C-K407Rev2 Amnds 01

Ref: CGW 0001 Date / Month of issue: Specification No.
(Rev. –3) Page 1 of 38

December, 2008 C-K407 (Rev. -02)
RDSO/Lucknow.
AMENDMENT SLIP
S.No. Description of Clause No. Page No. Reason for

Amendment Amendment
1 Modified para.5 as 5 7 Qualifying criteria
“Procedure for vendor elaborated
registration”
Add para. 6.2.10. New para. 9 To improve service
2 quality of
equipment.
RDSO’s Specification no. 6.5.6, 6.6.4,
STR ABR-94 had
3 “02-ABR-94” modified 6.7.2, 6.8.2 9 & 10
been revised.
as” 02-ABR-02”. &6.9.2
In clause 10.1.2 para no. To facilitate
4 10.1.2 13
“5” added. inspection.
5 Add new clause no. 14 Requirement
New clause 14
” Tolerance” updated.
Annexure – “A” added. New 15 Inspection checklist
6 provided
Add least count of
To facilitate
7 pressure gauge in test Annexure - 1 26
inspection.
set up for leveling valve.
Add material of
As recommended
8 installation lever in ----------- 32
by ICF.
SKETCH – K1050
Modify diameter of plug. Drawing no. As recommended
9 38
CG- K4025 by RCF.
RDSO/Lucknow.
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
III Referred Specification & Drawings
III.A Drawings (Enclosed)
1. SKETCH-K1049 Alt.1:Space Envelope for Leveling Valve

2. SKETCH-K1050 Alt.1:Instalation Assembly with Ball And Socket Ends
3. SKETCH-K1051:Space Envelope for Duplex Check Valve
4. SKETCH-K1052: Air Reservoir 150 Litres Capacity
5. SKETCH-K1053 Alt.1:Air Reservoir 20 Litres Capacity
6. SKETCH-K1054: Hose Connection for Air Spring Suspension Bogies.
7. CG-K4025 Alt.1: Add. Air Reservoir of 40 Litres capacity
8. CG-K4026Alt.1: Auxiliary Air Reservoir of 150 Litres capacity.
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
RDSO/Lucknow.
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.
****************************************
RDSO/Lucknow.
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.
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.
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.
RDSO/Lucknow.
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:
3.3 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.
3.4 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
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
RDSO/Lucknow.
5. PROCEDURE FOR VENDOR REGISTRATION:
5.1 Manufacturers willing to supply air spring assembly 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.
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. The pneumatic
suspension control equipments design shall be treated as
developmental during the period of service trials.
RDSO/Lucknow.
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, a sample of the control

equipments shall be subjected to the tests laid down at para 6. In case
these values are beyond permissible limits, the air spring design shall
be deemed to have failed the service trials.
e) Manufacturers shall be provided part-II status on successful completion

of service trials as defined above. A Vendor shall be considered eligible
for upgradation to Part-I status on completing successful supply of a
minimum of 100 coach sets of pneumatic suspension control
equipments and also after a minimum period of 18 months after issue of
first Inspection Certificate as a Part-II vendor.
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:
6.2.2 Leveling valve shall regulate the supply of air to the air springs so as to
maintain pre-defined height at all variable loads.
6.2.3 Outer dimension of leveling valve and its pipe connection ports shall as per
space envelope shown in RDSO SKETCH-K1049 Alt. 1.
6.2.4 Leveling valve shall have such a setting that under dynamic load variations of
the coach running, insignificant consumption of air takes place.
6.2.5 Effective length of its lever shall be 160mm.
6.2.6 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.
RDSO/Lucknow.
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:
6.3.2 Design of installation lever shall be as per RDSO SKETCH-K1050 Alt 2.
6.3.3 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.
6.3.4 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.
6.3.5 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.
6.3.6 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):
6.4.2 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 is
greater or equal to 1.5 ± 0.12 Kg/cm².
6.4.3 Duplex check valve design shall suit the space envelope and pipe connections
shown in RDSO SKETCH- K1051.
6.4.4 The test procedure for Duplex Check Valve shall be strictly as per Annexure-II
6.4.5 The test setup for Duplex Check valve is as per fig.2 enclosed in Annexure-II.
6.5 MAIN PRESSURE TANK (AUXILIARY RESERVOIR ) WITH DRAIN VALVE:
6.5.2 Main pressure tank should be of 150 dm³ (150 litres) capacity.
6.5.3 Design of pressure tank shall be as per RDSO Drawing No. CG-K4026 Alt.1.
for mainline coaches and vide drawing no. RDSO SKETCH – K1052 for
EMU/DMU coaches.
6.5.4 Drain cock assembly shall be as per RDSO SKETCH- 98003.
6.5.6 Except design and drawing the inspection, tests and painting shall be as per
Appendix-C (clause 6.0, 7.0 & 8.0) to RDSO specification No. 02-ABR-02.
RDSO/Lucknow.
(Rev. –3) Page 10 of 38
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 of 40 dm3
(20 litres OR 40 litres) capacity.
6.6.2 Design of 20 dm3 reservoir will be as per RDSO SKETCH-K1053 Alt.1 with
drain valve (for EMU/DMU bogies).
6.6.3 Design of 40 dm3 reservoir will be as per RDSO Drawing CG-K4025 Alt.1 with
drain valve (for main line ICF bogies).
6.6.4 Except design/drg. the inspection, testing and painting shall be as per
appendix-C (clause 6.0, 7.0 & 8.0) of RDSO specification No. 02-ABR-02.
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
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
6.10 HOSE CONNECTIONS:
6.10.1 The hose connection shall be as per RDSO SKETCH-K1054.
6.10.2 Material inspection and testing of hose connection as per Note given in 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.
2) Dimensional drawings of the equipments.
RDSO/Lucknow.
(Rev. –3) Page 11 of 38
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.
RDSO/Lucknow.
(Rev. –3) Page 12 of 38
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 manufacturer/ supplier.
10.1.2 Purchase inspection shall be done at the premises of manufacturer/supplier by

the representative of the Research Design and Standard Organisation or an
agency authorised by RDSO and supplier shall have to arrange for the
following and associate with the same:
RDSO/Lucknow.
(Rev. –3) Page 13 of 38
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.
10.2.2 10% of lot shall be picked up randomly for dimension & other specified
inspection as given above 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 RDSO Drawingg
tank (150 dm3) sources of CG-K4026 Alt.1.
RDSO Inspection as per technical requirement
clause 6.5 of this STR
2 Air Reservoir -Do- Dimensional checks as per RDSO
(20dm3 OR SKETCH- K1053 Alt. 1. OR RDSO
40dm3) Drawing CG-K4025 Alt. 1 .
Inspection as per technical requirement
3 Check valve -Do- Dimensional check as per RDSO
SKETCH- 98112
4 Two way dirt -Do- Dimensional check as per RDSO
collector SKETCH- 97005
5 Isolating cock -Do- Dimensional check as per RDSO
SKETCH- 97002
RDSO/Lucknow.
(Rev. –3) Page 14 of 38
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 Main pressure tank (Auxiliary reservoir 150 litres.) air reservoir (20 litres OR 40
litres) Check valve (non return valve), two way dirt collector & isolating cock
shall be painted as given in technical requirement using red enamel paint.
11.3 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
RDSO/Lucknow.
(Rev. –3) Page 15 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 16 of 38
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.
RDSO/Lucknow.
(Rev. –3) Page 17 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 18 of 38
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.
RDSO/Lucknow.
(Rev. –3) Page 19 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 20 of 38
6.0 INSPECTION FORMAT OF AIR RESERVOIR (20 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.
RDSO/Lucknow.
(Rev. –3) Page 21 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 22 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 23 of 38
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 greater or equal to 1.5 ± 0.12 Kg/cm².
RDSO/Lucknow.
(Rev. –3) Page 24 of 38
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.
RDSO/Lucknow.
(Rev. –3) Page 25 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 26 of 38
RDSO/Lucknow.
(Rev. –3) Page 27 of 38
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

/Discharging (seconds)
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
RDSO/Lucknow.
(Rev. –3) Page 28 of 38
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.
RDSO/Lucknow.
(Rev. –3) Page 29 of 38
RDSO/Lucknow.
(Rev. –3) Page 30 of 38
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
RDSO/Lucknow.
(Rev. –3) Page 31 of 38
RDSO/Lucknow.
(Rev. –3) Page 32 of 38
RDSO/Lucknow.
(Rev. –3) Page 33 of 38
RDSO/Lucknow.
(Rev. –3) Page 34 of 38
RDSO/Lucknow.
(Rev. –3) Page 35 of 38
RDSO/Lucknow.
(Rev. –3) Page 36 of 38
RDSO/Lucknow.
(Rev. –3) Page 37 of 38
RDSO/Lucknow.
(Rev. –3) Page 38 of 38
RDSO/Lucknow.

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Ref: CGW 0001 Date / Month of issue: Specification No.

(Rev. –3) Page 1 of 38

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

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)

0.1 This Schedule of Technical Requirements (STR) is issued under fixed

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

SCHEDULE OF TECHNICAL REQUIRMENTS OF

2.1 For Main Line/ Rajdhani & LHB Coaches :

2.2 For EMU / DMU & MEMU coaches

2.3 For All Type Of Stock:

SN Item Description Quantity per

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

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.

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

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

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

e) Manufacturers shall be provided part-II status on successful completion

6.1 GENERAL REQUIREMENT:

6.2 LEVELLING VALVE:

6.2.5 Effective length of its lever shall be 160mm.

6.3 INSTALLATION LEVER:

6.3.2 Design of installation lever shall be as per RDSO SKETCH-K1050 Alt 2.

6.4 DUPLEX CHECK VALVE (RELIEF VALVE):

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

6.5.4 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)

1) Test report on the proposed equipments based on the tests conducted

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

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

8) Expected life cycle in operating and environmental conditions enumerated

9) Authorisation certificate / License etc. from the original manufacturer

10) A write-up giving broadly the maintenance requirements on time/distance

12) Details of manufacturing and testing facilities available with the

7.4 RDSO reserves complete right of granting approval or otherwise to a firm.

8.1 Equipments supplied by the firms shall be guaranteed for satisfactory

8.2 In the event of 'non-satisfactory performance' of any of the items as indicated

9. INSTALLATION, COMMISSIONING & MAINTENANCE:

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.

9.3.8 Comprehensive details containing legible sectional views of defects normally

9.3.11 Do's and Don'ts for maintenance officials.