Signal Final

PREFACE

Indian Railway having a route length of over 62,000 KM are the largest undertaking in the world. With 16 lakhs employee running 8000 passenger trains and 5500 goods train every day, moving 1.36 crores passenger and 12 lakhs tones of goods daily. So railway are truly called the ‘life line of the nation’.

To maintain the punctuality and safety of train, maintenance of the gears is very important. In present condition maintenance artisan staff are not getting adequate time for proper maintenance due to train traffic. Maintenance time is also more on account of traditional tools. After any unusual like accident, derailment or bursting of point etc. restoration time is also more. To over come with the problem associated with tool, S&T artisan staff should use modern tools.

Railway Board has asked IRCAMTECH, Gwalior to prepare a report on modren tools applicable for S&T staff.. IRCAMTECH has organised a two days seminar and called the modern tool manufacturer from all over the country. All Principals, instructors of S&T training centres from Zonal Railways, field officers and supervisors have attended the seminar. Demonstration was given by the manufactures during the seminar.

Based on the tools quality, its applicability, life and cost, this report is prepared. In this report information on the tools like its specification, application, price and manufacturers with address including DOT phone numbers and fax numbers are given, which will help in procurement of modern tools. Efficiency of S&T artisan staff will increase which make the S&T system more reliable in day to day working.

Gwalior A.K.SagarDate: 12.7.2002 Director (S&T)

CAMTECH/2002/S/Tools(Signal)/1.0

INTRODUCTION

The present handbook is primarily intended to cover the modern tools and equipment for Signalling discipline based on their usefulness. Prior to the preparation of the handbook the problem related to the use of the conventional tools in the field and its possible replacement have been studied and discussed. To meet the desired end some of the tool manufacturers/suppliers have been contacted and their address have also been incorporated in the list for reference.

Owing to time constraints and other limitations CAMTECH could locate only limited manufacturers/suppliers. As such, the list of manufacturers/suppliers indicated for any tool provided in the handbook is in no way exhaustive and the Railways/ Indenters / Users/ are free to explore for the availability of more manufacturers/suppliers in the open market. The budgetary estimated cost for the tools is subjected to variation on account of market factors and / or number of units purchased. Further the power operated tools being operated on 220 V AC can suitably be re-designed by manufacturer for operation on 110V AC/ DC (which is readily available in yard) to meet the feasibility criteria.

Thus at the time of procurement of tools, based on its

merits, the above factors also need to be carefully looked into.

Handbook on Tools for Artisen staff (Signal) July’ 2002

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TOOL ALREADY IN USE

A) Tools list for Electric Signal Maintainer

Sr. Name of the tool Page no. of modern tool

1. Digital Multi meter 112. Megger 100 V and 500 V3. Hydrometer4. Measuring tape /Scale 205. Dummy wheel6. Ring Spanner set 297. Spanner set double ended 298. Adjustable spanner 12” and15” 9. Box spanner set 2910. Water pump spanner 1611. Nose pliers 4”, 6”, 8” 1412. Wire scraper 9 & 1413. Pliers 6” and 8” 15 & 1514. Insulated Screw driver Set 17 & 2915. Allen key 2916. Hammer (2.5, 5 Lbs.)17. Chisel18. Punch 3119. Seal punch20. Train shunt resistance meter21. Earth tester22. Grease gun23. Tommy bar24. Obstruction test piece


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25. Soldering iron (10W-125W) 1926. Crimping device 827. Vacuum cleaner 28. Hand gloves 29. Cell tester 30. Hand track drilling machine 23 & 2631. Electric drill machine 23 & 2632. Brush

B) Tools list for Mechanical Signal MaintainerSr. Name of the tool Page no. of

modern tool1. Hammer (2.5-20 lbs)2. Chisel3. Punch 314. File flat5. File flat smooth6. File round7. File triangular 8. File half round9. Spanner set 2910. Ring spanner set 2911. Box spanner set 2912. Calipers 13. Filter gauge 14. Grease gun15. Valve lifter 16. Screw driver set 29


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17. Tommy bar18. Pic-axe 19. Pharaoh 20. Hack saw frame 2821. Crow bar 22. Adjustable spanner

(10”,12”,15”,18”)23. Augur 2324. Reamer25. Drill machine 23 & 2626. Blower fan27. Smithy tongues 28. Tri square29. Electric grinder machine30. Brass ratchet 31. Sewal 32. Motor Pan 33. Blow lamp34. Iron Brush

C) TOOL LISTS FOR CARPENTER

Sr.Name of tool Page no. of

modern tool1. Hand Saw 282. Trying Angle3. Trying Plane 324. Jack Plane 325. Measuring Tape 206. Anvil


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modern tool7. Auger 238. Drill Machine 239. Gilmet 2310. File11. Adge12. Punch 3113. Vice

D) TOOL LISTS FOR MASON


modern tool1. Hammer2. Chisel3. Measuring Tape 204. Punch 315. Pic-axe6. Pharaoh7. Tommy bar8. File9. Crow bar


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MODERN TOOLS

1. Crimping tool

Name : Crimping ToolApplication : Crimping of wires.Make : Hil PreshArticle No. : 11731Specification : Crimping Range

0.5 - 1.5mm2

1.5 - 2.5mm2

4.0 - 6.0mm2

Budgetary estimated cost : Rs. 650/-

Source of supply : M/s Sumitron Exports Pvt. ltd.

***


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2. Stripping Plier

Name : Stripping PlierApplication : Removing of Conductor Insulation for Termination.Make : M/s Aven, Item No. 10.105Features :One light squeeze strips wire clean up to a full 7/8". Automatic feature holds jaws open to remove wire without crushing ends. Practically eliminates all nicking, cutting, or fraying. Strips teflon, silicon and PVC wire. Made of aluminum with plastic molded handles.

Model No. : 10.105Budgetary estimated Cost : Rs.900/- Source of Supplier : M/s Sumitron Exports Pvt. Ltd.

***


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3. Auto Ranging Digital Multimeter

Name : Auto Ranging Digital Multimeter

Application : Measurement of Voltage, Current Resistance, Checking of continuity

Make/ Model : 9a02

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


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DC Current 340a/3.4/34/340ma/3.4/20a (1.5%rdg + 8 dgt)

AC Current 340a/3.4/34/340ma/3.4/20a (2.2%rdg + 4 dgt)

Resistance 340/3.4/34/340k/3.4/34m (0.7%rdg + 4 dgt) on all ranges except (1.2rdg + 4 dgt) on 3.4m (2.5%rdg + 4 dgt) on 34m

Diode yesContinuity Buzzer yesFull Icon Display yesAuto Power Off/ Steep Mode

yes

Low Battery Display "batt" is indicatedInput Impedance (Voltage)

10 m

Power one 9v batteryBattery Life 200 hours typicalLCD Digit Size 17 mm

Budgetary estimated Cost : Rs. 8,000/-

Source of Supply : M/S Meco Instruments Pvt.Ltd.P.O. Box 6388, 301Bharat Industrial EstateTaj Road, Sewree (West), Mumbai - 400 015


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Make/ Model : Tektronix DMM916SPECIFICATION :

Display auto/ manual ranging, 4½ digit 40000 count LCD with analog bargraph

DC voltage range 400mV to 100 VDC voltage accuracy 0.1 %AC voltage range 4 V to 750 VAC voltage accuracy 0.7 %AC/DC current ranges

400 a to 10 Amp

AC/DC current accuracy

0.9 % / 0.3 %

Resistance range 4000 ohm to 40 mega ohmResistance accuracy 0.3 % Capacitance 4.000 nF to 40 mF ±1.0%Frequency ranges 400 hz to 2 MhzTemperature 50° to 980° ± 1° C

Budgetary estimated Cost : Rs. 14,000/-

Source of Supply : M/s SS Tools (India) Pvt. Ltd.234, 2nd Floor, Ajmeri Gate Delhi


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4. Wire Stripper

Name : Wire Stripper Application : Wire Stripper for Wide Range

Shear Cut Bolt Cutters, Wire Cutter

Make/Model :Specification : 1.1 To 2.7 MmBudgetary estimated Cost : Rs. 6500.00Source Of Supply : M/S Sumitron Export Pvt. Ltd.

27, Community Centre, Naraina Phase-1.New Delhi - 110 028


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5. Cable Cutter

Name : Cable cutter for copper and aluminum cables.

Application : Cuts the copper and aluminum cablesMake/Model : Hilpress/Article No. 11860Specification : Cutting Range : 400mm2

Max Outside Dia : 52mm Weight : 0.830kg Length : 280mm

Budgetary estimated Cost : Rs. 250.00 Source of Supply : M/S Sumitron Exports Pvt. Ltd.

P.O. Box 10227, Naraina Phase I, New Delhi - 110 028


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6. Grip Pliers

Name : Grip PlierApplication : For tightening and loosening. Make/Model : EVEREST/Article No. 266Specification : Based on IS 10372, Federal GGG-

W-00649(GSA-FSS)

Stock No. 266-7 266-10Length MM 175 250Weight GMS 235 470

Budgetary estimated Cost : Rs. 550.00Source of Supply : M/S Hindustan Everest Tools Ltd,

Dohil Chambers, 46, Nehru Place, New Delhi 19.


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7. Electric Screwdriver

Name : DC & AC Electric Screwdriver

Application : For screwing

Make/ Model : LOOVER/LT and KPT

Specification :ITEM/FIRM- M/S SUMITRON EXPORT

PVT. LTD.NDLS27, NARAINA PHASE-1

M/S KPT

NAME DC & AC ELECTRIC SCREWDRIVER

DC & AC ELECTRIC SCREWDRIVER

MAKE/ MODEL

LOOVER/LT E-3900

CAPACITY 6 MMWATTS 600 WRPM 0-4000 RPMBUDGETORY ESTIMATED COST :

RS.400/- RS.6950/-

Source of supply : I) M/S Sumitron Export Pvt. Ltd.II) KPT Sales and Service Ltd.


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8. Soldering Station

Name : Soldering station Application : For soldering of PCB etc.Make/Model : HAKKO/397Specification :Model No. 937Power Consumption 60 wOutput voltage AC 24 volts Heating element AC 24 volt 50 wWeight Approx 1.3 kg 900S Iron907 Iron908 Iron

25 gms44 gms54 gms

Budgetary estimated COST : Rs. 12,000/-Source of Supply : M/S Sumitron Exports Pvt. Ltd.

P.O. Box 10227, NarainaPhase I, New Delhi - 110 028


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9. Digital Range Finder DUS20

Description :The digital range finders are the right tools for

measuring any length and distance. Ideal for fast and precise measuring and for adding up lengths, areas and volumes.

Specification :Weight approx. 200 gmsMeasuring units m/ cm, ft/inchMeasuring Accuracy at -5to +50C 1%Measuring Accuracy at +10C to +40C

0.5%

Measuring range 20 mBattery 3 x CR 20032

4 x 1.5 V DCAutomatic cut off Approx. 10 sec.

Budgetary estimated Cost : Rs. 6,000/-Source of supply : M/s BOSCH

Motor Industries Co. Ltd., Power tool Division, Hosur road, Adugodi,Bangalore - 560030


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10. Hot Air Gun/Hot Air Blower

Name : Hot Air Gun/Hot Air BlowerApplication : Drying of moisture of silica jel & joint,

drying of moisture of control panels, point machine armature and winding portion etc.

Make/Model No. : CHG 600 CESPECIFICATIONS

Voltage 220-240Vor 110V AC/DC

Rated power consumption 550 WTemperature range 100-6000 CAir flow rate 350-550 Lit/minStepless temp. control Yes Airflow regulation 2 stage Weight 0.7 Kgs.

Budgetary estimated COST : Rs. 6,500/-Source of supply : M/s BOSCH

Motor Industries Co. Ltd.,Power tool division,Hosur road, Adugodi,Bangalore – 560030


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11. DC operated drill machine

Name : Cordless toolApplication : To drill in wooden & concrete

sleeper. To drill in rail in track circuited portion.

Make/Model No. : BOSCHSPECIFICATIONS

Model GBH 24 VREMax. screw dia. 20 mmDia in steel 10 mmDia in wood 20 mmBattery voltage 24 V DC/1.7 Ah Rated speed 0-4400 rpmWeight with battery pack 3.5 kg Budgetary estimated COST : Rs. 23,450/-Source of supply : M/s BOSCH



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12. Portable power drill machine

Name : Multi purpose portable power drill machine

Application : Use in signallingDrilling on lever frame, gate lock, Signal post, for connecting A Marker, for fixing Calling On Signal, split lock stretcher for fixing point lock etc. A. Make/Model : M/s BOSCH/ GBM 13-2

Order No. : 06011690Specifications

Power input 550 WR.P.M. 1000/1900 RPMWeight 2 KgVolt/amp./watts 230V or 110 VAC/DCDia. In metal 13 MMDia. In wood 12/32 MM

Budgetary estimated COST : Rs. 7,000/-Source of supply : M/s BOSCH /Bangalore –

560030


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B. Make/Model :1) M/s KPT PR 132 K1-2 speed pistol drill.

2) M/s KPT KD34C –End hand drill Specifications :

Item M/s KPT PR 132 K1-2 speed pistol drill.

M/s KPT KD34C –End hand drill

Power input 550 W 550 WVoltage- 220-240 AC OR

110 V AC/DC220-240 AC OR110 V AC/DC

RPM 1300/3000 RPM 1300 RPMWeight 2.2 kg 3.5 kgDia. In concrete

13 MM 13 MM

Dia. In metal

13MM 13MM

Dia. In wood 32 MM 32 MMDia. In Aluminum

20 MM 20 MM

Budgetary estimated cost

Rs. 5,000/- Rs. 7,190/-

Source of Supply : KPT Sales and Service Ltd. 309, Vasant Vihar Commercial Complex, Dr. C.Gidwani Road, Chembur, Mumbai – 400074, Maharastra IndiaPhone-5563002,5562965Fax-5576006E-mail - [email protected]


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13. Heavy duty power drill machine

Name : Heavy duty power drill machine

Application : To Drill holes on tongue rails, D-bracket, Stock rail etc.

Make/Model : 1. BOSCH/ GBM 23-2 2. KPT HD 115 13-23

Specifications :Item/ firm M/s KPT M/s BOSCH Model No. HD 115 13-23mm

morse taper drillGBM 23-2 with taper shank drill

Power input 1100 W 550 W approx Voltage 220-240V or

110 V AC/DC 220-240V or110V AC/DC

R.P.M. a)at no load speedB) On load speed

A) 500 RPMB) 380 RPM

--

Weight 8.8 Kg 5.5 Kg approx.Dia. In metal 19-23 MM 19-23 MMBudgetary estimated cost

Rs. 8,760/- Rs. 20,000/-


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Source of Supply :

1. M/s KPT Sales and Service Ltd. 309, Vasant Vihar Commercial Complex, Dr. C.Gidwani Road,

2. M/s BOSCHMotor Industries Co. Ltd.,Power tool division,Hosur road, Adugodi,Bangalore – 560030


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14. All purpose Saw

Name : All Purpose SawApplication : Cutting work of sheet metal, iron

angles, pipes, troughs etc.Make/ Model No. : PFX 550Specifications :

Saw in wood 150 MMSaw in steel 12 MMPower input 550W/ 220 V/

110V AC/DCNo load stroke rate 2600 stroke/min.Saw stroke length 26 MM

Weight 3.0 Kg.

Budgetary estimatedcost : Rs. 10,000/-Source of supply : M/s BOSCH



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15. Screw Driver Bit set

Name : Screw driver bit setApplication : For screwing different shape

screws Make/ Model No. : 1. BOSCH

2. M/s Jensen Cat No. 690-542

Specifications :BOSCH M/s Jensen Size SVC 46 pieces 28 –pieces Skewdriver Pro kit

gear driven offset Bit set 7/16" or 6mm to 7/16"

Removable handle with 41/2 ”

magnetic extension Skew socket: 5-10 mmTorx bit: T10,T15,T20,T27Slotted bits: 1/8”, 3/16” ,1/4”, 5/16”Allen bits:5/64” to 3/16”

Budgetary estimatedcost : M/s BOSCH : Rs. 1250/-

M/s JENSEN : Rs. 2250/-


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

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


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16. Punches

Name : Centre punchApplication : Use in removing the broken part

of channel in track circuit, broken bolts from track etc.

Make/ Model No. : M/s TapariaSpecifications : Each set consist of:

Item Code

Description Length in mm

Weight in gms.

1884 Centre punch 100 351984 Centre punch 100 501985 Centre punch 125 801004 Drift punch 100 45

Budgetary estimatedcost : Rs. 100/- each setSource of supply : M/s Taparia Tools Ltd.

423-424/A-2, Shah & Nahar,Lower Parel (W) Mumbai-013Phone: 022-4938646-50Fax: 022-4953230


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17. PLAINER

Name : PlanerApplication : Light weight one hand machine

for all kind of planing workMake/Model No. : BOSCH/GHO 31-82SPECIFICATIONS

Power output 750 W/ 220V/110 AC DCNo-Load speed 13000 rpmCutting depth adjustment

0 –3.1 mm

Planing width 82mmRebate depth 0 24 mmWeight 2.8 kg

Budgetary estimatedcost : Rs. 10,800.00 Source of supply : M/s BOSCH



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18. METAL DETECTOR

Name : Intelligent Measuring Instrument

Application : Detects the presence of iron and live wires inside the wall. Useful in masonry & carpentry work.

Make/Model No. : BOSCH/DMO 10

Specifications : Measuring unit – mmBattery – 9 V DC

Budgetary estimatedcost : Rs. 4500.00

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


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FOREWORD

Ever increasing traffic on Indian Railways has resulted in proportionate reduction in the time available for maintenance activities. Use of conventional tools demands greater maintenance slots and require more restoration period as well. As study has been conducted to over come such lapses arising due to the use of conventional tools.

The present handbook encompasses modern tools for signalling along with respective representative manufacturers/ suppliers for ready reference. It is earnestly hoped that the use of theses ergonomically designed modern tools will not only reduce artisan’s fatigue but will go a long way to increase the overall efficiency and productivity by drastically cutting short the maintenance time.

Gwalior M.L.Gupta Date : 26.07.2002 Executive Director


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Signal Final

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