Hand Tools Required in Coach Washing Cum Pit Lines

(Govt.
of India)
(Ministry of Railways)
HAND TOOLS REQUIRED IN
COACH WASHING CUM PIT LINES
(For official use only)
CAMTECH/99/M/TOOLS-WL/1.0
DECEMBER 1999
Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance
MAHARAJPUR, GWALIOR - 474020
FOREWORD
Standardisation of Hand Tools is an important step

towards ensuring implementation of effective and uniform
maintenance procedures. CAMTECH has taken an important
lead in this direction by preparing this handbook giving
compiled list of handtools required for coach washing cum
pit lines.
Apart from giving detailed description of each

handtool, the important parameters and specifications are
also given therein. This will prove to be useful to the
maintenance depots at the time of indenting the material
thereby ensuring availability of proper tools to the
maintenance staff.
CAMTECH, Gwalior D.K. Saraf

January 28, 2000 Director
PREFACE
CAMTECH has already circulated Standard Integrated

facilities for washing lines. CAMTECH has prepared this
handbook to supplement the same. This is aimed at having
standard tools in the washing lines. The detailed specification
of the tools with approximate cost taken from reputed
manufacturer’s price list have been given.
This handbook does not supersede any instructions

issued from Railway Board and RDSO.
CAMTECH, Gwalior Rakesh Bahl

Date : 27.01.2000 Joint Director (Mech.)
CONTENTS
Contents Page no.
FOREWORD ii
PREFACE iii
CONTENTS iv
CORRECTION SLIP v
Chapter 1 GENERAL 1
1.1 Introduction 1
1.2 Objective 2
1.3 Methodology 2
Chapter 2 INFORMATION ABOUT HANDTOOLS
WASHING CUM PIT LINES 4
2.1 Fitter Tools 4
2.2 Carpenter Tools 20
Chapter 3 TOOLS SUGGESTED FOR STANDARDISATION 29
3.1 Fitter Tools 29
3.2 Train Examiner Tool 31
3.3 Carpenter Tools 31
3.4 Trimmer Tools 33
3.5 Cleaner Tools 33
Appendix A Mechanical Gauges 34
Appendix B List of items to be kept at Primary
Examination points 35
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will

be numbered as follows :
CAMTECH/99/M/TOOLS-WL/1.0/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 Page no. and Item no. Remarks

of issue modified
C.Slip
CAMTECH/99/M/TOOLS-WL/1.0
CHAPTER 1
GENERAL
1.1 INTRODUCTION
Proper Standard Quality Hand Tools are the backbone of

the maintenance and repair. In absence of proper tools, wrong
practices will be followed viz for opening or tightening a nut
by tapping or hammering with the help of chisel/punch. In
such event component/assembly is bound to get damaged,
threads getting loose or stripped. Artisans will take more time
to repair or may not be able to repair. This may cause failure
or reduce the life of components.
Sub standard, poor quality tools may cause injury to staff

and life of the tool will be less, as such while standardising
tools proper material specification of tools as per job
requirement should be considered.
Tools should be of International Standard and pass the

meticulous and continuous testing from Raw Material up to
final finished products.
Hand Tools for Mechanical Artisans-Washing Line Dec’99

CAMTECH/99/M/TOOLS-WL/1.0 2
1.2 OBJECTIVE
To standardise Hand Tools needed for maintenance of

rakes comprising of coaches in washing line. This will ensure
proper quality maintenance of rolling stock, which in turn
shall:
 Minimise failure of rakes/coaches

 Damages to coach components shall be reduced to a great
extent, because, for want of proper tool, at present bad
practices are being adopted
 Fatigue of artisan staff shall be minimised.
1.3 METHODOLOGY
Opinion and suggestions were gathered from various

depots. Depots visited are:
 Kurla depot - Central Railway

 Basin Bridge - Southern Railway
 CSTM depot - Central Railway
 BCT depot - Western Railway
 Nizamuddin Depot - Northern Railway

Various zonal railways were contacted to send their

views and comments. Based on this the list of Hand Tools
required in washing line (mechanical) for artisans, carpenters,
trimmer and cleaner have been suggested

CHAPTER 2
INFORMATIONS ABOUT HAND TOOLS FOR

WASHING CUM PIT LINES
(MECHANICAL DEPARTMENT)
2.1 FITTER TOOLS

2.1.1 SPANNERS
2.1.1.A Adjustable Spanners
Generally Conforming to IS 6149-1984 Grade II
Length Least Max. Phosphate Finish Chrome Plated
Opening mm Price Each Rs
mm Price Each Rs
155 19 77.00 91.00
205 26 100.00 116.00
255 30 132.00 152.00
305 35 174.00 194.00
380 43 358.00 388.00

2.1.1.B Double Ended Open Jaw Spanners

Chrome Vanadium Steel, Chrome Plated
Generally Conforming IS 2028-1991
Size in Price Each Size in Price
MM Rs. Inch Each Rs
6x7 10.50 9/16 x 5/8 25.00
8x9 11.50 5/8 x ¾ 32.00
10 x 11 12.50 ¾ x 7/8 40.00
12 x 13 16.50 3/8 x 7/16 14.00
14 x 15 19.50
16 x 17 23.50
18 x 19 29.00
20 x 22 37.00
21 x 23 44.50
24 x 27 59.00
25 x 28 67.00
30 x 32 78.00
32 x 36 100.50

2.1.2 PLIERS
2.1.2.A Combination Pliers
INSULATED WITH THICK CELLULOSE ACETATE

SLEEVE (C.A.SLEEVE)
Generally Conforming to IS 3650-1981
Length Without Joint Cutters With Joint Cutters

mm Price Each Rs Price Each Rs
160 107.00 109.00
180 115.00 117.00
205 130.00 132.00

2.1.2.B Inner and External Circlip Pliers
INSULATED WITH THICK C.A. SLEEVE
Description Capacity Length in Price

mm Each Rs
Straight Nose 19-60 155 116.00

Bent Nose 19-60 160 116.00

2.1.2.C Long Nose Pliers
INSULATED WITH THICK C.A. SLEEVE
Description Length in mm Price Each Rs
Flat Nose 160 107.00

Round Nose 160 107.00

2.1.3 SCREW DRIVERS
2.1.3.A C.A Transparent Green Handle
Generally conforming to IS 844-1979

High grade steel, hardened and plated to give long life.
Blade Length Blade Dia Tip Dimension Price

(mm) (mm) (mm) Each Rs
50 3 1.6 x 0.4 15.50

75 3 3.0 x 0.5 19.00
75 4 4.3 x 0.6 19.00
150 6 6.0 x 0.8 34.50
250 8 8.0 x 1.2 60.00
400 10 10.0 x 1.5 104.00

2.1.4 SOCKETS- 12.7 mm (1/2” ), SQUARE DRIVE

AND ACCESSORIES
HIGH GRADE CHROME VANADIUM STEEL
As per IS 6131-1980 & 7381-1986

Bi-hexagonal & Hexagonal
ONE SET
Product Item Sockets Price Per Set

(mm) Rs.
22 Sockets + 8,9,10,11,12,13,14,
15,16,17,18,19,21,
22,23,24,26,27,28,
29,30,32 2650.00
5 Accessories Accessories
Product nos. 1753,1763,1773
1733,1715.

2.1.4.A Sockets Accessories
Product Item Length in Price each

No. mm Rs.
1753 Extension Bar 125 108.00
1763 Extension Bar 255 130.00
1773 Universal Joint 75 177.00
1733 “T” Handle 300 124.00
1715 Ratchet Handle 250 398.00
Product No. Contents Price each

(Rs.)
11 sockets + 10,11, 13,14,17, 19,22, 24, 27, 30, 32 1635.00
4 accessories Accessories
1753, 1763, 1703, 1715
14 sockets + 8, 9,10,11, 13,14,17, 18,19, 21, 22 1315.00
4 accessories Accessories
1753, 1734, 1763, 1733
6 sockets + 11, 14,17, 19,22, 24 440.00
1 accessory Accessories 1734

2.1.5 WRENCHES
2.1.5.A Universal Pipe
Generally Confronting to IS 4003-1978.

Drop forced Jaw and Shank
Length Least Max. Suitable for Price each

mm Opening (mm) pipe (inch) Rs
260 63 1½ 290.00
360 75 2 415.00

2.1.5.B Pipe Wrenches
Length Least Max. Price each

Opening mm Rs
mm
250 33 130.00
300 42 180.00
350 48 215.00
450 60 315.00
600 73 580.00

2.1.6 HAMMER WITH HANDLE

Head drop forged from high grade steel and heat treated
(Ball Pein, Claw, Cross pein)

Head as per IS 841-1983
2.1.6.A Ball pein and Cross pein
Weight in gms. Price Each Rs.

200 88.00
500 124.00
600 145.00
800 163.00
2.1.6.B Claw Hammer with handle
Weight in gms. Price Each Rs.

450 143.00

2.1.7 OCTAGONAL CHISELS
Made from high grade steel, forged and ground. Differential

heat treatment for cutting edge and striking end.
As per IS 402/ 74
Length In Cutting Edge in Price Each Rs.

mm mm
135 9 40.00
150 16 49.00
200 22 68.00

2.1.8 PUNCHES
Made out of high grade chrome steel accurately machined

and heat treated. Deep knurling on the body to ensures firm
grip.
Description Length in mm Price each Rs.
Centre Punch 100 22.50
Centre Punch 125 28.00
Drift Punch 100 23.50

2.1.9 RING SPANNERS

Bi-hexagonal and Hexagonal
Deep Off Set
Chrome vanadium steel, Chrome plated polish
Generally Conforming to IS-2029-1981
Range of set No. of pieces Price/Set
6-32 mm 10 699.00
6-32 mm 12 958.00
No. of Contents Price

pieces in Rs.
Size M
6 6x7, 8x9, 10x11, 12x13,14x15, 16x17 228.00
6 6x7, 8x9, 10x11, 14x15, 16x17, 18x19 253.00
8 6x7, 8x9, 10x11, 12x13, 14x15, 16x17, 18x19, 365.00
20x22
Size W
6 1/8x3/16, 3/16x1/4, 1/4x5/16, 5/16x3/8, 3/8x7/16, 346.00
7/16x1/2
9 1/8x3/16, 3/16x1/4, 1/4x5/16, 5/16x3/8, 3/8x7/16, 809.00
7/16x1/2, 1/2x9/16, 9/16x5/8

2.1.10 HACKSAW
IS : 2594
Dimensions for type C Straight Adjustable Flat

Hacksaw
Nominal size L Rs. each

250, 300 80,95

2.1.11 TOOL BAGS
Tool Bag has to be made as per requirement.

2.2 CARPENTER TOOLS
2.2.1 AXES
IS : 703
Weight and dimensions for Axes
Weight A±3 B±3 B1±3 A±3 A±3 Rs.

Kg
1.80 171 35 32 51 70 140
2.70 216 41 38 51 83 165

2.2.2 BRACE
IS : 7041, 7042
DIMENSIONS FOR CARPENTERS BRACE

( Dimensions are in mm)
Normal A±2 B C±3/0 D±3/0 E F Rs.

size
(2 x A)
250 125 12 130 150 14 24 110
300 150 12 145 160 14 24 125

2.2.3 PLANE
2.2.3.A Try Plane
IS : 8205
Dimensions for Carpenters Wooden Bodied Try Plane
Normal B±5 c±2 D±3 e±3 F±1.5 /0 Rs.

size a
54 600 75 75 250 55.5 150
57 600 78 75 250 58.5 165
2.2.3.B Smoothing Plane

IS : 8206
Dimensions for Carpenters Wooden Bodied Smoothing

Plane
Normal B±5 c±2 d±3 e±3 F±1.5 /0 Rs.
size a
45 200 75 63 60 46.5 105
51 200 75 63 60 52.3 125

2.2.4 ADZES
IS : 663
Dimensions for Adzes

(Dimensions are in mm)
Nominal A E Dia of Rs.
mass Kg Hole
1 50 80 24 95
2 75 100 23 165

2.2.5 HAMMER
2.2.5.A Cross Pein Hammer With Handle
IS : 841-1983
Dimensions for Cross Pein Hammer

Nominal mass A D G Rs.
grams
200 75 24 20 89
500 105 35 25 127

2.2.5.B Claw Hammer
IS : 6546
Dimensions for Claw Hammer

Nominal A G±1.5 N Rs.
size grams min.
450/500 120 28 30 143
700 135 30 35 225

2.2.6 PINCER
Generally confirming to IS: 2615
Length in mm Price in Rs. each
200 131.00

2.2.7 CLAMP
Length in mm Price in Rs. each
105 230.00
205 520.00

2.2.8 SAW
2.2.8.A Cross Cut Saw
IS : 5098
Dimensions of Cross Cut Saw

Length in mm Rs. Each
250 145
350 160
2.2.8.B Rip Saw

IS : 5098
Dimensions of Rip Saw

Length in mm Rs. Each
600 305
650 345124

CHAPTER 3
TOOLS SUGGESTED FOR STANDARDISATION
3.1 FITTER TOOL

Sr. Description Qty./ Cost
No. Set (Rs.)
01 Ball pein hammer with handle 600grms 1 149
02 Nylon hammer with handle, 2 lbs, 1 48.00
03 Sledge hammer with handle, 14 lbs 1 265
04 Chisel, Hexagonal Chrome Vanadium 8” 1 89
05 Pin punch 1 22.50
06 Combination plier,180 mm 1 117
07 Pipe wrench No. 14”, 18” 1 set 510
08 Measuring tape 2 m 1 25
09 Three cell torch (rechargeable) 1 90
10 Screw driver 250 mm (blade length) 1 51
11 Hacksaw 1 80
12 Inner circlip plier, Bent nose 1 116
13 Inner circlip plier, Straight nose 1 116
14 Feeler gauge 6” 1 set 65
15 Tommy bar 24” 1 45
16 Steel rule 12” 1 20
17 Double ended open spanner set (size in 1 set 450
mm) 6x7, 8x9, 10x11, 12x13,14x15,
16x17, 18x19, 20x22, 21x23, 24x27,
25x28, 27x32, 32x36


No. Set (Rs.)
18 Double ended open spanner set (size in W) 1 set 110
3/8x7/16, 9/16x 5/8, 5/8x3/4, 3/4x7/8
19 Ring spanner 10x11, 12x13, 14x15, 16x17, 1 set 310
18x19, 20x22, 24x27,30x32, 36x38
20 Socket 12.7 mm(1/2”), Square Drive 17, 1 410
18, 19, 24, 30, 32, 36, Chrome Vanadium
21 Socket accessory, Reversible Ratchet 1 391
(Square Drive) with extension rod 8”, 75
22 19mm special square drive socket spanner, 1 set 704
chrome vanadium steel, chrome plated
polished to IS 7381-1974 with extension
rod 215 mm with ratchet, size 34, 36 mm
for buffer to be ordered, having depth of 1
½ inch.
23 Adjustable spanner, 255 mm length 1 152
24 Wire brush 1 20
25 Paint brush 2” 1 40
26 Tool bag 1 1200
27 Wheel Barrow, Locally made 1 600
Suggestions 1 (Tools to be kept in tool room)

1. Electrical portable drill 2. Portable Surface Grinder
Suggestions 2
It is suggested that all the tools to be kept in Tool Bag with
little amount of spares like MU washers, BP and FP hose should be
taken one time in WHEEL BARROW, at the start by the artisan or
khallasi to his working place and need not to come time and again
in order to pickup tools required for maintenance from his cub-
board or from tool room. This in turn shall reduce, tremendous
fatigue to staff and time required to repair the rake/coach. One
wheel Barrow for 2 or 3 gangs may be provided.

3.2 TRAIN EXAMINER TOOL

No. Set (Rs.)
01 3 cell torch 1 90
02 Balance spring 1 120
3.3 CARPENTER TOOL

No. Set (Rs.)
01 Hand saw, cross cut 18” 1 125
02 Claw pein hammer with handle 500 gms 1 143
03 Pop rivet plier 1 117
04 Screw driver 8”, 10” 1 set 185
05 Cutting plier 6” PVC coated 1 103
06 Try square 8” 1 45
07 Diamond cutter 1 180
08 Pin punch 4” 1 45
09 Chisel Hexagonal 6” 1 50


No. Set (Rs.)
10 Grinding stone 8” 1 30
11 Foot rule folding 1 25
12 Triangular file 6” 1 45
13 File half round bastard 16” long 1 105
15 Pincer, 200 mm 1 131
16 Clamp, 105 mm 1 230
17 Tool bag 1 1200

3.4 TRIMMER TOOL

No. Set (Rs.)
01 Scissors 10” 1 85
02 3 cell torch (rechargeable) 1 90
03 Bent needle 1 20
04 Straight needle 1 10
05 Tailor measuring tape 40” 1 25
06 Paint brush for patching 3” 1 45
07 Hammer with handle, 500 gms, for 1 124
trimmer
3.5 CLEANER TOOL

No. Set (Rs.)
01 Broom 1 20
02 Washing brush with 6 ft bamboo handle 1 40
03 Washing brush ordinary 1 25
04 Cotton cloth piece (thick) 2 feet x 2 feet 1 30
05 Bucket (20 liters) 1 120
06 Washing rubber pipe, 20mm diameter 1 Stock
Item
07 Coupling 1 Stock
Item
08 Disposal bags 2 15
each
09 Duster 2 10
each


APPENDIX A
MECHANICAL GAUGES
(TO BE KEPT AT TOOL ROOM)
 Wheel distance gauge 1600 +2 /-1

 Calliper of wheel diameter
 Buffer height gauges in tare 1105/1090
 Axle diameter gauges for 16 Ton axle and 13 Ton axle
 Bolster Spring Suspension hanger gauge 387/386/384
 Tyre defect gauge
 Dash pot oil level stick
 Axle Box Clearance gauge
 Bolster clearance gauge
 SAB ‘A’ dimension gauge
 SAB ‘E” dimension gauge

APPENDIX B
LIST OF ITEMS TO BE KEPT AT PRIMARY

EXAMINATION POINTS
Following Spares and T&P item should be kept at Primary

Examination Points:
 Jacks (Screw and Bottle, at least 2 nos. each) with

Fixtures for Bolster Spring replacement.
 Wooden packing
 Wooden wedges
 Danger boards
 Master gauge (Vacuum)
 Master gauge (Air pressure)
 8 mm hole Test Plate
 7.5 mm hole Test Plate
 Set of Spanner
 Hammer
 Sledge Hammer
 Chisel
 Punch

 Wooden plug to dummy Vacuum cylinder and clappet

valve
 Lithium base grease for axle box
 Iron rod to lift the luggage sliding door (bottom)
 Bolster Springs of all types
 Equalizing stay
 Bolster Suspension Hanger
 Hanger Block
 Bolster Suspension Hanger Pin
 Truss Bar Hanger Pin
 Truss Bar Hanger
 Axle Box face plate with nuts
 Hose pipe complete
 Syphon pipe
 BP Air hose couplings
 FP Air hose couplings
 MU washers
 Brake blocks
 SAB with control rod
 BP-HP couplings
 Draw Bar assembly
 Shock absorber with nuts and bolts

 Guard van valve complete

 Buffer face protective plate
 Brake gear pins, cotters, nuts and bolts
 Clappet valve washer and cap
 PEASD resetting key
 Middle berth chain
 Push cock
 Door Handle



OUR OBJECTIVE
To upgrade maintenance technologies and

methodologies and achieve improvement in
productivity and performance of all Railway
assets and man power 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 : Joint Director (Mech.)
Postal address : Indian Railways,

Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior.
Pin code - 474 020
Phone : 0751- 470890, 0751-470803

Fax : 0751- 470841

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(Govt.

HAND TOOLS REQUIRED IN

COACH WASHING CUM PIT LINES

(For official use only)

Standardisation of Hand Tools is an important step

Apart from giving detailed description of each

CAMTECH, Gwalior D.K. Saraf

CAMTECH has already circulated Standard Integrated

This handbook does not supersede any instructions

CAMTECH, Gwalior Rakesh Bahl

The correction slips to be issued in future for this handbook will

Where “XX” is the serial number of the concerned

CORRECTION SLIPS ISSUED

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

Proper Standard Quality Hand Tools are the backbone of

Sub standard, poor quality tools may cause injury to staff

Tools should be of International Standard and pass the

Hand Tools for Mechanical Artisans-Washing Line Dec’99

To standardise Hand Tools needed for maintenance of

 Minimise failure of rakes/coaches

Opinion and suggestions were gathered from various

 Kurla depot - Central Railway

Hand Tools for Mechanical Artisans-Washing Line Dec’99

Various zonal railways were contacted to send their

Hand Tools for Mechanical Artisans-Washing Line Dec’99

INFORMATIONS ABOUT HAND TOOLS FOR

2.1 FITTER TOOLS

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.1.B Double Ended Open Jaw Spanners

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.2.A Combination Pliers

INSULATED WITH THICK CELLULOSE ACETATE

Length Without Joint Cutters With Joint Cutters

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.2.B Inner and External Circlip Pliers

INSULATED WITH THICK C.A. SLEEVE

Generally Conforming to IS 7989-1976

Description Capacity Length in Price

Straight Nose 19-60 155 116.00

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.2.C Long Nose Pliers

INSULATED WITH THICK C.A. SLEEVE

Generally Conforming to IS 3552-1989

Description Length in mm Price Each Rs

Flat Nose 160 107.00

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.3 SCREW DRIVERS

2.1.3.A C.A Transparent Green Handle

Generally conforming to IS 844-1979

Blade Length Blade Dia Tip Dimension Price

50 3 1.6 x 0.4 15.50

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.4 SOCKETS- 12.7 mm (1/2” ), SQUARE DRIVE

HIGH GRADE CHROME VANADIUM STEEL

As per IS 6131-1980 & 7381-1986

Product Item Sockets Price Per Set

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.4.A Sockets Accessories

Product Item Length in Price each

Product No. Contents Price each

Hand Tools for Mechanical Artisans-Washing Line Dec’99

2.1.5.A Universal Pipe

Generally Confronting to IS 4003-1978.

Length Least Max. Suitable for Price each