Govt.

of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

QM-C-7.1/CASTING/0001 (Rev 1)
Inspection Plan & Check Sheet for Adapter Class ‘E’(6”x11”)

Item : Narrow Jaw, Wide Jaw and Modified Adapters (6”x11”)

Specn. : AB/RB-39-2002, Rev.3
Amd. : 3 of October’ 2016
Drg. No.& Alt.:WD-89067-S-9 Alt.7; SK-78527,Alt.5&WD-85053-S-1,Alt.5
----------------------------------------------------------------------------------------------------------------------------- -----------------------

1 NAME OF MANUFACTURER

2 DATE OF OFFER

3 RDSO FILE NO.

4 DESCRIPTION OF MATERIAL

5 DRAWING & ALT. NO.

6 SPECIFICATION & GRADE

7 PURCHASE ORDER NO.

8 TOTAL QUANTIY ORDERED

9 QUANTITY EARLIER PASSED

10 QUANTITY NOW OFFERED

11 CONSIGNEE

12 DELIVERY PERIOD

1 DATE OF INSPECTION

2 QTY. ACCEPTED

3 QTY. REJECTED

4 BALANCE ORDER

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 1 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

(A)- METALLURGICAL REQUIREMENTS FOR ADAPTERS FOR CLASS ‘E’(6”x11”)

Specified Values
Specification Chemical Mechanical Properties
NO./Grade Composition,% UTS, YS, EL RA% Base Metal Micro/Heat treatment
Min. Min (Min.) Min. Hardness (BHN)
Kgf/mm² Kgf/mm² 2In, %
ASTM A 536 Not specified in 187-255 BHN, Microstructure of ductile
Gr.80-55-06 ASTM A-536 56.3 38.67 6 - Casting having cast iron shall consists
(Ductile Iron) however, the hardened crown substantially graphite
chemical or hardened nodules (minimum 80%)
composition of crown and thrust
iron shall be shoulders
such as to 217-255 BHN,
produce the Casting not
specified having any
mechanical hardened
properties surfaces or with
hardened thrust
shoulders only
ASTM A 148 S-0.06 max. 56.3 28.15 18 30 179-228 Full annealing,
Gr.80-40 P-0.05 max. normalizing, normalizing
(Steel Casting) & tempering or
quenching & tempering.

AAR M-201 C-0.32 max. 63.3 42.18 22 45 179-228 Normalised& tempered

Gr.C Mn – 1.85 max or quenched & tempered
Si – 1.5 max
S – 0.04 max
P – 0.04 max

1. Specification No. of the offered Adapter(6”x11”) material :-…………………….

2(A)SAMPLES REQUIRED FOR DESTRUCTIVE TESTING DURING PURCHASE INSPECTION:

(i) One sample per 1000(lot size) or part required for destructive testing of adapter.
(ii) Integrated test lug or machined test piece from finished product may be tested for
mechanical/chemical testing.

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 2 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

2.(B) CHEMICAL COMPOSITION (1 no.per heat)

HEAT NO. C% Mn% Si% S% P% Mg%

2.(C) MECHANICAL PROPERTIES (1 no.per heat)

HEAT NO. UTS YS EL RA MICRO HARDNESS Heat

Kgf/mm² Kgf/mm² % % Nodularity BHN clearance
&matrix date
Microstructure
of ductile cast
iron shall consist
substantially
graphite nodules
(minimum 80%)

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 3 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

(B)- I Dimension for Narrow Jaw Adapter Class ‘E’ (WD-89067-S/9)

S. Sample size Actual size

No.
1 (a) Visual Inspection-10 % of lot, randomly selected, for casting quality ( like cracks,
inclusions shrinks, porosity, application of rust preventive coating etc.) and marking.

(b) Rust-resistance coating as per Specification no. IS: 2074:10% of lots,randomly

selected shall be checked visually for uniform coating of the machined surface area
of adapter to prevent rusting.

(c) Colour matching of the adapter with the CTRB’s outer cup: 10% of lot shall be
checked-The adapter should be placed on the coloured CTRB outer ring & hand
pressure applied on the top of adapter. Then the adapter is removed from outer cup
and the adapter inner bore touching area with the CTRB outer cup to be inspected.
At least 80% of the area must be coloured matched.
2 Gauging: Lot size Sample size
281-500 50
501-1200 80
1201-3200 125
3201-10000 200
3 Hardness- All hardness values to checked on1 % of lot received for inspection.

S. Parameters Acceptance Std. Gauge No./gauge Observation

No. Gauged/Checked (mm unless Suffix & Name(As
specified per AAR M-924)
otherwise)
Machined Surfaces
1 Centrality Must be equal AM-45109-4
within 1.6 mm after (Centrality gauge)
bore is machined

2 Equal Thickness Within 0.5 mm after AM-45117-4

bore is machined (Equal thickness
gauge)
+0.4/ - 2.0 AM-45096-4
3 Bearing Thrust 13.5
Shoulder (Bearing thrust
Thickness shoulder thickness
gauge)
+0.015/ - 0.112 AM-45092-4 (Bore
4 Bore Diameter 110.5 R
diameter-Chordal
Gauge)
5 Concentricity & The max reading AM-45094 - 4
Taper (Use on any of the four (Concentricity &
gauge on clear indicators must taper gauge)
and unpainted not exceed 0.038
surfaces) mm (Top center
only).
+0.0/ - 0.914 AM-45095 - 4
6 Bearing Thrust 10.11
Shoulder Depth (Bearing thrust
shoulder depth
gauge)

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 4 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

+1.6 / - 0.0 AM-45097 - 4

7 Bearing Thrust 166.7
Shoulder Spacing (Bearing thrust
and Relief shoulder spacing &
relief gauge)
8 Bearing Thrust 35˚±2˚ AM-45104
Shoulder Chamfer (Bearing thrust
Angle shoulder
chamfer angle
gauge)
+ 0.796/ - 0 AM-45105 - 4
9 Bearing Thrust 4.76
Shoulder Chamfer (Bearing thrust
Location shoulder chamfer
location gauge)
10 Heat indicator hole 17.859 +0.25/-0.0 AM-45093 – 4
diameter and depth & 81.8 +1.2/-0.0 (Heat indicator hole
(When specified by diameter and depth
the customer) gauge)
+ 0.25/ - 0
11 Snap Ring Groove 19.13 AM-45101
(Snap ring groove
gauge)

12 Machined Surface 6.3 µm (N9) Comparator or

Finish surface roughness
measuring
instruments
UNMACHINED SURFACES
+0.5/ -2.0
13 Overall Width 225.56 AM-45084 - 4
(Overallwidthgauge)
+2/ - 0
14 Body Width 181 AM-45091 - 4
(Bodywidthgauge)
+4 / - 0
15 Side/Outer Thrust 97 AM-45085 - 4
Lugs Spacing (Outerthrustlugspaci
ng gauge)
+1.6/-0.7
16 Side/Outer Thrust 21.0 AM-45086-4
Lugs Height (OuterThrustLugHei
ght Gauge)
+2/-0
17 Crown/Top Thrust 155.5
Lugs Spacing
18 Crown/Top Thrust 24
Lugs Height
+0/ -508 R
19 Combined Crown 1524R AM-45110 – 4
Radius (Combined
crownradius gauge)
20 Pedestal Fit AM – 45102 – 4
(Pedestal fit gauge)
21 Marking As perDrg.
WD-89067- S/9
latest i.e
(Year of Cast,
Journal size,
Name of
manufacturer,
Material Code,
Heat Number)

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 5 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

22 Surface Hardnening

Location Hardness Observed

value
Crown 350- 450 BHN,
1.5 mm – 5.0 mm in
depth
Thrust 350- 450 BHN,
Shoulders 0.76 – 3.8 mm in
depth

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 6 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

(B)- II Dimension for Wide Jaw Adapter Class ‘E’ (SK-78527)

S. Sample size Actual size

No.
1 (a) Visual Inspection-10 % of lot, randomly selected, for casting quality ( like cracks,
inclusions shrinks, porosity, application of rust preventive coating etc.) and marking.

(b) Rust-resistance coating as per Specification no. IS: 2074: 10% of lots, randomly
selected shall be checked visually for uniform coating of the machined surface area
of adapter to prevent rusting.

(c) Colour matching of the adapter with the CTRB’s outer cup: 10% of lot shall be
checked-The adapter should be placed on the coloured CTRB outer ring & hand
pressure applied on the top of adapter. Then the adapter is removed from outer cup
and the adapter inner bore touching area with the CTRB outer cup to be inspected.
At least 80% of the area must be coloured matched.
2 Gauging: Lot size Sample size
281-500 50
501-1200 80
1201-3200 125
3201-10000 200
3 Hardness- All hardness values to checked on1 % of lot received for inspection.

S. Parameters Acceptance Gauge No./gauge Observation

No. Gauged/Checked Std.(mm unless Suffix & Name(As
specified per AAR M-924)
otherwise)
Machined Surfaces
1 Centrality Must be equal AM-45109 – 4
within 1.6 mm after (Centrality gauge)
bore is machined
2 Equal Thickness Within 0.4 mm AM-45117- 4
after bore is (Equal thickness
machined Gauge)
+0.0/ - 1.6
3 Bearing Thrust 13.5 AM-45096 - 4
Shoulder Thickness (Bearing thrust
Shoulder thickness
Gauge)
+0.015/ - 0.112
4 Bore Diameter 110.5 R AM-45092 - 4
(Bore diameter-
chordal Gauge)
5 Concentricity & The max reading AM-45094 - 4
Taper(Use gauge on any of the four (Concentricity &
on clear and indicators must not taper gauge)
unpainted surfaces) exceed 0.038 mm
(Top center only).
+0.009/-0.905
6 Bearing Thrust 10.1 AM-45095 - 4
Shoulder Depth (Bearing thrust
shoulder depth
gauge)
7 Bearing Thrust 162 max. AM-45097 - 4
Shoulder Spacing (Bearing thrust
and Relief shoulder spacing

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 7 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

&relief gauge)
8 Bearing Thrust 35˚±2˚ AM-45104
Shoulder Chamfer (Bearing thrust
Angle shoulderchamfer
angle gauge)
+ 0.796/ - 0
9 Bearing Thrust 4.76 AM-45105 - 4
Shoulder Chamfer (Bearing thrust
Location shoulder chamfer
location gauge)
10 Machined Surface 6.3 µm (N9) Comparator or
Finish surface roughness
measuring
instruments
UNMACHINED SURFACES
11 Overall Width 306 AM-45084 - 4
(OverallWidthGauge
)
+0.287/ -2.888
12 Body Width 268 AM-45091 –
4(BodyWidthGauge)
+3.175 / - 0.0
13 Side/Outer Thrust 130.175 AM-45085 - 4
Lugs Spacing (OuterThrustLugSp
acing Gauge)
+1.5/- 0.2
15 Side/Outer Thrust 19 AM-45086 – 4
Lugs Height (Outerthrust
lugheight gauge)
+ 2.75 / - 0.425
16 Crown/Top Thrust 156
Lugs Spacing
17 Crown/Top Thrust 24 min
Lugs Height
+ 0/ - 508 R
18 Combined Crown 1524R AM – 45110 – 4
Radius (Combined
crownradius gauge)
19 Pedestal Fit AM – 45102 – 4
(Pedestal fit gauge)
20 Marking As per Drg. No.
WD-78527 latest
i.e(Year of Cast,
Journal size,Name
of manufacturer,
Material Code,
Heat Number)

21 Surface Hardening:

Location Hardness Observed

value
Crown 350- 450 BHN,
1.5 mm – 5.0 mm
in depth
Thrust Shoulders 350- 450 BHN,
0.76 – 3.8 mm in
depth

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 8 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

(B)- III Dimension for Modified Adapter(WD-85053/S-1)

S. Sample size Actual size

No.
1 (d) Visual Inspection-10 % of lot, randomly selected, for casting quality ( like cracks,
inclusions shrinks, porosity, application of rust preventive coating etc.) and marking.

(e) Rust-resistance coating as per Specification no. IS: 2074:10% of lots, randomly
selected shall be checked visually for uniform coating of the machined surface area
of adapter to prevent rusting.

(f) Colour matching of the adapter with the CTRB’s outer cup: 10% of lot shall be
checked-The adapter should be placed on the coloured CTRB outer ring & hand
pressure applied on the top of adapter. Then the adapter is removed from outer cup
and the adapter inner bore touching area with the CTRB outer cup to be inspected.
At least 80% of the area must be coloured matched.
2 Gauging: Lot size Sample size
281-500 50
501-1200 80
1201-3200 125
3201-10000 200
3 Hardness- All hardness values to checked on1 % of lot received for inspection.

S. Parameters Acceptance Std. Gauge No./gauge Observation

No. Gauged/Checked (mm unless Suffix & Name(As
specified per AAR M-924)
otherwise)
Machined Surfaces
1 Centrality Must be equal AM-45109 - 4
within 1.6 mm after (Centrality gauge)
bore is machined
2 Equal Thickness Within 0.4 mm after AM-45117- 4
bore is machined (EqualthicknessGa
uge)
+0.0/ - 1.5
3 Bearing Thrust 13.5 AM-45096 - 4
Shoulder Thickness (BearingthrustSho
ulder
thicknessgauge)
+0.015/ - 0.112
4 Bore Diameter 110.5 R AM-45092 – 4
(ChordalGauge)
5 Concentricity&Tape The max reading AM-45094 – 4
r(Use gauge on on any of the four (Concentricity&tape
clear and unpainted indicators must r gauge)
surfaces) not exceed 0.038
mm (Top center
only).
+0.0/ -1.0
6 Bearing Thrust 10 AM-45095 – 4
Shoulder Depth (Bearingthrustshoul
der depth gauge)

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 9 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

7 Bearing Thrust 162 max AM-45097 - 4

Shoulder Spacing (Bearingthrustshoul
and Relief der spacing & relief
gauge
8 Bearing Thrust 35˚±2˚ AM-45104
Shoulder Chamfer (Bearingthrustshould
Angle erchamferangle
gauge)
+ 0.796/-0
9 Bearing Thrust 4.76 AM-45105 - 4
Shoulder Chamfer (Bearingthrustshoul
Location der chamferlocation
gauge)
10 Machined Surface 6.3 µm (N9) Comparator or
Finish surface roughness
measuring
instruments
UNMACHINED SURFACES
11 Overall Width 306 AM-45084 - 4
(Overallwidthgauge
)
+0/ -3.0
12 Body Width 268 AM-45091 - 4
(Bodywidthgauge)
+3.0 / -0
13 Side/Outer Thrust 130 AM-45085 - 4
Lugs Spacing (Outerthrustlugspac
ing gauge)
+1.5/-0.0
14 Side/Outer Thrust 19 AM-45086 – 4
Lugs Height (Outerthrust
lugheight gauge)
+3/-0
15 Crown/Top Thrust 156
Lugs Spacing
16 Crown/Top Thrust 24 min
Lugs Height
+ 0/ - 508 R
17 Combined Crown 1524R AM – 45110 – 4
Radius (Combined
crownradius gauge)
18 Pedestal Fit AM – 45102 – 4
(Pedestal fit gauge)
19 Marking As per Drg. No.
WD-85053/S-1
latest i.e(Year of
Cast, Journal size,
Name of
manufacturer,
Material Code,
Heat Number)

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 10 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

20 Surface Hardening :
Location Hardness Observed
value
Crown 350- 450 BHN,
1.5 mm – 5.0 mm in
depth
Thrust Shoulders 350- 450 BHN,
0.76 – 3.8 mm in
depth

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 11 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

(C)- IPacking of Class ‘E’ (6” X 11”) Narrow Jaw Adapter (WD-89067/S/9): procedure

STEP-01

TAKE WOODEN CRATE

STEP-02

PUT CORRUGATED SHEET & PLASTIC BAG

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 12 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

STEP-03

APPLY RUST-RESISTANCE COATING AS PER SPECIFICATION NO IS:2074 FOR

COATING THE MACHINED SERFACE AREA OF ADAPTER TO PREVENT RUSTING

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 13 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

STEP-04

PUT 4X4 PARTS AND USE BUBBLE SHEET BETWEEN EACH LAYERAS ABOVE

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 14 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

STEP-05

MAKE TOTAL 16 COLUMN(4X4) WITH 4 LAYERS AS PER ABOVE FIGURE

(TOTAL 64 PCS IN EACH CRATE)
&
SEAL THE PLASIC BAG

STEP-06

PUT &NAIL THE TOP COVER

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 15 of 16

 Govt. of India
Ministry of Railways
Research Designs & Standards Organisation
Manak Nagar, Lucknow-226 011

STEP-07

STRAP WITH POLYPROPYLENE /STEEL TAPE & PUT THE LABLE

Signature of firm’s Representative RDSO Representative

REVISION 1 QM-C-7.1/CASTING/0001 Page 16 of 16