specification final b

7/30/2019 Specification Final b

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TM/HM/6 Date: 17 -.7-2003

A- eq[; vfHk;Urk VSdekhu

I. Chief Engineer (Track Machines)

1- e/; jsyos] lh,lVh]

eqEcbZ&400 001

CST, C R, Mumbai - 400 001.

2- Qs;jyh Iysl] iwoZ jsyos]dksydkrk&700 001

Fairlie Place, E R, Kolkata-700 001.

3- cM+kSnk gkml] mRrj jsyos]u;h fnYyh&110 001

Baroda House, N R, New Delhi-110 001.

4- mRrjiwoZ jsyos] xksj[kiqj273012

N E R, Gorakhpur-273 012.

5- ekyhxkao] mRrjiwoZ lhekUrjsyos] xqokgkVh&781 011

Maligaon, N F R, Guwahati -781 011.

6- ikdZ Vkmu] nf{k.k jsyos]psUubZ&600 003

Park Town, S R, Chennai -600 003.

7- jsy fuyk;e] nf{k.k e/; jsyos]fldUnjkckn&500 371

Rail Nilayam, SCR, Secunderabad-500 371.

8- XkkMZu jhp] nf{k.kiwoZjsyos] dksydkrk&700 043

Garden Reach, S E R, Kolkata-700 043.

9- PkpZxsV] ifpe jsyos]eqEcbZ&400 020

Churchgate, W R, Mumbai-400 020

10

-

mRrj ifpe jsyos] t;iqj&302

001

N W R, Jaipur-302 001.

11-

iwoZ e/; jsyos] gkthiqj&844101

E C R, Hajipur-844 101

12-

nf{k.k ifpe jsyos]gqoyh&580 023

SWR, Hubli-580 023

13-

mRrj e/; jsyos]bykgkckn&211 001

NCR, Allahabad-211 001

14-

iwoZ rV jsyos]Hkqousoj&751 001

East Coast Rly, Bhubaneshwar-751 001

15- Ikfpe e/; jsyos] tcyiqj&482001

WCR, Jabalpur-482 001

16-

nf{k.k iwoZ e/; jsyos]fcykliqj&495 004

South East Central Rly, Bilaspur-495 004

II. mieq[; vfHk;Urkk @ VSdekhu] lh0ih0vk0s,p0

Dy. Chief Engineer (Track Machines),CPOH Workshop, NCR, Begum Sarai,

Allahabad-211012.

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odZkki] mRrj e/; jsyos] csxeljk;] bykgkckn&211 012

Sub: Amendment to specification no. TM/HM/6/26 (April 2001 of tamping toolsRef: Railway Board letter no. 96/Track-III/Tk/13 Vol. III dated 30-5-03

Amendmended specification of tamping tools iwhich have been approved byRailway Board vide reference above is enclosed herewith. This is for your informationand necessary action please.

Da: As above

lqjsUnz dqekjdk;Zdkjh

funskd@jsyiFk ekhu

Copy to: Executive Director (TM), Rly. Bd. Rail Bhawan, New Delhi.

dk;Zdkjh funskd jsyiFk ekhu] jsyos cksMZ] jsy Hkou]ubZ fnYyh

Director IRICEN Pune


funskd@jsyiFk ekhuSTANDARD SPECIFICATION OF TAMPING TOOL FOR USE

WITH ON-TRACK TAMPING MACHINES

Amended Specification no. TM/HM/6/26

1.0 This specification covers the technical requirements for manufacture of tampingtools for use with on-track tamping machines deployed on Indian Railways.Either 16 or 32 or 48 tamping tools are used on one tamping machine dependingupon its model. The shape of tamping tool differs from machine to machine forwhich relevant drawings should be referred to.

2.0 This specification is provisional and subject to modification based on experiencegained during service performance. This specification supersedes specificationno. TM/HM/6/26 of April 2001 on the subject.

3.0 REFERENCES: -

IS 2004:1991 Carbon steel forging for general engineering purpose specification (3rd revision)

IRS-SL.NO.R-16/95 Specification for steel axles for carriage and wagons.

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IS 5517:1993 Steels for hardening and tempering- Specification(second revision).

IS: 228 1959 Method of chemical analysis of pig iron, cast iron andplain carbon and low alloy steels

IS:1598-1977 Method for izod impact test of metals (first revision) .

IS:4163-1982 Method for determination of inclusion content in steelby Microscopic method.IS:1500-1983 Method for Brinell Hardness tests for steel (first

revision) .IS: 9862-1981 Specification for ready mixed paint, brushing,

bituminous, black, lead-free, acid, water and chlorineresisting.

IS:1875-1992 Carbon steel billets, blooms, slabs and bars (Vth

revision).IS 1387-1993 General requirements for the Supply of Metallurgical

Materials (second revision).

IS 1608-1995 Mechanical Testing of Metals Tensile Testing(2nd Revision).

4.0 MANUFACTURE OF STEEL AND TAMPING TOOL:-

4.1 Manufacturer should have the essential facilities required for manufacture of theabove components as appended below. In case steel making facilities are notavailable with the manufacturer, he will furnish a certificate having obtained rawmaterial of requisite quality from a reputed source, conforming to the stipulatedchemical composition and manufacturing process of steel.

4.2 PROCESS OF MANUFACTURE OF STEEL:- The tamping tool shall be

manufactured from steel made by electric or Basic oxygen process. The steelshall be of killed quality. However for continuously cast steel and for steel inspecially treated condition i.e. vacuum degassed secondary refined, etc., thesteel making process shall be as agreed at the time of inquiry & order.

The hydrogen content in the liquid steel shall not exceed 3 ppm.

The Nitrogen content in the liquid steel shall not exceed 0.007%.

4.3 CHEMICAL COMPOSITION:- The Ladle analysis of the steel, when carried outby the method specified in the relevant para of IS:228-1959 or any otherestablished instrumented/chemical method, shall conform to the chemicalrequirements of composition stipulated for Gr40Ni6Cr4 Mo2 to IS:5517-1993.

Table-1

Constituent (of steel tobe used for making

tamping tool)

Percent Permissible variationsin product Analysis (%)

(tamping tool)

C 0.35 to 0.45 + 0.02

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Mn 0.40 to 0.70 + 0.04Si 0.10 to 0.35 + 0.03Ni 1.20 to 1.60 + 0.05Cr 0.90 to 1.30 + 0.05Mo 0.10 to 0.20 + 0.05

S 0.035 to max + 0.005, -0.000P 0.035 max +0.005, -0.000

(*) (Vanadium to the extent of 0.15 to 0.25% may be added for achieving the

desired mechanical properties).

4.3.1 CHEMICAL ANALYSIS:-

The manufacturer shall supply a complete chemical analysis of each cast of thesteel and batch of forged and heat-treated tamping tool, whenever required to doso by the purchaser or the inspecting authority.

4.3.2 PRODUCT ANALYSIS:-

Product analysis shall be carried out on the finished product i.e. tamping tool.Variation in case of such product analysis from the Ladle analysis shall be withinpermissible variation as stipulated in table I of clause 4.3.

4.4 DISCARD:-

Sufficient discard shall be made from either end of each ingot to ensure freedomfrom piping, harmful segregation in case of forging manufactured from ingotroute.

4.5 MANUFACTURING PRACTICE: -

4.5.1 The forged tamping tool shall be manufactured from steel ingots rolled or forgeddown to bloom size but shall be finally shaped to profile by forging only, under ahammer or a press. Pneumatic / Electro-hydraulic / Belt Drop Forge hammers /hydraulic forge press of adequate capacity capable of delivering minimum energy

or force required for deformation during closed die forging of tamping toolsshould be available. The profile shall follow the contour of the tamping tool.

4.5.2 The minimum cross section of the ingots shall not be less than twice themaximum cross section of bloom and the minimum cross section of bloom shallnot be less than thrice the maximum cross section of the forged tamping tool.

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4.5.3 For continuously cast bar/billets a minimum reduction ratio of 6:1 between thecast product and the final product is essential. However, higher reduction ratiomay be mutually agreed upon between the manufacturer and the purchaser atthe time of inquiry and order.

4.5.4 The tamping tool shall be profile forged and then machining shall be done todimensions wherever required according to relevant drawing.

4.5.5 BRANDING: -

All forged tamping tools shall be branded with manufacturers code at appropriatelocation on the forging. Cold punching on the forging shall not be permitted. Hotstamping for year and sl. no. of manufacture of tamping tool shall be done.

5.0 SHOTBLASTING PROCESS:-

All forged tamping tool shall be shot blasted to ensure cleanliness of the surface.Shot blasting shall be done by use of sand or iron shots of size 0.75-1.0 mm size.

6.0 HEAT TREATMENT:-

The forged tamping tool shall be hardened (quenched) and tempered to achievethe desired mechanical properties throughout the cross section of thecomponent. Duration of quenching will depend on amount of quenching oil. Itshould be designed in such a way that it is able to achieve desired mechanicalproperties and tampered martensite micro-structure. Duration of travel fromfurnace to quenching should be such that the hardening temperature remains

within stipulated range. Heat treatment parameters shall be as under:

Hardening temp - 830 o to 850 o CQuenching medium - Oil (servo quench 107 or equivalent)Tempering temp - 550 o to 660o C

7.0 QUALITY OF MATERIAL:-

The tamping tool shall be free from surface and internal forging defect i.e. laps,seams, bursts, cracks, pits, porosity, improper edges etc. which may impair theend use. The tamping tool shall be supplied to the prescribed dimensions andtolerances as per drawing.

8.0 SAMPLING FOR TEST:-

8.1 Random sampling shall be done in accordance with clause 14 of IS:5517-1993.Each component found suitable after visual inspection shall be checked for theirdimensional characteristics as per relevant drawings. Tamping tools found satis-

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factory with regard to all these dimensional characteristics shall be acceptedsubject to testing as per clause 9.0 and 4.3 of this specification.

8.2 Forged and properly heat treated tamping tools shall be submitted in identifiablebatches of maximum 100 nos. and each batch shall contain forging from only one

cast. The selection of forged tamping tools for testing as specified in clause 9.0and 4.3 shall be at the rate of one forging per one batch or part thereof. Thesampling frequency shall be one test per cast per heat treatment batch.

8.3 One additional sample for each 500 forging manufactured shall be selected formacro examination.

9.0 TESTING:-

9.1 TENSILE STRENGTH:-

Tensile test shall be carried out in accordance with IS:1608-1995. The test pieceshall be taken from the central portion of the tamping tool. The tensile strength,yield strength and percentage elongation obtained from test piece shall be asunder:-

Tensile strength - 1100 1250 N/mm2

0.2% proof stress - 880 N/mm2

Elongation %min -11 %

9.2 IMPACT STRENGTH (U Notch):-

Impact test shall be carried out in accordance with the requirement of IS:1598-1977. Sample test piece shall be prepared from the tamping tool. The minimumimpact strength obtained through Izod impact test shall be 41 J at 20 o C.

9.3 METALLURGICAL ANALYSIS:-

9.3.1 MICRO EXAMINATION:-

Micro examination sample shall be taken from the tensile test specimen. Themicrostructure shall be tempered martensite and shall be uniform and typical ofthe heat treatment imparted to the forging. The sampling frequency shall be onetest per cast per heat treatment batch.

9.3.2 GRAIN SIZE:-

The sample shall be drawn from the same location of the tensile test specimen.The grain size, determined as per requirements of IS: 2853, shall not be coarser

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than 5. The sampling frequency shall be one test per cast per heat treatmentbatch.

9.4 CLEANLINESS OF STEEL:-

Inclusion rating of the steel shall be determined in accordance with IS: 4163-82from the tensile test specification. The inclusion rating shall not be worse than2.5 ABCD (thin series) to IS:4163-1982.

9.5 MACRO EXAMINATION:-

9.5.1 Macro examination shall be carried out on the transverse section of the forgedTamping tools. After polishing, the transverse cross sectional surface of theforged tamping tools, on examination with a magnification factor 5 or less, mustnot reveal any harmful discontinuity. The sampling frequency shall be one testper cast per heat treatment batch.

9.5.2 The macro examination shall indicate the presence of grain flow, which shallfollow the contour of the forging.

9.6 NON DESTRAUCTIVE EXAMINATION:-

9.6.1 VISUAL EXAMINATION:-

All tamping tools shall be inspected visually for presence of harmful surfacedefects arising out of manufacturing operation. The forging shall be free fromdefects mentioned at clause 7.0

9.6.2 MAGNETIC PARTICLE TEST:-

All tamping tools shall be tested by magnetic particle method, both in longitudinaland circular magnetization and shall not reveal any harmful surface cracks /defects. The forging revealing harmful surface defects shall be rejected. Allforging shall be demagnetized after the magnetic particle test.

9.6.3 HARDNESS TEST:-

Five percent of tamping tools of one heat treatment batch shall be tested forhardness in accordance with IS:1500-1983 `Method for Brinell Hardness Testsfor Steel' and shall conform to hardness range of 330 to 380 BHN. If required,testing facilities shall be provided by the manufacturer. Hardness value shall bedetermined at three different locations of the tamping tool i.e. shank, middle andtamping blade of tamping tool.

10.0 INSPECTION:-

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10.1 ACCESS TO FIRM PREMISES:-

The inspecting authority or purchaser shall have free access to the works of themanufacturer at all reasonable times. He shall be at liberty to inspect themanufacturer at any stage and to reject any material that does not conform to the

terms of this specification. Inspecting authority or the purchaser shall have powerto mark or deface in distinguishable manner all rejected tamping tools but shallnot be marked in such a manner so as to render them un-saleable to otherparties.

Power shall be reserved with the purchaser or the inspecting authority to bepresent at, and take such part as he thinks fit, in all analysis and physical /chemical/metallurgical examinations which manufacturer may undertake for hisown purposes or under the terms of this specifications, both of the tamping toolsand / or their materials in all stages of manufacturer.

10.2 TESTING FACILITIES:-

The manufacturer shall supply free of charge the material required for testing andshall at his own cost furnish and prepare necessary test pieces as per ISspecification, and supply / arrange testing facilities, gadgets, instrumentation,appliances and labor for such testing as may be carried out on his own premisesin accordance with this specification. Failing facilities at his own works forcarrying out the prescribed tests, the manufacturer shall bear the cost of carryingthe test elsewhere. The manufacturer shall provide necessary gadget requiredfor dimensional checks.

11.0 ACCEPTANCE CRITERIA:-

11.1 CHEMICAL ANALYSIS:-

If the results of the product analysis do not meet the composition requirementsgiven in table 1 of clause 4.3 of this specification, two new samples shall betaken on different pieces from the same batch. Should the two analysis satisfythe requirements, the lot represented shall be accepted. Should either of the testfails, the material shall be taken as not complying with the standard.

11.2 PHYSICAL AND METALLURGICAL ANALYSIS:-

If the results of the product analysis do not meet the requirements given in clause9.0 of this specification, two new samples shall be taken on different pieces fromthe same batch. Should the two analysis satisfy the requirements, the lotrepresented shall be accepted. Should either of the test fails, the material shallbe taken as not complying with the standard.

11.3 HARDNESS:-- 8


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If the sample selected fail to meet the requirement given in para 9.6.3 of thisspecification, two further samples shall be selected from same heat treatmentbatch. The consignment shall be considered to conform to the requirements ifboth the additional tests are satisfactory. Should either of the samples fail, the

manufacturer shall have the right, if he so desires, to repeat the heat treatment ofthe product before two fresh samples are taken for testing. Should the two testssatisfy the requirements of this standard, the lot represented shall be accepted.Should either of the samples fail, the material shall be taken as not complyingwith the standard.

12.0 PROTECTION:-

The components shall be carefully protected with three coats of ready mixedpaint, brushing bituminous black to IS:9862 or with any other equivalent antirustcompound approved by the purchaser, allowing sufficient drying time between

each coat.

13.0 QUALITY ASSURANCE PROGRAMME and COST OF COMPONENT:-

Cost of testing / QAP is for assurance of product - not always the cost of product.With introduction of stringent quality oriented specification, there is chances ofraising of cost of tamping tool. Hence railways should go for bulk procurement oftamping tools clubbing their demand of one to three years.

Authority : RDSOs revised Specification No. TM/HM/6/26 issued vide letter no.TM/HM/6 dated 17-7-2003.

TM/HM/6 Date:01/23.01.2004

A- eq[; vfHk;Urk VSdekhu

I. Chief Engineer (Track Machines)

1- e/; jsyos] lh,lVh] eqEcbZ&400001

CST, C R, Mumbai - 400 001.

2- Qs;jyh Iysl] iwoZ jsyos]dksydkrk&700 001

Fairlie Place, E R, Kolkata-700 001.

3- cM+kSnk gkml] mRrj jsyos]u;h fnYyh&110 001


4- mRrjiwoZ jsyos] xksj[kiqj273012

N E R, Gorakhpur-273 012.

5- ekyhxkao] mRrjiwoZ lhekUrjsyos] xqokgkVh&781 011

Maligaon, N F R, Guwahati -781 011.



- 9


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7- Jsy fuyk;e] nf{k.k e/; jsyos]fldUnjkckn&500 371


8- XkkMZu jhp] nf{k.kiwoZjsyos] dksydkrk&700 043


9- PkpZxsV] ifpe jsyos]eqEcbZ&400 020


10-

mRrj ifpe jsyos] t;iqj&302001

N W R, Jaipur-302 001.

11-

iwoZ e/; jsyos] gkthiqj&844101

E C R, Hazipur-844 101

12-

nf{k.k ifpe jsyos] gqoyh&580023

SWR, Hubli-580 023

13-

mRrj e/; jsyos] bykgkckn&211001

NCR, Allahabad-211 001

14-

iwoZ rV jsyos] Hkqousoj&751001

East Coast Rly, Bhubaneshwar-751 001

15-

Ikfpe e/; jsyos] tcyiqj&482001

WCR, Jabalpur-482 001

16-

Nf{k.k iwoZ e/; jsyos]fcykliqj&495 004


mieq[; vfHk;Urkk @ VSdekhu] lh0ih0vk0s,p0 odZkki]mRrj e/; jsyos] csxe ljk;]

bykgkckn&211 012

Dy. Chief Engineer (Track Machines), CPOHWorkshop, NCR, Begum Sarai, Allahabad-211012.

fo"k;% M;weSfVd] ;wuheSV rFkk lh0,l0,e0 VkbZ VSfEiaxekhu ds ,Dly dh fofkf"V;ka rFkk uDksA

Sub: Specifications and drawings of Axles of Duomatic, UNIMAT and CSM tietamping machine.

Lh0,l0,e0@M;kseSfVd rFkk ;wuheSV ekhu ds fuEufyf[krikVZl dh fofkf"V;ka rFkk uDks rS;kj fd;s x;s gSa rFkk mUgsaHkstk tk jgk gSA

Specification and drawings of the following parts pertaining to CSM/Duomaticand Unimat have been prepared and are being sent here with.

SN Item Spec. No. Drg. No.

1 Eccentric Vibration shaft with disc and nut of CSM(Part No. DL-23-401). TM/HM/6/127 TM/0321

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Lh0,l0,e0 dk blsfUVd okbZczsku'kkQ~V fMLd rFkk uV ds lkFk ikVZ l0Mh0,y0&23&401

2 CSM Satelite or driving bogie axle (Part No. UD-62-3301)

lh0,l0,e0 lSVsykbV ;k Mkbfoaxcksxh ,DlyikVZ l0 ;w0Mh0&62&3301

TM/HM/6/128 TM/0322

3 Running axle for CSM (Part No.CU-61-8502)

lh0,l0,e0 dk jfuax ,Dly ikVZ l0lh0;w0&61&8502

TM/HM/6/129 TM/0323

4 Driving axle for Duomatic tamping machine(Part No.UD-62-01)

M;kseSfVd VSfEiax ekhu ds fy,Mkbfoax ,Dly

ikVZ l0 ;w0Mh0&62&01

TM/HM/6/130 TM/0324

5 Driving axle (front) of Unimat (Part No.CU-61-8801)

;wukseSV dk vxyk Mkbfoax ,DlyikVZ l0 lh0;w0&61&8801

TM/HM/6/131 TM/0325

6 Driving axle (back) of unimat (Part No.UD-62-4901)

;wukseSV dk fiNyk Mkbfoax ,DlyikVZ l0 ;w0Mh0&62&4901

TM/HM/6/132 TM/0326

;g fofkf"V;ka rFkk udks izksfot+uy gSa] {ks=kh; jsyksa ls

vuqjks/k gS fd og mijksDr lanHkZ esa vius lq>ko lfoZl fu"iknu dsvk/kkj ij Hkstsa] ftlls muesa] vkxs lq/kkj fd;k tk ldsA

The drawings and specifications are provisional, the zonal railways are requested tosend the feedback about service performance on this basis, for future improvement.

DA: 1. Spec. & Drgs. (6 Nos.)2. Annexure-I - IR standard specification for Steel

Axles for C&W serial No. R-16-95 with 2Amendments.

3. Annexure-II - Code of procedure for ultrasonictesting.

lqjsUnz dqekjdk;Zdkjhfunskd@jsyiFk ekhu

d`rs egk funskd@jsyiFk ekhu

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Copy to: Executive Director (TM), Rly. Bd. Rail Bhawan, New Delhi-110001.

dk;Zdkjh funskd jsyiFk ekhu] jsyos cksMZ] jsy Hkou]ubZ fnYyh-110001.

DA: 1. Spec. & Drgs. (6 Nos.)2. Annexure-I - IR standard specification for Steel

Axles for C&W serial No. R-16-95 with 2Amendments.

3. Annexure-II -Code of procedure for ultrasonictesting.


funskd@jsyiFk ekhud`rs egk funskd

@jsyiFk ekhuSpecification No. TM/HM/6/127

SPECIFICATION OF ECCENTRIC VIBRATION SHAFT WITH DISC AND NUT(Part no. DL-23-401)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Eccentric Vibration Shaft with disc and nut forCSM tamping machine. This specification may be treated as provisional subjectto modifications based on service performance.

2.0 Reference documents: Following standards have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications, duly incorporating the up-dated corrections/amendments, shall beavailable for reference at manufacturer's works.

i) IRS-R 16-95 : Indian Railway standard specification for(with 1st & 2nd amendments) steel axles for carriages and wagons

(applicable to all gauges).

ii) RDSOs drawing no. TM/0321: Eccentric Vibration Shaft with disc and nut.(DL-23-401).

3.0 Functional Requirement: The Eccentric Vibration Shaft shall function fortransmitting high vibrations in the range of 35 Hz to the tamping arms of CSMtamping machine.

4.0 Material: The shaft shall be made of steel of grade EN-24 or Gr. 40Ni2Cr1Mo28of IS: 4367 and the disc & nut shall be made of EN-8 . Manufacturing process of

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steel and the vibration shaft shall be as per IRS-R 16-95 (with 1st & 2nd

amendments), a copy of which is enclosed as Annexure-I.

5.0 Test:

5.1 All the tests except ultra sonic test shall be carried out as per clause no. 6 to 8 ofthe IRS specification referred above.

5.2 The Ultra Sonic testing shall be conducted as per code of procedure issued byRDSO vide letter no. TM/HM/7 dated 07.02.2003, a copy of which is enclosed asAnnexure-II.

6.0 Inspection: The inspection of the vibration shaft shall be carried out as perclause no. 12 of the IRS specification referred above.

7.0 Protection and Packing: The protection and packing of the vibration shaft shallbe as per clause no. 14 of the IRS specification referred above.

Authority : RDSOs revised Specification No. TM/HM/6/127 issued vide letter no.TM/HM/6 dated 1/23-1-2004.

Specification No. TM/HM/6/128

SPECIFICATION OF CSM SATELLITE OR DRIVING BOGIE AXLE(Part no. UD-62-3301)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of CSM satellite or driving bogie axle. Thisspecification may be treated as provisional subject to modifications based on

service performance.


i) IRS-R 16-95 : Indian Railway standard specification for steel(with 1st & 2nd amendments) axles for carriages and wagons (applicable to

all gauges).ii) RDSOs drawing no.TM/0322:CSM satellite or driving bogie axle (part no.

UD- 62-3301).

3.0 Functional Requirement: The CSM satellite or driving bogie axle shall functionas driving bogie axle of CSM tamping machine.

4.0 Material: The detailed material specification shall be as per IRS-R 16-95 (with1st & 2nd amendments), a copy of which is enclosed as Annexure-I.

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5.0 Test:


5.2The Ultra Sonic testing shall be conducted as per code of procedure issued byRDSO vide letter no. TM/HM/7 dated 07.02.2003, a copy of which is enclosed asAnnexure-II.

6.0 Inspection: The inspection of the axle shall be carried out as per clause no. 12of the IRS specification referred above.

7.0 Protection and Packing: The protection and packing of the axle at journals, axlebody and wheel seats shall be as per clause no. 14 of the IRS specificationreferred above.



SPECIFICATION OF RUNNING AXLE FOR CSM(Part no. CU-61-8502)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Running axle for CSM. This specification maybe treated as provisional subject to modifications based on service performance.



(applicable to all gauges).ii) RDSOs drawing no. TM/0323: Running axle for CSM (part no. CU-61-

8502).

3.0 Functional Requirement: This axle shall function as running axle of CSMtamping machine.

4.0 Material: The detailed material specification shall be as per IRS-R 16-95 (with 1st

& 2nd amendments), a copy of which is enclosed as Annexure-I.

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5.0 Test:







SPECIFICATION OF DRIVING AXLE FOR DUOMATIC TAMPING MACHINE(Part no. UD-62-01)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Driving axle for Duomatic tamping machine.This specification may be treated as provisional subject to modifications based

on service performance.



(applicable to all gauges).ii) RDSOs drawing no.TM/0324:Driving axle for Duomatic tamping machine

(part no. UD-62-01).

3.0 Functional Requirement: This axle shall function as driving bogie axle ofDuomatic tamping machine.


& 2nd amendment), a copy of which is enclosed as Annexure-I.

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5.0 Test:5.1 All the tests except ultra sonic test shall be carried out as per clause no. 6 to 8 of

the IRS specification referred above.






SPECIFICATION OF DRIVING AXLE (FRONT) OF UNIMAT(Part no. CU-61-8601)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of driving axle (front) of UNIMAT. Thisspecification may be treated as provisional subject to modifications based onservice performance.



(applicable to all gauges).ii) RDSOs drawing no. TM/0325 : Driving axle (front) of UNIMAT (part no.

CU-61-8601).

3.0 Functional Requirement: This axle shall function as driving bogie axle (front) ofUNIMAT.


& 2nd amendment), a copy of which is enclosed as Annexure-I.

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5.0 Test:





Authority : RDSOs revised Specification No. TM/HM/6/131 issued vide letterno.TM/HM/6 dated 1/23-1-2004.


SPECIFICATION OF DRIVING AXLE (REAR) OF UNIMAT

(Part no. UD-62-4901)

1.0 Scope:This specification covers the dimensional functional and materialrequirements with testing criteria of Driving axle (rear) of UNIMAT. Thisspecification may be treated as provisional subject to modifications based onservice performance.



(applicable to all gauges).ii) RDSOs drawing no. TM/0326: Driving axle (rear) of UNIMAT (part no.

UD-62-4901).

3.0 Functional Requirement: This axle shall function as driving bogie axle (rear) ofUNIMAT (Tamping machine for points and crossings).

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4.0 Material: The detailed material specification including process of manufacturingof steel and the axle shall be as per IRS-R 16-95 (with 1 st & 2nd amendment), acopy of which is enclosed as Annexure-I.

5.0 Test:




7.0 Protection and Packing: The protection and packing of the axle at journals, axlebody and wheel seats shall be as per clause no. 14 of the IRS specification

referred above.


TM/HM/6 Date: 29.3/1-4-.2004

A- eq[; vfHk;Urk VSd ekhu I. Chief Engineer (Track Machines)1- e/; jsyos] lh,lVh] eqEcbZ&400 001 CST, C R, Mumbai - 400 001.2- Qs;jyh Iysl] iwoZ jsyos]

dksydkrk&700 001Fairlie Place, E R, Kolkata-700 001.

3- cM+kSnk gkml] mRrj jsyos] u;hfnYyh&110 001


4- mRrjiwoZ jsyos] xksj[kiqj 273012 N E R, Gorakhpur-273 012.5- ekyhxkao] mRrjiwoZ lhekUr jsyos]

xqokgkVh&781 011Maligaon, N F R, Guwahati -781 011.





8- XkkMZu jhp] nf{k.kiwoZ jsyos]dksydkrk&700 043


9- PkpZxsV] ifpe jsyos] eqEcbZ&400020


10-

mRrj ifpe jsyos] t;iqj&302 001 N W R, Jaipur-302 001.

11-

iwoZ e/; jsyos] gkthiqj&844 101 E C R, Hazipur-844 101

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12-

nf{k.k ifpe jsyos] gqoyh&580 023 SWR, Hubli-580 023

13-

mRrj e/; jsyos] bykgkckn&211 001 NCR, Allahabad-211 001

1

4-

iwoZ rV jsyos] Hkqousoj&751 001 East Coast Rly, Bhubaneshwar-751 001

15-

Ikfpe e/; jsyos] tcyiqj&482 001 WCR, Jabalpur-482 001

16-

nf{k.k iwoZ e/; jsyos] fcykliqj&495004


mieq[; vfHk;Urkk @ VSd ekhu]lh0ih0vk0s,p0 odZkki] mRrj e/;jsyos] csxe ljk;] bykgkckn&211 012

Dy. Chief Engineer (Track Machines), CPOHWorkshop, NCR, Begum Sarai, Allahabad-211012.

fo"k;% M~;weSfVd rFkk lh0,l0,e0 VkbZ VSfEiax ekhu

ds ikVZl dh fofkf"V;ka rFkk uDksASub: Specifications and drawings of spare parts of Duomatic and CSM tietamping machine.

Lh0,l0,e0 rFkk M~;kseSfVd ekhu ds fuEufyf[kr ikVZl dhfofkf"V;ka rFkk uDks rS;kj fd;s x;s gSa rFkk mUgsa Hkstk tk

jgk gSA

Specification and drawings of the following parts pertaining to CSM andDuomatic have been prepared and are being sent here with.

SN Item Spec. No. Drg. No.

1 Locking device of tamping unit of Duomatic TampingMachine

M~;kseSfVd VSfEiax ekhu ds VSfEiax;wfuV dh ykfdax ;qfDrA

TM/HM/6/133 TM/0401

2 Locking device of tamping unit of CSM Tamping Machine

lh-,l-,e- VSfEiax ekhu ds VSfEiax ;wfuVdh ykfdax ;qfDrA

TM/HM/6/134 TM/0402

3 Cover plate for squeezing cylinder of CSM (Part No.2E.34.50).

lh0,l0,e0 ds Ldohftax flfyUMj dh doj IysVikVZ l0 2bZ0 34-50

TM/HM/6/135 TM/0403

4 Cover plate for squeezing cylinder of CSM (Part No.2E.35.314).

lh0,l0,e0 ds Ldohftax flfyUMj dh dojTM/HM/6/136 TM/0404

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SPECIFICATION NO. TM/HM/6/133

SPECIFICATION OF LOCKING DEVICE OF TAMPING UNIT OF DUOMATIC

TAMPING MACHINE

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Locking device of tamping unit of Duomatictamping machine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following I S Specifications have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available forreference at manufacturer's works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.i) IS: 1599 -1985- Method for bend testii) IS: 77-1976 - Linseed oil for paints - specification.iii) RDSO Drg. No.TM/ 0401- Locking device of tamping unit of Duomatic.

3.0 Functional requirement: The Locking device of tamping unit of Duomatictamping machine shall be capable to secure the tamping unit in lifting or noneworking condition when tamping is not done. All surfaces meant for machiningshall be finished as mentioned in the drawing no. TM/ 0401.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Locking device oftamping unit shall be as mentioned in RDSO drawing no. TM/ 0401.

5.0 Material: The Locking device of tamping unit shall be made from Mild Steel ofGrade A or B Conforming to IS:2062-1992 having minimum tensile strength 410MPa i.e. 410 N/mm sq. with minimum percentage elongation of 23. Pin shall bemade of steel Gr. EN8.

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6.0 Heat treatment: The Locking device of tamping unit shall be suitably heattreated in a properly constructed furnace, having adequate means of temperaturecontrol, which shall permit the whole of the Locking device to be uniformly heatedto a temperature of 8000 to 8500C followed by natural cooling (air cooling). Afterheat treatment the Locking device shall achieve tensile strength of 410 N/mm.2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Locking device.

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the Lockingdevice of tamping unit for the following tests. All the three samples shall becollected at random basis from separate batch of heat treatment and shall be

duly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be madeusing the same material from the same lot as that of the prototype samples.

i) Visual and dimensional check: All the three sample of the Locking

device shall be visually checked for surface defects like, roughness,cracks, improper edges etc. Dimensions of the Locking device of tampingunit shall be as mentioned in the drawing no. TM/ 0401.

ii) Non-destructive test: For checking surface cracks, which can not bedetected by naked eyes, all the three samples shall be subjected to non-destructive tests like liquid penetration test/ radio graphic test. For

detection of internal flaws, ultrasonic tests shall be carried out.iii) Chemical composition test: One, out of three samples shall be

subjected to chemical composition test. The manufacturer shall arrangefor this test at his laboratory or at Govt. recognized laboratory if, in housefacility for this test is not available in the manufacturer's works. Onesample shall be sent to RDSO by the manufacturer for testing of chemicalcomposition and tensile strength. The inspecting officials during type tests,may witness the test of chemical composition at the manufacturer'spremises / out side laboratory, if desired by them. Before sending thesamples to RDSO, the same shall be duly sealed by the inspectingofficials and the manufacturer shall arrange for sending the sample to

RDSO. Cost of such testing shall be borne by the manufacturer. Thechemical composition shall be as per the grade mentioned in clause no.5.0.

iv) Test of tensile strength: Tensile strength of the Locking device oftamping unit shall be carried out on one of the two test bars in accordancewith IS:1608-1995 (Mechanical testing of metal - Tensile testing). Theminimum tensile strength shall be 410 Mpa (410 Kg/mm 2). The test shall

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be carried out in the manufacturer's premises or any Govt. recognizedtesting agency under witnessing of inspecting officials.

v) Bend Test: This test shall be carried out on one test bar in accordancewith IS:1599 1985, at the factory premises of the manufacturer. If in-house facility for conducting this test is not available, the same shall be

carried out at Govt. / Govt. registered test house, as desired by theinspecting officials. The test piece at room temperature shall withstandbending through 1800 to an internal diameter not greater than that given inTable-2 (I.S: 2062-1992) without cracking.

8.2 Acceptance Test: The acceptance test shall be conducted by the manufacturerbefore dispatch of material, as per following details.

i) Visual & Dimensional Check as per para 8.1 (i): for every Locking device,Non-destructive test as per para 8.1 (ii): for every Locking device.

ii) Chemical composition test as per para 8.1 (iii): One for every melt/batch ofheat treatment.,

iii) Test of tensile strength: one for every batch of heat treatment.iv) The manufacture shall issue certificate in respect of each Locking device

that the same conforms to the stipulated dimensions and physicalproperties. Any deviation in the test results from the requirements of thespecification shall be the cause of rejection of the component. Thesupplier shall also furnish certificate that the material used formanufacturing of the Locking device conforms to the requirementsmentioned in the specification.

9.0 Inspection: The inspection of the Locking device of tamping unit shall be carriedout as per following para.

9.1 Every Locking device of tamping unit shall be subjected to dimensional & visualcheck as per para 8.1 (i) and non-destructive test as per para 8.1 (ii).

9.2 Whenever the consignee considers it necessary, test of tensile strength shallalso be carried out under the witnessing of inspecting officials on minimum 10%of the consignment size or one whichever is more. The manufacturer shall alsoproduce all relevant documents as proof for conformity to the quality of the rawmaterial used in manufacturing of Locking device.

9.3 In case more than 10% of the samples of the consignment fail during inspectionin respect of para 9.1 & 9.2, fresh samples ( the numbers of which is equal tothose of failed samples ) shall be inspected as per para 9.1 & 9.2. and the failedsamples shall be rejected. If the samples, taken afresh again fail, the totalconsignment shall be rejected.

10. Protection: The Locking device of tamping unit shall be protected with one coatof boiled linseed oil conforming to IS:77-1976 (Linseed oil for paints) or with otherrust preventive compound.

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Authority : RDSOs revised Specification No. TM/HM/6/133 issued vide letter no.TM/HM/6 dated 29-3/1-4-2004.


SPECIFICATION OF LOCKING DEVICE OF TAMPING UNIT OF CSM TAMPINGMACHINE

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Locking device of tamping unit of CSMtamping machine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available forreference at manufacturers works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.

ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.iii) IS: 1599 -1985- Method for bend testiv) IS:77-1976 - Linseed oil for paints - specification.v) RDSO Drg. No.TM/ 0402- Locking device of tamping unit of CSM.

3.0 Functional requirement: The Locking device of tamping unit of CSM tampingmachine shall be capable to secure the tamping unit in lifting or none workingcondition when tamping is not done. All surfaces meant for machining shall befinished as mentioned in the drawing no. TM/ 0402.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Locking device of

tamping unit shall be as mentioned in RDSO drawing no. TM/ 0402.5.0 Material: The Locking device of tamping unit shall be made from Mild Steel of

Grade A or B Conforming to IS:2062-1992 having minimum tensile strength 410MPa i.e. 410 N/mm sq. with minimum percentage elongation of 23. Pin shall bemade of steel Gr. EN8.

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6.0 Heat treatment: The Locking device of tamping unit shall be suitably heattreated in a properly constructed furnace, having adequate means of temperaturecontrol, which shall permit the whole of the Locking device to be uniformly heatedto a temperature of 8000 to 8500C followed by natural cooling (air cooling). Afterheat treatment the Locking device shall achieve tensile strength of 410 N/mm.2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Locking device.

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the Lockingdevice of tamping unit for the following tests. All the three samples shall becollected at random basis from separate batch of heat treatment and shall beduly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be madeusing the same material from the same lot as that of the prototype samples.

i) Visual and dimensional check: All the three sample of the Locking

device shall be visually checked for surface defects like, roughness,cracks, improper edges etc. Dimensions of the Locking device of tampingunit shall be as mentioned in the drawing no. TM/ 0402.

ii) Non-destructive test: For checking surface cracks, which can not bedetected by naked eyes, all the three samples shall be subjected to non-destructive tests like liquid penetration test/ radio graphic test. Fordetection of internal flaws, ultrasonic tests shall be carried out.

iii) Chemical composition test: One, out of three samples shall besubjected to chemical composition test. The manufacturer shall arrange

for this test at his laboratory or at Govt. recognized laboratory if, in housefacility for this test is not available in the manufacturer's works. Themanufacturer for testing of chemical composition and tensile strength shallsend one sample to RDSO. The inspecting officials during type tests, maywitness the test of chemical composition at the manufacturer's premises /out side laboratory, if desired by them. Before sending the samples toRDSO, the same shall be duly sealed by the inspecting officials and themanufacturer shall arrange for sending the sample to RDSO. Cost of suchtesting shall be borne by the manufacturer. The chemical compositionshall be as per the grade mentioned in clause no. 5.0.

iv) Test of tensile strength: Tensile strength of the Locking device of

tamping unit shall be carried out on one of the two test bars in accordancewith IS:1608-1995 (Mechanical testing of metal - Tensile testing). Theminimum tensile strength shall be 410 Mpa (410 Kg/mm 2). The test shallbe carried out in the manufacturer's premises or any Govt. recognizedtesting agency under witnessing of inspecting officials.

v) Bend Test: This test shall be carried out on one test bar in accordancewith IS:1599 1985, at the factory premises of the manufacturer. If in-

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house facility for conducting this test is not available, the same shall becarried out at Govt. / Govt. registered test house, as desired by theinspecting officials. The test piece at room temperature shall withstandbending through 1800 to an internal diameter not greater than that given inTable-2 (I.S: 2062-1992) without cracking.


i) Visual & Dimensional Check as per para 8.1 (i): for every Locking device,Non-destructive test as per para 8.1 (ii): for every Locking device.

ii) Chemical composition test as per para 8.1 (iii): One for every melt/batch ofheat treatment.

iii) Test of tensile strength: one for every batch of heat treatment.iv) The manufacture shall issue certificate in respect of each Locking device

that the same conforms to the stipulated dimensions and physicalproperties. Any deviation in the test results from the requirements of the

specification shall be the cause of rejection of the component. Thesupplier shall also furnish certificate that the material used formanufacturing of the Locking device conforms to the requirementsmentioned in the specification.

9.0 Inspection: The inspection of the Locking device of tamping unit shall becarried out as per following para.

9.1 Every Locking device of tamping unit shall be subjected to dimensional & visualcheck as per para 8.1 (i) and non-destructive test as per para 8.1 (ii).

9.2 Whenever the consignee considers it necessary, test of tensile strength shallalso be carried out under the witnessing of inspecting officials on minimum 10%of the consignment size or one whichever is more. The manufacturer shall alsoproduce all relevant documents as proof for conformity to the quality of the rawmaterial used in manufacturing of Locking device.


10. Protection: The Locking device of tamping unit shall be protected with one coatof boiled linseed oil conforming to IS:77-1976 (Linseed oil for paints) or with otherrust preventive compound.

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SPECIFICATION OF COVER PLATE FOR SQUEEZING CYLINDER OF CSMTAMPING MACHINE (Part no. 2E.34.50)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Cover plate for Squeezing cylinder of CSMtamping machine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available forreference at manufacturer's works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.iii) IS: 1599 -1985- Method for bend testiv) IS:77-1976 - Linseed oil for paints - specification.v) RDSO Drg. No.TM/ 0403- Cover plate for Squeezing cylinder of CSM.

3.0 Functional requirement: The Cover plate for Squeezing cylinder of CSMtamping machine shall be capable to hold the gland bush and seal to movepiston of squeezing cylinder and shall withstand the pressure exerted in thecylinder .All surfaces meant for machining shall be finished as mentioned in the

drawing no. TM/ 0403.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Cover plate forSqueezing cylinder shall be as mentioned in RDSO drawing no. TM/ 0403.

5.0 Material: The Cover plate for Squeezing cylinder shall be made from Mild Steelof Grade A or B Conforming to IS:2062-1992 having minimum tensile strength410 MPa i.e. 410 N/mm sq. with minimum percentage elongation of 23.

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6.0 Heat treatment: The Cover plate for Squeezing cylinder shall be suitably heattreated in a properly constructed furnace, having adequate means of temperaturecontrol, which shall permit the whole of the Cover plate to be uniformly heated toa temperature of 8000 to 8500C followed by natural cooling (air cooling). Afterheat treatment the Cover plate shall achieve tensile strength of 410 N/mm.2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Cover plate.

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the Coverplate for Squeezing cylinder for the following tests. All the three samples shall becollected at random basis from separate batch of heat treatment and shall beduly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be made

using the same material from the same lot as that of the prototype samples.i) Visual and dimensional check: All the three sample of the Cover plate

shall be visually checked for surface defects like, roughness, cracks,improper edges etc. Dimensions of the Cover plate for Squeezing cylindershall be as mentioned in the drawing no. TM/ 0403.

ii) Non-destructive test: For checking surface cracks, which cannot bedetected by naked eyes, all the three samples shall be subjected to non-destructive tests like liquid penetration test/ radio graphic test. Fordetection of internal flaws, ultrasonic tests shall be carried out.

iii) Chemical composition test: One, out of three samples shall be

subjected to chemical composition test. The manufacturer shall arrangefor this test at his laboratory or at Govt. recognized laboratory if, in housefacility for this test is not available in the manufacturers works. Themanufacturer for testing of chemical composition and tensile strength shallsend one sample to RDSO. The inspecting officials during type tests, maywitness the test of chemical composition at the manufacturers premises /out side laboratory, if desired by them. Before sending the samples toRDSO, the same shall be duly sealed by the inspecting officials and themanufacturer shall arrange for sending the sample to RDSO. Cost of suchtesting shall be borne by the manufacturer. The chemical compositionshall be as per the grade mentioned in clause no. 5.0.

iv) Test of tensile strength: Tensile strength of the Cover plate forSqueezing cylinder shall be carried out on one of the two test bars inaccordance with IS:1608-1995 (Mechanical testing of metal Tensiletesting). The minimum tensile strength shall be 410 Mpa (410 Kg/mm2).The test shall be carried out in the manufacturers premises or any Govt.recognized testing agency under witnessing of inspecting officials.

v) Bend Test: This test shall be carried out on one test bar in accordancewith IS:1599 1985, at the factory premises of the manufacturer. If in-

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house facility for conducting this test is not available, the same shall becarried out at Govt. / Govt. registered test house, as desired by theinspecting officials. The test piece at room temperature shall withstandbending through 1800 to an internal diameter not greater than that given inTable-2 (I.S: 2062-1992) without cracking.

8.2Acceptance Test: The acceptance test shall be conducted by the manufacturerbefore dispatch of material, as per following details.

i) Visual & Dimensional Check as per para 8.1 (i): for every Cover plate,Non-destructive test as per para 8.1 (ii): for every Cover plate.


iii) Test of tensile strength: one for every batch of heat treatment.iv) The manufacture shall issue certificate in respect of each Cover plate that

the same conforms to the stipulated dimensions and physical properties.Any deviation in the test results from the requirements of the specification

shall be the cause of rejection of the component. The supplier shall alsofurnish certificate that the material used for manufacturing of the Coverplate conforms to the requirements mentioned in the specification.

9.0 Inspection: The inspection of the Cover plate for Squeezing cylinder shall becarried out as per following para.

9.1 Every Cover plate for Squeezing cylinder shall be subjected to dimensional &visual check as per para 8.1 (i) and non-destructive test as per para 8.1 (ii).

9.2 Whenever the consignee considers it necessary, test of tensile strength shall

also be carried out under the witnessing of inspecting officials on minimum 10%of the consignment size or one whichever is more. The manufacturer shall alsoproduce all relevant documents as proof for conformity to the quality of the rawmaterial used in manufacturing of Cover plate.


10. Protection: The Cover plate for Squeezing cylinder shall be protected with one

coat of boiled linseed oil conforming to IS:77-1976 (Linseed oil for paints) or withother rust preventive compound.

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SPECIFICATION OF COVER PLATE FOR SQUEEZING CYLINDER OF CSMTAMPING MACHINE (Part no. 2E.35.314)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Cover plate for Squeezing cylinder of CSMtamping machine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available for

reference at manufacturer's works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.iii) IS: 1599 -1985- Method for bend testiv) IS:77-1976 - Linseed oil for paints - specification.v) RDSO Drg. No.TM/ 0404- Cover plate for Squeezing cylinder of CSM.

3.0 Functional requirement: The Cover plate for Squeezing cylinder of CSMtamping machine shall be capable to hold the gland bush and seal to movepiston of squeezing cylinder and shall withstand the pressure exerted in the

cylinder. All surfaces meant for machining shall be finished as mentioned in thedrawing no. TM/ 0404.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Cover plate forSqueezing cylinder shall be as mentioned in RDSO drawing no. TM/ 0404.

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5.0 Material: The Cover plate for Squeezing cylinder shall be made from Mild Steelof Grade A or B Conforming to IS:2062-1992 having minimum tensile strength410 MPa i.e. 410 N/mm sq. with minimum percentage elongation of 23.

6.0 Heat treatment: The Cover plate for Squeezing cylinder shall be suitably heattreated in a properly constructed furnace, having adequate means of temperaturecontrol, which shall permit the whole of the Cover plate to be uniformly heated toa temperature of 8000 to 8500C followed by natural cooling (air cooling). Afterheat treatment the Cover plate shall achieve tensile strength of 410 N/mm.2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Cover plate.

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the Coverplate for Squeezing cylinder for the following tests. All the three samples shall be

collected at random basis from separate batch of heat treatment and shall beduly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be madeusing the same material from the same lot as that of the prototype samples.i) Visual and dimensional check: All the three sample of the Cover plate

shall be visually checked for surface defects like, roughness, cracks,improper edges etc. Dimensions of the Cover plate for Squeezing cylindershall be as mentioned in the drawing no. TM/ 0404.

ii) Non-destructive test: For checking surface cracks, which cannot bedetected by naked eyes, all the three samples shall be subjected to non-

destructive tests like liquid penetration test/ radio graphic test. Fordetection of internal flaws, ultrasonic tests shall be carried out.iii) Chemical composition test: One, out of three samples shall be

subjected to chemical composition test. The manufacturer shall arrangefor this test at his laboratory or at Govt. recognized laboratory if, in housefacility for this test is not available in the manufacturer's works. Themanufacturer for testing of chemical composition and tensile strength shallsend one sample to RDSO. The inspecting officials during type tests, maywitness the test of chemical composition at the manufacturer's premises /out side laboratory, if desired by them. Before sending the samples toRDSO, the same shall be duly sealed by the inspecting officials and themanufacturer shall arrange for sending the sample to RDSO. Cost of suchtesting shall be borne by the manufacturer. The chemical compositionshall be as per the grade mentioned in clause no. 5.0.

iv) Test of tensile strength: Tensile strength of the Cover plate forSqueezing cylinder shall be carried out on one of the two test bars inaccordance with IS:1608-1995 (Mechanical testing of metal Tensiletesting). The minimum tensile strength shall be 410 Mpa (410 Kg/mm2).

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SPECIFICATION OF FLY WHEEL (OUTER) OF DUO/ CSM TAMPING MACHINE(Part no. 2E.22.10A)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Fly Wheel (Outer) of DUO/CSM tampingmachine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in this

specification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available forreference at manufacturer's works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.iii) IS:77-1976 - Linseed oil for paints - specification.iv) RDSO Drg. No.TM/ 0405- Fly Wheel (Outer) of DUO/CSM

3.0 Functional requirement: Fly wheel (Outer) shall be capable to provide dynamicuniformity to vibration shaft on variable load. All surfaces meant for machining

shall be finished as mention in the drawing no TM\0405.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Fly wheel (Outer)shall be as mentioned in RDSO drawing no. TM/ 0405.

5.0 Material: The Fly wheel (Outer) shall be made from Mild Steel of Grade A or BConforming to IS:2062-1992 having minimum tensile strength 410 MPa i.e. 410N/mm sq. with minimum percentage elongation of 23.

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6.0 Heat treatment: The Fly wheel (Outer) shall be suitably heat treated in aproperly constructed furnace, having adequate means of temperature control,which shall permit the whole of the Fly wheel (Outer) to be uniformly heated to atemperature of 8000 to 8500C followed by natural cooling (air cooling). After heattreatment the Fly wheel (Outer) shall achieve tensile strength of 410 N/mm. 2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Fly wheel (Outer).

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the Flywheel(Outer) of DUO/CSM for the following tests. All the three samples shall becollected at random basis from separate batch of heat treatment and shall beduly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be made

using the same material from the same lot as that of the prototype samples.i) Visual and dimensional check: All the three sample of the Fly wheel

(Outer) shall be visually checked for surface defects like, roughness, cracks,improper edges etc. Dimensions of the Fly wheel (Outer) of DUO/CSMshall be as mentioned in the drawing no. TM/ 0405.

ii) Non-destructive test: For checking surface cracks, which can not bedetected by naked eyes, all the three samples shall be subjected to non-destructive tests like liquid penetration test/ radio graphic test. For detectionof internal flaws, ultrasonic tests shall be carried out.

iii) Chemical composition test: One, out of three samples shall be subjected

to chemical composition test. The manufacturer shall arrange for this test athis laboratory or at Govt. recognized laboratory if, in house facility for thistest is not available in the manufacturer's works. The manufacturer fortesting of chemical composition and tensile strength shall send one sampleto RDSO. The inspecting officials during type tests, may witness the test ofchemical composition at the manufacturer's premises / out side laboratory, ifdesired by them. Before sending the samples to RDSO, the same shall beduly sealed by the inspecting officials and the manufacturer shall arrange forsending the sample to RDSO. Cost of such testing shall be borne by themanufacturer. The chemical composition shall be as per the gradementioned in clause no. 5.0.

iv) Test of tensile strength: Tensile strength of the Fly wheel (Outer) shall becarried out on one of the two test bars in accordance with IS:1608-1995(Mechanical testing of metal - Tensile testing). The minimum tensilestrength shall be 410 Mpa (410 Kg/mm2). The test shall be carried out in themanufacturer's premises or any Govt. recognized testing agency underwitnessing of inspecting officials.

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i) Visual & Dimensional Check as per para 8.1 (i): for every Fly wheel(Outer), Non-destructive test as per para 8.1 (ii): for every Fly wheel(Outer).


iii) Test of tensile strength: one for every batch of heat treatment.iv) The manufacture shall issue certificate in respect of each Fly wheel (Outer)

that the same conforms to the stipulated dimensions and physicalproperties. Any deviation in the test results from the requirements of thespecification shall be the cause of rejection of the component. Thesupplier shall also furnish certificate that the material used formanufacturing of the Fly wheel (Outer) conforms to the requirementsmentioned in the specification.

9.0 Inspection: The inspection of the Fly wheel (Outer) shall be carried out as perfollowing para.

9.1 Every Fly wheel (Outer) of DUO/CSM shall be subjected to dimensional & visualcheck as per para 8.1 (i) and non-destructive test as per para 8.1 (ii).

9.2 Whenever the consignee considers it necessary, test of tensile strength shallalso be carried out under the witnessing of inspecting officials on minimum 10%of the consignment size or one whichever is more. The manufacturer shall alsoproduce all relevant documents as proof for conformity to the quality of the rawmaterial used in manufacturing of Fly wheel (Outer).

9.3 In case more than 10% of the samples of the consignment fail during inspectionin respect of para 9.1 & 9.2, fresh samples (the numbers of which is equal tothose of failed samples) shall be inspected as per para 9.1 & 9.2.and the failedsamples shall be rejected. If the samples, taken afresh again fail, the totalconsignment shall be rejected.

10. Protection: The Fly wheel (Outer) of DUO/CSM shall be protected with one coatof boiled linseed oil conforming to IS:77-1976 (Linseed oil for paints) or with otherrust preventive compound.

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SPECIFICATION OF FLY WHEEL (INNER) OF DUO/ CSM TAMPING MACHINE(Part no. U.21.01)

1.0 Scope: This specification covers the dimensional functional and materialrequirements with testing criteria of Fly Wheel (Inner) of DUO/CSM tampingmachine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in this

specification. Full sets of relevant drawings and the referred codes/specifications,duly incorporating the up-dated corrections/ amendments, shall be available forreference at manufacturer's works.

i) IS:2062 -1992 - Steel for general engineering purposes - specification.ii) IS:1608 -1992 - Mechanical testing of metals - tensile testing.iii) IS:77-1976 - Linseed oil for paints - specification.iv) RDSO Drg. No.TM/ 0406- Fly Wheel (Inner) of DUO/CSM

3.0 Functional requirement: Fly wheel (inner) shall be capable to transmit powerfrom hydraulic motor to vibration shaft with the help of part clutch. It also provide

ynamic uniformity to vibration shaft on variable load. All surfaces meant formachining shall be finished as mention in the drawing no TM\0406.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Fly wheel (inner)shall be as mentioned in RDSO drawing no. TM/ 0406.

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5.0 Material: The Fly wheel (inner) shall be made from Mild Steel of Grade A or BConforming to IS:2062-1992 having minimum tensile strength 410 MPa i.e. 410N/mm sq. with minimum percentage elongation of 23.

6.0 Heat treatment: The Fly wheel (inner) shall be suitably heat treated in a properlyconstructed furnace, having adequate means of temperature control, which shallpermit the whole of the Fly wheel (inner) to be uniformly heated to a temperatureof 8000 to 8500C followed by natural cooling (air cooling). After heat treatment theFly wheel (inner) shall achieve tensile strength of 410 N/mm.2

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Fly wheel Inner).

8.0 Tests:

8.1 Type test: The manufacturer shall make available three samples of the FlyWheel (Inner) of DUO/CSM for the following tests. All the three samples shall be

collected at random basis from separate batch of heat treatment and shall beduly numbered before commencement of the test. For test of mechanicalproperties like tensile strength, bending etc. separate test bars shall be madeusing the same material from the same lot as that of the prototype samples.

i) Visual and dimensional check: All the three sample of the Fly wheel

(inner) shall be visually checked for surface defects like, roughness,cracks, improper edges etc. Dimensions of the Fly Wheel (Inner) of DUO/CSM shall be as mentioned in the drawing no. TM/ 0406.

ii) Non-destructive test: For checking surface cracks, which can not bedetected by naked eyes, all the three samples shall be subjected to non-

destructive tests like liquid penetration test/ radio graphic test. Fordetection of internal flaws, ultrasonic tests shall be carried out.iii) Chemical composition test: One, out of three samples shall be

subjected to chemical composition test. The manufacturer shall arrangefor this test at his laboratory or at Govt. recognized laboratory if, in housefacility for this test is not available in the manufacturer's works. Themanufacturer for testing of chemical composition and tensile strength shallsend one sample to RDSO. The inspecting officials during type tests, maywitness the test of chemical composition at the manufacturer's premises /out side laboratory, if desired by them. Before sending the samples toRDSO, the same shall be duly sealed by the inspecting officials and themanufacturer shall arrange for sending the sample to RDSO. Cost of suchtesting shall be borne by the manufacturer. The chemical compositionshall be as per the grade mentioned in clause no. 5.0.

iv) Test of tensile strength: Tensile strength of the Fly wheel (inner) shallbe carried out on one of the two test bars in accordance with IS:1608-1995 (Mechanical testing of metal - Tensile testing). The minimum tensilestrength shall be 410 Mpa (410 Kg/mm2). The test shall be carried out in

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the manufacturer's premises or any Govt. recognized testing agencyunder witnessing of inspecting officials.

8.2 Acceptance Test: The acceptance test shall be conducted by the manufacturer

before dispatch of material, as per following details.

i) Visual & Dimensional Check as per para 8.1 (i): for every Fly wheel(inner), Non-destructive test as per para 8.1 (ii): for every Fly wheel(inner).

ii) Chemical composition test as per para 8.1 (iii): One for every melt/batch ofheat treatment.

iii) Test of tensile strength: one for every batch of heat treatment.iv) The manufacture shall issue certificate in respect of each Fly wheel (inner)

that the same conforms to the stipulated dimensions and physicalproperties. Any deviation in the test results from the requirements of thespecification shall be the cause of rejection of the component. Thesupplier shall also furnish certificate that the material used for

manufacturing of the Flywheel (inner) conforms to the requirementsmentioned in the specification.

9.0 Inspection: The inspection of the Fly wheel (inner) shall be carried out as perfollowing para.

9.1 Every Fly wheel (inner) of DUO/CSM shall be subjected to dimensional & visualcheck as per para 8.1 (i) and non-destructive test as per para 8.1 (ii).

9.2 Whenever the consignee considers it necessary, test of tensile strength shallalso be carried out under the witnessing of inspecting officials on minimum 10%

of the consignment size or one whichever is more. The manufacturer shall alsoproduce all relevant documents as proof for conformity to the quality of the rawmaterial used in manufacturing of Fly wheel (inner).

9.3 In case more than 10% of the samples of the consignment fail during inspectionin respect of para 9.1 & 9.2, fresh samples (the numbers of which is equal tothose of failed samples) shall be inspected as per para 9.1 & 9.2. and the failedsamples shall be rejected. If the samples, taken afresh again fail, the totalconsignment shall be rejected.

10. Protection: The Fly wheel (inner) of DUO/CSM shall be protected with one coatof boiled linseed oil conforming to IS:77-1976 (Linseed oil for paints) or with other

rust preventive compound.

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TM/HM/6 Date: 15-07-2004/05-08-2004

A- eq[; vfHk;Urk VSd ekhu I. Chief Engineer (Track Machines)1- e/; jsyos] lh,lVh] eqEcbZ&400 001 CST, C R, Mumbai - 400 001.2- Qs;jyh Iysl] iwoZ jsyos]

dksydkrk&700 001Fairlie Place, E R, Kolkata-700 001.

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4- mRrjiwoZ jsyos] xksj[kiqj 273012 N E R, Gorakhpur-273 012.5- ekyhxkao] mRrjiwoZ lhekUr jsyos]

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2 Body bearing for CSM/DUO Tamping Machine(Part No. 2E.22.11)

lh0,l0,e0 @M~;kseSfVd VSfEiax ekhudh ckWMhfc;fjax ikVZ l0 2bZ0 22-11

TM/HM/6/140 TM/ 0408

3 Support plate for Duomatic Tamping Machine(Part No. DL.10.53)

M~;kseSfVd VSfEiax ekhu dh liksVZIysV ikVZ l0 Mh-,y- 10-53

TM/HM/6/141 TM/ 0409

4 Support ring for lifting and lowering cylinder ofCSM/DUO Tamping Machine (Part No. DL.10.52)

lh0,l0,e0 @M~;kseSfVd VSfEiax ekhuds fyfVax rFkk yksvfjax flfyz.Mj dhliksVZ fjax ikVZ l0 Mh-,y-10.52

TM/HM/6/143 TM/ 0410

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The drawings and specifications are provisional. The zonal railways arerequested to send the feedback about service performance on this basis for futureimprovement.

DA: Spec. & Drgs. 4 Nos.

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SPECIFICATION OF BEARING COVER FOR CSM/DUO TAMPING MACHINE(Part no. 2E.22.16)

1.0 Scope: This specification covers the dimensional, functional and materialrequirements with testing criteria of Bearing Cover of CSM/DUO tampingmachine. This specification may be treated as provisional subject to

modifications based on service performance.2.0 Reference documents: Following IS Specifications have been referred to in this

specification. Full sets of relevant drawings and the referred codes/specifications, duly incorporating the up-dated corrections/amendments, shall beavailable for reference at manufacturers works.

i) IS:2062 1992 Steel for general engineering purposes specification.ii) IS:77-1976 Linseed oil for paints specification.iii) RDSO Drg. No.TM / 0407- Bearing Cover of CSM/DUO

3.0 Functional requirement: The Bearing Cover (Part no. 2E.22.16) is Provided in

squeezing cylinder to protect the bearing of vibration shaft. It shall be capable towithstand the vibration of vibration shaft i.e. 35 Hz. All surfaces meant formachining shall be finished as mentioned in the drawing no. TM/ 0407.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Bearing Cover shallbe as mentioned in RDSO drawing no. TM/ 0407.

5.0 Material: The Bearing Cover shall be made from Mild Steel of Grade A or Bconforming to IS:2062-1992 having minimum tensile strength 410 Mpa i.e. 410N/mm sq. with minimum percentage elongation of 23.

6.0 Manufacturing Process: Bearing Cover of CSM /DUO shall be made by

either machining from billet of specified material or by forging and machiningprocess which is convenient to reduce the cost.

7.0 Marking: Month and year of manufacture and manufacturers code /identification shall be engraved / embossed on the Bearing Cover.

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SPECIFICATION OF BODY BEARING FOR CSM/DUO TAMPING MACHINE(Part no. 2E.22.11)

1.0 Scope: This specification covers the dimensional, functional and materialrequirements with testing criteria of Body bearing of CSM/DUO tamping machine.This specification may be treated as provisional subject to modifications basedon service performance.

2.0 Reference documents: Following IS Specifications have been referred to inthis specification. Full sets of relevant drawings and the referred codes/specifications, duly incorporating the up-dated corrections/amendments, shall beavailable for reference at manufacturers works.

i) IS:2062 1992 Steel for general engineering purposes specification.ii) IS:77-1976 Linseed oil for paints specification.iii) RDSO Drg. No.TM / 0408- Body Bearing of CSM/DUO

3.0 Functional requirement: The Body bearing is a housing of the bearings ofvibration shaft. It shall be capable to bear the load of the bearing of the vibrationshaft and its vibration i.e 35 Hz. .All surfaces meant for machining shall befinished as mentioned in the drawing no. TM/ 0408.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Body bearing shallbe as mentioned in RDSO drawing no. TM/ 0408.

5.0 Material: The Body bearing shall be made from Mild Steel of Grade A or Bconforming to IS:2062-1992 having minimum tensile strength 410 Mpa i.e. 410N/mm sq. with minimum percentage elongation of 23.

6.0 Manufacturing Process: Body bearing of CSM /DUO shall be made by eithermachining from billet of specified material or by forging and machining process.

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7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Body bearing.

8.0 Inspection And Acceptance Criteria:

i) Each components offered by manufacturer shall be checked visually fortheir surface finish, freedom from defects like porosity, cracks, improperedges etc.

ii) The component found suitable after visual inspection, shall be checked fortheir dimensions as per relevant drawing.

iii) Supplier shall produce the certificate that the raw material use formanufacturing of the component conforms to the IS: 2062-1992 asmentioned in para 5.0.

iv) Manufacturer shall also produce a test result of chemical property/analysis report of billet/raw material used for manufacturing of thecomponent.

v) Any deviations in the test result from the requirement of the specificationand drawing shall be the cause of rejection of the component.

9.0 Packing and Protection: Each component shall be protected with one coat ofboil linseed oil conforming to IS: -77-1976 (linseed oil for paint) and shall bepacked in card board case.

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Authority : RDSOs revised Specification No. TM/HM/6/140 issued vide letter no.

TM/HM/6 dated 15-7/5-8-2004.


SPECIFICATION OF SUPPORT PLATE FOR DUOMATIC TAMPING MACHINE(Part no. DL.10.53)

1.0 Scope: This specification covers the dimensional, functional and materialrequirements with testing criteria of Support Plate and bolt for DUO tampingmachine. This specification may be treated as provisional subject tomodifications based on service performance.

2.0 Reference documents: Following IS Specifications have been referred to in thisspecification. Full sets of relevant drawings and the referred codes/specifications, duly incorporating the up-dated corrections/ amendments, shall beavailable for reference at manufacturer's works.

i) IS:2062-1992 - Steel for general engineering purposes - specification.ii) BS: 970 Part II - 1970 Specification of direct hardening alloy steel.iii) IS:77-1976 - Linseed oil for paints - specification.iv) RDSO Drg. No.TM/0409 - Support plate and bolt for lifting and lowering

cylinder of DUO (Part no. DL 10.53).

3.0 Functional requirement: The Support Plate for DUO tamping machine shall becapable to hold the lifting and lowering cylinder of tamping unit on body framewith the help of support ring. All surfaces meant for machining shall be finishedas mentioned in the drawing no. TM/ 0409.

4.0 Dimension & Tolerance: Dimensions and tolerances of the Support plate forlifting and lowering cylinder shall be as mentioned in RDSO drawing no. TM/

0409.5.0 Material: The Support plate for lifting and lowering cylinder shall be made from

Mild Steel of Grade A or B conforming to IS:2062-1992 having minimum tensilestrength 410 MPa i.e. 410 N/mm sq. with minimum percentage elongation of 23.Bolt shall be made of steel Gr. 817 M 40(EN -24) confirming to BS:970 Part II of1970.

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6.0 Manufacturing process : Support plate of CSM /DUO shall be made by eithermachining from plate, billet of specified material or by forging and machiningprocess and bolt shall be made by suitable machining process..

7.0 Marking: Month and year of manufacture and manufacturer's code / identificationshall be engraved / embossed on the Support plate.

8.0 Inspection And Acceptance Criteria:

i) Each components offered by manufacturer shall be checked visually fortheir surface finish, freedom from defects like porosity, cracks, improperedges etc. Machined surface shall be checked by any suitable pneumaticor electronic equipment.

ii) The component found suitable after visual inspection, shall be checked fortheir dimensions as per relevant drawing.

iii) Supplier shall produce the certificate that the raw material use formanufacturing of the component conforms to the specified material asmentioned in para 5.0.

iv) Manufacturer shall also produce a test result of chemical property/analysis report of billet/raw material used for manufacturing of thecomponent.

v) Minimum one no or 2 % sample of the bolts randomly picked up out ofeach lot of consignment

specification final b

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