Draft Hand Book on Integrated Rolling Stock Depotrdso.indianrailways.gov.in/works/uploads/File/Draft Handbook on...to prepare report on the “Handbook on Integrated Rolling Stock

Handbook on Integrated Rolling Stock Depot Page 1 of 61

(For official use only)

(Govt. of India)

(Ministry of Railways)

Draft

Hand Book

on

Integrated Rolling Stock Depot

IRCAMTECH/2017/M/GWL/IRS DEPOT/1.0

April- 2017

MAHARAJPUR, GWALIOR--474005


PREFACE

As per instructions from Railway Board, & CME conference item No. 1.10, CAMTECH

to prepare report on the “Handbook on Integrated Rolling Stock Depot”.

The Handbook has been prepared based on contents taken by nominated committee

for the purpose and visits of Coaching depots, MEMU sheds & DEMU sheds and

interaction with concerned officers / supervisors & concerned depots/divisions for

further course of actions.

Handbook has been prepared by CAMTECH with the objective to provide guidelines

for standardization of infrastructure and maintenance practices of MEMU/DEMU and

Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot.

It is clarified that this handbook does not supersede any existing procedures and

practices laid down in the maintenance instructions issued by manufacturers or by

Railway Board/RDSO.

April, 2017 (K.P.Yadav)

Place: CAMTECCH/GWL Director / Mechanical CAMTECH/Gwalior


Contents

SN Description Page No.

PART-A

01. Constitution of committee 4

02. Terms of reference of the committee 4

03. Details of visits made by the CAMTECH 4

04 Data collection:-

4.1 Dimensions of various coaches

4.2 Weight chart of various coaches

4.3 Arising out of course repairs

4

4

5

5

05 Discussion on the Terms of References 5

5.1 To suggest the infrastructure and facilities required in the new and existing

integrated rolling stock coaching depots –

(i) Short Term Measures

(ii) Long Term Measures

5

5

6

5.2 To suggest short term and long term measures for the integration of Trip,

Minor and Medium repairs of MEMU/DEMU trains in the mainline coaching

depots of IR.

5.2.1 Pit line infrastructure

5.2.2 Sick Line Infrastructure

(i) Machines and Plants required in the rolling stock depots

for maintenance of MEMU

(ii) Machines and plants required in the Rolling Stock

Depots for maintenance of DEMU

6

6

8

9

9

5.2.3 Record keeping 9

5.3 To suggest ways to utilize the released capacity in the existing sheds/Depots

for MEMU / DEMU for carrying out major repairs of MEMU/DEMU rakes.

(i) Maintenance of MEMU rakes in existing DEMU sheds

(ii) Maintenance of DEMU rakes in the existing MEMU sheds.

9

9

9

5.4 To Review the various maintenance schedules and their periodicity for MEMU,

DEMU & main line coaching stock and suggest ways for rationalizing the

same.

(i) Recommendations for various maintenance Sch.in Annexure-B

10

11

5.5 To suggest ways for the multi-skilling of staff and reducing the number of

cadres engaged in the work of maintenance of MEMU/DEMU/Main line

coaches by appropriate training and other methods.

(a) Actual staff deployment in DEMU/MEMU sheds

(b) Multi-skilling of staff and merger of trades

12

12

13

06. Recommendations of the committee 14

07. Lay out drawing of Integrated Coaching Depot 17

08 Annexure-A-Observations during the visits of DEMU/MEMU sheds 20

PART-B

09 Standardisation of Tool Kit and Gauges for Pit Line Maintenance 24

10 Items for Rolling-in/Rolling-out examinations for ICF & LHB coaches 49

11 Check list for inspection of Coaching depot 55

12 Check list for inspection of DEMU 59

13 Check list for Super checking of DEMU 61


1.0 Standardization of Infrastructure and maintenance practices of MEMU/DEMU and Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot.

Vide Railway Board’s letter No. ERB-I/2016/23/67 dated 09.12.2016, a committee was

constituted consisting of DME/Chg., Railway Board (Convenor), DEE(G), Railway

Board, DME(Traction), Railway Board & Director/Mech/CAMTECH on the subject of

“Standardization of Maintenance Infrastructure and practices of MEMU/DEMU and

mainline coaching stock in the integrated Rolling stock coaching depots”.

2.0 Terms of Reference of the Committee:

a. To suggest short term and long term measures for the integration of trip, minor and medium repairs of MEMU/DEMU trains in the Mainline Coaching Depots of IR.

b. To suggest the infrastructure and facilities required in the new and existing integrated Rolling stock coaching depots.

c. To suggest ways to utilize the released capacity in the existing sheds/depots for MEMU/DEMU for carrying out major repairs of MEMU/DEMU rakes.

d. To review the various maintenance schedules and their periodicity for MEMU, DEMU and Mainline Coaching stock and suggest ways for rationalizing the same;

e. To suggest ways for the multi-skilling of staff and reducing the number of cadres engaged in the work of maintenance of MEMU/DEMU/Mainline coaches by appropriate training and other methods.

3.0 Details of Visits made by the Committee: The following sheds/Depots have been visited for analysis of requirements for integrated maintenance of Coaches, DEMU & MEMU.

(i) Diesel / DEMU Shed / SSB / NR on 04 & 07.01.2017 (ii) DEMU maintenance Depot/Medta Road/NWR on 05 & 06.01.2017. (iii) EMU Car Shed, Ghaziabad/NR on 07.01.2017. (iv) MEMU maintenance shed/Saharanpur/NR on 19.01.2017

The observations of the committee during these visits are placed at Annexure A

4.0 Collection of data

4.1 Dimensions of various types of Rolling stock

SN Type of stock Width Length Height

01 LHB Coach (Except DD) 3240 mm 24000 mm 4265 mm

02 LHB Double decker 3050 mm 24000 mm 4366 mm

03 ICF Coach 3245 mm 22297 mm 4025 mm

04 BEML coach 3250 mm 22296 mm 3991 mm

05 DEMU (DPC) 3245 mm 21417 mm 3886 mm

06 MEMU (Motor Coach) 3245 mm 21417 mm 4255 mm

07 MEMU (Trailer Coach) 3245 mm 21337 mm 3886 mm


4.2 Weight Chart of various Coaches:

Type of

stock

Motor/Trailer Tare weight Pay load Total Weight

DEMU 1600 HP

Driving Power Coach(DPC) 72.79 T 07.99T 80.78T

Trailer Coach (TC) 36.25 T 21.51T 57.76T

Trailer Coach Vender (TCV) 35.20 T 22.75T 57.95T

MEMU Motor Coach 59.00 T 2.42T 71.42T

Trailer Coach 35.00 T 21.12T 56.12T

LHB LHB Coach 44.50 T

Double Decker Coach 49.53 T

ICF Coach

ICF Coach 50.00 T 03.68 T 53.68 T

4.3 Arising of out of course repairs per year:

S.N. Item EMU Car Shed/GZB

MEMU Maintenance

Shed/SRE

DEMU Shed SSB

DEMU NWR

Remarks

01 Traction motor change

55 to 60 12 per year Not avl Not done

02 TM Bearing change

18 to 20 (both type)

5 per year Not avl Not done

03 Wheel Change

05 N/A N/A N/A

04 Main Compressor Change

9-10 N/A N/A N/A N/A

These items shall be provided as a Unit exchange spare in the sick line of the integrated Rolling Stock Depot.

5.0 Discussion on the Terms of Reference: 5.1 To suggest short term and long term measures for the integration of trip,

minor and medium repairs of MEMU / DEMU trains in the Mainline Coaching Depots of IR.

The committee has listed the “Short term” and “Long term” measures as follows:

A. Short term measures:

i. DEMU and MEMU rakes can be based at the nearest and most suitable Rolling Stock (Mainline) Depot for carrying out trip schedule.


ii. Each Railway where DEMU and MEMU rakes are running / maintained shall identify one or two such Rolling Stock (Mainline) Depots where the trip maintenance of DEMU and MEMU rakes can be carried out.

iii. Few pit lines shall be nominated for the trip maintenance of MEMU / DEMU. It is preferred that the shorter length pit lines, in case available, shall be nominated for the purpose. This shall avoid wastage of pit line capacity.

iv. Necessary facilities as listed in Para 5.2 shall be created at these depots.

v. These pit lines shall be top wired and made fit for the maintenance of MEMU /

DEMUs. Proper system for isolation of the OHE shall be provided. The feasibility of providing re-tractable OHE, which is automatically slewed away from the rake during its maintenance, shall be explored. A similar system is available in the pit lines of DMRC (Sarita Vihar depot).

vi. Both Railway and Contractor staff working in the pit lines shall be trained and

sensitized for taking precautions while working on the rakes on the adjacent lines so as to prevent any possibility of electrocution (such as not directing the high pressure jet towards the OHE, etc.). Regular safety drives shall be carried out in order to ensure proper isolation of OHE and observance of precautions by both Railway and Contractor staff. Meticulous records of the training and safety drives shall be maintained.

vii. The rake links of DEMU/MEMU trains may be planned in such a manner that

each rake is brought to the Integrated Rolling Stock (Coaching) Depot once every 10 days for trip maintenance.

B. Long term measures:

i. The monthly schedule for DEMU and 45 days schedule for MEMU shall be

carried out in the integrated Rolling Stock (Mainline) Depot. Based on the expertise acquired, practical experience gained and infrastructure created, this may be extended upto 6 / 9 monthly schedules for MEMU / DEMU in future.

ii. Multi-skilling of staff shall be carried out and there shall be only two cadres, i.e.

Welder & Technician, besides Helper. The Technician shall be responsible for the maintenance of both Electrical, Mechanical and Pneumatic systems. Such a system is already prevailing in MEMU depot at SRE.

iii. The existing MEMU / DEMU sheds shall cater to the major schedules and shall

maintain both MEMU and DEMU rakes.

5.2 To suggest the infrastructure and facilities required in the new and existing Integrated Rolling Stock Coaching Depots.

5.2.1 Pit line infrastructure:

The infrastructural requirements at the Integrated Rolling Stock Coaching Depots are listed below:


i. Overhead power supply with Isolation facility shall be provided on the lines nominated for the maintenance of MEMU / DEMU. OHE supply will be required to test the Motor Coach operations like pantograph, transformers, etc.

ii. The cleaning / washing of the rakes shall be carried out in separate washing / stabling lines.

iii. Shunting neck facility should be provided at both ends, at least in the green

field depots, to facilitate the shunting of MEMU / DEMU rakes within the depot without requiring permission from traffic department.

iv. All lines shall be connected at both the ends for easy placement and removal of

rakes, at least in the green field depots. (Director CAMTECH may check these points, whether they can be merged).

v. A dedicated track of 200 mts length shall be provided for testing of the MEMU /

DEMU rakes, At least in the green field depots. vi. The activity of washing line needs to be separated from the pit line examination

in case of MEMU / DEMU. vii. Accordingly, separate washing lines shall be developed for MEMU / DEMU.

These lines shall be equipped with carriage watering system, high pressure water jet cleaning system, washable apron and all other facilities stipulated for other end maintenance vide Railway Board’s letter No. 95/M(C)/141/1 dated 31.01.2007.

viii. An adequate number of stabling lines shall be required for the Placement /

Removal of rakes. The cleaning / washing of the rakes can be carried out at these stabling lines provided suitable facilities are developed.

ix. Pneumatic pipe line with sufficient tapping points at each coach location shall

be provided for feeding of air pressure.

x. An opening of adequate size (say 2 m) in pit line needs to be provided at each coach location on alternative sides, for facilitating the entry of staff and portable trolleys under the coach for attention to the sub-assemblies. Alternatively, the feasibility of

xi. A cantilevered platform constructed of SS grating shall be provided for the roof

inspection on the lines nominated for MEMU / DEMU. It should be ensured that there is no obstruction on the catwalk due to the platform.

xii. All infrastructure should be Road approachable with the provision of drainage.

xiii. Protection wall / boundary wall is also recommended for the Integrated

Coaching Depot. xiv. Automatic Coach Washing Plant and Water Recycling Plant should be provided

in each integrated rolling stock depot.


A schematic layout drawing of the pit lines covering the above points is enclosed as Annexure - E) for guidance. While finalizing the drawing, the recommendations of the Task Force on Improving the Safety Performance of Indian Railways constituted vide Board’s letter No.ERB-I/2016/23/66 dated 06.12.2016, have been looked into by CAMTECH. Some of these recommendations given in Para 2.3 of the Task Force’s report are listed below:

(a) All pits to be provided with low voltage, energy efficient, bright LED lights. The lights should be directed upwards so that the under gear is illuminated.

(b) All future pitlines and those being renovated / expanded should be built for all-

weather use, i.e. with a covered shed with adequate provisions for lighting, drainage, etc.

(c) Tools and equipment for train examination should be standardised and issued

to each staff member with personal lockers too allotted each person for safe keeping.

(d) Proper Rolling-in Examination huts to be built to protect the TXR staff from

weather.

(e) Bright, light-weight and energy efficient LED lights to be introduced in place of the present design of clumsy, heavy lights.

(f) A switch to Machine Vision Systems with Automatic High Definition Camera

and Artificial Intelligence based fault detection and recording system to be introduced.

(g) Such Automatic Machine Vision devices should also be introduced in pit lines

to examine the under gear as trains are placed on them. Each new proposal of Coaching Depot should be that of an Integrated Rolling Coaching Stock Depot. The existing depots should also be provided with the requisite facilities and infrastructure to permit for maintenance of MEMU / DEMU, in addition to Mainline coaches, for trip, minor and medium repairs. 5.2.2 Sick line infrastructure:

i. One separate wheel parking line of approx. 80 mtrs. length is required in the integrated depot.

ii. RCC apron shall be provided upto 20 m outside of the shed on both sides.

iii. Pit Wheel Lathe machine should also be provided in the coaching depot for

coach holding more than 200 coaches. iv. Requirement of cranes / jacks :

MEMU : The weight of motor coach minus bogies (@ 10T each) = 39T. Thus, it shall be possible to lift the coach with synchronized jacks (15T) or 2x25T cranes that are available in the coaching sick lines.


DEMU : The weight of DPC minus bogies (@ 10T each) = 53T. Thus, it shall be not possible to lift the coach with 2x25T cranes that are available in the coaching sick lines. Instead at least two sets of synchronized jacks (15T) shall have to be available for lifting of these coaches.

v. Special Machines & Plants required in the Rolling Stock Depots (for maintenance of MEMU)

1. Filter cleaning plant 2. Battery charger 3. Oil centrifuging/filtering plant 4. EOT Cranes (5 Tons) for handling of traction motor, wheel, compressor,

radiator, etc. 5. Relay/sensor/gauge calibration Panels 6. Tirfors, hydraulic Jacks 7. DGA/BDV/Tan Delta / LCRQ / Lux meter / DPT / MPT/ Hardness testing /

spring testing kit, etc. 8. Portable platform for access to roof equipment.

vi. Special Machines & Plants required in the Rolling Stock Depots (for

DEMU) 1. HSD oil installation or CNG gas filling facility shall be provided in the integrated

Rolling Stock Depot. 5.2.3 Record Keeping: a. A computer based system for proper record keeping shall be adopted.

b. Proper systems shall be developed for the maintenance of IT based systems

that are progressively being provided in coaches such as EP brake systems; CCTV based surveillance system; Micro processor based controls; On-board condition monitoring systems; RFID tags, etc. The staff shall be trained in these systems.

c. Adequate availability of computers, printers with high speed Internet access shall be provided.

5.3 To suggest ways to utilize the released capacity in the existing sheds/depots for MEMU/DEMU for carrying out major repairs of MEMU/DEMU rakes.

i. The new facilities proposed to be created for the major maintenance of MEMU / DEMU should cater to both these type of stocks and should be created at centralized locations where these rakes could be send for major repairs.

ii. The capacity released in the existing MEMU / DEMU sheds due to the trip / monthly maintenance proposed to be carried out at the Integrated Rolling Stock Coaching Depots, will be utilized for carrying out major schedules and POH of more number of MEMU / DEMU coaches.


iii. The MEMU / DEMU rakes shall be fed to these sheds for the major schedules in the form of rakes.

iv. Facilities required at MEMU sheds to maintain DEMU and vice versa

Maintaining MEMU in the existing DEMU sheds and Maintaining DEMU in the existing MEMU sheds

(i) Following MEMU / DEMU sub-assemblies can be maintained / overhauled at

the DEMU / MEMU Depots with the existing facilities:

a. EP Brake system b. Bogies c. Passenger amenities d. Speedometers e. Traction Motors f. Auxiliary Motors g. Power Contactors h. Inter Vehicular Couplers i. Schaku coupler j. Reverser k. Master Controller l. Lights and Fans, etc.

(ii) Facilities for the maintenance / testing of following MEMU sub-assemblies shall

be created in the DEMU sheds:-

a. Transformer b. Tap changing contactors c. Rectifier single phase d. Pantograph e. Master Controller f. Auxiliary motor g. Reverser unit h. Compressor Section (for electrically driven compressor)

(iii) The DEMU sheds shall have to be top wired with proper isolation facilities.

(iv) Facilities for the maintenance / testing of following DEMU sub-assemblies will

need to be created in the MEMU sheds:

a. HSD oil installation or CNG gas filling facility. In case the installation is available at a nearby station, the same may be utilized for fuelling.

b. Power pack Section c. Compressor Section (for engine mounted compressor) d. Radiator section e. Hydraulic systems section f. Governor section


5.4 To review the various maintenance schedules and their periodicity for MEMU, DEMU and Mainline Coaching stock and suggest ways for rationalizing the same

The recommendations for the various maintenance schedules and their periodicity are included in Annexure B. In particular, the committee makes the following recommendations:

a. The UST of axle is carried out in every IC schedule as per SMI0037. The committee recommends that UST of both Motor and Trailer coaches of MEMU and DEMU be carried out after 9 months. This will require validation by RDSO.

b. The trip examination of DEMU shall be carried out after 10 days or 3500 Kms,

whichever is earlier. This has also been recommended vide ED/Carriage/RDSO’s letter No.MC/RLC/D dated 01.03.2017, on a trial basis. Based on the results of the trial, this periodicity of pit maintenance of DEMU may be regularized.

c. DEE/G/Railway Board has also informed that the maintenance periodicity of 3

phase MEMU rakes shall be revised upwards, as and when these rakes are inducted.

d. DEMU and MEMU should go for POH as a complete rake like EMU rake.

e. Automatic Schaku Coupler similar to Kolkata Metro coaches should be

provided on the end coaches of each unit of MEMU / DEMU for facilitating easy coupling and uncoupling. This was also mentioned in MRS inspection note of MEMU car shed, BRCY on 14.10.2016. This shall have to be validated by RDSO.

f. Bio-toilets should be provided in MEMU & DEMU. g. Testing of rakes (MEMU): The MEMU rakes are tested during TI schedule.

The details are entered in the log book. The engine turner takes charge of the rake. There is no separate system of issue of BPC.

h. Examination of MEMU / DEMU at the stabling points and issue of BPC

At present, the MEMU trains are turned out with 100% brake power by the sheds after the trip maintenance. Skeletal gangs have been provided by the MEMU sheds at the stations where these rakes are stabled. These staff peruse the log book and carry out visual examination of the rakes.

i. It is proposed that this activity shall be integrated with the duties of TXR staff, in

case the MEMU / DEMU rakes are stabled at the nominated TXR stations. The staff of the MEMU shed deputed at these stations shall not be withdrawn for at least 6 months and shall work under the control of TXR. In case of any unusual / trouble shooting, assistance of the MEMU shed can be sought by the TXR.


j. In case, the rakes are stabled at non-TXR stations, the existing system shall continue and skeletal gang shall be deputed by the base MEMU shed.

k. At present there is no system of daily maintenance of the DEMU rakes. It is

proposed that a system similar to that proposed for MEMU (para i & j above) shall be adopted for maintenance of DEMU. This is essential since the periodicity of trip examination is being enhanced from 7 days to 10 days. Moreover, proper cleaning, watering, etc. is essential.

l. On many of the Railways, the practice of issuing BPC for DEMU, for each

journey has already been discontinued. The base shed issues BPC which is valid for 7 days. The Committee propose to standardize the system across all the Railways.

6 To suggest ways for the multi-skilling of staff and reducing the number of

cadres engaged in the work of maintenance of MEMU/DEMU/Mainline coaches by appropriate training and other methods.

a. Staff deployment and time taken for trip and minor schedules : The

committee has reviewed the actual staff deployment and time taken for carrying out the trip / monthly / 45 days schedule at the DEMU / MEMU Sheds at SSB and SRE.

b. The committee interacted with the officers and supervisors of SSB DEMU shed.

The time taken for the trip schedule is 5 hours and the time taken for the monthly schedule is 8 hours. The staff deployment for trip and monthly schedule is as follows:

Activity Trip (Staff required/rake)

Man hours

(@5 hrs for trip sch.)

Monthly (Staff required/rake)

Man hours

(@8 hrs for trip sch.)

Remarks

Under gear 5 25 3 25

Upper gear 4 20 3 20

Engine (B check)

16 @ 4 staff per

DPC

Dashpot oiling

8 staff @ 0.5 staff per coach

The engine (B check) and dashpot oiling is generally staggered between the trip and monthly schedules in order to optimize the utilization of man power.

c. The committee interacted with the officers and supervisors of GZB MEMU shed. It is seen that a total of 16 staff are deputed for the trip schedule of 12 Car MEMU/EMU rake which is carried out in about 6 hours. Further, a total of 154 staff are deputed for the schedule inspection of 12 car EMU/MEMU rake


having IC, IB & IA inspection which is carried out in 8 hours. The detailed activity wise Staff Deployment at MEMU Shed/SRE is placed at Annexure C.

d. The committee has noted that there is some variation in the manpower

deployed and time taken by different sheds. Hence, the data at Annexure C and at Paras b & c above can at best serve as guidance for the actual staff deployment and the same shall have to be decided by the Railways based on local practices. Further, a fresh benchmarking study can be ordered in order to arrive at the optimal man power deployment and time taken for the trip, minor and medium schedules for MEMU and DEMU.

e. Multi skilling of staff and merger of trades

As a long term measure, the committee recommends that multi-skilling of staff shall be carried out and there shall be only two trades, i.e. Welder, Technician, besides Helper. The technician shall be responsible for the maintenance of Electrical, Mechanical and Pneumatic systems. The MPP Dte. of Railway Board shall issue necessary instructions for the multi-skilling of staff and merger of trades. Such a system is already prevailing in MEMU depot at SRE, where there is only one cadre of staff who can be rotated between electrical, mechanical and pneumatic jobs.

f. The Integrated Rolling Stock (Mainline) Depots nominated for maintaining DEMU and MEMU rakes, shall identify an adequate numbers of qualified and willing supervisors / staff who shall be trained in the maintenance of MEMU / DEMU. These ssupervisors / staff shall be given 2 Weeks training in MEMU and also DEMU, by the respective DEMU/ MEMU training centers.

Subsequently, the DEMU/ MEMU depots shall depute certain staff for working in the gang formed by the Rolling Stock (Mainline) Depot, so that the C&W / Electrical staff of the depots that are deputed in the gang can be given on job training. The practice of deputing the staff from DEMU / MEMU depots to Rolling Stock (Mainline) Depot shall be discontinued after a period of one year and the staff of the Rolling Stock (Mainline) Depot shall be responsible for carrying out the trip / 45 days and perhaps higher schedules of these rakes.

g. Posting / Rotation of Officers : Vide Board’s letter No.2015/M(L)/466/1 Pt. (A) dated 17.01.2017, Exec. Dir. Mech. Engg (Tr.) and Adviser Electrical (RS), Railway Board have issued joint instructions for the maintenance of Diesel Locos in Electric Loco Sheds and Electric Locos in Diesel Locos Sheds. It has also been stated that for the homing MEMUs in DEMU Shed and DEMUs in MEMU Shed, the same mechanism as detailed for Electric/Diesel Locomotives will be followed.

Accordingly, the responsibility for maintenance of MEMU homed in DEMU sheds shall devolve on the existing officers, staff and supervisors of the DEMU Shed. Suitable training in the maintenance of MEMU shall be arranged for them by CEE of the Railway. In order to assist the DEMU Shed Management in the maintenance of MEMU, one Junior scale officer would be posted by CEE in the DEMU shed. The


administrative control and reporting structure for this officer would be the same as other Junior Scale Officers of the Mechanical Engineering Department. A similar system shall be adopted for the maintenance of DEMU homed in MEMU sheds.

h. All technical issues pertaining to MEMUs will be dealt with by Adv. L(B)/EDEE(B)/CETE and those pertaining to DEMUs will be dealt with by EDME(Tr.)/CMPE at Headquarters/Railway Board level.

i. As per the recent reorganization of the various departments, the overall

responsibility for the proper maintenance of DEMU & MEMU shall be of CME on the Zonal Railway.

6.0 Recommendations of the Committee a. In the short term, DEMU and MEMU rakes shall be based at the nearest and

most suitable Rolling Stock Depot for carrying out trip schedules.

b. Few pit lines shall be nominated for the trip maintenance of MEMU / DEMU rakes at these depots and the required facilities as listed in Para 5.2 of the report shall be created at these depots.

c. The rake links of DEMU/MEMU trains may be planned such that each rake is

brought to the Integrated Rolling Stock (Coaching) Depot once every 10 days for trip maintenance.

d. In the long term, even the monthly schedule for DEMU and 45 days schedule

for MEMU shall be carried out in the integrated Rolling Stock (Mainline) Depot. Based on the expertise acquired, practical experience gained and infrastructure created, this may be extended upto the 6 / 9 monthly schedules for MEMU / DEMU in future.

e. Each new proposal of Coaching Terminal should be that of an integrated

Rolling Coaching Stock Depot.

f. CAMTECH shall finalize the drawing for the Integrated Depots within 2 months, including the facilities required to be created in the existing depots.

g. The existing MEMU / DEMU sheds shall cater to the major schedules and shall maintain both MEMU and DEMU rakes. The required facilities as listed in Para 5.3 of the report shall be created at these depots.

h. To the extent possible, proliferation of MEMU / DEMU car sheds should be

avoided. Larger sheds holding 10 rakes or more should be planned.

i. The new facilities proposed to be created for the major maintenance of MEMU / DEMU should cater to both these type of stocks and should be created at centralized locations where these rakes could be sent for major repairs.


j. The capacity released in the existing MEMU / DEMU sheds due to the trip / monthly maintenance proposed to be carried out at the Integrated Rolling Stock Coaching Depots, will be utilized for carrying out major schedules and POH of more number of MEMU / DEMU coaches.

k. Systems of automatic train inspection and condition monitoring shall be

introduced. For example, Machine Vision Systems with Automatic High Definition Camera and Artificial Intelligence based fault detection and recording system shall be introduced at the en-route stations as well as at the pit lines of the Integrated Rolling Stock Depots. This is also a Task Force recommendation.

l. The recommendations for the various maintenance schedules and their

periodicity are contained in Annexure B of the report.

m. DEMU and MEMU should go for POH as a complete rake like EMU rake.

n. Automatic Schaku Coupler similar to Kolkata Metro coaches should be provided on the end coaches of each unit of MEMU / DEMU for facilitating easy coupling and uncoupling.

o. The new MEMU / DEMU rakes shall be standardised as per RDSO’s

recommendations (Para5.4 (l)).

p. Bio-toilets should be provided in MEMU & DEMU.

q. The interior maintenance can be outsourced (as was done at the SRE MEMU Shed).

r. Toilets are being provided in DEMU and MEMU trains since 2011. Suitable

arrangements shall be made by the Railways for the cleaning of the coaches and toilets, including watering, of MEMU / DEMU at Terminals and also En-route.

s. Proper facilities for cleaning / watering of the rakes shall be provided at the

location of stabling the rakes, as well as at the intermediate stations.

t. Proper facilities for cleaning / examination of the rakes shall be provided at the location of stabling the rakes. Adequate illumination shall be ensured.

u. The rolling-in examination of MEMU / DEMU shall also be carried out at the

nominated stations by TXR staff, as is done for main line trains.

v. Examination of MEMU / DEMU at the stabling points and issue of BPC:

m. This activity shall be integrated with the duties of TXR staff, in case the MEMU / DEMU rakes are stabled at the nominated TXR stations. The staff of the MEMU shed deputed at these stations shall not be withdrawn for at least 6 months and shall work under the control of TXR. In case of any unusual / trouble shooting, assistance of the MEMU shed can be sought by the TXR.


In case, the rakes are stabled at non-TXR stations, the existing system shall continue and skeletal gang shall be deputed by the base MEMU shed. A system similar to that proposed for MEMU shall be adopted for maintenance of DEMU. This is essential since the periodicity of trip examination is being enhanced from 7 days to 10 days. Moreover, proper cleaning, watering, etc. is essential.

w. On many of the Railways, the practice of issuing BPC for DEMU, for each journey has already been discontinued. The base shed issues BPC which is valid for 7 days. The Committee propose to standardize the system across all the Railways. The train crew shall carry out the brake feel test as for the provision of G&SR. In no case should the safety of trains get compromised. The details of the checks made by the TXR / Skeletal gang shall be endorsed in the log book, as is being done for MEMU.

x. The Integrated Rolling Stock (Mainline) Depots nominated for maintaining

DEMU and MEMU rakes, shall identify an adequate numbers of qualified and willing supervisors / staff who shall be trained in the maintenance of MEMU / DEMU. These supervisors / staff shall be trained in the maintenance of DEMU/ MEMU.

y. The DEMU / MEMU depots shall depute supervisors / staff to the Integrated Rolling Stock Depot for a period of one year for providing on-job training to the C&W / Electrical staff of the Rolling Stock Depots and working in the gang.

z. The merger of trades and multi-skilling is recommended by the Committee.

aa. An ADEE shall be posted in the DEMU Shed and an ADME shall be posted in the MEMU shed by CEE / CME respectively.

bb. In case of any problem in the MEMU / DEMU, the base home shed shall be contacted who shall render necessary assistance.

cc. As per the recent reorganization of the various departments, the overall responsibility for the proper maintenance of DEMU & MEMU shall be of CME on the Zonal Railway.

dd. The benefits accruing out of the integration of maintenance of different types of Rolling Stock, in terms of improved maintenance, operational flexibility, and lesser infructuous movement of the MEMU / DEMU rakes shall be documented by the Railways.

ee. Replacement of conventional loco-hauled trains with MEMU/DEMU : In view of the advantages of MEMU / DEMU trains in terms of distributed powering, non-requirement of reversal, etc., the committee consider that it may be advisable to replace at least the short distance passenger trains with MEMU / DEMU in the congested corridors. This may also be necessary due to the decision to retrofit CBC in ICF coaches having a residual life of minimum 10 years. Replacement of passenger trains with MEMU / DEMU will reduce the requirement of retro fitment and also provide spare coaches for running the existing screw coupling ICF trains until they are converted to ICF with CBC or LHB.





Annexure A

Observations during the visits to DEMU/MEMU/Sheds

S

N

ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR

Total

Holding

Activity Maintains both EMU

and MEMU

Trip & Monthly

schedules

All schedules of

DEMU

Trip & Monthly

schedules

1 Pit lines 04 lines of 16 coach

length with covered

shed (extension for 20

coaches under

progress). Platform

provided only on one

side. All covered pit

lines are available for

12/16 cars for

maintenance of two

MEMUs/EMUs rakes

having length of

approx. 360 meters

each & width approx.

30.00 meters. Catwalks

of 1.5 meter width are

provided at one side &

open space is kept in

the middle for

movement of

lifter/listers for

loading/unloading of

minor assemblies. The

pit line is prepared on

steel pillars for easy

movement of hydraulic

trolleys for

dismounting/ mounting

of electrical machines/

equipments.

Two lines of

approx. 360

meters width

approx. 16.00

meters catwalk

1.5 meters open

space in middle

for movement of

lifters. The pit

lines are on RCC

pillars spacing 4.0

meters with

continuous RCC

beam.

Two lines of 480

mtrs length.

No crane was

planned in this

shed for lifting of

minor assemblies

like compressor

unit & Radiator etc.

as the heavy repair

section is available

for this task.

The covered pit line is

under construction for

maintenance of two

DEMU rakes having

length of 270 meters

(proposed 360 meters

for 16 cars) & width

approx. 16.97 meters

(for 12 coach rake).

Catwalks of 1.6 meter

width are being

provided at both sides

& open space is kept

in the middle for

movement of

lifter/listers for

loading/unloading of

minor assemblies. The

water filling & fuel

oil filling facilities

will also be provided

at platform itself. A

05 ton capacity crane

is planned in this shed

for lifting of minor

assemblies like

compressor unit &

Radiator etc.

2 Washing line One washing line of 16

coaches length

available with both side

platforms. Automatic

coach washing plant

also installed at one

end.

One washing line

of 12 MEMU

length with

ACWP

NO ACWP

provided

ACWP is proposed.


S

N


3 Heavy

Repair Bay

02 lines each of 06

coach length available

with 03 Nos. 30/10 ton

overhead cranes. 15 ton

Jamalpur screw jacks

available. Lifting

mostly being done with

overhead cranes.

One SR section

with 25 T, 2 Nos

EOT cranes for

(3+1)x2 coach

length.

One Heavy repairs

section is available.

One sick line for

(3+1) coach length X

2 is available in the

depot. Pit is provided

only on one line. At

present one No. 5 ton

capacity crane is

provided for this sick

line shed. In future,

30 ton capacity crane

would be installed.

4 Bogie

Section

One line of 06 coach

length & open area for

the overhauling of

bogies, with 03 nos.

15/5 ton overhead

cranes. A Bogie wash is

available.

Not required One bogie section

is available

Not required

5 Traction

motor

section

Traction motor section

is available

Not required Traction motor

section is available

Not required

6 Officers/

Sections

along

subassembly

bay

Ground floor and first

floor have been utilised

for accommodating

various section. First

floor lying almost

empty. One room for

each SSE/Incharge

dealt with POH activity.

One room for

SSE/incharge,

one room for

JE/SE shift, one

room for

Electrician, one

store, one welding

room, one

pneumatic section

and one test

room.

One room for

SSE/Incharge. One

room for JE/SSE

shift incharge. One

room for Diesel

Mechanic

/Electrician. One

welding set room.

Two rooms have

been constructed

for DPT testing and

engine lube oil

testing. One

supervisor and 3

staff are working

for this activity.

One room for

SSE/Incharge. One

room for JE/SSE shift

incharge. One room

for Diesel

Mechanic/Electrician

staff with sufficient

lockers. One room for

welding set. A service

building is under

construction,

including the offices

of Sr.DME /DME,

Training centre (One

hall for classes & one

model room), one hall

for hostel, one elect

panel room & one

canteen.

7 Coach

Repair shop

Coach repair shop of

one coach length

available for corrosion

repair and other

carpentry works.

Not required - Not available


SN ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR

9 Pit wheel

Lathe

Machine

Available (HYT make) Available Available Proposed

10 Stabling

Lines

Two stabling lines

capacity of 16+12 cars

each.

Not available - One line available

11 Turn table One turn table available

for turning of motor

coaches

Not required - Not required

12 RCD Not required Not required One RCD is

available. SSE

suggested that at

least 100 KL

capacity RCD is

required in depot.

One RCD is

proposed. At present

fuelling of DEMUs is

done at Jodhpur

13 Brake

System

/Pneumatic

Pipe line

One room for EP/air

brake section is

provided for testing of

brake equipments.

One pneumatic

section for valve

test bench, EP

unit test bench,

EP test bench &

bench vice etc.

One room for air

brake section for

testing of brake

equipments. One

compressor room

with the provision

of two air

compressors.

One room for air

brake section is

proposed for testing

of brake equipments.

One compressor room

is proposed.

14 Lubricatin

g oil testing

Facilities available with

C&M staff

Transformer oil

centrifuging plant

available

Facilities available

with C&M staff

One room is

constructed for DPT

testing and engine

lube oil testing. One

15 Store One AMM office/store

is available for

stocking/procurement

of items of

EMU/MEMU coaches.

One room for sub

store/Running store is

available.

One hall for main

store for approx

206 stock items

and 100 NS items

is available.

One hall for main

store having size

22x12 meters for

stocking of approx.

200 items of

DEMU. One hall

for sub store/Shift

store of size 20x10

meters. One

godown for storage

of engine oil

barrels.

One room for main

store is available for

stocking of items of

DEMU. One room for

sub-store/Running

store.

16 DM plant One DM plant is

provided for

requirement of distilled

water.

One DM plant is

provided for

requirement of

distilled water

DM plant is

provided for

requirement of

distilled water

One DM plant is

proposed


S.

N.


17 Computer

Room

Computer cell is

provided for

maintenance of data

and filling of

maintenance schedule

forms & day to day

works

One Computer

was available

with SSE/store

for material

procurement and

data filling.

Computer cell is

provided for the

maintenance of

data and filling of

maintenance

schedule forms &

day to day works

with one clerk.

Computer cell is

proposed for

maintenance of data

and filling of

maintenance schedule

forms & day to day

works with one clerk.

18 Tool room One separate tool room

is provided for keeping

tools, gauges, spanners,

pipe wrenches & UST

etc. for supply to

technicians & for

keeping record of

calibrations.

One tool room for

tools and gauges.

One tool room for

keeping tools,

gauges, spanners,

pipe wrenches etc.

for supply to

technicians &

keeping record of

calibrations

Separate tool room is

not available.

19 Material

handling

One suitable capacity

truck is available.

- One suitable

capacity truck is

provided.

Truck is not available.


(Govt. of India) (Ministry of Railways)

STANDARDISATION

OF

TOOL KIT & GAUGES

FOR

PIT LINE MAINTENANCE

[ For official use only ]

APRIL-2017


FOREWORD

Hand-Book on Standardisation of Hand Tool Kit for pit line

maintenance staff is an important step towards ensuring implementation of

effective and uniform maintenance procedures in coaching depots. CAMTECH &

Mech. Directorate/Railway Board has taken an important lead in this direction by

preparing this hand-book giving compiled list of hand tools & gauges required for

coach maintenance.

In this Hand Book, detailed description with use of each hand tool with

important parameters will prove to be useful to the maintenance depots. As a result

of introduction of hand tool kit, quality & timely maintenance can be ensured to

meet traffic requirements of coaches in the present scenario.

EDME/CAMTECH


PREFACE

Vide item No.12 of the inspection notes of RNCC on 15/02/2015, MRS has mentioned that the staff working in the pit lines should be given proper tools to enhance the work output and a standard tool kit shall be made available to all the fitters individually. CAMTECH has issued a Handbook on Standardization of Hand Tools for Coach Maintenance-April-2014 which is provided for tools to be kept on tool bag as well as tools be made available in tool room for maintenance by fitters. The list of tools / gauges mentioned therein is highly voluminous and it is not practically feasible to carry all the tools by the fitter in a bag. Therefore, a review based on the present requirements for pit line maintenance fitters was necessary. For this purpose, Director/Mech./CAMTECH & Director Mech. Engg.(Chg.)/Railway Board visited Coaching complex, New Delhi and DEE depots for analysis of practical feasibility of containing of tools in the hand bag by fitters. Based on the interaction with Depot Officers and Staff of NDLS Division (NDLS and DEE Depots), the set of tools and gauges that need to be carried by the under gear, side examination and pressure test gangs of pit line examination of LHB and ICF trains have been reviewed considering current working trends and requirements. Besides, tools / gauges that are not required frequently may be kept in the Tool Room. While finalizing the tool kit, inputs have also been obtained from BCT Depot of WR & Coaching depot/BPL & JBP of WCR. Other Items These may also be provided to the Pit line staff or kept in the tool room as mentioned below: 1. Tool Bag : The Tool Bag shall have 2 compartments. It shall be of canvas

of dimensions 15” width, 18” length and 4” thick. It shall have a shoulder strap.

2. Industrial safety shoes : Prevents slipping, protects feet. It shall be issued

to the fitters of each of the 3 gangs once every year along with the uniform.

3. Helmet : For reasons of hygiene, this should be made a personal item of

the staff. It shall be issued to the fitters of each of the 3 gangs once every year

along with the uniform.

4. Portable lights

A. Portable lights for Carrying out train examination and light repairs

:This shall be a tool room item. The specifications shall be White LED light of

minimum intensity 300-500 lux at a distance of approx. 18 inches. Magnetic fixing

arrangement shall be available on helmet. The light shall be re-chargeable and

have multifocal lengths.


B. Portable lights for Heavy Works : Further, additional portable White LED

re-chargeable lights of 20W and 50W should be available for carrying out heavy

work. These lights should be adjustable and shall be equipped with a proper stand

for keeping them inside or on the side of the pits while carrying out heavy work.

Photographs of such lights procured by BCT depot of WR are provided in the

report along with their detailed specification. The list of tools / gauges is provided

with photograph & indicating use of each tool.

(K.P.Yadav)

Director/Mech/CAMTECH


List of Tools and Gauges required for Pit line Gangs

S.N. Item LHB Gang

Utilization ICF Gang

Utilization

Under Gear Gang

A Tools:

01 Cotter Punch 12” Yes Split Pins Yes Split pin, bulb cotter

02 Pin Punch 12” Yes Split Pins Yes Split pin, bulb cotter

03 Nylon Mallet 200 gm Yes Tapping of Brake Disc No --

04 Allen Key 10 mm [ Full set ]

Yes Tighten studs of Longitudinal Bump stop

No --

05 Ball Pin Hammer 900 gm

Yes Split pins Yes Split pin, bulb cotter

06 Open Spanner-16x17 Yes Lateral Bump stop, lateral damper

No

07 Open Spanner-18x19 Yes Longitudinal Bump stop, lateral damper

Yes ESR Safety Bracket bolt

08 Ring Spanner-18x19 Yes Lateral damper Yes ESR safety bracket

09 Open Spanner-24x27 Yes Replace Brake pads Yes Truss bar safety wire rope bolt

10 Ring Spanner-24x27 Yes Rocker arm bolts Yes Truss bar safety wire rope bolt

11 Open Spanner-30x32 Yes Supporting device securing bolt

Yes Brake cylinder Mounting bolts

12 Ring Spanner-30x32 No Supporting device securing bolt

Yes Brake cylinder Mounting bolts

13 Open Spanner-32x36 Yes Buffer Bolt Yes Centre pivot bolts, anchor link bolt

14 Ring Spanner-32x36 No -- Yes Centre pivot bolts, anchor link bolt

15 Open Spanner-36x41 Yes Angle cock / ferrule check nut, adjusting brake cylinder

No --

16 Open Spanner-41x46 Yes Angle cock / ferrule check nut, adjusting brake cylinder

No --

17 Chisel 8 inch No -- Yes Cutting of defective split pins, bolts.


B Gauges: LHB Gang


Utilization

01 Steel measuring tape 2 m

Yes Buffer stroke, buffer Height, etc.

Yes Buffer stroke, buffer Height, etc.

02 Tyre Defect Gauge Yes Wheels Yes Wheels

03 Inside Calliper 2” Yes Gap between Lateral / Longitudinal / Vertical Bump Stops

No --

Following additional tools should also be kept in Tool Room for use by Pit

line maintenance gang -

1. Ratchet with goti set (small)

2. Torque wrench (Big) with goti set 170 mm

3. Allen Key set up to 10 mm


SN

Side Inspection Gang:

A Tools: LHB Gang


Utilization

01 Ball Pein Hammer 900gm

Yes Split pin

Yes Split pin, bulb cotter etc.

02 Cotter Punch 12” Yes Split Pins No --

03 Open Spanner 16x17

Yes Foot Board Yes Axle box crown bolt

04 Ring Spanner 16x17

Yes Foot Board Yes Axle box crown bolt


Yes Secondary Damper Yes Dashpot safety U bolt


Yes Secondary Damper Yes Dashpot safety U bolt


Yes Primary Damper, Axle Box Face Plate

Yes Brake head shoe bolt, dashpot vent screw

08 Ring Spanner 24x27 Or Box spanner with ratchet

Yes Primary Damper, Axle Box Face Plate

Yes Brake head shoe bolt, dashpot vent screw


No -- Yes Axle box face plate bolts, bolster safety U strap, shock absorber bolt (bottom)

10 Ring Spanner 30x32 Or Box spanner with ratchet.

No -- Yes Axle box face plate bolts, bolster safety U strap, shock absorber bolt (bottom)


No -- Yes Crown bolt, shock absorber bolt (Top)


No -- Yes Crown bolt, shock absorber bolt (Top)

13 Full set of Allen Keys

Yes For CBC lock bracket, speed sensor fixing etc

No --

14 Box spanner with ratchet, size 13,15

Yes For earthing device maintenance

No --

15 Circlip Plier 6 inches

Yes For earthing device maintenance

No --

16 Magnifying Glass for checking minor cracks

Yes For checking of minor cracks in the components.

Yes For checking of minor cracks in the components

B Gauges LHB Gang


Utilization

01 Resetting Key for ACP Yes CBC handle resetting key No --

Feeler Gauge No -- Yes To check rubber bonding of silent blocks

02 Steel scale 6 inches No -- Yes A, B, C dimension of bogie, gap between safety U strap and a lug.

03 Dip stick No -- Yes Dashpot oil level


SN Pressure Testing Gang:

A Tools: LHB Gang

Utilization ICF Gang Utilization

01 Ball Hammer 900gm Yes Ferrule,air hose change Yes Split pin, bulb cotter etc.

02 Pipe Wrench 14” Yes Air Hose change Yes Angle cock, air hose, drain cock, pipeline of ACP

03 Pipe Wrench 18’’ Yes Air Hose change Yes Angle cock, air hose, drain cock, pipeline of ACP

04 8 inches long ferrule punch(8X32) mm

Yes For replacing the ferrules No --

05 Screw Driver 9 inch No -- Yes Opening of PESD cover

06 Socket 10 mm Yes Angle cock Bracket No --

07 Open Spanner 10x11 Yes Angle cock Bracket No --

08 Open Spanner 11x12 No -- Yes PEASD and PEV fixing bolt, DV released choke

09 Ring Spanner 11x12 No -- Yes PEASD and PEV fixing bolt, DV released choke

10 Open Spanner 12x13 Yes Speed Sensor Stud No --

11 Open Spanner 18x19 No -- Yes DV / CR

12 Ring Spanner 18x19 Yes Tighten inspection stud of Axle Box Speed Sensor

No --

13 Open Spanner 24x27 No -- Yes Flexible hose of brake cylinder, brake pipeline, common pipe bracket / DV / CR, dirt collector, drain cock, AR dummy bolt, AR pipes.

14 Open Spanner 41x46 Yes Ferrules, BP/FP Mainline Yes Angle cock, air hoses

15 Resetting Key for ACP

Yes Resetting of ACP No --

16 Screw driver set (flat/Fillips)

Yes For WSP cards, connectors etc,hose clips for speed sensors.

No --

17 Wire stripper Yes For wiring related work No --

18 Multi-meter Yes For wiring related checks No --

19 Full set of Allen Keys Yes For ICV pull box, Junction box etc.

No --

B Gauges:

01 Feeler gauge Yes Gap between speed sensor & phonic wheel

No --


02 Pressure gauge adopter

For checking brake cylinder pressure

No --

03 Stop watch Yes For releasing time Yes For releasing time

04 Steel scale 6 inch / Piston stroke gauge (GO-NO GO type)

No -- Yes To check the piston travel

05 Spring balance (0-15 kg)

Yes To check the ACP apparatus

Yes To check the ACP apparatus

For TXR

01 Only measuring tape Yes For measuring dimensions

Yes For measuring dimensions


Description of Tools and Gauges:

1.0 Under Gear Gang

S.N. Item Details Photograph

A Tools:

01 Cotter Punch 12”

02 Pin Punch 12”

03 Nylon Mallet 200 gm

04 Allen Key 10 mm


05 Ball Pin Hammer 900 gm

06 Open Spanner-16x17


08 Ring Spanner-18x19











17 Chisel 8 inch

Additional tools for Tool Room :

18 Ratchet with goti set (small).

19 Torque wrench (Big) with goti set 170 mm

20

Allen Key set up to 10 mm.

B Gauges: Details Photograph

01 Steel measuring tape 2 m.

02 Tyre Defect Gauge

03 Inside Caliper 2” / Vernier Caliper


2.0 Side Inspection Gang:

A Tools: Details Photograph

01 Ball Pin Hammer 900gm

02 Cotter Punch 12”














14 Magnifying Glass for checking minor cracks

B Gauges Details Photograph

01 Steel scale 6 inches

02 Dip stick


3.0 Pressure Testing Gang:

A Tools: Details Photograph

01 Ball Hammer 900gm

02 Pipe Wrench 14”

03 Screw Driver 9 inch

04 Socket 10 mm












B Gauges:

01 Feeler gage

02 Stop watch

03 Steel scale 6 inch / Piston stroke gauge (GO-NO GO type)

04 Spring balance (0-15 kg.)


05 Pressure gauge adopter For checking brake cylinder pressure

For TXR

01 Measuring tape


Other Items [ PPEs]:

SN Item Details Photograph

01 Tool Bag - Canvas Tool Bag shall have 2 compartments. It shall be of leather of dimensions 15” width, 18” length and 4” thick. It shall have a shoulder strap.

02 Industrial safety shoes

Specs may be developed after market survey

03 Helmet

-

04 Portable lights for

Carrying out train examination and light repairs

The specifications shall be White LED light of minimum intensity 300-500 lux at a distance of approx. 18 inches.

05 Portable lights for Heavy Works

Portable White LED re-chargeable lights of 20W and 50W should be available for carrying out heavy work. These lights should be adjustable and shall be equipped with a proper stand for keeping them inside or on the side of the pits while carrying out heavy work.


APPENDIX-A

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, chisels, 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 chisels are intended for cutting, shaping and removing metal softer

than the cutting edge itself.

10. Always strike the struck base of a Chisel or punch. The striking face of the

hammer should have a dia. approximately 10 mm larger than the struck face of

the punch or Chisel.

11. Never use screw drivers with rounded tips.

12. Never use a screwdriver as a Chisel, punch, scraper or pry bar. Use screw driver

for screw driving only.


List of probable Source of Supply:

1. M/s SNAP-ON Tools Pvt. Ltd.

6/2, Begwmpur, Khatola

Behind TOYOTA, show room

NH-8, Delhi-Jaipur, Gurgaon

PIN- 122004

2. M/s Taparia Tools Ltd.

423/424, A-2, Shah & Nahar

Lower Parel (West)

Mumbai-400013

Web-site : http://www.tapariatools.com

3. M/s Mekaster Tools Ltd.

10168, East Park Road (K.C.P.)

Karol Bagh, New Delhi-110005

4. M/s Jhalani Tools (India) Ltd.

Gedore House

51-52, Nehru Place

New Delhi-110019

5 M/s BOSCH

Motor Industries Co.Ltd., Power tool division,

Hosur Road, Adugodi

Banglore-560030

6 Shree Ganesh Fibre Glass Co. (for safety helmet )

New Delhi-34

7. Chicago Pneumatic Sales (for pneumatic tools)

Chemtex house, Hiranandani Gardens

Powai, Mumbai-400076

Website: www.cp.com

8. M/s Hindustan Everest Tools Ltd.

Dohil Chambers, 46 Nehru Place

New Delhi-110019

Web-site : http://www.eversttools.com

http://www.tapariatools.com/

http://www.cp.com/

http://www.eversttools.com/


OPEN SPANNER 36 X41

OPEN SPANNER 16 X 17

RING SPANNER 32 X36


CENTRE FOR ADVANCED MAINTENANCE

TECHNOLOGY

Maharajpur, Gwalior – 474020

: 0751-2470890, Fax: 0751-2470841


(Govt. of India)

(Ministry of Railways)

Rolling-in/Rolling out Items


Rolling-in/Rolling out Items

of

ICF Coach

And

LHB Coach


Rolling-in and Rolling-out items.

As per discussions held with SSE/incharges, the following items should be

checked by Rolling in & Rolling out staff for safety of trains –

ICF Coach:

SN Component Remarks

01 Hanging part Truss bar, Hanger, Equalizing stay rod, J-Bracket, Axle

box cover etc.

02 Hot axle Smoke from axle box bearing

03 Broken part Spring, Truss bar hanger

04 Air Pressure leakage Hissing sound from air brake pipes

05 Deflated air spring Uneven air spring

06 Brake binding Sparking from wheels

07 Wheel skidding Unusual sound of flat places

08 Foot board bent Damaged/tilted foot board

09 Buffer height variation Nil Axle box clearance, excessive bolster clearance,

body resting on trolley (Thumping sound)

LHB Coach:


01 Hanging part Anti-roll bar, link, axle box face plate, water pipe etc.,

WSP Cable & Battery box securing arrangement.

02 Hot axle Smell/smoke from axle box

03 Broken part Primary & secondary Springs, Deflated air spring etc.

04 Wheel skidding Unusual sound from wheel tread

05 Air Pressure leakage Hissing sound from air brake pipes

06 Brake binding Brake indicator applied or released [ Green or Red ]

FIBA

07 Securing arrangement of

all tanks

CDTS tanks, Bio-toilet tanks, under-slung tank, AR tank

& Brake control module Including footboard and CBC

uncoupling device

08 I.V. Coupler sagging Sagging of IV coupler

09 Whistling sound From brake disc, brake pad, bearing front & back and

earthing box.


Following items to be checked in LHB Coach during Rolling-in/Rolling-out:


1 Hanging Part a. WSP Cable,

b. Axle box face

plate,

c. Anti-roll bar,

d. Link,

e Water Pipe &

f. Battery box

securing

arrangement.

,

2 Hot axle Smell/Smoke from Axle Box.

3 Broken Part

a. Primary Springs b. Secondary Springs,

4 Wheel Skidding Unusual sound from wheel tread

AXLE BOX FACE PLATE WSP CABLE

WATERING PIPE

LINK

PRIMARY SPRING

SECONDARY

SPRING

AXLE BOX

ANTI ROLL BAR

BATTERY BOX

SECURING

ARRANGEMEN

T


5 Air Pressure leakage Hissing sound from air brake pipes.

6 Deflated Air Spring Uneven Air Spring

7 Brake Binding

a. Brake indicator applied or released [ Green or Red ] b. Condition of FIBA

8 Securing

arrangement of all tanks. a. CDTS tanks,

b. Bio-toilet tanks,

c. Under-slung

tank,

d. AR tank

e. Brake control

module,

f. CBC uncoupling

device and

g. Footboard

AIR PRESSURE

LEAKAGE

BRAKE INDICATOR RELEASED BRAKE INDICATOR APPLIED

BRAKE CONTROL MODULE

FOOT BOARD CBC COUPLING DIVICE

CDTS TANK BIO-TPOILET TANK

UNDER SLUNG TANK

AIR SPRING


9

I.V. Coupler

Sagging of IV coupler

10 Whistling sound a. From brake pad, b. brake disc, c. Bearing front & back, and d. Earthing box

IV HOSE SAGGING

BRAKE PAD

BRAKE DISC


11.0 Inspection of Coaching Depot

Following areas to be inspected by the Supervisors/Officers to ensure general upkeep and smooth functioning of Coaching Depots.

Pit Examination and Cleanliness

Infrastructure availability and adequacy:

a. Condition of catwalks b. Water logging in pits c. Arrangements of cleaning of pit lines, adjoining areas and effectiveness thereof d. Pest controlling of the pit lines and adjoining areas e. Availability of garbage disposal system f. Availability of lights in the pit and illumination level at the pit, bogie and catwalk

level g. Availability of water storage and watering facilities. h. Availability of high pressure pipe line for cleaning. i. Availability and proper working of coach washing plant. j. Mechanized Coach Cleaning : Availability of Dosing machine for dispensation of

chemicals. k. Availability of Surveillance cameras in all Coaching Depots for monitoring the

maintenance activity. l. Any other deficiencies observed.

Train Maintenance

a. Whether all items prescribed for monthly / quarterly schedule, including intensive cleaning are carried out (check few coaches and comment on the discrepancies observed)

b. Check few rakes / coaches and give specific comments on the quality of repairs with respect to:

1. Cleaning / amenities 2. Safety / under gear 3. Air brake testing.

c. Whether rake cleaning and attention to passenger amenities items is adequate, whether all items as mentioned in the contract are carried out, Whether mechanized cleaning of coaches with high pressure jet is ensured.

d. Availability / proper functioning of automatic coach washing plant, ETP, water recycling plant.

e. Whether the prescribed procedure for rake maintenance is known the staff and is followed.

f. Availability of Standard tool kit and Portable lights for the staff working in Pit lines g. Comments with regard to maintenance of LHB coaches. h. Testing of WSP (LHB coaches) during each trip. i. Functioning of bio-toilets. j. Quality of washing of Linen in departmental / BOOT laundries available in the

depot. k. Comments on the proper functioning of service contracts.


l. Effectiveness of Cleaning contracts. m. Effectiveness of Pest and Rodent control contracts. n. Examination and certification of LPG pipe line system in pantry cars. o. System of record keeping p. System of monitoring complaints / feedback

Performance Indices

a. Review The performance indices of the depot, identify areas of weakness & strength.

b. Stock detained for long periods c. Whether coach failures analysis, enroute detachment, punctuality loss, etc. is

done. d. System of communication, reporting and follow up e. Analysis of unscheduled detachments at the primary end. f. Whether the coach failures are maintained in a data base to enable analysis. g. System of communication of defects in secondary / other end trains to the

primary depot. h. Coaches running overdue schedules.

i. Rake Links 1. Whether the rake links are as per provisions of RPC 4. 2. Coach holding vs Actual requirement. 3. Adequacy of pit examination time for various rakes. 4. Whether adequate berthing slot are available. 5. Whether any train gets continuous night maintenance. 6. Whether any train is being maintained in two or more parts.

j. Any other comments

Sick Line :

a. Adequacies of infrastructural facilities for IOH b. Road access and availability of material handling equipment. c. Availability of air dryers for compressors in pit line and sick line. d. Quality of repairs during IOH (check few coaches and give specific comments of

deficiencies observed). e. Whether “must change” items are replaced during IOH f. Quality of over hauled trolleys received from Workshops for IOH of Mail / Express

coaches. g. Adequacy of lifting facilities h. Comments on the welding practices, particularly earthing, and training of

welders. i. Steps taken for system improvement and innovations. j. Availability of units exchange spares. k. Comments on various certifications, quality audits by 3rd party, etc. l. Display of flex boards / banners containing relevant instructions, etc. m. Availability of standard tools and gauges and their usage. a. Knowledge of staff /supervisors. b. Whether policy letters, TSO’s are known to the Supervisor / Staff and system of

communication thereof


c. House keeping d. Are old files disposed off? Are the files kept properly in a readily retrievable

condition? n. Availability of personal protective equipment for staff. o. System of Record keeping, Whether data of Wheels, DV, CBC, Bearings, etc. in

the depot coach holding is available in form of a data base. p. Status of execution of works related to improvement in infrastructure. q. Any other comments

Train Duty on Platforms / Other End Attention

a. Whether all facilities prescribed vide Board's letter No.95/M(C)/141/1 dated 31.01.2007 for other end attention on platform / stabling lines are available.

b. Whether adequate halt is available for other end attention c. Quality of Terminal examination/attention in stabling lines/platforms (Check few

trains and give specific comments). d. Whether the rakes are properly locked and stabled at secure locations. e. Adequacy of watering facilities, whether booster pump is available and is

automatically operated. f. System of rolling-in examination of terminating and passing through trains

(availability of adequate lights and huts for rolling-in examination). g. Availability of adequate number of non-contact type axle box temperature gauge

with storage feature h. Availability of standard tools and gauges, portable lights, etc. i. Availability of proper means of communication (CUG /Walki Talkie) j. Availability of adequate spares, and display of the list k. Comments on the trouble-shooting of passing through trains and maintaining

records of the same. l. Any other comments

Materials / Store

a. Important item out of stock / in short supply. b. Whether the AAC’s of different items is adequate. c. Proper storage of rubber item d. System of raising warranty complaints. e. Comments regarding housekeeping and disposal of scrap. f. Any other comments

IT Based Systems

a. Whether proper systems are available for the maintenance of IT based systems that are progressively being provided in coaches such as GPS based passenger announcement and passenger information system; Infotainment system; Fire detection and fire suppression systems; Automated door closing arrangement; EP brake system; Brake system of LHB coaches; LED destination boards, CCTV based surveillance system in the coaches; Micro processor based controls; On-board condition monitoring systems; RFID tags, etc.

b. Whether staff are conversant in these systems. c. Whether AMCs are in place and operational.


d. Whether at least 1 staff / supervisor deputed full time on CMM and IT based systems.

e. Whether the different functionalities of CMM are being used, any issues thereof. f. Internet access and speed thereof. g. Adequate availability of computers, printers etc. h. Any other comments

Establishment

a. Whether adequate number of staff deputed for various activities b. Comments on vacancies and action taken thereof. c. Staff grievances d. Staff amenities e. Level of staff motivation and steps taken to increase the same. f. Any other comments

Training Needs / Staff Awareness

a. Method of imparting training and review of its effectiveness. b. Whether stimulation soft ware and audio visual training aids are utilized. c. Level of knowledge and motivation of the instructors. d. Training of staff / visits to other depots. e. Training calendar of BTC. f. Availability of Working Models. g. Availability of all coach and wagon components and cut sections for training

purpose. h. Availability of all Gauges. i. Availability of all latest manuals and instructions. j. Complete profile of staff and their details of training, Whether data base of staff

trained and overdue is available. k. Categorization of welders as per their skill set. l. Record of training conducted/courses organized . m. Seminars/Sessions organized in collaboration with respective filed expert. n. Any other comments

Date : Name of the Officer : Station : Designation :


12.0 Check List for Inspection of DEMU

Inspection should be done as per check list by the officers & inspectors and availability of

all standard equipments as well as any additional equipments, which may have been

provided on DPC should be ensured.

General:

1. Check Flasher Light, Head light, Marker light and tail light.

2. Check condition of buffers.

3. Check availability of screw coupling.

4. Check condition of Rail guard and Cattle Guard.

5. Check Working of wipers.

Oil Levels

(Check before starting)

1. Check Lube oil level by dipstick gauge.

2. Check Compressor oil level by dipstick gauge.

3. Check Hydraulic oil level in (up to 3/4th

of glass.)

4. Check Water level in water glow rod gauge

5. Check Fuel oil level in glow rod gauge.

6. Check brake releasing and ensure sufficient gap between brake block and wheel (5-6

mm)

Driver’s cabin:

1. Put battery Isolation Switch in ON Position.

2. Put 24 V Isolation Switch in ON Position.

3. Put LCC MCB in ON Position.

4. Check cab light by putting switch in ON position.

5. Before starting of DPC, priming of fuel pump to be done near main engine to avoid fuel

oil locking, till indication comes.

6. On engine block, FSD device should be in “Mechanical” but after starting, it should be

put in “Electrical”.

7. After priming, fuel lifting pump cock again to be put in closed position.

8. 24 V MCB and 110 V MCB to be put in ON position before pressing start button.

9. Now, push start button, till rpm reaches to 300 in tachometer at back panel.

10. Now press reset button for resetting safety devices (Indication LED).

11. Ensure MR pressure 5-7 Kg/Cm2 & BP pressure 5.0 Kg/Cm

2 on Driver’s control panel.

12. Now check B.C. pressure up to 1.6 kg/m2 on brake application (E.P).

13. DCS key, BIVS key, Master controller key should be applied.


-2-

14. Now check Red colour indication lamp for glow of lights, normally it should be in off

position.

15. Check functioning of Dead Man handle by putting reverser key in forward direction,

16. Check continuity of brake application by dropping B.P. pressure to zero.

Safety Material

01. Ensure availability of 4 nos. wooden wedges in each DPC.

02. Ensure availability of safety instructions in Driver’s cabin for detaching coaches in case

of fire.

03. Ensure availability of 03 nos. fire extinguishers in each DPC.

04. Ensure availability of 01 set BP & FP hose pipes & its extensions

Before Starting Train 1. Check functioning of horn by pressing foot pedal.

2. Ensure presetting of speed recorder by pushing display button.

3. Before starting, check availability of caution order and BPC.

4. Check the Driver’s repair book for any previous booking and its compliance.

5. Note down Driver’s name and Guard’s name.

6. Note down Driver’s particular, safety category, PME details, last counseling/

Monitoring and training particulars, learning particular etc.

7. Note down maintenance schedules of DPC and Trailer car.

8. Ensure cleanliness of Driver Cabin.

Date: Name of Officer:

DPC Depot: Designation:


13.0 Check Sheet for Super Checking of DEMU

DPC No. ………… Link __________ Date ____________ Shift ___________

Items checked Observations Action taken Radiator Room –

a. Check water leakage from water tank, pipe line and radiator cores

b. Check abnormal sound from radiator fan. c. Check cleanliness, oil & water spillage. d. Check hydraulic oil leakage from hydraulic motor and

flexible hoses. e. Check radiator room for hydraulic oil spillage and

cleanliness of hydraulic tank. f. Ensure proper locking of radiator compartment door.

Engine Room –

a. Check condition of lagging on air compressor outlet pipe, its clamp condition and support welding of air compressor.

b. Ensure that oil tray below engine sump is cleaned, there should be no muck or oil accumulation

c. Check vent motors for proper working and any leakage. d. Ensure that there is no leakage from exhaust pipeline. e. Check exhaust pipeline for cladding and TSC for exhaust

bellow. f. Ensure that fuel actuator is electrically operated. g. Check condition of belts of alternator, auxiliary generator,

air compressor h. Check fire extinguisher for expiry date.

Driver Cab-

a. Check driver cab for proper sealing of doors b. Check driver cabin light. c. Check driver seat for firm foundation. d. Check look out glass for securing and condition for

cleanliness e. Ensure that no TM is isolated.

Under Gear –

a. Check air dryer for working b. Ensure that aftercooler underneath floor is properly cleaned c. Check axle box, gear case and MSU bolts for sealing. d. Check helical springs for any crackness by hammering. e. Check dashpot for oil leakage. f. Check cattle guard for proper fitment.

Safety items –

a. Check Dead-man Relay working b. Check Head lights, Flasher lights for proper working. c. Check Horn for proper working. d. Check rail guard for proper fitment, height above rail level

(100mm) e. Check wiper for proper working. f. Check speedometer and parking brake for working.

Deferred repairs:

General-

a. Staff booked for maintenance b. DEMU rake time in

DEMU rake time out c. Check schedule form

Signature Name & Designation

Documents

Draft Hand Book on Integrated Rolling Stock Depotrdso.indianrailways.gov.in/works/uploads/File/Draft Handbook on...to prepare report on the “Handbook on Integrated Rolling Stock