1

CERTIFICATE



Certified that Mr. Dharmendra Mandal a student of B-TECH(Mechanical
Engineering) Roll No- 1153490 from Surya college of Engineering &
Technology,SSET,Punjab was placed under the supervision of undersigned for his
Industrial Training at our organization started from June 30,2013 and end on
August 14,2012. He was engaged in learning the various machines mechanism &
manufacturing of various equipment. Mr. Dharmendra Mandal is hardworking
person and punctual in attendance. His behavior and nature was liked by all the
staffs of our organization. To the best of my knowledge, Mr.Dharmendra Mandal
bears a good moral character. I wish him a better future.












Place:
Date: Training incharge:






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CONTENT



Safety 03
Acknowledgement 04
Introduction 05
BTC 06
BTC Staff 07
JMP History 08
Achievements 09
Diesel Shop 11
Machine Shop 17
Crane Shop 26











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1.SAFETY
GENERAL WORKSHOP RULES


Safety is most important in our life. Safety prevent accidents during any type of
work, which are done in our general life any industry or workshop.

1.WE SHOULD ALWAYS WEAR PROPER DRESS AND SHOES IN THE WORKSHOP

2. SAFETY GLASSES AND HAND GLOVES MUST BE WORN.

3. SAFETY FOOTWEAR MUST BE WORN WHENWORKING IN THE WORKSHOP.

4. ASK WORKSHOP SUPERVISOR BEFORE USING EQUIPMENT. YOU MUST HAVE
BEEN INDUCTED AND DEEMED COMPETENT!

5. VISITORS MUST REMAIN WITHIN MARKEDWALKWAYS.

6. LONG HAIR MUST BE TIED BACK.

7. CLEAN MACHINES AFTER USE.

8. TAKE CARE WHEN USING COMPRESSED AIR.

9.HEARING PROTECTION SHOULD BE WORN WHENUSING MACHINERY.







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2.ACKNOWLDGEMENT



The following description of the vocational training project work conducted by us
provides useful information of the following workshop. These are


1. Crane Shop
2. Machine Shop
3. Diesel Shop
4. BLC Shop

I am extremely indebted to all instructed teachers, of Basic Training Centre.
They provide us crucial pieces of advice, thus in a way helped our vocational
training in complete way.


I would like to thanks to all members of BTC, JAMALPUR for there co-
operate and help along with the moale boost and encouragement, which they
gave us throughout this vocational training.










Yours faithfull student



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3.INTRODUCTION


Jamalpur Locomotive Workshop was established on
the 8th day of February, 1862. Jamalpur Workshop
was the first full-fledged railway workshop facilities in
India, set up by the East Indian Railway.
The Railway age in Eastern India started on August 15,
1854, exactly ninety-three years before Independence.
A locomotive, carriage and wagon workshop was set
up in Howrah to put to commission imported rolling
stock of EIR and also to render economic repairs to
them but it proved unsuccessful because of problems
with procuring supplies and getting skilled labor. The
railways spread very fast, perhaps faster than the
anticipation of EIR. Within a short span of eight years
it became necessary to shift the site of workshop, as
there was hardly any scope for expansion at Howrah. And then Jamalpur
Workshop was established at Jamalpur.

Vital Statistics
Vital Statics of Jamalpur workshop
Area 574,654 sq. meters
Staff 11,485
No. of Machinery and Plants 1628
Power consumed 7 MVA
Water supply 7.3 million liters/day
Annual Turnover Rs. 1.56 billion



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4.BTC

B.T.C is an abbreviation of basic training
centre, it was opened on 26th Nov 1955 by
G.M of Eastern Railway.Special class training
are also available here.

1. S.C.R.A
2. Intermediate app.
3. Apprentice machining
4. Trains skilled Vishawakarma jee By BTC
5. Diploma engg Staff
6. Shed Staff
7. Shed trainees
8. Graduate engg. Trained.
B.T.C gives basic knowledge about all section and shops. It gives primary ideas
about any device, how to use and how should be work.
B.T.C is really a source where I acquired kind of knowledge about concerning of
work regarding safe of work, plant as human life. The center teaches first how to
work with safe.
Initially a man learns how to keep capability as dare to face a problem of work in
different shops.







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5.NAMES OF B.T.C STAFF

P/PTS- Sri Dushyant kumar
Training incharge- Sri S.K Sharma
Senior inst- Sri B.B Singh
JE/BTC- Sri B.D Yadav
Junior inst- Name Trade
Sri. B.N Singh Machine
Sri. R.B Pd. Electrical
Sri. Yogendra Pd. Fitting
Sri. Mukesh Kr. Carriage & Wagon
Sri. S.P Chourasia Welding
Sri. N.K Singh Welding
Sri. Avinash Kr. Welding
Clerk Gr I - Sri. B.N Chourasia
Clerk Gr II - Sri. Anil Kr.
Peon Jamadar - Sri. Kharagdari
Peon - Smt. Madhu Mamta




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6.History of Jamalpur
The Express is a 2-2-2 locomotive which was
preserved at the Jamapur workshop now used as
heritage special steam locomotive operated
between Egmore and Guindy railway stations as
part of Independence Day celebrations by
Southern Railway in Chennai on August 15,
2011. Her sister, The Fairy Queen is in regular
operation today, plying between New Delhi to
Alwar in India.
Fery Queen Steam loco.
Jamalpur Workshop has enjoyed the distinction of being the largest and the oldest
locomotive repair workshop with the most diversified manufacturing activities on
the Indian Railways. At first the Jamalpur shops were merely repairing
locomotives and also assembling locomotives from parts salvaged from other or
damaged locomotives. By the turn of the century they had progressed to producing
their own locomotives. In year 1899, CA 764 Lady Curzon was produced by the
Jamalpur Workshop. In 1893, the first railway foundry in India was set up at
Jamalpur Workshop. It also had a boiler workshop for repairing and building
boilers. A captive power plant of 5MVA was also developed in the Jamalpur
Workshop. In 1870 it was equipped with a rolling mill of its own; unfortunately
its not working at present. In addition to various repairs of wagons, coaches,
cranes and tower cars, and locomotives, Jamalpur also undertakes repair and
production of permanent-way fixtures. It also manufactures some tower cars such
as Mark II, Mark III and break-down cranes of 10, 20, and 140 tone capacities,
besides various kinds of heavy-duty lifting jacks.
Finally, it also manufactures wheel sets for coaches and wagons. Jamalpur
workshop was a significant supplier of cast-iron sleepers as well. Starting in 1961
it produced several rail cranes. It has also produced electric arc furnaces, ticket
printers. The high-capacity synchronized lifting jacks known as J amalpur J acks
were also produced by this workshop.
The school attached to the Jamalpur workshops eventually became the IR Institute
of Mechanical and Electrical Engineering.


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IRIMEE
About IRIMEE
Indian Railways Institute of Mechanical &
Electrical Engineering (IRIMEE) is
located at Jamalpur in the Munger
district of Bihar, on the Patna-Bhagalpur
rail route, about 8 kilometres from
Munger town. During the era of
Mahabharata, Munger was the capital of
Anga Pradesh ruled by Karna. Munger
was also the seat of Mir Kasim, Nawab
of Bengal, who fought the East Indian
Company here. The place had traditional skills of making firearms, and hence
selected by the East Indian Railway for one of its earliest workshops. The location
selected was at the foothills of Rajmahal range (a part of Chhota Nagpur plateau),
which was high enough to survive any threat of floods from Ganga, and the hills
secured it against any organised attack from an army. The location had a tomb of
Baba Jamal Saheb, after whom the place was called Jamalpur. Jamalpur Workshop
was established on 8th of February 1862.

The Indian Railways Institute of Mechanical & Electrical Engineering, Jamalpur is
the Centralised Training Institute of Indian Railways, for the training of officers
and supervisors of the Mechanical Engineering department.

IRIMEE had humble beginnings, when it started in 1905 as a technical school
attached to the Jamalpur Workshop. It came into national prominence when it
started the training of Special Class Railway Apprentices as Mechanical and
Electrical engineers, starting from the year 1927. In 1974, the school was made a
Centralised Training Institute (CTI), renamed as Indian Railways Institute of
Mechanical & Electrical Engineering, and brought under direct control of Railway
Board. It is, therefore, the oldest of the CTIs.

In 1988, the training of IRSME probationers was centralised under the control of
Director, IRIMEE but with HQ at Kharagpur, where there was an Officer on
Special Duty (OSD) co-ordinating the training with the Director. From 1997, HQ
of IRSME Probationers was shifted to Jamalpur.



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7.Achievements
Jamalpur workshop is the only workshop in Indian Railways that has a
captive Power house of 5 MVA
The workshop has a number of FIRSTS in India to its credit
[8]
., a few of
which are:
The First to manufacture a steam locomotive and a locomotive boiler
216 of which were manufactured between 1899 and 1923.
The First to have set up a rolling mill not only on the railways, but
probably in the country in 1870. It had 3 mills, steam driven Power
hammer, fish plate machine, billet shears, the mill was driven by
steam from boilers placed on the top of the furnaces and heated by gas
from the furnaces. It produced about 400 tons of rounds, channels,
angles and fishplates per month.
The First to establish a railway foundry in the year 1893.
The First to manufacture a rail crane in the country with indigenous
know-how in 1961.
The First to manufacture high capacity electrical lifting jacks and
ticket printing, ticket chopping, ticket slitting and ticket counting
machines.
The First and the only railway workshop to manufacture electrical arc
furnaces of tonne capacity in 1961 for production of steel castings.
The First to established Signal Equipment shop, more popularly
known as Points and Crossing and Interlocking shop was started in
1894. produced entire requirement of Interlocking frames of different
sizes for EIR
The First and only to manufacture 140 Tonne Diesel Break-down
Cranes.



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8.DIESEL POH SHOP
Periodical overhauling (POH) and repair of diesel locomotives
Periodical overhauling (POH) and repair of diesel locomotives at jamalpur
workshop started in 1982 the workshop caters full demand of Eastern Railway. The
Workshop also deals with Special repairs to accident involved locomotives and
locomotives owned by various Public Sector Undertakings like NTPC, CPT, SAIL
in the eastern region. So far 84 such Locomotives from PSUs have been repaired
and generated a cash inflow of Rs. 26 crores.

Railway diesel locomotive works on the diesel cycle. Diesel cycle consist of two
reversible adiabatic or isentropic, a constant pressure and a constant volume
process. It completes the cycle in four stages:
1. Suction stroke.
2. Compression stroke.
3. Expansion stroke.
4. Exhaust stroke.

GENERAL LOCOMOTIVE DATA
A. Design data : model no WDM2
B. Max speed :120
C. Gear ratio : 65/18
D. Max radius : 73.2 mm of curvature
E. Wheel base : Total locomotive
F. Eatch truck : 3810 mm
G. Fuel capacity : 5000 litre
H. Cooling water : 1210
I. Water expansion : 155




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ENGINE DATA
12 CYLINDER 16 CYLINDER
Bore & Stroke 9 to 10.5 inch 8 to 10.5 inch
Displacement 8016 cubic inch 10688 cubic inch
Compression ratio
Concave crown style 12.5 to 1 12.5 to 1
Hat crown style 11.5 to 1 11.5 to 1
Valve no per cylinder
Intake 2 2
Exhaust 2 2
Crank pin dia 6 6
Main bearing journal 8-1/2 8-1/2
No of main bearing 7 7
Following are the process ehich are completed in D.L.S for P.O.H work
1. Power pack & expressor removed dew heling be removed stripping of
boggie to start radiator.
2. Balance stripping to complete power pack expressor stripping to begin.
3. Washing to start wheel to work shop TM & TG to be send.
DIESEL LOCOMOIVE
Prime movers
Transmission system
Control system
Breaking system
Super structure


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POWER PACK SECTION



It gives power to engine, it is the heart of diesel engine.
Techinical data for power pack WDM2 locomotive.
A. CRANK SHAFT
1. Main journal dia- 8.498 to 8.500 inch
2. Crank pin dia 5.998 to 6.000 inch
3. Split gear coupling bolt tourqing valve.

B. MAIN BEARING
1. Crankmain bearing bolt elongation


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MAIN PARTS OF POWER PACK











Piston With Connecting Rod
In a reciprocating piston engine, the connecting rod or conrod connects the piston
to the crank or crankshaft. Together with the crank, they form a simple mechanism
that converts linear motion into rotating motion.
Connecting rods may also convert rotating motion into linear motion. Historically,
before the development of engines, they were first used in this way.
As a connecting rod is rigid, it may transmit either a push or a pull and so the rod
may rotate the crank through both halves of a revolution, i.e. piston pushing and
piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two-
stroke engines, the connecting rod is only required to push.
Today, connecting rods are best known through their use in internal combustion
piston engines, such as car engines. These are of a distinctly different design from
earlier forms of connecting rods, used in steam engines and steam locomotives.


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Crank Shaft


The crankshaft, sometimes casually abbreviated to crank, is the part of an engine
that translates reciprocating linear piston motion into rotation. To convert the
reciprocating motion into rotation, the crankshaft has "crank throws" or
"crankpins", additional bearing surfaces whose axis is offset from that of the crank,
to which the "big ends" of the connecting rods from each cylinder attach.
It typically connects to a flywheel, to reduce the pulsation characteristic of the
four-stroke cycle, and sometimes a torsional or vibrational damper at the opposite
end, to reduce the torsional vibrations often caused along the length of the
crankshaft by the cylinders farthest from the output end acting on the torsional
elasticity of the metal.




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Wheels of Rail Engine










Till early 1980s Indian Railways was importing about 55% of requirement of
wheels and axles. Indigenous capacity was available only at Tata Iron & Steel
Company [TISCO] and Durgapur Steel Plant [DSP]. The TISCO plant was
technically not capable of meeting the changing requirement of wheels and axles
for the new designs of rolling stock and production was discontinued. DSP was
only able to partially meet Indian Railways needs. The cost of imports was high
with prices rising in the world market. Financing of imports, delays in supplies and
limited availability of foreign exchange adversely affected wagon production and
rolling stock maintenance. It was in this context that in the early 1970s the Railway
Ministry felt the necessity for setting up a new specialized Production Unit for
manufacture of rolling stock wheels and axles as import substitute. The ultimate
objective was that DSP and the Rail Wheel Factory [RWF, formerly Wheel & Axle
Plant] should be able to totally meet Indian Railways requirement for standard
wheels and axles so that their import could be stopped.


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9.MACHINE SHOP






Conventional machining is a form of subtractive manufacturing, in which a
collection of material-working processes utilizing power-driven machine tools,
such as saws, lathes, milling machines, and drill presses, are used with a sharp
cutting tool to physically remove material to achieve a desired geometry.[1]
Machining is a part of the manufacture of many metal products, but it can also be
used on materials such as wood, plastic, ceramic, and composites.[2] A person who
specializes in machining is called a machinist. A room, building, or company
where machining is done is called a machine shop. Machining can be a business, a
hobby, or both.[3] Much of modern day machining is carried out by computer
numerical control (CNC). Computers are used to control the movement and
operation of mills, lathes, and variety of other cutting machines.



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Lathe Machine (Mother of machines)
A lathe is a machine tool which rotates the workpiece on its axis to perform
various operations such as cutting, sanding, knurling, drilling, or deformation with
tools that are applied to the workpiece to create an object which has symmetry
about an axis of rotation
Lathes are used in woodturning, metalworking, metal spinning, and glass-working.
Lathes can be used to shape pottery, the best-known design being the potter's
wheel. Most suitably equipped metalworking lathes can also be used to produce
most solids of revolution, plane surfaces and screw threads or helices. Ornamental
lathes can produce three-dimensional solids of incredible complexity. The material
can be held in place by either one or two centers, at least one of which can be
moved horizontally to accommodate varying material lengths.




.







19


A milling machine is a machine tool used to machine solid materials. Milling
machines are often classed in two basic forms, horizontal and vertical, which refers
to the orientation of the main spindle. Both types range in size from small, bench-
mounted devices to room-sized machines. Unlike a drill press, which holds the
workpiece stationary as the drill moves axially to penetrate the material, milling
machines also move the workpiece radially against the rotating milling cutter,
which cuts on its sides as well as its tip. Workpiece and cutter movement are
precisely controlled to less than 0.001 in (0.025 mm), usually by means of
precision ground slides and leadscrews or analogous technology. Milling machines
may be manually operated, mechanically automated, or digitally automated




Shaper machine
A shaper is a type of machine tool that uses linear
relative motion between the workpiece and a single-point cutting tool to machine a


20

linear toolpath. Its cut is analogous to that of a lathe, except that it is (archetypally)
linear instead of helical. (Adding axes of motion can yield helical toolpaths, as also
done in helical planing.) A shaper is analogous to a planer, but smaller, and with
the cutter riding a ram that moves above a stationary workpiece, rather than the
entire workpiece moving beneath the cutter. The ram is moved back and forth
typically by a crank inside the column; hydraulically actuated shapers also exist.



Slotter Machine


Types
Shapers are mainly classified as higher, draw-cut, horizontal, universal, vertical,
geared, crank, hydraulic, contour and traveling head.[1] The horizontal
arrangement is the most common. Vertical shapers are generally fitted with a
rotary table to enable curved surfaces to be machined (same idea as in helical
planing). The vertical shaper is essentially the same thing as a slotter (slotting


21

machine), although technically a distinction can be made if one defines a true
vertical shaper as a machine whose slide can be moved from the vertical. A slotter
is fixed in the vertical plane.
Small shapers have been successfully made to operate by hand power. As size
increases, the mass of the machine and its power requirements increase, and it
becomes necessary to use a motor or other supply of mechanical power. This
motor drives a mechanical arrangement (using a pinion gear, bull gear, and crank,
or a chain over sprockets) or a hydraulic motor that supplies the necessary
movement via hydraulic cylinders.
Operation


Shaper linkage. Note the drive arm revolves less for the return stroke than for the
cutting stroke, resulting in a quicker return stroke and more powerful cutting
stroke.
A shaper operates by moving a hardened cutting tool backwards and forwards
across the workpiece. On the return stroke of the ram the tool is lifted clear of the
workpiece, reducing the cutting action to one direction only.
The workpiece mounts on a rigid, box-shaped table in front of the machine. The
height of the table can be adjusted to suit this workpiece, and the table can traverse
sideways underneath the reciprocating tool, which is mounted on the ram. Table
motion may be controlled manually, but is usually advanced by an automatic feed
mechanism acting on the feedscrew. The ram slides back and forth above the work.
At the front end of the ram is a vertical tool slide that may be adjusted to either
side of the vertical plane along the stroke axis. This tool-slide holds the clapper


22

box and toolpost, from which the tool can be positioned to cut a straight, flat
surface on the top of the workpiece. The tool-slide permits feeding the tool
downwards to deepen a cut. This adjustability, coupled with the use of specialized
cutters and toolholders, enable the operator to cut internal and external gear tooth
profiles, splines, dovetails, and keyways.
The ram is adjustable for stroke and, due to the geometry of the linkage, it moves
faster on the return (non-cutting) stroke than on the forward, cutting stroke. This
action is via a slotted link or Whitworth link.


CNC Machine
Numerical control (NC) refers to the automation of machine tools that are operated
by abstractly programmed commands encoded on a storage medium, as opposed to
controlled manually via handwheels or levers, or mechanically automated via cams
alone. The first NC machines were built in the 1940s and 1950s, based on existing
tools that were modified with motors that moved the controls to follow points fed
into the system on punched tape. These early servomechanisms were rapidly
augmented with analog and digital computers, creating the modern computer
numerical control (CNC) machine tools that have revolutionized the machining
processes.
In modern CNC systems, end-to-end component design is highly automated using
computer-aided design (CAD) and computer-aided manufacturing (CAM)
programs. The programs produce a computer file that is interpreted to extract the
commands needed to operate a particular machine via a postprocessor, and then
loaded into the CNC machines for production. Since any particular component
might require the use of a number of different tools-drills, saws, etc., modern
machines often combine multiple tools into a single "cell". In other cases, a
number of different machines are used with an external controller and human or
robotic operators that move the component from machine to machine. In either
case, the complex series of steps needed to produce any part is highly automated
and produces a part that closely matches the original CAD design.


23







Power Hack Saw
A hacksaw is a fine-tooth saw with a blade held under tension in a frame, used for
cutting materials such as metal or plastics. Hand-held hacksaws consist of a metal
arch with a handle, usually a pistol grip, with pins for attaching a narrow


24

disposable blade. A screw or other mechanism is used to put the thin blade under
tension. The blade can be mounted with the teeth facing toward or away from the
handle, resulting in cutting action on either the push or pull stroke. On the push
stroke, the arch will flex slightly, decreasing the tension on the blade.


Blades
Blades are available in standardized lengths, usually 10 or 12 inches for a standard
hand hacksaw. "Junior" hacksaws are half this size. Powered hacksaws may use
large blades in a range of sizes, or small machines may use the same hand blades.
The pitch of the teeth can be anywhere from fourteen to thirty-two teeth per inch
(tpi) for a hand blade, with as few as three tpi for a large power hacksaw blade.
The blade chosen is based on the thickness of the material being cut, with a
minimum of three teeth in the material. As hacksaw teeth are so small, they are set
in a "wave" set. As for other saws they are set from side to side to provide a kerf or


25

clearance when sawing, but the set of a hacksaw changes gradually from tooth to
tooth in a smooth curve, rather than alternate teeth set left and right.
Hacksaw blades are normally quite brittle, so care needs to be taken to prevent
brittle fracture of the blade. Early blades were of carbon steel, now termed 'low
alloy' blades, and were relatively soft and flexible. They avoided breakage, but also
wore out rapidly. Except where cost is a particular concern, this type is now
obsolete. 'Low alloy' blades are still the only type available for the Junior hacksaw,
which limits the usefulness of this otherwise popular saw.
For several decades now, hacksaw blades have used high speed steel for their teeth,
giving greatly improved cutting and tooth life. These blades were first available in
the 'All-hard' form which cut accurately but were extremely brittle. This limited
their practical use to benchwork on a workpiece that was firmly clamped in a vice.
A softer form of high speed steel blade was also available, which wore well and
resisted breakage, but was less stiff and so less accurate for precise sawing. Since
the 1980s, bi-metal blades have been used to give the advantages of both forms,
without risk of breakage. A strip of high speed steel along the tooth edge is
electron beam welded to a softer spine. As the price of these has dropped to be
comparable with the older blades, their use is now almost universal.






10.CRANE SHOP
Current Activities


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With the gradual eclipse of steam traction on Indian Railways, steam locomotive
activities, which had peaked to 600 standard units per month in 1962-63, started
declining in the late 60s and finally the steam activities came to a complete end in
August 1992. The shop kept pace with both, the technology change and technology
up gradation on Indian Railways and diversified its activities to the Overhauling
and Repair of Diesel Locomotives, Overhauling and Repair of various types of
Wagons, Manufacture and Overhauling of Diesel Hydraulic Break Down Cranes
up to 140 tonne capacity and Manufacture and Repair of various types of Tower
Cars.
Apart from the above activity Jamalpur shops are also engaged following
activities:

140t Crane With Wire rope




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Rebuilding and repair of BOX wagons
Due to generation of a large no of unloadable BOX wagons in Eastern Railway and
thus limiting the usage of these wagons it was felt necessary to introduce special
type of repair to BOX wagons in between POH to make them earn revenue. These
scheme yielded results and Jamalpur shops gradually increased their production
from 2445 FWUs in 95-96 to 3602 FWUs in 99-2000.








Manufacturing of 20 T crane
20 tonne Diesel Crane is a Rail Mounted, Diesel operated, BG (Broad Gauge)
transportation crane. The crane is extensively used by Mechanical Department of
Indian Railway in sick lines for maintenance of wagons/coaches and
Transportation Department Indian Railway for handling of Goods.


28

First four 20T Diesel Crane was manufactured in 1980-81with mechanical control
system.
Later the control system was changed to Pneumatic as per RDSO Specification No.
CR.D.122/90. Since 89-90 the shop has been manufacturing the 20 Tonne cranes
as per this specification and has manufactured many such crane.
GLOSSARY OF TERMS

Auxiliary Hoist

A supplemental hoisting unit, usually of lower load rating and higher speed than
the main hoist.

Axis of Rotation

The vertical axis around which the crane's superstructure rotates.

Boom

In cranes and derricks usage, an inclined spar, strut, or other long member
supporting the hoisting tackle. Also defined as a structural member attached to the
revolving superstructure used for guiding and acting as a support for the load.


29



Boom Angle Indicator

An accessory device that measures the angle of the boom base section centerline to
horizontal.

Boom Stops

A devise used to limit the angle of the boom at its highest position.

Brake

A device used for retarding or stopping motion by friction or power means.

Block

Sheaves or grooved pulleys in a frame provided with hook, eye, and strap.

Crane

A machine consisting of a rotating superstructure for lifting and lowering a load
and moving it horizontally on either rubber tires or crawler treads.


30


Counterweight

Weights used for balancing loads and the weight of the crane in providing stability
for lifting.

Deck

The revolving superstructure or turntable bed.

Drum

The spool or cylindrical member around which cables are wound for raising and
lowering loads.

Gantry

A structural frame work (also known as an A Frame) mounted on the revolving
superstructure of the crane to which the boom supporting cables are reeved.

Headache Ball

A heavy weight attached above the hook on a single line or whip line to provide
sufficient weight to lower the hook when unloaded.


Holding Brake

A brake that automatically sets to prevent motion when power is off.

Jib

An extension attached to the. boom point to provide added boom length for lifting
specified loads.

Load

The weight of the object being lifted or lowered, including load block, ropes,
slings, shackles, and any other ancillary attachment.

Load Block



31

The assembly of the hook or shackles, swivel, sheaves, pins, and frame suspended
from the boom point.

Main Hoist

Hoist system or boom used. for raising and lowering loads up to maximum rated
capacity.

Mechanical Load
Brake

An automatic type of friction brake used for controlling loads in the lowering
direction. This device requires torque from the motor to lower a load but does not
impose additional loads on the motor when lifting a load.

Outriggers

Support members attached to the crane's carrier frame which are used to the crane
and may be blocked up to increase stability.

Pawl

Also known as "dog". It is a gear locking device for positively holding the gears
against movement.

Pendants

Stationary cables used to support the boom.

Radius

The horizontal distance from the axis of rotation of the crane's superstructure to the
center of the suspended load.

Reeving

The path that a rope takes in adapting itself to all sheaves and drums of a piece of
equipment.

Running Sheave



32

Sheaves that rotate as the hook is raised or lowered

Superstructure

The rotating frame, gantry and boom or other operating equipment.

Test Load

Any load or force, expressed in pounds, used for testing or certifying the
limitations within acceptable tolerances of the anticipated load.

Two-Block

The condition in which the lower load lock or hook assembly comes in contact
with the upper load block or boom point sheave assembly.

Quadrant of Operation

The area of operation that the lift is being made in. Usually divided into four
quadrants, i.e. front, rear and side(s) - left side and right side.


Manufacturing of Jamalpur jacks
The Jamalpur jacks have been gaining in popularity chiefly due to low initial
capital investment and minimum maintenance needs. It is worthwhile to mention
that the performance and cost factor of these Jacks have posed a serious challenge
to capital intensive Electrical Overhead Traveling Cranes.
Besides Indian Railways, these prestigious Jamalpur Jacks have been operating
successfully at various steel plants and allied industries.

Special Features


33

The Jamalpur jack has a capacity to lift a load of 25 Tonnes and four such Jacks
make one complete set with a total lifting capacity of 100 Tonnes. These Jacks can
be operated simultaneously or individually.

Construction Features
The jack is rigid and robust. The upright column is fabricated and welded to the
cast steel Gear Box. The elevating screw is provided with buttress thread supported
with single-acting thrust ball-bearing having a spherical seating at the top and self-
aligning ball-bearing at the bottom. This imparts self-aligning properties to the
screw under loaded condition. The elevating screw is under tension when loaded
and hence there is no chance of distortion due to buckling. While lifting the load,
the Jack rests firmly on its base. For movement from one place to another, the
lifting carriage is to be lowered by pressing the yoke which lifts the base and the
Jack rests on the three wheels with a ground clearance of 20 mm.



Utility
Jamalpur jacks have been designed for:
Lifting Diesel/Electric Loco for inspection and maintenance.
Wheeling and de-wheeling in Sheds/Workshops/C&W Depot.
Various other lifting purposes with suitable adaptors.
Tower cars
Jamalpur workshop is also involved in manufacturing of different tower cars such
as Mark-II, Mark-III, Mark-IV, DHTC/JMP.


34

A BRIEF HISTORY OF CRANE SHOP:
Crane Shop came into existence with the establishment of workshop in
1862; it wascalled Nut and Bolt Shop at that time.
For the first time in country, an order for manufacturing 27 NOS. 20T B.G
SteamCranes was taken by Jamalpur Workshop and the shop was renamed
as crane shopin 1956.
The first 20T BG Steam crane was turned out on 2nd
Oct 1961.
Total 135 steam cranes of 20T, 10T and 3T capacity was manufactured by
the shop.
16 Nos. of 75T B.D Steam crane was manufactured and turned out between
1972and 1977.
The crane shop turned out the first 140T B.D diesel hydraulic crane,
fullymanufactured at Jamalpur on 6
th
May 1994.
The technology shift to Diesel Engines prompted the crane shop to
manufacture 10Tand 20T Diesel Cranes.
43 Nos. 10T Diesel Cranes and 27 Nos. 20T Diesel Cranes were turned out
by thecrane shop between 1980 and 1999.
Activities of Crane Shop:
Manufacturing of 140T Diesel Hydraulic Crane @ Rs 7.56 crores.
POH of 140T Diesel Hydraulic Crane @ 1.75 Cr/crane- Old design and @
1.24Cr/crane- New Design.
Manufacturing of 20T Diesel Hydraulic Crane @ 1.53 Cr/crane.
POH of 20T Diesel Hydraulic Crane @ 0.13 Cr/crane
Manufacturing of Tower Car @ 1.22 Cr/ DHTC.
POH of Mark 2, Mark 3 and Mark 4 Tower Cars @ 0.08 Cr/M2 Tower Cars,
@0.38Cr/M3 and M4 Tower Cars.

Jamalpur as a site for EIR's Locomotive Workshops


This is a multi-exposure panoramic sepia print of the workshop


35

The place was adjacent to Munghyr now Munger, which was that time considered
as Birmingham of the East. There was a plentiful supply of skilled mechanics
from Munghyr, because inhabitants of Munghyr had been the mechanics by trade
for centuries, famous for manufacturing of iron wares, guns, pistols, spears and
other works.
When the selection was made it was probably thought that Jamalpur would be on
the proposed mainline of EIR which was subsequently changed and was directed to
Delhi via Ranigunj, Gaya, Mughalsarai, Allahabad and Kanpur. Initially, Jamalpur
was only a engine changing station and light repairs were done in the running shed
there. The original headquarters of the locomotive department of EIR was located
at Howrah had a great draw back because it was too confined for extensions as and
when needed. At Howrah, the original workshop was supposed to handle building
of locomotives, carriage and wagons.