(govt. of india) (ministry of railways) hand tools

(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

MAHARAJPUR, GWALIOR - 474020

Centre

for

Advanced

Maintenance

TECHnology Excellence in Maintenance

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.

of

C.Slip

Date of

issue

Page no. and Item no.

modified

Remarks


Hand Tools for Mechanical Artisans-Washing Line Dec’99

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.

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

mm

Least Max.

Opening mm

Phosphate Finish

Price Each Rs

Chrome Plated

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

MM

Price Each

Rs.

Size in

Inch

Price

Each Rs 6 x 7 10.50 9/16 x 5/8 25.00

8 x 9 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

mm

Without Joint Cutters

Price Each Rs

With Joint Cutters

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

mm

Length in Price

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

(mm)

Blade Dia

(mm)

Tip Dimension

(mm)

Price

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

(mm)

Price Per Set

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

Product nos.

Accessories

1753,1763,1773

1733,1715.



2.1.4.A Sockets Accessories

Product

No.

Item Length in

mm

Price each

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 +

4 accessories

10,11, 13,14,17, 19,22, 24, 27, 30, 32

Accessories

1753, 1763, 1703, 1715

1635.00

14 sockets +

4 accessories

8, 9,10,11, 13,14,17, 18,19, 21, 22

Accessories

1753, 1734, 1763, 1733

1315.00

6 sockets +

1 accessory

11, 14,17, 19,22, 24

Accessories 1734

440.00



2.1.5 WRENCHES

2.1.5.A Universal Pipe

Generally Confronting to IS 4003-1978.

Drop forced Jaw and Shank

Length

mm

Least Max.

Opening (mm)

Suitable for

pipe (inch)

Price each

Rs

260 63 1 ½ 290.00

360 75 2 415.00



2.1.5.B Pipe Wrenches

Length

mm

Least Max.

Opening mm

Price each

Rs

250 33 130.00

300 42 180.00

350 48 215.00

450 60 315.00

600 73 580.00



14

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



15

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

mm

Cutting Edge in

mm

Price Each Rs.

135 9 40.00

150 16 49.00

200 22 68.00



16

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



17

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

pieces

Contents Price

in Rs.

6

6

8

Size M

6x7, 8x9, 10x11, 12x13,14x15, 16x17

6x7, 8x9, 10x11, 14x15, 16x17, 18x19

6x7, 8x9, 10x11, 12x13, 14x15, 16x17, 18x19,

20x22

228.00

253.00

365.00

6

9

Size W

1/8x3/16, 3/16x1/4, 1/4x5/16, 5/16x3/8, 3/8x7/16,

7/16x1/2

1/8x3/16, 3/16x1/4, 1/4x5/16, 5/16x3/8, 3/8x7/16,

7/16x1/2, 1/2x9/16, 9/16x5/8

346.00

809.00



18

2.1.10 HACKSAW

IS : 2594

Dimensions for type C Straight Adjustable Flat

Hacksaw

Nominal size L Rs. each

250, 300 80,95



19

2.1.11 TOOL BAGS

Tool Bag has to be made as per requirement.



20

2.2 CARPENTER TOOLS

2.2.1 AXES

IS : 703

Weight and dimensions for Axes

Weight

Kg

A±3 B±3 B1±3 A±3 A±3 Rs.

1.80 171 35 32 51 70 140

2.70 216 41 38 51 83 165



21

2.2.2 BRACE

IS : 7041, 7042

DIMENSIONS FOR CARPENTERS BRACE

( Dimensions are in mm)

Normal

size

(2 x A)

A±2 B C±3/0 D±3/0 E F Rs.

250 125 12 130 150 14 24 110

300 150 12 145 160 14 24 125



22

2.2.3 PLANE

2.2.3.A Try Plane

IS : 8205

Dimensions for Carpenters Wooden Bodied Try Plane

Normal

size a

B±5 c±2 D±3 e±3 F±1.5 /0 Rs.

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

size a

B±5 c±2 d±3 e±3 F±1.5 /0 Rs.

45 200 75 63 60 46.5 105

51 200 75 63 60 52.3 125



23

2.2.4 ADZES

IS : 663

Dimensions for Adzes

(Dimensions are in mm) Nominal

mass Kg

A E Dia of

Hole

Rs.

1 50 80 24 95

2 75 100 23 165



24

2.2.5 HAMMER

2.2.5.A Cross Pein Hammer With Handle

IS : 841-1983

Dimensions for Cross Pein Hammer

(Dimensions are in mm) Nominal mass

grams

A D G Rs.

200 75 24 20 89

500 105 35 25 127



25

2.2.5.B Claw Hammer

IS : 6546

Dimensions for Claw Hammer

(Dimensions are in mm) Nominal

size grams

A G±1.5 N

min.

Rs.

450/500 120 28 30 143

700 135 30 35 225



26

2.2.6 PINCER

Generally confirming to IS: 2615

Length in mm

Price in Rs. each

200 131.00



27

2.2.7 CLAMP

Length in mm

Price in Rs. each

105 230.00

205 520.00



28

2.2.8 SAW

2.2.8.A Cross Cut Saw

IS : 5098

Dimensions of Cross Cut Saw

(Dimensions are in mm)

Length in mm Rs. Each

250 145

350 160

2.2.8.B Rip Saw

IS : 5098

Dimensions of Rip Saw

(Dimensions are in mm)

Length in mm Rs. Each

600 305

650 345124



29

CHAPTER 3

TOOLS SUGGESTED FOR STANDARDISATION

3.1 FITTER TOOL

Sr.

No.

Description Qty./

Set

Cost

(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

mm) 6x7, 8x9, 10x11, 12x13,14x15,

16x17, 18x19, 20x22, 21x23, 24x27,

25x28, 27x32, 32x36

1 set 450



30

Sr.

No.

Description Qty./

Set

Cost

(Rs.)

18 Double ended open spanner set (size in W)

3/8x7/16, 9/16x 5/8, 5/8x3/4, 3/4x7/8

1 set 110

19 Ring spanner 10x11, 12x13, 14x15, 16x17,

18x19, 20x22, 24x27,30x32, 36x38

1 set 310

20 Socket 12.7 mm(1/2”), Square Drive 17,

18, 19, 24, 30, 32, 36, Chrome Vanadium

1 410

21 Socket accessory, Reversible Ratchet

(Square Drive) with extension rod 8”,

1 391

75

22 19mm special square drive socket spanner,

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.

1 set 704

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.



31

3.2 TRAIN EXAMINER TOOL

Sr.

No.

Description Qty./

Set

Cost

(Rs.)

01 3 cell torch 1 90

02 Balance spring 1 120


3.3 CARPENTER TOOL

Sr.

No.

Description Qty./

Set

Cost

(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



32

Sr.

No.

Description Qty./

Set

Cost

(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



33

3.4 TRIMMER TOOL

Sr.

No.

Description Qty./

Set

Cost

(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

trimmer 1 124

3.5 CLEANER TOOL

Sr.

No.

Description Qty./

Set

Cost

(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



34

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



35

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



36

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



37

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

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

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.

OUR OBJECTIVE

(govt. of india) (ministry of railways) hand tools

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