C-K407 Rev. 3 - Final Draft - MAY 2018

Ref: CG-WI-4.2.1-1 Date / Month of issue: Specification No.
Ver 1.0 Page 1 of 34

May, 2018 C-K407 (Rev. -03)
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SCHEDULE OF TECHNICAL REQUIREMENTS
OF
AIR SUSPENSION CONTROL EQUIPEMENTS
FOR
AIR SPRING ASSEMBLY SYSTEM
WITH ICF/LHB TYPE BOGIE
S. No. Month / Year of Revision / Page No. Reason for

issue Amendment Amendment
As per the
1. July 2007 Revision 1 2
amendment slip
As per the
2. December 2008 Revision 2 2
amendment slip
To include the ISO
Revision 2/ Doc. No. QO-D-7.1-
3 October, 2016 5
Amendment 3 11 in Para no. 1 of
Scope
As per Amendment
4 March, 2018 Revision 3 ----
Slip
Issued By
Carriage Directorate
Research Designs and Standards Organisation
Manak Nagar Lucknow-226011.
Signature
Name & Prepared by: Checked By: Approved By:

Designation V. K. Singh/SSE/Design S.S. Raypa/DD/VDG Mohd. Saquib/Dir./VDG
May, 2018 C-K407 (Rev. -03)
AMENDMENT SLIP
S.No. Description Clause No. of Page No. of Reason for Amendment

earlier STR earlier STR
1 Modified para.5.4.b 5.4.b 7 As per instructions of
Railway Board & EDSC.
Typographical error
2 Modified para.5.4.d 5.4.d 8
corrected.
As per Railway Board
instructions regarding vendor
3 Modified para.5.4.e 5.4.e 8
development and as per ISO
procedure.
4 Para. 6.2.2 to 6.2.10 6.2.2 to 6.2.10 8-9 Numbering corrected.
Numbering corrected and
inclusion of latest drawing of
5 Para. 6.3.2 to 6.3.6 6.3.2 to 6.3.6 9
Installation lever.
Modification in para 6.3.4
Para. 6.4.2 to 6.4.5 6.4.2 to 6.4.5 9 Numbering corrected
6
7 Para.6.5.2 to 6.5.6 6.5.2 to 6.5.6 9 Numbering corrected,
Modified para. 6.5.3 ICF drawing include and
8 6.5.3 9
RDSO drawing removed
Removed para. 6.5.6 Removal of reference of
9 6.5.6 9 spec. 02 ABR02 as ICF
drawing of reservoir include.
Modified para. 6.6.2 and ICF drawing include and
10 6.6.2 and 6.6.3 10
6.6.3 RDSO drawing removed.
Removal of reference of
11 Removed para. 6.6.4 6.6.4 10 spec. 02 ABR02 as ICF
drawing of reservoir include.
Modify para. 10.2.1 and
Modified para. 10.2.1 and change in sample quantity
12 10.2.1 and 10.2.2 13
10.2.2 during inspection in para.
10.2.2
ICF drawings of reservoirs
13 Modified para. 10.3 10.3 13 include and RDSO drawing
removed.
As ICF drawings of
14 Removed para. 11.2 11.2 14 reservoirs included which are
of stainless steel.
Correction in inspection
15 4.0/Annexure - A 18 In reference of ICF drawing.
format
1. Inclusion of format for
Modification in heading and
40 lit. reservoir.
16 correction in inspection 6.0/Annexure - A 20
2. In reference of ICF
format
drawing.
17 Correction in note 9.0/Annexure - A 23 Error corrected.
As per feedback received
Modification in drawing of
18 ------ 32 from Railways and
Installation lever
QA/RDSO, NDLS
Removed the drawing no.
SKETCH-K1052, SKETCH- 34,35, 37 & As ICF drawings of
19 ------
K1053, CG-K 4025 & CG-K 38 reservoirs included
4026
Signature

May, 2018 C-K407 (Rev. -03)
CONTENTS
Description Page No.
I FOREWORD 4
II Air Spring Control Equipments

1. Scope 5
2. Operating Conditions 5
3. Environmental Condition 6
4. Scope of Supply 6
5. Particular Requirements 7
6. Technical Requirements 8
7. Submission of Offer 10
8. Guarantee 11
9. Installation, Commissioning & Maintenance 12
10. Inspection and Testing 12
11. Painting 14
12. Marking 14
13. Packing 14
14.Tolerance 14
15. General 14
16. Annnexure – A 15 – 24
17. Annexure – 1 25 – 27
18. Annexure – 2 28 - 30
III Referred Specification & Drawings
III.A Drawings (Enclosed)
1. SKETCH-K1049 Alt.1:Space Envelope for Leveling Valve

2. SKETCH-K1050 Alt.3:Instalation Lever Assembly with Ball And Socket Ends
3. SKETCH-K1051:Space Envelope for Duplex Check Valve
4. SKETCH-K1054: Hose Connection for Air Spring Suspension Bogies.
III.B Specification & Drawings (Not Enclosed)
1. RDSO specification No. 02-ABR-02 (Air Brake)

2. Drain Cock Assembly RDSO SKETCH-98003
3. Check Valve as RDSO SKETCH – 98112
4. Two Way Dirt Collector as RDSO SKETCH – 97005
5. Isolating Cock(OLP type) 20mm bore as SKETCH- 97002
6. ICF drawing of reservoirs
Signature

May, 2018 C-K407 (Rev. -03)
FOREWORD
0.1 This Schedule of Technical Requirements (STR) is issued under fixed serial
No. C-K407.The number K4 indicates the year of adoption/revision.
0.2 This Schedule of Technical Requirements (STR) is issued as second

revision to the earlier specification no. C-K407 of 2004.The earlier version
should be immediately withdrawn from use.
0.3 The purchaser will be at liberty to buy any part / component or all from this
specification.
0.4 This Schedule of Technical Requirements (STR) will be read along with
RDSO specification No.02-ABR-02 (Latest amendment).In case of any
conflict, the requirements given in this specification shall be final.
****************************************
Signature

May, 2018 C-K407 (Rev. -03)
SCHEDULE OF TECHNICAL REQUIRMENTS OF

AIR SUSPENSION CONTROL EQUIPEMENTS
1. SCOPE:
This schedule lays down the technical requirements for the design and supply of
control equipment for pneumatic suspension for use in existing two axle bogies of
EMU/DMU/MEMU/Mainline/ Rajdhani/ LHB type coaches of Indian Railways having
air-suspension. Scope of supply shall generally be as per clause-4 of this
specification. However if the supplier feels that certain additional items are
necessary for improved working performance of the system, he may quote for the
same. In any case, purchaser will be at liberty to buy all or part material from the
offer.
All the provisions contained in RDSO’s ISO procedures laid down in Document No.
QO-D-7.1-11 dated 19.07.2016 (titled “Vendor-Changes in approved status”) and
subsequent versions/amendments thereof, shall be binding and applicable on the
successful vendor/vendors in the contracts floated by Railways to maintain quality
of products supplied to Railways.
2. OPERATING CONDITIONS:
2.1 For Main Line/ Rajdhani & LHB Coaches :
2.1.1 Each coach fitted with air spring assemblies would have a feed pipe and one brake
pipe. Normally up to twenty six coaches form a train. These coaches would have
a maximum speed of up to 160 kmph and negotiate curves upto a minimum radius
of 175 meters and carry payload of upto 30 t.
2.1.2 Compressed air supply to the air spring assemblies shall be maintained through a
compressor provided in the Locomotive. The Locomotive compressor charges the
Feed pipe at 6 Kg/cm².Provision of air-drying does not exist on some of these
compressed air supply systems. The pneumatic circuit of air spring assembly
system is connected to the Feed pipe.
2.2 For EMU / DMU & MEMU coaches
2.2.1 Each set of EMU / DMU & MEMU coaches fitted with air spring assemblies would
consist of one power car/ motor coach and two or three trailer coaches. Two to four
of such sets would normally form a train. These coaches would have a maximum
speed of 110 kmph and will be required to negotiate curves upto a minimum radius
of 152.4 meters carrying a payload of upto 36t. The annual kilometer earning of
these coaches is approximately 2,00,000 (2 lakhs).
2.2.2 Compressed air supply to the air spring assemblies shall be maintained through a
compressor provided in the motor coach/power car. The compressor charges the
Main Reservoir pipe/ Feed pipe at 6 Kg/cm². Provision of air-drying may not exist
in the compressed air supply system. Pneumatic circuit of air spring assembly
system is connected to the Main Reservoir / Feed pipe.
Signature

May, 2018 C-K407 (Rev. -03)
2.3 For All Type Of Stock:
2.3.1 Each coach shall be fitted with four air spring assemblies (two per bogie) and each
air spring assembly shall be controlled by an independent leveling valve (4-point
control system). Two air springs of the same bogie shall be connected through a
duplex check valve set to act at a pressure differential of 1.5 Kg/cm² as per
requirement.
2.3.2 To maintain continuous supply of compressed air to the air spring assembly system,
an 150 litre auxiliary air reservoir has been provided.
2.3.3 Track-ballast during train operation may occasionally hit air spring assembly and
control equipments.
3 ENVIRONMENTAL CONDITIONS:
3.1 The control equipment for air suspension fitted in coaches described above shall
be subjected to following environmental conditions:
Max. Temperature under sun : 60ºC.
Ambient temperature : 0º to 45ºC in shade.
Average relative humidity : 70% to 90%, 100% on several days.
Rainfall : Fairly heavy, maximum being 200mm in
24 hours, typical to the coastal areas.
Atmosphere : Dusty for several months of the year.
3.2 The control equipment for Air spring assembly system may also come in contact
with the following, during coach maintenance operation:
• Chemical products (like cleaning compound of coach cleaning)
• Cotton waste smeared with oil and paint etc.
• Disinfectants.
• Oils & lubricants used in coach bogies.
4 SCOPE OF SUPPLY:
4.1 The air suspension system for which control equipment is required shall be
4-point control system.
4.2 The scope of supply shall cover the following items to suit air springs and their
characteristic. Technical requirements of these items are given in Clause-6.
SN Item Description Quantity per

coach
1 Leveling valve 4
2 Installation lever 4
3 Duplex check valve with 1.5±0.12 Kg/cm² pressure 2
setting
4 Main pressure tank (Auxiliary reservoir) 150 liters 1
capacity with ½” drain cock.
5 Air reservoir(Additional reservoir) of 20 dm3 (20 litres) 4
capacity with ½” drain valve . OR
40 dm3 (40 litres) capacity with ½” drain valve
Signature

May, 2018 C-K407 (Rev. -03)
6 Check valve (non return valve)20 mm bore with 3mm 1

choke
7 Two way centrifugal dirt collector (20mm bore) 1
8 Isolating cock (OLP type) 20mm bore
i) For main supply line pressure isolation 1
ii) For bogie pressure isolation 2
9 Hose connections 4
Note: Purchaser can purchase suitable fittings and hardwares in deviation of item
no. 8 under clause 4.2 from the sources developed by RDSO/RCF/ICF/MCF as per
their requirement based on the type of joint (single ferrule/double ferrule/Flange
joint) used in pneumatic suspension.
5. PROCEDURE FOR VENDOR REGISTRATION:
5.1 Manufacturers willing to supply air suspension control equipment for the use of
Indian Railways shall register themselves with Research Designs and Standards
Organization, Ministry of Railways, Lucknow-226011 (RDSO) and should be ISO
approved.
5.2 The manufacturer shall have adequate facilities for the manufacture and testing of
pneumatic suspension control system conforming to drawings approved by RDSO.
5.3 The manufacturer shall have a well-documented ‘Internal Quality Assurance

System’ to ensure quality of product being manufactured The Quality Assurance
System’ shall generally cover the following:-
5.3.1 System to ensure that correct raw material is being used. The type of material used
for the pneumatic suspension control equipments shall be specified by the
manufacturer.
5.3.2 System to ensure that components having manufacturing defects are identified and
destroyed so that such components are not used during assembly of pneumatic
suspension control equipments.
5.3.3 System to ensure that bought out components are strictly as per requirements laid
down in the STR / drawing.
5.3.4 System to maintain strict control of dimensions and workmanship of components

and assembled product.
5.3.5 System to test and establish that the pneumatic suspension control equipments
manufactured by the firm meets all the requirements laid down in STR / drawing.
5.3.6 System of periodical calibration of equipments/gauges to ensure accuracy of

product.
5.3.7 System to ensure cleaning & removal of dust/rust and moisture by dry air.
5.3.8 System to ensure that pneumatic suspension control equipments are properly
packed to meet the requirement of Clause-13 of this STR.
5.3.9 System to ensure traceability at least up to guarantee period.

Signature

May, 2018 C-K407 (Rev. -03)
5.4 Special Conditions:
a) Since pneumatic suspension control equipments are a safety related

suspension element, in-service trials shall be necessary before full
clearance is given for supply.
b) The control equipments shall be subjected to in-service trials on a minimum

of ten coach sets for one year on IR’s system. For this purpose, one time
trial order for ten coach sets shall be given to such vendor.
c) In case of any failure during service trials attributable to poor design or

material, the service trials shall be repeated. RDSO shall decide the cause
of failure after investigation in this regard.
d) After completion of service trial period, sample of the control equipments

shall be subjected to the tests laid down at para 6. In case the values
obtained during these tests are beyond permissible limits, the air spring
control equipments design shall be deemed to have failed the service trials.
e) Manufacturers shall be provided “Developmental” status on successful

completion of service trials as defined in clause 5.4.b above. A Vendor shall
be considered eligible for upgradation as “Approved Vendor” on completing
successful supply of a minimum of 100 coach sets of pneumatic suspension
control equipments along with the fulfillment of conditions mention in latest
apex ISO document of RDSO for “Vendor- Changes in approved status”
(document no. QO-D-7.1-11 ).
6. TECHNICAL REQUIREMENTS:
6.1 GENERAL REQUIREMENT:
6.1.1 All the valves and linkages offered shall be of proven design, easy to install, operate
and maintain.
6.1.2 All pneumatic suspension control equipments shall be able to work under pressure
between 1.0 Kg/cm2 to 10.0 Kg/cm2 and withstand an applied frequency of up to 10
Hz during run.
6.1.3 Any special requirements given in the drawings will over ride this STR.
6.2 LEVELLING VALVE:
6.2.1 Leveling valve shall regulate the supply of air to the air springs so as to maintain
pre-defined height at all variable loads.
6.2.2 Outer dimension of leveling valve and its pipe connection ports shall as per space
envelope shown in RDSO SKETCH-K1049 Alt. 1.
6.2.3 Leveling valve shall have such a setting that under dynamic load variations of the
coach running, insignificant consumption of air takes place.
6.2.4 Effective length of its lever shall be 160mm.

Signature

May, 2018 C-K407 (Rev. -03)
6.2.5 Design of leveling valve and its characteristics shall be approved by RDSO.
6.2.6 The leveling valve should function as per this specifications properly with installation
lever located on either side of the valve body.
6.2.7 The test procedure of leveling valve shall be strictly as test set up enclosed as
specified in Annexure – I.
6.2.8 The dead band angle of leveling valve shall not be greater than 10 ± 20’ on either
direction.
6.2.9 The charging and discharging time for 20 litres reservoir shall be as per the
proforma given in test record sheet enclosed as Annexure – I.
6.2.10 All internal parts of levelling valve should be made of stainless steel.
6.3 INSTALLATION LEVER:
6.3.1 Design of installation lever shall be as per RDSO SKETCH-K1050 Alt 3.
6.3.2 Installation lever shall have ball and socket joint at both the ends. It shall position
locking system at both the ends to avoid unnecessary rotation of the lever.
6.3.3 When connected to leveling valve lever; top and bottom ball and socket joints of
installation lever shall enable a free simultaneous or independent movement of the
order of 50 mm (minimum) lateral and 15 mm (minimum) longitudinal of the
assembly at top articulation with reference to the bottom fixed articulation.
6.3.4 The material of ball and socket joint and also Turn Buckle and threaded trunnion
rod shall be of corrosion resistant steel duly approved by RDSO. The ball and
socket joint shall be case hardened up to 1 mm depth.
OR
The material of ball and socket joint and also Turn Buckle and threaded trunnion
rod shall be of corrosion resistant steel duly approved by RDSO. Ball and socket
joint should be separated by injection moulded rubber to prevent wear.
6.3.5 The screws nuts and lock nuts shall be of high tensile steel of M10 x 60 at both
ends.
6.4 DUPLEX CHECK VALVE (RELIEF VALVE):
6.4.1 Duplex check valve shall be provided between the air springs on same bogie and
shall permit flow of air in either direction whenever pressure differential go beyond
1.5 ± 0.12 Kg/cm².
6.4.2 Duplex check valve design shall suit the space envelope and pipe connections
shown in RDSO SKETCH- K1051.
6.4.3 The test procedure for Duplex Check Valve shall be strictly as per Annexure-2
6.4.4 The test setup for Duplex Check valve is as per fig. enclosed in Annexure-2.
Signature

May, 2018 C-K407 (Rev. -03)
6.5 MAIN PRESSURE TANK (AUXILIARY RESERVOIR ) WITH DRAIN VALVE:
6.5.1 Main pressure tank should be of 150 dm³ (150 litres) capacity.
6.5.2 Design of 150 lit. pressure tank shall be as per ICF Drawing No. ICF/STD – 3-5-066
(latest alteration).
6.5.3 Drain cock assembly shall be as per RDSO SKETCH- 98003.
6.6 20 OR 40 dm3 (20 OR 40 LITRES) ADDITIONAL AIR RESERVOIR:
6.6.1 Air reservoir for additional air volume of air spring shall be 20 dm3 or 40 dm3 (20
litres OR 40 litres) capacity.
6.6.2 Design of 20 dm3 reservoir will be as per ICF Drawing No. ICF/SK3-0-5-008 (latest
alteration) with drain valve (for EMU/DMU bogies).
6.6.3 Design of 40 dm3 reservoir will be as per ICF Drawing No. LWGSCWAC-0-5-003
(latest alteration) with drain valve (for main line ICF bogies).
6.7 CHECK VALVE (NON RETURN VALVE):
6.7.1 The check valve shall be as per RDSO SKETCH- 98112.
6.7.2 Except drawing/sketch all clauses of appendix-I (clause 5.0, 6.0 & 7.0) of RDSO
specification 02-ABR-02 shall be followed.
6.8 TWO WAY DIRT COLLECTOR:
6.8.1 The two way dirt collector shell be as per RDSO SKETCH- 97005.
6.8.2 Except Drawing/sketch all clauses of appendix-E (clause 6.0, 7.0 & 8.0) of RDSO
6.9 ISOLATING COCK:
6.9.1 Isolating cock (OLP type) (20mm bore) as per RDSO SKETCH-97002.
6.9.2 Except Drawing/sketch all clauses of appendix-I (clause 6.0, 7.0 & 8.0) of RDSO
6.10 HOSE CONNECTIONS:
6.10.1 The hose connection shall be as per RDSO SKETCH-K1054.
7 SUBMISSION OF OFFER: (FOR FIRMS SEEKING RDSO's APPROVAL)
7.1 Firms desirous of seeking approval from RDSO for supply of material as per this
STR, shall submit their proposal accompanied by the documents containing the
following information to RDSO:-
1) Test report on the proposed equipments based on the tests conducted and
results compiled by manufacture to indicate the characteristics of the tested
equipments.
Signature

May, 2018 C-K407 (Rev. -03)
2) Dimensional drawings of the equipments.
3) Characteristics of the offered equipments.
4) Weight of offered equipments.
5) Whether proposed equipments are being used by any other rail-road system?
If yes, details regarding quantity, type of stock, maximum operating speed,
type of service, average annual running kilometers, life cycle obtained by the
user rail-road and maintenance cycle followed by them.
6) Details of deviation from the STR.
7) Content of indigenous and imported items in offered equipment.
8) Expected life cycle in operating and environmental conditions enumerated in

clauses 2 & 3 of this STR.
9) Authorisation certificate / License etc. from the original manufacturer

permitting supply / manufacture of the offered equipment. (For proposals from
other than the original manufacturers).
10) A write-up giving broadly the maintenance requirements on time/distance

basis along with the facilities that would be needed for proper
maintenance/upkeep of the offered equipment.
11) A detailed write-up giving the details of "Quality Assurance System" being
followed for manufacture of the offered items; and
12) Details of manufacturing and testing facilities available with the manufacturer.
7.2 The information as received above shall be used for preliminary evaluation of the
firm's capability in meeting with the requirements of this STR.
7.3 After preliminary evaluation, premises of the firm may also be visited by RDSO’s
officials for on-the-spot assessment of the firm's capability.
7.4 RDSO reserves complete right of granting approval or otherwise to a firm.
8. GUARANTEE:
8.1 Equipments supplied by the firms shall be guaranteed for satisfactory performance
for a minimum period of 24 months from the date of actual commission in bogies or
30 months from the date of supply. Satisfactory performance for this purpose
means that complete equipment or any of its part shall neither show any kind of
deterioration which is likely to render it unserviceable nor loose its characteristics as
stipulated in this STR, during the guarantee period for reasons attributable to
manufacturing/design defects.
8.2 In the event of 'non-satisfactory performance' of any of the items as indicated
above, supplier will have to replace the same at his own expense without levying
any cost involved in transportation, handling and replacement of such items on the
Purchaser.
Signature

May, 2018 C-K407 (Rev. -03)
9. INSTALLATION, COMMISSIONING & MAINTENANCE:
9.1 On placement of order, supplier whose equipment will be purchased for the "First
Time" for installation on the coaches, shall have to depute his representative at his
own expense to associate with the purchaser in installation and commissioning of
the equipment on first five coaches. He shall also depute his representative during
maintenance schedules undertaken on his equipment as per maintenance booklet
supplied by him.
9.2 With every order for supply of air spring control equipments to approved supplier;
the supplier shall have to supply two maintenance booklets (hard copy) and one
copy on Compact Disc (MS-Office compatible).
9.3 Maintenance booklet supplied by the supplier shall cover the following aspects in
detail:
9.3.1 Specification of the equipment.
9.3.2 Working principle based on the actual construction.
9.3.3 Constructional details giving sketches, drawings and photographs etc. identifying
various items and their part numbers etc. for easy identification.
9.3.4 Procedure for dismantling using sequential steps with the help of sketches etc.
9.3.5 Procedure for assembly, using sequential steps with the help of sketches etc.
9.3.6 Jigs, tools, other materials and details of special set-ups etc., necessary for items
4&5 above.
9.3.7 Testing procedures and facilities required along with their details.
9.3.8 Comprehensive details containing legible sectional views of defects normally

observed or may happen in equipollents with clear remarks whether the defect is
reject able or non-reject able.
9.3.9 List of other defects and their remedies.
9.3.10 Periodicity for various maintenance activities on time and distance basis.
9.3.11 Do's and Don'ts for maintenance officials.
10. INSPECTION AND TESTING:
10.1 GENERAL REQUIREMENTS:
10.1.1 During initial approval of a firm by RDSO (Clause 7.3) and later on when approval
has been granted, RDSO for purpose of ensuring quality of purchased product may
carry out periodic quality audit, inspection and testing of the equipment at the
premises of the manufacturer / supplier.
10.1.2 Purchase inspection shall be done at the premises of the manufacturer / supplier by
the representative of the Research Design and Standard Organization or an agency
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May, 2018 C-K407 (Rev. -03)
authorized by RDSO and supplier shall have to arrange for the following and
associate with the same:
1) Access to all records considered relevant for such activity by inspecting
officials.
2) Questioning of relevant personnel engaged in production, testing and quality
checking activities etc. or related issues.
3) Testing of few samples of items already produced by the firm to ascertain the
technical characteristics given in this STR.
4) Any other check considered necessary by the inspecting party.
5) Test bench for hydraulic test of reservoirs having facility to conduct test on
minimum five reservoirs at a time.
10.2 INSPENSION AND TESTING OF LEVELLING VALVE, DUPLEX CHECK VALVE,

INSTALLATION LEVER & HOSE CONNECTION.
10.2.1 Inspection of all control equipments shall be carried out as per approved drawings.
However, in cases where vendors source some items from RDSO approved
sources duly inspected by Quality Assurance Department of RDSO or RITES,
inspection of already inspected items will not undertaken and such items shall be
accepted against copy of Inspection Certificate issued by inspecting agency.
10.2.2 5% of lot or 10 nos. each item, whichever is more, shall be picked up randomly for
dimension & other specified inspection as given above in clause 10.2.1 of this STR.
10.2.3 In case any one picked up samples fails manufacture/supplier may offer rectifying
the defects. However, in such cases, double the quantity of samples shall be picked
up and check for dimension and other specified testing. In case any one samples
again fails the entire lot shall be rejected.
10.3 INSPECTION AND TESTING MAIN RESERVOIR TANK (150 dm3), AIR
RESERVOIR (20 dm3 OR 40 dm33) CHECK VALVE, TWO-WAY DIRT
COLLECTOR, AND ISOLATING COCK.
S.No. Item Make Ref.

1 Main Pressure Approved Dimensional check as per ICF drawing no.
tank (150 dm3) sources of ICF/STD – 3-5-066 (latest alteration).
RDSO/ICF/ RCF
2 Air Reservoir -Do- Dimensional check as per ICF Drawing No.
(20dm3 OR ICF/SK3-0-5-008 (latest alteration)
40dm3) OR LWGSCWAC-0-5-003(latest alteration)
3 Check valve Approved Dimensional check as per RDSO SKETCH-
sources of 98112
RDSO Inspection as per technical requirement
clause 6.7 of this STR
4 Two way dirt -Do- Dimensional check as per RDSO
collector SKETCH- 97005
Inspection as per technical requirement
5 Isolating cock -Do- Dimensional check as per RDSO SKETCH-
97002
Signature

May, 2018 C-K407 (Rev. -03)
Inspection as per technical requirement

11. PAINTING:
11.1 Leveling valve, Duplex check valve and Installation lever internal & external part
shall be given anticorrosion treatment. External surface, excluding the flange shall
be painted with Red enamel paint or red anodized.
11.2 Hose connection head shall be given anticorrosive treatment and painted with Red
enamel paint.
12. MARKING:
Every item of control equipment shall be legibly marked by using punching or

casting etc. to indicate the following:
1) Manufacturer's initials.
2) Month and year of manufacture.
3) Identification mark, i.e. Part No. and Batch No. etc.
13. PACKING:
13.1 All the ports of valve and cock shall be suitably covered with protection caps to
prevent ingress of foreign matter during handling and storage.
13.2 All pneumatic suspension control equipment shall be suitably packed to protect
against any damages during transit and handling by transport to the destination.
14. TOLERANCE:
Tolerance in different dimensions of pneumatic suspension control equipments

should be mentioned in drawing as under-
Fractions Decimals Angles
X.0 + 2 X.X + 1.0 X.XX + 0.50 X.XXX + 0.250 + 3.0 0
15. GENERAL:
15.1 RDSO reserve the right to modify any clause of this STR as per requirement of
Indian Railways.
15.2 Additional information if required may be obtained from the office of the Director
General (Carriage), RDSO, Manak Nagar, Lucknow – 226011.
Signature

May, 2018 C-K407 (Rev. -03)
ANNEXURE - A
CHECKLIST FOR INSPECTION OF PNEUMATIC CONTROL EQUIPMENTS
As per inspection and testing Clause no. 6.0
1.0 INSPECTION FORMAT OF INSTALLATION LEVER
S.No. Particulars Unit Specified Observations
1 Finish Smooth
2 Cut Nil
3 Burrs/Flash Nil
4 Rust/Corrosion Not allowed
5 Weld/Paint Marks Not allowed
6 Flatness/Parallelism
7 Thread mm As per approved drawing
8 Thread mm As per approved drawing
9 Overall Length mm As per approved drawing
10 Hex. Rod Length mm As per approved drawing
11 Hole Diameter mm As per approved drawing
12 Effective bolt length mm As per approved drawing
STATUS: Accepted / Not Accepted
Signature

May, 2018 C-K407 (Rev. -03)
2.0 INSPECTION FORMAT OF LEVELLING VALVE
1 Diameter of mm As per approved drawing

hole in leveling
valve handle.
2 Center mm As per approved drawing
Distance of
mounting holes
3 Square Size mm As per approved drawing
4 Mounting Hole mm As per approved drawing
Diameter
5 Overall mm As per approved drawing
dimension
6 Threading As per approved drawing
7 Handle mm As per approved drawing
Thickness
8 Handle Width mm As per approved drawing
9 Position mm As per approved drawing
10 Handle Length mm As per approved drawing
Pressure Test: Sample checked at 10 Kg/cm2 and no leakage observed.
Physical Condition: OK / Not OK
Marking: Done / Not Done
Painting: Red Done / Not Done
Remark: Found OK / Not OK.
Status: Accepted / Not Accepted.
Signature

May, 2018 C-K407 (Rev. -03)
3.0 INSPECTION FORMAT OF DUPLEX CHECK VALVE
1 Height mm As per approved drawing

2 Width mm As per approved drawing
3 Base to hole mm As per approved drawing
center line
4 Tapped hole to mm As per approved drawing
hole center line
5 Depth mm As per approved drawing
6 Port Threading As per approved drawing
7 Square size mm As per approved drawing
8 Square size mm As per approved drawing
Signature

May, 2018 C-K407 (Rev. -03)
4.0 INSPECTION FORMAT OF MAIN PRESSURE TANK (150 lit.)

2 Length over mm As per approved drawing
barrel
3 Plate width mm As per approved drawing
4 Plate to plate mm As per approved drawing
length
5 Outside dia. of mm As per approved drawing
reservoir
6 C/D tapped As per approved drawing
holes
7 Length of pad mm As per approved drawing
Pressure Test: Hydraulic test at 16 Kg/cm2 for min. 10 minutes and no leakage observed.
Signature

May, 2018 C-K407 (Rev. -03)
5.0 INSPECTION FORMAT OF TWO WAY DIRT COLLECTOR

1 Top to bottom mm As per approved drawing
distance.
2 Flange to flange mm As per approved drawing
distance
3 Mounting Hole mm As per approved drawing
diameter
4 Center distance mm As per approved drawing
of hole
5 Flange mm As per approved drawing
thickness
6 Air hole mm As per approved drawing
Signature

May, 2018 C-K407 (Rev. -03)
6.0 INSPECTION FORMAT OF AIR RESERVOIR (20 lit. / 40 lit.)

2 Shell Diameter mm As per approved drawing
3 End Cover mm As per approved drawing
Diameter
4 Pad to pad mm As per approved drawing
distance
5 Threaded hole mm As per approved drawing
6 Threaded hole As per approved drawing
7 Length of pad mm As per approved drawing
Pressure Test: Hydraulic test at 16 Kg/cm2 for min 10 minutes and no leakage observed.
Signature

May, 2018 C-K407 (Rev. -03)
7.0 INSPECTION FORMAT OF CHECK VALVE (NRV)
1 Flange to flange mm As per approved

distance drawing
2 Top to center mm As per approved
distance drawing
3 Flange thickness mm As per approved
drawing
4 Flange width mm As per approved
drawing
5 Mounting Hole mm As per approved
diameter drawing
6 Hole diameter of mm As per approved
air vent. drawing
7 Center distance mm As per approved
of holes drawing
8 Flange length mm As per approved
drawing
Signature

May, 2018 C-K407 (Rev. -03)
8.0 INSPECTION FORMAT OF ISOLATING COCK
1 Flange to flange mm As per approved drawing

distance
2 Top to center mm As per approved drawing
distance
3 Flange mm As per approved drawing
thickness
4 Centerline to mm As per approved drawing
handle end
5 Mounting hole mm As per approved drawing
diameter
6 Center distance mm As per approved drawing
of holes
Signature

May, 2018 C-K407 (Rev. -03)
9.0 Pressure Differential Test on DCV
S.No. DCV’s Single Direction Reverse Direction Remarks

No. P1(Bar) P2(Bar) Differential P1(Bar) P2(Bar) Differential
1.5 1.5
1. 4.0 4.0
6.0 6.0
1.5 1.5
2. 4.0 4.0
6.0 6.0
1.5 1.5
3. 4.0 4.0
6.0 6.0
1.5 1.5
4. 4.0 4.0
6.0 6.0
1.5 1.5
5. 4.0 4.0
6.0 6.0
1.5 1.5
6. 4.0 4.0
6.0 6.0
Note: Pressure differential should be 1.5 ± 0.12 Kg/cm².
Signature

May, 2018 C-K407 (Rev. -03)
10.0 Characteristic Test Of Levelling Valve
DB Angle Charging (2 to 6 bar) Discharging (2 to 6

S.No. Levelling (1.330- bar)
Valve No. 0.670) At 40 At 100 At 40 At 100
(15 to 45 (4 to 14 (33 to 93 (5 to 25
sec.) sec.) sec.) sec.)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Signature

May, 2018 C-K407 (Rev. -03)
ANNEXURE-1
TEST SET UP
• Install the valve in the test rack as shown in fig.1.

• All cocks IC-1, 1C-2, IC-3, & IC-4 should be closed.
• Adjust the air inlet pr. to 10 kg/cm2 as shown in pressure gauge (P-1) by opening cock
IC-1.
• Adjust the handle at 0 degree as shown in angle protector.
LEAKAGE TEST
Apply soap water all over the body, cap etc. of leveling valve.
• There should not be any leakages.
• Open cock IC-2. There should not any flow in flow indicator.
• Move the lever upto 0.50. there should not be any leakage and any flow throw the flow
indicator. Record no leakage.
• Similarly move the lever down to 0.50. There should not be any leakage.
FUNCTION TEST
1) Initial charging and discharging of air

• Open cock IC-3 and move the handle from 0 deg. to + 0.5 deg. Interval. Note at
what angle air flow start through flow indicator. This should be approximately
+(10±20’). Same procedure to be followed for discharge also. It will be
approximately -(10±20’) degree.
2) Normal charging and discharging

• Gradually increase the angle of handle clockwise to +100 as shown in the angle
protector. Check the time taken for the pressure shown on pressure gauge P-2 to
rise from 2 to 6 kg/cm2. Record the time in the test record sheet, which should be 9
+ 5 secs
• Gradually move the handle to -100 as shown in the angle protector. Check the time
taken for the pressure shown on pressure gauge P-2 to fall from 6 to 2 kg/cm2.
Record the time in the test record sheet which should be 15 + 10 secs
• Gradually increase the angle of handle clockwise to +40 as shown in the angle
protector. Check the time taken for the pressure shown on pressure gauge P-2 to
rise from 2 to 6 kg/cm2. Record the time in the test record sheet which should be 30
+ 15 secs
• Gradually move the handle to -40 as shown in the angle protector. Check the time
taken for the pressure shown on pressure gauge P-2 to fall from 6 to 2 kg/cm2.
Record the time in the test record sheet which should be 63 + 30 secs
Signature

May, 2018 C-K407 (Rev. -03)
Signature

May, 2018 C-K407 (Rev. -03)
TEST RECORD SHEET FOR LEVELLING VALVE (Test Pressure 10 bar)
Leakage Test
Parameter Standard Observed

1. Apply soap water to Body No Leak
/Cap
2. Move the lever to + ½ deg. No Leak, No rise of Float
Function: A (Test for Dead Band)
Initial Charging Standard Observed

/Discharging Degree of rotation Degree of rotation
Charging (When flow of air + (1°± 20’)
takes place by rotation of
lever in the forward
direction)
Discharging (When flow of - (1°± 20’)
air takes place by rotation
of lever in the reverse
direction)
Function: B
Initial Charging Standard Time (seconds) Observed Time (seconds)

/Discharging
With rotation of lever in 9±5
forward direction at +10
deg, time taken for change
in pressure from 2 kg/cm2
to 6 kg/cm2
With rotation of lever in 15 ± 10
reverse direction at -10
deg, time taken for change
in pressure from 6 kg/cm2
to 2 kg/cm2
forward direction at +4 deg,
time taken for change in
pressure from 2 kg/cm2 to 6
kg/cm2
reverse direction at -4 deg,
time taken for change in
pressure from 6 kg/cm2 to 2
kg/cm2
Signature

May, 2018 C-K407 (Rev. -03)
ANNEXURE-2
TEST SET UP
• Install the duplex check valve in the test rack as shown in fig.2. ensure clean and dry air
supply to the manifold as indicated. Close all cocks before starting the test. Open cock
IC-1. Regulate the air pressure on gauge to read 3 bar.
LEAKAGE TEST
Using soap solution check for any leakage at the joints. No leak permitted.
FUNCTION TEST 1
• Set pressure reducing valve PR to 0 bar.

• Open cocks IC-1 and IC-2.
• Slowly increase pressure at pressure reducing valve PR and watch pressure gauge M
(having least count 0.05 bar). Air must escape from cock IC-2 when the pressure reaches
the set value of 1.5 bar.
• Slowly reduce the pressure at pressure reducing valve PR and watch pressure gauge M
(having least count 0.05 bar). Air should stop escaping from cock IC-2 when the pressure
reaches the set value of 1.5 bar.
• Close cock IC-1.
• Set the pressure reducing valve PR to 4 bar and 6 bar respectively and repeat the test
procedure same as above to check valve opening and closing when the differential
pressure reaches around 1.5 bar.
To carry out function Test 2, install the duplex check valve in the test set up according to
fig. ‘ b’ of fig 2.(Reverse direction of air flow)
FUNCTION TEST 2
• Set pressure reducing valve PR to 0 bar.

• Open cocks IC-1 and IC-2.
• Slowly increase pressure at pressure reducing valve PR and watch pressure gauge M.
Air must escape from cock IC-2 when the pressure reaches the set value of 1.5 bar.
• Slowly reduce the pressure at pressure reducing valve PR and watch pressure gauge M.
Air should escape from cock IC-2 when the pressure reaches the set value of 1.5 bar.
END OF TEST
• Close IC-1. Vent the duplex check valve.

• Remove duplex check valve from test set up.
• Marked “Tested” stickers on the duplex check valve, which have passed.
Signature

May, 2018 C-K407 (Rev. -03)
Signature

May, 2018 C-K407 (Rev. -03)
TEST RECORD SHEET FOR DUPLEX CHECK VALVE (Test Pressure 10 bar)
1) Air flow in forward direction (P-1 to P-2)
Sr. No. Observed Observed Differential Remarks

pressure at pressure at pressure (bar)
P-1(bar) P-2(bar)
1 1.5
2 4.0
3 6.0
2) Air flow in reverse direction (P-2 to P-1)
Sr. No. Observed Observed Differential Remarks

pressure at pressure at pressure (bar)
P-1(bar) P-2(bar)
1 1.5
2 4.0
3 6.0
Signature

May, 2018 C-K407 (Rev. -03)
Signature

May, 2018 C-K407 (Rev. -03)
Signature

May, 2018 C-K407 (Rev. -03)
Signature

May, 2018 C-K407 (Rev. -03)
Signature


C-K407 Rev. 3 - Final Draft - MAY 2018

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C-K407 Rev. 3 - Final Draft - MAY 2018

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Ref: CG-WI-4.2.1-1 Date / Month of issue: Specification No.

Ver 1.0 Page 1 of 34

SCHEDULE OF TECHNICAL REQUIREMENTS

AIR SUSPENSION CONTROL EQUIPEMENTS

AIR SPRING ASSEMBLY SYSTEM

WITH ICF/LHB TYPE BOGIE

S. No. Month / Year of Revision / Page No. Reason for

Name & Prepared by: Checked By: Approved By:

S.No. Description Clause No. of Page No. of Reason for Amendment

Name & Prepared by: Checked By: Approved By:

Description Page No.

II Air Spring Control Equipments

III Referred Specification & Drawings

III.A Drawings (Enclosed)

1. SKETCH-K1049 Alt.1:Space Envelope for Leveling Valve

III.B Specification & Drawings (Not Enclosed)

1. RDSO specification No. 02-ABR-02 (Air Brake)

Name & Prepared by: Checked By: Approved By:

0.2 This Schedule of Technical Requirements (STR) is issued as second

Name & Prepared by: Checked By: Approved By:

SCHEDULE OF TECHNICAL REQUIRMENTS OF

2.1 For Main Line/ Rajdhani & LHB Coaches :

2.2 For EMU / DMU & MEMU coaches

Name & Prepared by: Checked By: Approved By:

2.3 For All Type Of Stock:

SN Item Description Quantity per

Name & Prepared by: Checked By: Approved By:

6 Check valve (non return valve)20 mm bore with 3mm 1

5. PROCEDURE FOR VENDOR REGISTRATION:

5.3 The manufacturer shall have a well-documented ‘Internal Quality Assurance

5.3.4 System to maintain strict control of dimensions and workmanship of components

5.3.6 System of periodical calibration of equipments/gauges to ensure accuracy of

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

Name & Prepared by: Checked By: Approved By:

5.4 Special Conditions:

a) Since pneumatic suspension control equipments are a safety related

b) The control equipments shall be subjected to in-service trials on a minimum

c) In case of any failure during service trials attributable to poor design or

d) After completion of service trial period, sample of the control equipments

e) Manufacturers shall be provided “Developmental” status on successful

6.1 GENERAL REQUIREMENT:

6.2 LEVELLING VALVE:

6.2.4 Effective length of its lever shall be 160mm.

Name & Prepared by: Checked By: Approved By:

6.3 INSTALLATION LEVER:

6.3.1 Design of installation lever shall be as per RDSO SKETCH-K1050 Alt 3.

6.4 DUPLEX CHECK VALVE (RELIEF VALVE):

Name & Prepared by: Checked By: Approved By:

6.5 MAIN PRESSURE TANK (AUXILIARY RESERVOIR ) WITH DRAIN VALVE:

6.5.3 Drain cock assembly shall be as per RDSO SKETCH- 98003.

6.6 20 OR 40 dm3 (20 OR 40 LITRES) ADDITIONAL AIR RESERVOIR:

6.7 CHECK VALVE (NON RETURN VALVE):

6.7.1 The check valve shall be as per RDSO SKETCH- 98112.

6.8 TWO WAY DIRT COLLECTOR:

6.9 ISOLATING COCK:

6.10 HOSE CONNECTIONS:

6.10.1 The hose connection shall be as per RDSO SKETCH-K1054.

7 SUBMISSION OF OFFER: (FOR FIRMS SEEKING RDSO's APPROVAL)

Name & Prepared by: Checked By: Approved By:

2) Dimensional drawings of the equipments.

3) Characteristics of the offered equipments.

4) Weight of offered equipments.

7) Content of indigenous and imported items in offered equipment.