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SPECIFICATION NO.TI/SPC/OHE/TOOLPL/0990 Rev-1

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR

GEARLESS HAND OPERATED PULLING AND

LIFTING MACHINES

[TIRFOR]

July 2020

ISSUED BY

TRACTION INSTALLATION DIRECTORATE

RESEARCH DESIGN AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW- 226011

(INDIA)
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SPECIFICATION FOR: Gearless Hand Operated Pulling and Lifting Machines

(Tirfor)

SPECIFICATION NUMBER: TI/SPC/OHE/TOOLPL/0990 Rev-1

Amendment Date of Total pages including Amendment/Revision

Amendment drawings

PREPARED BY CHECKED BY APPROVED BY

SIGNATURE
DATE
DESIGNATION

COPY NUMBER

ISSUED BY----------SIGNATURE-------------DATE-------------

ISSUED TO-------------------------------------------------------

------------------------------------------------------

------------------------------------------------------

NOTE-This specification is property of RDSO No reproduction shall

be done without permission from DG (TI), RDSO.
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INDEX

ITEM NO. HEADING PAGE

1. Scope 4
2. Service Conditions 4
3. Governing specification 4
4. Deviations from specification 4
5. Workmanship and construction 4
6. Material 6
7. Tolerances 7
8. Weight 7
9. Effort 7
10. Freedom from defects 7
11. Supply 7
12. Inspection, certificate of test and examination 7
13. Packing and Marking 8
14. Tests 9
15. Submission of data, drawings and particulars 10
16. Type tests 10
17. Acceptance tests 11
18. Criteria for acceptance 11
19. Routine tests 11
20. Method of tests 11
21. Guarantee 12
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226011

TECHNICAL SPECIFICATIONNO. TI/SPC/OHE/TOOLPL/0990 Rev-1

FOR
GEARLESS HAND OPERATED PULLING AND LIFTING MACHINES
[TIRFOR]

1. Scope:

1.1 This specification covers the requirements of “Gearless Hand Operated Pulling
and Lifting Machines herein called as the ‘Tirfor’ of 0.8 t,1.6 t and 3.2 t
capacities to be used in conjuction with the wire rope conforming to IS:2266 or
latest for maintenance of traction overhead lines. This specification revised to
update strandard, to incorporate A&C slip.

2. Service Conditions:

2.1The tirforalongwith its associated fittings/components is intended to be used

outdoor throughout india including marine/industrially polluted areas under
atmospheric conditions prevailing in india. The tirfor and its associated
fittings/components may be subjected to rough handling during the course of
maintenance of overhead traction lines and during transportation.

2.2 The “make in India” policy of government of India shall be applicable.

3. Governing specification:

3.1 The tirfor shall generally conform to IS:5604-1984 or latest which is

hereinafterreferred to as the “Governing specification”. The provisions of the
governing specification shall be applied in the manner altered, amended or
supplemented by this specification.

4. Deviations from specification:

4.1 Any deviation from this specification calculated to improve the performance,
utility and efficiency of the equipment, proposed by tenderer will be given due
consideration provided full particulars with justification thereof are furnished.

5. Workmanship and construction:

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5.1 General-The tirfor shall be as light in weight as possible and shall be robust in
construction, without gears, pawls or ratchets and shall be designed on draw
vise principle in which lifting/puling or lowering of the load is accomplished by
two pairs of forged steel jaws controlled by a lever. The wire rope shall pass
through the unit itself and not reeled on a drum. The grip on the wire rope shall
be self energizing in which the weight of the load actuates the jaws. The wire
rope at alltimes shall be held by one pair of jaws while the other pair having
been opened by cams, shall be moved by lever for next gripping or pulling
motion. The tirfor shall be so constructed that the movement is controlled in
either direction without jerking or snatching. The arrangement shall be such
that it is possible to draw the unlimited length of wire rope through the cable.
The machine shall be provided with forged steel anchoring hook at one end and
the forged steel cable hook slinged with wire rope at the other end. “As an
alternate Dee shackle with pin slinged to wire rope at load end may be provided
if required by the purchaser” Suitable length of galvanised steel wire rope as
required by the purchaser shall also be supplied alongwith the tirfor. The
manutacturer shall obtain the length of wire rope required from the purchaser.
The wire rope shall be procured from reputed manufacturers.

Permissible back slippage of the load as a percentage of total lift

in one stroke (forward and backward) shall be as follows:

Lifting capacity of Load applied Permissible back

Machine slip
(t) (t) (Percent)
0.8 0.8 10
1.6 1.6 10
3.2 3.2 15

5.2 Machine- The housing of tirfor shall be either cast or fabricated for proper
strength and shall be robust in construction and shall maintain alignment
under all expected conditions of service . if of fabricated construction, it shall be
stress relieved before machining and assembly. All parts of machine shall be
constructed with a minimum factor of safety of 5.
5.3 Blocks – Blocks and all components shall have adequate strength to withstand
the working load.

5.4 Bearings – The crank shall be provided with suitable rolling bearings or bearing
bushes. The bearing bushes should be of anti-friction type or of suitable non-
ferrous material.”Ball and parallel roller bearings shall comply with the
requirements of IS:5669-1970 and IS:5692-1970 with the provision that
needle roller bearing are permitted or may, alternatively, be of the self
lubricated type conforming to IS:3980-1967”. The bearing surfaces shall be
smoothly finished.
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5.5 Heat treatment – All components before machining shall be normalised or

hardened and tempered.

5.6 All components shall be treated for rust prevention.

6. Material:

6.1 Plates and bars- Structural steel to IS:2062Gr.A or latest.

Hooks & Other such items - Forged steel to IS:2004 or latest Class 2

Aluminium alloy - IS: 617 Grade 4600 M or latest

Cold drawn steel wire for - Table 1 of IS:4454(Pt.I) 1981 or latest

coil spring

Tin Bronze - IS: 306-1968 or latest

Phosphor Bronze - IS: 1385-1968 or latest

Dee Shackles - IS:6132 Pt. I & II or latest

Hooks - IS: 2759 and IS:8610 or latest

Galvanised steel wire ropes - 6x 19 construction upto 12mm diameter and

Suitable for the application - 6 x 36 or 6 x 37 construction above 12 mm
diameter, tensile grade 1770 Min, IWRC to
IS: 2266-1989 or latest. The zinc coating
shall conform to “Heavy coating” as laid
down in IS: 4826:1968 or latest .

6.1.1 The jaws shall be made from the alloy steel containing at least 0.90 percent
chromium to ensure resistance to abrasion. The alloy steel after suitable
heat treatment (hardening & tempering) shall have the following properties.

Tensile strength, Min. 900 MN/m2

Elongation (at gauge length

5.65 √ A), Min 15 Percent

Izod impact value 40 Nm

Hardness, Min 300 BHN

6.1.2 For quality & material of parts used, the manufacturer shall produce
adequate evidence including test certificates that such parts/components have
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been used strictly conforming to the requirements. Such test certificates shall
be included in the test report.

7. Tolerances:

7.1 Tolerances on forgings – Tolerances on forgings shall conform to the

requirements of IS: 3469 – 1974 or latest.

7.2 Machining tolerances – Machining tolerances shall conform to medium class of

IS: 2102 -1969 or latest.

8. Weight:

8.1 The machine shall be portable and the weight shall, therefore, be such that the
machine can be lifted and carried easily by two persons.

9. Effort:

9.1 The manufacturer shall specify the operating effort on the handle required to
raise the safe working load and also the velocity of wire rope in mm/stroke.

10. Freedom from defects:

10.1 All Parts of the machine shall be free from casting/manufacturing defects and
other irregularities. No repairs shall be done to the castings and other
components to hide their defects.

11. Supply

11.1 The tirfor shall be supplied complete in all respects including wire rope and
operating lever of sufficient length to facilitate application of required force. The
manufacturer shall obtain the following information from the purchaser before
manufacture of tirfor.

a) Load to be lifted and to be dragged,

b) Type of load, and

c) Length of wire rope used in the process.

12. Inspection certificate of test and examination:

12.1 The representative of the purchaser shall have access to the works of
manufacturer at all reasonable times for the purpose of witnessing the method
of manufacture, specified tests, inspecting the testing equipment and methods
of examination.
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12.2 Certificate of test and examination- A certificate of test and examination shall
be issued with every consignment of tirfor, giving the following information for
each one:

a) Distinguishing mark,

b) Description,

c) Back slippage of load per stroke.

d) Wire rope construction, size and grade,

e) Number tested,

f) Proof load applied,

g) Operational test load applied,

h) Rating, and

i) Month and year of manufacture.

13. Packing and Marking:

13.1. The tirfor shall be properly packed duly assembled in strong wooden boxes so
as to avoid damage during transit. One box shall contain not more than two
assemblies.

13.2 The following details shall be permanently and legibly marked on a suitable
part or name plate provided on each tirfor giving the following information:

a) Manufacturer’s name and trade mark.

b) Safe working load,

c)Maximum diameter of wire rope for which to be used.

d) Rating and

e) Month and year of manufacture

13.3 Every packing shall carry in legible and indelible lettering the following
information:

i) Type of machine packed,

ii) Number of machines packed,

iii) Production batch number,

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iv) Manufacturer’s name brand or trade mark,

v) Net and gross weight,

vi) Contract number/purchase order number and consignee,

vii) Date of inspection, and

viii) Any other particulars which the manufacturer wants to specify.

14. Tests:

14.1 All the tests specified in this specification shall be carried out at the
manufacturer’s works and shall be arranged without making any claim or
charges for such tests including labour, machinery/apparatus etc. However,
such tests, for which the facility is not available with the manufacturer, may be
conducted with reputed testing agencies after specific approval of purchaser. All
such tests shall be witnessed by the representative of RDSO/Purchaser. The
cost of samples or components destructed during type testing shall be borne by
the manufacturer.

14.2 Test certificates for the physical and chemical properties of the raw material
and that for hooks and wire ropes for their conformity to the specifications
stipulated/relevant specifications shall be obtained by the manufacturer from
the suppliers of material procured/processed. The test certificates shall be
produced at the time of inspection. The manufacturer shall also check the
chemical composition of every lot of raw material purchased and produced. The
certificate of these tests shall be produced at the time of inspection.

14.3 The representative of the RDSO/Purchaser shall be at liberty to test any or all
the components of the ‘tirfor’ to check their conformity to the specifications laid
down.

14.4 Before giving call to RDSO/Purchaser for inspection and testing of prototype,
the manufacturer shall submit a detailed test schedule consisting of the details
of each test, nature of the test, venue of the test, duration of each test and
total number of days required to complete the tests at one stretch. Once the
test schedule is approved the tests shall invariably be done accordingly.
However, during the process of type testing or even later RDSO/Purchaser’s
representative reserves the right to conduct any additional test(s) besides
those specified herein, on any equipment/sub-system or system so as to test
the system to his satisfaction or for gaining additional information and
knowledge. In case, any dispute or disagreement arises between the
manufacturer and RDSO/Purchaser’s representative during the process of
testing as regard to type test and for the interpretation and acceptability of the
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type test results, it shall be brought to the notice of Director General (Traction
Installation), Research Designs and Standards Organisation, Manak
Nagar,Luckow whose decision shall be final and bindind.

15. Submission of data drawings and particulars:

15.1 The manufacturer shall submit the detailed literature on handling operation
and maintenance of machine.

15.2 The manufacturer shall submit for scrutiny and approval, the following
drawings in triplicare in size of 210 x 297 or multiples thereof.

i) Drawing showing the assembly of machine (plan, elevation and cross section)
including a table indicating the description of item, material specification with
grade abd quantity of components used in the assembly.

ii) Individual assembly of parts wherever applicable.

iii) Detailed dimensioned drawings of each part and component.

15.2.1 After all the drawings are approved, the manufacturer shall submit three
reproducible tracing films for each drawings for signature of approving
authority.

15.3 Only after all the design and drawings have been approved and clearance
given by RDSO/Purchaser to this effect, the manufacturer shall take up
manufacture of the prototype for RDSO/Purchaser’s inspection. It is to be
clearly understood that any changes required to be done in the prototype as
required by RDSO/Purchaser shall be done expeditiously.

16. Type tests:

16.1 Type tests shall be carried out to demonstrate the suitability of

design,materials and method of construction and the capability of manufacturer
to produce the tirfor in accordance with the specification.

16.2 The manufacturer shall produce at least three prototype samples for
conducting following type tests:

i) Visual examination,

ii) Measurement of dimensions,

iii) Measurement of weight,

iv) Proof loading, and

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v) Operational test

The tests listed from (i) to (iii) above shall be conducted on three samples of
each type of tirfor. The tests listed at (iv) and (v) shall be conducted on one
sample.

17. Acceptance tests:

17.1All the tests listed in Clause 16.2 shall constitute acceptance tests.

17.2 Inspection and sampling procedure

17.2.1 The Tirfor shall be offered in lot of not more than 25 numbers, the
components essentially betonging to the same melt/batch and manufactured
from same raw material. There assemblies shall be selected at random from
every lot after it has been subjected to routine tests by the manufacturer.The
assemblies so selected shall be subjected to the tests specified in Clause 17.
Only one assembly shall be subjected to proff loading and operational test Rest
of the assemblies in a lot shall be subjected to operational test. Only such
assemblies which fail in operational test shall be rejected.

18. Criteria for acceptance:

18.1 The assemblies selected shall pass the specified tests otherwise the lot shall
be rejected. If failure occurs in proof loading and operational test of a assembly
selected, two numbers of other assemblies from the same lot shall be selected
and subjected to these tests. Lot shall be accepted if there is no failure in
retest.

18.2 Inspector shall affix an indelible stamp, punch mark or label indicating the
date of inspection and name of inspector. The label shall be affixed with special
glue so that it does not come off.

19. Routine tests:

19.1 The following tests shall be carried out by the manufacturer and records
maintained:

i) Visual examination,

ii) Measurement of dimensions, and

iii) Measurement of weight.

20. Methods of Tests

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20.1Visual Examination – The components/parts of the tirfor shall be visually

examined for any manufacturing defect, deformation of parts,
misalignment,rusting, pitting/corrosion etc. No such defects which may be
harmful to safe/satisfactory operation of tirfor shall be acceptable. The marking
shall also be seen on each tirfor for the provision of required details.

20.2Measurement of dimensions: The major and other critical dimensions of the

machine shall conform to the drawings approved by the RDSO/Purchaser.

20.3 Measurement of weight: The weight of each type of machine shall be

measured and shall be as per approved drawings.

20.4 Proof laoading- The ‘trifor’ shall be tested prior to operational test with a static
load of twice the safe working load of which it shall withstand for at least two
minutes without permanent deformation of any component.

20.5 Operational test – After proof loading the lifting and pulling machine shall be
made to lift 1.5 times the safe working load through a distance of 30 cm in
such a manner as to ensure that every part of mechanism comes under load.
During the test, there shall be no deformation of any component part.

20.6 Examination- After proof loading and the operational test, the tirfor shall be
thoroughly examined for freedom from deformation, cracks, flaws or other
defects on the components. It will be treated to comply with this standard only
if it is found free from deformation, cracks, flaws or other defects.

21. Guarantee:

21.1 All the tirfors supplied shall be guaranteed for a period of two years from the
date of receipt by the consignee.

22.0 All the provisions contained in RDSO’s ISO procedures laid down in
document No.- QQ-D-7.1-11 dated 19.07.2016 Titled “ Vendor- change in
approved status”) and subsequent versions/amendments thereof, shall be
binding and applicable on the successful vendor/vendors in the contracts
floated by Railways to maintain quality of products supplied to Railways”.