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Diesel Loco WDS6 AD
Diesel Loco WDS6 AD
Diesel Loco WDS6 AD
WDS-6 LOCOMOTIVE
(FOR 4-WEEK WINTER INTERNSHIP PROGRAMME at Diesel Shed,
Shakur Basti , New Delhi)
(Dec. 2012- Jan. 2013)
ACKNOWLEDGEMENT
INDEX
TOPIC
PAGE NO.
INTRODUCTION
EQUIPMENT LAYOUT.
GENERAL DATA...
LOCOMOTIVE SECTIONS..
LUBRICATION SYSTEM.
13
CONCLUSIONS.
16
SYNOPSIS
Indian Railway now a days a leading transport in India. It plays a very
significant role in increasing the Indian economic value of asset. Every asset
has a value and every individual expert to generate maximum benefit from it
hence they need to get their asset insured because they are likely to be
destroyed or made non functional through an accidental occasion.
We are heartily delighted to present our training report in Northern Railway
which believe enlighten the reader about the conceptual aspect of different
types of locomotives in India to a great extent.
This report also throw light about the different types of locomotives involved
and maintenance prevailing in the Indian Railway.
Indian Railway is the largest single networks in the world. Now a day Indian
Railway achieving a great success.
HISTORY OF RAILWAYS
The history of railways is closely linked with the growth if civilization of
mankind. As the necessity arose, man developed by his ingenuity various
methods of transporting goods from one place to another. In the primitive days
head loads carried the goods. As the civilization grew, the goods were
transported by cart drawn by man or animal. In the 15th century store slab or
wooden baulks were laid with road surface for carriage of heavy goods loaded
on cart and drawn by animal. These were called Tram Ways These
Tramways were extensively used in 16th century in mines in central Europe
for carriage of coal and other minerals.
Iron plates to reduce wear replaced the timber baulks and these were called
plate ways. These plates were also substituted in course of time by angle
irons to give lateral support for better safety. As a further improvement.
4
William Jessup of U.K in 1979 replaced iron plates with cast iron beams
having stone supports at the ends for better working. The present railway
track is a gradual evolution from these plate ways.
Efforts were simultaneously made to replace animal power also by mechanical
power. In 1769 French man called Nicholas Cygnet carried out for the first
time some pioneering work for development of steam energy. Then a
Scotsman William Murdoch did further
Trevithick designed and constructed a steam locomotive. This locomotive
however, could be used for traction on roads only. The credit of perfecting the
design finally goes to Gorge Stephenson who in 1814 produced the first steam
locomotive used for traction for railways.
The first public railways in the world was opened to traffic on 27th September,
1825, when the first train made its maiden journey between Stockton and
Darlington in U.K.
Simultaneously other countries introduced trains for carriages of passengers
traffic at that time. The first time in Germany was opened from Nuremberg to
Furth in the year 1835. In U.S.A. The first railway was opened in 1833
between Mohawk and Hudson.
Indian Railways
Founded
Head quarters
New Delhi
Key People
Area covered
India
Industry
Type of track
Area network
63,140 km
(In length)
Owner
Government of India
Website
http://www.indianrailways.gov.in/
The formal birth of Railway of in India was started in 1851. the first train in
India became operational on Dec 22, 1851, and was used for the hauling of
construction material in Roorkee. A year and a half later, on April 16, 1853,
the first passenger train service was inaugurated between Bori Bunder to
Thane (in Bombay) . Covering distance of 34 km (21miles). it was hauled
by three locomotives,Shaib,Sindh and Sultan. By 1947, the year of Indias
independence, there were forty two rail systems. In 1951 the systems were
nationalized as one unit, becoming one of the largest networks in the
world.
Indian Railways is the state owned Railway Company of India. Indian
Railways had until very recently; a monopoly on the countrys rail transport
.It is the largest and busiest rail networks in the world, transporting just
over six billion passengers and the almost 750 million tonnes of freight
annually. Indian Railways is the worlds largest commercial or utility
employer, with more than 1.6 million employees. The railways transverse
through the length and width of the country; the routes cover a length of
63,140 km (39,462miles). As of 2002 Indian Railways owned a total of
216717 wagons, 39236 coaches and 14444 trains daily including about
8702 passenger trains. Indian Railways operates both long distance rail
systems. For administrative purposes it is divided into 16 sections.
DIESEL ENGINE:-
Introduction of Shakur Basti Diesel Shed: Shakur Basti Diesel Shed was established in 1955. It carry as a facility
of repair or maintenance of all type of diesel locomotives nominated to
come under its holding or as per as schedules of maintenance and to
make available for service as per as requirements of traffic department
of the railways. It is a field unit functioning under the dual control of the
zonal office, Baroda house, New Delhi; and the office of divisional
headquarters of northern railway.
Indian Railways has a fleet of about 3800 BG Diesel Locomotives,
which are based in about 47-maintenance sheds spread all over the
8
Organizational structure staff strength: Shakur Basti shed has a sanctioned strength of 854 against which 698
persons are on-roll.
There are 9 posts of officers in the shed. The shed is headed by a Sr.
DME who is assisted by 2 Sr. Scale and 6 Jr. Scale officers.
9
Sections under Shakur Basti Shed:1. Running Mechanical & Goods/Mail Section: This section attends the locos of trip, monthly, four monthly and twelve
monthly schedules. Following items are repaired /checked during each
schedule:1) T1 , T2 Schedule :- TRD, Cylinder Heads, Manifolds & joints, Any loose
or defective part, Any unusual sound, Lube oil pressure, Brake system,
Water sample, Water or oil leakage, Lube oil system, Expresser, After
Cooler, Traction Motor Blower, Gear Case, Cyclonic Filters etc.
2) M2 Schedule:- Cooling Water System, Expresser Crankcase, Air
system, Lube oil system, Fuel oil system, Cylinder valve, Engine crank
case, Expresser, radiator, Exhaust manifold, Air brake system, Traction
motor blower, Suspension bearing, Bogie etc.
3) M4 Schedule:- Repetition of trip and monthly schedule,
Fuel oil
system, Cylinder heads, Engine crankcase cover, Strainers and filters, Air
& vacuum brake system, Expresser Governor, Expansion tank water level
gauge, Air intake system, Roller bearing axle boxes, Traction motor
blower, suspension bearing, Speed indicator etc.
4) M12 schedule:- Repetition of above mentioned schedules, Expresser,
Engine, Filters, Lube oil cooler, Air brake cylinders, Cattle guards,
Buffers, Suspension bearing brackets, Firing pressure, Overhauling of
TSC, Air intake filter, After cooler, Compressor Governor, OST, Cleaning
of Wick Pads, Air system, Brake Connections, Air Dryer, MSU etc.
10
2. Fuel Section:-
It keeps the record of the amount of fuel oil and different types of lube oils
issued to a loco. This section stores high speed diesel, RR 813 M lube oil
for engine sump; T 78 lube oil for governor, wick pads and loading pads;
SP 150 lube oil for expresser and Cardiam Compound for gear box.
3. FIP Section: Fuel injection pump (FIP) supplies fuel at high pressure to the cylinder in
which the fuel is burnt. In FIP, fuel nozzle contains 9 holes through which
fuel is sprayed. In this section assembly and testing of FIP is done and
problems i.e. chattering, dribbling are removed. Here calibration of FIP is
also done because it has to release a particular quantity of fuel at correct
time called Phasing.
FIP is present in the side of engine block over the cross head.
It is operated by the cam shaft. FIP sends the fuel through
The high pressure pipe and then into the injector. This section
Has 2 types of FIP, modified and unmodified. Unmodified
Type has 15 mm. dia. Plungers and modified type has17 mm.
dia. Plungers. The section Checks the fuel pressure in
FIP, spray pattern of the injector, pressure drop in injector
Etc.
The cylinder head contains the inlet and exhaust valves, push rods for
operating these valves & fuel injector. The section replaces the damaged
valve seat inserts, valve guides & injector sleeve. The main body of
cylinder head is checked by Hydraulic testing. Valve seats are ground
before inserting the valves. After this blow bye test is done to check the
compression leakage from the valves and from the liner cylinder head
joint.
11
6. Bogie Section:-
The section has two types of bogies, 2 axle bogies and 3 axle bogies. A
bogie has axles, axle boxes, wheels, traction motors, main bogie,
suspension bearing and suspension system. In the section the bogie is
dismantled, traction motors, axles and wheels are removed off. After this
all the respective clearances are checked. Main frame is checked for
cracks by RDP test and axles are checked by Ultrasonic test. The 2 types
of axle boxes i.e. conventional and high speed are cleaned and lubricated
again by grease. Suspension system of the bogie consisting of
compression springs and hydraulic shockers is also inspected on the test
bench.
12
The framework on which the power pack, generator etc. rest on. There
are many parts combined to form bogie:(a) Axle:- It is a shaft connecting both wheels & has a bull gear.
(b) Axle box: - The part of axle on which the under frame rests.
It is having compression spring acting as shock absorbers.
(c) Traction motor:- DC series motor which take electricity
From generator & gives motion to wheels.
(d) Wheels:- There is two per axle. The surfaces of wheels are
Flange & treads which prevent derailment & part which comes
in contact with rail respectively.
(e) Suspension bearings:- It rests on the axle which is used for
For provide the it rests on the axle which is used for
Provide the lubrication to axle to prevent seizure.
(f) Suspension - It prevents jerks due to irregularities on track
& protects the power pack as jerks can cause serious
damage to power pack.
It is also known as M24 section. This time taken for this schedule to
complete is 15 days.
8. Speedometer Section:-
fault, junction fault, memory card fault etc. Also they set the speedometer
at a definite speed of 110Km/Hr.
9. Pump Section:-
The section deals with water & lube oil pumps and cross heads. The
condition of bearings, oil and water seals of the pump is checked here. The
section also replaces the damaged rollers of the cross head.
This section has the following different parts: N.D.T. lab:- Here different components are checked before reusing for
any type of crack or breakage. The components are tested without
destroying them. Zyglo test, red dye penetration test, ultrasonic test and
magna flux test are employed for testing the cracks.
Shift lab:- This lab checks the presence of water in lube oil, viscosity of
lube oil, water contamination etc.
Spectrographic lab:- This lab checks the presence of different elements
in the lube oil like copper, lead, tin, iron, chromium, sodium, aluminum,
silicon & boron.
Diesel lab:- This lab checks the viscosity, Density, Sulphur content,
Pour point, Flash point of the diesel when it is delivered to the shed by
the company.
11. Turbo supercharger Section: A TSC is used to increase the horse power of the diesel engine. For higher
HP we need to inject more fuel and for burning more fuel we have to
supply higher amount of air. This condition is achieved by a TSC. A TSC
increases the HP up to 30 to 50% . TSC is attached to the exhaust
manifold of the engine; the exhaust drives the turbine which in turn drives
an impeller. The impeller sucks the fresh air from outside and this air
passes through the diffuser ring which compresses it and this compressed
14
air is passed into different cylinders. Currently TKD shed is using 5 type of
TSC. They are ALCO, ABB, NAPIER, HISPANO SUIZA and GE.
In the section overhauling of the TSC is done. The defective parts are
repaired or replaced.
(a) ALCO:- for 2600Hp Conventional WDM-2 Locos
15
(d) Hi-Spano Suiza:- for 3100Hp Locos (high life duration & Air cooled)
16
12. Expresser Section: Expresser is a component in diesel engine which is used to create 65 to
70 cm. of Hg vacuum and compressed air up to a pressure of 10.2
Kg/cm Sq. The vacuum produced is used in breaking system and
compressed air fills the MR tanks. The air in MR2 is used in breaking
system and air in MR1 is used in other supplementary operations like
horn, feed valve, loading/unloading, for operating sanders etc.
The expresser section overhauls the expresser, its different parts like
safety valve, pump, loader unloading assembly, governor, vacuum
maintaining valve, pressure needle etc. are checked on the test bench.
CHIEF TECHNICAL ADVISOR CELL (CTA) : The main works in this section are following:(a) Loco failure analysis by complete investigation of cause
Of failure.
(b) To record of performance & suggested new innovation or
Modify design.
17
It works as an operating unit and notes the following parameters: Arrival time of the loco in the shed.
Leaving time of the loco from the shed.
For how much time the loco remained in the shed.
How much distance the loco has traveled.
How much lube oil the loco has consumed per
100 kilometers.
15. DEMU:-
The DEMU is controlled on either end of the train set. The four 19-pin
control cables run through the length cf the train and are interconnected
from one car to the other using couplers. The diesel engine is governed
by an electronic load and speed control card supplied by Governors
America Corp(GAC). This controls the fuel supply to the fuel actuator
18
and hence controls the supply of fuel into the diesel engine by sensing
the load of the train.
WDM2
WDM2C
WDP1
WDG4
Year of
introduction
1962
1994
1995
2000
Tractive
effort max (in
kg)
30450
45600
21000
53000
Tractive
effort cont.
24600 kg at
28050 kg at
22.8 KMPH
15050 kg at
42500 kg at
31.5 KMPH
20 KMPH
Adhesion
0.27%
0.27%
0.25%
0.42%
Weight in
working
order
(in tonnes)
112.8
112.80
80.0
126.0
Axle load
max.
in tonnes)
18.8
18.8
20.0
21.0
18 KMPH
19
Speed
potential
(in KMPH)
120
120
120
100
Length
15862
15862
14810
19964
10516
10516
8800
13868
Wheel
arrangement
Co-Co
Co-Co
Co-Co
Co-Co
Tri- Mount
Tri-Mount
Tri-Mount
High Adhesion
Lube Oil
sump
Capacity
910
1270
740(SS)
950
(in mm)
Distance
between
Bogie
(in mm)
760(LS)
(in Ltrs)
5000
5000
3000
6000
1210
1210
1210
1144
(in Ltrs)
Water Oil
sump
Capacity
(in Ltrs)
20
Transmission
DC-DC
AC-DC
AC-DC
AC-DC
Driving
Right Hand
Left Hand
Left Hand
Left
Hauling
Capacity
3600T on level
gradient at
75KMPH, 900T on
level gradient at
120KMPH.17
coaches
(with2AC/SG)
at 100KMPH and
9AC
coaches(EOG) at
a speed of
120KMPH
4700T on
load1:500up
gradient at
balancing speed
of 69KMPH,
1100 Tonnes on
level gradient
at 100KMPH.
21 coaches
(with2AC/SG)
at 100KMPH
17Coaches
58 Box Load
i.e.4700Tonnes
in 1:150 up
gradient
Diesel Engine
make and
type
ALCO/DLW-251B
DLW
DLW
GM
251B
251B
710 G-3B
Cylinder
Formation
45 degree
45 degree
45 degree
45 degree
V-type
V-type
V-type
No. of Engine
16
16
12
16
Bore &
Stroke(mm)
228.6 X 266.7
228.6 X 266.7
228.6 X 266.7
230.19 X 279.4
Comp. Ratio
12.5:1
12.5:1
13:1
16:1
Hand
V-type
Cylinder
/loco
21
Engine RPM
rated/idle
1000/400
1050/400
1000/350
904/269
(200low speed)
B.E.M.P. (kg
/cm^2)
13.6
15.041
15.75
11.23
Mean Piston
Speed(m/sec)
8.89
9.33
8.89
8.38
HP at Std.
UIC condition
2600
3100
2300
4000
HP at Site
2400
3007
2231
4012
(55C-600mm)
(47C-600mm)
(47C-600mm)
(47C-600mm)
HP input to
TM
2250
2750
2000
3780CV
Type of
Injection
System
Jerk, direct
Jerk, direct
Jerk, direct
Direct injector
Type of
Pump
Injector
Mico-APFICO AKK
Mico-APFICO
AKK
Mico-APFICO
AKK
Mico-APFICO
AKK
(at rated
output)
4132CV(AAR
condition)
22
ABB
ABB
EMD
VTC-304-VG15,
VTC-304-VG15,
model
NapierNA295IR,
NapierNA295IR,GE
GE 7S1716
GE 7S1716
1.4-1.6
1.97
1.67
Engine
Governor
EDC Wood
Ward
EDC Wood
Ward
Engine Water
Pump
Centrifugal
Centrifugal
Centrifugal
Centrifugal
OSTA
Tripping
Range(RPM)
1120-1160
1120-1160
1180-1220
SFC
153-155
155-157
157-159
(gm/bhp/hr.)
161-165
IRAB-1
28LAV-1
BAP
ALCO-720
(kg/cm2)
(ALCO TSC)
Loco Brake
System
28LAV-1
23
KNORR/NYAB
CCB
Type of Brake
Expresser/
Compressor
A-9,SA-9,
A-9,SA-9,
A-9,SA-9,
Hand, Dynamic
Hand, Dynamic
Parking&
&Emergency
Brake
&Emergency
Emergency
Brake
Brake
KPC-6CD4UC
KCW-523/623
ELGI-LG3CDE
KPC KE-6
ELGI-6CD3UC
Air, Hand,
Dynamic(Pure
Air Brake
System)
KNORR
CCB-W L N A
9B,2
Stage,3Cylinder
Fan drive
Eddy Current
Clutch
Eddy Current
Clutch
Eddy Current
Clutch
AC Motor
Make& Type
BHEL-TG
BHEL-TA
Tr. Alt-
Of Tr. Gen./
10931-AZ/M
BHEL-TA10102CW/DW
10106 AZ
GM TA-17
Alternator
Rating
680V,2480A,
1100V,1760A,
760V,1850A,
(continuous)
1000rpm,1690kW
1000rpm/HV.
1000rpm/HV.
Cyli.Head
Insulation
525V,3700A,
413V,3400A,
1050rpm/LV.
1000rpm/LV.
BHEL-TM 165 M/
4906AZ
BHEL-4906AZ
BHEL-4906AZ
Make& Type
Of Tr. Motor
SIEMENSITB-2622
24
OTA02
Rating
285V,980A,
2850V,960A,
285V,980A,
(continuous)
360rpm,248kW
360rpm,248kW,
3600rpm,248kW,
Cyli.Head
Insulation
Cyli.Head
Insulation
Cyli.Head
Insulation.
Gear Ratio
18:65
18:65
18:65/22:61
90:17
Make& Type
of Aux.
Gen/Exictor
BHEL-
BHELAG3101AY/
BHEL-AG2702AZ
GM-5A-814/
Rating
75V,160A,
75V,160A,
75V,160A,
(continuous)
850-2380rpm,
950-2380rpm
950-2620rpm
12kW
as AG
as AG
CLF Insulation
95V,220A,
95V,220A,
950-2380rpm
950-2620rpm
as Exictor
as Exictor
AG51/M
500kW
GM-CA6B
AY1
74V DC at
904rpm
Front
Centrifugal
Centrifugal
Centrifugal
Movable
Tm Blower
multi vane
multi vane
multi vane
inlet guide
vane.
275-285A
230-240A
Gear Driven
GFOLR
Setting
230-240A
25
Transition
3 Transition
1 Transition
1 Transition
31.5,49&
49KMPH
60KMPH
2(CK1,2)
3(CK1,2,3)
3(CK1,2,3)
Power
Contactor
(3S+6P)
(3S+6P)
(P1,P2,P3,P4)
FS Contactor
NIL
Battery
64V/450AH
74V/450AH
64V/500AH
Battery
(10hr.)
(10hr.)
(10hr.)
Exide-MGD-19
Exide4HMFG31KP
Exide4HMFG31KP
Surrette
78KMPH
Cranking
Contactor
26
Exide-16H-25
INTRODUCTION
Diesel-electric transmission
Diesel electric transmission or diesel-electric power train is used by a no. of
vehicles and ship types for providing locomotion. It includes a diesel engine
connected to an electric generator creating electricity that powers electric
traction motors. No clutch is required.
Diesel electric power plants became popular because they greatly simplified
the way motive power was transmitted to the wheels and because they were
both more efficient and had greatly reduced maintenance requirements.
WDS6 AD
The six motors WDS6 AD locomotive are designed for shunting service.
Controls are applied for multiple unit operation with all units controlled from
one cab.
Each locomotive is powered by a 6 cylinder inline, 228 mm x 267 mm, turbosupercharged, diesel engine of four stroke cycle having an open combustion
chamber with solid fuel Injection. The engine speed is governed by an electrohydraulic governor (W.W.Governor).
27
Type
WDS6
Diesel
Electric
Shunting Loco
5 ft 6"
Co-Co
Vacuum Braked
1400 HP
DLW design of the 80's to
meet
heavy
shunting
needs. Incorporates a
YDM4 Alco power pack.
All IR
6***,36***
No.36197, Ratlam shed,
WR
Gauge
Wheel Argmt
Brakes
Power
History & Devpt
Railways
No.Series
Unit shown
28
The diesel engine has an all welded steel frame. Full pressure lubrication on
all parts is provided. A closed cooling system is used the cooling water flows
successively through the engine the radiators and the lubricating oil cooler
and is circulated by an engine driven centrifugal pump. Lubricating oil is
cooled by the water in the lubricating oil cooler, and the water by fan cooled
radiators.
29
EQUIPMENT LAYOUT
1. ENGINE
2. TRACTION
3. ALTERNATOR BHEL
4. COMPRESSOR
5. RADIATOR FAN
6. CONTROL DESK (NID)
7. BRAKE VALVES
8. CONTROL COMPARTMENT
9. TURBOSUPERCHARGER
10.FILTERS-CYCLONIC
11. T.M. BLOWER FRONT
12. LUBE OIL COOLER
13. LUBE OIL FILTER
14. RECTIFIER
15. AIR & VACUUM BRAKE
PANEL
16. T.M. BLOWER REAR
17. EDDY CURRENT CLUTCH
18. BATTERY BOX ARRGT.
19. FUEL TANK
20. WATER EXPANTION
TANK
21. AIR RESERVOIR
22. RADIATOR
23. GEAR COUPLING
24. FLEXIBLE COUPLING
25. HEAD LIGHT
26. MOTOR TRUCK
30
GENERAL DATA
MODEL NUMBER...................................................... WDS6AD
CLASS - AAR............................................................. Co-Co
ENGINE HORSE POWER .......................................... 1350 / 1150
GEAR RATIO........................................................ 74 / 18
LOCOMOTIVE SPEED MAX................................... 65 KMPH
TRACK GAUGE.......................................................... 1676 mm
BRAKE EQUIPMENT.............................................. 28LAV - 1
FUEL OIL TANK CAPACITY ........................................ 3000 litre
SUPPLIES - TOTAL CAPACITY :
FUEL OIL TANK.......................................................... 5000 litres
LUBRICATING OIL ...................................................... 530 litre
COOLING WATER ................................................. 645 litre
SAND ......................................................................... 0.40 M3
WHEEL DIAMETER (NEW) ........................................ 1097 mm
JOURNAL SIZE .......................................................... 150 mm
PRINCIPAL DIMENSIONS :
HEIGHT (MAX) ............................................................ 4027 mm
WIDTH (MAX) ............................................................. 3022 mm
LENGTH OVERALL .................................................... 17430 mm
TRACK CURVATURE (MAX)................................ .... 170-10
Rad. 73.2 m
WEIGHT :
TOTAL LOCOMOTIVE................................................. 114000 Kg
31
LOCOMOTIVE SECTIONS
1. RADIATOR
All locomotives are provided with a radiator assembly designed to reduced the
temperature of the engine cooling water system On some locomotive the
engine lubricating oil is cooled in a section of the radiator.Radiator assemblies
are made up of one or more panels which, in turn, are made up of one or
more cores. The radiator core is the basic unit of the assembly and is bolted to
cast iron or fabricated steel tanks using a gasket seal. Ceres are constructed
of thin walled tubes which are passed through cooling fins and attached to
tube sheets or headers at each end.Two specific types of construction are
used by radiator manufacturers, the soldered core construction and the
brazed core construction.
Maintenance of each core construction differs from that of the other and care
should be used to determine the construction of the core being repaired.
Brazed construction core have .018 inch wall seamless copper tubes fitted
through copper cooling fins and brazed to a copper alloy header. Soldered
construction cores are made up of .012 inch wall lock seam soldered copper
tubing fitted through copper cooling fins and soldered to a copper alloy
header. Identification of the construction may be determined by scraping the
braze or solder at the joint between the tube and header with the blade of a
pocket knife. If the metal uncovered is soft and white, the construction is
soldered; while if the metal is harder and has a yellowish hue, it indicates
brazed construction.
32
Each radiator is hinge-mounted to two angle irons, the top angle being
secured to the compartment by flat head machine screws and the bottom
angle to the floor by welding. Bolts, into a bolting strip, at the rear of the
radiator secure the radiator to the compartment bulkhead.
2. DIESEL ENGINE
Each locomotive is powered by a 6 cylinder inline, 228 mm x 267 mm, turbo
supercharged, diesel engine of four stroke cycle having an open combustion
chamber with solid fuel Injection. The engine speed is governed by an electrohydraulic governor (W.W.Governor).
Each cylinder requires two engine revolutions for four strokes of the
piston to complete one working cycle.
One complete piston working cycle is as follows :
Air is blown into the cylinder on the down or intake stroke
Compression stroke: This air is compressed by the rising piston with
a large increase in air temperature.
Just before the end of the compression stroke, fuel is injected into
the cylinder where it is ignited by the heat of the compressed air.
The resulting combustion increases the cylinder pressure and on the
third or power stroke, this gas pressure forces the piston down.
33
On the fourth or exhaust stroke, the burnt gases are expelled by the
piston travelling upwards, and by scavenging action of the inlet made
possible by a large intake and exhaust valve overlap.
4. TRACTION MOTORS
Each traction motor is supported by axle suspension bearings and a resilient
support spring nest mounted on the truck transoms. Shrunk on to the motor
armature shaft is a pinion which meshes with a drive gear pressed onto the
wheel axle.
34
6. AUXILIARY EQUIPMENT
An extension shaft from the diesel engine drives the compressor exhauster
through a flexible coupling. A shaft from the compressor exhauster then drives
the radiator fan through an eddy current clutch and right angle gear box.
7. COMPRESSOR
Locomotives equipped with vacuum brake systems have a compressorexhauster unit, which furnishes compressed air for purposes of locomotive
control and vacuum for the train brakes. Power to drive the compressorexhauster unit comes from the diesel engine through a flexible coupling major
components are crankcase. crankshaft pistons, connecting rods, low pressure
and high pressure compressor cylinders, intercooler, exhauster cylinders
connected in parallel and fan for cooling.
The air intake strainers used at inlet of the low-pressure cylinders are of the
cartridge type which permits removal of the strainer element without the
necessity of dismounting or disconnecting from the air compressor. Air
passing through the strainer unit enters the compressor intake.
Since these compressors are of the compound type, each is fitted with an
intercooler through, which the discharge air from each low pressure cylinder
passes to the intake of the high pressure cylinder. The use of an intercooler
reduces the temperature of the discharge air and improves the volumetric and
overall efficiency of the compressor; The intercooler is of the radiator type,
employing finned copper tubing mounted between cast iron headers except
on the 6 CD-3UC machine.
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Fig 1:
BOGIE GENERAL ARRANGEMENT
The locomotive body weight is supported on bogie frame through four rubber
side bearers directly mounted on bogie side beams. Center pivot does not
take any vertical load and is used only for transfer of traction and braking
forces. The bogie frame in turn is supported on axles through helical coil
spring mounted on equalizer beams. The equalizing mechanism consists of
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equalizers hung directly on end axle boxes and supported on middle axle box
through a link and compensating beam arrangement.
9. BRAKING SYSTEM
Bogies are provided with conventional brake gear arrangement as shown in
Fig. 2.
Compressed air tapped from the compressor is stored in the MI tank. From
here, compressed air is extracted and pushed into the pistons as shown in fig
2.
Fig 2
The system is mechanically linked such that when the piston moves out due to
the incoming compressed air, the brake shoe comes in contact with the
wheels and the brakes are actuated. The amount of braking force applied
depends upon the amount of displacement of the piston which in turn depends
upon the amount of compressed air supplied.
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Along with the air brakes, vacuum brakes may also be used for which the
brake compressor-exhauster unit is used as explained above.
10.FILTERS
AIR FILTERS
The engine lubricating oil system contains single-unit cartridge type oil filters,
fig 1 attached to the left side of the engine There are two different types of
filter cartridges in use. One is a cotton waste type sock which requires the use
of a cage assembly. If a sock is not used and is hand packed, it require 7-1/2
pounds of long strand cotton waste packing. The other is a full flow pleated
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cotton paper filter cartridge which does not require the use of a cage
assembly.
PANEL FILTERS
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LUBRICATION SYSTEM
Lubrication is the process or technique employed to reduce wear of one or
both surfaces in close proximity and moving relative to each other ,by
interposing a substance called lubricant between the surfaces to carry or to
help carry the load between the opposing two surfaces .Adequate lubrication
allows smooth continuous operation of equipment with only mild wear.
Brand names of various industrial lubricants (other than engine oil and
greases) listed herein are in lieu with International Organization for
Standardization (ISO) classification. The ISO viscosity grade number
designates the mid point of kinematics viscosity range in Cs at 40C.
ISO Viscosity
Grade
ISOVG
2
3
5
7
10
15
22
32
46
68
100
150
220
320
460
680
100
1500
Kinematics Viscosity
(Centistokes @ 40)
Min.
Max.
1.98
2.42
2.88
3.52
4.14
5.06
6.12
7.48
9.0
11.0
13.5
16.5
19.8
24.2
28.8
35.2
41.4
50.6
61.2
74.8
90
110
135
165
198
242
288
352
414 .
506
612
748
900
1100
1 350
1 650
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HANDLING OF LUBRICANTS
Handling of lubricants must be done carefully. It should be ensured that no
two lubricants are handled in the same service container, even though these
Lubricants may appear to be similar. Lubricants container should also be kept
under covered condition Use of dirty hands in handling lubricants should be
avoided.
IMPORTANT
Following points should also be kept in mind:
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710-760
280
15
Black
1
Cooling water from the water circulating pump flows into the cooler at the end
cover connection, through the tubes and out of the other end of the cooler.
The hot lubricating oil enters the shell at a flange connection on the top at one
end, circulates back and forth across the tubes, and leaves the cooler at the
bottom flange connection at the other end of the cooler. During this process
Heat is removed from the oil due to its contact with the tubes, through which
the cooling water is flowing. Baffles are provided inside the shell to channel
the oil flow in the most efficient manner.
CONCLUSIONS
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44