050 °F + 25 °F and hold at temperature for 1 hour.
5.1.7.2 Castings must be grit or shot blasted for cleaning after any heat treatment above the crit-
ical temperature.
5.1.8 Documentation
The reconditioner is required to develop and document heat treating standards that describe the
processes, process control procedures, and record-keeping requirements. These documents are to
be presented and reviewed as part of the approval process and are intended to ensure that castings
are properly heat treated. Furnace temperatures for heat treatment shall be controlled by pyrome-
ters having associated recording equipment that produces time-temperature record charts that are
identified by date and furnace number. A log sheet shall be maintained for each heat-treat load
that includes the type of product, the prescribed heat treatment, and the actual time of heat treat-
ment. Alternate procedures will be considered, provided a detailed proposal is submitted in writ-
ing to the AAR for approval. This submission must ensure that the intent of this specification is
being complied with. Pyrometers shall be calibrated every 3 months. Records of time-temperature
charts, furnace log sheets, and pyrometer calibrations will be maintained for 3 years and made
available upon request.
5.2 When any modifications are done to a side frame or bolster that change the AAR code num-
ber, the new AAR code number shall be applied by grinding off the digits to be changed and apply-
ing new digits in a workmanlike manner by electric arc welding using a maximum
1/8-in.-diameter electrode. Subsequent heat treatment is not required for pencil welding of code
number changes. Markings other than the AAR code number are not to be modified or altered in
any manner, with the exception of the casting date, which may be relocated if modifications such
as change of side bearing location require relocation of the date in order for it to remain visible. It
also is permissible to add weld to an existing date to ensure visibility and prevent premature wear.
S [M-214] 318 10/2010

Casting Details
M-214 APPENDIX A
APPENDIX A
INSTRUCTIONS REGARDING APPLICATION FOR
STATUS AS AN APPROVED
CLASSIFICATION OR RECONDITIONING FACILITY
1.0 Application for status as an approved classification or reconditioning facility must be
submitted to the Chief—AAR Technical Standards.
2.0 Application must be accompanied by description or brochures that describe facilities and
processes and is to include detailed information on quality control procedures. If more than one
facility is involved, each must be fully described as a separate entity and applied for on an
individual basis. Application must include the company marks and shop identification symbol
required by paragraph 3.1.3.1 or paragraph 4.1.6.1.
3.0 Application must be accompanied by an advanced payment of $1,000. Application must state
that the applicant will reimburse the AAR for all costs that exceed the amount of the advanced
payment. In addition, application must be accompanied by a $200 non-refundable service fee
(non-members only).
4.0 The AAR will publish annually a list of approved facilities. In the event that a facility is
deleted from this list for cause, reapplication for approval will be required.
5.0 Approval status will be valid for a period of 2 years from the date of notice of approval. A
reinspection will be required prior to the expiration date in order to maintain the approved status.
It is the responsibility of the facility to initiate a request for reinspection 2 months in advance of
the expiration date. The request for reinspection must state that the applicant will reimburse the
AAR for all inspection expenses. In addition, application for reinspection must be accompanied by
a $1,000 advance payment.
6.0 Upon attaining approved status, facilities must grant an AAR representative free entry at all
times to all parts of the facility. This access is for the purpose of providing assurance that industry
standards are being maintained. The facility must afford the AAR representative all reasonable
support and assistance to ensure that materials are being furnished in accordance with this
specification.
7.0 Based on unsatisfactory inspection results or performance, a reinspection and/or a reduction
in the period of approval may be required.
8.0 Applicants requesting certification or recertification in accordance with the reconditioning
requirements of this specification must meet the requirements of AAR Manual of Standards and
Recommended Practices, Section J, Specification M-1003, “Specification for Quality Assurance.”
10/2010 S [M-214] 319

Casting Details
APPENDIX B M-214
APPENDIX B
AAR PROCEDURE FOR THE INSPECTION
OF RECONDITIONING FACILITIES
1.0 REQUIREMENTS
The AAR inspection program is designed to qualify and evaluate each reconditioner’s capability of
reconditioning castings to AAR specifications. This program is directed toward establishing a min-
imum acceptable level of performance and capability with respect to experience, procedure, ability,
and equipment to recondition castings of the required quality. Each reconditioner will be evaluated
on the following requirements during an inspection of the facilities by the AAR inspector:
1.1 Observe entire plant operation, with emphasis on procedures that affect quality and unifor-
mity of product.
1.2 Inspect production and quality control equipment and facilities to determine ability to meet
production requirements.
1.3 Interview supervisors with respect to procedures and methods used in production.
1.4 Interview workers with respect to knowledge of procedure and methods applicable to the
worker’s area.
1.5 Review results of inspection with plant management and advise if any deficiencies are noted.
1.6 Inspect representative samples of in-process work and finished products.
2.0 PROCEDURES
2.1 The reconditioning facility inspector should verify bolster and side frame reclamation done in
accordance with this Specification M-214.
2.2 Initial Inspection of Castings
Check gauging technique and visual inspection procedures. Reconditioning shop should have a
good understanding of critical and noncritical casting areas and how these relate to repair proce-
dures.
2.3 Removal of Casting Defects
Observe arc-air or oxy-acetylene scarfing methods for complete removal of defects before weld
repair.
2.4 Weld Repair of Defects
Verify that AWS welding electrodes, designated for the appropriate type of material, are used
exclusively for repairs. Verify that low-hydrogen electrodes are properly stored in ovens prior to
use. Welders should be tested and qualified in the positions in which welding is to be performed in
accordance with AWS D15.1, latest revision. Weld repairs must be free of any cracks.
2.5 Heat Treating of Grade C Castings After Welding
When required, heat treatment will be in conformance to this Specification M-214. Furnaces
should be adequate to ensure uniform temperature throughout. Temperature controls and record-
ing equipment should be in proper working order. Furnace calibration equipment should be
observed. Quenching tanks must have circulating capability, and equipment used to transfer parts
from furnace to quench tank should be in good condition. Reclaimer should have thorough knowl-
edge of heat treatment principles and types of heat treatment required depending on casting type.
S [M-214] 320 10/2010

Casting Details
M-214 APPENDIX B
2.6 Finishing
Observe finish grinding of castings to ensure surface discontinuities resulting from weld repair are
contoured to the surrounding surfaces.
2.7 Ascertain that gauges required by the applicable AAR specification are present and used
properly.
2.8 Quality Control
Discuss additional quality control steps taken by the reclaiming party to ensure proper workman-
ship. These may include the following:
• Gauge calibration procedures and documentation
• Failure analysis program. The reconditioner must be knowledgeable in the mechanics of
critical castings flaws that lead to failure.
• Organization policy with respect to the following:
• Proper separation between production responsibility and quality control responsibility.
• Procedure for resolving controversy between operations and quality control of non-con-
forming items.
• Disposition of non-conforming items.
2.8.1 Personnel
2.8.1.1 Procedures for qualifying workers for particular jobs. Training provided for new employ-
ees.
2.8.1.2 Procedures for qualifying supervisors and methods of training and determining perfor-
mance.
2.8.1.3 Determine if there are proper welding procedures and competent expertise in the plant to
perform welding tests and solve welding problems. Determine how and when welders are quali-
fied. Welder qualification papers are to be in the personnel files.
10/2010 S [M-214] 321

Casting Details
APPENDIX C M-214
APPENDIX C
CHECK LIST FOR THE APPROVAL OF FACILITIES TO
RECONDITION SIDE FRAMES AND TRUCK BOLSTERS
Indicate whether or not the facility has the following:
Item: Yes No
1. The physical capability to do the following:
• Clean components
• Inspect and classify components
• Restore functional dimensions by welding
• Machine/grind to required blueprint dimensions
• Confirm the accuracy of dimensional repairs made
• Heat treat castings, if required
• Paint, store, maintain records for delivery requirements
• Clean components
2. Maintenance manuals or other dimensional, material, and component reference data for the type (pattern)
of casting being reconditioned.
3. Identification of supplier certification procedures
4. Written procedures for the following:
• Inspection, identification, and segregation of incoming castings
• Acceptance/rejection criteria and limits
• Dismantling, modifying, or component removal
• Defining the necessary repair work to be done
• Performing the repair work, including welding
• Materials to be used (including part numbers and weld filler material)
• Verifying the integrity and dimensional accuracy of the reconditioned castings
• Controlling critical operations [welding parameters, dimensional inspection/layout, heat application,
heat treatment (if applied), etc.]
• Inspection, identification, and segregation of reconditioned product
• The training, testing, and certification of workers in critical occupations
5. A written or formal training program for employees in key operations with written notice or certificate of
completion
6. A requirement and program for the qualification of welders and non-destructive testing (NDT) employees, if
used
7. The required AAR-certified gauges for the types of castings being processed
8. An acceptable gauge control program for the maintenance and recertification of gauges, measuring devices,
and other test equipment as may be used in the reconditioning process
9. The latest issues of all AAR specifications and standards that concern the quality levels, dimensional
requirements, gauging, and processing limitations of new side frames and truck bolsters as well as the
Manual of Standards and Recommended Practices series that pertain specifically to the reconditioning of
these castings, including the welding, final inspection, and gauging of the reconditioned castings
S [M-214] 322 10/2010

Casting Details
M-214 APPENDIX D
APPENDIX D
TABLES AND FIGURES
1.0 SIDE FRAME AND BOLSTER ACCEPTANCE GAUGES
Table D.1 lists AAR standard gauges for side frames and bolsters. The gauge application figures
contained in this specification illustrate only application. Alternate gauge construction may be
used if the gauging method does not change.
Table D.1 Side frame and bolster acceptance gauges
Gauge
Application Gauge
Figure No. Number Gauge Description
AAR Specification M-210
Side Frames (4 1/2 × 8, 5 × 9, 5 1/2 × 10, 6 × 11, 6 1/2 × 12, and 7 × 12)
8.5 EC 1107–1 Wheel base gauge for side frames
8.4 EC 1107–2 Enlarged view of scale on wheel base gauge
8.7 EC 1120 Column “Go” gauge for side frames
8.8 EC 1121 Column “No-Go” gauge for side frames
Bolsters (4 1/4 × 8, 5 × 9, 5 1/2 × 10, 6 × 11, 6 1/2 × 12, and 7 × 12)
8.19 EC 1090–2 Application of key slot gauge and journal roof to key slot gauge for pedestal side frames
8.21 EC 1109 As-cast center plate go gauge for truck bolster
8.22 EC 1126 Center plate go gauge for truck bolster center plate wear liners
8.23 EC 1110 As-cast center plate no-go gauge for truck bolster
8.24 EC 1127 Center plate no-go gauge for truck bolster vertical ring wear liners
AAR Specification M-214
D.2 EC-1200 Side frame pedestal roof wear limits gauge
D.5 EC-1148-C Gauge for bolster gib restoration
EC-1157-A Pedestal roof to key slot gauge (may be used in lieu of EC-1090)
Table D.2 M-214 New gauge tolerances (where tolerances are not specified)
Critical gauged dimensions (underlined or listed as important).
Flatness tolerance as specified on the drawing.
Maximum tolerance of ±0.02 in. is allowed for all gauges under any and all conditions.
Noncritical gauged dimensions.
Flatness—All Gauges –0.000 in. to 0.010 in.
Size of Gauge (in.) Tolerance (in.)
0.000 to 4.000 ±0.031 (1⁄32)
4.001 to 12.000 ±0.047
12.001 to 48.000 ±0.062 (1⁄16)
48.001 to 96.000 ±0.125 (1⁄8)
96.001 and Greater ±0.188
Notes:
1. To provide for wear, gauge dimensions may vary from those on the gauge drawing in the direction and be
more restrictive on casting tolerances as provided in Fig. D.4 of this specification.
2. Worn gauges must be within the dimensions on the gauge drawing and the tolerances listed in Table D.2.
10/2010 S [M-214] 323
Casting Details
APPENDIX D M-214
Weld and heat treatments in specified side frame and bolster areas
Grade Steel B and B+ C
Two or more equal
Temper (localized or
Welds in lined area passes—no heat treatment
furnace temper)
required
Welds in
Heat treat optional Heat treat optional
crosshatched area
NOTES:
1. REPAIR IS RESTRICTED TO THE LINED AND CROSS-HATCHED AREAS.
2. THE REPAIR, REMOVAL, AND ADDITION OF SIDE FRAME SPRING RETAINERS IS ALLOWED AND IS LIMITED TO THE FLAT PORTION OF THE SPRING SEAT.
Fig. D.1 Prohibited service crack and weld repair areas and identification marking locations
S [M-214] 324 10/2010

Casting Details
M-214 APPENDIX D
Fig. D.2 EC-1200

Side frame pedestal roof wear limits gauge
10/2010 S [M-214] 325

Casting Details
APPENDIX D M-214
Fig. D.3 Application of new gibs, wear plates, and cast integral horizontal level support
S [M-214] 326 10/2010

Casting Details
M-214 APPENDIX D
Fig. D.4 Weld contour
10/2010 S [M-214] 327

Casting Details
APPENDIX D M-214
Line
Type of Truck A B C D E Marking
No.
1 Ride Control 9.500
5.12 2.750 1.25 2.38 70 and 100 ton
Ride Control
2 Barber S-2 Regular 7.500 1.50 .875 .75 .75 70 and 100 ton
AAR Standard S-2 Regular
for Bolsters Cast 3 Barber S-2 Wide Land 9.000 1.50 1.625 .75 .75 70 and 100 ton
after 01/01/1987 S-2 Wide Land
4 Barber S-2 Combination 9.500 1.50 1.875 .75 .75 100 ton
S-2 Combination
5 Barber S-2- HD 10.875 1.50 2.625 .75 .75 100 ton S-2-HD
6 Ride Control 9.375 5.12 2.500 1.25 2.39 70 and 100 ton
Ride Control
7 Barber S-2 Regular 7.375 1.50 .625 .75 .75 70 and 100 ton
AAR Standard S-2 Regular
Optional
8 Barber S-2 Wide Land 8.875 1.50 1.375 .75 .75 70 and 100 ton
for Bolsters Cast
S-2 Wide Land
after 01/01/1987
9 Barber S-2 Combination 9.375 1.50 1.625 .75 .75 100 ton
S-2 Combination
5 Barber S-2-HD 10.875 1.50 2.625 .75 .75 100 ton S-2-HD
NOTES:
1. FOR TRUCK DESIGNS NOT LISTED, SEE DESIGNER’S MAINTENANCE MANUAL.
2. APPLY GAUGE AS ILLUSTRATED IN EACH BOLSTER POCKET WITH GAUGE CONTACTING LAND SURFACES “X” AND “Y” AND POCKET INNER WALL “Z.” IF THE GAUGE
CANNOT BE APPLIED TO CONTACT SURFACES “X,” “Y,” AND “Z,” TRIM THE INNER SURFACE (S) OF EITHER THE OUTER OR INNER GIB TO PROVIDE THE NECESSARY
CLEARANCE.
3. WITH GAUGE IN POSITION, DETERMINE CLEARANCE BETWEEN GAUGE AND EACH GIB SURFACES “F” AND “G.” BUILD UP SURFACES “F” AND “G,” IF REQUIRED, BY
WELDING, TO PROVIDE .06 MAXIMUM CLEARANCE WITH GAUGE. GRIND EXCESS WELD DEPOSIT FLUSH WITH TOP, BOTTOM, AND OUTSIDE CASTING SURFACES.
APPLY GAUGE AT ALL FOUR POCKETS AND GIBS REWORKED WHERE REQUIRED.
4. SUGGESTED WELDING ELECTRODES: AWS CLASS E-7016, E-7018, E-9016, OR E-9016, OR EQUIVALENT WELDING WIRES. FOLLOW PREHEAT REQUIREMENTS OF
THE FIELD MANUAL OF THE AAR INTERCHANGE RULES, RULE 82. HEAT TREATMENT OF THE CASTING AFTER WELDING IS NOT REQUIRED.
5. UNDERSCORED DIMENSIONS ARE IMPORTANT.
Fig. D.5 EC-1148-C

Gauge for bolster gib restoration
S [M-214] 328 10/2010

M-214
10/2010
S [M-214] 329
Casting Details
TABLE OF TOLERANCES Aa/ B C Db/ E F H

TOLERANCE + (IN.) 3⁄16 1⁄8 1⁄8 5⁄32 3⁄32 3⁄16 1⁄16
TOLERANCE – (IN.) 3⁄16 1⁄16 1⁄16 1⁄16 1⁄32 1⁄4 1⁄8
a/ Must be gauged per Specification M-210, Figs. 8.3 and 8.4, and satisfy the requirements of
AR Manual of Standards and Recommended Practices, Section S-II, Standard S-378.
Fig. D.6 Dimension tolerances for reconditioned truck side frames and bolsters
b/ Within the specified +5⁄32 in. –1⁄16 in. tolerance range, distance between friction plates at bot-
tom shall not exceed +1⁄8 in. –1⁄16 in. relative to top.
APPENDIX D
APPENDIX D
S [M-214] 330
Casting Details
TABLE OF TOLERANCES Aa/ B C Db/ E F H I J

TOLERANCE + (IN.) 3⁄16 1⁄8 1⁄8 5⁄32 3⁄32 3⁄16 1⁄16 3⁄32 0
TOLERANCE – (IN.) 3⁄16 1⁄16 1⁄16 1⁄16 1⁄32 1⁄4 1⁄8 0 1⁄16
b/ Within the specified +5⁄32 in. –1⁄16 in. tolerance range, distance between friction plates at bot-
Fig. D.6 Dimension tolerances for reconditioned truck side frames and bolsters (page 2 of 5)
tom shall not exceed +1⁄8 in. –1⁄16 in. relative to top.
M-214
10/2010
M-214
10/2010
S [M-214] 331
Casting Details
TABLE OF TOLERANCES Aa/ B C Db/ E F H

TOLERANCE + (IN.) 3⁄16 1⁄8 1⁄8 1⁄8 3⁄32 3⁄16 1⁄16
TOLERANCE – (IN.) 3⁄16 0 1⁄16 1⁄8 1⁄32 1⁄4 1⁄8
b/ See designer’s drawings in MSRP Section S-II.
APPENDIX D
Casting Details
APPENDIX D M-214
1⁄8
H
0
1⁄16
1⁄8
Fa/
See maintenance instructions from truck designer.

1 1⁄2
1 1⁄2
E
1⁄16
1⁄16
D
1⁄16
1⁄8
C
1⁄16
1⁄16
B
1⁄16
1⁄8
A
TABLE OF TOLERANCES
TOLERANCE + (IN.)
TOLERANCE – (IN.)
a/
S [M-214] 332 10/2010

Casting Details
M-214 APPENDIX D
1⁄8
G
1⁄8 0
D
0
1⁄16
1⁄8
C
1⁄16
1⁄16
B
1⁄16
1⁄8
A
TABLE OF TOLERANCES
TOLERANCE + (IN.)
TOLERANCE – (IN.)
10/2010 S [M-214] 333

Casting Details
APPENDIX D M-214
NOTES:
1. DIMENSIONS “H” AND “W” VARY ACCORDING TO DESIGN AND SPRING TRAVEL. THE INTENT IS TO HAVE A 1⁄2-IN. BEARING SURFACE AROUND THE PERIMETER OF
THE WEAR PLATE APPLIED.
2. USE A STRAIGHT EDGE IN ALL DIRECTIONS ACROSS ALL SHADED AREAS TO ENSURE A PLANE AND FLAT SURFACE TO 1⁄32 IN.
3. IF NECESSARY ON GRADE B CASTINGS, APPLY WELD IN SHADED AREAS WITH E-7018 OR EQUIVALENT AND FINISH GRIND TO ACHIEVE SURFACE.
4. IF NECESSARY ON GRADE B+ CASTINGS, WELD IN SHADED AREAS WITH E-8018 OR EQUIVALENT AND FINISH GRIND TO ACHIEVE SURFACE.
5. ON GRADE C CASTINGS, USE E-9018 OR EQUIVALENT FOLLOWING PREHEAT GUIDELINES IN PARAGRAPH 5.1.6 AND FINISH GRIND TO ACHIEVE REQUIRED
SURFACE.
Fig. D.7 Minimum acceptable contact area for worn truck side frame column wear plate area—shown with wear plate
removed—typical bolted application
S [M-214] 334 10/2010

M-214
10/2010
S [M-214] 335
Casting Details
Fig. D.8 EC-1157-A

Pedestal roof to key slot gauge
51⁄2 × 10 6 × 11 61⁄2 × 12 7 × 12 REPAIR GAUGE APPLIED
A 8.375 9.000 10.000 11.125 WELDED LINER AFTER LINER
A´ 8.500 9.125 10.125 11.250 SNAP-ON LINER BEFORE LINER
NOTE: SURFACES MARKED “X” AND UNDERSCORED DIMENSIONS ARE IMPORTANT.

APPENDIX D
Casting Details
APPENDIX D M-214
S [M-214] 336 10/2010

10/2010
Casting Details
M-215
COUPLING SYSTEMS
Specification
M-215

1.0 SCOPE
This specification covers coupling system requirements to connect adjacent freight cars or units of
a multi-unit freight car for use in interchange service. This does not include AAR standard cou-
plers covered by Specification M-211. This includes the following applications:
1.1 Couplers that mate to AAR standard couplers.
1.2 One pivot systems: articulated connectors that support all or part of the car/unit load on a
suspension.
1.3 Two pivot systems: slackless drawbar systems, cushioned drawbar systems, reduced slack
coupling systems with integral draft/buff gear.
1.4 Couplers near to AAR standard couplers.
2.0 GENERAL REQUIREMENTS
2.1 Approval Submission
The manufacturer will provide eight sets of drawings and other informational items to the AAR,
Chief—Technical Standards, Transportation Technology Center, Inc., P.O. Box 11130, 55500 DOT
Road, Pueblo, CO 81001, for use by the AAR Cushioning and Draft Systems Committee. Addi-
tional copies may be requested if the system requires AAR Equipment Engineering Committee
evaluation. The manufacturer’s approval submission must address each of this specification’s
numbered paragraphs in sequential order. The AAR may choose to approve the proposed coupling
system components contingent upon the associated car design approval by the AAR Equipment
Engineering Committee.
2.2 Approval Drawings and Data
2.2.1 The manufacturer will provide appropriate drawings and related data showing and defin-
ing the following:
• System application including all related car or unit structure components
• The load path of buff, draft, vertical, lateral, and twist loads through the system compo-
nents from car to car
2.2.2 Drawings shall be provided on a proprietary basis for AAR evaluation.
2.3 System Definition
2.3.1 The manufacturer will clearly define the coupling system application range to include the
following:
• The cars to which the system is intended for use
• Whether the system will be used in full AAR interchange service
• A definition of the minimum vertical and horizontal curves that the system can negotiate
when applied to a car or unit whose design characteristics are compatible with the stated
range
• All applicable specified loads when applied to a car or unit whose characteristics are con-
sistent with the stated capabilities
10/2010 S [M-215] 337

10/2010
Casting Details
M-215
2.3.2 For one or two pivot systems as defined under paragraph 1.0, the maximum moment
allowed at the pivots, due to car angularity and yaw rotational resistance, shall not exceed the
requirements of AAR Manual of Standards and Recommended Practices, Section C, Part II, Speci-
fication M-1001.
2.4 System Description
A detailed system description will be provided, including a review of the slack in the system. Part
or component friction and wear characteristics will be provided on adjacent wearing parts having a
direct bearing on curving and load carrying system capabilities.
2.5 Materials
2.5.1 When AAR material is used in the approval request, the manufacturer will provide a list,
including all provisions contained in Specification M-201 and Specification M-211, pertaining to
casting requirements, inspection, repair, weld repair, internal solidity, and all material property
specifications.
2.5.2 When other than AAR material is used in the approval request, the manufacturer will pro-
vide the following:
2.5.2.1 A material list and the industry specifications to which they conform.
2.5.2.2 A list of welding and other assembly specifications required.
2.6 Markings shall be molded in rubber, cast on castings, and stamped on forgings in an area not
subject to wear or stress concentrations and, if possible, where they can be readily seen without
removal of the unit from the car. Each unit shall be legibly marked as follows: Manufacturer name,
unit, type designation, letters “AAR”, specification and date of issue or reissue of those specifica-
tions to which they conform, and month and year.
2.7 Maintenance Instructions
Preliminary maintenance instructions must be included and will define the following:
• A slack level that the system can provide and tolerate
• Wearing surfaces, part or component friction, and wear characteristics that will be pro-
vided on adjacent wearing parts having a direct bearing on curving and load carrying sys-
tem capabilities
• Dimensions subject to change
• Measurement means to monitor change
• Assembly/disassembly procedures
• Coupling and uncoupling procedures
• Lubrication plan, if required
3.0 DESIGN CRITERIA
3.1 General Requirements
A car or unit coupling system for application in full unrestricted general interchange service will
meet all applicable design criteria of the referenced specifications outlined herein. The AAR will
consider criteria deviations providing that the deviations are clearly explained and documented. If
the deviations are not acceptable for full unrestricted interchange service, limitations may be
imposed by the AAR. For designs that are not intended for full unrestricted general interchange
service, the manufacturer will do the following:
3.1.1 Clearly define the design parameters.
3.1.2 List any operational and other limitations that will pertain to the design, manufacturing,
and use of the coupling system.
S [M-215] 338 10/2010

10/2010
Casting Details
M-215
3.1.3 State the reason(s) for the limitations and, if deviations are requested, the proposed design
criteria and criteria basis.
3.2 Coupler Load
The system must meet the structural requirements of Specification M-211 or be consistent with
strength capability of systems as defined under paragraph 2.3.
3.3 Vehicle Performance
The system must meet all applicable criteria in MSRP Section C, Part II, Chapter 2, Specification
M-1001, especially the following:
3.3.1 Curve Negotiability—The minimum curves to be negotiated are defined in MSRP Section C,
Part II, Chapter 2, Specification M-1001.
3.3.2 System Criteria—The system, including all components and attachment/connection means,
shall meet the requirements of the following topics, codified in MSRP Section C, Part II, Chapter 4
(curve stability is documented in Chapter 11):
• General requirements for the design of loads and forces
• Vertical loads on couplers
• Jacking loads
• Draft loads
• Compressive end loads
• Impact loads
• Curve stability
3.4 Fatigue
A fatigue analysis of the coupling system shall be conducted on available environmental load data
based on the approach outlined in Specification M-211, paragraph 4.2.6.
3.5 Analyses
Analytic requirements will consist of a complete specific application curve negotiability and stress
analysis, including a fatigue analysis, and will be submitted indicating compliance with Specifica-
tion M-211 requirements. Based on the system stress analysis, critical importance areas will be
identified. The analyses will include an application of the attachment to the car body.
4.0 MANUFACTURING REQUIREMENTS
4.1 Quality Assurance Provisions
All manufacturers and foundries must have a formal quality assurance program and be approved
by the AAR under the provisions of AAR Manual of Standards and Recommended Practices, Sec-
tion J, Specification M-1003.
4.2 Gauges and Inspection Techniques
The manufacturer must submit gauge lists or any other pertinent inspection techniques, proce-
dures, or processes to the AAR.
4.3 Steel Castings
Steel castings must comply with all applicable provisions of Specification M-201 and Specification
M-211, including the surface finish and solidity requirements of Specification M-211,
paragraphs 8.0, 9.0, and 11.0. Deviations from these specifications must be stated with reasons for
the deviation request. Alternative procedures and processes will be considered by the AAR.
10/2010 S [M-215] 339

10/2010
Casting Details
M-215

5.1 System Verification Tests
System verification tests will be conducted to verify the car design’s coupling system integrity. At
the discretion of the AAR, an AAR representative may be required for test observation. All applica-
ble paragraphs of the Manual of Standards and Recommended Practices, Section C, Part II, Speci-
fication M-1001, Chapter 11, “Static and Impact Test Requirements,” including the following
topics, will be adhered to:
• Coupler vertical loads
• Curve stability
• Jacking
• Impact tests
5.2 component Verification Tests
Detailed component design verification tests will be conducted to verify the manufacturer’s stated
strength characteristics of the coupling system for the following:
5.2.1 Buff/Draft Strength
The manufacturer’s stated buff and draft strength will be verified by testing. The test setup will
simulate the application.
5.2.2 Buff/Draft Maximum Resistance Moment
The maximum moment as defined under paragraph 2.3 shall be verified by physical testing. The
test shall be conducted with alternating draft and buff loading cycles to ensure that the system
develops maximum moment.
5.2.3 Vertical Strength
The manufacturer’s stated vertical strength will be verified by testing. The test setup will simulate
the application.
5.2.4 Lateral Strength
The manufacturer’s stated lateral strength will be verified by physical testing as referenced in
paragraph 3.0 of this specification.
6.0 TEST APPROVAL AND SERVICE PERFORMANCE
6.1 In-Service Test
The coupling system in-service performance will be determined by its ability to remain effective
during the system’s stated life cycle.
6.1.1 Test Approval Application
Coupling system test approval application will be considered for manufacturer’s requested number
of car sets by the AAR.
6.1.2 Performance Evaluation Procedure
The manufacturer will set up an in-service performance evaluation procedure, approved by the
AAR, to establish the appropriate measurements. Ten% of the cars or at least ten cars will be mon-
itored for in-service performance. The remaining cars will be monitored for wearing, cracking, gall-
ing, or any other type of failure.
S [M-215] 340 10/2010

10/2010
Casting Details
M-215
6.2 Reports
6.2.1 General
The manufacturer will submit to the AAR in-service performance reports and semiannual service
performance reports during the test period as described in the following paragraphs. Approval for
additional applications will be contingent upon receipt of in-service performance and semiannual
service performance reports. Upon successful completion of 250,000 miles of in-service perfor-
mance on the 10%/10-car control group, consideration will be given to granting full approval. The
proponent will notify the AAR of any failures and proposed corrective action.
6.2.2 In-Service Performance Report
The in-service performance report will be submitted to the AAR as information/data become or are
made available or every month, whichever comes first. The in-service performance report will
include information as outlined in the AAR Manual of Standards and Recommended Practices,
Section B, Standard S-101 with the following:
• Tear-down inspection reports
• Reports to explain field complaints
• Any manufacturer’s special analyses to determine component quality and performance
6.2.3 Semiannual Service Performance Report
The semiannual service performance report will include information as outlined in MSRP Stan-
dard S-101 with the following:
• Accounting of additional car sets in service
• Any in-service performance reports that were not previously submitted
6.3 Teardown Inspection
A teardown inspection will be conducted at intervals agreed on by the manufacturer and the AAR.
In-service wear performance measurements shall be made. The presence of an AAR representative
may be required.
6.4 Design Changes
Major design changes must be submitted in writing to the AAR for handling.
7.0 RETEST REQUIREMENTS
Full approval will be granted upon successful completion of in-service testing and upon submission
of service performance reports as outlined in paragraph 6.0. In the event clarification is required,
a retest under the provisions of paragraph 5.0 may be required on service worn components.
8.0 FAILURE MODE EFFECTS AND ANALYSIS (FMEA)
An FMEA must be submitted to identify critical failure mode effects. This analysis will provide the
AAR with a recommended procedure for handling any bad-ordered cars to destination shops for
repair. All failure contingencies will be covered in this recommended procedure.
9.0 LIMITATIONS ON USE
The manufacturer will advise the AAR of specific limitations on use of the proposed coupling sys-
tem. For example, yard impact limitations may be prescribed.
10/2010 S [M-215] 341

Casting Details
M-215
S [M-215] 342 10/2010

Casting Details
M-216
KNUCKLES, TYPES E AND F—FATIGUE TEST
Specification
M-216

1.0 SCOPE
1.1 This specification covers
• knuckles for North American interchange freight equipment
• fatigue test requirements
• test procedures (including test machine requirements, load spectrum, and reporting
requirements)
This specification requires fatigue testing of four samples in addition to the static testing defined
in Specification M-211.
1.2 Every knuckle design, existing and new, from each foundry from a manufacturer must be
approved by the Coupling Systems and Truck Castings Committee (CSTCC) before continuing or
being placed in interchange freight service to comply with this specification. E-type knuckles must
be retested on a 3-year interval. F-type knuckles must be retested on a 6-year interval. Failure of a
test implies only that the particular design is not approved for the specific manufacturer and/or
facility.
1.3 Application for approval of new designs, or for testing of current designs as described in
paragraph 1.2, shall be addressed to the Chief—Technical Standards, Transportation Technology
Center, Inc. Application shall be accompanied by copies of general product drawings. The preferred
method of transmission is electronic, submitted in either .tif or .pdf format to techstds@aar.com.
Application fees as described in the Office Manual of the AAR Interchange Rules, Appendix E,
shall be submitted.
1.4 Manufacturers of existing knuckles will have 1 year after implementation of this specification
to meet the fatigue test requirement for each of their products. If an existing product fails to meet
the requirement by the end of the first year, that product will be placed on conditional approval for
up to 1 year. If, after 1 year of conditional approval, that product fails to meet requirements,
approval will be removed for that knuckle design, and the manufacturer must reapply for approval
at a later date.
1.5 If manufacturer makes structural design changes, then knuckle must be retested.
1.6 Manufacturers of new knuckle designs must meet the fatigue test requirements as part of the
approval process and before conditional approval is granted.
2.0 DESIGN
All standard fundamental AAR requirements, in addition to those specifically mentioned herein,
shall govern.
tative approved by the Committee must witness tests and provide test data and certification to the
3.2 The applicant requesting approval of the knuckle shall make all arrangements for these tests
in accordance with these requirements.
10/2010 S [M-216] 343

Casting Details
M-216
4.0 DYNAMIC FATIGUE TEST REQUIREMENTS

4.1 Test Machine
4.1.1 The test machine will be capable of inputting draft (tensile) loads into a knuckle through an
AAR-approved standard production coupler body. The test knuckle must mate with an adjacent
AAR-approved, standard production knuckle. The mating knuckle may also be a test knuckle, thus
allowing two test knuckles to be evaluated concurrently. In this circumstance, the mating “test
knuckle” must also be attached to an AAR-approved standard production coupler body.
4.1.2 C-10 pins will be used for all official testing.
4.1.3 It is preferred that the tests are performed in the horizontal position, although vertical is
accepted after review of the system by the CSTCC. The loads shall be applied in line with the cen-
terline of the coupler. It is preferred that the machine can accommodate the proof test load require-
ments described in Specification M-211. Test inputs must be sinusoidal, and frequency rates must
allow the loads listed in Table 4.1 to be achieved.
4.2 Test Specimen Selection
The proponent shall provide the Chief—Technical Standards a lot of 25 samples from which to
choose the four knuckle test samples for fatigue testing. The lot shall be typical foundry product of
recent production (cast date within 6 months).
4.3 Test Instrumentation
Test instrumentation for the fatigue testing shall allow analysis to show that the test machine is
imparting accurate and consistent loads. The load measurement and control system must be cali-
brated and traceable to a known calibration standard on an annual basis. Calibration records
must be available for review during testing.
4.4 Standard Input Load Spectra
Table 4.1 lists the required input load spectra. Repeat segments 1 through 13 sequentially until
failure.
Table 4.1 Knuckle fatigue test load cycles
Number of Cycles Total Cycle Load Range
Segment (Sinusoidal Form) Elapsed Cycles (Min to Max)a/
1 4 4 18–283 kips
2 2 6 18–265 kips
3 7 13 18–245 kips
4 10 23 18–227 kips
5 31 54 18–209 kips
6 77 131 18–189 kips
7 65 196 18–171 kips
8 73 269 18–154 kips
9 89 358 17–133 kips
10 105 463 17–115 kips
11 129 592 17–97 kips
12 187 779 17–79 kips
13 279 1058 15–59 kips
a/ ±5% margin of error on minimum loads
±2% margin of error on maximum loads
S [M-216] 344 10/2010

Casting Details
M-216
4.5 Test Requirements

Test loads shall be applied until each test knuckle fails (or until the proponent is satisfied with the
number of cycles for logistics purposes). Failure is defined as the occurrence of separation of any
segment of the knuckle from the parent structure. The proponent may elect to withdraw the appli-
cation at any time during testing. To reapply, the proponent must explain the modifications made
to the design. To be approved, the average life of the four knuckles tested must exceed 600,000
cycles with no individual knuckle exhibiting a life below 400,000 cycles.
4.6 Reporting
4.6.1 Test reports shall be prepared for all tests that pass the requirements if certification
approval is to be sought from the CSTCC. If the proponent chooses not to submit a test report, the
AAR test file will be labeled “Test Failed,” and the file will be closed.
4.6.2 The test report shall include descriptions of all procedures followed and all results pro-
duced, including cycles to failure for each knuckle with descriptions and photographs of each fail-
ure. Reports must be prepared by the tester and reviewed by the official observer. The official
observer shall prepare a cover summary letter and shall submit the report and letter to the
Chief—Technical Standards, Transportation Technology Center, Inc.
4.6.3 The report shall have a section for each major section in this specification. Brief descrip-
tions of test equipment and procedures shall be provided in the body of the report. More detailed
procedures and instrumentation lists should be provided as appendices. In the body of the report,
test results shall be presented in enough detail to demonstrate compliance with the test criteria.
Sections providing conclusions and recommendations must be provided.
4.6.4 A second phase of reporting shall include the following information on the actual test speci-
mens. It is understood that these data will likely follow the fatigue test report by a period of up to
60 days due to the time necessary for gathering this information. This information shall be
archived for later use if and when failures occur in service (compare these results with results
from the failed specimen).
• Internal solidity levels as defined per Specification M-211
• Chemistry
• Grain size1/
• Manufacturer, model number, serial number, cast date
• Weight
4.6.4.1 Manufacturer shall measure the actual test specimens for metal thickness readings as
compared to drawing dimensions1/. The results will be retained by the manufacturer for 6 years
and will be made available to the CSTCC if and when failures occur in service.
1/ To be recorded for (1) the throat area; (2) distance between the C-10 pin hole and the nearest
pulling face; and (3) the wall thickness of tail adjacent to radius of the pulling lugs.
10/2010 S [M-216] 345
Casting Details
M-216
S [M-216] 346 10/2010

M-220
Part 1M-220
CASTING COMPONENT NONDESTRUCTIVE TESTING REQUIREMENTS
Specification
M-220

1.0 SCOPE
1.1 This specification establishes the minimum nondestructive testing (NDT) requirements for
cast components used on railway rolling stock equipment. Requirements specific to the component
being tested will be listed as an appendix for the respective component, including any require-
ments specific to manufacturers, reconditioners, reclamation shops, car repair shops, RIP tracks,
mobile operations, or other field inspection operations. The necessity for inspections by car repair
shops, RIP tracks, mobile operations, or other field inspections is defined in the Field Manual of
the AAR Interchange Rules.
1.2 Components covered by this specification and the respective appendix are listed below:
Knuckles . . . . . . . . . . . Appendix A
1.3 The Coupling Systems and Truck Castings Committee (CSTCC) must approve alternative
test methods for components being placed in interchange freight service.
2.0 METHOD
Facilities conducting nondestructive tests shall maintain documented procedures that detail the
processes and the requirements associated with each test. The procedures must be approved by an
ASNT Level III professional or equivalent AAR member-railroad, corporate-certified professional.
The professional must be qualified in the appropriate NDT discipline.
3.0 INSPECTOR QUALIFICATION
Personnel conducting nondestructive tests must be trained in accordance with a written training
manual developed with the requirements of this specification as outlined in the appendices. Records
of initial training and annual requalification must be kept and be available for review.
4.0 EQUIPMENT
Equipment used in the conduct of nondestructive tests must be capable of meeting all test param-
eters established by this specification.
5.0 RECORDS
The facilities conducting nondestructive tests shall maintain for a minimum of 3 years inspection
records of all tests conducted and required by this specification. These records shall be made avail-
able to the purchaser, casting owner, or AAR upon request. The records shall provide traceability
from the serial number of individual castings, where serial numbers are required in the manufac-
ture of the respective component. Recorded information shall include as a minimum the date of in-
spection, type of test conducted, method used, and results of the test. Requirement for records is
further defined in each appendix, inasmuch as not all components require record keeping or this
level of record keeping.
10/2010 S [M-220] 347

Casting Details
APPENDIX A M-220
APPENDIX A
MAGNETIC PARTICLE INSPECTION OF RAILROAD
KNUCKLES—GUIDELINES AND PROCEDURES
1.0 SCOPE
1.1 The purpose of this magnetic particle test (MT) inspection procedure is to outline the process
and requirements for conducting magnetic particle inspection of railroad knuckles by manufactur-
ers, reclamation shops, car repair shops, RIP tracks, and mobile operations. The “continuous” MT
method is used in conjunction with dry powder magnetic particle application at the knuckle
inspection area.
1.2 The scope of this procedure applies to the AC yoke technique method using dry powder mag-
netic particle application at the knuckle inspection area. Alternative methods of inspection of
knuckles (including but not limited to wet mag dip tank under black light inspection) are accept-
able if approved by the CSTCC.
1.3 The MT inspection monitors iron particles that collect at areas of flux leakage, which can
then be interpreted as an indication of a surface crack, hot tear, void, etc., or a non-relevant indica-
tion such as geometry change, scale, rust, etc.
1.4 Manufacturers and reclamation shops must nondestructively test each cast component
covered by this appendix. Manufacturers may request a waiver from the CSTCC for relief of 100%
inspection and must provide a description of their process and results for CSTCC review.
2.0 INSPECTOR QUALIFICATION
2.1 Personnel performing magnetic particle inspection of railroad knuckles shall be certified to
Level I or higher in accordance with the ASNT Recommended Practice No. SNT-TC-1A or shall be
certified to an equivalent AAR member railroad corporate program. An ASNT Level III profes-
sional or equivalent AAR member railroad corporate certified professional must approve the train-
ing and requalification programs, which will cover the necessary requirements of magnetic
particle testing and its application to a railroad knuckle. Training must include the content of this
document.
3.0 REQUIRED EQUIPMENT FOR DRY INSPECTION
• Electromagnetic AC yoke—used for inducing magnetism into the knuckle being inspected
• Dry powder magnetic particles (6 μm to 8 μm iron oxide powder)—used during magnetic
particle inspection
• White powder liquid penetrant aerosol spray developer, used to create high contrast
between the magnetic powder and the inspection surface. Developer usage is mandatory
for field inspections and reclamation facilities and not required for knuckle manufacturers
or associated finishing facilities.
• Magnetic particle field indicator (pie gauge)
• Light source (ambient or produced) that provides a minimum of 50 footcandles at the
inspection surface
• Lint-free rags
• Cleaner
• Ruler/tape measure accurate to 1⁄16 in.
S [M-220] 348 10/2010

Casting Details
M-220 APPENDIX A
4.0 KNUCKLE INSPECTION PROCEDURE

4.1 Prior to performing MT, visually inspect all visible parts of the knuckle, including the front
and pulling faces and the flag hole.
4.1.1 For knuckles discovered with visible cracks greater than 1⁄4 in. long, refer to paragraph 5.0
for handling.
4.1.2 For knuckles discovered without visible cracks or with cracks up to 1⁄4 in. long, proceed to
paragraph 4.2 for MT inspection.
4.2 Perform an MT inspection on the pulling-face area of the knuckle highlighted in Fig. A.1.
For car repair shops and field inspections, it is not necessary to remove the knuckle from the cou-
pler.
4.3 On a daily basis, the MT yoke shall be verified to have an AC lifting power of 10 lb (4.5 kg)
minimum at the maximum pole spacing used.
4.4 Clean the pulling face area of the knuckle, shown in Fig. A.1, to be free of extraneous rust,
scale, flux, grease, oil, or any material that may interfere with the inspection. If using liquid or
oil-based cleaner, ensure the knuckle is completely dry before applying magnetic particles. A
recently sand- or shot-blasted surface is acceptable for inspection.
PULLING FACE AREA (VISUAL AND

MAGNETIC PARTICLE INSPECTIONS)
Fig. A.1 Pulling-face area of knuckle

4.5 Perform a second visual inspection of the pulling face area of the knuckle.
4.6 Spray a light coat of developer onto the pulling face area of the knuckle unless a powder will
be used that provides a sufficient level of contrast to identify defects. This step is not required for
manufacturers.
10/2010 S [M-220] 349

Casting Details
APPENDIX A M-220
4.7 Set the yoke current to AC and position it at knuckle placement #1 as illustrated in Fig. A.2.
PLACEMENT #1
PLACEMENT #4
PLACEMENT #2
PLACEMENT #3 PLACEMENT #5
Fig. A.2 Horizontal yoke placement on knuckle Fig. A.3 Vertical yoke placement on knuckle
4.8 Use a pie gauge to verify magnetic field strength and direction. Conduct the verification at
the beginning of each shift, starting with the first knuckle.
4.9 With the yoke energized, apply the dry magnetic particles with a bulb applicator or powder
blower in such a manner that a light, uniform, dust-like coating settles on the pulling face area.
4.10 Examine the knuckle for any accumulations of magnetic powder at flux leakage areas.
4.11 Car repair shops, RIP tracks, and mobile operations: repeat for knuckle placements 2 and 3
with the yoke in the horizontal position only, as shown in Figs. A.2 and A.4.
Fig. A.4 Yoke in placement #3
S [M-220] 350 10/2010

Casting Details
M-220 APPENDIX A
4.12 Manufacturers and reclamation shops: repeat for knuckle placements 2 through 5, as shown
in Figs. A.2 and A.3. Placements 1 through 3 are with the yoke in the horizontal position (as shown
in Fig. A.4, although knuckle does not have to be in the coupler body), and placements 4 and 5 are
with the yoke placed in the vertical position (as shown in Fig. A.5).
Fig. A.5 Yoke in placement #5

4.13 Clean the inspection area of the knuckle to remove magnetic particle dust and excess devel-
oper.
5.0 CAUSES FOR REJECTION
5.1 Repair Shop and Field Inspections
Knuckles shall be free of cracks greater than 1/4 in. long. Knuckles containing defects shall be
addressed in accordance with the latest edition of the Field Manual of the AAR Interchange Rules,
Rule 16, 17, or 18.
5.2 Manufacturer and Reclamation Inspections
Knuckles must be free of
• surface cracks
• surface discontinuities (hot tears, inclusions, porosity) with width, length, or depth dimen-
sions greater than 1/8 in.
• a grouping of five or more pin holes within a 1 in.2 area and 3/16 in. or greater deep
• individual pin holes greater than 1/16 in. in diameter and greater than 3/16 in. deep
6.0 KNUCKLE INSPECTION RECORDS
Knuckle manufacturers and reclamation facilities must demonstrate that NDT inspections are
part of their production process. A written process must be made available upon request by AAR
representatives.
10/2010 S [M-220] 351

Casting Details
APPENDIX A M-220
S [M-220] 352 10/2010

Casting Details
M-975
SPAN BOLSTERS
Specification
M-975
Adopted: 2000
1.0 SCOPE
1.1 This specification covers the design, test, and approval requirements for span bolsters,
whether cast or fabricated, used to support a car body or an upper span bolster by two or more
trucks or by lower span bolsters.
1.2 Approved span bolsters will be rated for the combined gross rail load of the trucks supporting
them.
1.3 Once approved under this specification, the span bolster may be used in different freight car
designs. Car designs utilizing span bolsters approved under this specification are subject to sepa-
rate review and approval by the Equipment Engineering Committee.
1.4 Existing span bolsters having an AAR identification number will be considered to comply
with the design and test requirements of this specification. Upon review of their production and
service history, other existing span bolster designs may be approved without test or analysis. In
either case, the proponent is to submit an identification number and rated gross rail load, as called
for in paragraph 5.1. Upon approval, such span bolsters are to be marked in accordance with
paragraph 5.2.
2.0 DESIGN REQUIREMENTS
2.1 Basis of Design
2.1.1 Static Design
A finite-element stress analysis of the span bolster shall be performed using the design loads, load
factors, and allowable stresses specified below. The boundary conditions of the analysis shall not
provide moment restraint at the center plate/center bowl interfaces except as generated by gravity.
2.1.2 Fatigue Analysis
A fatigue analysis shall be performed in accordance with the requirements of AAR Manual of
Standards and Recommended Practices, Section C-II, Specification M-1001, Chapter VII. The
design shall be for a fatigue life of 1,000,000 miles and shall use the environmental load spectra
(REPOS) provided for 100-ton open hopper cars unless environmental data more applicable to the
intended car are available. 50% of the car’s mileage shall be assumed to be loaded and 50% to be
empty. Vertical force values provided in the hopper car REPOS shall be adjusted by the ratio of the
gross weight supported by the span bolster, including its own weight and not including the weight
of the lower span bolsters (if any) beneath the span bolster or the trucks, to 121,000 lb, i.e.,
Force value used = REPOS value × Gross weight supported = 121, 000 lb
10/2010 S [M-975] 353

Casting Details
M-975
2.2 Design Loads

2.2.1 Dead Load
The dead weight shall be the weight of the span bolster and any appurtenances attached thereto.
2.2.2 Live Load
The live load for the span bolster shall be the portions supported by the span bolster of the follow-
ing: the load limit of the car, the weight of the upper car body and the upper span bolsters, if any.
The live load shall be applied at the upper center bowl, and its reaction shall be distributed among
the lower center plates by static equilibrium or other appropriate methods of analysis.
2.2.3 Vertical Loads on Coupler
Span bolsters equipped with draft arms shall be designed to withstand a vertical up and down load
of 50,000 lb applied at the pulling face of coupler. Span bolsters are not required to support vertical
loads on the coupler shank sufficient to lift the span bolster out of the outermost truck center bowl.
2.2.4 Draft Load
Span bolsters interposed between the coupler and the upper car body shall be designed to sustain
a draft (tensile) or buff (compressive) coupler load of350,000 lb. The load shall be reacted at the
vertical wall of the upper center plate bowl and applied at the front or rear draft lugs along the
nominal centerline of coupler or, if the span bolster is an intermediate unit between lower span
bolsters and the upper car body, applied at the vertical wall of the lower center plate closest to the
coupler. Attachment of front draft lugs shall be in accordance with MSRP Section C-II, Specifica-
tion M-1001.
2.2.5 Compressive End Load
a compressive end load of 1,000,000 lb. The compressive end load shall be applied and reacted in
the same manner as the buff load described in paragraph 2.2.4. When eccentricity between the
application point of the 1,000,000-lb compressive end load at the rear draft lugs and the reaction
point at the upper center plate bowl results in redistribution of the vertical reactions at the sup-
porting trucks or lower span bolsters, no reaction may be reduced to less than 5% of its static
value.
2.2.6 Impact Load
a longitudinal inertia reaction force of 1,250,000 lb resulting from single-ended impact. The impact
load shall be applied and reacted in the same manner as the buff load described in
paragraph 2.2.4. The vertical reaction resulting from longitudinal impact shall be combined as
shown in paragraph 2.3.
S [M-975] 354 10/2010

Casting Details
M-975
2.2.7 Center Plate and Side Bearing Loads

2.2.7.1 If P is defined as the vertical load statically transferred between the center plate and cen-
ter bowl at any location on the span bolster when the car is loaded to full capacity, the center plate
load shall be 2.2 P and the side bearing load shall be 1.4 P. The center plate loads shall be applied
uniformly distributed over the bearing surface of the upper center bowl and the lower center
plates. In addition, the center plate load shall be applied as a line load offset laterally from the lon-
gitudinal center line by 40% of the bowl diameter from the center of the lower center plates and as
a line load offset longitudinally from the transverse center line by 40% of the bowl diameter fore
and aft from the center of the upper center bowl. The side bearing load shall be applied separately
to each side bearing. Under each of these loadings, the reactions at the other center plates and side
bearings shall be such as to produce static equilibrium with the applied load, and the entire span
bolster structure shall be designed to sustain the load distribution thereby derived.
2.2.7.2 The attachment of center plates to the main span bolster structure shall be subjected to a
longitudinal load of 10 times the weight of the truck supporting the center plate or 200,000 lb,
whichever is greater. The attachment of center plates that rest on lower span bolsters shall be sub-
jected to a longitudinal force of seven times the combined weight of the lower span bolster and its
supporting trucks or 200,000 lb, whichever is greater.
2.2.7.3 The application to the span bolster of the design loads specified above is illustrated in
Fig. 2.1.
Symbol Load Reference

B Buff 2.2.4
CP1 Vertical center plate 2.2.7.1
CP2 Longitudinal center plate 2.2.7.2
CEL Compressive end load 2.2.5
D Draft 2.2.4
I Impact 2.2.6
LL Live load 2.2.2
SB Side bearing 2.2.7.1
VLP Vertical load on coupler pullling face 2.2.3
Fig. 2.1 Application of design loads to span bolster
10/2010 S [M-975] 355

Casting Details
M-975
2.3 Load Factors and Allowable Stresses

Each portion of the span bolster shall be investigated for its most critical loading condition. Such
critical loading may result from loads applied singly or in combination with other loads, provided
such combination can rationally occur in service. The design loads defined in paragraph 2.2 shall
be applied to the span bolster in the combinations listed below and multiplied by the stated load
factors. The calculated stresses are not to exceed the allowable stresses listed below.
Applied Loads Paragraph References Load Factor Maximum Allowable Stress

Live + Dead 2.2.1, 2.2.2 1.8 Y.S., 80% US or CBSa/
Live + Dead + Draft 2.2.1, 2.2.2, 2.2.4 1.8 Y.S., 80% US or CBSa/
Live + Dead + Buff 2.2.1, 2.2.2, 2.2.4 1.8 Y.S., 80% US or CBSa/
Live + Dead + Vertical Coupler 2.2.1, 2.2.2, 2.2.3 1.0 Y.S., 80% US or CBSa/
Live + Dead + Compressive End 2.2.1, 2.2.2, 2.2.5 1.0 Y.S., 80% US or CBSa/
Liveb/ 2.2.2 2.2 Y.S., 80% US or CBSa/
+ Dead 2.2.1 1.8
+ Impact 2.2.6 1.0
Vertical Center Plate 2.2.7.1 1.0 Y.S., 80% US or CBSa/
Vertical Side Bearing 2.2.7.1 1.0 Y.S., 80% US or CBSa/
Longitudinal Center Plate 2.2.7.2 1.0 Y.S., 80% US or CBSa/
a/ Yield stress, 80% of ultimate stress (US), or the critical buckling stress (CBS),
whichever is lower.
b/ In this load combination, the 2.2 load factor applied to the vertical load at the
upper center bowl represents the dynamic amplification factor resulting from
the horizontal impact force.

The following tests apply to span bolsters that are interposed between the coupler and the upper
car body. They are to be performed on a complete car that incorporates the span bolster to be
approved.
3.1 Compressive End Load
The empty test car shall be subjected to a longitudinal compressive static load of 1,000,000 lb. The
test shall be conducted in accordance with the requirements of MSRP Section C-II, Specification
M-1001.
3.2 Impact
3.2.1 The empty test car shall be impacted into a string of standing cars configured as specified in
MSRP Section C-II, Specification M-1001. The standing cars shall be on level, tangent track. The
test shall be performed with the striking couplers adjusted to within 1/2 in. of each other and also
with the coupler of the lead car of the standing cars adjusted to 3 in. below that of the test car.
3.2.2 A series of impacts shall be made at increments of 2 mph, starting at 4 mph, until a coupler
force of 1,250,000 lb or a speed of 8 mph has been reached, whichever occurs first. If during any
impact, the bearing surface of any center plate rises above the rim of the center bowl beneath it,
any wheels lift off the rail, or the span bolster sustains permanent damage as defined in MSRP
Section C-II, Specification M-1001, then sufficient cause will exist for disapproval of the span bol-
ster.
S [M-975] 356 10/2010

Casting Details
M-975
4.0 MATERIALS
4.1 The top and bottom cover plates of the draft sill and primary longitudinal beam of fabricated
span bolsters are to be made of fine grain, controlled rolled steel having a minimum Charpy
V-notch value of 15 ft·lb at –200 F° as obtained under ASTM Specifications A370 and A673 on a
heat lot basis.
4.2 If cast steel span bolsters have fabricated draft sills welded on, they are to be stress-relieved
after application of the draft sill.
5.0 APPROVAL
5.1 Application for approval of span bolster designs shall be submitted to the Association of
American Railroads in care of the Chief—Technical Standards, of the Transportation Technology
Center, Inc. The proponent shall state the gross rail load rating for which approval is sought and
shall provide an identification number for the span bolster, which is not to exceed 10 characters.
Fifteen copies of relevant supporting documents, including drawings, identification of material
grades used, and the results of stress calculations, shall accompany the application. Additional
requirements for approval may be established by the Equipment Engineering Committee beyond
those listed in this specification for span bolsters that it deems to be of unconventional configura-
tion.
5.2 Span bolsters approved under this specification shall be marked with this specification num-
ber, the span bolster identification number, and the rated gross rail load of the trucks supporting
them. The markings shall be applied adjacent to the upper center bowl, either on the side of the
side bearing supports on each side or on top of the span bolster facing the draft arm (if used). They
shall be cast on or applied by steel stamp in letters and numerals no less than 1/2 in. high in a
manner similar to the following:
AAR M-975-2000
YYYYYYYYYY
ZZZZZZ LB
5.3 Once approved under a given identification number, changes to span bolsters shall be limited
to non-structural appurtenances, such as brake rigging supports and end platforms; accommoda-
tion of different draft arms, couplers, and/or cushioning components; and substitution of alternate
material grades having comparable tensile, ductility, fatigue, and welding properties. Changes
beyond those listed above must be submitted to the Equipment Engineering Committee for
approval.
10/2010 S [M-975] 357

Casting Details
M-975
S [M-975] 358 10/2010

MSRP-S 10

Uploaded by

Copyright:

Available Formats

MSRP-S 10

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MSRP-S 10

Uploaded by

Copyright:

Available Formats

10/2010

Association of American Railroads

The Association of American Railroads

Copyright © 2010 by the Association of American Railroads (AAR)

ORDERS FOR Publications Department

THIS PAGE LEFT BLANK INTENTIONALLY

Subject Standard Page

Standard Subject Page

FORGINGS, CARBON STEEL BLOOMS, BILLETS, AND SLABS

Adopted: 1905; Last Revised: 1964

3.0 CHEMICAL REQUIREMENTS

Note: Silicon, if specified, should conform to standard limitations as follows:

3.2 Ladle Analysis

4.0 WORKMANSHIP AND FINISH

4.2 Surface Conditioning

7.0 SUPPLEMENTARY REQUIREMENTS

Table 7.2 Permissible variations for check analysis of electric-furnace steels

FORGINGS, CARBON STEEL

Adopted: 1945; Last Revised: 1968

3.2 Ladle Analysis

4.0 PHYSICAL REQUIREMENTS

4.2 Tension Test Specimens

Fine-Grained Uniform Structure—Desired (×100) Maximum-Grained Structure—Acceptable (×100)

Fig. 4.2 Microscopic test—Grades D and E

Fine-Grained Uniform Structure—Desired (×100) Maximum-Grained Structure—Acceptable (×100)

Fig. 4.3 Microscopic test—Grade F

Oil-Quenched—Desired (×100) Water-Quenched—Desired (×100)

Fig. 4.4 Desired microstructure for the referenced quench method

5.0 WORKMANSHIP AND FINISH

8.0 SUPPLEMENTARY REQUIREMENTS

THIS PAGE LEFT BLANK INTENTIONALLY

FORGINGS, ALLOY STEEL

Adopted: 1945; Last Revised: 1964

• Grades A, B, and C—Normalized and tempered

2.7 Heat Treatment

3.3 Check Analysis

4.0 PHYSICAL REQUIREMENTS

4.3 Microscopic Test

Fine-Grained Uniform Structure—Desired) Maximum-Grained Structure—Acceptable

Fine-Grained Uniform Structure—Desired Maximum-Grained Structure—Acceptable

Fine-Grained Uniform Structure—Desired Maximum-Grained Structure—Acceptable

4.4 Number of Tests

7.0 INSPECTION AND REJECTION

BLOOMS, BILLETS, AND SLABS—ALLOY STEEL

Adopted: 1953; Revised: 1964

Blooms Cross-sectional area greater than 36 in.2

Over 0.25 to 0.40, incl. 0.07 a/ 0.10b/ 0.06a/ 0.09b/

4.0 LADLE ANALYSIS

5.0 CHECK ANALYSIS

Lots Number of Pieces

Area of Cross-Section Approximate

6.0 WORKMANSHIP AND FINISH

6.2 Surface Conditioning

9.0 SUPPLEMENTARY REQUIREMENTS

THIS PAGE LEFT BLANK INTENTIONALLY

Adopted: 1923; Last Revised: 2005

5.2 Normalized Steel Castings

Alternate procedures will be considered, provided a detailed proposal is submitted in writing to

Grades A, B, and B+ Grades C, D, and E