The document details the periodic overhauling process and maintenance operations for coach frames, diesel engines, and various mechanical components like braking systems and bogies. It includes descriptions of specific parts, their functions, and the assembly techniques used in the repair process. The workshop's infrastructure, including machine specifications and historical milestones, is also outlined.

5. 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

6. PIVOT DRAW HAIR PIN
TRAVERSOR

8. AIR BRAKES
AIR BRAKES USE COMPRESSED AIR TO MAKE
THEM 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.

13. 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

15. ASSEMBLY OF ROLLER BEARING
REAR COVER
DISTANCE RING
O RING
Axle Box
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.

16. O RING
Axle Box
REAR COVER
ASSEMBLY OF
ROLLER BEARING
DISTANCE RING

18. 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

19. POWER HAMMER

20. HYDRAULIC PRESS

21. 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
2. Class – 2 steel
3. Class – 3 steel
Carbon 0.05-0.15%
Carbon 0.15-0.25%
Carbon 0.25-0.35%
Only three heat treatment operation are carried out in this section
1. Annealing
2. Normalising
3. Hardening

22. SPRING SECTION
Two types of coil springs are used for suspension :
Bolester Plate Spring
Axle Box Spring

23. MACHINE SHOP

24. LATHE MACHINE

25. SLOTTER MACHINE

26. PLANNER MACHINE

28. CNC WHEEL SURFACE LATHE

29. CNC VERTICAL TURRET LATHE

30. CNC BIG BORE LATHE WITH SPINDLE

32. INTRODUCTION
1876
1896
1979
1997
2007
Central Workshop Established
1ST Steam Loco Manufactured
POH of MG Diesel Loco Started
POH of first BG Wagon
POH of first BG Diesel Loco
Details Of Existing Infrastructure
T
otal area of W
orkshop
Covered Area (Shed)
M
eters
No. of machines
160000 Sq. Meters
71363 Sq.
475

34. 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.


35. DIESEL ENGINE
COMPONENTS
1. ENGINE BASE:
–
C.I. blocks are generally
used for their manufacturing.
1. GOVERNOR:
The governor helps the engine in
following 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.

36. 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.

37. 6.
7.
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.
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.

38. 8.
FUEL INJECTION:
Fuel injection pump is of single acting
constant stroke & plunger type. It has
basically 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.
•
•