Spec Detc 241011emu

Page 1 of 80 Effective from 01.08.2011 Spec No.TI/SPC/OHE/8WDEIC/0090(02/09) Rev.
SPECIFICATION NO.TI/SPC/OHE/8WDEIC/0090 (02/09) Rev.1
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION
FOR
8-WHEELER DIESEL ELECTRIC INSPECTION &
MAINTENANCE OHE CAR UNDERSLUNG TYPE
FOR
OPERATION ON BROAD GAUGE (1676 mm)
(August’ 2011)
Issued by
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226011
(For Official use only)
Page 2 of 80 Effective from 01.08.2011 Spec No.TI/SPC/OHE/8WDEIC/0090(02/09) Rev.1
SPECIFICATION NO.TI/SPC/OHE/8WDEIC/0090 (02/09) Rev.1
Amendment Date of Total pages including Amendment/Revision

Number Amendment annexure
0 NA First issue
Nil 1.08.2011 80 Revision-1
PREPARED BY CHECKED BY APPROVED BY

SIGNATURE
DATE
DESIGNATION SSE/TW Dy Director/TI EDTI
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. This specification is not for general use.
Chapter - I
GENERAL CONDITIONS
1.1 Scope
1.1.1 This specification covers the design, manufacture, supply, testing & commissioning of
self-propelled 8-Wheeler Inspection & Maintenance OHE car for operation on broad
gauge (1676mm) electrified (25 kV a.c.) routes of Indian Railways. The 8-Wheeler
Inspection & Maintenance OHE car is a self-propelled 4-axle vehicle and is used for
periodical inspection, patrolling and maintenance of traction overhead equipment (OHE).
It shall also be used for attending to sites of break down, restoration and damaged OHE
etc. It is also required to erect small lengths of catenary and contact wire by way of
repairs of damaged OHE. The 8-Wheeler Inspection & Maintenance OHE car uses the
power generated by the Diesel Alternator set provided in the OHE car for propulsion and
not the power from live OHE.
1.1.2 In case of difference between the specification and / or exhibited drawings, the tenderer
shall get an immediate clarification from RDSO which shall be final authority for
clarification.
1.2 CLIMATIC CONDITIONS
1.2.1 The power pack & electrics of the OHE car shall be in continuous operation under the
following atmospheric and climatic conditions: -
1 Atmospheric Metallic surface temperature under Sun: 75° C max. and in shade:
temperature 55 °C max.
Minimum temperature: - 10°C (Also snow fall in certain areas

during winter season).
2 Humidity 100% saturation during rainy season.
3 Reference site i) Ambient Temp. : 50° C
conditions ii) Humidity: 100 %
iii) Altitude: 1000 m above mean sea level.
4 Rain fall (i) Ranging from 1750 mm to 6250 mm.
(ii) Number of rainy days/annum 120
5 Atmosphere Extremely dusty and desert terrain in certain areas. The dust
during hot concentration in air may reach a high value of 1.6 mg/m³. In many
weather iron ore and coalmine areas, the dust concentration is very high
affecting the filter and air ventilation system.
6 Coastal area OHE car and its equipments shall be designed to work in coastal
areas in humid and salt laden atmosphere with maximum. pH
value of 8.5, sulphate of 7mg per liter, max. concentration of
chlorine 6 mg per liter and maximum conductivity of 130 micro
siemens/cm.
7 Vibration The equipment, sub-system and their mounting arrangement shall
be designed to withstand satisfactorily the vibration and shocks
encountered in service as specified in clause 1.2.2.
High level of 50 g vibration and shocks. Accelerations over 500

m/s² have been recorded at axle box levels for long periods during
run. Vibrations during wheel slips are of even higher magnitude.
8 Wind speed High wind speed in certain areas, with wind pressure reaching
200kg/m²
1.2.2 The equipments and their arrangement shall withstand satisfactorily, the vibration and
shocks normally encountered in service which are as below:-
(a) Maximum vertical acceleration 3.0g

(b) Maximum longitudinal acceleration 5.0g
(c) Maximum train acceleration 2.0g (g - being acceleration due to
gravity)
1.2.3 The OHE car shall be able to negotiate water logged tracks at 10 kmph, with water level
of 102 mm above the rail top, for which the equipment shall be suitably designed.
1.2.4 The OHE car and its principal assemblies shall be designed and manufactured to give
satisfactory performance in the tropical climate, having very dry & dusty regions in arid
zones of the country, to humid coastal areas and extreme cold climate of the northern
region..
1.3 Examination of the Tender Offer:
1.3.1 The tenderer is required to furnish clause by clause comments to this specification, either
confirming acceptance of the clause or indicating deviation therefrom.
1.3.2 A comprehensive specification of the OHE car as offered shall be submitted separately.
1.3.3 In the event a tenderer is unable to comply, either partially or fully, to any of the
stipulations made in this specification, it must be brought to the notice of purchaser with
full particulars of the deviations, technical details, cost implications and past service
performance, etc.
1.3.4 The evaluation of bids shall, inter-alia, take into consideration the fuel efficiency of the
diesel engine. For this purpose the bids shall be loaded by capitalized cost of additional
fuel and lubricating oil consumption over and above the base consumption at 75% of the
rated output of the diesel engine. The lowest values of fuel and lubricating oil
consumption quoted by the technically suitable tenderer shall form the basis for the
purpose of comparison .The bidders shall enclose fuel and lubricating oil consumption in
litres per hour at 75% of the rated output of the diesel engine as issued by the OEM of the
diesel engine.
The fixed parameters for evaluating the capitalized cost shall be as under :-
1. Life of the diesel engine 18 years

2. Annual operating period 2000 hrs.
3. Cost of fuel per litre } Prevalent on the
4. Cost of lubricating oil / litre} date of opening of bid
5. Rate of interest 12%
1.4 Design Development:
1.4.1 The successful tenderer (hereafter called as contractor) shall develop the design based on
the details given in this specification and sound engineering practices. The entire design
& technical data along with calculations shall be submitted to RDSO for approval before
commencing construction of OHE car or placing orders on sub-contractors.
1.4.2 The design shall be based on S.I. Units.
1.4.3 From the information given in this specification and instructions of RDSO, the contractor
shall prepare a full set of engineering drawings and submit the same to RDSO for
approval.
1.4.4 When submitting drawings of a particular detail, other details depending on it shall be
shown in juxtaposition.
1.4.5 Material specifications, manufacturing tolerances and other details, which are necessary
for manufacture for each component shall be indicated on the drawings.
1.5 Approval of Drawings:
1.5.1 “Approval” to the drawing means the approval to the general adoptability of the design
features. RDSO shall not be responsible for the correctness of dimensions on the
drawings, materials used, strength or performance of the components. The contractor
shall be wholly and completely responsible for all these variables. The contractor, when
submitting proposals or designs for approval of the RDSO, shall draw attention to any
deviation or departure from the specification involved in his proposals or drawings.
1.5.2 Drawing for approval shall be submitted in standard size (s) as per IS: 696 along
with main calculation details in triplicate. List of drawings/calculations to be submitted to
RDSO for approval before undertaking manufacture of prototype DETC are given in
ANNEXURE-2. Any other drawings of which manufacturer desires to obtain approval
of RDSO shall also be submitted to RDSO.
1.6 Prints:
1.6.1 One set of tracing, two sets of their prints & two DVD of the RDSO approved drawings/
calculations shall be supplied by the successful contractor with each tower wagon. The
tracings shall be on RTF of durable quality. Drawings shall be made on Auto CAD. Two
sets of tracing, two sets of prints and two copies of approved drawings & calculations
along with 3 DVDs shall be supplied to RDSO.
1.6.2 Each set of tracings shall form a complete set of working drawings, the first sheet being
the index and the following sheets being arranged properly to show the various
assemblies, sub- assemblies and components of complete works in the following
sequence:-
(a) Diagram sheets show the overall dimensions of the equipment, weights and the
relation of overall dimensions to the space in the OHE car.
(b) Lists of all parts grouped in to major assembly with details of numbers per set,
weight, specification material and drawing reference against each item.
(c) General arrangement drawings of complete equipment sets. Diagram of lubrication
points indicating type of lubricant. Sub-assembly arrangement, drawing in proper
and logical sequence.
(d) Detailed drawings:- On detailed drawing sheets, each part shall be identified by an
alphabetic letter and the list of all parts forming the sub-assembly shall be tabulated
just above the title block on the same sheet giving details against each alphabetic
letter.
1.7 Contractor’s responsibility:
1.7.1 The contractor shall be entirely responsible for the execution of the contract strictly in
accordance with the terms of this specification and the conditions of contract,
notwithstanding any approval which RDSO or the Inspecting officer may have given:
(a) Of the detailed drawing prepared by the contractor.

(b) Of the sub-contractors for materials.
(c) Of other parts of the work involved by the contractor.
(d) Of the tests OHE carried out either by the contractor or by the RDSO or the
Inspecting Officer.
1.8 Guarantee:
1.8.1 Any component of the OHE car failing or proving unsatisfactory in service within 36
months from the date of commissioning in India due to defective design, material or
workmanship shall be repaired/ replaced by the contractor free of cost. Further, should
any design or material modification be made in any part of the equipment supplied or as
a result of any defect/lacuna/ fault/short-coming in the original design features or material
the period of 36 months for that assembly/sub-assembly would commence from the date
modified part is commissioned in service. Spares required if any during the warranty
period shall be supplied & commissioned free of cost by the contractor. The tenderer
shall specify the maintenance schedule required to be OHE carried out by railway during
and after the expiry of warranty period.
1.9 Exhibited Drawings and standard Specifications:
1.9.1 “Exhibited Drawings” means the drawings which are exhibited or provided by RDSO
for the guidance of the contractor.
1.9.2 The exhibited drawings, illustrative of a range of standardized dimensions and fittings,
are listed in Annexure -1. The design of the OHE car must comply with the dimensions,
and fittings included in the exhibited drawings as far as possible. Any deviation
therefrom shall be clearly mentioned in the form of a table on the drawing.
1.9.3 The exhibited drawings are not guaranteed to be free from discrepancies. The contractor
while preparing the engineering drawings shall ensure that these are free from
discrepancies. He shall also incorporate all modifications desired by the RDSO,
subsequently, without prejudice to the date of delivery or contracted price, except as
provided for under the conditions of contract.
1.9.4 To improve upon the performance, modifications and corrections are made in the
specification and drawings from time to time. The contractor must, therefore, satisfy
himself that the drawings being used by him are of the latest version. In case of any
doubt, he must get it clarified from RDSO.
1.9.5 The Contractor shall procure at his own expense all the drawings and specifications
required for the manufacture of the OHE car.
1.9.6 Copies of drawings referred to in this specification and given in Annexure-1 may be
obtained from RDSO on payment.
1.9.7 Indian Railways Standard (IRS) specifications and Schedules of Maximum Moving
Dimensions may be obtained on payment from the Manager, Government of India
Publications, Civil Lines, Delhi 110 006 (INDIA).
1.9.8 Indian Standard Specifications (ISS) are available from Bureau of Indian Standards, 9-
Bahadur Shah Zafar Marg, Delhi 110 002.
1.10 Materials:
1.10.1 Materials used in the construction of the OHE car shall comply with the relevant IRS
specifications or Indian Standard Specifications. Where IRS or ISS do not exist for
specific components, the contractor shall submit proposed material specification for
approval of RDSO.
1.11 Service Engineers:
1.11.1 The Contractor shall arrange for the supervision of commissioning of the OHE car
immediately after their receipt at ultimate destination. He is also required to OHE carry
out joint check of the receipt of components regarding short shipment or transit
damages.
1.11.2 The contractor shall ensure commissioning of the OHE car within 30 days from the date
of intimation by the consignee.
1.11.3 The performance of OHE car shall be demonstrated by the contractor after its successful
commissioning at the consignee‟s works.
1.11.4 The contractor shall provide and ensure servicing facilities in India through out the
warranty period. After the warranty period is over, he shall, on call, give service support
for troubleshooting and for obtaining spare parts.
1.12 Training:
1.12.1 The Contractor shall arrange to provide training in operation & maintenance of the OHE
car at their manufacturing works one man week per tower wagon. The charges for
providing these facilities (excluding travel, boarding and lodging) should be indicated
separately. The charges for travel, boarding and lodging shall be borne by the Railways.
1.12.2 Technical experts of the manufacturer, during commissioning of OHE car at consignee‟s
premises, shall also adequately train operators/ maintenance staff nominated by the
consignee for minimum period of 3 days.
1.13 Service Manuals and Spare Parts Catalogues:
1.13.1 Detailed Maintenance & Service Manuals including the manual for trouble shooting &
operational requirement, spare parts catalogues for the driver and maintenance staff for
the OHE car shall be prepared and three copies supplied free of charge, per OHE car, to
the consignee. Before printing the final version of the manual, the draft of the Manuals
shall be got approved from RDSO.
1.13.2 Three copies per OHE cars of Spare Parts Catalogues & list of must change items with
periodicity & sources of supply shall also be supplied to the consignee.
1.13.3 In addition, three copies each of the Maintenance/Service and trouble shooting manual
alongwith shall be supplied to RDSO.
1.14 Electric Arc Welding:
1.14.1 Indian Railways Standard Code of Practice for Electrical Arc Welding shall be followed.
If the contractor desires to follow any other code of practice, it shall first be submitted for
approval of RDSO.
1.14.2 Welding symbols shall be in accordance to IS:813. Drawings on which such symbols
appear, are to bear a note on the bottom left hand corner, “WELDING SYMBOLS AS
PER IS:813”.
1.14.3 Railway Initial Letters: Where parts are required to be marked with Railway initial
letters, they shall be „I.R‟
1.15 Sublet Orders for Materials: Any subletting of orders for materials/work shall have
prior approval of RDSO.
1.16 Spare Parts:
1.16.1 Unit exchange spare parts shall be indicated. However, final decision to buy these will
rest with the purchaser.
1.16.2 The prices for these spares shall be quoted separately. These spares shall be for every set
of 10 OHE cars or part thereof. The prices shall not be used for tender evaluation
purpose.
i) Flexible coupling/ - 1 set

engine connection (complete)
ii) Traction alternator alongwith - 1 set

power rectifier
iii) Air compressor (complete) - 1 unit
iv) Motorised bogie (complete with

break gear) - 1 set
v) Battery charger for charging of - 1 unit

starter batteries
vi) Auxiliary alternator - 1 set

1.16.3 The tenderer shall be responsible to ensure subsequent availability of the spare parts for
the normal life of the respective equipment.
1.17 Tools: List of tools required for maintenance and overhaul of the OHE cars shall be
submitted by the tenderer in accordance with Clause 6.1 of this specification. The
successful tenderer shall submit the drawings and specification of special maintenance
tools required for the maintenance of the OHE car.
1.18 Testing Kit: The tenderer shall quote for each tower OHE car testing equipment
required for ensuring optimum performance and trouble-free service of the equipments &
accessories provided in the OHE car (e.g. diesel engine, traction alternator, traction motor
and other equipments with other accessories). The testing equipment shall be listed and
quoted for item wise. The tenderer shall also offer separately special jigs, tools and
instruments, which shall essentially be required for maintenance of OHE car body.
Essential equipments and facilities required for attending local damage to stainless steel
structures, OHE car interiors etc. in case of accidental damages should also be furnished.
The contractor shall demonstrate to the IR, the satisfactory functioning of the tools, jigs
& instruments supplied by him. The specification of testing equipments shall be provided
by successful tenderer.
1.19 A themovision camera as per RDSO‟s specification No. ,video camera to capture
picture at 100 kmph along with software to transfer the picture and video shoots on the
computer , one hydraulic jack of 5 t capacity, one tirfer 3t, two tirfer 3/2 t, three pull-lift
3/4t, two pull-lift3/2 t and one pull-lift 3t shall besupplied along with OHE car.
1.20 Quality Assurance Plan
1.20.1 The contractor should posses valid ISO-9001:2000 certificate for his work‟s address,
covering the items for which he is participating in the contract. The contractor shall
formulate Quality Assurance program (QAP) detailing the methodology proposed to be
followed to ensure a quality product. QAP shall cover quality assurance procedures and
procedures to be followed during all stages of design, manufacture, testing and
commissioning of the equipment. The Contractor shall define the role of each functional
group in the organisation for achieving the required quality of the product and submit a
comprehensive document “ Quality assurance manual” in accordance with IS 10201-1982
as the basic guideline. The preparation of necessary charts and proforma shall be to IS:
7200 (Part- III)-82.
1.20.2 The tenderer whose bid is accepted, shall be required to submit a “Quality Assurance
Manual” by giving details as to how the quality of specific product is proposed to be
assured. Supply of the equipment shall commence only after “Quality Assurance Plan”
has been approved by RDSO.
The above shall apply to the main contractor as well as sub-contractors.
1.21 Annual Maintenance Contract (AMC) :

1.21.1 The tenderer shall quote for AMC comprehensive of all in all inclusive of all equipment
including diesel engine complete with transmission, compressor unit and cooling system
for 3 years during the warranty period of 36 months and separately for 5 years after
warranty is over. The tenderer shall quote year wise rates of AMC detailing the various
schedule enlisting the requirement of material/ spare parts and services to be rendered by
him after regular intervals. The tenderer shall keep adequate spares in stock for regular
schedule of AMC so that maintenance schedules are completed timely. AMC shall be all
inclusive of replacement of parts if required either due to breakdown or wear. The AMC
cost shall be considered while evaluating the inter-se tender position. It shall be
compulsory for the tenderer to quote for AMC. However, the decision to enter into AMC
shall vest with Railway alone.
Chapter -II
DIMENSIONAL OPERATING AND OTHER REQUIREMENTS FOR OHE CAR
2.0 The OHE car shall dimensionally conform to the following:
1. Track gauge 1676 mm

2. Minimum radius of 175 m. It should also be capable of negotiating.
curve i) a radius of 213m in case of 1 in 8-1/2 BG turnout with 6.4
m over-riding switch.
ii) 175 m radius in case of 1 in 8-1/2 scissors crossing.
3. Maximum super 185 mm

elevation
4. Maximum Super - 100mm
elevation
deficiency
5. Maximum wind 200 kg/m2
pressure
6. Maximum moving Maximum moving dimensions shall conform to diagram 1D of
Dimensions Indian Railway Schedule of Dimension (SOD) 1676 mm gauge
(BG) revised 2004 with the pantograph and platform in lock
down condition. Infringements, if unavoidable and fully
justified, may be considered, if within the limits shown in SOD
1676 mm gauge (BG) revised 2004.
7. Maximum These shall conform to Indian railway, schedule of dimension

permissible wheel 1676 mm gauge (BG) Revised 2004. Adequate clearance shall
base length of the be allowed so that no component of the OHE car shall infringe
OHE car, over a minimum of 102 mm above rail level with wheels in fully
hang beyond worn conditions, full deflection of springs and effect of
bogie center, buffer dynamics.
height draw bar
height
8. Maximum Axle 20.32 t
load
9. (i) Maximum 105 Km/h
Speed when
coupled to a
train
(ii) Max operating 105 km/h
speed under its
own power
10. Brakes All wheels with clasp brakes.
11. Service Braking Pneumatic

12. Performance i) Pay load (excluding Power equipment Approx.12 t
capabilities:- and hydraulic platform)
ii) Period of continuous running at 110 km/h 5-1/2h total
on generally tangent track followed by (4h+1-1/2h)
frequent to and fro movement at
walking pace for 1-1/2 h).
iii) Period of continuous running at 40 km/h 5-1/2h total

up or down gradient of 1 in 60 to be (4h+1-1/2h)
followed by frequent to and fro
movement up to 5 km/h for 1-1/2 h on
same gradient with speed control.
iv) Performance in monsoon and squally Un- restricted

conditions.
v) OHE car shall be capable of running at a speed of 75kmph
with 2-loaded flat wagons weighing 120t at tangent track.
vi) The OHE car shall be capable of running at a speed of 25
km/h on 1 in 33 up gradient
vii) The OHE car shall be capable of starting and hauling 2 nos
loaded bogie flat rail wagon weighing 120 ton on an up
gradient of 1 in 33. Maximum operating speed of the OHE
car for level and 1 in 33 up gradients shall be indicated with
the offer.
viii) With the hydraulic platform in raised condition the OHE

car shall run at a maximum speed of 10 km/h.
ix) The emergency braking distance (EBD) for fully loaded
(20.32x4=81.28 t) OHE car from maximum speed of
110km/h to zero shall not be more than 800m on flat
section. The contractor shall also submit calculation for
EBD on 1 in 33 down gradient.
2.1 The purchaser may at his option revise the layout so as to provide for an arrangement for
front opening on one side to load and unload collapsible ladders from the trackside.
Tenderer may offer alternative proposals with full details of the advantages of his system.
2.2 The OHE car shall be an 8-wheeler vehicle. The disposition of equipment storage space
shall be such as to ensure equal axle loads. Design shall be such as to afford easy
inspection and maintenance.
2.3 Provision shall be made for the following in the OHE car:
2.3.1 Driving Cabs:
i) Two driving cabs shall be provided, one at each end, with complete operating & driving
control with dash boards to facilitate operation from either cab. Driver‟s seat shall be on
the left side. Adequate leg space shall be provided for the driver when he is seated. The
general layout and arrangement of equipment in Driver‟s cab shall follow UIC CODEX
651 with respect to dimensions, safety features, furnishing, lighting, ventilation, noise
level, field of view, driver‟s desk, seats etc. Spot lights shall be provided at suitable
locations. The cab shall be ergonomically designed for better view and comfort and also
the various panels /equipments meant for Driver shall be so laid that they are easily
readable and Driver is not required to move physically for any operation during run.
ii) Foldable cushion sheet shall be provided in each of the driving cabs for 4 persons in
addition to the Driver.
iii) All controls, brake handle, hand brake, Dead Man‟s device for horn and indication
lamps/meters shall be within easy access and view of the Driver.
iv) The OHE car shall be equipped with inter-communication equipment between cabs,
Inspection compartment, working platform through hand free sets with their own battery.
v) Both the cabs shall be provided with 6 Inch TFT monitor connected with one portable
CCTV camera at each end on deck.
vi) 2 numbers, 110 V sockets for hand signals in each cab.
vii) Head Light, Flasher lights search lights and marker lights at both ends of the cab, refer
para 4.5.
viii) OHE voltage sensing device in both the cabs.
ix) Full width single piece stone proof lookout glass with sun screen shall be provided in the
end wall of each Driver‟s compartment and these shall be glazed, clear, colourless
polyOHE carbonate to ICF spec no.ICF/MD/SPEC-159 (latest revision).
x) Provision of wind screen wiper arm and blade assembly to be provided as per RDSO
specification no.C-K306 (Rev 01). Provision shall be made for water spraying on wind
screen to avoid any scratches on wind screen during wiping.
2.3.2 It is proposed to keep one drum each of contact and catenary wire, duly mounted on the
stand, for erection during the restoration of breakdowns. Provision shall be made for
rotating the contact wire drum by 180 degree for matching contact wire groove in either
direction is possible so that it shall be possible to pay out the wire in either direction.
Stands shall be provided with hand brakes to control the tension in the wires during the
laying out process. It shall be possible to lay-out wires in either direction and therefore
these drum shall preferably be in the middle of the OHE car. The drums be loaded from a
sliding door of adequate size on both sides. The laying out of the wire shall be from two
of the openings of suitable size in the roof vertically above each of the drums. These
openings shall normally be covered so as to prevent water falling into the OHE car.
2.3.3 Successful tenderer shall submit mounting drawings for conductor drum as per principle
details given below for approval of RDSO.
The principal details of the conductor drums are-

(a) Diameter- 1900 mm
(b) Width- 950 mm
(c) Bore for mounting on the stand- 105mm x 105mm
(d) Facility shall be provided to rotate the conductor drums to enable pay out the
conductor in either direction
2.3.4 The facilities to be provided in the OHE car shall be as described briefly in the following
Clauses.
2.3.4.1 Material Cabin: A material cabin shall be provided adjoining one of the driving cabs
having adequate space and proper locking arrangement for the storage of costly
equipments and fittings. A reasonable number of cup-boards having sufficient number of
pigeon holes shall be provided inside the material cabin for storage of fittings, tools and
tackles, lighting equipment and other fragile spares. Suitable shelves/racks shall also be
provided for storage of about 50 MS tubes of upto 47mm dia and upto 4m long, hangers
for insulators, apart from these two steel almirah (with five shelves) shall be provided for
keeping costly items & essential records.
2.3.4.2 Workshop: A well-ventilated workshop shall be provided in the middle equipped with
exhaust fans, ceiling fans and windows, with a room for 4 persons to stand and work. On
one side a workbench of size 2500mm x 900mm shall be provided. It shall be fitted with
two vices to under take minor repair work along with one drilling machine. On the side
opposite the workbench, racks/cup board shall be provided for tools and plant. Design/
drawings of these equipments shall be submitted to RDSO for approval.
2.3.4.3 Storage space: Adequate space shall be provided for installation and storage of
equipment such as emergency lighting equipment and other items supplied with the OHE
car.
2.3.4.4 Staff Cabins: One cabin for officers/staff with four cushioned berths shall be provided.
The cabins shall have separate entry and have windows on both sides. The cabins shall
preferably be not over the wheels and made sound proof as far as possible. An Indian
style WC with separate over tank, stainless steel sink and other accessory fitting and a
folding cushioned seat including shower with flexible hose shall be provided. The WC
shall be provided with an exhaust fan. The officers/staff cabin shall be insulated properly
and shall be air conditioned. Provision of two mobile charging points to be made in
officer/staff‟s cabin as well as in both the driving cab and working area. In addition two
folding berths shall be provided at suitable location without cabin.
2.3.4.5 Communicating doors: Each driving cab shall have independent entry from both sides.
The OHE car lobby shall have entry from both the cab. Through communication inside
the OHE car shall be provided. It shall be possible to isolate the cabins using sliding
doors with locking arrangements.
2.3.5 Facilities on roof:
i) The OHE car shall be provided with a pantograph similar to AM-12 type with foot
insulators and its complete actuating mechanism on one bogie center. Pantograph shall
be graduated to enable manual measurement of stagger on either side of track center.
ii) For illumination of roof for night inspection four water proof industrial plug points
shall be provided for fixing portable lights.
iii) Two pneumatic points for connecting pneumatic operated/driven tools and fasteners
shall be provided.
iv) Observation dome: An observation dome shall be provided in the roof near the
pantograph so as to observe interaction between the contact wire of the OHE and the
pantograph. Two to three persons shall be able to sit comfortably in the observation
dome. The upper portion of the dome shall be of polyOHE carbonate /FRP with
reinforcement if required for adequate strength and shall also be insulated for 25 KV.
This shall be properly insulated & segregated for air conditioning. The arrangement
shall be such that an unobstructed view of the contact between contact wire and
pantograph is obtained by the persons in the observation dome without any strain. For
this it is essential to have suitable ergonomical design of sitting arrangement. The
chair provided in the observation dome shall have adjustable height, back rest with
back and front adjustment just like in an automobile OHE car. The part of dome shall
be air conditioned and partitioned / separated for effective air conditioning in
observation area by making suitable provision of A/C plant, refer para 5.8.1(ix) (ix).
v) A lifting and swiveling platform with hydraulically operated mechanized adjustment

for height and rotation and capable of taking minimum 600 kg load with under-noted
features shall be provided over the fixed platform:-
(a) Length 5700 mm

(b) Width 1600 mm
(c) Platform floor 6150 mm

level above rail when elevated.
(d) Maxim lifting time to full height 45 s
(e) Rotation range of 900

Platform towards sides.
(f) Side shifting reach of platform 4200 mm
(g) Full height of collapsible 800 mm

railing above platform floor
(h) Maxm. time of rotation from 45 s

00 position to 900
NOTE:
(i) Control for lifting, lowering and swiveling shall be provided on the platform.
The raising and swiveling of the platform shall be gradual and without jerks. In
addition two emergency stop switches shall be provided on each side of the
platform to bring the OHE car to an emergency halt.
(ii) Two search lights of 250 W metal halide lamps shall be provided on the
platform for inspection of the overhead equipment while on the run.
Searchlights shall be capable of swiveling on universal joints type support and
swiveling control shall be from inside of the either cab.
(iii) Except space for pantograph and observation dome the remaining roof shall be
covered with a 2325mm wide fixed working platform at maximum possible
height but within the maximum moving dimensions. This fixed platform shall
be provided with four approach ladders, two on each side to climb on to the
platform from the ground.
2.3.6 Provision shall be made to OHE carry 3 OHE masts of 9.5 m and 1of 12 m lengths. The
masts may either be rolled I beam of 150mm x 200mm size or fabricated structure of
250mm x 300mm.
2.3.7 Suitable safety measures including interlocks between various equipments, access doors
and line equipment shall be provided to ensure.
(i) Safety of men and

(ii) Stability of the OHE car while in operation.
The tenderer shall indicate the proposed interlocking and safety aspects.
2.3.8 The entire OHE car including bogies, superstructure alongwith equipment is to be
effectively earthed as per standard practice for rolling stock. Schematic and other detailed
drawings for earthing shall be got approved by RDSO.
2.3.9 The equipment fixed to the under frame shall be secured properly by providing extra
metallic chains of adequate strength to safeguard the equipment and to perform
efficiently.
Chapter - III
3.0 MECHANICAL DESIGN
3.1 Superstructure:
3.1.1 General: The OHE car shall be of welded light weight construction, generally to
maximum moving dimensions to diagram 1D of Indian Railways Schedule of Dimension
1676 mm gauge (BG) revised 2004 (SOD) with pantograph and platform in lowered
condition. Infringements, if unavoidable and fully justified, may be considered, if within
limits shown in the SOD. Weight of the OHE car shall be kept as low as possible, without
compromising with the strength. The structure shall withstand end load of 200 t (divided
equally between the two buffers) applied in conjunction with full payload. Under such
loading no permanent deformation should occur and stresses should remain below the
yield point. The design shall be sufficiently rigid to withstand stresses imposed due to
lifting with overhead or breakdown cranes or by jacks applied to the headstocks. The
superstructure shall be designed as a tubular girder for the purpose of withstanding
vertical loading, but the inner sheeting of the roof and walls shall not be stress- bearing
members.
3.1.2 The under frame shall be designed to meet the following loads:
i. A vertical load of 4 t/meter run uniformly distributed. The weight of the various
equipment mounted in the OHE car shall be considered as concentrated load and
shall be simulated as such during load/strain testing.
ii. A horizontal squeeze load of 100 t applied at each buffers.
iii. A combination of loads specified at (i) & (ii).
3.1.3 The stresses estimated by an approved method shall not exceed 139.3 MPa (14.2 kgf
/sq.mm) for members made from steel to IS:2062 Fe 410CuWC and 221.7 Mpa (22.6Kgf/
sq.mm) for members made from corrosion resistant steel to IRS:M 41 for the uniformly
distributed vertical load. Also for the squeeze load referred to above, the stress should not
exceed 90% of the lower yield point or proportional limit of the material in the load OHE
carrying member of the shell and 95% of the lower yield point or proportional limit of the
material in the end construction. The estimated vertical deflection of the shell at the
center of the OHE car shall also not exceed 10mm under any loading condition detailed
at (i) to (iii) above.
Completed shell of prototype OHE car shall be strain gauged for stress analysis under
tare and loaded conditions with squeeze load. OHE car shall be tested for leakage through
roof and body sides and ends at the works of the manufacturer. To OHE carry out this
test, the manufacturer shall provide a test rig to the satisfaction of the inspecting
authority.
3.1.4 Side and End Wall

(i) Material: The frame work shall be of low alloy high tensile corrosion resistant steel to
IRS M-41 with latest revision/amendment.
(ii) Side wall and pillars: The material of body pillar shall be IRS M-41. Pillars shall be
continuous from sole bar to cant-rail, except below window openings, and shall be braced
by longitudinal members between adjacent pillars. Bracing being designed to act as
integral part of the exterior sheeting.
3.1.5 Body shell Structure: The body shell including sheathing shall be of IRS: M 41 steel.
3.1.6 Underframe: The underframe material shall be of corrosion resistant structural steel to
IRS: M 41 or copper bearing quality steel to IS: 2062 Cu WC, of welded integral
structure. The under frame design shall be as per ICF drawing No AC/DC/EMU/C2-1-1-
201 with latest alteration. They shall be assembled in jigs and fabricated by welding.
Trough floor of 2.0 mm thick of steel to IRS: M 41 steel shall be provided in covered
area.
3.1.7 Headstocks: These shall be of robust design suitable for coupling and buffing gear
arrangements as detailed in this specification. Head stock material shall be IRS:M 41
steel.
3.1.8 Draw gear members: The members provided for OHE carrying the trimmer casting shall
be of strong and rigid construction capable of transmitting buffing forces specified in
Clause - 3.1 under the most adverse operating conditions. They shall be braced together
to the main sills in such a manner as to form, in conjunction with the flooring system
between the transom and headstock a rigid assembly capable of withstanding all cross-
racking forces, which may occur in service. The design shall, as far as possible, ensure
that the load is applied symmetrically about the neutral axis of the longitudinal and is
concentric to them.
3.1.9 Draw & Buff Gear: The OHE car shall be provided with high tensile centre buffer
transition coupler conforming to RDSO specification no.56-BD-07 along with the side
buffers arrangement to RDSO‟s Drg. No. SK-98145. The arrangement shall be such that
OHE car shall be able to couple with existing BG rolling stock of Indian Railways.
3.1.10 Lifting Pads: The OHE car body shall lend itself to repeated lifting in workshop by
overhead cranes or jacks without risk or damage. Suitable lifting pads shall be provided
and marked in a readily distinguishable manner on the OHE car body.
3.1.11 Sole bar: These shall be continuous members from headstock to headstock, adequately
braced together to withstand the head on loading and cross racking forces and shall be
capable to withstand jacking for the purpose of lifting the OHE car. The sole bar shall be
of corrosion resistant structural steel to IRS: M 41 steel. The design of sole bar shall be as
per ICF drawing No EMU/M2-1-1-541.
3.1.12 Body bolster: These may be fabricated from pressed section and shall have suitable pads
on which lifting slings may be placed. Body bolster shall be of copper bearing quality
steel to IS: 2062 Cu WC of welded integral structure.
3.1.13 Floor bearers: The design of floor bearers shall include robust main floor bearers placed
transversely between the main sills and an adequate numbers of racking panels between
the main sills and diagonal braces. The transverse floor bearers shall be so designed to
OHE carry the maximum super-imposed load under maximum load conditions as well as
bracing between the main sills, and shall be flushed with the top faces of the main sills,
and a suitable surface for the floor covering. The design shall generally ensure adequate
drainage, so that corrosion is avoided, or is confined to parts, which can be readily
renewed without affecting the main flooring members. Floor bearers shall be conforming
to IRS: M 41 steel.
3.2 Roof
3.2.1 The roof shall be designed to form a satisfactory chord to the superstructure considered as
a girder, and to take a concentrated load of 6 men standing (450 kg), close together at any
point. The structure shall consist generally of two main longitudinal members running
from end to end of the OHE car, braced at frequent intervals along their lower flanges,
and rigidly connected to the arch bars, and to the grab pillars by rigid transverse
members. At partition and semi bulkheads, the sills shall be attached to vertical pillars
within or forming part of the partitions or semi-bulk-heads The roof top at both ends i.e.
back & front ends shall be flat. Roof should be so designed that no water is accumulated
in cavities to avoid the damage/rusting. Proper channels to be provided for easy exit of
rain water. The construction through out shall be absolutely watertight and shall permit
easy renewal of corroded sheets. The material of the roof shall be of IRS: M 41 steel
sheet.
3.2.2 Four openings shall be provided in the roof for erection of catenary and contact wires in
either direction. The openings shall be of suitable size to permit paying out of the
conductors in any direction, when the OHE car is moving slowly at 5-10 km/h speed,
without any obstruction, rubbing or scrapping.
3.2.3 Roof Ventilators: Roof ventilators shall be provided as per the ICF Drg No WL.RRM4-
7-3-401 with latest alteration shall be used. The ventilator shall not violate the schedule
of dimensions & drawings to be got approved from RDSO.
3.2.4 Air Space: The air space between the outer and inner sheeting of the roof shall be
suitably ventilated as also the air space inside walls and end walls. Attachments may pass
through the air space as required, but must be designed, so that they do not cause sections
to form sealed chambers or lodgments for condensed moisture.
3.3 Windows:
Lift type window made of powder coated aluminum to ICF drawing No EMU/4C/ASR-5-
4-402 with latest alteration with fixed type poly OHE carbonate louver on top and
movable glass window at the bottom.
3.3.1 All window and door glasses shall be of laminated plate glass set in sun heat resistant
synthetic rubber section.
3.3.2 All window openings shall be true to dimensions square and of uniform width. The
window opening shall not at any point exceed 2mm over or under the specified
dimensions and shall not be out of square by more than 2mm.
3.3.3 The windowsills of the body side windows shall have an outward slope of approximately
50.
3.3.4 The body side windows shall have two shutters, one louver on the outside and a glass on
the inside.
3.3.5 The glass used for windows/shutters shall be of safety laminated quality to IS: 2553,
weighing not less than 9.76 kg/m2. Gravity safety latches of approved design shall be
provided at two intermediate positions to arrest the glass and louver shutters from falling
down. The shutters should be balanced by balancers of suitable design.
3.3.6 The louver shutters shall be provided with shoot bolt type safety latches to secure the
shutters firmly in closed and open position.
3.4 Doors
3.4.1 All door openings shall be true to specified dimensions and perfectly square. The
openings shall be tested for size and squareness with templates so that doors open and
close freely and when closed shall be reasonably weather proof and dust proof.
3.4.2 Hinged doors provided on the side walls for entry of drivers from outside of the OHE car
shall be of inward opening type and will give an opening of 750 mm approx.
3.4.3 Single leaf inward opening hinged or sliding doors with locking arrangement shall be
provided in driver‟s compartment for entry in the corridor and shall have a clear opening
of 550 mm.
3.4.4 Other doors on sidewalls shall preferably be of sliding type with a clear opening of 1300
mm. The door leaves shall slide on roller bearing OHE carriers suspended from top rail
and shall work in retaining guides on the doorsills. Each leaf shall have a window
opening. Since the tenderer is expected to develop layout, location of doors may be
decided in the most suitable manner.
3.4.5 Latches shall be fitted on all doors so as to secure them from inside in the closed position.
3.4.6 Door locks: All doors shall be fitted with reliable locks to be operated from outside and
inside. Hasps for external padlocking shall also be provided on all doors opening out of
the OHE car.
3.4.7 Door Footsteps: The door footsteps assembly shall be of mild steel chequered plate of
6.0 mm thick edges shall be protected with metallic treads. Any other suitable
arrangement shall also be considered.
3.4.8 Door hand holds: Door hand holds of chromium plated steel tube, with malleable cast
iron brackets shall be provided on either side of all body side doors and shall be so fitted
as to clear the side walls sufficiently to prevent injury to knuckles. Hand holds shall also
be within the OHE car profile.
3.5 Lavatories: The OHE car shall have one Indian style lavatory, which shall be provided
with fittings of stainless steel as being used on passenger train and approved by the
RDSO.
3.6 Roof Water Tank: Roof water tank of stainless steel of not less than 450 litres capacity
shall be provided. The tank shall be mounted so as to be readily removable for repairs.
Side filling arrangement only shall be provided for water filling.
3.7 BOGIES:
3.7.1 General Design: OHE car shall have two 4 wheel bogies of robust welded design suitable
for taking brake gear, suspension etc. and capable of withstanding the maximum static
and dynamic stresses under its full load condition. The weight of the bogie shall be as
low as possible, consistent with strength and robustness. The bogie frame shall be of
copper bearing steel plates to IS 2062 Fe 410 Cu WC and shall be fabricated by welding.
3.7.2 Bogie suspension design shall be coil steel suspension in primary and air suspension in
secondary stage. The bogie design shall be as per ICF Drawing No AC//EMU/M/ASR-0-
0-001 with latest alteration.
3.7.3 The design shall be capable of negotiating curves of 152.4 m radius, turnout of 1 in
8and1/2 and gradients of 1 in 100.
3.8 WHEEL, AXLES AND AXLE BOXES
3.8.1 Wheel and axle dimensions shall meet the requirements of Indian Railways Schedule of
Dimensions 1676 mm gauge-(BG) revised 2004.
3.8.2 Wheel assembly shall be of 952 mm dia and shall be provided with roller bearings No
22328 C/C3. The wheels of tower wagon shall be solid forged wheels to RDSO drawing
No SK-K4004 with latest alteration. All wheels sets shall be machined to take a
speedometer drive.
3.8.3 Axles shall be to IRS-R43/92 stress calculations/FEM of wheel and axles shall be
submitted. The calculations shall be done as per ARR/UIC specification.
3.8.4 The wheel profile shall be to RDSO sketch No 91146 with latest alteration of appendix 1
and width of wheel shall be 127mm minimum.
3.8.5 The rim thickness of the wheel will be adequate to provide for specified wheel wear.
3.8.6 40% dynamic augmentation of the vertical journal load will be used in calculating the
axle stress in addition to vertical and horizontal forces and moments.
3.8.7 All wheel and gear seats and traction motor suspension bearing journals are required to
be cold rolled together with stress relieving groves machined in the axle, between wheel
seat and gear seat and between the wheel and traction motor suspension bearing journal
of the axles.
3.8.8 Facilities for oil injection for removal of wheel shall necessarily be provided.
3.8.9 Standard axle boxes shall be used. Roller bearings will be grease lubricated and of type
which have given satisfactory performance/service on railway stock. Special attention
shall be paid to sealing arrangement of the ends of axle, to prevent ingress of water, dirt
and loss of lubricants. This aspect requires special attention as the axle box may remain
submerged in flood water during heavy rains. The sealing arrangement shall ensure that
axle box will not need special maintenance even if it is submerged in water. The design
of labyrinth will be such as to prevent the ingress of dust in to or outflow of grease from
axle boxes.
3.8.10 One of the axle box and cover (not the leading one) shall house speedometer generator
with suitable adopter. OHE care shall be taken to provide special protection arrangement
for the generator and cable connection against flying ballast and any other extraneous
objects. The connection shall preferable be taken from the top of the axle box.
3.8.11 Complete working drawing of the axle box , guide arrangement with bearing and its
components shall be submitted for approval along with maintenance instructions
3.8.12 The axle box body shall preferably be of cast steel.
3.8.13 The contractor will be required to provide recommended lubricants which should have
been proven in similar railway service of the axle bearings.
3.8.14 An alternative lubricant, manufactured in India shall also be identified by the contractor
in conjunction with the bearing manufacturer, and the lubricants manufacturing industry.
3.8.15 Design calculation for the powered axle shall be submitted for approval of RDSO.
3.9 Brake System:
3.9.1 The OHE car shall be fitted with graduated release air brakes. The brake system shall be
of UIC approved type and shall meet all UIC requirements. It shall have the following
distinct positions.
i) Release Position
ii) Minimum reduction position.
iii) Full service position.
iv) Emergency position.
Note Panel mounted air brake system of approved make conforming to specification. No. MP-
0.01.00.19 (Rev-01), June‟2010 as approved by RDSO should be provided in order to
achieve high reliability, low weight, better sensitivity and easy maintainability.
3.9.2 Brake Blocks: The composition „K‟ type non-asbestos brake blocks to RDSO
specification no. C-9508 with latest revision/amendment shall be used. Brake rigging
shall be as per ICF drawing No. EMU/M-3-2-064 with latest alteration shall be provided
to prevent the brake blocks riding down the wheel tapers. The brake cylinder pressure for
20.32 t axle load bogies shall be 1.6 kg/cm2
3.9.1 The emergency braking distance (EBD) for fully loaded (20.32x4=81.28 t) OHE car from
maximum speed of 110 km/h to zero shall not be more than 800 m on flat section. The
contractor shall also submit calculation for EBD on 1 in 33 down gradient.
3.9.2 It is proposed to use the OHE car for hauling two loaded bogie flat wagon weighing 120 t
[see Item-11 (vii & ix) of table at Clause 2.0]. The manufacturer shall indicate the
emergency braking distance that can be obtained with above loaded wagons in the rear in
un-braked state.
3.9.3 The OHE car shall be provided with the following additional brake requirements:
i) An emergency brake valve in each driving cab on extreme right hand side.
ii) Stand-by brakes, in case of failure of distributor valve or any component in the
main brake system.
iii) Parking brake to RDSO spec CK 408 (latest revision) capable of holding fully
loaded OHE car with 120 t trailing load of two loaded bogie flat wagons in un
braked state on 1 in 33 down gradient under wet condition.
iv) Flexible hose connection shall conform to SAE 100R1
3.9.4 Application of any type of brake provided on the OHE car shall result in simultaneous
cutting of the power to the driving axles. Interlock for this arrangement may be included
in governor system for safety precaution.
3.9.5 The brake rigging arrangements shall be light and as simple as possible with minimum
number of levers and fulcrum points permitting easy access to brake blocks and other
wearing parts. Composite brake block shall only be used as per the standard approved
drawing.
3.9.6 Brake system shall be provided with automatic slack adjuster built into the brake
cylinder.
3.9.7 Adequate safety straps shall be provided below the moving components of the brake
rigging and other components to prevent falling on the track in the event of failure of any
component.
3.9.8 The supplier shall submit details of brake system covering brake schematic diagram,
working principle, brake power diagram calculation for EBD, number, dimension and
type of brake blocks and literature on brake equipments proposed along with offer and
get the brake system approved from RDSO before manufacture of the prototype.
3.9.9 Air dryer of approved make conforming to Spec. No. MP-0.01.00.09 (Rev-05),
March‟2011 shall be provided. (In line with latest equipment on EMU/DEMU)
3.9.10 Main air reservoirs of adequate capacity shall be provided. In addition, a separate braking
reservoir and a non-return valve be provided for braking only. Suitable drain
valves/cocks shall be provided to drain off the condensate in the reservoir (s).Cut off
cock may be provided at inlet of auto drain valve.
3.9.11 The tenderer shall be required to supply the detailed drawings, specifications and testing
procedure for rubber components/parts of all the valves/cocks used in the brake system.
3.9.12 The supplier shall get the brake schematic approved by the RDSO.
3.9.13 Stand–alone VCD of approved make conforming to spec No MP-0.34.00.04(Rev.04) Dec

2008 shall be provided.
3.9.14 Brake system shall be such that in dead condition of 8 WDETW can be hauled by another
air brake stock.
3.10 Piping & Pipe fitting:
3.10.1 Seamless stainless steel pipe bright annealed to ASTM A 269 Gr. 304, which can be bent
cold shall be used. The layout of piping shall be designed to keep all pipes, especially the
brake cylinder pipes, as short and straight as possible Bends should be used throughout,
but where elbows have to be used; they shall be of round type. Where the pipes itself are
bent, their internal area shall be maintained uniformly.
3.10.2 Double ferule pipe fitting consisting of body, front ferrule, back ferrule and nut shall
provided. The body and nut shall be of OHE carbon steel of ASTM A-108 Grade –II with
electro cobalt zinc plating with chromic passivation. The from ferrule and back ferrule
shall be made from stainless steel to ASTM A276 TP 316 SS and conforming to ICF
specification no. ICF/MD/SPEC-166 with latest revision/amendment.
3.10.3 All pipes shall be adequately clamped to the frame assembly. Compreg to RDSO spec.
No. C-9407- type II shall be used for clamp.
3.10.4 Pipes, ducts and conduits shall conform to an identification colour scheme. Which shall
be approved by RDSO?
3.10.5 Chart showing the colours for identification of pipes shall be displayed in cab at a
prominent place where it is likely to be needed for reference.
3.11 Interior furnishing: The OHE car shall be furnished with light weight fire retardant
material. The material used for finishing and furnishing shall be suitable for use under
Indian climatic conditions and shall be as for as possible fire proof, non-hygroscopic and
vermin and rot proof. The furnishing shall be as agreed between the contractor and
RDSO. It may be noted that Indian Railways are presently using 3 mm decorative/resin
bonded thermosetting laminated plastic sheets of approved shades, possessing resistance
to spread of flame as indicated in para 5.16 of IS:2046. With a view to retarding the
spread of fire, the continuity of LP sheets shall be broken by the provision of suitable
metal barriers. The laminated plastic sheets shall conform to STR No. C-K-514 (Latest
Revision) for decorative thermosetting synthetic resin bonded laminated sheet for OHE
car
3.12 Ceiling and paneling: The ceiling in compartments shall be of minimum 2 mm thick
NFTC to RDSO spec. No. C- K 511 (Latest Revision) or non- asbestos limpet sheet to
RDSO spec. No C-K601 (Latest Revision). The ceiling material shall be IRSM-41 where
ever required.
3.13 Flooring construction: Floor of the vehicle shall be as per ICF drg. No. EMU/MASR-
41-001 with latest alteration. The opening in the flooring for passage of pipes and cables
through the floor shall be so constructed as to prevent any seepage of the oil. In addition
to give effective protection against the spread of fire originating beneath the body.
3.14 Extra Fitting:
(i) Door steps shall be provided at all body side doors.
(ii) Continuous water wriggles from one end of the OHE car to the other shall be
provided.
(iii)Tail lamp bracket to IRS Drg. No.C.BF-113 shall be fitted at each end of the shell.
(iv) Rain water channels of suitable design over the doors & windows way shall be
provided.
(v) Tenderers may note that the OHE car may be washed mechanically. Tenderers may
also note that the exterior of the OHE car may be washed in automatic OHE car
washing plants. Exterior of the OHE car shall be designed keeping this in view.
3.15 Cattle Guard: Detachable type cattle guards shall be provided under each buffer beam.
The cattle guard shall be fitted with adjustable rail guards so as to maintain the minimum
free space above the rails under all conditions (see item 7 of clause 2.0).
i) Cattle guard and RCF drg. No. EM26108 with latest amendment.
Or Cattle guard and ICF drg. No. EMU-2-6-046 with latest alteration.
3.16 Insulation: An insulation layer of suitable thickness of non-asbestos material shall be

provided inside the OHE car shell. End walls and sidewalls shall be provided with
suitable anti-drumming and anti-corrosive compound. Underside of the under frame over
the engine area shall be properly insulated to minimize heat transfer to the compartment.
The material used for insulation shall be non-inflammable type. All other parts shall be
provided with anti-corrosive compound.
3.17 Noise Suppression: The tenderers shall indicate noise suppression features incorporated
in the design. Maximum noise level should not exceed 75 dB in side the cab.
3.18 Trap Doors: Suitable trap doors shall be provided on the flooring for attention of
underslung equipments, during service. The design of trap door shall be such that it can
be conveniently lifted when attention to equipment is required but strong enough to
withstand normal passenger loading. The trap door shall remain in level to the floor of the
OHE car.
3.19 Anti–pilferage measures: While securing compartment fittings, anti-pilferage measures

shall be incorporated.
3.20 Fire extinguishers and first aid equipment: Four fire extinguishers CO2 type of 5 kg
capacity shall be provided, one each in both the cabs and two in workmen‟s lobby. Space
shall be provided for keeping a first aid box and one stretcher.
3.21 Corrosion protection:
i) Sheets and plates (other than stainless steel) used for OHE car construction shall be
suitably treated against corrosion before fabrication.
ii) Sub- assemblies shall be treated against corrosion as per UIC Code 842-5 after they
are manufactured.
iii) OHE car shall be treated after fabrication as per UIC Code 842-5.
iv) In addition to above, the OHE car design shall be such as to minimize the incidence
of corrosion. Indian Railways experience is that most corrosion takes place due to
seepage of water from the floor and window openings.
v) The tenderer may suggest any better corrosion protection system that he may have
adopted with success in OHE cars manufactured by him.
vi) The tenderer shall note that OHE car floors are washed regularly at certain time
intervals. Hence the floor construction should be such that it does not permit water to
seep through the floor and cause corrosion to trough floor and under frame members.
vii) Tenderers may note that Indian Railway have noticed heavy corrosion on OHE car
under the lavatories. As such, corrosion resistant steel shall be used for construction
of floor and adjacent members under lavatories and the neighboring bays.
3.22 Information to be submitted by the tenderer
(a) The following information shall be furnished by the tenderer along with the
offer:
1) Transverse cross section of the proposed OHE car alongwith principal dimensions so
as to illustrate the general construction of the shell. Also superimposed upon this
should be the schedule of dimensions as embodied in the Indian Railways Schedule
of dimensions –1676 mm gauge, revised 2004. Infringements, if any, should be
accurately defined in the sketch.
2) A “Section” view of the plan of the OHE car, showing the layout of the major
equipments alongwith principal dimensions.
3) Side elevation of the proposed OHE car.
4) A “Sectional” side elevation of the OHE car underframe showing the disposition of
the major equipments on the underframe.
5) To demonstrate his capability for designing OHE car body, the tenderer shall submit a
set of actual calculations pertaining to OHE car structure for any bogie vehicle,
designed by him in the past . These shall be submitted alongwith his tender.
6) The schematics of the brake pneumatic alongwith the internal schematics of the
valves proposed to be used shall be furnished alongwith the tender. The schematics
shall be accompanied with a write up on sequence of events during application,
release and emergency.
7) Type of compressor and its capacity shall be indicated along with tender. This will be
accompanied with a technical justification for the compressor capacity selected.
8) Estimated weight of the OHE car structure shall be furnished alongwith the tender.
Also weights of principal assemblies mounted on the OHE car structure shall also be
furnished.
(b) The other relevant information but not limited to following shall be furnished at
design approval stage by the successful tenderer.
1) A representative sectional view of the OHE car floor, illustrating the floor
construction. The specifications of the materials used in its construction should
be identified.
2) Furnishing material intended to be used by the tenderers-specifications should be

identified.
3) Insulating material proposed by the manufacturer specifications should be identified.
4) Ceiling material proposed to be used by the manufacturer specifications should be

identified.
5) Principal features of noise suppression shall be identified and submitted.
6) Principal features showing adequate fire redundancy shall be identified and submitted.
7) Tentative brake rigging diagram alongwith details of brake cylinder and slack
adjuster proposed to be used shall be submitted.
8) In case parking brakes are proposed the features of the brake actuator, its type and
the schematics of its operation shall be furnished.
3.23 The guaranteed technical particulars of the inspection OHE car shall be submitted as per
Annexure-7.
Chapter - IV
ELECTRICAL EQUIPMENT
4.0 Illumination: Driving cabs, staff cabins, workshop & storage space shall be provided with
level of illumination of at least 30 lux at the working plane level (1m above the floor
level). OHE Car lighting shall be provided with 18 W, 600 mm x 26 mm double capped
fluorescent tube lights along with its fittings and electronic lamp ballast as per RDSO
specification No. RDSO/PE/SPEC/TL/0011-2000 (Rev.1) with the latest revision shall be
used.
4.1 Driving cabs, staff cabins and workshop shall be provided with two, 110V, 300mm sweep
fans conforming to IS: 6680.
4.2 BATTERY: Lead acid maintenance free storage battery of capacity as mentioned at
Clause no.5.3.2.20 of Chapter-V, conforming to IS: 6848–1972 shall be provided in
under slung battery boxes. The battery fuses shall be located close to the battery
terminals.
4.2.1 Terminals for charging the batteries from external charging equipment shall also be
provided. The location of the batteries shall be such that there is no danger of their
getting damaged due to tools and equipment inadvertently falling on them. If the cells are
packed in two rows in the battery box, a hylam sheet shall separate the two rows.
4.3 Alternator for battery charger & DG sets:
4.3.1 An engine mounted alternator with rectifier and regulating equipment of suitable capacity
shall be provided. The output of the generator shall cater for battery charging for diesel
engine starting (battery voltage 24V). The maximum power demand will be required
when the OHE car is stationary and with engine running at low idling speed.
4.3.2 Battery charger for charging batteries of 110 V of 120 Ah capacity Lead acid
maintenance free storage battery of capacity as mentioned at Clause no.5.3.2.20. The
battery charger shall comply the with ICF specification No. ICF/Elect/067 (Rev.1) and
battery charger for 24 V
4.3.3 A 10 kVA, 3-phase, 415V, low noise diesel generating set for power supply to lifting
platform and machines in workshop shall be provided with OHE car. The Gen set shall
be mounted on anti-vibration mounting to reduce the vibrations.
4.3.4 A skid mounted portable diesel generator similar to Honda make (petrol start kerosene
run or petrol start petrol run) of 3 kVA (minimum), 240V, 50 Hz along with transformer
shall be provided to meet 150 Amps light weight IGBT welding machine load and other
auxiliary load of search lights (2x250 watts), emergency light and for other such
purposes.
4.4 Circuitry
The load shall be suitably distributed based on standard practice.
Electrical equipment such as switches, lamp holders and other items shall conform
to the following specifications:
IS:6965: Switches for use in Railway stock.

IS:1258: Bayonet lamp holders.
IS:1293: Three pin plug and socket outlets.
IRS:EA-199: For ceiling light fittings like CFL within transparent enclosure.
4.5 Power for head lights, tail lights
4.5.1 Following lights shall be worked on the alternator/ rectifier provided with diesel engine.
This is to ensure that failure in the other lighting system does not affect the mobility of
the OHE car.
4.5.2 Twin beam Head light: Twin Beam head lights shall be provided at both ends. The head
light shall confirm to RDSO‟s specification No ELRS/SPEC/PR/0024 (Rev-1) Oct. 2004.
The operating voltage of head light shall be 110 V DC.
4.5.3 Tail light: Two aspect (red and white) LED type 24 V 15 W tail light shall be provided at
each end to comply with General & Subsidiary Rules of Indian Railways.
4.5.4 Flasher light: One flasher light each of LED type as per RDSO‟s specification No
ELRS/ SPEC/LFL/0017 (Rev-1) Sept, 2004 shall be provided on the roof at either end of
the OHE car.
4.5.5 Marker Light: Marker light of LED type as per RDSO‟s specification No ELRS/
SPEC/PR/0022 (Rev-1) Oct. 2004 shall be provided on either end of the OHE car.
4.5.6 Search Light: OHE car shall be provided with two 250 W searchlights with Metal Halide
lamps, one on each end, for inspection of the OHE while on the run. Searchlights shall
provide a high intensity illuminating beam and capable of swiveling on universal joint
type supports.
4.5.7 Wiring-All Electrical wiring in the tower wagon shall be done with e-beam cables
conforming to RDSO‟s specification No ELRS/SPEC/ELC/0019 Rev.-1 dated
06.07.2010 with latest amendment.
4.5.8 Horns: The OHE car shall be fitted with two horns with different tones on both sides.
Horns shall be operated on compressed air. These shall be operated by a hand switch
provided within the access of the Driver. Horn cover to RDSO drg. No. CG-K5056.
4.5.9 SPEED INDICATOR / RECORDER: Speed indicator and recording equipment of 0 -

160 km/h range. The equipment shall conform to RDSO specification No.MP-0.3700-07
(Rev.03) of April‟2003. One cab of OHE car shall have one recorder-cum-indicator and
the other cab shall have one indicator only.
4.5.10 Mobile Charging: Four mobile charging points one each in staff cabin and both the
Driver‟s cab shall be provided.
4.5.11 Cab Heaters: Both the cabs shall be provided with electrical heaters to keep cab
environment warm during winter season. The power supply to heater shall be given from
the auxiliary alternators as specified in clause 5.7.4.1.
4.5.12 Flood lights: Four flood lights giving diffused light of 75 watts shall be provided with
each OHE car.
4.5.13 Emergency push-buttons (Mushroom Type): Five emergency push-buttons shall be

fitted on the chassis sides and one on the roof. When activated, they provoke:-
(i) Idling of the engine & removal of excitation of alternator.

(ii) Stop of elevating platform.
(iii) Braking of the vehicle.
4.5.14 Earthing Arrangement of Tower OHE car:
All metallic parts of tower wagon including the working platform, shell structure & bogie
shall be integrated electrically to ensure proper earthing of tower OHE car through
wheels to Rail. The body of the lifting motor, control panels, swiveling motor at platform
and other electrical equipment shall be connected to the earth. Traction motor shall be
provided with earth brush. The schematic diagram of earthing arrangement to be
provided for the tower OHE car & equipment in it shall be submitted by the successful
tenderer for approval of RDSO.
Chapter - V
5.0 POWER EQUIPMENT & CONTROL
5.1 The different speeds of the twin-power pack from idle to maximum speed and the
corresponding power developed should be so selected that all the conditions
mentioned in Clause - 2.0 of Chapter-II can be satisfactorily met. However the number
of speeds and power levels chosen should not be less than 8 (herein after referred to as
notch positions) in addition to the idle position. The performance of the power pack shall
be optimum in each notch position in addition to being able to meet the traction load and
demand by the auxiliaries.
5.2 Detailed calculations shall be submitted along with tender indicating the power demand by
the traction motors for different conditions and the demand on the power pack. These
calculations shall indicate whether adequate reserve power has been provided for.
Characteristic curves for the traction alternator rectifier indicating the performance for
different notch positions should be furnished. These curves, inter-alia, should indicate
speed, bhp, power consumption by auxiliaries, excitation voltage and a.c. and d.c.
currents. These characteristics should clearly indicate the extent of matching or
mismatching of power.
5.3 DIESEL ENGINE AND TRANSMISSION SYSTEM
5.3.1 The OHE car will have two independent diesel electric transmission systems, each
comprising a diesel engine, an alternator along with its power rectifier, two traction
motors mounted on one bogie, auxiliary alternators with their rectifier-cum regulator
units, engine and traction controls, synchronised for operation from a common master
controller from the driving cab(s). In case of failure of one of the transmission systems,
provision shall be made so that the same can be isolated and the OHE car can still be
worked at reduced power from the healthy transmission.
5.3.2 Diesel Engine

5.3.2.1 Two independent under-slung naturally aspirated, turbo-charged and after cooled
horizontal diesel engines of proven design of indigenous make (like Cummins NTA 855
R), complete with all accessories, suitable for traction service under the climatic and
operating conditions obtained in India, shall be provided. The engine should be preferable
of Common Rail Direct Injection (CRDI) type. Alternative proposal with other
indigenously manufactured, proven designs of horizontal diesel engines may be offered.
The continuous traction rating of each engine shall not be less than 285 hp or higher at
1800 rpm after due de-rating for environmental temperature of 55 0C. It shall be battery
started. Specific Fuel Consumption (SFC) shall be low. Robust construction, low
maintenance and satisfactory record of past performance are of paramount importance.
Tenderer shall furnish full particulars of the engine with the offer. Adequate allowance
shall be made in the power of the diesel engine for the de-rating under most adverse
climatic conditions stated in Clause-1.2 of Chapter-I of this specification. Successful
tender shall give detailed calculations for engine‟s suitability and its rating.
5.3.2.2 The supplier shall indicate the total horse power required for the auxiliaries with the
break up power for each of the auxiliary machines at rated output.
5.3.2.3 The tenderer shall indicate the net horse power available for input to traction under the
conditions mentioned under para-1.2 of Chapter - I of this specification.
5.3.2.4 The idling speed of the diesel engine shall be such so as to match the requirement of
various auxiliary machines driven by the engine.
5.3.2.5 The diesel engine shall work satisfactorily with fuel oil to Indian Standard Specification
no.1460-grade A, but shall also be able to function in a trouble free manner even with
Grade B fuel oil to the same specification.
5.3.2.6 Suitable hand priming pump shall be provided to avoid air lock in the fuel system.
5.3.2.7 The engine shall be provided with suitable end on mounting arrangement to SAE-O
dimensions for coupling with and driving the traction alternator. The mounting and
coupling arrangement shall be of adequate capacity to withstand high deflection and
torque (at starting, stopping and due to misfiring of cylinders) so that no damage is
caused to the alternator and engine components in service.
5.3.2.8 The drive gear for driving compressor, auxiliary alternator and electric fan drive for the
radiator shall also be in the scope of supply of the tenderer.
5.3.2.9 Detailed torsional vibration analysis of the complete system under normal engine
working as well as under conditions of one cylinder misfiring for the complete operating
range including 10% over speed shall be furnished.
5.3.2.10 Air inlet to the engine shall be from inside the OHE car with proper ducting
arrangement from the filters.
5.3.2.11 Piping from the air cleaner to the turbo-driven air handling unit shall be in the scope of
supply.
5.3.2.12 The exhaust pipe shall not leave OHE carbon soot on important assemblies like traction
motors, axle drive etc. The pipe shall be taken to the roof with adequate insulation to
with stand 7000C. The silencer shall be provided on the dished rooftop.
5.3.2.13 Filters shall be of adequate air flow capacity/filtering efficiency to ensure satisfactory
performance under dusty environment.
5.3.2.14 The tenderer shall submit graphs showing the BMEP/engine output torque and SFC at
all notch positions from idling speed to rated speed.
5.3.2.15 Lube oil consumption at rated output as a percentage of the fuel oil consumption should
also be indicated.
5.3.2.16 The tenderer shall furnish a copy of the Type Test report of the engine by a statutory
body in support of their claim regarding performance, reliability and specific fuel
consumption. In case the engine offered is not type tested earlier, the testing shall be
done in the presence of RDSO‟s representative. In case engine is already type tested
and found satisfactory then routine test report is to be submitted for all the engines by
the firm to the purchaser. RDSO may like to conduct acceptance test, if required.
5.3.2.17 Fuel tank of at least 700 liters capacity indicating tower wagon‟s operating time with
700 liter fuel oil to be given.
5.3.2.18 The noise level in the driver‟s cabin with the doors and windows in closed condition
shall be less than 75 db (A) and in the inside of the OHE car shall not exceed 80 db (A)
at maximum output and speed of the engine.
5.3.2.19 The exhaust emission shall be below the limit laid down in UIC/ORE no. B13/RP22/E
Clause-4 of the entire engine range of operation from idle to full power and shall be
measured as per UIC/ORE/B13/RP21E. The exhaust opacity shall not exceed 20 as
measured by Hartridge smoke Meter or equivalent scale under all conditions including
acceleration of the engine. A suitable catalytic converter shall be connected in exhaust
pipe to limit the emission.
5.3.2.20 The tenderer shall supply the complete system including engine starter and battery
chargers. Batteries shall be of following ratings:-
1. 24 V, 290 Ah battery for engine cranking.

2. 110 V, 120Ah battery for control and auxiliary circuits.
5.3.2.21 Suitable anti-vibration mountings for the engine, alternator, auxiliary alternator, and
compressor shall be used.
The anti-vibration mountings (AVMs) shall be of approved make. The type and number
of AVMs offered shall be specified. To meet the vibration limit, any increased numbers
if required shall be to the contractors account. The deflection characteristics of the
AVMs shall be submitted.
5.3.2.22 Drawings for the suspension brackets shall be got approved by RDSO before
manufacture/ supply.
5.3.2.23 All threaded fasteners shall be of RDSO approved make.
5.3.2.24 The engine manufacturer shall provide necessary safety devices to protect the engine
against hot engine, low lube oil pressure, engine over speed and low water levels etc.
two high water temperature thermostats with 50C difference in setting shall be
provided.
5.3.2.25 List of all accessories that are offered with the diesel engine, clearly indicating those
mounted on the engine and those supplied loose shall be furnished by the tenderers.
5.3.2.26 Electrically operated gauges for the various indication requirements and fault indication
lamps shall be provided in each driving cab.
5.3.2.27 The stopping of the engine shall be by de-energising a fuel solenoid valve.
5.3.2.28 The initial fill of lube oil for the engine as recommended by the engine manufacturer
shall be in the tenderer‟s scope of supply.
5.3.2.29 The tenderer shall submit along with the offer, complete engine data as per Annexure -
3, as applicable to the engine offered.
5.4 COOLING EQUIPMENT
5.4.1 The cooling equipment shall be guaranteed to work efficiently under the climatic
conditions specified in para-1.2 of Chapter- I of the spec. The radiator and fan shall be
of adequate capacity with 30% choked condition of the radiator used. Air flow required
for the radiator fan shall be at least 15% more than that actually required to make up for
any reduction in air flow due to train movement. The limiting ambient capability of the
cooling system shall be minimum 55 0 C with 30 % chocked condition
5.4.2 The complete technical details of the radiator and its fan shall be furnished.
5.4.3 Two independent sets of cooling equipment (i.e roof mounted radiator, hydraulic tank,
hydraulic oil cooler and water pipes) shall be provided. The individual radiator will
take OHE care of the cooling requirements of respective engines and the hydraulic
cooler.
5.4.4 The maximum operating water temperature shall normally not exceed 950C.
5.4.5 The radiator shall be roof mounted either with proven electric fan drive system or
hydraulic fan drive arrangement which shall have thermostatic control to regulate the
fan speed depending upon the water temperature shall be provided. Complete technical
details of the radiator and its type of fan & drive shall be furnished to RDSO. The most
suitable and reliable design and type of fan & drive shall be selected at the design
approval stage. If there is any cost differential for electric driven radiator cooling fan
and hydraulic driven radiator cooling fan shall be clearly indicated by the tenderer.
5.4.6 Suitable water raising apparatus, using mono block pumps for topping up the water in
the radiator shall be in the scope of supply. A stainless steel tank for the radiator of not
less than 100 litres capacity shall also be provided.
5.4.7 The installation drawings of the radiator and fan with details of fan drive shall be
supplied by the tenderer.
5.4.8 Cooling Proving trials shall be OHE carried out in a test bed at the contractor‟s
premises to prove the adequacy of the cooling system comprising of radiator and
hydraulic oil cooler for the prototype in the presence of RDSO‟s representative. The
procedure for such testing shall be submitted and got approved from RDSO.
5.4.9 The following calculations in support of offered cooling system shall be submitted:
 Cooling requirement for all sources of heat (with break up)
 Heat dissipation characteristics of the radiator and its resistance characteristics.
 Radiator fan characteristics showing the air flow Vs total heat at different speeds.
 Cooling system-matching calculations.
 Schematic cooling circuit diagram showing water, oil and air flow through each
equipment.
5.4.10 The tenderer shall submit drawing for mounting details of radiator assembly, fan drive
arrangement and ensure that these fit completely within the overall dimensions of OHE
OHE car.
5.4.11 Compressor
5.4.11.1 Two engine driven air-cooled compressors (one with each engine) of adequate capacity
and complete with all accessory suitable for continuous operation at a nominal
maximum pressure of 8 kg/sq.cm shall be offered. The capacity of the air compressor
shall not be less than 10 cfm at engine low idling speed. The essential accessories as
under shall also be in the tenderer‟s Scope of supply: -
Note: i The compressor capacity and expected power consumption shall be specified at low
idle and max operating speed of the engine.
ii The compressor offered shall be of proven capability in Railway Rolling stock
application.
5.4.11.2 Suitable after cooler shall be provided.
5.4.11.3 The compressor shall be provided with suitable governor to cut in and cut out at 7
kg/cm2 and 8 kg/cm2 respectively and a safety valve set at 8.5 kg/cm2.
5.5 Engine Control
The CRDI engine shall be electronically controlled using suitable and proven ECUs.
5.5.1 The engine control system should return the engine to idling (no traction load) position in
case of emergency brake application.
5.5.2 Tenderers shall indicate notch wise speed and power of the engine offered.
5.6 TRANSMISSION SYSTEM
Three phase a.c./d.c. transmission system shall be used. The tenderer shall furnish full
technical details as per Annexure -4 for the transmission system offered. Tenderer shall
submit block diagram of power circuit for approval of RDSO.
5.7 Alternator
5.7.1 A three phase variable speed self-ventilated, self-excited, brushless and under slung
traction alternator shall be provided (two alternators per OHE car). The alternator shall
either be end on mounted or connected to the engine through a torsional coupling. The
alternator shall have a load regulation system that shall ensure optimum utilisation of the
installed power of the diesel engine at all notch positions.
5.7.2 The alternators offered shall be of Single Bearing type.
5.7.3 The winding of the traction alternator for both stator and rotor shall be with C-200
Insulation withstanding the dusty working conditions without deterioration of electrical
and other properties. The tenderer shall give details of the insulation scheme, proposed to
be used for approval by RDSO. Filters if felt necessary by the alternator manufacturer
shall be provided at the alternator intake. The filter shall be of dry fire retardant type.
Details shall be indicated in the tender. It is, however, preferable not to use filters.
5.7.4 The alternator shall have a rating adequate to meet the full specified traction load under
the prescribed site conditions, besides capability to meet the higher starting load and
sustained and momentary over loads.
NOTE: The tenderer shall clearly specify.
i) The VI characteristics of the Traction Alternator in d.c. at full load.

ii) The continuous rating near the top of the VI curve (higher voltage, low current) and
near the bottom of the VI curve (higher current, low voltage) at 1800 rpm and the
corresponding one hour ratings.
iii) Overload capability as a percentage of the full load and deviations.
iv) Short circuit capability and deviations thereof.
5.7.5 External cables
5.7.5.1 For connecting the alternator with the rest of the associated traction equipment, the thin
walled e-beam cables as per RDSO approved spec No ELRS/SPEC/ELC/0019(Rev.1)
with latest amendment shall be provided. However, the cable sizes and the voltage grade
for the power and control cables shall be given by the manufacturer.
5.7.5.2 The terminal box shall be located at the non drive end. Suitable cutaway with a cover
plate having cable entry holes with suitable cable glands/ grommets to permit entry of
insulated cables as selected above, shall be provided. The internal and external cable
terminations shall be on a terminal board made of fiber glass SMC or better material,
suitably mounted inside the alternator terminal box. The galvanized/ cadmium coated MS
terminal studs of adequate size shall be located across each other without criss-crossing
and they shall be suitable for crimped terminations connected palm to palm. The head of
the terminal studs (preferably hexagonal) shall be embedded on the rear side of the
terminal board and shall be further secured on top by a nut. For securing cable lugs, nuts,
locknuts, flat and spring washers shall be provided. Adequate number of crimping
sockets suitable for recommended size and number of output cables shall be supplied
along with the alternator. The Crimping sockets shall be of Dowell‟s make only.
NOTE: The Terminal box location, internal and overall arrangement and
dimensions shall have prior approval of RDSO.
5.7.5.3 The alternator housing shall be of fabricated steel construction designed to withstand high
torsional stresses, shocks and vibrations. The minimum ground clearance in half worn
wheel wear condition under tare weight shall not be less than 230 mm.
5.7.5.4 The provisions shall be made for driving the auxiliary alternator from engine through V-
Belts and pulley on the extended shaft of the Alternator, pulley of C-section to IS: 3142
shall have a suitable PCD to be approved during design approval stage. The pulley shall
be push-fit with suitable securing arrangement.
5.7.6 TESTS:
5.7.6.1 Type, routine and acceptance tests on the alternator if required, shall be performed in
accordance with IEC 60349.
5.7.6.2 The type test procedure for prototype power pack (engine plus alternator) testing shall be
submitted and got approved from RDSO. Type testing of prototype power pack shall be
OHE carried out in the presence of RDSO‟s representative. If already type testing is done
for the power pack, routine/acceptance tests shall be done in the presence of RDSO‟s
representative after getting the procedure approved from RDSO by the contractor.
NOTE:-
(i) The temperature rise for the windings allowed by IEC 349 shall be reduced by 30
0
C to allow for higher ambient temperatures.
(ii) The characteristics curves as applicable to the traction alternator shall be
submitted, duly indicating therein, the selected locations corresponding to the
different notch positions.
(iii) The successful tenderer shall submit the bearing life and shaft calculations and get
them approved before offering the alternator for inspection.
(iv) The tenderer shall clearly indicate the rating, weight, current, voltage and power
and also dimensional details.
(v) The excitation system adopted shall be explained in detail giving all relevant
characteristics for different notch positions of the engine and their matching with
engine characteristics.
(vi) The detailed calculations for arriving at the alternator rating to meet the specified
requirements shall be furnished.
(vii) Any special item (for e.g. Screened cables) required for any signal/ control feed
between engine, alternator and electronic governor shall be in the scope of supply.
5.7.6.3 Auxiliary Drive: An auxiliary drive of adequate capacity shall be provided to meet all
the auxiliary loads of DEIC. The drive shall be suitable for minimum of 8 kW auxiliary
alternator.
5.7.6.4 Power Rectifier: Each alternator power output shall be rectified by a full wave 3 phase
silicon diode bridge rectifier (two rectifiers per OHE car). The rectifiers shall be suitable
for under slung naturally cooled and well protected. The technical constructional
requirements along with testing as given in Annexure-5 shall be complied with. The
output of bridge shall be connected to suitable filter chock if considered necessary. The
design should adequately take OHE care of the service conditions of the traction motors.
5.7.6.5 The OGA drawings shall be got approved prior to manufacture and supply against each
contract.
5.7.7 TRACTION MOTOR
5.7.7.1 Tower wagon shall be fitted with 4 traction motors, two on each bogie, The motors shall
be typed 4601 BX with pinion and earth return brush assembly as per BHEL schedule
item No 000501 B and gear case as per schedule item No 000502 B and shall be series
wound working on the pulsating current.
5.7.7.2 Motor rating: The one hour rating of traction motor shall be of 97% excitation and
continuous rating shall be adequate t give the required performance. The motor will be
provided with 3% permanent ohmic field shunting.
5.8 Motor Suspension & Axle drive: The traction motor nose suspended with plane sleeve
bearing arrangement. Each traction motor shall be drive one axle of its motor bogie
through a single reduction gear drive enclosed in a rigid and water tight gear case firmly
secured to prevent damage by movement and vibration under the most severe operating
condition but easily removable for attention to the gear.
5.9.1 The gear wheels and pinion shall be as per RDSO,s specification No. C-K-303 with latest
revision.
5.9 Bearings: The armature shall be mounted on anti-friction bearing of approved make.
The inner race shall have adequate interference for the duty.
5.10 Motor Contactor: Motor contactor of BHEL supply, one contactor for each motor,
suitable for operation in combination with overload relays, for opening the traction
motor circuit in overload and under fault conditions shall be provided. These contactors
shall be located in dust-proof cubicle mounted on the underframe in such a way as to
prevent all risk and damage to other apparatus from arcs formed by their operation.
Mounting of the motor switch group No. 1 and 2 shall be as per ICF drawing No.
EMU/M2-9-0-503(latest).
5.11 All motor contactor on OHE car shall be suitable for remote operation from any driving
cab through the traction motor overload „reset‟ switch. The motor contactors shall be of
electro-pneumatic type of BHEL make shall be provided with blow out coils and arcing
horns, etc to brake the current without deriment to their working parts or adjacent
equipment. All contact trip, interlocks, pins and plungers etc. shall be easily accessible
for maintenance.
5.12 Connection and operation of the contactors of the contactors shall be as per ICF drawing
No. EMU/M7/ASR-7-0-706 (latest version)
5.13 The motor contactor shall open the circuit they protect automatically on over load and
shall be capable of clearing the resultant arcs under all conditions of overload.
5.13.1.1 Traction motor contactors, reversers, protective relays and other control gears shall be
as specified in Annexure-6 They shall be housed in box and dust proof enclosures to be
mounted in the underframe, however, alternate location may also be considered subject
to clearance of the offered layout by RDSO.
5.13.1.2 The temperature rise for the windings allowed by IEC-60349 shall be reduced by
300C to allow for higher ambient temperatures.
5.13.1.3 SUSPENSION BEARINGS: Taper roller suspension bearing shall be grease

lubricated.
5.8.0 AUXILIARY ALTERNATOR WITH RECTIFIER-REGULATOR

5.8.1 Two auxiliary self-cooled, brushless alternators one with each engine shall be provided in
the inspection OHE car with suitable regulating equipment and battery charger to supply
122 V d.c. + 5% regulated voltage from idle speed to max. Speed of the engine for
meeting the following loads:-
i. Battery charging (110 volts, 120 Ah batteries) provided on the OHE car- 10
amps.
ii. Lights and fans load of the OHE car-25 amps.
iii. Flood Lights
iv. Search lights
v. Control system 10 amps.
vi. Twin beam head light of 250 watts,110 V d.c. as specified in Chapter-IV of this
specification.
vii. Power required for forced cooling for rectifier, if warranted, approximately 1 kW.
viii. Heater load one each of 1 kW in both the cab.
ix. The air conditioning & ventilation load of observation dome and officer‟s cabin.
x. The alternator shall have a rating of minimum 9 kW.(Electrical load requirement
shall be got approved from RDSO)
5.8.2 The insulation of the alternator shall be class F or better and the same shall not be
affected by the engine area environment, which may have traces of diesel and lube oil
fumes.
5.8.2.1 Drive arrangement: The auxiliary alternators shall be driven from the main engine by a
single pulley and V-belt arrangement.
5.8.3 Mounting: Suitable base frame and mounting arrangement shall be supplied alongwith the
auxiliary alternator. The base frame shall have suitable belt tensioning provision. The
base frame drawing shall be got approved by RDSO before manufacture. Driving and
driven pulley dimensions, pulley groove details, material specification, box dimensions
etc. Shall be furnished in a drawing and got approved.
NOTE: Alternatively, companion alternator made as an integral part of the main alternator may
also be offered.
5.8.4 Rectifier- Regulator: The rectifier-regulating equipment will be under frame mounted.
The crimping sockets shall be of Dowell‟s make only. The rectifier regulator box shall
have an openable front cover, which shall be capable of being closed and locked in
position by suitable hinged bolts of M12 size and wing nuts.
5.8.5 The rectifier-regulator box shall be of protection level IP:65 (Completely protected
against dust and jet of water from all directions).
5.8.6 The rectifier–regulator box shall be electro-galvanised and painted gray.

5.8.7 The regulator shall have provision of potentiometers for current and voltage setting for
adjustment depending upon the service conditions.
5.8.8 The overall efficiency of the alternator alongwith its rectifier-regulator shall not be less
than 60%.
5.8.9 The rectifier-regulator shall conform to IEC: 571.
5.8.10 Details of the equipment shall be as per Annexure- 5.
5.9 TESTING:
The following tests shall constitute type tests which are to be OHE carried out at the
manufacturer‟s works to ensure compliance of the specifications.
1. Verification of dimensions of assemblies of alternator, rectifier and regulating
equipment.
2. Temperature rise test at minimum speed for full output as well as the maximum speed
without Air over the auxiliary Alternator and the rectifier regulator box.
3. Insulation resistance test.
4. High voltage test
5. Load test
6. Mechanical over speed and induced voltage test.

7. Drooping voltage characteristics test.
8. Current limiting characteristics test.
9. Surge protection test.
10. Measurement of stator and field resistance.
11. Water tightness test for rectifier – regulator.
12. ROUTINE TESTS:All tests other than those indicated at serial nos. 2,7 and 9 of type
tests mentioned above, shall be OHE carried out.
13. CONTROL AND INSTRUMENTATION: The basic control scheme shall ensure
matching of traction load with that of the diesel engine output preventing any overloading.
The two power packs will independently feed two motors each (the motors fed from one
power pack being on the same bogie). In case of failure of one power pack, it shall be
possible to isolate the same, on line, by the driver, and the OHE car shall continue to be
worked with the healthy power pack, at reduced power.
14. Motor speed will be controlled by varying the applied voltage. The two traction
motors fed from one power pack shall be connected in parallel.
15. The tenderer shall furnish, along with schematic circuit diagrams, the power,
auxiliary and control scheme proposed to be followed.
5.9.1 Traction Control Gear: General Design Consideration: Control gear for the motors and
other switch gear shall comply with IEC-77 and shall be suitable for 110V d.c. supply.
5.9.2 The winding of all magnet coils shall be properly dried, impregnated, baked and moulded
with epoxy resins.
5.9.3 All auxiliary machines operated on 110V d.c. supply shall be provided with adequately
rated dc contactors.
5.9.4 All the contactors used for breaking dc current of value 10 A and above shall have
properly designed arc chutes and blow out coils.
5.9.5 DC contactors shall be operate for one million operation during endurance test for an
electrical endurance capability of 1 million operations at the rated voltage and current.
5.10 SCOPE OF CONTROL GEARS: Control gears which are in the scope of supply of the
contractor shall comprise of all apparatus and connections necessary for the safe and
efficient operation of the equipment and shall include the following.
5.10.1 Energizing and controlling traction alternator and main motor circuits and protecting
these circuits from overload or short circuits.
5.10.2 Operating traction motor contactors, reversers, etc. By means of low voltage control
circuits through any master controller and automatically regulating the same as required
for operation.
5.10.3 Providing means for annunciation of different healthy and fault conditions, through
necessary auxiliary contacts and LED indication lamps, for traction and brake circuits at
the driving cab.
5.10.4 Providing low tension supply of the main lighting circuits, ventilation equipments,
charging the 120 Ah, 110 V battery and driving of the auxiliary machines.
5.10.5 Earthing in an approved manner, all equipment boxes and cases supporting or containing
live parts and of the main traction motor and auxiliary machine circuits.
5.10.6 Protecting and isolating all auxiliary circuits by means of circuit breakers and by
manually operated isolating switches or links and fuses.
5.10.7 CONTACTOR BOX(S)
5.10.7.1 All the power contactors of a power pack shall be housed and inter-connected through
bus bar in a separate cubicle called “CONTACTOR BOX”, which shall preferably be
underslung however, alternate location may also be considered subject to
clearance of the offered layout by RDSO and designed for IP-55 (hose proof)
protection. For each OHE car, two such boxes shall be supplied (one per power pack).
5.10.7.2 REVERSER: Electro pneumatically operated reverser of BHEL make for changing the
direction of rotation shall be provided in in each motor circuit.These shall be mounted
in cubicle on the underframe and shall be of robust design, remote controlled and
suitably interlocked to ensure that no movement can take place while they carry
current.Provision shall be made for hand operatation.In emergency, the reverser
contact shall have self-wiping action.
5.10.7.3 Mounting arrangement shall be as per ICF drawing No. EMU/M2-9-0-503 (latest
alteration)
5.10.7.4 Motor Cut out Switch: Two four position rotary switches, of BHEL make, one for
motor 1&2 and other for motor 2 &3 shall be provided. The first switch will have
position marked as „normal‟,‟1 out‟, „1 & 2 out‟ and „2 out‟. The second switch shall
have markings „normal‟, „3 out‟, „3 and 4 out‟ and „4 out‟. The switches shall have 16
contacts to provide various facilities for control as required including the following.
(i) To energies the shunt coils of the current limit relay to reduce the drop out
power current value suitably, if any motor is cut out.
(ii) To prevent operation of „motor switches trip‟ lights when motor have been
deliberately cut out.
(iii) To permit operation of the unit while CABR is tripped, provided that a pair of
motors has been cut out.
(iv) To control feeds to the individual motor contactors, to isolate the contactors
and cut the motors out of the circuit.
5.10.7.5 MOTOR NEGATIVE CUTOUT SWITCH: Hand operated motor negative contactor
switch of BHEL make shall be provided on the negative side of the motors and it shall be
possible to isolate defective motors both on positive and negative side. Suitable interlock
as required shall be provided. The contactors shall be of adequate capacity to withstand
the short circuit current.
5.10.8 RELAY PANEL:
5.10.8.1 All the control relays required for the system shall be supplied duly mounted on a
panel, name-tagged, wired and properly terminated.
5.10.9 INSTRUMENTS AND SAFETY DEVICES:
5.10.9.1 The following instruments & safety devices shall be part of supply for safe and
satisfactory operation of the OHE car. The equipment and controls shall be arranged in
both the driving cabs of the OHE car so that the OHE car can be worked from any one
of the driving cabs. Interlocks shall be provided such that OHE car can be operated
from one cab only at a time. The driver should be able to start or shut down the engine
from his cab.
5.11 Instruments:
5.11.1 Diesel Engines.

5.11.2 Switches, meters and gauges
(i) Engine starting switch/ push buttons

(ii) Lube oil pressure gauges
(iii) Lube oil temperature gauges
(iv) Cooling water temperature gauges
(v) Battery charge/ discharge ammeter for 24 V battery.
(vi) Engine hour meter and engine speed indicators
(vii) Engine stop switch/push buttons
(viii) Low cooling water level indicators
(ix) Over speed devices
(x) Emergency stop for engine by Borden wire
5.12 Safety Devices:
a) Water temperature too high- engine to idle. However, driver shall be able to
raise the engine speed during the operation of the hot water temperature switch.
b) Low lube oil pressure - engine to shut down
c) Engine over speed - engine to shut down
d) Radiator water level low - engine to shut down
e) Low Hydraulic oil level - engine to shut down
A. Traction Alternator:
a) Voltmeters reading phase to phase voltage

b) Control battery (110 V) Voltmeters.
c) Control battery (110 V) Ammeter
d) for protecting the source, earth fault relay shall be provided.
B. Rectifiers:
Traction Ammeter - To indicate the current drawn from rectifiers.
5.13 SAFETY DEVICES:
5.13.1 Alternators:
5.13.1.1 Earth fault relay – for earth faults in the traction circuit.
5.13.1.2 Traction motor:
(i) Overload relay/ over current protection-resetting type with reset in the Driver‟s
cab.
(ii) Earth fault relay.
(iii)Scheme for isolation of faulty motor: A scheme of isolation shall be provided

individually for all the four traction motors to facilitate their isolation by the driver
quickly.
NOTE: Recommended settings for all the aforementioned relays shall be specified by the
tenderer.
5.14 Control and Auxiliary Circuits: All circuits shall be protected by MCBs of
appropriate ratings and type. Ratings of the MCBs to be provided shall be furnished by
the tenderer.
5.14.1 All coils of contactors and relays shall be provided with suitably rated freewheeling
diodes.
5.14.2 DRIVER’S DESK.
5.14.2.1 The driver‟s desk complete in all respect with all the control gear items duly fitted,
wired and terminated on a terminal board shall form the scope of supply of contractor.
5.14.2.2 DRIVER’S CONTROL SWITCH: The driver‟s control circuit shall be energized
through the driver‟s control key. The interchangeability provided shall be such that the
key can be removed from the lock only when the switch is turned to off position and
when the key has been removed, the switch cannot be turned to the ON position. The
key shall be common for both drivers‟ key switches.
5.14.2.3 MASTER CONTROLLER :
i) The number and arrangement of step shall be marked on the master controller.
ii) Contacts and operating mechanism shall be easily accessible and of suitable
design for railway service. All live portions and contacts, cables and terminal
mountings within the master controller shall be kept well clear of exhaust from all
pipe unions to, any pneumatic equipment.
iii) The reversing drum operating boss shall be fenced in such a manner that the key
can only be inserted and withdrawn when the drum is in the neutral/off position
and the drum shall be mechanically interlocked so that it can only be placed in
this position when the master controller handle is in the OFF position.
iv) The master controller shall be fitted with a Dead Man‟s handle (depression type)
designed to switch OFF power and apply brakes automatically whenever the
driver releases his pressure on the handle, if it is in any but the OFF position and
in the OFF position if the reverser key is in FORWARD or REVERSE positions.
The Dead Man‟s handle mechanism shall be suitably enclosed to prevent
interference with it or the insertion of any form of packing to wedge the handle
down.
v) Spare contacts provided to be paralleled to prevent the tower wagon from not
responding in case of any bad contacts on any of the interlocks.
5.15 INDICATION LIGHTS :

5.15.1 The indications of LED type shall be provided in both driving cabs of the OHE OHE
car as given in Clause – 5.11. Built in redundancy should be there so that in case of
failure of one LED the indication is available.
5.15.2 The “LED” indication provided in the OHE car shall have illumination level of minimum
30 mcd High intensity type LED, capable of being seen even against Direct Sunlight. The
arrangement of LED indication panel with LEDs connected with series resistor is NOT
preferred.
5.15.3 The Driver‟s desk shall be fabricated in two or more parts for ease of loading.
5.16 CONTROL PANEL

5.16.1 A suitably designed control panel shall be provided in the OHE car for housing all the
control accessories. The panel shall be so situated so as to provide easy access to all the
components for their maintenance /service.
5.16.2 Adequate Control Equipment including gauges, instruments and cab safety devices shall
be provided for safe and satisfactory operation of the DEIC. The controls shall be so
arranged in the driver‟s cab that it will be within easy reach of the driver from all drivers‟
position. All gauges shall be of proven, reliable design and of LED lit type. Gradations of
all gauges shall be in metric unit. Following gauges shall be provided in the cab:-
i) Diesel Engine lube oil pressure gauge.

ii) Cooling water temperature gauge (Electronic)
iii) Fuel oil pressure gauge.
iv) Boost pressure gauge.
v) Traction Motor load ammeter.
vi) Air brake gauges.
vii) Battery charge and discharge ammeter.
viii) Water level indicator (Electronic)
ix) Speedo Meter.
5.16.3 The following audio-visual signals or reference panel lights shall be provided in the cab
for operation of the inspection OHE car:
i) Low lubricating oil pressure

ii) Lube oil temperature too high
iii) Radiator water temperature too high
iv) Engine 1 ON
v) Engine 2 ON
vi) Engine shut-down
vii) Wheel slip indication
viii) Battery discharge indication
ix) Aux Gen failure indication
x) Low idle rpm indication
xi) Power ground

xii) Cranking contactor welding indication
xiii) Traction control supply ON
xiv) Alternator 1 Excitation ON
xv) Alternator 2 Excitation ON
xvi) Alternator overload
xvii) Alternator winding temp
xviii) Alternator bearing temp
xix) Engine 1 Trip
xx) Engine 2 Trip
xxi) Rectifier 1 fuse failure
xxii) Rectifier 2 fuse failure
xxiii) Rectifier 1 fan failure
xxiv) Rectifier 2 fan failure
xxv) Aux . Alternator failure.
xxvi) Motor over load.
xxvii) Motor Earth fault.
xxviii) Parking Brake applied.
xxix) Emergency Brake applied
xxx) Drive function released.
xxxi) Common annunciation.
5.16.4 The following safety devices, inter alia, shall be provided:
i) Water temperature too high - Transmission cut off and engine returned to idle.
ii) Low water in radiator-Power to transmission cut-off and engine shut down.
iii) Low lube oil pressure- Power to transmission cut-off and engine shut down.
iv) Engine speed too high (over speed trip)- Power to transmission cut-off and engine
shut down
Adequate protection of an approved design shall be provided against electrical over loads
and grounding.
5.17 Surge suppression capacitors :

Capacitors of suitable rating shall be wired in the control circuits to reduce the arcing at
contacts to a minimum.
5.18 Operating Keys and Locks :
One set of operating keys of the approved design and dimensions having the following
function shall be provided with each unit:-
(i) Door lock key.
(ii) Driver‟s control Switch key.
(iii) Master controller locking key, (Reverser key)
(iv) Any other control key offered as necessary.
(v) Brake controller key.
Chapter – VI
MISCELLANEOUS:
6.1 Tools
6.1.1 Each OHE car shall be supplied with a complete kit of tools and spare parts required by a
driver in an emergency and for normal working of the OHE car. These will be arranged
in a tool box provided in a cab. These tools shall be listed in the offer.
6.1.2 The complement of tools to be provided for use in Maintenance Depot shall include tools
necessary for maintenance and repair of the entire OHE car including specified
equipment for auxiliary and ancillary equipment. The tenderer should list and quote for
these tools. The rate shall however not be used for tender evaluation purpose. It shall not
be mandatory for railways to buy these tools.
6.1.3 All special tools shall be listed and catalogued illustrating the method of application.
6.2 Maker‟s test certificate
6.2.1 Copies of maker‟s test certificates guaranteeing the performance of the OHE car shall be
supplied in duplicate alongwith the delivery of each OHE car.
6.3 Weighment:
6.3.1 Each completed OHE car shall be weighed 4 times successively and vertical load exerted
by each wheel on the track shall be measured, with due regard as to the accuracy of the
measuring equipment. The pre-weighment run shall be over a section of track containing
difference of levels. No alteration or adjustment shall be made to the OHE car after
passing or adjustment shall be made to the OHE car after passing over this section of
track and before weighment. The arithmetic mean of the values taken during 4 successive
weighment shall be the value of measurements.
6.3.2 After weighment, a check shall be made to ensure the following:

i) Total weight is within the nominal weight.
ii) Axle load is within +/- 2 % of the nominal axle load.
iii) The difference between the two wheel loads of any axle is not more than 4% of
the axle load. Each completed OHE car shall be subjected to squeeze test to
ensure that it shall withstand a maximum end load of 200t without any signs or
permanent distortion. The test conditions shall be as specified in clause-3.1.1
Chapter-VII
INSPECTION
7.1 The whole of the materials or fittings used for works covered by this specification shall
be subjected for inspection by the Inspecting officer to be nominated by the purchaser
and shall be to his entire satisfaction.
7.2 The Inspecting officer shall have the power to: -

a. Adopt any means he may think advisable to satisfy himself that the materials
for fittings specified are actually used throughout the construction.
b. Take samples for such tests as he may consider necessary by an approved
Metallurgist selected by him, whose report shall be final and binding on the
contractors.
c. Visit at any reasonable time and without previous notice the contractor‟s works to
inspect the progress and quality of the work and the contractor shall provide free of
charge all equipment and labour required by him for this purpose.
d. Reject any material or fittings that do not conform to the relevant specification or
good practice, which shall be marked in a distinguishable manner, and shall be
disposed off in such a manner as the Inspecting Officer directs. Such rejected parts
shall be replaced by the contractor without extra charge.
7.3 Tests of materials and fittings shall as far as possible be OHE carried out at the works of
the maker‟s of the materials or fittings. The contractor shall provide such additional
materials or fittings as may be required or arrange for test pieces to be incorporated in
forgings and castings as required by the Inspecting Officer and for their removal in his
presence for test purposes. All tests in the works of the contractors and their sub-
Contractors shall be at the cost of the contractors.
7.4 No material shall be dispatched or packed until it has been passed by the Inspecting
Officer. Such passing shall in no way exonerate the contractor from their obligation in
respect of quality and performance of the OHE car.
7.5 In the event of dispute between the Inspecting Officer and the Contractor, the decision of
the purchaser shall be final and binding.
7.6 Radiographic testing of steel castings.
7.6.1 All steel castings wherever used and welding joints shall be subjected to radiographic
testing after manufacture / repair, to a suitable scheme/ standard suggested/approved by
RDSO.
7.7 One of the power and trailer bogies shall be subjected to exhaustive stationary tests at
Contractor‟s works in the presence or RDSO representative. The tests on bogies shall
include dynamic fatigue testing and strain measurement. The test shall be under
simulated loading conditions to represent the service load. The body shell shall also be
subjected to loads for validating the design calculations of shell. The contractor shall
afford all facilities for conducting these tests at his cost.
7.8 Acceptance tests.

Besides the checking and testing OHE carried out during manufacture and before
dispatch of the OHE car to India it shall be subjected to the following tests before final
acceptance.
7.9 Performance capability tests.

The OHE car shall be subjected to tests to establish its performance based on the supply
by the tenderer against the specification. The contractor shall at his own expense provide
the services of competent Engineers/Supervisors and supporting staff during the
performance capability tests of the prototype.
7.10 Riding quality tests.

7.10.1 The riding quality tests shall be conducted at a speed which is 10% higher than the
maximum specified operating speed, i.e. 121 km/h on a section of mainline track over
which there are no temporary speed restrictions and which is considered by the railway as
being in a generally run down condition for main line standards but without speed
restrictions. The tests shall be conducted from a reasonably low speed, which is
considered safe by the Indian Railways, upwards insteps of 10-15 km/h to establish the
performance at the specified speeds.
7.10.2 The following shall be the track standards of the test section:
(i) Track structure:

90R rail with M+4 sleeper density and 200 mm ballast cushion below sleeper,
of which at least 75mm shall be clean and rest in caked up condition.
(ii) Permitted irregularities:
The Criteria approved by “Standing Criteria Committee” for selection of Test Stretches
for Oscillation Trials on BG routes of IR shall be considered.
Ten isolated peaks/km of track exceeding the limits of irregularity are permitted.
7.11 Acceptance criteria:
7.11.1 The dynamic augment at maximum speed of 110 km/h plus 10% shall preferably be
within 50% at rail level. The lateral forces at maximum speed will be within 4-t per axle.
The vertical acceleration shall not exceed 0.3 g both in vertical and lateral modes in tare
and loaded conditions. The sparling ride index shall not exceed four. The derailment co-
efficient shall not exceed one. OR, latest as laid down by RDSO at the time of inspection
or oscillation.
ANNEXURE - 1
LIST OF EXHIBITED DRAWINGS
S.No. Drawing No. Description Clause Ref.

1 Diagram ID 1676 mm gauge Maximum moving dimension. 2.2.6
(BG) of IR schedule of
dimension
2 RDSO/SK.No.99003 Draw gear arrangement. 3.8.4
3 RDSO/SK.No.98145 Side buffer arrangement. 3.8.4
4 RDSO/SK.No.99001 Screw coupling assembly. 3.8.4
5 C/BF/113 Tail lamp bracket. 3.15.1
6 W/WL-1660 Wheel 3.21.2
7 RDSO STR no.56-BD-07 For CBC
8 ICF Bogie suitable for 20 t 3.20.1
axle load capacity and 952
mm wheel dia.
9 ICF Drawing No under frame design
AC//EMU/M/ASR-0-0-
001 with latest alteration.
10 ICF Drg No WL.RRM4- Roof Ventilators
7-3-401 with latest
alteration
11 ICF AC//EMU/M/ASR- bogie design
0-0-001 with latest
alteration.
12 ICF EMU/4C/ASR-5-4- Lift type window made of
402 with latest alteration powder coated aluminum
13 ICF drg. No. Flooring construction of the
EMU/M.ASR-41-001 vehicle
with latest alteration.
14 RDSO sketch No 91146 The wheel profile.
with latest alteration
ANNEXURE - 2
List of Drawings/calculations to be submitted to RDSO for approval before undertaking

manufacture of prototype inspection OHE car
SN Drawing/Documents to be submitted to RDSO for approval

1 Layout of OHE OHE car
2 Suspension arrangement.
3 Helical coil spring
4 Load vs deflection diagram of helical coil spring
5 Suspension calculation
6 Enlarged View of Driver‟s window
7 Normal Visibility diagram of Driver
8 Cooling circuit diagram
9 Axle Box Guide arrangement
10 Brake rigging assembly
11 Schematic Diagram of Brake system
Braking effort and Emergency Braking Distance calculation on plane section with
12
maximum load and without load.
13 Wheel and axle (non powered)
14 Wheel Diameter 952 (machined)
15 Shell arrangement
16 Side wall assembly ( Right)
17 End wall (Right)
18 Roof Assembly
19 Transverse cross section
20 Vogel Diagram
21 Alignment of OHE OHE car
22 Power pack arrangement
23 Under frame arrangement
24 Trammeling diagram
25 OHE car lifting arrangement
26 Details of weight transfer calculation.
27 Loading Diagram
28 Roof Equipment layout
Estimated weight of the OHE car structure and weight of principal assembly
29
mounted on the OHE car
30 FEM calculation of body shell and bogie.
31 Un sprung mass OHE OHE car
Calculation of centre gravity from rail level and Balancing calculation under tare
32
and loaded condition.
33 Power pack arrangement
34 Axle (powered)/ Motorised Bogie.
35 Axle drive Gear box assembly

36 Fuel Tank
37 Enlarged view of drivers window
38 Ant pilferage measure
39 Checking of squareness of door and end wall
40 Measurement of deflection of underframe.
41 Measurement of distortions of doorways along the length of OHE car
42 Measurement of distortions of shell across width at door way
43 Drawing showing location of strain gauges on the under frame.
44 Speed v/s tractive effort characteristics of OHE car
45 The block diagram showing power circuit.
Calculation for safety against derailment. Calculation for stability of the OHE OHE
46
car against wind force.
47 Details of weight transfer calculation.
48 Electrical wiring diagram for electrical gadgets.
ANNEXURE-3
10 The following details pertaining to electrical equipment shall be submitted by the

tenderer :
I. Diesel Engine
1. Exact description and model of the engine

2. Rated output under UIC site conditions
3. Site Conditions
- Ambient Temperature 55 oC
- Altitude above mean sea level 1000 m
- Relative humidity above 40%
4. Rated speed at continuous rating

5. Type of cycle (two/four stroke)
6. Method of pressure charging
- pressure ratio of compressor at the rated output
- Single stage/two stage
- No. of turbochargers used
- Make and model of turbocharger
7 Type of exhaust system

Constant pressure/pulse type/multi pulse type
8 Method of cooling the charge air
9 Type of combustion chamber
10 Fuel injection equipment
- type of injection system
- diameter of pump plunger
- nozzle opening pressure
- maximum duration of injection in degrees of crank
11. Number, arrangement and angle of cylinder.
12. Cylinder bore
13. Piston stroke
14. Cubic capacity/cylinder
15. Compression ratio
16. Firing order
17. Mean piston speed at rated speed
18. Brake mean effective pressure
19. Maximum combustion pressure at no load at minimum idling speed
20. Compression pressure at rated output
21. Minimum no-load idling speed – whether a low idle feature is provided on the engine
22. Minimum no load speed under steady conditions
23. Speed ranges which should not be used continuously
24. Break away torque when the cooling water temperature is 5 oC

25. Minimum firing speed when the cooling water temperature is 50C or at the lowest
possible temperature of air intake air in rev/minute.
26. Torque resistance to the firing speed required to turn the engine when the cooling water
temperature is 5 0C at the lowest temperature of intake air.
27. Piston
1. type of piston used – whether single piece or composite
2. no. of piston rings used.
3. configuration of the rings
4. whether all the rings are located above the gudgeon pin
5. method of cooling required for the piston
6. oil flow rate and temperature of oil at the piston oulet
28. Cooling system
1. single/double cooling circuit
2. whether cooling system is pressurized
3. coolant temperature at outlet from the engine
4. heat absorbed by the cooling water at the rated output
5. rate of flow of water
6. inter cooler coolant temperature at entry to the cooler
7. treatment recommended for water
29. Lube oil system
1. temperature of cooling oil with the indication of the point of measurement
2. maximum permissible temperature of cooling oil
3. heat absorbed by the cooling oil at rated output
4. swamp capacity
5. quantity required to commission
6. brand of oil recommended
30. Consumption of lubricating oil at the rated output in litres/hour and as a percentage of
fuel consumption.
31. Total capacity of lubricating oil pump (s) at the rated output speed in litres/min
32. Lubricating oil pressure at rated speed on entering the engine and at the normal operating
temperature
33. Maximum pressure of charge air in the intake manifold at the rated output.
34. Maximum pressure of gases at the turbo inlet at the rated output
35. Maximum speed of the turbocharger at rated output
36. Maximum permissible speed of the turbocharger.
37. Temperature of exhaust gases at turbo inlet at the rated output under UIC and site
conditions.
38. Maximum permissible temperature for which the turbocharger components have been
designed
39. Heat balance of the engine
40. weight of the engine complete with all items excluding water and lubricating oil.
41. weight of water contained in the engine
42. weight of oil contained in the engine
43. weight of major components to be handled during maintenance

1. turbocharger
2. inlet cooler
3. crank case bare
4. crank shaft
5. piston and connecting rod
6. cylinder liner
7. cylinder head
44. Specific fuel consumption with the tolerance band under UIC and site conditions –
indicate the lower heating value of the fuel used in arriving at the specific fuel
consumption figures
45. Fuel oil consumption at idle in litres/hour
46. Requirement of fuel specification or any other restriction on the use of duel with different
sulphur contents
47. Number of such engines used in rail traction and the period since the engines have been
in service and their performance
48. Safety devices provided on the engine
1. overspeed
2. low lube oil pressure
3. overload
4. high exhaust temperature
5. high intake temperature
6. any other
49. Specification of lube oil suitable for engine
50. Method of starting
51. Governor
1. Make and type
2. Full load speed and drop characteristics
3. Torque required at the output shaft
52. Estimated period between top and major overhauls
53. periodicity of overhauling the following critical components
1. Turbocharger
2. Piston and piston rings
3. Cylinder liner
4. Air and exhaust valves
5. Fuel pump
6. Injector/Nozzle assembly
7. Main bearings
8. Connecting rod bearings
54. Whether the diesel engine is suitable for satisfactory sustained operation under :
1. Site conditions mentioned in para 2
2. Dusty environment
3. Frequent starting and stopping of diesel engine
4. Average load factor 60%
55. Inlet and exhaust valve timings
56. Special design features of diesel engine highlighting the measures which have been taken
to achieve :
1. Low specific fuel oil consumption
2. Low lubricating oil consumption
3. Low idling fuel oil consumption
4. High reliability
- Maximum availability
- Reduced level of thermal and mechanical loading of critical components
57. General arrangement and dimensional details.
58. Characteristic curves of diesel engine under UIC and site conditions-
i) Curves for torque, output and specific fuel consumption expressed and guaranteed
without upper tolerance for different settings of the injector pump, i.e.
- Setting at which the engine develops the rated output at its rated speed.
- Setting at which the engine develops ¾ of the rated output at its rated speed.
- Setting at which the engine develops ½ of the rated output at its rated speed.
- Setting at which the engine develops ¼ of the rated output at its rated speed.
rated speed.
ii) The torque speed curve which the manufacturer considers to be the maximum torque
that should be used for rail traction. This should cover the range from idling speed to
the point corresponding to the international rated output at the rated speed.
iii) The curve of fuel consumption for no-load running, commencing from the
minimum idling speed, expressed in litre/h
ANNEXURE -4
TRANSMISSION SYSTEM PARTICULAR
I Alternator
1. Description Make & type
2. Drive – Details of arrangement of bearings and coupling
3. Classification – No. poles, number of phases and phase connections
4. Maximum permissible speed –
Max. voltage a.c.
d.c. (i.e. rectified)
Max. current a.c..
5. Rating -
i) One hour rating – Voltage, current, output & speed
ii) Continuous rating –
(a) High voltage
(b) Low voltage
6. Class and type of insulation
a) Stator
b) Rotor
7. Temperature rise
a) Rotor winding
b) Stator winding
8. Resistance at 25 oC
a) Rotor winding
b) Stator winding
9. Synchronous impedance at max. frequency and load
10. Stator details
a) Overall dimensions
b) No. and size of slots
c) Winding
i) Type
ii) Conductor size and material
iii) Turns per coil
iv) Pitch
11. a) Rotor-type, No. of poles, length, bore, size and air gap
b) Details of rotating armature exciter and rectifier assembly
12. Bearing:
a) Single or double
b) Type-sealed or open
c) Grease-type, capacity and time interval for regreasing
d) Bearing life and shaft size calculations.
13. Mountings – Details of mounting arrangement.
14. Coupling-Type and details
15. Cooling
Calculations of cooling capacity
16. Weight
a) Complete unit with accessories
b) Alternator only
c) Rotor (with fan if any)
17. Characteristic curves
a) Natural curves
b) V-I curves (Notch wise)
c) Efficiency vs. current
18. Tests : Results of –
a) Type test
i) Temp. rise test and its calculation
ii) Rating
iii) Characteristic curves
b) Routine test
i) Temp. rise test
ii) Overspeed test
iii) Dielectric test
19. Tractive efforts vs. road speed curve along with alternator rectifier current vs. voltage
curve showing method of calculations.
II Auxiliary Alternator with rectifier – regulator
1. Make
2. Model
3. Continuous & short time rating and details of voltage and current regulation
4. Bearing life and shaft size calculations.
5. Weight
III Traction Motor
1.1 Type
1. V - volts
2. I - Amps
3. N – rpm
4. S – km/h
5. N max/N
6. N shaft
7. N max
1.2 Armature
1. Diameter.
2. Length
3. Air ducts – surface
- section
4. No. of slots.
5. Conductor size.
6. Conductor area.
7. A) Cont ........ for ........ amps
1 Hr ........ for ....... amps
8. Cont ............. A/sq.mm for ....... A
1 Hr ............. A/sq. mm for ....... A
9. A) Cont ..........
1 hr ...........
10. ADNL 10-9 .......... at cont FF

...... at 1 hr rating
...... at S max.
11. B (B/A) ......... at cont FF

......... at 1 hr rating
........ at S max.
12. S max ....................km/h
13. N max ................... rpm
14. Wheel dia (half worn)
15. Gear Ratio (New)
16. Suspension
17. Armature bearing – commutator end
- pinion end
18. Turns/coil
19. Type of winding
20. Coil Throw
21. Length mean turn
22. Resistance at 110°C
23. Inductance at 30 cps.
24. Weight of copper (kg)
25. Tooth volume
26. Core volume
27. Arm. Turns/pole
28. Arm. At/pole - FF
29. Arm. Core int.dia
30. Net core depth
31. Arm. Steel tech. spec.
32. Banding material
33. No. of bands cc
34. Band width.
35. S (cont) .................. M/s ................. rpm ............ km/h
1.3 Main poles
1. Insulation
2. Number
3. External ................ D Internal ............ D
4. Number of turns per pole.

Frame end
Arm end
5. Conductor dimension – Frame end
- Arm. end
6. Current density - Frame end
- Arm. end.
7. Length of mean turn - Frame end
- Arm. End.
8. Resistance at 110°C
9. Inductance at 50 cps
10. Radial gap length - Tip
Centre
Mean
Eff
11. Field At
------------- @ FF
Arm. AT
12. Pole Arc.
13. Total fringe
14. Eff. Pole arc
15. Eff gap area
16. Pole flux density.
17. Pole copper weight.
18. Pole steel tech spec.
19. Yoke steel tech. spec.
1.4 Commutation poles
1. Insulation
2. Number
3. External ............ D Internal ........... D
4. Number of turns per pole – Frame end
- Arm end
5. Conductor dimensions - Frame end
- Arm end
6. Current density - Frame end
- Arm end
7. Length of mean turn - Frame end
- Arm end
8. Resistance at 110° c
9. Inductance a t 50 cps
10. Radial gap length - Tip
- Centre
- Mean
- Eff
11. Int. Pole flux density
12. Copper weight
13. Pole steel tech. spec.
1.5 Equalisers (commutator end)

1. Total number
2. Copper weight
1.6 Ventilation
1. Number of fans
2. Flow ................. m3/min (at continuous speed)
3. N ............. rpm .............. 1.35 N max (overspeed)
1.7 Commutator and brushes
1. Useful diameter
2. Useful length
3. No. Of commutator bars.
4. Bar pitch
5. Average bar/brush
6. Voltage between segments
7. Reactance voltage
8. Insulation thickness between bars.
9. Number of brush arms
10. Brush/arm
11. Brush/size
12. Quality
13. Current density
For ........ Amps (cont)
For ........ Amps (1Hr.)
For ......... Amps (start)
14. S (cont) .......... m/s ............ rpms
15. S (1hr) ........... m/s ............. rmps

16. S (max ) .......... m/s ........... km/h
17. Type of commutator construction

1.8 Weight
1. Motor without gearing ......... kg ............ N
2. Armature without pinion .......kg ............ N
CONT 1 Hr
kg N kg N
3. Wt/kw
4. Wt/hp
5. Pinion (kg)
6. Gear wheel (kg)
7. Gear case (kg)
8. Frame (kg)
9. Total weight (kg)
1.9 Losses and Efficiency

1 hr Cont.
1. I2 R (ARM)
2. I2 F (Series)
3. Core
4. Brush drop
5. Brush friction
6. Bearing F and W
1.10 Magnetic Circuit
1. 1 hr rating values
Magnetic FF Leakage
Area length B AT
Tooth
Core
Pole
Yoke
Gap
Total AT
2.0 Gears and pinions
1. Type of gearing
2. Module
3. Grade of steel used for pinions and gears
4. Particulars of heat treatment
5. Kilometerage guarantee for bull gears
6. Kilometerage guarantee for pinions

7. Material and type of construction for gear case.
IV. Power Rectifier
1. Diode – Make & type

2. No. of parallel paths & no. Of diodes /path
3. Overall dimensions of rectifier unit
4. Ratings
a) Current rating
- max. Cont. (direct) forward current
b) Thermal rating
- Max. & Min. Operating junction temp
- Max. & Min. Storage temperature
5. Resistance
a) Forward
b) Reverse
6. Details of damping circuit
a) Resistance value & circuit
b) Capacitance value & connection
7. Bus bar arrangement
8. Weight
9. Mounting arrangement
10. Characteristic curves
a) Voltage vs. Current
b) Power dissipation as a function of reference point temperature
11. Semi-conductor fuses
a) Make
b) Fusing characteristics
c) I2 t characteristic
ANNEXURE-5
POWER RECTIFIER SPECFICATION
1.0 Technical requirements including the design features.
1.1 The rectifier unit shall comprise of three phase full wave bridges using silicon diodes. It
shall prefer-ably consist of three separate bridges connected in parallel on the input and
output side.
1.2 Device Rating
1.2.1 The current rating of the devices shall be such that even under one bridge (n-1) failure
condition the rectifier, with two remaining effective three phase bridges shall be capable
of meeting the full tractive power duty/duty cycles and abnormal conditions including
short circuit.
1.2.2 An unbalance of 20% shall be considered in the sharing of the load between the bridges,
for design purposes, though, in actual testing the unbalance shall be limited to 10% only.
1.2.3 The diodes shall have a PIV rating of not less than 3000 V or not less than 2.8 times the
maximum crest working voltage whichever is higher.
1.2.4 Characteristics curves of the diodes indicating power loss, forward voltage drop, slope
resistance, thermal resistance characteristics and characteristics curves of the fuse shall
be submitted in A4 size.
1.2.5 The permissible junction and case temperature for the device shall be declared.
1.2.6 Diodes in the cubicle shall belong to one FVD group while they shall be in three
consecutive FVD groups for all the units to be supplied. FVD shall have a band width of
50 milli-volts at the full rated diode current.
1.2.7 The semiconductor device junction temperature shall be calculated for (n-1) condition
operation at rated permissible current for three duty cycles after temperature
stabilisation in heat run test at a current value equal to the one hour rating of the traction
motors.
For this purpose, RMS value of the starting current over the notching up duration for 1
minute followed by RMS value of the steady state one hour rating current for eight
minutes, followed by zero current for thirty seconds will form one cycle. At the end of
three such successive cycles the junction temperature shall be computed. There shall be
enough margin.
1.2.8 The devices shall meet all the requirements as per IS:7788.
1.2.9 The use of capsule type diodes are acceptable.
1.3 Snubber And Damping Networks
1.3.1 Each diode shall be provided with RC network to overcome the hole storage effect.
1.3.2 RC damping networks shall be provided to protect against switching surges expected.
Supporting calculations shall be furnished.
1.3.3 The resistors and capacitors for the RC network shall be respectively of silicon coated,
non-bursting type suitable for traction duty duly approved by RDSO.
1.3.4 Resistances – Silicon coated, non inductive, wire wound resistors and stud mounting
type with lug terminals shall be used. The wattage ratings shall be three times the
calculated maximum wattage in the circuit under worst loading and high ambient
conditions.
1.3.4 Capacitors – shall be of non- bursting type. The clearance and creepage distance
between the live terminals and also the body shall comply with table 5 of IS-7788. The
maximum working voltage across any capacitor shall not exceed 50% of the rated
repetitive voltage. In the case of hole storage capacitors the voltage rating shall not to be
less than PIV rating of the semiconductor device. The capacitors shall be designed for
operation at 85 oC. The capacitors will be of IOHE CAR of GE make. Use of indigenous
make shall have the prior approval of RDSO.
1.4 Fuses
1.4.1 The diodes shall be protected by semi-conductor fuses whose selection shall be
supported by the calculation to ensure their matching with the diodes. I 2 t values for the
diode shall be more than the I2 t for the fuse. Diode and fuse characteristics shall be
furnished along with the tender. The fuse selection shall withstand the short circuit
current expected.
Note: The expected short circuit current/impedance with duration shall be specified.
1.4.2 The semiconductor fuses used for the diode protection shall be of approved makes.
Fuses of la Ferraz, Bussman or English Electric make only are approved at present.
1.4.3 Since the rectifier unit consists of multi-bridges connected in parallel, signalling fuses,
associated suitable relays and micro switches shall be provided to given an indication in
case of single bridge failure and to trip the load on the alternator in case of double
bridge failure.
1.5 Constructional Features
1.5.1 The tenderer shall submit details of the overall dimensions of the rectifier along with the
offer.
1.5.2 The cubicle as well as internal sub-assemblies shall be interchangeable from one unit to
the other.
1.5.2.1 The cubicle shall be of cold rolled steel metal sheet with strong frame work suitable for
underframe mounting to withstand shocks and vibrations encountered in service run
with a maximum speed of 105 kmph. This shall be protected against damages due to
ballast hitting. The minimum thickness of panels shall be 12.0mm and may be increased
as panel width increases as mentioned below.
Maximum Panel Widht Thickness

Upto 750 mm 2.0 mm
> 750mm but < 1500 mm 2.5 mm
>1500 mm but < 2000 mm 3.2 mm
1.5.2.3 The cubicle shall be provided with two numbers of earthing bosses with M12x20 tapped
hole on each side. The bosses shall have 5 mm thick copper/brass plate brazed.
1.5.3 Easily interchangeable inspection doors with locking arrangement shall be provided to
facilitate easy access to vital parts like fuses, diodes etc.
1.5.4 Withdrawable bridge racks consisting of diodes, fuses and associated components shall
be provided on rails for withdrawing during maintenance.
1.5.5 The equipment layout shall provide easy accessibility for maintenance.
1.5.6 Suitable ventilating louvers shall be provided for air outlet.
1.5.7 The devices with heat sink shall be mounted of FRP (SMC)/ Epoxy panels of adequate
thickness (not less than 10mm) with hand holds for easy removal and insertion in
position.
1.5.7.1 Heat sinks shall be of extruded constructions. The sand casted or gravity die casted are
not acceptable. OHE care shall be taken to have proper surface finish and surface
flatness. Current collection through heat sink shall be avoided. In case it is not possible,
the heat sink device mounting surface and the current collection contact area shall be
treated to prevent electro corrosion and bimetallic action.
1.5.7.2 Recommended optimum pressures for mounting the devices on the heat sink shall be
furnished. Suitable thermal compound having low thermal resistance shall be used to fill
up the void between the mating surfaces of heat sink and device. The same shall seal the
joint against moisture.
Note : Transient thermal impedance characteristics curves of the heat sink at different cooling
air rate shall be submitted for approval.
1.5.8 Blower shall be mounted as an independent unit connected suitably to the duct with
adequate resistance to reduce vibrations. Blower Motor shall be easily accessible for
maintenance.
1.5.9 The unit shall be painted with two coats of red oxide followed by two coats of white
stove enamel on inside and aircraft grey on outside to IS-5:1961.
1.5.10 Fasteners used in the cubicle shall be of minimum M6 and screws of M10 and above
shall be of high tensile strength.
1.5.10.1 Studs of the terminal board shall have adequate current rating with minimum size not
less than M6 and shall be coated with cadmium plating. The method of connections
shall be such that the current should not pass through the studs. Number of connections
per stud shall be limited to two. The insulating boards shall be fire retarding FRP sheet
moulding type. They shall pass the fire retardant test as per specification IS – 2046.
Separate terminal board shall be provided for different voltages. Positive and negative
terminals shall be separately located. All the terminal studs shall be legibly identified
with their circuit numbers.
1.5.11 The bus sizes on the a.c. & d.c. sides shall be such that the final temperature when
corrected to 47 oC ambient is not more than 100 oC copper bus bar must be tin plated
after bending/drilling the required holes, with thickness of plating not less than 8
microns.
1.5.11.1 The bus bars used shall be of high conductivity electrolytic copper as per IS:613 with
current density not exceeding 4 A/mm2. The bus bar shall have colour code with red,
yellow and blue on the a.c. side and brown and black respectively for positives and
negatives on the d.c. side. Bus bars supports shall be made with insulators and be
identified by engraving the respective circuit numbers with contrast colour paint applied
on the engraved marking.
1.5.12 All the cable wire ends shall be terminated with suitable sockets using proper dies and
tools.
1.5.13 Cables – All the cables/wires shall be multi-strand flexible insulated cables conforming
to E/14-01/parts I,II and III. PTFE insulated cables of adequate voltage rating and size
shall be used for inter-connection snubber circuits and signalling fuses.
1.5.14 All the wires shall be numbered with cables ferrules of approved design on both ends of
the cables.
1.5.15 Wiring layout- The quality of workmanship and layout of wiring shall be of high
standard to ensure long life. The following guidelines shall be kept in view.
a) Complete separation of low, medium and high voltages.

b) Separation temporarily and permanently energised cables with separate
bunching.
c) Avoiding of sharp bends.
d) Provision of grommets for cables entries.
e) Supporting of cable bunches with insulated supports using nylon ties.
2.0 Tests :
2.1 Type tests on silion diodes – At least ten diodes shall be subjected to type tests as per
IS-7788 in the presence of RDSO Inspecting Official sufficiently in advance to avoid
delay of prototype testing of the rectifier unit.
2.2 Routine tests on each diode shall be conducted as per IS-7788 and the results recorded
by the manufacturer. 10% of the lot offered selected at random shall be subjected to
routine tests in the presence of inspecting official of RDSO.
2.3 Type test on rectifier assembly:
2.3.1 Temperature rise test – with normal ventilation, the rectifier shall be subjected to the
duty cycle expected on the traction motors with the temperature maintained at 47 oC and
until steady temperature is obtained. The temperature stabilisation can be deemed when
three successive readings taken at 15 minutes intervals do not vary by more than 0.5 oC.
The maximum diode junction temperature arrived shall be less than the permissible
junction temperature as declared by the diode manufacturer after the duty cycles as
described in clause 1.2.7. The temperature rise test shall be conducted both for n and (n-
1) bridge conditions.
2.3.2 Heat run test with (n-1) parallel paths will be conducted on first prototype and
afterwards the test may be conducted corresponding to normal duty cycle with all
bridges in operation.
2.3.3 Fuse blade temperature and bus temperature shall not exceed 100 deg. C for (n-1)
parallel paths.
2.3.4 Instruments used for type testing shall be of 0.5 clause accuracy and shall have been
calibrated within 6 months from the date of testing.
2.3.5 Power losses measured for the diodes shall not exceed 10% of the declared value.
3. Guarantee :
The diodes of the main rectifier shall be guaranteed for satisfactory working for a period
of five years from the date of commissioning.
ANNEXURE - 6
DESIGN OF TRACTION MOTORS AND SWITCH GEARS
1.0 Number and arrangement of motors
1.1 Each OHE OHE car shall be fitted with four numbers of DC traction motors, two on
each bogie. The motors shall be axle hung nose suspended type and shall be series
wound, working on the pulsating current. The motors shall be designed to comply with
the conditions stipulated in IEC-349. The temperature rise allowed by IEC shall be
reduced by 30 Deg. C, to allow for higher ambient temperatures. All motors shall be
permanently connected in parallel.
1.2 The motor shall be designed to comply with the operating requirements specified with
exceeding the temperature-rise limits.
1.3 The motors shall be so designed that severe damage will be avoided in case of transients
such as fluctuations of the voltage, switching surges. The traction motor circuit shall
comprise all the protective devices which will prevent any damage to them due to
transients. The general design and maintenance of the motors shall be of the highest
standard in accordance with the modern traction practices. The particulars of the motors
shall be furnished as per Annexure IV.
ANNEXURE -7
PARTICULARS TO BE SUPPLIED FOR THE INSPECTION OHE CAR
The following data shall be supplied for the OHE car along with the tender offer:
1 Length of the OHE car over head stock. …mm
2 Total wheel rigid base …mm
3 Height of OHE car floor (under tare) …mm
4 Distance between bogie centers.
5 Distance between side buffers …mm
6 Height of buffers when wheels
are:
(i) new .....mm
(ii) fully worn out. .... mm
7 Maximum height of the OHE car with …mm
wheels in new condition.
8 Maximum height of the cab at …mm
corners with wheels in new condition.
9 Maximum width of the OHE car. …mm
10 Minimum height above rail level …mm
of any component with the OHE car
wheels in maximum worn conditions.
11 Reduction in the above height in the …mm

event of spring rigging failure.
12 Diameter of wheels over tread …mm (new)
... mm (worn out)
13 Axle load. …t (max.)
....t (min.)
14 Total weight of the OHE car.
- in fully loaded condition …t
- in empty condition …t
15 Maximum speed of the OHE car.
- attached to a train …km/h
- Self-propelled …km/h
16 Maximum tractive effort at rail …kg
17 Maximum continuous tractive effort …kg
18 Maximum speed of operation …km/h
at maximum continuous tractive
effort.
19 (a) Fuel oil consumption at 75% of …litre/h
rated output of the diesel engine.
(b) Lubricating oil consumption at 75% …litre/h
of rated output of the diesel engine.
SN Proposed as per EMU spec Remarks
1. Service Braking has been specified Pneumatic
2. 3.8.16 Side and End Wall
(iii) Material: The frame work shall be of low alloy high tensile
corrosion resistant steel to IRS M-41 with latest
revision/amendment.
(iv) Side wall and pillars: The material of body pillar shall be IRS
M-41. Pillars shall be continuous from sole bar to cant-rail,
except below window openings, and shall be braced by
longitudinal members between adjacent pillars. Bracing being
designed to act as integral part of the exterior sheeting.
3 3.9 Roof
3.9.1 The roof shall be designed to form a satisfactory chord to the

superstructure considered as a girder, and to take a
concentrated load of 6 men standing (450 kg), close together
at any point. The structure shall consist generally of two main
longitudinal members running from end to end of the OHE
car, braced at frequent intervals along their lower flanges,
and rigidly connected to the arch bars, and to the grab pillars
by rigid transverse members. At partition and semi bulkheads,
the sills shall be attached to vertical pillars within or forming
part of the partitions or semi-bulk-heads The roof top at both
ends i.e. back & front ends shall be flat. Roof should be so
designed that no water is accumulated in cavities to avoid the
damage/rusting. Proper channels to be provided for easy exit
of rain water. The construction through out shall be
absolutely watertight and shall permit easy renewal of
corroded sheets. The material of the roof shall be of IRS: M 41
steel sheet.
4 3.9.2 Roof Ventilators: Roof ventilators shall be provided as per

the ICF Drg No WL.RRM4-7-3-401 with latest alteration shall
be used. The ventilator shall not violate the schedule of
dimensions & drawings to be got approved from RDSO.
5 3.10 Windows:
Lift type window made of powder coated aluminum to ICF
drawing No EMU/4C/ASR-5-4-402 with latest alteration with
fixed type poly OHE carbonate louver on top and movable
glass window at the bottom.
3.10.1 All window and door glasses shall be of laminated plate glass
set in sun heat resistant synthetic rubber section.
3.10.2 All window openings shall be true to dimensions square and

of uniform width. The window opening shall not at any point
exceed 2mm over or under the specified dimensions and shall
not be out of square by more than 2mm.
3.10.3 The windowsills of the body side windows shall have an

outward slope of approximately 50.
3.10.4 The body side windows shall have two shutters, one louver on
the outside and a glass on the inside.
3.10.5 The glass used for windows/shutters shall be of safety

laminated quality to IS: 2553, weighing not less than 9.76
kg/m2. Gravity safety latches of approved design shall be
provided at two intermediate positions to arrest the glass and
louver shutters from falling down. The shutters should be
balanced by balancers of suitable design.
3.10.6 The louver shutters shall be provided with shoot bolt type
safety latches to secure the shutters firmly in closed and open
position.
6 3.10.7 Door hand holds: Door hand holds of chromium plated steel
tube, with malleable cast iron brackets shall be provided on
either side of all body side doors and shall be so fitted as to
clear the side walls sufficiently to prevent injury to knuckles.
Hand holds shall also be within the OHE car profile.
7 3.10.8 General Design: OHE car shall have two 4 wheel bogies of
robust welded design suitable for taking brake gear,
suspension etc. and capable of withstanding the maximum
static and dynamic stresses under its full load condition. The
weight of the bogie shall be as low as possible, consistent with
strength and robustness. The bogie frame shall be of copper
bearing steel plates to IS 2062 Fe 410 Cu WC and shall be
fabricated by welding.
3.10.9 Bogie suspension design shall be coil steel suspension in
primary and air suspension in secondary stage. The bogie
design shall be as per ICF Drawing No AC//EMU/M/ASR-0-0-
001 with latest alteration.
8 3.10.10 Wheel assembly shall be of 952 mm dia and shall be provided

with roller bearings No 22328 C/C3. The wheels of tower
wagon shall be solid forged wheels to RDSO drawing No SK-
K4004 with latest alteration. All wheels sets shall be machined
to take a speedometer drive.
3.10.11 Axles shall be to IRS-R43/92 stress calculations/FEM of wheel

and axles shall be submitted. The calculations shall be done as
per ARR/UIC specification.
3.10.12 The wheel profile shall be to RDSO sketch No 91146 with latest
alteration of appendix 1 and width of wheel shall be 127mm
minimum.
9 3.9.3 Brake Blocks: The composition ‘K’ type non-asbestos brake
blocks to RDSO specification no. C-9508 with latest
revision/amendment shall be used. Brake rigging shall be as
per ICF drawing No. EMU/M-3-2-064 with latest alteration
shall be provided to prevent the brake blocks riding down the
Page 85 of 80 wheel tapers.
Effective The brake cylinder
from 01.08.2011 pressure
Spec for 20.32 t axle load
No.TI/SPC/OHE/8WDEIC/0090(02/09) Rev.1
bogies shall be 1.6 kg/cm2
10 v) Parking brake to RDSO spec CK 408 (latest revision) capable

of holding fully loaded OHE car with 120 t trailing load
of two loaded bogie flat wagons in un braked state on
1 in 33 down gradient under wet condition.
vi) Flexible hose connection shall conform to SAE 100R1
11 3.22 Piping & Pipe fitting:
3.22.1 Seamless stainless steel pipe bright annealed to ASTM A 269

Gr. 304, which can be bent cold shall be used. The layout of
piping shall be designed to keep all pipes, especially the brake
cylinder pipes, as short and straight as possible Bends should
be used throughout, but where elbows have to be used; they
shall be of round type. Where the pipes itself are bent, their
internal area shall be maintained uniformly.
3.22.2 Double ferule pipe fitting consisting of body, front ferrule, back
ferrule and nut shall provided. The body and nut shall be of
OHE carbon steel of ASTM A-108 Grade –II with electro cobalt
zinc plating with chromic passivation. The from ferrule and
back ferrule shall be made from stainless steel to ASTM A276
TP 316 SS and conforming to ICF specification no.
ICF/MD/SPEC-166 with latest revision/amendment.
3.22.3 All pipes shall be adequately clamped to the frame assembly.

Compreg to RDSO spec. No. C-9407- type II shall be used for
clamp.
12 3.23 Ceiling and paneling: The ceiling in compartments shall be of

minimum 2 mm thick NFTC to RDSO spec. No. C- K 511 (Latest
Revision) or non- asbestos limpet sheet to RDSO spec. No C-
K601 (Latest Revision). The ceiling material shall be IRSM-41
where ever required.
13 3.24 Flooring construction: Floor of the vehicle shall be as per ICF

drg. No. EMU/MASR-41-001 with latest alteration. The opening
in the flooring for passage of pipes and cables through the
floor shall be so constructed as to prevent any seepage of the
oil. In addition to give effective protection against the spread
of fire originating beneath the body.
14 3.9 Cattle Guard: Detachable type cattle guards shall be provided

under each buffer beam. The cattle guard shall be fitted with
adjustable rail guards so as to maintain the minimum free space
above the rails under all conditions (see item 7 of clause 2.0).
i) Cattle guard and RCF drg. No. EM26108 with latest
amendment.
Or Cattle guard and ICF drg. No. EMU-2-6-046 with
latest alteration.
SN Clauses deleted from the specification.

1 Annexure -6
2.0 MOTOR DESIGN FEATURES
2.1 Insulation
The insulation of the traction motor windings shall be class H

material.
2.2 Armature and Commutator
The armature and the commutator shall unless otherwise

approved, be mounted upon sleeves pressed on the armature
shaft and shall be dynamically balanced after winding and
banding. The design shall permit withdrawal of shaft without
disturbing the winding and commutator connections.
2.2.1 The commutator shall be preferably of arch bound construction.

The commutation bars shall be made from silver bearing copper
conforming to the relevant standard specification. The
commutator shall be seasoned for a minimum of five cycles of
seasoning and this aspect shall be clearly brought out in the clause
by clause comments. The commutator shall have adequate safe
wearing depth measured radially. The commutator riser
connections shall be through the TIG welding process.
2.2.3 The exposed V- ring insulation shall be mica or superior material

and finished smooth. The commutator riser side shall properly
sealed to prevent ingress of dust and consequential flash overs.
2.2.4 The brush box design shall be such that they are staggered to
cover the entire working surface of the commutator. The brush
spring pressure shall remain fairly constant over the entire
wearing length of the brush holder.
2.2.5 The brush positions shall be accessible for easy maintenance.

Necessary opening shall be made on the body of the traction
motor for this purpose. These openings shall have a machined
surface and suitable gaskets shall be provided to make them dust
and water proof.
2.2.6 The Arcing studs shall be renewable type.
2.3 Main and commutating pole field coils

2.3.1 All field coils, field coil terminals and connections shall be held
firmly in position to prevent abrasion of the external insulation or
any weakening or loosening of the connections due to vibration.
Flexible connections will be preferred. No portion of the field and
interpole coils shall be left bare and unisulated.
2.4 Motor Field Coil Connections
2.4.1 The interpole coils and the armature winding of each motor shall
be permanently connected in series through the brushes. The field
coils may be connected together in pairs to simplify weak field
switching and the reverser connections ,but each pair of field coils
shall be connected next to the pair of the armature with which
they are associated.
2.5 Motor Ventilation
2.5.1 The motors shall be self ventilated. The ventilation fans shall be of
robust design. The air inlets shall be connected to the OHE car
body by leather bellows. The air outlets shall be ducted or
shielded to prevent water entering the motor case.
2.6 Motor Rating
2.6.1 Ratings : The one hour rating of traction motors shall be at 97%
excitation and the continuous rating shall be adequate to give the
required performance. The motors shall be provided with 3%
permanent Ohmic field shunting.
2.7 Motor Suspension and Axle Drive
2.7.1 The traction motor shall be nose suspended. The nose suspension
shall be of approved design. Each traction motor shall drive one
axle of its motor bogie through single reduction gear drive
enclosed in a rigid oil and water tight gear case firmly secured to
prevent damage by movement and vibration under the most
severe operating conditions but easily removable for attention to
the gear case firmly secured to prevent damage by movement and
vibration under the most severe operating conditions but easily
removable for attention to the gear. A hole of suitable size with a
plug in arrangement shall be provided to facilitate topping up of
the gear compound to the correct level.
2.7.2 The gear wheels and pinion shall be made in conformation to

RDSO specn. No.71-B-M-55 of Nov.’1979 (latest one). The
procurement shall be made from RDSO approved source. The gear

ratio adopted shall be suitable to achieve maximum permissible
speed. The drawings for gear wheel and pinion shall be got
approved by RDSO before starting the manufacturing
/procurement action.
2.7.4 The gear ratio shall be guaranteed to give trouble free service for
7,00,900 kms and 3,50,000 kms per pinion.
2.8 Bearings
2.8.1 The armature shall be mounted on anti-friction bearings of
approved design and make. The inner races shall have adequate
interference for the duty.
2.8.2 The bearing housing on the pinion end shall be of sealed type and
on the commutator side semi-sealed bearing may be used with
provision made for re greasing plug with an overflow valve for
discharging grease.
2.9 An earthing brush shall be provided in the traction motor

assembly with suitable termination.
2.10 A fabricated construction for the magnet frame is preferred to a

cast steel frame.
2.11 Motor Contactors

2.11.1 Motor contactors, at one contactor for each motor suitable for
operation in combination with overload relays for opening the
traction motor circuit in over load and under fault conditions shall
be provided. These contactors shall be covered in a dust proof
cubicle mounted on the under frame in such a way as to prevent all
risk of damage to other apparatus from arcs formed by their
operation.
2.11.2 The motor contactors shall open the circuit they protect
automatically on overload and shall be capable of clearing the
resultant arcs under all conditions of overload.
2.11.3 All motor contactors on a train shall be suitable for remote

operation from any driving cab through the traction motor overload
reset switch.
2.11.4 The motor contactors shall be of electro pneumatic type and of

ample capacity provided with blowout coils and arcing horns, etc to
break the current without detriment to their working parts or
adjacent equipment. All contact tips, interlocks, pins and plungers
etc shall be easily accessible for maintenance.
3 Reverser
Electro-pneumatically operated reversers for the changing the

direction of rotation shall be provided in each motor circuit. These
shall be mounted in the same cubicle as the contactors and shall be
of robust design, remote controlled and suitably interlocked to
ensure that no movement can take place while they OHE carry
current. Provision shall be made for hand operation. The reverser
contacts shall have self wiping action.
4 Motor Overload Relays
4.1 Each motor shall be protected by as overload relay which trips the
motor contactor in case of overload. It shall not be possible to reset
the overload relay before the master controller is returned to the
OFF position. The relays shall be provided with indicating trip flags.
Remote resetting of these relays from the driving cabs shall be
possible. The settings shall be adjustable and the various settings
shall be clearly marked. These relays shall also be housed in the
same cubicle as the respective motor contactors and reversers.
Note : The control connections for the above cubicle shall be terminated
externally with hearting connectors. The power connections shall
be of bus bar type suitable for connection with palm type crimping
sockets. These also shall be brought to the exterior.
5 Motor Cutout Switch
5.1 Two four position rotary switches one for motors 1 & 2 and the other
for motors 3 & 4 shall be provided. The switches shall have
adequate number of contacts to provide various facilities for
control as required including the following :-
i) To disconnect the equipment of the motor OHE car from all the lines
except the reverser operation wires when the switches are set to cut out all
four motors.
ii) To prevent operation of motor switches trip’ indication when motors

have been deliberately cutout.
iii) To control feeds to the individual motor contactors, to isolate the

contactors and cut the motors out of circuit.
5.19.1.1 The tenderer shall submit the characteristic curves of the

traction motor.
5.19.1.2 Type, routine and acceptance tests if required on the traction

motor shall be performed in accordance with IEC-60349.
5.19.1.3 The Traction Motor’s thermal capability shall be adequate to

meet the operational requirement of lowest road speed (i.e. 5
kmph) for 90 minutes. A special test shall be OHE carried out at
the time of type test to establish/confirm this aspect. For this
purpose, at an output equal to one fourth of the calculated
power required for the lowest road speed and the corresponding
cooling available, the temperature rise shall not exceed the limit
prescribed above.

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Page 1 of 80 Effective from 01.08.2011 Spec No.TI/SPC/OHE/8WDEIC/0090(02/09) Rev.

SPECIFICATION NO.TI/SPC/OHE/8WDEIC/0090 (02/09) Rev.1

SPECIFICATION NO.TI/SPC/OHE/8WDEIC/0090 (02/09) Rev.1

Amendment Date of Total pages including Amendment/Revision

Nil 1.08.2011 80 Revision-1

PREPARED BY CHECKED BY APPROVED BY

ISSUED BY ……………. SIGNATURE…….. DATE……………

NOTE: This specification is property of RDSO. No reproduction shall be done without

1.2 CLIMATIC CONDITIONS

Minimum temperature: - 10°C (Also snow fall in certain areas

High level of 50 g vibration and shocks. Accelerations over 500

(a) Maximum vertical acceleration 3.0g

1.3 Examination of the Tender Offer:

1. Life of the diesel engine 18 years

1.4 Design Development:

1.4.2 The design shall be based on S.I. Units.

1.5 Approval of Drawings:

1.7 Contractor’s responsibility:

(a) Of the detailed drawing prepared by the contractor.

1.9 Exhibited Drawings and standard Specifications:

1.11 Service Engineers:

1.13 Service Manuals and Spare Parts Catalogues:

1.14 Electric Arc Welding:

1.16 Spare Parts:

i) Flexible coupling/ - 1 set

ii) Traction alternator alongwith - 1 set

iii) Air compressor (complete) - 1 unit

iv) Motorised bogie (complete with

v) Battery charger for charging of - 1 unit

vi) Auxiliary alternator - 1 set

1.20 Quality Assurance Plan

The above shall apply to the main contractor as well as sub-contractors.

1.21 Annual Maintenance Contract (AMC) :

2.0 The OHE car shall dimensionally conform to the following:

1. Track gauge 1676 mm

3. Maximum super 185 mm

7. Maximum These shall conform to Indian railway, schedule of dimension

11. Service Braking Pneumatic

iii) Period of continuous running at 40 km/h 5-1/2h total

iv) Performance in monsoon and squally Un- restricted

viii) With the hydraulic platform in raised condition the OHE

vi) 2 numbers, 110 V sockets for hand signals in each cab.

viii) OHE voltage sensing device in both the cabs.

The principal details of the conductor drums are-

2.3.5 Facilities on roof:

v) A lifting and swiveling platform with hydraulically operated mechanized adjustment

(a) Length 5700 mm

(b) Width 1600 mm

(c) Platform floor 6150 mm

(d) Maxim lifting time to full height 45 s

(e) Rotation range of 900

(f) Side shifting reach of platform 4200 mm

(g) Full height of collapsible 800 mm

(h) Maxm. time of rotation from 45 s

(i) Safety of men and

ii. A horizontal squeeze load of 100 t applied at each buffers.

iii. A combination of loads specified at (i) & (ii).

3.1.4 Side and End Wall

3.8 WHEEL, AXLES AND AXLE BOXES

3.8.12 The axle box body shall preferably be of cast steel.