PREFACE Indian Railway having a route length of over 62,000 KM are the largest undertaking in the world.

With 16 lakhs employee running 8000 passenger trains and 5500 goods train every day, moving 1.36 crores passenger and 12 lakhs tones of goods daily. So railway are truly called the ‘life line of the nation’. To maintain the punctuality and safety of train, maintenance of the gears is very important. In present condition maintenance artisan staff are not getting adequate time for proper maintenance due to train traffic. Maintenance time is also more on account of traditional tools. After any unusual like accident, derailment or bursting of point etc. restoration time is also more. To over come with the problem associated with tool, S&T artisan staff should use modern tools. Railway Board has asked IRCAMTECH, Gwalior to prepare a report on modren tools applicable for S&T staff.. IRCAMTECH has organised a two days seminar and called the modern tool manufacturer from all over the country. All Principals, instructors of S&T training centres from Zonal Railways, field officers and supervisors have attended the seminar. Demonstration was given by the manufactures during the seminar. Based on the tools quality, its applicability, life and cost, this report is prepared. In this report information on the tools like its specification, application, price and manufacturers with address including DOT phone numbers and fax numbers are given, which will help in procurement of modern tools. Efficiency of S&T artisan staff will increase which make the S&T system more reliable in day to day working. Gwalior Date: 12.7.2002 A.K.Sagar Director (S&T)

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INTRODUCTION The present handbook is primarily intended to cover the modern tools and equipment for Signalling discipline based on their usefulness. Prior to the preparation of the handbook the problem related to the use of the conventional tools in the field and its possible replacement have been studied and discussed. To meet the desired end some of the tool manufacturers/suppliers have been contacted and their address have also been incorporated in the list for reference. Owing to time constraints and other limitations CAMTECH could locate only limited manufacturers/suppliers. As such, the list of manufacturers/suppliers indicated for any tool provided in the handbook is in no way exhaustive and the Railways/ Indenters / Users/ are free to explore for the availability of more manufacturers/suppliers in the open market. The budgetary estimated cost for the tools is subjected to variation on account of market factors and / or number of units purchased. Further the power operated tools being operated on 220 V AC can suitably be re-designed by manufacturer for operation on 110V AC/ DC (which is readily available in yard) to meet the feasibility criteria. Thus at the time of procurement of tools, based on its merits, the above factors also need to be carefully looked into.

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TOOL ALREADY IN USE Tools list for Electric Signal Maintainer Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Name of the tool Digital Multi meter Megger 100 V and 500 V Hydrometer Measuring tape /Scale Dummy wheel Ring Spanner set Spanner set double ended Adjustable spanner 12” and15” Box spanner set Water pump spanner Nose pliers 4”, 6”, 8” Wire scraper Pliers 6” and 8” Insulated Screw driver Set Allen key Hammer (2.5, 5 Lbs.) Chisel Punch Seal punch Train shunt resistance meter Earth tester Grease gun Tommy bar Obstruction test piece Page no. of modern tool 11 20 29 29 29 16 14 9 & 14 15 & 15 17 & 29 29 31

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Sr. 25. 26. 27. 28. 29. 30. 31. 32. A)

Name of the tool Soldering iron (10W-125W) Crimping device Vacuum cleaner Hand gloves Cell tester Hand track drilling machine Electric drill machine Brush

Page no. of modern tool 19 8

23 & 26 23 & 26

Tools list for Mechanical Signal Maintainer Sr. Name of the tool Page no. of modern tool 1. Hammer (2.5-20 lbs) 2. Chisel 3. Punch 31 4. File flat 5. File flat smooth 6. File round 7. File triangular 8. File half round 9. Spanner set 29 10. Ring spanner set 29 11. Box spanner set 29 12. Calipers 13. Filter gauge 14. Grease gun 15. Valve lifter 16. Screw driver set 29
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Sr. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. C)

Name of the tool Tommy bar Pic-axe Pharaoh Hack saw frame Crow bar Adjustable spanner (10”,12”,15”,18”) Augur Reamer Drill machine Blower fan Smithy tongues Tri square Electric grinder machine Brass ratchet Sewal Motor Pan Blow lamp Iron Brush

Page no. of modern tool

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23 23 & 26

Tool lists for Carpenter Name of tool Sr. 1. 2. 3. 4. 5. 6. Hand Saw Trying Angle Trying Plane Jack Plane Measuring Tape Anvil

Page no. of 28 32 32 20

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Sr. 7. 8. 9. 10. 11. 12. 13. D)

Name of tool Auger Drill Machine Gilmet File Adge Punch Vice

Page no. of 23 23 23 31

Tool lists for Mason Name of tool Sr. 1. 2. 3. 4. 5. 6. 7. 8. 9. Hammer Chisel Measuring Tape Punch Pic-axe Pharaoh Tommy bar File Crow bar

Page no. of

20 31

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MODERN TOOLS 1. Crimping tool

Name Application Make Article No. Specification

: : : : :

Crimping Tool Crimping of wires. Hil Presh 11731 Crimping Range 0.5 - 1.5mm2 1.5 - 2.5mm2 4.0 - 6.0mm2 Rs. 650/M/s Sumitron Exports Pvt. ltd. ***

Budgetary estimated cost : Source of supply :

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2.

Stripping Plier

Name Application

: :

Make : Features : One light squeeze strips wire clean up to a full 7/8". 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 aluminum with plastic molded handles. Model No. : Budgetary estimated Cost : Source of Supplier : 10.105 Rs.900/M/s Sumitron Exports Pvt. Ltd. ***
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Stripping Plier Removing of Conductor Insulation for Termination. M/s Aven, Item No. 10.105

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3.

Auto Ranging Digital Multimeter

Name Application

: :

Auto Ranging Digital Multimeter Measurement of Voltage, Current Resistance, Checking of continuity 9a02
auto/ manual ranging, 33/4 digit 3400 count lcd with Analog bargraph 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 3.4/34/340/750v ± (1.0%rdg + 8 dgt) on all ranges except ± (1.5%rdg + 8 dgt) on 750v

Make/ Model Specification
Display DC voltage

: :

AC voltage

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DC Current AC Current Resistance

Diode Continuity Buzzer Full Icon Display Auto Power Off/ Steep Mode Low Battery Display Input Impedance (Voltage) Power Battery Life LCD Digit Size

340µ a/3.4/34/340ma/3.4/20a ± (1.5%rdg + 8 dgt) 340µ a/3.4/34/340ma/3.4/20a ± (2.2%rdg + 4 dgt) 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 yes yes yes yes "batt" is indicated 10 mΩ one 9v battery 200 hours typical 17 mm

Budgetary estimated Cost : Source of Supply :

Rs. 8,000/M/S Meco Instruments Pvt.Ltd. P.O. Box 6388, 301 Bharat Industrial Estate Taj Road, Sewree (West), Mumbai - 400 015

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Make/ Model Specification
Display

: :

Tektronix DMM916
auto/ manual ranging, 4½ digit 40000 count LCD with analog bargraph 400mV to 100 V 0.1 % 4 V to 750 V 0.7 % 400 µ a to 10 Amp 0.9 % / 0.3 % 4000 ohm to 40 mega ohm 0.3 % 4.000 nF to 40 mF ±1.0% 400 hz to 2 Mhz 50° to 980° ± 1° C

DC voltage range DC voltage accuracy AC voltage range AC voltage accuracy AC/DC current ranges AC/DC current accuracy Resistance range Resistance accuracy Capacitance Frequency ranges Temperature

Budgetary estimated Cost : Source of Supply :

Rs. 14,000/M/s SS Tools (India) Pvt. Ltd. 234, 2nd Floor, Ajmeri Gate Delhi

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4.

Wire Stripper

Name Application

: :

Wire Stripper Wire Stripper for Wide Range Shear Cut Bolt Cutters, Wire Cutter 1.1 To 2.7 Mm Rs. 6500.00 M/S Sumitron Export Pvt. Ltd. 27, Community Centre, Naraina Phase-1. New Delhi - 110 028

Make/Model : Specification : Budgetary estimated Cost : Source Of Supply :

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5.

Cable Cutter

Name Application Make/Model Specification

: Cable cutter for copper and aluminum cables. : Cuts the copper and aluminum cables : Hilpress/Article No. 11860 : Cutting Range : 400mm2 Max Outside Dia : 52mm Weight : 0.830kg Length : 280mm

Budgetary estimated Cost : Rs. 250.00 Source of Supply : M/S Sumitron Exports Pvt. Ltd. P.O. Box 10227, Naraina Phase I, New Delhi - 110 028

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6.

Grip Pliers

Name Application Make/Model Specification

: : : :

Grip Plier For tightening and loosening. EVEREST/Article No. 266 Based on IS 10372, Federal GGGW-00649(GSA-FSS) 266-7 175 235 266-10 250 470

Stock No. Length MM Weight GMS

Budgetary estimated Cost : Rs. 550.00 Source of Supply : M/S Hindustan Everest Tools Ltd, Dohil Chambers, 46, Nehru Place, New Delhi 19.

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7.

Electric Screwdriver

Name Application Make/ Model Specification

: : : :

DC & AC Electric Screwdriver For screwing LOOVER/LT and KPT

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ITEM/FIRMNAME MAKE/ MODE L CAPACITY WATTS RPM BUDGETORY ESTIM ATED COST :

M/S SUMITRON EXPORT PVT. LTD.NDLS27, NARAINA PHASE-1 DC & AC ELECTRIC SCREWDRIVER LOOVER/LT

M/S KPT DC & AC ELECTRIC SCREWDRIVE R E-3900 6 MM 600 W 0-4000 RPM RS.6950/-

RS.400/-

Source of supply

:

I) M/S Sumitron Export Pvt. Ltd. II) KPT Sales and Service Ltd.

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8.

Soldering Station

Name : Soldering station Application : For soldering of PCB etc. Make/Model : HAKKO/397 Specification : Model No. 937 Power Consumption 60 w Output voltage AC 24 volts Heating element AC 24 volt 50 w Weight Approx 1.3 kg 900S Iron 25 gms 907 Iron 44 gms 908 Iron 54 gms Budgetary estimated COST : Rs. 12,000/Source of Supply : M/S Sumitron Exports Pvt. Ltd. P.O. Box 10227, Naraina Phase I, New Delhi - 110 028
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9.

Digital Range Finder DUS20

Description

: The digital range finders are the right tools for measuring any length and distance. Ideal for fast and precise measuring and for adding up lengths, areas and volumes. Specification : Weight approx. 200 gms Measuring units m/ cm, ft/inch Measuring Accuracy at -5°to +50°C ± 1% Measuring Accuracy at +10°C to ± 0.5% +40°C Measuring range 20 m Battery 3 x CR 20032 4 x 1.5 V DC Automatic cut off Approx. 10 sec. Budgetary estimated Cost : Rs. 6,000/Source of supply : M/s BOSCH Motor Industries Co. Ltd., Power tool Division, Hosur road, Adugodi, Bangalore - 560030
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10.

Hot Air Gun/Hot Air Blower

Name : Application :

Make/Model No. Specifications Voltage

Hot Air Gun/Hot Air Blower Drying of moisture of silica jel & joint, drying of moisture of control panels, point machine armature and winding portion etc. : CHG 600 CE 220-240V or 110V AC/DC 550 W 100-6000 C 350-550 Lit/min Yes 2 stage 0.7 Kgs.

Rated power consumption Temperature range Air flow rate Stepless temp. control Airflow regulation Weight Budgetary estimated COST : Rs. 6,500/Source of supply : M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030
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11.

DC operated drill machine

Name Application

: :

Make/Model No. : Specifications Model Max. screw dia. Dia in steel Dia in wood Battery voltage Rated speed Weight with battery pack Budgetary estimated COST : Source of supply :

Cordless tool To drill in wooden & concrete sleeper. To drill in rail in track circuited portion. BOSCH GBH 24 VRE 20 mm 10 mm 20 mm 24 V DC/1.7 Ah 0-4400 rpm 3.5 kg Rs. 23,450/M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030
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12.

Portable power drill machine

Name

Multi purpose portable power drill machine Application : Use in signalling Drilling on lever frame, gate lock, Signal post, for connecting A Marker, for fixing Calling On Signal, split lock stretcher for fixing point lock etc. A. Make/Model : M/s BOSCH/ GBM 13-2 Order No. : 06011690 Specifications Power input 550 W R.P.M. 1000/1900 RPM Weight 2 Kg Volt/amp./watts 230V or 110 VAC/DC Dia. In metal 13 MM Dia. In wood 12/32 MM Budgetary estimated COST : Rs. 7,000/Source of supply : M/s BOSCH /Bangalore – 560030
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B.

Make/Model :1) M/s KPT PR 132 K1-2 speed pistol drill. 2) M/s KPT KD34C –End hand drill Specifications : Item M/s KPT PR 132 M/s KPT KD34C – K1-2 speed pistol End hand drill drill. Power input 550 W 550 W Voltage220-240 AC OR 220-240 AC OR 110 V AC/DC 110 V AC/DC RPM 1300/3000 RPM 1300 RPM Weight 2.2 kg 3.5 kg Dia. In 13 MM 13 MM concrete Dia. In 13MM 13MM metal Dia. In wood 32 MM 32 MM Dia. In 20 MM 20 MM Aluminum Budgetary Rs. 5,000/Rs. 7,190/estimated cost Source of Supply : KPT Sales and Service Ltd. 309, Vasant Vihar Commercial Complex, Dr. C.Gidwani Road, Chembur, Mumbai – 400074, Maharastra India Phone-5563002,5562965 Fax-5576006 E-mail - kpt.mum@gems.vsnl.net.in

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13.

Heavy duty power drill machine

Name Application

: :

Heavy duty power drill machine To Drill holes on tongue rails, D-bracket, Stock rail etc. 1. BOSCH/ GBM 23-2 2. KPT HD 115 13-23
M/s KPT HD 115 13-23mm morse taper drill 1100 W 220-240V or 110 V AC/DC A) 500 RPM B) 380 RPM 8.8 Kg 19-23 MM Rs. 8,760/M/s BOSCH GBM 23-2 with taper shank drill 550 W approx 220-240V or 110V AC/DC -5.5 Kg approx. 19-23 MM Rs. 20,000/-

Make/Model : Specifications :
Item/ firm Model No. Power input Voltage R.P.M. a)at no load speed B) On load speed Weight Dia. In metal Budgetary estimated cost

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Source of Supply : 1. M/s KPT Sales and Service Ltd. 309, Vasant Vihar Commercial Complex, Dr. C.Gidwani Road, M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030

2.

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14.

All purpose Saw

Name Application Make/ Model No. Specifications Saw in wood Saw in steel Power input No load stroke rate Saw stroke length Weight

: : : :

All Purpose Saw Cutting work of sheet metal, iron angles, pipes, troughs etc. PFX 550 150 MM 12 MM 550W/ 220 V/ 110V AC/DC 2600 stroke/min. 26 MM 3.0 Kg. Rs. 10,000/M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030
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Budgetary estimated cost : Source of supply :

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15.

Screw Driver Bit set

Name Application Make/ Model No.

: : :

Screw driver bit set For screwing different shape screws 1. BOSCH 2. M/s Jensen Cat No. 690-542 M/s Jensen 28 –pieces Skewdriver Pro kit gear driven offset Removable handle with 41/2 ” magnetic extension Skew socket: 5-10 mm Torx bit: T10,T15,T20,T27 Slotted bits: 1/8”, 3/16” ,1/4”, 5/16”
Allen bits:5/64” to 3/16”

Specifications : BOSCH Size SVC 46 pieces Bit set 7/16" or 6mm to 7/16"

Budgetary estimated cost : M/s BOSCH : Rs. 1250/M/s JENSEN : Rs. 2250/-

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Source of supply : M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030

M/s S.S. Tools (India) Pvt. Ltd. 234, 2nd Floor, Ajmeri Gate Delhi

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16.

Punches

Name Application

Centre punch Use in removing the broken part of channel in track circuit, broken bolts from track etc. Make/ Model No. : M/s Taparia Specifications : Each set consist of: Item Description Length Weight Code in mm in gms. 1884 Centre punch 100 35 1984 Centre punch 100 50 1985 Centre punch 125 80 1004 Drift punch 100 45 Budgetary estimated cost : Rs. 100/- each set Source of supply : M/s Taparia Tools Ltd. 423-424/A-2, Shah & Nahar, Lower Parel (W) Mumbai-013 Phone: 022-4938646-50 Fax: 022-4953230

: :

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17.

PLAINER

Name Application

: :

Make/Model No. : Specifications Power output 750 W/ 220V/110 AC DC No-Load speed 13000 rpm Cutting depth 0 –3.1 mm adjustment Planing width 82mm Rebate depth 0 24 mm Weight 2.8 kg Budgetary estimated cost : Rs. 10,800.00 Source of supply : M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030
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Planer Light weight one hand machine for all kind of planing work BOSCH/GHO 31-82

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18.

METAL DETECTOR

Name Application

: :

Intelligent Measuring Instrument Detects the presence of iron and live wires inside the wall. Useful in masonry & carpentry work. BOSCH/DMO 10 Measuring unit – mm Battery – 9 V DC Rs. 4500.00 M/s BOSCH Motor Industries Co. Ltd., Power tool division, Hosur road, Adugodi, Bangalore – 560030

Make/Model No. Specifications

: :

Budgetary estimated cost : Source of supply :

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 FOREWORD

Ever increasing traffic on Indian Railways has resulted in proportionate reduction in the time available for maintenance activities. Use of conventional tools demands greater maintenance slots and require more restoration period as well. As study has been conducted to over come such lapses arising due to the use of conventional tools. The present handbook encompasses modern tools for signalling along with respective representative manufacturers/ suppliers for ready reference. It is earnestly hoped that the use of theses ergonomically designed modern tools will not only reduce artisan’s fatigue but will go a long way to increase the overall efficiency and productivity by drastically cutting short the maintenance time.

Gwalior Date : 26.07.2002

M.L.Gupta Executive Director

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