dksfpax vvuqj {k.k dds ffy, gLr vkSt kj on Hand-Tools for... · dksfpax vvuqj {k.k dds f fy, ggLr vkSt kj HAND-TOOLS for COACHING MAINTENANCE QUALITY POLICY “To develop safe, modern

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

HAND-TOOLS for

COACHING MAINTENANCE

egkjktiqj, Xokfy;j & 474 005 Maharajpur, GWALIOR - 474 005

dsoy dk;Zky;hu mi;ksx gsrq

(For Official Use Only)

dSeVsd@bZ@2014&15@dksfpax VwYl@1-0 CAMTECH/ E/ 2014-15/Coaching Tools/ 1.0 vçsy 2014 April, 2014

mi;ksx drkZ dksfpax vuqj{k.k deZpkjh

END USER: COACHING MAINTENANCE STAFF

ddkkssffppaaxx vvuuqqjj{{kk..kk ddss ffyy,,

ggLLrr vvkkSSttkkjj

ddkkssffppaaxx vvuuqqjj{{kk..kk ddss ffyy,, ggLLrr vvkkSSttkkjjHAND-TOOLS

for COACHING MAINTENANCE

QUALITY POLICY

“To develop safe, modern and cost

effective Railway Technology complying with Statutory and

Regulatory requirements, through excellence in Research, Designs and

Standards and Continual improvements in Quality Management System to cater to growing demand of passenger and freight traffic on the

railways”.

ÁDdFku

Hkkjrh; jsyksa esa ;k=h ;rk;kr dh c<+rh gqbZ ekax dks ns[krs gq, jsy ij vf/kd dksfpax ¼lckjh fMCcksa½ dh miyO/krk gksuk vko’;d gSA

ftls vk/kqfud fMtk;u ds mi;qDr vkStkjksa ds }kjk lokjh fMCcksa dk de le; esa mi;qDr vuqj{k.k djds miyO/k djk;k tk ldrk gSA

vr% dSeVsd us ;g gLr iqfLrdk Þdksfpax vuqj{k.k ds fy, gLr vkStkjß dksfpax vuqj{k.k ds dk;Z esa fu;qDr fo|qr deZpkfj;ksa ds fy, rS;kj dh gSA ftlesa ÁR;sd vkStkj dk foLr`r fooj.k vko’;d iSjkehVj ds lkFk fn;k x;k gSA tks dksfpax fMiks rFkk vksfiu ykbu ds fy, mi;ksxh fl) gksxkA ;g flQkkfj’k dh tkrh gS fd jsYos bu vkStkjksa dks ;k muds leku vkStkjksa dks rduhf’k;uksa dks miyO/k djk;s] rkdh os vius lkSisa x;s dk;Z dks n{krk iwoZd iw.kZ dj ldsaA

eS vk’kk djrk gw¡ fd ;g gLr iqfLrdk dksfpax vuqj{k.k esa O;fDrxr :i ls mi;ksxh fl) gksxhA

dSeVsd] Xokfy;j ,- vkj- rqis

FNUKAD % 28-04-2014 DK;ZDKJH FUNS’KD

FOREWORD

Growing demand of passenger traffic on Indian Railways, requires more availability of coaching stock on rails. This can be achieved by proper maintenance of stocks in less time using proper tools with modern design.

CAMTECH has prepared this handbook on “Tools for Coaching Maintenance” for the

use of electrical staff of coaching maintenance. Detailed description of each hand tools with important parameters will prove to be useful to the coaching depot & open line.

It is recommended that Railways may supply these tools/ similar tools to artisan staff so

that they can perform their assigned work efficiently. I hope this handbook will prove to be useful for the coaching maintenance personnel.

CAMTECH, Gwalior A.R.Tupe Date : 28th April 2014 Executive Director

Hkwfedk

dk;Z laikfnr djus okys deZpkfj;ksa dks mi;qDr vkStkj Ánku djds dk;Z dh xq.koRrk ,oa mRikndrk c<+kbZ tk ldrh gSA mi ekud ;k [kjkc xq.koRrk ds gLr vkStkjksa dk ifj.kke dsoy [kjko vuqj{k.k gh ugha gksrk] vfirq bldk ifj.kke dk;Z djus okys deZpkjh dk t[eh gksuk] dk;Z laikfnr djus esa vf/kd le; o dkexkjksa dk yxuk] dkexkjksa dk Fkduk rFkk vekudh; dk;Z dk mRikn ÁkIr gksuk vkfn Hkh gks ldrk gSA

;g gLr iqfLrdk dSeVsd }kjk fofHkUu dsVkfxjh ds fo|qr vuqj{k.k LVkQW ds fy;s tks dksfpax esaUVhusUl dk;Z esa yxs gq;s gS Þdksfpax vuqj{k.k ds fy, gLr vkStkjß ij cukbZ xbZ gSA bl gLr iqfLrdk esa fofHkUu vk/kqfud vkStkjksa dk foLr`r fooj.k Hkh lfUufgr gSA dksfpax fMiks vkSj vksiu ykbu esa yxus okys vkStkjksa dh lwph Hkh bl gLr iqfLrdk esa nh x;h gSA

;g Li"V fd;k tkrk gS fd ;g gLr iqfLrdk jsYos cksMZ vkj-Mh-,l-vks- vFkok jsYos }kjk Áfrikfnr funsZ’kksa dks lqijlhM ¼vf/kØe.k½ ugha djrh ;g gLr iqfLrdk oS/kkfud ugha gSA ofYd blesa lq>k;s x;s funsZ’k dsoy ekxZn’kZu gsrq gSA eS QhYM vfHkdfeZ;ksa dk ân; ls vkHkkjh gw¡ ftUgksus bl gLriqfLrdk ds lEiknu esa gesa lg;ksx Ánku fd;k gSA

pwfd rduhdh muU;u ,oa f’k{k.k ,d Øfed Áfd;k gS vr% bl gLr iqfLrdk esa ;fn vki dqN tksM+us ;k lq/kkjus dh vko’;drk eglwl djrs gS] rks vki iw.kZr% Lora= gSA bl fn’kk esa vkids lq>koksa dks ge vR;kf/kd ljkgsxsaA

dSeVsd] Xokfy;j ¼ih;w"k xqIrk½ fnukad % 25-04-2014 funs’kd fo|qr e - mail id : [email protected]

PREFACE

The productivity and quality of work can be enhanced by providing proper tools to the work force. Sub-standard/ poor quality hand tools not only results in poor maintenance work but also results into injury to working staff, executing more labour, fatigue to the staff and non-standard work output etc.

This handbook on “Hand Tools for Coaching Maintenance” has been prepared by

CAMTECH for different categories of electrical maintenance staff engaged in coaching stock maintenance. This handbook also contains various modern tools along with their brief description. Compiled list of hand tools required for coaching depot & open line is available in this handbook.

It is clarified that this handbook does not supersede any existing provisions laid down

by Railway Board, RDSO or Railways. This hand book is for guidance only and it is not a statutory document.

I am sincerely thankful to all field personnel who helped us in preparing this handbook.

Technological up-gradation & learning is a continuous process. Please feel free to

write to us for any addition/ modification in this handbook. We shall highly appreciate your contribution in this direction.

CAMTECH, Gwalior (Peeyoosh Gupta) Date: 25th April 2014 Director Electrical

e - mail id : [email protected]

fo"k; & lwph

CONTENTS

Øe la- Sr.No. fooj.k Description i`"B Øekad Page No.

ÁkDdFku Foreword iii

Hkwfedk Preface iv

fo"k;&lwph Contents v

la’kks/ku iphZ dk Ádk’ku Correction Slip vi 1. ÁLrkouk INTRODUCTION 01 2. gLr vkStkjksa ds Á;ksx gsrq lqj{kk fu;ekoyh

SAFETY RULES FOR HAND TOOLS 01 3. ,-lh ,LdksfVZax LVkWQ ds fy, ekud VwyfdV esa vkStkjksa dh lwph

LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF 02 4. Vh,y@,-lh ikflax LVkWQ ¼LVs’ku ij½ ds fy, Vwy fdV

TOOL KIT FOR TL/AC PASSING STAFF (AT STATIONS) 03 5. Vªsu ykbZfVax vuqj{k.k fMiksa LVkWQ ds fy, vkStkj

TOOLS FOR TL MAINTENANCE DEPOTS 04

5.1 Vh ,y rduhf’k;u ds fy, Vwy fdV Tools kit for TL Fitter 04

5.2 Vªsu ykbZfVax ¼fiV ykbZu½ fMiks esa j[ks tkus okys vkStkj

Tools to Be Kept In TL (Pit Line) Depot 05 6. ,lh dksp vuqj{k.k fMiks ds fy;s vkStkj

TOOLS FOR AC COACH MAINTENANCE DEPOTS 07

6.1 ,lh rduhf’k;u ds fy, Vwy fdV ¼,lh dksp fMiks½

Tools Kit for AC Mechanic (AC Coach Depot) 07

6.2. ,lh dksp fMiks esa j[ks tkus okys vkStkj

Tools to Be Kept In AC Coach Depot 08


gLr vkStkjksa dk fooj.k DETAILS OF HAND TOOLS 11

1. ckbZfMax bUlwys’ku jftLVsal esljesaV ehVj

Winding Insulation Resistance Measurement 12 2. bUÝkjsM FkeZy besftax dSejk

Infrared Thermal Imaging Camera 13 3. cSVjh pSd djus ds fy;s ijh{k.k midj.k Testing Instruments For Batteries 14

4. ikWoj DokfyVh ,ukykbtj Power Quality Analyzer 16

5. yhdst djaV VsLVj Leakage Current Tester 17

6. vkWVks jsfUtax fMftVy eYVhehVj Auto Ranging Digital Multimeters 18

7. fMthVy esxj Digital Meggar 19

8. fØfEiax Vwy Crimping Tool 20

9. fLVªfiax Iyk;j Stripping Pliers 20

10. okW;j dVj Wire Cutter 20

11. dkWEchus’ku Iyk;j Combination Pliers 21

12. v- VQyksu Vsi ¼20 ,e,e½ a. Teflon Tape (20mm) 21

c- ihohlh Vsi ¼25 ,e,e½ b. PVC Tape (25mm) 21

l- ,ejh DykWFk c. Emery Cloth 21

13 v- cafUpax VkbZ a. Bunching Tie 21

c- ,ejh isij b. Emery Paper 21

14. vkWy ijit lkW All Purpose Saw 22

15. iksVsZoy fo|qr xzkbUMj Portable Electric Grinder 22

16. V~;wo csUMj Tube Bender 23

17. Cyksvj@MLV ,DlVªsDVj Blower/Dust Extractor 23

18. fMftVy fLÁV ysoy Digital Spirit Level 24

19. V~;wo dVj Tube Cutter 24

20. fMthVy FkekZehVj Digital Thermometer 25

21. iafpax Vwy Pinching Tool 25

22. fMftVy ofuZ;j dsyhilZ Digital Vernier Calipers 26

23. fMftVy ekbØksehVj Digital Micrometer 26

24 v- fo|qr lksYMj vk;ju ¼vkbZ,lvkbZ ekdZ½ a. Electric Solder Iron (ISI Mark) 27

c- Mh & lksYMfjax vk;ju b. De- Soldering Iron 27

25. ¶ys;j Vwy Flare Tool 27

26. fMftVy DySEi ehVj Digital Clamp Meters 28

27. ch;fjax iqyj Bearing Pullar 29

28. ,ysu dh lsV Allen Key Set 29


29. phlyl ¼NSuh½ Chisels 30

30. gSd lkW ¼vkjh½ Hack Saw 30

31. QkbZy ¼jsrh½ File 31

32. gFkkSMk gRFkk lfgr ¼gsej foFk gsfUMy½ Hammer with Handle 31

33. ikbZi fjap Pipe Wrenches 32

34. ,MtsLVsfoy Lisuj Adjustable Spanners 32

35. nksuks fljksa ij [kqys ikus ¼Moy vksiu ,aM Lisuj½ Double Open End Spanners 33

36. fjax Lisujl Ring Spanners 33

37 v- lkWdsV 12-5 ,e,e ¼1@2**½] LDok;j MªkbZo ,.M ,lsljht

a. Sockets- 12.5 Mm (1/2”), Square Drive and Accessories 34 c- VkdZ fjap b. Torque Wrench 34

38. lh DySEi C Clamp 34

39. MLVj Duster 34

40. vkWVksesfVd lSYQ ,MtsfLVax Leky Lisuj Automatic Self-Adjusting Small Spanner 35

41. Lisuj eYVh & fjap ¼jsfpV VkbZi½ 10 bu ou Spanner Multi-Wrench (Ratchet Type) 10 In One 35

42. eYVh & fjap@Lisuj Multi-Wrench/ Spanner 36

43. jsfpV fjap & jsfpV VkbZi Lisuj Ratchet Wrench-Ratchet Type Spanner 36

44. gkWV ,;j xu@gkWV ,;j Cyksvj Hot Air Gun/Hot Air Blower 37

45. fMftVy ,uheksehVj Digital Anemometer 37

46. ’kkWd iYl ehVj Shock Pulse Meter 38

47. bUÝkjsM VsEijspj xu ¼ghV Vªsdj½ Infrared Temperature Gun (Heat Tracer) 38

48. Vwy oSx Tool Bag 39

50. iksVsZoy ikWoj ,axqyj xzkbMaj Portable Power Angular Grinder 39

51. fMftVy VSdksehVj Digital Tachometer 40

52. eYVh ijit iksVsZoy ikWoj fMªy e’khu

Multi Purpose Portable Power Drill Machine 40 53. fMftVy ykbZV ¼yDl½ ehVj Digital Light (Lux) Meter 41

54. yhfFk;e & yksu Moy LihM dksMZySl fMªy e’khu

Lithium-Ion Two Speed Cordless Drill Machine 41 55. dksMZySl LØwMªkbZoj jhpktsZfoy Cordless Screwdriver Rechargeable 42

56. fu;ksu cYo VsLVj de LØwMªkbZoj lsV ¼8 ux CysM lfgr½

Neons Bulb Tester Cum Screw Driver Set With 8 Nos of Blade. 42 57. ukbZQ lSV Knife Set 43

58 v- okW;j czq’k ¼150 ,e,e½ a. Wire Brush (150mm) 43

c- ukbZyksu czq’k ¼100 ,e,e½ b. Nylon Brush (100mm) 43

l- isaV czq’k c. Paint Brush (75mm) 43


59. VkspZ ¼,ybZMh½ Torch (Led) 43

60. iksVsZoy LØw tSd Portable Screw Jack 43

62. Vh Lisuj vkWQ lkbZt 10] 13] 15 vkSj 17 T Spanner of Size 10 , 13, 15, 17 44

63. nks ySEi rhu rkj vFkZ VsLVj Tool Lamp Three Wire Earth Tester 44

64. gsyesV Helmet 44

65. VsLV ysEi gksYMj Test Lamp Holder 44 Ifjf’k"V&v ANNEXURE ‘I’ 45 fo|qr ijh{k.k lqfo/kk, TESTING FACILITIES (ELECTRICAL)

Ifjf’k"V&c ANNEXURE’II’ 49 lanHkZ gsrq vko’;d Hkkjrh; ekud ¼vkbZ ,l½

IMPORTANT INDIAN STANDARDS (IS) FOR REFERENCE

Ifjf’k"V&l ANNEXURE ‘III’ 49

midj.kksa dh foQyrkvksa ds dkj.kksa dh Nkuchu gsrq ÁLrko

AN APPROACH TO EQUIPMENT FAILURE INVESTIGATION lanHkZ REFERENCES 50

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :

CAMTECH/E/2014-15/Coaching Tools/C.S. # XX date--------- Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards). CORRECTION SLIPS ISSUED

Sr. No. Date of issue Page no. and Item no. modified

Remarks

ppssrrkkoouuhh

lanHkZ % & vkbZ,l 2615 % 1989 ¼la’kks/ku II – Iyk;lZ] fiullZ rFkk fuIij½

;g lR; gS fd Iyk;lZ] fiullZ

rFkk fuIij ds gsfUMy Áfrjks/kd gksrs gSA fdUrq fo|qrh; >Vds ls lqjf{kr gksus dh dksbZ xkjUVh ugha gSA tcfd Áfrjksf/kr vkStkj mPp oksUVst ds

fy;s Áfrjksf/kr gkrs gSaA ;g Áfrjks/kdrk vkstkjksa ds vpkud fxjus] rjyrk dh mifLFkfr] ijLik;js’ku vkfn ds dkj.k

{kfrxzLr gks tkrh gSA

vr% ;g lq{kko fn;k tkrk gS fd vkStkjksa ds Áfrjksf/kr gsfUMy ij

iw.kZr% Hkjkslk u djsaA

CCAAUUTTIIOONN Ref: IS 2615: 1989 (Revision Second- Pliers, Pincers and Nipper)

The fact that handles of pliers, pincers and nippers

are insulated is no guarantee of immunity from

electric shock. Although insulated tools may have withstood high voltages,

damage due to subsequent dropping or the presence of

liquid or perspiration may impair insulation. It is,

therefore, recommended that complete reliance

should not be placed on insulated handles.

CAMTECH/E/2014-15/Coaching Tools/1.0 1

Hand-Tools for Coaching Maintenance April, 2014

1. ÁLrkouk INTRODUCTION

One of the methods to reduce the down time of the coaching stock is to provide the proper tools with modern design. Railway Board vide letter No. 2007/M (C) /141/1 dated 12.03.2014 has communicated to take up a project on “Hand-tools for Coaching Maintenance”.

Availability of proper tools with artisan staff is essential to enhance the productivity and quality of work. CAMTECH has prepared a handbook enlisting conventional as well as modern tools which should be available with artisan staff of coaching maintenance depot. Tools in the form of toolkit have been prepared by CAMTECH. The approximate weight of all the tools of a kit is not more than 5 kg.

Performance record of tools is required to be kept to review their performance.

Accordingly Zonal Railway may fix the codal life of tools. DG S&D rates of some tools are also available vide rate contract no. GENTESTING/IT-9/RC-D 2010000/0414/83/ F0801/1999 dated 01/07/2013.

2. gLr vkStkjksa ds Á;ksx gsrq lqj{kk fu;ekoyh SAFETY RULES FOR HAND TOOLS

1. Always use the right size and type of tool for the job being done. Keep tools in proper working condition. Never alter a tool from its original condition.

2. Always wear safety goggles when using punches, chiesels, hammers and cutting tools. 3. Never use a tool as a hammer unless manufactured for that purpose. 4. Never use a pipe extension to increase the leverage of any wrench. 5. Adjustable wrenches should be tightly adjusted to the nut and pulled so that the force is

on the side of the fixed jaw. 6. Never use a pipe wrench to bend, raise or lift a pipe. 7. Ratchet mechanisms should be cleaned and lubricated periodically with light grade oil. 8. Keep hammer heads tight on the handle. Never use a hammer with a loose or damaged

handle. 9. Metal cutting chiesels are intended for cutting, shaping and removing metal softer than

the cutting edge itself. 10. Always strike the struck base of a chiesel or punch. The striking face of the hammer

should have a dia. approximately 10 mm larger than the struck face of the punch or chiesel.

11. Never use screw drivers with rounded tips. 12. Never use a screwdriver as a chiesel, punch, scraper or pry bar. Use screw driver for

screw driving only.

2 CAMTECH/E/2014-15/Coaching Tools/1.0

April, 2014 Hand- Tools for Coaching Maintenance

3. ,-lh ,LdksfVZax LVkWQ ds fy, ekud VwyfdV esa vkStkjksa dh lwph LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF

(Circulated vide RDSO letter No. EL/7.2.2 dated 17.01.2006)

(In Proper Tool Bag)

S.No. Description Qty Reference Sr.No.

1. Tool box of size 325x440x120 mm (Approx.) with fixing arrangement for tools and locking arrangement with 2 no. keys

1 set 48

2. Neons bulb tester cum Screw driver set with 8 nos of blade. 1 set 56

3. Combination plier insulated with thick CA sleeve with joint cutter length 205 mm

1 11a

4. Digital multimeter 1 06

5. T spanner of sizes 10, 13, 15, 17 1 62a

6. Panel key square type ¼ size suitable for opening of control panel of AC coaches

1 --

7. Key for opening fittings of AC coaches 1 --

8. Test lamp holder (brass) fitted with two mtrs. of 2 core flexible copper wire

1 65

9. Torch with cells (+2 cell spare) 1 59

10. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 16/17, 18/19, 20/22

1 set 35

11. Allen key size 4 mm, 3/16, 7/32 1 28

12. Heavy duty cable cutting knife adjustable in aluminium casing over all size 140 mm

1 57

13. Adjustable spanner length 255 mm 1 34

14. Infrared Digital Thermometer (Temperature gun) 1 47

15. Insulated Nose plier 6” 1 11h

16. Tongue tester A.C. (0-100 A) 1 26

17. Hammer ½ kg 1 32b

18. Hacksaw frame with blade (+ 1 spare blade) 1 30

19. PVC Insulating tape 25 mm 1 12b

20. Wire fuse 1 --



4. Vh,y@,-lh ikflax LVkWQ ¼LVs’ku ij½ ds fy, Vwy fdV

TOOL KIT FOR TL/AC MAINTENANCE PASSING STAFF (AT STATIONS)

(In proper tool bag)

S. Name of Tools Qty. Referene Sr.No.


1 no. 11a

2. Insulated Wire Stripper & Cutter 16 sqmm 1 no. 09

3. Insulated Long Nose Pliers 6” 1 no. 11h

4. Neon bulb tester cum Screw driver set with 8 nos of blade similar

1 no. 56

5. Fitting Opening Key (FDB/CFL/Tube light/RRU) 1 no. --


1 set 35

7. Adjustable spanner length 255 mm 1 no. 34


1 no. 65b

9. Hacksaw frame with blade (12") + One extra blade 1 no. 30

10. Flat file 150 mm 1 no. 31

11. Ball pen Hammer 300 gms 1 no. 32b

12. Torch with cell, LED 1 no. 59

13. Fuse puller 150mm 1 no. 11b

14. Digital Multimeter with tongue tester 1 no. 26

15. PVC Insulating Tape 25mm 01 roll 12b


01 no. 57

17. Infrared Digital Thermometer (Temperature Gun) 01 no. 47

18. Chiesel 150 mm 01 no. 29

19. Fuse Wires 01 set --

20. Spare lamp/CFL/FTL 01 set --

21. Capacitor for AC fan 03 nos. --



5. Vªsu ykbZfVax vuqj{k.k fMiksa LVkWQ ds fy, vkStkj TOOLS FOR TL MAINTENANCE DEPOTS

5.1 Vh ,y rduhf’k;u ds fy, Vwy fdV Tools Kit for TL Fitter

(In Proper Tool Bag)

S. Name of Tools Qty. Reference Sr. No.


1 no. 11a

2. Insulated Wire Stripper & Cutter 16 sqmm 1 no. 09

3. Insulated Long Nose Pliers 6” 1 no. 11h

4. Neon bulb tester cum Screw driver set with 8 nos of blade similar

1 each 56

5. Fitting Opening Key (FDB/CFL/Tube light/RRU) 1 no. --


1 set 35

7. Ring Spanner Set 1 set 36



1 no. 65b

10. Flat file 150mm 1 no. 31

11. Ball pen Hammer (300 gm) 1 no. 32b

12. Torch, 4 cell (LED) 1 no. 59

13. Fuse puller 6” 1 no. 11b

14. Hydrometer 1 no. 3c

15. Cell tester (Range 12V DC) 1 no. 3b

16. Digital Multimeter with tongue tester 1 no. 26

17. PVC Insulating Tape 25mm 01 roll 12b


01 no. 57

19. Infrared Digital Thermometer (Temperature gun) 01 no. 47

20. Chiesel 150mm 01 no. 29

21. Cleaning Brush 01 no. 58c

22. Fuse Wires 01 set --



5.2 Vªsu ykbZfVax ¼fiV ykbZu½ fMiks esa j[ks tkus okys vkStkj Tools to be Kept In TL (Pit Line) Depot (Qty. will be decided by divisional officers depending upon work load)

S. Name of Tool Reference Sr.No.


11a

2. Insulated Wire Stripper & Cutter 16 sqmm 09

3. Insulated Long Nose Pliers 6” 11h

4. Neon bulb tester cum Screw driver set with 8 nos of blade similar to Jhalani P. No. 830 or equivalent

56

5. 4 way keys --

6. Ring spanner set ( 8- 32) 36

7. Set of box spanner with 1/2" socket set containing 19 socket (11 to 32) and 6 attachment

37a

8. Double open end spanner set ( 8 - 32) 35a

9. Single end open Spanner (36mm) 35b

10. Allen Key set 28

11. Adjustable spanner length 255 mm 34


65b

13. Hacksaw frame with blade (12") + Extra Blades 30

14. Flat, round, triangular files 31

15. Ball pein Hammer ( 200gm, 300gm, 500gm, 800 gm, 1kg) 32b

16. Nylon hammer 32a

17. Chiesel flat 150mm 29

18. Infrared Digital Thermometer (Temperature gun) 47

19. Torch, 4 cell, LED for each staff 59

20. Fuse puller 6” 11b

21. Crimping tool ( 0.5 - 1.6 mm2 ) 08

22. Crimping tool (1.5 - 16 mm2 ) 08

23. Hydraulic crimping machine (upto 300 mm²) 08b


57

25. Multipurpose Portable power drill machine 52



S. Name of Tool Reference Sr.No.

26. Auto ranging Digital Multimeter 06

27. Hydrometer 3c

28. Digital clamp meter 26

29. Bearing/ Pulley Puller 27

30. Pulley V groove “GO” , “NO GO” gauge Testing 9

31. Portable electric straight grinder 15

32. Digital lux meter 53

33. Cell tester (0-12) V DC 03b

34. Digital Tachometer 51

35. Digital Vernier caliper 22

36. Digital Micrometer 23

37. Digital Meggar

(500 V to 5000 V )

07

38. Heavy duty Pipe wrench 33

39. Soldering iron 24a

40. De-soldering gun 24b

41. Hot air gun / Hot air blower 44

42. Portable Blower / Dust extractor 17

43. 1/2" socket set containing 19 socket (11 to 32) with 6 attachment

37a

44. Torque wrench 0-5kg-m 37b

45. Shock pulse meter (SPM) 46

46. All purpose saw 14

47. Infrared Digital Thermometer 47

48. Cable cutter 150mm 10

49. Insulating Tapes 25mm 12b

50. Safety helmet for each staff 64

51. Gum boot for each staff 61

52. Tool bag for each technician 48



6. ,lh dksp vuqj{k.k fMiks ds fy;s vkStkj TOOLS FOR AC COACH MAINTENANCE DEPOTS

6.1 ,lh rduhf’k;u ds fy, Vwy fdV ¼,lh dksp fMiks½

Tools Kit for AC Mechanic (AC Coach Depot) (In Proper Tool Bag)

S.No. Name of Tools Qty. Reference Sr.No.


1 no. 11a

2. Insulated Nose plier 6” 1 no. 11h

3. Neon bulb tester Screw driver set with 8 nos of blade

1 set 56

4. Panel key square type ¼ size suitable for opening of control panel of AC coaches

1 no. --

5. 4 way key & fitting opening key (FDB/CFL/tubelight/RRU)

1 no. --


1 set 35a

7. T spanner of sizes 10, 13, 15, 17 1 62a


1 no 65b


1 no. 57

10. Allen key ( 3- 15m) 1 no 28

11. Flat file 150mm 1 no 31

12. Hammer 200 g 1 no 32b

13. Torch, cells (+2 cell spare) 1 no 59

14. Auto ranging Digital Multimeter 1 no. 06

15. Tongue tester A.C. (0-100 A) 26


17. Infrared Digital Thermometer (Temperature gun) 1 47

18. PVC Insulating tape 25mm 1 12b

19. Wire fuse 1 --



6.2. ,lh dksp fMiks esa j[ks tkus okys vkStkj Tools to be kept in AC Coach Depot

(Qty. will be decided by divisional officers depending upon work load)

S.No. Name of Tools Reference Sr.No.


11a

2. Insulated Wire Stripper & Cutter 16 sqmm 09

3. Insulated Nose plier 6” 11h

4. Neon bulb tester cum Screw driver set with 8 nos of blade equivalent

56

5. 4 way key --

6. Ring spanner set ( 8- 32) 36

7. Set of box spanner with 1/2" socket set containing 19 socket (11 to 32) and 6 attachment

37a

8. Double open end spanner set ( 8 - 32) 35a

9. Single end open Spanner (36mm) 35b

10. T spanner set 62

11. Allen Key set 28

12. Adjustable spanner length 255 mm 34

13. Test lamp/ Hand lamp 65b

14. Hacksaw frame with blade (12") + extra blades 30

15. Flat round, file 31

16. Ball pein Hammer 200 gm, 500gm, 1kg. 32b

17. Nylon hammer 100gm 32a

18. Chiesel (Flat) - 8" 29

19. C Clamp 38

20. Crimping tool (0.5 - 6 mm²) 08

21. Crimping tool (1.5 -1 6 mm²) 08

22. Pinching tool 21

23. Tube bender (3/8", 5/8", 7/8") 16

24. Flare tool 25

25. Tube cutter 19

26. Torch (4 cell) + extra cells for each staff 59

27. Digital Tachometer 51

28. Digital Clamp meter 26




29. Hydrometer 03c

30. Auto ranging Digital Multimeter 06

31. Cell tester (0-12) volt DC 3b

32. Battery analyzer 3a

33. Digital meggar ( 500 V, 1000 V, 2500V, 5000V) 7

34. Digital Micrometer 23

35. Digital Vernier calipers 22

36. Blower / Dust extractor 17

37. Portable electric straight grinder 15

38. Torque wrenches 37b

39. Pipe wrench 33

40. Multipurpose Portable Power drill machine 52

41. Soldering iron 24a

42. De-soldering Gun 24b

43. Hot air gun / Hot air blower 44

44. Shock pulse meter (SPM) 46

45. All purpose saw 14

46. Pulley V groove “GO” , “NO GO” gauge Testing 9

47. Pulley/ Bearing puller 27

48. Digital Anemometer 45

49. Infrared Digital thermometer (Temperautre gun) 47

50. Digital lux meter 53

51. Winding insulation Resistance meter 01

52. Cable cutter/ wire cutter 10

53. Gum boot for each staff 61

54. Infrared thermal imaging camera 02

55. Power quality analyzer 04

56. Leakage current tester 05

57. Fuse puller 11b

58. Teflon tape 12a

59. PVC tape 12b

60. Bunching tie 13a

61. Amery paper 13s




62. Amery cloth 13c

63. Digital spirit level 18

64. Digital thermometer 20

65. Duster cloth 39

66. Automatic self adjusting small spanner 40

67. Spanner multi wrench 10 in one 41

68. Multi wrench/ Spanner 42

69. Ratchet wrench – Ratchet type spanner 43

70. Angular grinder 50

71. Cord less drill machine 54

72. Cord less screw driver 55

73. Knife set 57

74. Wire brush 58a

75. Nylon brush 58b

76. Paint brush 58c

77. Portable screw jack 60

78. Safety helmet for each staff 64

79. Tool Bag for each technician 48



gLr vkStkjksa

dk fooj.k

Details of

Hand Tools



1. ckbZfMax bUlwys’ku jftLVsal esljesaV ehVj WINDING INSULATION RESISTANCE MEASUREMENT

Name of equipment : Winding insulation resistance meter

Application : To measure Insulation Resistance of all voltage components like transformer winding, CTs, PTs, bushings, cables, motor and Alternator windings etc.

Make : Indigenious

Technical Specifications :

Test voltage 500 V to 5000 V DC

IR Range 0 – 5 TΩ

Accuracy As per IS 2992

Display Digital

Short circuit current < 2mA

Advantages:

i. Healthiness of winding insulation can be checked.

ii. The equipment has a LED based provision for visual indication for discharge condition. This LED shall glow after the HT is switch OFF, till the voltage on test object/ HV terminal is below 50 V approximate.

iii. Equipment have HV, LV & Guard and Internal discharge of object after test, memory for measurement results, ability to transfer the data to a PC, polarization index and dielectric absorption ratio.



2. bUÝkjsM FkeZy besftax dSejk INFRARED THERMAL IMAGING CAMERA

Name of instrument Infrared thermal imaging camera

Application Thermal imaging infrared camera identifies electrical and mechanical problems like hot spots, heat development on loose connections etc. before they result in failures.

It is a non-contact device which detects infrared radiations and converts it into electronic signals. These signals are then processed to produce thermal image of the object.

Make Indigenious

Technical Specifications : RDSO Spec. No. TI/Spec/OHE/TI-PS/1030 (6/2005 Rev.1)

1. Temperature measurement range from – 20°C to 1200°C. 2. Temperature measurement accuracy of ± 2%; ± 2°C of

reading 3. Image quality of 200 x 150 pixels 4. Thermal sensitivity of 0.1°C 5. IFOV of lens should be 2.18 mrad or less. 6. Spectral range of 7.5 to 13 μm 7. Built in digital visual camera of 1.3 m pixels 8. Standard lens with FOV of 25° x 19° 9. Permissible relative humidity range 10% to 95% non-

condensing 10. Operating & storage temperature range with all accessories in

-15°C to 50°C & -40°C to 70°C respectively. 11. Software should have the feature to prepared report & can be

saved in PDF format. 12. At least 3 palettes should be available with 2 color palettes;

grey with white hot & grey with black hot etc. 13. LCD color display 3.5 should be available in camera. 14. Data can be stored in removable SD card with storage

capacity of 1000 + images 15. Menu operation should be available via touch screen as well

as via toggle button. 16. Auto focuses facility available in camera along with manual

focus. 17. Focusable from 0.4mt. to infinity.



Advantages:

i. It helps to find out electrical hot spots and faulty equipments in incipient conditions.

ii. It is an ideal means for professionals looking for safety and reliability when conducting routine surveys of electrical systems, switchgear and electrical components.

iii. It is a light weight, comfortable and sensitive test instrument with touch screen, text features.

3- cSVjh pSd djus ds fy;s ijh{k.k midj.k

TESTING INSTRUMENTS FOR BATTERIES

Repeated recharging of a secondary battery can lead to battery deterioration and increase in its internal resistance. Problem can intensify when there is a short circuit in the internal cell leading to voltage drop, increase in internal resistance, overheating and complete battery malfunction. These problems can cause severe fires and other accidents. It is important and necessary to conduct battery testing to check the above defects periodically.

Following parameters can be checked to determine the health of the battery: • Voltage • Impedance • Specific gravity • Sulfation (relative to the amount of battery charge capacity degradation

due to sulfation) • Dryout (relative to the amount of battery charge capacity degradation

due to dryout) a. Battery Analyser b. Cell Tester c. Hydrometer

Name of instrument Electro chemical battery analyser

Application Electro chemical battery analyser accurately measures health of lead acid battery (chemical and electrical) in terms of sulfation, dry out, voltage and impedance.

Make Indigenious



Technical Specifications

Voltage

Range 0 to 17 V DC

Resolution 10mV

Accuracy ± 0.5%

Repeatability ± 0.5%

Impedance

Measurement range 50 μΩ to 1Ω

Resolution 0.001 mΩ for all measurable impedance value.

Accuracy ± 1.0 % (for impedance > 1mΩ to 1Ω)

± 1.0 % (for impedance > 100 μΩ to mΩ)

Amp–Hour capacity range for batteries under test

5 Ah to 2,000 Ah; specified performance range

1 Ah to 9,999 Ah, operating range

Sulfation

Range

Accuracy

0 to 100%

± 5%

Dryout

Range

Accuracy

0 to 100%

±5%

Cell terminal strap impedance (μΩ)

Measurement range

Resolution

Accuracy

50 μΩ to 1Ω

0.001mΩ

±1.0%

Specific Gravity Manual logging

Safety Feature

Over voltage auto reset breaker

Trigger point – 17VDC

Warning – 50VDC

Damage point – 600VDC max.

Advantages:

i. It can store large amount of data and auto hold and auto-data storage facility also available.

ii. It has ability to measure AC voltage and low resistance.

iii. It can memorize the value on the spot.

iv. It can enhance resistance against noise.



4. ikWoj DokfyVh ,ukykbtj POWER QUALITY ANALYZER

Power Quality Analyzer for energy analysis Included accessories

• i430-Flexipack 4 current clamps

• 5 Test leads, 4 black, 1 green

• 5 Alligator clips, 4 black, 1 green

• BC430 Battery charger eliminator

• Power Log Software

• OC4USB Optical cable for USB

• WC100 Color localization set

• Getting Started (booklet)

• User Manual (CD-ROM

Application Power Quality analysers help locate , predict , prevent , and troubleshoot power quality problem in three & single phase power distribution system.

Make Indigenious or similar.



5. yhdst djaV VsLVj LEAKAGE CURRENT TESTER

Name : Leakage Current tester Application : For measuring AC leakage current blowing into

ground conductor.

Make : Indigenious Features

• 10 A Ultra High resolution • Large conductor diameter (30mm) • AC current in 5 Ranges (40mA, 400mA, 4A, 40A,

60A) • Wide Frequency response (40Hz - 1 KHz) • ACA, ACV, and Continuity • Large 3¾ Digit LCD (4000 Count) with 40 segment bargraph • Fast bargraph display (20 times/sec.) • Data hold and Max. Min hold • Relative measurement • 600 V rms overload protection in resistance range

Specification

Conductor size 30mm. max. (approx.) Battery Type Two 1.5V SUM-3 Display 3¼ LCD with 40 segment bargraph Range Selection Manual Overload Indication OL Power Consumption 15mA (approx.)

Low battery indication

Sampling Time

2 time/sec. (display) 30 time/sec. (bar graph)

Operating Environment -10° to 50°C, RH < 85% Storage Environment -20°C to 60°C, RH < 75% Altitude up to 2000M Dimensions 210 (H) x 72(w) x 36(D) mm Weight 210 gm (battery included) Accessories Carrying Case x 1

Users manual x 1 1.5V Battery x 2 Test leads x 1 pair

B



6. vkWVks jsfUtax fMftVy eYVhehVj AUTO RANGING DIGITAL MULTIMETERS

Name : Auto Ranging Digital Multimeter

Application : Measurement of voltage, current resistance, checking of continuity

Specification :

Display Auto/ Manual ranging, 33/4 Digit 3400 count LCD with Analog bargraph

DC Voltage 340mV/3.4/34/340/1000V ± (0.5%rdg + 4 dgt) on 340mV/ 3.4V ± (0.7%rdg + 4 dgt) on 34/340V ± (1.0%rdg + 4 dgt) on 1000V

AC Voltage 3.4/34/340/750V ± (1.0%rdg + 8 dgt) on all ranges except ± (1.5%rdg + 8 dgt) on 750V

DC Current 340μA/3.4/34/340mA/3.4/20A ± (1.5%rdg + 8 dgt)

AC Current 340μA/3.4/34/340mA/3.4/20A ± (2.2%rdg + 4 dgt)

Resistance 340Ω/3.4/34/340kΩ/3.4/34MΩ ± (0.7%rdg + 4 dgt) on all ranges except ± (1.2rdg + 4 dgt) on 3.4MΩ ± (2.5%rdg + 4 dgt) on 34MΩ

Diode Yes Continuity Buzzer Yes Full Icon Display Yes Auto power off/ Steep mode Yes Low battery display "BATT" is indicated Input impedance (Voltage) 10 MΩ Power One 9V battery Battery life 200 hours typical LCD digit size 17 mm



7. fMthVy esxj DIGITAL MEGGAR

Name : Digital Insulation tester

Application : Insulation measurement of cables, motors, transformers etc.

Make : Indigenious

Features : • 3½ Digit (1999 counts) Large LCD Display.

• High accuracy ± (3% rdg + 5 digit) for Insulation Measurement ± (2% rdg + 5 digit) fr AC voltage measurement.

• Range selection & single person push button operation.

• LCD back light function with indicator switch

• Data holding function, fnction icons on display.

• measurement of AC voltage upto 600 V AC

• Measurement of phase sequence between (Phase- Phase voltages) with LED indicators and beep facility.

• Auto range (Insulation test)

• LED indicator for HV (High Voltage)

• Inbuilt Protection circuit to prevent the harm of revenue voltages.

• Battery operated with AC adaptor

• 3 Ranges of Voltage & Insulation resistance

Specification :

Insulation resistance Test voltage : 1000V/ 2500V/ 5000V Range : 0.1MΩ Accuracy : ± (3% rdg + 5 dgt.) Resolution : 0.01MΩ AC Voltage Measurement Test voltage : 0 – 600V AC (50-60Hz) Accuracy : ± (2% rdg + 5 dgt.) Resolution : 1V Phase sequence test Test voltage : 100V – 450V (Phase – Phase) 40 – 60 Hz



Display : 3½ digit (1999 counts) large LCD display with 29mm digit height

Accuracy ± (3% rdg + 5 digit) for insulation resistance ± (2% rdg + 5 digit) for AC voltage Power 12V (8 x 1.5V) (R6AA size batteries) or AC adaptor

12V DC 8. fØfEiax Vwy CRIMPING TOOL

Name : Crimping Tool Availability : Available in local market in major cities.

9. fLVªfiax Iyk;j STRIPPING PLIERS

Name : Stripping Pliers IS: 087 Application : Removing of wire insulation for termination.

Size : Strips wire up to 7/8" or 4mm2

Features : Automatic feature holds jaws open to remove wire without crushing

ends. Practically eliminates all nicking, cutting, or fraying. Strips teflon, silicon and PVC wire. Made of aluminium with plastic molded handles.

10. okW;j dVj WIRE CUTTER

Name : Wire Cutter, IS: 4378-1990 Application : Cutting of cables, wires (solid /

stranded) upto 10mm2 length 160mm approx.

Size : Cut round cable and wire cutter to multi - conductor cable Up to 10 mm2

Availability : Available in local market in major cities.



11. dkWEchus’ku Iyk;j COMBINATION PLIERS

a. Combination side cutting plier: IS 3650 for insulation IS 2615 1989 Rev.2 b. Nose plier IS 3552 1989 c. Cutting plier IS 4378 1990 d. Pin Cers IS 4095 1991 a.

b. c. d. e. f. g. h. 12.a) TEFLON TAPE (20mm) b) PVC TAPE (25mm)

v- VQyksu Vsi ¼20 ,e,e½ c- ihohlh Vsi ¼25 ,e,e½ 13a. BUNCHING TIE 13b. EMERY PAPER 13c. EMERY CLOTH v- cafUpax VkbZ c- ,ejh isij l- ,ejh DykWFk



14. vkWy ijit lkW ALL PURPOSE SAW

Name : All Purpose Saw

Application : Cutting work of sheet metal, nut/bolts, iron angles, pipes etc.

Make : Indigineous

Specifications :

Saw in wood 130 MM Saw in steel 20 MM Power input 600 W No load stroke rate 2600 stroke/min. Saw stroke length 28 MM Weight 3.1 Kg.

15. iksVsZoy fo|qr xzkbUMj PORTABLE ELECTRIC GRINDER

Name : Straight Grinder Application : For grinding, sanding, rust removing etc. Specifications :

Grinding points MAX. 25 MM DIA No load speed 27000 RPM Power input 500 W Tool holder Collet-Cap Max.8 MM DIA Spindle coller dia 43 MM Weight 1.3 Kgs.



16. V~;wo csUMj TUBE BENDER

Name of Tool : Tube Bender Application : For bending copper tubes used in air conditioning Description : Calibrated angle marking from 10° to 180° for left, right or offset

bends. Made of tie cast alloy . Available Sizes : 3/8", 5/8", 7/8". Availability : Available in local market in major cities.

17. Cyksvj@MLV ,DlVªsDVj BLOWER/DUST EXTRACTOR

Name : Blower/Dust Extractor Application : Blowing of dust from equipment. Make : Indigineous Model : GBL 550

Specifications : Power input 550 W Pressure 800 mm Aq Air volume 2.7 M3/Min. Weight 1.7 Kgs.

Availability : Local market in major cities



18. fMftVy fLÁV ysoy DIGITAL SPIRIT LEVEL

Name : Digital Spirit Level Application : Checking of alignment of foundations of pumps,

transformers, DG sets etc. and other applications which require accurate level.

Specification :

Length 600mm Measuring Accuracy at 0°/ 90° max. ± 0, 05° Measuring Accuracy at 1°to 89° max. ± 0, 2° Battery 9V DC6 LR 61

19. V~;wo dVj TUBE CUTTER

Name of Tool : Tube Cutter Application : To cut copper tubes used in air-conditioning. Features : Larger knob for greater torque, harden flare grooved roller Size : 1/8" to 7/8" Availability : Available in Local market in major cities.



20. fMftVy FkekZehVj DIGITAL THERMOMETER

Name : Digital Thermometer Application : For measuring the temperature and relative humidity. Features : Simulteneous readout of °C or °F (switchable) and % RH.

Minimum/ Maximum memory functions for both temperature and humidity

Specification :

Range 30 to 90% RH, 0-50 °C Temp. Resolution 1% RH, 0.1°F or °C

Availability : Available in Local market in major cities.

21. iafpax Vwy PINCHING TOOL

Name of Tool : Pinching Tool Application : For squeezing the copper tube used in air-conditioning. Feature : Product based on IS: 10372 Size : 1/4" Availability : Available in Local market in major cities.



22. fMftVy ofuZ;j dsyhilZ DIGITAL VERNIER CALIPERS

Name : Digital Vernier Calipers

Application : Measurement of depths, gaps, thickness, outside and inside diameters etc.

Specification : Measuring range 0 - 200 mm Resolution 0.01 mm Instrumental error + 0.03 mm or + .0015"/+0.03 mm Repeatability 0.01 mm or .0005"/0.01 mm Maximum response speed Not particularly provided

(No counting error due to scale speed) Power supply SR44 (silver oxide cell, 1 pc Battery life 3.5 years under normal use Operation temperature 00C to 400C Storage temperature -100C to 600C

Availability : Available in Local market in major cities. 23. fMftVy ekbØksehVj DIGITAL MICROMETER

Name : Digital Micrometer Application : Measurement of small thickness and diameters of wires etc. Specification :

Measuring range 0 - 25 mm Instrumental error (20°C) ± (L/75) Resolution 0.001 mm (.0005") Quantizing error ± 1 count Measuring force 5 to 10N Display LCD (6 digits and a minus sign) Power Supply SR44x1 Battery life 1.2 years Operation temperature 50C to 400C Storage temperature -100C to 600C




24a. fo|qr lksYMj vk;ju ¼vkbZ,lvkbZ ekdZ½ ELECTRIC SOLDER IRON (ISI MARK)

Name : Electric Solder Iron (ISI mark) 230V – 35w Applications : To solder joint Description : Rugged, manual loading tool for volume de-soldering. High

vacuum heavy-duty plastic, fully enclosed shaft for safety. Plunger locks for compact storage.

Availability : Available in Local market in major cities. 24b. Mh & lksYMfjax vk;ju DE- SOLDERING IRON

Name : De-Soldering Iron Applications : Removal of solder joint Description : Rugged, manual loading tool for volume

de-soldering. High vacuum heavy-duty plastic, fully enclosed shaft for safety. Plunger locks for compact storage.


25. ¶ys;j Vwy FLARE TOOL Name of Tool : Flare Tool Application : For making flare shape for

copper pipes used in air-conditioning.

Availability : Available in local market in

major cities.



26. fMftVy DySEi ehVj DIGITAL CLAMP METERS

Name : Digital Clamp meter

Application : On line measurement of current, voltage, resistance, frequency

Specification :

AC Current 20A, 200A, 1000 A Accuracy ± (2%rdg + 4 dgt) on 200/1000A

± (3%rdg + 4 dgt) on 20A Over load 1000 A AC max. for 1 min. AC Voltage 200v, 750V (50-500 Hz) Accuracy ± (1.2%rdg + 4 dgt) on 200V

± (1.5%rdg + 4 dgt) on 750V DC Voltage 2V( in 2250 only), 200V, 1000V Accuracy ± (0.5%rdg + 1 dgt) on all ranges Resistance 200Ω, 200KΩ Frequency 10 Hz - 34 MHz

(± 1%rdg + 2 dgt) Accuracy ± (1%rdg + 1 dgt) on all ranges in 2250 and

± (1.5%rdg + 3 dgt) on all ranges in 2250F Audible continuity diode test function power

One 9 V battery

Battery life 200 hours typical Low battery "BATT" is indicated in 2250 Dimension 250(H)x98(W)x35(D)mm Weight 400 gms approx. Accuracy Supplied with a pair of test leads, carrying

case, battery and instruction manual Jaw opening 55mm max.




27. ch;fjax iqyj BEARING PULLAR

Type : Three leg bearing puller, Confirming IS: 9193-1979

Material : Legs, housing, central bolt and link plates shall be made from suitable alloy steel meeting with the requirement.

Hardness : Legs - 400 – 450 HV (≈ 40 – 45 HRC) Housing - 400 – 450 HV (≈ 40 – 45 HRC) Central bolt - 400 – 450 HV (≈ 40 – 45 HRC) Link plate - 400 – 450 HV (≈ 40 – 45 HRC)

Test Load : The bearing puller shall be able to withstand the following load:

Type Minimum test load N Three leg 98000

Type Range Reach (mm) Width across Central Bolt flats of Size central bolt

(mm)

Three leg Min. 36 130 24 M22 x 1.5 Max. 250

28. ,ysu dh lsV ALLEN KEY SET IS 3082 1988

Description : Chrome Vanadium Steel, Burnished finish Generally conforming to IS 3082-1988

Range of set No. of pieces 1.5-10 mm

(1.5mm, 2mm, 2.5mm, 3mm, 4mm, 5mm, 6mm, 8mm, 10mm)

09



29. phlyl ¼NSuh½ CHISELS

Description : Octagonal Chiesel made from high grade steel, forged and ground. Differential heat treatment for cutting edge and striking end to ensure long life.

As per IS 402/ 1990

Length In mm Cutting Edge in mm 150 16 200 25 250 30 300 32

Flat Chiesel

Length In mm Cutting Edge in mm

150 25 200 25 250 25

30. gSd lkW ¼vkjh½ HACK SAW

Description : Generally Conforming to IS: 2594

Dimensions for type C Straight Adjustable Flat Hacksaw Nominal size L

250, 300



31. QkbZy ¼jsrh½ FILE Description : Engineer’s file with plastic handle

Generally Conforming to IS 1931-1962

Description Finish Size (mm) Flat file Bastard 200 Flat file Bastard 300 Flat file Smooth 200 Flat file Smooth 300

Half round file Bastard 200 Half round file Bastard 300 Half round file Smooth 200 Half round file Smooth 300

Round file Bastard 200 Round file Bastard 250 Round file Smooth 150 Round file Smooth 250

32. gFkkSMk gRFkk lfgr ¼gsej foFk gsfUMy½ HAMMER WITH HANDLE

a) Nylon Hammer Description : Head drop forged from high grade steel and heat treated with good

quality knotless seasoned wooden handles. (Ball Pein, Cross pein)

Head as per IS 841-1983

Ball pein and Cross pein Weight in gms. 200 500 600 800

b. Ball Pein Hammer



33. ikbZi fjap PIPE WRENCHES

Description : Conforming to IS 4003-1978 (Part-I), Heavy duty housing with

integral I-beam handle made of SG Iron for maximum strength. Suitably proportioned handle for comfortable grip (powder coated).

IS 4003 Part II 1986

Size mm Capacity mm 250 35 300 44 350 48 450 60 600 76

34. ,MtsLVsfoy Lisuj ADJUSTABLE SPANNERS

Description : Standard pattern Chrome Vanadium steel Generally Conforming to IS 6149-1984 Grade II

Length (mm) Capacity (mm) Black Phosphate Finish Price Each Rs

150 19 81.00 205 26 100.00 255 30 132.00 305 35 174.00 380 43 358.00



35. nksuks fljksa ij [kqys ikus ¼Moy vksiu ,aM Lisuj½ DOUBLE OPEN END SPANNERS

a. Spanner Double ended b. Single end Spanner Description : Drop forged Chrome Vanadium Steel, Chrome Plated, Generally

Conforming IS 2028-2004 Rev. V or latest.

Size in mm Size in Inch 6 x 7 3/8 x 7/16 8 x 9 9/16 x 5/8

10 x 11 5/8 x 3/4 12 x 13 3/4 x 7/8 14 x 15 16 x 17 18 x 19 20 x 22 21 x 23 24 x 26 25 x 27 30 x 32 30 x 36

36. fjax Lisujl RING SPANNERS

Bi-hexagonal and Hexagonal Deep Off Set Description : Chrome vanadium steel,

Chrome plated polish Generally Conforming to IS-2029-1998 (Rev.IV)

Range of set No. of pieces 6-22 mm 08 6-32 mm 12

No. of Pieces Contents 6 6

Size M 6x7, 8x9, 10x11, 12x13,14x15, 16x17 16x17,18x19,20x22, 24x26, 25x28,30x32

6

1/8x3/16,3/16x1/4, ¼x5/16,5/16x3/8,3/8x7/16,7/16x1/2



37a. SOCKETS- 12.5 MM (1/2”), SQUARE DRIVE AND ACCESSORIES v- lkWdsV 12-5 ,e,e ¼1@2**½] LDok;j MªkbZo ,.M ,lsljht b. Torque Wrench c- VkdZ fjap Description: High Grade Chrome Vanadium Steel. As per IS 6131-1980 & 7381-1986

Bi-hexagonal & Hexagonal One Set Product Item Sockets (mm) 22 Sockets 10,11,12,13,14,15,16,17,18,19,21,22,23,24,26,27,28,29,30,32,33,345 Accessories

Extension bar 125mm,255mm, Universal joint T Handle , Ratchet Handle

38. lh DySEi C. CLAMP

Length in mm 105 205

39. MLVj DUSTER

Feature : Khadi cloth Use : Dusting work,panel,

window glass etc cleaning work.



40. vkWVksesfVd lSYQ ,MtsfLVax Leky Lisuj AUTOMATIC SELF-ADJUSTING SMALL SPANNER

Description: Automatic self- adjusting small spanner having functional capacity A/F 6

mm to 22 mm or SAE A/F 1/4" to 7/8" Material: - Alloy steel duly hardened jaw, nylon 6 moulded upon steel strip & insulated

up to -1000 volts and stainless steel rivet. (Source of supply – M/s. A Dinisha Marketing Co./ Everest Tools or similar.

41. Lisuj eYVh & fjap ¼jsfpV VkbZi½ 10 bu ou

SPANNER MULTI-WRENCH (RATCHET TYPE) 10 IN ONE

Description: Spanner multi-wrench (ratchet type) -16 effective sizes in one wrench

having functional capacity A/F 10,12,16,17,19 mm & BS 1/4", 4/16, 3/8", 7/16", 1/2" 1/2".

Material:- Alloy steel duly hardened jaw; nylon 6 moulded on steel strip handle. (Source of supply – M/s. A Dinisha Marketing Co./Everest tools or

similar



42. eYVh & fjap@Lisuj MULTI-WRENCH/ SPANNER

Description: Multi-wrench/ Spanner ( 22 sizes of METRIC and SAE in two wrenches)

having functional capacity A/F MM 5,7,8,10,12,13 & MM 14,15,17,18,21.

Material:- Alloy steel duly hardened jaw; nylon 6 moulded on steel strip handle (Source of supply – M/s. A Dinisha Marketing Co. ./Everest tools or

similar 43. jsfpV fjap & jsfpV VkbZi Lisuj RATCHET WRENCH-RATCHET TYPE SPANNER

Description: Ratchet wrench- ratchet type spanner (12 sizes of MM & 5 sizes of SAE

in three wrenches). The three spanners cover 12 sizes in MM – 8,10,11,12,13,15,16,17,18,19,21,22.

Material:- Alloy steel duly hardened. (Source of supply – M/s. A Dinisha Marketing Co. ./Everest tools or

similar



44. gkWV ,;j xu@gkWV ,;j Cyksvj HOT AIR GUN/HOT AIR BLOWER

Name : Hot Air Gun/Hot Air Blower Application : Drying of moisture of silica jel, drying of varnish of motors

coil, drying of moisture of control panels, relays, CTs, PTs etc.

Specifications :

Rated power consumption 2000 W Temperature range 100-6000 C Air flow rate 350-550 Lit/min Stepless temp. control Yes Airflow regulation 2 stage Weight 0.7 Kgs.


45. fMftVy ,uheksehVj

DIGITAL ANEMOMETER

Name : Digital Hygro Anemometer

Application : To measure the air flow velocity of blowers

Specification :

Range Resolution Accuracy Air Flow 80 - 4000 ft/min.

0.4 - 20 m/sec 1

0.01 m/s +/- 3% FS +/- 3% FS

Battery Life 100 Hours Display Size 37mm x 42mm Display Type LCD Temp. -10°C to 50° C

+14°F to 122°F 0.1 0.1

+/- 1.0°C +/- 2.0 °F

Range Max. Reading 9999 Dimensions 133 mm(L) x 51mm (W) x 25mm (D) Fan Diameter 70mm ( 2 7/8") Weight 135 gms with battery (Approx.)

Availability : : Any approved source



46. ’kkWd iYl ehVj SHOCK PULSE METER

Name : Shock Pulse Meter

Application : Used for monitoring health of bearings of pump motors, DG sets, alternators, compressor motors & other motors.

Specifications :

Measuring range, SPM -9 to 99 dbsv Resolution, SPM 1 dbsv Measuring range, VIB 0.5 to 99.9 mm/s RMS Resolution, VIB 0.1 mm/s Measuring range, TAC 10 to 20 000 r.p.m. optical Measuring distance max. 0.6 m Resolution, TAC 1 r.p.m. Temperature range 0° to 50°C Power 6 x 1.5 V LR6 cells Display Liquid crystal Dimensions 300 x 150 x 85 mm Weight 0.85 Kgs.

Availability : Indigenous

47. bUÝkjsM VsEijspj xu ¼ghV Vªsdj½ INFRARED TEMPERATURE GUN (HEAT TRACER)

Name : Infra Red Heat Tracer Application : Measurement of temperature of joints,

connectors and other electrical equipments.

Specification : Battery operated non contact thermometer suitable to read -32 to 600° C with circular laser beam and LED display.

Temperature range - 32 to 600° C Repeatability ≤ ± 0.5 % or ≤ ± 1°C (± 2°F), whichever is greater Response time ≤ 0.5 Sec, 95% response Ambient operating range 0 to 50 °C Power 9 v Alkaline or Ni Cd Battery Weight 320 gms. Distance to spot 30 : 1 Laser Sighting Offset 8 Point circular Data logging 12 point Display resolution 0.1 °C/ F



48. Vwy oSx TOOL BAG

Source of supply : Available in local market in major cities.

49. vYVjusVj fyf¶Vax tSd

ALTERNATOR LIFTING JACK

50. iksVsZoy ikWoj ,axqyj xzkbMaj

PORTABLE POWER ANGULAR GRINDER

Name : Angular Grinder

Application : For grinding welding spots/ joints back gouging, sanding and rust removing.

Specifications :

Grinding & cutting discs 100 MM DIA Rubber packing pad 100 MM DIA Cup brushes 60 MM DIA No load speed 11000 RPM Power input 670 W Weight 1.4 Kgs.




51. fMftVy VSdksehVj DIGITAL TACHOMETER

Name : Digital Tachometer

Application : Safe and accurate measurement of RPM without attachment to the motor or any other rotary object.

Description : Non contact type MASTECH brand digital tachometer, Model DT - 2234A having measurement ranges 5 to 99999 RPM complete with brief case type carrying case, reflective tape and batteries.

Specification :

Test range 5 to 99999 RPM ± 0.05 % Sampling time 1 Second (Over 60 RPM) Test range select Automatic Memory Last value, Max. value, Min. value Detecting distance 50 to 150 mm (Max. 300 mm) Max. display/ LCD size 99999/ 18.5 x 48 mm Dimension 72 x 190 x 38 mm Weight 250 g

Availability : Any approved make 52. eYVh ijit iksVsZoy ikWoj fMªy e’khu

MULTI PURPOSE PORTABLE POWER DRILL MACHINE

Name : Multi purpose portable power drill machine

Application : Drilling of holes in metal, concrete and wood.

Specifications :

Power input 400 W Impact rate 44800 / min. R.P.M. 2200/2800 RPM Weight 1.4 Kg Battery backup in min. NA Volt/amp./watts 230V Dia. in concrete 10 MM Dia. in metal 8 MM Dia. in wood 20 MM

Availability : ISI marked and approved make from market



53. fMftVy ykbZV ¼yDl½ ehVj DIGITAL LIGHT (LUX) METER

Name : Digital Light (Lux) Meter Application : For measuring the

intensity of light. Features

• Wide light range • Remote light sensor • Cosine and color

corrected • Compact & light weight • Low battery indication

Specification :

Range/ Resolution Accuracy Foot candle 20.00/ 200.00/ 2000,0/ 20.000 2% Lux 20.00/ 200.00/ 2000.0/ 20.000 2%


54. yhfFk;e & yksu Moy LihM dksMZySl fMªy e’khu LITHIUM-ION TWO SPEED CORDLESS DRILL MACHINE

Compact design with Li-ion battery,

light weight, ideal for tight space or overhead working

18 stage cluth for precise torque setting 2 Speed: High-low mechanical switch

over Fan-cooled motor with long lasting

motor life LED Working light Easy-to-operate push button reversing

switch Soft grip handle for anti-slip and

comfortable use Variable-speed Reversing Trigger For

accurate bit starting as well as removing fasteners or bound bits and with electric feedback for increased power and control.

Specification Item Parameter No-load Speed： 0-350r/min,0-1350r/min Keyless Chuck 0.8~10 mm Max Troque 30 N.m Battery: Lithium-ion 12V~1400Amh Charger 60mins fast charger



55. dksMZySl LØwMªkbZoj jhpktsZfoy

CORDLESS SCREWDRIVER RECHARGEABLE • Brand: Rolson

• Type: Electronic screwdriver

• Dimensions: 27X21X7 cm

• Colour: Black & sliver

• Material: PVC & metal

• A cordless screwdriver that includes 4 bits, slotted 4.5 mm

• Helps illuminate dark work areas

• Features LED battery level indicator

• Has a 4.8 V rechargeable tool

• Charging time : 3 to 5 hours, one full charge will last 20 minutes

• See package for detailed technical specifications

56. fu;ksu cYo VsLVj de LØwMªkbZoj lsV ¼8 ux CysM lfgr½

NEONS BULB TESTER CUM SCREW DRIVER SET WITH 8 NOS OF BLADE.

PCS, Screw driver set consisting of:

Handle with phase tester ranging 80V to 500V

Philips 3.5 x 125, PH0 Philips 5 x 125,

Engg. S. Driver 3.5 x 125, 5 x 125

Engg. S.Driver 6 x 125

Poker 125



57. ukbZQ lSV KNIFE SET

58a. okW;j czq’k ¼150 ,e,e½ c- ukbZyksu czq’k ¼100 ,e,e½ l- isaV czq’k ¼75 ,e,e½ WIRE BRUSH b. NYLON BRUSH c. PAINT BRUSH

(150mm) (100mm) (75mm)

59. VkspZ ¼,ybZMh½ TORCH (LED) 60. iksVsZoy LØw tSd

PORTABLE SCREW JACK (100 kg capacity)

61. xe cwV GUM BOOT



62. Vh Lisuj vkWQ lkbZt 10] 13] 15 vkSj 17 T SPANNER OF SIZE 10 , 13, 15, 17

(a) (b) 63. nks ySEi rhu rkj vFkZ VsLVj

TWO LAMP THREE WIRE EARTH TESTER

64. gsyesV HELMET

65a. gSUM ysEi HAND LAMP

65b. VsLV ysEi TEST LAMP



Ifjf’k"V&v ANNEXURE ‘I’

fo|qr ijh{k.k lqfo/kk,¡ TESTING FACILITIES (ELECTRICAL) Following testing facility should also be developed

1. Pit mounted 25 kW AC test drive complete set (2

unit per set) for alternator and regulator testing.

2. Floor mounted 45 kW AC test drive complete set with regenerative load testing for alternator and regulator testing.

3. 1kW Portable motor drive set for testing

alternator and regulator.

4. Power supply analyzer, oscilloscope dual channel, storage type

5. Surge comparison tester for testing windings of motor



6. Test benches for testing OVP relays & contactors

with contacts testing with chart .



7. Alternator pulley gap checking facility Filler guage 8. Alternator pulley adjusting guage 9. Alternator pulley groove go-nogo guage

10. Spring testing facility for testing of

alternator spring



11. ERRU testing facility all make 12. ‘V’ belt pre stretching machine (Grading machine) 14. Laptop with printer for data recording



Ifjf’k"V&c ANNEXURE ‘II’

lanHkZ gsrq vko’;d Hkkjrh; ekud ¼vkbZ ,l½ IMPORTANT INDIAN STANDARDS (IS) FOR REFERENCE

Sr.No. Item Reference IS 1. Open end Spanner

(Single & Double ended open jaw spanners)

IS 2028 – 2004 (Rev.V)

2. Ring spanners IS 2029 (Rev.IV)- 1998 3. Combination wrenches with equal

openings IS 6389 – 1998 (Rev. II)

4. Ring slugging wrenches (Spanner) IS 4509 – 1992 (Rev. I) 5. Open ended slugging wrenches

(Spanners) IS 4508 – 1992 (Rev.I) with amendment 2 – Jan. 2003

6. Single ended open jaw adjustable wrenches

IS 6149 - 1971

7. Insulated pliers, pincers and nippers – Technical supply conditions

IS 2615 – 1989 (Rev.2)

8. Combination side cutting pliers - specification

IS 3650 1981 (Rev.2)

9. Pipe wrenches - specification IS 4003 (Part 1, Rev.I) 1978 – General purpose IS 4003 (Part 2, Rev.1) 1986 Heavy duty with amendment 1 Sept. 1990.

10. Chain pipe wrenches - specification

IS 4123 – 1982 (Rev. I) with amendment 2, June 1986

11. Bolt clippers specification IS 5200 – 1998 (Rev.I) 12. Bearing puller - specification IS 9193 – 1979 13. Steel hammers – Specification IS 841 – 1983 (Rev.2)

Amendment no.1 – July 1984 Amendment no.2 – Jan 1987

14. Screw drivers – Specification IS 844 (Part I, Rev.I) – 1972 – Technical supply condition IS 844 (Part II, Rev.I) – 1972 – DimensionsIS 844 (Part II, Rev.2) – 1979 - Dimensions, – Reaffirmed – 1984. IS 844 (Rev.I) Part III -1974- Dimensions for Screw drivers for recessed head screws.



Ifjf’k"V&l ANNEXURE ‘III’

midj.kksa dh foQyrkvksa ds dkj.kksa dh Nkuchu gsrq ÁLrko AN APPROACH TO EQUIPMENT FAILURE INVESTIGATION

A. On Failure Aspects ¼foQyrkvksa ds igyw½

1. Occurrence 2. Date of occurrence 3. Past similar occurrences if any 4. Analysis of failure i.e. why did it happen? 5. Whether the rate of failure is worse than other installations?

B. On Maintenance Aspects ¼vuqj{k.k ds igyw½

1. Whether schedule maintenance & required testing have been carried out on the failed equipment as per norms stipulated?

2. Does the frequency of maintenance require change? 3. Was the work properly supervised? 4. Was any RDSO modification required to be done? 5. Is any modification possible to avoid failure?

C. About Staff ¼deZpkjh ds ckjs esa½

1. Is the quality of work done satisfactorily? 2. Is the skilled staff properly trained to carry out the work? 3. Is the SMI available with them? 4. Are proper tools available with the staff?

D. About Material ¼lkeku ds ckjs esa½

1. Is the material received from approved source? 2. Whether the material is as per approved specification? 3. Can a better material be used?

E. About Testing ¼ijh{kk ds ckjs esa½

1. Is the testing equipment available? 2. Could testing procedure be improved to weed out the failures? 3. Whether testing equipment are calibrated?

F. General Points ¼lkekU; foUnq½

Whether following points were checked / performed properly? 1. Proper contact 2. Clearances 3. Capacity 4. Proper contact pressure 5. Crack detections 6. Cleaning 7. Proper connections/alignment 8. Cross checks/super checks



lanHkZ REFERENCE

1. Different IS issued by Bureau of Indian standards on different types of tools. 2. Various catalogues of tools manufacturers collected from various firms. 3. Handbook published by this Centre in the 2002 on Artisan tools for OSM, TL and AC

Depot. 4. Details collected from various field units and workshops. 5. Suggestions received during the seminar held on 03.04.2014 at CAMTECH. 6. Input received during the seminar held on 07.04.2014 organised by Mechanical

Directorate/ CAMTECH.

To upgrade maintenance technologies and methodologies and achieve improvement in productivity, performance of all Railway assets and manpower which inter-alia would cover reliability, availability, utilisation and efficiency.

If you have any suggestions and any specific Comments please write to us. Contact person : Director (Elect.) Postal Address : Indian Railways

Centre for Advanced Maintenance technology, Maharajpur, Gwalior. Pin code – 474 005

Phone : 0751 – 2470740

0751 – 2470803 Fax : 0751 – 2470841 Email : [email protected]

OUR OBJECTIVE

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dksfpax vvuqj {k.k dds ffy, gLr vkSt kj on Hand-Tools for... · dksfpax vvuqj {k.k dds f fy, ggLr vkSt kj HAND-TOOLS for COACHING MAINTENANCE QUALITY POLICY “To develop safe, modern