LEVER GEAR REGULATOR RGVP-675T

1. Main parameters and characteristics
1.1 The cylinder must comply with the requirements of DSTU GOST 31402, these technical specifications and the set of design documentation (CD) in accordance with specification 188B.000.
1.2 When supplied for export, cylinders must additionally comply with the requirements of the supply agreement (contract), the requirements of international, regional and national standards of consumer countries, as well as the legislative acts of Ukraine on the supply of products for export.
1.3 The main parameters and dimensions of the cylinders must comply with those specified in Table 1.

Table 1.

2. Indicators (characteristics) of functional purpose

2.1 Reliability indicators
2.1.1 The intended service life of cylinders is not less than 20 years.
The decision on the possibility of further operation is made separately for each cylinder after examining its technical condition.
2.1.2 Mean time between failures – 120,000 braking cycles.
2.1.3 Installed failure-free service life – 12,000 braking cycles.
2.1.4 The specified service life of the cuffs, seals and cylinder gaskets is 6 years.
2.1.5 The failure criterion for cylinders is:
– breakage or failure of parts and components;
– cylinder leak.
2.1.6 Limit state criteria:
– wear of the inner diameter of the cylinder body is more than 359 mm;
– presence of chips on the cylinder body flanges, if the chipped part covers the bolt holes;
– the presence of cracks in the housing that extend to the working surfaces.
2.2 Technological processes for manufacturing cylinders must ensure the economical use of raw materials, materials, fuel, energy and labor resources.

3. Design requirements
3.1 Cylinders consist of the following main parts and assemblies:
– hull;
– rear covers;
– front covers;
– piston assembly;
– release springs;
– other parts and standardized products according to specification 188B.000.
3.2 Cylinders must remain operational at temperatures from minus 60 °C to plus 60 °C. Short-term (no more than 4 hours) operation at temperatures of plus 80 °C is possible.
3.3 The cylinder assembly must be leak-proof at a working pressure of 0.6 MPa (6.12 kgf/cm2).

3.4 The movement of the piston to its full stroke should be smooth, without jerks or stops.
At sub-zero test temperatures, a jolt is allowed at the beginning of the movement of the piston with the rod.
3.5 The movement of the piston in the cylinder must take place under the air pressure specified in Table 2.
At sub-zero ambient temperatures, a pressure deviation of ±0.005 MPa (±0.05 kgf/cm2) from the values specified in Table 2 is allowed.

Table 2

3.6

The maximum piston stroke is 240 mm.

3.7

The release spring must be compressed six times until the coils touch, and during control compression must not exhibit residual deformation.
The surface of the springs must not have cracks or signs of overheating.
The end coils of the spring must be pressed so that the spring has a stable position when placed vertically on a horizontal surface (plate).

3.8

Metric and pipe threads on cylinder parts must comply with the requirements of the design documentation (DD).

3.9

Permissible dimensional deviations of parts must not exceed the values specified in the DD.

3.10

After machining, and on unmachined casting surfaces, no cracks, hairlines, or chips are allowed.

3.11

Before assembly, all cylinder parts must be cleaned of contaminants, moisture, packaging materials, and preservation materials.

3.12

Friction surfaces of cylinder parts must be lubricated with the oil specified in the DD.

4. Coating Requirements

4.1

Unmachined surfaces of cylinder parts must have protective paint-and-lacquer coating. The color and type of coating must comply with DD requirements and current regulatory documents.
Delivery of cylinders in primed condition is allowed.

4.2

The type and brand of the coating must be indicated in the DD.

4.3

The release spring must have an anti-corrosion coating as specified in the drawing.

4.4

Surface preparation for coating shall be carried out according to DSTU ISO 12944-4 (ISO 12944-4, IDT).

4.5

Surfaces of cylinder parts without protective coating, except those intended for preservation, must be lubricated with the oil specified in the DD.

5. Requirements for Materials and Purchased Components

5.1

Materials used for cylinder production must comply with current regulatory documents and these Technical Specifications (TS).
Material quality must be confirmed by certificates of conformity (quality certificates) issued by material manufacturers.

5.2

The cylinder body, front and rear covers, piston, and rod head must be cast from gray cast iron grades SCh150, SCh200, SCh250, SCh300 per DSTU 8833; or cast iron grades GJL-150, GJL-200, GJL-250, GJL-300 per DSTU EN 1561 according to the DD.

5.3

Castings must be cleaned of molding sand, scale, and burn-on.
Flash, fins, shrinkage cavities, and runners must be removed by any method. Removal points must be cleaned or chiseled.

5.4

Castings must be free of cracks, blowholes, local looseness, porosity, slag inclusions, and foreign inclusions.

5.5

The release spring and retaining ring must be manufactured from steel wire according to DSTU ISO 8458-2.

5.6

The expander ring blank and its lugs must be made from 65G steel strip in accordance with DSTU 8429.

5.7

The tube and thrust ring must be manufactured from seamless cold-drawn tube according to DSTU 8939.

5.8

All other metal parts shall be made from rolled quality carbon structural steel according to DSTU 7807 and DSTU 7809.

5.9

Rubber seals, cuffs, and gaskets must be made of oil-resistant rubber compounds according to the DD and must comply with applicable standards.

5.10

Materials used for manufacturing cylinders must ensure operability at limiting temperatures.

6. Completeness

6.1

The delivery set must include:
– Cylinder assembly complete according to specification 188B.000;
– Operating manual;
– Passport (for the batch) according to DSTU GOST 2.601.

6.2

Each delivered batch must be accompanied by documents containing:
– Name and/or trademark of the manufacturer;
– Cylinder designation number;
– Designation of these TS;
– Manufacturing date (month, year);
– Quantity of cylinders in the batch;
– Quality control department (QCD) stamp.

7. Manufacturability Requirements

7.1

The design of the cylinder and its parts must ensure manufacturability and inspectability during production, operation, and repair.

7.2

When repairing wagons, cylinders must be interchangeable with cylinders from other manufacturers.

8. Marking

8.1

Marking must comply with these TS and the DD for the product.

8.2

Each cylinder body must bear the following markings, applied in the locations defined by the working drawings:
– Manufacturer’s trademark;
– Manufacturer’s code;
– Cylinder model name;
– Cylinder diameter;
– Serial number since the beginning of the year;
– Month and last two digits of the year of manufacture;
– QCD mark.

8.3

Marking must be applied by stamping or casting.

8.4

Marking must remain visible for the entire service life of the cylinder.

9. Packaging Requirements

9.1

Packaging must protect cylinders from direct atmospheric precipitation, water splashes, UV radiation, dust, sand, and aerosols. Packaging must prevent damage during transportation and storage.
Transportation without packaging is allowed by agreement with the customer per DSTU GOST 31402.

9.2

Unpainted surfaces must be preserved with gun grease or other oil according to DD. The guaranteed storage period without re-preservation is one year from the manufacturing date.

9.3

Through holes of cylinder bodies must be closed with plugs (stopper and cargo screw according to DD).

9.4

Preserved cylinders must be packed on a pallet or, at customer request, in wooden crates per applicable standards.

9.5

Shipped products must be accompanied by documents listed in section 1.6 of these TS. Documents must be placed in a sealed polyethylene bag.