Report On Competency Based Training in Workshops

(Govt.
of India)
(Ministry of Railways)
Report on
COMPETENCY BASED TRAINING
IN
WORKSHOPS
(Coaching, Wagon & Diesel)
(For official use only)
CAMTECH/2003 / M /TRG/ 01
April- 2003
Centre
for
Advanced
Maintenance
TECHnology
Excellence in Maintenance
MAHARAJPUR, GWALIOR--474020
i
Preface
In partial fulfillment to the report of Khanna Committee, as assigned by

Railway Board (reference letter enclosed), CAMTECH/GWL as first phase of
implementation of competency based training has prepared this report
detailing the infrastructure needed, syllabus and frequency of training.
Jhansi, Bhopal and Parel workshop of central railway were associated in

the study of wagon, coaching and diesel shops. The group identified the
areas bearing with safety and the syllabus of each such area has been
framed. Welding being a significant one, the railway board has approved to
set up five regional welding training institutes at DLW, ICF, RCF, Kharagpur
and Bhopal. Hence a unified syllabus for welders has been framed for wagon
carriage and locomotive workshops.
Keeping in view the no. of trainees, availability of facilities and capacity of the
shops to spare the artisan without effecting the outturn, the frequency of the
course has been decided four years,.
The training resources have been listed out to provide latest aides for
imparting training, using audio, visual and practical aspect.
The training modules have been framed for the artisans of workshops for
P.O.H. and Rehabilitation activities. The artisans who are imparted this
training need not undergo any separate refresher training.
(MANISH PRADHAN) (R.K.SHARMA) (H.K. RAGHU) (ANIL SHARMA)

DyCME/CRWS DyCME/R DyCME/P Director (Mech)
C.Rly. Bhopal C. Rly. Jhansi C. Rly. Parel CAMTECH Gwalior
ii
GOVERNMENT 0F INDIA
MINISTRY OF RAILWAYS
(RAILWAY BOARD)
No.98/M (Safety)7/11/1/Pt. Khanna Committee New Delhi, dated 04.02.2002
The Executive Director

CAMTECH
Gwalior.
Sub: Competency based training in workshops
000
Para 5.10 of Railway Safety Review Committee (Khanna Committee) part I

report which has been accepted by the Board recommends introduction of
competency based training as under-
Competency based training and certification 'should be introduced, in stages,in
work centres such as TXR depots, sick lines, ROH depots, workshops, Flash
Butt welding plants etc; Only those possessing certification of competency
should be allowed to work on the identified safety critical assemblies.
Welding has been identified as one such area which has bearing on safety.
Railway Board has already approved setting up of five regional welding training
institutes at DLW, ICF, RCF, Bhopal and Kharagpur. The implementation of above
recommendation for other safety related sections of the Coaching and Wagon workshop
would require design of syllabus along with laying down frequency of course and
identification of facilities required for imparting training in the workshops. It has been
decided to nominate CAMTECH for this work. CAMTECH should submit its
recommendations in the following areas-
1. Identify safety related sections of Coaching, wagon and Diesel shops.

2. Lay down syllabus for competency based training at induction level and as a
refresher course. Also prescribe frequency of refresher course.
3. List facilities required to impart the training.
Jhansi, Bhopal and Parel workshops of C. Rly shall be associated in the study
for Wagon, Coaching and Diesel shops. Competency based t1-ainillg and
certification should be introduced, in stages, in work centres such as TXR
depots, sick lines ROH depots, workshops. The report should be submitted to
the Railway Board latest by 30'h April.
iii
CONTENTS
DESCRIPTION PAGE NO.

Preface i
Copy of Railway Board’s letter ii
Contents iii
Chapter-1 General 01-09
Chapter-2 Coaching
2.1 Training Module for Fitters of 10-22
Bogie Section, Air Brake section &
Roller Bearing Section
2.2 Training Module for Machinist 23-31
of Wheel Shop
Chapter-3 Wagon
3.1 Training Module for Fitters
(Brake System) 32-44
(Draw & Buffing Gear) 45-54
(Suspension) 55-62
3.4 Training Module for Machinists
(Wheel Shop) 63-65
3.5 Training Module for Blacksmiths
(Black smithy Shop) 66-70
Chapter-4 Diesel
4.1 Training Module for Machinists 71-83
4.2 Training Module for Diesel Mechanics
of Bogie Section 84-97
4.3 Training Module for Diesel Mechanics
of Chassis Section 98-111
of Wheel Shop 112-124
Chapter-5 Welding
5.1 Unified Training Module for Welders 125-137
CHAPTER 1
IN
WORKSHOP
(GENERAL)
CAMTECH/2003 / M /TRG/ 01 1
GENERAL
1.0 Following areas of locomotive, coach and wagon workshops have been
identified as critical areas, with regard to safety where competency levels
of artisan staff need more attention, in order to achieve continual
improvement in competency level.
COACHING WORKSHOPS
1. Bogie, Air Brake, Roller Bearing

2. Wheel shop Section
3. Welding*
WAGON WORKSHOPS
1. Brake System
2. Draw and Buffing Gear
3. Suspension (Fitters)
4. Suspension (Machinist)
5. Suspension (Black Smith)
6. Welding*
DIESEL WORKSHOPS
1. Wheel Shop Activities (For machinist)

2. Bogie, Air Brake, Cab (For Diesel Mechanic)
3. Chassis, Radiator, Right Angle Gear Box do
4. Wheel Shop (Fitter) do
5. Welding* (For welders)
*Syllabus for training of welders of coaching, wagon and Diesel has been
made common.
Competency Based Training For Workshops

As a first phase of competency based training, the report covers the

mechanical (coaching, wagon and diesel) workshops of Indian Railways
and accordingly the training syllabus/ modules have been prepared.
Every workshop is having Training Centre/ Basic Training Centre (BTC)

and training facilities in shop floor where technicians are imparted training
at the time of promotion and for refresher purpose. These training centres
shall be updated according to the competency based training
requirements.
2.0 TRAINING IN WORKSHOPS
1. The training programme has high emphasis on competency development

in production and maintenance personnel. About 65% of total training time
shall be utilized for developing practical skills. Theory sessions has been
kept as three hours per day. Rest the time shall be utilized for practical
training in training centre/ workshop.
2. Workshop based training plan has been designed for identified groups,
directly related to safety and this shall be followed by the participants
during supervised practice sessions. A dedicated space is required at
workshops for practical work consisting of demonstration and practice
sessions. Tools, fixtures and equipments required should be provided so
that arrangement can be made for effective use of facilities. It is further
emphasised that the manual skills can be acquired through highly
focussed practice oriented workshop based training.

3.0 TRAINING RESOURCES

3.1. Man power requirement
The training officer will be overall Incharge and he will exercise his control
in training centers and workshops equally to maintain coordination of
theoretical classes and practical training in workshops.
A competent SSE/SE shall be incharge of training centre who will assist

training officer to maintain coordination between classroom and workshop
training sessions. He should preferably have undergone training of
trainers (TOT) programme on developing competency pertaining to
training technology. He should have skills of analysing tasks performed
by maintenance personal and also identifying critical sub skills for
designing sessions plans for skill demonstration.
Sufficient number of instructors should be provided so as to have

minimum one instructor in each trade for a class of 25 trainees.
Visiting officers/Supervisors shall be invited regularly for their lecturers on

selected topics.
3.2. Infrastructural facilities
a) Class Room
A well furnished class room to accommodate 25 to 30 participants
would be essential, with training hardware and necessary furniture.
One more class room would be required for syndicate work or
group activities. The list of hardware and allied software is given in
Annexure- I.

b) Training-Workshop
A well furnished and appropriately equipped “Workshop” has to be

developed. One instructor will train a group of 6-7 trainees at a time
on each specific work station. Two groups of 6-7 trainees should be
able to participate the specific task in practice session of two hour
duration. It is proposed to have workshops facilities in vicinity of
class room. The list of M&P, tools and equipment is given in
ANNEXURE-2. The additional M&P/ Equipments may be finalised
by the workshops accordingly to their specific training needs.
c) Model Room
Each training centre should have a model room which should have
cut models, working models, test stands etc. A list of few models is
given in “Annexure” 3,4 &5 for training centres attached to
coaching, wagon and diesel shops respectably. The training
centres may have additional models depending on their specific
needs
4.0 CERTIFICATION
The artisans shall be imparted training in BTC/TTC according to the

syllabus. However, the certification shall be done by concerned officer/
shop incharge, of the respective shop where the artisan is working. The
methodology of certification shall however, be reviewed after five years.

Annexure – 1
LIST OF CLASS ROOM EQUIPMENTS
Sr.No. Name & brief specification Quantity
01 Over head projector. One per class room
02 Magnetic chalk board/clip board One per class room
03 Magnetic chalk board/ clip board similar to One per work station
items no. 02 for assisting in practical exercise
in workshops.
04 Television with VCD One set.
05 LCD data video projection system. One per class room
06 Computer / Multimedia with all peripherals One per class room

including work station, CD writer, printer, web
camera, UPS
07 35 mm automatic slide projector with linear One

and circular tray, with facility of remote control
08 OHP screen 1.5 m x 1.5 m One per class room
09 Digital camera One
10 Laptop computer One
11 Furniture One table + One chair

per trainee/ instructor
in each class room
and One table + One
chair for each
instructor in office
One set
12 PA system
13 Internet connection with MTNL/BSNL One

telephone connection
One
14 Reso graph Machine
One
15 Fax

Annexure-2
LIST OF PLANT AND MACHINERY

Sr. No. Description quantity
1. Screw cutting lathe One
2 Lathe Junior One
3 Centre lathe One
4 Precision lathe One
5 Invest drilling One
6 Crank Shaper One
7 Tool Grinding machine One
8 Welding transformer (Oil cooled) One
9 Welding transformer (Air cooled) One
10 Arc Welding Rectifier Two
11 CO2 Plant alongwith Wire Feeder One
12 Gas Welding Equipment One
13 CNC lathe/ milling One

Annexure-3
LIST OF MODELS IN COACH WORKSHOP

1. Bogie with all Components Complete 01
2 Air brake system Complete 01
3 C3W type distributor valve Cut model 01
4 KE type distributor valve Cut model 01
5 P4 type distributor valve Cut model 01
6 Cut-off angle cock Cut model 01
7 Isolating cock Cut model 01
8 Check valve with chock Cut model 01
9 Dirt collector Cut model 01
10 Guard emergency brake valve Cut model 01
11 Auxiliary reservoir Complete 01
12 Single car test rig Complete 01
13 Roller bearing Cut model 01
14 Buffer assembly Cut model 01
15 Draft gear Complete 01
16 Brake gear components Complete 01

Annexure-4
LIST OF MODELS IN WAGON WORKSHOP

1. Bogie with all Components Complete 01
2. Air brake system Complete 01
3. C3W type distributor valve Cut model 01
4. KE type distributor valve Cut model 01
5. Cut-off angle cock Cut model 01
6. Isolating cock Cut model 01
7. Check valve with chock Cut model 01
8. Dirt collector Cut model 01
9. Guard emergency brake valve Cut model 01
10. Auxiliary reservoir Complete 01
11. Single wagon test rig Complete 01
12. „E‟ Type vacuum cylinder Cut model 01
13. „F‟ Type vacuum cylinder Cut model 01
14. Roller bearing Cut model 01
15. CTRB Cut model 01
16. Draft gear Complete 01

Annexure-5
LIST OF MODELS IN DIESEL WORKSHOP

1. Buffer Cut model
2 Draft Gear Cut model
3 Roller Bearing Cut model
4 A-9 Automatic Brake Valve Cut model
5 SA-9 Independent Brake Valve Cut model
6 MU-2B Valve Cut model
7 VA-1B Control Valve Cut model
8 HS-4 Valve Cut model
9 H-5 Cut model
10 HB-5 Cut model
11 Sander Valve Cut model
12 Wiper Motor Cut model
13 Air Flitters Cut model
14 A-9 Automatic Brake Valve Test Stand
application and release
15 SA-9 Independent Brake Valve Test Stand
application and release
16 Complete bogie with all components Model

CHAPTER -2
FOR
ARTISANS
IN
COACHING WORKSHOP
CAMTECH/2003 / M /TRG/ 01 10
2.1 TRAINING MODULE FOR FITTER OF

BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Work Shop : Coaching

Trade : Fitter
Activity Centre : Bogie Section / Air Brake/ R.B. Section.
Periodicity : Once In Four Years
Duration : 12 Days
Sr.No. Description Day

1 INTRODUCTION 01
a) Introduction of Course, attitudinal changes & motivation.
b) General awareness of ISO & EMS.
c) Safety & Environments.
2 a) Introduction and General Data of ICF, RCF and BEML 01
Coaches.
b) Difference between ICF & BEML coaches.
3 a) Introduction to corrosion. 01
b) Corrosion prone area in coaches & its inspection.
c) Corrosion prevention in coaches
4 BOGIE SECTION 01
a) Stripping,inspection,repairing & gauging of Bogie Frame.
b) Assembly of Bolster, Guide Gauging, Brake Gear.
c) Testing of Bogie components.
5 a) Bogie Lowering on wheels. 01
b) Bogie testing on test stand.
c) Buffer Height adjustment on coaches.
6 a) Introduction of Buffing Gear. 01
b) Repair of Buffer Assembly.
7 a) Introduction of Draft Gear. 01
b) Repair of Draft Gear assembly.
8 AIR BRAKE SECTION 01
a) General knowledge of Brake system of coaches.
b) Brief knowledge of Vacuum Brake system in coaches.
9 a) Working of Air Brake system in coaches. 01
b) Overhauling & testing of Air Brake components.
10 a) Overhauling & testing of DV. 01
b) Single car testing of coach.
11 ROLLER BEARING SECTION 01
a) Introduction of Roller Bearing in coaches.
b) Inspection of Roller Bearing & its rejectable defects.
c) Assembly of Roller Bearing.
Latest modification & CAI of the coaches.
12 FEED BACK & VALIDATION 01
a) Assessment Test.
b) Interaction with trainees regarding result.
c) Feedback from trainees.
d) Valedictory function

CAMTECH/2003 / M /TRG/ 01 11
2.1.1 TRAINING MODULE FOR FITTER OF

Workshop : Coaching
Technicians : Fitter
Description : Introduction Of Course, Attitudinal Changes &

Motivation
General Awareness Of Iso & Ems
Safety, P.P.E, & Environments.
Duration : 01 Day ( 1st Day)
DURATION
PERIOD CONTENTS (Hours)
01 i. Introduction of Course 01
ii. Changing the attitude related to the
works
iii. Role of Fitter in improving the Quality of
work & responsibility
02 i. Need of ISO certificate 01

ii. ISO 9000& 14000 series,
iii. Terms related to ISO 9000& 14000
03 i. Personal safety and safety environment. 01

ii. Safety in workshop.
iii. Fire safety and fire fighting equipments.
iv. Safety with electrical power
v. First Aid.

CAMTECH/2003 / M /TRG/ 01 12

Workshop : Coaching
Description : Introduction And General Data Of Icf, Rcf And

Beml Coaches, Difference Between Icf &
Beml ,Emu, Coaches.
Duration : 01 Day ( 2nd Day)
PERIOD CONTENTS DURATION

(Hours)
1. Introduction of ICF, RCF and BEML Coaches 01
2. General Data of ICF, RCF and BEML Coaches 01
3. Difference between ICF & BEML coaches. 01

CAMTECH/2003 / M /TRG/ 01 13

Workshop : Coaching
Description : Introduction To Mlr Concept, Objectives &

Advantages.
Duration : 01 Day ( 3rd Day)

(Hours)
1.
Introduction to corrosion. 01
2.
Corrosion prone area in coaches & its inspection. 01
3.
Corrosion prevention in coaches 01

CAMTECH/2003 / M /TRG/ 01 14

Workshop : Coaching
Description : Bogie Section

Stripping & Overhauling Of Bogie
Frame. Assembly Of Bolster, Guide Gauging,
Brake Gear. Testing Of Bogie Components.
Duration : 01 Day ( 4th Day)

(Hours)
1. Stripping, inspection, repairing & gauging of 01

Bogie Frame.
2. Assembly of Bolster, Guide Gauging, Brake 01

Gear.
3. Testing of Bogie components. 01

CAMTECH/2003 / M /TRG/ 01 15

Workshop : Coaching
Description : Bogie Lowering On Wheels.

Bogie Testing On Test Stand.
Buffer Height Adjustment On Coaches.

(Hours)
1. Bogie Lowering on wheels. 01
2. Bogie testing on test stand. 01
3. Buffer Height adjustment on coaches. 01

CAMTECH/2003 / M /TRG/ 01 16

Workshop : Coaching
Description : Introduction Of Buffing Gear.

Repair Of Buffer Assembly.

(Hours)
1. Introduction of Buffing Gear. 01
2. Inspection & Repair of Buffer Assembly. 01
3. Inspection of buffer assembly after repair. 01

CAMTECH/2003 / M /TRG/ 01 17

Workshop : Coaching
Description : Introduction Of Draft Gear.

Repair Of Draft Gear Assembly.

(Hours)
1. Introduction of Draft Gear. 01
2. Inspection & Repair of Draft Gear assembly. 01
3. Testing of Draft Gear assembly & its 01

components.

CAMTECH/2003 / M /TRG/ 01 18

Workshop : Coaching
Description : Air Brake Section

General Knowledge Of Brake System Of Coaches.
Brief Knowledge Of Vacuum Brake System.

(Hours)
1. General knowledge of Brake system of coaches. 01
2. Description of vacuum brake system. 01
3. Brief knowledge of Vacuum Brake components in 01

coaches.

CAMTECH/2003 / M /TRG/ 01 19

Workshop : Coaching
Description : Working Of Air Brake System ( Bmabs)

Overhauling & Testing Of Air Brake Components.
DURATION
01 Working of Air Brake system & its components 01

in coaches.( BMABS)
02 Functions of Air Brake components. 01
03 Overhauling & testing of Air Brake components 01

CAMTECH/2003 / M /TRG/ 01 20

Workshop : Coaching
Description : Overhauling & Testing Of Dv.

Single Car Testing Of Coach.

(Hours)
01 Constructional details & function of DV. 01
02 Overhauling & testing of DV. 01
03 Single car testing of coach. 01

CAMTECH/2003 / M /TRG/ 01 21

Workshop : Coaching
Description : Roller Bearing Section &
Latest Modification & Cai Of The Coaches.

(Hours)
01 Introduction of Roller Bearing in coaches. 01
02 i. Inspection of Roller Bearing & its 01

rejectable defects.
ii. Assembly of Roller Bearing.
03 Latest modification & CAI of the coaches. 01

CAMTECH/2003 / M /TRG/ 01 22

Workshop : Coaching
Description : Feed Back & Validation

(Hours)
01 Assessment Test. 01
02 Interaction with trainees regarding result. 01
03 Feedback from trainees. 01

CAMTECH/2003 / M /TRG/ 01 23
2.2 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching
Trade : Machinist
Activity Centre : Wheel Shop
Periodicity : Once In Four Year
Duration : 08 Days (03 Clock Hours Each Day)
Sr.No. Description Day

1 a) Introduction of Course, attitudinal changes & motivation. 01
b) General awareness of ISO & EMS.
c) Safety & Environments.
2 a) Limits, Fits & Tolerance. 01
b) Precision measuring Instruments.
c) Gauges & Templates.
3 a) Various types of cutting tools. 01
b) Various types of Machine tools.
c) Multi purpose & special purpose Machine tools.
4 a) VTL . 01
b) Wheel Press (Hydraulic) .
c) Axle Grinding m/c
d) Wheel lathe
5 a) Introduction of Wheel shop . 01
b) Main activities of Wheel shop .
6 a) Axle turning on ATL. 01
b) Axle Grinding on AGL.
c) Drilling & tapping of holes in Axle on Radial Drill M/c.
d) Boring of Wheel Disc on VTL..
e) Wheel pressing.
7 a) Wheel Inspection & testing. 01
b) Worn wheel profile.
c) Profile tyre turning of wheels on wheel lathe.
8 FEED BACK & VALIDATION 01
a) Assessment Test.
b) Interaction with trainees regarding result.

CAMTECH/2003 / M /TRG/ 01 24
2.2.1 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching
Technicians : Machinist
Description : Introduction Of Course ,

Attitudinal Changes & Motivation
General Awareness Of Iso & Ems
Safety, P.P.E, & Environments.
Duration : 01 Day ( 1st Day)
DURATION
01 i. Introduction of Course 01
ii. Changing the attitude related to the
works
iii. Role of Fitter in improving the Quality of
work & responsibility
02 I. Need of ISO certificate 01

II. ISO 9000& 14000 series,
III. Terms related to ISO 9000& 14000
03 i. Personal safety and safety environment. 01

ii. Safety in workshop.
iii. Fire safety and fire fighting equipments.
iv. Safety with electrical power
v. First Aid.

CAMTECH/2003 / M /TRG/ 01 25
Workshop : Coaching
Description : Limits, Fits & Tolerance.

Precision Measuring Instruments.
Gauges & Templates.
Duration : 01 Day ( 2nd Day)
DURATION
1. Limits, Fits & Tolerance. 01
2. Precision measuring Instruments. 01
3. Gauges & Templates 01

CAMTECH/2003 / M /TRG/ 01 26
Workshop : Coaching
Description : Various Types Of Cutting Tools.

Various Types Of Machine Tools.
Multi Purpose & Special Purpose Machine Tools.
Duration : 01 Day ( 3rd Day)
DURATION
1. Various types of cutting tools. 01
2. Various types of Machine tools. 01
3. Multi purpose & special purpose Machine tools. 01

CAMTECH/2003 / M /TRG/ 01 27
Workshop : Coaching
Description : Vtl ,Wheel Press (Hydraulic) .

Axle Grinding M/C,Wheel Lathe.
DURATION
1. VTL. 01
2. Wheel Press (Hydraulic). 01
3. Axle Grinding m/c & Wheel lathe. 01

CAMTECH/2003 / M /TRG/ 01 28
Workshop : Coaching
Description : Introduction Of Wheel Shop .

Main Activities Of Wheel Shop .
DURATION
1. Introduction of Wheel shop . 01
2. Inspection of incoming wheels. 01
3. Re-discing, Re-axling & Re-turning of wheels. 01

CAMTECH/2003 / M /TRG/ 01 29
Workshop : Coaching
Description : Axle Turning On Atl.,Axle Grinding On Agl.

Drilling & Tapping Of Holes In Axle On Radial Dr
M/C.Boring Of Wheel Disc On Vtl..Wheel Pressing.
DURATION
1. Axle turning on ATL.,Axle Grinding on AGL. 01
2. i) Drilling & tapping of holes in Axle on 01

Radial Drill M/c.
ii) Boring of Wheel Disc on VTL.
3. Wheel pressing & de-pressing. 01

CAMTECH/2003 / M /TRG/ 01 30
Workshop : Coaching
Description : Wheel Inspection & Testing.

Worn Wheel Profile.
Profile Tyre Turning Of Wheels On Wheel Lathe.
DURATION
1. Wheel Inspection. 01
2. Ultra-sonic testing of wheels & magna-flux testing 01

of Axle.
3. i. Worn wheel profile. 01

ii. Profile tyre turning of wheels on wheel lathe.

CAMTECH/2003 / M /TRG/ 01 31
Workshop : Coaching
Description : Feed Back & Validation
DURATION
01 Assessment Test. 01
02 Interaction with trainees regarding result. 01
03 Feedback from trainees. 01

CHAPTER -3
FOR
ARTISANS
IN
WAGON WORKSHOP
CAMTECH/2003 / M /TRG/ 01 32
3.1 TRAINING MODULE FOR FITTER

(BRAKE SYSTEM)
WORKSHOP : WAGON
TRADE : FITTERS
ACTIVITY CENTRE : VACUUM BRAKE/ AIR BRAKE
PERIODICITY : ONCE IN FOUR YEAR
DURATION : 12 DAYS
Sr No. Description Duration

1. General introduction (Vacuum Brake System) One day
2. Maintenance and repairs (Vacuum Brake System) One day
3. Brake under gear (Vacuum Brake System) One day
4. Introduction to DV (Air Brake System) One day
5. Maint. & Testing of DV (Air Brake System) One day
6. Precaution & Feed Back (Air Brake System) One day
7. Cut Of Angle Cock, Isolating Cock, Check Valve One day

with Choke (Air Brake System)
8. Pipe Brackets, Couplings & Control Reservoir One day
(Air Brake System)
9. Dirt Collector, Auxiliary Reservoir & Guard’s One day
Emergency Brake Valve (Air Brake System)
10. Brake rigging (Air Brake System) One day
11. Repair & Maintenance of SAB (Air Brake System) One day
12. Single Wagon & Rake Test (Air Brake System) One day

CAMTECH/2003 / M /TRG/ 01 33
3.1.1 TRAINING MODULE FOR FITTER

(VACUUM BRAKE)
Workshop : Wagon
Description : General introduction

Duration : 1 day- (1st day)
Sr.No Description Hours
1.
General introduction
01
2.
Constructional detail to vacuum brake
Vacuum brake cylinders
I. type of vacuum brake (E type and F type)

II. advantages of F type cylinders
3.
Principal & operation
01
I. Principal of operation
II. Limits of vacuum brake system

CAMTECH/2003 / M /TRG/ 01 34

(VACUUM BRAKE)
Workshop : Wagon
Description : Maintenance and repairs
Duration : 1 day- (2nd day)
1. Modifications
01
2. Maintenance and repairs
I. Examination and maintenance of Guard Van 01

Valve
II. Cleaning, inspection and maintenance of vacuum
brake cylinders
3. Examination and maintenance of release valve 01
i) Vacuum retaining capacity test

ii) Operation test

CAMTECH/2003 / M /TRG/ 01 35

(VACUUM BRAKE)
Workshop : Wagon
Description : Brake under gear
Duration : 1 day- (3rd day)
1.
Brake rigging 01
I. Constructional details
II. Working principle
III. Maintenance and repairs
2.
Introduction to SAB
01
I. Introduction to SAB
II. Working principle of SAB
III. Maintenance and repair of SAB
3.
Tools and Equipments & Feedback
01
I. Tools and Equipments
II. Feedback of the training

CAMTECH/2003 / M /TRG/ 01 36

(AIR BRAKE)
Workshop : Wagon
Description : Introduction to DV
Duration : 1 day- (4th day)
Sr.No Contents Hours

1. Introduction And Working Principle Of DV
I. C 3W Type distributor valve 01

II. KE Type distributor valve
2. Dismantling And Cleaning Of Distributor Valve

3. Examination Of Individual Parts


CAMTECH/2003 / M /TRG/ 01 37

(AIR BRAKE)
Workshop : Wagon
Description : Maint. & Testing of DV
Duration : 1 day-(5th day)

1. Assembly Of Distributor Valve

2. Testing Of DV On Test Stand As Per Testing

Performa
01
I. C 3W Type distributor valve
3. Trouble Shooting During Testing Of DV


CAMTECH/2003 / M /TRG/ 01 38

(AIR BRAKE)
Workshop : Wagon
Description : Precaution & Feed Back

1. Precautions
Precaution during overhauling of DV 01
2. Tools and Equipments

01
Tools and Equipments
3. Feed back
Feed back of the training 01

CAMTECH/2003 / M /TRG/ 01 39

(AIR BRAKE)
Workshop : Wagon
Description : Cut Of Angle Cock, Isolating Cock
Check valve with Choke

1. Cut Of Angle Cock
I. Introduction and constructional detail. 01
III. Maintenance
2. Isolating Cock
III. Maintenance
3. Check Valve with Choke

III. Maintenance

CAMTECH/2003 / M /TRG/ 01 40

(AIR BRAKE)
Workshop : Wagon
Description : Pipe Brackets, Couplings & Control reservoir

1. Common Pipe Brackets With Control Reservoir
And Intermediate Piece
01
I. Introduction and constructional detail.
III. Maintenance
2. Brake Pipe And Feed Pipe Couplings

III. Maintenance
3. Air Hose Coupling

III. Maintenance

CAMTECH/2003 / M /TRG/ 01 41

(AIR BRAKE)
Workshop : Wagon
Description : Dirt Collector, Auxiliary Reservoir &
Guard’s Emergency Brake Valve

1. Dirt Collector
III. Maintenance
2. Auxiliary Reservoir
III. Maintenance
3. Guard’s Emergency Brake Valve

III. Maintenance

CAMTECH/2003 / M /TRG/ 01 42

(AIR BRAKE)
Workshop : Wagon
Description : Brake rigging

1. Handbrake
I. General Introduction &

II. Constructional detail
01
Empty Load Device
I. General &
II. Constructional detail
2. Components 01
I. Sliding brake beam &

II. Body under frame components
3. Brake Head Replacement

Composition brake block - Do’s and don’ts for
fitment of composition brake block
01
I. To be done
II. Not to be done

CAMTECH/2003 / M /TRG/ 01 43

(AIR BRAKE)
Workshop : Wagon
Description : Repair & Maintenance of SAB

1. Overhauling of Slack Adjuster (SAB)
I. Introduction
II. Disassembling
III. Cleaning and inspection 01
IV. Lubrication
V. Reassembling
VI. Safety precautions
2. Testing Of Slack Adjuster On Test Rack
I. Take up test or Pay in test

01
II. Pay out test
III. Testing of slack adjuster and brake rigging
without handbrake
3. Setting And Measurements

I. Painting
II. Procedure for brake rigging - setting and 01
measurements of A+C dimensions
III. Tools and Equipments

CAMTECH/2003 / M /TRG/ 01 44

(AIR BRAKE)
Workshop : Wagon
Description : Single Wagon & Rake Test

1. Single Wagon Test
Different test for subassemblies

I. Leakage test
II. Sensitivity and insensitivity test 01
III. Brake application and release test
IV. Graduated application and release test
V. Check and adjust slack adjuster
2. Procedure
I. Single wagon Test rig (SWTR)

II. Procedure for single wagon test 01
III. Performa for single wagon test for
wagons other than BOBR and BOBRN
3. Rake Test
By RTR - Upto 56 nos. of wagons

I. Visual examination 01
II. Prepare setup (rig) for rake test
III. Conduct leakage service application and
release test
IV. Feed of the training

CAMTECH/2003 / M /TRG/ 01 45

(DRAW & BUFFING GEAR)
WORKSHOP : WAGON
TRADE : FITTERS
PERIODICITY : ONCE IN FOUR YEARS
DURATION : 9 DAYS
1. Introduction Buffing Gear One day
2. Buffing Gear Repairs One day
3. Reclamation Of Draw Bars Part-1 One day
4. Centre Buffer Coupler & Draw Gear One day
5. Coupler Reclamation Practices One day
6. Maintenance Of RF-361- Draft Gear Part-1 One day
7. Maintenance Of RF-361- Draft Gear Part-2 One day
8. Maintenance of MARK-50 - Draft Gear Part-1 One day
9. Maintenance of MARK-50 - Draft Gear Part-2 One day

CAMTECH/2003 / M /TRG/ 01 46

Workshop : Wagon
Description : Introduction buffing gear
S No Description Hours
1 Introduction - General
01
Conventional buffing gear
2
Type of buffing gear
01
I. Long case
II. Short case
3 Components
01
The main components of buffing gear (Sub components)

CAMTECH/2003 / M /TRG/ 01 47

Workshop : Wagon
Description : Buffing Gear Repairs
(For POH of buffing gear IRCA Pt. !!! rule No.2.13 to be followed. Accordingly
repairs practices of following components of sub assemblies)
S No. Description Hours

1 Repairs of
01
Buffing casing
2 Repairs of
01
Spindle
3 Repairs of
Outer and inner coil spring

01
I. Buffer projection
II. Buffer height

CAMTECH/2003 / M /TRG/ 01 48

Workshop : Wagon
Description : Reclamation Of Draw Bars
Procedure for reclamation of draw bars in workshops
S No Description Hour
1
Screening 03
Screening draw bar for reclamation

CAMTECH/2003 / M /TRG/ 01 49

(DRAW BAR AND BUFFING GEAR)
Workshop : Wagon
Description : Centre Buffer Coupler & Draw Gear
S No. Description Hour
Centre Buffer Coupler & Draw Gear

1
Parts of centre buffer coupler assembly and its inspection 01
2 Inspection of CBC (Coupler’s operating mechanism ) 01
3 Inspection of draft gear (HR-40-1 & MF-400-1-IR) 01

CAMTECH/2003 / M /TRG/ 01 50

Workshop : Wagon
Description : Coupler Reclamation Practices
(Coupler body, shank, cuard arm, knuckle, lock, clevis and clevis pin)
1
Draft Gear Reclamation Practices For Card Well
Westing House(HR-40-1) GEAR
Yoke, housing integral follower, rubber pads, rubber 01

packs, rear cushioning units wagon packet.
2
Reclamation Practices For National Rubber(Type Mf-
400-1-Ir) Draft Gear
Yoke & Yoke pin, followers, front compensating units. 01
3
Development Of High Tensile Coupler& High Capacity
Draft Gear(Make-50 &Pf-361)
Components of RF-361-Draft gear

List of gauges for RF-361-Draft gear
I. Gauges for housing. 01

II. Gauges for shoes
III. Gauges for wedge
IV. Final inspection gauge

CAMTECH/2003 / M /TRG/ 01 51

Workshop : Wagon
Description : Maintenance Of RF-361- Draft Gear
1
Disassembly 01
Disassembly procedure for RF-361- Draft gear
2
Inspection
01
Inspection of components
Shoes, wedge, housing or cylinders
3
Reconditioning 01
Complete reconditioning

CAMTECH/2003 / M /TRG/ 01 52

Workshop : Wagon
Description : Maintenance Of RF-361- Draft Gear
1
Inspection
Visual inspection of rubber pads 01
2
Static test
I. Inspection of internal followers

II. Inspection of forged 01
III. Inspection of housing(Cylinders)
IV. Preparation of housing prior to reassemble
3
Re-assembly
Re-assembly of reconditioned RF-361 Draft gear 01

CAMTECH/2003 / M /TRG/ 01 53

(DRAW AND BUFFING GEAR)
Workshop : Wagon
Description : Maint Of MARK-50 - Draft Gear
1
Inspection 01
2
Removal Of Draft Gear From Wagon Pocket
I. Normal condition
II. Follower broken 01
III. Partially stuck gear
IV. Fully stuck draft gear
V. Removal of stuck or damaged draft gear
3
Removal of stuck draft gear so as to re use 01

CAMTECH/2003 / M /TRG/ 01 54

(DRAW AND BUFFING GEAR)
Workshop : Wagon
Description : MAINT. OF MARK-50 - DRAFT GEAR
1.
Inspection 01
Inspection of Mark-50 gear for reconditioning
2.
Guide To Dismantle 01
Summarized guide to dismantle Mark-50 draft gear
3.
List of gauges
For Mark-50 draft gear 01
I. Housing gauges for initial inspection

II. Housing weld repair gauges

CAMTECH/2003 / M /TRG/ 01 55

(SUSPENSION)
WORKSHOP : WAGON
TRADE : FITTERS
DURATION : 7 DAYS
1.
INTRODUCTION- SUSPENSION One day
(FOUR WHEELED SUSPENSION)
2.
CASNUB BOGIE One day
3.
BOX (U I C )BOGIE One day
4.
CAST STEEL BOGIE One day
5.
DIAMOND FRAME BOGIE One day
6.
MAINTENANCE OF ROLLER BEARING One day
7.
MAINTENANCE OF CTRB One day

CAMTECH/2003 / M /TRG/ 01 56

(SUSPENSION)
Workshop : Wagon
Description : INTRODUCTION- SUSPENSION
(FOUR WHEELED SUSPENSION)
THE SUSPENSION OF FOUR WHEELED WAGON

1 Introduction
Introduction to suspension 01
2 Individual Elements
The brief description of the individual elements of four 01

wheeler suspension;
I. Scroll iron
II. Shackle pins
III. Shackle plates
IV. Spring shackle
V. Bearing spring
VI. Shackle pin washers
VII. Split cotters/ bulb cotters
3
Repairs during POH 01

CAMTECH/2003 / M /TRG/ 01 57

(SUSPENSION)
Workshop : Wagon
Description : CASNUB BOGIE
Casnub Bogie
1 Introduction & Construction details of CASNUB Bogie 01

and its sub-assemblies
2 Repair and maintenance during POH. 01
3 1. Nominal clearances.
2. Wear limits of the components. 01
3. Relevant drawings numbers

CAMTECH/2003 / M /TRG/ 01 58

(SUSPENSION)
Workshop : Wagon
Description : BOX (U I C )BOGIE
1 BOX (U I C) Bogie
Construction details of BOX (U I C) Bogie and its sub- 01

assemblies
2
Repair and maintenance during POH. 01
3
1. Nominal clearances.

CAMTECH/2003 / M /TRG/ 01 59

(SUSPENSION)
Workshop : Wagon
Description : CAST STEEL BOGIE
1 CAST STEEL Bogie
Construction details of CAST STEEL Bogie and its 01

sub-assemblies.
2
3

CAMTECH/2003 / M /TRG/ 01 60

(SUSPENSION)
Workshop : Wagon
Description : DIAMOND FRAME BOGIE
1 DIAMOND FRAME BOGIE
Construction details of diamond frame bogie and its 01

sub-assemblies.
2
3

CAMTECH/2003 / M /TRG/ 01 61

(SUSPENSION)
Workshop : Wagon
Description : MAINTENANCE OF ROLLER
BEARING
1. Inspection and maintenance of 20.3 tonne cylindrical roller bearing. WT-77-1

(First Revision 1985)
2. Instruction for inspection and maintenance of 16.3 tonne cylindrical roller

bearing. WT-79-1( First Revision 1987

1 Dismounting and dismantling
I. Roller bearing axle box dismounting.

II. Identification of roller bearing box and its
classification. 01
III. Roller bearing axle box dismantling by press
machine.
2 Cleaning and inspection
I. Axle box housing and its components cleaning

II. Inspection of the components
III. Condemnation of defective parts and their 01
repair and replacement.
IV. General cleaning and examination.
3 Assembly and mounting
I. Replacement of defective parts (inner races

and throwers) 01
II. Assembly of roller bearing by hydraulic press.
III. Greasing of axle box
IV. Mounting of roller bearing axle box.

CAMTECH/2003 / M /TRG/ 01 62

(SUSPENSION)
Workshop : Wagon
Description : MAINTENANCE OF CTRB

1 Dismounting and dismantling
I. CTRB dismounting.
II. Transportation.
III. CTRB dismantling. 01
2 Cleaning and inspection
I. CTRB components cleaning

II. Inspection of the components
III. General cleaning and final examination. 01
IV. Marking of over hauling- W/Shop, Month &
Year.
3 Assembly and mounting
I. Adjust lateral play of CTRB on bench.

II. Assembly Greasing of CTRB 01
III. Packing of CTRB.
IV. Transportation.
V. Mounting of CTRB on BN wheels

CAMTECH/2003 / M /TRG/ 01 63
3.4 TRAINING MODULE FOR MACHINIST

(WHEEL SHOP)
WORKSHOP : WAGON
TRADE : MACHINIST
ACTIVITY CENTRE : WHEEL SHOP
DURATION : 2 DAYS
8.
INSPECTION OF WHEELS One day
9.
MACHINING OF WHEELS One day

CAMTECH/2003 / M /TRG/ 01 64
3.4.1 TRAINING MODULE FOR MACHINIST

(WHEEL SHOP)
Workshop : Wagon
Description : INSPECTION OF WHEELS

Introduction
1
Type of wheels 01
Inspection
I. Wheel defects.
2 II. Diameter of wheels with condemnation limits
III. Axle 01
IV. Wheel disc
Gauges
3
Use of different gauges 01
NOTE: Only the ultra sonically tested and OK wheels are to be taken for further
repair / machining.

CAMTECH/2003 / M /TRG/ 01 65

(WHEEL SHOP)
Workshop : Wagon
Description : MACHINING OF WHEELS

Reaxling
1 01
I. Machining of new axle
II. Machining of disc
III. Assembly
Rediscing
01
2 I. Machining of new disc
II. Machining of axle
III. Assembly
Tread profile
3 01
Machining for tread profile to match road gauge
NOTE: Pairing of the wheels to be done by the Fitter staff.

CAMTECH/2003 / M /TRG/ 01 66
3.5 TRAINING MODULE FOR BLACKSMITH

(BLACKSMITHY SHOP)
TRADE : BLACKSMITH
ACTIVITY CENTRE : BLACKSMITHY SHOP
DURATION : 04 DAYS
Sr. No. Description Duration
1 Reclamation Of Draw Bars One day
2 Maintenance of LB spring One day
3 Spring manufacturing One day
4 Heat treatment of LB springs One day

CAMTECH/2003 / M /TRG/ 01 67
3.5.1 TRAINING MODULE FOR BLACKSMITH

(BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Blacksmith
Description : Reclamation Of Draw Bars
DRAW & BUFFING GEAR
Procedure for reclamation of draw bars in workshops
1 Reconditioning and Identification 01
Reconditioning by stamping/ forging at location ‘a’ and ‘b’
Stamping for identification
2 Heat treatment ( Draw Bar and Screw Coupling)
I. Hardening 01
II. Tampering
3 Load Test 01
Proof load test

(As per IRS specification No.R-11-67 clause 7.1)

CAMTECH/2003 / M /TRG/ 01 68

(BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Black smith
Description : MAINTENANCE OF LB SPRING
S.No. Description Hours
Inspection of spring during POH

1
I. Rejectable defects of the springs
II. Load deflection test 01
III. Grading of the spring.
2 Identification of the spring for repair in BSS

01
3 Material specification of the parts 01

CAMTECH/2003 / M /TRG/ 01 69

(BLACKSMITHY SHOP)
Workshop : Wagon
Description : SPRING MANUFACTURING


Coil spring manufacturing
1
RDSO Specification No WD-01-HLS-94 (Rev.-1 May
95-with latest amendment.) 01
Board letter No. 76/M(W) 814/43 dated 12.03.64 &
03.06.68
LB Spring manufacturing
2
I. RDSO letter No.M&C/STC/2/1 dated 26.03.75
01
II. RDSO letter No MW/!! Spring dated 18.07.77
(Approved v, and IRS specification RS-68)
3 RDSO pamphlet Laminated spring failure-

description, classification and repotting- issued in 1969 01
with a corrigendum in 1972

CAMTECH/2003 / M /TRG/ 01 70

(BLACKSMITHY SHOP)
Workshop : Wagon
Description : Heat Treatment Of Lb Springs

Duration : 1 Day- ( 4th Day)

Heat Treatment
(Spring after BS work shell be heat-treated.)
1 I. Hardening a) Water hardening b) Oil hardening

II. Tempering
III. Temperature control 01
IV. Rolled eye
V. Indentation
2 Testing of the spring after BS work 01

I. Scrag test
II. Load defection
3 Important Do’s and Don’ts 01

CHAPTER -4
FOR
ARTISANS
IN
DIESEL WORKSHOP
CAMTECH/2003 / M /TRG/ 01 71
4.1 TRAINING MODULE FOR MACHINIST

Workshop : Diesel
Trade : Machinist
Activity Centre : Wheel Shop
Periodicity : Once In Four Year.
Duration : 12 Days
SR.NO DESCRIPTION DAY
.
1 1 Introduction of Course, Attitudinal change & Motivation.
2 General Awareness of ISO. 01
3 Safety & Environment.
2 1 Limits Fits and Tolerance.
2 Precision Measuring Instruments. 01
3 Gauges and Templates.
3 1 Various types of Cutting tools.
2 Various types of Machine tools. 01
3 Multipurpose, Single purpose and special purpose Machine Tools.
4 1 Automatic Lathe..
2 NC/ CNC & Hydraulic Machines. 01
3 Other special purpose machines.
5 1 Introduction of Wheel Shop.
2 Main activities of Wheel shop. 01
3 Lathe accessories and attachments.
6 1 Quality control.
2 Quality improvement. 01
3 Inspection.
7 1 Profile turning of wheel.
2 Press in side coller and press in Bull gear. 01
3 Boring of Wheel disc.
8 1 Journal Burnishing.
2 Bearing Seat machining. 01
3 Shrinking of the inner race.
9 1 Tyre Boring.
2 Profile tyre turning. 01
3 Crank pin returning.
10 1 Crank pin rethreading.
2 Boring of the Wheel disc. 01
3 Bearing Seat Machining.
11 1 Visual inspection of Armature.
2 Armature shaft press out & press in. 01
3 Matching the pinion seat on the armature shaft.
12 1 Handling, Storage and packing.
2 Failure analysis and Customer feed back. 01
3 Feed back from trainees.

CAMTECH/2003 / M /TRG/ 01 72

Workshop : Diesel
Description : Introduction Of Course, Attitudinal Changes &
Motivation. General Awareness Of ISO.
Safety And Environment.
Duration : 01 Day (1st day)
Duration
Period Contents (Hours)
Introduction of the course.
01 Changing the attitude related to the work.
Role of technicians in improving the Quality of work. 01
Need of ISO Certification.
02 ISO 9000 Series. 01
Guiding principles for implementing systems.
Terms related to ISO 9000.
Probable causes of accidents in workshop.
03 Basic steps for accident prevention. 01
Fire Prevention.
House keeping.

CAMTECH/2003 / M /TRG/ 01 73
Workshop : Diesel
Description : Limits, Fits And Tolerance.

Precision Making Instruments.
Gauges And Templates.
Duration : 01 Day (2nd day)
Duration
(a) Limits, Fits and tolerance.
01 (b) System of tolerance.
(c) Maximum and Minimum allowance. 01
(a) Types functions, Material and specification of
02 preliminary measuring Instruments. 01
(b) Reading of Vernier Caliper, Micrometer,
Depth gauge, and Height gauge.
(a) Different types of gauges.
03 (b) Master gauges, Inspection gauges. 01
(c) Go & Not go Gauge, Snap Gauge, Plug
gauge, Thread gauge and Filler gauge.

CAMTECH/2003 / M /TRG/ 01 74
Workshop : Diesel
Description : Various Types Of Cutting Tools.

Various Types Of Machine Tools.
Multipurpose, Single Purpose & Special Purpose
Machine Tools.
Duration : 01 Day (3rd day)
Duration
(a) Types of Material used for cutting tools.
01 (b) Composition and characteristics.
(c) Uses of tools. 01
(a) Operations performed on Machine tools.
02 (b) Speed, feed, Cutting speed & Depth of cut. 01
(c) Definition
(a) Classes of Machine tools.
03 (b) Multipurpose and single purpose. 01
(c) Special purpose Machine Tools.
(d) Machine Tools used in Machine shop and
wheel shop.

CAMTECH/2003 / M /TRG/ 01 75
Workshop : Diesel
Description : Automatic Lathe.

NC/ CNC & Hydraulic Machines.
Other Special Types Of Machines.
Duration : 01 Day (4th day)
Duration
(a) Mass production Lathe with complete automatic
01 control.
(b) Functions of automatic lathe and it‟s operations. 01
(c) Cutting tools used on automatic lathe.
(a) NC/CNC and Hydraulic Machines.
02 (b) Axle turning centre, Chucker and Break press. 01
(c) TCM, VTL co-ordinate Measuring Bolt, Forging,
Shearing machine.
(a) Other special types of machines.
03 (b) Wheel lathe and Gap bed lathe. 01
(c) „T‟ lathe and Duplicating.
(d) Missile lathe.

CAMTECH/2003 / M /TRG/ 01 76
Workshop : Diesel
Description : Introduction Of Wheel Shop.

Main Activities Of Wheel Shop.
Lathe Accessories & Attachments.
Duration
(a) Types of Wheels, Axles, Bearing, POH of
01 WDM2 wheel. 01
(b) WDM2 wheel repair practice and Inspection.
(c) Rail cars.
(a) Press out TQ & Tap Roller Bearing.
02 (b) Remove inner race. 01
(c) Press out wheel centre and Bull gear.
(d) Press in Bull gear coller and wheel centre to
Axle.
(a) Lathe Accessories & attachments.
03 (b) Lathe centre, Catch plate and Carriers. 01
(c) Other Holding and Holding supporting the work.
(d) Attachment used for stops, ball turning rest ,
threading, chasing dials.

CAMTECH/2003 / M /TRG/ 01 77
Workshop : Diesel
Description : Quality Control. Quality Improvement.

Inspection.
Duration
(a) Quality Control.
01 (b) Quality Cyclic behaviour pf production. 01
(c) Rejection of Jobs.
(a) Quality Improvement.
02 (b) Quality Control activities. 01
(c) Benefits of Quality Control.
(a) Inspection.
03 (b) Functions of Inspections.
(c) Accuracy and Precision. 01
(d) Kinds of Inspection of manufactured product.

CAMTECH/2003 / M /TRG/ 01 78
Workshop : Diesel
Description : Profile Turning Of Wheel.

Press In Side Coller And Press In Bull Gear.
Boring Of Wheel Disc.
Duration
(a) Profile turning of Wheel.
01 (b) Face inside the disc.
(c) Turn the disc. 01
(d) Fit the profile gauge.
(a) Press inside Coller and press in Bull gear.
02 (b) Align the Axle with the Coller on the Hydraulic 01
press.
(c) Set the Axle.
(a) Boring of Wheel disc.
03 (b) Face the hub of the disc at bottom. 01
(c) Face the disc at top to maintain the Hub.

CAMTECH/2003 / M /TRG/ 01 79
Workshop : Diesel
Description : Journal Burnishing. Bearing Seat Machining.

Shrinking Of Inner Race.
Duration
(a) Journal Burnishing.
01 (b) Face Axle coller to maintain suspension gauge. 01
(c) Remove burn and clean the turned off Axle.
(d) Burnish the journal.
(a) Bearing Seat machining.
02 (b) Rough and finish turned Axle. 01
(c) Burnish the Bearing Seat
(a) Shrinking of Inner Race.
03 (b) Induction heating of Inner Race. 01
(c) Fitting of Inner Race.

CAMTECH/2003 / M /TRG/ 01 80
Workshop : Diesel
Description : Tyre Boring. Profile Tyre Turning.

Crank Pin Re-Turning.
Duration
(a) Tyre Boring.
01 (b) Grooving of Tyre. 01
(c) Fitting of gauge.
(d) Final Boring of the Tyre.
(a) Profile Tyre turning.
02 (b) Facing of inside of Tyre to maintain the road
gauge. 01
(c) Turning of tyre and fitting of Profile gauge.
(a) Crank pin re-turning.
03 (b) Rough turning of the C P.
(c) Facing the wheel centre to maintain the length. 01
(d) Final turning of the C P.

CAMTECH/2003 / M /TRG/ 01 81
Workshop : Diesel
Description : Crank Pin Threading..

Boring Of The Wheel Disc.
Bearing Set Machining.
Duration : 01 Day (10th Day)
Duration
(a) Crank pin re-threading.
01 (b) Light turning on threaded portion. 01
(c) Re-threading and grooving of C.P.
(a) Boring of the wheel disc.
02 (b) Face the disc at top to maintain the Hub length. 01
(c) Bore the disc, machine the groove finish
boaring.
(a) Bearing seat Machining.
03 (b) Turn the Bearing seat. 01
(c) Filing Bearing seat.

CAMTECH/2003 / M /TRG/ 01 82
Workshop : Diesel
Description : Visual Inspection Of Armature.

Armature Shaft Press Out..
Match Of The Pinion Seat On Armature Shaft.
Duration
(a) Visual Inspection of Armature.
01 (b) Check for any damage on main body. 01
(c) Check for any damage on the Coil.
(a) Armature shaft press out and press in.
02 (b) Align the shaft with the Ram of the press
(c) Place a Copper or M.S.Pad between Ram & 01
shaft.
(d) Press out Armature shaft.
(a) Match of the Pinion seat on the Armature shaft.
03 (b) Keep the Armature horizontally.
(c) File the Pinion. 01
(d) Seat and feed the gauge.

CAMTECH/2003 / M /TRG/ 01 83

Workshop : Diesel
Description : Handling Storage Packing..

Failure Analysis And Analytical Approach.
Feed Back Of The Trainees.
Duration
Handling storage packing
01 (a) While shifting the Wheel.
(b) While loading the wheel. 01
(c) After burnishing operation of the wheel.
(a) Failure analysis and analytical approach.
02 (b) Examine looseness of distance pieces.
(c) Examine ales and discs. 01
(d) Apply mod colour to all defective parts
indicating attention to be paid.
(a) Feed back of trainees according to modern
03 practices inspection.
(b) Record and special studies are used to Identify 01
problems and their causes.

CAMTECH/2003 / M /TRG/ 01 84
4.2 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE

SECTION
WORKSHOP : DIESEL
TRADE : DIESEL MECHANIC
ACTIVITY CENTRE : BOGIE /AIR BRAKE/CAB SECTION
PERIODICITY : ONCE IN FOUR YEAR
DURATION : 12 DAYS (3 CLOCK HOURS EACH DAY)
Sr. Description Day

No.
a) Introduction of course, Attitudinal change & motivation 01
1 b) General awareness of ISO
c) Safety & Environment
2 a) Introduction and General data of WDM2 locomotive 01
3 a) Introduction to Vehicle Section. 01
4 BOGIE SECTION 01
a) Stripping & Overhauling of Bogie frame.
5 a) Assembly of Traction motor, Gear Case, Wick pad, 01
6 a) Assembly of foundation brake components 01

b) Bogie Run Test on testing stand
c) Placing of Bogie frame on Chassis.
7 AIR BRAKE SECTION 01

a) General knowledge of brake system of WDM2
b) Overhauling of different type of brake valve assembly
c) Working of safety device on loco
8 a) Working of auto flasher system on WDM2 loco 01
b) Overhauling and testing lube oil relief regulating
bypass & OSTA.
c) Brief Description of AIR BRAKE system & different
types of Breaking circuits A9,SA9, with conjunction
working & IRABP
9 CAB-SECTION 01
a) Overhauling of cab and super structure
b) Overhauling of hand brake assembly
c) Modification of cab & EAI

CAMTECH/2003 / M /TRG/ 01 85
10 a) Explanation of all BD items (EAI) as per RDSO 01

Instructions
11 a) Customer feed-back session 01
12 (a) Assessment Test 01

(b) Interaction with trainees regarding result
(c) Feedback from trainees.
(d) Valedictory function

CAMTECH/2003 / M /TRG/ 01 86
4.2.1 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE

SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Introduction Of Course, Attitudinal Change
& Motivation.
General Awareness Of Iso.
Duration : 01 Day (1st Day)
Sr. No. Period

Contents (Hours)
a) Introduction of course, Attitudinal change &
01 Motivation. 01
b) Introduction of course and advantage.
c) Attitudinal changes related to their work.
General awareness of ISO.

02 a) Introduction of ISO, importance, advantages, 01
various terms related to ISO, Quality policy,
Work instruction , changes of the Work shop.
Safety & environment

03 a) safety items related to Work shop & related to 01
Bogie Section.
b) Better house keeping.

CAMTECH/2003 / M /TRG/ 01 87

SECTION
Workshop : Diesel
Section : Bogie , Air Brake, Cab & Power

Pack
Description : Introduction And General Data Of Wdm2
Loco.
Duration : 01 Day (2nd Day)
Period
Sr. no. Contents (Hours)
General data of WDM2 Loco.
a) Introduction, parts list, function of
each parts, Capacity of L.Oil, Fuel
01 Oil, Water cooling of WDM2 Loco & 01
General data.
b) Final testing.(Load Box)
Introduction of Power pack section.
a) Knowledge of FIP, Injector and
testing.
02 b) FIP & Calibration. 01
c) Blowers, Water Pump and
L.O.Pump.
a) Cylinder head and testing.

b) Piston.
03 c) Working principle of TSC & 01
Expressor.

CAMTECH/2003 / M /TRG/ 01 88

SECTION
Workshop : Diesel
Description : Introduction To Chassis, Rt. Angle

Gear Box &Radiator.
Duration : 01day (3rd Day)
Period
Sr. no. Content (Hours)
01 a) Knowledge of chassis, and its

Components 01
b) Stripping & overhauling
02 a) Knowledge of Right Angle Gear 01

Box. & Its maintenance
.
03 b) Knowledge of Radiator. & It‟s 01

overhauling.

CAMTECH/2003 / M /TRG/ 01 89

SECTION
Workshop : Diesel
Description : Stripping And Overhauling Of Bogie Frame.
Sr. Period
Contents
No. (Hours)
01 a) Complete stripping procedure of Bogie frame.

b) Cleaning of Bogie frame with chemical 01
solvents and water pressure.
c) Visual inspection and Detection of crack at
critical location- DPT.
a) Removing of all liner, provision of new liner.

02 b) Bogie alignment. 01
a) Checking of Centre pivot liner.

03 b) Centre Pivot sizes, inspection & repairing of 01
side bearers.

CAMTECH/2003 / M /TRG/ 01 90

SECTION
Workshop : Diesel
Technicians : Diesel Mechanics
Description : Assembly Of T /Motor, Gear Case,

Wick Pad & Resilience Pad
Period
Assembly of Traction Motor

a) Visually Inspection of Pinion i.e. pitting
mark & damaged teeth.
b) Pinion Checking & Magnaflux testing
and Fitting on Traction Motor
01 c) Inspection of Axle journal & their sizes. 01
d) Inspection of Suspension bearing &
Ultrasonic test.
e) Checking of Radial & Lateral
clearances
02 Gear Case Assembly 01
03 Resilience Pad & Assembly 01

a) Visual Inspection & Cleaning

CAMTECH/2003 / M /TRG/ 01 91

SECTION
Workshop : Diesel
Description : Assembly Of Foundation Bracket Component

Boogie Run Test Stand Test
Placing Of Bogie Frame On Chassis
Period
Assembly of foundation bracket component .
a) condition of Brake shoe, Hanger lever, Slack
adjuster ,Pull rod. 01
01 b) Condition of Brake cylinder &Piston.
c) Checking of ovality of brake cylinder.
d) Assembly of all bogie frame pipe line.
Bogie Run test on test stand

a) Precaution to be taken while connection of
02 T/Motor 01
b) Checking of unusual sound
c) Testing limitation Minutes.
PLACING OF BOGIE FRAME ON CHASSIS

a) Visual inspection of U bracket.
b) Sealing of Wicks pad bolt, all gear case. 01
c) Sealing of Traction Motor Axle cap bolts,
03 Gear case bolts.
d) Checking of slack adjuster for brake
adjustment.
e) Final tightness of bottom stay
plates(Pedestal cap)

CAMTECH/2003 / M /TRG/ 01 92

SECTION
Workshop : Diesel
Description : General Knowledge Of Brake System.

Overhauling Of Different Types Of
Brake Valve Assembly.
Sr.No. Contents Period

(Hours)
a) Necessity of Air brake system.
b) Introduction of Air and Vacuum brake
01 system. 01
c) Introduction of air brake system IRAD-1
BRAKE VALVE ASSEMBLY

a) Working of A9 valve.
02 b) Working of SA9 valve. 01
c) Working of C2 Relay valve
a) Safety devices used on WDM2 loco.
b) APS Air flow measuring valve & PATB
03 c) H5 & HB5 valve. 01
d) Working of sand valve and Wiper Motor &
Horns.

CAMTECH/2003 / M /TRG/ 01 93

SECTION
Workshop : Diesel
Technicians : (Diesel Mechanic)
Description : Working Of Auto Flasher System.

Overhauling And Testing Of L /O Valves
& Ost Assembly.
Air Brake Circuits.
Duration : 01 Day(08th Day).

(Hours)
01 Working of Auto flasher system on WDM2 01

Loco.
Overhauling and testing of L.O. Relief

02 Regulating By pass valve and OST Assembly. 01
03 Brief description of Air brake Circuits, A9 01

Circuits with conjunction working, IRAB–1
circuits.

CAMTECH/2003 / M /TRG/ 01 94

SECTION
Workshop : Diesel
Description : Overhauling Of Cab & Super Structure.

Overhauling Of Hand-Brake Assembly.
Duration : 01 Day (9th Day )

(Hours)
CAB & SUPER STRUCTURE

a) Checking of Driver cab
01 b) Maintenance of cab doors, cracks & 01
glass.
c) Proper locking of cab door
prevention from water.
d) Safety precaution.
HAND BRAKE ASSEMBLY

a) Uncoupling of hand brake from loco.
b) Stripping and visual inspection(For
02 wear and tear) 01
c) Assembly of hand brake.
d) Safety precautions.
03 Modification of cab & EAI. 01

CAMTECH/2003 / M /TRG/ 01 95

SECTION
Workshop : Diesel
Description : Explanation Of All Bd Items (Eai)

As Per Rdso Instructions.
Sr. No. Contents Period

(Hours)
Brief knowledge of all BD items related BOGIE
01 SECTION
a) BD-11, BD-14, BD-23, BD-54,BD-55, 01
Brief knowledge of all BD items related to AIR

02 BRAKE SECTION 01
a)BD-12, BD-33, BD-50, BD-65 BD-71
Brief knowledge of all BD items related to CAB

03 SSECTION 01
BD-38, BD-56, BD-61, BD-64, BD-72, BD-73

BD-81.

CAMTECH/2003 / M /TRG/ 01 96

SECTION
Workshop : Diesel
Description : Customer Feed Back Session
Duration : 01 Day ( 11th Day )

(Hours)
01 Customer complaint., 01
02 Remedies of customer complaint 01
03 Practical on complaint 01

CAMTECH/2003 / M /TRG/ 01 97

SECTION
Workshop : Diesel
Description : Assessment Test.
Sr. Contents Period

No. (Hours)
Assessment test on the topic of General
01 WDM2 data, Bogie, Air brake, Cab Sec. 01
02 Interaction with trainees regarding result 01
03 Feed back from trainees 01

Valedictory function

CAMTECH/2003 / M /TRG/ 01 98
4.3 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Trade : Diesel Mechanic
Activity Centre : Chassis Section
Periodicity : Once In Four Year
Duration : 12 Days
Sr. Description Day

No.
a) Introduction of course, Attitudinal change & motivation 01
1 b) General awareness of ISO
c) Safety & Environment
2 a) Introduction and General data of WDM2 locomotive 01
b) Introduction of Power Pack Section
3 a) Introduction to Vehicle Section. 01
4 CHASSIS SECTION 01
a) Overhauling of Reservoir carried out by Sheet Metal
shop.
e) Overhauling of Cattle guard carried out by chassis
section.
c) Overhauling of CBC
5 a) Overhauling of Fuel Tank. 01
b) Overhauling of Centre pivots.
c) Overhauling of chassis
6 a) Overhauling of L.W. S. 01
b) Overhauling of Draft Gear.
c) Final checking of chassis before dispatch.
7 RADIATOR SECTION 01
a) Over hauling of Radiator
b) Overhauling of Lube oil cooler.
c) Overhauling of car body, air intake filter
8 RIGHT ANGLE GEAR BOX 01
a) Stripping & overhauling of Radiator Fan.
b) Stripping & overhauling of Right angle Gear Box.
c) Hydraulic testing of L/oil filter drum.
9 a) Overhauling of Drive Shaft. 01
b) ECC outer drum , Bearing assembly
c) Overhauling of Spline Shaft.
10 a) Explanation of all BD items (EAI) as per RDSO 01
Instructions

CAMTECH/2003 / M /TRG/ 01 99
11 a) Customer feed-back session 01
12 a) Assessment Test 01
b) Interaction with trainees regarding result

CAMTECH/2003 / M /TRG/ 01 100
4.3.1 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS

SECTION
Workshop : Diesel
Description : Introduction Of Course, Attitudinal Change .

& Motivation
General Awareness Of Iso
Safety & Environment
Duration : 01 Day ( 1st Day )
Sr. No. Period

Contents (Hours)
Introduction of course , Attitudinal change &
01 Motivation.
a ) Introduction of course , advantages 01
b ) Attitudinal changes related to their work
.
General awareness of ISO.
02 a)Introduction of ISO, importance, advantages, 01
various terms related to ISO, Quality policy,
Work instruction , changes of the Work shop.
Safety & environment

03 a) Safety items related to Work shop & related to 01
Chassis section

CAMTECH/2003 / M /TRG/ 01 101

SECTION
Workshop : Diesel
Description : Introduction And General Data Of WDM-2 Loco.
Period
General data of WDM2 Loco.
a) Introduction , Parts list, Function of each
parts, Capacity of Lube Oil, Fuel Oil of
01 WDM2 Loco. 01
b) General Data.
c) Final testing.(Load Box)
Introduction of Power pack II section.
a) Knowledge of FIP, Injector & testing
b) FIP Calibration.
02 c) Blowers, Water Pump and L.O.Pump. 01
a) Cylinder Head
b) Piston
03 c) Working principle of TSC & Expressor 01

CAMTECH/2003 / M /TRG/ 01 102

SECTION
Workshop : Diesel
Description : Introduction Of Vehicle Section
Duration : 01 Days (3rd Day)
Period
Sr. no. Content (Hours)
01 a) Brief knowledge of chassis and

modifications. 01
02 a) Basic principles of Right Angle

Gear Box. 01
b) Basic principles of Radiator.
03 a) Introduction of Bogie section. 01

CAMTECH/2003 / M /TRG/ 01 103

SECTION
Workshop : Diesel
Description : Overhauling Of Reservoir Carried Out

By Sheet Metal Shop.
Overhauling Of Cattle Guard
Overhauling Of C.B.C.
Duration : 01 Days (4th Day)
Period
Sr. Contents (Hours)
No.
Overhauling of reservoir
01 a) Uncoupling of reservoir & inspection of thread. 01
b) Hydraulic testing of reservoir , erecting on loco.
Overhauling of cattle guard

02 a) stripping procedure of cattle guard
b) visual inspection
c) Explanation of BD 84 modified cattle guard as 01
per RDSO instruction
d)Explanation of back support & alignment with
chassis.
Overhauling of CBC
03 a) stripping of CBC
b)Visual inspection of CBC coupler, Knuckle & pin
clevis transmission screw coupling locking 01
arrangement, CBC straightness of shank ware
c) Fitment of CBC on loco

CAMTECH/2003 / M /TRG/ 01 104

SECTION
Workshop : Diesel
Description : Overhauling Of Fuel Oil Tank

Over Hauling Of Centre Pivot
Overhauling Of Chassis
Sr.No. Period
Contents (Hours)
OVERHAULING OF FUEL OIL TANK

a) Draining of tank
01 b) Cutting of tank plate 01
c) Filling of Cement water
d) Cleaning & Hydraulic testing
OVERHAULING OF CENTRE PIVOT

a) Visual inspection of Centre pivot
02 b) Purpose of welding new liner
c) Checking clearances as per 01
RDSO/SK/DL/2069
CI/ FRA/ 5 MPM 1- 140/88
OVERHAULING OF CHASSIS
a) Inspection of Load Pin, centre Pivot
& Cracks or damage after
03 application of chalk.
b) Checking of cracks under frame.
c) Welding of side load bearer. 01
d) Straightness of Buffer beam.
e) Main ting sizes of center pivot, side
load pin.

CAMTECH/2003 / M /TRG/ 01 105

SECTION
Workshop : Diesel
Description : Overhauling Of L W S.
Overhauling Of Draft Gear
Final Safety Checks Of Chassis
Before Despatch

(Hours)
OVERHAULING OF LWS
01 a) Stripping & Electrical testing
b) Checking of float puncture with water.
c) Testing on test stand & erecting on loco BD-60 01
water pressurisation cap assembly.
OVERHAULING OF DRAFT GEAR.

02 a) Types of Draft Gear. 01
b) Inspection of rubber pad.
c) Overhauling & erection on loco.
FINAL SAFETY CHECKS OF BOGIE ASSEMBLY

a) Checking of U bracket, CBC operation, split pin,
bottom stud plate, rod adjustment, Adjuster,
equalizing pipe, Z pipe, rail Guard, Leakages of
all pipeline when the Load Box is conducted.
Clamping of all pipeline before despatch of loco. 01
03 Buffer height & Height of Rail guard to be
maintained.

CAMTECH/2003 / M /TRG/ 01 106

SECTION
Workshop : Diesel
Description : Overhauling Of Radiator

Overhauling Of Lube Oil Cooler
Overhauling Of Car Body, Air Intake Filter

(Hours)
OVERHAULING OF RADIATOR.
a) Stripping of Radiator.
01 b) Cleaning of Radiator
c) Hydraulic & Pneumatic testing of tubes. 01
OVERHAULING OF LUBE OIL COOLER.

a) Stripping of lube oil cooler
02 b) Cleaning
c) Replacement of Gasket 01
d) Hydraulic testing & EI BD 12
OVERHAULING OF CARBODY, AIR INTAKE

FILTER
03 a) Disassemble of Air maze oil bath. filter 01
b) Overhauling of Air maze filter
c) Fitting on loco & oil filling

CAMTECH/2003 / M /TRG/ 01 107

SECTION
Workshop : Diesel
Description : Stripping And Overhauling Of Radiator Fan.

Stripping And Overhauling Of Right T Angle
Gear Box.
Hydraulic Testing Of Lube Oil Filter Drum

(Hours)
STRIPPING & OVERHAULING OF RADIATOR FAN
a) Stripping of fan from shaft.
b) Stripping of upper and lower housing cover, Bearing from
shaft.
01 c) Checking of damaged thread of Fan shaft. 01
d) Removing of Bearing from the shaft.
e) Visual inspection of Bearing.
f) Assembly of Radiator fan.
STRIPPING AND OVERHAULING OF RIGHT ANGLE GEAR
BOX.
a) Stripping from loco.
b) Oil drain from loco.
c) Stripping of Gear Box.
d) Removal of vertical and horizontal shaft assembly.
e) Inspection of Bearing.
f) Draining of Oil reservoir. 01
02 g) Inspection and fitment of Horizontal & Vertical shaft.
h) Checking of Backlash and endplay.
i) Filling of oil in Gear Box.
HYDRAULIC TESTING OF LUBE OIL FILTER DRUM.
03 a) Stripping of Lube Oil Filter Drum and top cover. 01
b) Cleaning and visual inspection of tank.
c) Provision of BD 82 & suitable height of gasket plate.
d) Checking and maintaining of depth of “O” ring groove
e) Hydraulic testing at 10Kg/Cm2.
f) D.P.Test.
g) Erection of new Filter drum on loco.

CAMTECH/2003 / M /TRG/ 01 108

SECTION
Workshop : Diesel
Description : Overhauling Of Drive Shaft.

Ecc Outer Drum., Bearing Assembly.
Overhauling Of Spline Shaft.

Hrs.
OVERHAULING OF DRIVE SHAFT.
a) stripping of drive shaft.
01 b) Pulling of flexible coupling from shaft.
c) Removing of bronze bushing. 01
d) Provision of BD85 (15” pulley).
e) Fitment of bronze bushing.
f) Maintain clearance between hub & bronze
bush.
ECC OUTER DRUM., BEARING ASSEMBLY.

a) Stripping of ECC Drum.
02 b) Removing off set screw & shaft nut from end 01
of rotor.
c) Removing of cap, flinger, housing
d) Cleaning of housing & shaft
e) Checking of shaft size.
f) Assembly of ECC.
g) Testing of ECC drum on test stand.
OVERHAULING OF SPLINE SHAFT.

03 a) Stripping of Spline shaft from slip joint & 01
bearing assembly
b) Cleaning of all parts
c) Inspection of Bearing & Cross journal.
d) Fitment of Bearing in cross journal.
e) Filling of Grease in sleeve yoke for
lubrication
f) Assembly of universal coupling.

CAMTECH/2003 / M /TRG/ 01 109

SECTION
Workshop : Diesel
Description : Explanation Of All Bd Items(Eai) As Per

Rdso Instructions.

(Hours)
Brief knowledge of all BD items related to
01 CHASSIS SECTION.
a) BD-19. BD-20, BD-24, BD-10, BD-27, BD- 01
45, BD-53, BD-60, BD-77, BD-57, BD-83, BD-
84, BD-86, BD-72
RADIATOR & CHASSIS SECTION
02 a) BD-15, BD-16, BD-22, BD-63, BD-36, BD- 01
88,

03 RIGHT ANGLE GEAR BOX SECTION. 01
a) BD-85, BD-82

CAMTECH/2003 / M /TRG/ 01 110

SECTION
Workshop : Diesel
Description : Customer Feed Back Session

(Hours)
01 a) Customer complaint. 01
02 a) Remedies of customer complaint. 01
03 a) Practical on complaint 01

CAMTECH/2003 / M /TRG/ 01 111

SECTION
Workshop : Diesel
Description : Assessment Test.

(Hours)
01 a) Assessment test on the topic General

WDM2 data Chassis, Radiator, Right
Angle Gear Box. 01
02 a) Interaction with trainees regarding

result. 01
03 a) Feed back from trainees.

b) Valedictory function. 01

CAMTECH/2003 / M /TRG/ 01 112
4.4 TRAINING MODULE FOR FITTERS OF WHEEL SHOP

WORKSHOP : DIESEL
TRADE : FITTER
ACTIVITY CENTRE : WHEEL SHOP
PERIODICITY : ONCE IN FOUR YEAR.
DURATION : 12 DAYS
SR.NO DESCRIPTION DAY

.
1 Introduction of the course, Attitudinal change and Motivation.
1 2 General Awareness of ISO. 01
3 Safety and Environment.
1 Measurement and Measuring Instruments.
2 2 Precision Measuring Instruments. 01
3 Gauges :- types and Uses.
1 Limit, Fits and Tolerance.
3 2 Main Activity of wheel shop. 01
3 Checking of wheel seat Diameter.
1 Press in Axle Coller.
4 2 Press in disc. 01
3 Press in Bull gear.
1 Shrinking of Inner race.
5 2 Checking of Bearing seat Diameter. 01
3 Visual inspection of Wheel Centre.
1 Press in Wheel disc.
6 2 Visual Inspection of Bearing. 01
3 Checking of Axle bearing seat diameter.
1 Disc press in.
7 2 Visual Inspection of Armature. 01
3 Armature shaft press out.
1 Checking of armature shaft bore.
8 2 Press to Armature shaft. 01
3 Match-up Pinion seat of the armature shaft.
1 Press in Bearing.
9 2 Tyre shrinking. 01
3 Bevel gear fitment & bearing press in.
1 Bearing press in.
10 2 Press in crank Pin. 01
3 Handling, storage and Packing.
1 Frequent customer complaints.
11 2 Failure analysis. 01
3 Inspection.
1 Quality Improvement.
12 2 Assessment test. 01
3 Feed back from trainees.

CAMTECH/2003 / M /TRG/ 01 113
4.4.1 TRAINING MODULE FOR FITTERS OF WHEEL SHOP

Workshop : Diesel
Description : Introduction Of Course, Attitudinal Change &

Motivation.
General Awareness Of Iso.
Duration : 01 Day (01st Day)
Duration
Introduction of the course.
01 Changing the attitude related to the work.
Role of technicians in improving the Quality of work. 01
Need of ISO Certification.
02 ISO 9000 Series. 01
Guiding principles for implementing systems.
Terms related to ISO 9000.
Probable causes of accidents in workshop.
03 Basic steps for accident prevention. 01
Fire Prevention.
House keeping.

CAMTECH/2003 / M /TRG/ 01 114
Workshop : Diesel
Description : Measurement And Measuring Instruments.

Precision Measuring Instruments.
Gauges :- Types And Uses.
Duration
(a) Measurement and different types of
01 Measurements.
(b) Standard units of linear measurement,
Measuring Methods. 01
(c) Measuring Instruments:- Steel rule & it‟s
types, Callipers- Firm joint callipers, Spring
joint callipers, types of callipers.
(a) Micrometer: - Principle, Least count,
02 Construction, types of Micrometers.
(b) Vernier Calliper :- Material, Size, Principle, 01
Construction.
(c) Reading of Micrometers and Callipers.
(a) Introduction, Material, advantages of
03 Gauges.
(b) Classification and types of Gauges. 01
(c) Types of gauges and their uses.

CAMTECH/2003 / M /TRG/ 01 115
Workshop : Diesel
Technicians : Fitter.
Description : Limit, Fits, And Tolerance.

Main Activities Of Wheel Shop.
Checking Of Wheel Seat Diameter.
Duration : 01 Day (3rd Day)
Duration
(a) Interchangeability & it‟s advantages.
01 (b) Limits :- Definition, & advantages, High and
Lower limit.
(c) Fits :- Types of Fits, Different systems of 01
Limit & Fit, Tolerance and system of
tolerance.
(a) WDM2 Wheel repair practice & and
02 Inspection.
(b) Press out TQ and Tap roller, Remove inner 01
race.
(c) Press out Wheel centre and Bull gear.
(a) Cleaning and removing the Burrs.
03 (b) Visual checking. 01
(c) Check the dia on three places on wheel
seat length horizontally and vertically.

CAMTECH/2003 / M /TRG/ 01 116
Workshop : Diesel
Description : Press In Axle Coller.

Press In Disc.
Press In Bull Gar.
Duration
(a) Removing the Burrs & cleaning of coller &
01 bore of coller.
(b) Apply the mixture of White lead and linsed
oil.
(c) Align the Axle with the coller on the 01
Hydraulic press.
(d) Press the coller to maintain gap of 1-4 mm
between gear and coller.
(a) Setting the disc on the press.
02 (b) Apply the mixture & align the bore of the Disc
and Axle. 01
(c) Press in on side Disc to maintain gap
between coller and Hub.
(a) Remove the Burrs & clean gear seat.
03 (b) Apply the Mixture. 01
(c) Align the Axle with gear on the Hydraulic
press and pressing Bull gear.

CAMTECH/2003 / M /TRG/ 01 117

Workshop : Diesel
Description : Shrinking Of Inner Race.

Checking Of Bearing Seat Dia.
Visual Inspection Of Wheel Centre.
Duration
(a) Cleaning of Inner Race & Axle Journal.
01 (b) Heating of Inner race by Induction heating. 01
(c) Fitting of Inner race on the Axle.
(a) Cleaning of Bearing seat.
02 (b) Visual checking of Bearing seat. 01
(c) Checking of Taper & Ovality of Bearing on
wheel seat..
(a) Cleaning of wheel Centre and Rivet hole.
03 (b) Visual Inspection of Wheel centre for 01
Crack/Damages on the Rim, Spoke & Hub.
(c) Attend the damage if any.

CAMTECH/2003 / M /TRG/ 01 118

Workshop : Diesel
Description : Press In Wheel Centre.

Visual Inspection Of Bearing.
Checking Of Axle Bearing Seat Dia.
Duration
(a) Remove Burrs on the bore and set the wheel
01 coller vertically on the press.
(b) Apply the mixture and align the keyways of 01
wheel centre.
(c) Press in both the wheel centres.
(a) Cleaning of Bearing with Kerosene.
02 (b) Checking of distance piece. 01
(c) Checking the Bearing for damage.
(a) Cleaning of Bearing and removing the Burrs
03 on the axle.
(b) Visual Inspection of Bearing. 01
(c) Checking of Ovality of Bearing seat.

CAMTECH/2003 / M /TRG/ 01 119
Workshop : Diesel
Description : Disc Press In.

Visual Inspection Of Armature.
Armature Shaft Press Out.
Duration
(a) Setting the Disc.
01 (b) Align the bore of Disc and Axle on the press.
(c) Align the bore of Disc and Axle on the press. 01
(a) Cleaning of armature shaft.

02 (b) Checking of damage, if any. 01
(c) Attend the damage.
(a) Setting of Armature on the press.
03 (b) Align the shaft on press. 01
(c) Safety precautions to be taken.

CAMTECH/2003 / M /TRG/ 01 120

Workshop : Diesel
Description : Checking Of Armature Shaft Bore.

Pressing Of Armature Shaft.
Matching Of Pinion Seat Of The Armature Shaft.
Duration
a) Clean the bore of Armature shaft.
01 b) Visual inspection for any damage.
c) Checking the taper of in the Bore. 01
a) Armature Bore cleaning.

02 b) Heating of Armature. 01
c) Press in the Armature shaft on the Fixture.
a) Placing of Armature.
03 b) Filing the pinion seat. 01
c) Fitting of the gauge.

CAMTECH/2003 / M /TRG/ 01 121

Workshop : Diesel
Description : Press In Bearing.

Tyre Shrinking.
Bevel Gear Fitment & Bearing Press In.
Duration
a) Inserting the Enclosure & finger Ring on the
01 bearing seat.
b) Align the wheel on the Hydraulic press. 01
c) Align the bearing with the Axle, place adopter
and press.
a) Induction heating of tyre.
02 b) Clean the wheel centre by keeping the wheel 01
in Vertical position.
c) Placing the Wheel centre in tyre bore.
a) Removal of Burrs, Aligning of gear holes &
03 tight nut bolts.
b) Check the bearing seat dia & insert the bush. 01
c) Insert the lubricant with ring on the Axle,
Align the Axle and press the ring.

CAMTECH/2003 / M /TRG/ 01 122
Workshop : Diesel
Description : Bearing Press In.

Crank Pin Press In..
Handling, Storage And Packing.
Duration
a) Clean the Bearing seat and check bearing
01 seat dia.
b) Insert the inner ring on the Axle. 01
c) Inserting of other loose rings.
a) Removal of Burrs on Crank Pin.
02 b) Align the wheel with Crank pin. 01
c) Safety precautions to be taken while pressing.
a) Apply grease on the shaft.
03 b) Cares to be taken while shifting the Armature.
c) Cares to be taken while shifting the Armature. 01

CAMTECH/2003 / M /TRG/ 01 123
Workshop : Diesel
Description : Frequent Customer Complaints.

Inspection.
Inspection.
Duration
a) Frequent customer complaints.
01 b) Common failures and remedies. 01
c) Common failures and remedies.
a) Examine looseness of distance pieces.
02 b) Examine looseness of Axle & discs. 01
c) Apply colour to all defective parts indicating
attention to be paid.
a) Function of Inspection department.
03 b) Accuracy and precision. 01
c) Types of Inspection of manufacture products.

CAMTECH/2003 / M /TRG/ 01 124

Workshop : Diesel
Description : Quality Improvement.

Assessment Test.
Feed Back From Trainees.
Duration
a) Quality Improvement.
01 b) Quality control Activities. 01
c) Benefits of Quality Control.
a) Assessment test.
02 b) Assessment test. 01
c) Assessment test.
a) Feed back from trainees.
03 b) Feed back from trainees 01
c) Feed back from trainees

CHAPTER -5
FOR
WELDERS
IN
WORKSHOPS
Training Modules For Artisans Of Wagon Workshop
S. No. Trade Activity Centre Periodicity Duration
1
Fitter Vacuum Brake Section Once in four 12 days
Air Brake Section year
2
Fitter W.R. Shop Once in four 9 days
year
2
Machinist Wheel shop Once in four 8 days
year
CAMTECH/2003 / M /TRG/ 01 125
5.1 UNIFIED TRAINING MODULE FOR WELDERS

Trade : Welder
Activity Centre : Welding Shop
Periodicity : Once In Four Years
Duration : 12 Days
Sr. No. Description Duration

1 Introduction of course One day
2 Industrial safety One day
3 Introduction of welding technology One day
4 Welding technology One day
5 Study of electrode. One day
6 Welding and cutting machine. One day
7 TIG and MIG/MAG welding machines One day
8 Welding defects and testing of weld. One day
9 Welding of wagon components One day
10 Welding of locomotive components One day
11 Welding of coaching stock items One day
12 Feed back from technicians (Welders) and group One day

discussion.

CAMTECH/2003 / M /TRG/ 01 126
5.1.1 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder
Description : Introduction of course
Period Contents Duration

(Hours)
01 I. Introduction of course 01
I. Importance of training 01
II. Role of technician in improving the quality work.
02
01
03 I. Need of ISO certification.

II. Awareness of ISO 9000

CAMTECH/2003 / M /TRG/ 01 127

Description : Industrial safety

(Hours)
Industrial safety
01 I. Personal safety.
II. Safety of work place 01
02 I. Safety of welding and gas cutting equipment.

II. Fire safety and fire fighting equipment. 01
03 I. First aids 01

CAMTECH/2003 / M /TRG/ 01 128

Description : Introduction of welding

technology

(Hours)
Introduction of welding technology
01 Importance of good welding. 01
02 Equipment used in welding and gas cutting. 01
03 Introduction of manifold system and welders role in 01

saving of industrial gases.

CAMTECH/2003 / M /TRG/ 01 129

Description : Welding terminology

(Hours)
Welding terminology.
01. I. Welding terminology such as Arc length, leg
length, Angle of Berel, Root gap, and Roof face 01.
II. Welding positions.
02. I. Type of welding joints.

01.
II. Joint preparation.
03 I. Introduction of welding processes;

Such as thermit welding, resistance welding, forge 01.
welding, sub-merge arc welding, plasma cutting.

CAMTECH/2003 / M /TRG/ 01 130

Description : Study of Electrode

(Hours)
Study of Electrode.
01 I. RDSO classification of Electrode as per IRS:M:28

and specification as per IS:814.
II. Selection of Electrode and current. 01
02 I. Importance of flux coating.
II. Low hydrogen Electrodes. 01
III. Pre heating of Electrodes.
03 I. Electrode for root run and subsequent runs.

01
II. Sequence of run and inter pass temperature

CAMTECH/2003 / M /TRG/ 01 131

Description : Welding and cutting machine

(Hours)
Welding and cutting machine.
01 I. Welding transformer and its principle.

II. Welding rectifier.
III. Use of Electric Arc welding machine. 01
02 I. Principle of oxy acetylene cutting.

II. Types of flames. 01
03 I. Principle of Air plasma cutting.

II. Safety precautions. 01

CAMTECH/2003 / M /TRG/ 01 132

Description : TIG and MIG/MAG Welding

machines

(Hours)
TIG and MIG/MAG Welding machines.
01 I. TIG welding machine. 01
02 I. MIG/MAG welding machine.

01
II. Advantage of MIG/MAG welding.
03 I. Parts used in TIG and MIG/MAG welding. 01

CAMTECH/2003 / M /TRG/ 01 133

Description : Welding Defects and Testing of

weld.
Period
Contents Duration
(Hours)
Welding Defects and Testing of weld.
01 I. Introduction of good welding.

II. Important factors to obtain good welding 01
02 I. Welding defects and its remedy. 01
.
03 I. Destructive and non-destructive test. 01

CAMTECH/2003 / M /TRG/ 01 134

Description : Welding of wagon components

(Hours)
Welding of wagon components
I. Welding of casnub bogie items (Side frame friction

01 liner, Pedestal jaw liner, centre pivot etc.) as per
RDSO pamphlet G-95.
II. Welding of UIC bogie items as per RDSO 01
pamphlet G-16.
I. Reclamation of brake beam as per RDSO

02 pamphlet G-95.
II. Welding of pull rod, push rod of BOXN wagon. 01
III. Welding of brake beam of Casnub bogie as per
RDSO letter no. MW/PLNG/CSMB dated 28-10-99
I. Reclamation of Knuckle "C" “D” and "E" grade as

03 per M&C report no K262 and RDSO letter no 01
MW/CPL/BG/M dated 18/20.2.97 and RDSO
sketch No.SK-69075.
II. Welding of corten steel of BOXN wagon as per
RDSO maintenance manual. G-70.
III. Trunion, Trunion nuts, shackle pins and shackles
of screw coupling.
IV. Welding of reassembled Reconditioned Draft Gear
RF-361
a. Welding of rear plate after assembly

b. Post run welding
c. Filler pass welding

CAMTECH/2003 / M /TRG/ 01 135

Description : Welding of locomotive

components.

(Hours)
Welding of locomotive components.
01 I. Welding of flange coupling on L.O. cooler of 01

WDM2 LOCO.
02 I. Welding of bogie cracks of WDM2 LOCO.
II. Welding of Mn-steel liner of WDM2 LOCO. 01
03 I. Welding of camshaft lobes, Gas inlet casing and

traction motor magnet frame of WDM2 LOCO. 01

CAMTECH/2003 / M /TRG/ 01 136

Description : Welding of coaching stock items

(Hours)
Welding of coaching stock items.
01 Welding of deferent type of bogie. 01
02 Welding of main line coach components. 01

Sole bar, head stock, draw bar yoke, tubular structure,
cross bearer with sol bar & body bolster with sole bar
03 Welding of Aluminium water tank of BG coaches by

MMAW. 01

CAMTECH/2003 / M /TRG/ 01 137

Description : Feed back & group discussion

(Hours)
Feed back from Technicians (Welders) and group

discussion
01 Group Discussion 01
02&03 Feed Back. 02

Report On Competency Based Training in Workshops

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(Govt.

COMPETENCY BASED TRAINING

(Coaching, Wagon & Diesel)

(For official use only)

In partial fulfillment to the report of Khanna Committee, as assigned by

Jhansi, Bhopal and Parel workshop of central railway were associated in

(MANISH PRADHAN) (R.K.SHARMA) (H.K. RAGHU) (ANIL SHARMA)

No.98/M (Safety)7/11/1/Pt. Khanna Committee New Delhi, dated 04.02.2002

The Executive Director

Sub: Competency based training in workshops

Para 5.10 of Railway Safety Review Committee (Khanna Committee) part I

1. Identify safety related sections of Coaching, wagon and Diesel shops.

DESCRIPTION PAGE NO.

Chapter-1 General 01-09

COMPETENCY BASED TRAINING

1. Bogie, Air Brake, Roller Bearing

1. Wheel Shop Activities (For machinist)

Competency Based Training For Workshops

As a first phase of competency based training, the report covers the

Every workshop is having Training Centre/ Basic Training Centre (BTC)

2.0 TRAINING IN WORKSHOPS

1. The training programme has high emphasis on competency development

Competency Based Training For Workshops

3.0 TRAINING RESOURCES

A competent SSE/SE shall be incharge of training centre who will assist

Sufficient number of instructors should be provided so as to have

Visiting officers/Supervisors shall be invited regularly for their lecturers on

Competency Based Training For Workshops

A well furnished and appropriately equipped “Workshop” has to be

The artisans shall be imparted training in BTC/TTC according to the

Competency Based Training For Workshops

LIST OF CLASS ROOM EQUIPMENTS

Sr.No. Name & brief specification Quantity

01 Over head projector. One per class room

02 Magnetic chalk board/clip board One per class room

04 Television with VCD One set.

05 LCD data video projection system. One per class room

06 Computer / Multimedia with all peripherals One per class room

07 35 mm automatic slide projector with linear One

08 OHP screen 1.5 m x 1.5 m One per class room

09 Digital camera One

10 Laptop computer One

11 Furniture One table + One chair

13 Internet connection with MTNL/BSNL One

Competency Based Training For Workshops

LIST OF PLANT AND MACHINERY

Competency Based Training For Workshops

LIST OF MODELS IN COACH WORKSHOP

Competency Based Training For Workshops

LIST OF MODELS IN WAGON WORKSHOP

Competency Based Training For Workshops

LIST OF MODELS IN DIESEL WORKSHOP

Competency Based Training For Workshops

COMPETENCY BASED TRAINING

2.1 TRAINING MODULE FOR FITTER OF

Work Shop : Coaching

Sr.No. Description Day

Competency Based Training For Workshops

2.1.1 TRAINING MODULE FOR FITTER OF

Description : Introduction Of Course, Attitudinal Changes &

Duration : 01 Day ( 1st Day)

02 i. Need of ISO certificate 01

03 i. Personal safety and safety environment. 01