In this section all the P.O.H. work is done under the frame Before lifting the coach frame from the bogies the cotter pin is removed from the center pivot.

Main function of this shop is P.O.H. of the following parts & operations done on them.

BUFFER PLUNGER

PIVOT DRAW HAIR PIN

TRAVERSOR

AIR BRAKESAIR BRAKES

AIR BRAKES USE COMPRESSED AIR TO MAKETHEM WORK. YOU CAN APPLY ALL THE BRAKING FORCE YOU NEED TO EACH WHEEL OF A VEHICLE, EVEN TRACTORS PULLING TRAILERS. IF MAINTAINED AND USED PROPERLY THEY WILL SAFELY STOP LARGE VEHICLES.

Bogie is very important part of the coach. It is to carry the motors , brake system and suspension system, all within a tight envelop.

The line diagram of a bogie is given below. The different parts of the bogie are as follows :

SIDE FRAME

BOLESTEN PLATE

SPRING PLANK

WHEELS

BRAKE BEAM

EQUALIZING LEVER`

BRAKE BLOCK

CENTRAL PIVOT

PRIMARY SUSPENSION SPRINGS

SECONDARY SUSPENSION SPRINGS

ASSEMBLY OF ROLLER BEARINGREAR COVER

DISTANCE RING

O RING

In assembly section roller bearing is assembled on the journal by using various processes. Introduction heating is done for expanding inner race of the bearing of so that it can be mounted on the journal of the wheel without any problem. Induction heating includes following features :

1. Temperature is maintained at 120°C.

2. Minimum time for heating between induction coils is 5 to 7 min.

Axle Box

REAR COVERO RING

DISTANCE RING ASSEMBLY OF ROLLER BEARINGAxle Box

Smithing involves heating the metal or waste material in an open hearth furnace and give it the desired shape by forging. Optimal utilization of waste metal can be made through this shop

Various sections of Smithy Shop are :

1. HAMMER SECTION

2. SPRING SECTION

3. HEAT TREATMENT & TENSILE TESTING SECTION

POWER HAMMER

HYDRAULIC PRESS

Heat treatment of different material is done to relieve them from internal stresses developed during various cold working operations.

CLASSIFICATION OF STEEL BY INDIAL RAILWAY.

1. Class – 1 steel Carbon 0.05-0.15%

2. Class – 2 steel Carbon 0.15-0.25%

3. Class – 3 steel Carbon 0.25-0.35%

Only three heat treatment operation are carried out in this section

1. Annealing

2. Normalising

3. Hardening

SPRING SECTION

Two types of coil springs are used for suspension :

Bolester Plate Spring

Axle Box Spring

MACHINE SHOP

LATHE MACHINE

SLOTTER MACHINE

PLANNER MACHINE

CNC WHEEL SURFACE LATHE

CNC VERTICAL TURRET LATHE

CNC BIG BORE LATHE WITH SPINDLE

INTRODUCTIONINTRODUCTION

1876 Central Workshop Established 1896 1ST Steam Loco

Manufactured1979 POH of MG Diesel Loco

Started1997 POH of first BG Wagon 2007 POH of first BG Diesel

Loco

Details Of Existing InfrastructureDetails Of Existing InfrastructureTotal area of Workshop 160000 Sq. MetersCovered Area (Shed) 71363 Sq. MetersNo. of machines 475No. of Employees (On Roll) 1919

INTRODUCTION In this shop periodic overhauling and

also some instant failure repair are carried out for diesel engine.

The time lag between two overhauls may vary from 3-5 years.

In the process of ‘periodic overhauling’, a diesel engine is completely disassembled and then the condemned parts are completely replaced by new parts.

DIESEL ENGINE COMPONENTSDIESEL ENGINE COMPONENTS1. ENGINE BASE:

– C.I. blocks are generally used for their manufacturing.

2. GOVERNOR:The governor helps the engine infollowing ways-

– At the time of low pressure of lubrication oil, it stops the engine.

– It controls the main generator to protect against overload and under load.

– At the time of starting, lubrication oil pressure of low, so it prevents the engine from stopping upto 40 sec.

– It shuts downs the engine when water level is low.

3. RADIATOR:

– It has a no. of long copper tubes arranged in vertical or horizontal direction. Metallic strips are used which surrounds the tubes.

4. CYLINDER HEAD:

– Each head has a suitable space for the two air inlet valves, two exhaust valves and of fuel injector.

5. CONNECTING ROD:

The connecting rod is a high strength alloy steel forging with high strength capacity. It is bronze lined.

6. CAM SHAFT:It is located in the

cylinder blocks. It contains of three section which are bolted together male & female joints. The bearings, which are pressed into the cam shaft, support it. Each section of the cam shaft which extends through the entire length carries integral cams, which actuate the inlet, exhaust and injection valves.

7. WATER PUMP:It is a positive

displacement gear pump. It is provided on the free end of the base and is driven by engine crank shaft extension gear.

8. FUEL INJECTION:Fuel injection pump is of single actingconstant stroke & plunger type. It hasbasically 3 functions:-• To raise the fuel oil pressure to a value

this will efficiently atomize the fuel.• To supply the correct quantity of the

fuel to the fuel injection nozzle according to the speed requirement & power of the engine.

• Accurately time the fuel delivery for efficient & economical operation of the engine.

9. PISTON:• It is the component

which converts the heat & pressure energy of cylinder, into mechanical energy.

• It compresses air to required pressure and temperature.

• It receives the thrust of expanding gases and transmits the force through connecting rod.