NO. 49-BD-08 (Supersedes 49-BD-02) INDIAN RAILWAYS SCHEDULE OF TECHNICAL REQUIREMENT NO.

49-BD-08

FOR HIGH CAPACITY DRAFT GEAR FOR HIGH TENSILE CENTRE BUFFER COUPLER (B.G. BOGIE WAGONS)

ISSUED BY RESEARCH DESIGNS & STANDARDS ORGANISATION MINISTRY OF RAILWAYS LUCKNOW- 226011

June, 2008

Price Rs. 00 /-

INDEX

S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DESCRIPTION SUMMARY OF CHANGES MADE IN 49-BD-08 (FROM 49BD- 02 WITH AMENDMENT NO.1 & 2 SCOPE PARTICULAR REQUIREMENTS MATERIAL AND DESIGN INSPECTION GENERAL MARKINGS INSPECTIONS AND REJECTION PAINTING SUPPLY OF SPARES WARRANTY/GUARANTEE RECONDITIONG RECORD OF INTERNAL ACCEPTANCE TEST APPENDIX-I
ACCEPTANCE SCHEDULE FOR PURCHASE ACCEPTANCE

PAGE NO. 3 4 4 6 6 8 9 10 10 9 10 10 10 11-14 15-20

OF HIGH CAPACITY DRAFT GEARS AS PER AAR M-901 E APPENDIX-II

OF HIGH CAPACITY DRAFT GEARS AS PER AAR M-901 G

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Summary of changes made in 49-BD-08 (from 49-BD-02 with Amendment No.1 & 2) Page 2 Index Index updated Index S.No, Painting, Supply of spares, Warranty/Guarantee, Reconditioning, Record of internal acceptance test added Index (Appendix-I) As per AAR M-901 E added after Gears Index (Appendix-II) As per AAR M-901 G added after Gears Page 4 Heading revised Clause 1.4 49-BD-02 changed to 49-BD-08 Clause 2.4 Approval Requirements heading added Clause 2.4 (ii) Clause added as per Amendment No. 1 Page 5 Clause 2.4 (iii) New clause added Clause 2.7 /Applicant manufacturer added after collaborator Clause 2.8 /Manufacturer added after collaborator Page 6 Clause 2.15 Access changed to Assess Clause 3.2 /Manufacturer added after collaborator Clause 4.1.1 2.8.1 changed to 2.8 and /Manufacturer added after collaborator Page 7 Clause 4.1.2.5(i) Manufacturer added after principal Clause 4.1.2.5(iii)&(iv) Clause added as per Amendment No. 1 Clause 4.1.2.5(v) New clause added Page 7 Clause 4.1.3 Annexure changed to Appendix and /Manufacturers added after collaborators Page 8 Clause 4.1.5 Or as specified by added after approval and /Manufacturer added after manufacturer Clause 5.3 Tracing cloth changed to and one copy in electronic format (CD) Page 9 Clause 5.10 Tracing on cloth changed to Drawing copy along with copy in electronic format (CD) Page 9 Clause 6.4 Procedure deleted before marking Clause 10 48 & 36 months changed to 54 & 42 months respectively Clause 10 Later changed to Earlier as per Amendment No.2 Page 10 Clause 12 New clause added Page 11 As per AAR M-901 E added after Gears Clause 2 /Manufacturers added after collaborators Clause 3.2 /Drawing approved by RDSO added after Drawing Clause 5 Internal Quality Assurance Program deleted before following Page 12 Clause 8.2.2 Para 7.1 changed to 7.1.1 Clause 8.2.4 Para 7.1 changed to 7.1.1 Page 14 Clause 12 48-BD-02 changed to 48-BD-08 Clause 12.1 48-BD-02 changed to 48-BD-08 Clause 12.3 Collaborators deleted before drawings Page 15 Clause 1.4 48-BD-02 changed to 48-BD-08 Page 16 Clause 4.3 M 901-E changed to M 901-G Page 17 Clause 5.4 Which changed to with Page 18 Clause 7.1.1 closet changed to Closest Page 18 Clause 7.2.1 closet changed to Closest Page 18 Clause 9.1 Produces changed to Proceed Page 19 Clause 12.1.1 /Manufacturers added after collaborators

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SPECIFICATION FOR HIGH CAPACITY DRAFT GEAR ALONG WITH DRAFT GEAR FOLLOWER FOR HIGH TENSILE CENTRE BUFFER COUPLER FOR B.G. BOGIE WAGONS 1. 1.1 SCOPE: This specification covers the particular requirements for the supply of High Capacity Draft Gears along with draft gear follower suitable for application in freight stock having a standard 625.5mm. (24 5/8) pocket. The draft gear shall be approved as per AAR spec. M-901E or as per AAR specification M-901G as referred to in Particular specification of wagons. This specification is issued under the fixed serial 49-BD-08. The number after BD indicates the year of revision. This revision 49-BD-08 supersedes all previous revisions. PARTICULAR REQUIREMENTS: The draft gear along with draft gear follower shall be suitable for running long and heavy trains over undulating terrain and long sustained gradients. These trains shall be upto 2400m long with 232 wagons and a gross load upto 18000t. The draft gear alongwith draft gear follower shall be suitable for freight stock having a draft gear pocket of 625.5mm. These freight stock shall be fitted with 'E' type AAR CBC and a modified 'F' type AAR shank, as per arrangement Drg. No. WD-81010-S-03 latest alteration. The draft gear and draft gear follower shall be interchangeable. The draft gear shall have high-energy absorption capacity with a low recoil. The level of energy absorption shall be not less than 70%. APPROVAL REQUIREMENTS: Indigenously manufactured draft gear shall have the certificate of approval from the principle manufacturer and the same shall be submitted to RDSO by the Indian manufacturer. The draft gear manufactured by AAR approved manufacturer shall have unconditional approval of AAR for their draft gear under AAR Specification number M-901E or specification number M-901G. Copies of all the test results and other data submitted/recorded in the process of this approval shall be furnished.

1.2 1.3 1.4 2 2.1

2.2

2.3 2.4 2.4 (i)

2.4 (ii) In cases where, Draft Gear model is already approved by Indian Railways and foreign principal manufacturer has discontinued the model, for the purpose of indigenous vender development, the applicant manufacturer will acquire the design details, drawings and manufacturing process etc. from any of the existing RDSO approved Indian original collaborators (who had collaboration with Foreign principal manufacturer) for the same model of Draft Gear and develop the same.
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2.4 (iii) In case of Draft Gears, which are no longer in production by the foreign principal manufacturer and it is difficult to obtain the details (design details, drawings, manufacturing and quality control requirement etc.) from other sources, then in such cases for the purpose of indigenous vendor development the applicant manufacturer can develop the design details, drawings and manufacturing process etc. based on his expertise in manufacturing similar items. 2.5 The draft gear offered shall have a proven experience on any Railway System operating under similar operating conditions. Necessary data on "In Service" experience and certificate from User Railways shall be furnished. Draft gear follower shall be to AAR Catalogue No. Y46HTE and AAR Standard S -119. The manufacturer shall carry out PRODUCTION TESTING as given in clause 11.3 of APPENDIX - I of this Specification as a part of their Internal Quality Assurance Programme (QAP). The Internal Quality Assurance Programme shall meet manufacturing standards set by collaborator/ applicant manufacturer. The manufacturers QAP shall ensure that the components are strictly being manufactured to specified dimensions and material and also meet the requirement of chemical and mechanical properties recommended by collaborator/manufacturer. No deviation in dimension, chemical properties and mechanical properties of components from collaborators/manufacturers recommendations will be permitted. In addition to above clause 2.8, the manufacturer shall submit QAP as per the guidelines indicated for preparation of QAP in RDSO Document No. IL: 03 :2000 with latest revision. The complete QAP shall be got periodically reapproved from RDSO as and when it becomes due. The manufacturer shall supply Maintenance Manuals for proper maintenance of draft gears. The number of manuals to be supplied shall be 25 per contract and shall be free of cost. The manual shall contain following information:i) ii) iii) iv) v) vi) 2.11 Principle of operation and important design features Illustration explaining the working and maintenance practices Details of attention during overhauling Special tools, capacity & specification of press etc. Details of welding equipment & method of welding List of spares along with specification & part No. etc.

2.6 2.7

2.8

2.9

2.10

The manufacturers shall also supply along with draft gear, the following free of cost for each contract:i) 2 Nos. of cut model.

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ii) 2.12

25 sets of colored wall charts explaining working of draft gear, components and details of maintenance requirements.

One complete set of maintenance gauges for every 1000 Nos, or part thereof, of draft gear being supplied to Indian Railways or for use of Indian Railways. The Manufacturer shall obtain distribution of maintenance gauges from Purchaser and ensure that gauges are delivered to Workshops of Indian Railways. The manufacturer shall also provide training to sufficient Nos. of Railway Maintenance Supervisors/Staff in consultation with Purchaser, free of cost, at his own premises or in Railway Workshops. The manufacturer shall supply spares for maintenance of draft gear to Railways/Railway Workshops against their demand/Purchase Order. FIELD PERFORMANCE: The supplier shall regularly collect data and samples of previous supply from field to assess the actual life obtained, nature of defects occurring in the service and should take necessary corrective action to improve quality. Halfyearly report should be submitted to RDSO/LKO on data, samples collected and corrective action taken.

2.13

2.14 2.15

3 3.1

MATERIAL AND DESIGN Supplier shall furnish material and design information including the amount of pre-compression (in Kgs.) for each part of the draft gear offered to the inspecting official. The information regarding material shall include the collaborator's/manufacturers recommendation and quality standards applicable to the same and the heat treatment details etc. to enable inspection.

3.2

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4 4.1

INSPECTION DEVELOPMENTAL INSPECTION:

4.1.1 The new manufacturer shall submit a detailed Quality Assurance Programme as per requirement of clause 2.8, and approved by the collaborator/manufacturer to RDSO for advance approval. The QAP shall ensure that the components are strictly being manufactured to specified dimensions and material and also meet the requirements of chemical and mechanical properties recommended by collaborator/manufacturer. No deviation on dimension, chemical properties and mechanical properties of components from collaborators / manufacturers recomendations will be permitted. 4.1.2 Developmental inspection shall be undertaken for the initial supplies of the draft gear from the contractor. Developmental inspection shall be carried out separately for different type of draft gear and the type approved for one manufacturer shall not be applicable for another Manufacturer. Developmental inspection of indigenous manufacture shall be done by the Design Wing of Wagon Dte. of RDSO and request for developmental inspection shall accompany the following : Memorandum of Understanding signed with the collaborator stating that the intending manufacturer is authorised to produce the draft gears in India for sale to Indian Railvays. Certificate regarding AAR unconditional approval under clause M-901E and / or M-901 G. Certificate from collaborator/manufacturer that the indigenously manufactured draft gear has already been tested by the collaborator/manufacturer in their premises to satisfy all requirements under M-901E and/or M-901G have been found satisfactory. Results of tests conducted for the above. If documents asked in para 4.1.1 to 4.1.2.4 are not furnished then following information are required: i) Submission of drawings of draft gear and its components with a letter from the Principal Manufacturer regarding authenticity of the drawings and that these are current. Submission of detailed specifications, chemical and physical properties and manufacturing process used for manufacturing the draft gear and its components. In cases of applicability of clause 2.4 (ii), the Indian original collaborator will be considered as principal manufacturer.

4.1.2.1

4.1.2.2 4.1.2.3

4.1.2.4 4.1.2.5

ii)

iii)

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iv)

All documents required vide clause 4.1.2.5 (i) and (ii) will need approval by Wagon Design Directorate of RDSO. In case of RF-361 model Draft Gear, submission of drawings of Draft Gear and its components and information as per clause (ii) above to RDSO for approval.

v)

4.1.3

The Developmental Inspection shall be done in accordance with Appendix - I & II of the specification and latest AAR Specification No. M-901-E and / or M-901G at Collaborators / manufacturers works or the works having required facilities and authorised by RDSO. The test certificate alongwith the complete test data shall be submitted to RDSO. The selection of the samples for the purposes of Developmental Inspection shall be undertaken by the Inspector from a lot of not less than 50 draft gears. All parts shall be made of the material having the same physical and chemical properties as specified for the draft gears originally offered for AAR approval or as specified by principle manufacturer/manufacturer.

4.1.4

4.1.5

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4.1.6 4.2 4.2.1

Subsequently, no change in the design, material and/or process shall be made. PURCHASE ACCEPTANCE. After the initial supplies have successfully undergone the Developmental Inspection, the Purchase Acceptance Inspection shall be undertaken for further supplies. The Purchase Acceptance Inspection shall be as per procedure detailed in Appendix - I for draft gear to AAR spec. M-901 E or as per procedure given in Appendix - II for draft gear to AAR M-901 G. GENERAL PATENT RIGHTS: The Contractor shall indemnify patent rights. the Purchaser regarding patents and

4.2.2

5 5.1

5.2

COMPONENT SPECIFICATION: The specifications for the component material shall be furnished to the purchaser alongwith the initial supply in order to facilitate inspection.

5.3

AS MADE' DRAWINGS: The contractor shall submit one set of 'As Made' drawings and one copy in electronic format (CD) with important controlling dimensions and tolerances thereon alongwith surfaces and dimensions necessary to be gauged.

5.4

INTERCHANGEABILITY: All components including draft gear castings and springs/rubber pads shall be interchangeable.

5.5

GAUGING PROCEDURE: The Contractor shall submit the gauging procedure including the gauge drawings for approval to RDSO before commencement of supply. No change shall thereafter be carried out without the prior approval of RDSO.

5.6

INSPECTION GAUGES: The Contractor shall set aside one set of gauges for exclusive use of Inspecting Authorities. Gauge drawings, in original, shall also be made available for checking tolerance and dimensions on these gauges.

5.7

TEST EQUIPMENT: The Contractor shall provide, at his own cost, labour, appliances and tools necessary for the testing and inspection of the draft gears in accordance with this specification.
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5.8

DEVIATION FROM TEST PROCEDURES: Any deviation from the inspection in respect of test details shall be worked to with prior concurrence of the Purchaser.

5.9

DEVIATION STATEMENT: In case the offer does not correspond to this specification in any respect, a 'DEVIATION STATEMENT' shall be submitted by the supplier. This statement shall clearly give the deviations clausewise with technical reasons for the same. Changes in drawings, if any, shall be described and accompanied by a copy of revised drawing. In case the supplier does not require any deviation from this specification, a clear 'NO DEVIATION' certificate shall be submitted.

5.10

In case of modifications, drawing copy along with copy in electronic format (CD) incorporating all the modifications shall be supplied duly certified by the Inspector. The authority approving the modifications of contract drawings shall be indicated on the tracings. These tracings shall conform to the requirements indicated in clause 3.2 of IRS Specification R6-59. The size of the drawings (A-1) shall conform to size of sheets detailed in IS: 696.

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6 6.1

MARKINGS: Draft gear shall have Manufacture's Name/Initial, Date of Manufacture, Serial No., and type of Draft gears at suitable location on housing in 10mm raised type. Draft gear follower and draft gear components shall also have the markings of Manufacturer's Name/Initials, Date of Manufacture and S.No. raised/stamped in 5 mm type at suitable locations. The manufacturer shall get the marking scheme for manufacturers monogram and code, batch no., serial no. etc approved from RDSO. All draft gear components should have clear and legible manufacturers name in short and code and batch no. etc. which shall remain legible through out the entire service period of Draft Gear. The Draft Gear components found having illegible marking at the time of fitment in Railway Workshops, Maintenance depot or on Wagon Builders premises shall be treated as rejected and shall be replaced by the manufacturer free of cost. The cost of transportation shall be borne by the manufacturer. The marking shall be made at the casting/forging stage itself so that the marking shall remain legible during entire service life of the components. The manufacturer will not be permitted to provide manufacturer's code batch no., serial no. etc by electric arc welding in case these are not visible at casting / forging stage. INSPECTION AND REJECTION: The inspection and rejection shall be done in accordance with relevant clauses of Special Conditions of Contract issued by Railway Board.

6.2

6.3

6.4

PAINTING: Draft gear and draft gear follower shall be painted with black paint on only exposed surfaces excluding working portions.

SUPPLY OF SPARES: The manufacturer should furnish a list of spares and their quantity required during maintenance of Draft Gear The manufacturer shall supply spares for draft gear against Railways requirment.

10

WARRANTY/ GUARANTEE. The Draft Gear shall be guaranteed for satisfactory performance for a period of 54 months after supply or 42 months after putting into service, whichever is earlier. The guarantee shall cover Design, material and workmanship. The defective draft gears supplied against relevant contract shall be replaced by the supplier at his own expense.

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11

RECONDITIONING The manufacturer shall also undertake reconditioning of Draft gear against Zonal Railways request. The reconditioned draft gear assembly shall perform satisfactory in service and shall meet the requirements laid down in clause 10 above.

12

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

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APPENDIX-I ACCEPTANCE SCHEDULE FOR PURCHASE ACCEPTANCE INSPECTION OF HIGH CAPACITY DRAFT GEARS AS PER AAR M-901 E 1. 1.1 SCOPE: This Appendix covers the inspection procedure for purchase acceptance of the High Capacity Draft Gears. The Inspecting Authority shall audit check the QAP records of manufacturer to ensure that draft gear components are manufactured as per QAP of the manufacturer and meets the requirements of dimensions, chemical properties, mechanical properties as laid down in collaborator's / manufacturers Quality Standards. It should be possible for Inspecting Authority to find out QAP test / inspection records of draft gear components with Serial no. cast on draft gear housing. On failure to meet this requirement, whole lot shall be rejected. SAMPLE SELECTION FOR TESTS: Two draft gears shall be selected by the Inspector from a lot of not less than fifty (50) draft gears. One draft gear out of the above shall be measured both assembled and disassembled. The other draft gear shall be measured assembled and subjected to further tests. In order to pass this inspection, the draft gear must be in agreement with the contractor's collaborator drawings/ Drawings approved by RDSO. Inspecting Authority shall confirm from the records that the PRODUCTION TESTING as stipulated in clause 2.7 of the Particular Requirements has been carried out strictly for the draft gear offered for the inspection and the draft gear tested for PRODUCTION TESTING has attained the minimum capacity requirement. At least 5 draft gears out of every 500 draft gear or part there of shall be witnessed by Inspecting Authority for minimum capacity requirements during production of draft gears being offered for final inspection. After verifying the requirement of para 2 , 3 & 4, following tests shall be under taken before the commencement of supply of draft gears on one draft gear once in 6 months:i) Capacity Test. ii) Sturdiness Test. iii) Sticking. iv) Uniformity of Action.
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2.

2.1

3. 3.1

3.2

4.

4.1

5.

6. 6.1

TEST SET-UP: Capacity Test and sturdiness Test shall be undertaken on a standard Tup Hammer. Tup Hammer Set-Up The Tup Hammer set-up shall be in accordance with para 6 of AAR Specification No. M-901-E.

7.

CAPACITY TEST:

7.1 Test Procedure on Tup Hammer 7.1.1 The procedure for tup hammer test, shall be in accordance with para 9 of AAR Specification No. M-901-E. 8. 8.1 STURDINESS TEST: After the draft gear has successfully undergone the capacity test, the sturdiness test shall be undertaken. Test Procedure on Tup Hammer:

8.2

8.2.1 Based on the free fall of the hammer which produced the Maximum Travel during the capacity Test, proceed as under:1. Ten drops at plus 1/2" 2. Ten drops at plus 1" 8.2.2 8.2.3 Calibrate for capacity according to para 7.1.1 Proceed further as under: 1. Ten drops at plus 1.1/2" 2. Ten drops at plus 2" 8.2.4 Calibrate for capacity according to para 7.1.1 8.2.5 At the end of this test, the draft gear shall be taken apart for inspection. 8.2.6 In order to pass this test, the draft gear shall not develop any of the 1. Shortening, bending, crushing or deforming to an extent which makes solid height of the draft gear and follower 6mm less than the original solid height. 2. Breakage of an essential part.
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3. Widening or separating of any part or parts to casue binding in the standard draft gear pocket. 4. A reduction of capacity below 70% of the capacity measured in the capacity tests. 9. STICKING: Action of the draft gear throghout the above tests will determine whether they are acceptable from this consideration. If any draft gear found sticking during testing against para 4 & 5 regularly or persistently the whole lot shall be rejected. 10. UNIFORMITY OF ACTION: The draft gear shall meet the following requirements: 10.1 In the Official Capacity Test, the "Official Capacity" of no individual draft gear shall be more than 15 percent above or below the average capacity. In regard to uniformity of action of the draft gear, the travel of the draft gear should increase if the height of drop or the impacting speed is increased. Serious deficiencies in this respect shall be the cause of rejection. TEST REPORT: The Test Report for the tests undertaken on the tup hammer shall be in accordance with the format used for approval of the draft gears by AAR. The condition of the draft gear with regard to sticking and uniformity of action shall be recorded in inspection report in order to meet the requirement of the respective tests. PRODUCTION TESTING: Draft gears consisting of 5% of each production lot of each model or 5 gears of each production lot and model, whichever is greater, shall be drop hammer tested to ensure minimum capacity of the specification under which it has been approved by AAR. The test shall consist of the minimum number of blows required to produce the minimum capacity-required. If any unacceptable gears are found, this will necessitate the testing of the next 50 untested gears to 100% capacity. If any defective gears are found within that 50, 100% capacity testing shall be continued until 50 consecutive gears have been tested without failure.

10.2

11. 11.1

11.2

11.3

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(a) Procedure: 1. Draft gears with friction elements may be cycled between compression and release as necessary to achieve its capacity. 2. The total fall of the tup to be used in calculating capacity shall be the sum of the free fall of the tup and the travel of the draft gear before recoil. (b) Capacity: 1. Where the housing limits the travel, the capacity shall be attained prior to full closure. 2. Where the housing does not limit the travel, both the minimum free height of the draft gear and the maximum travel from this height shall be as specified by the manufacturer. The capacity shall be attained prior to this travel to ensure maintenance of the standard 13mm coupler horn clearance. 3. Each draft gear-requiring test shall have a minimum capacity of 4979 kgm. 4. If any draft gear fails this test, it shall be either reworked and retested or scrapped. 11.3.1 During production test, draft gear not meeting the requirement ``STICKING shall be rejected. The reason of sticking shall be identified. Corrective action shall be taken on all draft gear manufactured in that particular lot. Cast steel follower shall be inspected as per procedure given in RDSO Specification No. 48-BD-08 for the following requirement : (a) Chemical composition (b) Mechanical properties (c) Impact Test. (d) Hardness Test. (e) General requirement of casting acceptance. (f) Marking. (g) Weight variation (h) Dimensions The requirements against para 12 (a) to para 12 (g) above shall be requirement of grade E steel as referred in of RDSO Specification 48. BD-08. The hardness shall be tested at location marked in figure 1. The dimensions shall be checked with gauges which should be in conformity with Manufacturer's approved drawings.

12.

12.1

12.2 12.3

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APPENDIX-II ACCEPTANCE SCHEDULE FOR PURCHASE ACCEPTANCE INSPECTION OF HIGH

CAPACITY DRAFT GEARS AS PER AAR M-901 G 1. 1.1 Scope: This Appendix-II covers the particular requirements for the supply of High capacity Draft gear as per AAR specification M-901 G. facilities set up and testing procedure for freight wagons having AAR. Standard 625.5 mm pocket and having a minimum impact rating velocity of 8 kmph (five miles per hour) at a reaction force of 227272 Kgs. ( 500,000 pounds). The manufacturer manufacturing draft gear indigenously shall have the certificate of approval from their Principal manufacturers and the same shall be submitted to RDSO by the Indian Manufacturer. The draft gear manufactured by AAR approved manufacturer shall have unconditional approval of AAR for their draft gear under the AAR specification No. M-901G. Copies of all the test results and other data submitted/recorded in the process of this approval shall be furnished. The draft gear offered shall have a proven experience on any railway system operating under similar operating conditions. Necessary data on 'In service' experience and certificate from users railway shall be furnished. The supplier shall meet the requirements of clause 3 of the specification 49-BD-08 as regards material and design requirements are concerned. The Indian manufacturer shall submit a detailed Quality Assurance Programme as approved by their collaborator for advance approval. The QAP shall ensure that the components are strictly being manufactured to dimensions and material and meets all the requirement of chemical and mechanical properties recommended by the collaborators. No deviation on dimensions, chemical properties and mechanical properties of components from collaborators recommendation will be permitted. The manufacturer must meet the requirements of clause 2.9, 2.10 and 2.11 of this specification for maintenance instructions, special tools requirements, list of spares, supply of maintenance manuals, cut models, wall charts training etc. The manufacturers shall agree to supply spares for maintenance of draft gear to railways/railway workshops against this demand/purchase order. Definitions Travel:

1.2

1.3

1.4 1.5

1.6

2. 2.1

2.1.1. The design travel shall not be less than 50 mm (2 inches) in buff and the combined draft and buff travel shall not exceed 165 mm ( 6-1/2 inches). Max buff design travel must be attained at a coupler horn clearance of 13 mm (1/2 inch). Max. draft travel must be attained at a coupler horn clearance of not more than 178 mm ( 7 inches).
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2.1.2 Maximum travel shall be the travel that will produce a reaction of 363636 kg 800,000 pounds) or greater in buff and 227272 kg,( 500,000 pounds) or greater in draft. 2.1.3 Rating travel shall be the travel at a reaction of 227272 kg (500,000 pounds). Impact Velocity: 2.2.1 Rating impact velocity shall be the velocity, which produces 227272 kg (500000 pounds) reaction force. 2.2.2 Maximum Impact Velocity shall be the velocity at 363636 kg (800,000 pounds ) reaction force. 2.2:3 Official Rating Velocity shall be average of the final rating impact velocity of the gear tested. 3. Datum: The datum line for determining free fall of the tup and travel of the gear shall be established by lowering the tup until the plunger in the test frame is contacted. 4. 4.1 TRUCK IMPACT TEST SETUP: The test wagon shall be a 71 tonnes (70-ton) nominal capacity covered hopper wagon loaded to maximum gross rail weight of 100,000 kg (220,000 pound) with dry sand. The test wagon shall be in all instances the struck wagon and shall be free to roll after impact with the no back up wagons to be used. The test wagon shall be capable of withstanding the test forces without permanent set The hammer wagon shall be a 71 tonne (70 ton) nominal capacity covered hopper wagon loaded to a maximum gross rail weight of 100,000 kg (220,000 pound) with dry sand. The draft gear shall be a conventional standard pocket gear Approved under AAR specification M 901 G Draft Gear to be selected by inspecting authority. A means for accelerating the hammer wagons (preferably a calibrated inclined track) shall be provided. The accelerating means and its associated equipments shall be capable of producing the required velocity with an accuracy of 0.32 kmph ( 0.2 miles per hour) In order to minimize the effect of varying atmospheric conditions the gears shall be tested when ambient temperature is between -6deg. C to 32 deg. C (20 deg F to 90 deg. F). DROP HAMMER TEST SETUP: In order to minimize the effect of atmospheric conditions, the testing laboratory shall be in the building having a uniform room temperature and the
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4.2

4.3 4.4

4.5

5 5.1

gears shall stand in the laboratory at least 24 hours before being tested. The friction surfaces shall be protected from atmosphere, grease, dust etc. 5.2 5.3 5.4 All tests shall be made under the AAR type 12273 kg ( 27000 pounds) drop test machine, the anvil of which is supported on a rigid foundation. The method for measuring, recording and reading draft gear reaction shall be as described in specification M-901 F. Gears shall be placed in test frames which rest upon the anvil and are designed to hold the gear to normal length with the regular complement of followers as used in service. The sides of test frame must be enclosed to simulate conditions of the yoke and draft gear pocket. The draft gear shall be positioned in the test frame according to the recommendations of the manufacturer The travel of the gear shall be measured by the use of mechanical travel gauges or other approved methods. When the draft and buff characteristics of a gear are not identical, test must be made on both sections of the gear. During the drop hammer test reaction records from the anvil load cell shall be secured from selected blows. Gear reaction may be determined from these records. No gear shall be subjected to more than 41574 kg-m ( 300,000 foot pounds) of energy inputs in any half hour, except a minimum of three drops each half hour shall be made. DEVELOPMENTAL INSPECTION 6. 6.1. SELECTION AND INSPECTION OF TEST SPECIMENS: Two gears (or four gears when drop units require separate tests) shall be selected by a representative of the inspecting authority from a lot of not less than 25 gears. The gears (or 4 gears) shall be subjected to test described herein. Two gears shall be tested in buff and when required, two gears shall be tested in draft. TRACK IMPACT TEST: Rating Impact Velocity Test

5.5 5.6 5.7

5.8

6.2 7. 7.1

7.1.1 The rating of each device shall be determined as follows: Start with an impact of 6.4 kms/hour (4 miles per hour) and continue in 0.8 km per hour (0.5 miles per hour) increments upto a velocity, which produces a reaction force of at least 204545 kg (450,000 pounds) but not less than 227272 kg (500,000 pounds). Thereafter continue in 0.4 kms/hour (0.25 mile/per hour) increments until a reaction force of 227272 Kgs. (500,000 pounds) is reached or exceeded. The rating velocity obtained by straight line
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graphical interpolation between the closest points above and below the 227272 kg (500,000 pounds) reaction force level to the nearest 0.16 kmph (0.1 mile per hour). 7.1.2 In order to pass this test the rating velocity shall not be less than 8 kmph (5 miles per hour). 7.2. Maximum Impact Velocity Test

7.2.1 Continue impact velocity test in 0.4 kmph ( 0.25 miles per hour) increments until a reaction force of 363636 kg (800,000 pounds) or a velocity of 19 kms per hour or (12 miles per hour) is reached. The maximum velocity shall be obtained by straight-line graphic interpolation between closest points above and below 363636 kg (800,000 pounds) reaction force level to the nearest 0.16 kmph (0.1 mile per hour) 7.3 Train Action Requirement

7.3.1 The draft gear must have a minimum preload of 3636 kg (8000 pound) in static machine at a load rate of 12.5 mm (0.5 inches) per minute. 7.4 7.5 7.6 Each gear must comply with a horn clearance requirement at "Maximum Travel (Paragraph 2.1.) Each gear must be visually inspected for apparent damage. To evaluate the uniform action of all gears tested, in the impact velocity test, no individual gear shall be more than 15% above or below the average velocity. DROP HAMMER TEST: Endurance Test

8. 8.1.

8.1.1 All gears shall be subjected to the endurance test. The cycle will be as follows: One blow at 76mm ( 3 inch), free fall. One blow at 76 mm ( 3 inch), and one at 152 mm ( 6 inch), free fall. One blow at 76mm ( 3 inch), one at 152 mm ( 6 inch), and one at 229 mm ( 9 inch) free fall etc. Proceed thus up to a free fall which produces the rating travel established in the Rating Impact Velocity Test or to within 2.5mm (0.1 inch) from solid, which ever occurs first. When this point is reached, the endurance cycle shall start over again. 8.1.2 The test shall end when no less then 1000 total drops have been delivered to each gear, provided failure does not occur before this point. 9. 9.1. Sturdiness Test All gears shall be subjected to the Sturdiness Test. Based on the maximum
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travel established in the official maximum velocity test (or "Rating Travel" established in the official rating impact velocity Test in the Wagon of the two gears tested in the draft ) with a few drops of the tup as possible, determine the free fall of the tup which produces 363636 kg ( 800,000 pounds) reaction force on two successive drops. Using this free fall height, proceed as follows: Ten drops at plus 12.5 mm (half inch) Ten drops at plus 25 mm (one inch) Continue, the test in plus 12.5mm (half inch) increments until two successive drops produces reaction force of 454545 kg ( 1000,000 pounds). Then make ten drops at this free fall height. A minimum of 30 drops must be made. 10. 10.1. FINAL TRACK IMPACT CALIBRATION TEST: In order to satisfactorily pass these specifications, each gear will be subjected to a rating impact velocity test and must meet the following conditions:

10.1.1 At no time during the test may be rating velocity of any gear fall below 8 kms per hour (5 miles per hour) at 227272 kg (500,000 pounds) reaction. 10.1.2. The final rating impact velocity of each gear shall be obtained by averaging the rating velocities obtained before and after the Endurance and Sturdiness tests as defined in paragraph 7.1.1. 10.1.3. Each gear shall withstand one impact velocity test at 19kmph (12 miles per hour) or a reaction force of 454545 kg (1000.000 pounds) whichever occurs first 10.2. 11. 11.1 The official Rating Velocity for the gear shall be the average of final rating impact velocities of the gears tested. This must be publicised value. DEFECTS: Sticking a very serious fault in a draft gear. There is not definite test for sticking and the action of gears throughput all of the other tests will determine whether they are acceptable from this standpoint. Any type of gear which regularly and persistently sticks will not be acceptable. During following tests each gear shall be examined for loss of fluid. Loss of fluid may be ground for rejection by the test personnel and in any event, it must be reported to the Sub-committee. If necessary, the gear shall be disassembled for such examination following test programme. PURCHASE INSPECTION SAMPLE SELECTION FOR TESTS:

11.2

12 12.1

12.1.1 The Inspecting Authority shall audit check the QAP records of manufacturer to ensure that draft gear components are manufactured as per QAP of the manufacturer and meets the requirements of dimensions, chemical
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properties, mechanical properties manufacturers Quality Standards.

as

laid

down

in

collaborator's/

12.1.2 It should be possible for inspecting Authority to find out QAP test/inspection records of draft gear components with Serial No. cast on the draft gear housing. On failure to meet this requirement, whole lot shall be rejected. 12.1.3 Two draft gears shall be selected by the Inspector from a lot of not less than fifty (50) draft gears. 12.1.4 One draft gear out of the above shall be measured both assembled and disassembled. The other draft gear shall be measured assembled and subjected to further tests. In order to pass this inspection, the draft gear must be in agreement with the contractor's collaborator drawings. 12.1.5 After verifying the requirement of para 12.1.1, internal quality assurance program, following tests shall be under taken before the commencement of supply of draft gears on one draft gear once in 6 months. Capacity test Sturdiness test. Sticking Uniformity of action PRODUCTION TESTING: At least 5 draft gears out of every 500 draft gear or part there of shall be witnessed by Inspecting Authority for minimum capacity requirements during production of draft gears being offered for final inspection. The test shall consist of the minimum number of blows required to produce the minimum capacity required. If any unacceptable gears are found, this will necessitate the testing of the next 50 untested gears to 100% capacity. If any defective gears are found within that 50. 100% capacity testing shall be continued until 50 consecutive gears have been tested without failure 14. 15. The manufacturer shall furnish all the test result of the tests conducted at different stages to RDSO. The supplier shall assist Indian railways during fitment of these draft gears in the initial stage. The supplier shall agree to provide all help in solving any fitment problem, if observed. *******

12.2 12.3 13.3 12.4 13.

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