Draft Spec RDSO-2011-CG-04 Rev - 2

CG-F-4.2.1-4 (Rev.1) Page 1 of 36 Latest (Rev./Amed.) issue: June’22 Spec. No. RDSO/2011/CG-04 (Rev.
02)
INDIAN RAILWAYS
Document Technical Specification Yes

content Schedule of Technical Requirement No
Description SPECIFICATION FOR AXLE MOUNTED DISC BRAKE SYSTEM FOR
of item LHB TYPE BG MAINLINE COACHES
Remarks Nil
Revision/
S. No. Month/Year of Issue Page No. Reason for Amendment
Amendment
1. November, 2012 - - First issue
6, 17, 20, 21,
2. November, 2014 Rev.-1
32, 33 & 35
To include the ISO Doc. No. QO-
D-7.1-11. New sub clause No.1.3
3. September, 2016 Amendment-1 3
added under clause no. 1.0 of
Foreword
To improve clarity with focus on
4-12, 14-18, 20,
functional requirements for
4. June, 2022 Rev.-2 23-24, 26, 28-
enhancing indigenous vendor
32 & 34-37
base
Issued By:
Carriage Directorate
Research Designs and Standards Organization
Manak Nagar, Lucknow - 226011
Signature
Name & Prepared by: Mahesh Checked by: Vivek Anand Approved by: Sudhir Singh
Designation JE/Carriage SSE/Carriage Jt. Director/Carriage
CG-F-4.2.1-4 (Rev.1) Page 2 of 36 Latest (Rev./Amed.) issue: June’22 Spec. No. RDSO/2011/CG-04 (Rev.02)
CONTENTS
PART – I GENERAL CONDITION

CLAUSE DESCRIPTION PAGE NO.
NO.
1. FOREWORD 4
2. DEFINITION AND EXPLANATORY 4
3. SCOPE 5
4. PARTICULAR REQUIREMENTS 5
5. GURANTEE/WARRANTY 5
6. SPARE PARTS, RESERVE APPARATUS & WEARING PIECES 5
7. AFTER SALES SERVICE 6
8. TRAINING 6
PART – II TECHNICAL REQUIREMENTS
9. SCOPE OF SUPPLY 7
10. PERFORMANCE REQUIREMENTS 10
11. DESIGN REQUIREMENTS 10
12. SUBMISSION OF TECHNICAL DOCUMENTS 11
13. APPROVAL OF DRAWING 11
14. MANUFACTURE 11
15. INSPECTION 12
16. FIELD TRIAL 12
17. MARKING 12
18. PACKING 13
Signature
APPENDIX
APPENDIX – A SPECIFICATION FOR BRAKE CONTAINER MODULE

APPENDIX – B SPECIFICATION FOR BRAKE CYLINDER
APPENDIX – C SPECIFICATION FOR BRAKE CALIPER ASSEMBLY
APPENDIX – D SPECIFICATION FOR PASSENGER EMERGENCY ALARM SYSTEM
APPENDIX – E SPECIFICATION FOR EMERGENCY BRAKE ACCELERATOR VALVES
APPENDIX – F SPECIFICATION FOR WHEEL SLIDE PROTECTION UNIT (WSP)
APPENDIX – G SPECIFICATION FOR BRAKE INDICATORS
ANNEXURE – I DATA AND INTERFACES
Signature
PART-I: GENERAL CONDITIONS
1.0 FOREWORD
1.1 This specification is intended to cover Axle mounted disc brake system for all AC (EOG), AC(SG),
Power Car and Double Decker and Non-AC types of LHB design coaches with LHB shell fitted with
FIAT bogies having twin pipes graduated release compressed air brake system for operation on BG
(1676 mm) system of Indian Railway.
1.2 Following specification may be referred to in conjunction with this specification:
i. UIC specification no.540
ii. UIC specification no.541-1
iii. UIC specification no.541-3
iv. UIC specification no.541-5
v. UIC specification no.542
vi. UIC specification no.543
vii. UIC specification no.544-1
viii. UIC specification no.545
ix. UIC specification no.546
x. UIC specification no.547
xi. UIC specification no.831 R
xii. RDSO specification no.02-ABR-02
xiii. RDSO specification no.04-ABR-02
xiv. RDSO specification no.C-K209
xv. RDSO specification no.C-K013
xvi. T.S.No.17.503 Part Doc 100 version-00
xvii. T.S.No.17.614 Part Doc 100 version-01
xviii. T.S.No.17.501 Part Doc 100 version-00
xix. T.S.No.17.505 Part Doc 100 version-00
xx. T.S.No.17.499 Part Doc 100 version-00
xxi. Relevant DIN, EN & ISO standards as applicable
1.3 General:
1.3.1 Following shall be applicable when this item appears in RDSO’s vendor directory:
“All the provisions contained in RDSO’s ISO procedures laid down in Document No. QO-D-7.1-11
dated 19.07.2016 (titled “Vendor-Change 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.”
1.3.2 The Govt. of India policy on ‘Make in India’ shall apply.
1.3.3 Manufacturer will ensure the usage of environment friendly material and energy efficient
instruments/equipments.
2.0 DEFINITION AND EXPLANATION
2.1 ‘TENDERER’ means firm/company from whom the offer for the supply of disc brake equipment is
invited.
2.2 ‘CONTRACTOR’ means the firm/company on whom the order for the supply of the brake equipment is
placed/will be placed.
2.3 ‘PURCHASER’ means the Indian Railways on behalf of the President of the Republic of India who are
purchasing the brake equipment.
Signature
2.4 ‘INSPECTING AUTHORITY’ means the organization or its representative nominated by the purchaser
to inspect the brake equipment on his behalf.
2.5 The Research Designs & Standards Organization, Manak Nagar, Lucknow-226011 is hereafter referred
to as ‘RDSO’.
2.6 Rail Coach Factory, Kapurthala (Punjab) is hereafter referred to as RCF.
2.7 The Indian Railways is hereafter referred to as IR.
2.8 In case the tenderer needs any clarification in respect of any clause of this specification or regarding
the exhibited drawings, the tenderer shall obtain the same from RCF/RDSO.
2.9 The Axle Mounted Disc Brake system is hereafter referred to as ‘AMDBS’.
3.0 SCOPE
3.1 This specification covers the technical requirements related to inspection, testing and performance of
Axle mounted disc brake system for LHB design coaches fitted with FIAT bogies of Indian Railways
and does not include all the necessary provisions of the contracts.
4.0 PARTICULAR REQUIREMENTS
4.1 The firm seeking registration for Axle mounted disc brake system shall register online on RDSO
websites. All relevant documents like Vendor Approval guidelines & Application form, latest version of
all specifications and drawings shall be provided on websites. The firm shall follow the latest vendor
approval guidelines for registration with RDSO.
4.2 The firm should possess ISO:9001 certificate issued by International Accreditation Forum (IAF) under
Multilateral Recognition Arrangement (MLA) for his works address, covering the items for which he
seeks registration with RDSO.
4.3 The firm along with their principals shall have adequate infrastructures for manufacturing, testing and
quality control requirements for complete disc brake system. This will be verified by RDSO at the time
of registration of the firm.
5 GUARANTEE/WARRANTY
5.1 For brake system supplied by the contractor, in case of any part of the brake system failing or proving
unsatisfactory in service due to defective design, material or workmanship, within 36 months from the
date of delivery or 24 months from the date of placing in service whichever is earlier, shall be replaced
by the contractor at his own expense. For Distributor Valve, warranty clause of RDSO spec C-K209
shall be applicable.
5.2 Brake system shall be subjected to detailed trials as discussed in clause 17 of the specification. Any
modifications found necessary as a result of these tests or further service trials shall be carried out by
the contractor at his own cost in the coaches in a manner approved by the purchaser. All schematic
layout and installation drawings incorporating the modifications shall be submitted to RDSO for final
approval.
6 SPARE PARTS, RESERVE APPARATUS & WEARING PIECES
6.1 The offer shall include recommended list of spare parts required for day-to-day maintenance of the
brake equipment and spares in the form of kit for the various sub-assemblies for the maintenance at
the time of POH. The list shall include the part number, quantity required and price of each component.
6.2 Firm shall ensure availability of all spares for a period of at least 10 years. This shall be irrespective of
the fact whether the tenderer or his sub contractor(s) have stopped manufacturing of the equipment to
the design supplied to IR.
Signature
6.3 In order to ensure the highest availability and utilization of brake system, a certain number of standby
units of principal assemblies are required. In addition, the firm may stock sufficient minor components
and spares to meet renewal and replacement on account of wear or occasional failure, for a period of 5
years’ service. Tenderer shall, therefore, submit a classified list of spares, (unit exchange, spares &
stage/normal maintenance) for each type of equipment of brake system, which he recommends for
stocking.
6.4 The firm shall indicate in an itemized list, the life expectancy of components subjected to wear under
Indian conditions.
7 AFTER SALES SERVICE
7.1 Firm may be required to send his their technical expert during the installation and commissioning of
their equipment on coach/coaches. The charges for this service shall be quoted separately.
7.2 Firm shall also depute his their technical expert on request by the Purchaser/RDSO to investigate and
attend to specific problems that may come up during actual operation of disc brake system.
7.3 Firm shall associate with Indian Railways during the trials with disc brake system. He It shall also
undertake to modify the equipment supplied, if required as a result of trials.
7.4 Firm shall supply at least 10 05 copies (soft & hard copy both) of the Operation & Maintenance
Manuals and Servicing Instructions per 100 Sets of disc brake system. PU’s will ensure that copies of
these maintenance manuals are issued to respective Railways where the coaches were allotted. These
should normally include:
7.4.1 Brief Details of functioning of each equipment.
7.4.2 Details of attention to be given during IOH/POH or any other schedule examination.
7.4.3 Test procedure and standards for various brake equipments on test bench as well as single coach/rake
testing.
7.4.4 Details of gauges, jigs & fixtures, tools, machinery and plant for maintenance of brake
equipment/system.
7.4.5 Typical defects and their remedial measures.
7.4.6 List of spares for day to day maintenance and at the time of IOH/POH in the form of periodic overhaul
kit.
7.4.7 Maintenance standards including clearances and tolerances at various locations and permissible limits
of wear for good service performance of equipments.
7.4.8 Firm shall submit the frequency and detailed work content of various inspection/maintenance
schedules necessary for maintenance of air brake system offered by him. Whether these requirements
are time based or distance travelled based shall be indicated for each schedule.
7.4.9 List of maintenance spares for disc brake system.
8 TRAINING
Manufacturer will organize free of cost Seminar/Workshops on Disc Brake system once in a year in
coaching having coach holding less than 50 and twice in a year in coaching depot having coach
holding more than 50 at coaching depot/workshop where LHB coaches are being maintained.
Signature
PART-II: TECHNICAL REQUIREMENT

9 SCOPE OF SUPPLY
9.1 Scope of supply of Axle mounted disc brake system for all AC(EOG), AC (SG) & Non-AC(EOG) type of
LHB design coaches shall cover the following equipments. It is the prerogative of purchaser to procure
the system as complete set or in part:
S.No. Description Specification Qty./coach Remarks
1. Brake Container Module Appendix – A 1 Set $Max. BC pressure 3.0
Kg/cm2
2. Brake Cylinder (LH) Appendix – B 4
3. Brake Cylinder (RH) Appendix – B 4
4. Brake Caliper Assly. (LH) Appendix – C 4 Brake Caliper ratio is
2.17 for all EOG & SG
Coaches except for the
5. Brake Caliper Assly. (RH) Appendix – C 4 ACCN (SG). For
ACCN (SG) coach
Brake Caliper ratio is
2.48.
6. Passenger Emergency Alarm Appendix – F D 1
Valve
7. Passenger Emergency Alarm Appendix – F D *As reqd.
Pilot Valve with micro switch &
indication Device
8. Brake Accelerator Valves Appendix – E 1
9. Wheel Slide Protection Unit Appendix – G F 1 Set
(WSP)
10. Brake Indicators Appendix – H G 4
11. Cut off angle cock 1-1/4” Appendix – D of 84
spec 02-ABR-02
12. Reducing Bush 1-1/4x1” - 84
13. Hose coupling assembly for BP Appendix – F of 42 Hose length 455 660+6
spec 02-ABR-02 mm & Hose assembly
585 790+6 mm
14. Hose Coupling Assembly for FP Appendix – F of 42 Hose length 455 660+6
spec 02-ABR-02 mm & Hose assembly
585 790+6 mm
15. Hose Connection (10 ID/30 OD) RDSO Drg. 4 600 650mm long#
for Bogie CG-19036
(Alt.-latest)
16. Hose Coupling connection (10 RDSO Drg. 8 500 mm long#
ID/30 OD) for brake cylinders CG-19037
(Alt.-latest)
17. Isolating cock 1” - 1 #
(*): Quantity may vary for different types of coaches.
(#): As per approved OEM drawing.
($): DV should have provision for pressure adjustment.
Signature
9.2 Scope of supply of Axle mounted disc brake system for LHB type Power Car and SLR coaches shall
cover the following equipments. It is the prerogative of purchaser to procure the system as complete
set or in part:
1. Brake Container Module Appendix – A 1 Set $Max. BC pressure 3.0
Kg/cm2
4. Brake Cylinder (LH) with Hand Appendix – B 2
Brake Arrangement
6. Brake Caliper Assly. (RH) Appendix – C 4 2.48 for Power Car and
Brake caliper ratio is
2.17 for & SLR
7. Passenger Emergency Alarm Valve Appendix – F 1
D
8. Passenger Emergency Alarm Pilot Appendix – F *As reqd.
Valve with micro switch & indication D
Device
10. Wheel Slide Protection Unit (WSP) Appendix – G 1 Set
F
11. Brake Indicators Appendix – H 6
G
12. Cut off angle cock 1-1/4” Appendix – D 84
of spec
02-ABR-02
14. Hose coupling assembly for BP Appendix – F 42 Hose length 455 660+6
of spec mm & Hose assembly
02-ABR-02 585 790+6 mm
15. Hose Coupling Assembly for FP Appendix – F 42 Hose length 455 660+6
of spec mm & Hose assembly
02-ABR-02 585 790+6 mm
16. Hose Connection (10 ID/30 OD) for RDSO Drg. 4 600 650mm long#
Bogie CG-19036
(Alt.-latest)
17. Hose Coupling (10 ID/30 OD) for RDSO Drg. 8 500 mm long#
brake cylinders CG-19037
(Alt.-latest)
18. Isolating cock 1” 1 #
19. Guard’s emergency Brake Valves 1 #
20. Pressure Gauges for Brake Pipe Appendix – H 1
of spec
02-ABR-02
21. Pressure Gauges for Feed Pipe Appendix – H 1
of spec
02-ABR-02
Signature
22. Pressure Gauges for Brake Cylinder Appendix – H 1

of spec
02-ABR-02
23. Flex ball Cable – Long G=4024mm - 1 #
24. Flex ball Cable – Short G=2333mm - 1 #
25. Flex ball Cable – Coach G=2197mm - 2 #
26. Roller operated Cam valve - 1 #
9.3 Scope of supply of Axle mounted Disc brake system for LHB type Double Decker Coaches shall cover
the following equipments. It is the prerogative of purchaser to procure the system as complete set or in
part:
1. BP Panel Assembly Appendix – A 1 Set $Max BC pressure 3.8
Kg/cm2
2. FP Panel Assembly Appendix – A 1 Set
3. Auxiliary reservoir – 125ltr Appendix – A 1
with drain cock (for brake
system)
4. Auxiliary reservoir – 75ltr with Appendix – A 1
drain cock (for CDTS)
5. Control reservoir – 6 ltr. Appendix - A 1
6. Strap for 125 ltr reservoir Appendix - A 1
7. Strap for 75 ltr reservoir Appendix - A 1
11. Brake Caliper Assly. (RH) Appendix – C 4 2.48
12. Passenger Emergency Alarm Appendix – F D 1
Valve
13. Passenger Emergency Alarm Appendix – F D *As reqd.
Pilot Valve with micro switch &
indication Device
15. Wheel Slide Protection Unit Appendix – G F 1 Set
(WSP)
16. Brake Indicators Appendix – H G 4
17. Cut off angle cock 1-1/4” Appendix – D of 84
spec 02-ABR-02
19. Hose coupling assembly for Appendix – F of 42 Hose length 455 660+6
BP spec 02-ABR-02 mm & Hose assembly
585 790+6 mm
20. Hose Coupling Assembly for Appendix – F of 42 Hose length 455 660+6
FP spec 02-ABR-02 mm & Hose assembly
585 790+6 mm
Signature
21. Hose Connection (10 RDSO Drg. 4 600 650mm long#

ID/30OD) for Bogie CG-19036
(Alt.-latest)
22. Hose Coupling (10 ID/30 OD) RDSO Drg. 8 500 mm long#
for brake cylinders CG-19037
(Alt.-latest)
23. Isolating cock 1” 1 #
10 PERFORMANCE REQUIREMENTS
10.1 The brake system shall be twin pipe graduated release type and its performance shall conform to the
latest revision of UIC Specification 540 and 547.
10.2 The brake equipment shall give a trouble free service for a period of minimum six years from the date
of commission or date of placement in service, whichever is later, with maintenance as per OEMs
recommendation.
10.3 The brake system must allow safe running of the train down the longest and steepest gradient as
indicated in Annexure-I and it shall be possible to control the speed at operating speed levels permitted
on this gradient.
10.4 The brake system shall have ability to stop the train in emergency (quick acting) and full service
application without affecting stability of the train during braking.
10.5 The brake system shall have stopping ability from a speed after continuous braking for prolonged time
during downhill travel.
10.6 The brake system shall give satisfactory performance under wet conditions also.
11 DESIGN REQUIREMENTS
11.1 The Axle Mounted Disc Brake offered by the firm shall be compatible with the existing brake system
being used for LHB/FIAT design coaches.
11.2 The disc brake equipments shall be designed and constructed in such a way that in normal conditions
of use and vibrations, to which it may be subjected to, should not cause its premature failure or in any
way affect the functional efficiency.
11.3 Design of the disc brake equipments shall be such that the performance of the system is not adversely
affected under extreme positions of wheel and suspension movements under maximum wear
conditions.
11.4 The disc brake system shall be of proven design, which has worked successfully in India or
International Railway Passenger trains in similar operating conditions. Copies of UIC approval
wherever applicable shall be submitted by the firm along with the offer.
11.5 Equipments should be designed in such a way that it has minimum wear and tear and maintenance
possibility.
11.6 Each Power Car/SLR/Guard Van/Parcel Van type shall be provided with F=lex Ball type parking brakes
system having accommodation in Guard’s compartment. Parking brakes should brake atleast one
bogie (minimum two axle). Parking Brake system shall be latest Proven Design and shall be capable of
holding train on steepest and longest down gradient of 1% as indicated in Annexure–I, when applied
Signature
from two Power Car/SLR/Guard Van/Parcel Van type coaches. Firm shall submit detailed calculation in
this regard.
11.7 All pins in the proposed brake system shall be with bushes, which will have long life.
12 SUBMISSION OF TECHNICAL DOCUMENTS
12.1 Firm shall submit the following technical documents/details for axle mounted disc brake equipment at
the time of registration to RDSO:
12.1.1 Schematic diagram for the pneumatic systems.
12.1.2 Descriptive literature explaining the systems.
12.1.3 Descriptive literature explaining the individual equipment used in the system.
12.1.4 Layout dispositions of all the components/equipments on bogie, underframe and body.
12.1.5 QAP for manufacture and supply of Axle Mounted Disc Brake System. The ‘Quality Assurance Plan’
shall be prepared in accordance with the guidelines given in brochure relevant ISO document of RDSO
No. CG-G-7.1-2.
12.1.6 Operation and maintenance manual and covering instructions, maintenance schedule & list of spares
required for all individual items.
12.1.7 The complete set of drawings in A1/A2 size for each item of disc brake equipment which shall contain
details regarding material specification, dimensions, estimated weight, testing parameters, reference to
manufacturing/original collaborator’s drawing etc.
12.1.8 Electrical wiring diagram.
12.1.9 Electrical power requirement i.e. voltage, current (AC/DC) for WSP.
12.1.10 Thermal loading details and calculations with the use of disc brakes.
12.1.11 Instantaneous/ average co-efficient of friction for disc pads for a speed up to 200kmph under different
brake pad pressures (should be as per relevant UIC).
13 APPROVAL OF DRAWING
13.1 The design/drawing of the disc brake equipment shall be developed based on the technical and
performance requirements given in this specification and sound engineering practice. The entire
drawing shall be submitted by the firm with technical data and calculations to RDSO for approval.
13.2 The drawing shall be developed in SI units.
13.3 Material grade/specifications for each component shall be indicated on the relevant drawings of the firm
and the firm shall supply copies of translation in English of such specifications/drawings other than
Indian standard specifications to purchaser/RDSO.
13.4 Approval of the design means the approval of the general design features. Notwithstanding the
approval, the contractor will be wholly responsible for the performance of the disc brake equipment as
well as individual components offered.
13.5 Further changes/modifications in the disc brake equipment may be called for with a view to achieve
standardization and interchangeability. Firm shall be obliged to incorporate necessary changes in the
design of his equipment for this purpose.
14 MANUFACTURE
14.1 Brake Equipments shall be strictly manufactured as per drawing and specification submitted by the
manufacturer.
Signature
14.2 Equipments to be supplied shall be free from injurious defects that may impair their strength.
Contractor shall also ensure that all items are adequately treated and painted (excluding flange faces)
to prevent corrosion.
14.3 All parts of brake system shall be given suitable anti-corrosive treatment and painted with two coats of
paints with colours as specified by IR before supply (if required). The surface of light alloy castings
shall be anodized.
15 INSPECTION
15.1 The complete brake equipment to be supplied by the firm shall be inspected and accepted by the
inspecting authority nominated by the purchaser in the supplier’s plant. The cost shall be borne by
contractor.
15.2 During Prototype development the firm shall offers at least one sets of complete Axle Mounted Disc
Brake Equipments to carry out the following test/check:
15.2.1 Checking of dimensions & tolerances, interchange ability of components and general workmanship.
15.2.2 Performance testing of disc brake equipments.
15.3 Contractor shall be responsible for the proper functioning of the disc brake equipment, as per
procedure laid down to be mutually agreed to between the contractor and Purchaser.
15.4 Inspection authority shall have access to all detailed manufacturing/original collaborator’s drawings for
all items of equipment. Contractor shall be obliged to table these drawings as and when called for.
15.5 The inspection authority may deviate from the agreed procedure if and when found necessary to
reassure that the material is being furnished in accordance with these specifications. In this regard the
contractor shall not be entitled to object on any ground whatsoever on the nature and procedure of
testing that may be followed by the inspecting authority.
15.6 During the fabrication, subsequent inspection visit, the brake supplier shall allow IR inspection authority
for inspection officer.
16 FIELD TRIAL
16.1 The disc brake equipments shall be subjected to field trials on minimum 18 coaches (Preferably 1 rake)
for a period of minimum 18 12 months.
16.2 In case of any modifications carried out by the registered suppliers of AMDBS, the design will be
validated in RDSO test lab, thereafter subjected to field trial as given below:
16.2.1 Items viz. Brake container module, Brake Cylinder, Brake Caliper assembly & Wheel Slide Protection -
06 months.
16.2.2 Items other than the Para 16.2.1 above - 03 months.
16.3 Any modifications found necessary as a result of these tests/trial or further service trials shall be carried
out by the manufacturer at their own cost in the coaches in a manner approved by the
purchaser/RDSO. All key and manufacturing drawings incorporating the modifications shall be
submitted to RDSO for final approval.
16.4 After the satisfactory performance of the field trials, the firm may be considered for approval. The
existing suppliers who have been successfully supplying Axle mounted Disc Brake system for LHB
coaches to Indian Railways will be exempted from the field trial.
17 MARKING
Signature
Identification codes (manufacturer’s name / trade mark), month/week & year of manufacture and serial
number is to be applied to main equipment and subcomponents in a minute, clearly recognizable way;
(Plate, label, or stamped, laser marking) to avoid mixing and for settling down warranty claim.
18 PACKING
18.1 Supplier shall ensure that all outer parts and exposed threaded portions of the various items of axle
mounted disc brake system are suitably covered with protection caps to prevent ingress of foreign
matter / damage to threads during handling and storage.
18.2 Supplier shall also ensure that all items of disc brake equipment in an assembled condition are
adequately packed before dispatch to prevent damage in transporting, handling and storage. The safe
transportation shall be the responsibility of manufacturer.
Signature
APPENDIX -A
Specification for Brake Container Module for axle mounted disc brake system AMDBS for LHB type
coaches on Indian Railways
1 SCOPE
This specification covers the technical requirements related to the performance, inspection and testing
of Brake Container Module for axle mounted disc brake system of LHB type coaches and does not
include other necessary provisions of the contract.
2 EQUIPMENT DESIGN
2.1 The brake container module for AC - Non AC (EOG), AC (SG) and Power Car shall be mounted on the
underframe of the vehicle near sidewall using a cradle frame made of stainless steel to AISI 304.
Dimensions shown in Drawing No. 110113.0.09.110.001 At-D shall be referred to for envelope size of
the equipment including brake control panel. Broad dimension & location of sub-equipment of brake
panel shall be as per RDSO drawing no.CG-18088 (Alt.-latest).
2.2 The brake container module for AC-Non AC (EOG), AC (SG) and Power Car shall consist of the
following components:
S.No. Description Qty. /Set Remarks
I. Brake Frame 1
II. Brake Control Panel 1
III. Distributor Valve 1 As per RDSO
spec. C-K209
IV. Control Reservoir 6 ltr. 1
V. Control Reservoir 5 ltr.(Min.) 1 For Hand Brake
only
VI. Air Filter for BP & FP 2
VII. Isolating Cock without vent 2
VIII. Isolating Cock with vent 2
IX. Check valve 2
X. Check valve 1 For Power Car
only
XI. Test Point – BP, FP, BC & CR 4
XII. Pressure switch mounting assembly (in FP line) 1 (1.3 Kg/cm2 falling
XIII. Pressure switch 1 pressure and 1.8
Kg/cm2 rising
pressure)
XIV. Auxiliary reservoir – 125ltr. with drain cock (for brake 1
system)
XV. Auxiliary reservoir – 75ltr. with drain cock (for CDTS) 1
2.3 For Double Decker coaches, the brake control panel shall be designed suiting to the space availability.
Preferably the reservoirs are to be accommodated in the diamond area whose approach shall be from
inside of the coach. Brake Panel shall be made of split type to accommodate outside the diamond area
leaving and adequate safe margin from bogie as 200mm and 235mm ground clearance. The mounting
frame of control panels and reservoirs shall be stainless steel to AISI 304. RCF Drg. No. DD11235 and
Body shell Drg. No. DD10250 shall be referred for envelope size of the Panels and reservoirs.
Mounting accessories such as belts etc. for reservoirs and control panels shall be in the scope of the
equipment supplier.
2.4 The brake control equipment on underframe for Double Decker Coaches shall consist of the following
Signature
components:
S.No. Description Qty. /Set Remarks
I. BP Panel assembly 1
II. FP Panel assembly 1
III. Distributor Valve 1 As per RDSO
spec. C-K209
IV. Control Reservoir 6 ltr. 1
V. Air Filter for BP & FP 2
VI. Isolating Cock without vent 2
VII. Isolating Cock with vent 2
VIII. Check valve 2
IX. Test Point – BP, FP, BC & CR 4
X. Pressure switch mounting assembly (in FP line) 1
XI. Pressure switch (1.3 Kg/cm2 falling pressure and 1
1.8 Kg/cm2 rising pressure)
XII. Auxiliary reservoir – 125 ltr. with drain cock (for 1
brake system)
XIII. Auxiliary reservoir – 75 ltr. with drain cock (for 1
CDTS)
XIV. Strap for 125 ltr reservoir 1
XV. Strap for 75 ltr. reservoir 1
2.5 The brake control panel shall be made of Aluminum Alloy/Stainless steel to AISI 304 with fittings on
specified location.
2.6 All the accessories to be mounted on brake control panel shall be of panel mounted type so that they
can be easily mounted and removed from the panel.
2.7 The brake container module shall be protected against track stone hitting, dust, rain and salt-water
influences.
2.8 Sizes of pipes as shown in Alstom Drawing Nos. 1 10113.0.09.100.002 Alt-D, 1 10113.0.09.100.003
Alt-B, 1 10113.0.09.100.004 Alt-C and 1 10113.0.09.100.005 Alt-C for various connections shall be
used. These drawing are only for the purpose of guidance with regard to size of pipes.
2.9 The distributor valve (DV) shall be mounted on the panel through intermediate piece in such a way that
it will be possible to replace one type of distributor with another without any difficulty. RCF Drawing No.
MI001696 alt-nil shall be referred for port hole location on front face of brake control panel and
distributor valve. DV isolating cock shall form part of the DV or intermediate piece or could be directly
mounted on the panel.
2.10 The various pipe connections should as far as possible be located on top of the brake panel.
2.11 The weight of brake panel with and without components shall be indicated.
2.12 The layout of the various apparatus etc. on the brake panel shall be finalized in consultation with the
RDSO.
2.13 Test points shall be provided on the brake control panel to measure pressures of brake cylinder,
auxiliary reservoir, control reservoir and brake pipe.
2.14 The material of all reservoirs/pressure tanks shall be of stainless steel to AISI 304.
2.15 The cradle shall be made of stainless steel to AISI 304 with wire-mesh of stainless steel at the bottom.
All the critical Isolating cocks at front location in the control panel shall be covered with Stainless Steel
Signature
mesh with sliding door arrangements to prevent their operation by unauthorized persons.
2.16 The control panels shall be designed and constructed in such a way that in normal conditions of use
and vibrations, to which it may be subjected to, should not cause its premature failure or in any way
affect the functional efficiency.
2.17 The manufacturer shall either fixed a name plate or engrave below every fitting on control panel which
should last as long as the control panel.
3 MECHANICAL INTERFACES
3.1 All piping of underframe to Brake Control Panel & Air suspension control panel shall be of Single ferrule
type.
3.2 The supplier specifies the single weights (which can be summarized appropriately) of all components of
the brake control panel to be mounted to the car body in order to guarantee the mechanical strength of
the connecting points.
3.3 The supplier shall guarantees all internal interfaces of the brake equipment.
3.4 If the components included in the scope of delivery of the brake supplier are to be connected with the
brake pipes of the car body and/or the bogie, they are to be suitable for Single ferrule type connections.
4 MANUFACTURE
4.1 Brake container module shall be manufactured as per drawing and specification submitted by the
manufacturer.
4.2 Equipment to be supplied shall be free from injurious defects that may impair their strength. The firm
shall also ensure that all items are adequately treated and painted (excluding flange faces) to prevent
corrosion.
4.3 All parts of Brake Container Module shall be given suitable anti-corrosive treatment if required, painted
with two coats of paints with colours as specified by IR before supply. The surface of light alloy castings
shall be anodised.
5 PURCHASE INSPECTION
5.1 The purchase inspection shall be carried out at the firm’s premises who are cleared for the regular
manufacture and registered with the RDSO for manufacture and supply of Brake container module.
5.2 The inspecting authority shall make audit checks of the manufacturing procedure/“Internal Quality
Assurance System” to ensure that the brake container module offered for inspection is manufactured
strictly as per “Internal Quality Assurance System” and the manufacturer has carried out all the
tests/inspection during manufacturing stage to ensure that brake container module offered are strictly
to the specification and drawings. During such audit checks the Inspection Authority shall also see from
the records of ‘Internal Quality Assurance’ that the Raw material used for the manufacture of brake
container module is as per specification laid down.
5.3 Inspection Authority will ensure that each Distributor valve has been tested by the manufacturer as per
clause 7.2 of the RDSO specification C-K209 before fitment on the brake control panel. Manufacturer
shall have to maintain the internal tests record and submit against the Inspection Authority at the time
of inspection.
5.4 Inspection Authority will ensure that each Brake container module has been tested by the manufacturer
as per clause 6.0 of this specification. Manufacturer shall have to maintain the internal tests record and
submit against the Inspection Authority.
5.5 The Inspection Authority shall conduct the following checks/tests of the Brake container from a lot of 50
Signature
coach set or part thereof.

5.5.1 2% or minimum two numbers Brake container module picked up at random shall be checked for
dimensions and tolerances, interchangeability of components, general workmanship and surface finish
as per RDSO approved drawings.
5.5.2 10% or minimum two numbers Brake container module picked up at random shall be subjected to
performance tests as given at clause 6.0
5.6 In case the samples picked up fails in any of the tests/checks indicated at clause 5.5.1 & 5.5.2, the
entire lot of the brake container module shall be rejected by the Inspecting Authority.
5.7 Inspecting authority shall have access to all detailed manufacturing / original collaborator's drawings for
all items of equipment. The firm shall be obliged to provide these drawings as and when called for.
5.8 The inspecting authority may deviate from the agreed procedure if and when found necessary to re-
assure that the material is being furnished in accordance with these specifications. In this regard the
manufacturer shall not be entitled to object on any ground whatsoever on the nature and procedure of
5.9 During the fabrication, subsequent inspection visit, the brake supplier shall allow IR Inspection
Authority for Inspection.
6 PERFORMANCE TESTS
6.1 The Brake container shall be mounted on the test bench and tested for the following features. All the
test shall be conducted with twin pipe system except the test mentioned at clause 6.1.2 which shall be
carried out with single pipe system.
S.No Check Specified Values As Observed
6.1.1 Leakage Test for Brake Control Panel Assembly
Leakage from mounting of sub-assemblies and No leakage
components at air pressure of 10 Kg/cm2
6.1.2 Charging Time
a) Time for auxiliary reservoir (AR) pressure to rise from 0 -
to 4.8 kg/cm².
b) Time for Control reservoir (CR) pressure to rise from 0 to -
4.8 kg/cm².
6.1.3 Leakage from mounting of sub- assemblies during
I) Release No leakage
II) Service Application No leakage
Iii) Emergency No leakage
6.1.4 Full Service Application & Release
i) BC Filling time from 0 to #2.8 kg/cm² under service 3 - 5 Sec
application with eight brake cylinders of 255 mm dia.
ii) BC Release time from *3.0+0.1 to 0.4 kg/cm² after 15 - 20 Sec
service application with eight brake cylinders of 255 mm
dia.
iii) Maximum Brake Cylinder pressure *3.0 + 0.1 kg/cm²
6.1.5 Emergency Application & Release
i) BC Filling time from 0 to #2.8 kg/cm² under emergency 3 - 5 Sec
application with eight brake cylinders of 255 mm dia.
ii) BC Release time from *3.0+0.1 to 0.4 kg/cm² after 15 - 20 Sec
emergency application with eight brake cylinders of 255
mm dia.
Signature
iii) Maximum Brake Cylinder pressure *3.0 + 0.1 kg/cm²

6.1.6 Graduated Application & Release Test
i) Brake Cylinder pressure attained when Brake pipe -
pressure is reduced in steps (at least seven steps).
ii) Brake Cylinder pressure attained when Brake pipe -
pressure is increase in steps (at least seven steps).
iii) Brake pipe pressure when cylinder pressure is 0.4 4.85 kg/cm²
kg/cm². (Approx.)
6.1.7 Sensitivity Test
Response of brakes when Brake pipe (BP) pressure is Brake should apply
reduced at a rate of 0.6 kg/cm² in six seconds when BP is within 6 Sec
isolated from main reservoir.
6.1.8 Insensitivity Test
Response of brakes when Brake pipe (BP) pressure is Brake should not
reduced at a rate of 0.3 kg/cm² in 60 seconds when BP is apply
isolated from main reservoir.
6.1.9 Refeeding Test
Response of valve when Brake cylinder pressure is slowly Refeeding should
exhausted by 2mm choke be available
6.1.10 Over Charge Protection Test Control Reservoir
Overcharge Brake Pipe (BP) to 6 kg/cm² after full service pressure Should not
application rise within 10 sec.
6.1.11 Bogie Isolation Test for Brake control panel
Increase the BC pressure to *3.0+0.1 kg/cm² in 3-5 sec.
i) Turn the first bogie Isolation Cock to close position. BC1
OK
Pressure Gauge should show zero pressure.
ii)Turn the second bogie Isolation Cock to close position. OK
BC2 Pressure Gauge should show zero pressure.
iii)Turn the first bogie Isolation Cock to open position. BC1 OK
Pressure Gauge should show *3.0+0.1 kg/cm² pressure.
iv)Turn the second bogie Isolation Cock to open position. OK
BC2 Pressure Gauge should show *3.0+0.1 kg/cm²
pressure.
6.1.13 Toilet Cock Isolation Test
Open cock for toilet on panel. Check the pressure gauge It should show
for pressure 6Kg/cm2
6.1.14 Quick Release Valve Test @ CR & BC pressure
Automatic exhausting of Brake Cylinder and Control should
reservoir test of quick release valve automatically
exhaust to zero
6.1.14 Hand Brake Cock Isolation & Reservoir Leakage Test
(In Power Car only)
Check leakage from the connection on reservoir No leakage
(*): For Double Decker Coach max BC pressure shall be 3.8 kg/cm²
(#): For Double Decker Coach BC filling time shall be recorded from 0 to 3.6 kg/cm²
(@): In case of any ambiguity regarding parameters above, provisions mentioned in relevant UIC shall
be used for guidance.
Signature
Note:- Specified values of test Indicated at clause 6.1.2(a), 6.1.2(b) & 6.1.6 (i) & (ii) shall be furnished by the
manufacturer and approved by RDSO
6.2 Testing of Auxiliary Reservoir of 125ltrs and 75ltrs shall be carried out as per Clause 7.0 of Appendix-C
of 02-ABR-02.
6.3 The purchaser/Inspection Authority may specify any other test to satisfy himself for the performance of
the requirements and manufacturer shall assist for conduct of these tests.
Signature
APPENDIX- B
Specification for Brake Cylinder for Axle Mounted Disc Brake System AMDBS of for LHB type coaches
on Indian railways
1. SCOPE
This specification covers the technical requirements related to performance, Inspection and testing of
Brake Cylinder to be used for Axle Mounted Disc Brake system of LHB type coaches and does not
2. EQUIPMENT DESIGN
2.1 The brake cylinder with automatic wear adjustment serves in the operation of the brake clasp of the
disc brake.
2.2 The brake cylinder shall be built with a compact, simple method and small dimensions. It is suitable for
installation in brake caliper for axle mounted brake discs.
2.3 The main characteristic of the cylinder is the built-in power controlled wear adjustment mechanism. It
acts as a single-acting play regulator and performs unaffected by the spring-action elongation of the
brake caliper, which is dependent on brake power. During the braking process, the regulator quickly
and automatically corrects the play in the brake shoe, which has been enlarged due to wear, in the
entire area of adjustment.
2.4 Play in the brake cylinder remains constant. The piston stroke remains largely constant. Manual
regulation of the brake cylinder/brake caliper is not required.
2.5 The brake cylinder shall be provided with a spindle release device, which allows, simple replacement of
the used brake linings.
2.6 Basic parameters of the brake cylinder shall be as under:
Piston Strokes 21 mm (max.)
Slack capacity 120 mm (min.)
Cylinder size 10”
Max. BC pressure 3.9Kg/cm2
2.7 Air connection to brake cylinder shall be through 15 mm diameter pipe.
2.8 All parts of brake cylinder shall be design for fatigue strength (with the exception of parts subject to
wear).
2.9 A minimum true specific weight for the brake cylinder is of great importance.
2.10 The weight of brake cylinder must be evident on the drawing.
2.11 A drop in pressure in the service brakes shall not exceed 0.1 Kg/cm2 within 10 minutes.
2.12 All moveable parts (such as spindles) are to be provided with an appropriate protective covering. If
bellows are used, they must be heat and flame resistant.
2.13 The functioning of the brake cylinders must be guaranteed against wear, corrosion and leakage. The
permissible limits for wear, corrosion and leakage are to be specified by the supplier.
2.14 The brake cylinder is to be protected from water infiltration due to splashing of water in rainy seasons
or water wash of the coach at station/sick line.
2.15 For brake lining replacement, an easy-operated release device is to be provided for the wear
adjustment mechanism.
Signature
2.16 The return device must be easily accessible.

2.17 The type of release must be evident on the drawing.
2.18 It must not be possible for the release device to release unintentionally, such as from vibrations or
blows.
2.19 Even when used in a counter-clockwise manner (wrong direction of turn), no damage should be caused
to the return device.
3. DIMENSIONS AND TOLERANCES
3.1 For all coaches, brake cylinder shall come within the space as shown in FIAT-SIG Drawing No.
1268820 and for one bogie of power car and second class luggage cum guard coach FIAT-SIG
drawing no. 1272116 will be applicable.
3.2 Fixing arrangement of calipers with brake cylinder piston and brake cylinder body shall be as per RCF
Drg. No. MI000524. Tenderer may please take note of the fixing hole size etc. as shown in this
drawing.
3.3 The dimensions and tolerances of Brake cylinder shall be as indicated in the RDSO/OEMs approved
drawings.
3.4 Discrepancies in dimensions if noticed shall be brought to the notice of RDSO at the developmental
stage and sorted out.
4. MANUFACTURE
4.1 Brake Cylinder shall be manufactured as per drawing and specification submitted by the manufacturer.
4.2 Brake cylinder to be supplied shall be free from injurious defects that may impair their strength. The
firm shall also ensure that all items are adequately treated and painted to prevent corrosion.
4.3 All parts of Brake Cylinder shall be painted with two coats of paints in grey or black colours or as
specified by IR before supply. The surface of light alloy castings shall be anodized.
5. PURCHASE INSPECTION
5.1 The purchase inspection shall be carried out at the premises of manufacturers who are cleared for the
regular manufacture of Brake cylinder. The following procedure shall be followed for the purchase
inspection: -
5.1.1 The Inspecting authority shall make audit checks of the manufacturing procedure/`’Internal Quality
Assurance System’` to ensure that the brake cylinder offered for inspection is manufactured strictly as
per ‘‘Internal Quality Assurance System’’ and the manufacturer has carried out all the tests/inspection
during manufacturing stage to ensure that brake cylinder offered are strictly to the specification. During
such audit checks the Inspecting Authority shall also see from the records of `Internal Quality
Assurance` that the Raw Material used for the manufacture of brake cylinder is as per specification laid
down.
5.1.2 The Inspecting Authority shall conduct the following checks from a lot of not more than 50 Nos.
5.1.2.1 Two percent brake cylinder picked up at random shall be checked for dimensions with respect to
assembly drawing.
5.1.2.2 Two percent or minimum one brake cylinder shall be dismantled and dimensions and general
workmanship of each component checked as per RDSO approved drawings.
5.1.2.3 Ten percent brake cylinder picked up at random shall be subjected to tests as given at clause 6.1 of
this specification.
Signature
5.1.2.4 Two piston packing per every contract shall be tested for conformity with UIC code 831-R. In case
piston packing is imported from OEM, test certificate should be produced.
5.1.3 In case the samples picked up fail in any of the tests/checks indicated in clause 5.1.2.1 to 5.1.2.3 the
reasons for such failure shall be identified. The Inspecting Authority shall verify the reasons by
conducting audit check on ‘Internal Quality Assurance System’. If it is found that such failures are due
to non-implementation of ‘Internal Quality Assurance System’ the entire lot of brake cylinders shall be
rejected. In case the failures are on account of reasons other than non-implementation of ‘Internal
Quality Assurance System’ the manufacturers may re-offer the lot after rectifying the defects. However,
in such cases, double the quantity of the samples shall be picked up and tests/checks conducted as
clause 5.1.2.1 to 5.1.2.4. In case the samples again fail in any of the tests/checks the entire lot shall be
rejected.
6. TESTS
6.1 Leakage & Function Test for Brake Cylinder complete
a) The brake cylinder shall be mounted on the fixture to limit the piston stroke to 21mm. Apply 0.7
kg/cm2 air pressure and observe the leakage is not exceeded 0.1 kg/cm2 in 10 minutes.
b) Adjust the piston stroke to 21mm and apply 3.8 kg/cm2 air pressure and observe the leakage is not
exceeded 0.1 kg/cm2 in 10 minutes.
Signature
APPENDIX- C
Specification for Brake Caliper Assembly for Axle Mounted Disc Brake System AMDBS of for LHB type
coaches on Indian railways
1. SCOPE
Brake Caliper Assembly for Axle Mounted Disc Brake system of LHB type coaches and does not
2. EQUIPMENT DESIGN
2.1 The Brake Caliper serves in the transmission of power from the brake cylinder to the brake disc for
certain braking processes and powers.
2.2 The Brake Caliper is built with a compact, simple method and to be designed so as to provide simple
assembly and disassembly, in particular of the brake linings as well as bolts and sockets.
2.3 The Brake Caliper is connected with spring action to the bogie structure over the caliper yoke support
and drag link support.
2.4 A minimum true specific weight for the Brake Caliper is of great importance.
2.5 All parts shall be designed for fatigue strength.
2.6 All hinged supports and exposed parts are to be provided with lubricant or appropriate corrosion
protection.
2.7 Stainless steel pins with non-metallic self-lubricating property bushes, which have long life are to be
used in brake calipers for better operation & maintainability shall be used in caliper.
2.8 For reasons of weight, brake levers for calipers without locking brakes have been built in a lighter
version, possible due to the absence of interfering force. An exchange of the two brake calipers must
be prevented with a simple construction measure.
2.9 The forces and loads are evident on the braking calculation.
2.10 The kinematic movements of the brake lining with respect to the brake disc must be examined by the
manufacturer for all operational instances. Floatation of the brake caliper must be guaranteed for all
operational conditions.
2.11 Brake Calipers shall give effective brake radius of 247 mm with lever ratio of 2.17 per disc for all types of
coaches except for Generator/Power Car/SLR/Guard Van/Parcel Van type and Double Decker coaches
for which caliper ratio is to be 2.48.
2.12 Brake Calipers shall be suitable for operation with brake cylinders as specified in Appendix-B.
2.13 The brake Pad holder is designed for the installation of the brake Pad according to UIC 541-3.
2.14 The brake Pad holder is provided with a simple, safe device for Pad arrest and Pad replacement.
2.15 The size of the brake Pad holder is evident on the braking calculation.
2.16 If special Pads are used, confusions with normal Pads are to be excluded by using simple constructive
measures.
3. DIMENSIONS AND TOLERANCES
3.1 Manufacturer shall ensure that Brake caliper assembly offered by them shall be suitable for mounting in
space as shown in RCF Drawing No. 1268820, 1272112 and 1272116 (Power car) and shall be able to
be mounted on mounting brackets and hole sizes shown in these drawings including Bogie frame
Signature
drawing No. 1267401 201 version-04.

3.2 Brake caliper assembly shall be suitable for fitting UIC type 200x2 cm2 brake pads of thickness 35 mm.
3.3 MANUFACTURE
4.1 Brake caliper assembly shall be manufactured as per drawing and specification submitted by the by the
OEMs/Collaborator.
4.2 Brake caliper assembly to be supplied shall be free from injurious defects that may impair their
strength. The firm shall also ensure that all items are adequately treated and painted (excluding flange
faces) to prevent corrosion.
4.3 All parts of Brake Caliper assembly shall be painted in grey or black colors with two coats of paints or
as specified by IR before supply.
4.4 All hinged supports and exposed parts are to be provided with lubricant or appropriate corrosion
prevention.
5.1 The purchase inspection shall be carried out at the premises of the manufactures who are cleared for
the regular manufacture of Brake Caliper assembly and registered with RDSO. The following procedure
shall be followed: -
5.2 The Inspecting Authority shall make audit checks of the manufacturing procedure ‘Internal Quality
Assurance System’ to ensure to that the Brake Caliper assembly offered for inspection is manufactured
strictly as per ‘Internal Quality Assurance System’ and the manufacturer has carried out all the tests
inspection during manufacturing stage to ensure that the Brake Caliper assembly as well as their
components are manufactured strictly to the specification/drawing and quality standard of the
collaborator. During audit checks the inspection Authority shall see from the records of ‘Internal Quality
Assurance’ that the Raw material used for the manufacture of Brake Caliper assembly is as per
specification laid down.
5.3 Inspection Authority will ensure that each Brake Caliper Assembly has been tested by the manufacturer
as per clause 6.0 of this specification. Manufacturer shall have to maintain the internal tests record and
submit against the Inspection Authority.
5.4 The Inspection Authority shall conduct the following checks/tests of the Brake Caliper from a lot of 100
Nos. or part thereof.
5.4.1 2% or minimum two numbers Brake Caliper Assembly picked up at random shall be checked for
dimensions and tolerances, interchangeability of components, general workmanship and surface finish
as per RDSO approved drawings.
5.4.2 10% or minimum five numbers Brake Caliper Assembly picked up at random shall be subjected to tests
as given at clause 6.0
5.5 In case the samples picked up fails in any of the tests/checks indicated at clause 5.4.1 & 5.4.2, the
entire lot of the Brake Caliper assembly shall be rejected by the Inspecting Authority.
5.6 Inspecting authority shall have access to all detailed manufacturing / original collaborator's drawings for
all items of equipment. The firm shall be obliged to show these drawings as and when called for.
5.7 The inspecting authority may deviate from the agreed procedure if and when found necessary to re-
assure that the material is being furnished in accordance with these specifications. In this regard the
manufacturer shall not be entitled to object on any ground whatsoever on the nature and procedure of
Signature
5.8 During the fabrication, subsequent inspection visit, the brake supplier shall allow IR Inspection
Authority for Inspection.
5. TESTS
6.1 Torque Test
6.1.1 Check the tightening torque of nut on hanging link, pad holder, Bridge Piece, Brake lever and Hex head
screw with the torque wrench. The tightening torque should not be less than the value as specified in
drawing/specification approved by RDSO.
Signature
APPENDIX- D
Specification for Passenger Emergency Alarm system for AMDBS for LHB type coaches on Indian
railways.
1. SCOPE
Passenger Emergency alarm system for LHB type coaches and does not include other necessary
provisions of the contract.
2. EQUIPMENT DESIGN
2.1 Design of the passenger emergency alarm system for LHB type coaches shall conform to UIC 541-1 &
UIC 543.
2.2 Passenger Emergency Brake Valve is to be directly connected to the Brake Pipe.
2.3 Passenger Emergency Brake valve is to be operated through the emergency brake pull box.
2.4 Each passenger emergency pull box shall be provided with pilot valve and micro switch & indication
LED.
2.5 The design of the passenger alarm system shall be such that as the handle of passenger emergency
brake pull box is moved the air pressure in brake pipe will be exhausted via large orifice (at least 19mm
diameter cross section) of passenger emergency Brake valve.
2.6 Emergency Brake valve must be designed in such a way that, when the alarm signal is triggered, the
pressure in the train pipe falls rapidly to 2 Kg/cm2 (+0/-0.5 Kg/cm2) and remains at that level thereafter.
2.7 The alarm signal resetting device must be placed inside the vehicle and easy to operate from there. It
must be designed in such a way that passengers are not able to activate it.
2.8 Passenger emergency alarm system shall be reset by a guard’s key. The guard’s key for passenger
emergency alarm resetting shall be 8mm square.
2.9 There should be provision of an Isolating cock on branch pipe connecting to Brake Pipe to the
Passenger Emergency Valve.
the regular manufacture of Passenger Emergency Brake Valve and Passenger Emergency Alarm Pull
Box and registered with RDSO. The following procedure shall be followed: -
3.1.1 The Inspecting Authority shall make audit checks of the manufacturing procedure ‘Internal Quality
Assurance System’ to ensure to that the Passenger Emergency Brake Valve and Passenger
Emergency Alarm Pull Box offered for inspection is manufactured strictly as per ‘Internal Quality
Assurance System’ and the manufacturer has carried out all the tests inspection during manufacturing
stage to ensure that the Passenger Emergency Brake Valve and Passenger Emergency Alarm Pull
Box are manufactured strictly to the specification /drawing and quality standard of the collaborator.
3.2 After having satisfied about the quality standards, 10% of each lot of 100 Passenger Emergency Brake
Valve and Passenger Emergency Alarm Pull Box shall be tested as per procedure given in clause 4.
4. TESTS
4.1 PASSENGER EMERGENCY BRAKE VALVE
4.1.1 The valve is tested on the test bench by connecting the portion provided for brake pipe side and the
outlet portion should be connected to PEAPB or a pipe line with isolating cock with suitable choke
Signature
provided. Charge the valve to a pressure of 10kg/cm2. There should not be any leakage if checked with
soap water.
4.1.2 Now exhaust the outlet portion through PEAPB or Isolating cock, the air should start escaping through
the large orifice (at least 19mm diameter) provided on the valve. The pressure should not fall below
2Kg/cm2 (+0/-0.5 Kg/cm2) and remains at that level thereafter.
4.2 PASSENGER EMERGENCY ALARM PULL BOX (PEAPB)
4.2.1 The Passenger Emergency Alarm Pull Box is tested on the test bench. Apply air at a pressure of 10
kg/cm2 through the portion provided for the connection to PEAPB and check for the leakage with soap
water.
4.2.2 Now pull the alarm handle of this valve. The air should start escaping through the exhaust provided in
the pilot valve.
4.2.3 Check for resetting of alarm signal device by alarm valve reset key.
Signature
APPENDIX- E
Specification for Emergency Brake Accelerator Valve for AMDBS for LHB type coaches on Indian
railways.
1. SCOPE
Emergency Brake Accelerator Valve for LHB type coaches and does not include other necessary
2. EQUIPMENT DESIGN
2.1 The emergency brake accelerator valve is mounted into the brake pipe.
2.2 The emergency brake accelerator valve sense the fast pressure reduction of brake pipe in emergency
brake application and vents the brake pipe via large orifice. This causes an equal brake pressure
reduction speed over the whole train in the brake pipe.
2.3 The emergency brake accelerator will stop to vent the brake pipe between pressure of 2.5 and
1.5Kg/cm2.
3. DIMENSIONS AND TOLERANCE
3.1 Fixing The mounting arrangement of emergency brake accelerator valve in LHB coach underframe
shall be as per RDSO Drg. No. CG-11062 Alstom Drawing No.1 10113.0.09.100.004. Tenderer may
please take note of the fixing holes size etc. as shown in this drawing. Dimensions of the equipment
should within space envelope shown in above drawing.
the regular manufacture of Emergency Brake Accelerator Valve and registered with RDSO. The
following procedure shall be followed: -
Assurance System’ to ensure to that the Brake Accelerator Valve offered for inspection is
manufactured strictly as per ‘Internal Quality Assurance System’ and the manufacturer has carried out
all the tests inspection during manufacturing stage to ensure that the Emergency Brake Accelerator
Valve as well as their components are manufactured strictly to the specification /drawing and quality
standard of the collaborator.
4.1.2 After having satisfied about the quality standards, 10% of each lot of 100 Brake Accelerator Valve shall
be tested as per procedure given in Clause 5.
5. TESTS
5.1 Leakage Testing
5.1.1 The emergency brake accelerator valve is tested on the test bench. Charge the valve to a pressure of
10 kg/cm2. There should not be any leakage in vent hole if checked with soap water.
5.2 Functional Testing
5.2.1 Insensitivity Test
5.2.1.1 BP pressure by to be reduced at the rate from 5.0 to 3.2 Kg/cm2 in 6sec, the air should not start
escaping through the exhaust provided on the valve.
5.2.2 Sensitivity Test
5.2.2.1 BP pressure to be reduced at the rate from 5.0 to 3.2 Kg/cm 2 in 3sec, the air should start escaping
through the exhaust provided on the valve.
Signature
APPENDIX- F
Specifications of the for Wheel Slide Protection Unit AMDBS for LHB Ttype Coaches on Indian
Railways.
1. SCOPE
This specification covers the technical requirements related to Wheel slide protection Unit (WSP) used
on Axle Mounted Disc Brake system for LHB type coaches and does not include other necessary
2. PARTICULAR REQUIREMENT
2.1 The WSP Unit is to be approved by UIC and is to meet the corresponding requirements especially UIC
541-05.
2.2 The WSP Unit shall retain full functionality, regardless of the braking force requested, up to a speed
20% greater than the maximum running speed of the vehicle for which it is designed.
2.3 The WSP Unit shall function reliably from maximum speed to a minimum speed of approx. 5 Km/h.
2.4 The WSP Unit shall function reliably independent of the moving direction.
2.5 The WSP Unit shall have provision for automatically switch on and switch off for electrical supply to
WSP Unit on receiving an electrical signal from pressure switch mounted in FP line in Brake Control
Panel when the coaches are not in use.
2.6 The WSP Unit shall have Additional output lines for attachment of speedometer, vacuum toilet system
and door sub-systems.
2.7 The WSP shall so vary the braking force as to make maximum use of available adhesion and improve
it by providing controlled wheel slide.
2.8 The WSP Unit is to guarantee a sufficient and safe operation. Moreover, a failure of the WSP Unit
should not have any influence on the braking function of this vehicle or of the whole train set.
3. EQUIPMENT DESIGN
3.1 The WSP unit shall consist of the following components:
3.1.1 Microprocessor-based control unit (1 pc) consisting of the following
I. Power Supply
II. Control Unit
III. Micro processor
IV. Input/Output
3.1.2 Connector (1 Pc.)
3.1.3 Speed sensors (with cable of 2000mm length) with integrated amplifier (4 Pc) and mounting bracket
3.1.4 Connector Plug (4 Pc 1set)
3.1.5 Anti-Skid Valve (4 Pc)
3.1.6 Junction boxes with mil-grade connectors & plugs for speed sensors and Dump valves (4 pcs)
3.1.7 Junction boxes for Dump valve (2 pcs)
3.1.8 Housing (4 pcs)
3.1.9 Phonic Wheels (4 pcs) with M8 bolts to IS:1364 Pt.III clause 10.9 and washers to IS:3063 type-B.
3.1.10 Cable for complete wiring of anti-skid system 150Mtr.
Signature
3.1.11 Pressure switch (1 pc) 1.3/1.8 Kg/cm2 in FP line (if necessary to switch on/off the WSP depending on
the pressure).
3.2 The WSP Unit should have sturdy design, long maintenance intervals and easy to repair.
3.3 The WSP Unit has to work axle-selective, that means it has to be a four-axle/four channel
configuration.
3.4 It is to be ensured, that manual correction for wheel diameter is not required by WSP.
3.5 The standard execution unit shall apart from the wheel slide protection be equipped with the following
additional speed depending signal and functions for: Controlled Discharge Toilet at 30kmph. The speed
output signal of WSP to CDTS should be remain closed contact for speed less than 30kmph.
3.6 The microprocessor wheel slide protection shall have additional module for kilometre performance. So
that total kilometre earned by the coach (WSP unit) can be recorded and it can be correlated with the
Error Code.
3.7 The microprocessor unit housing shall have a standard 19” rack for the minimal execution. Supplier
shall indicate maximum temperature and humidity for safe working of his equipment. The unit is
proposed to be mounted in non-air conditioned area of the coaches.
3.8 WSP software should have suitable user friendly interface and should store at least the following data
w.r.t. time and date for minimum period of three months. WSP software for downloading WSP fault
data shall be provided free of cost by the firm to the user Railway. Fault data can be downloaded to any
Windows laptop/computer using RS232/USB/Ethernet cables. If RS232 connector is used, suitable
cable to connect RS232 to USB should be supplied by the firm;
a) Error code
b) Dump valve activation date & time; Axle number and reference speed/speed of all four axles.
3.9 Supply voltage to microprocessor rack shall be 110V DC nominal.
3.10 The supply of the microprocessor shall switch-off automatically after a certain period of time when the
vehicle is not in use.
3.11 Wheel slide protection system shall employ pole wheel of 80 teeth fitted on to Security disc to FIAT-SIG
Drg. No. 1902094 ver-4 on the one end of each axle as shown in FIAT-SIG drawing No. 1268823 ver-
02. For the purpose of standardization and enabling physical interfacing with the bearings, it is
desirable that the pole wheel should be as per Parizzi Drawing No. V12014.
3.12 Axle box mounted speed sensor (one for each axle) shall be employed as a transmitter and shall fulfill
the requirements of this specification. In order to achieve physical interfacing of speed sensor with front
cover of axle box and pole wheel, the sensor shall be fitted in the front cover as per FIAT-SIG Drawing
no. 1902713 ver-06 and 1902714 ver-07. The tenderer shall ensure it that proper gap between pole
wheel and speed sensor is maintained for proper functioning of the wheel slide protection system.
3.13 The speed sensor should have the following characteristics:
 Protection against mechanical damage.
 Resistance to corrosion.
 Durable and maintenance free.
 Protection against HF interference.
 Temperature range from -5 deg. C to + 60 deg. C.
 Protection on all input and output against reverse polarity, and short circuit connection.
 Constant output signal, when stationary for functional diagnosis.
Signature
 Permissible insulation test voltage of 1500 VAC and 50 Hz for one minute.
 Blank flange with cover.
3.14 The WSP wiring layout & Junction Boxes shall be as per RDSO drawing no. CG-18246 & CG-19005
with latest alterations.
4. ENVIRONMENTAL AND AMBIENT CONDITIONS
4.1 Environmental and Ambient Conditions for the WSP Unit
4.1.1 Climatic Conditions
4.1.1.1 All materials selected must withstand these external influences during their lifetime without any
restrictions on their function and safety.
4.1.2 Protection against Corrosion
4.1.2.1 Due to the climatic conditions defined above, protection against corrosion as well as an anticorrosive
design and material selection are of special importance for the parts and components of the WSP Unit
and must be realized accordingly. All WSP components to be arranged in the vehicle’s underframe are
to be painted completely. The following coats of paint have been provided (colours may change).
 Anticorrosive primer beige-red RAL 3012, epoxy metal primer with hardener approved by DBI,
layer thickness 60 µm.
 Intermediate coat: sand yellow RAL 1002, PUR priming paint with normal hardener, layer
thickness 60 µm.
 Top coat quartz grey RAL 7039, PUR varnish paint with normal hardener, layer thickness 60
µm.
4.1.2.2 Before painting, the inspection addresses with the company labels are to be covered. Bolts, slide
surfaces, threaded spindles, valves, etc. are not to be painted. If necessary, the inner walls of the
WSP Unit components are to be molatened with corrosion protection oil.
4.1.3 Energy Supply for Electrical/Electronic Components of the WSP Equipment
4.1.3.1 For the energy supply of electrical and electronic components of the WSP Unit a 110 V direct current
voltage is available in the vehicles.
4.1.4 Mechanical Strength Requirements
4.1.4.1 All components of the WSP Unit are to be designed according to the mechanical strength requirements
stipulated in UIC 566. If required corresponding proofs are to be submitted.
4.1.5 Service Life
4.1.5.1 The coaches manufactured by Indian Railways are designated for a service life of 35 years. The WSP
Unit is to be developed and designed accordingly. The supplier should specify the recommended
maintenance schedules/practices clearly to achieve the desired life.
4.1.6 Reliability
4.1.6.1 The reliability of the WSP Unit or the parts and components included in the supplier’s scope of delivery
is to guarantee a mileage of 200,000 km without any failures. The conditions for proving a trouble free
mileage are to be coordinated with LHB. The design of all parts has to guarantee that under normal
operating conditions a mileage of 1,000,000 km will be reached without any replacements. The supplier
should specify the recommended maintenance schedules/practices clearly to achieve the desired life.
4.1.7 Design Suitable for Easy Maintenance
Signature
The design of the WSP Unit is to allow an easy maintenance.

4.1.8 Environmental and Ambient Conditions caused by the WSP Unit
4.1.8.1 Environmental Acceptability
When selecting the materials, the general aspects of environmental acceptability, the degradability of
the materials used without residues, if possible, or the later recycling are to be taken into consideration.
4.1.8.2 Electromagnetic Compatibility
The legal rules concerning the protection requirements for the EMC of electrical parts and components
within the scope of supply of the WSP Unit supplier are to be considered and corresponding proofs are
to be submitted.
5. DESIGN DOCUMENTS
5.1 The following documentations for the development and design of the WSP Unit are to be prepared by
the supplier:
 A set of drawings consisting of drawings and parts lists, including block diagrams, pneumatic flow
charts and wiring schemes, list of operating subassemblies etc. (for documentation of electrical
and pneumatic components).
 A description of the WSP Unit incl. the description of diagnostics
 An operation and maintenance manual
 A list of spare parts.
Signature
APPENDIX- G
Specification for Brake Indicators for Axle Mounted Disc Brake System AMDBS of for LHB type
coaches on Indian railways.
1. SCOPE
Brake Indicators for Axle Mounted Disc Brake system for LHB type coaches and does not include other
necessary provisions of the contract.
2. EQUIPMENT DESIGN
2.1 The design of the brake indicators shall be of UIC Pattern.
the regular manufacture of Brake Indicators and registered with RDSO. The following procedure shall
be followed: -
Assurance System’ to ensure to that the Brake Indicators offered for inspection is manufactured strictly
as per ‘Internal Quality Assurance System’ and the manufacturer has carried out all the tests inspection
during manufacturing stage to ensure that the Brake Indicators as well as their components are
manufactured strictly to the specification /drawing and quality standard of the collaborator.
3.1.2 After having satisfied about the quality standards, 10% of each lot of 100 Brake Indicators shall be
tested as per procedure given in clause 4.
4. TESTS
4.1 Leakage Test
4.1.1 Apply a pressure of 10 Kg/cm2. There should not be any leakage if checked with soap water.
4.2 Functional Test
4.2.1 Apply a pressure of 0.5 to 0.6 Kg/cm2. Red colours should appears in Window of indicator.
4.2.2 Now release the pressure to 0 kg/cm2. Green colours should appears in Window of indicator.
Signature
ANNEXURE-I
1. OVERALL DIMENSIONS OF COACH
1.1 Gauge 1676 mm

1.2 Length over coach body 23540 mm
1.3 Length over buffer 24000 mm
1.4 Width over body 3250 mm
1.5 Buffer centres 1956 mm
1.6 Maximum distance between wheel 12340 mm
1.7 a. Maximum operating speed [AC(EOG) & 160 kmph
Generator Car]
b. Maximum operating speed [AC (SG)& 120 kmph
Non-AC]
1.8 a. Maximum test speed [AC(EOG) & 180 kmph
Generator Car]
b. Maximum test speed [AC (SG)& Non-AC] 140 kmph
1.9 Wheel diameter New 915 mm
Worn 845 mm
1.10 Wheel base 2560 mm
1.11 Minimum clearance above rail level 102 91 mm under
loaded and worn
condition
1.12 Maxuimum bogie rotation & swing 3.50, 82 mm
2. RAKE COMPOSITION:
2.1 For speed 160 kmph (EOG type)
2.1.1 Generator car cum luggage & brake van 2

(Power Car)
2.1.2 AC first class 2
2.1.3 AC chair car 14
2.2 For Speed 120 kmph (SG type)
2.2.1 AC-three tier (SG) 3

2.2.2 AC -2 tier (SG) 2
2.2.3 AC Ist (SG) 1
2.2.4 SLR 2
2.2.5 SCN 10
2.2.6 GS 4
3. TENTATIVE TARE AND GROSS WEIGHT OF COACHES (Tonnes)

3.1 For Speed 160 kmph (EOG type)
COACH TYPE TARE GROSS

3.1.1 Generator car cum luggage & brake van 53.2 56.6
3.1.2 AC first class (EOG) 41.0 48.3
3.1.3 AC chair car(EOG) 40.9 48.9
Signature
3.1.4 AC Ist Sleeper 43.0 47.8

3.1.5 AC-3T (EOG) 46.5 54.5
3.1.6 AC-2T (EOG) 43.0 50.4
3.1.7 AC Hot Buffet Car 40.9 48.9
3.2 For Speed 120 kmph (SG type)
COACH TYPE TARE GROSS

3.2.1 AC Three tier (SG) 50.50 58.50
3.2.2 AC Two tier(SG) 48.00 55.04
3.2.3 AC-Ist (SG) 45.90 50.70
3.2.4 SLR 35.40 44.50
3.2.5 SCN 36.28 42.91
3.2.6 GS 35.29 50.49
4. LOCO PARTICULARS
4.1 Length of Loco 19974 mm
4.2 Gross mass 113 t
4.3 Horse power 3600
(Multiple consists of two locos may be used for 18 coach train haulage).
5. ENVIRONMENTAL CONDTIONS
5.1 Maximum temperature under sun 70 deg. C
5.2 Maximum temperature under shade 45 deg. C
5.3 Minimum temperature 5 -10 deg. C
5.4 Altitude Sea level to 652 1776 meter
5.5 Humidity 100% saturation during rainy Season
5.6 Rain falls Fairly heavy
5.7 Atmosphere during hot weather Extremely dusty and desert terrain in certain areas
Environment: Coaches shall be working in coastal area with salt laden and corrosive atmosphere.
6. TRACK PARAMETERS
6.1 Maximum gradient and their length 1% and 250 m 1 in 37

6.2 Sharpest curvature 175 145.83 m radius
6.3 Max. super elevation 1765 185 mm max.
7. INTERFACES OF THE BRAKE SYSTEM
7.1 Mechanical interfaces
7.1.1 The supplier specifies the interfaces of all brake components with the car-body or with the bogie thus
allowing the design of the corresponding mounting parts.
7.1.2 The supplier of the brake system specifies the single connecting points of the parts and components at
the car-body or at the bogie as well as their position. Moreover, the supplier has to specify
corresponding requirements or restrictions.
7.1.3 The supplier specifies the single weights (which can be summarized appropriately) of all components of
the brake system to be mounted to the vehicles in order to guarantee the mechanical strength of the
connecting points.
Signature
7.1.4 The supplier guarantees all internal interfaces of the brake system (car-body equipment/bogie
equipment/wheel slide protection equipment).
7.1.5 If the components included in the scope of delivery of the brake supplier are to be connected with the
brake pipes of the car-body and/or the bogie, they are to be suitable for ferrule connections. Ferrule
connections type B are used (Ferrule are made of stainless steel, screwed connections are made of
galvanized steel, the car-body pipes are made of stainless steel).
7.2 Electrical interfaces
7.2.1 In order to guarantee an easy exchangeability, the single electrical/electronic parts of the brake control
system are to be connected by means of plug in connectors, if possible. The plug in connections and
the mating connectors for connecting the electrical/electronic components are to be delivered by the
supplier of the brake system.
7.2.2 The supplier of the brake system defines the connection of the brake control system to the vehicle’s
energy supply system. The power consumption and the requirements on the energies to be supplies
are to be specified (e.g. voltage tolerances, ripple etc.).
7.3 Pneumatic interfaces
7.3.1 The hose coupling heads of the pneumatic system have to correspond to those of the existing vehicles.
7.3.2 The supplier defines the requirements of the pneumatic brake system on the components generating
the compressed air under the aspect of a steady readiness for braking or the corresponding safety.
7.4 Interfaces with the wheel slide protection unit
7.4.1 The interfaces with the wheel slide protection are technically to be coordinated according to the
integration of the wheel-slide protection into the brake system of the brake supplier. As far as known,
these interfaces are situated at the pressure switches 1.3/1.8 Kg/cm 2 in FP line (functional and electric
interface) and at the valves of the wheel slide protection (functional and pneumatic interface).
7.5 List of Applicable Drawings
S.No. Drawing No. Description
1. LW02100 (RCF) Axles for FIAT Bogies
2. LW03002 (RCF) Bogie Frame Assembly with air spring
3. DD11235 (RCF) Underframe complete for Double Decker
4. DD10250 (RCF) Body Shell assembly for Double Decker Coach
5. MI000524 (RCF) Axle Mounted Brake Cylinder
6. MI001696 (RCF) DV port hole location on brake control panel
7. LD36001 Layout of air brake on underframe for Double Decker
8. 1 10113.0.09.100.002 (Alstom) Compressed air brake mounting NPP end
9. 1 10113.0.09.100.003 (Alstom) Compressed air brake mounting PP middle
10. 1 10113.0.09.100.004 (Alstom) Compressed air brake mounting NPP middle
11. 1 10113.0.09.100.005 (Alstom) Compressed air brake mounting PP end
12. 1272112 (FIAT-SIG) Brake equipments
13. 1902094 (FIAT-SIG) Securing Disc
14. 1902713 (FIAT-SIG) Axle end cover
15. 1902714 (FIAT-SIG) Axle end cover
16. V12014 (PARIZZI) Frequency Generator (Toothed wheel)
17. CG-11061 (RDSO) Mounting arrangement of Brake Accelerator valve
Signature

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CG-F-4.2.1-4 (Rev.1) Page 1 of 36 Latest (Rev./Amed.) issue: June’22 Spec. No. RDSO/2011/CG-04 (Rev.

Document Technical Specification Yes

PART – I GENERAL CONDITION

APPENDIX – A SPECIFICATION FOR BRAKE CONTAINER MODULE

PART-I: GENERAL CONDITIONS

PART-II: TECHNICAL REQUIREMENT

22. Pressure Gauges for Brake Cylinder Appendix – H 1

21. Hose Connection (10 RDSO Drg. 4 600 650mm long#

coach set or part thereof.

iii) Maximum Brake Cylinder pressure *3.0 + 0.1 kg/cm²

2.16 The return device must be easily accessible.

drawing No. 1267401 201 version-04.

The design of the WSP Unit is to allow an easy maintenance.

1.1 Gauge 1676 mm

2.1 For speed 160 kmph (EOG type)

2.1.1 Generator car cum luggage & brake van 2

2.2 For Speed 120 kmph (SG type)

2.2.1 AC-three tier (SG) 3

3. TENTATIVE TARE AND GROSS WEIGHT OF COACHES (Tonnes)

COACH TYPE TARE GROSS

3.1.4 AC Ist Sleeper 43.0 47.8

3.2 For Speed 120 kmph (SG type)

COACH TYPE TARE GROSS

6.1 Maximum gradient and their length 1% and 250 m 1 in 37

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