R.D.S.O
 

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR SELF-STEERING

Co-Co BOGIES OF 4000/4500 HP BROAD GAUGE (1676 mm)
DIESEL ELECTRIC LOCOMOTIVES

SPECIFICATION NO. MP- 0.4900.15

(Revision – 04)

July 2011

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RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226 011
 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

TECHNICAL SPECIFICATION FOR SELF-STEERING

Co-Co BOGIES OF 4000/4500 HP BROAD GAUGE (1676 mm)
DIESEL ELECTRIC LOCOMOTIVES
1. INTRODUCTION
1.1 To cater for rapid growth in freight traffic, it has become necessary that freight locomotives are
equipped with bogie, which has longer wheel life, longer period between two-wheel turnings and
lesser track forces. To ensure high levels of performance, availability and operational reliability of
locomotives, Indian Railways is seeking supply of track friendly self-steering bogie for diesel electric
locomotives with a cutting edge technology along with complete Transfer of Technology for their
design, development and manufacturing.
1.2 This specification is for design development, supply and Transfer of Technology of Self-steering Co-
Co bogies of Broad Gauge (1676 mm) WDG4 EMD design freight diesel electric locomotives.
1.3 The bogie design will be primarily applied on WDG4 locomotive (GT46MAC locomotive). The
WDG4 locomotives are equipped with two bogies with three axles, two-stage suspension and axle
hung nose suspended traction motor with single shoe type brake rigging arrangement and a rigid
axle guidance.

2. DEFINITIONS
2.1 'Tenderer' means the firm/ company submitting the offer for the supply of self-steering Co-Co bogies
for 4000/4500 HP Broad Gauge (1676 mm) freight diesel electric locomotives conforming to this
specification.
2.2 'Purchaser' means the President of Republic of India.
2.3 'RDSO' means Research Designs and Standards Organisation, Ministry of Railways, Manak Nagar,
Lucknow-226011, India.
2.4 'Inspecting Officer' means person, firm, or department nominated by the purchaser to inspect the
locomotive bogie on his behalf or the representative of the Inspecting Officer so nominated.
2.5 'DLW' means Diesel Locomotive Works, Varanasi - 221004 or their successors.
2.6 'Contractor' means any firm or company with whom the order for supply of self-steering Co-Co
bogies for 4000/4500 HP Broad Gauge (1676 mm) freight diesel electric locomotives conforming to
this specification has been placed or is intended to be placed.
2.7 'Sub-supplier'/ 'Sub-Vendor' means any person, firm or company from whom the contractor may
obtain any material, sub-assemblies or assemblies used for the manufacture of locomotive self-
steering bogies.
2.8 The ‘Bogie Kit’ implies assembled self-steering bogie. It, however, excludes the wheel & axle sets
with gear wheel, traction motors with TM pinion, suspension tube assembly including bearing
housings, end fittings, suspension bearings and fasteners.
2.9 The ‘Component Kit’ implies all the components of complete self-steering bogie. It, however,
excludes the wheel & axle sets with bull gear, traction motors, suspension tubes including
suspension bearings and other components marked ‘X’ in column E of Table 1.
2.10 'Braking effort' means net retarding force at the rail level.
2.11 GT46MAC locomotive means WDG4 locomotives presently operating on Indian Railways.
2.12 ‘IRS’ means Indian Railway Standard.
2.13 ‘ToT’ means Transfer of Technology.
2.14 ‘UIC’ means Union Internationale Des Chemins De Fer (International Union of Railways).
2.15 ‘AAR’ means Association of American Rail Roads.
2.16 The time frame specified in this specification is indicative and given with reference to date of
contract (‘D’ date). However the contractor may indicate their time frame as practicable in its offer.

Motive Power Directorate (VDG), RDSO, Lucknow Specification No. 0.4900.15 (Rev.04) of July 2011 Page No. 1
 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
2.17 ‘IR’ means Indian Railways.

3. ENVIRONMENTAL & TRACK CONDITIONS

The track parameters and environment details given here are indicative only and for easy appreciation of
operating conditions. The prospective bidder is responsible and is expected to have read and understood
all relevant parameters for functionality & effective supply of self-steering bogies.

3.1 Climatic and Environmental Conditions

Parameter Requirement
3.1.1 Maximum temperature Under Sun : 70º C
(Atmospheric) In Shade : 50º C
3.1.2 Humidity 100% saturation during rainy season.
3.1.3 Reference site Ambient temp. : 47º C
conditions Humidity : 60 %
Altitude :160 m
3.1.4 Rainfall Very heavy in certain areas.
The bogie shall be designed to permit locomotive running at 10
km/h in a flood water level of 102 mm above rail level.
3.1.5 Atmosphere during hot Extremely dusty and desert terrains in certain areas.
weather
3.1.6 Coastal area The bogie shall be designed to permit locomotive operation in
coastal areas in humid and salt laden atmosphere.

3.2 Track Parameters

Parameters Requirements

3.2.1 Gauge Broad Gauge (BG) 1676 mm (nominal).

3.2.2 Track Structure The track is to a standard of:
60 kg, 90 UTS rails on pre-stressed concrete sleepers, 1660 per km
sleeper density, 300 mm depth of ballast cushion below the
sleepers
Or 52 kg, 90 UTS rails on pre-stressed concrete sleepers, 1540 per
km sleeper density, 250 mm depth of ballast cushion below the
sleepers
3.2.3 Sharpest curve & turn 174 m radius.
out to be negotiated The locomotive shall also be checked for passage in both directions
over standard BG 1 in 8½ turnouts. Vogel’s layout or its
internationally accepted equivalent for negotiability, throw over at
headstock and coupler movement with details of clearances shall
be prepared and supplied by the contractor.
Maximum Super Elevation : 185 mm
Maximum Cant Deficiency : 100 mm
3.2.4 Schedule of Dimensions Indian Railways 'Schedule of Dimensions’ for Broad Gauge
(1676 mm), 2004.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

Parameters Requirements
3.2.5 Overall Moving The offered design of self-steering bogie with new wheels when
dimensions interfaced with WDG4 locomotive carbody in empty condition shall
be within the dimensions shown in IR MMD EDO/T – 2202.
3.2.6 Clearance above the The offered self-steering bogie shall be so designed that when
Rail level interfaced with WDG4 locomotive carbody, no component shall
infringe minimum clearance of 97mm above rail level with the
locomotive fully loaded and wheels in fully worn condition to a
diameter of 1016 mm.

3.3 Permissible Track Tolerances

Permissible Track B.G. Main Lines B.G. High Speed Route
Tolerances (Other than C&M 1 Vol. 1) (C&M 1 Vol. 1)

3.3.1 Unevenness (3.6 m base) < 15 mm <10 mm

3.3.2 Twist (3.6 m base) < 2.78 mm / meter <2.08 mm / meter

3.3.3 Gauge Variation < ± 6 mm < ± 3 mm

3.3.4 Alignment (Versine on 7.2 m

< 5 mm < 5 mm
Chord)

3.3.5 Gauge Widening

On curves of ≥ 350m radius - 5mm to + 3mm

On curves of < 350m radius Up to + 10mm

4. FIELD PERFORMANCE AND DESIGN REQUIREMENTS OF SELF-STEERING BOGIE

4.1 Stability and Riding Quality Requirements

Parameter Requirements

4.1.1 Maximum Lateral Force 4.5 tonnes (at a speed of 115 Kmph)

4.1.2 Derailment Co-efficient <1

4.1.3 Lateral & Vertical Acceleration in the ≤ 0.35 g (0.3g preferable)
driving cab and over the pivots in the loco Remark: Number of acceleration peaks
car body exceeding 0.2g to be kept to a minimum.

4.1.4 Ride Index in the driving cab at floor level ≤ 3.75

As optimized by the contractor,details of which

4.1.5 Angle of Attack (A.O.A.) should be brought out in the technical proposal
as well as other appropriate stages.
The procedure for testing the above mentioned parameters shall be generally as per RDSO Report no.
MT-288,April 2001, a copy of which may be obtained from RDSO.
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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
4.2 Field Performance Requirements

Parameter Requirements

4.2.1 Speed Potential When self-steering bogie with fully worn wheels of 1016 mm diameter is
put under GT46MAC car body, the bogie shall be suitable on straight
tangent track for:
Operating Speed : 105 km/h (Maximum)
Test Speed : 115 km/h
4.2.2 Weight The offered design of self-steering bogie and allied components with the
steering arrangement should not exceed the weight of existing HTSC
bogie of WDG4 locomotive without wheel axle and motor assembly.

4.2.3 Adhesion Load A WDG4 locomotive equipped with the self-steering bogies shall be
Capability capable of providing the same or better starting and continuous
adhesion on straight tangent track as obtained with the HTSC bogie for
the GT46MAC. The starting adhesion of WDG4 locomotive on straight
tangent track is 0.42. The tractive effort Vs speed characteristic of
WDG4 locomotive for straight tangent track is enclosed.
On curved track, WDG4 locomotive equipped with the self-steering
bogies shall be capable of providing the adhesion higher than the value
obtained with HTSC bogies on the existing WDG4 locomotives and the
offer should indicate the extent of improvement in the adhesion value.
The contractor may give details of quantification and clarify with a
detailed note.
4.2.4 Curve Negotiability The self-steering bogie offered shall be capable of negotiating curve of
radius 100 m by itself, and not necessarily when coupled with WDG4
locomotives.

4.2.5 Un-sprung mass The maximum un-sprung mass per axle shall preferably be limited to 4
tonnes.

4.2.6 Dynamic The dynamic augment shall not exceed 30% at maximum permissible
Augmentation speed.

4.3 Qualifying Requirements

The tenderer shall essentially provide satisfactory evidence acceptable to the purchaser as follows:

4.3.1 That they design, manufacture and supply service-proven self-steering locomotive bogies and have
at least 20 locomotive sets in satisfactory service. (A declaration indicating the number of such
locomotives fitted with radial bogies supplied by the tenderer along with owning rail roads shall be
provided by the tenderer.)

4.3.2 They are in a position to transfer the complete technology for the design and manufacture of the
complete offered self-steering bogie.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
4.3.3 A complete technical proposal (in the technical bid) clearly bringing out specific features and
benefits of its offer, conceptual details of bogies offered, duly meeting the specification etc should be
submitted by the tenderer.

5. ACTION PLAN FOR ADAPTION OF SELF-STEERING TECHNOLOGY

It is planned to adapt the complete technology of self-steering bogies as under:

5.1 The scope of bogie kits (Column ‘D’) involves supply, assembly, oscillation trials & steady state
curving test as well as field performance evaluation and TOT for 10 complete self-steering functional
bogies along with one such bogie frame for endurance testing.

5.2 The Contractor shall also supply 40 sets component kits (as per Column ‘E’ of the table given
below) . The sourcing of 40 component kits whether indigenous / imported is also given in the
column ‘F’ of the table.
Table 1
A. B. C. D. E. F.
Common / First 10 11th to 50th bogies 11th to 50th bogies
Items
Uncommon Prototype Component
Items bogies Contractor to supply Items to be
Vis-à-vis ‘Component Kits’, necessarily
WDG4 HTSC (Contractor to excluding items marked ‘X’ indigenized(sourced
non self- supply ‘Bogie from India) marked
steering Kits’, excluding ‘√’
bogie items marked
(Tentative) ‘X’)
5.2.1 Bogie frame assembly Uncommon √* X# X
with brackets, bolts, To be procured by
liners & miscellaneous (06 +01 bogie (Balance 44 nos. to be
frame) procured by IR through IR (Indigenous
hardware source(s) to be
indigenous sources)
developed by the
contractor)
5.2.2 Self-steering Uncommon √ √ √
mechanism and
components
5.2.3 Traction Motor with Common X X -
Suspension tube &
allied components,
suspension bearing &
pinion
5.2.4 Wheel, axle &
gearwheel
Common X X -
5.2.5 Bearing adopter Uncommon √ √ X
Assembly with bearings
(End and middle axle)
with components &
hardware
Lateral thrust pad -do- √ √ X

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

5.2.6 Traction rod Uncommon √ √ X

application: Traction
rod assembly with
Traction rod machined,
rubber bushing &
miscellaneous
hardware
5.2.7 Nose link application: Preferably to be √ √ X
Nose link assembly kept common
with Nose link
machined, rubber
bushing &
miscellaneous
hardware
5.2.8 Primary helical coil X
springs
Uncommon √ √
5.2.9 Secondary rubber X
springs
Uncommon √ √
5.2.10 Primary vertical damper Uncommon √ √ X
Secondary yaw/ lateral Uncommon √ √ X
damper
5.2.11 Centre pivot assembly Preferably to be X
kept common
√ √
Car body link assembly -do- √ √ X
Miscellaneous
hardware of carbody -do- √ √ √
linkage assembly
5.2.12 Brake rigging Uncommon √ X
arrangement with brake
(These 40 nos. to be
cylinders and
miscellaneous
procured by IR through -
indigenous sources)
hardware &
components
5.2.13 Pneumatic pipe line Uncommon √ X
and fittings for brake
(These 40 nos. to be
system, including
procured by IR through -
Parking brake
indigenous sources)
arrangement
5.2.14 Rubber parts of Preferably to
X
Sanding arrangement be kept
(These 40 nos. to be
(Sander guide common √ procured by IR through
-
assembly with Sander
hose) indigenous sources)
Other items & Preferably to be X
miscellaneous kept common
(These 40 nos. to be
hardware of Sanding √ procured by IR through
-
arrangement
indigenous sources)
5.2.15 Any other relevant
bogie items not √ √ -
covered above

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

5.3.1 * The 10 bogie kits under column ‘D’ shall be supplied with only 7 bogie frames wherein 6
bogie frames are for the self-steering bogie assembly and the seventh bogie frame is spare
for endurance testing.
5.3.2 # Rest 44 bogie frames shall be procured by Indian Railways from indigenous sources with
technical assistance from the contractor including development of tooling, jigs and fixtures.
The cost of which is not to be quoted by the supplier.
5.3.3 Development of at least one indigenous source by the contractor in line with column ‘F’ of the
above table is a must for items to be sourced indigenously. For other components, the
contractor may decide to supply through import or through indigenous source. The drawing,
specification and test certificates for all such components shall be provided by the contractor
to IR.
5.3.4 The tenderer shall also offer per unit price for rubber or rubber bonded components, special
fasteners like Huck bolts, helical springs, dampers & special bearings etc. such that IR may
order such components in sets of ten loco sets for 51st self-steering bogie onwards.
5.3.5 All indigenous components shall be subjected to fresh inspection involving type testing,
design validation and field trials for the first set of components, except as mentioned in Para
8.2 to 8.5.
5.3.6 For this tender requirements, the tenderer must select at least one appropriate Indian partner
for indigenous manufacture of all fabricated components given that the Indian partner should
have an established record of manufacturing bogie frames and components.
5.3.7 In case, the offer is made by this Indian partner, the evidence in respect of design,
manufacture and supply of service-proven self-steering locomotive bogies and the capability
to transfer complete technology, as mentioned above, shall be provided on behalf of the
overseas manufacturer.

6. DESIGN REQUIREMENTS OF SELF-STEERING BOGIE

6.1 Bogie Construction
Self-steering bogie shall be with a weld fabricated bogie frame for the Indian Railways GT46MAC
(WDG4) locomotive.
The contractor shall ensure fitment of self-steering bogie in WDG4 locomotives as follows:
6.1.2 Any modifications required for successful adaptation of offered self-steering bogie under
WDG4 underframe including changes like re-location of TM air duct openings and secondary
rubber spring seats etc should be clearly brought out by the contractor along with feasibility
and methodology to achieve it. The contractor shall identify & indicate these design changes
in existing WDG4 underframe.
Preparation of engineering drawings for underframe & its manufacture shall be the
responsibility of IR.
6.1.3 The existing location of centre pivots on WDG4 locos shall not be changed. Similarly, the
length of the self-steering bogie shall not be more than that of the existing WDG4 HTSC non
self-steering bogie to avoid infringements with MMD and other locomotive assemblies.
In case these conditions are not met, the tenderer shall bring out the reasons for the same in
their offer. The car body centre pivot link design of WDG4 locomotives shall, in any case, be
retained.
6.1.4 The self-steering bogie shall be so designed that when interfaced with the WDG4 carbody, it
shall fit within the MMD envelope as mentioned in Para 3.2.5.
6.1.5 Reduction of axle spacing, if required to improve the negotiability & weight, shall be done
without infringing the component accessibility requirements for maintenance.

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6.1.6 Suitable arrangement should be provided to lock the self-steering mechanism whenever
required.
6.2 Bogie Dimensions
The offered design of self-steering bogie with new wheels when interfaced with existing WDG4
locomotive carbody in empty condition shall be within the dimensions shown in IR MMD mentioned
in Para 3.2.5. The OGA drawing of the existing HTSC bogie is enclosed.
6.3 Wheel/ Axle/ Gears/ Traction Motor Assembly and Un-sprung Mass
The wheel/axle/gear/traction motor assembly shall be the same as that for the GT46MAC (HTSC
non self-steering) bogie. This assumes use of the EMD / Siemens 1TB 2525-OTA-02 as well as
1TB 2622-OTA-02 AC traction motor. The un-sprung mass shall not exceed that of the HTSC bogie
on the GT46MAC locomotive. Layout drawings for the bogie assembly with aforesaid AC traction
motor is enclosed.
Mono block wheels of solid one-piece multi wear type made of heavy-duty steel confirming to EMD
drawing no. 40077314 & axle to EMD drawing no. 40076350 shall be used. The wheel roller bearing
used shall conform to EMD drawing no. 40077969.
6.4 Bogie Frame
Design: The weld fabricated self-steering bogie frame shall be designed for an axle load of 22.5
metric tonnes. It shall preferably consist mainly of straight box sections designed to integrate the
necessary steering components. The bogie frame shall be of a robust, high quality and cost-
effective design suited for ease of manufacture. It must be optimized for the manufacturing
techniques of weldments to achieve a high life expectancy and reliability.
The contractor shall, however, be required to work out a 25 tonne variation of the design also for IR
to employ the same in future; it being understood that this requirement is for the structural design of
the frame and suspension and does not imply that the other equipment like traction motors would be
suited for the higher tractive effort associated with 25 tonne application. An additional bogie weight
allowance of 1000 kg per bogie for the structural enhancement of bogie frame, steering beams,
traction rods and bearing adapters shall be permitted. It is also understood that both primary and
secondary springs, vertical dampers, brake units, and possible other components may need
replacement if the bogie design is upgraded from 22.5t axle load to 25.0t axle load application.
The requirement of 25.0t variation of the design is an optional item. Contractor may quote
separately for this requirement duly giving details of time schedule needed as well as complete
price and a complete broad outline of this item.
Material: The major structural material for the bogie frame shall be ASTM A572 Grade 50 or
equivalent, with minimum yield strength of 345 MPa or 50,000 psi. Special purpose low hydrogen
welding processes will be utilized. No pre-heat shall be required for plate sizes up to 1.5” inclusive.
For plate thickness of more than 1.5”, low carbon steel, not requiring pre-heat or post-heat, shall be
considered.
If required by the contractor, Indian Railways shall provide a list of readily available structural steel
plate sizes in India for the bogie structural steel.
6.5 Steering Components
The bogie self-steering mechanism including various steering components should be suitably
designed to:
6.5.1 Meet the intended speed potential with WDG4 locomotive carbody.
6.5.2 Must be robust and reliable to operate on IR track standard.
6.5.3 Ensure component accessibility requirement during maintenance.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
6.6 Brake Rigging
All wheels shall be provided with single composition brake shoe acting on the wheel tread. The
gross braking ratio shall be the same as for the WDG4 HTSC non self-steering bogie operating on
Indian Railways. The system shall include a suitable device for taking up slack etc.
Detailed calculations for the brake power along with brake rigging diagram shall be provided by the
contractor.
Adequate safety straps below the moving components of brake rigging (or any other alternative
arrangement) shall be provided to prevent fouling with track in the event of failure of any
component.
6.7 Parking Brake
Electrically or pneumatically operated parking brake shall be provided so that no manually powered
operation is required to apply and release the parking brake. Locomotive with self-steering bogies
shall have equivalent or higher parking brake holding capability than that of existing WDG4
locomotives.
6.8 Bogie Suspension
With the fabricated bogie frame consisting of box sections, the primary helical coil springs and the
secondary rubber springs should be suitably accommodated such that the loco does not infringe the
prescribed IR MMD when the bogie is interfaced with the WDG4 locomotive carbody.
6.9 Sanders
The bogies shall have 4 inboard and out board sand nozzles and hardware that are compatible with
the sanding equipment on the WDG4 car body. Pneumatic sanding shall be provided for both bogies
and it shall be effective in either direction of travel. Sand pipe nozzles shall be located at a distance
of 30mm from rail level and the height of the nozzles shall be adjustable to cater for the wheel wear.
6.10 Wheel Set Trolley
To handle the eventuality of axle getting locked on line, a suitable working procedure to lift (suspend
the affected axle on bogie frame) the locked axle should be specified by the contractor.
In case this is not feasible, the contractor shall assist IR in developing drawings for a wheel set
trolley (towing equipment) of appropriate design with instruction manual for safely towing the
locomotive to the maintenance shed. It should be lightweight and reliable design easy to carry to the
site and convenient to assemble.
6.11 The tenderer should bring out in the technical proposal, any other relevant technical requirements
other than those mentioned above, which are essential for successful operation of these bogies.

7. METHODOLOGY OF DESIGN DEVELOPMENT

7.1 The methodology used for design development shall provide for active involvement of IR personnel,
mainly from RDSO & DLW, broadly as per the activities and milestones as follows:
Though RDSO would prefer the time schedule indicated, however contractor may quote its best
possible offer.
Activity by the Contractor Activity of IR Personnel Remarks Completion
By
(Weeks)
7.1.1 Preparation of concept layout in line - - D + 32
with the specification.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

7.1.2 Dynamic simulations with new as Two IR personnel to be involved in Conceptual

well as worn wheel profiles based the process of simulations such that layout and
on the said concept layout using a they can run simulations on ADAMS simulation
Multibody dynamics simulation / Rail dynamics simulation package results shall be
software. or equivalent at the contractor’s delivered to IR.
premises.
7.1.3 Concept design review with IR techno-managerial team and experts’ team
of the contractor, and approval of the concept by IR.
Activity by the Contractor Activity of IR Personnel Remarks Completion
By
(Weeks)
7.1.4 Preparation of Engineering Four IR personnel to be involved in The solid model
drawings. the process of solid modeling on shall be
Unigraphics and drafting at delivered to IR.
contractor’s premises.
7.1.5 FEA of bogie frame and major Two IR personnel to be associated FEA results
components. in the process of FEA for insight into shall be D + 60
the methodology used by the delivered to IR.
contractor at contractor’s premises.

7.1.6 Finalization of Engineering design.

7.1.7 Detailed design review with IR techno-managerial team at contractor’s D + 65

premises and approval of the design.
7.1.8 Review of the drawings from Four IR personnel to be associated
manufacturability standpoint in in the process at contractor’s
association with the suppliers of premises.
major components
7.1.9 Development of static and fatigue Two IR personnel to be associated
(dynamic) structural test during the development of test
procedures, load levels and cycling procedure at contractor’s premises. D + 72
sequences and association with IR
during actual testing.
7.1.10 Release of final solid model of the Preparation of final 2-D drawings A set of final solid
bogie assembly with all components work based on the said model shall model shall be
based on the results of all previous be done at RDSO. delivered to IR.
studies and fatigue testing.

7.2 Based on the above model, the working man days of IR personnel who shall be deputed to work at
the R&D/Design centre of the contractor during design and drafting vehicle dynamics modeling and
simulation and FEA etc., as mentioned in para 7.1 above, shall be indicated by the contractor
activity-wise, given that this shall not be less than 150 man days and that the to and fro fare and
living expenses of all such IR staff shall be borne by Indian Railways.
7.3 In addition to the above exercise of association during design, two specific higher level detailed
design review meetings shall be held between representatives of Indian Railways and the
contractor to ensure suitability of design and smooth progress of ToT. These meetings shall be
held in the manufacturer's premises.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
7.4 Besides, the contractor shall also undertake the following activities and furnish the relevant
calculations / computerized analysis results showing the extent of improvements in various
parameters as follows vis-à-vis WDG4 HTSC non self-steering bogie:
7.4.1 Angle of Attack (AoA) of the leading axles on curves.
7.4.2 Lateral forces at axle box level.
7.4.3 Rail / wheel wear.
7.4.4 Flange wear index on curves.
7.4.5 L/V ratio (derailment co-efficient).
8. TYPE TESTS, DESIGN VALIDATION AND FIELD TRIALS
8.1 The above exercise shall constitute the following stages:
Stage Responsibility Inspection Remarks Completion
Agency By (Weeks)
8.1.1 Stage inspection of Contractor IR -
fabrication at
D + 95
manufacturer’s
premises
8.1.2 Static load test of bogie Contractor IR -
frame at manufacturer’s D + 100
premises
8.1.3 Fatigue testing of bogie Contractor IR Actual fatigue testing shall be The
frame + done at RDSO on the spare contractor
RDSO bogie frame. On completion of may quote
testing, the said bogie frame their
shall be scrapped. alternatives
Strain gauging to be done so as to
under the supervision of RDSO meet the
as per the stipulations of IR. end
Supply of items for strain objective in
gauging shall be ensured by proper time
the contractor. frame.
8.1.4 Final Inspection of Contractor IR -
bogie frames and
components at D + 104
manufacturer’s
premises
8.1.5 Final Assembly DLW under IR The contractor shall depute
Inspection at DLW supervision of their design and ToT team
contractor during the assembly of the D + 116
prototype bogies at DLW.
8.1.6 Road Run Trial at DLW IR IR In association with the
contractor.
8.1.7 Oscillation Trials IR RDSO In association with the
(See Clause 8.3 also) contractor, who shall provide a
minimum of six instrumented
bearing adapters for fitment in
the leading bogie of the D + 128
locomotive. The detailed
drawings of adapters shall also
be given by the contractor to IR
for use in future.
8.1.8 Steady State Curving IR RDSO In association with the
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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
Test contractor, who shall provide
(See Clause 8.4 also) the details of the
instrumentation and test
method.
8.1.9 Performance Rating IR RDSO In association with the
Trials contractor

8.1.10 Service Trial and IR IR - D + 136

Evaluation
(See Clause 8.5 also)

8.2 Three prototype locomotives shall be initially assembled by DLW and therefore the contractor shall
supply first six prototype bogie kits initially including one spare bogie frame for fatigue testing (i.e. a
total of seven bogie frames) by D + 108 weeks.
8.3 The first prototype locomotive fitted with self-steering bogies shall be subjected to the oscillation
trials by IR to ascertain the operational performance, capability and safety; the contractor shall,
however, associate and actively assist IR during the trials. The locomotive fitted with the self-
steering bogie shall fulfill the prescribed stability and riding quality criteria.
The prototype locomotive shall be subjected to trials on track maintained to main line as well as
C&M1 Volume 1 standards at test speeds up to 115 Km/h (10% above operating speed), in four
configurations viz., instrumented bogie leading and trailing with new and condemning wheel profile.
The trial procedure shall be as per RDSO report no. MT-288, April 2001.

The following criteria will be adopted for clearing the stock for regular operations:
8.3.1 The lateral/ transverse forces lasting more than 2 meters shall not exceed 4.5 tonnes, when
measured at the wheel axle box level.
8.3.2 Evaluation shall also be done in terms of ride index which shall not be greater than 3.75.
8.3.3 A derailment coefficient should be worked out in the form of ratio between the lateral force
(Hy) and the wheel load (Q) acting continuously over a period of 1/20th second and the value
of Hy/Q shall not exceed 1.
8.3.4 The value of acceleration recorded as near as possible to the bogie pivot in the driving cab,
shall be limited to 0.3g both in vertical and lateral mode. A peak value upto 0.35g may be
permitted, if the records do not indicate a resonant tendency in the region of the peak value.
8.3.5 A general indication of stable running characteristic of the locomotives as evidenced by the
movement of the bogie on straight and curved track and by the acceleration reading and
instantaneous wheel load variation/ spring deflections.
8.4 The first prototype locomotive shall also be used for Steady State Curving test. The contractor shall
provide the method of measurement of desired parameters as well as the method of calculation of
AOA (Angle of attack) on leading bogie from the test data. The contactor shall also provide the list
and details of equipments required for the measurement of AOA, along with the price list.
8.5 The other two prototype locomotives fitted with the self-steering bogie shall be evaluated during field
operation under actual load conditions for a minimum of three months, mainly to evaluate the
superiority or equivalence of maintainability, accessibility, reliability and availability of the self-
steering bogies vis-à-vis the conventional WDG4 bogies.
This evaluation is also intended to prove not only reliability of the operational performance under
different conditions of track, load, operating conditions, etc. but also assess the maintainability,
accessibility of components and such other aspects which have been envisaged in this specification.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
8.6 Mutually agreed modifications found necessary as a result of the tests/ trials shall be incorporated
by the contractor at his own cost in the locomotives in a manner approved by the purchaser.
Drawings incorporating the modifications found necessary, as a result of tests and trials, shall be
submitted by the contractor to RDSO and DLW.
8.7 After successful oscillation and field trials, duly certified by RDSO, the contractor shall be given
clearance to supply the balance 04 bogie kits (excluding bogie frames and components marked ‘X’
in Table-1 Column ‘D’) and 40 component kits. Any specific field trial requirement for indigenous kit
shall be mutually decided by IR and the contractor.
8.8 The supply of balance 04 bogie kits shall be completed by D + 140 weeks and 40 component kits by
D + 158 weeks.
8.9 All supplies shall be subjected to pre-inspection by RDSO/ authorized representatives before their
dispatch.
8.10 Complete bogie assembly for first 05 loco sets shall be done at DLW under the supervision and
guidance of the contractor.

8.11 Fatigue testing shall be done concurrently with oscillation trials and field evaluations.

9. SCOPE FOR TRANSFER OF TECHNOLOGY

9.1 As mentioned in Clause 7, the contractor shall ensure involving IR, mainly RDSO and DLW,
actively in design of self-steering bogies so that it greatly complements the TOT activity as such. In
addition to the transfer of know-how already covered under the Clause 7, the contractor shall
undertake to transfer complete technical know-how (the offer should bring out clearly how same
shall be transferred including form/ format and mode) for design, manufacture and maintenance of
self-steering bogie including:
9.1.1 Design calculations and use of computer aided design packages utilized for development of
design of bogies described in this specification comprising entire UG model of the radial
bogie designed for IR, the vehicle model for simulation through ADAMS Rail or equivalent,
the dynamic simulation report, FEA report of bogie frame, steering beams, bearing adapters,
and other components.
9.1.2 The contractor shall supply a complete set of drawings for tools, jigs and fixtures to be used
for assembly of self-steering bogies and extend their technical support and assistance for
indigenous manufacture and development of indigenous source(s) as laid down in para 5.3.3
and 5.3.6.
9.1.3 Detailed key and manufacturing drawings, type and routine test details, batch analysis and
QAP (Quality Assurance Plan) of the bogie assembly and its components, including stage &
final inspection and testing, with special stress on bogie assembly facilities and plant layout.
The drawings shall include dimensions, tolerances, surface finish and material specification
of all equipment/components.
9.1.4 Manufacturing process sheets including detailed comments on special techniques for
welding, forging or casting, heat treatment, assembly etc, wherever applicable.
9.1.5 Detailed specifications for special machines and plants, including details of jigs, fixtures and
special tools required for manufacture, inspection and testing of the bogie assembly and its
component etc.
9.1.6 Test and inspection plan for raw materials used in manufacture of bogie assembly and its
components.
9.1.7 Detailed maintenance instructions for the bogie assembly, to be tailor-made to coincide with
the schedules of maintenance in vogue for WDG4 locomotives

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
9.1.8 Other technical clarifications and supplementary instructions as may be required for
successful manufacture of bogies.
9.2 The contractor shall depute their adequate & qualified staff to DLW during assembly of the first 10
bogie kits.
9.3 The contractor shall ensure continuous transfer of updated design and manufacturing technology
during the period of collaboration, which shall be 4 years, or till completion of the entire scope of
supply, whichever is later. After this period, all the design and manufacturing documents &
deliverables shall be the property of IR without any let or hindrance for use in India. Besides, for all
the drawings of self-steering bogie designed for IR, the contractor will continue to provide all
updating information for aforesaid period for all drawings which have been revised. Indian Railway
will have the full right to get the bogies of this design and its components covered by the TOT,
manufactured in its own units or that of its vendors in India, for use in India, during the period of
collaboration agreement or after the end of this period.
9.4 The technology transfer shall get under way immediately after the agreement is signed.
9.5 Successful completion of the ToT shall require that a series of ToT meetings be held at the
premises of the manufacturer as well as at DLW & RDSO, over and above the design review
meetings mentioned earlier. The contractor shall allot a minimum of 100 man-days of their design
and ToT team personnel exclusively for this activity, it being understood that this is the minimum
requirement and the contractor may well require deputing their personnel beyond this minimum to
fulfill the requirements of this specification.
10. TRAINING
Contractor shall arrange to train Indian Railways personnel in his premises or premises of his sub-
suppliers in design, manufacture, quality control, inspection, inventory control, cost benefit analysis
& maintenance of self-steering bogies. In addition, for maintenance and repair practices, the
contractor shall arrange for training of Indian Railway personnel with some of the user railroads. A
minimum of 300 working man-days shall be provided for IR personnel who shall be deputed for
training in batches of not less than six persons. The contractor shall allot a minimum of 50 man-
days of their personnel exclusively for this activity
The training shall include the following
(a) FEA of bogie frame, self steering components, bearing adopters, traction rods and other
bogie components,
(b) Fatigue analysis, yield analysis
(c) load case analysis and formulation
(d) Vehicle dynamic analysis and simulation
(e) Review of related Technical Specifications, concept design review, UG modelling
reviews, ,Product requirements review, Detail Design review , Production information
review
(f) Study of bogie manufacturing & assembling practices including study- visit(s) to
factory(ies) manufacturing self steering bogies
(g) Repair and maintenance practices of self steering bogies
(h) Welding Techniques
(i) Development of fixtures for bogie frame
(j) Inspection and testing practices for bogie
(k) Production informations, Spares and inventories required for self steering bogies.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
For the purpose of training, to and fro fare and living expenses of IR personnel shall be borne by
Indian Railways. The training imparted shall be adequate to develop design capability and to ensure
full technology transfer.
Tenderer should bring out the scope and depth of training plan envisaged.
11. WARRANTY, SPARE PARTS AND SERVICE MANUALS

11.1 The self-steering bogie as a whole, as well as equipment, systems and sub-systems shall have
warranty for satisfactory performance for a period of 3 years from date of commissioning. All
aspects of workmanship and design shall be covered by this warranty. Only wearing parts, which
require recurring replacement shall be excluded. A list of such parts should be furnished by
contractor in his technical offer. This warranty shall include:
11.1.1 Replacement of defective components, free of cost C.I.F. India by the contractor.
11.1.2 The contractor shall provide free of cost assistance in replacement of defective
components/ assembly.
11.1.3 Any specialized tools etc not available with Indian Railways shall be supplied/ loaned free of
cost by the contractor.
11.2 The contractor shall indicate, in an itemized list, life expectations of components subject to wear
under Indian ambient conditions.
11.3 The contractor shall make recommendation suggesting scale of spares and necessary tools, jigs
and fixtures required for maintenance of 50 such bogies for a period of 06 years at the time of
submitting the final design for approval to the Railway. Price proposal for these shall also be
submitted along with this recommendation by the contractor. The contractor shall ensure continuous
availability of spares and other equipments at these prices for maintenance of self steering bogies.
11.4 The contractor shall furnish Instruction Manuals for operation and maintenance of bogies and its
components, trouble shooting instructions, Spare Parts Catalogue and other technical information
as may be required for maintenance of bogies in India. These manuals / instructions shall be
supplied in electronic copy to RDSO, Lucknow and DLW, Varanasi.

12. DELIVERABLES AND SCOPE OF SUPPLY

12.1 Supply & assembly of six bogies kits functionally working as per this specification.
12.2 One Self Steering radial bogie frame for endurance testing as per the prescribed scheme.
12.3 Oscillation Trials: Successful completion of oscillation trial in line shall be considered as one
deliverable.
12.4 Satisfactory Field Trials as mentioned in clause 8.5.
12.5 Supply & assembly, trials and field performance of balance 4 bogies kits functionally working as per
this specification.
12.6 Training as per relevant Para of this specification.
12.7 Complete Transfer of Technology as per this specification.
12.8 Forty (40) component kits as per Column ‘E’ & ‘F’ of Table 1 under Para 5.
12.9 Other Items as mentioned in this specification or as considered essential by the tenderer under
various clauses. (Firm should bring out any other relevant deliverable essential for the completion of
this self steering project).
12.10 Tenderer should quote for each of the above heads separately & clearly and in appropriate
currencies, duly indicating all taxes & duties including withholding tax etc and any other charges
applicable. If these are not mentioned, same will be considered as inclusive.

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives
12.11 Tenderer should also indicate clearly, the total all inclusive cost.

13. DEVIATIONS & TECHNICAL CLARIFICATIONS

Deviations to this specification, if any, shall be indicated clearly and the same shall be considered
on merit. Any further technical clarifications required by the tenderer, can be obtained from Director
General, (Motive Power) Research Designs and Standards Organisation, Manak Nagar, Lucknow-
226011 (India).

14. Special Clauses

14.1 The tenderer shall quote separately for the following item wise:
• Design development and supply of bogie components as per the specification
• Transfer of Technology
• Training
14.2 Payment Schedule
Activity Payment
14.2.1 Completion of activities as per Para 7 of this specification 50% of the contract value
followed by: of supply of 6 bogie kits
Supply and assembly of six (06) bogie kits functionally working and one spare bogie frame
as per this specification.
Supply of one self-steering bogie frame for endurance testing as
per the prescribed scheme.

14.2.2 Successful completion of: Balance payment for

i. Oscillation trials and Steady State Curving test of the first supplies of 6 bogie kits
prototype locomotive fitted with self-steering bogies in India. and one spare bogie frame
ii. Evaluation of other two locomotives fitted with self-steering
bogies during field operation under actual load conditions for
a minimum of three months.
Successful modifications found necessary as a result of the
tests/ trials shall be incorporated by the contractor at his own
cost in the locomotives in a manner approved by the purchaser.
Drawings incorporating the modifications found necessary, as a
result of tests and trials, including their submission by the
contractor to RDSO and DLW.
14.2.3 Supply & assembly, trials and field performance (subsequent to To be made in lots of 04
successful oscillation and field trials of first six (06) bogie kits) of bogie kits each on pro-rata
balance 04 bogie kits functionally working as per this basis.
specification (excluding bogie frames and components marked
‘X’ in Table-1 Column ‘D’ of this specification).
Supply from 11th to 50th bogie kits to be made in lots of 04.
14.2.4 Successful completion of Transfer of Technology as per this
specification.
(a) Completion of activities under paras 7.1.1, 7.1.2 and 7.1.3 of 20% of TOT contract value
this specification. against bank guarantee

(c)Completion of activities under paras 7.1.4, 7.1.5, 7.1.6 and 25% of TOT contract value
7.1.7 of this specification. against bank guarantee

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 Technical Specification for Self-steering Co-Co Bogies of 4000/4500 HP Broad Gauge (1676 mm) Diesel Electric Locomotives

(d) Completion of activities under paras 7.1.8, 7.1.9 and 7.1.10 20% of TOT contract value
of this specification. against bank guarantee
(e)Completion of activities as at para 7.4, final assembly 20% of TOT contract value
inspection of the first loco set of prototype bogies against bank guarantee
(f) Completion of activities as at para 7.4, final assembly 10% of TOT contract value
inspection of the first loco set of prototype bogies against bank guarantee

(g)Completion of all TOT works 10% of TOT contract value

against bank guarantee
14.2.5 Successful completion of training as per this specification. 90%of the training contract
value on completion of
training in two instalments.
The first instalment of 45%
will be paid after 150
working man-days of
training and the other
instalment of 45% after
completion of remaining
training man-days.
14.2.6 Expiry of Contract including completion of all supplies, ToT and All balance payment of the
training contract on execution of the
necessary Warranty bank
guarantee
“On completion of each milestone/activity, party will submit invoice for material supplied and
successful completion of activity to be certified by ED/MP/RDSO. All payments will be made through
electronic means /irrevocable unconfirmed LC”.
14.3 Payment shall be made after Stage wise Certification by RDSO on completion of each activity as
above.
14.4 Tenderer shall be responsible for safe delivery (inclusive of loading, unloading and safety /
protection and installation/ commissioning) of all consignments / physical deliverable and
accordingly quote as up to Destination.
14.5 Delivery for all bogie and component kits shall be made to DLW, Varanasi, India and for the
endurance test, bogie frame delivery shall be made to RDSO, Lucknow, India.
14.6 Firm should separately bring out the freight component for each such delivery.
14.7 Successful tenderer shall nominate a project monitoring group to ensure timely and satisfactory
completion of all activities related to this project in a professional manner and to liaison with Motive
Power Directorate of RDSO and DLW/ Varanasi.
14.8 For the products which are manufactured in India, the payment shall be done in Indian Rupees after
successful delivery of materials to the consignee. For items manufactured outside India, payments
will be made in the currency(ies) of the country(ies) where they are manufactured.

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