HEAVY MACHINE SHOP (08)

The products manufactured at heavy machine shop are Hitachi suspension tube (conventional
loco spare), Loco Roof (Three phase), Traction bar, Traction motor stator welding and
machining, assembly of wheel set with traction motor, head stock, central under frame items.
The HMS has 8 sections according to their respective works.

We will discuss all the products we have seen in HMS from where they are supplied to HMS
and then where they dispatched.

Items Source Operations Destination

Hitachi suspension Steel foundry Machining, drilling, WS-09
Tube boring, tapping,
milling
Loco roof Shop no 17 oxy Machining, Welding ELF-26,ELF-12
cutting section
Traction bar LMS -07 Welding
Stator TM-21 Outside Machining, TM-21
Welding
Wheel set and TM WS-09 and TM-21 Fabrication ELB-18
assembly
Head Stock Shop no-17 oxy Machining, Welding, Shop no-17
cutting section grinding
Central under frame LMS Machining, welding Shop no-17
items
Axle support(Arm LMS, ELB-25 Machining, Welding, ELB -18
support) Grinding
Central transum ELB-25 Machining, Beveling ELB-25
 OPERATIONS FOR HITACHI SUSPENSION TUBE

1. First the chalking will be done on the entire surface of raw suspension tube came from
steel foundry of cast iron. Then marking and punching to be done on them
subsequently according to their dimensions.
2. Then the both end of suspension tube is undergoes milling operation.
3. Then the bottom pad milling is done.
4. Then the side pad milling is done.
5. Then the inside gap between two base of suspension tube is undergoes the milling
operations.
6. Then the joint face (TM joint) raw milling is done.
7. Then the joint face finish milling is done with very high accuracy.
8. Then the relief cutting operation is done.
9. Then the joint face drilling and tapping is done subsequently.
10. Then rough boring is done in finish B hole on the joint face.
11. Then finish boring is done thereafter.
12. Then marking is done for end drilling and tapping.
13. Then overall dressing and cleaning is done.
14. Then the final inspection is done according to standards and dimensions.
15. If there is any deviation work is needed, then it will be done.
16. At last painting is done.
17. Then it will be given to consumer shop (mainly WS-09).

Figure 1: Hitachi Suspension Tube

 HEAD STOCK ASSEMBLY

1. The oxy cutting of steel plate is done in shop no-17.

2. Then it will be given to HMS-08(Sec-0820).
3. Here the raw plates are undergoes outside machining operation.
4. Then the drilling operation is done on plates.
5. Then subsequently the tapping operation is done.
6. Then boring of front plate is done.
7. Then it is given to next section for welding operations
8. In welding section different parts are to be fabricated along to make the final head
stock.
9. Then the final inspection is done according to dimensions.
10. If the head stock is ok then it is painted subsequently.
11. Then it is given to consumer shops (Shop no-17,shop-03, Steel foundry).
Items required for head stock assembly.
Item Thickness(in mm) Quantity per Loco
Front Plate 50 02
Top Plate 20 02
Stiffener 25 02
Coupler pocket LH side 45 02
Coupler pocket RH side 45 02
Draft lug 45 04
WEB 45 04
Coupler Pocket Stiffener 40 02
Coupler pocket Gusset 45 04
Base Plate 45 02
Side Plate LH 20 02
Side Plate RH 20 02
Buffer Support 45 04
Figure 2: Headstock Complete Assembly
 STATOR WORKS AT HMS

The Stator is received from TM-21 shop then in HMS-08 it is given to Universal machining
Centre (MAG IAS Gmbh GERMANY) , then it is given to welding section for final welding.

Particulars of Universal machining centre.

1 NAME OF THE MACHINE UNIVERSAL MACHINING CENTRE

2 COST 10 CRORE
3 SUPPLIER’S NAME MAG IAS Gmbh GERMANY
4 M/C RECEIVED 25.06.2013
5 M/C COMMISSIONED 27.06.2013
6 CNC UNIVERSAL COMPLETE MACHINING
MACHINING CENTRE Boring, Milling, Drilling, Tapping and
Chamfering of WAP5, WAG9/WAP7 STATOR
7 M/C POSITIONING
ACCURACY
A. REPEATIBILITY IN 7µ(0.007mm)
X,Y,Z AXIS
B. POSITIONAL 14µ(0.014mm)
UNCERTAINITY PER
METER IN X,Y,Z AXIS
C. ROTARY AXIS FOR 4X ±0.002 degree
90 degree.
8 M/C No. 08/1833/01

HMS WELDING SECTION (STATOR WELDING)

a) Stator received from Shop no – 21.

b) Grinding done on welded zone.
c) NT spatter compound applied adjacent welding zone.
d) Stator component received from store (ACCESSORY BAR SMALL, ACCESSORY
BAR BIG, and CROSS-PIECE AND RIBS).
e) Dimensionally checked as per as drawing and grinding done all over welding zone.
f) Stator loaded on manipulator properly and tightens.
 g) MIG welding done all over, by rotating manipulator.
h) All stator components assembled in stator as per drawing and welding with stator.
i) After cooling stator unloaded & grinding operation done all over the stator.
j) Stator got passed by inspection; if any defect occurs then it will be rectified.
k) Finally checking done and move for next machining operation.
l) As per drawing, after machining stator was moved for same fitment like terminal box
in fitting section.
m) Finally inspection done, and dispatch to TM-21.

WHEEL SET – MOTOR ASSEMBLY AND TESTING

FOR WAG-9 LOCO:

1. Clean Pinion, Gear, Suspension tube, Ring etc. properly fit ‘O’ ring on motor and
complete motor wheel assembly.
2. Check back lash with lead wire (Limit 0.290-0.490mm).
3. Take the motor-wheel assembly on running stand for stage-II trial run without
gear case and trial run for 30 minutes. Get it cleared by Works inspector.
4. Clean properly the both halves of gear case and fit in position. Use locktite
sealant as and when required.
5. Tighten all the sub-assemblies with torque wrench with various torque values as:-

Sl No. Description Torque values

01 Suspension Tube Bolt M 30*140 1260N-m

02 Gear Case Bolt M 12*30, M 12*70, M12*80 80N-m

03 Gear Case Bolt M 16*200 205N-m

04 Support Plate M 30*160 1330 N-m

6. Fill 06 liters of SERVO RR 460 oil in each Gear Case.

7. Place motor assembly on trial run stand; connect the cables and trial run for 60
minutes. Get it cleared by works inspector.
8. Then it is dispatched to the ELB-18 work shop for further works.
 PROCEDURE FOR AXLE SUPPORT
The axle support or arm support is a vital part of bogie. It holds the Traction
motor with the help of central transom and suspension tube. The procedure are
given below
1. First the oxy-cutting of plates in ELB-25 then it is give to the HMS.
2. The cylindrical ring shaped material came from LMS-07.
3. They all passed through machining for acquire the correct dimension.
4. Then entire fabrication of parts is done by welding.
5. Then grinding is done over welding zone.
6. Then it passes through the inspection.
7. Then painting is done on the outer parts.
8. After painting it is dispatched to the ELB -18 and ELB-05 shops.

LOCO ROOF FABRICATION

1. The plates required for roof were cut in the shop-17 by oxy cutting or profile
cutting operation.
2. Then they dispatched to HMS-08.
3. In HMS-08 the first operation is machining of outer surface.
4. Then the Beveling is done over the edges of the plates,
5. Then the Plates joined by using welding.
6. After welding the grinding is done all over the welding zones.
7. Then the complete roof is undergoes the inspection.
8. After inspection it is painted.
9. If pass in the inspection then it is given to the consumer shop(ELF-26, ELF-
12).
 ELECTRIC LOCO FABRICTION SHOP-12
AND
ELECTRIC LOCO FABRICATION SHOP-26
INTRODUCTION:-
Both shops are mainly related with shell fabrication. The major difference between these
two shops is that the shell of WAG9 Loco is fabricated in ELF-26 whereas shell of WAP7
AND WAP5 is fabricated in ELF-12. Both shops receives the under frames from SHOP NO-
17. After that under frames undergoes different stages and cabin (CAB) is welded on the base
plate along with side frames. Following stages are involved in fabrication of shell.

1. LONG BEAM STRUCTURE

2. UNDERFRAME STRUCTURE
3. RWU-I (RIGHT WAY UP)
4. MANIPULATOR
5. UPSIDE DOWN (USD)
6. RIGHT WAY UP- II (RWU-II)
7. CHAMBER- (I) CAB, (II) SIDE WALL, (III) ROOF GIRDER
8. SHELL
9. DISPATCH

LONG BEAM STRUCTURE

1. This is manufactured with the help of thick plates. The thick plates are of 32 mm, 16
mm and 25 mm.
2. The long beam is usually manufactured in SHOP no-17(Long beam Section).
3. The Main long beam structures are central seal and side beams.
4. These are later became part of under frame.
5. The fabrication of long beam generally done by MIG welding process.
6. After the welding the grinding is done all over the welding zones.
7. After the inspection these beams are ready for fabricate the under frame.
 UNDERFRAME STRUCTURE
1. The main parts of under frames are central seal, central under frame, bolster,
headstocks and side beams.
2. In this stage long beams (two in number) were placed on the jig in the under frame
BIB structure.
3. Under frames are manufactured here with help of box type transverse member,
channel plates, Z-plates and L-plates were welded here for the formation of the
transformer opening which is known as the SL-42 opening.
4. This type of opening is provided at the both end structure thus it is made and sends
to the next stage.

RWU-I (RIGHT WAY UP)

In this stage all kind of channels, angles etc. are fitted for mounting tools for electrical
equipments. Name of the components which are fabricated in this stage are given below.

1. SHELL MARKING
2. INFILL PLATE ASSEMBLY
3. SPRING POCKET COVERING PLATE
4. FLOOR VENTILATION
5. DRILLING ON OIL COOLING BASE UNIT
6. DRILLING ON FRONT SHEET (FOR STRIKER CASTING).

MANIPULATOR

The manipulator is a wheel like structure with two parts of semicircle. By the help of
manipulator the under frame is changes it’s stage from RWU to USD (upside down).For this
operation the shaft of manipulator the vital part. Under frame structure comes to manipulator
RWU-1 and all types of welding of under frame are carried out here and completed.
 USD (UPSIDE DOWN)

Following items are fitted in this stage.

1. CENTRAL PIVO
2. COMPRESSOR LEG
3. BATTERY BOX LEG
4. HOLDING ITEMS (PIPE LINE HOLDING ITEMS)
5. DIN RAIL (UNISTUD)
6. LUMING BAR
7. SOCKET
8. DRILLING ON DRAFT GEAR BOX
9. CONDUIT PIPE
10. JUNCTION BOX(06 Nos)
11. CONNECTING BOX
12. SAFETY SHEILING ( COMPRESSOR)
13. PITCH STOPPER(08 Nos)
14. SECUIRITY LOCK (02 Nos)
15. DRILLING AND TAPPING FOR AIR BELLOW ASSEMBLY(DRILL 8mm, TAP
10mm)
16. REFERENCE 38
17. SPRING POCKET PLATE(08 Nos)
18. CENTRAL PIVOT HOUSING ASSEMBLY(ALKATHIN RUBBER RING USED
AS A BUSH)

INSPECTION

In USD stage generally two types of inspection is done.

1. Ultra Sonography Tests (UTS): This test is used for testing of headstock-bolster
plate joints and bolster plate-central seal joints.
2. Dye Penetrate Test (DPT): This test is used to find out the welding defects present
in pivot joint.
 RWU-II (RIGHT WAY UP)

In this stage, we use the jigs, fixture and side walls (as a reference)for following item
fitment:-

1. MAIN RESERVOIR(03 Nos)

2. CUBICLE AUXIALLARY CIRCUIT (HB-1)
3. CUBICLE CONTROL CIRCUIT (SB-1)
4. AUXIALLARY CONVERTER
5. OIL COOLING UNIT
6. FILTER BLOCK
7. BLOWER FLANGE
8. CAPACITOR BRACKET
9. HAND BRAKE POCKET

SHELL

1. After USD stage, under frame brought to RWU-II stage.

2. The CABs and side walls are now outsourced by Indian Railways.
3. The CABs are fitted at both ends.
4. Then the side walls are fitted at both sides of under frame.
5. Then locate and weld the cross girders.
6. After that match the roofs with cross girders and side wall.
7. Then weld the roof mounting brackets and I-bolts.

DISPATCH

At this stage after the fitting of CBC (centre Buffer Coupling) and cattle guard assembly are
done. Then the complete Shell is under goes the inspection and dispatched to the ELS-16 for further
assembly works. The dispatch is done by the help of dummy bogies.