Report On Competency Based Training in Workshops

(Govt.
of India)
(Ministry of Railways)
Report on
COMPETENCY BASED TRAINING
IN
WORKSHOPS
(Coaching, Wagon & Diesel)
(For official use only)
CAMTECH/2003 / M /TRG/ 01
April- 2003
Centre
for
Advanced
Maintenance
TECHnology
Excellence in Maintenance
MAHARAJPUR, GWALIOR--474020
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)
DyCME/CRWS
C.Rly. Bhopal
DyCME/R
C. Rly. Jhansi
(H.K. RAGHU)
(ANIL SHARMA)
DyCME/P
C. Rly. Parel
Director (Mech)
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 underCompetency 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 areas1. 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
Preface
Copy of Railway Boards letter
Contents
Chapter-1
General
Chapter-2
Coaching
PAGE NO.
i
ii
iii
01-09
2.1
Training Module for Fitters of

Bogie Section, Air Brake section &
Roller Bearing Section
10-22
2.2
Training Module for Machinist

of Wheel Shop
23-31
Chapter-3
3.1
3.2
3.3
3.4
3.5
Chapter-4
Wagon
Training Module for Fitters
(Brake System)
32-44

(Draw & Buffing Gear)
45-54

(Suspension)
55-62
Training Module for Machinists

(Wheel Shop)
63-65
Training Module for Blacksmiths

(Black smithy Shop)
66-70
Diesel
4.1
Training Module for Machinists
71-83
4.2
Training Module for Diesel Mechanics

of Bogie Section
84-97
Training Module for Diesel Mechanics

of Chassis Section
98-111
4.3
4.4
Chapter-5
5.1

of Wheel Shop
112-124
Welding
Unified Training Module for Welders
125-137
CHAPTER 1
IN
WORKSHOP
(GENERAL)
GENERAL
1.0
Following areas of locomotive, coach and wagon workshops have been

identified as critical areas, with regard to safety where competency levels
of artisan staff need more attention, in order to achieve continual
improvement in competency level.
COACHING WORKSHOPS
1. Bogie, Air Brake, Roller Bearing
2. Wheel shop Section
3. Welding*
WAGON WORKSHOPS
1. Brake System
2. Draw and Buffing Gear
3. Suspension (Fitters)
4. Suspension (Machinist)
5. Suspension (Black Smith)
6. Welding*
DIESEL WORKSHOPS
1. Wheel Shop Activities
(For machinist)
2. Bogie, Air Brake, Cab
(For Diesel Mechanic)
3. Chassis, Radiator, Right Angle Gear Box
do
4. Wheel Shop (Fitter)
do
5. Welding*
(For welders)
*Syllabus for training of welders of coaching, wagon and Diesel has been
made common.
Competency Based Training For Workshops
As a first phase of competency based training, the report covers the

mechanical (coaching, wagon and diesel) workshops of Indian Railways
and accordingly the training syllabus/ modules have been prepared.
Every workshop is having Training Centre/ Basic Training Centre (BTC)
and training facilities in shop floor where technicians are imparted training
at the time of promotion and for refresher purpose. These training centres
shall
be
updated
according
to
the
competency
based
training
requirements.
2.0
TRAINING IN WORKSHOPS
1.
The training programme has high emphasis on competency development

in production and maintenance personnel. About 65% of total training time
shall be utilized for developing practical skills. Theory sessions has been
kept as three hours per day. Rest the time shall be utilized for practical
training in training centre/ workshop.
2.
Workshop based training plan has been designed for identified groups,
directly related to safety and this shall be followed by the participants
during supervised practice sessions. A dedicated space is required at
workshops for practical work consisting of demonstration and practice
sessions. Tools, fixtures and equipments required should be provided so
that arrangement can be made for effective use of facilities. It is further
emphasised that the manual skills can be acquired through highly
focussed practice oriented workshop based training.
3.0
TRAINING RESOURCES
3.1.
Man power requirement
The training officer will be overall Incharge and he will exercise his control
in training centers and workshops equally to maintain coordination of
theoretical classes and practical training in workshops.
A competent SSE/SE shall be incharge of training centre who will assist

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

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

selected topics.
3.2.
Infrastructural facilities
a)
Class Room
A well furnished class room to accommodate 25 to 30 participants
would be essential, with training hardware and necessary furniture.
One more class room would be required for syndicate work or
group activities. The list of hardware and allied software is given in
Annexure- I.
b)
Training-Workshop
A well furnished and appropriately equipped Workshop has to be
developed. One instructor will train a group of 6-7 trainees at a time
on each specific work station. Two groups of 6-7 trainees should be
able to participate the specific task in practice session of two hour
duration. It is proposed to have workshops facilities in vicinity of
class room. The list of M&P, tools and equipment is given in
ANNEXURE-2. The additional M&P/ Equipments may be finalised
by the workshops accordingly to their specific training needs.
c)
Model Room
Each training centre should have a model room which should have
cut models, working models, test stands etc. A list of few models is
given in Annexure 3,4 &5 for training centres attached to
coaching, wagon and diesel shops respectably. The training
centres may have additional models depending on their specific
needs
4.0
CERTIFICATION
The artisans shall be imparted training in BTC/TTC according to the

syllabus. However, the certification shall be done by concerned officer/
shop incharge, of the respective shop where the artisan is working. The
methodology of certification shall however, be reviewed after five years.
Annexure 1
LIST OF CLASS ROOM EQUIPMENTS

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

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

and circular tray, with facility of remote control
08
OHP screen 1.5 m x 1.5 m
One per class room
09
Digital camera
One
10
Laptop computer
One
11
Furniture
12
PA system
One table + One chair

per trainee/ instructor
in each class room
and One table + One
chair for each
instructor in office
One set
13
Internet
connection
telephone connection
14
Reso graph Machine
One
15
Fax
One
with
MTNL/BSNL One
Annexure-2
LIST OF PLANT AND MACHINERY

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

Sr. No.
1.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Bogie with all Components
Air brake system
C3W type distributor valve
KE type distributor valve
P4 type distributor valve
Cut-off angle cock
Isolating cock
Check valve with chock
Dirt collector
Guard emergency brake valve
Auxiliary reservoir
Single car test rig
Roller bearing
Buffer assembly
Draft gear
Brake gear components
quantity
Complete
Complete
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Complete
Complete
Cut model
Cut model
Complete
Complete
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
Annexure-4
LIST OF MODELS IN WAGON WORKSHOP

Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Description
Bogie with all Components
Air brake system
C3W type distributor valve
KE type distributor valve
Cut-off angle cock
Isolating cock
Check valve with chock
Dirt collector
Guard emergency brake valve
Auxiliary reservoir
Single wagon test rig
E Type vacuum cylinder
F Type vacuum cylinder
Roller bearing
CTRB
Draft gear
quantity
Complete
Complete
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Complete
Complete
Cut model
Cut model
Cut model
Cut model
Complete
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
Annexure-5
LIST OF MODELS IN DIESEL WORKSHOP

Sr. No.
1.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Buffer
Draft Gear
Roller Bearing
A-9 Automatic Brake Valve
SA-9 Independent Brake Valve
MU-2B Valve
VA-1B Control Valve
HS-4 Valve
H-5
HB-5
Sander Valve
Wiper Motor
Air Flitters
A-9 Automatic Brake Valve
application and release
SA-9 Independent Brake Valve
application and release
Complete bogie with all components
quantity
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Cut model
Test Stand
Test Stand
Model
CHAPTER -2

FOR
ARTISANS
IN
COACHING WORKSHOP
10
2.1 TRAINING MODULE FOR FITTER OF

BOGIE SECTION, AIR BRAKE & ROLLER BEARING SECTION.
Work Shop
Trade
Activity Centre
Periodicity
Duration
:
:
:
:
:
Coaching
Fitter
Bogie Section / Air Brake/ R.B. Section.
Once In Four Years
12 Days
Sr.No.
Description
1
INTRODUCTION
a) Introduction of Course, attitudinal changes & motivation.
b) General awareness of ISO & EMS.
c) Safety & Environments.
2
a) Introduction and General Data of ICF, RCF and BEML
Coaches.
b) Difference between ICF & BEML coaches.
3
a) Introduction to corrosion.
b) Corrosion prone area in coaches & its inspection.
c) Corrosion prevention in coaches
4
BOGIE SECTION
a) Stripping,inspection,repairing & gauging of Bogie Frame.
b) Assembly of Bolster, Guide Gauging, Brake Gear.
c) Testing of Bogie components.
5
a) Bogie Lowering on wheels.
b) Bogie testing on test stand.
c) Buffer Height adjustment on coaches.
6
a) Introduction of Buffing Gear.
b) Repair of Buffer Assembly.
7
a) Introduction of Draft Gear.
b) Repair of Draft Gear assembly.
8
AIR BRAKE SECTION
a) General knowledge of Brake system of coaches.
b) Brief knowledge of Vacuum Brake system in coaches.
9
a) Working of Air Brake system in coaches.
b) Overhauling & testing of Air Brake components.
10
a) Overhauling & testing of DV.
b) Single car testing of coach.
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.
12
FEED BACK & VALIDATION
a) Assessment Test.
b) Interaction with trainees regarding result.
c) Feedback from trainees.
d) Valedictory function
Day
01
01
01
01
01
01
01
01
01
01
01
01
11
2.1.1 TRAINING MODULE FOR FITTER OF

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

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

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

Safety in workshop.
Fire safety and fire fighting equipments.
Safety with electrical power
First Aid.
01
12

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
13

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
Corrosion prone area in coaches & its inspection.
01
Corrosion prevention in coaches
01
2.
3.
14

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
15

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
1.
Bogie Lowering on wheels.
DURATION
(Hours)
01
2.
Bogie testing on test stand.
01
3.
Buffer Height adjustment on coaches.
01
16

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
17

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
18

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
1.
CONTENTS
DURATION
(Hours)
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
19

Workshop
Coaching
Technicians
Fitter
Description
Working Of Air Brake System ( Bmabs)

Overhauling & Testing Of Air Brake Components.
Duration
01 Day ( 9th Day)
DURATION
(Hours)
PERIOD
CONTENTS
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
20

Workshop
Coaching
Technicians
Fitter
Description
Overhauling & Testing Of Dv.

Single Car Testing Of Coach.
Duration
01 Day ( 10th Day)
PERIOD
CONTENTS
01
Constructional details & function of DV.
DURATION
(Hours)
01
02
Overhauling & testing of DV.
01
03
Single car testing of coach.
01
21

Workshop
Coaching
Technicians
Fitter
Description
Roller Bearing Section &

Latest Modification & Cai Of The Coaches.
Duration
PERIOD
01 Day ( 11th Day)
CONTENTS
01
Introduction of Roller Bearing in coaches.
02
i.
ii.
03
Inspection of Roller Bearing

rejectable defects.
Assembly of Roller Bearing.
DURATION
(Hours)
01
&
Latest modification & CAI of the coaches.
its
01
01
22

Workshop
Coaching
Technicians
Fitter
Description
Feed Back & Validation
Duration
01 Day ( 12th Day)
PERIOD
CONTENTS
DURATION
(Hours)
01
01
Assessment Test.
02
Interaction with trainees regarding result.
01
03
Feedback from trainees.
01
23
2.2 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP

Workshop
Coaching
Trade
Machinist
Activity Centre
Wheel Shop
Periodicity
Once In Four Year
Duration
08 Days (03 Clock Hours Each Day)
Sr.No.
1
5
6
Description
a) Introduction of Course, attitudinal changes & motivation.
b) General awareness of ISO & EMS.
c) Safety & Environments.
a) Limits, Fits & Tolerance.
b) Precision measuring Instruments.
c) Gauges & Templates.
a) Various types of cutting tools.
b) Various types of Machine tools.
c) Multi purpose & special purpose Machine tools.
a) VTL .
b) Wheel Press (Hydraulic) .
c) Axle Grinding m/c
d) Wheel lathe
a) Introduction of Wheel shop .
b) Main activities of Wheel shop .
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.
a) Wheel Inspection & testing.
b) Worn wheel profile.
c) Profile tyre turning of wheels on wheel lathe.
FEED BACK & VALIDATION
a) Assessment Test.
b) Interaction with trainees regarding result.
Day
01
01
01
01
01
01
01
01
24
2.2.1 TRAINING MODULE FOR MACHINIST OF WHEEL SHOP

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

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

Safety in workshop.
Fire safety and fire fighting equipments.
Safety with electrical power
First Aid.
25

Workshop
Coaching
Technicians
Machinist
Description
Limits, Fits & Tolerance.

Precision Measuring Instruments.
Gauges & Templates.
Duration
01 Day ( 2nd Day)
PERIOD
1.
CONTENTS
Limits, Fits & Tolerance.
DURATION
(Hours)
01
2.
Precision measuring Instruments.
01
3.
Gauges & Templates
01
26

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
1.
CONTENTS
Various types of cutting tools.
DURATION
(Hours)
01
2.
Various types of Machine tools.
01
3.
Multi purpose & special purpose Machine tools.
01
27

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
28

Workshop
Coaching
Technicians
Machinist
Description
Introduction Of Wheel Shop .

Main Activities Of Wheel Shop .
Duration
01 Day ( 5th Day)
CONTENTS
Introduction of Wheel shop .
DURATION
(Hours)
01
2.
Inspection of incoming wheels.
01
3.
Re-discing, Re-axling & Re-turning of wheels.
01
PERIOD
1.
29

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.
01
ii) Boring of Wheel Disc on VTL.

3.
Wheel pressing & de-pressing.
01
30

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
1.
CONTENTS
Wheel Inspection.
DURATION
(Hours)
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
31

Workshop
Coaching
Technicians
Machinist
Description
Feed Back & Validation
Duration
01 Day ( 8th Day)
PERIOD
01
CONTENTS
Assessment Test.
DURATION
(Hours)
01
02
Interaction with trainees regarding result.
01
03
01
CHAPTER -3

FOR
ARTISANS
IN
WAGON WORKSHOP
32
3.1 TRAINING MODULE FOR FITTER

(BRAKE SYSTEM)
WORKSHOP
WAGON
TRADE
FITTERS
ACTIVITY CENTRE
VACUUM BRAKE/ AIR BRAKE
PERIODICITY
ONCE IN FOUR YEAR
DURATION
12 DAYS
Sr No.
1.
Description
General introduction
(Vacuum Brake System)
Duration
One day
2.
Maintenance and repairs
One day
3.
Brake under gear
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)
Pipe Brackets, Couplings & Control Reservoir
(Air Brake System)
Dirt Collector, Auxiliary Reservoir & Guards
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
8.
9.
One day
One day
33
3.1.1 TRAINING MODULE FOR FITTER

(VACUUM BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Duration
1 day- (1st day)
Sr.No
Description
Hours
1.
01
2.
Constructional detail to vacuum brake
Vacuum brake cylinders
I.
II.
type of vacuum brake (E type and F type)

advantages of F type cylinders
3.
Principal & operation
I.
II.
Principal of operation
Limits of vacuum brake system
01
34

(VACUUM BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Duration
1 day- (2nd day)
Sr.No
Description
1.
Modifications
2.

I.
3.
Examination and maintenance of Guard Van

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

Operation test
Hours
01
01
01
35

(VACUUM BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Brake under gear
Duration
1 day- (3rd day)
Sr.No
Description
Hours
1.
Brake rigging
I.
II.
III.
01
Constructional details
Working principle
2.
Introduction to SAB
01
I.
II.
III.
Introduction to SAB
Working principle of SAB
Maintenance and repair of SAB
3.
Tools and Equipments & Feedback
I.
II.
Tools and Equipments

Feedback of the training
01
36

(AIR BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Introduction to DV
Duration
1 day- (4th day)
Sr.No
Contents
1.
Introduction And Working Principle Of DV
2.
3.
I.
C 3W Type distributor valve
II.
KE Type distributor valve
Hours
01
Dismantling And Cleaning Of Distributor Valve

I.
II.
01
Examination Of Individual Parts

I.
II.
01
37

(AIR BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Maint. & Testing of DV
Duration
1 day-(5th day)
Sr.No
Contents
1.
Assembly Of Distributor Valve
2.
I.
II.
Hours
01
Testing Of DV On Test Stand As Per Testing

Performa
01
3.
I.
II.
Trouble Shooting During Testing Of DV

I.
II.
01
38

(AIR BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Precaution & Feed Back
Duration
1 day- (6th day)
Sr.No
1.
Precautions
Contents
Precaution during overhauling of DV

2.
Hours
01

01
3.
Feed back
Feed back of the training
01
39

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

I.
II.
Working principle
III.
Maintenance
01
40

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

1 day-(8th day)
Sr.No
Contents
1.
Common Pipe Brackets With Control Reservoir
And Intermediate Piece
2.
3.
I.
II.
Working principle
III.
Maintenance
Hours
01
Brake Pipe And Feed Pipe Couplings

I.
II.
Working principle
III.
Maintenance
01
Air Hose Coupling

I.
II.
Working principle
III.
Maintenance
01
41

(AIR BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Duration
Dirt Collector, Auxiliary Reservoir &

Guards Emergency Brake Valve
1 day-(9th day)
Sr.No
1.
Dirt Collector
2.
3.
Contents
Hours
I.
01
II.
Working principle
III.
Maintenance
Auxiliary Reservoir
I.
II.
Working principle
III.
Maintenance
01
Guards Emergency Brake Valve

I.
II.
Working principle
III.
Maintenance
01
42

(AIR BRAKE)
Workshop
Wagon
Technicians
Fitter
Description
Duration
:
:
Brake rigging
1 day-(10th day)
Sr.No
1.
Contents
Hours
Handbrake
I.
II.
General Introduction &

Constructional detail
01
Empty Load Device

I.
II.
2.
Components
I.
II.
3.
General &
Constructional detail
01
Sliding brake beam &

Body under frame components
Brake Head Replacement

Composition brake block - Dos and donts
fitment of composition brake block
I.
To be done
II.
Not to be done
for
01
43

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

1 day-(11th day)
Sr.No
Contents
1.
Overhauling of Slack Adjuster (SAB)
I.
II.
III.
IV.
V.
VI.
2.
01
Testing Of Slack Adjuster On Test Rack

I.
II.
III.
3.
Introduction
Disassembling
Cleaning and inspection
Lubrication
Reassembling
Safety precautions
Hours
Take up test or Pay in test

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

I.
Painting
II.
Procedure for brake rigging - setting and

measurements of A+C dimensions
III.
01
44

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

1 day- (12th day)
Sr.No
1.
Contents
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
2.
01
Procedure
I.
II.
III.
3.
Hours
Single wagon Test rig (SWTR)

Procedure for single wagon test
Performa for single wagon test for
wagons other than BOBR and BOBRN
01
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
45

(DRAW & BUFFING GEAR)
WORKSHOP
WAGON
TRADE
FITTERS
PERIODICITY
ONCE IN FOUR YEARS
DURATION
Sr No.
9 DAYS
Description
Duration
1.
Introduction Buffing Gear
2.
Buffing Gear Repairs
3.
Reclamation Of Draw Bars
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.
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
One day
One day
Part-1
One day
46

Workshop
Wagon
Technicians
Fitter
Description
Introduction buffing gear
Duration
1 day- (1st day)
S No
1
Description
Hours
Introduction - General
01
Conventional buffing gear
2
Type of buffing gear
01
I.
II.
3
Long case
Short case
Components
01
The main components of buffing gear (Sub components)
47

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.
1
Description
Hours
Repairs of
01
Buffing casing
Repairs of
01
Spindle
Repairs of
Outer and inner coil spring
01
I.
II.
Buffer projection
Buffer height
48

Workshop
Wagon
Technicians
Fitter
Description
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
49

(DRAW BAR AND BUFFING GEAR)
Workshop
Wagon
Technicians
Fitter
Description
Duration
1 day- (4th day)
S No.
Description
Hour

1
Parts of centre buffer coupler assembly and its inspection
01
Inspection of CBC (Couplers operating mechanism )
01
Inspection of draft gear (HR-40-1 & MF-400-1-IR)
01
50

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
1
Description
Hour
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 Mf400-1-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.
II.
III.
IV.
Gauges for housing.

Gauges for shoes
Gauges for wedge
Final inspection gauge
01
51

Workshop
Wagon
Technicians
Fitter
Description
Duration
1 day- (6th day)
S No
1
Description
Disassembly
Hour
01
Disassembly procedure for RF-361- Draft gear

2
Inspection
01
Inspection of components
Shoes, wedge, housing or cylinders
3
Reconditioning
Complete reconditioning
01
52

Workshop
Wagon
Technicians
Fitter
Description
Duration
1 day- (7th day)
S No
1
Description
Hour
Inspection
Visual inspection of rubber pads
01
2
Static test
I.
II.
III.
IV.
Inspection of internal followers

Inspection of forged
Inspection of housing(Cylinders)
Preparation of housing prior to reassemble
01
3
Re-assembly
Re-assembly of reconditioned RF-361 Draft gear
01
53

(DRAW AND BUFFING GEAR)
Workshop
Wagon
Technicians
Fitter
Description
Maint Of MARK-50 - Draft Gear
Duration
1 day- (8th day)
S No
1
Description
Inspection
Hour
01
2
Removal Of Draft Gear From Wagon Pocket
I.
II.
III.
IV.
V.
Normal condition
Follower broken
Partially stuck gear
Fully stuck draft gear
Removal of stuck or damaged draft gear
01
3
Removal of stuck draft gear so as to re use
01
54

(DRAW AND BUFFING GEAR)
Workshop
Wagon
Technicians
Fitter
Description
MAINT. OF MARK-50 - DRAFT GEAR
Duration
1 day- (9th day)
S No
1.
Description
Inspection
Hour
01
Inspection of Mark-50 gear for reconditioning

2.
Guide To Dismantle
01
Summarized guide to dismantle Mark-50 draft gear

3.
List of gauges
For Mark-50 draft gear
I.
II.
Housing gauges for initial inspection

Housing weld repair gauges
01
55

(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
CASNUB BOGIE
One day
BOX (U I C )BOGIE
One day
CAST STEEL BOGIE
One day
DIAMOND FRAME BOGIE
One day
MAINTENANCE OF ROLLER BEARING
One day
MAINTENANCE OF CTRB
One day
2.
3.
4.
5.
6.
7.
56

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
Duration
INTRODUCTION- SUSPENSION
(FOUR WHEELED SUSPENSION)
1 day- (1st day)
THE SUSPENSION OF FOUR WHEELED WAGON

S No
Description
1
Introduction
Introduction to suspension
2
Hour
01
Individual Elements
The brief description of the individual elements of four
wheeler suspension;
I.
II.
III.
IV.
V.
VI.
VII.
01
Scroll iron
Shackle pins
Shackle plates
Spring shackle
Bearing spring
Shackle pin washers
Split cotters/ bulb cotters
3
Repairs during POH
01
57

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
CASNUB BOGIE
Duration
1 day- (2nd day)
S No
Description
Hour
Casnub Bogie
1
Introduction & Construction details of CASNUB Bogie

and its sub-assemblies
01
Repair and maintenance during POH.
01
1. Nominal clearances.
2. Wear limits of the components.
3. Relevant drawings numbers
01
58

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
BOX (U I C )BOGIE
Duration
1 day- (3rd day)
S No
1
Description
Hour
BOX (U I C) Bogie
Construction details of BOX (U I C) Bogie and its subassemblies
01
01
01
59

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
CAST STEEL BOGIE
Duration
1 day- (4th day)
S No
1
Description
Hour
CAST STEEL Bogie

Construction details of CAST STEEL Bogie and its
sub-assemblies.
01
01
01
60

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
DIAMOND FRAME BOGIE
Duration
1 day- (5th day)
S No
1
Description
DIAMOND FRAME BOGIE
Hour
Construction details of diamond frame bogie and its

sub-assemblies.
01
01
01
61

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
Duration
MAINTENANCE OF ROLLER
BEARING
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.
1
Description
Dismounting and dismantling
I.
II.
III.
01

I.
II.
III.
IV.
Roller bearing axle box dismounting.

Identification of roller bearing box and its
classification.
Roller bearing axle box dismantling by press
machine.
Hour
Axle box housing and its components cleaning

Inspection of the components
Condemnation of defective parts and their
repair and replacement.
General cleaning and examination.
01
Assembly and mounting

I.
II.
III.
IV.
Replacement of defective parts (inner races

and throwers)
Assembly of roller bearing by hydraulic press.
Greasing of axle box
Mounting of roller bearing axle box.
01
62

(SUSPENSION)
Workshop
Wagon
Technicians
Fitter
Description
MAINTENANCE OF CTRB
Duration
1 day- (7th day)
S No.
1
Description
Dismounting and dismantling
I.
II.
III.
01

I.
II.
III.
IV.
CTRB dismounting.
Transportation.
CTRB dismantling.
Hour
CTRB components cleaning

Inspection of the components
General cleaning and final examination.
Marking of over hauling- W/Shop, Month &
Year.
01
Assembly and mounting

I.
II.
III.
IV.
V.
Adjust lateral play of CTRB on bench.

Assembly Greasing of CTRB
Packing of CTRB.
Transportation.
Mounting of CTRB on BN wheels
01
63
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
MACHINING OF WHEELS
One day
9.
64
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
Introduction
1
Type of wheels
Inspection
I.
Wheel defects.
II.
Diameter of wheels with condemnation limits
III.
Axle
IV.
Wheel disc
01
01
Gauges
3
Use of different gauges
01
NOTE: Only the ultra sonically tested and OK wheels are to be taken for further
repair / machining.
65

(WHEEL SHOP)
Workshop
Wagon
Technicians
Machinist
Description
MACHINING OF WHEELS
Duration
1 day- (2nd day)
S No.
Description
Hour
Reaxling
1
01
I.
II.
III.
Machining of new axle

Machining of disc
Assembly
Rediscing
01
2
I.
II.
III.
Machining of new disc

Machining of axle
Assembly
Tread profile
3
01
Machining for tread profile to match road gauge
NOTE: Pairing of the wheels to be done by the Fitter staff.
66
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
One day
Maintenance of LB spring
One day
Spring manufacturing
One day
Heat treatment of LB springs
One day
67
3.5.1 TRAINING MODULE FOR BLACKSMITH

(BLACKSMITHY SHOP)
Workshop
Wagon
Technicians
Blacksmith
Description
Duration
1 day- (1st day)
DRAW & BUFFING GEAR

Procedure for reclamation of draw bars in workshops
S No
1
Description
Reconditioning and Identification
Hour
01
Reconditioning by stamping/ forging at location a and b

Stamping for identification
2
Heat treatment ( Draw Bar and Screw Coupling)

I.
II.
Hardening
Tampering
Load Test
Proof load test
(As per IRS specification No.R-11-67 clause 7.1)
01
01
68

(BLACKSMITHY SHOP)
Workshop
Wagon
Technicians
Black smith
Description
MAINTENANCE OF LB SPRING
Duration
1 day- (2nd day)
S.No.
Description
Hours
Inspection of spring during POH

1
I.
II.
III.
Rejectable defects of the springs

Load deflection test
Grading of the spring.
01
Identification of the spring for repair in BSS

01
Material specification of the parts
01
69

(BLACKSMITHY SHOP)
Workshop
Wagon
Technicians
Blacksmith
Description
SPRING MANUFACTURING
Duration
1 day- (3rd day)
S.No.
Description
Coil spring manufacturing
Hours
1
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
LB Spring manufacturing
2
I.
RDSO letter No.M&C/STC/2/1 dated 26.03.75

01
II.
RDSO letter No MW/!! Spring dated 18.07.77

(Approved v, and IRS specification RS-68)
RDSO pamphlet Laminated spring failuredescription, classification and repotting- issued in 1969
with a corrigendum in 1972
01
70

(BLACKSMITHY SHOP)
Workshop
Wagon
Technicians
Blacksmith
Description
Heat Treatment Of Lb Springs
Duration
1 Day- ( 4th Day)
S.No.
Description
Hours
Heat Treatment
(Spring after BS work shell be heat-treated.)
1
I.
Hardening a) Water hardening b) Oil hardening
II.
Tempering
III.
Temperature control
IV.
Rolled eye
V.
Indentation
Testing of the spring after BS work

I.
Scrag test
II.
Load defection
Important Dos and Donts
01
01
01
CHAPTER -4

FOR
ARTISANS
IN
DIESEL WORKSHOP
71
4.1 TRAINING MODULE FOR MACHINIST

Workshop
Diesel
Trade
Machinist
Activity Centre
Wheel Shop
Periodicity
Once In Four Year.
Duration
12 Days
SR.NO
.
1
1
2
3
2 1 1
2
3
3
1
2
3
4
1
2
3
5
1
2
3
6
1
2
3
7
1
2
3
8
1
2
3
9
1
2
3
10
1
2
3
11
1
2
3
12
1
2
3
DESCRIPTION
Introduction of Course, Attitudinal change & Motivation.
General Awareness of ISO.
Safety & Environment.
Limits Fits and Tolerance.
Gauges and Templates.
Various types of Cutting tools.
Various types of Machine tools.
Multipurpose, Single purpose and special purpose Machine Tools.
Automatic Lathe..
NC/ CNC & Hydraulic Machines.
Other special purpose machines.
Introduction of Wheel Shop.
Main activities of Wheel shop.
Lathe accessories and attachments.
Quality control.
Quality improvement.
Inspection.
Profile turning of wheel.
Press in side coller and press in Bull gear.
Boring of Wheel disc.
Journal Burnishing.
Bearing Seat machining.
Shrinking of the inner race.
Tyre Boring.
Profile tyre turning.
Crank pin returning.
Crank pin rethreading.
Boring of the Wheel disc.
Bearing Seat Machining.
Visual inspection of Armature.
Armature shaft press out & press in.
Matching the pinion seat on the armature shaft.
Handling, Storage and packing.
Failure analysis and Customer feed back.
Feed back from trainees.
DAY
01
01
01
01
01
01
01
01
01
01
01
01
72

Workshop
Diesel
Technicians
Machinist
Description
Introduction Of Course, Attitudinal Changes &

Motivation. General Awareness Of ISO.
Safety And Environment.
Duration
Period
01
02
03
01 Day (1st day)
Contents
Introduction of the course.
Changing the attitude related to the work.
Role of technicians in improving the Quality of work.
Need of ISO Certification.
ISO 9000 Series.
Guiding principles for implementing systems.
Terms related to ISO 9000.
Probable causes of accidents in workshop.
Basic steps for accident prevention.
Fire Prevention.
House keeping.
Duration
(Hours)
01
01
01
73

Workshop
Diesel
Technicians
Machinist
Description
Limits, Fits And Tolerance.

Precision Making Instruments.
Gauges And Templates.
Duration
Period
01
(a)
(b)
(c)
(a)
02
(b)
03
(a)
(b)
(c)
01 Day (2nd day)
Contents
Limits, Fits and tolerance.
System of tolerance.
Maximum and Minimum allowance.
Types functions, Material and specification of
preliminary measuring Instruments.
Reading of Vernier Caliper, Micrometer,
Depth gauge, and Height gauge.
Different types of gauges.
Master gauges, Inspection gauges.
Go & Not go Gauge, Snap Gauge, Plug
gauge, Thread gauge and Filler gauge.
Duration
(Hours)
01
01
01
74

Workshop
Diesel
Technicians
Machinist
Description
Various Types Of Cutting Tools.

Various Types Of Machine Tools.
Multipurpose, Single Purpose & Special Purpose
Machine Tools.
Duration
Period
01
02
03
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
(d)
01 Day (3rd day)
Contents
Types of Material used for cutting tools.
Composition and characteristics.
Uses of tools.
Operations performed on Machine tools.
Speed, feed, Cutting speed & Depth of cut.
Definition
Classes of Machine tools.
Multipurpose and single purpose.
Special purpose Machine Tools.
Machine Tools used in Machine shop and
wheel shop.
Duration
(Hours)
01
01
01
75

Workshop
Diesel
Technicians
Machinist
Description
Duration
Period
(a)
01
02
03
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
(d)
Automatic Lathe.
NC/ CNC & Hydraulic Machines.
Other Special Types Of Machines.
01 Day (4th day)
Contents
Mass production Lathe with complete automatic
control.
Functions of automatic lathe and its operations.
Cutting tools used on automatic lathe.
NC/CNC and Hydraulic Machines.
Axle turning centre, Chucker and Break press.
TCM, VTL co-ordinate Measuring Bolt, Forging,
Shearing machine.
Other special types of machines.
Wheel lathe and Gap bed lathe.
T lathe and Duplicating.
Missile lathe.
Duration
(Hours)
01
01
01
76

Workshop
Diesel
Technicians
Machinist
Description
Introduction Of Wheel Shop.

Main Activities Of Wheel Shop.
Lathe Accessories & Attachments.
Duration
01 Day (5th day)
Period
(a)
01
02
03
(b)
(c)
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(d)
Contents
Types of Wheels, Axles, Bearing, POH of
WDM2 wheel.
WDM2 wheel repair practice and Inspection.
Rail cars.
Press out TQ & Tap Roller Bearing.
Remove inner race.
Press out wheel centre and Bull gear.
Press in Bull gear coller and wheel centre to
Axle.
Lathe Accessories & attachments.
Lathe centre, Catch plate and Carriers.
Other Holding and Holding supporting the work.
Attachment used for stops, ball turning rest ,
threading, chasing dials.
Duration
(Hours)
01
01
01
77

Workshop
Diesel
Technicians
Machinist
Description
Quality Control. Quality Improvement.

Inspection.
Duration
01 Day (6th day)
Period
01
02
03
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
(d)
Contents
Quality Control.
Quality Cyclic behaviour pf production.
Rejection of Jobs.
Quality Improvement.
Quality Control activities.
Benefits of Quality Control.
Inspection.
Functions of Inspections.
Accuracy and Precision.
Kinds of Inspection of manufactured product.
Duration
(Hours)
01
01
01
78

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
01
02
03
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(a)
(b)
(c)
Contents
Profile turning of Wheel.
Face inside the disc.
Turn the disc.
Fit the profile gauge.
Press inside Coller and press in Bull gear.
Align the Axle with the Coller on the Hydraulic
press.
Set the Axle.
Boring of Wheel disc.
Face the hub of the disc at bottom.
Face the disc at top to maintain the Hub.
Duration
(Hours)
01
01
01
79

Workshop
Diesel
Technicians
Machinist
Description
Journal Burnishing. Bearing Seat Machining.

Shrinking Of Inner Race.
Duration
Period
01
02
03
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(a)
(b)
(c)
01 Day (8th day)
Contents
Journal Burnishing.
Face Axle coller to maintain suspension gauge.
Remove burn and clean the turned off Axle.
Burnish the journal.
Bearing Seat machining.
Rough and finish turned Axle.
Burnish the Bearing Seat
Shrinking of Inner Race.
Induction heating of Inner Race.
Fitting of Inner Race.
Duration
(Hours)
01
01
01
80

Workshop
Diesel
Technicians
Machinist
Description
Tyre Boring. Profile Tyre Turning.

Crank Pin Re-Turning.
Duration
01 Day (9th day)
Period
01
02
03
Contents
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(a)
(b)
(c)
(d)
Tyre Boring.
Grooving of Tyre.
Fitting of gauge.
Final Boring of the Tyre.
Profile Tyre turning.
Facing of inside of Tyre to maintain the road
gauge.
Turning of tyre and fitting of Profile gauge.
Crank pin re-turning.
Rough turning of the C P.
Facing the wheel centre to maintain the length.
Final turning of the C P.
Duration
(Hours)
01
01
01
81

Workshop
Diesel
Technicians
Machinist
Description
Crank Pin Threading..

Boring Of The Wheel Disc.
Bearing Set Machining.
Duration
01 Day (10th Day)
Period
01
02
03
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
Contents
Crank pin re-threading.
Light turning on threaded portion.
Re-threading and grooving of C.P.
Boring of the wheel disc.
Face the disc at top to maintain the Hub length.
Bore the disc, machine the groove finish
boaring.
Bearing seat Machining.
Turn the Bearing seat.
Filing Bearing seat.
Duration
(Hours)
01
01
01
82

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
01
02
03
(a)
(b)
(c)
(a)
(b)
(c)
(d)
(a)
(b)
(c)
(d)
Contents
Visual Inspection of Armature.
Check for any damage on main body.
Check for any damage on the Coil.
Armature shaft press out and press in.
Align the shaft with the Ram of the press
Place a Copper or M.S.Pad between Ram &
shaft.
Press out Armature shaft.
Match of the Pinion seat on the Armature shaft.
Keep the Armature horizontally.
File the Pinion.
Seat and feed the gauge.
Duration
(Hours)
01
01
01
83

Workshop
Diesel
Technicians
Machinist
Description
Handling Storage Packing..

Failure Analysis And Analytical Approach.
Feed Back Of The Trainees.
Duration
01 Day (12th day)
Period
01
02
03
Contents
Handling storage packing
(a) While shifting the Wheel.
(b) While loading the wheel.
(c) After burnishing operation of the wheel.
(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.
(a) Feed back of trainees according to modern
practices inspection.
(b) Record and special studies are used to Identify
problems and their causes.
Duration
(Hours)
01
01
01
84
4.2 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE

SECTION
WORKSHOP
DIESEL
TRADE
DIESEL MECHANIC
ACTIVITY CENTRE
BOGIE /AIR BRAKE/CAB SECTION
PERIODICITY
ONCE IN FOUR YEAR
DURATION
12 DAYS (3 CLOCK HOURS EACH DAY)
Sr.
No.
Description
Day
a)
b)
c)
Introduction of course, Attitudinal change & motivation

General awareness of ISO
Safety & Environment
01
a)
Introduction and General data of WDM2 locomotive
01
b)
a)
c)
Introduction to Vehicle Section.

Introduction of Power Pack Section
01
BOGIE SECTION
a) Stripping & Overhauling of Bogie frame.
01
a)
Assembly of Traction motor, Gear Case, Wick pad,
01
a)
b)
b)
c)
Assembly
of pad.
foundation brake components
&Resilience
Bogie Run Test on testing stand
Placing of Bogie frame on Chassis.
01
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
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
CAB-SECTION
a) Overhauling of cab and super structure
b) Overhauling of hand brake assembly
c) Modification of cab & EAI
01
01
01
85
10
a)
Explanation of all BD items (EAI) as per RDSO

Instructions
01
11
a)
Customer feed-back session
01
12
(a)
(b)
(c)
(d)
Assessment Test
Interaction with trainees regarding result
Valedictory function
01
86
4.2.1 TRAINING MODULE FOR DIESEL MECHANIC OF BOGIE

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
Introduction Of Course, Attitudinal Change

& Motivation.
General Awareness Of Iso.
Duration
01 Day (1st Day)
Sr. No.
Contents
01
02
03
a) Introduction of course, Attitudinal change &

Motivation.
b) Introduction of course and advantage.
c) Attitudinal changes related to their work.
General awareness of ISO.
a) Introduction of ISO, importance, advantages,
various terms related to ISO, Quality policy,
Work instruction , changes of the Work shop.
Safety & environment
a) safety items related to Work shop & related to
Bogie Section.
b) Better house keeping.
Period
(Hours)
01
01
01
87

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Section
Description
Duration
Bogie , Air Brake, Cab & Power

Pack
Introduction And General Data Of Wdm2
Loco.
01 Day (2nd Day)
Sr. no.
01
02
03
Contents
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)
Introduction of Power pack section.
a) Knowledge of FIP, Injector and
testing.
b) FIP & Calibration.
c) Blowers, Water Pump and
L.O.Pump.
a) Cylinder head and testing.
b) Piston.
c) Working principle of TSC &
Expressor.
Period
(Hours)
01
01
01
88

SECTION
Workshop
Diesel
Technicians
Description
Duration
Diesel Mechanic
Introduction To Chassis, Rt. Angle
Gear Box &Radiator.
01day (3rd Day)
Sr. no.
Content
01
a) Knowledge of chassis, and its

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

Box. & Its maintenance
01
b) Knowledge of Radiator. & Its

overhauling.
01
03
89

SECTION
Workshop
Sr.
No.
01
02
03
Diesel
Technicians
Diesel Mechanic
Description
Stripping And Overhauling Of Bogie Frame.
Duration
01 Day (4th Day)
Contents
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.
a) Removing of all liner, provision of new liner.
b) Bogie alignment.
a) Checking of Centre pivot liner.

b) Centre Pivot sizes, inspection & repairing of
side bearers.
Period
(Hours)
01
01
01
90

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

Wick Pad & Resilience Pad
Duration
: 01 Day (5th Day)
Sr. no.
01
Contents
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
Period
(Hours)
01
02
Gear Case Assembly
01
03
Resilience Pad & Assembly

a) Visual Inspection & Cleaning
01
91

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.
01
Contents
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.
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.
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)
Period
(Hours)
.
01
01
01
92

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
General Knowledge Of Brake System.

Overhauling Of Different Types Of
Brake Valve Assembly.
Duration
Sr.No.
01
02
03
01 Day (7th Day)
Contents
a) Necessity of Air brake system.
b) Introduction of Air and Vacuum brake
system.
c) Introduction of air brake system IRAD-1
BRAKE VALVE ASSEMBLY
a) Working of A9 valve.
b) Working of SA9 valve.
c) Working of C2 Relay valve
a)
b)
c)
d)
Safety devices used on WDM2 loco.

APS Air flow measuring valve & PATB
H5 & HB5 valve.
Working of sand valve and Wiper Motor &
Horns.
Period
(Hours)
01
01
01
93

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

Overhauling And Testing Of L /O Valves
& Ost Assembly.
Air Brake Circuits.
Duration
01 Day(08th Day).
Sr.No.
01
02
03
Contents
Working of Auto flasher system on WDM2

Loco.
Overhauling and testing of L.O. Relief
Regulating By pass valve and OST Assembly.
Brief description of Air brake Circuits, A9
Circuits with conjunction working, IRAB1
circuits.
Period
(Hours)
01
01
01
94

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
Overhauling Of Cab & Super Structure.

Overhauling Of Hand-Brake Assembly.
Duration
01 Day (9th Day )
Sr.No.
01
02
03
Contents
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.
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.
Modification of cab & EAI.
Period
(Hours)
01
01
01
95

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
01
Brief knowledge of all BD items related BOGIE

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

BRAKE SECTION
01
02
Period
(Hours)
a)BD-12, BD-33, BD-50, BD-65 BD-71
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
96

SECTION
Workshop
Technicians
Diesel Mechanic
Description
Customer Feed Back Session
Duration
01 Day ( 11th Day )
Sr. No.
Diesel
Contents
Period
(Hours)
01
Customer complaint.,
01
02
Remedies of customer complaint
01
03
Practical on complaint
01
97

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
98
4.3 TRAINING MODULE FOR DIESEL MECHANIC OF CHASSIS SECTION

Workshop
Diesel
Trade
Diesel Mechanic
Activity Centre
Chassis Section
Periodicity
Once In Four Year
Duration
12 Days
Sr.
No.
1
2
3
4
10
Description
Day
a) Introduction of course, Attitudinal change & motivation

b) General awareness of ISO
c) Safety & Environment
a) Introduction and General data of WDM2 locomotive
b) Introduction of Power Pack Section
a) Introduction to Vehicle Section.
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
a) Overhauling of Fuel Tank.
b) Overhauling of Centre pivots.
c) Overhauling of chassis
01
a) Overhauling of L.W. S.
b) Overhauling of Draft Gear.
c) Final checking of chassis before dispatch.
RADIATOR SECTION
a) Over hauling of Radiator
b) Overhauling of Lube oil cooler.
c) Overhauling of car body, air intake filter
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.
a) Overhauling of Drive Shaft.
b) ECC outer drum , Bearing assembly
c) Overhauling of Spline Shaft.
a) Explanation of all BD items (EAI) as per RDSO
Instructions
01
01
01
01
01
01
01
01
01
99
11
a) Customer feed-back session
01
12
a) Assessment Test
b) Interaction with trainees regarding result
01
100
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
01
02
03
Introduction of course , Attitudinal change &

Motivation.
a ) Introduction of course , advantages
b ) Attitudinal changes related to their work
.
General awareness of ISO.
a)Introduction of ISO, importance, advantages,
various terms related to ISO, Quality policy,
Work instruction , changes of the Work shop.
Safety & environment
a) Safety items related to Work shop & related to
Chassis section
Period
(Hours)
01
01
01
101

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
Introduction And General Data Of WDM-2 Loco.
Duration
01 Day (02nd Day)
Sr. no.
01
02
03
Contents
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)
Introduction of Power pack II section.
a) Knowledge of FIP, Injector & testing
b) FIP Calibration.
c) Blowers, Water Pump and L.O.Pump.
a) Cylinder Head
b) Piston
c) Working principle of TSC & Expressor
Period
(Hours)
01
01
01
102

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)
b)
03
Basic principles of Right Angle

Gear Box.
Basic principles of Radiator.
a) Introduction of Bogie section.
01
01
103

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.
01
02
03
Contents
Overhauling of reservoir
a) Uncoupling of reservoir & inspection of thread.
b) Hydraulic testing of reservoir , erecting on loco.
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.
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
Period
(Hours)
01
01
01
104

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
01
02
03
OVERHAULING OF FUEL OIL TANK

a) Draining of tank
b) Cutting of tank plate
c) Filling of Cement water
d) Cleaning & Hydraulic testing
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
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.
Period
(Hours)
01
01
01
105

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.
01
02
03
Contents
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.
OVERHAULING OF DRAFT GEAR.

a) Types of Draft Gear.
b) Inspection of rubber pad.
c) Overhauling & erection on loco.
FINAL SAFETY CHECKS OF BOGIE ASSEMBLY
a) Checking of U bracket, CBC operation, split pin,
bottom stud plate, rod adjustment, Adjuster,
equalizing pipe, Z pipe, rail Guard, Leakages of
all pipeline when the Load Box is conducted.
Clamping of all pipeline before despatch of loco.
Buffer height & Height of Rail guard to be
maintained.
Period
(Hours)
01
01
01
106

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.
01
02
03
Contents
OVERHAULING OF RADIATOR.
a) Stripping of Radiator.
b) Cleaning of Radiator
c) Hydraulic & Pneumatic testing of tubes.
OVERHAULING OF LUBE OIL COOLER.
a) Stripping of lube oil cooler
b) Cleaning
c) Replacement of Gasket
d) Hydraulic testing & EI BD 12
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
Period
(Hours)
01
01
01
107

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
Duration
Stripping And Overhauling Of Radiator Fan.

Stripping And Overhauling Of Right T Angle
Gear Box.
Hydraulic Testing Of Lube Oil Filter Drum
01 Day (8th Day)
Sr.No.
01
02
03
Contents
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.
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.
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.
Period
(Hours)
01
01
01
108

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.
01
02
03
Contents
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.
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.
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) .
Period
Hrs.
01
01
01
109

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

Rdso Instructions.
Duration
01 Day (10th Day)
Sr.No.
01
02
03
Contents
Brief knowledge of all BD items related to
CHASSIS SECTION.
a) BD-19. BD-20, BD-24, BD-10, BD-27, BD45, BD-53, BD-60, BD-77, BD-57, BD-83, BD84, BD-86, BD-72
RADIATOR & CHASSIS SECTION
a) BD-15, BD-16, BD-22, BD-63, BD-36, BD88,
RIGHT ANGLE GEAR BOX SECTION.
a) BD-85, BD-82
Period
(Hours)
01
01
01
110

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
111

SECTION
Workshop
Diesel
Technicians
Diesel Mechanic
Description
Assessment Test.
Duration
01 Day ( 12th Day )
Sr. No.
Contents
01
a) Assessment test on the topic General

WDM2 data Chassis, Radiator, Right
Angle Gear Box.
02
03
a)
Interaction with trainees regarding

result.
a) Feed back from trainees.

b) Valedictory function.
Period
(Hours)
01
01
01
112
4.4 TRAINING MODULE FOR FITTERS OF WHEEL SHOP

WORKSHOP
DIESEL
TRADE
FITTER
ACTIVITY CENTRE
WHEEL SHOP
PERIODICITY
ONCE IN FOUR YEAR.
DURATION
12 DAYS
SR.NO
.
DESCRIPTION
10
11
12
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
Introduction of the course, Attitudinal change and Motivation.

General Awareness of ISO.
Safety and Environment.
Measurement and Measuring Instruments.
Gauges :- types and Uses.
Limit, Fits and Tolerance.
Main Activity of wheel shop.
Checking of wheel seat Diameter.
Press in Axle Coller.
Press in disc.
Press in Bull gear.
Shrinking of Inner race.
Checking of Bearing seat Diameter.
Visual inspection of Wheel Centre.
Press in Wheel disc.
Visual Inspection of Bearing.
Checking of Axle bearing seat diameter.
Disc press in.
Visual Inspection of Armature.
Armature shaft press out.
Checking of armature shaft bore.
Press to Armature shaft.
Match-up Pinion seat of the armature shaft.
Press in Bearing.
Tyre shrinking.
Bevel gear fitment & bearing press in.
Bearing press in.
Press in crank Pin.
Handling, storage and Packing.
Frequent customer complaints.
Failure analysis.
Inspection.
Assessment test.
DAY
01
01
01
01
01
01
01
01
01
01
01
01
113
4.4.1 TRAINING MODULE FOR FITTERS OF WHEEL SHOP

Workshop
: Diesel
Technicians
Fitter
Description
Motivation.
Introduction Of Course, Attitudinal Change &

General Awareness Of Iso.
Duration
Period
01
02
03
01 Day
(01st Day)
Contents
Introduction of the course.
Changing the attitude related to the work.
Role of technicians in improving the Quality of work.
Need of ISO Certification.
ISO 9000 Series.
Guiding principles for implementing systems.
Terms related to ISO 9000.
Probable causes of accidents in workshop.
Basic steps for accident prevention.
Fire Prevention.
House keeping.
Duration
(Hours)
01
01
01
114

Workshop
Diesel
Technicians
Machinist
Description
Measurement And Measuring Instruments.

Gauges :- Types And Uses.
Duration
01 Day
Period
(a)
01
(b)
(c)
(a)
02
(b)
(c)
(a)
03
(b)
(c)
(2nd Day)
Contents
Measurement and different types of
Measurements.
Standard units of linear measurement,
Measuring Methods.
Measuring Instruments:- Steel rule & its
types, Callipers- Firm joint callipers, Spring
joint callipers, types of callipers.
Micrometer: - Principle, Least count,
Construction, types of Micrometers.
Vernier Calliper :- Material, Size, Principle,
Construction.
Reading of Micrometers and Callipers.
Introduction, Material, advantages of
Gauges.
Classification and types of Gauges.
Types of gauges and their uses.
Duration
(Hours)
01
01
01
115

Workshop
02
03
Diesel
Technicians
Fitter.
Description
Limit, Fits, And Tolerance.

Main Activities Of Wheel Shop.
Checking Of Wheel Seat Diameter.
Duration
01 Day
Period
01
(3rd Day)
Contents
(a) Interchangeability & its advantages.
(b) Limits :- Definition, & advantages, High and
Lower limit.
(c) Fits :- Types of Fits, Different systems of
Limit & Fit, Tolerance and system of
tolerance.
(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.
(a)
Cleaning and removing the Burrs.
(b)
Visual checking.
(c)
Check the dia on three places on wheel
seat length horizontally and vertically.
Duration
(Hours)
01
01
01
116

Workshop
Fitter.
Description
Press In Axle Coller.

Press In Disc.
Press In Bull Gar.
Duration
01 Day
(a)
01
(b)
(c)
(d)
(a)
(b)
(c)
03
Diesel
Technicians
Period
02
(a)
(b)
(c)
(4th Day)
Contents
Removing the Burrs & cleaning of coller &
bore of coller.
Apply the mixture of White lead and linsed
oil.
Align the Axle with the coller on the
Hydraulic press.
Press the coller to maintain gap of 1-4 mm
between gear and coller.
Setting the disc on the press.
Apply the mixture & align the bore of the Disc
and Axle.
Press in on side Disc to maintain gap
between coller and Hub.
Remove the Burrs & clean gear seat.
Apply the Mixture.
Align the Axle with gear on the Hydraulic
press and pressing Bull gear.
Duration
(Hours)
01
01
01
117

Workshop
02
03
Diesel
Technicians
Fitter.
Description
Shrinking Of Inner Race.

Checking Of Bearing Seat Dia.
Visual Inspection Of Wheel Centre.
Duration
01 Day
Period
01
(a)
(b)
(c)
(a)
(b)
(c)
(a)
(b)
(c)
(05th Day)
Contents
Cleaning of Inner Race & Axle Journal.
Heating of Inner race by Induction heating.
Fitting of Inner race on the Axle.
Cleaning of Bearing seat.
Visual checking of Bearing seat.
Checking of Taper & Ovality of Bearing on
wheel seat..
Cleaning of wheel Centre and Rivet hole.
Visual Inspection of Wheel centre for
Crack/Damages on the Rim, Spoke & Hub.
Attend the damage if any.
Duration
(Hours)
01
01
01
118

Workshop
Technicians
Fitter.
Description
Press In Wheel Centre.

Visual Inspection Of Bearing.
Checking Of Axle Bearing Seat Dia.
Duration
01 Day (06th Day)
Period
(a)
01
(b)
02
(c)
(a)
(b)
(c)
(a)
03
(b)
(c)
Diesel
Contents
Remove Burrs on the bore and set the wheel
coller vertically on the press.
Apply the mixture and align the keyways of
wheel centre.
Press in both the wheel centres.
Cleaning of Bearing with Kerosene.
Checking of distance piece.
Checking the Bearing for damage.
Cleaning of Bearing and removing the Burrs
on the axle.
Visual Inspection of Bearing.
Checking of Ovality of Bearing seat.
Duration
(Hours)
01
01
01
119

Workshop
Technicians
Fitter.
Description
Disc Press In.

Visual Inspection Of Armature.
Armature Shaft Press Out.
Duration
01 Day
Period
01
02
03
: Diesel
(07th Day)
Contents
(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.
(a)
(b)
(c)
(a)
(b)
(c)
Cleaning of armature shaft.

Checking of damage, if any.
Attend the damage.
Setting of Armature on the press.
Align the shaft on press.
Safety precautions to be taken.
Duration
(Hours)
01
01
01
120

Workshop
02
03
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
01
Contents
a) Clean the bore of Armature shaft.
b) Visual inspection for any damage.
c) Checking the taper of in the Bore.
a) Armature Bore cleaning.
b) Heating of Armature.
c) Press in the Armature shaft on the Fixture.
a) Placing of Armature.
b) Filing the pinion seat.
c) Fitting of the gauge.
Duration
(Hours)
01
01
01
121

Workshop
Diesel
Technicians
Fitter
Description
Press In Bearing.
Tyre Shrinking.
Bevel Gear Fitment & Bearing Press In.
Duration
01 Day (09th Day)
Period
a)
01
b)
c)
02
a)
b)
c)
a)
03
b)
c)
Contents
Inserting the Enclosure & finger Ring on the
bearing seat.
Align the wheel on the Hydraulic press.
Align the bearing with the Axle, place adopter
and press.
Induction heating of tyre.
Clean the wheel centre by keeping the wheel
in Vertical position.
Placing the Wheel centre in tyre bore.
Removal of Burrs, Aligning of gear holes &
tight nut bolts.
Check the bearing seat dia & insert the bush.
Insert the lubricant with ring on the Axle,
Align the Axle and press the ring.
Duration
(Hours)
01
01
01
122

Workshop
02
03
Diesel
Technicians
Fitter.
Description
Bearing Press In.

Crank Pin Press In..
Handling, Storage And Packing.
Duration
01 Day (10th Day)
Period
01
Contents
a) Clean the Bearing seat and check bearing
seat dia.
b) Insert the inner ring on the Axle.
c) Inserting of other loose rings.
a) Removal of Burrs on Crank Pin.
b) Align the wheel with Crank pin.
c) Safety precautions to be taken while pressing.
a) Apply grease on the shaft.
b) Cares to be taken while shifting the Armature.
c) Cares to be taken while shifting the Armature.
Duration
(Hours)
01
01
01
123

Workshop
02
03
Diesel
Technicians
Fitter.
Description
Frequent Customer Complaints.

Inspection.
Inspection.
Duration
01 Day (11th Day)
Period
01
a)
b)
c)
a)
b)
c)
a)
b)
c)
Contents
Frequent customer complaints.
Common failures and remedies.
Common failures and remedies.
Examine looseness of distance pieces.
Examine looseness of Axle & discs.
Apply colour to all defective parts indicating
attention to be paid.
Function of Inspection department.
Accuracy and precision.
Types of Inspection of manufacture products.
Duration
(Hours)
01
01
01
124

Workshop
02
03
Diesel
Technicians
Fitter.
Description
Assessment Test.
Feed Back From Trainees.
Duration
01 Day (12th Day)
Period
01
a)
b)
c)
a)
b)
c)
a)
b)
c)
Contents
Quality control Activities.
Benefits of Quality Control.
Assessment test.
Assessment test.
Assessment test.
Duration
(Hours)
01
01
01
CHAPTER -5

FOR
WELDERS
IN
WORKSHOPS
Training Modules For Artisans Of Wagon Workshop
S. No.
Trade
Activity Centre
Periodicity
Duration
1
Fitter
Vacuum Brake Section

Air Brake Section
Once in four
year
12 days
Fitter
W.R. Shop
Once in four
year
9 days
Machinist
Wheel shop
Once in four
year
8 days
125
5.1 UNIFIED TRAINING MODULE FOR WELDERS

Trade
Welder
Activity Centre
Welding Shop
Periodicity
Once In Four Years
Duration
12 Days
Sr. No.
Description
Duration
Introduction of course
One day
Industrial safety
One day
Introduction of welding technology
One day
Welding technology
One day
Study of electrode.
One day
Welding and cutting machine.
One day
TIG and MIG/MAG welding machines
One day
Welding defects and testing of weld.
One day
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
126
5.1.1 UNIFIED TRAINING MODULE FOR WELDERS

Technicians
Welder
Description
Duration
1 day- (1st day)
Period
01
Contents
Duration
(Hours)
I.
01
I.
II.
Importance of training
Role of technician in improving the quality work.
01
02
01
03
I.
II.
Need of ISO certification.

Awareness of ISO 9000
127

Technicians
Welder
Description
Industrial safety
Duration
1 day- (2nd day)
Period
Contents
Duration
(Hours)
Industrial safety
01
02
03
I.
II.
Personal safety.
Safety of work place
01
I.
II.
Safety of welding and gas cutting equipment.

Fire safety and fire fighting equipment.
01
I.
First aids
01
128

Technicians
Welder
Description
Duration
Introduction of welding
technology
1 day- (3rd day)
Period
Contents
Duration
(Hours)
Introduction of welding technology
01
Importance of good welding.
01
02
Equipment used in welding and gas cutting.
01
03
Introduction of manifold system and welders role in

saving of industrial gases.
01
129

Technicians
Welder
Description
Welding terminology
Duration
1 day- (4th day)
Period
01.
02.
Contents
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.
Duration
(Hours)
01.
01.
03
I.
Introduction of welding processes;

Such as thermit welding, resistance welding, forge
welding, sub-merge arc welding, plasma cutting.
01.
130

Technicians
Welder
Description
Study of Electrode
Duration
1 day- (5th day)
Period
Contents
Duration
(Hours)
Study of Electrode.
01
02
03
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
131

Technicians
Welder
Description
Welding and cutting machine
Duration
1 day- (6th day)
Period
Contents
Duration
(Hours)
Welding and cutting machine.

01
02
03
I.
II.
III.
Welding transformer and its principle.

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

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

Safety precautions.
01
132

Technicians
Description
Duration
Period
Welder
TIG and MIG/MAG Welding
machines
1 day- (7th day)
Contents
Duration
(Hours)
TIG and MIG/MAG Welding machines.

01
I.
TIG welding machine.
02
I.
MIG/MAG welding machine.
II.
Advantage of MIG/MAG welding.
I.
Parts used in TIG and MIG/MAG welding.
01
01
03
01
133

Technicians
Welder
Description
Duration
Welding Defects and Testing of

weld.
1 day- (8th day)
Period
Contents
Duration
(Hours)
Welding Defects and Testing of weld.

01
I.
II.
Introduction of good welding.

Important factors to obtain good welding
01
02
I.
Welding defects and its remedy.
01
03
.
I.
Destructive and non-destructive test.
01
134

Technicians
Welder
Description
Duration
1 day- (9th day)
Period
Contents
Duration
(Hours)

I.
01
II.
I.
02
II.
III.
I.
03
II.
III.
IV.
Welding of casnub bogie items (Side frame friction

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

pamphlet G-95.
Welding of pull rod, push rod of BOXN wagon.
Welding of brake beam of Casnub bogie as per
RDSO letter no. MW/PLNG/CSMB dated 28-10-99
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.
Welding of corten steel of BOXN wagon as per
RDSO maintenance manual. G-70.
Trunion, Trunion nuts, shackle pins and shackles
of screw coupling.
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
135

Technicians
Welder
Description
Duration
Welding of locomotive
components.
1 day- (10th day)
Period
Contents
Duration
(Hours)
Welding of locomotive components.

01
I.
Welding of flange coupling on L.O. cooler of

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

traction motor magnet frame of WDM2 LOCO.
01
03
01
136

Technicians
Welder
Description
Welding of coaching stock items
Duration
1 day- (11th day)
Period
Contents
Duration
(Hours)
Welding of coaching stock items.

01
Welding of deferent type of bogie.
01
02
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
01
03
Welding of Aluminium water tank of BG coaches by

MMAW.
01
137

Technicians
Welder
Description
Feed back & group discussion
Duration
1 day- (12th day)
Period
Contents
Duration
(Hours)
Feed back from Technicians (Welders) and group

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

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(Govt.

New Delhi, dated 04.02.2002

The Executive Director

Training Module for Fitters of

Training Module for Machinist

Training Module for Fitters

Training Module for Fitters

Training Module for Machinists

Training Module for Blacksmiths

Training Module for Machinists

Training Module for Diesel Mechanics

Training Module for Diesel Mechanics

Training Module for Fitters

COMPETENCY BASED TRAINING

Following areas of locomotive, coach and wagon workshops have been

2. Bogie, Air Brake, Cab

(For Diesel Mechanic)

3. Chassis, Radiator, Right Angle Gear Box

4. Wheel Shop (Fitter)

Competency Based Training For Workshops

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

The training programme has high emphasis on competency development

Competency Based Training For Workshops

Man power requirement

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

Sufficient number of instructors should be provided so as to have

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

Competency Based Training For Workshops

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

Competency Based Training For Workshops

LIST OF CLASS ROOM EQUIPMENTS

Name & brief specification

Over head projector.

One per class room

Magnetic chalk board/clip board

One per class room

Television with VCD

LCD data video projection system.

One per class room

Computer / Multimedia with all peripherals One per class room

35 mm automatic slide projector with linear One

OHP screen 1.5 m x 1.5 m

One per class room

One table + One chair

Reso graph Machine

Competency Based Training For Workshops

LIST OF PLANT AND MACHINERY

Competency Based Training For Workshops

LIST OF MODELS IN COACH WORKSHOP

Competency Based Training For Workshops

LIST OF MODELS IN WAGON WORKSHOP

Competency Based Training For Workshops

LIST OF MODELS IN DIESEL WORKSHOP

Competency Based Training For Workshops

COMPETENCY BASED TRAINING

2.1 TRAINING MODULE FOR FITTER OF

Competency Based Training For Workshops

2.1.1 TRAINING MODULE FOR FITTER OF

Introduction Of Course, Attitudinal Changes &

01 Day ( 1st Day)

Need of ISO certificate

Personal safety and safety environment.

Competency Based Training For Workshops