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QUALITY POLICY
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.
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
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.
1. ÁLrkouk INTRODUCTION 01
Ifjf’k"V&c ANNEXURE’II’ 49
lanHkZ gsrq vko’;d Hkkjrh; ekud ¼vkbZ ,l½
IMPORTANT INDIAN STANDARDS (IS) FOR REFERENCE
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).
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.
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.
5. Adjustable wrenches should be tightly adjusted to the nut and pulled so that the force is
on the side of the fixed jaw.
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.
12. Never use a screwdriver as a chiesel, punch, scraper or pry bar. Use screw driver for
screw driving only.
2. Neons bulb tester cum Screw driver set with 8 nos of blade. 1 set 56
4. Digital multimeter 1 06
10. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 1 set 35
16/17, 18/19, 20/22
S. Referene
Name of Tools Qty.
Sr.No.
4. Neon bulb tester cum Screw driver set with 8 nos of 1 no. 56
blade similar
8. Test lamp holder (brass) fitted with two mtrs. of 2 1 no. 65b
core flexible copper wire
S. Reference
Name of Tools Qty.
Sr. No.
1. Combination plier insulated with thick CA sleeve with 1 no. 11a
joint cutter length 205 mm
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 1 each 56
blade similar
5. Fitting Opening Key (FDB/CFL/Tube light/RRU) 1 no. --
6. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 1 set 35
14/15, 16/17, 18/19, 20/22
7. Ring Spanner Set 1 set 36
8. Adjustable spanner length 255 mm 1 no. 34
9. Test lamp holder (brass) fitted with two mtrs. of 2 core 1 no. 65b
flexible copper wire
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
18. Heavy duty cable cutting knife adjustable in aluminium 01 no. 57
casing over all size 140 mm
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)
Reference
S.No. Name of Tools Qty.
Sr.No.
1. Combination plier insulated with thick CA sleeve 1 no. 11a
with joint cutter length 205 mm
2. Insulated Nose plier 6” 1 no. 11h
3. Neon bulb tester Screw driver set with 8 nos of 1 set 56
blade
4. Panel key square type ¼ size suitable for opening of 1 no. --
control panel of AC coaches
5. 4 way key & fitting opening key 1 no. --
(FDB/CFL/tubelight/RRU)
6. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 1 set 35a
14/15, 16/17, 18/19, 20/22
7. T spanner of sizes 10, 13, 15, 17 1 62a
8. Test lamp holder (brass) fitted with two mtrs. of 2 1 no 65b
core flexible copper wire
9. Heavy duty cable cutting knife adjustable in 1 no. 57
aluminium casing over all size 140 mm
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
16. Adjustable spanner length 255 mm 1 no. 34
17. Infrared Digital Thermometer (Temperature gun) 1 47
18. PVC Insulating tape 25mm 1 12b
19. Wire fuse 1 --
gLr vkStkjksa
dk
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Details
of
Hand Tools
Make : Indigenious
Technical Specifications :
IR Range 0 – 5 TΩ
Display Digital
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.
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.
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 5 Ah to 2,000 Ah; specified performance
batteries under test range
1 Ah to 9,999 Ah, operating range
Sulfation
Range 0 to 100%
Accuracy ± 5%
Dryout
Range 0 to 100%
Accuracy ±5%
Cell terminal strap impedance (μΩ)
Measurement range 50 μΩ to 1Ω
Resolution 0.001mΩ
Accuracy ±1.0%
Specific Gravity Manual logging
Safety Feature Trigger point – 17VDC
Over voltage auto reset breaker 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.
Application Power Quality analysers help locate , predict , prevent , and troubleshoot
power quality problem in three & single phase power distribution
system.
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
Size : Cut round cable and wire cutter to multi - conductor cable Up to 10 mm2
a.
b. c. d. e. f. g. h.
Description : Calibrated angle marking from 10° to 180° for left, right or offset
bends. Made of tie cast alloy .
Length 600mm
Measuring Accuracy at 0°/ 90° max. ± 0, 05°
Measuring Accuracy at 1°to 89° max. ± 0, 2°
Battery 9V DC6 LR 61
Features : Larger knob for greater torque, harden flare grooved roller
Specification :
Size : 1/4"
24a. fo|qr lksYMj vk;ju ¼vkbZ,lvkbZ ekdZ½ ELECTRIC SOLDER IRON (ISI MARK)
Test Load : The bearing puller shall be able to withstand the following load:
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
32. gFkkSMk gRFkk lfgr ¼gsej foFk gsfUMy½ HAMMER WITH HANDLE
Description : Head drop forged from high grade steel and heat treated with good
quality knotless seasoned wooden handles.
(Ball Pein, Cross pein)
35. nksuks fljksa ij [kqys ikus ¼Moy vksiu ,aM Lisuj½ DOUBLE OPEN END SPANNERS
b. Torque Wrench
c- VkdZ fjap
Length in mm
105
205
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.
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
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.
44. gkWV ,;j xu@gkWV ,;j Cyksvj HOT AIR GUN/HOT AIR BLOWER
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.
Availability : Indigenous
Availability : Indigenous
• Dimensions: 27X21X7 cm
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)
62. Vh Lisuj vkWQ lkbZt 10] 13] 15 vkSj 17 T SPANNER OF SIZE 10 , 13, 15, 17
(a) (b)
lanHkZ
REFERENCE
3. Handbook published by this Centre in the 2002 on Artisan tools for OSM, TL and AC
Depot.
Email : direlcamtech@gmail.com