SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHP .
R.D.S.OHkkjr ljdkj] jsy eU zky;GOVERNMENT OF INDIAMINISTRY OF RAILWAYSSPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLYFOR HHP LOCOMOTIVESSpecification no. MP- 0.4100.11(Revision - 00)February 2016vuql/a kku vfHkdYi vkSj ekud laxBuy[kuÅ&226 011RESEARCH DESIGNS & STANDARDS ORGANISATIONLUCKNOW ‐ 226 011
R.D.S.OHkkjr ljdkj] jsy eU zky;GOVERNMENT OF INDIAMINISTRY OF RAILWAYSSPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLYFOR HHP LOCOMOTIVESSpecification no. MP- 0.4100.11(Revision - 00)February 2016SSE/MPJD/MPEDSMPPrepared ByChecked ByApproved Byvuql/a kku vfHkdYi vkSj ekud laxBuy[kuÅ&226 011RESEARCH DESIGNS & STANDARDS ORGANISATIONLUCKNOW ‐ 226 011
{PRIVATE }INDEXPARADESCRIPTIONPAGE1.SCOPE12.DESIGN REQUIREMENTS13.MAINTENANCE REQUIREMENTS54.APPROVAL REQUIREMENTS55.ENVIRONMENTAL CONDITIONS66.FIELD PERFORMANCE:67.MATERIAL AND DESIGN68.INSPECTION69.GENERAL79.DEVIATION STATEMENT710.MARKINGS811.INSPECTIONS AND REJECTION812.PAINTING813.SUPPLY OF SPARES814.WARRANTY/ GUARANTEE815.RECONDITIONING816.RECORD OF INTERNAL ACCEPTANCE TESTS8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHP LOCOMOTIVES- DLWPART NOS. 17451115 & 17454530 (EMD PART NOS. 8420236 & 8439090)1.0SCOPE1.1. This specification covers the particular requirements for the supply of Draft Gears along withdraft gear follower suitable for application in EMD goods and passenger locomotives.1.2. The draft gear shall be approved as per AAR spec. M-901E.2.0DESIGN REQUIREMENTSMECHANICAL2.1. PAC Draft Gear has dynamic capacity of 27700 ft.– lb(Minimum) and for MAC draft gear shouldhave (Min. Dynamic Capacity 35000 ft. – lb).2.2. Material of draft gear housing, front follower, rear follower and other mechanical componentsshall be steel to AAR M-201 Grade E and shall withstand drag and buff load 300 t for PAC draftgear and 450 t for MAC draft gear.2.3. Pre compression load at installed height of draft gear assembly to be kept 7 1 ton for PAC &12 2 ton for MAC draft gear.2.4. The draft gear shall have travel of 38mm for MAC and 41mm for PAC mm in compression withend load 300 t (max) and 450 tones respectively.2.5. Rubber components should be tested as per IS: 3400.2.6. Draft Gear should be suitable to be fitted in Pocket to EMD Drawing no. 10661268 & 10630876.2.7. PHYSICAL PROPERTIES OF RUBBERSl.PROPERTIESVALUEi)Tensile strength(kg/sq.cm)150 min.ii)Elongation at break (%)255 min.iii)Tear Strength40 Kg/cm Miniv)Compression set(%) at 70 1 deg. C for 24 0/-2 hrs35 max.v)Ash content (%)5 max.vi)*Resistance to Ozone Test (Quality Retention Rating) as per ASTM 85% Min.D1171vii)*Low Temperature resistance at-40 C for 3 minutes as per ASTM No Brittle & NoD1171Cracksviii)Specific Gravity1.2Max.ix)Hardness (Shore ‘A’)70 7/-3Variation of hardness on single pad5 max.Motive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 1 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-2.8. ACCELERATED AGEINGTests shall be as per IS: 3400 and shall be carried out from the finished product. After ageing at70 1/-1 deg.C in an air oven for 72 0 hrs., the hardness, tensile strength and elongation atbreak(%) shall not vary from the value obtained with the unaged specimen by more than thefollowing:Sl.PropertiesValue1.Hardness (Shore ‘A’) 7/-02.Tensile strength 25%3.Elongation at break (%) 10%-30%It shall be the responsibility of the manufacturer to carry out accelerated ageing tests as above.The manufacturer shall carry out the tests on test pieces prepared out of 4 pads for every 4000pads manufactured. Record of this testing shall be put up to RDSO along with every lot offeredfor inspection. Apart from inspection of these records, RDSO shall carry out accelerated ageingtests during confirmatory tests.2.9. STATIC LOAD –DEFLECTION CHARACTERISTIC AND DYNAMIC TESTSl.PARAMETERDRAFT GEARGOODS LOCO1.Free Height216 6 mm206 6 mm2.Installed Height185 mm170 2 mm3.Load at installed height 12 5 tons7 1 tons4.End Load450 tons 20 tons300 tons min5.Static Energy4200 kg-m maximum24kj min6.Totaltravelfrom 38 mm min.installed height toheight at 450 tons load42 mm min.7.Cyclic endurance testThe purpose of this test is todetermine if rubber pad canservice 1000 closers withoutany material failure under padcompressed from installedheight 185 to end load of 450tThe purpose of this test is todetermine if rubber pad canservice 1000 closers withoutany material failure under padcompressed from installedheight 185 to end load of 300Tons8.Dynamic energy testAs per AAR specificationM901E official capacity testagainst buff shall not be lessthan 42kj the travel of draftgear 38 mm minAs per AAR specificationM901E official capacity testagainst buff shall not be lessthan 37kj the travel of draftgear 42 mm (min.)Motive Power DirectorateforHHP DRAFT GEAR forPASSENGER LOCOSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 2 of 8HHP
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-STATIC CAPACITY18,300ft‐lbs, TRAVEL 1.49 INCHESDYNAMIC CAPACITY27,700FT‐LBS, TRAVEL 1.49 INCHESMotive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 3 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-STATIC CAPACITY30,400 ft‐lbs, TRAVEL 1.49INCHESDYNAMIC CAPACITY35,00 ft‐lbs, TRAVEL 1.49INCHES2.10. The draft gear alongwith draft gear follower shall be suitable for EMD goods and passengerlocomotives having a draft gear pocket as detailed at Annexure-I. Draft gears for EMD goodsloco shall be fitted with 'E' type Coupler and Draft gears for EMD passenger locomotive shallbe fitted with H-type coupler or 'E' type Coupler.2.11. All Components including draft Gear, casting and rubber pads shall be interchangeable.2.12. OTHER REQUIREMENTSa)b)c)Motive Power DirectorateNo Draft Gear pads should be found sticking during testing.Submission of test results of chemical and physical properties and manufacturingprocesses used for manufacturing draft gear and its components.All Components including draft Gear, casting and rubber pads shall be interchangeable.Spec No. MP.0.4100.11 (Rev.00) of February 2017Page 4 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-d)e)3.0Gauge drawings with tolerances and dimensions on the gauges in original shall besubmitted for approval of RDSO.Mechanical fitment of the offered draft gear in the pocket provided on IR passengerlocomotives shall be the sole responsibility of the manufacturer.MAINTENANCE REQUIREMENTSThe supplier shall provide the maintenance manual for Draft gear with Yoke assembly for EMDlocomotives- DLW Part nos. 17454530 & 17451115 (EMD Part nos. 8439090 & 8420236). Detailingmaintenance procedure, schedule/ frequency, list of spares required during routine maintenance/overhauling. The manufacturer shall set aside one set of gauges for exclusive use of inspectingauthority.Gauge drawings in original shall also be made available for checking tolerances of these gauges. Themanufacturer shall supply Maintenance Manuals for proper maintenance of draft gears. The number ofmanuals to be supplied shall be in sufficient quantity and shall be free of cost. The manual shallcontain following information:i)ii)iii)iv)v)vi)Principle of operation and important design featuresIllustration explaining the working and maintenance practicesDetails of attention during overhaulingSpecial tools, capacity & specification of press etc.Details of welding equipment & method of weldingList of spares along with specification & part No. etc.3.1. Material of draft gear pad should be Rubber/synthetic polymer/ hytrel with high damping andshould have minimum service life of 5 years.3.2. There shall be an arrangement to adjust the pre-load of draft gear with an increment of 500 kg.There shall be provision for suitable wear plate to be made at location where relative movementtakes place during service.4.0APPROVAL REQUIREMENTS4.1The manufacturer shall submit QAP as per the guidelines indicated for preparation of QAP.The complete QAP shall be got periodically reapproved from RDSO after Quality Audit.4.2The manufacturer’s QAP shall ensure that the components are strictly being manufactured tospecified dimensions and material and also meet the requirement of chemical and mechanicalproperties recommended by collaborator/manufacturer. No deviation in dimension, chemicalproperties and mechanical properties of components from collaborator’s/manufacturer’srecommendations will be permitted.The manufacturers shall also supply along with draft gear, the following free of cost for eachcontract:i)ii)1 Nos. of cut model.20 sets of colored wall charts explaining working of draft gear,4.3 One complete set of maintenance gauges for every 200 Nos, or part thereof, of draft gearbeing supplied to Indian Railways or for use of Indian Railways. The Manufacturer shall obtainMotive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 5 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-distribution of maintenance gauges from Purchaser and ensure that gauges are delivered toWorkshops of Indian Railways.4.4 The manufacturer shall supply spares for maintenance of draft gear to Railways/RailwayWorkshops against their demand/Purchase Order.4.5 Castings shall be procured from classes ‘A’ foundry as per IS: 12117 if it is manufactured inIndia. The firm shall also be ISO 9000 certified organization.5.0Environmental ConditionsDraft gear shall be required to work continuously at full load under following atmospheric conditions:6.0Maximum temperature(Atmospheric):55 ºC (under sun).Minimum temperature (Atmospheric)-20 ºC.Humidity90 % (Up to 100% during rainy season).AltitudeMax. 1200 meter above mean sea levelAnnual rainfallBetween 1750 mm to 6250 mmDustExtremely dusty and desert terrain in certain areas.Atmospheric conditionsin coastal areas in humidity salt laden and corrosiveatmosphereMaximum PH value : 8.5Max. concentration of chlorine : 6 mg / litreFIELD PERFORMANCEThe supplier shall regularly collect data and samples of previous supply from field to assess the actuallife obtained nature of defects occurring in the service and should take necessary corrective action toimprove quality. Half yearly report should be submitted to RDSO/LKO on data, samples collected andcorrective action taken.7.08.0MATERIAL AND DESIGN7.1Supplier shall furnish material and design information including the amount of preCompression (in Kgs.) for each part of the draft gear offered to the inspecting official.7.2The information regarding material shall include the collaborator's/manufacturer’srecommendation and quality standards applicable to the same and the heat treatment detailsetc. to enable inspection.INSPECTION8.1DEVELOPMENTAL INSPECTION:The new manufacturer shall submit a detailed Quality Assurance Programme as perguidelines, and approved by the collaborator/manufacturer to RDSO for advance approval.The QAP shall ensure that the components are strictly being manufactured to specifieddimensions and material and also meet the requirements of chemical and mechanicalproperties recommended by collaborator/manufacturer. No deviation on dimension, chemicalMotive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 6 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-properties and mechanical properties of components from collaborator’s / manufacturer’srecomendations will be permitted.8.2Developmental inspection shall be undertaken for the initial supplies of the draft gear fromthe contractor. Developmental inspection shall be carried out separately for different type ofdraft gear. Developmental inspection of indigenous manufacture shall be done by the DesignWing of Motive Power Dte. of RDSO.8.3Draft gear official capacity, studiness test, tup hammer shall be satisfy all requirements underM-901E have been found satisfactory.8.4Results of tests conducted for the above.Following information is also required: i)Submission of drawings of draft gear and its components with a letter from the PrincipalManufacturer regarding authenticity of the drawings and that these are current.ii) Submission of detailed specifications, chemical and physical properties and manufacturingprocess used for manufacturing the draft gear and its components.9.08.5The Developmental Inspection shall be done in accordance with specification and latest AARSpecification No. M-901 E .8.6All parts shall be made of the material having the same physical and chemical properties asspecified for the draft gears by principle manufacturer/manufacturer.8.7Subsequently, no change in the design, material and/or process shall be made.GENERAL9.0AS MADE' DRAWINGS:The contractor shall submit one set of 'As Made' drawings and one copy in electronic format(Autocad) with important controlling dimensions and tolerances thereon alongwith surfacesand dimensions necessary to be gauged.9.1GAUGING PROCEDURE:The Contractor shall submit the gauging procedure including the gauge drawings for approvalto RDSO before commencement of supply. No change shall thereafter be carried out withoutthe prior approval of RDSO.9.2TEST EQUIPMENT:The Contractor shall provide, at his own cost, labour, appliances and tools necessary for thetesting and inspection of the draft gears in accordance with this specification.10.0DEVIATION STATEMENTIn case the offer does not correspond to this specification in any respect, a 'DEVIATIONSTATEMENT' shall be submitted by the supplier. This statement shall clearly give the deviationsclause wise with technical reasons for the same. Changes in drawings, if any, shall be described andaccompanied by a copy of revised drawing. In case the supplier does not require any deviation fromthis specification, a clear 'NO DEVIATION' certificate shall be submitted.Motive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 7 of 8
SPECIFICATION FOR DRAFT GEAR WITH YOKE ASSEMBLY FOR HHPLOCOMOTIVES-11.012.013.0MARKINGS11.1Draft gear shall have manufacture’s Name/initial, date of manufacture, serial no. and type ofdraft gear at suitable location of housing in 10 mm raised type letters.11.2Marking on pad shall be moulded in an area not subjected to wear or stress concentration, ifpossible, where they can be readily seen without removal of pads.11.3Draft gears with illegible markings shall not be acceptable.INSPECTIONS AND REJECTION12.1.The inspection and rejection shall be done in accordance with the relevant clauses of specialconditions of the contract issued by the Railway Board.12.2.The manufacturer shall provide labour, appliances and other facilities necessary for theinspection at his own cost.PAINTINGDraft gear and draft gear follower shall be painted with black paint on only exposed surfaces excludingworking portions.14.0SUPPLY OF SPARESThe manufacturer should furnish a list of spares and their quantity required during maintenance ofDraft Gear. The manufacturer shall supply spares for draft gear against Railways requirement.15.0WARRANTY/ GUARANTEEThe Draft Gear shall be guaranteed for satisfactory performance for a period of 54 months aftersupply or 42 months after putting into service, whichever is earlier. The guarantee shall cover Design,material and workmanship. The defective draft gears supplied against relevant contract shall bereplaced by the supplier at his own expense.16.0RECONDITIONINGThe manufacturer shall also undertake reconditioning of Draft gear against Zonal Railways request.The reconditioned draft gear assembly shall perform satisfactory in service and shall meet therequirements laid down in clause 11 above.17.0RECORD OF INTERNAL ACCEPTANCE TESTSThe manufacturer will maintain a list of all internal acceptance tests being carried out by him at variousstages of manufacturing of the product. Proper record of such internal acceptance tests shall bemaintained by him and also included in the QAP. At the time of inspection of the product, theserecords shall be put up to the Inspecting Authority for scrutiny and countersign.Motive Power DirectorateSpec No. MP.0.4100.11 (Rev.00) of February 2017Page 8 of 8
shall be steel to AAR M-201 Grade E and shall withstand drag and buff load 300 t for PAC draft gear and 450 t for MAC draft gear. 2.3. Pre compression load at installed height of draft gear assembly to be kept 7 1 ton for PAC & 12 2 ton for MAC draft gear. 2.4.
Work out the gear ratios of these gears: (numbers inside the circles are the numbers of teeth on each gear) Blue drive gear, green driven gear, pink idler gear, yellow compound gear 1: Simple meshed gear 2: Simple gear train with idler gear 15 3: Compound gear train 4: Choose the correct words to make these statements true for these gear trains.
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3. Explain what a gear train does? 4. Explain what a simple gear train is? 5. Explain torque? 6. What does a larger gear driving a smaller gear achieve? 7. What does a smaller gear driving a larger gear achieve? 8. What is the driven gear? 9. What is the driver gear? 10. What is the idler gear? 11. What is the calculation for working out gear .
form a gear set or a gear train . In a gear set, the input gear is called _ gear. The output gear is called the _ gear. Note: An idler gear or intermediate gear changes direction of rotation without change in gear set speed or torque Spinner &
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