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dsoy dk;Zky;hu mi;ksx gsrq

(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA


jsy ea=ky; MINISTRY OF RAILWAYS

dksfpax vuqj{k.k ds fy,


gLr vkStkj
HAND-TOOLS
for
COACHING MAINTENANCE
mi;ksx drkZ dksfpax vuqj{k.k deZpkjh
END USER: COACHING MAINTENANCE STAFF

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


vçsy 2014 April, 2014

egkjktiqj, Xokfy;j & 474 005


Maharajpur, GWALIOR - 474 005
dksfpax vuqj{k.k ds fy, gLr vkStkj
HAND-TOOLS
for
COACHING MAINTENANCE

QUALITY POLICY

“To develop safe, modern and cost


effective Railway Technology
complying with Statutory and
Regulatory requirements, through
excellence in Research, Designs and
Standards and Continual
improvements in Quality Management
System to cater to growing demand of
passenger and freight traffic on the
railways”.
ÁDdFku
Hkkjrh; jsyksa esa ;k=h ;rk;kr dh c<+rh gqbZ ekax dks ns[krs gq, jsy ij vf/kd
dksfpax ¼lckjh fMCcksa½ dh miyO/krk gksuk vko’;d gSA
ftls vk/kqfud fMtk;u ds mi;qDr vkStkjksa ds }kjk lokjh fMCcksa dk de le; esa
mi;qDr vuqj{k.k djds miyO/k djk;k tk ldrk gSA
vr% dSeVsd us ;g gLr iqfLrdk Þdksfpax vuqj{k.k ds fy, gLr vkStkjß dksfpax
vuqj{k.k ds dk;Z esa fu;qDr fo|qr deZpkfj;ksa ds fy, rS;kj dh gSA ftlesa ÁR;sd vkStkj dk
foLr`r fooj.k vko’;d iSjkehVj ds lkFk fn;k x;k gSA tks dksfpax fMiks rFkk vksfiu ykbu
ds fy, mi;ksxh fl) gksxkA ;g flQkkfj’k dh tkrh gS fd jsYos bu vkStkjksa dks ;k muds
leku vkStkjksa dks rduhf’k;uksa dks miyO/k djk;s] rkdh os vius lkSisa x;s dk;Z dks n{krk
iwoZd iw.kZ dj ldsaA
eS vk’kk djrk gw¡ fd ;g gLr iqfLrdk dksfpax vuqj{k.k esa O;fDrxr :i ls mi;ksxh
fl) gksxhA

dSeVsd] Xokfy;j ,- vkj- rqis


FNUKAD % 28-04-2014 DK;ZDKJH FUNS’KD
FOREWORD

Growing demand of passenger traffic on Indian Railways, requires more availability of


coaching stock on rails. This can be achieved by proper maintenance of stocks in less time using
proper tools with modern design.

CAMTECH has prepared this handbook on “Tools for Coaching Maintenance” for the
use of electrical staff of coaching maintenance. Detailed description of each hand tools with
important parameters will prove to be useful to the coaching depot & open line.

It is recommended that Railways may supply these tools/ similar tools to artisan staff so
that they can perform their assigned work efficiently.

I hope this handbook will prove to be useful for the coaching maintenance personnel.

CAMTECH, Gwalior A.R.Tupe


Date : 28th April 2014 Executive Director
Hkwfedk

dk;Z laikfnr djus okys deZpkfj;ksa dks mi;qDr vkStkj Ánku djds dk;Z dh
xq.koRrk ,oa mRikndrk c<+kbZ tk ldrh gSA mi ekud ;k [kjkc xq.koRrk ds gLr vkStkjksa
dk ifj.kke dsoy [kjko vuqj{k.k gh ugha gksrk] vfirq bldk ifj.kke dk;Z djus okys
deZpkjh dk t[eh gksuk] dk;Z laikfnr djus esa vf/kd le; o dkexkjksa dk yxuk] dkexkjksa
dk Fkduk rFkk vekudh; dk;Z dk mRikn ÁkIr gksuk vkfn Hkh gks ldrk gSA
;g gLr iqfLrdk dSeVsd }kjk fofHkUu dsVkfxjh ds fo|qr vuqj{k.k LVkQW ds fy;s
tks dksfpax esaUVhusUl dk;Z esa yxs gq;s gS Þdksfpax vuqj{k.k ds fy, gLr vkStkjß ij cukbZ
xbZ gSA bl gLr iqfLrdk esa fofHkUu vk/kqfud vkStkjksa dk foLr`r fooj.k Hkh lfUufgr gSA
dksfpax fMiks vkSj vksiu ykbu esa yxus okys vkStkjksa dh lwph Hkh bl gLr iqfLrdk esa nh
x;h gSA
;g Li"V fd;k tkrk gS fd ;g gLr iqfLrdk jsYos cksMZ vkj-Mh-,l-vks- vFkok jsYos
}kjk Áfrikfnr funsZ’kksa dks lqijlhM ¼vf/kØe.k½ ugha djrh ;g gLr iqfLrdk oS/kkfud ugha
gSA ofYd blesa lq>k;s x;s funsZ’k dsoy ekxZn’kZu gsrq gSA eS QhYM vfHkdfeZ;ksa dk ân; ls
vkHkkjh gw¡ ftUgksus bl gLriqfLrdk ds lEiknu esa gesa lg;ksx Ánku fd;k gSA
pwfd rduhdh muU;u ,oa f’k{k.k ,d Øfed Áfd;k gS vr% bl gLr iqfLrdk esa
;fn vki dqN tksM+us ;k lq/kkjus dh vko’;drk eglwl djrs gS] rks vki iw.kZr% Lora= gSA
bl fn’kk esa vkids lq>koksa dks ge vR;kf/kd ljkgsxsaA

dSeVsd] Xokfy;j ¼ih;w"k xqIrk½


fnukad % 25-04-2014 funs’kd fo|qr
e - mail id : direlcamtech@gmail.com
PREFACE

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

This handbook on “Hand Tools for Coaching Maintenance” has been prepared by
CAMTECH for different categories of electrical maintenance staff engaged in coaching stock
maintenance. This handbook also contains various modern tools along with their brief
description. Compiled list of hand tools required for coaching depot & open line is available
in this handbook.

It is clarified that this handbook does not supersede any existing provisions laid down
by Railway Board, RDSO or Railways. This hand book is for guidance only and it is not a
statutory document.

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


handbook.

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


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

CAMTECH, Gwalior (Peeyoosh Gupta)


Date: 25th April 2014 Director Electrical
e - mail id : direlcamtech@gmail.com
fo"k; & lwph
CONTENTS

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

ÁkDdFku Foreword iii


Hkwfedk Preface iv
fo"k;&lwph Contents v
la’kks/ku iphZ dk Ádk’ku Correction Slip vi

1. ÁLrkouk INTRODUCTION 01

2. gLr vkStkjksa ds Á;ksx gsrq lqj{kk fu;ekoyh


SAFETY RULES FOR HAND TOOLS 01

3. ,-lh ,LdksfVZax LVkWQ ds fy, ekud VwyfdV esa vkStkjksa dh lwph


LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF 02

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


TOOL KIT FOR TL/AC PASSING STAFF (AT STATIONS) 03

5. Vªsu ykbZfVax vuqj{k.k fMiksa LVkWQ ds fy, vkStkj


TOOLS FOR TL MAINTENANCE DEPOTS 04
5.1 Vh ,y rduhf’k;u ds fy, Vwy fdV Tools kit for TL Fitter 04
5.2 Vªsu ykbZfVax ¼fiV ykbZu½ fMiks esa j[ks tkus okys vkStkj
Tools to Be Kept In TL (Pit Line) Depot 05

6. ,lh dksp vuqj{k.k fMiks ds fy;s vkStkj


TOOLS FOR AC COACH MAINTENANCE DEPOTS 07
6.1 ,lh rduhf’k;u ds fy, Vwy fdV ¼,lh dksp fMiks½
Tools Kit for AC Mechanic (AC Coach Depot) 07
6.2. ,lh dksp fMiks esa j[ks tkus okys vkStkj
Tools to Be Kept In AC Coach Depot 08
Øe la- Sr.No. fooj.k Description i`"B Øekad Page No.

gLr vkStkjksa dk fooj.k DETAILS OF HAND TOOLS 11


1. ckbZfMax bUlwys’ku jftLVsal esljesaV ehVj
Winding Insulation Resistance Measurement 12
2. bUÝkjsM FkeZy besftax dSejk
Infrared Thermal Imaging Camera 13
3. cSVjh pSd djus ds fy;s ijh{k.k midj.k Testing Instruments For Batteries 14
4. ikWoj DokfyVh ,ukykbtj Power Quality Analyzer 16
5. yhdst djaV VsLVj Leakage Current Tester 17
6. vkWVks jsfUtax fMftVy eYVhehVj Auto Ranging Digital Multimeters 18
7. fMthVy esxj Digital Meggar 19
8. fØfEiax Vwy Crimping Tool 20
9. fLVªfiax Iyk;j Stripping Pliers 20
10. okW;j dVj Wire Cutter 20
11. dkWEchus’ku Iyk;j Combination Pliers 21
12. v- VQyksu Vsi ¼20 ,e,e½ a. Teflon Tape (20mm) 21
c- ihohlh Vsi ¼25 ,e,e½ b. PVC Tape (25mm) 21
l- ,ejh DykWFk c. Emery Cloth 21
13 v- cafUpax VkbZ a. Bunching Tie 21
c- ,ejh isij b. Emery Paper 21
14. vkWy ijit lkW All Purpose Saw 22
15. iksVsZoy fo|qr xzkbUMj Portable Electric Grinder 22
16. V~;wo csUMj Tube Bender 23
17. Cyksvj@MLV ,DlVªsDVj Blower/Dust Extractor 23
18. fMftVy fLÁV ysoy Digital Spirit Level 24
19. V~;wo dVj Tube Cutter 24
20. fMthVy FkekZehVj Digital Thermometer 25
21. iafpax Vwy Pinching Tool 25
22. fMftVy ofuZ;j dsyhilZ Digital Vernier Calipers 26
23. fMftVy ekbØksehVj Digital Micrometer 26
24 v- fo|qr lksYMj vk;ju ¼vkbZ,lvkbZ ekdZ½ a. Electric Solder Iron (ISI Mark) 27
c- Mh & lksYMfjax vk;ju b. De- Soldering Iron 27
25. ¶ys;j Vwy Flare Tool 27
26. fMftVy DySEi ehVj Digital Clamp Meters 28
27. ch;fjax iqyj Bearing Pullar 29
28. ,ysu dh lsV Allen Key Set 29
Øe la- Sr.No. fooj.k Description i`"B Øekad Page No.

29. phlyl ¼NSuh½ Chisels 30


30. gSd lkW ¼vkjh½ Hack Saw 30
31. QkbZy ¼jsrh½ File 31
32. gFkkSMk gRFkk lfgr ¼gsej foFk gsfUMy½ Hammer with Handle 31
33. ikbZi fjap Pipe Wrenches 32
34. ,MtsLVsfoy Lisuj Adjustable Spanners 32
35. nksuks fljksa ij [kqys ikus ¼Moy vksiu ,aM Lisuj½ Double Open End Spanners 33
36. fjax Lisujl Ring Spanners 33
37 v- lkWdsV 12-5 ,e,e ¼1@2**½] LDok;j MªkbZo ,.M ,lsljht
a. Sockets- 12.5 Mm (1/2”), Square Drive and Accessories 34
c- VkdZ fjap b. Torque Wrench 34
38. lh DySEi C Clamp 34
39. MLVj Duster 34
40. vkWVksesfVd lSYQ ,MtsfLVax Leky Lisuj Automatic Self-Adjusting Small Spanner 35
41. Lisuj eYVh & fjap ¼jsfpV VkbZi½ 10 bu ou
Spanner Multi-Wrench (Ratchet Type) 10 In One 35
42. eYVh & fjap@Lisuj Multi-Wrench/ Spanner 36
43. jsfpV fjap & jsfpV VkbZi Lisuj Ratchet Wrench-Ratchet Type Spanner 36
44. gkWV ,;j xu@gkWV ,;j Cyksvj Hot Air Gun/Hot Air Blower 37
45. fMftVy ,uheksehVj Digital Anemometer 37
46. ’kkWd iYl ehVj Shock Pulse Meter 38
47. bUÝkjsM VsEijspj xu ¼ghV Vªsdj½ Infrared Temperature Gun (Heat Tracer) 38
48. Vwy oSx Tool Bag 39
50. iksVsZoy ikWoj ,axqyj xzkbMaj Portable Power Angular Grinder 39
51. fMftVy VSdksehVj Digital Tachometer 40
52. eYVh ijit iksVsZoy ikWoj fMªy e’khu
Multi Purpose Portable Power Drill Machine 40
53. fMftVy ykbZV ¼yDl½ ehVj Digital Light (Lux) Meter 41
54. yhfFk;e & yksu Moy LihM dksMZySl fMªy e’khu
Lithium-Ion Two Speed Cordless Drill Machine 41
55. dksMZySl LØwMªkbZoj jhpktsZfoy Cordless Screwdriver Rechargeable 42
56. fu;ksu cYo VsLVj de LØwMªkbZoj lsV ¼8 ux CysM lfgr½
Neons Bulb Tester Cum Screw Driver Set With 8 Nos of Blade. 42
57. ukbZQ lSV Knife Set 43
58 v- okW;j czq’k ¼150 ,e,e½ a. Wire Brush (150mm) 43
c- ukbZyksu czq’k ¼100 ,e,e½ b. Nylon Brush (100mm) 43
l- isaV czq’k c. Paint Brush (75mm) 43
Øe la- Sr.No. fooj.k Description i`"B Øekad Page No.

59. VkspZ ¼,ybZMh½ Torch (Led) 43


60. iksVsZoy LØw tSd Portable Screw Jack 43
62. Vh Lisuj vkWQ lkbZt 10] 13] 15 vkSj 17 T Spanner of Size 10 , 13, 15, 17 44
63. nks ySEi rhu rkj vFkZ VsLVj Tool Lamp Three Wire Earth Tester 44
64. gsyesV Helmet 44
65. VsLV ysEi gksYMj Test Lamp Holder 44

Ifjf’k"V&v ANNEXURE ‘I’ 45


fo|qr ijh{k.k lqfo/kk, TESTING FACILITIES (ELECTRICAL)

Ifjf’k"V&c ANNEXURE’II’ 49
lanHkZ gsrq vko’;d Hkkjrh; ekud ¼vkbZ ,l½
IMPORTANT INDIAN STANDARDS (IS) FOR REFERENCE

Ifjf’k"V&l ANNEXURE ‘III’ 49


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

lanHkZ REFERENCES 50
ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :
CAMTECH/E/2014-15/Coaching Tools/C.S. # XX date---------

Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).

CORRECTION SLIPS ISSUED

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


no. modified
psrkouh
lanHkZ % & vkbZ,l 2615 % 1989 ¼la’kks/ku II – Iyk;lZ] fiullZ rFkk fuIij½

;g lR; gS fd Iyk;lZ] fiullZ


rFkk fuIij ds gsfUMy Áfrjks/kd gksrs
gSA fdUrq fo|qrh; >Vds ls lqjf{kr
gksus dh dksbZ xkjUVh ugha gSA tcfd
Áfrjksf/kr vkStkj mPp oksUVst ds
fy;s Áfrjksf/kr gkrs gSaA ;g
Áfrjks/kdrk vkstkjksa ds vpkud
fxjus] rjyrk dh mifLFkfr]
ijLik;js’ku vkfn ds dkj.k
{kfrxzLr gks tkrh gSA

vr% ;g lq{kko fn;k tkrk gS fd


vkStkjksa ds Áfrjksf/kr gsfUMy ij
iw.kZr% Hkjkslk u djsaA
CAUTION
Ref: IS 2615: 1989 (Revision Second- Pliers, Pincers and Nipper)

The fact that handles of


pliers, pincers and nippers
are insulated is no
guarantee of immunity from
electric shock. Although
insulated tools may have
withstood high voltages,
damage due to subsequent
dropping or the presence of
liquid or perspiration may
impair insulation. It is,
therefore, recommended
that complete reliance
should not be placed on
insulated handles.
CAMTECH/E/2014-15/Coaching Tools/1.0 1

1. ÁLrkouk INTRODUCTION

One of the methods to reduce the down time of the coaching stock is to provide the proper
tools with modern design. Railway Board vide letter No. 2007/M (C) /141/1 dated
12.03.2014 has communicated to take up a project on “Hand-tools for Coaching
Maintenance”.
Availability of proper tools with artisan staff is essential to enhance the productivity
and quality of work. CAMTECH has prepared a handbook enlisting conventional as well as
modern tools which should be available with artisan staff of coaching maintenance depot.
Tools in the form of toolkit have been prepared by CAMTECH. The approximate weight of
all the tools of a kit is not more than 5 kg.

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


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

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

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

2. Always wear safety goggles when using punches, chiesels, hammers and cutting tools.

3. Never use a tool as a hammer unless manufactured for that purpose.

4. Never use a pipe extension to increase the leverage of any wrench.

5. Adjustable wrenches should be tightly adjusted to the nut and pulled so that the force is
on the side of the fixed jaw.

6. Never use a pipe wrench to bend, raise or lift a pipe.

7. Ratchet mechanisms should be cleaned and lubricated periodically with light grade oil.

8. Keep hammer heads tight on the handle. Never use a hammer with a loose or damaged
handle.

9. Metal cutting chiesels are intended for cutting, shaping and removing metal softer than
the cutting edge itself.

10. Always strike the struck base of a chiesel or punch. The striking face of the hammer
should have a dia. approximately 10 mm larger than the struck face of the punch or
chiesel.

11. Never use screw drivers with rounded tips.

12. Never use a screwdriver as a chiesel, punch, scraper or pry bar. Use screw driver for
screw driving only.

Hand-Tools for Coaching Maintenance April, 2014


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

3. ,-lh ,LdksfVZax LVkWQ ds fy, ekud VwyfdV esa vkStkjksa dh lwph


LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF
(Circulated vide RDSO letter No. EL/7.2.2 dated 17.01.2006)
(In Proper Tool Bag)

S.No. Description Qty Reference


Sr.No.

1. Tool box of size 325x440x120 mm (Approx.) with fixing 1 set 48


arrangement for tools and locking arrangement with 2 no.
keys

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

3. Combination plier insulated with thick CA sleeve with joint 1 11a


cutter length 205 mm

4. Digital multimeter 1 06

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

6. Panel key square type ¼ size suitable for opening of control 1 --


panel of AC coaches

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

8. Test lamp holder (brass) fitted with two mtrs. of 2 core 1 65


flexible copper wire

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

10. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 1 set 35
16/17, 18/19, 20/22

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

12. Heavy duty cable cutting knife adjustable in aluminium 1 57


casing over all size 140 mm

13. Adjustable spanner length 255 mm 1 34

14. Infrared Digital Thermometer (Temperature gun) 1 47

15. Insulated Nose plier 6” 1 11h

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

17. Hammer ½ kg 1 32b

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

19. PVC Insulating tape 25 mm 1 12b

20. Wire fuse 1 --

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 3

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


TOOL KIT FOR TL/AC MAINTENANCE PASSING STAFF (AT STATIONS)
(In proper tool bag)

S. Referene
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 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 no. 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. Adjustable spanner length 255 mm 1 no. 34

8. Test lamp holder (brass) fitted with two mtrs. of 2 1 no. 65b
core flexible copper wire

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

10. Flat file 150 mm 1 no. 31

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

12. Torch with cell, LED 1 no. 59

13. Fuse puller 150mm 1 no. 11b

14. Digital Multimeter with tongue tester 1 no. 26

15. PVC Insulating Tape 25mm 01 roll 12b

16. Heavy duty cable cutting knife adjustable in 01 no. 57


aluminium casing over all size 140 mm

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

18. Chiesel 150 mm 01 no. 29

19. Fuse Wires 01 set --

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

21. Capacitor for AC fan 03 nos. --

Hand-Tools for Coaching Maintenance April, 2014


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

5. Vªsu ykbZfVax vuqj{k.k fMiksa LVkWQ ds fy, vkStkj


TOOLS FOR TL MAINTENANCE DEPOTS

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


(In Proper Tool Bag)

S. 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 --

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 5

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

S. Name of Tool Reference


Sr.No.
1. Combination plier insulated with thick CA sleeve with joint 11a
cutter length 205 mm
2. Insulated Wire Stripper & Cutter 16 sqmm 09
3. Insulated Long Nose Pliers 6” 11h
4. Neon bulb tester cum Screw driver set with 8 nos of 56
blade similar to Jhalani P. No. 830 or equivalent
5. 4 way keys --
6. Ring spanner set ( 8- 32) 36
7. Set of box spanner with 1/2" socket set containing 37a
19 socket (11 to 32) and 6 attachment
8. Double open end spanner set ( 8 - 32) 35a
9. Single end open Spanner (36mm) 35b
10. Allen Key set 28
11. Adjustable spanner length 255 mm 34
12. Test lamp holder (brass) fitted with two mtrs. of 2 65b
core flexible copper wire
13. Hacksaw frame with blade (12") + Extra Blades 30
14. Flat, round, triangular files 31
15. Ball pein Hammer ( 200gm, 300gm, 500gm, 800 gm, 1kg) 32b
16. Nylon hammer 32a
17. Chiesel flat 150mm 29
18. Infrared Digital Thermometer (Temperature gun) 47
19. Torch, 4 cell, LED for each staff 59
20. Fuse puller 6” 11b
21. Crimping tool ( 0.5 - 1.6 mm2 ) 08
22. Crimping tool (1.5 - 16 mm2 ) 08
23. Hydraulic crimping machine (upto 300 mm²) 08b
24. Heavy duty cable cutting knife adjustable in 57
aluminium casing over all size 140 mm
25. Multipurpose Portable power drill machine 52

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

S. Name of Tool Reference


Sr.No.
26. Auto ranging Digital Multimeter 06
27. Hydrometer 3c
28. Digital clamp meter 26
29. Bearing/ Pulley Puller 27
30. Pulley V groove “GO” , “NO GO” gauge Testing 9
31. Portable electric straight grinder 15
32. Digital lux meter 53
33. Cell tester (0-12) V DC 03b
34. Digital Tachometer 51
35. Digital Vernier caliper 22
36. Digital Micrometer 23
37. Digital Meggar 07
(500 V to 5000 V )
38. Heavy duty Pipe wrench 33
39. Soldering iron 24a
40. De-soldering gun 24b
41. Hot air gun / Hot air blower 44
42. Portable Blower / Dust extractor 17
43. 1/2" socket set containing 19 socket (11 to 32) with 37a
6 attachment
44. Torque wrench 0-5kg-m 37b
45. Shock pulse meter (SPM) 46
46. All purpose saw 14
47. Infrared Digital Thermometer 47
48. Cable cutter 150mm 10
49. Insulating Tapes 25mm 12b
50. Safety helmet for each staff 64
51. Gum boot for each staff 61
52. Tool bag for each technician 48

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 7

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TOOLS FOR AC COACH MAINTENANCE DEPOTS

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

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 --

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

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Tools to be kept in AC Coach Depot
(Qty. will be decided by divisional officers depending upon work load)

S.No. Name of Tools Reference


Sr.No.
1. Combination plier insulated with thick CA sleeve with joint 11a
cutter length 205 mm
2. Insulated Wire Stripper & Cutter 16 sqmm 09
3. Insulated Nose plier 6” 11h
4. Neon bulb tester cum Screw driver set with 8 nos of blade 56
equivalent
5. 4 way key --
6. Ring spanner set ( 8- 32) 36
7. Set of box spanner with 1/2" socket set containing 19 37a
socket (11 to 32) and 6 attachment
8. Double open end spanner set ( 8 - 32) 35a
9. Single end open Spanner (36mm) 35b
10. T spanner set 62
11. Allen Key set 28
12. Adjustable spanner length 255 mm 34
13. Test lamp/ Hand lamp 65b
14. Hacksaw frame with blade (12") + extra blades 30
15. Flat round, file 31
16. Ball pein Hammer 200 gm, 500gm, 1kg. 32b
17. Nylon hammer 100gm 32a
18. Chiesel (Flat) - 8" 29
19. C Clamp 38
20. Crimping tool (0.5 - 6 mm²) 08
21. Crimping tool (1.5 -1 6 mm²) 08
22. Pinching tool 21
23. Tube bender (3/8", 5/8", 7/8") 16
24. Flare tool 25
25. Tube cutter 19
26. Torch (4 cell) + extra cells for each staff 59
27. Digital Tachometer 51
28. Digital Clamp meter 26

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CAMTECH/E/2014-15/Coaching Tools/1.0 9

S.No. Name of Tools Reference


Sr.No.
29. Hydrometer 03c
30. Auto ranging Digital Multimeter 06
31. Cell tester (0-12) volt DC 3b
32. Battery analyzer 3a
33. Digital meggar ( 500 V, 1000 V, 2500V, 5000V) 7
34. Digital Micrometer 23
35. Digital Vernier calipers 22
36. Blower / Dust extractor 17
37. Portable electric straight grinder 15
38. Torque wrenches 37b
39. Pipe wrench 33
40. Multipurpose Portable Power drill machine 52
41. Soldering iron 24a
42. De-soldering Gun 24b
43. Hot air gun / Hot air blower 44
44. Shock pulse meter (SPM) 46
45. All purpose saw 14
46. Pulley V groove “GO” , “NO GO” gauge Testing 9
47. Pulley/ Bearing puller 27
48. Digital Anemometer 45
49. Infrared Digital thermometer (Temperautre gun) 47
50. Digital lux meter 53
51. Winding insulation Resistance meter 01
52. Cable cutter/ wire cutter 10
53. Gum boot for each staff 61
54. Infrared thermal imaging camera 02
55. Power quality analyzer 04
56. Leakage current tester 05
57. Fuse puller 11b
58. Teflon tape 12a
59. PVC tape 12b
60. Bunching tie 13a
61. Amery paper 13s

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

S.No. Name of Tools Reference


Sr.No.
62. Amery cloth 13c
63. Digital spirit level 18
64. Digital thermometer 20
65. Duster cloth 39
66. Automatic self adjusting small spanner 40
67. Spanner multi wrench 10 in one 41
68. Multi wrench/ Spanner 42
69. Ratchet wrench – Ratchet type spanner 43
70. Angular grinder 50
71. Cord less drill machine 54
72. Cord less screw driver 55
73. Knife set 57
74. Wire brush 58a
75. Nylon brush 58b
76. Paint brush 58c
77. Portable screw jack 60
78. Safety helmet for each staff 64
79. Tool Bag for each technician 48

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 11

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Details
of
Hand Tools

Hand-Tools for Coaching Maintenance April, 2014


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

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WINDING INSULATION RESISTANCE MEASUREMENT

Name of equipment : Winding insulation resistance meter

Application : To measure Insulation Resistance of all voltage


components like transformer winding, CTs, PTs,
bushings, cables, motor and Alternator windings etc.

Make : Indigenious

Technical Specifications :

Test voltage 500 V to 5000 V DC

IR Range 0 – 5 TΩ

Accuracy As per IS 2992

Display Digital

Short circuit current < 2mA

Advantages:
i. Healthiness of winding insulation can be checked.
ii. The equipment has a LED based provision for visual indication for discharge
condition. This LED shall glow after the HT is switch OFF, till the voltage on test
object/ HV terminal is below 50 V approximate.
iii. Equipment have HV, LV & Guard and Internal discharge of object after test, memory
for measurement results, ability to transfer the data to a PC, polarization index and
dielectric absorption ratio.

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2. bUÝkjsM FkeZy besftax dSejk INFRARED THERMAL IMAGING CAMERA

Name of instrument Infrared thermal imaging camera


Application Thermal imaging infrared camera identifies electrical and
mechanical problems like hot spots, heat development on
loose connections etc. before they result in failures.
It is a non-contact device which detects infrared radiations
and converts it into electronic signals. These signals are then
processed to produce thermal image of the object.
Make Indigenious

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


1. Temperature measurement range from – 20°C to 1200°C.
2. Temperature measurement accuracy of ± 2%; ± 2°C of
reading
3. Image quality of 200 x 150 pixels
4. Thermal sensitivity of 0.1°C
5. IFOV of lens should be 2.18 mrad or less.
6. Spectral range of 7.5 to 13 μm
7. Built in digital visual camera of 1.3 m pixels
8. Standard lens with FOV of 25° x 19°
9. Permissible relative humidity range 10% to 95% non-
condensing
10. Operating & storage temperature range with all accessories in
-15°C to 50°C & -40°C to 70°C respectively.
11. Software should have the feature to prepared report & can be
saved in PDF format.
12. At least 3 palettes should be available with 2 color palettes;
grey with white hot & grey with black hot etc.
13. LCD color display 3.5 should be available in camera.
14. Data can be stored in removable SD card with storage
capacity of 1000 + images
15. Menu operation should be available via touch screen as well
as via toggle button.
16. Auto focuses facility available in camera along with manual
focus.
17. Focusable from 0.4mt. to infinity.

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

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.

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TESTING INSTRUMENTS FOR BATTERIES

Repeated recharging of a secondary battery can lead to


battery deterioration and increase in its internal resistance.
Problem can intensify when there is a short circuit in the internal
cell leading to voltage drop, increase in internal resistance,
overheating and complete battery malfunction. These problems
can cause severe fires and other accidents.

It is important and necessary to conduct battery testing to


check the above defects periodically.

Following parameters can be checked to determine the health of the battery:


• Voltage
• Impedance
• Specific gravity
• Sulfation (relative to the amount of battery charge capacity degradation
due to sulfation)
• Dryout (relative to the amount of battery charge capacity degradation
due to dryout)

a. Battery Analyser b. Cell Tester c. Hydrometer

Name of instrument Electro chemical battery analyser


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

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

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.

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

iii. It can memorize the value on the spot.


iv. It can enhance resistance against noise.

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

4. ikWoj DokfyVh ,ukykbtj POWER QUALITY ANALYZER

Power Quality Analyzer for energy analysis


Included accessories
• i430-Flexipack 4 current clamps
• 5 Test leads, 4 black, 1 green
• 5 Alligator clips, 4 black, 1 green
• BC430 Battery charger eliminator
• Power Log Software
• OC4USB Optical cable for USB
• WC100 Color localization set
• Getting Started (booklet)
• User Manual (CD-ROM

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

Make Indigenious or similar.

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CAMTECH/E/2014-15/Coaching Tools/1.0 17

5. yhdst djaV VsLVj LEAKAGE CURRENT TESTER

Name : Leakage Current tester

Application : For measuring AC leakage current blowing into


ground conductor.

Make : Indigenious

Features
• 10 A Ultra High resolution
• Large conductor diameter (30mm)
• AC current in 5 Ranges (40mA, 400mA, 4A, 40A,
60A)
• Wide Frequency response (40Hz - 1 KHz)
• ACA, ACV, and Continuity
• Large 3¾ Digit LCD (4000 Count) with 40 segment bargraph
• Fast bargraph display (20 times/sec.)
• Data hold and Max. Min hold
• Relative measurement
• 600 V rms overload protection in resistance range

Specification

Conductor size 30mm. max. (approx.)


Battery Type Two 1.5V SUM-3
Display 3¼ LCD with 40 segment bargraph
Range Selection Manual
Overload Indication OL
Power Consumption 15mA (approx.)
Low battery indication B
Sampling Time 2 time/sec. (display)
30 time/sec. (bar graph)
Operating Environment -10° to 50°C, RH < 85%
Storage Environment -20°C to 60°C, RH < 75%
Altitude up to 2000M
Dimensions 210 (H) x 72(w) x 36(D) mm
Weight 210 gm (battery included)
Accessories Carrying Case x 1
Users manual x 1
1.5V Battery x 2
Test leads x 1 pair

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

6. vkWVks jsfUtax fMftVy eYVhehVj AUTO RANGING DIGITAL MULTIMETERS

Name : Auto Ranging Digital Multimeter


Application : Measurement of voltage, current resistance, checking of continuity
Specification :
Display Auto/ Manual ranging, 33/4 Digit 3400 count LCD with
Analog bargraph
DC Voltage 340mV/3.4/34/340/1000V
± (0.5%rdg + 4 dgt) on 340mV/ 3.4V
± (0.7%rdg + 4 dgt) on 34/340V
± (1.0%rdg + 4 dgt) on 1000V
AC Voltage 3.4/34/340/750V
± (1.0%rdg + 8 dgt) on all ranges except
± (1.5%rdg + 8 dgt) on 750V
DC Current 340μA/3.4/34/340mA/3.4/20A
± (1.5%rdg + 8 dgt)
AC Current 340μA/3.4/34/340mA/3.4/20A
± (2.2%rdg + 4 dgt)
Resistance 340Ω/3.4/34/340kΩ/3.4/34MΩ
± (0.7%rdg + 4 dgt) on all ranges except
± (1.2rdg + 4 dgt) on 3.4MΩ
± (2.5%rdg + 4 dgt) on 34MΩ
Diode Yes
Continuity Buzzer Yes
Full Icon Display Yes
Auto power off/ Steep mode Yes
Low battery display "BATT" is indicated
Input impedance (Voltage) 10 MΩ
Power One 9V battery
Battery life 200 hours typical
LCD digit size 17 mm

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 19

7. fMthVy esxj DIGITAL MEGGAR

Name : Digital Insulation tester


Application : Insulation measurement of cables, motors, transformers etc.
Make : Indigenious
Features :
• 3½ Digit (1999 counts) Large LCD Display.
• High accuracy ± (3% rdg + 5 digit) for Insulation Measurement ±
(2% rdg + 5 digit) fr AC voltage measurement.
• Range selection & single person push button operation.
• LCD back light function with indicator switch
• Data holding function, fnction icons on display.
• measurement of AC voltage upto 600 V AC
• Measurement of phase sequence between (Phase- Phase voltages)
with LED indicators and beep facility.
• Auto range (Insulation test)
• LED indicator for HV (High Voltage)
• Inbuilt Protection circuit to prevent the harm of revenue voltages.
• Battery operated with AC adaptor
• 3 Ranges of Voltage & Insulation resistance
Specification :
Insulation resistance
Test voltage : 1000V/ 2500V/ 5000V
Range : 0.1MΩ
Accuracy : ± (3% rdg + 5 dgt.)
Resolution : 0.01MΩ
AC Voltage Measurement
Test voltage : 0 – 600V AC (50-60Hz)
Accuracy : ± (2% rdg + 5 dgt.)
Resolution : 1V
Phase sequence test
Test voltage : 100V – 450V (Phase – Phase) 40 – 60 Hz

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

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


digit height
Accuracy ± (3% rdg + 5 digit) for insulation resistance
± (2% rdg + 5 digit) for AC voltage
Power 12V (8 x 1.5V) (R6AA size batteries) or AC adaptor
12V DC
8. fØfEiax Vwy CRIMPING TOOL

Name : Crimping Tool


Availability : Available in local market in major cities.

9. fLVªfiax Iyk;j STRIPPING PLIERS

Name : Stripping Pliers IS: 087


Application : Removing of wire insulation for termination.
Size : Strips wire up to 7/8" or 4mm2
Features : Automatic feature holds jaws open to remove wire without crushing
ends. Practically eliminates all nicking, cutting, or fraying. Strips
teflon, silicon and PVC wire. Made of aluminium with plastic
molded handles.

10. okW;j dVj WIRE CUTTER

Name : Wire Cutter, IS: 4378-1990


Application : Cutting of cables, wires (solid /
stranded) upto 10mm2 length
160mm approx.

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

Availability : Available in local market in major cities.

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 21

11. dkWEchus’ku Iyk;j COMBINATION PLIERS


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

a.

b. c. d. e. f. g. h.

12.a) TEFLON TAPE (20mm) b) PVC TAPE (25mm)


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13a. BUNCHING TIE 13b. EMERY PAPER 13c. EMERY CLOTH


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Hand-Tools for Coaching Maintenance April, 2014


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

14. vkWy ijit lkW ALL PURPOSE SAW

Name : All Purpose Saw


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

Saw in wood 130 MM


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

15. iksVsZoy fo|qr xzkbUMj PORTABLE ELECTRIC GRINDER

Name : Straight Grinder


Application : For grinding, sanding, rust removing etc.
Specifications :

Grinding points MAX. 25 MM DIA


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

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 23

16. V~;wo csUMj TUBE BENDER

Name of Tool : Tube Bender

Application : For bending copper tubes used in air conditioning

Description : Calibrated angle marking from 10° to 180° for left, right or offset
bends. Made of tie cast alloy .

Available Sizes : 3/8", 5/8", 7/8".

Availability : Available in local market in major cities.

17. Cyksvj@MLV ,DlVªsDVj BLOWER/DUST EXTRACTOR

Name : Blower/Dust Extractor


Application : Blowing of dust from equipment.
Make : Indigineous
Model : GBL 550
Specifications :

Power input 550 W


Pressure 800 mm Aq
Air volume 2.7 M3/Min.
Weight 1.7 Kgs.

Availability : Local market in major cities

Hand-Tools for Coaching Maintenance April, 2014


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

18. fMftVy fLÁV ysoy DIGITAL SPIRIT LEVEL

Name : Digital Spirit Level

Application : Checking of alignment of foundations of pumps,


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

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

19. V~;wo dVj TUBE CUTTER

Name of Tool : Tube Cutter

Application : To cut copper tubes used in air-conditioning.

Features : Larger knob for greater torque, harden flare grooved roller

Size : 1/8" to 7/8"

Availability : Available in Local market in major cities.

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 25

20. fMftVy FkekZehVj DIGITAL THERMOMETER

Name : Digital Thermometer

Application : For measuring the temperature and relative humidity.

Features : Simulteneous readout of °C or °F (switchable) and % RH.


Minimum/ Maximum memory functions for both temperature
and humidity

Specification :

Range 30 to 90% RH, 0-50 °C Temp.


Resolution 1% RH, 0.1°F or °C

Availability : Available in Local market in major cities.

21. iafpax Vwy PINCHING TOOL

Name of Tool : Pinching Tool

Application : For squeezing the copper tube used in air-conditioning.

Feature : Product based on IS: 10372

Size : 1/4"

Availability : Available in Local market in major cities.

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

22. fMftVy ofuZ;j dsyhilZ DIGITAL VERNIER CALIPERS

Name : Digital Vernier Calipers


Application : Measurement of depths, gaps, thickness, outside and inside diameters etc.
Specification :
Measuring range 0 - 200 mm
Resolution 0.01 mm
Instrumental error + 0.03 mm or + .0015"/+0.03 mm
Repeatability 0.01 mm or .0005"/0.01 mm
Maximum response speed Not particularly provided
(No counting error due to scale speed)
Power supply SR44 (silver oxide cell, 1 pc
Battery life 3.5 years under normal use
Operation temperature 00C to 400C
Storage temperature -100C to 600C
Availability : Available in Local market in major cities.

23. fMftVy ekbØksehVj DIGITAL MICROMETER

Name : Digital Micrometer


Application : Measurement of small thickness and diameters of wires etc.
Specification :
Measuring range 0 - 25 mm
Instrumental error (20°C) ± (L/75)
Resolution 0.001 mm (.0005")
Quantizing error ± 1 count
Measuring force 5 to 10N
Display LCD (6 digits and a minus sign)
Power Supply SR44x1
Battery life 1.2 years
Operation temperature 50C to 400C
Storage temperature -100C to 600C
Availability : Available in Local market in major cities.

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CAMTECH/E/2014-15/Coaching Tools/1.0 27

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

Name : Electric Solder Iron (ISI mark)


230V – 35w

Applications : To solder joint


Description : Rugged, manual loading tool for volume de-soldering. High
vacuum heavy-duty plastic, fully enclosed shaft for safety.
Plunger locks for compact storage.
Availability : Available in Local market in major cities.

24b. Mh & lksYMfjax vk;ju DE- SOLDERING IRON


Name : De-Soldering Iron
Applications : Removal of solder joint
Description : Rugged, manual loading tool for volume
de-soldering. High vacuum heavy-duty
plastic, fully enclosed shaft for safety.
Plunger locks for compact storage.
Availability : Available in Local market in major
cities.

25. ¶ys;j Vwy FLARE TOOL

Name of Tool : Flare Tool


Application : For making flare shape for
copper pipes used in air-
conditioning.
Availability : Available in local market in
major cities.

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

26. fMftVy DySEi ehVj DIGITAL CLAMP METERS

Name : Digital Clamp meter


Application : On line measurement of current, voltage, resistance, frequency
Specification :
AC Current 20A, 200A, 1000 A
Accuracy ± (2%rdg + 4 dgt) on 200/1000A
± (3%rdg + 4 dgt) on 20A
Over load 1000 A AC max. for 1 min.
AC Voltage 200v, 750V (50-500 Hz)
Accuracy ± (1.2%rdg + 4 dgt) on 200V
± (1.5%rdg + 4 dgt) on 750V
DC Voltage 2V( in 2250 only), 200V, 1000V
Accuracy ± (0.5%rdg + 1 dgt) on all ranges
Resistance 200Ω, 200KΩ
Frequency 10 Hz - 34 MHz
(± 1%rdg + 2 dgt)
Accuracy ± (1%rdg + 1 dgt) on all ranges in 2250 and
± (1.5%rdg + 3 dgt) on all ranges in 2250F
Audible continuity diode test One 9 V battery
function power
Battery life 200 hours typical
Low battery "BATT" is indicated in 2250
Dimension 250(H)x98(W)x35(D)mm
Weight 400 gms approx.
Accuracy Supplied with a pair of test leads, carrying
case, battery and instruction manual
Jaw opening 55mm max.

Availability : Available in Local market in major cities.

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 29

27. ch;fjax iqyj BEARING PULLAR

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


1979

Material : Legs, housing, central bolt and link plates shall be


made from suitable alloy steel meeting with the
requirement.

Hardness : Legs - 400 – 450 HV (≈ 40 – 45 HRC)


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

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

Type Minimum test load N


Three leg 98000

Type Range Reach (mm) Width across Central Bolt


flats of Size
central bolt
(mm)
Three leg Min. 36 130 24 M22 x 1.5
Max. 250

28. ,ysu dh lsV ALLEN KEY SET


IS 3082 1988

Description : Chrome Vanadium Steel, Burnished finish


Generally conforming to IS 3082-1988
Range of set No. of pieces
1.5-10 mm 09
(1.5mm, 2mm, 2.5mm, 3mm, 4mm, 5mm,
6mm, 8mm, 10mm)

Hand-Tools for Coaching Maintenance April, 2014


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

29. phlyl ¼NSuh½ CHISELS

Description : Octagonal Chiesel made from high grade steel, forged and ground.
Differential heat treatment for cutting edge and striking end to ensure
long life.
As per IS 402/ 1990
Length In mm Cutting Edge in mm
150 16
200 25
250 30
300 32

Flat Chiesel

Length In mm Cutting Edge in mm


150 25
200 25
250 25

30. gSd lkW ¼vkjh½ HACK SAW

Description : Generally Conforming to IS: 2594

Dimensions for type C Straight Adjustable Flat Hacksaw


Nominal size L
250, 300

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 31

31. QkbZy ¼jsrh½ FILE

Description : Engineer’s file with plastic handle


Generally Conforming to IS 1931-1962

Description Finish Size (mm)


Flat file Bastard 200
Flat file Bastard 300
Flat file Smooth 200
Flat file Smooth 300
Half round file Bastard 200
Half round file Bastard 300
Half round file Smooth 200
Half round file Smooth 300
Round file Bastard 200
Round file Bastard 250
Round file Smooth 150
Round file Smooth 250

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

a) Nylon Hammer b. Ball Pein Hammer

Description : Head drop forged from high grade steel and heat treated with good
quality knotless seasoned wooden handles.
(Ball Pein, Cross pein)

Head as per IS 841-1983

Ball pein and Cross pein Weight in gms.


200
500
600
800

Hand-Tools for Coaching Maintenance April, 2014


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

33. ikbZi fjap PIPE WRENCHES

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


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

IS 4003 Part II 1986


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

34. ,MtsLVsfoy Lisuj ADJUSTABLE SPANNERS

Description : Standard pattern Chrome Vanadium steel Generally Conforming to


IS 6149-1984 Grade II

Length (mm) Capacity (mm) Black Phosphate Finish


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

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 33

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

a. Spanner Double ended b. Single end Spanner


Description : Drop forged Chrome Vanadium Steel, Chrome Plated, Generally
Conforming IS 2028-2004 Rev. V or latest.
Size in mm Size in Inch
6x7 3/8 x 7/16
8x9 9/16 x 5/8
10 x 11 5/8 x 3/4
12 x 13 3/4 x 7/8
14 x 15
16 x 17
18 x 19
20 x 22
21 x 23
24 x 26
25 x 27
30 x 32
30 x 36

36. fjax Lisujl RING SPANNERS

Bi-hexagonal and Hexagonal

Deep Off Set


Description : Chrome vanadium steel,
Chrome plated polish
Generally Conforming to IS-2029-1998 (Rev.IV)
Range of set No. of pieces
6-22 mm 08
6-32 mm 12

No. of Pieces Contents


Size M
6 6x7, 8x9, 10x11, 12x13,14x15, 16x17
6 16x17,18x19,20x22, 24x26, 25x28,30x32
6 1/8x3/16,3/16x1/4,
¼x5/16,5/16x3/8,3/8x7/16,7/16x1/2

Hand-Tools for Coaching Maintenance April, 2014


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

37a. SOCKETS- 12.5 MM (1/2”), SQUARE DRIVE AND ACCESSORIES


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

b. Torque Wrench
c- VkdZ fjap

Description: High Grade Chrome Vanadium Steel.


As per IS 6131-1980 & 7381-1986
Bi-hexagonal & Hexagonal One Set

Product Item Sockets (mm)


22 Sockets 10,11,12,13,14,15,16,17,18,19,21,22,23,24,26,27,28,29,30,32,33,34
5 Accessories Extension bar 125mm,255mm, Universal joint T Handle ,
Ratchet Handle

38. lh DySEi C. CLAMP

Length in mm
105
205

39. MLVj DUSTER

Feature : Khadi cloth


Use : Dusting work,panel,
window glass etc cleaning
work.

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 35

40. vkWVksesfVd lSYQ ,MtsfLVax Leky Lisuj


AUTOMATIC SELF-ADJUSTING SMALL SPANNER

Description: Automatic self- adjusting small spanner having functional capacity A/F 6
mm to 22 mm or SAE A/F 1/4" to 7/8"

Material: - Alloy steel duly hardened jaw, nylon 6 moulded upon steel strip & insulated
up to -1000 volts and stainless steel rivet.
(Source of supply – M/s. A Dinisha Marketing Co./ Everest Tools or similar.

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


SPANNER MULTI-WRENCH (RATCHET TYPE) 10 IN ONE

Description: Spanner multi-wrench (ratchet type) -16 effective sizes in one wrench
having functional capacity A/F 10,12,16,17,19 mm & BS 1/4", 4/16,
3/8", 7/16", 1/2" 1/2".

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

Hand-Tools for Coaching Maintenance April, 2014


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

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

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


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

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

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

Description: Ratchet wrench- ratchet type spanner (12 sizes of MM & 5 sizes of SAE
in three wrenches). The three spanners cover 12 sizes in MM –
8,10,11,12,13,15,16,17,18,19,21,22.

Material:- Alloy steel duly hardened.


(Source of supply – M/s. A Dinisha Marketing Co. ./Everest tools or
similar

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 37

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

Name : Hot Air Gun/Hot Air Blower


Application : Drying of moisture of silica jel, drying of varnish of motors
coil, drying of moisture of control panels, relays, CTs, PTs etc.
Specifications :
Rated power consumption 2000 W
Temperature range 100-6000 C
Air flow rate 350-550 Lit/min
Stepless temp. control Yes
Airflow regulation 2 stage
Weight 0.7 Kgs.
Availability : Available in Local market in major cities.

45. fMftVy ,uheksehVj


DIGITAL ANEMOMETER

Name : Digital Hygro Anemometer


Application : To measure the air flow velocity of blowers
Specification :
Range Resolution Accuracy
Air Flow 80 - 4000 ft/min. 1 +/- 3% FS
0.4 - 20 m/sec 0.01 m/s +/- 3% FS
Battery Life 100 Hours
Display Size 37mm x 42mm
Display Type LCD
Temp. -10°C to 50° C 0.1 +/- 1.0°C
+14°F to 122°F 0.1 +/- 2.0 °F
Range
Max. Reading 9999
Dimensions 133 mm(L) x 51mm (W) x 25mm (D)
Fan Diameter 70mm ( 2 7/8")
Weight 135 gms with battery (Approx.)

Availability : : Any approved source

Hand-Tools for Coaching Maintenance April, 2014


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

46. ’kkWd iYl ehVj SHOCK PULSE METER

Name : Shock Pulse Meter


Application : Used for monitoring health of bearings of pump motors,
DG sets, alternators, compressor motors & other motors.
Specifications :
Measuring range, SPM -9 to 99 dbsv
Resolution, SPM 1 dbsv
Measuring range, VIB 0.5 to 99.9 mm/s RMS
Resolution, VIB 0.1 mm/s
Measuring range, TAC 10 to 20 000 r.p.m. optical
Measuring distance max. 0.6 m
Resolution, TAC 1 r.p.m.
Temperature range 0° to 50°C
Power 6 x 1.5 V LR6 cells
Display Liquid crystal
Dimensions 300 x 150 x 85 mm
Weight 0.85 Kgs.
Availability : Indigenous

47. bUÝkjsM VsEijspj xu ¼ghV Vªsdj½


INFRARED TEMPERATURE GUN (HEAT TRACER)
Name : Infra Red Heat Tracer

Application : Measurement of temperature of joints,


connectors and other electrical equipments.
Specification : Battery operated non contact thermometer
suitable to read -32 to 600° C with circular
laser beam and LED display.
Temperature range - 32 to 600° C
Repeatability ≤ ± 0.5 % or ≤ ± 1°C (± 2°F), whichever is greater
Response time ≤ 0.5 Sec, 95% response
Ambient operating range 0 to 50 °C
Power 9 v Alkaline or Ni Cd Battery
Weight 320 gms.
Distance to spot 30 : 1
Laser Sighting Offset 8 Point circular
Data logging 12 point
Display resolution 0.1 °C/ F

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 39

48. Vwy oSx TOOL BAG

Source of supply : Available in local


market in major
cities.

49. vYVjusVj fyf¶Vax tSd


ALTERNATOR LIFTING JACK

50. iksVsZoy ikWoj ,axqyj xzkbMaj


PORTABLE POWER ANGULAR GRINDER

Name : Angular Grinder


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

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

Availability : Indigenous

Hand-Tools for Coaching Maintenance April, 2014


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

51. fMftVy VSdksehVj DIGITAL TACHOMETER

Name : Digital Tachometer


Application : Safe and accurate measurement of RPM
without attachment to the motor or any
other rotary object.
Description : Non contact type MASTECH brand digital
tachometer, Model DT - 2234A having
measurement ranges 5 to 99999 RPM
complete with brief case type carrying case,
reflective tape and batteries.
Specification :
Test range 5 to 99999 RPM ± 0.05 %
Sampling time 1 Second (Over 60 RPM)
Test range select Automatic
Memory Last value, Max. value, Min. value
Detecting distance 50 to 150 mm (Max. 300 mm)
Max. display/ LCD size 99999/ 18.5 x 48 mm
Dimension 72 x 190 x 38 mm
Weight 250 g
Availability : Any approved make

52. eYVh ijit iksVsZoy ikWoj fMªy e’khu


MULTI PURPOSE PORTABLE POWER DRILL MACHINE

Name : Multi purpose portable power drill machine


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

Availability : ISI marked and approved make from market

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 41

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

Name : Digital Light (Lux) Meter

Application : For measuring the


intensity of light.
Features
• Wide light range
• Remote light sensor
• Cosine and color
corrected
• Compact & light weight
• Low battery indication
Specification :

Range/ Resolution Accuracy


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

Availability : Indigenous

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


LITHIUM-ION TWO SPEED CORDLESS DRILL MACHINE
¾ Compact design with Li-ion battery,
light weight, ideal for tight space or
overhead working
¾ 18 stage cluth for precise torque setting
¾ 2 Speed: High-low mechanical switch
over
¾ Fan-cooled motor with long lasting
motor life
¾ LED Working light
¾ Easy-to-operate push button reversing
switch
¾ Soft grip handle for anti-slip and
comfortable use
¾ Variable-speed Reversing Trigger For
accurate bit starting as well as removing
fasteners or bound bits and with
electric feedback for increased power and control.
Specification
Item Parameter
No-load Speed: 0-350r/min,0-1350r/min
Keyless Chuck 0.8~10 mm
Max Troque 30 N.m
Battery: Lithium-ion 12V~1400Amh
Charger 60mins fast charger

Hand-Tools for Coaching Maintenance April, 2014


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

55. dksMZySl LØwMªkbZoj jhpktsZfoy


CORDLESS SCREWDRIVER RECHARGEABLE
• Brand: Rolson

• Type: Electronic screwdriver

• Dimensions: 27X21X7 cm

• Colour: Black & sliver

• Material: PVC & metal

• A cordless screwdriver that includes 4 bits,


slotted 4.5 mm

• Helps illuminate dark work areas

• Features LED battery level indicator

• Has a 4.8 V rechargeable tool

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

• See package for detailed technical specifications

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


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

PCS, Screw driver set consisting of:


Handle with phase tester ranging 80V to 500V
Philips 3.5 x 125, PH0 Philips 5 x 125,
Engg. S. Driver 3.5 x 125, 5 x 125
Engg. S.Driver 6 x 125
Poker 125

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 43

57. ukbZQ lSV KNIFE SET

58a. okW;j czq’k ¼150 ,e,e½ c- ukbZyksu czq’k ¼100 ,e,e½ l- isaV czq’k ¼75 ,e,e½
WIRE BRUSH b. NYLON BRUSH c. PAINT BRUSH
(150mm) (100mm) (75mm)

59. VkspZ ¼,ybZMh½ TORCH (LED)

60. iksVsZoy LØw tSd


PORTABLE SCREW JACK
(100 kg capacity)

61. xe cwV GUM BOOT

Hand-Tools for Coaching Maintenance April, 2014


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

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

(a) (b)

63. nks ySEi rhu rkj vFkZ VsLVj


TWO LAMP THREE WIRE EARTH
TESTER

64. gsyesV HELMET

65a. gSUM ysEi HAND LAMP

65b. VsLV ysEi TEST LAMP

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 45

Ifjf’k"V&v ANNEXURE ‘I’


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

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


unit per set) for alternator and regulator testing.

2. Floor mounted 45 kW AC test drive


complete set with regenerative load testing
for alternator and regulator testing.

3. 1kW Portable motor drive set for testing


alternator and regulator.

4. Power supply analyzer, oscilloscope


dual channel, storage type

5. Surge comparison tester for testing windings of motor

Hand-Tools for Coaching Maintenance April, 2014


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

6. Test benches for testing OVP relays & contactors


with contacts testing with chart .

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 47

7. Alternator pulley gap checking facility


Filler guage

8. Alternator pulley adjusting guage

9. Alternator pulley groove go-nogo guage

10. Spring testing facility for testing of


alternator spring

Hand-Tools for Coaching Maintenance April, 2014


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

11. ERRU testing facility all make

12. ‘V’ belt pre stretching machine (Grading machine)

14. Laptop with printer for data recording

April, 2014 Hand- Tools for Coaching Maintenance


CAMTECH/E/2014-15/Coaching Tools/1.0 49

Ifjf’k"V&c ANNEXURE ‘II’

lanHkZ gsrq vko’;d Hkkjrh; ekud ¼vkbZ ,l½


IMPORTANT INDIAN STANDARDS (IS) FOR REFERENCE

Sr.No. Item Reference IS


1. Open end Spanner IS 2028 – 2004 (Rev.V)
(Single & Double ended open jaw
spanners)
2. Ring spanners IS 2029 (Rev.IV)- 1998
3. Combination wrenches with equal IS 6389 – 1998 (Rev. II)
openings
4. Ring slugging wrenches (Spanner) IS 4509 – 1992 (Rev. I)
5. Open ended slugging wrenches IS 4508 – 1992 (Rev.I)
(Spanners) with amendment 2 – Jan. 2003
6. Single ended open jaw adjustable IS 6149 - 1971
wrenches
7. Insulated pliers, pincers and IS 2615 – 1989 (Rev.2)
nippers – Technical supply
conditions
8. Combination side cutting pliers - IS 3650 1981 (Rev.2)
specification
9. Pipe wrenches - specification IS 4003 (Part 1, Rev.I) 1978 – General
purpose
IS 4003 (Part 2, Rev.1) 1986 Heavy duty
with amendment 1 Sept. 1990.
10. Chain pipe wrenches - IS 4123 – 1982 (Rev. I)
specification with amendment 2, June 1986
11. Bolt clippers specification IS 5200 – 1998 (Rev.I)
12. Bearing puller - specification IS 9193 – 1979
13. Steel hammers – Specification IS 841 – 1983 (Rev.2)
Amendment no.1 – July 1984
Amendment no.2 – Jan 1987
14. Screw drivers – Specification IS 844 (Part I, Rev.I) – 1972 – Technical
supply condition
IS 844 (Part II, Rev.I) – 1972 – Dimensions
IS 844 (Part II, Rev.2) – 1979 -
Dimensions, – Reaffirmed – 1984.
IS 844 (Rev.I) Part III -1974- Dimensions
for Screw drivers for recessed head screws.

Hand-Tools for Coaching Maintenance April, 2014


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

Ifjf’k"V&l ANNEXURE ‘III’

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


AN APPROACH TO EQUIPMENT FAILURE INVESTIGATION

A. On Failure Aspects ¼foQyrkvksa ds igyw½


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

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


1. Whether schedule maintenance & required testing have been carried out on the failed
equipment as per norms stipulated?
2. Does the frequency of maintenance require change?
3. Was the work properly supervised?
4. Was any RDSO modification required to be done?
5. Is any modification possible to avoid failure?

C. About Staff ¼deZpkjh ds ckjs esa½


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

D. About Material ¼lkeku ds ckjs esa½


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

E. About Testing ¼ijh{kk ds ckjs esa½


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

F. General Points ¼lkekU; foUnq½


Whether following points were checked / performed properly?
1. Proper contact
2. Clearances
3. Capacity
4. Proper contact pressure
5. Crack detections
6. Cleaning
7. Proper connections/alignment
8. Cross checks/super checks
April, 2014 Hand- Tools for Coaching Maintenance
CAMTECH/E/2014-15/Coaching Tools/1.0 51

lanHkZ
REFERENCE

1. Different IS issued by Bureau of Indian standards on different types of tools.

2. Various catalogues of tools manufacturers collected from various firms.

3. Handbook published by this Centre in the 2002 on Artisan tools for OSM, TL and AC
Depot.

4. Details collected from various field units and workshops.

5. Suggestions received during the seminar held on 03.04.2014 at CAMTECH.

6. Input received during the seminar held on 07.04.2014 organised by Mechanical


Directorate/ CAMTECH.

Hand-Tools for Coaching Maintenance April, 2014


OUR OBJECTIVE

To upgrade maintenance technologies and


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

If you have any suggestions and any specific


Comments please write to us.

Contact person : Director (Elect.)

Postal Address : Indian Railways


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

Phone : 0751 – 2470740


0751 – 2470803

Fax : 0751 – 2470841

Email : direlcamtech@gmail.com