2. RAILWAY WORKSHOP OVRVIEW
• Jagadhri workshop is situated on the outskirt of Yamuna Nagar with an
independent Railway station called Jagadhri workshop
• The foundation stone of this workshop was laid on 08-12-1952 with bare minimum
facilities for undertaking the POH work of 3 units of coaching stock and 9 unit of
goods stock per day.
• In the coming years, the workshop capacity was expanded and developed to reach
the current level target outturn of 1150 units of Wagons and 135 Coaches per
month.
• Kalka Workshop is also under the administrative and technical control of Chief
Works Manager, Jagadhari Workshop, and caters to POH and manufacture of
Narrow Gauge stock and foundry activities.
5. ROLLING STOCK CLASSIFICATION
While numerous types of rolling stocks are in use in the railways, some of the important terms which should
be know even to railway-men not directly associated with the rolling stock are described below:
• Rolling stock
• Locomotive
• Coaches
• Wagons
• Train
• Train Load
• Electrical Multiple Unit
• Diesel multiple Units
• Rail Cars /Buses
6. IMPORTANT COMPONENT OF ROLLING SYSTEM
• Body
• Running Gear
• Bogies
• The bogie frame
• Wheels
• Axle
• Axle-box
• Springs
7. It is the place where machining, finishing and fitting of wheel is done on several machines.
Before fitting, an axle undergoes various stages to obtain a high quality product.
First of all, surface finishing or smoothening of the axle takes place. It is sent to an Axle
turning Lathe (AXL), which is a CNC machine. In it rough axle changes into a smooth axle.
Then the smooth axle is sent to Axle Grinding Lathe (AXL) again a CNC machine. In it
grinding of the wheel sheet takes place according to the diameter of the disc.
Then axle and disc is sent to a ‘hydraulic press’ where of the wheel axle is checked. At a
certain fixed pressure, the axle fits into the disc.
After fixing, wheel axle is sent to the drilling machine where drilling on the axle takes
place.
Then polishing of the wheel axle is done and finally, bearings are fitted.
WHEEL SHOP
9. ZYGLO TEST FOR ROLLER BEARING
• Bearing: It is an additional part attached to the axle along wheel disc to minimize friction.
The whole load of the coach is imparted to the bearing. The load on the axle is reduced. Thus,
its main function is to save the wheel and axle from any damage like stress or strain. It can be
of various types like: roller type, cartridge type, etc.
• Zyglo test : At the places where ultrasonic test does not works like at the surface of
axle, bearing, etc . The zyglo test works. Thus this test is used for the detection of
faults like cracks on surfaces of bearings, axle, etc.
10. PROCEDURE OF ZYGLO TEST
• First of all, bearing is dipped in a tank of ‘fluorescent dye
• Then the bearing is put into a rinse tank so that excess dye can be rinsed off is costly.
• Then, roller is washed under a low-pressure water tap to remove the unwanted dye.
• Roller is placed in a hot chamber for round about 20-25 min. to make it completely dry.
• Now, roller is put in a tank full of developer powder. The function of this powder is to impart
a different color (green) to the cracks.
• Now, roller is placed in a dark room where a violet lamp is moved all round the bearing. If
any crack exists, it can be seen in the form of a zigzag line of green color. Then that bearing
is rejected.
This method is also used for heavy pieces which are difficult to carry, are repaired on the site itself. This
process is called RDP (Red Dye Penetrate) method.
11. ULTRASONIC TEST FOR AXEL
• Ultrasonic rays : Ultrasonic rays are those rays whose frequency range is beyond
hearing range i.e. greater than 20,000 cycles per sec.
• Principle: This test is based on the principle of piezoelectric effect i.e. if a material
is subjected to mechanical vibrations there will be an e.m.f. generated at both
surface or vice -versa. This test is used to detect any fault i.e. cracks, blowholes,
slag inclusion etc, in the axle and wheel; internally i.e. this test is for internal defect
only.
• Procedure: Its procedure is divided into three stages:-
1. Normal scanning test
2. Low angle testing
3. High angle testing
12. BRAKING SYSTEM
• Brake have utmost importance in a moving body. Every moving body has brakes to
control the speed or motion. Various mechanisms are employed for braking system.
Frictional force is utilized in process of application of brakes. Therefore, our
braking system issues maximum development of frictional forces. In the Indian
Railway, there are used two type of braking system in the engines and all type of
coaches.
• The two types of brake systems are –
1. Vacuum brake system
2. Air brake system
13. VACCUM BRAKE
Vacuum brakes have so far being considered standard on Indian Railways, but now it is
gradually replaced by Air Brakes. It is now considered for coaching stocks except in
BG Electrical multiple units and BG/MG diesel Rail Cars.
• PRINCIPLE OF APPLICATION OF VACUUM BRAKES
Engine creates the vacuum, which is transferred to the boogie by hose pipe. Proper
vacuum is maintained throughout the system. If vacuum pressure exceed from the
prescribed limits the brakes are applied. Chain pulling and mechanism used by the
driver are just procedure to input air into the system.
14. AIR BRAKE
• In it, compressed air is used for operating the brake system. The locomotive compressor
charges the feed pipe and the brake pipes throughout the length of the train, the feed pipe
is connected to the auxiliary reservoir and the brake pipe is connected to the brake
cylinder through the distributor valve. Brake application takes place by dropping the
pressure in the brake pipe.
• In the system coaches are provided with twin pipe, brake pipe and feed pipe. The brake
pipe is charged to 5Kg/Sq. cm while the auxiliary reservoir charged the feed pipe at 6
Kg/sq.cm. For apply the brake the pressure of the brake pipe is reduced which in charge
the brake cylinder through the distributor value to a pressure 3 Kg/sq.cm when the
brakes are released then the brake pipe is charged to 5 Kg/sq.cm land the air of brake
cylinder is exhausted to the atmosphere. The release spring in the intake cylinder forces,
the piston to go inside the brake cylinder thereby realizing the
16. CYLINDER PROCEDURE OF REPAIR OF AIR BRAKE
• Open all the parts of brake cylinder piston and clean them with kerosene oil
and if anyone is damage then change it.
• Apply the grease inside the brake cylinder and change all the rubber kits.
• Fit brake cylinder on testing bench.
• Charge brake cylinder at 0.7 KG/ CM*CM pressure and check the leakage
problem by application of mixture of soap.
• Charge the brake cylinder again at 3.8 KG/ CM*CM pressure and check the
leakage .
• Cannot be more than 0.1 KG/ CM*CM in 10 minutes.
• After testing the brake cylinder must be painted properly.
17. MAIN PARTS OF TRAIN TROLLY
• Main frame
• Wheels
• Air brake cylinder
• Axle boxes Brakes (material is farado)
• Bolster suspension
• Bearing pieces for guidance
• Primary suspension springs
• Secondary suspension springs
• Shockers for load resistance
• Pulley and belts
• Alternator and battery box
