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Handbook on Integrated Rolling Stock Depot Page 1 of 61
(For official use only)
(Govt. of India)
(Ministry of Railways)
Draft
Hand Book
on
Integrated Rolling Stock Depot
IRCAMTECH/2017/M/GWL/IRS DEPOT/1.0
April- 2017
MAHARAJPUR, GWALIOR--474005
Handbook on Integrated Rolling Stock Depot Page 2 of 61
PREFACE
As per instructions from Railway Board, & CME conference item No. 1.10, CAMTECH
to prepare report on the “Handbook on Integrated Rolling Stock Depot”.
The Handbook has been prepared based on contents taken by nominated committee
for the purpose and visits of Coaching depots, MEMU sheds & DEMU sheds and
interaction with concerned officers / supervisors & concerned depots/divisions for
further course of actions.
Handbook has been prepared by CAMTECH with the objective to provide guidelines
for standardization of infrastructure and maintenance practices of MEMU/DEMU and
Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot.
It is clarified that this handbook does not supersede any existing procedures and
practices laid down in the maintenance instructions issued by manufacturers or by
Railway Board/RDSO.
April, 2017 (K.P.Yadav)
Place: CAMTECCH/GWL Director / Mechanical CAMTECH/Gwalior
Handbook on Integrated Rolling Stock Depot Page 3 of 61
Contents
SN Description Page No.
PART-A
01. Constitution of committee 4
02. Terms of reference of the committee 4
03. Details of visits made by the CAMTECH 4
04 Data collection:-
4.1 Dimensions of various coaches
4.2 Weight chart of various coaches
4.3 Arising out of course repairs
4
4
5
5
05 Discussion on the Terms of References 5
5.1 To suggest the infrastructure and facilities required in the new and existing
integrated rolling stock coaching depots –
(i) Short Term Measures
(ii) Long Term Measures
5
5
6
5.2 To suggest short term and long term measures for the integration of Trip,
Minor and Medium repairs of MEMU/DEMU trains in the mainline coaching
depots of IR.
5.2.1 Pit line infrastructure
5.2.2 Sick Line Infrastructure
(i) Machines and Plants required in the rolling stock depots
for maintenance of MEMU
(ii) Machines and plants required in the Rolling Stock
Depots for maintenance of DEMU
6
6
8
9
9
5.2.3 Record keeping 9
5.3 To suggest ways to utilize the released capacity in the existing sheds/Depots
for MEMU / DEMU for carrying out major repairs of MEMU/DEMU rakes.
(i) Maintenance of MEMU rakes in existing DEMU sheds
(ii) Maintenance of DEMU rakes in the existing MEMU sheds.
9
9
9
5.4 To Review the various maintenance schedules and their periodicity for MEMU,
DEMU & main line coaching stock and suggest ways for rationalizing the
same.
(i) Recommendations for various maintenance Sch.in Annexure-B
10
11
5.5 To suggest ways for the multi-skilling of staff and reducing the number of
cadres engaged in the work of maintenance of MEMU/DEMU/Main line
coaches by appropriate training and other methods.
(a) Actual staff deployment in DEMU/MEMU sheds
(b) Multi-skilling of staff and merger of trades
12
12
13
06. Recommendations of the committee 14
07. Lay out drawing of Integrated Coaching Depot 17
08 Annexure-A-Observations during the visits of DEMU/MEMU sheds 20
PART-B
09 Standardisation of Tool Kit and Gauges for Pit Line Maintenance 24
10 Items for Rolling-in/Rolling-out examinations for ICF & LHB coaches 49
11 Check list for inspection of Coaching depot 55
12 Check list for inspection of DEMU 59
13 Check list for Super checking of DEMU 61
Handbook on Integrated Rolling Stock Depot Page 4 of 61
1.0 Standardization of Infrastructure and maintenance practices of MEMU/DEMU and Mainline Coaching Stock in the Integrated Rolling Stock (Coaching) Depot.
Vide Railway Board’s letter No. ERB-I/2016/23/67 dated 09.12.2016, a committee was
constituted consisting of DME/Chg., Railway Board (Convenor), DEE(G), Railway
Board, DME(Traction), Railway Board & Director/Mech/CAMTECH on the subject of
“Standardization of Maintenance Infrastructure and practices of MEMU/DEMU and
mainline coaching stock in the integrated Rolling stock coaching depots”.
2.0 Terms of Reference of the Committee:
a. To suggest short term and long term measures for the integration of trip, minor and medium repairs of MEMU/DEMU trains in the Mainline Coaching Depots of IR.
b. To suggest the infrastructure and facilities required in the new and existing integrated Rolling stock coaching depots.
c. To suggest ways to utilize the released capacity in the existing sheds/depots for MEMU/DEMU for carrying out major repairs of MEMU/DEMU rakes.
d. To review the various maintenance schedules and their periodicity for MEMU, DEMU and Mainline Coaching stock and suggest ways for rationalizing the same;
e. To suggest ways for the multi-skilling of staff and reducing the number of cadres engaged in the work of maintenance of MEMU/DEMU/Mainline coaches by appropriate training and other methods.
3.0 Details of Visits made by the Committee: The following sheds/Depots have been visited for analysis of requirements for integrated maintenance of Coaches, DEMU & MEMU.
(i) Diesel / DEMU Shed / SSB / NR on 04 & 07.01.2017 (ii) DEMU maintenance Depot/Medta Road/NWR on 05 & 06.01.2017. (iii) EMU Car Shed, Ghaziabad/NR on 07.01.2017. (iv) MEMU maintenance shed/Saharanpur/NR on 19.01.2017
The observations of the committee during these visits are placed at Annexure A
4.0 Collection of data
4.1 Dimensions of various types of Rolling stock
SN Type of stock Width Length Height
01 LHB Coach (Except DD) 3240 mm 24000 mm 4265 mm
02 LHB Double decker 3050 mm 24000 mm 4366 mm
03 ICF Coach 3245 mm 22297 mm 4025 mm
04 BEML coach 3250 mm 22296 mm 3991 mm
05 DEMU (DPC) 3245 mm 21417 mm 3886 mm
06 MEMU (Motor Coach) 3245 mm 21417 mm 4255 mm
07 MEMU (Trailer Coach) 3245 mm 21337 mm 3886 mm
Handbook on Integrated Rolling Stock Depot Page 5 of 61
4.2 Weight Chart of various Coaches:
Type of
stock
Motor/Trailer Tare weight Pay load Total Weight
DEMU 1600 HP
Driving Power Coach(DPC) 72.79 T 07.99T 80.78T
Trailer Coach (TC) 36.25 T 21.51T 57.76T
Trailer Coach Vender (TCV) 35.20 T 22.75T 57.95T
MEMU Motor Coach 59.00 T 2.42T 71.42T
Trailer Coach 35.00 T 21.12T 56.12T
LHB LHB Coach 44.50 T
Double Decker Coach 49.53 T
ICF Coach
ICF Coach 50.00 T 03.68 T 53.68 T
4.3 Arising of out of course repairs per year:
S.N. Item EMU Car Shed/GZB
MEMU Maintenance
Shed/SRE
DEMU Shed SSB
DEMU NWR
Remarks
01 Traction motor change
55 to 60 12 per year Not avl Not done
02 TM Bearing change
18 to 20 (both type)
5 per year Not avl Not done
03 Wheel Change
05 N/A N/A N/A
04 Main Compressor Change
9-10 N/A N/A N/A N/A
These items shall be provided as a Unit exchange spare in the sick line of the integrated Rolling Stock Depot.
5.0 Discussion on the Terms of Reference: 5.1 To suggest short term and long term measures for the integration of trip,
minor and medium repairs of MEMU / DEMU trains in the Mainline Coaching Depots of IR.
The committee has listed the “Short term” and “Long term” measures as follows:
A. Short term measures:
i. DEMU and MEMU rakes can be based at the nearest and most suitable Rolling Stock (Mainline) Depot for carrying out trip schedule.
Handbook on Integrated Rolling Stock Depot Page 6 of 61
ii. Each Railway where DEMU and MEMU rakes are running / maintained shall identify one or two such Rolling Stock (Mainline) Depots where the trip maintenance of DEMU and MEMU rakes can be carried out.
iii. Few pit lines shall be nominated for the trip maintenance of MEMU / DEMU. It is preferred that the shorter length pit lines, in case available, shall be nominated for the purpose. This shall avoid wastage of pit line capacity.
iv. Necessary facilities as listed in Para 5.2 shall be created at these depots.
v. These pit lines shall be top wired and made fit for the maintenance of MEMU /
DEMUs. Proper system for isolation of the OHE shall be provided. The feasibility of providing re-tractable OHE, which is automatically slewed away from the rake during its maintenance, shall be explored. A similar system is available in the pit lines of DMRC (Sarita Vihar depot).
vi. Both Railway and Contractor staff working in the pit lines shall be trained and
sensitized for taking precautions while working on the rakes on the adjacent lines so as to prevent any possibility of electrocution (such as not directing the high pressure jet towards the OHE, etc.). Regular safety drives shall be carried out in order to ensure proper isolation of OHE and observance of precautions by both Railway and Contractor staff. Meticulous records of the training and safety drives shall be maintained.
vii. The rake links of DEMU/MEMU trains may be planned in such a manner that
each rake is brought to the Integrated Rolling Stock (Coaching) Depot once every 10 days for trip maintenance.
B. Long term measures:
i. The monthly schedule for DEMU and 45 days schedule for MEMU shall be
carried out in the integrated Rolling Stock (Mainline) Depot. Based on the expertise acquired, practical experience gained and infrastructure created, this may be extended upto 6 / 9 monthly schedules for MEMU / DEMU in future.
ii. Multi-skilling of staff shall be carried out and there shall be only two cadres, i.e.
Welder & Technician, besides Helper. The Technician shall be responsible for the maintenance of both Electrical, Mechanical and Pneumatic systems. Such a system is already prevailing in MEMU depot at SRE.
iii. The existing MEMU / DEMU sheds shall cater to the major schedules and shall
maintain both MEMU and DEMU rakes.
5.2 To suggest the infrastructure and facilities required in the new and existing Integrated Rolling Stock Coaching Depots.
5.2.1 Pit line infrastructure:
The infrastructural requirements at the Integrated Rolling Stock Coaching Depots are listed below:
Handbook on Integrated Rolling Stock Depot Page 7 of 61
i. Overhead power supply with Isolation facility shall be provided on the lines nominated for the maintenance of MEMU / DEMU. OHE supply will be required to test the Motor Coach operations like pantograph, transformers, etc.
ii. The cleaning / washing of the rakes shall be carried out in separate washing / stabling lines.
iii. Shunting neck facility should be provided at both ends, at least in the green
field depots, to facilitate the shunting of MEMU / DEMU rakes within the depot without requiring permission from traffic department.
iv. All lines shall be connected at both the ends for easy placement and removal of
rakes, at least in the green field depots. (Director CAMTECH may check these points, whether they can be merged).
v. A dedicated track of 200 mts length shall be provided for testing of the MEMU /
DEMU rakes, At least in the green field depots. vi. The activity of washing line needs to be separated from the pit line examination
in case of MEMU / DEMU. vii. Accordingly, separate washing lines shall be developed for MEMU / DEMU.
These lines shall be equipped with carriage watering system, high pressure water jet cleaning system, washable apron and all other facilities stipulated for other end maintenance vide Railway Board’s letter No. 95/M(C)/141/1 dated 31.01.2007.
viii. An adequate number of stabling lines shall be required for the Placement /
Removal of rakes. The cleaning / washing of the rakes can be carried out at these stabling lines provided suitable facilities are developed.
ix. Pneumatic pipe line with sufficient tapping points at each coach location shall
be provided for feeding of air pressure.
x. An opening of adequate size (say 2 m) in pit line needs to be provided at each coach location on alternative sides, for facilitating the entry of staff and portable trolleys under the coach for attention to the sub-assemblies. Alternatively, the feasibility of
xi. A cantilevered platform constructed of SS grating shall be provided for the roof
inspection on the lines nominated for MEMU / DEMU. It should be ensured that there is no obstruction on the catwalk due to the platform.
xii. All infrastructure should be Road approachable with the provision of drainage.
xiii. Protection wall / boundary wall is also recommended for the Integrated
Coaching Depot. xiv. Automatic Coach Washing Plant and Water Recycling Plant should be provided
in each integrated rolling stock depot.
Handbook on Integrated Rolling Stock Depot Page 8 of 61
A schematic layout drawing of the pit lines covering the above points is enclosed as Annexure - E) for guidance. While finalizing the drawing, the recommendations of the Task Force on Improving the Safety Performance of Indian Railways constituted vide Board’s letter No.ERB-I/2016/23/66 dated 06.12.2016, have been looked into by CAMTECH. Some of these recommendations given in Para 2.3 of the Task Force’s report are listed below:
(a) All pits to be provided with low voltage, energy efficient, bright LED lights. The lights should be directed upwards so that the under gear is illuminated.
(b) All future pitlines and those being renovated / expanded should be built for all-
weather use, i.e. with a covered shed with adequate provisions for lighting, drainage, etc.
(c) Tools and equipment for train examination should be standardised and issued
to each staff member with personal lockers too allotted each person for safe keeping.
(d) Proper Rolling-in Examination huts to be built to protect the TXR staff from
weather.
(e) Bright, light-weight and energy efficient LED lights to be introduced in place of the present design of clumsy, heavy lights.
(f) A switch to Machine Vision Systems with Automatic High Definition Camera
and Artificial Intelligence based fault detection and recording system to be introduced.
(g) Such Automatic Machine Vision devices should also be introduced in pit lines
to examine the under gear as trains are placed on them. Each new proposal of Coaching Depot should be that of an Integrated Rolling Coaching Stock Depot. The existing depots should also be provided with the requisite facilities and infrastructure to permit for maintenance of MEMU / DEMU, in addition to Mainline coaches, for trip, minor and medium repairs. 5.2.2 Sick line infrastructure:
i. One separate wheel parking line of approx. 80 mtrs. length is required in the integrated depot.
ii. RCC apron shall be provided upto 20 m outside of the shed on both sides.
iii. Pit Wheel Lathe machine should also be provided in the coaching depot for
coach holding more than 200 coaches. iv. Requirement of cranes / jacks :
MEMU : The weight of motor coach minus bogies (@ 10T each) = 39T. Thus, it shall be possible to lift the coach with synchronized jacks (15T) or 2x25T cranes that are available in the coaching sick lines.
Handbook on Integrated Rolling Stock Depot Page 9 of 61
DEMU : The weight of DPC minus bogies (@ 10T each) = 53T. Thus, it shall be not possible to lift the coach with 2x25T cranes that are available in the coaching sick lines. Instead at least two sets of synchronized jacks (15T) shall have to be available for lifting of these coaches.
v. Special Machines & Plants required in the Rolling Stock Depots (for maintenance of MEMU)
1. Filter cleaning plant 2. Battery charger 3. Oil centrifuging/filtering plant 4. EOT Cranes (5 Tons) for handling of traction motor, wheel, compressor,
radiator, etc. 5. Relay/sensor/gauge calibration Panels 6. Tirfors, hydraulic Jacks 7. DGA/BDV/Tan Delta / LCRQ / Lux meter / DPT / MPT/ Hardness testing /
spring testing kit, etc. 8. Portable platform for access to roof equipment.
vi. Special Machines & Plants required in the Rolling Stock Depots (for
DEMU) 1. HSD oil installation or CNG gas filling facility shall be provided in the integrated
Rolling Stock Depot. 5.2.3 Record Keeping: a. A computer based system for proper record keeping shall be adopted.
b. Proper systems shall be developed for the maintenance of IT based systems
that are progressively being provided in coaches such as EP brake systems; CCTV based surveillance system; Micro processor based controls; On-board condition monitoring systems; RFID tags, etc. The staff shall be trained in these systems.
c. Adequate availability of computers, printers with high speed Internet access shall be provided.
5.3 To suggest ways to utilize the released capacity in the existing sheds/depots for MEMU/DEMU for carrying out major repairs of MEMU/DEMU rakes.
i. The new facilities proposed to be created for the major maintenance of MEMU / DEMU should cater to both these type of stocks and should be created at centralized locations where these rakes could be send for major repairs.
ii. The capacity released in the existing MEMU / DEMU sheds due to the trip / monthly maintenance proposed to be carried out at the Integrated Rolling Stock Coaching Depots, will be utilized for carrying out major schedules and POH of more number of MEMU / DEMU coaches.
Handbook on Integrated Rolling Stock Depot Page 10 of 61
iii. The MEMU / DEMU rakes shall be fed to these sheds for the major schedules in the form of rakes.
iv. Facilities required at MEMU sheds to maintain DEMU and vice versa
Maintaining MEMU in the existing DEMU sheds and Maintaining DEMU in the existing MEMU sheds
(i) Following MEMU / DEMU sub-assemblies can be maintained / overhauled at
the DEMU / MEMU Depots with the existing facilities:
a. EP Brake system b. Bogies c. Passenger amenities d. Speedometers e. Traction Motors f. Auxiliary Motors g. Power Contactors h. Inter Vehicular Couplers i. Schaku coupler j. Reverser k. Master Controller l. Lights and Fans, etc.
(ii) Facilities for the maintenance / testing of following MEMU sub-assemblies shall
be created in the DEMU sheds:-
a. Transformer b. Tap changing contactors c. Rectifier single phase d. Pantograph e. Master Controller f. Auxiliary motor g. Reverser unit h. Compressor Section (for electrically driven compressor)
(iii) The DEMU sheds shall have to be top wired with proper isolation facilities.
(iv) Facilities for the maintenance / testing of following DEMU sub-assemblies will
need to be created in the MEMU sheds:
a. HSD oil installation or CNG gas filling facility. In case the installation is available at a nearby station, the same may be utilized for fuelling.
b. Power pack Section c. Compressor Section (for engine mounted compressor) d. Radiator section e. Hydraulic systems section f. Governor section
Handbook on Integrated Rolling Stock Depot Page 11 of 61
5.4 To review the various maintenance schedules and their periodicity for MEMU, DEMU and Mainline Coaching stock and suggest ways for rationalizing the same
The recommendations for the various maintenance schedules and their periodicity are included in Annexure B. In particular, the committee makes the following recommendations:
a. The UST of axle is carried out in every IC schedule as per SMI0037. The committee recommends that UST of both Motor and Trailer coaches of MEMU and DEMU be carried out after 9 months. This will require validation by RDSO.
b. The trip examination of DEMU shall be carried out after 10 days or 3500 Kms,
whichever is earlier. This has also been recommended vide ED/Carriage/RDSO’s letter No.MC/RLC/D dated 01.03.2017, on a trial basis. Based on the results of the trial, this periodicity of pit maintenance of DEMU may be regularized.
c. DEE/G/Railway Board has also informed that the maintenance periodicity of 3
phase MEMU rakes shall be revised upwards, as and when these rakes are inducted.
d. DEMU and MEMU should go for POH as a complete rake like EMU rake.
e. Automatic Schaku Coupler similar to Kolkata Metro coaches should be
provided on the end coaches of each unit of MEMU / DEMU for facilitating easy coupling and uncoupling. This was also mentioned in MRS inspection note of MEMU car shed, BRCY on 14.10.2016. This shall have to be validated by RDSO.
f. Bio-toilets should be provided in MEMU & DEMU. g. Testing of rakes (MEMU): The MEMU rakes are tested during TI schedule.
The details are entered in the log book. The engine turner takes charge of the rake. There is no separate system of issue of BPC.
h. Examination of MEMU / DEMU at the stabling points and issue of BPC
At present, the MEMU trains are turned out with 100% brake power by the sheds after the trip maintenance. Skeletal gangs have been provided by the MEMU sheds at the stations where these rakes are stabled. These staff peruse the log book and carry out visual examination of the rakes.
i. It is proposed that this activity shall be integrated with the duties of TXR staff, in
case the MEMU / DEMU rakes are stabled at the nominated TXR stations. The staff of the MEMU shed deputed at these stations shall not be withdrawn for at least 6 months and shall work under the control of TXR. In case of any unusual / trouble shooting, assistance of the MEMU shed can be sought by the TXR.
Handbook on Integrated Rolling Stock Depot Page 12 of 61
j. In case, the rakes are stabled at non-TXR stations, the existing system shall continue and skeletal gang shall be deputed by the base MEMU shed.
k. At present there is no system of daily maintenance of the DEMU rakes. It is
proposed that a system similar to that proposed for MEMU (para i & j above) shall be adopted for maintenance of DEMU. This is essential since the periodicity of trip examination is being enhanced from 7 days to 10 days. Moreover, proper cleaning, watering, etc. is essential.
l. On many of the Railways, the practice of issuing BPC for DEMU, for each
journey has already been discontinued. The base shed issues BPC which is valid for 7 days. The Committee propose to standardize the system across all the Railways.
6 To suggest ways for the multi-skilling of staff and reducing the number of
cadres engaged in the work of maintenance of MEMU/DEMU/Mainline coaches by appropriate training and other methods.
a. Staff deployment and time taken for trip and minor schedules : The
committee has reviewed the actual staff deployment and time taken for carrying out the trip / monthly / 45 days schedule at the DEMU / MEMU Sheds at SSB and SRE.
b. The committee interacted with the officers and supervisors of SSB DEMU shed.
The time taken for the trip schedule is 5 hours and the time taken for the monthly schedule is 8 hours. The staff deployment for trip and monthly schedule is as follows:
Activity Trip (Staff required/rake)
Man hours
(@5 hrs for trip sch.)
Monthly (Staff required/rake)
Man hours
(@8 hrs for trip sch.)
Remarks
Under gear 5 25 3 25
Upper gear 4 20 3 20
Engine (B check)
16 @ 4 staff per
DPC
Dashpot oiling
8 staff @ 0.5 staff per coach
The engine (B check) and dashpot oiling is generally staggered between the trip and monthly schedules in order to optimize the utilization of man power.
c. The committee interacted with the officers and supervisors of GZB MEMU shed. It is seen that a total of 16 staff are deputed for the trip schedule of 12 Car MEMU/EMU rake which is carried out in about 6 hours. Further, a total of 154 staff are deputed for the schedule inspection of 12 car EMU/MEMU rake
Handbook on Integrated Rolling Stock Depot Page 13 of 61
having IC, IB & IA inspection which is carried out in 8 hours. The detailed activity wise Staff Deployment at MEMU Shed/SRE is placed at Annexure C.
d. The committee has noted that there is some variation in the manpower
deployed and time taken by different sheds. Hence, the data at Annexure C and at Paras b & c above can at best serve as guidance for the actual staff deployment and the same shall have to be decided by the Railways based on local practices. Further, a fresh benchmarking study can be ordered in order to arrive at the optimal man power deployment and time taken for the trip, minor and medium schedules for MEMU and DEMU.
e. Multi skilling of staff and merger of trades
As a long term measure, the committee recommends that multi-skilling of staff shall be carried out and there shall be only two trades, i.e. Welder, Technician, besides Helper. The technician shall be responsible for the maintenance of Electrical, Mechanical and Pneumatic systems. The MPP Dte. of Railway Board shall issue necessary instructions for the multi-skilling of staff and merger of trades. Such a system is already prevailing in MEMU depot at SRE, where there is only one cadre of staff who can be rotated between electrical, mechanical and pneumatic jobs.
f. The Integrated Rolling Stock (Mainline) Depots nominated for maintaining DEMU and MEMU rakes, shall identify an adequate numbers of qualified and willing supervisors / staff who shall be trained in the maintenance of MEMU / DEMU. These ssupervisors / staff shall be given 2 Weeks training in MEMU and also DEMU, by the respective DEMU/ MEMU training centers.
Subsequently, the DEMU/ MEMU depots shall depute certain staff for working in the gang formed by the Rolling Stock (Mainline) Depot, so that the C&W / Electrical staff of the depots that are deputed in the gang can be given on job training. The practice of deputing the staff from DEMU / MEMU depots to Rolling Stock (Mainline) Depot shall be discontinued after a period of one year and the staff of the Rolling Stock (Mainline) Depot shall be responsible for carrying out the trip / 45 days and perhaps higher schedules of these rakes.
g. Posting / Rotation of Officers : Vide Board’s letter No.2015/M(L)/466/1 Pt. (A) dated 17.01.2017, Exec. Dir. Mech. Engg (Tr.) and Adviser Electrical (RS), Railway Board have issued joint instructions for the maintenance of Diesel Locos in Electric Loco Sheds and Electric Locos in Diesel Locos Sheds. It has also been stated that for the homing MEMUs in DEMU Shed and DEMUs in MEMU Shed, the same mechanism as detailed for Electric/Diesel Locomotives will be followed.
Accordingly, the responsibility for maintenance of MEMU homed in DEMU sheds shall devolve on the existing officers, staff and supervisors of the DEMU Shed. Suitable training in the maintenance of MEMU shall be arranged for them by CEE of the Railway. In order to assist the DEMU Shed Management in the maintenance of MEMU, one Junior scale officer would be posted by CEE in the DEMU shed. The
Handbook on Integrated Rolling Stock Depot Page 14 of 61
administrative control and reporting structure for this officer would be the same as other Junior Scale Officers of the Mechanical Engineering Department. A similar system shall be adopted for the maintenance of DEMU homed in MEMU sheds.
h. All technical issues pertaining to MEMUs will be dealt with by Adv. L(B)/EDEE(B)/CETE and those pertaining to DEMUs will be dealt with by EDME(Tr.)/CMPE at Headquarters/Railway Board level.
i. As per the recent reorganization of the various departments, the overall
responsibility for the proper maintenance of DEMU & MEMU shall be of CME on the Zonal Railway.
6.0 Recommendations of the Committee a. In the short term, DEMU and MEMU rakes shall be based at the nearest and
most suitable Rolling Stock Depot for carrying out trip schedules.
b. Few pit lines shall be nominated for the trip maintenance of MEMU / DEMU rakes at these depots and the required facilities as listed in Para 5.2 of the report shall be created at these depots.
c. The rake links of DEMU/MEMU trains may be planned such that each rake is
brought to the Integrated Rolling Stock (Coaching) Depot once every 10 days for trip maintenance.
d. In the long term, even the monthly schedule for DEMU and 45 days schedule
for MEMU shall be carried out in the integrated Rolling Stock (Mainline) Depot. Based on the expertise acquired, practical experience gained and infrastructure created, this may be extended upto the 6 / 9 monthly schedules for MEMU / DEMU in future.
e. Each new proposal of Coaching Terminal should be that of an integrated
Rolling Coaching Stock Depot.
f. CAMTECH shall finalize the drawing for the Integrated Depots within 2 months, including the facilities required to be created in the existing depots.
g. The existing MEMU / DEMU sheds shall cater to the major schedules and shall maintain both MEMU and DEMU rakes. The required facilities as listed in Para 5.3 of the report shall be created at these depots.
h. To the extent possible, proliferation of MEMU / DEMU car sheds should be
avoided. Larger sheds holding 10 rakes or more should be planned.
i. The new facilities proposed to be created for the major maintenance of MEMU / DEMU should cater to both these type of stocks and should be created at centralized locations where these rakes could be sent for major repairs.
Handbook on Integrated Rolling Stock Depot Page 15 of 61
j. The capacity released in the existing MEMU / DEMU sheds due to the trip / monthly maintenance proposed to be carried out at the Integrated Rolling Stock Coaching Depots, will be utilized for carrying out major schedules and POH of more number of MEMU / DEMU coaches.
k. Systems of automatic train inspection and condition monitoring shall be
introduced. For example, Machine Vision Systems with Automatic High Definition Camera and Artificial Intelligence based fault detection and recording system shall be introduced at the en-route stations as well as at the pit lines of the Integrated Rolling Stock Depots. This is also a Task Force recommendation.
l. The recommendations for the various maintenance schedules and their
periodicity are contained in Annexure B of the report.
m. DEMU and MEMU should go for POH as a complete rake like EMU rake.
n. Automatic Schaku Coupler similar to Kolkata Metro coaches should be provided on the end coaches of each unit of MEMU / DEMU for facilitating easy coupling and uncoupling.
o. The new MEMU / DEMU rakes shall be standardised as per RDSO’s
recommendations (Para5.4 (l)).
p. Bio-toilets should be provided in MEMU & DEMU.
q. The interior maintenance can be outsourced (as was done at the SRE MEMU Shed).
r. Toilets are being provided in DEMU and MEMU trains since 2011. Suitable
arrangements shall be made by the Railways for the cleaning of the coaches and toilets, including watering, of MEMU / DEMU at Terminals and also En-route.
s. Proper facilities for cleaning / watering of the rakes shall be provided at the
location of stabling the rakes, as well as at the intermediate stations.
t. Proper facilities for cleaning / examination of the rakes shall be provided at the location of stabling the rakes. Adequate illumination shall be ensured.
u. The rolling-in examination of MEMU / DEMU shall also be carried out at the
nominated stations by TXR staff, as is done for main line trains.
v. Examination of MEMU / DEMU at the stabling points and issue of BPC:
m. This activity shall be integrated with the duties of TXR staff, in case the MEMU / DEMU rakes are stabled at the nominated TXR stations. The staff of the MEMU shed deputed at these stations shall not be withdrawn for at least 6 months and shall work under the control of TXR. In case of any unusual / trouble shooting, assistance of the MEMU shed can be sought by the TXR.
Handbook on Integrated Rolling Stock Depot Page 16 of 61
In case, the rakes are stabled at non-TXR stations, the existing system shall continue and skeletal gang shall be deputed by the base MEMU shed. A system similar to that proposed for MEMU shall be adopted for maintenance of DEMU. This is essential since the periodicity of trip examination is being enhanced from 7 days to 10 days. Moreover, proper cleaning, watering, etc. is essential.
w. On many of the Railways, the practice of issuing BPC for DEMU, for each journey has already been discontinued. The base shed issues BPC which is valid for 7 days. The Committee propose to standardize the system across all the Railways. The train crew shall carry out the brake feel test as for the provision of G&SR. In no case should the safety of trains get compromised. The details of the checks made by the TXR / Skeletal gang shall be endorsed in the log book, as is being done for MEMU.
x. The Integrated Rolling Stock (Mainline) Depots nominated for maintaining
DEMU and MEMU rakes, shall identify an adequate numbers of qualified and willing supervisors / staff who shall be trained in the maintenance of MEMU / DEMU. These supervisors / staff shall be trained in the maintenance of DEMU/ MEMU.
y. The DEMU / MEMU depots shall depute supervisors / staff to the Integrated Rolling Stock Depot for a period of one year for providing on-job training to the C&W / Electrical staff of the Rolling Stock Depots and working in the gang.
z. The merger of trades and multi-skilling is recommended by the Committee.
aa. An ADEE shall be posted in the DEMU Shed and an ADME shall be posted in the MEMU shed by CEE / CME respectively.
bb. In case of any problem in the MEMU / DEMU, the base home shed shall be contacted who shall render necessary assistance.
cc. As per the recent reorganization of the various departments, the overall responsibility for the proper maintenance of DEMU & MEMU shall be of CME on the Zonal Railway.
dd. The benefits accruing out of the integration of maintenance of different types of Rolling Stock, in terms of improved maintenance, operational flexibility, and lesser infructuous movement of the MEMU / DEMU rakes shall be documented by the Railways.
ee. Replacement of conventional loco-hauled trains with MEMU/DEMU : In view of the advantages of MEMU / DEMU trains in terms of distributed powering, non-requirement of reversal, etc., the committee consider that it may be advisable to replace at least the short distance passenger trains with MEMU / DEMU in the congested corridors. This may also be necessary due to the decision to retrofit CBC in ICF coaches having a residual life of minimum 10 years. Replacement of passenger trains with MEMU / DEMU will reduce the requirement of retro fitment and also provide spare coaches for running the existing screw coupling ICF trains until they are converted to ICF with CBC or LHB.
Handbook on Integrated Rolling Stock Depot Page 17 of 61
Handbook on Integrated Rolling Stock Depot Page 18 of 61
Handbook on Integrated Rolling Stock Depot Page 19 of 61
Handbook on Integrated Rolling Stock Depot Page 20 of 61
Annexure A
Observations during the visits to DEMU/MEMU/Sheds
S
N
ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR
Total
Holding
Activity Maintains both EMU
and MEMU
Trip & Monthly
schedules
All schedules of
DEMU
Trip & Monthly
schedules
1 Pit lines 04 lines of 16 coach
length with covered
shed (extension for 20
coaches under
progress). Platform
provided only on one
side. All covered pit
lines are available for
12/16 cars for
maintenance of two
MEMUs/EMUs rakes
having length of
approx. 360 meters
each & width approx.
30.00 meters. Catwalks
of 1.5 meter width are
provided at one side &
open space is kept in
the middle for
movement of
lifter/listers for
loading/unloading of
minor assemblies. The
pit line is prepared on
steel pillars for easy
movement of hydraulic
trolleys for
dismounting/ mounting
of electrical machines/
equipments.
Two lines of
approx. 360
meters width
approx. 16.00
meters catwalk
1.5 meters open
space in middle
for movement of
lifters. The pit
lines are on RCC
pillars spacing 4.0
meters with
continuous RCC
beam.
Two lines of 480
mtrs length.
No crane was
planned in this
shed for lifting of
minor assemblies
like compressor
unit & Radiator etc.
as the heavy repair
section is available
for this task.
The covered pit line is
under construction for
maintenance of two
DEMU rakes having
length of 270 meters
(proposed 360 meters
for 16 cars) & width
approx. 16.97 meters
(for 12 coach rake).
Catwalks of 1.6 meter
width are being
provided at both sides
& open space is kept
in the middle for
movement of
lifter/listers for
loading/unloading of
minor assemblies. The
water filling & fuel
oil filling facilities
will also be provided
at platform itself. A
05 ton capacity crane
is planned in this shed
for lifting of minor
assemblies like
compressor unit &
Radiator etc.
2 Washing line One washing line of 16
coaches length
available with both side
platforms. Automatic
coach washing plant
also installed at one
end.
One washing line
of 12 MEMU
length with
ACWP
NO ACWP
provided
ACWP is proposed.
Handbook on Integrated Rolling Stock Depot Page 21 of 61
S
N
ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR
3 Heavy
Repair Bay
02 lines each of 06
coach length available
with 03 Nos. 30/10 ton
overhead cranes. 15 ton
Jamalpur screw jacks
available. Lifting
mostly being done with
overhead cranes.
One SR section
with 25 T, 2 Nos
EOT cranes for
(3+1)x2 coach
length.
One Heavy repairs
section is available.
One sick line for
(3+1) coach length X
2 is available in the
depot. Pit is provided
only on one line. At
present one No. 5 ton
capacity crane is
provided for this sick
line shed. In future,
30 ton capacity crane
would be installed.
4 Bogie
Section
One line of 06 coach
length & open area for
the overhauling of
bogies, with 03 nos.
15/5 ton overhead
cranes. A Bogie wash is
available.
Not required One bogie section
is available
Not required
5 Traction
motor
section
Traction motor section
is available
Not required Traction motor
section is available
Not required
6 Officers/
Sections
along
subassembly
bay
Ground floor and first
floor have been utilised
for accommodating
various section. First
floor lying almost
empty. One room for
each SSE/Incharge
dealt with POH activity.
One room for
SSE/incharge,
one room for
JE/SE shift, one
room for
Electrician, one
store, one welding
room, one
pneumatic section
and one test
room.
One room for
SSE/Incharge. One
room for JE/SSE
shift incharge. One
room for Diesel
Mechanic
/Electrician. One
welding set room.
Two rooms have
been constructed
for DPT testing and
engine lube oil
testing. One
supervisor and 3
staff are working
for this activity.
One room for
SSE/Incharge. One
room for JE/SSE shift
incharge. One room
for Diesel
Mechanic/Electrician
staff with sufficient
lockers. One room for
welding set. A service
building is under
construction,
including the offices
of Sr.DME /DME,
Training centre (One
hall for classes & one
model room), one hall
for hostel, one elect
panel room & one
canteen.
7 Coach
Repair shop
Coach repair shop of
one coach length
available for corrosion
repair and other
carpentry works.
Not required - Not available
Handbook on Integrated Rolling Stock Depot Page 22 of 61
SN ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR
9 Pit wheel
Lathe
Machine
Available (HYT make) Available Available Proposed
10 Stabling
Lines
Two stabling lines
capacity of 16+12 cars
each.
Not available - One line available
11 Turn table One turn table available
for turning of motor
coaches
Not required - Not required
12 RCD Not required Not required One RCD is
available. SSE
suggested that at
least 100 KL
capacity RCD is
required in depot.
One RCD is
proposed. At present
fuelling of DEMUs is
done at Jodhpur
13 Brake
System
/Pneumatic
Pipe line
One room for EP/air
brake section is
provided for testing of
brake equipments.
One pneumatic
section for valve
test bench, EP
unit test bench,
EP test bench &
bench vice etc.
One room for air
brake section for
testing of brake
equipments. One
compressor room
with the provision
of two air
compressors.
One room for air
brake section is
proposed for testing
of brake equipments.
One compressor room
is proposed.
14 Lubricatin
g oil testing
Facilities available with
C&M staff
Transformer oil
centrifuging plant
available
Facilities available
with C&M staff
One room is
constructed for DPT
testing and engine
lube oil testing. One
15 Store One AMM office/store
is available for
stocking/procurement
of items of
EMU/MEMU coaches.
One room for sub
store/Running store is
available.
One hall for main
store for approx
206 stock items
and 100 NS items
is available.
One hall for main
store having size
22x12 meters for
stocking of approx.
200 items of
DEMU. One hall
for sub store/Shift
store of size 20x10
meters. One
godown for storage
of engine oil
barrels.
One room for main
store is available for
stocking of items of
DEMU. One room for
sub-store/Running
store.
16 DM plant One DM plant is
provided for
requirement of distilled
water.
One DM plant is
provided for
requirement of
distilled water
DM plant is
provided for
requirement of
distilled water
One DM plant is
proposed
Handbook on Integrated Rolling Stock Depot Page 23 of 61
S.
N.
ITEM MEMU/EMU GZB MEMU/SRE DEMU/ SSB DEMU/NWR
17 Computer
Room
Computer cell is
provided for
maintenance of data
and filling of
maintenance schedule
forms & day to day
works
One Computer
was available
with SSE/store
for material
procurement and
data filling.
Computer cell is
provided for the
maintenance of
data and filling of
maintenance
schedule forms &
day to day works
with one clerk.
Computer cell is
proposed for
maintenance of data
and filling of
maintenance schedule
forms & day to day
works with one clerk.
18 Tool room One separate tool room
is provided for keeping
tools, gauges, spanners,
pipe wrenches & UST
etc. for supply to
technicians & for
keeping record of
calibrations.
One tool room for
tools and gauges.
One tool room for
keeping tools,
gauges, spanners,
pipe wrenches etc.
for supply to
technicians &
keeping record of
calibrations
Separate tool room is
not available.
19 Material
handling
One suitable capacity
truck is available.
- One suitable
capacity truck is
provided.
Truck is not available.
Handbook on Integrated Rolling Stock Depot Page 24 of 57
(Govt. of India) (Ministry of Railways)
STANDARDISATION
OF
TOOL KIT & GAUGES
FOR
PIT LINE MAINTENANCE
[ For official use only ]
APRIL-2017
Handbook on Integrated Rolling Stock Depot Page 25 of 57
FOREWORD
Hand-Book on Standardisation of Hand Tool Kit for pit line
maintenance staff is an important step towards ensuring implementation of
effective and uniform maintenance procedures in coaching depots. CAMTECH &
Mech. Directorate/Railway Board has taken an important lead in this direction by
preparing this hand-book giving compiled list of hand tools & gauges required for
coach maintenance.
In this Hand Book, detailed description with use of each hand tool with
important parameters will prove to be useful to the maintenance depots. As a result
of introduction of hand tool kit, quality & timely maintenance can be ensured to
meet traffic requirements of coaches in the present scenario.
EDME/CAMTECH
Handbook on Integrated Rolling Stock Depot Page 26 of 57
PREFACE
Vide item No.12 of the inspection notes of RNCC on 15/02/2015, MRS has mentioned that the staff working in the pit lines should be given proper tools to enhance the work output and a standard tool kit shall be made available to all the fitters individually. CAMTECH has issued a Handbook on Standardization of Hand Tools for Coach Maintenance-April-2014 which is provided for tools to be kept on tool bag as well as tools be made available in tool room for maintenance by fitters. The list of tools / gauges mentioned therein is highly voluminous and it is not practically feasible to carry all the tools by the fitter in a bag. Therefore, a review based on the present requirements for pit line maintenance fitters was necessary. For this purpose, Director/Mech./CAMTECH & Director Mech. Engg.(Chg.)/Railway Board visited Coaching complex, New Delhi and DEE depots for analysis of practical feasibility of containing of tools in the hand bag by fitters. Based on the interaction with Depot Officers and Staff of NDLS Division (NDLS and DEE Depots), the set of tools and gauges that need to be carried by the under gear, side examination and pressure test gangs of pit line examination of LHB and ICF trains have been reviewed considering current working trends and requirements. Besides, tools / gauges that are not required frequently may be kept in the Tool Room. While finalizing the tool kit, inputs have also been obtained from BCT Depot of WR & Coaching depot/BPL & JBP of WCR. Other Items These may also be provided to the Pit line staff or kept in the tool room as mentioned below: 1. Tool Bag : The Tool Bag shall have 2 compartments. It shall be of canvas
of dimensions 15” width, 18” length and 4” thick. It shall have a shoulder strap.
2. Industrial safety shoes : Prevents slipping, protects feet. It shall be issued
to the fitters of each of the 3 gangs once every year along with the uniform.
3. Helmet : For reasons of hygiene, this should be made a personal item of
the staff. It shall be issued to the fitters of each of the 3 gangs once every year
along with the uniform.
4. Portable lights
A. Portable lights for Carrying out train examination and light repairs
:This shall be a tool room item. The specifications shall be White LED light of
minimum intensity 300-500 lux at a distance of approx. 18 inches. Magnetic fixing
arrangement shall be available on helmet. The light shall be re-chargeable and
have multifocal lengths.
Handbook on Integrated Rolling Stock Depot Page 27 of 57
B. Portable lights for Heavy Works : Further, additional portable White LED
re-chargeable lights of 20W and 50W should be available for carrying out heavy
work. These lights should be adjustable and shall be equipped with a proper stand
for keeping them inside or on the side of the pits while carrying out heavy work.
Photographs of such lights procured by BCT depot of WR are provided in the
report along with their detailed specification. The list of tools / gauges is provided
with photograph & indicating use of each tool.
(K.P.Yadav)
Director/Mech/CAMTECH
Handbook on Integrated Rolling Stock Depot Page 28 of 57
List of Tools and Gauges required for Pit line Gangs
S.N. Item LHB Gang
Utilization ICF Gang
Utilization
Under Gear Gang
A Tools:
01 Cotter Punch 12” Yes Split Pins Yes Split pin, bulb cotter
02 Pin Punch 12” Yes Split Pins Yes Split pin, bulb cotter
03 Nylon Mallet 200 gm Yes Tapping of Brake Disc No --
04 Allen Key 10 mm [ Full set ]
Yes Tighten studs of Longitudinal Bump stop
No --
05 Ball Pin Hammer 900 gm
Yes Split pins Yes Split pin, bulb cotter
06 Open Spanner-16x17 Yes Lateral Bump stop, lateral damper
No
07 Open Spanner-18x19 Yes Longitudinal Bump stop, lateral damper
Yes ESR Safety Bracket bolt
08 Ring Spanner-18x19 Yes Lateral damper Yes ESR safety bracket
09 Open Spanner-24x27 Yes Replace Brake pads Yes Truss bar safety wire rope bolt
10 Ring Spanner-24x27 Yes Rocker arm bolts Yes Truss bar safety wire rope bolt
11 Open Spanner-30x32 Yes Supporting device securing bolt
Yes Brake cylinder Mounting bolts
12 Ring Spanner-30x32 No Supporting device securing bolt
Yes Brake cylinder Mounting bolts
13 Open Spanner-32x36 Yes Buffer Bolt Yes Centre pivot bolts, anchor link bolt
14 Ring Spanner-32x36 No -- Yes Centre pivot bolts, anchor link bolt
15 Open Spanner-36x41 Yes Angle cock / ferrule check nut, adjusting brake cylinder
No --
16 Open Spanner-41x46 Yes Angle cock / ferrule check nut, adjusting brake cylinder
No --
17 Chisel 8 inch No -- Yes Cutting of defective split pins, bolts.
Handbook on Integrated Rolling Stock Depot Page 29 of 57
B Gauges: LHB Gang
Utilization ICF Gang
Utilization
01 Steel measuring tape 2 m
Yes Buffer stroke, buffer Height, etc.
Yes Buffer stroke, buffer Height, etc.
02 Tyre Defect Gauge Yes Wheels Yes Wheels
03 Inside Calliper 2” Yes Gap between Lateral / Longitudinal / Vertical Bump Stops
No --
Following additional tools should also be kept in Tool Room for use by Pit
line maintenance gang -
1. Ratchet with goti set (small)
2. Torque wrench (Big) with goti set 170 mm
3. Allen Key set up to 10 mm
Handbook on Integrated Rolling Stock Depot Page 30 of 57
SN
Side Inspection Gang:
A Tools: LHB Gang
Utilization ICF Gang
Utilization
01 Ball Pein Hammer 900gm
Yes Split pin
Yes Split pin, bulb cotter etc.
02 Cotter Punch 12” Yes Split Pins No --
03 Open Spanner 16x17
Yes Foot Board Yes Axle box crown bolt
04 Ring Spanner 16x17
Yes Foot Board Yes Axle box crown bolt
05 Open Spanner 18x19
Yes Secondary Damper Yes Dashpot safety U bolt
06 Ring Spanner 18x19
Yes Secondary Damper Yes Dashpot safety U bolt
07 Open Spanner 24x27
Yes Primary Damper, Axle Box Face Plate
Yes Brake head shoe bolt, dashpot vent screw
08 Ring Spanner 24x27 Or Box spanner with ratchet
Yes Primary Damper, Axle Box Face Plate
Yes Brake head shoe bolt, dashpot vent screw
09 Open Spanner 30x32
No -- Yes Axle box face plate bolts, bolster safety U strap, shock absorber bolt (bottom)
10 Ring Spanner 30x32 Or Box spanner with ratchet.
No -- Yes Axle box face plate bolts, bolster safety U strap, shock absorber bolt (bottom)
11 Open Spanner 32x36
No -- Yes Crown bolt, shock absorber bolt (Top)
12 Ring Spanner 32x36
No -- Yes Crown bolt, shock absorber bolt (Top)
13 Full set of Allen Keys
Yes For CBC lock bracket, speed sensor fixing etc
No --
14 Box spanner with ratchet, size 13,15
Yes For earthing device maintenance
No --
15 Circlip Plier 6 inches
Yes For earthing device maintenance
No --
16 Magnifying Glass for checking minor cracks
Yes For checking of minor cracks in the components.
Yes For checking of minor cracks in the components
B Gauges LHB Gang
Utilization ICF Gang
Utilization
01 Resetting Key for ACP Yes CBC handle resetting key No --
Feeler Gauge No -- Yes To check rubber bonding of silent blocks
02 Steel scale 6 inches No -- Yes A, B, C dimension of bogie, gap between safety U strap and a lug.
03 Dip stick No -- Yes Dashpot oil level
Handbook on Integrated Rolling Stock Depot Page 31 of 57
SN Pressure Testing Gang:
A Tools: LHB Gang
Utilization ICF Gang Utilization
01 Ball Hammer 900gm Yes Ferrule,air hose change Yes Split pin, bulb cotter etc.
02 Pipe Wrench 14” Yes Air Hose change Yes Angle cock, air hose, drain cock, pipeline of ACP
03 Pipe Wrench 18’’ Yes Air Hose change Yes Angle cock, air hose, drain cock, pipeline of ACP
04 8 inches long ferrule punch(8X32) mm
Yes For replacing the ferrules No --
05 Screw Driver 9 inch No -- Yes Opening of PESD cover
06 Socket 10 mm Yes Angle cock Bracket No --
07 Open Spanner 10x11 Yes Angle cock Bracket No --
08 Open Spanner 11x12 No -- Yes PEASD and PEV fixing bolt, DV released choke
09 Ring Spanner 11x12 No -- Yes PEASD and PEV fixing bolt, DV released choke
10 Open Spanner 12x13 Yes Speed Sensor Stud No --
11 Open Spanner 18x19 No -- Yes DV / CR
12 Ring Spanner 18x19 Yes Tighten inspection stud of Axle Box Speed Sensor
No --
13 Open Spanner 24x27 No -- Yes Flexible hose of brake cylinder, brake pipeline, common pipe bracket / DV / CR, dirt collector, drain cock, AR dummy bolt, AR pipes.
14 Open Spanner 41x46 Yes Ferrules, BP/FP Mainline Yes Angle cock, air hoses
15 Resetting Key for ACP
Yes Resetting of ACP No --
16 Screw driver set (flat/Fillips)
Yes For WSP cards, connectors etc,hose clips for speed sensors.
No --
17 Wire stripper Yes For wiring related work No --
18 Multi-meter Yes For wiring related checks No --
19 Full set of Allen Keys Yes For ICV pull box, Junction box etc.
No --
B Gauges:
01 Feeler gauge Yes Gap between speed sensor & phonic wheel
No --
Handbook on Integrated Rolling Stock Depot Page 32 of 57
02 Pressure gauge adopter
For checking brake cylinder pressure
No --
03 Stop watch Yes For releasing time Yes For releasing time
04 Steel scale 6 inch / Piston stroke gauge (GO-NO GO type)
No -- Yes To check the piston travel
05 Spring balance (0-15 kg)
Yes To check the ACP apparatus
Yes To check the ACP apparatus
For TXR
01 Only measuring tape Yes For measuring dimensions
Yes For measuring dimensions
Handbook on Integrated Rolling Stock Depot Page 33 of 57
Description of Tools and Gauges:
1.0 Under Gear Gang
S.N. Item Details Photograph
A Tools:
01 Cotter Punch 12”
02 Pin Punch 12”
03 Nylon Mallet 200 gm
04 Allen Key 10 mm
Handbook on Integrated Rolling Stock Depot Page 34 of 57
05 Ball Pin Hammer 900 gm
06 Open Spanner-16x17
07 Open Spanner-18x19
08 Ring Spanner-18x19
09 Open Spanner-24x27
10 Ring Spanner-24x27
Handbook on Integrated Rolling Stock Depot Page 35 of 57
11 Open Spanner-30x32
12 Ring Spanner-30x32
13 Open Spanner-32x36
14 Ring Spanner-32x36
15 Open Spanner-36x41
16 Open Spanner-41x46
Handbook on Integrated Rolling Stock Depot Page 36 of 57
17 Chisel 8 inch
Additional tools for Tool Room :
18 Ratchet with goti set (small).
19 Torque wrench (Big) with goti set 170 mm
20
Allen Key set up to 10 mm.
B Gauges: Details Photograph
01 Steel measuring tape 2 m.
02 Tyre Defect Gauge
03 Inside Caliper 2” / Vernier Caliper
Handbook on Integrated Rolling Stock Depot Page 37 of 57
2.0 Side Inspection Gang:
A Tools: Details Photograph
01 Ball Pin Hammer 900gm
02 Cotter Punch 12”
03 Open Spanner 16x17
04 Ring Spanner 16x17
05 Open Spanner 18x19
06 Ring Spanner 18x19
Handbook on Integrated Rolling Stock Depot Page 38 of 57
07 Open Spanner 24x27
08 Ring Spanner 24x27
09 Open Spanner 30x32
10 Ring Spanner 30x32
11 Open Spanner 32x36
12 Ring Spanner 32x36
Handbook on Integrated Rolling Stock Depot Page 39 of 57
13 Resetting Key for ACP
14 Magnifying Glass for checking minor cracks
B Gauges Details Photograph
01 Steel scale 6 inches
02 Dip stick
Handbook on Integrated Rolling Stock Depot Page 40 of 57
3.0 Pressure Testing Gang:
A Tools: Details Photograph
01 Ball Hammer 900gm
02 Pipe Wrench 14”
03 Screw Driver 9 inch
04 Socket 10 mm
05 Open Spanner 10x11
06 Open Spanner 11x12
Handbook on Integrated Rolling Stock Depot Page 41 of 57
07 Ring Spanner 11x12
08 Open Spanner 12x13
09 Open Spanner 18x19
10 Ring Spanner 18x19
11 Open Spanner 24x27
12 Open Spanner 41x46
Handbook on Integrated Rolling Stock Depot Page 42 of 57
13 Resetting Key for ACP
B Gauges:
01 Feeler gage
02 Stop watch
03 Steel scale 6 inch / Piston stroke gauge (GO-NO GO type)
04 Spring balance (0-15 kg.)
Handbook on Integrated Rolling Stock Depot Page 43 of 57
05 Pressure gauge adopter For checking brake cylinder pressure
For TXR
01 Measuring tape
Handbook on Integrated Rolling Stock Depot Page 44 of 57
Other Items [ PPEs]:
SN Item Details Photograph
01 Tool Bag - Canvas Tool Bag shall have 2 compartments. It shall be of leather of dimensions 15” width, 18” length and 4” thick. It shall have a shoulder strap.
02 Industrial safety shoes
Specs may be developed after market survey
03 Helmet
-
04 Portable lights for
Carrying out train examination and light repairs
The specifications shall be White LED light of minimum intensity 300-500 lux at a distance of approx. 18 inches.
05 Portable lights for Heavy Works
Portable White LED re-chargeable lights of 20W and 50W should be available for carrying out heavy work. These lights should be adjustable and shall be equipped with a proper stand for keeping them inside or on the side of the pits while carrying out heavy work.
Handbook on Integrated Rolling Stock Depot Page 45 of 57
APPENDIX-A
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, chisels, 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 chisels are intended for cutting, shaping and removing metal softer
than the cutting edge itself.
10. Always strike the struck base of a Chisel or punch. The striking face of the
hammer should have a dia. approximately 10 mm larger than the struck face of
the punch or Chisel.
11. Never use screw drivers with rounded tips.
12. Never use a screwdriver as a Chisel, punch, scraper or pry bar. Use screw driver
for screw driving only.
Handbook on Integrated Rolling Stock Depot Page 46 of 57
List of probable Source of Supply:
1. M/s SNAP-ON Tools Pvt. Ltd.
6/2, Begwmpur, Khatola
Behind TOYOTA, show room
NH-8, Delhi-Jaipur, Gurgaon
PIN- 122004
2. M/s Taparia Tools Ltd.
423/424, A-2, Shah & Nahar
Lower Parel (West)
Mumbai-400013
Web-site : http://www.tapariatools.com
3. M/s Mekaster Tools Ltd.
10168, East Park Road (K.C.P.)
Karol Bagh, New Delhi-110005
4. M/s Jhalani Tools (India) Ltd.
Gedore House
51-52, Nehru Place
New Delhi-110019
5 M/s BOSCH
Motor Industries Co.Ltd., Power tool division,
Hosur Road, Adugodi
Banglore-560030
6 Shree Ganesh Fibre Glass Co. (for safety helmet )
New Delhi-34
7. Chicago Pneumatic Sales (for pneumatic tools)
Chemtex house, Hiranandani Gardens
Powai, Mumbai-400076
Website: www.cp.com
8. M/s Hindustan Everest Tools Ltd.
Dohil Chambers, 46 Nehru Place
New Delhi-110019
Web-site : http://www.eversttools.com
Handbook on Integrated Rolling Stock Depot Page 47 of 57
OPEN SPANNER 36 X41
OPEN SPANNER 16 X 17
RING SPANNER 32 X36
Handbook on Integrated Rolling Stock Depot Page 48 of 57
CENTRE FOR ADVANCED MAINTENANCE
TECHNOLOGY
Maharajpur, Gwalior – 474020
: 0751-2470890, Fax: 0751-2470841
Handbook on Integrated Rolling Stock Depot Page 49 of 61
(Govt. of India)
(Ministry of Railways)
Rolling-in/Rolling out Items
Handbook on Integrated Rolling Stock Depot Page 50 of 61
Rolling-in/Rolling out Items
of
ICF Coach
And
LHB Coach
Handbook on Integrated Rolling Stock Depot Page 51 of 61
Rolling-in and Rolling-out items.
As per discussions held with SSE/incharges, the following items should be
checked by Rolling in & Rolling out staff for safety of trains –
ICF Coach:
SN Component Remarks
01 Hanging part Truss bar, Hanger, Equalizing stay rod, J-Bracket, Axle
box cover etc.
02 Hot axle Smoke from axle box bearing
03 Broken part Spring, Truss bar hanger
04 Air Pressure leakage Hissing sound from air brake pipes
05 Deflated air spring Uneven air spring
06 Brake binding Sparking from wheels
07 Wheel skidding Unusual sound of flat places
08 Foot board bent Damaged/tilted foot board
09 Buffer height variation Nil Axle box clearance, excessive bolster clearance,
body resting on trolley (Thumping sound)
LHB Coach:
SN Component Remarks
01 Hanging part Anti-roll bar, link, axle box face plate, water pipe etc.,
WSP Cable & Battery box securing arrangement.
02 Hot axle Smell/smoke from axle box
03 Broken part Primary & secondary Springs, Deflated air spring etc.
04 Wheel skidding Unusual sound from wheel tread
05 Air Pressure leakage Hissing sound from air brake pipes
06 Brake binding Brake indicator applied or released [ Green or Red ]
FIBA
07 Securing arrangement of
all tanks
CDTS tanks, Bio-toilet tanks, under-slung tank, AR tank
& Brake control module Including footboard and CBC
uncoupling device
08 I.V. Coupler sagging Sagging of IV coupler
09 Whistling sound From brake disc, brake pad, bearing front & back and
earthing box.
Handbook on Integrated Rolling Stock Depot Page 52 of 61
Following items to be checked in LHB Coach during Rolling-in/Rolling-out:
SN Component Remarks
1 Hanging Part a. WSP Cable,
b. Axle box face
plate,
c. Anti-roll bar,
d. Link,
e Water Pipe &
f. Battery box
securing
arrangement.
,
2 Hot axle Smell/Smoke from Axle Box.
3 Broken Part
a. Primary Springs b. Secondary Springs,
4 Wheel Skidding Unusual sound from wheel tread
AXLE BOX FACE PLATE WSP CABLE
WATERING PIPE
LINK
PRIMARY SPRING
SECONDARY
SPRING
AXLE BOX
ANTI ROLL BAR
BATTERY BOX
SECURING
ARRANGEMEN
T
Handbook on Integrated Rolling Stock Depot Page 53 of 61
5 Air Pressure leakage Hissing sound from air brake pipes.
6 Deflated Air Spring Uneven Air Spring
7 Brake Binding
a. Brake indicator applied or released [ Green or Red ] b. Condition of FIBA
8 Securing
arrangement of all tanks. a. CDTS tanks,
b. Bio-toilet tanks,
c. Under-slung
tank,
d. AR tank
e. Brake control
module,
f. CBC uncoupling
device and
g. Footboard
AIR PRESSURE
LEAKAGE
BRAKE INDICATOR RELEASED BRAKE INDICATOR APPLIED
BRAKE CONTROL MODULE
FOOT BOARD CBC COUPLING DIVICE
CDTS TANK BIO-TPOILET TANK
UNDER SLUNG TANK
AIR SPRING
Handbook on Integrated Rolling Stock Depot Page 54 of 61
9
I.V. Coupler
Sagging of IV coupler
10 Whistling sound a. From brake pad, b. brake disc, c. Bearing front & back, and d. Earthing box
IV HOSE SAGGING
BRAKE PAD
BRAKE DISC
Handbook on Integrated Rolling Stock Depot Page 55 of 61
11.0 Inspection of Coaching Depot
Following areas to be inspected by the Supervisors/Officers to ensure general upkeep and smooth functioning of Coaching Depots.
Pit Examination and Cleanliness
Infrastructure availability and adequacy:
a. Condition of catwalks b. Water logging in pits c. Arrangements of cleaning of pit lines, adjoining areas and effectiveness thereof d. Pest controlling of the pit lines and adjoining areas e. Availability of garbage disposal system f. Availability of lights in the pit and illumination level at the pit, bogie and catwalk
level g. Availability of water storage and watering facilities. h. Availability of high pressure pipe line for cleaning. i. Availability and proper working of coach washing plant. j. Mechanized Coach Cleaning : Availability of Dosing machine for dispensation of
chemicals. k. Availability of Surveillance cameras in all Coaching Depots for monitoring the
maintenance activity. l. Any other deficiencies observed.
Train Maintenance
a. Whether all items prescribed for monthly / quarterly schedule, including intensive cleaning are carried out (check few coaches and comment on the discrepancies observed)
b. Check few rakes / coaches and give specific comments on the quality of repairs with respect to:
1. Cleaning / amenities 2. Safety / under gear 3. Air brake testing.
c. Whether rake cleaning and attention to passenger amenities items is adequate, whether all items as mentioned in the contract are carried out, Whether mechanized cleaning of coaches with high pressure jet is ensured.
d. Availability / proper functioning of automatic coach washing plant, ETP, water recycling plant.
e. Whether the prescribed procedure for rake maintenance is known the staff and is followed.
f. Availability of Standard tool kit and Portable lights for the staff working in Pit lines g. Comments with regard to maintenance of LHB coaches. h. Testing of WSP (LHB coaches) during each trip. i. Functioning of bio-toilets. j. Quality of washing of Linen in departmental / BOOT laundries available in the
depot. k. Comments on the proper functioning of service contracts.
Handbook on Integrated Rolling Stock Depot Page 56 of 61
l. Effectiveness of Cleaning contracts. m. Effectiveness of Pest and Rodent control contracts. n. Examination and certification of LPG pipe line system in pantry cars. o. System of record keeping p. System of monitoring complaints / feedback
Performance Indices
a. Review The performance indices of the depot, identify areas of weakness & strength.
b. Stock detained for long periods c. Whether coach failures analysis, enroute detachment, punctuality loss, etc. is
done. d. System of communication, reporting and follow up e. Analysis of unscheduled detachments at the primary end. f. Whether the coach failures are maintained in a data base to enable analysis. g. System of communication of defects in secondary / other end trains to the
primary depot. h. Coaches running overdue schedules.
i. Rake Links 1. Whether the rake links are as per provisions of RPC 4. 2. Coach holding vs Actual requirement. 3. Adequacy of pit examination time for various rakes. 4. Whether adequate berthing slot are available. 5. Whether any train gets continuous night maintenance. 6. Whether any train is being maintained in two or more parts.
j. Any other comments
Sick Line :
a. Adequacies of infrastructural facilities for IOH b. Road access and availability of material handling equipment. c. Availability of air dryers for compressors in pit line and sick line. d. Quality of repairs during IOH (check few coaches and give specific comments of
deficiencies observed). e. Whether “must change” items are replaced during IOH f. Quality of over hauled trolleys received from Workshops for IOH of Mail / Express
coaches. g. Adequacy of lifting facilities h. Comments on the welding practices, particularly earthing, and training of
welders. i. Steps taken for system improvement and innovations. j. Availability of units exchange spares. k. Comments on various certifications, quality audits by 3rd party, etc. l. Display of flex boards / banners containing relevant instructions, etc. m. Availability of standard tools and gauges and their usage. a. Knowledge of staff /supervisors. b. Whether policy letters, TSO’s are known to the Supervisor / Staff and system of
communication thereof
Handbook on Integrated Rolling Stock Depot Page 57 of 61
c. House keeping d. Are old files disposed off? Are the files kept properly in a readily retrievable
condition? n. Availability of personal protective equipment for staff. o. System of Record keeping, Whether data of Wheels, DV, CBC, Bearings, etc. in
the depot coach holding is available in form of a data base. p. Status of execution of works related to improvement in infrastructure. q. Any other comments
Train Duty on Platforms / Other End Attention
a. Whether all facilities prescribed vide Board's letter No.95/M(C)/141/1 dated 31.01.2007 for other end attention on platform / stabling lines are available.
b. Whether adequate halt is available for other end attention c. Quality of Terminal examination/attention in stabling lines/platforms (Check few
trains and give specific comments). d. Whether the rakes are properly locked and stabled at secure locations. e. Adequacy of watering facilities, whether booster pump is available and is
automatically operated. f. System of rolling-in examination of terminating and passing through trains
(availability of adequate lights and huts for rolling-in examination). g. Availability of adequate number of non-contact type axle box temperature gauge
with storage feature h. Availability of standard tools and gauges, portable lights, etc. i. Availability of proper means of communication (CUG /Walki Talkie) j. Availability of adequate spares, and display of the list k. Comments on the trouble-shooting of passing through trains and maintaining
records of the same. l. Any other comments
Materials / Store
a. Important item out of stock / in short supply. b. Whether the AAC’s of different items is adequate. c. Proper storage of rubber item d. System of raising warranty complaints. e. Comments regarding housekeeping and disposal of scrap. f. Any other comments
IT Based Systems
a. Whether proper systems are available for the maintenance of IT based systems that are progressively being provided in coaches such as GPS based passenger announcement and passenger information system; Infotainment system; Fire detection and fire suppression systems; Automated door closing arrangement; EP brake system; Brake system of LHB coaches; LED destination boards, CCTV based surveillance system in the coaches; Micro processor based controls; On-board condition monitoring systems; RFID tags, etc.
b. Whether staff are conversant in these systems. c. Whether AMCs are in place and operational.
Handbook on Integrated Rolling Stock Depot Page 58 of 61
d. Whether at least 1 staff / supervisor deputed full time on CMM and IT based systems.
e. Whether the different functionalities of CMM are being used, any issues thereof. f. Internet access and speed thereof. g. Adequate availability of computers, printers etc. h. Any other comments
Establishment
a. Whether adequate number of staff deputed for various activities b. Comments on vacancies and action taken thereof. c. Staff grievances d. Staff amenities e. Level of staff motivation and steps taken to increase the same. f. Any other comments
Training Needs / Staff Awareness
a. Method of imparting training and review of its effectiveness. b. Whether stimulation soft ware and audio visual training aids are utilized. c. Level of knowledge and motivation of the instructors. d. Training of staff / visits to other depots. e. Training calendar of BTC. f. Availability of Working Models. g. Availability of all coach and wagon components and cut sections for training
purpose. h. Availability of all Gauges. i. Availability of all latest manuals and instructions. j. Complete profile of staff and their details of training, Whether data base of staff
trained and overdue is available. k. Categorization of welders as per their skill set. l. Record of training conducted/courses organized . m. Seminars/Sessions organized in collaboration with respective filed expert. n. Any other comments
Date : Name of the Officer : Station : Designation :
Handbook on Integrated Rolling Stock Depot Page 59 of 61
12.0 Check List for Inspection of DEMU
Inspection should be done as per check list by the officers & inspectors and availability of
all standard equipments as well as any additional equipments, which may have been
provided on DPC should be ensured.
General:
1. Check Flasher Light, Head light, Marker light and tail light.
2. Check condition of buffers.
3. Check availability of screw coupling.
4. Check condition of Rail guard and Cattle Guard.
5. Check Working of wipers.
Oil Levels
(Check before starting)
1. Check Lube oil level by dipstick gauge.
2. Check Compressor oil level by dipstick gauge.
3. Check Hydraulic oil level in (up to 3/4th
of glass.)
4. Check Water level in water glow rod gauge
5. Check Fuel oil level in glow rod gauge.
6. Check brake releasing and ensure sufficient gap between brake block and wheel (5-6
mm)
Driver’s cabin:
1. Put battery Isolation Switch in ON Position.
2. Put 24 V Isolation Switch in ON Position.
3. Put LCC MCB in ON Position.
4. Check cab light by putting switch in ON position.
5. Before starting of DPC, priming of fuel pump to be done near main engine to avoid fuel
oil locking, till indication comes.
6. On engine block, FSD device should be in “Mechanical” but after starting, it should be
put in “Electrical”.
7. After priming, fuel lifting pump cock again to be put in closed position.
8. 24 V MCB and 110 V MCB to be put in ON position before pressing start button.
9. Now, push start button, till rpm reaches to 300 in tachometer at back panel.
10. Now press reset button for resetting safety devices (Indication LED).
11. Ensure MR pressure 5-7 Kg/Cm2 & BP pressure 5.0 Kg/Cm
2 on Driver’s control panel.
12. Now check B.C. pressure up to 1.6 kg/m2 on brake application (E.P).
13. DCS key, BIVS key, Master controller key should be applied.
Handbook on Integrated Rolling Stock Depot Page 60 of 61
-2-
14. Now check Red colour indication lamp for glow of lights, normally it should be in off
position.
15. Check functioning of Dead Man handle by putting reverser key in forward direction,
16. Check continuity of brake application by dropping B.P. pressure to zero.
Safety Material
01. Ensure availability of 4 nos. wooden wedges in each DPC.
02. Ensure availability of safety instructions in Driver’s cabin for detaching coaches in case
of fire.
03. Ensure availability of 03 nos. fire extinguishers in each DPC.
04. Ensure availability of 01 set BP & FP hose pipes & its extensions
Before Starting Train 1. Check functioning of horn by pressing foot pedal.
2. Ensure presetting of speed recorder by pushing display button.
3. Before starting, check availability of caution order and BPC.
4. Check the Driver’s repair book for any previous booking and its compliance.
5. Note down Driver’s name and Guard’s name.
6. Note down Driver’s particular, safety category, PME details, last counseling/
Monitoring and training particulars, learning particular etc.
7. Note down maintenance schedules of DPC and Trailer car.
8. Ensure cleanliness of Driver Cabin.
Date: Name of Officer:
DPC Depot: Designation:
Handbook on Integrated Rolling Stock Depot Page 61 of 61
13.0 Check Sheet for Super Checking of DEMU
DPC No. ………… Link __________ Date ____________ Shift ___________
Items checked Observations Action taken Radiator Room –
a. Check water leakage from water tank, pipe line and radiator cores
b. Check abnormal sound from radiator fan. c. Check cleanliness, oil & water spillage. d. Check hydraulic oil leakage from hydraulic motor and
flexible hoses. e. Check radiator room for hydraulic oil spillage and
cleanliness of hydraulic tank. f. Ensure proper locking of radiator compartment door.
Engine Room –
a. Check condition of lagging on air compressor outlet pipe, its clamp condition and support welding of air compressor.
b. Ensure that oil tray below engine sump is cleaned, there should be no muck or oil accumulation
c. Check vent motors for proper working and any leakage. d. Ensure that there is no leakage from exhaust pipeline. e. Check exhaust pipeline for cladding and TSC for exhaust
bellow. f. Ensure that fuel actuator is electrically operated. g. Check condition of belts of alternator, auxiliary generator,
air compressor h. Check fire extinguisher for expiry date.
Driver Cab-
a. Check driver cab for proper sealing of doors b. Check driver cabin light. c. Check driver seat for firm foundation. d. Check look out glass for securing and condition for
cleanliness e. Ensure that no TM is isolated.
Under Gear –
a. Check air dryer for working b. Ensure that aftercooler underneath floor is properly cleaned c. Check axle box, gear case and MSU bolts for sealing. d. Check helical springs for any crackness by hammering. e. Check dashpot for oil leakage. f. Check cattle guard for proper fitment.
Safety items –
a. Check Dead-man Relay working b. Check Head lights, Flasher lights for proper working. c. Check Horn for proper working. d. Check rail guard for proper fitment, height above rail level
(100mm) e. Check wiper for proper working. f. Check speedometer and parking brake for working.
Deferred repairs:
General-
a. Staff booked for maintenance b. DEMU rake time in
DEMU rake time out c. Check schedule form
Signature Name & Designation
Recommended