Front Fork Specification Test Plan - 2021-2022: Gabriel India Limted Sanand

DOC. NO.
PLQ02
Gabriel India Limted Sanand Front Fork Specification Test Plan - 2021-2022 REV. 01
DATE. 30.07.2021
Test Frequency APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
Sr. Test
Part Name Test parameter Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL
No Specification Supplier Gabriel
P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A
1 Assembly tensile strength -- Once / Month P P P P P P P P P P P P
2 Assembly compressive strength -- Once / Month P P P P P P P P P P P P
Once / Development or if 4M
3 Fork Pipe bending strength -- Already done test during development and submitted to HMSI
condition change in MP
4 Outer tube bending strength test (Longitudinal ) -- Already done test during development and submitted to HMSI
5 Outer tube bending strength test (Lateral ) -- Already done test during development and submitted to HMSI
As per Spec STD. 5140Z- Once / Development or if 4M
6 Brake boss strength -- Already done test during development and submitted to HMSI
GHA-6700 condition change in MP
7 Brake durability -- Already done test during development and submitted to HMSI
Axle holder static breaking strength (Through- Once / Development or if 4M
8 -- Already done test during development and submitted to HMSI
hole type) condition change in MP
9 Fork Assly. L / R Stroking durability (Reaction force system) -- Already done test during development and submitted to HMSI
Change in MP
10 Stroking endurance (Damping system ) -- Already done test during development and submitted to HMSI
Change in MP
11 Drum durability -- Already done test during development and submitted to HMSI
Change in MP
12 Damping Force Tension -- 05 Pieces /Lot Refer IPIR Report
13 Damping Force Compression -- 05 Pieces /Lot Refer IPIR Report
14 Oil Lock Force -- Once / 06 Months P P

As per Spec STD. 5140Z-
K0PA-D010-M1
15 Assy Reaction force -- Once / 06 Months P P
16 Friction characterstics -- Once / 06 Months P P
17 Contamination test -- Once / Month P P P P P P P P P P P P
18 Hardness Raw AS PER RIS - 05 AS PER RIS - 05 Receiving Inspection Report
Chemical Test AS PER RIS - 05 Once / 06 Months P P
19 Tensile Strength AS PER RIS - 05 Once / 06 Months P P
20 Yield Point AS PER RIS - 05 Once / 06 Months P P
21 Elongation % AS PER RIS - 05 Once / 06 Months P P

22 Fork Pipe (inner Tube) Tensile strength of sub assy -- Once /Month P P P P P P P P P P P P
GHA-6810-M1 & HES D 2011
23 Plating thickness -- Once /Lot Refer IPIR Report
24 CASS TEST -- Once /Month P P P P P P P P P P P P
25 Plating Hardness -- Once /Month P P P P P P P P P P P P
26 Adhesion test -- Once /Month P P P P P P P P P P P P
27 Microcrack -- Once /Month P P P P P P P P P P P P
28 Material AC2B-F AS PER RIS - 02 Once / 06 Months P P
29 Tensile strength (MPa) Once / 03 Months Once / 06 Months P P P P P P
30 0.2% Yield Strength (MPa) Once / 03 Months Once / 06 Months P P P P P P
As per Spec STD 0093Z-

30 Elongation (%) Once / 03 Months Once / 06 Months P P P P P P
GHA-C410-M1
31 Impact property (J/cm²) Once / 03 Months Once / 06 Months P P P P P P
32 Hardness (HRB) AS PER RIS - 02 AS PER RIS - 02 Receiving Inspection Report
33 Quality of Cast AS PER RIS - 02 N=02 / Month P P P P P P P P P P P P
33 A X-ray Test -- 04 Piece / Month P P P P P P P P P P P P
34 Salt spray Test Each Lot Once / Month P P P P P P P P P P P P
35 Filiform test -- Already done test during development and submitted to HMSI
36 Weather resistance -- Already done test during development and submitted to HMSI
37 water resistance -- Once / 06 Months P P
38 Humidity resistance -- Already done test during development and submitted to HMSI
Case Bottom L/ R condition change in MP
(Outer Tube) Once / Development or if 4M
39 Volatile solution resistance -- Already done test during development and submitted to HMSI
40 Xylene resistance -- Already done test during development and submitted to HMSI
41 Spot resistance -water/acid/alkali/gasolene -- Already done test during development and submitted to HMSI
As per Sec. STD HES D 2016
42 Hardness -- Once /Lot Refer IPIR Report
- 07
43 Specular gloss -- Once / 06 Months P P
44 Color Retention -- Already done test during development and submitted to HMSI
45 Polishing resistance -- Already done test during development and submitted to HMSI
46 Coating Adhesion Once /Lot Once /Lot Refer IPIR Report
47 Print Resistance -- Already done test during development and submitted to HMSI
48 Recoat performance -- Already done test during development and submitted to HMSI
49 Impact resistance -- Already done test during development and submitted to HMSI
50 Bending resistance -- Already done test during development and submitted to HMSI
51 Film thickness -- Once /Lot Refer IPIR Report

52 MTC Once / 06 Months Once / 06 Months P P P P
As per Spec STD IS 4454 GR
Spring front fork (Spring -1) SAGAR
SH
53 Endurance test Once /Year NA P

Spring front fork (Spring -1) SUMA
SH

Spring front fork (Spring -1) EMKAY
SH

Pipe Seat (Piston) HARSHAD ENGG As per IS 3074 CEW-1
59 Tensile strength Once/Lot Once /03 Month P P P P

Pipe Seat (Piston) NARINDER PRAKASH As per IS 3074 CEW-1
62 SST AS PER RIS - 20 AS PER RIS - 20 P P P P P P P P P P P P P P P P

Bolt A front fork (Bolt Cap) SANGKAJ ENGG As per SAE 1010 / SAE 1018

Bolt A front fork (Bolt Cap) NARINDER PRAKASH As per SAE 1010 / SAE 1018
66 O ring CAMATA ENTERPRIZE MTC (R) As per HES C201 AS PER RIS - 21 NA For Rubber Parts GIL Will Not Conduct Test (Supplier MTC OK)
67 O ring BYMER ELOSTOMERS MTC (R) As per HES C201 AS PER RIS - 21 NA For Rubber Parts GIL Will Not Conduct Test (Supplier MTC OK)
68 MTC (R) AS PER RIS - 13 NA
69 Seal Dust HITECH ARAI Recovery Rate of Seal (R) As per Drawing
Once/ Development or if 4M
NA Already done test during development and submitted to HMSI
70 Ozone Resistance (R) Once / 06 Months NA

Ring oil seal stop (Circlip) EMKAY AUTO As per IS 4454

Ring oil seal stop (Circlip) BELLITE SPRING As per IS 4454

Seal Oil As per Drawing
76 Recovery Rate of Seal (R) Once/ Development or if 4M
77 Ring Piston JAIRAJ ANCILLARY MTC (P) As per GRM 1402

specification
Once / 06 Months NA For Plastic Parts GIL Will Not Conduct Test (Supplier MTC OK)
78 Ring Piston SUBA INJECTION MTC (P) As per GRM 1402

specification

Spring Rebound (Spring - 2) SAGAR As per IS 4454
80 Endurance test Once / Year NA P

Spring Rebound (Spring - 2) SUMA As per IS 4454
Washer Special 8 MM As per GRM 0801

(Gasket Copper) CITIZEN PRESS COMPONENTS specification

(Gasket Copper) GOLDY specification

Bolt socket M8 Hex. DHAM FASTNERS As per IS 1367 specification

Bolt socket M8 Hex. SANGKAJ ENGG As per IS 1367 specification

Bolt socket M8 Hex. SINGLA FORGING As per IS 1367 specification
As per GRM 0101

91 Piece Oil Lock (Spindle Taper) SANGKAJ ENGG. MTC Once / 06 Months Once / 06 Months P P P P
specification
As per GRM 0101

92 Piece Oil Lock (Spindle Taper) SIGMA CNC MTC Once / 06 Months Once / 06 Months P P P P
specification
Seat Rebound (Seat Spring Lower) CITIZEN PRESS

93 MTC As per IS 513 specification Once / 06 Months Once / 06 Months P P P P
COMPONENTS
94 Collar Oil Lock (Spacer Oil Lock) SSPL MTC As per Drawing AS PER RIS - 08 Once / 06 Months P P P P
95 Collar Oil Lock (Spacer Oil Lock) NINGHBO CHINA MTC As per Drawing AS PER RIS - 09 Once / 06 Months P P P P
96 Guide Spring JAIRAJ ANCILLARY MTC (P) As per GRM 1402

specification
97 Guide Spring SUBA INJECTION MTC (P) As per GRM 1402

specification
Spring Valve As per GRM 1201

(Spring Wave Washer) SHREE RAM ENGG. specification

(Spring Wave Washer) GOLDY specification
REMARKS :-
1. (P) - PLASTIC PARTS & (R) RUBBER PARTS P PLAN
2. GIL will not conduct third party & inhouse test for plastic and rubber components DD ACTUAL
3. Delay in Plan Vs. Actual, Marked with (D) D IF ANY DELAY IN PLAN Vs. ACTUAL
Prepared By : SAIL KHHAMBHATI Approved By :- LAXMAN RAO
Sr. No Description Revision Number Revision Date
1 New Released 0 01.12.2019
2 Revised as per AHQC 1 30.07.2021
PLQ02/0119
DOC. NO. PLQ02
Gabriel India Limted Sanand Front Fork Specification Test Plan - 2022-2023 REV. 01
DATE. 30.07.2021
Test Frequency APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
Sr. Test
Part Name Test parameter Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL Supplier GIL
No Specification Supplier Gabriel
P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A P A
1 Assembly tensile strength -- Once / Month P P P P P P P P P P P P
2 Assembly compressive strength -- Once / Month P P P P P P P P P P P P
3 Fork Pipe bending strength -- Already done test during development and submitted to HMSI
4 Outer tube bending strength test (Longitudinal ) -- Already done test during development and submitted to HMSI
5 Outer tube bending strength test (Lateral ) -- Already done test during development and submitted to HMSI
As per Spec STD. 5140Z- Once / Development or if 4M
6 Brake boss strength -- Already done test during development and submitted to HMSI
GHA-6700 condition change in MP
7 Brake durability -- Already done test during development and submitted to HMSI
Axle holder static breaking strength (Through- Once / Development or if 4M
8 -- Already done test during development and submitted to HMSI
hole type) condition change in MP
9 Fork Assly. L / R Stroking durability (Reaction force system) -- Already done test during development and submitted to HMSI
Change in MP
10 Stroking endurance (Damping system ) -- Already done test during development and submitted to HMSI
Change in MP
11 Drum durability -- Already done test during development and submitted to HMSI
Change in MP
12 Damping Force Tension -- 05 Pieces /Lot Refer IPIR Report
13 Damping Force Compression -- 05 Pieces /Lot Refer IPIR Report
14 Oil Lock Force -- Once / 06 Months P P

K0PA-D010-M1
15 Assy Reaction force -- Once / 06 Months P P
16 Friction characterstics -- Once / 06 Months P P
17 Contamination test -- Once / Month P P P P P P P P P P P P
18 Hardness Raw AS PER RIS - 05 AS PER RIS - 05 Receiving Inspection Report
Chemical Test AS PER RIS - 05 Once / 06 Months P P
19 Tensile Strength AS PER RIS - 05 Once / 06 Months P P
20 Yield Point AS PER RIS - 05 Once / 06 Months P P
21 Elongation % AS PER RIS - 05 Once / 06 Months P P

22 Fork Pipe (inner Tube) Tensile strength of sub assy -- Once /Month P P P P P P P P P P P P
GHA-6810-M1 & HES D 2011
23 Plating thickness -- Once /Lot Refer IPIR Report
24 CASS TEST -- Once /Month P P P P P P P P P P P P
25 Plating Hardness -- Once /Month P P P P P P P P P P P P
26 Adhesion test -- Once /Month P P P P P P P P P P P P
27 Microcrack -- Once /Month P P P P P P P P P P P P
28 Material AC2B-F AS PER RIS - 02 Once / 06 Months P P
29 Tensile strength (MPa) Once / 03 Months Once / 06 Months P P P P P P
30 0.2% Yield Strength (MPa) Once / 03 Months Once / 06 Months P P P P P P
As per Spec STD 0093Z-

30 Elongation (%) Once / 03 Months Once / 06 Months P P P P P P
GHA-C410-M1
31 Impact property (J/cm²) Once / 03 Months Once / 06 Months P P P P P P
32 Hardness (HRB) AS PER RIS - 02 AS PER RIS - 02 Receiving Inspection Report
33 Quality of Cast AS PER RIS - 02 N=02 / Month P P P P P P P P P P P P
33 A X-ray Test -- 04 Piece / Month P P P P P P P P P P P P
34 Salt spray Test Each Lot Once / Month P P P P P P P P P P P P
35 Filiform test -- Already done test during development and submitted to HMSI
36 Weather resistance -- Already done test during development and submitted to HMSI
37 water resistance -- Once / 06 Months P P
38 Humidity resistance -- Already done test during development and submitted to HMSI
Case Bottom L/ R condition change in MP
(Outer Tube) Once / Development or if 4M
39 Volatile solution resistance -- Already done test during development and submitted to HMSI
40 Xylene resistance -- Already done test during development and submitted to HMSI
41 Spot resistance -water/acid/alkali/gasolene -- Already done test during development and submitted to HMSI
As per Sec. STD HES D 2016
42 Hardness -- Once /Lot Refer IPIR Report
- 07
43 Specular gloss -- Once / 06 Months P P
44 Color Retention -- Already done test during development and submitted to HMSI
45 Polishing resistance -- Already done test during development and submitted to HMSI
46 Coating Adhesion Once /Lot Once /Lot Refer IPIR Report
47 Print Resistance -- Already done test during development and submitted to HMSI
48 Recoat performance -- Already done test during development and submitted to HMSI
49 Impact resistance -- Already done test during development and submitted to HMSI
50 Bending resistance -- Already done test during development and submitted to HMSI
51 Film thickness -- Once /Lot Refer IPIR Report

Spring front fork (Spring -1) SAGAR
SH

Pipe Seat (Piston) HARSHAD ENGG As per IS 3074 CEW-1

Pipe Seat (Piston) NARINDER PRAKASH As per IS 3074 CEW-1

Bolt A front fork (Bolt Cap) SANGKAJ ENGG As per SAE 1010 / SAE 1018

Bolt A front fork (Bolt Cap) NARINDER PRAKASH As per SAE 1010 / SAE 1018
66 O ring CAMATA ENTERPRIZE MTC (R) As per HES C201 AS PER RIS - 21 NA For Rubber Parts GIL Will Not Conduct Test (Supplier MTC OK)
67 O ring BYMER ELOSTOMERS MTC (R) As per HES C201 AS PER RIS - 21 NA For Rubber Parts GIL Will Not Conduct Test (Supplier MTC OK)
69 Seal Dust HITECH ARAI Recovery Rate of Seal (R) As per Drawing
Once/ Development or if 4M
70 Ozone Resistance (R) Once / 06 Months NA

Ring oil seal stop (Circlip) BELLITE SPRING As per IS 4454

Seal Oil As per Drawing
76 Recovery Rate of Seal (R) Once/ Development or if 4M
77 Ring Piston JAIRAJ ANCILLARY MTC (P) As per GRM 1402

specification
78 Ring Piston SUBA INJECTION MTC (P) As per GRM 1402

specification

Spring Rebound (Spring - 2) SAGAR As per IS 4454

(Gasket Copper) CITIZEN PRESS COMPONENTS specification

(Gasket Copper) GOLDY specification

Bolt socket M8 Hex. DHAM FASTNERS As per IS 1367 specification

Bolt socket M8 Hex. SANGKAJ ENGG As per IS 1367 specification
As per GRM 0101

91 Piece Oil Lock (Spindle Taper) SANGKAJ ENGG. MTC Once / 06 Months Once / 06 Months P P P P
specification
As per GRM 0101

92 Piece Oil Lock (Spindle Taper) SIGMA CNC MTC Once / 06 Months Once / 06 Months P P P P
specification
Seat Rebound (Seat Spring Lower) CITIZEN PRESS

93 MTC As per IS 513 specification Once / 06 Months Once / 06 Months P P P P
COMPONENTS
94 Collar Oil Lock (Spacer Oil Lock) SSPL MTC As per Drawing AS PER RIS - 08 Once / 06 Months P P P P
96 Guide Spring JAIRAJ ANCILLARY MTC (P) As per GRM 1402

specification
97 Guide Spring SUBA INJECTION MTC (P) As per GRM 1402

specification

(Spring Wave Washer) GOLDY specification
REMARKS :-
1. (P) - PLASTIC PARTS & (R) RUBBER PARTS P PLAN
2. GIL will not conduct third party & inhouse test for plastic and rubber components DD ACTUAL
3. Delay in Plan Vs. Actual, Marked with (D) D IF ANY DELAY IN PLAN Vs. ACTUAL
Prepared By : TOFEEK ALI Approved By :- LAXMAN RAO
Sr. No Description Revision Number Revision Date
1 New Released 0 01.12.2019
2 Revised as per AHQC 1 30.07.2021
PLQ02/0119

Front Fork Specification Test Plan - 2021-2022: Gabriel India Limted Sanand

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Front Fork Specification Test Plan - 2021-2022: Gabriel India Limted Sanand

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DOC. NO.

1 Assembly tensile strength -- Once / Month P P P P P P P P P P P P

2 Assembly compressive strength -- Once / Month P P P P P P P P P P P P

12 Damping Force Tension -- 05 Pieces /Lot Refer IPIR Report

13 Damping Force Compression -- 05 Pieces /Lot Refer IPIR Report

14 Oil Lock Force -- Once / 06 Months P P

16 Friction characterstics -- Once / 06 Months P P

17 Contamination test -- Once / Month P P P P P P P P P P P P

18 Hardness Raw AS PER RIS - 05 AS PER RIS - 05 Receiving Inspection Report

Chemical Test AS PER RIS - 05 Once / 06 Months P P

19 Tensile Strength AS PER RIS - 05 Once / 06 Months P P

20 Yield Point AS PER RIS - 05 Once / 06 Months P P

21 Elongation % AS PER RIS - 05 Once / 06 Months P P

As per Spec STD. 5141Z-

23 Plating thickness -- Once /Lot Refer IPIR Report

24 CASS TEST -- Once /Month P P P P P P P P P P P P

25 Plating Hardness -- Once /Month P P P P P P P P P P P P

26 Adhesion test -- Once /Month P P P P P P P P P P P P

27 Microcrack -- Once /Month P P P P P P P P P P P P

28 Material AC2B-F AS PER RIS - 02 Once / 06 Months P P

29 Tensile strength (MPa) Once / 03 Months Once / 06 Months P P P P P P

30 0.2% Yield Strength (MPa) Once / 03 Months Once / 06 Months P P P P P P

As per Spec STD 0093Z-

31 Impact property (J/cm²) Once / 03 Months Once / 06 Months P P P P P P

32 Hardness (HRB) AS PER RIS - 02 AS PER RIS - 02 Receiving Inspection Report

33 Quality of Cast AS PER RIS - 02 N=02 / Month P P P P P P P P P P P P

33 A X-ray Test -- 04 Piece / Month P P P P P P P P P P P P

34 Salt spray Test Each Lot Once / Month P P P P P P P P P P P P

37 water resistance -- Once / 06 Months P P

43 Specular gloss -- Once / 06 Months P P

46 Coating Adhesion Once /Lot Once /Lot Refer IPIR Report

51 Film thickness -- Once /Lot Refer IPIR Report

54 MTC Once / 06 Months Once / 06 Months P P P P

56 MTC Once / 06 Months Once / 06 Months P P P P

58 MTC Once / 06 Months Once / 06 Months P P P P

60 MTC Once / 06 Months Once / 06 Months P P P P

62 SST AS PER RIS - 20 AS PER RIS - 20 P P P P P P P P P P P P P P P P

64 SST AS PER RIS - 20 AS PER RIS - 20 P P P P P P P P P P P P P P P P

68 MTC (R) AS PER RIS - 13 NA

70 Ozone Resistance (R) Once / 06 Months NA

71 MTC Once / 06 Months Once / 06 Months P P P P

73 MTC Once / 06 Months Once / 06 Months P P P P

75 MTC (R) AS PER RIS - 11 NA

77 Ring Piston JAIRAJ ANCILLARY MTC (P) As per GRM 1402

78 Ring Piston SUBA INJECTION MTC (P) As per GRM 1402

79 MTC Once / 06 Months Once / 06 Months P P P P

81 MTC Once / 06 Months Once / 06 Months P P P P

Washer Special 8 MM As per GRM 0801

Washer Special 8 MM As per GRM 0801

85 MTC Once / 06 Months Once / 06 Months P P P P

87 MTC Once / 06 Months Once / 06 Months P P P P

89 MTC Once / 06 Months Once / 06 Months P P P P

As per GRM 0101

As per GRM 0101

Seat Rebound (Seat Spring Lower) CITIZEN PRESS

96 Guide Spring JAIRAJ ANCILLARY MTC (P) As per GRM 1402

97 Guide Spring SUBA INJECTION MTC (P) As per GRM 1402

Spring Valve As per GRM 1201

Spring Valve As per GRM 1201

1. (P) - PLASTIC PARTS & (R) RUBBER PARTS P PLAN

Sr. No Description Revision Number Revision Date

1 New Released 0 01.12.2019

2 Revised as per AHQC 1 30.07.2021