FUEL OIL SYSTEM FOR

HHP(WDG4) LOCOS
Lecturer (Diesel)/IRIMEE
 Purpose of FOS
 The fuel oil system is designed to introduce fuel oil
in to the engine cylinders-
 At Correct time(15.8’c before TDC,Cut off 0.8’c after
TDC)
 In Correct quantity and

 At Correct pressure.

 To cool & lubricate the close tolerance injector part.

4-Aug-20
 Major Components FOS
 Fuel tank.
 Fuel strainer
 Fuel Booster Pump
 Primary F.O Filter
 Secondary F.O filter

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FOS

4-Aug-20
 FUEL OIL SYSTEM
FOS WDG4(Normal)
WDG4

4-Aug-20
 FUEL OIL SYSTEM
FOS WDG4(Primary filer
WDG4 choked)
Primary filter
choke

Primaryfilter choke

4-Aug-20
 FUEL OIL SYSTEM
FOS WDG4(secondary filter
WDG4 choked)
Primary &
Secondary
Fuel starvation filter choke
in system

Primary filter chock

4-Aug-20
 Fuel Tank

F/oil Tank
6000 lts 4-Aug-20
 FUEL SUCTION STRAINER
 It has screen type
element (1No).
 Suspended particles up
to 600 micron filtered
here.
 Protects the fuel
booster P/p against
damage from foreign
material.
 Cleaned in monthly
schedule or replace if
required.

4-Aug-20
 FUEL BOOSTER PUMP
 Positive displacement
p/p.
 AC motor driven &
RPM-1200
 Capacity=
24.6Litre/Min.
 It is identical to Turbo
lube oil Pump.
 Overhauling & testing
done in Yearly sch.
4-Aug-20
Fuel Booster Pump(modified)

4-Aug-20
 Fuel booster P/P
 When the pump is
started ,there is an
increase in volume as
the teeth of the idler
and rotor come out of
mesh .this creates a
partial vacuum,
drawing oil into the
pump through the
suction port.
4-Aug-20
 PRIMARY FUEL OIL FILTER
 Also called as Two stage primary filter assembly.
 Consists 2 Nos 13 micron filter elements.
 Re-new in 90 /180 days.
 Equipped with a “By pass valve & gauge” set at 30 Psi
differential pressure.
 Having Green ,Yellow & Red zones to show condition of
the fuel primary filter.
 Yellow and Red zone indicates chocked filter needs
renewal.
 Size- 9 7/8” OD X 29 3/8” long.

4-Aug-20
PRIMARY FUEL OIL FILTER

4-Aug-20
 Primary Fuel Filter Gauge
 This gauge indicates
the condition of the
primary fuel filter.
 Normally, with new
primary filters, the
gauge should read in
the green zone.

4-Aug-20
 Sight glass No:1
 Sight glass No-1(known as
“Return fuel sight glass) is
provided with a Regulating V/v
set at 5 Psi.
 The excess fuel returning from the
Unit injectors collected in fuel
return header and passes
through “Return fuel sight glass”
before returning to the fuel tank.
 In normal condition, the “Return
fuel sight glass” will be full of
clean & clear fuel.
 Air bubble in “Return fuel sight
glass” at higher notch with full
load indicates in-sufficient fuel
supply.

4-Aug-20
Secondary filter-layout

4-Aug-20
 Secondary F.O Filter assembly
 Mounted on front right
corner of the engine.
 Particle upto 2 to 3
microns in size may
filtered.
 Two sight glasses are
located on filter housing
to give visual indication
of fuel system condition.
 Sight glass No-1
 Sight glass No-2

4-Aug-20
 Sight glass No-2
 Sight glass No-2 (Known
as By pass sight glass) is
provided with a “pressure
control relief & By pass
valve” and set at 60 Psi
differential pressure.
 When fuel filter choked, SG No-2
By pass V/v open and
diverts the fuel oil back to
tank.
 In normal condition ,this
“By pass sight glass” is
empty.

4-Aug-20
 Fuel in - out manifold
 The excess fuel is used
to cool & lubricate the
close tolerence of
Injector.

4-Aug-20
 Mechanical Unit Injector
 Rotation of plunger by means
of the rack and gear controls
the quantity of fuel injected
into the cylinder during each
stroke.
 Rack position is controlled by
Governor through the injector
control lever and linkage.
 Excess fuel is need to cool &
lubricate the close tolerance
injector part.
 External working parts are
lubricated by oil coming from
rocker-arm adjusting screw.

4-Aug-20
 Various Parts of MUI
 Nut(Injector body)
 Needle Valve
 Valve spring
 Spacer
 Bushing
 Plunger
 Plunger follower
 Follower spring
 Gear
 Rack
 Filter
 Filter cap

4-Aug-20
 Inspection of MUI-Overhauling
 Plunger should be closely examined for scores and scratches
on the lapped surface.
 The helices should be inspected for face .the helices should
be inspected for chipping or eroding.
 To test for cleanliness, insert the plunger in its bushing and
spin the bushing .if both the plunger and bushing have been
properly cleaned, the bushing will spin freely. If the bushing
does not spin freely, the cleaning operations should be
repeated or the parts replaced.
 The Rack must be straight so as not to bind in the injector
during operation.
 New valve springs should be used when the injectors are
rebuilt.
4-Aug-20
Reconditioning/Overhauling procedure

 Lapping of the following parts may be done-

 Bushing

 Plunger

 Spray tip
 Spring cage

 Spacer

 Flat check valve

4-Aug-20
 Bushing-Polishing
 To Polishing the injector bushing ,wrap a sufficient
amount of toilet tissue around a small diameter rod
so that it may be inserted into the bushing.
 Apply a small amount off the jewellers rough paste
to the toilet tissue and insert into the bushing bore
.Work bushing back and forth over tissue ,using a
rotary motion.

4-Aug-20
 Plunger-Polishing
 The plunger is polished using some of the jewelers
rough paste on toilet tissue held in the hand .the
plunger is then worked back and forth through the
tissue using a rotary motion. When the plunger and
mating bushing have been thoroughly cleaned and
polished ,the bushing should be able to be spun
around the inserted plunger. It is important in
making this check that both the plunger and bushing
are absolutely dry and clean.

4-Aug-20
 Spray tip-Lapping
 Select the correct size lapping tool from the set.
 Place a small amount of 800 grit lapping compound on
the lap seat of the lapping tool .Place tool into spray
tip. Use extreme caution to prevent the tool with
compound from touching the side walls ,since this will
destroy the selective fit of the plunger and spray tip
and will be cause for rejection.
 Revolve the lapping tool between the thumb and index
finger applying a light pressure while revolving.
 Lift the tool slightly each turn to permit the compound to
be drawn under the lap. Three or four complete
revolutions should reseat the tip.

4-Aug-20
 Calibration injector output
 High output Injectors……(184-195) cc/300 Strokes
 One complete turn of the adjusting screw in a
counterclockwise direction will increase injector
output……………… (6-7) cc
 One turn in a clockwise direction will decrease
output…………….....(6-7) cc

4-Aug-20
Injector calibrating stand

4-Aug-20
 Testing of MUI
 All given below
testings are carried
out on MUI Injector
tester-
 Holding Pressure
test/Leak off test
 Rack freeness test

 Binding plunger test

MUI Injector Tester

4-Aug-20
Holding pressure test /leak off test
 For better atomization and to avoid fuel dilution.
 Pump up pressure to1800 -2000Psi & hold it. No
leakages is permitted at the Nut to body seal ,filter
gap, gasket, body plug or between spray tip and
injector nut.
 In case of used injector, Time should not be less than
20 sec for pressure drop from 2000Psi to 1500Psi.
If less than reject.

4-Aug-20
 Rack freeness test
 Injector rack must be free.
 Rack binding results-
 Sluggish/Erraticspeed changes of engine.
 Over speed trip action.

 Cause of Rack binding-

 Damaged Teeth (Pinion,Rack).
 Scored plunger & bushing.

4-Aug-20
 Binding Plunger test
 This testing is done on Tester with help of popping lever
.
 Slowly release popping lever and simultaneously move
injector rack repeatedly in and out through its full
travel.
 Plunger binding results-
 Erratic cylinder firing.
 In extreme case, Engine may trip due to over speed.
 Causes of Plunger binding-
 Scoring of plunger.
 Broken of springs.

4-Aug-20
 Sticking of Injectors
 Usually occurs on injectors which are held with the
plungers down when the engine is stopped.
 In no case should injectors be cut out and the engine
operated.
 The engine should be shut down until corrective
action has been taken.

4-Aug-20
 Causes of low fuel oil pressure
 Inadequate fuel in fuel tank.
 Stuck Pressure relief valve
 Fuel filter choked.
 Suction line leak or restriction
 Injector with tip leakage
 Fuel pump malfunction
 Foreign material in the fuel tank

4-Aug-20
 Cyl. Pressure check/Blow Bye test
 Possible causes:
 Badly leaking exhaust valve
 Excessive ring blow-by
 Cracked piston
 Blow-by check procedure :
 Shut down the engine.
 Remove cylinder test valve from the cylinder to be checked.
 Rotate the crankshaft to bring the piston at apprx.TDC position.
 Apply 60 psi air pressure.
 Open flow valve & record steady state pressure.
 Valve leakage, Cracked piston is indicated if gauge reads
below 56 psi.
4-Aug-20
Exhaust Valve Tester

4-Aug-20
 Draining condensate from Fuel Tk
 Condensate should be drained from the locomotive
fuel tank at the intervals.
 During draining, the locomotive should be placed on
an incline with the drain end of the tank facing
downhill to ensure condensate accumulation at the
water drain valve.

4-Aug-20
FUEL PRIME/ ENGINE START Switch
 FP/ES, mounts on a box on the side of the equipment rack
on the right side of the long hood.
 FUEL PRIME-
 Lever turned to counter-clockwise stop. PRIME position tells the
computer to start the fuel pump motor and pressurize the fuel
system for starting.Also energizes auxiliary turbocharger lube oil
pump, ensuring supply of lube oil under pressure to turbocharger
bearings during engine startup.
 ENGINE START-
 Lever turned to clockwise stop. Applies locomotive battery power
to starting motors. Starting motor pinions engage engine ring
gear, then starting motors crank engine until engine starts and
FP/ES switch is released.

4-Aug-20
Fuel prime /Engine start switch

4-Aug-20
 GM Vs ALCO (On base of FOS)
 Fuel tank capacity of GM is 6000 Ltrs and Alco loco is
5000Lts.
 In Alco,FIP and injectors are connected by H.P tube, In
GM, Unit Injector with in built FIP. No HP tube.
 No Fuel oil pressure gauge in GM loco,Fuel oil pressure
at 8th notch in ALCO loco is about 3.2 kg/cm2.
 Both have paper type Primary filter. In GM a sight
glass is also provided on primary filter housing.
 Both have secondary filter, but in GM loco a spin on
type 02 secondary filter with return sight glass and by
pass sight glass are provided on filter housing.

4-Aug-20
 Schedule maintenance
 MONTHLY schedule
 Cleaning of fuel suction strainer.
 Draining of condensate from fuel
tank & checking for any leaks.
 Visual check of any fuel leaks in
top deck, examination of all
linkages.
 90/180 DAYS:-
 Renewing fuel primary and
secondary spin on filters.
 Checking the torque value of
fuel line bolts.
 Examination of fuel booster
pump gears for any scoring or
damage.
 YEARLY/2 YEARLY:-
 Renewing sight glass gaskets.
 Checking fuel relief valve and
Bye pass valves on test stand.
 Cleaning fuel tank glow rod
gauges and renewing ‘O-rings.
 Overhauling fuel pump, testing on
test stand and refitting.
 3 YEARLY:-
 Overhauling all fuel injectors and
refitting.
 Renewing worn out rack linkage
bearings and pins.
4-Aug-20
FORCED AIR SYSTEM FOR
GM LOCO
Lecturer(Diesel)/IRIMEE
 Objective
 Purpose of FAS
 FAS-Components & their role
 Lay out of compressed air system
 Process of Forced Air system
 schedule

4-Aug-20
 Forced Air System-Purpose
 Combustion air for Diesel engine.
 Cooling air for Main Generator and Companion
Alternator.
 Cooling air for Traction Motors.
 Cooling air for Traction inverter equipment.
 Pressurization of electrical cabinets.

4-Aug-20
 Major Components-involve
 Major parts involved in Forced air systems are –
 Central Air Compartment.
 Cyclonic filters.

 Baggie filter housing.

 Air Dust bin blower.

 Turbocharger .

 After cooler.

4-Aug-20
3
CAS

2
4
6
7

4-Aug-20
Lay out of Compressed Air system
TSC

4-Aug-20
 Central Air Compartment
 This compartment is used–
 for drawing the ambient air through cyclonic filters (inertial
air filters).
 Its location is in between the TCCs and engine
compartment.
 It is properly sealed so that unfiltered air should not
rush into it.
 Entry of air is done through inertial filters located at
either side of the locomotive car body and dirt blower
expels separated dirt, out to the atmosphere to the
bottom of the locomotive..
4-Aug-20
 Cyclonic Filter/Inertial air filter
 02 filter panel.
 Made up of a series
of tube to produce
cyclonic action.
 Each tube contain
special designed vane
that induce spinning
motion to the
contaminated incoming
air.

4-Aug-20
 Baggie filter/Engine Air intake filter
 Fiberglass bag filter element.
 Equipped with Pressure switches,
located inside the electrical cabinet,
connected by tubes, sense the
pressure difference between
Turbocharger inlet and ambient.
 Inside the electrical cabinet.
 They work as follows:
 If pressure difference exceed
356 mm/ 14 of water
column,(Filter Vacuum Switch
tripped).
 If pressure difference reaches
610 mm/ 24 of water
column, EM 2000 will reduce
engine speed and load to 6th
notch.

4-Aug-20
 Engine Air Filter-Precaution
 The used filter elements should be disposed-off. No
attempt should be made to clean & re-use.if re-applied
may result in serious damage to the engine.
 Improper alignment of filter elements can result in air
by passing the filters and entering directly into the
engine. This condition can be detected by a low
pressure drop reading across the filters.
 Ensure that there are no air gaps around the front
sealing surface.
 Fiberglass filter is designed to be maintained on a
scheduled. It should be replaced every 3 months
regardless of the pressure drop

4-Aug-20
 Main Generator Blower
 Mounted on Aux Gen
shaft.
 Both MG Blower and TM
blower are a internal
partition .
 Air from MGB, first cools
Main Gen Rectifier, then
M.Gen & Companion
alternator and goes to
Engine room.
 Filtered air is also used
by Air compressor. MG
BLWR
4-Aug-20
 Front Traction Motor Blower
 Mounted on Aux gen
closest to the Main
generator shaft .
 it supplies air for-
 Cooling of front Tr
Motors,
 Cooling of Traction
computer.
 Main electrical cabinet
pressurization. Front Tr.motor
Blower
4-Aug-20
 TCC Electronic Blower
 Located in central air
compartment
 Driven by AC motor
powered by
Companion Alternator.
 Supply air for cooling
and pressurizing of
some part of the
Inverter cabinet.

4-Aug-20
 TCC Blower
 2 Nos blowers, one for
each cabinet.
 3 phase AC motor
driven & powered by
Companion alternator.
 Supplying air for
cooling phase module
and cabinet.

4-Aug-20
 Air Dust Bin Blower
 Located in Central air
compartment.
 AC motor driven get
power from Companion
Alternator.
 Dirt and dust particles
present in the air which
are heavier than air is
thrown out through the
Dust bin motor to the
bottom of the
locomotive.
Dust bin blower
motor
4-Aug-20
 Process-Air intake system
 Air is initially filtered through
cyclonic filters.
 Finally filtered in baggie filters
and entered into the
Turbocharger.
 The intake air is compressed by
the turbo impeller & the outlet
air from the turbo enters both
banks After coolers
 Compressed air after cooling in
after coolers enter both bank air
boxes of the engine.
 Always pressurized air is filled in
the air boxes by Turbo.

4-Aug-20
 Turbocharger
 Engine driven through
gear train .
 Necessary for engine
starting, light load
operation and rapid
acceleration.
 Switches over to exhaust
gas drive from 6th notch
onwards by disengaging
mechanical drive with
the help of a Turbo
Over Running Clutch.
Blower
casing
4-Aug-20
 Why TSC requires mechanical drive?

 Positive pressure of air is required to enter the

chamber

4-Aug-20
 Oil leakage inspection of TSC
 Check turbocharger for external oil leaks & for
evidence of leaks in compressor section by oil at
joint of compressor scroll & by oil coming through
After cooler cores.
 Inspect interior of turbo exhaust duct for evidence
of internal oil leaks.

4-Aug-20
 Turbo screen/Adapter assembly
 Broken piston rings
,small exhaust valve
pieces etc entering the
turbine may damage the
turbine vanes.
 Function as a protective
device and fitted at
rear end of the
Exh.manifold.
 A small trap box
provided at the base of
the adapter.
Turbo
screen
4-Aug-20
 TRD of TSC
 Run the engine at 8th notch(retain for at least 15 min)
 See, all temperature and pressure should be in normal
condition
 Shut down the engine with the help of Law L.O pressure shut
down plunger.
 Wait for stop of crankshaft movement(it will take fraction of
time ).
 Now, start STOP WATCH and put ear near Tsc for listening
of sound coming .
 As sound stops, stop STOP WATCH.
 The time interval as noted should be minimum 50 sec or 71
to 72 Sec(ideal).

4-Aug-20
 Air box inspection
Three important air-box checks :
1. Inspect rings for blow-by.
This can be done visually. A
ring in good condition will
be bright & free from
vertical brown streaks.
2. With piston at BDC, inspect
piston crown for evidence
of broken pieces, oil, water
etc.
3. Inspect air-box for foreign
material

4-Aug-20
Air box inspection

4-Aug-20
 Air box condition
 Check TSC for oil leaks & for evidence of leaks in
compressor section by oil at joint of compressor
scroll & by oil coming through Aftercooler cores.

4-Aug-20
 Air box drain
 Air-box is designed to have a constant draining
feature
 Operation of air-box drains is to be checked and
cleaned, if necessary
 Cleaning tool (fabricated from music wire) is fed
into the drain hole to loosen carbon & sludge from
inside of drain pipes.
 External piping & drain flange is removed and hole
cleaned with brush and solvent
 Once cleared, flush the piping with fuel oil
4-Aug-20
 Causes of infiltration of Air
 Compartment door not tightly closed.
 Bolts missing/gaskets/ Seals are not properly
applied.
 Engine room partition and attached cover plates
are not properly secured and closed.
 Dust bin blower motor may not working and
rotating in the correct direction to exhaust the dust
particles.
 Inertial filter tubes may not be clean.
4-Aug-20
 SCHEDULES
 MONTHLY
 Cleaning and blowing cyclonic filters in reverse direction of
normal air Flow.
 Record pressure drop across cyclonic filters and baggie filters.
 90 DAYS
 Renew baggie filters.
 Visually examine the condition of Turbo Impeller.
 3 YEARLY
 Overhaul Turbo Clutch and refit.
 6 YEARLY
 Overhaul Turbo and re-fit. Re-conditioning is not advisable by
EMD

4-Aug-20
4-Aug-20