R.D.S.

Hkkjr ljdkj, jsy eU=zky;

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL REQUIREMENTS
FOR
HYDRAULIC DAMPERS
OF
WDG4 & WDP4 LOCOMOTIVES

No. MP.0.40.99.03
(Revision - 01)
December 2007

vuql/a kku vfHkdYi vkSj ekud laxBu

y[ku&226 011
RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226 011
Cost (Rs).

R.D.S.O

Hkkjr ljdkj, jsy eU=zky;

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

TECHNICAL REQUIREMENTS
FOR
HYDRAULIC DAMPERS
OF
WDG4 & WDP4 LOCOMOTIVES

No. MP.0.40.99.03
(Revision - 01)
December 2007

Prepared By

S.P.Govil
Asstt. Design Engineer (MP)

Checked By

Approved By

Naresh Kumar
Director (MP/VDG)

S.Mani
Executive Director(MP)

vuql/a kku vfHkdYi vkSj ekud laxBu

y[ku&226 011
RESEARCH DESIGNS & STANDARDS ORGANISATION
LUCKNOW - 226 011
Cost (Rs).

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

CONTENTS
Sr. No.

Description

Page No.

Scope

Definitions

Deviation(s)

Drawings

Minimum General Requirements of the Firm

Damper Performance Description

Test Results

Guarantee / Warranty

General

10

General Inspection

11

Training and Infrastructural Facilities

12

Marking

13

Packing

14

Field Trials

Appendix - I

Quality Assurance & Guarantee Certificate

Enclosure

RDSO Drawing No. SK.VL - 484

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

TECHNICAL REQUIREMENTS FOR HYDRAULIC DAMPERS

OF
WDG4 & WDP4 LOCOMOTIVES
1.

2.

SCOPE
1.1

This document covers the technical requirements relating to design and performance
characteristics for lateral, vertical & yaw hydraulic dampers for use in WDG4 & WDP4
locomotive bogies. However, this it does not include all the necessary provisions required
for a supply contract.

1.2

The document covers the supply of damping unit with end fittings /mountings as an
assembly termed as hydraulic dampers.

DEFINITIONS
i.

ii.

iii.

iv.

v.
vi.
3.

Overall damping characteristic shall, for all type of Hydraulic Dampers, refer to the
damping forces and corresponding relative velocities between the attachment points of the
Hydraulic Damper to the vehicle.
Hydraulic Damper Temperature shall refer to the temperature of the oil in the Hydraulic
Dampers. For measurement purpose, the temperature of the outside surface of bottom
side of the main body of the Hydraulic Damper shall be taken.
Compressed length between the mounting eyes i.e. center-to-center distance (in case of
stem/ eye type) or mounting faces (in case of stem-type) of a Hydraulic Damper when it is
compressed to the maximum of stroke.
Extended length between the mounting eyes i.e., center to center distance (in case of
stem/ eye type) or mounting faces (in case of stem type) of a Hydraulic Damper when it is
pulled out to the maximum of stroke.
Stroke is the difference between the extended length and the compressed length (effective
maximum travel of the Hydraulic Damper).
Wherever Inspecting Agency has been mentioned in this document, it shall be taken as
Authorised Inspecting Agency mentioned in the purchase order.

DEVIATION(s)
If deviations from original design, dimensions, etc. are desired by the tenderer, specific proposals
with reasons shall be submitted to the purchaser. Commencement of manufacture shall not be
done till the purchaser grants clear authorization for acceptance of the deviation(s).

4.

DRAWINGS
The Hydraulic Damper shall conform to RDSO Drawing No. SK.VL- 484 or recommended EMDs/
OEM's drawing(s).

5.

MINIMUM GENERAL REQUIREMENTS OF THE FIRM

5.1

The firm shall have acquired ISO: 9000 series certification for manufacturing of Hydraulic
Dampers.

5.2

The manufacturer shall have adequate infrastructure, manufacturing and testing facilities for
the manufacture and testing of Hydraulic Dampers.

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 1

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

5.3

The firm shall have a system of easy traceability of the product from raw material stage to
finished product stage. Stamped Identification marking with serial number of Hydraulic
Damper should be used for this purpose.

5.4

The firm shall have a Quality Assurance Plan (QAP) for the product detailing various
manufacturing aspects. The QAP shall include the following:
.1

Organization chart

.2

Process flow chart

.3

Stage Inspection details

.4

Record of finished product

.5

Policy of disposal of rejected product

.6

Identification Marking

5.5

The firm shall maintain a record of implementation of QAP for documentary evidence.

5.6

Firm shall have a Quality Manual indicating the extent of control over production.

5.7

The firm shall have a system of documentation in respect of rejection at customer end,
warranty replacement and failure of items supplied by them during service.

5.8

Calibration of the Testing / Measuring Equipments should be done at least once in a year
unless stated otherwise.

5.9

The firm shall have a system of recording the plant, machinery and control equipments
remaining out of service, nature of repairs done etc.

5.10 Training needs for all personnel shall be identified & organized by the firm on regular basis.
The Inspection staff conducting testing shall be adequately qualified, trained & having
adequate experience.
6.

DAMPER PERFORMANCE DESCRIPTION

6.1

OPERATIONAL REQUIREMENTS
6.1.1 Service Conditions
.1

Service Interval
The service interval of the damper, the maximum admissible percent
deterioration of damping characteristics at the end of service interval in
comparison to the nominal damping characteristic and the maximum admissible
rate of failure shall be as follows:
S.No. Conditions

Requirements

1.

Service interval of the damper

2.

The maximum admissible percent Deterioration shall not be

deterioration of the F- V characteristic at more than 25 %
the end of service interval in comparison
to the nominal F- V characteristic

3.

The maximum admissible rate of failure

Motive Power Directorate (VDG), RDSO, Lucknow

10,00,000 kms or 4 years

0.05/ MKm
or
0.05/4 years

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 2

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

.2

Operational Environment Conditions

The damper shall be resistant to the following operating environmental
conditions to which it may be exposed during service:

projection of ballast
exposure to oil or petroleum
exposure to organic waste
Wind, rain, snow, cold dust, sand storms
sand, brake and ferric oxide dust (abrasion of wheels, brake blocks and
tracks)
saline spray
washing plant agent (both acids and alkalis)
100% humidity
.3

Operating Temperatures ( To,min - To,max )

The damper is required to function safely at minimum operating temperature To,
min and maximum operating temperature To, max as follows:
Sl.

Conditions

Requirements

1.

Minimum Operating Temperature To, min

- 20 C

2.

Maximum Operating Temperature To, max

+ 70 C

After operating to these extremes, the damper shall be required to fully recover
its functionality. Furthermore, the damper shall not display any fluid leaks and
any signs of failure or cracking in the damper components.
6.1.2 Storage Temperatures ( Ts,min - Ts,max )
The damper shall withstand the following temperature range during transport or
storage:
Sl.

Conditions

Requirements

1.

Minimum temperature to withstand during transport

or storage Ts, min

- 20 C

2.

Maximum temperature to
transport or storage Ts, max

+ 70 C

withstand

during

6.1.3 Other Conditions

.1 Vibrational exposure / Effect of oscillation frequency on overall damping
characteristic
In order to clarify the damper vibrational exposure, the OEMs Damper
Performance Description shall specify:
damper location in vehicle
resonant sources frequency
The dampers should satisfactorily withstand the vibration levels at the intended
application in primary / secondary suspension stages of locomotive bogie.

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 3

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

6.2

PHYSICAL REQUIREMENTS
6.2.1 Strength
The construction of Hydraulic Damper shall be such as to withstand the static
compressive axial load of 3 tonnes when fully closed and a tensile load of 3 tonnes
when fully extended respectively without any failure, damage or permanent change in
damping characteristic or reduction in service interval.
6.2.2 Dimensional Parameters
Various dimensional parameters of the damper shall be as per RDSO Drawing No.
SK.VL - 484 or recommended EMDs/ OEM's drawing(s).
6.2.3 Adjustability
The damper capacity shall be adjustable and the adjustment shall be easy to perform. It
shall be clearly indicated if any special tools and devices are required. The maintenance
instructions for the damper shall cover the procedure to perform such adjustments.
6.2.4 Surface Protection
All the parts of the damper in contact with the ambient air shall be protected from
corrosion. The protection can be ensured either by the nature of materials used or by
suitable painting / surface treatments.
The following requirements for the damper painting and other anti-corrosion surface
protections (in particular, the stem surface treatment or plating) shall be maintained:
Painting Parameters

Requirements

Colour: RAL number

RAL 7012

Minimum dry film thickness according to ISO 2808

120

Adhesion

ISO 2409 or EN 24624

Gloss to ISO 2813 (Angle of incidence: 60)

<5%

Rubber parts shall not be painted. Otherwise, the Supplier has to produce test results
or return from service experience data demonstrating that painting process doesnt
alter rubber mechanical characteristics for the whole damper service life.
6.2.5 Damper Oil
The details of damper oil including type, viscosity and amount of the damper oil shall be
provided by the supplier.
6.2.6 Leakage
The damper shall operate without excessive loss of oil throughout its operating life. Oil
loss is excessive when there is visible evidence of accumulation of oil in the form of
drip on the body of the damper.
Once leakage seems to be present in service, the damper has to be cleaned from oil &
dust and shall be checked after one week or 1000 km. If oil is again present on the
damper and/ or oil is bonded in an area of 100 cm2 of dust, the damper is classified as
leaking.
6.2.7 Noise
When determined as being necessary, the damper shall provide no noise during
work.
Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 4

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

6.3. FUNCTIONAL REQUIREMENTS

6.3.1 Orientation
The range of various damper angular positions during fitment and operation shall be as
per RDSO Drawing No. SK.VL- 484 or recommended EMDs/ OEM's drawing(s).
6.3.2 Overall Damping Characteristics
The overall damping forces on the compression and extension strokes of the damper,
taken separately, shall be within the following tolerances at dampers temperature range
of 20 2 C inclusive:
Hydraulic Damper
Type

Loco Type

Damper Capacity (N at 0.1 m/sec)

Compression

Extension

5600 20%

5600 20%

Primary (Vertical)

WDG4 & WDP4

Secondary (Yaw)

WDG4

12200 20%

12200 20%

Secondary (Yaw)

WDP4

6000 20%

6000 20%

The Hydraulic Damper shall be assembled in such a manner that the damping shall
be uniform throughout the stroke i.e the damping characteristics shall not have any
sudden deviation or changes throughout the stroke.
The stipulated tolerances and requirements shall apply at all points within the required
working stroke of the Hydraulic Damper.
6.3.3 Force - Displacement Characteristic
The Force - Displacement characteristic is the variation in damper Force as a function
of damper displacement under harmonic motion of established strokes and frequencies
depending on the type of application. Moreover, it is also referred to a given damper
length and operating temperature.

The shape of the Force - Displacement curve or Hysteresis Cycle (see above figure),
shall turn out to be regular and symmetrical, in particular shall be free from:
flex as shown in above figure with letter A, B and C
local vibrational phenomena
jumps and sudden change in the shape of the curve
6.3.4 Priming
The damper must not loose priming during service or after storage or transport.

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 5

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

7.

TEST RESULTS
The manufacturer shall submit internal test results in support of various performance
characteristics as laid down in this document, duly signed by manufacturer or his authorized
representative.

8.

GUARANTEE / WARRANTY
The manufacturer shall furnish a guarantee that each new Hydraulic Damper supplied, shall
function satisfactorily without attention and in accordance with the requirements of this document
for 10,00,000 kms of service running on a vehicle or for 4 years from the date of fitting to a
vehicle, whichever is earlier. A format of the certificate is given at Appendix - I.

9.

10.

GENERAL
9.1

All welded joints of the Hydraulic Damper shall be free from welding defects and shall be
sufficiently strong to withstand the loads intended.

9.2

The external dimensions & characteristics of the Hydraulic Dampers shall not be altered by
the manufacturer without the prior written consent of RDSO. Unless otherwise specified in
the respective drawing, the tolerance in compressed and extended length of all types of
Hydraulic Dampers shall be within 3mm of the specified dimension.

9.3

After suitable pretreatment, Hydraulic Damper shall be painted with primer under coat and
finishing coat. The Hydraulic Dampers shall be painted as specified. Paint must not be
permitted to adhere to the working portion of the piston rods.

9.4

The Hydraulic Damper shall be manufactured, assembled and tested at the manufacturers
own works.

9.5

Hydraulic Damper found to be defective after delivery within the warranty period will be
returned to the manufacturer for replacement at his own expenses, not withstanding that
they may have passed the relevant tests and have been accepted by the Inspecting
Agency.

GENERAL INSPECTION
10.1 Records of all the materials or fittings used in Hydraulic Dampers shall be scrutinized by the
Inspecting Authority and shall be to his entire satisfaction.
10.2 The manufacturer shall supply the necessary labour and appliances for testing and
inspection of the Hydraulic Dampers, if felt necessary by the inspecting authority.
10.3 The Inspecting Authority shall have right to:
10.3.1 Adopt any means he may think advisable to satisfy himself that the materials or
fittings as per the specifications are actually used in the manufacture.
10.3.2 Take samples of components/parts for such tests, as he may consider necessary
by an approved metallurgist selected by him whose report shall be final and binding
on the manufacturer.
10.3.3 Visit at any reasonable time and without previous notice, the manufacturers works
to inspect progress & the quality of the work and the manufacturer shall provide all
equipments, gauges and other facilities required by him for the purpose, free of
charge.
10.3.4 Reject any material or fittings, which do not conform the relevant specifications or
good practice. These shall be marked in a distinguishable manner and shall be

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 6

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

disposed of in such a manner as the inspecting authority directs. Such rejected

parts shall be replaced by the manufacturer without extra charges.
10.3.5 In the event of a dispute between the inspecting authority and the manufacturer,
the decision of RDSO shall be final and binding.
11. TRAINING AND INFRASTRUCTURAL FACILITIES
The manufacturer shall provide the requisite training to the staff of purchaser to use, repair and
overhaul the Hydraulic Dampers. He shall also supply 10 sets of maintenance/instruction manuals
for each order, indicating dimension of critical items and its permissible wear, specification, quantity
of oil etc to the user Railways.
12. MARKING
Marking identification plate should be of Aluminium and should be fixed by Aluminium rivets. The
Hydraulic Dampers shall be marked with:
a. Manufacturers name or Code
b. Serial No.
c. Type of Damper
d. Rated Capacity
e. Month & Year of manufacture
f.

IR

g. RDSO drawing No.

In addition to marking plate, the manufacturers name or code, rated capacity, serial number and
month & year of manufacture shall also be marked in 10 mm height letters by punch mark with
minimum depth of 0.25mm on outer surface at bottom side of the damper.
13. PACKING
The manufacturer shall ensure that Hydraulic Dampers are suitably packed in polyethylene covers
using suitable cartons to prevent ingress of foreign matter and damage during handling and
storage.
14. FIELD TRIALS
Before approval in Part II in RDSO vendor directory, the field performance for a period of one year
shall be monitored.

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.01) December 07

Page No. 7

Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

APPENDIX I
QUALITY ASSURANCE & GUARANTEE CERTIFICATE
(Reference Clause 8 of Specification No. MP.0.40.99.03)
No.

..

Dated:.

Railway :

..

P.O. No. :

..

Dated:.

Quantity :

..

Consignee:

Hydraulic Damper Description: .

.

i.

THIS IS TO CERTIFY THAT THE HYDRAULIC DAMPERS INDICATED IN THIS PURCHASE

ORDER HAVE BEEN SUBJECTED TO OUR INSPECTION AND TEST PROCEDURES AND ARE
FOUND TO CONFORM TO THE ORDER/DRAWING/SPECIFICATION REQUIREMENTS.

ii.

THE QUALITY CONTROL PROCEDURES IN RESPECT OF THIS SUPPLY ARE IN

ACCORDANCE WITH OUR QUALITY MANUAL AND AS PER APPROVED QUALITY
ASSURANCE PLAN.

iii.

THIS IS TO CERTIFY THAT EACH HYDRAULIC DAMPER SUPPLIED AGAINST THIS

PURCHASE ORDER SHALL FUNCTION SATISFACTORILY FOR THE INTENDED
APPLICATION

Dated:

Q.C. INCHARGE
(SIGNATURE & SEAL OF THE MANUFACTURER)

Motive Power Directorate (VDG), RDSO, Lucknow

No. MP.0.40.99.03 (Rev.00) December 07

Page No. i