18-8. Shop Procedure
18-9. Shop Buildings
The general procedure in the operation of a
The requirements for service buildings will
heavy repair facility on the progressive system will be
be dependent on the facilities which are housed in the
somewhat as outlined below, subject to wide variations
main shop building and the volume of work to be
for different classes of cars.
As noted above, the fabricating and
blacksmith shops should be in an area adjacent to the
assembly line, also a toolroom, an airbrake room, an
The cars are spotted at one or more
electric shop, a pipe shop, offices, a washroom, and a
positions where they are stripped to the underframe or
locker room in the main building.
to the point where all corroded, defective, or broken
steel or wooden parts are removed. This work is done
by oxyacetylene torch. Cranes are used to remove
The wheel shop, which is a desirable feature
scrap. Lumber should be piled and burned to eliminate
of a large shop, will preferably be in a separate building
because of outside storage space necessary for wheels,
axles, and wheel pairs.
The next general location provides means
for cleaning the car and preparing it for the assembly
Lighting in buildings should be adequate for
line. Sandblasting, grit-blasting, acid cleaning, or hand-
necessary work when night work is required. Heating
cleaning methods are used for this purpose. The cars
should be provided in all enclosed buildings for winter
are then moved to the painting area where they receive
operations. It may also be desirable to provide motor-
one or more prime coats of paint or a protective coating
driven exhaust ventilators to remove fumes and heat
before the start of the assembly work.
from shops, forges, and furnaces.
Car bodies are removed from the trucks at
18-10. Shop Machinery and Equipment
some point on the assembly line and are moved by
The machinery needed in a car repair shop
dummy trucks or supported on pedestals until rebuilt
trucks can be applied.
Truck overhaul is usually
can only be determined after a careful analysis of the
machinery and of the characteristics of the work to be
performed on a separate track or at a suitable location
performed in the shop. Tables of organization and
where trucks can be returned to the assembly line
without interfering with the work on the body or
equipment dictate the equipment authorized for Army
railway shop units. In oversea areas, the equipment is
necessitating excessive handling.
augmented by local equipment found in the shops or
Actual assembly locations may consist of a
local area. By securing car sets of prefabricated
few or many positions, depending on the output,
material, it is possible to rebuild cars on a program basis
personnel, extent of work, etc. The work done at each
or to build new cars with very little machinery.
location must be carefully planned and supervised. The
The machinery provided for the steel-
fabrication and blacksmith shops will have an important
underframe for new reinforcements, parts, or
subassemblies; the installation of such parts; the
bearing on the repair of old cars or the construction of
new ones. Special machinery is required for shearing,
installation of airbrakes equipment; and the work on
rolling, bending, forming, and forging the heavy steel
sides, ends, or roofs. Further work consists of the
plate and parts in modern freight car construction, and it
application of draft gear and couplers and, for a boxcar,
should be used only where the volume of work justifies
the installation of floor and lining. Final operations
cover the installation of handbrakes, ladders, and
running boards, if required.
Most freight cars now in service consist of a
riveted or welded frame assembly of steel plates,
The completed cars are then moved to the
standard rolled sections, and pressed shapes. The older
painting area, which also may comprise two or more
cars of all-riveted construction include many plate
spot locations, for painting and stenciling. A scale
assemblies with flanged sections-some with offset bends
should be provided near the shop for weighing. After
the car has been weighed, it is stenciled with the light
which originally were formed on giant hydraulic presses.
The initial cutting of the plates and rolled-steel sections
load weight and is then ready for service.
can be performed with power shears provided with roller
tables or supports for easy handling. Oxyacetylene
torches, either a hand torch or a straight line cutting
machine, may be used.