ISRAEL RAILWAYS LTD

INFRASTRUCTURE DIVISION
TRACK AND RIGHT OF WAY DEPARTMENT

Technical Specifications
for
Mechanical Trackside Lubricator
for
Various Types of Rails

No. E-01-0019
June 2013

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

Contents
1
2
3
4
5
6
7
8
9
10

SCOPE
REFERENCE DOCUMENTS
DEFINITIONS
ISR SUPERSTRUCTURE AND LOCAL CONDITIONS
MECHNICAL TRACKSIDE LUBRICATOR - REQUIRMENTS
LUBRICANT FILLER EQUIPMENT - REQUIREMENTS
MANUFACTURE'S TECHNICAL DRAWINGS
MANUFACTURE
MARKING LABELING
MANUFACTURING QUALIFICATION MANAGEMENT
LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S
11
PROPOSAL
LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY
12
ISR ORDER
13 PACKING
14 WARRANTY AND TRAINING
APPENDIXES ISRAEL CLIMATE AND ENVIRONEMENTAL
APPENDIX A
CONDITIONS
APPENDIX B DSB 82-1 WHEEL PROFILE DRAWING
APPENDIX C RAIL HEAD PERMISSIBLE WEAR
APPENDIX D LUBRICANT REQUIREMENT
APPENDIX E ISR LOADING GAUGE
LIST OF DOCUMENTS TO BE SUBMITTED WITH
APPENDIX F
BIDDER'S PROPOSAL

2
2
2
2
3
4
4
5
5
5
6
7
7
8
9
10
11
12
14

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

1.
1.1

SCOPE
This technical specification pertains to the technical requirements for
mechanical trackside lubricators ("MTL") manufacturing, supply and
installation. To reduce friction and wear at wheel/rail interface by lubricant
the rail gauge side corner and rail gauge side face.

1.2

The MTLs shall be supplied with Lubricant filler equipments.

1.3

The MTLs shall be supplied with installation and adjustment tools for
efficiently assembled the MTLs to the rails.

2.

REFERENCE DOCUMENTS (*)

EN 15427
Railway applications Wheel/rail friction
management - Flange lubrication.
EN 16028
Railway application Wheel/rail friction
management - Lubricants for trainborne and
trackside applications
EN 13674-1
Railway applications - Track - Rail - Part 1
Vignole railway rails 46 kg_m and above.
UIC 510-2
Trailing stock: wheels and wheelsets. Conditions
concerning the use of wheels of various diameters
(*) latest edition of the referenced document

3.

DEFINITIONS
Gauge side face:

Area "A" as defined in EN15427, section 3.

Gauge side corner:

Area "B" as defined in EN15427, section 3.

ISR:

Israel Railways Ltd.

4.
4.1

ISR SUPERSTRUCTURE AND LOCAL CONDITIONS:

Nominal track gauge 1435 mm

4.2

Minimum curve radius - 140 m.

4.3

Maximum track gradient - 30.

4.4

Israel climate and environmental conditions as specified in appendix A

4.5

The MTL shall be designed for installation on rail types: 60E1, 60E2, 54E1
and 50E6 (rail types in accordance with EN13674-1).

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

4.6

The MTL shall be designed for efficient operation with ISR wheels type ISR using wheels of several diameters the wheels profile types are in
accordance with UIC 510-2, and DSB82-1 wheel type (IC3 trains) see
appendix B.

4.7

Rail head permissible wear see appendix C.

4.8

Maximum track load - 22.5 ton/axle.

4.9

Maximum On-Track Vehicle speed - 160km/h.

5.
5.1

MECHNICAL TRACKSIDE LUBRICATOR - REQUIREMENTS

The MTL shall be designed to operate properly and efficiently with
lubricant which its properties prescribed in appendix D, and with ISR
Superstructure and Local Conditions prescribed in section 4.

5.2

The MTL shall apply lubricant to take effect in the active interface applied
in areas "A" and "B" of the rail throughout the intended length of the rail to
be lubricated.

5.3

The MTL shall work independently and do not require external energy
source, and shall provide uniform amount of lubricant direct to areas "A"
and "B" by each passing wheel.

5.4

The MTL reservoir shall be designed with a capacity of 9-12 kg.

5.5

The MTL pumping lubricant quantity per stroke shall be 0.1-0.15 gram.

5.6

The MTL shall be installed to the track without rail drilling and shall be
conformed to ISR nominal track gauge.

5.7

The MTL shall be designed with two lubricant distribution units.

5.8

The MTL shall include a means of checking and adjusting the amount and
position of lubricant dispensed.

5.9

The means of adjusting the height of the lubricant application unit shall be
separate from the means of installing to the rail.

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

5.10 The MTL shall be on a safe distance from the on-track vehicles, in such a
way that it cannot be damaged as a result of rail maintenance work (see
ISR Loading Gauge appendix E).
5.11 The MTL components shall be designed and manufactured from materials
which the nature and main characteristics and chemical composite shall be
stated and their fluffiness to the requirements of the relevant standards and
could not be modified without approved by ISR.
5.12 The means shall be provided in the MTL to indicate the quantity of
lubricant remaining in the lubricant reservoir.
5.13 All parts which are non-metallic shall be made of hot weather resistant
materials, suitable for use at temperature of up to 70C and under high
corrosion conditions. Plastic parts shall be UV protected. Israel climate
condition should be considered (see appendix A).
5.14 The MTL reservoir shall be cleaned and corrosion protected before
painting. The painting shall be done with two layers - premier layer and
second layer. The second paint layer shall have high resistance to the
environment condition including UV sun radiation, and corrosion
environment, and high resistance to wear.
All other metallic parts shall be corrosion protected.
6.
6.1

LUBRICANT FILLER EQUIPMENT- REQUIREMENTS

The lubricant filler equipment shall be a manually device and shall be
designed for quick and efficient lubricant filling with minimum hands dirty
and soiling the ballast and the ground.

6.2

The lubricant filler equipment shall enable filling the lubricator reservoir
efficiently. It shall include all means to pump lubricant from tanks (pails,
kegs, drums) with different sizes and capacities.

7.
7.1

MANUFACTURE'S TECHNICAL DRAWINGS

The manufacturer shall submit, together with its proposal, a complete set of
technical drawings with dimensions, tolerances and material main
characteristics of the MTL for 60E1, 60E2, 54E1 and 50E6 rails of:
The assembled MTL,
Blow up drawings,
Components drawings.

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

7.2

The manufacturer shall submit, together with its proposal, a complete set of
technical drawings and material main characteristics of the lubricant filler
equipment.
The assembled lubricant filler equipment,
The operation of lubricant filler equipment drawing.

7.3

The manufacturer shall submit, together with its proposal, a complete set of
technical drawings and material main characteristics of the installation and
adjustment tools.

8.
8.1

MANUFACTURE
The MTL shall manufactured in accordance with the technical drawings
submitted by the manufacturer and approved by ISR, and must present a
clean surface, smooth and free from blow-holes, flaws, cracks, folds or
other faults.

9.
9.1

MARKING LABELING
Each MTL shall be inscribed with at least the following marks:
The manufacturer mark,
The last two figures of the manufacturing year,
The product identification type.

9.2

9.3

lubricant filler equipment shall be inscribed with at least the following

marks:
The manufacturer mark,
The last two figures of the manufacturing year,
The product identification type.
Installation and adjustment tool shall be inscribed with at least the
following marks:
The manufacturer mark,
The last two figures of the manufacturing year,
The product identification type.

10. MANUFACTURING QUALITY MANAGEMENT

10.1 The supplier shall have quality management system for the MTL
manufacturing processes in accordance with all the requirements of this
technical specification.

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

11.

LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S

PROPOSAL
11.1 The manufacturer shall submit reference list of the MTLs which have been
manufactured and supplied.
11.2 The manufacturer shall submit technical information regards lubricant
spread affectivity (including lubricant distance along area "A" and area
"B").
11.3 The manufacturer shall submit spare parts list.
11.4 The manufacturer shall submit together with his proposal quality
management system process for MTL manufacturing in accordance with all
the requirements in this technical specification and quality management
system based on ISO 9001:2008.
11.5 The manufacture shall submit certificates of approving use on electrified
track with 25 kV AC and on non-electrified track with CWR and jointed
track and the relevant technical documents.
11.6 If manufacturer uses welded assembly steel. weldability shall be tested and
the certificate shall be submitted for ISR's approval.
11.7 The manufacturer shall submit process procedure for protection against
corrosion and painting.
11.8 The manufacturer shall submit environmental certificates for the painting
used.
11.9 The manufacturer shall submit technical information for the corrosion
protection.
11.10 The manufacturer shall submit 2 magnetic copies of all the manufacturing
technical drawings.
11.11 The manufacturer shall add to the technical drawings 2 softcopies the
relevant technical descriptions of the MTL. And 2 softcopies signed and
approved installation, lubricant filling, maintenance (include an inspection
and a method for fault diagnosis to check that the lubricator is not partially
or fully blocked or misaligned and all components are securely installed to
their mountings, maintenance intervals) and safety manuals.

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

11.12 The manufacturer shall declare in a signed document the estimate for the
MTL and it components life cycle.
11.13 The manufacturer shall submit the nature and main characteristics of the
metallic and non-metallic material and chemical composite for every
component.
11.14 The manufacturer shall submit 2 magnetic copies of all the manufacturing
technical drawings and the relevant technical descriptions of MTL and its
components, the lubricant filler equipment and the installation and
adjustment tool.

12.

LIST OF DOCUMENTS TO BE DELIVERED WITH EVERY

ISR ORDER

12.1 Each order shall be delivered with certificate that each components has
manufactured according to technical drawings submitted and the
requirements of this technical specification.

13.

PACKING

13.1 The MTL components shall be packed in wooden boxes and will put in
container. The wooden box arrangement shall enable easy and safe
unpackaged and storage the goods.
13.2 The dimensions of the wooden shall be according to EN standard, to enable
maximum effective storage capacity in containers.
It shall be possible to put at least 3 wooden boxes one on the other.
Each package gross weight shall not exceed 1 tone.
Each package shall be labeled with the following details:
o Component name and type;
o Production batch number;
o Date of manufacture;
o Component barcode;
o Component quantity in box;
o Gross and net weight;
o Manufacturer recognition number or name;
o ISR recognition number;
o ISR order number;
o Ordinal number on the packing list.
The labeling shall be with black letters and shall be on 3 spots on the
package (one on top of the package and the two others on the sides).

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

13.3 The installation and adjustment tools shall be packed separately.

13.4 The lubricant filler equipments shall be packed separately.
14. WARRANTY AND TRAINING
14.1 The warranty period for the MTL shall be 2 years.
14.2 The warranty must be valid for unlimited volume of traffic.
14.3 During the warranty period no incipient cracks, fractures and clearly
critical damage through corrosion may occur especially on welded
connections. All the repairs of defects and replacing the various
components shall be included in the basic price.
14.4 Training course for MTL installation and maintenance shall be take place
on-track in Israel by the manufacturer qualified crew. ISR shall have the
right to document the training course including by video camera or other
digital means.

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX A ISRAEL CLIMATE AND ENVIRONMENTAL

CONDITIONS
A.1

Climate and Environmental Conditions

Max. ambient temperature
50 C (shade)
Min. ambient temperature
-5 C
Relative humidity
10 to 90 %
Altitude
-400 to +800 meter
Sunny
3300 hours per year
UV Radiation
360 to 600 MJ/m per year
Rainfall
400 to 800 mm/year

A.2

Dust Conditions in the atmosphere

Maximum Half Hour
Value*
NOx
1064
SO2
780
O3
312
Suspended Dust
*(Microgram per m atmosphere)

Maximum Daily
Value*
560
260
143
350

A.3

Suspended Particulate Matter (SPM)

Particle size to 0.5-1 micron

A.4

Sea Salt Concentrations in the Atmosphere

Salt Element
Na*
Cl*
Position
Dry Wet Dry
Sea Air at Coast Line 7.3 16.0 12.0
600 m from Shore
3.1 4.8
4.2
6000 m from Shore
1.1 1.4
1.5
* (Micrograms per m atmosphere)

Wet
22.0
7.9
1.7

SO4*
Dry
5.3
1.9
1.3

Average
71
21
84
100

Wet
7.0
2.0
1.4

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX B DSB 82-1 WHEEL PROFILE DRAWING

10

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX C - RAIL HEAD PERMISSIBLE WEAR

Maximal
horizontal
wear [mm]
16
17
18

Maximal
vertical wear
[mm]
13
14
17

Minimal
height of the
rail [mm]
140
145
155

11

Height of
the new rail
[mm]
153
159
172

Type of rail
(EN 13674-1)
50E6 (U-50)
54E1 (UIC-54)
60E1 (UIC-60), 60E2

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX D LUBRICANT REQUIREMENT

Lubricant requirements are in accordance with EN16028, Annex A, table A.1:
property
Appearance
Color
Consistency (NLGI)
Worked grease
penetration 60 stroke @
25C

unit
-

Test method
Visual
ISO 2049 or equivalent
ISO 6743-99

values
Homogenous
Homogenous
1 or 1.5

0.1 mm

ISO 2137 or equivalent

290-340

Drop point

Flash point

Water content

% mass

Water resistance @ 40 C
Adhesion to sheet steel
(0.05 mm, 24 h @ 60 C)
Volatile components

Level

ISO 2176 or IP 396 or

equivalent
EN ISO 2592 or equivalent
ISO 760 or DIN 51777-2 or
ISO 3733 or equivalent
DIN 51807-1 or equivalent

Stage

EN16028, Annex D

% mass

EN16028, Annex E

Oil separation/ "bleeding"

(168 h [7 days] @ 40 C)

% mass

DIN 51817 or its equivalent

standard

10
7% maximum
by weight for
NLGI No. 1
grease

Corrosion test steel

Rating

Corrosion test - copper

Compatibility with
elastomers (60 C for 168
h) change in volume for
NBR1
Compatibility with
elastomers (60 C for 168
h) change in hardness
for NBR1
Identity testing:
Using Infra-red, or
X-ray fluorescence, or
Inductively coupled
plasma
Apparent viscosity (1
cone, s-300 s, D=1000 s-1)
@ 25 C
Apparent viscosity (1
cone, s-300 s, D=1000 s-1)
@ 0 C
Apparent viscosity (1

Grade

ISO 11007 using water or its

equivalent standard
DIN 51811 or equivalent

150
200
1.0

0; 0
1

ISO 6072 or its equivalent

standard

+15/-0

IRHD

ISO6072 or its equivalent

standard

Standard laboratory method:

DIN 51418-1, DIN 51418-2,
DIN 51451, DIN 51820-1 or
its equivalent standard
mPas

DIN51810-1 or its equivalent

standard

150

mPas

DIN51810-1 or its equivalent

standard

400

mPas

DIN51810-1 or its equivalent

4000

12

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

cone, s-300 s, D=1000 s-1)
@ -25 C
Four ball test wear test
rating (300 N, 1 h @ 1500
r/min)
Four ball test Extreme
pressure
Effect of water (water
wash-off test)
Biodegradability

standard

mm

DIN 51350-5; Method D or

its equivalent standard

kg

DIN 51350-4

visual

EN16028, Annex B

OECD suite or its equivalent

standard

13

0.8
Weld load not
less than 315kg
No corrosion
after 72 h
>60 after 28
days

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX E ISR LOADING GAUGE

14

ISRAEL RAILWAYS LTD

Mechanical Trackside Lubricator for Various Types of Rails Lubricant

APPENDIX F - LIST OF DOCUMENTS TO BE SUBMITTED WITH

BIDDER'S PROPOSAL
F.1.

The bidder shall supply technical description for the Lubricant filler
equipments. And the means to pump lubricant from tanks (pails, kegs,
drums) with different sizes and capacities.

F.2.

The bidder shall supply technical description for the installation and
adjustment tools.

F.3.

The bidder shall supply technical description for the nature and main
characteristics and chemical composite of the MTL components materials.
And stated their fluffiness to the requirements of the relevant standards.

F.4.

the bidder shall submit MTL reservoir paint parameters and painting
procedure.

F.5

the bidder shall submit the corrosion protection process for the metallic
parts.

15