Signature Not

Verified
Digitally signed by
RATNAKER TIWARI
Date: 2023.04.17
14:33:31 IST
Reason: IREPS-CRIS
Location: New Delhi
 Ref: ( (i-F-J.2.1-J (ller'. | ) Page 2 of 58 Latest (Rev/Am€nd) issue : Specification No.
April, 202J RDSO/CC/5/23002, Rev. nil

CONTENTS
Description Page
I FOREWORD 3

I AtR SPRTNG ASSEMBLY (SECT|ON - A)

1. Scope 4
2. OperatingConditions 4
3. EnvironmentalCondition
4. Scope of Supply 6
5. Procedure for Vendor Registration 6
6. TechnicalRequirements 11
7. Submission of Offer 15
8. Guarantee 17
L lnstallation, Commissioning, & Maintenance 17
'10. lnspection and Testing 17
11. Marking 20
12. Packing 21
13. l\4aintenanceManual 21
14. General 21
ANNNEXURE . A 22 lo 25
ANNNEXURE - B 26 lo 27
III EMERGENCY RUBBER SPRINGS ( SECTION - B )

1. Scope zo
2. Requirements 28
3. StiffnessCharacteristics 29
4. Testing of Emergency Rubber Spring 29
5. Bonding Strength Test 30
6. Vertical Load vs Deflection Test (Before Endurance Test) 30
7. Shear Load vs Deflection Test (Before Endurance Test)
8. Endurance Test 31
9. Vertical Load vs Deflection Test (After Endurance Test) JJ
10. Shear Load vs Deflection Test (After Endurance Test) JJ
11 . Superimposition of Acquired Data JJ
12. Creep Test )1
13. General 34

IV SCHEOULE OF TECHNICAL RE EMEN 35 to 41

V ANNEXURE - lto X 42 lo 51

DRAWINGS
1, CG -K 4023 alt. "1": Space Envelope (180 KN capacity Air Spring) 52
2. CG -K 5065 alt "b": Space Envelope (1601120 KN capacity Air Spring)
3. CG -K 4017 Space Envelope ('140 KN capacity Air Spring)
4. CG -K 4022 all. "a": Base Plate (180 KN capacity Air Spring)
5. CG -K 5057 alt. "c": Base Plate (160/120 KN capacity Air Spring) 56
6. SKETCH-K4O18 Alt. "1": Base Plate (140 KN cap. Air Spring for ICF Bogie
7. CG-18228: Base Plate (140 KN capacity Air Spring for FIAT Bogie) 58

Signature

Name &
(y
Prepared b1:
\
ec by: Approved by:
designation Ratnaker Tirvari, n Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage irector/VDG/Carr c Director/VDG/Ca c
 Ref: CC-[--].2.1-l (llcv. l) Page 3 of 58 Lrtcst (Rev/Amend) issue : Specification No.
April,202J RDSO/CG/S/23002, Rev. nil

FOREWORD
This specification spells out the technical requirements of following type of Air
Springs assemblies:

'1. Air Spring assembly (180 KN Capacity) for higher Capacity Loads used on
EMU/DIVIU/ MEMU Coaches for ICF type Bogies.

2. Higher capacity Air Spring Assembly (160 KN) lbr LHB Coaches having FIAT Bogie

3. Air Spring Assembly (140 KN capacity) for Mainline / [Link] / MEMU Coaches for
ICF Type Bogies and Mainline/Rajdhani LHB coaches for FIAT type Bogies.

4. Air Spring Assembly ('120 KN capacity) for LHB Coaches for FIAT Type Bogies

It has been decided to rationalize and ease vendor approval process while keeping
sufficient safeguard for ensuring quality. lf a vendor is found capable and competent
to successfully design and manufacture any design / type of air spring for any type of
bogie (FIAT or ICF type bogie), service trial of that type / design of air spring for that
type of bogie has been completed successfully in past, service trials of any type /
design of air spring for that type of bogie has not been failed / repeated in past due to
complaints regarding poor performance related to quality or design for any type /
design of air springs for that type of bogie, and the vendor has not been delisted due
to poor performance related to quality or design of any type of air spring in past,
design and manufacluring capabilities of the vendor may be relied upon.

This specification consists of Section-A, Section-B and Seclion-C. Section-A is

concerned with the entire Air Spring Assembly whereas the Section-B contains details of the
requirements & tests for the Emergency Springs and Section-C contains infrastructural
requirement.

Note: Specification No. RDSO/CG/S/23002, Rev. nil supersede the old no. of this
SIR r'.e. SIR No. RDSO/2020/CG-01.

The specification shall not be altered /modified or reproduced in any form without the
written permission of the Director General (Carriage), RDSO, Lucknow.

Signa tu re

Name &
il/
Prepa red b-r": h by: Approved by:
designation Ratnaker Tirvari, vetn K umar, Shobhit Pratap Singh
SSE/V DG/Carriaqe . Director/VDG/Ca rria l)i lector/Vl)G/Ca rtia
 Ref: CG-F-.1.2.1-4 (Rev. l) Page 4 of 58 l,atest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CC/S/23002, Rev. nil

(sEcTroN - A)
TECHNICAL REQUIREMENTS OF AIR SPRING ASSEMBLIES FOR MAINLINE
COACHES AND EMU/DMU TYPE COACHES

1. SCOPE:

1.1 This schedule lays down the technical requirements for the design and supply of
following types of air spring assemblies:

S. No. Type of Air Spring Assembly Bogie & Stock

1 AirSpring assembly (180 KN Conventional ICF type bogies
Capacity) for higher Capacity Of EMU / DMU/ MEMU
Loads used on EMU/DMU/ MEMU coaches.
Coaches for ICF type Bogies.
2 Higher capacity Air Spring FIAT (Y - frame) Bogie of LHB
Assembly (160 KN) for LHB mainline coaches.
Coaches having FIAT Bogie.
3 Air Spring Assembly (140 KN Conventional ICF type Bogie
capacity) for Mainline /
Rajdhani / and FIAT Bogie for Mainline /
MEMU Coaches for ICF Type Rajdhani / MEMU Coaches.
Bogies and Mainline/Rajdhani LHB
coaches for FIAT type Bogies.
4 Air Spring Assembly (120 KN FIAT (Y - frame) Bogie of LHB
capacity) for LHB Coaches for mainline LHB AC coaches.
FIAT Type Bogies.

Scope of supply shall generally be as per clause 4 of this specification. However, if

the supplier feels that certain additional items are necessary for improved working
performance of the system, he may quole for the same. ln any case, purchaser will
be at liberty to buy all or part material from the offer.

1.2 Control equipment for the air spring assembly should be supplied to RDSO's STR C-
K407 (Latest Revision). The air spring assembly should be compatible with the
control equipment described in the above STR. The purchaser will be at liberty to buy
any part or complete control equipment to STR C-K407 (Latest Revision) and air
spring assembly to this specificatron from different source of supply.

t.J All the provisions contained in RDSO's ISO procedures laid down in Document No.
QO-D-8.1-11 dated 08.05.2019 (titled "Vendor-Changes in approved status") and
subsequent versions/amendments thereof, shall be binding and applicable on the
successiul vendor/vendors in the contracts floated by Rallways to maintain quality of
products supplied to Railways.

2. OPERATING CONDITIONS:

2.1 Each coach fitted with air spring assemblies would have a feed pipe and one brake
pipe. Normally up to twenty-six coaches form a train. Maximum operating speed and
radius of curve which is negotialed by coaches of lR are as under:

Signa tu re

Name &
0"-z
Prepared bt':
\Jp't"''
(l c )
97---
Approvcd by:
(lcsignation llitnxker Tilvari. cen Kumar, Shobh it l'ratap Singh
SSE/VDC/Carria I) . Director/VDG/Carria e Director/VDG/Ca rria
 Ref: CG-F-.1.2.1-{ (Rev. l) Page 5 of 58 Latest (Rcv/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002. Rer. nil

Type of coach Maximum Minimum radius of Maximum

operating curye (negotiated Gross
speed by coaches) load
EMU/DMU/MEMU 110 Kmph 152.4 meter 81.2 r
fitred with lcF Bogie.
/ MEMU
Mainline/Rajdhani 130 Kmph 152.4 meter 65.0 t
type ICF
conventional
coaches fitted with
convenlional ICF type Boqie.
LHB coaches fitted with FIAT 160 Kmph 152.4 meter 65.0 t
Bogie.

2.2 Compressed air supply to the air spring assemblies shall be maintained through a
compressor provided in the Locomotive. The Locomolive compressor charges the
Feed pipe at 6 Kg/cm'z. Provision of air-drying does not exist in some of the
compressed air supply system. Pneumatic circuit of air spring assembly system is
connected to the Feed pipe.

2.3 Each coach shall be fitted with four air spring assemblies (two per bogie) and each
air spring assembly shall be controlled by an independent levelling valve (4-point
control system). Two air springs of the same bogie shall be connected through a
duplex check valve set to acl at a pressure differential of 1.5 + 0.12 Kg/cm'.

2.4 To maintain continuous supply of compressed air to the air spring assembly system,
a 1so-litre auxiliary air reservoir has been provided.
2.5 Track-ballast during train operation may occasionally hit the air spring assembly and
control equipments.

2.6 Following shall be applicable when this item appears in RDSO's vendor directory:
"All the provisions contained in RDSO'S ISO procedures laid down in Document No.
QO-D-8.1-11, Version No. 2.5 (or latest) with title "Vendor-Changes in approved
status" and subsequent versions/amendments thereof, shall be binding and
applicable on the successful vendor/vendors in the contracts floated by Railways to
maintain quality of producls supplied to Railways."

2.7 The Government of lndia policy on 'Make in lndia' shall apply

3. ENVIRONMENTAL CONDITIONS:

3.1 Air springs fitted In coaches shall be [Link] to following environmental conditions:
Max. Temperature under sun : 60"C.
Ambient temperature : -250C to 50oC.
Average relative humidity :70o/o lo 9oo/o, 100% on several days.
Rainfall : Fairly heavy, maximum being 200mm in
24 hours, typical to the coastal areas.
Atmosphere : Dusly for several monlhs ofthe year.
Elevation : 2m (MSM) to 3500m (MSM) approx. and
atmospheric pressure upto 0.65 atm approx.

Air spring assembly system also come in contact with the following, during
coach maintenance operation
Signature

Name &
A7
Preparcd by:
\1(
C by:
<4=-
Approved by:
designation Ratnaker Tirvari. rayeen Kumar, Shobhir Pratap Singh
SSE/VDC/Carriage Dy. Director/VDG/Carriage Director/VDG/Ca rriage
 Ref: CG-F-.1.2,l -,1 (Rev. | ) Pagc 6 of 58 Latest ( Rcv/Amentl) issuc : Spccification No.
April,2023 RDSO/CG/S/21002, Rev. nil

Chemical products (like cleaning compound of coach cleaning)

Cotton waste smeared with oil and paint etc.
Disinfectants.
Oils & lubricants used in coach bogies.
Organic waste

4. SCOPE OF SUPPLY:

4.1 The scope of supply covers the following items:

i) For each air spring assembly

c Item Quantity
1 Air spring (Rubber bellow) 1

2 Top interfacing plate with bolsler, with spigot 1

3 Sealing O-rings 2
,|
4 Base plate
5 Emergency spring 1

6 Mounting Fasteners 4 sets

ii) Any other item, which in the view of the supplier is considered essential for
operation or enhances the performance ofthe system, may also be offered.

5. PROCEDURE FOR VENDOR REGISTRATION:

5.1 Vendors willing to supply any particular type of air spring or more than one type of air
spring assemblies (as stipulated in para. 1.1 above) for the use of lndian Railways
shall register themselves with Research Designs and Standards Organization,
Ministry of Railways, Lucknow-226011 (RDSO). Vendor should possess valid ISO
certificate for manufacture of same or similar item at his works address.

5.2 The firm should possess ISO:9001 certificate for his works address, covering the
items for which he seeks registration with RDSO.

Vendor along with their OEM (if applicable) shall have adequate infrastructure for
manufacluring, testing and quality control requirements for air spring assemblies as
stipulated in "Section-C" of this specification. This will be verified by the RDSO official
at the time of registration of the flrm or as per requiremenl.

5.4 Conditions for manufacturers. hav nq MOU with anv established OEM:

a) Air spring vendors shall be recognized on the basis of the OEM design. An OEM
for this purpose shall be defined as a company having the facilities for designing
the air spring and the necessary infrastructure to carry out detailed type tests at
their own facility. Their air spring designs should have been approved over any
railway systems and been in regular passenger service.

b) Application for registration shall therefore be considered from OEMs or from

companies enlering into a valid MOU/Agreement wth OEM air spring
manufacturers as defined above. The lvlou should clearly state that the OEM
undertakes to fulfill the rranty and support obligations with respect to

Signa tu r€

Name &
r,)r
Prepared by:
\\"Y""
CMc by:
y
,(6-pprovetl by:
dcsignation Ratnaker Tiwari, tl Ku ma r. Shobhit Pratap Singh
SSE/VDC/Carriage Dr trc ctor/VDC/Carriage Director/VDC/Ca rriage
 Reft CG-F-{.2.1-,1 (Rer,. I ) Page 7 of 58 l,at€st (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rer'. nil

technology up-gradations as and when required for the air spring assembly, even
in case lhe MOU is rescinded at some later slage.

c) Since air springs are a safety related suspension element, in-service trials shall
be necessary for OEM design before full clearance is given for supply.

d) OEMs whose air springs have completed five years satisfactory service on other
Railway Systems on at least two hundred fifty coach sets, shall only be
considered. Vendors shall be required to submit verifiable documentary proof of
satisfactory performance of lhe same. Any vendor can submit one online
application of registration for supply of one or more than one type of air spring
assemblies.

e) Only one type/ design of air spring for each type of bogie i.e. FIAT bogie & ICF
type bogie, separately, shall undergo for service trials for period of 6 months on
lR's system subject to conditions mention in para. 5.4.f and 5.4.i of Section - A
of this specification. For this purpose, trial order for minimum ten coach sets shall
be given to such vendors. For other type/ design of air springs of the vendor,
whose air springs for FIAT bogie and/or ICF type Bogies covered in this
specification have successfully completed service trials in past, other type/
design of air springs for lhe same type of bogie (FIAT or ICF type bogie) for
which atleast one type/ design of air spring has completed the service trials
successfully, will not be required to put under service trials before registration in
future.

f) ln case of any failure during service trials attributable to poor design

/quality/material, the service trials of that parlicular type of air spring may be
repeated with upgraded design or material. ln case of repeated trials, supplier
should offer the upgraded design of the air spring within 4 months from the date
of communication regarding failure of the trials.

g) After completion of service trial period, both air springs of one bogie shall be
subjected to the tests laid down at paras 1 0.2.1 , 10.2.2 and 10.2.3 of Section - A
of this specification. ln case the values obtained during these tests are beyond
permissible limits, the air spring design shall be deemed to have failed the
service lrials.

h) Vendors providing a particular OEM design as defined at (a) above shall be

given "Developmental" status on successful completion of service trials on a
minimum of len coach set air springs for 6 months from date of commissioning. A
Vendor shall be considered eligible for up-gradation as "Approved Vendor" for
particular type of air spring on completing successful supply of a minimum of 100
coach sets of that particular type of air spring along with the fulfillment of
conditions mention in latest apex ISO document of RDSO for "Vendor- Changes
in approved status" (document no. QO-D-8.1-1 'l
)

i) lf any vendor is delisted from RDSO'S vendor directory for one or more type of
air spring covered in this specification for poor design /quality/material, and / or
service trial of one or more type of air spring is failed attributable to poor design
/quality/material and requires retrial, air springs of the vendor will be put under
service trials before registration in future, until the vendor reestablishes and
proves again its design d manufacturin g capabilities by successful service
SignatuIe
Name &
r)'.-z-
Prepared bv:
\(
chlhed'by:
9{-
-A-pproved by:
designation Ratnaker Tiwari, Zl]DrfJeenKumar. Shobhit Pratap Singh
SSE/VDG/Carriaqe Dv. Director/VDG/Carriage Di rector/VDG/Ca rriage
 Ref: C (i-F-J.2.1-{ (Rer. l) Page 8 of 58 l-atest (Rcl /Amend) issue : Specification No.
A ril 202J RDSO/CG/S/23002. Rev. nil

trials as per para. 5.4.e of atleast one type air spring for particular type of bogie
(lCF type or FIAT Bogie), for which registration is applied.

j) ln case any part of the air spring assembly is manufactured outside lndia, a
certificate of country of origin shall be provided with initial supply clearly
establishing the source of manufacture. Source of manufacture of each
component shall be provided by the vendor at the time of design approval.

k) After type tests, a particular OEM design will be approved by RDSO. Vendors
shall ensure that air springs to that particular design are supplied with
components manufactured from the sources as indicated at the time of design
approval and used for type testing.

l) In case design of critical component i.e. Rubber Bellow, top plate or emergency
spring is changed, fresh type test shall be required. However, on the basis of
reasons for change and extent of modification, service trials can be conducted
afresh as per discretion of Carriage Directorate / RDSO, if any service trials of
the vendor repeated / failed in past or vendor has been delisted for poor
performance of any type of air spring in past. Status of approved vendor will not
be changed if, there is any design up-gradation / improvement in approved
design/drawing of air spring assembly to meet the upgraded requirements of
lndian Railways, with the approval of Competent Authority.

m) ln case, source of any critical component of air spring assembly is changed or

any additional new source is introduced, fresh type tests shall be required.
However, the OEM/vendor should provide the detail information of the source
changed/ additional source introduced for critical as well as non-critical
components both along with the documentary evidences for the record of this
office. OEM shall validate the source in all respects i.e. material, manufacturing
process, quality control and inspection & testing etc. to conform to originally
approved design and process. Compliance to all obligations including
guarantee/warrantee (As per Para 8/Section - A) shall remain the responsibility
of oEM.

n) Vendor in MOU with OEM (as mentioned in para.5.4.b above) must undertake
manufacluring of minimum one of three critical/major components of Air Spring
assembly i.e. either Air Bellow or Emergency Spring or Top Plate assembly in-
house or at allied/sister concern. Facilities and process of manufacturing
(indigenous) shall be validated by OEM. At this stage fresh type test shall be
essential. The sample air spring assembly shall be picked up by RDSO. Vendor
shall arrange the detail type testing of sample air spring assembly at his own
cost at OEM's type test facilities.
. The vendor has to submit lhe fresh drawing and modified QAP for approval
before undertaking in-house manufacture of these components.
. Essential documents as per clause 5.4.b/Section - A of specilication shall be
submitted for review.

5.5 Conditions for completelv indioenous m a nufacturers without MOU with anv
establis Ed OEM:
a) Supplier should have adequate in-house facilities for design, manufacture and Type
testing of Air Spring. Facilities available and type testing shall be witnessed / verified
by RDSO officials right fro \ e stage of fitment on machines and intermittently as
Signatu rc

Name &
U'
Prepared by:
\,r\g"
CYec by:
€5//
X[provetl by:
designation Ratnaker Tiwari, ecn K umar, Shobhit Pratap Singh
SSE/VDG/Carriage D1' ircctor/VDG/Carriage Director/VDG/Ca rriage
 Rcf: ( (l-F-1.2.1-.1 (Rcr. |) Page 9 of 58 Latest (Rev/A mend) issue : Specification No.
ADril,2023 RDSO/CC/S/23002, Rev. nil

decided by RDSO till completion. fi/anufacturing of some components may be

done at reputed sister/allied/outsourced concern with approval of RDSO.

b) Only one type/ design of air spring for each type of bogie i.e. FIAT bogie & ICF
type bogie, separately, shall undergo for service trials for period of one year on
lR's system subject to conditions mention in para. 5.5.c), 5.5. d), 5.5.e), 5.5.f)
and 5.5.i) of Section - A of this specification. For this purpose, trial order for
minimum ten coach sets shall be given to such vendors. For other type/ design
of air springs of the vendor, whose air springs for FIAT bogie and/or ICF type
Bogies covered in this specification have successfully completed service trials in
past, other type/ design of air springs for the same type of bogie FIAT or ICF
type bogie for which atleast one type/ design of air spring has completed the
service trials successfully, will not be required to put under service trials before
registration in future.

c) After complete type testing of air spring followed by salisfactory test results, flrm
will supply minimum 10 coach set air springs only to lR for service trials, which
shall be preferably fitted in coaches like Power Car, SLR, Motor Coach etc.
where passenger occupancy is relatively lesser.

d) Field performance of minimum l0 coach set air springs shall be monitored for
six months and after six months of service, characteristics of 04 at springs i.e.
leak test, Pressure vs Load test of air spring assembly and load vs deflection
test of emergency spring of in-service air spring shall be checked at supplier's
premises. lf results of above lests are found within the specified limit then trials
of min. 10 coach sets shall be continued for 6 more monlhs.

e) ln case of any failure during service trials attributable to poor design

/quality/material, the service trials of that particular type of air spring may be
repeated with upgraded design or material for specified quantity & trial period. ln
case of repeated trials, supplier should offer the upgraded design of the air
spring within 4 months from the date of communicatlon regarding failure of the
trials.

f) After successful trial reports from Zonal Railways for one year of service (06
months + 06 months) followed by satisfactory characteristic testing results of h/ee
04 nos. sample in-service air springs at firm's premises as per para. 10.2.1,
10.2.2 and 10.2.3 of Section - A of lhis specification, vendor shall be allowed for
regular supply of air springs as a developmenlal vendor.

S) A Vendor shall be considered eligible for up-gradation as "Approved Vendor" for

particular lype of air spring on completing successful supply of a minimum of
100 coach sets of that particular type of air spring along with the fulfillment of
conditions mention in latest apex ISO document of RDSO for "Vendor- Changes
in approved status" (document no. OO-D-8.1-11)

h) lf any vendor is delisted from RDSO's vendor directory for one or more type of
air spring covered in this specification for poor design /quality/material, and / or
service trial of one or more type of air spring is failed atributable to poor design
/quality/material and requires retrial, air springs of lhe vendor will be put under
service trials before registration in future, until the vendor reestablishes and
proves again its design and manufacturing capabilities by successful service

Signaturc
Nanre &
07
Prepared by:
\
h It1" Approvcd [l:
dcsignation Ratnaker Tiwari, !eeD Kumar, Shobh it Pratal) Singh
SSE/VDG/Carriaqe Dircctor/Vl)(;/Carria e Director/VDG/Carria c
 Reft CC-F-{.2.1-4 (Rev. l) Page l0 of58 Latest (Rev/Amend) issue : Specification No.
April, 2023 RDSO/CC/S/23002, Rev. nil

trials as per para. 5.5.c, 5.5.d and 5.5.e of atleast one type air spring for
particular type of bogie (lCF type or FIAT Bogie), for which registration is
applied.

i) Source of manufacture of each component of air spring assembly shall be

provided by the vendor at the time of design approval. Sources of critical
components shall be verified by RDSO.

j) After type tests, a particular vendor design will be approved by RDSO, vendors
shall ensure that air springs to that particular design are supplied with
components manufactured from the sources as indicated at the time of design
approval and used for type testing.

k) ln case design of critical component i.e. Rubber Bellow, top plate or emergency
spring is changed, fresh type test shall be required. However, on the basis of
reasons for change and extent of modification, service trials can be conducted
afresh as per discretion of Carriage Directorate / RDSO, if any service trials of
the vendor repeated / failed in past or vendor has been delisted for poor
performance of any lype of air spring in past.

l) ln case, source of any crilical component of air spring assembly is changed or

any additional new source is introduced, fresh type tests shall be required. The
vendor should provide the detail information of the source changed/ additional
source introduced for critical as well as non-critical componenls both along with
the documentary evidences for the record of this office. Vendor shall validate the
source in all respects i.e. material, manufacturing process, quality control and
inspection & testing etc. to conform to originally approved design and process.
Compliance to all obligations including guaranlee/warrantee (As per Para
8/Section - A) shall remain the responsibility of Vendor.

m) Vendor must undertake manufacturing of minimum two of three critical/major

components of Air Spring assembly i.e. Air Eellow and either Emergency Spring
or Top Plate assembly in-house or at allied/stster concern.

5.6 Capability and capacity assessment of vendors:

Verification of STR and QAP along with assessment of capacity and capability of
manufacturer of Air Spring shall be undertaken by authorized representative of
RDSO at the premises of firm. ln case of the firm having their sub assembly
manufacturers located at different locations, the facilities at the location of
manufacturing of critical components i.e. Air Bellow, Top Plate assembly and
Emergency spring will be verified along with witnessing of assembly of air spring and
Type Testing of Air spring assembly.

5.7 Prototype lnspection:

5.7.1 Vendor shall offer at least two nos. prototype air springs assemblies of particular
type, for which they are seeking registration in RDSO, for necessary inspection and
testing as per paras. 10.2.1 , 10.2.2 and 1 0.2.3 of Section - A of this Specification.

5.7 .2 The prototype inspection of air spring assemblies shall be carried out by Carriage
Directorate of RDSO or their nominee at manufacturing premises of firm. The
manufacturer shall provides , tool and an y other assistance without any extra
Signatu [c

Name &
&:r
Prcprred b\': ( herk )
4{--ppror ctl b1:
designation Ratnakcr Tiwari, Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage or/VDG/Calria e l)irector/V DG/Carria c
 Ref: CG-F-4.2.1-4 (Rev. l) Page ll of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/2J002, Ilcv. nil

charges which may consider necessary for any test / examination and dimensional
test.

5.8 Service trials quantity:

As per the requirement of lndian Railways, RDSO at its discretion with approval of
competent authority can increase the trial quantity of air springs of particular vendor
based on the satisfactory performance of air springs supplied earlier against
developmental orders for service trials.

5. TECHNICAL REQURIEMENTS:

6.1 Static load & oressure oer air sDrino assemblv:

6.1 .1 The air spring assembly shall be capable of withstanding following range of static
vertical loads by using compressed air with a limiting pressure value of 6 Kg/cm'z.
S. No. Type of air spring Load
Minimum Tare load Maximum Full load
i) 180 KN capacity 50 KN 1BO KN
ii) 160 KN capacity 50 KN 160 KN
iii) 140 KN capacity 50 KN 140 KN
iv) 120 KN capacity 60 KN 120 KN

Further, the air spring assembly should be capable of meeting the maximum vertical
load at an air pressure of 5.5-5.8 Kg/cm2 to allow for minor pressure drops along the
train length during run.
6.1 .2 It shall be possible to inflate the proposed air spring assembly from its deflated
condition when preJoaded with a static vertical full load mention in above table,
simply by supply of compressed air through levelling valve without any other external
assistance.

6.2 Deflection c haracteri stics of air sorino assemblv

During dynamic (running) condition of coaches, the air springs shall be [Link] to
the following defleclions at frequencies of upto 3Hz. The design of the spring should
be able to cater for the same:
S Type of atr Deflection
spring Max. Vertical deflection Max. Lateral deflection of
No.
of sprinq (dz.) sprinq (dy.)
i) 180 KN capacity t30mm !60mm
ii) 160 KN capacity 130mm t80mm
iii) 140 KN capacity 130mm t 60 mm (lCF Bogie) & +80
mm (FIAT boqie)
iv) 120 KN capacity 130mm t80mm

6.3 Air spring assembly shall be designed for use wilh an additional air reservoir of
following capacity (volume) permanently connected lo air spring:

S. No. Type of air spring Additional Volume

i) 180 KN ca 20 or 40 dm3

S ignatu re
Q->-
Nanre & Prepared by: cc by: Approved by:
designation Ilatnaker Tiwari, Pr Ku ma l, Shobhit Pratap Singh
SSE/VDG/Carriage rcc tor/VDG/Carria e Director/VDG/Ca rria c
 Ref: CG-F-{.2. | -{ (Rer'. l) Page l2 of 58 Latcst (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

ii) 160 KN capacity 60 dm3

iii) 140 KN capacity 20 or 40 or 60 dm3
iv) 1 20 KN capacily 60 dm3

6.4 Vertical stiffness of air sprinq assembly

6.4.1 Minimum air cushion provided under minimum tare load condition shall be 25 mm,
with following installed heights:

S. No. Type of air spring lnstalled / Design Height

i) 180 KN capacity 255*5,0 mm
ii) 160 KN capacity 294'0-s mm
iii) 140 KN capacily 255*o,s mm (for ICF Bogie)
294.0-s mm (for FIAT Bogie)
iv) 120 KN capacity 294'o-s mm

6.4.2 At dz + 20 mm at constant speed of smm/sec, the vertical stiffness (Cz) shall be as

under:

S. Type of atr Vertical Stiffness under load

No. spring

i) 180 KN
capacity Load in Vertical stiffness (Cz)
KN Additional Additional volume
(Static) Volume 20dm3 40dm3
50 600t'100 N/mm 5501100N/mm
165 1200r200N/mm 1 0001200N/mm
180 13501200N/mm 1 'l 501200N/mm

ii) 160 KN
capacity Load in Vertical stiffness (Cz)
KN (With Additional Volume 60dm3)
(Static)
60 285 + 20 N/mm
90 360 + 25 N/mm
120 430 + 30 N/mm
160 530 + 40 N/mm

iii) 140 KN
capacity Load in Vertical stiffness (Cz)
KN Additional Additional volume
(Static) Volume 20dm3 40dm3
50 550150 N/mm 400150N/mm
875t75N/mm 625t75N/mm
140 1 0001100N/mm 700t'100N/mm

Signature
N, nre &
0-z
l'repared by;
\.{htl
dt/"9grd ry,
')?
--'{pproved by:
tlcsignation Ratnak€r Titi'ari, .Prd-l een Kumar, Shobhit Pratap Singh
SS E/VD(;/Cat'riage D]'. Director/VDC lCarriage Director/V DC/Carriage
 Ref: C(i-F-4.2.l-{ (Rev. I ) Page l3 of58 Latest (Rev/Amend) issue : Specification No.
April,2021 RDSO/CG/S/23002, Rev. nil

iv) 12O KN
capacity Load in Verticalstiffness (Cz)
KN (With Additional Volume 60dm3)
(Static)
60 350125 N/mm
90 400t50N/mm
120 500175N/mm

6.5 Lateral sprinq sliffness of air sprinq assemblv

At dy +20 mm at constant speed of 5 mm/sec, the lateral stiffness (Cy) shall be as

under:

S. Type of air Lateral Stiffness under load

No spring
i) 180 KN
capacity Load in KN (Static) Lateral stiffness (Cy)

50 250 t50 N/mm

165 4501100 N/mm
180 5001100 N/mm
ii) 160 KN
capacity Load in KN (Static) Lateral stiffness (Cy)

60 130 + 20 N/mm
90 165 + 25 N/mm
120 200 + 30 N/mm
160 250 + 40 N/mm

iii) 140 KN
capacity Load in KN (Static) Lateral stiffness (Cy)

50 150 r25 N/mm

115 175125 N/mm
140 200125 N/mm

iv) 120 KN
capacity Load in KN (Static) Lateral stiffness (Cy)

60 175130 N/mm
90
120

6.t The air spring should be able to withstand an occasional 50% dynamic augment over
the maximum static load.

6.7 Burstinq slrenqth of the air sorino:

Air spring shall be capable of withstanding a minimum bursting pressure of 30

Kg/cm'. Test procedure for c

4r-'
ursting strength of air spring should be as follows
Signaturc { )-z \ {'(/'
Name & Prepared by: Cldgg/tt uy: Ap-fl-proved by:
designa tion Ratnaker Tiwari, *Br:a96en Kumar, Shobh it Pratap Singh
SSE/VDC/Carriage Dv. Dircctor/VDG lCarriagc Director/VDG/Ca rriage
 Ref: CG-F-4.2.1-.1 (Rev. l) Page l;l of 58 Latest (Rev/Amend) issu€ : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

This test shall be performed with water at an ambient temperature above or around
200c.
- lnstall the air spring assembly that was subjected to one million cycles
endurance test at design height.
- Inflate the air spring assembly with minimum 30 kg/cm2 internal pressure and
hold the air spring assembly at this pressure for a minimum of 5 minutes.
- Observe if there is any damage or visible crack.

6.8 ln case of accidental deflation of the air spring assembly during dynamic condition of
the coach due to reasons other than leakage/bursting/puncture etc. of the air spring,
when the coach sits on emergency springs (Clause 6.9.3), there shall be no
damage to air spring assembly under normal operating conditions.

6.9 Emerqencv sprinq

6.9.1 During train operation, deflation of an air spring due to depletion of pneumatic
pressure either on account of ieakage or disruption in air supply cannot be ruled out.

6.9.2 To counter such situations, an emergency rubber spring shall be required to be

installed in the air spring assembly, which shall act as suspension element during
such happenings.

6.9.3 This spring shall be capable of safely carrying the affected vehicle as above (either
fully or partially loaded) upto distance of 4500 km al speed of at least 60 kmph in
mainline coaches fitted with air springs of 160 KN capacity / 140 KN capacity / '120
KN capacity and upto destination at speed of at least 60 kmph in EMU / DMU /
NIEMU type coaches fitted with air spring of 180 KN capacity under normal operating
conditions without suffering any self-damage or any further damage to the air spring
which will make them unfit for further use. This situation is likely to arise occasionally
in the

service life of the air spring. Operational speed in the range of 100 Kmph or above in
deflated condition shall be preferable.

6.10 SpaceConstraints:

Air spring assembly consisting of top plate with spigot (for air connection), air spring
bellow, rim, external / internal emergency rubber spring, base plate etc. in inflated
condition (at 6.0 kg/cm, bellow pressure) shall be within the space envelope shown
in RDSO Drawings. Some of the leading parameters of air spring assembly and
drawing no. in inflated condition are enclosed as Annexure - Vlll (enclosed). Profile &
overall dimensions of inflated air spring assembly in extreme lateral, vertical &
torsional load/ force to be prepared during the type test as per para 6.4.3 of EN
13597:2003 and shall be submitted to RDSO.

6.1 1 N,4ou ntinq arranoementl

The material of the base plate shall be stainless steel or corrosion resistant steel or
equivalent even if this arrangement is an integral part of the emergency spring to
avoid inter-metallic corrosion. The base plate shall be provided with 04 nos. mounting

S igna tu rc (Yz
Name & Prepa red by: C ec v pproved by:
designation Ratnaher Tirvari, P cn Ku nra r, Shobhit l'ratap SiDgh
SSE/VDG/Carriage I rec tor/VDG/Carria Director/VDG/Carria e
 [Link]: C (i - ['--1.2. I --l ( Rer. l) Page l5 of 58 Latest (Rer,/Amend) issue : Spccification No.
April,2023 RDSO/CG/S/2J002, Rev. nil

fasteners. Details of base plate and mounting fasleners are specified in Annexure -
Vlll (enclosed)
6.12 Pneumatic supplV conneclion:

Air inlet connection poinl to the air spring shall be located at the centre of top plate
through a spigot made air tight by using minimum two rubber O-rrngs. The
dimension of spigot for all type of Air Springs shall be as under:

i) Outer diameter of spigot = @ 85-0 036.0 ozr mm.

ii) Height of spigot = 35 + 0.5 mm.
iii) Cross section diameter of "O" ring over spigot = 5.7 + 0.'l mm.

Detailed dimensions of Spigot and O-ring over spigot are given in Annexure - lX
(enclosed).

6.13 Other Details:

6.13.1 The fasteners shall be zinc coated as mention in Annexure - Vlll. All exposed metal
parts of the air spring assembly shall be of stainless steel or corrosion resistant steel
or equivalent. Salt spray test, for assessment of corrosion resistance of metal should
be carried out according to ISO 9227. The specimen should not have any "Red Rust"
on the surface exposed to air. Test report of salt spray test should be as per ISO
9227 and also part of type test report. Moreover, as quality control measure, salt
spray test should also be repeated by the firm at every 3 years for any one type of air
spring assembly and report along with clear photographs (before and after) of the
same also to be submitted to RDSO. The testing time should be minimum 720 Hrs.
AII exposed metal parts should be painted as follows:

S. No. Type of air spring Colour and shade

i) 180 KN capacity Grey (RAL no.7042)
ii) 160 KN capacity Sky Blue (RAL no. 5012)
ii,) 140 KN capacity Red (RAL no. 302413020)
iv) 120 KN capacity Light Green (RAL no. 6037)

6.13.2 Any alternate material for manufacturing of emergency spring and metal parts of air
spring assembly, which fulfills the functional and technical requirement of metal
parts/emergency spring can also be considered provided that it is proven and
established globally, which is to be demonstrated by firm, subject to clearance by
RDSO,

6.14 Phvsical tests of air sprino bellow

Physical tests of the air spring bellow as specified at para. 5 of Annexure "A" of this
specification shall form a part of the type test report.

7 SUBMISSION OF OFFER:

7.1 Vendors desirous of seeking approval from RDSO for supply of material as per this
Specification, should submit their proposal accompanied by the documents
containing the following i n to RDSO: -
Signatu re (Pz 9-L'
Name & l'repared b1': Ch br': -dpprovetl by:
dcsignation Ratnakcr Tilvari, r een Kumar, Shobhit Pratap Singh
SSE/VDG/Carria . Director/VDC/Carr e Director/VDG/Carriage
 Rcf: CC-F-.1.2,1-,1 (Rev. l) Page l6 of58 Lfltest (Rev/Amend) issue : Specification No.
April, 2023 RDSO/CG/S/23002, Rev. nil

1 Dimensional drawing of air spring assembly.

2 lnner volume, effective area and effective diameter of springs.

3 Self damping characteristic of air spring assembly an inflated condition at 1 Hz to

3 Hz frequency.

4 Self damping characteristic of emergency spring at 1 Hz to 3 Hz frequency.

5 Diameter of air bellow at 6 Kg/cm2 under design height.

b Vertical and lateral stiffness of emergency spring under tare, gross and
intermediate loads as specified in Specification.

7 Data for particular type of air spring as mention in Annexure - X (enclosed).

Same details shall be required for modeling of air spring system of particular
vendor in simulation soft\ /are.

8 Weight of one air spring assembly.

9 Whether proposed air spring is being used by any other rail-road system? lf yes,
details regarding quantity, type of stock, max. operating speed and type of
service shall be furnished.

10 Details of deviation from the Specification.

11 Content of indigenous and imported items in offered air spring assembly.

12 Expected life cycle in operating and environmental conditions enumeraled in

clause 2 & 3.

13 MOU / Agreement with the OEM permitting supply/manufacture of the offered

springs. (For proposals from other than OEMS).
14 A write-up giving broadly the maintenance requiremenls on time/dislance basis
along with the facilities that would be needed for proper maintenance/upkeep of
the offered air spring assembly.
15 A detailed wrate-up giving the details of "Quality Assurance System" being
followed for manufacture of the offered items: and

16. Details of manufacturing and testing facilities available with the manufacturer

The information as received above shall be used for preliminary evaluation of the
firm's capability in meeting with the requirements of this Specification.

The firm shall be required to submit a Type Test Report of a proposed design after
the preliminary evaluation carried oul as per para 7.2 is found satisfactory. Type Test
Report shall be complying with Annexure "A" of this Specification.

7.4 The premises of the firm shall be visited by RDSO's officials for on-the-spot
assessment of the firm's capability.

7.5 RDSO reserves complete right in granting approval or otherwise to a firm.

Signaturc (Pz \"{.(

'tzv
Name & Prepared b."-: C hec -d-pproved by:
designation Ratnxker Tirvari. n Kumar, Shobhit Pratap Singh
SSE/V I)G/Carriage irector/VDG/Ca c Director/VDG/Carriase
 Ref: CC-F-,1.2.I -.1 (Rer'. l) Page l7 of58 Latest (Rev/A mend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

8 GUARANTEE:

8.1 Complete air spr;ng assembly including emergency spring shall be guaranteed for
satisfactory performance for a minimum period of 60 months from the date of actual
commission in bogies or 72 months from the date of supply whichever is earlier.
Satisfactory performance for this purpose means that complete air spring assembly
or any of its part shall neither show any kind of deterioration which is likely to render
it unserviceable nor lose its characteristics as stipulated in this Speciflcation, during
the guarantee period for reasons attributable to manufacturing/design defects.
8.2 ln the evenl of 'non-satisfactory performance'of any of the items as indicated above,
supplier will have to replace the same at his own expense without levying any cost
involved in transportation, handling and replacement of such items on the Purchaser.

9 INSTALLATION, COMMISSIONING & MAINTENANCE:

9.1 On placement of order, supplier whose equipment will be purchased for the "First
Time" for installation on the coaches, shall have to depute his .epresentative at his
own expense lo associate with the purchaser in installation and commissioning of the
equipment on the first five coaches. He shall also depute his representative during
maintenance schedules undertaken on his equipment as per maintenance booklet
supplied by him.

9.2 With every order for supply of the air spring assembly, the supplier shall have to
supply maintenance instructions in the form of a booklet (hard copy / soft copy).

9.3 Maintenance booklet supplied by the supplier shall cover the following aspects in
detail:
1) Specification of the air spring assembly.
2l Drawing and specification of gauge for measuring spring height in installed
condition in coach.
3) Drawing and specification of other gauges required for maintenance.
4) Working principle based on the actual construction.
5) Constructional details giving sketches, drawings and photographs etc.
identifying various items and their part numbers etc. for easy identirication.
6) Procedure for dismantling using sequential steps with the help of sketches.
7) Procedure for assembly, using sequential steps with the help of sketches.
8) Jigs, tools, other materials and details of special set-ups etc., necessary for
item6&7above.
9) Testing procedures and facilities required along with their details.
10) Comprehensive details containing legible sectional views of defects normally
observed or may happen on air spring and emergency spring with clear
remarks whether the defect is rejectable or non-rejectable.
1 1 ) List of oiher defects and their remedies.
12) Periodicity for various maintenance activities on time and distance basis.
13) Do's and Don'ts for maintenance officials.

1O INSPECTION AND TESTING:

10.1 Generalrequirements

During initial approval of a firm RDSO (Clause 7) and later on when approval has
bee n ranted, RDSO for pur f ensuring quality of purchased uct m
Signatu re

Name &
0?
Prepared by:
\-t
Chec
44-
[[Link] by:
designation Ratnaker Tirvari, en Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage rector/VDG/Carria e Director/VDG/Carriage
Ref: CG-F-,1.2.1-4 (Rev. l) Page l8 of 58 Latest (Rev/Amcnd) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

out periodic quality audit, inspection and testing of the equipment at the premises of
the manufacturer. Purchase inspection shall be done at lhe premises of the
manufacturer by a representative of the Research Designs and Standards
Organization or an agency authorized by RDSO. The supplier shall have to arrange
for the following and associate with the same:

1) Access to all records considered relevant for such activity by inspecting officials.

2) Questioning of relevant personnel engaged in production, testing and quality

checking activities etc. or related issues.

3) Testing of few samples of items already produced by the firm to ascertain the
technical characteristics given in this Specification.

4) Any other check considered necessary by the inspecting party

5) The inspecting official will carry out purchase inspection as per updated checklist
approved by RDSO. The general format of inspectlon checklist is attached at
Annexure "8" of this Specification.

10.2 lnsDection and testin o of air sorino assemblv (air bellow and em eroencv sorino)

10.2.1 Dimensional check

ITEM REFERENCE DOCUMENTS

Air spring Top Plate with
spiqot, As per Firm's assembly drawing approved by
Diameter of air bellow at 6 RDSO & technical requirements of clause 6 of
Kg/cm2 under design height. this Specification.
"o" Rinq
Base plate

10.2.2 Leak test of air sprino bellow:

Leak test of air spring assembly shall be carried out as follows-

- lnstall the air spring assembly at design height.
- Gradually raise the air pressure to 9 kg/cm'? and disconnect the air supply.
- Air spring assembly shall be checked for pressure drop at the following
pressure and time intervals.
a) After one hour at internal pressure 9.0 kg/cm2.
b) After 15 minutes at internal pressure 6.0 kg/cm'?. The above tests shall be
conducted with the air supply and drain system of test device turned off.
Drop of pressure at the completion of test shall be measured. The pressure
drop is required to be within 1% of the test pressure i.e. 9-0 kg/cm2 or 6.0
kg/cm2 as applicable.

I 0.2.3 Characteristics tesls

[Link] Air bellow

Pressure vs load test of air ng assembly

SigDature

Nanre &
0-z
Preparetl by: cc by:
4-/
ffirovetl by:
designation Ratnaker Tiwari, een Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage . Director/VDG/Carria e Director/VDG/Ca rriage
 Re f: ('C-F-J.2.1-1 (Rer'. l) Page l9 of 58 l,atest (Rev/Amentl) issuc ; Specification No.
April,2021 RDSO/CG/S/21002, Rer'. nil

Air spring assembly at fixed installation height (paru.6.4.11 Section - A) and with
additional volume (para. 6.3 / Section - A) shall be tested at pressure starting from 1,
2, 3,4, 5 and upto 6 kg/cm2. The recordings shall be done as given below: -

S,N Pressure Specitied Observed Vertical Load in kN

in Kg/cm2 Vertical Load
in kN Spg. No. Spg No [Link] [Link].

The Pressure v/s Load relationship of air spring assembly shall be same as given in
type test report / QAP approved by RDSO.

[Link] Emerqencvsprino:

Vertical load vs. deflection characteristics measured at vertical loads on Emergency

spring given in type test report / QAP approved by RDSO.

[Link] Periodical tests of Air Spring Assemblies, as a quality control measure to

ensure quality of this critical suspension element:

To ensure consistency in quality of rubber components of this critical suspension

component (Air Springs), following lests shall be done periodically. Tests shall be
conducted by the vendors & reports along with pholographs shall be submitted to
RDSO. Plan & schedule of these tests shall be communicated to RDSO & RDSO
might depute its personnel to witness the tests by suitable means including video
call.

S. Description of test Sample qty Periodicity of tests from

No date of issue of this
specification
1 Salt spray test of all exposed 01 no Every 3 years or supply
metal parts of air springs of every
500 coach sets,
whichever is later
2. Lateral load v/s deflection test 05 Nos Yearly/ After supply of
of Air spring assembly upto 500 coach sets of
deflection menlioned in para particular type of air
6.2 of Section-A of RDSO spring, whichever is
Specification No. later.
RDSO/CG/S/23002, Rev. nil
3. Lateral load vs. deflection of 05 Nos. Yearly/ After supply of
Emergency spring as per 500 coach sets of
para 4.1 of Section-B of particular type of air
RDSO Specification No. spring, whichever is
RDSO/CG/S/23002, Rev. nil later.
4. Lateral stiffness of air spring 05 Nos Yearly/ After supply of
assemblies as per para 6.5 of 500 coach sets of
Section-A of RDSO particular type of air
Specification No. spring, whichever is
RDSO/CG/S/23002, Rev. nil later.

Signatu re

Nane & Prepared by: cti(eu_!yt2 ffiroved by:

designation Ratnaker Tirrari, Py3yee{Kumar. Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG/Carriage Director/VDG/Ca rriage
Ref: CC-F-,1.2.1-,1 (Rev. I) Page 20 of 58 Latest (ReY/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

5 Vertical stiffness of air spring 05 Nos Yearly/ After supply of

assemblies as per para 6.4 of 500 coach sets of
Section-A of RDSO particular type of air
Specification No. spring, whichever is
RDSO/CG/S/23002, Rev. nil later.
6 Fatigue test of air spring 01 no. of each type Every 5 years
assemblies (All the tests of of air spring
para 8 & 9) of Annexure-A of assembly approved
RDSO Specification no. by RDSO (i.e. 120
RDSO/CG/S/23002, Rev. nil kN, 140 kN, 160 kN
to be done. & '180 kN capacity).

10.3 10% samples of the lot or a minimum 10 samples whichever is maximum shall be
picked up randomly for dimensional test as given in clause 10.2.1/ Section -A of this
Specification.

10.4 For other specified inspections as given in clause 10-2.2 / Section - A and 10.2.3 /
Section - A of this Specification, samples shall be picked up randomly as under:

Lot size upto '10 25 50 100

No of samples 2 3 4 6

For lot sizes more than 100, 6% of the samples shall be picked up randomly for the
above inspections.

10.5 In case any picked up sample fails, manufacturer/supplier shall re-offer, rectifying the
defects. However, in such cases, double the quantity of samples shall be picked up
and shall be checked for dimension and other specified tests. ln case any one
sample fails again, the entire lot shall be [Link].

11 MARKING;

Marking on air spring assembly shall be legibly marked to indicate the following:

S Detail of item of Particulars to be marked

No. air spring
assembly
1 Every item of the 1) Manufacturer's initials (Vendor code/OEI\/ Name).
air spring assembly 2) Month and year of manufacture (t\ilM^/YYY).
(Top plate, Bottom 3) ldentification marks, i.e. Part Number, Batch Number,
plate, Air bellow & Serial Number etc.
Emergency spring) 4) Capacity of air spring (180 KN/ 160 KN/ 140 KN/ 120 KN)
2 Base plate of air "Air Spring capacity (180 KN / 160 KN / 140 KN / 120 KN)"
spring assembly on two adjacent edges of base plate.
3 ldentification plate 1) Type of Stock (lCF Coaches/LHB Coaches/MEMU
of ai( spring Coaches/EMU type coaches)
assembly. 2) Capacity of air spring (180 KN/ 160 KN/ 140 KN/ 120 KN)
3) lnstalled height (255 mm / 294 mm)
4) Name of Vendor.
5) Month & year of manufacturer (MM^/Y)
lvlarking on air spring assem should be lastin s

Signaturc
0v \q^Y qy/-.-
Name & Prepared by: C by: --$proved by;
designation Ratnaker Tilvari, raYeen Kumar, Shobhit Pratbp Singh
SSE/VDG/Carriage Dl. Director/VDG/Carriage Director/VDG/Carriagc
 Rcf: C(i -F-{.2.1-{ (Rer. l) Page 2 | of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rer'. nil

12 PACKING:
The air spring assembly shall be suitably packed along with its loose parts and
exposed threaded portion, to protect against any damage that may occur during
transit and handling. The opening of the spigol of the spring shall be suitably covered
with a plastic/rubber cap to prevenl ingress of dust or foreign material in the air
spring.

.I3 MAINTENANCEMANUAL:

The supplier shall provide at least one copy of maintenance manual, free of cost with
each consignment, for maintenance and overhaul purpose.
,14 GENERAL:

14.1 RDSO may draw samples for quality check to test any property mentioned in this
specification at it's discretion. The vendor shall arrange testing of these samples at a
reputed outside laboratory as decided between RDSO and the vendor. The testing
charges should be borne by the vendor.

14.2 RDSO reserve the right to modiry any clause of this Specification as per requirement
of lndian Railways.

14.3 Additional information if required may be obtained from the office of the Director
General (Carriage), RDSO, Manak Nagar, Lucknow - 22601 '1.

Signirtu rc

Name &
,o-
Prepared by:
\
c by: -{pproved by:
designation Ratnaker Tiwari, een Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage . Dircctor/Vl)G/Carria e Dircctor/VDG/Carriage
Ref: CG-F-4.2.1-4 (Rev. l) Page 22 of 58 Latcst (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

Annexure - A

REQUIREMENTS OF TYPE TEST REPORT

The type test report of air spring assembly shall consist of the following, clearly
represented by graphs as well as in tabulation forms, with detailed test procedures and their
results: -

1) Lateral characteristics measurement at speed V= 5 mm/sec, using triangular wave

form of vibrations in lateral direction with following conditions:

S Type of
air Conditions at which characteristics shall be measured
No. spring Vertical Load Stroke (dy) Additional
Volume
i) 180 KN capacity s0, 115, 165 r10, r20, r30, 140, r50, 20 tit
& 180 KN t60 mm
ii) 160 KN capacity 50, 60, 90, 110, r20, r30, i40, r50, 60 tit.
120 & 160 KN 160, 170 & 180 mm
iii) 140 KN capacity 50, 70, 115 & t10, 120, r30, r40, r50, 40 tit
140 KN 160 mm, +80mm (FIAT
bogie)
iv) 120 KN capacity 60, 90 & 120 110, 120, 130, 140, r50, 60 tit.
KN 160, 170 & 180 mm

2) Vertical characteristics measurement at speed V= 5 mm/sec, using triangular wave

form of vibrations in vertical direction with following conditions:

s. Type of atr Conditions at which characteristics shall be

No s pring measured
Vertical Load Stroke (dz) Additional
Volume
i) 180 KN capacity 50, 115, 165& |10, r20, 130 mm 20, 30 & 40 tir
180 KN
ii) 160 KN capacity 50, 60, 90, 120 110, r20, r30 mm 40, 60 & 80 rir
& 160 KN
iii) 140 KN capacity 50, 70, 1 15 & 110, r20, t30 mm 20, 30,40 & 60
140 KN tit.
iv) 120 KN capacity 60, 90 & '120 110, r20, r30 mm 40, 60 & 80 tit
KN

3) Rotational stiffness of air spring assembly*

A) The rotational stiffness at constant velocity, shall be tested and mentioned in the type
lest report as per para [Link] & [Link].4 of EN '13597:2003 (E), for tare to full load
conditions for each type of air spring assemblies i.e. 120 kn, 140 kn, 160 kn & 180 kn
capacities at respective installation heighls.

B) The rotational stiffness under sinusoidal motion, shall be tested and mentioned in the
type test report as per para [Link] &[Link].4 of EN 13597:2003 (E) for tare to full load

Signature

Namc &
t)-? \i*(--
c1g*d
q----
Preparcd by; uv: --d'pproved by:
designation Ratnaker Tiwari, ----Pf-a veen Kuma r, Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG/Carriage Director/VDG/Ca rriage
 Rcf: C(i-F-.1.2. l-.1 (Rcv. I ) Pagc 23 of 58 l,atcst ( I{cv/A|nend) issue : Specification No.
ril 2023 RDSO/CC/S/23002, Rev. nil

conditions for each type of air spring assemblies i.e. 120 kn, 140 kn, 160 kn & '180 kn
capacjties at respective installation heights.
.Similar tests as per applicable alternate standards shall also be acceptable.

4) Vertical force versus internal pressure characteristic measurements of air spring.

5) Effective area versus deflection curve of alr bellow.

6) Salt spray test of metal part as per para. 6.13 / Section - A of Specification.

7l PHYSICAL TESTS

a) For Air Spring Bellow:

(i) Abrasion test as per para.6.2.5 of EN 13597 : 2003 (E).

(ii) Resistance to "Oil and Petroleum Product" as per para. 6.2.3 of EN 13597: 2003 (E)
(iii) Adherences between plies as per para. 7.3.3 of EN 13597 : 2003 (E).
(iv) Resistant to ozone test as per para. 6.2.2 of EN 13597 : 2003 (E).

(iiv) Low temperature test as per para. 6.2.1 of EN 13597 : 2003 (E).

b) For Emergency Spring:

(i) Abrasion test as per para. 7.2.7 of EN '13913 : 2003 (E).

(ii) Resistance to "Oil and Petroleum Product" as per para. 7.2.5 of EN 13913: 2003 (E)

(iii) Heat ageing test as per para. 7 .2.3.1 of EN 13913:2003(E).

(iv) Resistant to ozone test as per para. 7.2.4 of EN 13913 : 2003 (E).
v) Low temperature test as per para. 6.2.1 of EN 13597: 2003 (E)
8) Durability test at 6 Kg/cm2 internal pressure (Endurance Test) of air bellow as follows.

ENDURANCE TEST OF AIR SPRING ASSEMBLY:

a) The endurance test is conducted to access suitability of the air spring assembly
provided at secondary stage suspension in coach bogie by simulating service
conditions in the laboratory.
b) The test on air spring assembly shall be conducted only when the results of load
deflection characteristics are obtained and found satisfactory.
c) The test shall be conducted in vertical and horizontal directions.

(i) Vertical Endurance Test:

a) The air spring shall be installed on an endurance testing machine by maintaining the
installed height of air spring as mention in para. 6.4.1/ Section - A and pressure 6
kg/cm2. Vertical load shall be measured at this stage. Value of load should not be
less than gross static vertical load as specified in para 4.1(Section- B).
b) The above air spring assembly is subjected to vertical oscillation at sinusoidal

Signatu !-c (tr

frequency of 1.0 Hz or more deflection of + 30 mm

\.rtr( d--
Name & Prepared by: Ut b1:
---K'pprov
ed by;
designation Ratnaker Tiwari, K uma r,
r_tveen Shobhit Pratap Singh
SSE/VDG/Carriage Dv. Director/V DG/Carriage Director/VDG/Carriage
 Ref: CG-F-,1.2.1-4 (Rev. l) Page 2.1 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

c) Endurance test shall be conducted for a total 1 million cycles at a stretch with
conditions stipulated in para (a) and (b) above.
d) At the end of 1 million cycles following measurements/ observations shall be
recorded after 30 minutes from load release.

S. No. Parameters Result

1 Adhesion anomalies
2 Obvious sion of failure
3 Excessive wear or abrasion
4 Any visible crack or rupture

(ii) Shear Endurance Test:

a) The base plate of air spring assembly is clamped rigidly on a fixed horizontal table.
b) Air spring shall be installed on an endurance testing machine by maintaining the
installed height of air spring as menlion in paa. 6.4.11 Section - A and pressure
mentioned below. Vertical load shall be measured at this stage.

c) The above air spring assembly is subjected to lateral displacement of + 30 mm & +

56 mm as per the table mentioned below at a sinusoidal frequency of 1.0 Hz or more
in lateral direction.
Sequence Number of cycles Pressure Offset Amplitude
1 800000 cycles 6.0 Kg/Cm'? +25mm +30mm
2 50000 cycles 5.8 Kg/Cm'? 0 +56mm
3 50000 cycles 5.2 KglCmz 0 +56mm
4 50000 cycles 5.8 Kg/Cm'? +25mm t56mm
5 50000 cycles 5.2 KglCm'z +25mm +56mm

d) Endurance test shall be conducted for a total 1 million cycles at a stretch with
conditions stipulated in para (a) and (b) above. Shear Endurance Test with lateral
offset of 25 mm between top and botlom plate of air spring assembly shall be
conducled as per the provision of BS EN 13597: 2003 E (Annexure - C) and fixture/
test setup also to be made as per Figure C.2 ofthe Annexure - C ofthe same.

The test specified under para 8 (i) and para 8 (ii) above shall be carried out on the
same air spring assembly and it shall not exhibit deterioration such as tearing, wear,
cracks etc. upto 800000 cycles during shear endurance test. Minor surface cracks on
bellow may be permitted during & after sequence 2-5 mentioned in the above table of
shear endurance test. After test, the same air spring assembly shall be subjected to
Bursl Resistance Test as per paru.6.7 of Section - A of this Specification and leak
test as per para. 10.2.2 of Section - A of this Specification subsequent of completion
of endurance testing as above and resulls reported.

e) At the end of I million cycles following measurements/ observations shall be

recorded after 30 minutes from load release.

S. No Parameters Result
1 Adhesion anomalies
2 Obvious sign of failure
3 Excessive wear or abrasion
4 Any visible crack or ruplure
Signature

Name & Prepared by:

----deekedby;
-Approved bv:
dcsignation Ratnaker Tiwari, Praveen Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG lCarriage Director/VDG/Carriage
 Rcf: CG-F-4.2.1-4 (Rer,. l) Page 25 of 58 Latest (ReY/Amend) issue : Specification No.
April,2023 RDSO/CG/S/21002, Rev. nil

9) Inflatability test:
After completion of shear endurance test mentioned in para 8, Inflatability test of air
spring assembly shall be done at 56 mm lateral displacement at respective vertical loads
mentioned in paru 6.4.2 of Section-A of this Specification for different types of air spring
assemblies. For this lnflatability test, air spring assembly shall be inflated upto specified
vertical loads from tare to full load conditions as mentioned in pa.a 6.4.2 of Section-A of
this Speciflcation and shall be shifted laterally by 56 mm. Further, deflate the air spring
assembly on same loads and hold for one minute in deflated condition. Now inflate the
air spring assembly in same load conditions. Air spring assembly should inflate smoothly
on all load conditions from tare to full load.

10) Burst pressure test of air spring bellow after endurance test, as per para 6.7 of Section
-A of this Specification.

1 1) Load vs deflection characteristics of emergency spring in vertical and lateral mode as

per paras 6 and 7 of Section - B of this Specification.

12) Endurance test of emergency spring alongwith vertical and lateral characteristics for
minimum 1 million cycles, as per para 8 of Section - B of this Specification.

13) Hysterisis loops of emergency spring in vertical mode wlth following vertical pre load

S. No. Type of air spring Vertical pre load

i) 180 KN capacity 50, 1 15, '165 & 180 KN
ii) '160 KN capacity 50, 60, 90, 120 & 160 KN
iii) 140 KN capacitv 50,70, 115& 140KN
iv) 120 KN capacitv 60, 90 & 120 KN

14) Lateral characteristics (Load Vs. Deflection) of air spring assembly in no-air condition

1s) lVaterial test report (supported by standard test specificalions)

16) Any other test felt necessary by the manufacturer

17) Leak test of air spring bellow as detailed at para 10.2.2 of "Section - A" of this
Specification.

18) Type lest of emergency spring shall be canied out as detailed in Section - B of this
specification and reports as per annexure I to Vll of Section - B of this Specification
provided with lhe same.

'19) Tolerance in different dimensions of air spring assembly should be as per lS 2102 (Paft
-l) and mentioned in Type Test Report / drawing.

20) Tolerance in measured values during characteristic tests should be mentioned in type
test report given as under:

S. No Characteristic Tolerance
1 Pressu re Force Characteristic + s\o
2 Load Deflection Characteristic + 100k

SigDatuIe

Name &
Av
Preparcd bv:
\i(*'
prekCd bv: /
:;f '
Approved by:
designation llatnalier Tirvari, -----fraveen Kumar. Shobhit Pratap Singh
SSE/VDG/Ca rriage Dy. Director/VDG/Carriage Director/VDG/Carriage
 Rcf: CG-F-{.2.1-{ (Rev, l) Page 26 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CC/S/23002, Rev. nil

ANNEXURE . B
CHECKLIST FOR INSPECTION OF AIR SPRING
As per inspection and testing Clause no.'10.0
1. nd visual check 1 of eL or mtntm m 10 whichever is maximum
1.1 Visual lnspection
SN Particulars Specified Observation
1 Finish Smooth
2 Cut Nil
3 Burrs / Flash Nii
4 Rust i Corrosion Not Allowed
5 Weld / Paint [,{arks Not Allowed
6 Flatness / Parallelism OruNot OK
7 ldentification As per Specification
8 "o" Ring OK/ Not OK
I Marking As per Para 1 '1 of 'Section-A' of specification
9. '1
Top Plate Ol( Not OK
9.2 Bottom Plate OK/ Not OK
9.3 Emergency Spring OK/ Not OK
9.4 ldentification plate Ol( Not oK
10 Colour & shade OKNot OK (As per para 6.13.1)
1.2 Dimensional test
SN Particula r S pecifie d Observation
1 Base Plate Length As per Firm's
width RDSO
Thickness Approved Drg
/ RDSO
lMounting hole dia
Speciflcation
Centre distance of
mounting holes (single /
both side)
PCD (in case of 180 KN
capacity air sprinq)
2 Top Plate Spigot Dia
Spigot Height
Top plate dia
Cross section diameter of
"O' ring
3 Air Bellow Diameter of air bellow at 6
diameter Kg/cm2 under design
height.
4 Min. height Min. height of air spring As per Firm's
of air spring under full load with no air RDSO
and without spiqot (mm) Approved Drg
2. Leak Test of Air Sprino : As per Clause '10.2.2 of section A

Air Springs Pressure after 60 Pressure after 15 Pressure drop with

SN
Number minutes when minutes when inflated in specified limit
inflated at 9 Kg/cm2 at 6 Kg/cm2 (Yes / No )
,|

Signature

Naurc & Prcpa red bl: Ch ec lrl proi ed by:

dcsignntion Ratnxker Tili ari, CCN Ku nr lrr Shobhit Pratap Singh
SSE/V DG/Carriage rector/VDG/Ca rria Dircctor/VDG/Ca rria c
 Ref: CC-F-.1.2.1-4 (Rev. l) Page 27 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

3. Pressure v/s Load test of Air Sprinq assemblv: As per Clause [Link] of Section - A.

Test should be carried out as per the formats as below

Pressure v/s Load Test

S.N. Pressu re in Specified Vertical Load (kN) Measured Vertical Load

kg/cm2 or bar (As per Type Tesl Report) (kN)
,|
1

2 2
3 3
4 4
5 5
6 6

4. Test for Emerqencv Sprino:

4.1 Vertical load v/s deflection Test: As per Clause [Link] of Section-A.

Test should be carried out as per the formats as below:

S. N. Specified Load (vertical) Specified Deflection Measured

in KN (vertical) in mm Deflection in mm
(As per Type Test Report) (As per Type Test Report)
1

2
J.
4.

4.2 Bonding strength test (for metal bonded emergency spring design)
Bonding strength lest of 02 samples from each batch to be done as per para 5.0 of
'SECTION - B" of RDSO Specification no. RDSO/CG/S/23002, Rev. nil during the
purchase inspection. The test piece shall be taken from the same batch used for the
manufacturing of the emergency spring.

Sample size for the tests at S. No. 2, 3 & 4 above are given as under:

Lot Size upto 10 25 50 100 Above 1 00

(nos. )
Number of 2 3 4 6 6% of Lot
Samples
Check

Signaturc qv
Name & Prepared by: by pproved by;
designation Ratnaker Tiwari, veenKumar, Shobhit Pratap Singh
SSE/VDG/Carriage . Director/VDG/Carria e Director/VDG/Ca rria
 Ref: CG-F-:1.2.1-,1 (Rev. I) Page 28 of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CC/S/23002. Rev. nil

(sEcTroN - B)

REQUIREMENTS FOR
EMERGENCY RUBBER SPRINGS USED IN AIR SPRINGS

1.0 SCOPE

1.1 This Specification Covers the technical requirements relating to material,

constructions and tests for emergency rubber used in the air spring for bogie having
pneumatic suspension at secondary level. This does not include all the necessary
provisions required for a supply contracl.

1.2 This Specification specifies the operating and performance requiremenl and method
of testing the emergency spring. These Emergency rubber springs are used in
conjunction with the air bellow and are an integral part of air spring acting in series or
parallel with the load and stiffness provided by compressed air inside the air bellow.

1.3 The emergency rubber springs are subjected to static and dynamic loading in
compressive and shear modes simultaneously during operating conditions. The
maximum compressive and shear loads are given in subsequent paragraphs.

1.4 The Emergency rubber spring shall be capable of withstanding wide climatic variation
prevailing in the country without physical deterioration and change in compressive
and shear stiffness characteristics.

2.0 REQU IREMENTS:

2.1 Material

2.1.1 Rubber:
The Emergency rubber spring used in the air spring should be manufactured from
natural rubber suitably compounded to conform to the requirements stipulated in
Specification.

2.1.2 Steel:

a) The end mounting plates and inter leaves, shall be of stainless steel or corrosion
resistance steel or equivalent.
b) ln the preparation process of metal plates or inter leafs it shall be ensured that all
sharp edges and burrs are removed and they are chemically treated and cleaned
before shot grit blasting as per lS: 9139-GM30.

2.1.3 Bonding of Metal to Rubber (for metal bonded emergency spring design):

a) Before applying primer coat for achieving the required bond strength between metal
part and rubber, the metal parts which are ready for use should be stored suitably to
avoid contamination on the surface.
b) The process and bonding agent adopted for bonding of rubber to metal plates shall
be of proven quality.
c) The temperature and moulding time shall be optimrzed for proper curing of rubber.
d) The rubber should be smooth and free from pinholes, blister and other visual flaws.

Signature (Yz ?"/=-

Na nre & Prepared by: C ec -.4pproved by
dcsignation Ratnaker Tiwari, P cll Kuma r. Shobhit Pratap Singh
SSE/VDG/Carriage ircctor/VDG/Ca rria c Director/VDG/Carriage
 Re f: C (i-F-{.2. 1-"1 ( Ro'. l ) Page 29 of 58 Latest (Rev/Amend) issu€ : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

2.2 Operatingconditions:

2.2.1 fhe emergency rubber spring is an integral part of Air spring and acts in series or
parallel wrth the compressed air provlded inside the air bellow, taking full load.

2.2.2 The maximum dynamic load on the air spring is 507o more than the static gross
vertical load.

2.2.3 Under deflated conditlon of air spring the Emergency rubber spring acts as bumper /
suspension and supports the full operating vertical and shear load at such lower
speed which is considered safe as per standing criteria.

2.3 Environmental conditions:

2.3.1 Emergency spring being an integral part of air spring which is provided at secondary
stage in mainline coaches is subjected to following environmental conditions:

Maximum temperature at sun 600 c

Ambient Temperature -25 oC to to +500 C
Average relative humidity TOlo lo 90o/o, 100% on several days
Rail fall Fairly heavy, maximum being 200mm in 24
hrs. typical to coastal areas
Atmosphere Dusty for several months of the years
Elevation 2m (MSM) to 3500m (lt/SM) approx. and
atmospheric pressure upto 0.65 atm approx

3.0 STIFFNESSCHARACTERISTICS:

3.1 The vertical and lateral stiffness of emergency rubber spring can not be specified
precisely as it acts in series with the vertical and Iateral stiffness provided by
compressed air inside air bellow, under inflated condition of air spring and their
reciprocal equivalence determines over all stiffness characteristics which is guided by
Specification for a,r spring system.

Under the deflated condition of air spring, the stiffness and damping of emergency
spring is decided on transmissibility considerations which should be as minimum as
possible at higher frequencies. However, minimum height of air spring under full load
with no air and without spigot shall be strictly maintained as per S. No. 4 of Annexure
- Vlll of Specification.
4.0 TESTING OF EMERGENCY RUBBER SPRING:

The emergency rubber spring shall be subjected to following tests independently.

a) Bonding strength test (for metal bonded emergency spring design).

b) Vertical load Vs deflection test. (Before and after endurance test)
c) Shear load Vs deflection test. (Before and after endurance test)
d) Endurance test (vertical & lateral)
e) Creep test.
Test (b) and test (c) are required to be conducted before and after test (d)

4.1 Load conditions:

Signature

Name &
Uv
Preparcd by;
\ -,ln'"
Cheched Approved by:
designation Ratnaker Tiwari. P mar, Shobhit Pratap Singh
SSE/V DG/Carriage t'ector/VDG/Ca rriagc Director/VDG/Ca rria e
 Ref: CG-F-.1.2.1-,1 (Rev. l) Page 30 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

4.1 .1 Static Vertical Loads

The tare and gross vertical loads, on each air spring for different type of BG coaches
are given as under.

S. No. Air Spring Coach Type Tare Load Gross Load

1 180 KN capacity Ett4U Coach (HCC Bogle) 50 KN 180KN
DMU Coach
2 160 KN capacity LHB Coaches (FIAT Bogie) 50 KN 160KN
3 '140 KN capacity ICF Coach (lCF Bogie) 50 KN 140KN
LHB Coaches (FIAT Bogie) 50 KN 140KN
4 120 KN capacity LHB Coaches (FIAT Bogie) 60 KN 12OKN

4.1.2 Shear Loads

The maximum operating shear load on particular type of air spring shall be calculated
as under:

a) Max shear load = l\4aximum load (180/160/140/120KN) X Max. friction coefficient

Max. shear load should be calculated in deflated condition.

OR
b) Max. Shear Load = Max. value of (Lateral stiffness of air spring x Corresponding def.)

Lateral stiffness should be calculated upto maximum lateral deflection as mention in

para. 6.2/Section - A of Specification.

For shear endurance test and shear load vs deflection test, the value of maximum
shear load may be obtained by both the above methods and used that value of shear
Ioad whichever is higher.

5.0 BONDING STRENGTH TEST:

The objective of this test is to determine bond strength between metal plate and
rubber, under pre-determined load or deflection. This test is conducted as per lS:
3400 (Part - XIV). The bond should be capable of bearing a minimum slress level of
35 Kg/cm2.

6.0 VERTICAL LOAD vs DEFLECTION TEST: {Before Endurance test)

The emergency spring should be [Link] to three successive load cycles up to

150% of gross static vertical load as specified in para 4.1 (Section - B) at quasistatic
frequency of 0.1H2. for pre conditioning. ln the fourth cycle the emergency spring
shall be compressed wilh a load of 0.50 KN and the deflection taken as zero at this
point. The fourth cycle is completed to record force vs deflection curve in the form of
hysterisis loop for a deflection range as obtained during initial three load cycle
(loading and unloading). The load and deflection values shall be recorded digitally
and lhe values shall be provided in the form of X - Y plot and digital table. (Ref.
Annexure - l). The following geometric parameter shall be recorded:

Signature

Name &
designation
0?-
Prepared bv:
Ratnaker Tiwari,
\{,
Che by:
7v
4pproved by:
Yeen Kumar. Shobhit Pratap Singh
SSE/VDG/Carriage . Director/VDG/Carria e Director/VDG/Carriage
 Rcf: CC-F-J.2.1-1 (Rer,. l) Page 3l of 58 Latest (Rev/Amend) issu€ : Specification No.
April,2023 RDSO/CC/S/23002, Rev. nil

S, NO Parameters Before Endurance Test After Endurance Test *

1 Free height (mm)
2 Outer dia (mm)
3 Vertical axis orientation
(mm)
. Ref. Para 9.0

Vertical deflection in emergency spring should be given in tabulated form and with
tolerance in value of deflection at different vertical loads upon which test had been
done.

7.0 SHEAR LOAD vs DEFLECTION TEST: (Before Endurance test)

In this test the base plate of emergency spring is rigidly clamped to a fixed horizontal
plate and shear load is applied at the top of emergency spring to measure the shear
load Vs shear displacement characteristics. The maximum lateral load shall be 150%
of maximum shear load as specified in para 4.1 which shall be applied in both
directions (Positive and Negative) from the mean position at a quasistatic frequency
of 0.1 H.. The pre-conditioning of emergency spring is done by giving three
successive lateral load cycles and in the fourth cycle measurements are taken for
applied shear load and corresponding shear displacement of emergency spring. The
above test is conducted under gross vertical loads.

The measurements shall be done using digital methods and the measured data shall
be provided in the form of hysteresis loop and tables (Ref. Annexure - ll). The
following geometric parameters shall be recorded as:

S Parameters Before Endurance After Endurance Test *

No Test

'l Free height (mm)

2 Outer dia (mm)
3 Vertical axis orientation (mm)
. Ref. Para 10.0

Shear deflection in emergency spring should be given in tabulated form and with
tolerance in value of deflection at different shear loads upon which test had been
done.

8.0 ENDURANCE TESTi

a) The Endurance test is conducted to assess suitability of the emergency springs for
use in air spring provided at secondary stage suspension in coach bogie by
simulating service conditions in the laboratory.
b) The test on emergency springs shall be conducted only when the results of load
deflection characteristics are obtained and found satisfactory.
c) The test shall be conducted in vertical and shear modes.

I
Signature

Name &
b?
Prepared by:
\,,1(Chca(ed bv: y'pprovedby:
designation Ratnaker Tilvari, ,---?/rav een [Link], Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Directorny'DC/Carriage Di rector/VDG/Carriage
 Ref; CG-F-'1.2.1-4 (Rev. l) Page 32 of58 Latest (Rcv/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

8.1 Vertical Endurance Test:

a) The emergency spring is subjected to a pre compressive load, which is equal to the
gross load as specified in para 4.1 on an endurance testing machine. This load is
taken as datum and further tests are conducted in load control mode.

b) With load datum as given in para (a) above, the plunger is made to oscillate
vertically in sinusoidal manner at a frequency of 1.0H. or more with 50 % of
maximum gross load on the air spring such that the maximum compressive load on
the plunger does nol exceed 150% of the gross vertical load.

c) Endurance test shall be conducted for a total 1 million cycles at a stretch with
conditions as stipulated in para (a) and (b) above.

d) During endurance test of 1 million cycle if the temperature build up in emergency

spring exceeds 7cC with respect to the ambient air temperature in the
surroundings, the oscillating frequency ofthe plunger can be reduced by 0.5H,.
e) At the end of every 0.2 million cycles following parameters are required to be
measured (Ref. Annexure lll)

i. Hysteresis loop for 5 successive cycles of loads Vs deflections record (after

every 0.2 million cycles of endurance testing)
ii. Plungeroscillatingfrequency.
[Link] spring temperature rise.
iv. Ambient/Room temperature.
At the end of 'l million cycles following measurements/observations shall be recorded
after 30 minutes from load release.

S. No Parameters Results
1 Adhesion of bond
2 Obvious sions of failures
3 Excessive wear or Abrasions
4 Free height
5 Permanent set

8.2 Shear endu rance test;

a) The base plate of emergency spring is clamped rigidly on a fixed horizontal table
and subjected to a vertical pre compressive load which is equal to gross vertical
load as specified in para 4.1 acting at the geometric centre of top plate. The test is
conducted in load control mode and a horizontal force with sinusoidal frequency of
'l .OHz or more having peak load value as + 150% of maximum shear load as
specified in para 4.1 is applied simultaneously for 1 million cycles.

b) During endurance test of 1 million cycle as per para (a) above, if the temperature
build up in the emergency spring exceeds 70 C with respect to the ambient air
temperature in the surroundings the horizontal Oscillating frequency of the plunger
can be reduced by 0.5 H,.
c) At the end of every 0.2 million horizontal oscillating cycles of the actuator plunger
following parameters are required to be measured. (Ref Annexure lV)

Signature

Name &
()?
Prepared by:
\i(
Ch by:
? v
/Approved by:
tlesignation Ratnaker Tiwari, veen K umar, Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG/Carriage Director/VDG/Carriage
 l{ef: ('( i- F-'1.2.1-.1 (Ro. l) Page 33 of 58 Latest (ReY/Amend) issue : Spccification No.
April,2023 RDSO/CC/S/23002, Rev. nil

i) Hystersis loop for 5 successive cycle of horizontal load vs horizontal

displacement record. After every 0.2 million Cycle of endurance test
ii) Actuator plunger frequency.
iii) Emergency Spring temperature rise.
iv) AmbienVroom temperature.

At the end of 1 million horizontal cycle, following measurement /observations shall

be recorded after 30 minutes from vertical and lateral load release.

S. No Parameters Results
1 Adhesion of bond
2 Obvious signs of failures
3 Excessive wear or Abrasions
4 Free height
5 Permanent set.
6 Tilt angle of vertical axis

9.0 VERTICAL LOAD vs DEFLECTION TEST.( afler endurance test )

This Test is required to be conducted after salisfactory Endurance test and shall be
carried out on the similar line as given in para 6.0.

10.0 SHEAR LOAD vs DEFLECTION TEST: (afler endurance test).

The test is required to be conducted after satisfactory shear Endurance Test and
shall be carried out on the similar lines given in para 7.0.
,I
1.0 SUPERIMPOSITION OF ACQUIRED DATA :

The following data obtained before and after Endurance Test shall be superimposed
over each other as details given below:

11.1 Vertical Load Vs Deflection test data

The object is to determine the loss in vertical properties/characteristics of rubber due

to endurance test. The characteristics test obtained vide para 6.0 and 9.0 shall be
superimposed over each other in the form of hysterisis loop and comparative digital
table (Ref. Annexure - V).

11.2 Shear load vs deflection test data

The object is to determine the loss in shear properties/characteristics of rubber due

to shear endurance test. The characteristic data obtained vide para 7.0 and 10.0
shall be superimposed over each other of hysterisis loop and comparative digital
table. (Ref Annexure Vl)

12.0 CREEP TEST

The Creep Test is conducted on an emergency rubber spring by applying a

predetermined maximum vertical load, which is borne by the spring for a sufficiently

Sigrxtu Ic

Name &
Qv
Prepared b1:
\
(lr cc proved b1':
designation Ratnalier Tiwari, ccn Kunrt r. Shobh it I)rn ta p Singh
SSE/VDG/Carriage irector/VDG/Ca c Director/VDC/Carria e
Reft CG-F-4.2.l-4 (Rev. l) Page 3,1 of58 Latest (ReY/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

long period to determine the magnitude of permanent set or loss in free height under
the influence of load with respect to time.
The predetermined maximum vertical load (150% of gross static load should be
applied) continuously for a period not less than 5 days. The following measurements
are required to be taken.

1 . lvlagnitude of applied vertical load

2. Frce height of rubber spring (before and after creep lest)

3. Height of rubber spring with respect to time. The height of the spring should
be measured after every 3 hrs for the first 2 days (48 hrs) and after every
6 hrs. thereafter.

The vertical deflection vs time curve should be drawn for the minimum period of 5
days. lt can then be extrapolated depending on the expected working age of rubber
spring (Ref. - Annexure Vll).

13.0 GENERAL

a) All the tests mentioned in this specification shall be conducted on the same
specimen of Emergency rubber spring except creep test. Creep test shall be
done on separate specimen of Emergency rubber spring.
b) All measurements shall be given in Sl units.
c) The test results shall be furnished by conlractor in the form of a type lest
report.
d) Digital photographs /pictures of test rig should be provided by the contractor
in type test report.
e) Any other relevant details in support of accuracy of test shall be given in type
test report.

*+++++++++**

Signalure

Name &
0rz
Prepared by:
\'i('
Ch v:
7Y---
-fpprovetl by:
tlesignation Ratnaker Tiwari, veen Kumar, Shobhit Pratap Singh
SSE/VDC/Carriage Dv. Dircctor/VDC/Carriage Director/VDG/Carriage
 Itef: CC-F-4,2.1-4 (Rev. l) Page 35 of 5fl Latest (ReY/Amend) isstle : Specification No.
April,202J RDSO/CG/S/23002, Rct'. nil

SECTION.C (SCHEDULE OF TECHNICAL REQUIREMENTS)

INFRASTRUCTURE & FACILITIES REQUIRED FOR MANUFACTURE & TESTING
OF AIR SPRING ASSEMBLIES.

'1.0 scoPE
This Section covers the infrastructural requirements for manufaclure and supply of
following Air Spring assemblies: -

(i) Air Spring assembly (180 KN Capacity) for higher Capacity Loads used on
EMU/DMU/ MEMU Coaches for ICF type Bogies.

(ii) Higher capacity Air Spring Assembly (160 KN) for LHB Coaches having FIAT
Bogie.

(iii) Air Spring Assembly (140 KN capacity) for Mainline / Rajdhani / MEMU Coaches
for ICF Type Bogies and Mainline/Rajdhani LHB coaches for FIAT type Bogies.

(iv) Air Spring Assembly (120 KN capacity) for LHB Coaches for FIAT Type Bogies.

2.0 REQUIREMENTS
All vendors seeking registration with RDSO shall comply all requirements mentioned
below.
3.0 PLANT, MACHINERY AND INFRASTRUCTURE REQUIREMENTS

3.1 The Manufacturer shall have adequate space and covered area with proper floor to
accommodate the following and for smooth logistics:

a Damp-free place for storage of raw materials.

b Adequate manufacturing area.
c Laboratories for material testing
d Machining Facilities as per Quality Assurance Plan.
Manufacluring facilities along with assembly line.
f) Finishing, Assembly, Rejection and lnspection area.
s) Assembly & testing area.
h) Painting facility
i) Facilities for Storage, Packing and dispatch of finished products.
i) Proper Conveyer/ OHE/ Fork & lift etc. for lifting and transportation of Air
Spring assembly/ sub- assemblies.

3.2 Design & Development facilities (Mandatory for OEM/ Vendor)

i) R&D cell and team of competent & qualified Engineers wlth experience in air
spring designing & development for Railway passenger coaches.
ii) CAD center for Computer-Aided Design
iii) FEA and design validation software
iv) Auto CAD/ UG/ Solid Works or suitable software for drawing & design works
v) Valid license for designing software and tool.
vi) CAM center for Computer-Aided Manufacturing process and control for precise
works

Signr

Name &
tu re (Pz'
Prepared by:
\ {{r" by: /Approved by:
(lesignation Ratnaker Tiwari, ralecn K uma r, Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG/Carriage Director/VDG/Ca rriagr
 Ref: C(;-F-4.2.1-.1 (Rev. l) Page J6 of sft Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

3.3 T Testin Facilities Mandato for OEM /Vendor

S Name of Machine / Capacity / lvlin Remarks
no Equipment / Description / Qtv
Software Specification
1 Universal testing Having suitable 01 Testing of bumper, ply-
machine capacities adhesion, static load vs.
deflection of emergency
bumper, metal to rubber
adhesion of emergency
bumper, physrcal properties of
cured rubber sample of
unaged, heat aged, oil aged
samples
? DIN Abrader Lab standard 01 Testing of abrasion resistance
3 Ozone chamber Lab standard 01 Testing of ozone resistance
4 Dynamic testing Suitable capacity 0'1 Testing of vertical, lateral/shear
equipment with load cell actuator, and torsional stiffness, vertical
programmable with hydraulic pump and lateral endurance testing of
and conlroller, air spring assembly, Testing of
cooling system, vertical stiffness, endurance of
additional reservoir emergency bumper, ve(ical
load vs. deflection, shear load
vs. defleclion etc.
5 Burst pressure Water pump with 0'r Testing of burst pressure (Upto
fixture controller 30 Kg/Cm'?)
t) Curing press S0ten Having 01 Curing of sample for metal lo
suitable capacity rubber adhesion test, test slab
for petroleum resistance testing
7 Ageing oven Lab standard 01 Ageing of test samples for
petroleum / oil resistance, heat
resistance
8 Vernier caliper, 1 .0m length, 10bar Effective diameter
pressure gauge with 0.0'l bar least measurement, pressure
count checking

Suitable testing machinery and infraslructure is required to conduct the complete

type testing and Endurance tests of air spring assemblies and Emergency Spring as
menlioned in this specification.

3.4 Manufacturing facilities for Air Spring Bellow (For OEMA/endor/Allied/ Sister
Concern
5 Name of Machine/ Capacity/ Description Min.
No EquipmenU Software iSpecification Required Qtv
1 Weighing balance for Rubber, Rubber 01 No
chemicals, Filler weiqhino
2 Twist checking, tensile testing machine, 01 No
shrinkage tester, ageing oven
3. Kneader / Intermix / Banbury mixer for 01 No
mixing of rubber compound
4 Two roll mill
r\ 01 No

Signxtu rc

Name & I'rcpa red bt : ccbr

yv
-A-pproved by:
d esigna tion Itatnaker Ti\ ari. l Kumrr,
CCn Shobhit Pratap Singh
SSE/V DC/Carriage . Director/VDG/Carria ti Di rector/VDG/Ca rriage
 Ref: C(;-F-{.2.1-4 (Rev. l) Page J7 of 58 [,atest (Rev/Amend) issue : Specification No.
April, 2023 RDSO/CG/5/23002, Rev. nil

5 3 roll calender for Calendering of inner 01 No

liner and outer cover
6. 4 roll calender for Rubber coating on 01 No
fabric
7 Bias cuttrng machine 0'l No.
8. Build drum 01 Nos.
9 Build machine 01 Nos.
10 Ton Curing press (min. 85 T) 01 No.
11 Hardness tester, Specific gravity 01 No
balance, Mooney viscometer,
Rheometer, Lab curing press

3.5 Manufacturing facilities for Emergency Spring: - (For OEM/Vendor/allied/sister

co nce rn
S Name of Machine/ Capacity/ Description/ tvlin Required
No Equipmenv Software Specification Qtv
1 Weighing balance for Rubber, Rubber 01 No
chemicals, Filler weighinq
2 Twist checking, tensile testing machine, 01 No
shrinkage tester, ageing oven
J Kneader / lntermix / Banbury mixer for 01 No
maxinq of rubber compound
4 Mould 1No
5 Compression moulding press 1No
6 Curing press
7 Carousal chemical storage tank 1No
o Scada (PLC)-chemical and carbon one
weighing control
o Kneader for mixing of final batch 1No
10. Bonding agent application spray unit 1No
11. Painting booth for base plate & Metal 1No.
parts
12. Hardness tesler 1No

3.6 Manufacturing facilities for Top Plate and other metal parts (For OEM/ Vendor/
Allied/ Sister Concern
S Name of Machine/ Capacity/ Description/ Min.
No EquipmenU Software Specification Required Qty
1 Vertical turning Lathe 01
2 CNC Lath 01
J Radial Drilling machine 01
4. Jig & Fixtures 01
5 MIG Welding 01
6 Hydraulic Press 01
7 Vertical milling centre
(l-
01

Signatu rc

Name & Preparcd by: Che c by pproYed b\':

designation Ratnaker Tiwari, I teD Ktrmar, Shobh it Pratap Singh
SSE/VDG/Carriage . Director/VDG/Carria e Dircctor/VDG/Carr c
 Ref: CG-F-4.2.1-.1 (Rev. l) Page 38 of 58 Lat€st (Rev/Amend) issue : Specification No,
April,2023 RDSO/CG/5/23002, Rev. nil

8 Test bench for leakage testing of top 01

plate
9 Testing facility for weld test 01
10. CIVN/ 01
11. Shot/Grit Blasting machine 01
12. Painting booths & l\ilachinery 01
13. Hand Grinder & Grinding M/c 01

A/ote.' For manufacturing of top plate through casi/hg process, firm should
additionally have adequate facility with suitable moulds & die, lnjection Press,
lnduction furness, Tanks for pre coat and de-waxing tank, dehumidifier &
coofing tower, costing equipments, heat treatment facility, MPI testing
machine, contactless thermometer etc. to carry out the entire manufacturing
process with quality control.
3.7 Assembl and testin Facilities:
S Name of Machine/ Capacity/ Description/ Min Required
No EquipmenV Software Specification Qtv
1 Dusl free assembly line 01 No.
2 Load cell equipped with computer, Software should give the 01 No.
printer & software for pressure v/s result in tabular and
load test graphical form
3 UTM test bench with computer, Soflware should give the 0'1 No.
printer & software for load v/s result in tabular and
deflection test of Emergency graphical form
spring
4. Leakage testing equipment with With digital gauges & least 0'r No
digital gauge and supply upto min count of the gauges
10 Kg/Cm2 should be 0.01 Kq/Cm'z
5 Surface table for measurement of With suitable capacity for 01 No
air spring assembly measurement of offered
air spring assemblies
6 Pneumatic compressor As per requirement of 01 No
testing and manufacturing
of Air Spring assemblies.
7 Vernier caliper, go/no-go gauges, As per
micrometre, plug gauges and other requirement
suitable tools and qauqes
8 Weighing balance for Air Spring 01 No
Assembly
I Salt spray testing machine and 0'l No
setup

3.8 Tools and gauges

The lVlanufacturer shall have at least following testing equipment/facility with
controlled temperature and humidity:
a) Digital Vernier Caliper (500mm): Min. 01 Nos.
b) Dial Gauges (least count 0.01 Kg/Cm,): As per requirement for all leak lest
benches and testing machines.
c) D-Tape for measurem spring dia

d
Siguature

Name &
esign a tion
G=
Prepared by:
Ratnakcr Tirvari,
\iry
Che by:
vcen K umar,
<7-
dflproved by:
Shobhit Pratap Singh
SSE/VDG/Carriage y. Director'/VDG/Carriage Director/VDG/Carriage
 Rcf: CCi-F-1.2.1-.1 (Rer. I) Page J9 of 58 Latest (Rcv/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

d) l\rlicrometer ('100mm, least counl 0.000'1): Min. 01 Nos.

e) Measuring tapes (3 mtr): Min. 01 Nos.
0 Thread Plug Gauge: Min. 02 Sets
S) Steel Scale: Min. 02 Nos.
h) Digital Weight scale (200 Kg): Min. 01 Nos.
i) Stop watch: Min. 01 Nos.
j) Surface table: lVlin. 01 No.
k) Radius gauges: Min. 01 Set
I) Torque Wrench (50-450 kgfm)- Min.- 01 No.
m) Any other essential measuring equipment's for dimensional & functional test
for compliance of this specification.
3.9 Limited outsourcing in supersession to above clause 3 in this section of this
specification may also be permitted while ensuring compliance to clause 5.4/5.5 of
Section-A of this specification.

3,10 Requirements of infrastructure & facilities for type testing & manufacturing in clause
3.3-3.8 in this section are bare minimum requirements. Any other facilities required to
comply this specification or required for fully functional performance of air springs
shall also be ensured by the vendor.

However, vendor may also propose for alternate methodology/ processes for
manufacturing/ type testing, which might require different set of M&P and tools. For
such alternate of methodology & process, vendor shall establish that such M&P and
facilities are adequate for manufacturing & testing of air spring assemblies/ critical
components and compliance of this specification.

4.0 Qual ity control requirements:

4.1 The firm should have acquired ISO:9000 series certiflcation for the product for which
an approval is sought.

4.2 The Vendor shall have a well-documented 'lnternal Quality Assurance System' to
ensure sustained quality of product being manufactured. The Quality Assurance
System' shall generally cover the following:-

4.2.1 System to ensure that correct raw material is being used. The type of rubber used for
the air spring bellow shall be specified by the OEM.

4.2.2 System to ensure that components having manufacturing defects are identified and
destroyed so that such components are not used during assembly of air spring.

4.2.3 System to ensure that bought out components are strictly as per requirements laid
down in the specification/ drawing.

4.2.4 System to maintain strict control of dimensions and workmanship of components and
assembled product.

4.2.5 System to test and establish that the air spring assembly manufactured by the firm
meets all the requirements laid down in specification / drawing.

4.2.6 System of periodical calibration of equipments/gauges to ensure accuracy of product.

Signrture
Namc &
(r/
Prepared b1:
\ { (( qZ-=
by;
Eed€dby; --ffiroved
designation Ratnaker Tilvari, ._----ffav een Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG lCariage Director/VDG/Ca rriage
 Ref: C(l-F-1.2.1-l (Rer'. I ) Page 40 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

4.2.7 System to ensure cleaning & removal of dust/rust and moisture by dry air.

4.2.8 System to ensure that air spring assembly is properly packed to meet the
requirement of Clause-12 of Section-A this specification.

4.2.9 System to ensure traceability at least up to guarantee period.

4.3 Quality manual of the firm for lSOr9000 should clearly indicate at any stage the
control over manufacturing and testrng of the railway product.

4.4 The firm should submit the Quality Assurance Plan (QAP) as per RDSO ISO doc no.
Qtv-RF-7.1-3.

4.5 The firm must ensure that proper analysis is being done on regular basis to study the
rejections at various internal stages and it is well documented.

4.6 The firm should ensure that latest version all the relevant speciflcations, lS Standards
are available with the flrm.

4.7 System for calibratjon of testing & measuring equipment

4.8 Facilities included in Section-C of the specification are bare-minimum, entire

responsibility for compliance of the specification shall lie with the vendor

4.9 Firm shall have an internal system of checking of chemical properties of the steel as
well as rubber components or through NABL accredited laboratory.

4.10 The firm shall have a system of component level traceability right from raw material
to the finished product stage.

4.'11 There shall be proper stacking of raw material and their record. FIFO system should
be implemented, especially for non-metallic components. Non-metallic components
shall be kept in proper dust & moisture free atmosphere.

5.0 Qualification of Man Power

5.1 The Quality Control Section shall be separately headed by a full time technical expert
having a minimum bachelor's degree in Mechanical/ Automobile/ Mechatronics with
at least 5 years of experience or diploma in Mechanical/ Automobile/ Mechatronics
with at least 8 years of experience. He shall be free from day-to-day production &
testing responsibilities. He shall be mainly responsible for developmenl for product,
failure analysis, planning corrective and preventive action, control over raw material,
devising actions in case of difficulties in achieving the parameters etc.

5.2 Production/ inspection activities shall be headed by a graduate engineer with at least
5 years of experience or a diploma holder with at least 8 years of experience. He
shall be actively involved in day-to-day activities of stage inspection / compliance of
QAP etc.

5.3 Welders shall be qualified in accordance with prevalent National / lnternational

standard.

Signature

Name &
0v
Prepared by:
\5'('
cjss.t+e*6y:
9Y-.-
.'fiprored by:
designation llatnaker Tirvari, .--P-raveen Kumar. Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDC /Carriage Director/VDG/Carriage
 Ref: CG-F-4.2.1-4 (Rev. l) Pagc 4l of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

6.0 DOCUMENTATION
Firm shall maintain the following documents/ records:
6.1 A well-documented Quality Plan.

6.2 lncoming raw material regrster with Test Certificates references of suppliers and
internal test results.

6.3 Stage inspection results including finished products results

6.4 Records of internal rejection and its analysis vis-a-vis action plan.
6.5 Records of final products inspection by external agencies (like RDso/Railways),
Non-Conformity Reports and case analysis as well as action taken thereof.

6.6 There should exist a system of documentation in respect of rejection at customer

end, warranty replacement and in service performance.

6.7 Records of raw material received and supplies made to Railways against the raw
material. lncoming raw material with TC reference of supplier as well as internal
tesUaudit checking from outside agency.

6.8 The details regarding Stage inspection and test result.

Signa tu re

Name &
0z-
Prepared by:
\.i(
Ch
q--
by: -d-pproved by:
designation Ratnaker Tiwari, Ieen Kumar, Shobhit Pratap Singh
SSE/VDG/Carriage Dr'. Dircctor/VDC/Carriage Director/VDG/Ca rriage
 Ref: CC-F-,1.2.1-,1 (Rev. I) Page tl2 of 58 Latest (Rcv/Amend) issue : Specification No.
April,2023 RDSO/CC/S/23002, Rev. nil

ANNEXURE-I
VERTICAI, LOAD VS. DEFLECTION
(trlor. .rd /ln r [Link]&c. T..t)

1
2 (
t )
{
rI <)
a
a
4
J

a
N
II \

[Link]. [Link]€Dt Il]AI,,

LrdtrrS Udlordina
I dr br

da t q
3. ds ba

a, d{ \
5 do \

-I
EMERGENCY BUMPER

S ignatu re

Name &
tlesignation
0z-
Prepared by:
Ratnaker Tiwari,
u('
c!;k*ly:
Kumar.
<)*-
A7p-roved by:
Shobhit Pratap Singh
SSE/V DG/Ca rriage ---Pr-aveen
Dy. Director/VDG/Carriage Director/VDG/Carriage
 Ref: CG-F-4,2.1-4 (Rev. l) Page 43 of 58 Latest (Rev/Amend) issue : Specification No,
Anril,2023 RDSO/CG/S/23002, Rev. nil

ANNEXURE-II
SHEAR LOAD VS. DET'LECTION
(BGlorc rad A,t.r EDdurrEcc Tret)

F:(PRE-VERTICAT. LOAD)
lrAt
+vG [Link]
+B -8 -rc Dl'phccEcot

8lllrrn rc,ro - l*rn ot Lr. abcrr tolo.

lr^D(& )

?r =cror. Loed (B)

[Link]. [Link]! (ED) cRoss ul^r (a)

t. -dt
-4a
3.

a.

+dr

Signa

Name &
tu

dcsignation
re ()-?
Prepared by:
Ratnaker Tiwari,
u('
Ch
f.
\'ccn Ku
by:
<=y:==
Apflf-oved by:
tna Shobhit Pratap Singh
SSE/VDC/Carriage Dy. Director/VD(i/Carriage Dircctor/VDG/Carriage
 Ref: CG-F-'1.2.1-4 (Rev. t) Page ,14 of 5tl Latest (Rev/Amend) issue : Specification No.
April, 2021 RDSO/CG/S/2J002, Rev. nil

ANNEXURE-III
HYSTERISYS LOOP (VERTI CAL ENDURANCE TEST)

ioorl caoas t4^D

J
i-I- f

--

r ro.@.ooo z a t to

TEMPERATURE BUILD. UP (VERTICAL ENDURANCE TEST )

rsrarr$.av (t ) lx!-lt rool l!8. lEEtt r*.

t,

6.
I
altaattt oaStgval'@c, / rugrtlEal!
-
Obne. dar .a t rht
!1..dE a .ru..td
Itrqer.l -lt [Link] -t

Sigllat

Name &
u rc
*z-
Prepared by: Ch
\J'(' '%'-
Aplproved by:
designation Ratnaker Tiwari. Kumar,
reD Shobhit Pratap Singh
SSE/VDG/Carriaqe D} irector/VDG/Carriage Director/VDG/Carriage
 Rcf: C(l-F-.1.2.1-,1 (Rer,. l) Page 45 of58 Latcst (Rev/Amentl) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

HYSTERISIS LOOP SHEAR ENDURANCE TEST

Iltr too! otolEl r,o^!,

_E +&

&= TSOZ OF I{AJ(IUUM SHEAR LOAD

+lt
o.o

-3 e al
Shear Diophceoent

TEMPERATURE BUILD-UP SHEAR ENDURANCE TEST

rlEltit toov tEP,

o&B8vlttoru / [Link]

2. ob .6 .l.! d ,.llu
irc.-(E rlJ t .d!-I.!
/r5a6.l ld.r.-t r.a

I]

Signa tu re

Name &
0z
Prepared by:
\('
bY:
4V---
9!ic-l<6il --A4frovedbyl
designation Ratnaker Tiwari, .----frraveen Kumar. Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG/Carriage Di rector/VDC/Ca rriage
 Ref: CG-F-.1.2.1-4 (Rev. l) Page ,16 of 58 Lat€st (Rev/Amend) issue : Specification No,
April,202J RDSO/CC/S/23002, Rev. nil

ANNEXUNE_V

YERTICAL I,OAD VS DEFI,ECTIO!{ ?8S?

(,ATA ST.,PER_IUPOSED )

slrsrl oxr Eur.x e(1r, '.'r

.'.t 5t,l,l gi.,!

DTSPLACtrX&}{r

_L-
7 z
_--.r'.
4r" (,

Z 4
3

4,r,
{ ,{/
<-Y V

Signa tu re

Name &
Oz
Prepared lry:
.\ (
I

c@rf,u1t
7>=
Angflroved bv:
designation Ratnaker Tirvari, .--h1een Kumar. Shobhit Pratap Singh
SSE/VDG/Carriage Dy. Director/VDG lCarriage Director/VDC/Carriage
 Ref: CG-F-1.2.1-4 (Rev, l) Page 47 of 58 Lat€st (Rev/Amend) issue : Spccification No.
April,2023 RDSO/CC/S/23002, Rev. nil

ANNEXURE_VI

SHEAR II)AD VS DETLECNON TEST

(DA?A SUPBR_IUPOSED)

rI
3.1{o.
otr(,rt or(l tlllron qtclra lt?ta ollx lq-uoN cfcl,....a

II
rrr"r-Mt (EE) E rr@t (n6)
l.

t,

I II
a.
II
a
II I
SEBA.R FORCE

SEETR DISPIACSIENT

Signrtu re

Nanrc &
07
Prcpx rcd by: Chec pproY ed by:
tlesignation Ratnakcr Tiwari. Kumar, Shobhit Prata p Singh
SSE/VDG/Carriage rcctor/\'D(i/Ca rria Director/VDG/Ca
 Ref: CG-F-;1.2.1-4 (Rev. l) Page 48 of58 Latest (ReY/Amend) issue : Specification No.
April,2023 RDSO/CG/5/23002, Rev. nil

ANNSXURE*VII

CNENP TEST

\
sxr(*',oIlT10N
c

?
o
lr
o
lat
1S0 U GR(}SS InAIt
,-a

F
&
lt
I 9C t'av cntsEP

6€ SECONDS 3ll Dr,Y3

TIM}: .,,

e"

t- Dltlrgltoa{ rrrEn ao atcorra

e.* SOUB [Link]{ {tllst rO ttrY'} USiX STPETTT SEETT

6. .L Eout DtllaqnoN (tast rt olls) USG SXPfdG SEIE

DAft cnod so Da1.s
^FIlt
rEE AStOrtr trlaB lrao Eltrr,sl (&b)
l! Dlla clalP valJ,l (sa)
too DaY! [Link] Y^tl'l (Ee)

Signatu rc

Name &
0z'
Preparcd by:
\
cc by: Approved by:
designation Ratnaker Tiwari, n Kumar. Shobhit Pratap Singh
SSE/VDC/Carriage irector/VDG/Carria e Director/VDG/Carria e
 Ref: CG-F-4.2.1-4 (Rev, l) Page 49 of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CC/S/23002, Rev. nil

Annexure - Vlll
Leadinq oarameters of air sprinos and drawinqs

S Item T e of airs
No. 180 KN 160 KN 140 KN capacity 12O KN
capacity capacity capacity
For ICF For FIAT
Bogie Bogie
1 lnstalled height 294'0 s 255'o-s 294'0-s 294*0.s
without spigot
(mm)
2 Maximum o 740 a 700 g 740 @ 700 o 700
permissible
diameter of ait
spring (mm)
3 Maximum a 750 o 700 o 750 a 700 a 700
permissible
external diameter
of top plale of air
spring (mm)

4 Min. height of air 215 240 210 240 240

spring under full
load with no air
and without spigot
(mm)
5 Drawing no. of cG-K4023 cG-K5065 cG-K4017 cG-K5065 cG-K506s
space envelope "Alt. 1". "Att. b". 'Atr. b'. "Att. b".

6 Drawing no. of cG-K4022 cG-K5057 SKETCH. cG-\8228 cG-K5057

base plate "Alt. a". "Att. c". K4018 "Alt. c".
"Atr. 1',
7 Length of base 600 404 400 404 404
plate (mm)
8 Width of base plate 400 404 400 404 404
(mm)
9 Thickness of base 12 (min.) 20 12 (min.) 20 20
plate (mm) (at
mounting
holes
location)
10 Centre distance 250 344 + 0.2 325 344 + 0.2 344 + 0.2
between mounting (at (both side) (both side) (both side) (both side)
holes (mm) sh orter
side)
11 Dimension of 932 444 b26 944 444
mounting hole. (counler bore) (counter bore) (counter bore) (counter bore) (counter bore)
s22 \ @22 s17 b2? 422
Signrtu rc (Pz' --
Nanre & Prepared by: Chec t: kfl-proved by:
dcsignation Ratnaker Tiwari, l'cen Kurnar, Shobh it Pratap Singh
SSE/VDG/Carriage Dy. Director/VD(i/Carriagc Director/VDC/Carriage
 Ref: CG-F-{,2.1-.1 (Rev. l) Page 50 of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CGlS/23002, Rev. nil

(mm) (thru hole) {thru hole) (thru hole) (thru hole) (lhru hole)

IZ I\,4 ou nting Type, High High High High tensile High

Fasteners Size tensile tensile tensile hexagonal tensile
Details & hexagonal hexagonal hexagonal socket-head hexagonal
Grade socket socket socket- cap screw, socket-
of head cap head cap head cap M20X55 head cap
screw screw, screw, screw, Iong, screw,
M20 X 50 M20X55 M16 X 45 lS: 2269 M20X55
long, long, long, (latest) long,
lS: 2269 lS: 2269 lS: 2269 class 10.9 lS: 2269
(latest) (latest) (latest) (latest)
class '10.9 class 10.9 class 10.9 class 10.9
or hiqher or hiqher or hiqher or hiqher
Type, Hardened Hardened Hardened Hardened Hardened
Size and and and and and
& tempered tempered tempered tempered tempered
Grade washer washer washer washer washer
of with 300 with 300 with 300 with 300 HV with 300
wash HV class HV class HV class class (300 HV class
er (300 HV - (300 HV - (300 HV - HV -370 (300 HV -
370 HV) 370 HV) 370 HV) HV) 370 HV)
hardness. hardness. hardness. hardness. hardness.
A 22, A 18, 422,
lS:2016 lS:2016 lS:2016 lS:20't6 lS:2016
(latest) (latest) (latest) (latest) (latest)
Type, Prevailing Prevailing Prevailing Prevailing Prevailing
Size torque torque type torque type torque type torque
& type hexagonal hexagonal hexagonal type
Grade hexagonal nuts (with nuts (with nuts (with hexagonal
of nut. nuts (with non non non metallic nuts (with
non metallic metallic insert), non
metallic insert), insert), M20:8, metallic
insert), M20:B, M16:8, lS:7002 insert),
M20:8, lS: 7002 lS: 7002 (latest) M20:B,
lS: 7002 (latest) (latest) class 'l 0 lS: 7002
(latest) class 10
class 10 (latest)
class 10 class 10
S u rface All fasteners (screws, washers & nuts) shall be "Zinc electroplated to A3L
finish of finish of lS:1367 (Part - 1 1)"
fasteners

Signature

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dcsignation Ratnaker Tiwari, n Kumar. S6obhit Pra tap Singh
SSE/VDC/Carriase D\ I rcc tor/VDG/C{rriage Director/VDG/Ca rriage
 Rcf: CG-F-,1.2.1-4 (Rev. l) Page 5l of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

Annexure - lX

Details of dimensions of Spiqot and O-rinq

A
B

E C r(P HATEOFAIRSPRXIS
sPt@t

s
G

O-RING

Description Dimension in "mm"

External diameter of spigot (A) O 85-o o36,[Link]

r

Diameter of spigot without grooves (B) 75.6 + 0.5

Height of spigot (C) 35.0 + 0.5
Height of Groove (D) 6.7 + 0.6
Depth of Groove (E) 4.7 + 0.5
lnternal diameter of O- ring (F) 74.1 + 0.6
Cross section diameter of O- ring (G) 5.7 + 0.1

Note - The mating bolster hole diameter where spigot shall be fitted is O 85 H8 mm (Bore)

S ignatu rc

Name &
A.z'
l'reparcd b1,: Che pproved by:
designation Ratnak€r Tiwari, ecn Kuma[, Shobhit I'ratap Singh
SSE/VDG/Carriagc rector/VDG/Carria e Director/VDG/Carri
 Reft CC-F-4.2.1-4 (Rev. I) I'age 52 of 5ll Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/Si23002. Rcr. nil

Annexure - X

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SSE/VDG/Carriage rect0 r/VDC/Carria Director/VDG/Ca rria
 Rcf: CG-F-{.2.1-{ (Rev. l) Page 53 of Stt Lat€st (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rcv. nil

Annexure - Xl

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 Ref: CG-F-4,2.1-4 (Rev. l) Page 54 of 58 Latest (R€v/Amend) issue : Specification No.
April,2023 RDSO/CG/S/21002, Rev. nil

Annexure -Xll

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SSE/VDG/Carriage Dy. Director/VDG/Carriage Director/VDG/Carriage
 Ref: (-G-F-J.2.I -.1 (Rev. l) Page 55 of58 Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

Annexure - Xlll

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Ref: CC-F-,1.2.1-4 (Rev. l) Page 56 of 58 Latest (Rev/Amend) issue : Specification No.
April,2023 _ RDSO/CG/S/23002, Rev. nil

Annexure - xtv

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 Ref: CC-F-{.2.1-.1 (Rev. l) Page 57 of 58 Latest (Rev/Amend) issre : Specification No.
April,202J RDSO/CG/S/23002, Rev. nil

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 Rcf: CG-F-4.2.1-.1 (Rev. l) I'agc 5ll of 5ll Latest (Rev/Amend) issue : Specification No.
April,2023 RDSO/CG/S/23002, Rev. nil

Annexure - XVI

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