SPECIFICATION OF HYDRAULIC TRACK JACK 10T Cap.

(NON
INFRINGING)

(No.TM/SM/15 dt. 22.07.1991)

1.0 Scope:
1.1 The non-infringing lightweight hydraulic track jack should have a safe working load of
10t. The non infringing feature would be that the jack could be released instantaneously in
the face of an approaching train and non of its component would project above the rail
level during the passage of a train

1.2 The jack may be designed for a single or multiple stage lifting.
2.0 Materials:
The jack shall be of a special Aluminium alloy of high strength generally confirming to
IS: 617-1975 alloy 2550 (A-12) or alloy steel of equivalent strength similar to IS:3930-
66,Design:40Ni2 Cr1 Mo28 or En81-En91 EN24to Bs:970 for ram material.
Manufacturers may also explore possibilities of using fibre glass material wherever
feasible keeping in view the lightweight and guaranteed life of jack units to withstand 10
tones of load and working pressure of 400-500 kg/sq cm suitably designing the body and
ram diameters.
3.0 Chemical Analysis:
3.1 The contractor shall supply a complete analysis of the materials of all the different
component parts of the jack when required to do so by the purchaser or the inspecting
officer. Such analysis should be got done by him from a Government approved
laboratory/Test House.
3.2 In case of any doubt in the use of specified materials, the Inspecting Officer shall be free
to take samples from the component for complete C&M analysis at the expense of the
supplier.
4.0 Workmanship and finish:
4.1 All metal surfaces shall be properly finished. Rough and sharp edges shall be removed.
4.2 All the working parts and the parts subjected to wear shall be accurately machined to such
tolerances as will ensure the fitting of spares with minimum of adjustments.
5.0 Functional specifications:
5.1 Hydraulic track jack should be lightweight. Its weight should be around 10.5 kg and
should have easy portability.
5.2 The jack should have rigid, mono block construction of cylinder reservoir and pump with
base area approximately 300 cm2. it should be of single casting r fabrication for rough and
rugged use in the field and to prevent leakage of hydraulic oil through joints and oil seals
etc., during normal operation.

5.3 The hydraulic jack should have a sufficiently large capacity pump such that in about 90/95
strokes, the pump should lift the load through a height of about 80+3 mm.
5.4 The ram shall be of one single diameter throughout its length for single stage lifting and of
uniform diameters for multiple stage lifting for each part of the ram. It shall have a
swiveling ram cap or saddle for better grip.
5.5 Release valve should be so provided as can be closed by the clockwise movement of the

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 handle at the time of operation. The anti-clockwise movement of the handle should enable
the release valve to open there by lowering the jack ram. The position of the release valve
shall be facing the operator.
5.6 Release should be instantaneous and preferably obtained by a single twist of the handle
5.7 The hydraulic track jack should be fitted with a two-way overload safety release valve,
which bypasses the pump, when the jack reaches its maximum or present load, and
instantaneously causes the jack to field safety, if a sudden overload occurs.
5.8 The maximum capacity of the overload safety release valve should be 12.0 tonnes, but it
should normally be possible to preset to a load of 7 tonnes for BG and 5 tonnes for MG so
that the release device will trip automatically under the wheel load of an approaching
train. This should be used as a safety measure only for emergency tripping when a
Gangman fails to release the jack manually.

5.9 The jack should be provided with a carrying handle/sling.

5.10 The oil used for hydraulic jack shall be SAF-30/40 or its equivalent.
5.11 Oil seals (Nutring, O-Ring, Washer, etc.) should be of special high pressure brand of
synthetic Neoprene/Nitrile rubber/Viton of Taflon material (superior brand to be provided)
generally conforming to IS:6838-73.

6.0 Dimensional Specifications and Operating Torque:

6.1 Dimension:
i) Maximum lifting capacity : 10 tonnes
ii) Maximum close height : 166 mm + 3 mm
iii) Hydraulic lift of load : 80 mm +3mm
(Travel of ram)
iv) Weight of jack (excluding : 10.5 kg + 0.5 kg.
operating handle):
v) Length of operating : 750 mm (approx.) made of tubular section and
handle: gripping end should have suitable bend so as not to
hit the ballast profile during operation.
Other tolerances will be within 5% of nominal dimensions approved by purchaser
/Railway Board/RDSO except those of mating/moving parts.
6.2 Operating torque:
The maximum operating torque required for lifting by up and down movement of the
operating handle should not exceed 500 kg cm with maximum effort of 35 kgf at the end
of handle. (As per ISI standard)
7.0 Sample :
7.1 The manufacturer shall submit to the purchaser or their Inspecting official two sample
jacks and manufacture in bulk shall not be processed with, until these samples have been
tested as per procedure laid down in clause 7.2 to 7.4 and approved. Such samples shall
not be specially prepared and must have been manufacture by the same procedure with
which general manufacture will be carried out.
7.2 Both these sample jacks shall first be subjected to type tests mentioned in clause 8.0.
7.3 In one sample submitted fails initially, then the supplier shall submit afresh two new

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 sample jacks which shall be tested as per procedure detailed in clause 8 and both should
withstand the tests.
8.0 Tests schedule for testing of jacks:
8.1 Type tests:

Two jacks shall be supplied for type tests. Both the hydraulic jacks shall be subjected to
the following tests for ascertaining their suitability generally conforming to IS 4552 (Pt.2):
1993.
8.1.1 Visual test :
The jacks shall be free from material as well as manufacturing defects like cracks, blow
holes, etc.
8.1.2 Dimensional and material check:
The jacks shall be subjected to detailed dimensional check and shall conform to the
functional dimensions as mentioned on clause 6.1 or manufacturers drawings approved by
Railway Board/RDSO/Standing Committee on small track machines. Jacks shall conform
for material, heat treatment/ hardness, etc., as stipulated in the applicable drawings &
specifications mentioned under various clauses. Supplier/Manufacturer shall submit all
necessary test certificate in this respect.
8.1.2.1 Test:
Jack shall be subjected to the following tests in order of sequence as given in clause 8.1.9.
The tests shall be carried out either on actual vehicle/trailer/work or on a rig simulating
operating of a jack on a vehicle /actual use for ascertaining their conformity to this
standard. In these cases the jacks may be subjected to titled loads up to +50 angle.
Necessary arrangements for test shall made by manufacturer/supplier.
8.1.3 No load test:
The jacks shall be operated without load to its maximum lift during which it shall work
smoothly jerk free and there shall be no leakage. After the jack lifts to its maximum the
release valve shall be opened and the ram shall be made to retract to its closed height by
applying a load of maximum 30 kg. The Jack shall not show any sign of leakage.
8.1.4 Overload Test Before Performance:
Jacks shall be loaded with a load of 120 percent of rated capacity and operated from the
minimum to maximum position and back. During this test the jack shall operate smoothly
throughout the range without any slip or other visible damage. During this test safety
valve, when provided, shall be adjusted to higher pressure.
8.1.5 Performance Test:
Jacks shall be loaded with a load of rated capacity and operated from the minimum to the
maximum position and back. After repeating the cycle 100 times with an interval of 10
minutes between each cycle, the jack shall work smoothly throughout the range without
undue play or slip between the moving parts.
8.1.6 Safety valve opening test:
The safety valve (when provided) shall be set in such way that opens between the pressure
range corrosponding to 110 percent to 120 percent load shall be checked at the end of all
tests.
8.1.7 Over Load Test After Performance:
The test shall be repeated in accordance with 8.1.4.

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8.1.8 Load Sustaining Test:
The saddle of the jack shall be lifted to the middle of its stroke and loaded to 120 percent
of the nominal lifting capacity. The load shall be sustained for one hour. After end of one
hour, the reduction in the height of the saddle shall not be more than 3 mm. The load shall
be removed after the end of this period and the test repeated three times. After this test,
Jack shall be left for 24 hours and room temperature and shall not show any sign of
distortion or leakage of oil at the end of this test. This test shall be conducted after
adjusting the safety valve for higher pressure an d preferably at a temperature of 270 C.
8.1.9 Sequence of Testing for Type tests:
i) Visual (8.1.1),
ii) Dimensional and Material Check (8.1.2),
iii) No load test (8.1.3),
iv) Over load test before performance (8.1.4),
v) performance test (8.1.5),
vi) Safety Valve opening test (8.1.6),
vii) Over load test after performance (8.1.7)
viii) Load sustaining test for one hour (8.1.8).

8.2 ACCEPTANCE TESTS:

The following shall constitute acceptance tests:

a) Visual (Sec. 8.1.1) : Every Jack

b) Dimensional check (Sec. 8.1.2) : Every Jack
c) Material check (Sec. 8.1.2) : Every Jack
d) No load test (Sec. 8.1.3) : Every Jack
e) Overload test before performance test : Every Jack
(sec. 8.1.4)
f) Performance test for 25 operations : One out of every 20 or
only (sec. 8.1.5) part thereof
g) Safety valve opening test (sec. 8.1.6) : Every Jack
h) Over load test after performance (sec : Jack subjected to
8.1.7) performance test
i) Load sustaining for one hour (sec. : For the jack subjected to
8.1.8) performance test.

The necessary arrangement for acceptance test shall be made by manufacturer/

supplier.

9.0 PROTECTION FROM RUST:

All working surfaces of the jack shall be coated with suitable rust preventive. All
other surfaces shall be painted with the paint of approved colour and specification.
The jack shall be supplied packed in suitable wooden crates, according to best trade
practices generally conforming to IS 5415-69. All the working parts shall be oiled
before being assembled.

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10.0 MARKING:

The jacks shall be legibly and indelibly marked with:

i) Name, initials and trade-marks of manufacturer.
ii) Nominal, lifting capacity of the jack in tones.
iii) Serial number of jack.

11.0 REJECTION:

Any of the jacks which fail to comply with the requirements of this specification
may be rejected. All the rejected jacks shall be marked with a paint of different
colour or otherwise for identification to the satisfaction of the inspecting official.

12.0 TECHNICAL DATA:

Each set of jack shall be supplied with the following information in booklet or
pamphlet form:
i) Instructions for safe operation of the jacks.
ii) Salient feature of the jack.
iii) Parts list, with isometric drawing of the components for easy identification.
iv) Sequential procedure for increasing/decreasing the load carrying capacity of
the automatic safety release mechanism.
v) Detailed instruction pamphlet for replacing oil periodically if needed.

13.0 SPARE PARTS:

13.1 Each set of jack shall be supplied with the following spares.
i) Oil Seals – Two nos. of each side Suitably parked in a carrying case
ii) Valves – Two nos. of each type

13.2 The supplier shall ensure prompt and continuous service and delivery of
spare parts for a minimum period of five years.

14.0 GUARANTEE:

14.1 The jacks shall be covered by a guarantee for one year for manufacturing
defects and one year for material defects.
14.2 The manufacturer shall bear the entire cost of the repair or replacement of
any parts found deficient/defective due to faulty material, poor
workmanship etc. during the period of guarantee.

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