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(For official use only) 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)
Transcript

(For official use only)

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

CHAPTER 1

COMPETENCY BASED TRAINING

IN

WORKSHOP

(GENERAL)

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

CHAPTER -2

COMPETENCY BASED TRAINING

FOR

ARTISANS

IN

COACHING WORKSHOP

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

CHAPTER -3

COMPETENCY BASED TRAINING

FOR

ARTISANS

IN

WAGON WORKSHOP

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

CHAPTER -4

COMPETENCY BASED TRAINING

FOR

ARTISANS

IN

DIESEL WORKSHOP

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

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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

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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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Competency Based Training For Workshops

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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Competency Based Training For Workshops

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

CHAPTER -5

COMPETENCY BASED TRAINING

FOR

WELDERS

IN

WORKSHOPS

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


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