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CAMTECH/2003 / M /TRG/ 01
April- 2003
Centre
for
Advanced
Maintenance
TECHnology
Excellence in Maintenance
(Govt. of India)
(Ministry of Railways)
MAHARAJPUR, GWALIOR--474020
Report on
COMPETENCY BASED TRAINING
IN
WORKSHOPS
(Coaching, Wagon & Diesel)
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
3.2 Training Module for Fitters (Draw & Buffing Gear) 45-54
3.3 Training Module for Fitters (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
4.4 Training Module for Fitters of Wheel Shop 112-124
Chapter-5 Welding
5.1 Unified Training Module for Welders 125-137
CAMTECH/2003 / M /TRG/ 01 1
Competency Based Training For Workshops
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.
CAMTECH/2003 / M /TRG/ 01 2
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.
CAMTECH/2003 / M /TRG/ 01 3
Competency Based Training For Workshops
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.
CAMTECH/2003 / M /TRG/ 01 4
Competency Based Training For Workshops
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.
CAMTECH/2003 / M /TRG/ 01 5
Competency Based Training For Workshops
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 items no. 02 for assisting in practical exercise in workshops.
One per work station
04 Television with VCD One set.
05 LCD data video projection system. One per class room
06 Computer / Multimedia with all peripherals including work station, CD writer, printer, web camera, UPS
One per class room
07 35 mm automatic slide projector with linear and circular tray, with facility of remote control
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 per trainee/ instructor in each class room and One table + One chair for each instructor in office
12 PA system One set
13 Internet connection with MTNL/BSNL telephone connection
One
14 Reso graph Machine One
15 Fax One
CAMTECH/2003 / M /TRG/ 01 6
Competency Based Training For Workshops
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
CAMTECH/2003 / M /TRG/ 01 7
Competency Based Training For Workshops
Annexure-3
LIST OF MODELS IN COACH WORKSHOP
Sr. No. Description quantity 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
CAMTECH/2003 / M /TRG/ 01 8
Competency Based Training For Workshops
Annexure-4
LIST OF MODELS IN WAGON WORKSHOP
Sr. No. Description quantity 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
CAMTECH/2003 / M /TRG/ 01 9
Competency Based Training For Workshops
Annexure-5
LIST OF MODELS IN DIESEL WORKSHOP
Sr. No. Description quantity 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 application and release
Test Stand
15 SA-9 Independent Brake Valve application and release
Test Stand
16 Complete bogie with all components Model
CAMTECH/2003 / M /TRG/ 01 10
Competency Based Training For Workshops
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 a) Introduction of Course, attitudinal changes & motivation. b) General awareness of ISO & EMS.
c) Safety & Environments.
01
2 a) Introduction and General Data of ICF, RCF and BEML Coaches.
b) Difference between ICF & BEML coaches.
01
3 a) Introduction to corrosion. b) Corrosion prone area in coaches & its inspection. c) Corrosion prevention in coaches
01
4 BOGIE SECTION a) Stripping,inspection,repairing & gauging of Bogie Frame. b) Assembly of Bolster, Guide Gauging, Brake Gear. c) Testing of Bogie components.
01
5 a) Bogie Lowering on wheels. b) Bogie testing on test stand. c) Buffer Height adjustment on coaches.
01
6 a) Introduction of Buffing Gear. b) Repair of Buffer Assembly.
01
7 a) Introduction of Draft Gear. b) Repair of Draft Gear assembly.
01
8 AIR BRAKE SECTION a) General knowledge of Brake system of coaches. b) Brief knowledge of Vacuum Brake system in coaches.
01
9 a) Working of Air Brake system in coaches. b) Overhauling & testing of Air Brake components.
01
10 a) Overhauling & testing of DV. b) Single car testing of coach.
01
11 ROLLER BEARING SECTION 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.
01
12 FEED BACK & VALIDATION a) Assessment Test. b) Interaction with trainees regarding result. c) Feedback from trainees. d) Valedictory function
01
CAMTECH/2003 / M /TRG/ 01 11
Competency Based Training For Workshops
2.1.1 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
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)
PERIOD
CONTENTS
DURATION (Hours)
01 i. Introduction of Course ii. Changing the attitude related to the
works iii. Role of Fitter in improving the Quality of
work & responsibility
01
02 i. Need of ISO certificate ii. ISO 9000& 14000 series, iii. Terms related to ISO 9000& 14000
01
03 i. Personal safety and safety environment. ii. Safety in workshop. iii. Fire safety and fire fighting equipments. iv. Safety with electrical power v. First Aid.
01
CAMTECH/2003 / M /TRG/ 01 12
Competency Based Training For Workshops
2.1.2 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter 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
Competency Based Training For Workshops
2.1.3 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Introduction To Mlr Concept, Objectives & Advantages. Duration : 01 Day ( 3rd Day)
PERIOD
CONTENTS
DURATION
(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
Competency Based Training For Workshops
2.1.4 TRAINING MODULE FOR FITTER OF
BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION. Workshop : Coaching Technicians : Fitter Description : Bogie Section Stripping & Overhauling Of Bogie Frame. Assembly Of Bolster, Guide Gauging, Brake Gear. Testing Of Bogie Components. Duration : 01 Day ( 4th Day)
PERIOD
CONTENTS
DURATION
(Hours)
1. Stripping, inspection, repairing & gauging of Bogie Frame.
01
2. Assembly of Bolster, Guide Gauging, Brake Gear.
01
3. Testing of Bogie components.
01
CAMTECH/2003 / M /TRG/ 01 15
Competency Based Training For Workshops
2.1.5 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Bogie Lowering On Wheels. Bogie Testing On Test Stand. Buffer Height Adjustment On Coaches. Duration : 01 Day ( 5th Day)
PERIOD
CONTENTS
DURATION
(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
Competency Based Training For Workshops
2.1.6 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Introduction Of Buffing Gear. Repair Of Buffer Assembly. Duration : 01 Day ( 6th Day)
PERIOD
CONTENTS
DURATION
(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
Competency Based Training For Workshops
2.1.7 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Introduction Of Draft Gear. Repair Of Draft Gear Assembly. Duration : 01 Day ( 7th Day)
PERIOD
CONTENTS
DURATION
(Hours)
1. Introduction of Draft Gear.
01
2. Inspection & Repair of Draft Gear assembly.
01
3. Testing of Draft Gear assembly & its components.
01
CAMTECH/2003 / M /TRG/ 01 18
Competency Based Training For Workshops
2.1.8 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Air Brake Section General Knowledge Of Brake System Of Coaches. Brief Knowledge Of Vacuum Brake System. Duration : 01 Day ( 8th Day)
PERIOD
CONTENTS
DURATION
(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 coaches.
01
CAMTECH/2003 / M /TRG/ 01 19
Competency Based Training For Workshops
2.1.9 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Working Of Air Brake System ( Bmabs) Overhauling & Testing Of Air Brake Components. Duration : 01 Day ( 9th Day)
PERIOD
CONTENTS
DURATION (Hours)
01 Working of Air Brake system & its components in coaches.( BMABS)
01
02 Functions of Air Brake components.
01
03 Overhauling & testing of Air Brake components
01
CAMTECH/2003 / M /TRG/ 01 20
Competency Based Training For Workshops
2.1.10 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter
Description : Overhauling & Testing Of Dv. Single Car Testing Of Coach.
Duration : 01 Day ( 10th Day)
PERIOD
CONTENTS
DURATION
(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
Competency Based Training For Workshops
2.1.11 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Roller Bearing Section & Latest Modification & Cai Of The Coaches. Duration : 01 Day ( 11th Day)
PERIOD
CONTENTS
DURATION
(Hours)
01 Introduction of Roller Bearing in coaches.
01
02 i. Inspection of Roller Bearing & its rejectable defects.
ii. Assembly of Roller Bearing.
01
03 Latest modification & CAI of the coaches.
01
CAMTECH/2003 / M /TRG/ 01 22
Competency Based Training For Workshops
2.1.12 TRAINING MODULE FOR FITTER OF BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Workshop : Coaching Technicians : Fitter Description : Feed Back & Validation Duration : 01 Day ( 12th Day)
PERIOD
CONTENTS
DURATION
(Hours)
01 Assessment Test.
01
02 Interaction with trainees regarding result.
01
03 Feedback from trainees.
01
CAMTECH/2003 / M /TRG/ 01 23
Competency Based Training For Workshops
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. b) General awareness of ISO & EMS.
c) Safety & Environments.
01
2 a) Limits, Fits & Tolerance. b) Precision measuring Instruments. c) Gauges & Templates.
01
3 a) Various types of cutting tools. b) Various types of Machine tools. c) Multi purpose & special purpose Machine tools.
01
4 a) VTL . b) Wheel Press (Hydraulic) . c) Axle Grinding m/c d) Wheel lathe
01
5 a) Introduction of Wheel shop . b) Main activities of Wheel shop .
01
6 a) Axle turning on ATL. 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.
01
7 a) Wheel Inspection & testing. b) Worn wheel profile. c) Profile tyre turning of wheels on wheel lathe.
01
8 FEED BACK & VALIDATION a) Assessment Test. b) Interaction with trainees regarding result. c) Feedback from trainees. d) Valedictory function
01
CAMTECH/2003 / M /TRG/ 01 24
Competency Based Training For Workshops
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)
PERIOD
CONTENTS
DURATION (Hours)
01 i. Introduction of Course ii. Changing the attitude related to the
works iii. Role of Fitter in improving the Quality of
work & responsibility
01
02 I. Need of ISO certificate II. ISO 9000& 14000 series,
III. Terms related to ISO 9000& 14000
01
03 i. Personal safety and safety environment. ii. Safety in workshop. iii. Fire safety and fire fighting equipments. iv. Safety with electrical power v. First Aid.
01
CAMTECH/2003 / M /TRG/ 01 25
Competency Based Training For Workshops
2.2.2 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Limits, Fits & Tolerance. Precision Measuring Instruments. Gauges & Templates. Duration : 01 Day ( 2nd Day)
PERIOD
CONTENTS
DURATION (Hours)
1. Limits, Fits & Tolerance.
01
2. Precision measuring Instruments.
01
3. Gauges & Templates
01
CAMTECH/2003 / M /TRG/ 01 26
Competency Based Training For Workshops
2.2.3 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Various Types Of Cutting Tools. Various Types Of Machine Tools. Multi Purpose & Special Purpose Machine Tools. Duration : 01 Day ( 3rd Day)
PERIOD
CONTENTS
DURATION (Hours)
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
Competency Based Training For Workshops
2.2.4 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Vtl ,Wheel Press (Hydraulic) . Axle Grinding M/C,Wheel Lathe. Duration : 01 Day ( 4th Day)
PERIOD
CONTENTS
DURATION (Hours)
1. VTL.
01
2. Wheel Press (Hydraulic).
01
3. Axle Grinding m/c & Wheel lathe.
01
CAMTECH/2003 / M /TRG/ 01 28
Competency Based Training For Workshops
2.2.5 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Introduction Of Wheel Shop . Main Activities Of Wheel Shop . Duration : 01 Day ( 5th Day)
PERIOD
CONTENTS
DURATION (Hours)
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
Competency Based Training For Workshops
2.2.6 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist 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 : 01 Day ( 6th Day)
PERIOD
CONTENTS
DURATION (Hours)
1. Axle turning on ATL.,Axle Grinding on AGL.
01
2. i) Drilling & tapping of holes in Axle on Radial Drill M/c. ii) Boring of Wheel Disc on VTL.
01
3. Wheel pressing & de-pressing.
01
CAMTECH/2003 / M /TRG/ 01 30
Competency Based Training For Workshops
2.2.7 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Wheel Inspection & Testing. Worn Wheel Profile. Profile Tyre Turning Of Wheels On Wheel Lathe. Duration : 01 Day ( 7th Day)
PERIOD
CONTENTS
DURATION (Hours)
1. Wheel Inspection.
01
2. Ultra-sonic testing of wheels & magna-flux testing of Axle.
01
3. i. Worn wheel profile. ii. Profile tyre turning of wheels on wheel lathe.
01
CAMTECH/2003 / M /TRG/ 01 31
Competency Based Training For Workshops
2.2.8 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP
Workshop : Coaching Technicians : Machinist Description : Feed Back & Validation Duration : 01 Day ( 8th Day)
PERIOD
CONTENTS
DURATION (Hours)
01 Assessment Test.
01
02 Interaction with trainees regarding result.
01
03 Feedback from trainees.
01
CAMTECH/2003 / M /TRG/ 01 32
Competency Based Training For Workshops
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 with Choke (Air Brake System)
One day
8. Pipe Brackets, Couplings & Control Reservoir
(Air Brake System)
One day
9. Dirt Collector, Auxiliary Reservoir & Guard’s Emergency Brake Valve (Air Brake System)
One day
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
Competency Based Training For Workshops
3.1.1 TRAINING MODULE FOR FITTER
(VACUUM BRAKE)
Workshop : Wagon
Technicians : Fitter
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 I. Principal of operation II. Limits of vacuum brake system
01
CAMTECH/2003 / M /TRG/ 01 34
Competency Based Training For Workshops
3.1.2 TRAINING MODULE FOR FITTER
(VACUUM BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Maintenance and repairs
Duration : 1 day- (2nd day)
Sr.No Description Hours
1. Modifications
01
2. Maintenance and repairs I. Examination and maintenance of Guard Van
Valve II. Cleaning, inspection and maintenance of vacuum
brake cylinders
01
3. Examination and maintenance of release valve
i) Vacuum retaining capacity test ii) Operation test
01
CAMTECH/2003 / M /TRG/ 01 35
Competency Based Training For Workshops
3.1.1 TRAINING MODULE FOR FITTER
(VACUUM BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Brake under gear
Duration : 1 day- (3rd day)
Sr.No Description Hours
1. Brake rigging I. Constructional details II. Working principle III. Maintenance and repairs
01
2. Introduction to SAB I. Introduction to SAB II. Working principle of SAB III. Maintenance and repair of SAB
01
3. Tools and Equipments & Feedback I. Tools and Equipments II. Feedback of the training
01
CAMTECH/2003 / M /TRG/ 01 36
Competency Based Training For Workshops
3.1.4 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
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
II. KE Type distributor valve
01
2. Dismantling And Cleaning Of Distributor Valve
I. C 3W Type distributor valve
II. KE Type distributor valve
01
3. Examination Of Individual Parts
I. C 3W Type distributor valve
II. KE Type distributor valve
01
CAMTECH/2003 / M /TRG/ 01 37
Competency Based Training For Workshops
3.1.5 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Maint. & Testing of DV
Duration : 1 day-(5th day)
Sr.No Contents Hours
1. Assembly Of Distributor Valve
I. C 3W Type distributor valve
II. KE Type distributor valve
01
2. Testing Of DV On Test Stand As Per Testing Performa
I. C 3W Type distributor valve
II. KE Type distributor valve
01
3. Trouble Shooting During Testing Of DV
I. C 3W Type distributor valve
II. KE Type distributor valve
01
CAMTECH/2003 / M /TRG/ 01 38
Competency Based Training For Workshops
3.1.6 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Precaution & Feed Back
Duration : 1 day- (6th day)
Sr.No Contents Hours
1. Precautions
Precaution during overhauling of DV
01
2. Tools and Equipments
Tools and Equipments
01
3. Feed back
Feed back of the training
01
CAMTECH/2003 / M /TRG/ 01 39
Competency Based Training For Workshops
3.1.7 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Cut Of Angle Cock, Isolating Cock
Check valve with Choke
Duration : 1 day-(7th day)
Sr.No Contents Hours
1. Cut Of Angle Cock
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
2. Isolating Cock
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
3. Check Valve with Choke
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
CAMTECH/2003 / M /TRG/ 01 40
Competency Based Training For Workshops
3.1.8 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Pipe Brackets, Couplings & Control reservoir
Duration : 1 day-(8th day)
Sr.No Contents Hours
1. Common Pipe Brackets With Control Reservoir And Intermediate Piece
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
2. Brake Pipe And Feed Pipe Couplings
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
3. Air Hose Coupling
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
CAMTECH/2003 / M /TRG/ 01 41
Competency Based Training For Workshops
3.1.9 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Dirt Collector, Auxiliary Reservoir & Guard’s Emergency Brake Valve
Duration : 1 day-(9th day)
Sr.No Contents Hours
1. Dirt Collector
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
2. Auxiliary Reservoir
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
3. Guard’s Emergency Brake Valve
I. Introduction and constructional detail.
II. Working principle
III. Maintenance
01
CAMTECH/2003 / M /TRG/ 01 42
Competency Based Training For Workshops
3.1.10 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Brake rigging
Duration : 1 day-(10th day)
Sr.No Contents Hours
1. Handbrake I. General Introduction & II. Constructional detail Empty Load Device I. General & II. Constructional detail
01
2. Components I. Sliding brake beam & II. Body under frame components
01
3. Brake Head Replacement
Composition brake block - Do’s and don’ts for fitment of composition brake block
I. To be done
II. Not to be done
01
CAMTECH/2003 / M /TRG/ 01 43
Competency Based Training For Workshops
3.1.11 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Repair & Maintenance of SAB
Duration : 1 day-(11th day)
Sr.No Contents Hours
1. Overhauling of Slack Adjuster (SAB)
I. Introduction
II. Disassembling III. Cleaning and inspection IV. Lubrication V. Reassembling VI. Safety precautions
01
2. Testing Of Slack Adjuster On Test Rack
I. Take up test or Pay in test II. Pay out test III. Testing of slack adjuster and brake rigging
without handbrake
01
3. Setting And Measurements
I. Painting
II. Procedure for brake rigging - setting and measurements of A+C dimensions
III. Tools and Equipments
01
CAMTECH/2003 / M /TRG/ 01 44
Competency Based Training For Workshops
3.1.12 TRAINING MODULE FOR FITTER (AIR BRAKE)
Workshop : Wagon
Technicians : Fitter
Description : Single Wagon & Rake Test Duration : 1 day- (12th day)
Sr.No Contents Hours
1. Single Wagon Test Different test for subassemblies I. Leakage test II. Sensitivity and insensitivity test III. Brake application and release test IV. Graduated application and release test V. Check and adjust slack adjuster
01
2. Procedure I. Single wagon Test rig (SWTR) II. Procedure for single wagon test III. Performa for single wagon test for
wagons other than BOBR and BOBRN
01
3.
Rake Test By RTR - Upto 56 nos. of wagons I. Visual examination II. Prepare setup (rig) for rake test III. Conduct leakage service application and
release test IV. Feed of the training
01
CAMTECH/2003 / M /TRG/ 01 45
Competency Based Training For Workshops
3.2 TRAINING MODULE FOR FITTER
(DRAW & BUFFING GEAR)
WORKSHOP : WAGON
TRADE : FITTERS PERIODICITY : ONCE IN FOUR YEARS DURATION : 9 DAYS
Sr No. Description Duration
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
Competency Based Training For Workshops
3.2.1 TRAINING MODULE FOR FITTER (DRAW & BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Introduction buffing gear
Duration : 1 day- (1st day)
S No Description Hours
1
Introduction - General Conventional buffing gear
01
2 Type of buffing gear
I. Long case II. Short case
01
3 Components The main components of buffing gear (Sub components)
01
CAMTECH/2003 / M /TRG/ 01 47
Competency Based Training For Workshops
3.2.2 TRAINING MODULE FOR FITTER (DRAW & BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Buffing Gear Repairs
Duration : 1 day- (2nd day)
(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 Buffing casing
01
2 Repairs of Spindle
01
3 Repairs of
Outer and inner coil spring I. Buffer projection II. Buffer height
01
CAMTECH/2003 / M /TRG/ 01 48
Competency Based Training For Workshops
3.2.3 TRAINING MODULE FOR FITTER (DRAW & BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Reclamation Of Draw Bars
Duration : 1 day- (3rd day)
Procedure for reclamation of draw bars in workshops
S No Description Hour
1 Screening Screening draw bar for reclamation
03
CAMTECH/2003 / M /TRG/ 01 49
Competency Based Training For Workshops
3.2.4 TRAINING MODULE FOR FITTER (DRAW BAR AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Centre Buffer Coupler & Draw Gear
Duration : 1 day- (4th day)
S No. Description Hour
1
Centre Buffer Coupler & Draw Gear 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
Competency Based Training For Workshops
3.2.5 TRAINING MODULE FOR FITTER (DRAW BAR AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Coupler Reclamation Practices
Duration : 1 day- (5th day)
(Coupler body, shank, cuard arm, knuckle, lock, clevis and clevis pin)
S No Description Hour
1 Draft Gear Reclamation Practices For Card Well Westing House(HR-40-1) GEAR Yoke, housing integral follower, rubber pads, rubber packs, rear cushioning units wagon packet.
01
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. II. Gauges for shoes III. Gauges for wedge IV. Final inspection gauge
01
CAMTECH/2003 / M /TRG/ 01 51
Competency Based Training For Workshops
3.2.6 TRAINING MODULE FOR FITTER
(DRAW BAR AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Maintenance Of RF-361- Draft Gear
Duration : 1 day- (6th day)
S No Description Hour
1 Disassembly Disassembly procedure for RF-361- Draft gear
01
2 Inspection Inspection of components Shoes, wedge, housing or cylinders
01
3 Reconditioning Complete reconditioning
01
CAMTECH/2003 / M /TRG/ 01 52
Competency Based Training For Workshops
3.2.7 TRAINING MODULE FOR FITTER (DRAW BAR AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Maintenance Of RF-361- Draft Gear
Duration : 1 day- (7th day)
S No Description Hour
1 Inspection Visual inspection of rubber pads
01
2 Static test I. Inspection of internal followers II. Inspection of forged III. Inspection of housing(Cylinders) IV. Preparation of housing prior to reassemble
01
3 Re-assembly Re-assembly of reconditioned RF-361 Draft gear
01
CAMTECH/2003 / M /TRG/ 01 53
Competency Based Training For Workshops
3.2.8 TRAINING MODULE FOR FITTER
(DRAW AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : Maint Of MARK-50 - Draft Gear
Duration : 1 day- (8th day)
S No Description Hour
1 Inspection
01
2 Removal Of Draft Gear From Wagon Pocket I. Normal condition II. Follower broken III. Partially stuck gear IV. Fully stuck draft gear V. Removal of stuck or damaged draft gear
01
3 Removal of stuck draft gear so as to re use
01
CAMTECH/2003 / M /TRG/ 01 54
Competency Based Training For Workshops
3.2.9 TRAINING MODULE FOR FITTER (DRAW AND BUFFING GEAR)
Workshop : Wagon
Technicians : Fitter
Description : MAINT. OF MARK-50 - DRAFT GEAR Duration : 1 day- (9th day)
S No Description Hour
1. Inspection Inspection of Mark-50 gear for reconditioning
01
2. Guide To Dismantle Summarized guide to dismantle Mark-50 draft gear
01
3. List of gauges For Mark-50 draft gear I. Housing gauges for initial inspection II. Housing weld repair gauges
01
CAMTECH/2003 / M /TRG/ 01 55
Competency Based Training For Workshops
3.3 TRAINING MODULE FOR FITTER (SUSPENSION)
WORKSHOP : WAGON
TRADE : FITTERS
PERIODICITY : ONCE IN FOUR YEARS DURATION : 7 DAYS
Sr No. Description Duration
1. INTRODUCTION- SUSPENSION (FOUR WHEELED SUSPENSION)
One day
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
Competency Based Training For Workshops
3.3.1 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : INTRODUCTION- SUSPENSION (FOUR WHEELED SUSPENSION)
Duration : 1 day- (1st day)
THE SUSPENSION OF FOUR WHEELED WAGON
S No Description Hour
1 Introduction
Introduction to suspension
01
2 Individual Elements
The brief description of the individual elements of four 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
01
3 Repairs during POH
01
CAMTECH/2003 / M /TRG/ 01 57
Competency Based Training For Workshops
3.3.2 TRAINING MODULE FOR FITTER
(SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : CASNUB BOGIE
Duration : 1 day- (2nd day)
S No Description Hour
1
Casnub Bogie Introduction & Construction details of CASNUB Bogie and its sub-assemblies
01
2
Repair and maintenance during POH.
01
3
1. Nominal clearances. 2. Wear limits of the components. 3. Relevant drawings numbers
01
CAMTECH/2003 / M /TRG/ 01 58
Competency Based Training For Workshops
3.3.3 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : BOX (U I C )BOGIE
Duration : 1 day- (3rd day)
S No Description Hour
1 BOX (U I C) Bogie Construction details of BOX (U I C) Bogie and its sub-assemblies
01
2 Repair and maintenance during POH.
01
3 1. Nominal clearances. 2. Wear limits of the components. 3. Relevant drawings numbers
01
CAMTECH/2003 / M /TRG/ 01 59
Competency Based Training For Workshops
3.3.4 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : CAST STEEL BOGIE
Duration : 1 day- (4th day)
S No Description Hour
1 CAST STEEL Bogie Construction details of CAST STEEL Bogie and its sub-assemblies.
01
2 Repair and maintenance during POH.
01
3 1. Nominal clearances. 2. Wear limits of the components. 3. Relevant drawings numbers
01
CAMTECH/2003 / M /TRG/ 01 60
Competency Based Training For Workshops
3.3.5 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : DIAMOND FRAME BOGIE
Duration : 1 day- (5th day)
S No Description Hour
1 DIAMOND FRAME BOGIE Construction details of diamond frame bogie and its sub-assemblies.
01
2 Repair and maintenance during POH.
01
3 1. Nominal clearances. 2. Wear limits of the components. 3. Relevant drawings numbers
01
CAMTECH/2003 / M /TRG/ 01 61
Competency Based Training For Workshops
3.3.6 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : MAINTENANCE OF ROLLER BEARING
Duration : 1 day- (6th day)
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
S No. Description Hour
1 Dismounting and dismantling I. Roller bearing axle box dismounting. II. Identification of roller bearing box and its
classification. III. Roller bearing axle box dismantling by press
machine.
01
2 Cleaning and inspection
I. Axle box housing and its components cleaning II. Inspection of the components III. Condemnation of defective parts and their
repair and replacement. IV. General cleaning and examination.
01
3 Assembly and mounting
I. Replacement of defective parts (inner races and throwers)
II. Assembly of roller bearing by hydraulic press. III. Greasing of axle box IV. Mounting of roller bearing axle box.
01
CAMTECH/2003 / M /TRG/ 01 62
Competency Based Training For Workshops
3.3.7 TRAINING MODULE FOR FITTER (SUSPENSION)
Workshop : Wagon
Technicians : Fitter
Description : MAINTENANCE OF CTRB
Duration : 1 day- (7th day)
S No. Description Hour
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. IV. Marking of over hauling- W/Shop, Month &
Year.
01
3 Assembly and mounting
I. Adjust lateral play of CTRB on bench. II. Assembly Greasing of CTRB III. Packing of CTRB. IV. Transportation. V. Mounting of CTRB on BN wheels
01
CAMTECH/2003 / M /TRG/ 01 63
Competency Based Training For Workshops
3.4 TRAINING MODULE FOR MACHINIST (WHEEL SHOP)
WORKSHOP : WAGON
TRADE : MACHINIST
ACTIVITY CENTRE : WHEEL SHOP PERIODICITY : ONCE IN FOUR YEARS DURATION : 2 DAYS
Sr No. Description Duration
8. INSPECTION OF WHEELS
One day
9. MACHINING OF WHEELS
One day
CAMTECH/2003 / M /TRG/ 01 64
Competency Based Training For Workshops
3.4.1 TRAINING MODULE FOR MACHINIST (WHEEL SHOP)
Workshop : Wagon
Technicians : Machinist
Description : INSPECTION OF WHEELS
Duration : 1 day- (1st day)
S No. Description Hour
1
Introduction Type of wheels
01
2
Inspection I. Wheel defects. II. Diameter of wheels with condemnation limits III. Axle IV. Wheel disc
01
3
Gauges
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
Competency Based Training For Workshops
3.4.2 TRAINING MODULE FOR MACHINIST (WHEEL SHOP)
Workshop : Wagon
Technicians : Machinist
Description : MACHINING OF WHEELS
Duration : 1 day- (2nd day)
S No. Description Hour
1
Reaxling
I. Machining of new axle II. Machining of disc III. Assembly
01
2
Rediscing
I. Machining of new disc II. Machining of axle III. Assembly
01
3
Tread profile
Machining for tread profile to match road gauge
01
NOTE: Pairing of the wheels to be done by the Fitter staff.
CAMTECH/2003 / M /TRG/ 01 66
Competency Based Training For Workshops
3.5 TRAINING MODULE FOR BLACKSMITH (BLACKSMITHY SHOP)
TRADE : BLACKSMITH ACTIVITY CENTRE : BLACKSMITHY SHOP PERIODICITY : ONCE IN FOUR YEARS 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
Competency Based Training For Workshops
3.5.1 TRAINING MODULE FOR BLACKSMITH (BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Blacksmith
Description : Reclamation Of Draw Bars
Duration : 1 day- (1st day)
DRAW & BUFFING GEAR Procedure for reclamation of draw bars in workshops
S No Description Hour
1
Reconditioning and Identification Reconditioning by stamping/ forging at location ‘a’ and ‘b’ Stamping for identification
01
2
Heat treatment ( Draw Bar and Screw Coupling)
I. Hardening II. Tampering
01
3
Load Test
Proof load test (As per IRS specification No.R-11-67 clause 7.1)
01
CAMTECH/2003 / M /TRG/ 01 68
Competency Based Training For Workshops
3.5.2 TRAINING MODULE FOR BLACKSMITH (BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Black smith
Description : MAINTENANCE OF LB SPRING
Duration : 1 day- (2nd day)
S.No. Description Hours
1
Inspection of spring during POH I. Rejectable defects of the springs II. Load deflection test III. Grading of the spring.
01
2
Identification of the spring for repair in BSS
01
3
Material specification of the parts
01
CAMTECH/2003 / M /TRG/ 01 69
Competency Based Training For Workshops
3.5.3 TRAINING MODULE FOR BLACKSMITH (BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Blacksmith
Description : SPRING MANUFACTURING
Duration : 1 day- (3rd day)
S.No. Description Hours
1
Coil spring manufacturing
RDSO Specification No WD-01-HLS-94 (Rev.-1 May 95-with latest amendment.) Board letter No. 76/M(W) 814/43 dated 12.03.64 & 03.06.68
01
2
LB Spring manufacturing I. RDSO letter No.M&C/STC/2/1 dated 26.03.75 II. RDSO letter No MW/!! Spring dated 18.07.77
(Approved v, and IRS specification RS-68)
01
3
RDSO pamphlet Laminated spring failure- description, classification and repotting- issued in 1969 with a corrigendum in 1972
01
CAMTECH/2003 / M /TRG/ 01 70
Competency Based Training For Workshops
3.5.4 TRAINING MODULE FOR BLACKSMITH (BLACKSMITHY SHOP)
Workshop : Wagon
Technicians : Blacksmith
Description : Heat Treatment Of Lb Springs
Duration : 1 Day- ( 4th Day)
S.No. Description Hours
1
Heat Treatment
(Spring after BS work shell be heat-treated.)
I. Hardening a) Water hardening b) Oil hardening
II. Tempering
III. Temperature control
IV. Rolled eye
V. Indentation
01
2
Testing of the spring after BS work
I. Scrag test
II. Load defection
01
3
Important Do’s and Don’ts
01
CAMTECH/2003 / M /TRG/ 01 71
Competency Based Training For Workshops
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. 3 Safety & Environment.
01
2 1 1 Limits Fits and Tolerance. 2 Precision Measuring Instruments. 3 Gauges and Templates.
01
3 1 Various types of Cutting tools. 2 Various types of Machine tools. 3 Multipurpose, Single purpose and special purpose Machine Tools.
01
4 1 Automatic Lathe.. 2 NC/ CNC & Hydraulic Machines. 3 Other special purpose machines.
01
5 1 Introduction of Wheel Shop. 2 Main activities of Wheel shop. 3 Lathe accessories and attachments.
01
6 1 Quality control. 2 Quality improvement. 3 Inspection.
01
7 1 Profile turning of wheel. 2 Press in side coller and press in Bull gear. 3 Boring of Wheel disc.
01
8 1 Journal Burnishing. 2 Bearing Seat machining. 3 Shrinking of the inner race.
01
9 1 Tyre Boring. 2 Profile tyre turning. 3 Crank pin returning.
01
10 1 Crank pin rethreading. 2 Boring of the Wheel disc. 3 Bearing Seat Machining.
01
11 1 Visual inspection of Armature. 2 Armature shaft press out & press in. 3 Matching the pinion seat on the armature shaft.
01
12 1 Handling, Storage and packing. 2 Failure analysis and Customer feed back. 3 Feed back from trainees.
01
CAMTECH/2003 / M /TRG/ 01 72
Competency Based Training For Workshops
4.1.1 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Introduction Of Course, Attitudinal Changes &
Motivation. General Awareness Of ISO.
Safety And Environment.
Duration : 01 Day (1st day)
Period
Contents
Duration (Hours)
01
Introduction of the course. Changing the attitude related to the work. Role of technicians in improving the Quality of work.
01
02
Need of ISO Certification. ISO 9000 Series. Guiding principles for implementing systems. Terms related to ISO 9000.
01
03
Probable causes of accidents in workshop. Basic steps for accident prevention. Fire Prevention. House keeping.
01
CAMTECH/2003 / M /TRG/ 01 73
Competency Based Training For Workshops
4.1.2 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Limits, Fits And Tolerance. Precision Making Instruments. Gauges And Templates. Duration : 01 Day (2nd day)
Period
Contents
Duration (Hours)
01
(a) Limits, Fits and tolerance. (b) System of tolerance. (c) Maximum and Minimum allowance.
01
02
(a) Types functions, Material and specification of preliminary measuring Instruments.
(b) Reading of Vernier Caliper, Micrometer, Depth gauge, and Height gauge.
01
03
(a) Different types of gauges. (b) Master gauges, Inspection gauges. (c) Go & Not go Gauge, Snap Gauge, Plug
gauge, Thread gauge and Filler gauge.
01
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4.1.3 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Various Types Of Cutting Tools. Various Types Of Machine Tools.
Multipurpose, Single Purpose & Special Purpose Machine Tools.
Duration : 01 Day (3rd day)
Period
Contents
Duration (Hours)
01
(a) Types of Material used for cutting tools. (b) Composition and characteristics. (c) Uses of tools.
01
02
(a) Operations performed on Machine tools. (b) Speed, feed, Cutting speed & Depth of cut. (c) Definition
01
03
(a) Classes of Machine tools. (b) Multipurpose and single purpose. (c) Special purpose Machine Tools. (d) Machine Tools used in Machine shop and
wheel shop.
01
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4.1.4 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Automatic Lathe. NC/ CNC & Hydraulic Machines. Other Special Types Of Machines. Duration : 01 Day (4th day)
Period
Contents
Duration (Hours)
01
(a) Mass production Lathe with complete automatic control.
(b) Functions of automatic lathe and it‟s operations. (c) Cutting tools used on automatic lathe.
01
02
(a) NC/CNC and Hydraulic Machines. (b) Axle turning centre, Chucker and Break press. (c) TCM, VTL co-ordinate Measuring Bolt, Forging,
Shearing machine.
01
03
(a) Other special types of machines. (b) Wheel lathe and Gap bed lathe. (c) „T‟ lathe and Duplicating. (d) Missile lathe.
01
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4.1.5 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Introduction Of Wheel Shop. Main Activities Of Wheel Shop. Lathe Accessories & Attachments. Duration : 01 Day (5th day)
Period
Contents
Duration (Hours)
01
(a) Types of Wheels, Axles, Bearing, POH of WDM2 wheel.
(b) WDM2 wheel repair practice and Inspection. (c) Rail cars.
01
02
(a) Press out TQ & Tap Roller Bearing. (b) Remove inner race. (c) Press out wheel centre and Bull gear. (d) Press in Bull gear coller and wheel centre to
Axle.
01
03
(a) Lathe Accessories & attachments. (b) Lathe centre, Catch plate and Carriers. (c) Other Holding and Holding supporting the work. (d) Attachment used for stops, ball turning rest ,
threading, chasing dials.
01
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4.1.6 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Quality Control. Quality Improvement. Inspection. Duration : 01 Day (6th day)
Period
Contents
Duration (Hours)
01
(a) Quality Control. (b) Quality Cyclic behaviour pf production. (c) Rejection of Jobs.
01
02
(a) Quality Improvement. (b) Quality Control activities. (c) Benefits of Quality Control.
01
03
(a) Inspection. (b) Functions of Inspections. (c) Accuracy and Precision. (d) Kinds of Inspection of manufactured product.
01
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4.1.7 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Profile Turning Of Wheel. Press In Side Coller And Press In Bull Gear. Boring Of Wheel Disc. Duration : 01 Day (7th day)
Period
Contents
Duration (Hours)
01
(a) Profile turning of Wheel. (b) Face inside the disc. (c) Turn the disc. (d) Fit the profile gauge.
01
02
(a) Press inside Coller and press in Bull gear. (b) Align the Axle with the Coller on the Hydraulic
press. (c) Set the Axle.
01
03
(a) Boring of Wheel disc. (b) Face the hub of the disc at bottom. (c) Face the disc at top to maintain the Hub.
01
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4.1.8 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Journal Burnishing. Bearing Seat Machining. Shrinking Of Inner Race. Duration : 01 Day (8th day)
Period
Contents
Duration (Hours)
01
(a) Journal Burnishing. (b) Face Axle coller to maintain suspension gauge. (c) Remove burn and clean the turned off Axle. (d) Burnish the journal.
01
02
(a) Bearing Seat machining. (b) Rough and finish turned Axle. (c) Burnish the Bearing Seat
01
03
(a) Shrinking of Inner Race. (b) Induction heating of Inner Race. (c) Fitting of Inner Race.
01
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4.1.9 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Tyre Boring. Profile Tyre Turning. Crank Pin Re-Turning. Duration : 01 Day (9th day)
Period
Contents
Duration (Hours)
01
(a) Tyre Boring. (b) Grooving of Tyre. (c) Fitting of gauge. (d) Final Boring of the Tyre.
01
02
(a) Profile Tyre turning. (b) Facing of inside of Tyre to maintain the road
gauge. (c) Turning of tyre and fitting of Profile gauge.
01
03
(a) Crank pin re-turning. (b) Rough turning of the C P. (c) Facing the wheel centre to maintain the length. (d) Final turning of the C P.
01
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4.1.10 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Crank Pin Threading.. Boring Of The Wheel Disc. Bearing Set Machining. Duration : 01 Day (10th Day)
Period
Contents
Duration (Hours)
01
(a) Crank pin re-threading. (b) Light turning on threaded portion. (c) Re-threading and grooving of C.P.
01
02
(a) Boring of the wheel disc. (b) Face the disc at top to maintain the Hub length. (c) Bore the disc, machine the groove finish
boaring.
01
03
(a) Bearing seat Machining. (b) Turn the Bearing seat. (c) Filing Bearing seat.
01
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4.1.11 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Visual Inspection Of Armature. Armature Shaft Press Out.. Match Of The Pinion Seat On Armature Shaft. Duration : 01 Day (11th day)
Period
Contents
Duration (Hours)
01
(a) Visual Inspection of Armature. (b) Check for any damage on main body. (c) Check for any damage on the Coil.
01
02
(a) Armature shaft press out and press in. (b) Align the shaft with the Ram of the press (c) Place a Copper or M.S.Pad between Ram &
shaft. (d) Press out Armature shaft.
01
03
(a) Match of the Pinion seat on the Armature shaft. (b) Keep the Armature horizontally. (c) File the Pinion. (d) Seat and feed the gauge.
01
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4.1.12 TRAINING MODULE FOR MACHINIST
Workshop : Diesel
Technicians : Machinist
Description : Handling Storage Packing.. Failure Analysis And Analytical Approach. Feed Back Of The Trainees. Duration : 01 Day (12th day)
Period
Contents
Duration (Hours)
01
Handling storage packing (a) While shifting the Wheel. (b) While loading the wheel. (c) After burnishing operation of the wheel.
01
02
(a) Failure analysis and analytical approach. (b) Examine looseness of distance pieces. (c) Examine ales and discs. (d) Apply mod colour to all defective parts
indicating attention to be paid.
01
03
(a) Feed back of trainees according to modern practices inspection.
(b) Record and special studies are used to Identify problems and their causes.
01
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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. No.
Description Day
1
a) Introduction of course, Attitudinal change & motivation b) General awareness of ISO c) Safety & Environment
01
2 a) Introduction and General data of WDM2 locomotive b) c) Introduction of Power Pack Section
01
3 a) Introduction to Vehicle Section.
01
4 BOGIE SECTION a) Stripping & Overhauling of Bogie frame.
01
5 a) Assembly of Traction motor, Gear Case, Wick pad, b) &Resilience pad.
01
6 a) Assembly of foundation brake components b) Bogie Run Test on testing stand c) Placing of Bogie frame on Chassis.
01
7 AIR BRAKE SECTION a) General knowledge of brake system of WDM2 b) Overhauling of different type of brake valve assembly c) Working of safety device on loco
01
8 a) Working of auto flasher system on WDM2 loco 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
01
9 CAB-SECTION a) Overhauling of cab and super structure b) Overhauling of hand brake assembly c) Modification of cab & EAI
01
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10 a) Explanation of all BD items (EAI) as per RDSO Instructions
01
11 a) Customer feed-back session
01
12 (a) Assessment Test (b) Interaction with trainees regarding result (c) Feedback from trainees. (d) Valedictory function
01
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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.
Safety And Environment.
Duration : 01 Day (1st Day)
Sr. No.
Contents
Period (Hours)
01
a) Introduction of course, Attitudinal change & Motivation.
b) Introduction of course and advantage. c) Attitudinal changes related to their work.
01
02
General awareness of ISO. a) Introduction of ISO, importance, advantages,
various terms related to ISO, Quality policy, Work instruction , changes of the Work shop.
01
03
Safety & environment a) safety items related to Work shop & related to
Bogie Section. b) Better house keeping.
01
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4.2.2 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Section : Bogie , Air Brake, Cab & Power Pack
Description : Introduction And General Data Of Wdm2 Loco.
Duration : 01 Day (2nd Day)
Sr. no.
Contents
Period (Hours)
01
General data of WDM2 Loco. a) Introduction, parts list, function of
each parts, Capacity of L.Oil, Fuel Oil, Water cooling of WDM2 Loco & General data.
b) Final testing.(Load Box)
01
02
Introduction of Power pack section. a) Knowledge of FIP, Injector and
testing. b) FIP & Calibration. c) Blowers, Water Pump and
L.O.Pump.
01
03
a) Cylinder head and testing. b) Piston. c) Working principle of TSC &
Expressor.
01
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4.2.3 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Introduction To Chassis, Rt. Angle
Gear Box &Radiator.
Duration : 01day (3rd Day)
Sr. no.
Content
Period (Hours)
01
a) Knowledge of chassis, and its Components b) Stripping & overhauling
01
02
a) Knowledge of Right Angle Gear
Box. & Its maintenance .
01
03
b) Knowledge of Radiator. & It‟s
overhauling.
01
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4.2.4 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Stripping And Overhauling Of Bogie Frame. Duration : 01 Day (4th Day)
Sr. No.
Contents Period (Hours)
01
a) Complete stripping procedure of Bogie frame. b) Cleaning of Bogie frame with chemical
solvents and water pressure. c) Visual inspection and Detection of crack at
critical location- DPT.
01
02
a) Removing of all liner, provision of new liner. b) Bogie alignment.
01
03
a) Checking of Centre pivot liner. b) Centre Pivot sizes, inspection & repairing of
side bearers.
01
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4.2.5 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanics Description : Assembly Of T /Motor, Gear Case,
Wick Pad & Resilience Pad Duration : 01 Day (5th Day)
Sr. no.
Contents
Period (Hours)
01
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 c) Inspection of Axle journal & their sizes. d) Inspection of Suspension bearing &
Ultrasonic test. e) Checking of Radial & Lateral
clearances
01
02 Gear Case Assembly
01
03
Resilience Pad & Assembly a) Visual Inspection & Cleaning
01
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4.2.6 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Assembly Of Foundation Bracket Component Boogie Run Test Stand Test Placing Of Bogie Frame On Chassis Duration : 01 Day (6th Day)
Sr. no.
Contents
Period (Hours)
01
Assembly of foundation bracket component a) condition of Brake shoe, Hanger lever, Slack
adjuster ,Pull rod. b) Condition of Brake cylinder &Piston. c) Checking of ovality of brake cylinder. d) Assembly of all bogie frame pipe line.
.
01
02
Bogie Run test on test stand a) Precaution to be taken while connection of T/Motor b) Checking of unusual sound
c) Testing limitation Minutes.
01
03
PLACING OF BOGIE FRAME ON CHASSIS a) Visual inspection of U bracket. b) Sealing of Wicks pad bolt, all gear case. c) Sealing of Traction Motor Axle cap bolts,
Gear case bolts. d) Checking of slack adjuster for brake
adjustment. e) Final tightness of bottom stay
plates(Pedestal cap)
01
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4.2.7 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : General Knowledge Of Brake System.
Overhauling Of Different Types Of Brake Valve Assembly.
Duration : 01 Day (7th Day)
Sr.No.
Contents
Period (Hours)
01
a) Necessity of Air brake system. b) Introduction of Air and Vacuum brake
system. c) Introduction of air brake system IRAD-1
01
02
BRAKE VALVE ASSEMBLY a) Working of A9 valve. b) Working of SA9 valve. c) Working of C2 Relay valve
01
03
a) Safety devices used on WDM2 loco. b) APS Air flow measuring valve & PATB c) H5 & HB5 valve. d) Working of sand valve and Wiper Motor &
Horns.
01
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4.2.8 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE 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).
Sr.No.
Contents
Period (Hours)
01
Working of Auto flasher system on WDM2 Loco.
01
02
Overhauling and testing of L.O. Relief Regulating By pass valve and OST Assembly.
01
03
Brief description of Air brake Circuits, A9 Circuits with conjunction working, IRAB–1 circuits.
01
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4.2.9 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Overhauling Of Cab & Super Structure. Overhauling Of Hand-Brake Assembly.
Duration : 01 Day (9th Day )
Sr.No.
Contents
Period (Hours)
01
CAB & SUPER STRUCTURE
a) Checking of Driver cab b) Maintenance of cab doors, cracks &
glass. c) Proper locking of cab door
prevention from water. d) Safety precaution.
01
02
HAND BRAKE ASSEMBLY
a) Uncoupling of hand brake from loco. b) Stripping and visual inspection(For
wear and tear) c) Assembly of hand brake. d) Safety precautions.
01
03
Modification of cab & EAI.
01
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4.2.10 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Explanation Of All Bd Items (Eai)
As Per Rdso Instructions. Duration : 01 Day (10th Day)
Sr. No.
Contents
Period (Hours)
01
Brief knowledge of all BD items related BOGIE SECTION a) BD-11, BD-14, BD-23, BD-54,BD-55,
01
02
Brief knowledge of all BD items related to AIR BRAKE SECTION a)BD-12, BD-33, BD-50, BD-65 BD-71
01
03
Brief knowledge of all BD items related to CAB SSECTION BD-38, BD-56, BD-61, BD-64, BD-72, BD-73 BD-81.
01
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4.2.11 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Customer Feed Back Session Duration : 01 Day ( 11th Day )
Sr. No.
Contents
Period (Hours)
01
Customer complaint.,
01
02
Remedies of customer complaint
01
03
Practical on complaint
01
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4.2.12 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Assessment Test. Duration : 01 Day ( 12th Day )
Sr. No.
Contents
Period (Hours)
01
Assessment test on the topic of General WDM2 data, Bogie, Air brake, Cab Sec.
01
02
Interaction with trainees regarding result
01
03
Feed back from trainees Valedictory function
01
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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. No.
Description Day
1
a) Introduction of course, Attitudinal change & motivation b) General awareness of ISO c) Safety & Environment
01
2 a) Introduction and General data of WDM2 locomotive b) Introduction of Power Pack Section
01
3 a) Introduction to Vehicle Section. 01
4 CHASSIS SECTION a) Overhauling of Reservoir carried out by Sheet Metal shop.
e) Overhauling of Cattle guard carried out by chassis section.
c) Overhauling of CBC
01
5 a) Overhauling of Fuel Tank. b) Overhauling of Centre pivots. c) Overhauling of chassis
01
6 a) Overhauling of L.W. S. b) Overhauling of Draft Gear. c) Final checking of chassis before dispatch.
01
7 RADIATOR SECTION a) Over hauling of Radiator b) Overhauling of Lube oil cooler. c) Overhauling of car body, air intake filter
01
8 RIGHT ANGLE GEAR BOX a) Stripping & overhauling of Radiator Fan. b) Stripping & overhauling of Right angle Gear Box. c) Hydraulic testing of L/oil filter drum.
01
9 a) Overhauling of Drive Shaft. b) ECC outer drum , Bearing assembly c) Overhauling of Spline Shaft.
01
10 a) Explanation of all BD items (EAI) as per RDSO Instructions
01
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11 a) Customer feed-back session 01
12 a) Assessment Test b) Interaction with trainees regarding result c) Feedback from trainees. d) Valedictory function
01
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4.3.1 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Introduction Of Course, Attitudinal Change . & Motivation General Awareness Of Iso Safety & Environment Duration : 01 Day ( 1st Day )
Sr. No.
Contents
Period (Hours)
01
Introduction of course , Attitudinal change & Motivation. a ) Introduction of course , advantages b ) Attitudinal changes related to their work .
01
02
General awareness of ISO. a)Introduction of ISO, importance, advantages, various terms related to ISO, Quality policy, Work instruction , changes of the Work shop.
01
03
Safety & environment a) Safety items related to Work shop & related to Chassis section
01
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4.3.2 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Introduction And General Data Of WDM-2 Loco. Duration : 01 Day (02nd Day)
Sr. no.
Contents
Period (Hours)
01
General data of WDM2 Loco. a) Introduction , Parts list, Function of each
parts, Capacity of Lube Oil, Fuel Oil of WDM2 Loco.
b) General Data. c) Final testing.(Load Box)
01
02
Introduction of Power pack II section. a) Knowledge of FIP, Injector & testing b) FIP Calibration. c) Blowers, Water Pump and L.O.Pump.
01
03
a) Cylinder Head b) Piston c) Working principle of TSC & Expressor
01
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4.3.3 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Introduction Of Vehicle Section Duration : 01 Days (3rd Day)
Sr. no.
Content
Period (Hours)
01
a) Brief knowledge of chassis and
modifications.
01
02
a) Basic principles of Right Angle
Gear Box. b) Basic principles of Radiator.
01
03
a) Introduction of Bogie section.
01
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4.3.4 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Overhauling Of Reservoir Carried Out
By Sheet Metal Shop. Overhauling Of Cattle Guard
Overhauling Of C.B.C.
Duration : 01 Days (4th Day)
Sr. No.
Contents
Period (Hours)
01
Overhauling of reservoir a) Uncoupling of reservoir & inspection of thread. b) Hydraulic testing of reservoir , erecting on loco.
01
02
Overhauling of cattle guard a) stripping procedure of cattle guard b) visual inspection c) Explanation of BD 84 modified cattle guard as
per RDSO instruction d)Explanation of back support & alignment with chassis.
01
03
Overhauling of CBC a) stripping of CBC
b)Visual inspection of CBC coupler, Knuckle & pin clevis transmission screw coupling locking arrangement, CBC straightness of shank ware c) Fitment of CBC on loco
01
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4.3.5 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Overhauling Of Fuel Oil Tank
Over Hauling Of Centre Pivot Overhauling Of Chassis
Duration : 01 Day ( 05th Day)
Sr.No.
Contents
Period (Hours)
01
OVERHAULING OF FUEL OIL TANK
a) Draining of tank b) Cutting of tank plate c) Filling of Cement water d) Cleaning & Hydraulic testing
01
02
OVERHAULING OF CENTRE PIVOT a) Visual inspection of Centre pivot b) Purpose of welding new liner c) Checking clearances as per
RDSO/SK/DL/2069 CI/ FRA/ 5 MPM 1- 140/88
01
03
OVERHAULING OF CHASSIS a) Inspection of Load Pin, centre Pivot
& Cracks or damage after application of chalk.
b) Checking of cracks under frame. c) Welding of side load bearer. d) Straightness of Buffer beam. e) Main ting sizes of center pivot, side
load pin.
01
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4.3.6 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Overhauling Of L W S. Overhauling Of Draft Gear
Final Safety Checks Of Chassis Before Despatch
Duration : 01 Day ( 6th Day)
Sr.No.
Contents
Period (Hours)
01
OVERHAULING OF LWS
a) Stripping & Electrical testing b) Checking of float puncture with water. c) Testing on test stand & erecting on loco BD-60
water pressurisation cap assembly.
01
02
OVERHAULING OF DRAFT GEAR.
a) Types of Draft Gear. b) Inspection of rubber pad. c) Overhauling & erection on loco.
01
03
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.
Buffer height & Height of Rail guard to be maintained.
01
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4.3.7 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Overhauling Of Radiator Overhauling Of Lube Oil Cooler
Overhauling Of Car Body, Air Intake Filter
Duration : 01 Day (7th Day)
Sr.No.
Contents
Period (Hours)
01
OVERHAULING OF RADIATOR. a) Stripping of Radiator. b) Cleaning of Radiator c) Hydraulic & Pneumatic testing of tubes.
01
02
OVERHAULING OF LUBE OIL COOLER. a) Stripping of lube oil cooler b) Cleaning c) Replacement of Gasket d) Hydraulic testing & EI BD 12
01
03
OVERHAULING OF CARBODY, AIR INTAKE FILTER
a) Disassemble of Air maze oil bath. filter b) Overhauling of Air maze filter c) Fitting on loco & oil filling
01
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4.3.8 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Stripping And Overhauling Of Radiator Fan.
Stripping And Overhauling Of Right T Angle Gear Box.
Hydraulic Testing Of Lube Oil Filter Drum Duration : 01 Day (8th Day)
Sr.No.
Contents
Period (Hours)
01
STRIPPING & OVERHAULING OF RADIATOR FAN a) Stripping of fan from shaft. b) Stripping of upper and lower housing cover, Bearing from
shaft. c) Checking of damaged thread of Fan shaft. d) Removing of Bearing from the shaft. e) Visual inspection of Bearing. f) Assembly of Radiator fan.
01
02
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. g) Inspection and fitment of Horizontal & Vertical shaft. h) Checking of Backlash and endplay. i) Filling of oil in Gear Box.
01
03
HYDRAULIC TESTING OF LUBE OIL FILTER DRUM. a) Stripping of Lube Oil Filter Drum and top cover. 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.
01
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4.3.9 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic
Description : Overhauling Of Drive Shaft. Ecc Outer Drum., Bearing Assembly. Overhauling Of Spline Shaft. Duration : 01 Day (9th Day)
Sr.No.
Contents
Period
Hrs.
01
OVERHAULING OF DRIVE SHAFT. a) stripping of drive shaft. b) Pulling of flexible coupling from shaft. c) Removing of bronze bushing. d) Provision of BD85 (15” pulley). e) Fitment of bronze bushing. f) Maintain clearance between hub & bronze
bush.
01
02
ECC OUTER DRUM., BEARING ASSEMBLY. a) Stripping of ECC Drum. b) Removing off set screw & shaft nut from end
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.
01
03
OVERHAULING OF SPLINE SHAFT. a) Stripping of Spline shaft from slip joint &
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.
a) .
01
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4.3.10 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Explanation Of All Bd Items(Eai) As Per
Rdso Instructions. Duration : 01 Day (10th Day)
Sr.No.
Contents
Period
(Hours)
01
Brief knowledge of all BD items related to CHASSIS SECTION. a) BD-19. BD-20, BD-24, BD-10, BD-27, BD-45, BD-53, BD-60, BD-77, BD-57, BD-83, BD-84, BD-86, BD-72
01
02
Brief knowledge of all BD items related to RADIATOR & CHASSIS SECTION a) BD-15, BD-16, BD-22, BD-63, BD-36, BD-88,
01
03
Brief knowledge of all BD items related to RIGHT ANGLE GEAR BOX SECTION. a) BD-85, BD-82
01
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4.3.11 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Customer Feed Back Session Duration : 01 Day ( 11th Day )
Sr. No.
Contents
Period (Hours)
01
a) Customer complaint.
01
02
a) Remedies of customer complaint.
01
03
a) Practical on complaint
01
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4.3.12 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION
Workshop : Diesel
Technicians : Diesel Mechanic Description : Assessment Test. Duration : 01 Day ( 12th Day )
Sr. No.
Contents
Period (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
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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
1 Introduction of the course, Attitudinal change and Motivation. 2 General Awareness of ISO. 3 Safety and Environment.
01
2
1 Measurement and Measuring Instruments. 2 Precision Measuring Instruments. 3 Gauges :- types and Uses.
01
3
1 Limit, Fits and Tolerance. 2 Main Activity of wheel shop. 3 Checking of wheel seat Diameter.
01
4
1 Press in Axle Coller. 2 Press in disc. 3 Press in Bull gear.
01
5
1 Shrinking of Inner race. 2 Checking of Bearing seat Diameter. 3 Visual inspection of Wheel Centre.
01
6
1 Press in Wheel disc. 2 Visual Inspection of Bearing. 3 Checking of Axle bearing seat diameter.
01
7
1 Disc press in. 2 Visual Inspection of Armature. 3 Armature shaft press out.
01
8
1 Checking of armature shaft bore. 2 Press to Armature shaft. 3 Match-up Pinion seat of the armature shaft.
01
9
1 Press in Bearing. 2 Tyre shrinking. 3 Bevel gear fitment & bearing press in.
01
10
1 Bearing press in. 2 Press in crank Pin. 3 Handling, storage and Packing.
01
11
1 Frequent customer complaints. 2 Failure analysis. 3 Inspection.
01
12
1 Quality Improvement. 2 Assessment test. 3 Feed back from trainees.
01
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4.4.1 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter Description : Introduction Of Course, Attitudinal Change & Motivation. General Awareness Of Iso. Safety And Environment. Duration : 01 Day (01st Day)
Period
Contents
Duration (Hours)
01
Introduction of the course. Changing the attitude related to the work. Role of technicians in improving the Quality of work.
01
02
Need of ISO Certification. ISO 9000 Series. Guiding principles for implementing systems. Terms related to ISO 9000.
01
03
Probable causes of accidents in workshop. Basic steps for accident prevention. Fire Prevention. House keeping.
01
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4.4.2 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Machinist Description : Measurement And Measuring Instruments. Precision Measuring Instruments. Gauges :- Types And Uses. Duration : 01 Day (2nd Day)
Period
Contents
Duration (Hours)
01
(a) Measurement and different types of Measurements.
(b) Standard units of linear measurement, Measuring Methods.
(c) Measuring Instruments:- Steel rule & it‟s types, Callipers- Firm joint callipers, Spring joint callipers, types of callipers.
01
02
(a) Micrometer: - Principle, Least count, Construction, types of Micrometers.
(b) Vernier Calliper :- Material, Size, Principle, Construction.
(c) Reading of Micrometers and Callipers.
01
03
(a) Introduction, Material, advantages of Gauges.
(b) Classification and types of Gauges. (c) Types of gauges and their uses.
01
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4.4.3 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Limit, Fits, And Tolerance. Main Activities Of Wheel Shop. Checking Of Wheel Seat Diameter. Duration : 01 Day (3rd Day)
Period
Contents
Duration (Hours)
01
(a) Interchangeability & it‟s advantages. (b) Limits :- Definition, & advantages, High and
Lower limit. (c) Fits :- Types of Fits, Different systems of
Limit & Fit, Tolerance and system of tolerance.
01
02
(a) WDM2 Wheel repair practice & and Inspection.
(b) Press out TQ and Tap roller, Remove inner race.
(c) Press out Wheel centre and Bull gear.
01
03
(a) Cleaning and removing the Burrs. (b) Visual checking. (c) Check the dia on three places on wheel
seat length horizontally and vertically.
01
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4.4.4 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Press In Axle Coller. Press In Disc. Press In Bull Gar. Duration : 01 Day (4th Day)
Period
Contents
Duration (Hours)
01
(a) Removing the Burrs & cleaning of coller & bore of coller.
(b) Apply the mixture of White lead and linsed oil.
(c) Align the Axle with the coller on the Hydraulic press.
(d) Press the coller to maintain gap of 1-4 mm between gear and coller.
01
02
(a) Setting the disc on the press. (b) Apply the mixture & align the bore of the Disc
and Axle. (c) Press in on side Disc to maintain gap
between coller and Hub.
01
03
(a) Remove the Burrs & clean gear seat. (b) Apply the Mixture. (c) Align the Axle with gear on the Hydraulic
press and pressing Bull gear.
01
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4.4.5 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Shrinking Of Inner Race. Checking Of Bearing Seat Dia. Visual Inspection Of Wheel Centre. Duration : 01 Day (05th Day)
Period
Contents
Duration (Hours)
01
(a) Cleaning of Inner Race & Axle Journal. (b) Heating of Inner race by Induction heating. (c) Fitting of Inner race on the Axle.
01
02
(a) Cleaning of Bearing seat. (b) Visual checking of Bearing seat. (c) Checking of Taper & Ovality of Bearing on
wheel seat..
01
03
(a) Cleaning of wheel Centre and Rivet hole. (b) Visual Inspection of Wheel centre for
Crack/Damages on the Rim, Spoke & Hub. (c) Attend the damage if any.
01
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4.4.6 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Press In Wheel Centre. Visual Inspection Of Bearing. Checking Of Axle Bearing Seat Dia. Duration : 01 Day (06th Day)
Period
Contents
Duration (Hours)
01
(a) Remove Burrs on the bore and set the wheel coller vertically on the press.
(b) Apply the mixture and align the keyways of wheel centre.
(c) Press in both the wheel centres.
01
02
(a) Cleaning of Bearing with Kerosene. (b) Checking of distance piece. (c) Checking the Bearing for damage.
01
03
(a) Cleaning of Bearing and removing the Burrs on the axle.
(b) Visual Inspection of Bearing. (c) Checking of Ovality of Bearing seat.
01
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4.4.7 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Disc Press In. Visual Inspection Of Armature. Armature Shaft Press Out. Duration : 01 Day (07th Day)
Period
Contents
Duration (Hours)
01
(a) Setting the Disc. (b) Align the bore of Disc and Axle on the press. (c) Align the bore of Disc and Axle on the press.
01
02
(a) Cleaning of armature shaft. (b) Checking of damage, if any. (c) Attend the damage.
01
03
(a) Setting of Armature on the press. (b) Align the shaft on press. (c) Safety precautions to be taken.
01
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4.4.8 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter Description : Checking Of Armature Shaft Bore. Pressing Of Armature Shaft. Matching Of Pinion Seat Of The Armature Shaft. Duration : 01 Day (08th Day)
Period
Contents
Duration (Hours)
01
a) Clean the bore of Armature shaft. b) Visual inspection for any damage. c) Checking the taper of in the Bore.
01
02
a) Armature Bore cleaning. b) Heating of Armature. c) Press in the Armature shaft on the Fixture.
01
03
a) Placing of Armature. b) Filing the pinion seat. c) Fitting of the gauge.
01
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4.4.9 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter Description : Press In Bearing. Tyre Shrinking. Bevel Gear Fitment & Bearing Press In. Duration : 01 Day (09th Day)
Period
Contents
Duration (Hours)
01
a) Inserting the Enclosure & finger Ring on the bearing seat.
b) Align the wheel on the Hydraulic press. c) Align the bearing with the Axle, place adopter
and press.
01
02
a) Induction heating of tyre. b) Clean the wheel centre by keeping the wheel
in Vertical position. c) Placing the Wheel centre in tyre bore.
01
03
a) Removal of Burrs, Aligning of gear holes & tight nut bolts.
b) Check the bearing seat dia & insert the bush. c) Insert the lubricant with ring on the Axle,
Align the Axle and press the ring.
01
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4.4.10 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Bearing Press In. Crank Pin Press In.. Handling, Storage And Packing. Duration : 01 Day (10th Day)
Period
Contents
Duration (Hours)
01
a) Clean the Bearing seat and check bearing seat dia.
b) Insert the inner ring on the Axle. c) Inserting of other loose rings.
01
02
a) Removal of Burrs on Crank Pin. b) Align the wheel with Crank pin. c) Safety precautions to be taken while pressing.
01
03
a) Apply grease on the shaft. b) Cares to be taken while shifting the Armature. c) Cares to be taken while shifting the Armature.
01
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4.4.11 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Frequent Customer Complaints. Inspection. Inspection. Duration : 01 Day (11th Day)
Period
Contents
Duration (Hours)
01
a) Frequent customer complaints. b) Common failures and remedies. c) Common failures and remedies.
01
02
a) Examine looseness of distance pieces. b) Examine looseness of Axle & discs. c) Apply colour to all defective parts indicating
attention to be paid.
01
03
a) Function of Inspection department. b) Accuracy and precision. c) Types of Inspection of manufacture products.
01
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4.4.12 TRAINING MODULE FOR FITTERS OF WHEEL SHOP
Workshop : Diesel
Technicians : Fitter. Description : Quality Improvement. Assessment Test. Feed Back From Trainees. Duration : 01 Day (12th Day)
Period
Contents
Duration (Hours)
01
a) Quality Improvement. b) Quality control Activities. c) Benefits of Quality Control.
01
02
a) Assessment test. b) Assessment test. c) Assessment test.
01
03
a) Feed back from trainees. b) Feed back from trainees c) Feed back from trainees
01
Training Modules For Artisans Of Wagon Workshop
S. No. Trade Activity Centre Periodicity Duration
1 Fitter
Vacuum Brake Section Air Brake Section
Once in four
year
12 days
2 Fitter
W.R. Shop
Once in four
year
9 days
2 Machinist
Wheel shop
Once in four
year
8 days
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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 discussion.
One day
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5.1.1 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder
Description : Introduction of course
Duration : 1 day- (1st day)
Period
Contents
Duration (Hours)
01 02 03
I. Introduction of course
I. Importance of training II. Role of technician in improving the quality work.
I. Need of ISO certification. II. Awareness of ISO 9000
01 01 01
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5.1.2 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder Description : Industrial safety Duration : 1 day- (2nd day)
Period
Contents
Duration (Hours)
01 02 03
Industrial safety I. Personal safety. II. Safety of work place I. Safety of welding and gas cutting equipment. II. Fire safety and fire fighting equipment. I. First aids
01 01 01
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5.1.3 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder Description : Introduction of welding
technology Duration : 1 day- (3rd day)
Period
Contents
Duration (Hours)
01 02 03
Introduction of welding technology Importance of good welding. Equipment used in welding and gas cutting. Introduction of manifold system and welders role in saving of industrial gases.
01 01 01
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5.1.4 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder Description : Welding terminology Duration : 1 day- (4th day)
Period
Contents
Duration (Hours)
01. 02. 03
Welding terminology. I. Welding terminology such as Arc length, leg
length, Angle of Berel, Root gap, and Roof face II. Welding positions. I. Type of welding joints. II. Joint preparation. I. Introduction of welding processes; Such as thermit welding, resistance welding, forge
welding, sub-merge arc welding, plasma cutting.
01. 01. 01.
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5.1.5 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Study of Electrode Duration : 1 day- (5th day)
Period
Contents
Duration (Hours)
01 02 03
Study of Electrode. I. RDSO classification of Electrode as per IRS:M:28
and specification as per IS:814. II. Selection of Electrode and current. I. Importance of flux coating. II. Low hydrogen Electrodes. III. Pre heating of Electrodes. I. Electrode for root run and subsequent runs. II. Sequence of run and inter pass temperature
01 01 01
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5.1.6 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Welding and cutting machine Duration : 1 day- (6th day)
Period
Contents
Duration (Hours)
01 02 03
Welding and cutting machine. I. Welding transformer and its principle. II. Welding rectifier. III. Use of Electric Arc welding machine. I. Principle of oxy acetylene cutting. II. Types of flames. I. Principle of Air plasma cutting. II. Safety precautions.
01 01 01
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5.1.7 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : TIG and MIG/MAG Welding
machines Duration : 1 day- (7th day)
Period
Contents
Duration (Hours)
01 02 03
TIG and MIG/MAG Welding machines. I. TIG welding machine. I. MIG/MAG welding machine. II. Advantage of MIG/MAG welding. I. Parts used in TIG and MIG/MAG welding.
01 01 01
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5.1.8 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Welding Defects and Testing of
weld. Duration : 1 day- (8th day)
Period Contents
Duration (Hours)
01 02 03
Welding Defects and Testing of weld. I. Introduction of good welding. II. Important factors to obtain good welding I. Welding defects and its remedy. . I. Destructive and non-destructive test.
01 01 01
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5.1.9 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Welding of wagon components Duration : 1 day- (9th day)
Period
Contents
Duration (Hours)
01 02 03
Welding of wagon components I. Welding of casnub bogie items (Side frame friction
liner, Pedestal jaw liner, centre pivot etc.) as per RDSO pamphlet G-95.
II. Welding of UIC bogie items as per RDSO pamphlet G-16.
I. Reclamation of brake beam as per RDSO
pamphlet G-95. II. Welding of pull rod, push rod of BOXN wagon. 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
per M&C report no K262 and RDSO letter no 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
01 01 01
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5.1.10 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Welding of locomotive
components. Duration : 1 day- (10th day)
Period
Contents
Duration (Hours)
01 02 03
Welding of locomotive components. I. Welding of flange coupling on L.O. cooler of
WDM2 LOCO. I. Welding of bogie cracks of WDM2 LOCO. II. Welding of Mn-steel liner of WDM2 LOCO. I. Welding of camshaft lobes, Gas inlet casing and
traction motor magnet frame of WDM2 LOCO.
01 01 01
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5.1.11 UNIFIED TRAINING MODULE FOR WELDERS
Technicians : Welder Description : Welding of coaching stock items Duration : 1 day- (11th day)
Period
Contents
Duration (Hours)
01 02 03
Welding of coaching stock items. Welding of deferent type of bogie. Welding of main line coach components. Sole bar, head stock, draw bar yoke, tubular structure, cross bearer with sol bar & body bolster with sole bar Welding of Aluminium water tank of BG coaches by MMAW.
01 01 01
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5.1.12 UNIFIED TRAINING MODULE FOR WELDERS Technicians : Welder Description : Feed back & group discussion Duration : 1 day- (12th day)
Period
Contents
Duration (Hours)
01 02&03
Feed back from Technicians (Welders) and group discussion Group Discussion Feed Back.
01 02