ProductSpec 8019731RAWFORK14IN2005

RAW FORK 14IN 2005 8019731
IN STORE: CREATION: 20/07/2020 LAST UPDATE: 28/02/2022

Product : 8019731 - RAW FORK 14IN 2005 Specification ref : 004 - 8019731 - PER_345 STRUCTURE (DP
Bangladesh - RFL (BANGLADESH))
Perimeter : PER_345 - STRUCTURE Supplier : DP Bangladesh / RFL (BANGLADESH)
Product Engineer : Ludovic RIDON

Product Manager :
Sourcing Contact : Sifullah KHAN
Project Code Grid Value Model Code MPC Descr.

8421696 . 8421696
Description :
Part Of Product Percentage Composition Comment

Main part 100.0 43.4% Steel
39.62% Steel
16.98% Steel
PRODUCED BY: PRINTED THE:

This document is the property of DECATHLON Production All rights reserved DECATHLON, 4 boulevard de Mons, 59650 VILLENEUVE D'ASCQ, FRANCE Alexandre FRANÇOIS 28/02/2022 PAGE 1/3
RAW FORK 14IN 2005 8019731

DOCUMENTS INCLUDED IN THE SPECIFICATION
Component Nature Component Name
Document Types Document Name Content Files Names
Product Document _Frame & Fork - A04 appendix - TIG welding 2006 a04_tig_welding_2006.pdf
Product Document BRAKE PIVOT C51AAW00 c51aaw00.pdf

Assembly report: Romania Fisa de Testare 4 furci Bangladesh 14 Arctic.xlsx
Product Document _Frame & Fork - A04 appendix - MIG welding a04_mig_welding.pdf
Lab test report: Pilot run RELV1368221_01_signed.pdf
Product Document _Frame & Fork - A08 appendix - Fork geometric tolerances a08_fork_geometric_tolerances_2006.pdf
2006
Test Report: Trial run RELV1169421_signed.pdf
A2 APPENDIX : RAW FORK 14IN 2005 F-C-A2_14IN 2005 raw Fork__DPBangladesh_RLF_V1_-
_20220120.pdf
Product Document _Frame & Fork - A07 appendix - Fork exhaust holes a07_fork_exhaust_holes.pdf
Product Document 0999-CAD-2940 FORK_HEAD_STEM_14 0999-CAD-2940 FORK_HEAD_STEM_14.2D.AB.dwg

Making technical files 0999-CAD-2940 FORK_HEAD_STEM_14.2D.AB.pdf
0999-CAD-2940 FORK_HEAD_STEM_14.3D.AB.stp
f04aaw01 f04aaw01.stp
0332-CAD-1464_14IN_2005_RAW_FORK.2D.AB.pdf
f04aaw01_d.dwg
FREE PAINTING 14 FORK.pdf
f04aaw01_d.pdf

RAW FORK 14IN 2005 8019731

ITEMS BAR CODES
8421696 - null (R3 Code: 8421696)

DECATHLON Production
Cellule Cycle
TECHNICAL SPECIFICATION APPENDIX
A.4. MIG Welding specification :
Propriété DECATHLON Production A.4. - 1 / 5 Property of DECATHLON Production

Reproduction interdite a04_mig_welding.doc All rights reserved
le : 12.Jun.2006 DECATHLON Production, 4 Bd de Mons, BP 299, 59665 Villeneuve d'Ascq, France
¾ Holes, porosity :
No holes or porosity in welds are acceptable.
The cavity at the end of the welding line, due to the welding process, is acceptable if it's not
excessive and if it's possible to paint it.
Accepted Not Accepted
¾ Cracks :
No internal or external crack in welds are acceptable.
¾ Undercuts :
The undercut depth : k < 5% of the welded tube thickness.

¾ Lack of penetration, fusion :
No lack of penetration or fusion of welding is acceptable.

p > 50% of the welded thinner tube thickness
The angle between weld border and tube have to be open, β > 100°
GOOD NO GOOD
¾ Excess of penetration :
No excess of penetration of welding are acceptable. e = 0
¾ Weld width :
The weld width have to be smooth and

the weld dimensions have to correspond with welded tubes dimensions
L1 / L2 < 1.4
The weld width have to be :

For the opened angle, L = 8 Maximum
For the closed angle, L = 4 Minimum

¾ Weld non symmetry :
b1 / b2 < 1.4
¾ Dimension du cordon / Weld dimension :
a > 1.6 x welded tube thickness
¾ Welds surfaces have to be even and smooth ( no cutting edges ).
¾ No welding wire on or close to the welding line is acceptable
¾ No spatters on the tubes is acceptable
¾ No traces of weld arc initiation is acceptable

Each page of the technical sheet appendix have to be signed.
This page have to shown the name and the function, the signature and the trademark of each part,
the supplier and DECATHLON
DECATHLON FOURNISSEUR
SUPPLIER
Name : Name :
Function : Function :
Signature : Signature :
Date : Date :
Cachet de l'Entreprise Cachet de l'Entreprise

Maker's Trademark : Maker's Trademark :

Cellule Cycle
A.4. TIG Welding specification

Reproduction interdite a04_tig_welding_2006.doc All rights reserved
¾ Holes, porosity :
No holes or porosity in welds are acceptable.
¾ Cracks :
No internal or external crack in welds are acceptable.
¾ Caniveaux, morsures / Undercuts :
The undercut depth : k < 5% of the welded tube thickness.
¾ Lack of penetration, fusion :
No lack of penetration or fusion of welding is acceptable.

P > 50% of the welded tube thickness and > 120°
GOOD NO GOOD

¾ Excess of penetration :
No excess of penetration of welding are acceptable. e = 0
¾ Weld width :
The weld width has to be smooth and the weld dimensions have to correspond with welded tubes
dimensions
L1 / L2 < 1.4
The welds width have to be :

For Steel : opened angle, L = 8 Maximum
closed angle, L = 4 Minimum
For Alluminium : opened angle, L = 12 Maximum

closed angle, L = 8 Minimum
¾ Weld non symmetry :
b1 / b2 < 1.4

¾ Weld dimension :
a > 1.6 x welded tube thickness
¾ Waves number in welding :
For the steel, v = 2 ± 0.5

For Alloy, v = 2.5 ± 0.5
¾ Welds surfaces have to be even and smooth ( no cutting edges ).
¾ No welding wire on or close to the welding line is acceptable
¾ No spatters on the tubes is acceptable
¾ No traces of weld arc initiation is acceptable

Each page of the technical sheet appendix have to be signed.
SUPPLIER
Name : Name :
Date : Date :

Cellule Cycle
A.7. Fork Exhaust Holes Specification :

Reproduction interdite a07_fork_exhaust_holes.doc All rights reserved
This drawing can not be interpreted as a fork design reference.
It show the exhaust holes size only and which are needed on the fork.

Each page of the technical sheet appendix has to be signed.
SUPPLIER
Name : Name :
Date : Date :
Cachet de l'Entreprise Cachet de l'Entreprise


Cellule Cycle
A.8. Fork Geometric Tolerances :

Reproduction interdite a08_fork_geometric_tolerances_2006.doc All rights reserved
1. Appendix Main Objective :
The main objective is to obtain the position of
each parts of a fork in a same plane.
The position tolerances are defined in this
appendix.
For the Cantilever Pivots Medium Plane (B),

the Dropout Medium Plane (C)
the reference is Head Stem Fork Plane (A).
2. Requirement :
2.1 Tolerance application rules :

The tolerances in this geometry appendix are only applicable to the dimensions on the drawings which
have no tolerances.
If a specific tolerance is attached to the dimension on the drawing(s), the tolerance of the drawing
replaces the tolerance specified in this appendix.
3. Fork Classification :
The fork will be classified as follows. The fork classification is defined in the Fork Technical Sheet.
Low Range Medium Range High Range

4. Geometry Control :
4.1 Hub Center Symmetry :
Reference Plane α is middle of Head Stem.

Tolerance Area is centered on the Reference Plane α, width β. Tolerance Area is fixed around the
Reference Plane α. ( β / 2 )
Seat Tube Axis has to be within the Tolerance Area.
Ref. plane α
β
β/2
β = 4 mm β = 3 mm β = 2 mm

4.2 Rim Symmetry between Blades :
δ2
δ1
Measure to be taken at the tire clearance specified on the fork
drawing.
δ1 − δ2 < 4 mm δ1 − δ2 < 3 mm δ1 − δ2 < 1.5 mm
4.3 Rim Symmetry between Cantilever Pivot :
δ1
δ2
δ1 − δ2 < 3 mm δ1 − δ2 < 2 mm

4.4 Fork Stem Hole Symmetry :
Standard Hole :
δ1 − δ2 < 2 mm
Hole for Caliper Brake :

δ1 − δ2 < 2 mm δ1 − δ2 < 1 mm

4.5 Caliper Boss Axis Orientation :
Reference Axis α is Dropout axis.

Tolerance Area is centered on the Reference Plane α, angle β. Tolerance Area is fixed around the
Reference Axis α. ( β / 2 )
Caliper Boss axis has to be within the Tolerance Area.
Ref. plane α
β/2
β
Hole for Caliper Brake :

β=2°

4.6 Brake Pivot Parallelism :
Reference Plane α is external face of the control tool.

Tolerance Area is 2/3 of the control tool thickness, β = 5.3 mm. This point is represented by the red dot
on the diagrams below. If this point is above the plane of the reference plane, the brake pivots are out of
tolerance.
α3
α1 α2 α4
β
Ref. plane α
-3° < α 1 < 3°

-3° < α 2 < 3°
-3° < α 3 < 3°
-3° < α 4 < 3°
α 1 - α 2 < 3°
α 3 - α 4 < 3°

4.7 Brake Pivot Alignement :
δ1 δ2
δ1 - δ2 < 1 mm

DECATHLON SUPPLIER
Name : Name :
Date : Date :

Test Report
Product Testing Laboratory
Can be checked at www.ipac.pt
Nº: RELV1169421 DATE OF EDITION: 2021 / 06 / 17
DECATHLON SE - LABORATOIRE D`ESSAIS MKNIX

Test results are only available for the sample identified in the present test report. This document may only be reproduced in full. IPAC is a signatory to the EA MLA and ILAC MRA for testing and calibration
CUSTOMER: 4 Rue du Professeur LANGEVIN Request n.º N.º OF SAMPLES:

59000 BTWIN VILLAGE (Campus) FRANCE L002-01-2102-0137 1
Sample Nr L002-01-2102-0137-001
DESIGNATION OF Sample description 529452-RAW FORK 14IN 2005
THE SAMPLE:
CNUF - Supplier 45925 - Rangpur Metal Industries Ltd. Item code 529452
Purchase order Trial run W7 2021 Batch number Trial run W7 2021
MAIN EQUIPMENT: Fatigue test equipment.
TYPE OF TEST: REFERENCE DOCUMENTS:

Conformity test to bicycle components. DS-000847 version 5
RESULTS:
Figure 1 - Picture of the sample
Global Result: APPROVED (*)
The detailed results, of the specified standard, are presented in the following pages.
The tests marked with (*) are not included in the scope of accreditation
The samples received are responsibility of the customer, assuming that the declarations of the customer / applicant regarding
the identification of the items to be tested and their identification are true, being these data of their entire responsibility.
DATE OF TEST: 2021 / 06 / 15 - 2021 / 06 / 17

PAGE: 1 /3
EXECUTED BY LABORATORY RESPONSIBLE
Nuno Filipe Abrantes da Cruz Assinado por : PAULO RENATO PIRES DA SILVA
Num. de Identificação: BI09475375
Data: 2021.06.17 21:02:56+01'00'
IMDL13-9
ASSOCIAÇÃO NACIONAL DAS INDÚSTRIAS DE DUAS RODAS, FERRAGENS, MOBILIÁRIO E AFINS

Rua Ramiro Soares de Miranda, 133 | 3750-866 Borralha - Águeda, Portugal | T. (351) 234 612 640 | www.abimota.org | geral@abimota.pt
Test Report

1 - SCOPE
The present document has the purpose to present the results of the tests carried out, in the sample with the applicable standard.
The test was carried out on the sample according to the following standard:
- ISO 8098: 2014; Cycles - Safety requirements for bicycles for young children
The test were carried out at Laboratório de Ensaios da Abimota - Águeda (Portugal).
3 – RESULTS
To verify the conformity of the sample the following points were accessed.
The identification (numeration) used in the following points (items), correspond to the ones used in the standard.
4.10 Front fork
F115_ISO 8098 4.10.2 Front fork – bending fatigue test

DS-000847
version 5 4.10.2.1 Requirement Approved
Test frequency [Hz]: 1,0

Nominal load applied [N]: 400
Number of test cycles (nominal 100 000) [cycles]: 100000
Observations:
Nothing to register.
PAGE: 2 /3
IMDL13-9

Test Report

ANNEXE A
Test request
ANNEXE A
PAGE: 3 /3
IMDL13-9

Test Report
Nº: RELV1368221 -01(**) DATE OF EDITION: 2021 / 12 / 20
DECATHLON SE - LABORATOIRE D`ESSAIS MKNIX

CUSTOMER: 4 Rue du Professeur LANGEVIN Request n.º N.º OF SAMPLES:

59000 BTWIN VILLAGE (Campus) FRANCE L002-01-2108-0115 1
Sample Nr L002-01-2108-0115-001
DESIGNATION OF Sample description 529452-RAW FORK 14IN 2005
THE SAMPLE:
CNUF - Supplier 45925 - Rangpur Metal Industries Ltd Item code 529452
Purchase order W33 2021 Pilot run Batch number W33 2021 Pilot run
MAIN EQUIPMENT: Fatigue test equipment.
TYPE OF TEST: REFERENCE DOCUMENTS:

Conformity test of the fork DS-000847 version 6
RESULTS:
(*) - This report cancels and substitutes the emitted in 2021/11/18 with the number RELV1368221.
Figure 1 - Picture of the sample
Global Result: MODEL APPROVED (*)
The detailed results, of the specified standard, are presented in the following pages.
The reported expanded uncertainty is based on a standard uncertainty multiplied by a coverage factor K=2, providing a level of
confidence of approximately 95%.
The tests marked with (*) are not included in the scope of accreditation
The samples received are responsibility of the customer, assuming that the declarations of the customer / applicant regarding
the identification of the items to be tested and their identification are true, being these data of their entire responsibility.
DATE OF TEST: 2021 / 11 / 16 - 2021 / 11 / 18

PAGE: 1 /4
EXECUTED BY LABORATORY RESPONSIBLE
Nuno Filipe Abrantes da Cruz

Assinado por : PAULO RENATO PIRES DA SILVA
Num. de Identificação: BI094753750
Data: 2021.12.20 19:36:29+00'00'
IMDL13-9

Test Report

1 - SCOPE
The present document has the purpose to present the results of the tests carried out, in the sample with the applicable standard.
The test was carried out on the sample according to the following standard:
- DS - 000847 - Version 6 - Bicycles – Frame and fork requirements for - Development validation
- ISO 8098: 2014; Cycles - Safety requirements for bicycles for young children
The test were carried out at Laboratório de Ensaios da Abimota - Águeda (Portugal).
2 – RESULTS
To verify the conformity of the sample the following points were accessed.
The identification (numeration) used in the following points (items), correspond to the ones used in the standard ISO 8098.
PAGE: 2 /4
IMDL13-9

Test Report

4.10 Front fork
F115_DEV 4.10.2 Front fork – bending fatigue test

DS-000847
version 6 4.10.2.1 Requirement Approved
Test frequency [Hz]: 1,0

Nominal load applied [N]: 400
Number of test cycles (nominal 150 000) [cycles]: 150000
Observations:
Nothing to register.
PAGE: 3 /4
IMDL13-9

Test Report

ANNEXE A
Test request
ANNEXE A
PAGE: 4 /4
IMDL13-9

A.2. Technical Sheet Modification

Raw Fork 14IN 2005 for RFL, D.P. BANGLADESH
1 .Technical Sheet Modification General Conditions :
Property of DECATHLON S.A. A.2. Page 1 of 13
All right reserved F-C-A2_14IN 2005 raw Frame__DPBangladesh_RLF_V1_-_20220120

The : 20th Jan. 2022 DECATHLON Production, 4 Bd de Mons, BP 299, 59665 Villeneuve d'Ascq, France
DECATHLON Production allows the identified supplier to modify some dimensions or some choice of
design written in the identified Technical Sheet.
A Technical Sheet can have only one Technical Sheet Appendix which include all modifications. The
validated modifications are always specified in the last updated Appendix.
Those modifications are clearly identified in this appendix and are only applicable to the identified
Product.
Only the modifications identified in this appendix cancel and replace the dimensions or the choice of
design of the identified Technical Sheet.
All other modifications of the Technical Sheet that are not specified in this appendix have to be written in
a new signed appendix.
The application of those modifications to another product can be done only if a new appendix has been
signed.
If the modification of the Technical Sheet by a supplier concern some dimensions, this proposition has to
be attached to a drawing with dimensions and tolerances. This drawing have to be provide on paper and
with a computerized file readable by DECATHLON Production. (readable computerized file : PRT, DXF,
CGM, IGES, DWG )
The proposed drawing of the supplier has to shown:

- the same title as the original DECATHLON drawing (product designation )
- the no of the original DECATHLON drawing (for example : C04ABJ10 )
- the creation date of the proposed drawing

2. Product designation :
➢ Concerned Product : 14IN 2005 RAW FORK

➢ Concerned Size: Model no 8421696 , CHILDREN'S BICYCLE
This Forks exist in one size - 135mm
➢ Attached Technical Sheet : ProductSpec_8019731RAWFORK14IN2005

➢ Drawing nb : f04aaw01 Rev.O
➢ Region of Production : D.P. Bangladesh
➢ Supplier : Rangpur metal industries ltd U-2 (RFL, Bangladesh)
3. Identification of the modifications :
General introduction of the modification:
1. Modification of the material for the steerer tube of Head stem

2. Modification of the material for the head stem Crown
3. Modification of the material for the Fork blade
4. Modification of the material for the Pivot.
5. Modification of dimensions for the Head stem
6. Modification of dimensions for the Cantilever Pivot
7. Modification of dimensions for the Fork drawing
8. Welding on Crown .
Material change:
Supplier proposition Cancel and replace the DECATHLON

specification
Material for the Steerer tube of Head stem: Material for the Steerer tube of Head stem:
ISO 8488, Ø1.005 – 24 6g

HRC JIS G-3132 SPHT1
-Yield Tensile Strength, Re > 200 MPa,

- Ultimate Tensile Strength, Rm > 270 MPa,
- Elongation , A > 30%
Material of the head stem crown : Material of the head stem crown :
Q195 ISO 8488, Ø1.005 – 24 6g
- Yield Tensile Strength Re>195 MPa mini

- Ultimate Tensile Strength Rm> 315MPa mini
- Elongation ,A> 33% mini
Material for the Fork Blade : Material for the Fork Blade :
JIS G 3141 SPCC SD 22.2X1.4 JIS G 3131, SPHC - Ø 22.2 x 1.2

-Yield Tensile Strength, Re > 200 MPa,
- Ultimate Tensile Strength, Rm > 270 MPa,
- Elongation , A > 37%
Material of the Pivot: Material of the Pivot:
GB ML08 Steel

Geometry change:

specification
Head stem ( 0999-CAD-2940.AB ) Head stem (0999-CAD-2940.AB)

5.5 +1/0 5.5 +0.1/0
Pivot (C51AAW00) Pivot (C51AAW00)

11.9 +0.1/-0.15 16.5±0.5
6±0.5 5.5 +0.5/0
9.8±0.1 10 ± 0.1
Fork drawing (f04aaw01 Rev.O) Fork drawing (f04aaw01 Rev.O)

32±1 31
12±1 16
4 +0.5/-0.15 4 +0.5/0
82 ± 1 82 ±0.5
11 ± 2 (Diameter for the wheel axle 8+0.5/0 mm) 11 ± 1 (Diameter for the wheel axle 8+0.5/0 mm).
➢ Modification of dimensions for Head stem ( 0999-CAD-2940.AB ) :

Original :
Proposed:

➢ Modification of dimensions for the Pivot (C51AAW00)
Original :
Proposed :

➢ Modification of dimensions for the Fork drawing (f04aaw01 Rev.O)
Original :
Proposed :

Original :
Proposed :

Original :
Proposed :

Original :
Proposed :

Welding on Crown:

specification
Welding between the Crown & steerer tube : Welding between the Crown & steerer tube :
- To make a hole on crown with 6.5mm - Not specified in techpack
- Fill the hole with MAG welding.
- No facing at bottom end of the steerer
tube.

Picture : Not available

A copy of the proposed drawing from the supplier has to be signed.

PROMILES Component Engineer
Name : Md. Sifullah Khan Name : Alexandre FRANCOIS
Function : PLQI Function : CE
Date :14h Feb July 2022 Date :


ProductSpec 8019731RAWFORK14IN2005

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RAW FORK 14IN 2005 8019731

IN STORE: CREATION: 20/07/2020 LAST UPDATE: 28/02/2022

Product Engineer : Ludovic RIDON

Project Code Grid Value Model Code MPC Descr.

Part Of Product Percentage Composition Comment

PRODUCED BY: PRINTED THE:

IN STORE: CREATION: 20/07/2020 LAST UPDATE: 28/02/2022

Product Document BRAKE PIVOT C51AAW00 c51aaw00.pdf

Product Document 0999-CAD-2940 FORK_HEAD_STEM_14 0999-CAD-2940 FORK_HEAD_STEM_14.2D.AB.dwg

PRODUCED BY: PRINTED THE:

IN STORE: CREATION: 20/07/2020 LAST UPDATE: 28/02/2022

PRODUCED BY: PRINTED THE:

TECHNICAL SPECIFICATION APPENDIX

A.4. MIG Welding specification :

Propriété DECATHLON Production A.4. - 1 / 5 Property of DECATHLON Production

No holes or porosity in welds are acceptable.

Accepted Not Accepted

No internal or external crack in welds are acceptable.

The undercut depth : k < 5% of the welded tube thickness.

Propriété DECATHLON Production A.4. - 2 / 5 Property of DECATHLON Production

No lack of penetration or fusion of welding is acceptable.

No excess of penetration of welding are acceptable. e = 0

The weld width have to be smooth and

The weld width have to be :

Propriété DECATHLON Production A.4. - 3 / 5 Property of DECATHLON Production

¾ Dimension du cordon / Weld dimension :

a > 1.6 x welded tube thickness

¾ Welds surfaces have to be even and smooth ( no cutting edges ).

¾ No welding wire on or close to the welding line is acceptable

¾ No spatters on the tubes is acceptable

¾ No traces of weld arc initiation is acceptable

Propriété DECATHLON Production A.4. - 4 / 5 Property of DECATHLON Production

Cachet de l'Entreprise Cachet de l'Entreprise

Propriété DECATHLON Production A.4. - 5 / 5 Property of DECATHLON Production

TECHNICAL SPECIFICATION APPENDIX

A.4. TIG Welding specification

Propriété DECATHLON Production A.4. - 1 / 5 Property of DECATHLON Production

No holes or porosity in welds are acceptable.

No internal or external crack in welds are acceptable.

¾ Caniveaux, morsures / Undercuts :

The undercut depth : k < 5% of the welded tube thickness.

¾ Lack of penetration, fusion :

No lack of penetration or fusion of welding is acceptable.

Propriété DECATHLON Production A.4. - 2 / 5 Property of DECATHLON Production

The welds width have to be :

For Alluminium : opened angle, L = 12 Maximum

¾ Weld non symmetry :

Propriété DECATHLON Production A.4. - 3 / 5 Property of DECATHLON Production

a > 1.6 x welded tube thickness

¾ Waves number in welding :

For the steel, v = 2 ± 0.5

¾ Welds surfaces have to be even and smooth ( no cutting edges ).

¾ No welding wire on or close to the welding line is acceptable

¾ No spatters on the tubes is acceptable

¾ No traces of weld arc initiation is acceptable

Propriété DECATHLON Production A.4. - 4 / 5 Property of DECATHLON Production

Maker's Trademark : Maker's Trademark :

Propriété DECATHLON Production A.4. - 5 / 5 Property of DECATHLON Production

TECHNICAL SPECIFICATION APPENDIX

A.7. Fork Exhaust Holes Specification :

Propriété DECATHLON Production A.7. - 1 / 3 Property of DECATHLON Production

Propriété DECATHLON Production A.7. - 2 / 3 Property of DECATHLON Production