AN INTERNSHIP REPORT ONWDS-6 LOCOMOTIVE (FOR 4-WEEK WINTER INTERNSHIP PROGRAMME at Diesel Shed, Shakur Basti , New Delhi) (Dec. 2012- Jan. 2013) (Delhi Technological University) Presented by: Mohit Gupta Jayson K. Varkey Swapna Singhal Manas Chitransh Jayati Takkar Gopal Kumar 1 ACKNOWLEDGEMENT A project of this magnitude cannot be completed without the support of many individuals, who constantly guided, supported and critically examined the efforts put in to the making of this report. We would like to express my sincere gratitude to my guide Mr. S. R. Pathak (Section Engineer, SSB) for his useful guidance and constructive criticism, throughout the making of this report; he was able to bring out areas of improvement, which proved to be very useful. We must concede that this project would never have been completed without the support and encouragement of Mr. R. K. Mehta ( Senior Section Engineer, SSB) .I would also like to thank all the railway employees & faculty members of our institute for their continuous assistance and useful guidance throughout the making of this report. 2 INDEX TOPIC INTRODUCTION………………………………………………………… EQUIPMENT LAYOUT…………………………………………………. GENERAL DATA………………………………………………………... LOCOMOTIVE SECTIONS…………………………………………….. LUBRICATION SYSTEM………………………………………………. CONCLUSIONS…………………………………………………………. PAGE NO. 3 5 6 7 13 16 3 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 when the first train made its maiden journey between Stockton and Darlington in U.K. The present railway track is a gradual evolution from these plate ways. 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.K in 1979 replaced iron plates with cast iron beams having stone supports at the ends for better working. In U.William Jessup of U.09.A. The first railway was opened in 1833 between Mohawk and Hudson.000 route km‟s and crises-crossing this great country from Himalayan foothill in the North to Cape Comorian in the south. Efforts were simultaneously made to replace animal power also by mechanical power. 5 . This was followed by a spate of development of railways system throughout the word and the firs railways was opened in Indian in 1853. The first time in Germany was opened from Nuremberg to Furth in the year 1835. This locomotive however. Simultaneously other countries introduced trains for carriages of passengers traffic at that time. Starting from this humble beginning the Indian railways system has grown up today into a giant network consisting of about 1. 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. could be used for traction on roads only.S. The maiden trip on Indian soil of the first train consisting of steam engine and 4 coaches was made on 16th April 1853 when it traversed a 21 mile stretch between Bombay and Thana in about 4 hours. 1825. 6 .Ahammed” Chairman of Railway Board “S. Amalgamation on 1947 Head quarters : New Delhi Key People : Union Railway Minister “Mamta Banerjee” Minister of State of Railways “Shri E.S. Narrow gauge and Wide Gauge.Indian Railways Founded : April 16. Khurana” Area covered : India Industry : Railways and Locomotives Type of track : Broad gauge. 1853. The railways transverse through the length and width of the country. In 1951 the systems were nationalized as one unit. Indian Railways had until very recently. Indian Railways operates both long distance rail systems. A year and a half later. the routes cover a length of 63. the year of India‟s independence. Indian Railways is the state owned Railway Company of India.Sindh and Sultan. 1853. it was hauled by three locomotives. and was used for the hauling of construction material in Roorkee. with more than 1. on April 16.in/ Introduction of Indian Railway:- The formal birth of Railway of in India was started in 1851. Covering distance of 34 km (21miles). transporting just over six billion passengers and the almost 750 million tonnes of freight annually. By 1947.Area network : 63. Indian Railways is the world‟s largest commercial or utility employer.It is the largest and busiest rail networks in the world. For administrative purposes it is divided into 16 sections.140 km (39. a monopoly on the country‟s rail transport .6 million employees. the first train in India became operational on Dec 22.indianrailways. 39236 coaches and 14444 trains daily including about 8702 passenger trains.Shaib. As of 2002 Indian Railways owned a total of 216717 wagons.gov. there were forty two rail systems. 1851. the first passenger train service was inaugurated between Bori Bunder to Thane (in Bombay) .140 km (In length) Owner : Government of India Website : http://www.462miles). becoming one of the largest networks in the world. 7 . It can however. Introduction of Shakur Basti Diesel Shed: Shakur Basti Diesel Shed was established in 1955. Indian Railways has a fleet of about 3800 BG Diesel Locomotives. the fuel is cheaper because it is less refined than petrol and it can do heavy work under extended periods of overload. be sensitive to maintenance and noisy. as opposed to the petrol (or gasoline) engine. his engine was in use on locomotives and he had set up a facility with sulzer in Switzerland to manufacture them. In 1892 and he is actually got a successful engine working by 1897. which is why it is still not popular for passenger automobiles. in a high speed form. Rudolf Diesel (1853-1913) in Germany. which are based in about 47-maintenance sheds spread all over the 8 .5 bar) and will increase the air temperature to over 800°F(427°C). The advantage of the diesel engine over the petrol engine is that it has a higher thermal capacity (it gets more work out of the fuel). At this stage. It is a field unit functioning under the dual control of the zonal office.DIESEL ENGINE:- The diesel engine patented by Dr. The diesel engine is a compression ignition engine. His death was mysterious in that he simply disappeared from a ship taking him to London. This would be expressed as a compression ratio of 7 to 10 will give an air pressure of 500 lbs/in2 (35. The sparks ignition engine uses an electrical spark from a “spark plug” to ignite the fuel in the engine‟s cylinders is ignited by the heat caused by air suddenly compressed in the cylinder. when he died. 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. which is a spark-ignition engine. by 1913. Baroda house. the air gets compressed into an area 1/25th of its original volume. New Delhi. and the office of divisional headquarters of northern railway. Diesel Shed.141 Sq. The heavy repair and bogie shed (3 berths for heavy & 2 lifting points).417 Sq. Shakur Basti is one such premier shed in Northern Railways homing 165 Diesel Locos. There are 9 posts of officers in the shed.m out of which 15. 4. Total manpower of shed is 854 . 3. The shed has a total berthing capacity for 17 locomotives under 4 covered bays. which has been connected. Because of its geographical location and being in the Capital.it serves a large number of Mail/ Express trains which run across the length & breadth of the country besides catering to goods operation. 2. Scale officers.m is covered.35 litres/EKM of lube oil consumption. Diesel Shed. Shakur Basti was established in the year 1955 with a planned holding of locomotives and initial holding of 82 WDS locomotives Shed containing a capacity of 3. 9 . Goods and out of course running bay (6 berths). The subassemblies section. There is one old steam shed. This shed has a capacity for berthing 4 locomotives and is not equipped with lighting and overhead crane . Shakur Basti has got one of the best staff/ loco ratio on Indian Railways. Mail running repair bay (6 berths). The main bays are:1.this shed can hence be used for light repairs only. The shed is headed by a Sr.country. Shakur Basti is spread over an area of 41. Scale and 6 Jr. Organizational structure staff strength: Shakur Basti shed has a sanctioned strength of 854 against which 698 persons are on-roll. DME who is assisted by 2 Sr. Air brake system. Air brake cylinders. Strainers and filters. Firing pressure. Any loose or defective part. Air intake system. Air intake filter. Expansion tank water level gauge. 10 . Brake system. suspension bearing. Lube oil pressure. Brake Connections. Buffers. These officers also report to the Sr. Overhauling of TSC. Fuel oil system. Manifolds & joints. Traction Motor Blower. DME. Lube oil system. 4) M12 schedule:.Repetition of trip and monthly schedule. Exhaust manifold. Water or oil leakage. Expresser Governor. Suspension bearing. Engine crankcase cover. Bogie etc. Filters. Running Mechanical & Goods/Mail Section: This section attends the locos of trip. MSU etc. Roller bearing axle boxes. Lube oil system. The training school and simulator centre have been entrusted to a separate assistant officer. Suspension bearing brackets. Air system. After cooler. Engine crank case. Air system. Cylinder Heads.Cooling Water System.Repetition of above mentioned schedules. Cylinder heads. Expresser. Expresser. 3) M4 Schedule:. Air & vacuum brake system. Gear Case. Following items are repaired /checked during each schedule:1) T1 . Sections under Shakur Basti Shed:1. Cylinder valve. Traction motor blower. Speed indicator etc. Compressor Governor. Lube oil cooler. T2 Schedule :. Expresser. Cattle guards. Traction motor blower. 2) M2 Schedule:. Expresser Crankcase. Cleaning of Wick Pads. The laboratory is looked by an ACMT and the attached stores depot by an AMM. monthly. four monthly and twelve monthly schedules. Engine. Any unusual sound. Air Dryer. Fuel oil system. radiator.TRD. After Cooler. Water sample. Cyclonic Filters etc. OST. Cylinder Head Section:- The cylinder head contains the inlet and exhaust valves. Unmodified Type has 15 mm. Valve seats are ground before inserting the valves. Plungers and modified type has17 mm. This section Has 2 types of FIP. SP 150 lube oil for expresser and Cardiam Compound for gear box. Plungers. RR 813 M lube oil for engine sump. 3. pressure drop in injector Etc. In this section assembly and testing of FIP is done and problems i. chattering. modified and unmodified. spray pattern of the injector. After this blow bye test is done to check the compression leakage from the valves and from the liner cylinder head joint. 4. FIP is present in the side of engine block over the cross head. wick pads and loading pads. 11 . The section Checks the fuel pressure in FIP. The main body of cylinder head is checked by Hydraulic testing. T 78 lube oil for governor. This section stores high speed diesel. FIP sends the fuel through The high pressure pipe and then into the injector. fuel nozzle contains 9 holes through which fuel is sprayed.e. FIP Section: Fuel injection pump (FIP) supplies fuel at high pressure to the cylinder in which the fuel is burnt. push rods for operating these valves & fuel injector.2. The section replaces the damaged valve seat inserts. dia. Here calibration of FIP is also done because it has to release a particular quantity of fuel at correct time called Phasing. In FIP. It is operated by the cam shaft. dribbling are removed. valve guides & injector sleeve. dia. Fuel Section:- It keeps the record of the amount of fuel oil and different types of lube oils issued to a loco. VSI. Main frame is checked for cracks by RDP test and axles are checked by Ultrasonic test. piston and piston ring and connecting rod. traction motors. 12 . suspension bearing and suspension system. axle boxes. connecting rods etc. all these components are disassembled and sent to their respective sections. lube oil and Water pump. Bogie Section:- The section has two types of bogies. Power Pack Section:- In this section dismantling of whole engine block takes place. Here the conversion of chemical energy released by burning of diesel is converted to mechanical power at the main crank shaft and this is done with the help of various components like Crank shaft. FIP. Cylinder heads. liners. After proper inspection The engine is reassembled. joining the connecting rod with crank shaft.e. It is the most important part in the diesel locomotive which generates power. Suspension system of the bogie consisting of compression springs and hydraulic shockers is also inspected on the test bench. In the section the bogie is dismantled. There they are checked for defects and cracks by various methods. 6. cylinder head and valves. All these Components are assembled in main engine block and this assembly is called Power Pack. Cross heads. axles and wheels are removed off. 2 axle bogies and 3 axle bogies. main bogie. are replaced. conventional and high speed are cleaned and lubricated again by grease. A bogie has axles. Condemned parts like piston rings. wheels. camshaft. Water and lube oil pump. After this all the respective clearances are checked. traction motors. The 2 types of axle boxes i. cylinder lining.5. pistons. pistons. Extreme care is taken in setting the piston rings. 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. The framework on which the power pack. The surfaces of wheels are Flange & treads which prevent derailment & part which comes in contact with rail respectively. There are many parts combined to form bogie:(a) Axle:. main bearing fitment. This time taken for this schedule to complete is 15 days. In the section they rectify the speedometer defects like cable 13 . In this schedule whole loco is dismantled and all parts are sent to their respective sections for repair and replacement. An indicator is also placed in the driver cabin for speed matching. (d) Wheels:. (e) Suspension bearings:. Removing the generator deflection. generator etc. OST calibration. crankshaft and camshaft thrust deflection setting.It prevents jerks due to irregularities on track & protects the power pack as jerks can cause serious damage to power pack.The part of axle on which the under frame rests.DC series motor which take electricity From generator & gives motion to wheels. (b) Axle box: .There is two per axle. (f) Suspension . block alignment are some activities which require extreme care.It is a shaft connecting both wheels & has a bull gear. (c) Traction motor:. Speedometer Section:- Speedometer is a device installed in the loco to measure and store the speed of the train. It is also known as M24 section. 7. It is having compression spring acting as shock absorbers. 8. rest on. Yearly Mech. Section:- Yearly schedule takes place in 24 months. ultrasonic test and magna flux test are employed for testing the cracks.D. This condition is achieved by a TSC. Metallurgical Lab:- This section has the following different parts: N. Shift lab:. The impeller sucks the fresh air from outside and this air passes through the diffuser ring which compresses it and this compressed 14 . Zyglo test. junction fault. Also they set the speedometer at a definite speed of 110Km/Hr.Here different components are checked before reusing for any type of crack or breakage. viscosity of lube oil. For higher HP we need to inject more fuel and for burning more fuel we have to supply higher amount of air. 11. TSC is attached to the exhaust manifold of the engine. red dye penetration test. Spectrographic lab:. The components are tested without destroying them. Turbo supercharger Section: A TSC is used to increase the horse power of the diesel engine. oil and water seals of the pump is checked here. Pour point. the exhaust drives the turbine which in turn drives an impeller.This lab checks the viscosity. chromium. silicon & boron. iron. lab:. Pump Section:- The section deals with water & lube oil pumps and cross heads. 9. Sulphur content. Density. water contamination etc. Flash point of the diesel when it is delivered to the shed by the company. tin.This lab checks the presence of water in lube oil. sodium. memory card fault etc. lead. Diesel lab:. A TSC increases the HP up to 30 to 50% . The condition of bearings. 10.This lab checks the presence of different elements in the lube oil like copper.fault. aluminum. The section also replaces the damaged rollers of the cross head.T. (a) ALCO:. 3100hp Locos 15 .air is passed into different cylinders. The defective parts are repaired or replaced. HISPANO SUIZA and GE.for 2600Hp Conventional WDM-2 Locos (b) ABB:. Currently TKD shed is using 5 type of TSC.for 2300Hp. NAPIER. In the section overhauling of the TSC is done. ABB. 2600hp. They are ALCO. for 3100Hp Locos (d) Hi-Spano Suiza:.for 3100Hp Locos (high life duration & Air cooled) 16 .(c) Napier:. 17 . The air in MR2 is used in breaking system and air in MR1 is used in other supplementary operations like horn. The expresser section overhauls the expresser.(e) GE:. vacuum maintaining valve. governor. loading/unloading. feed valve.for 3100Hp Loc 12.2 Kg/cm Sq. for operating sanders etc. are checked on the test bench. 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. CTA Cell:- CHIEF TECHNICAL ADVISOR CELL (CTA) : The main works in this section are following:(a) Loco failure analysis by complete investigation of cause Of failure. 13. The vacuum produced is used in breaking system and compressed air fills the MR tanks. (b) To record of performance & suggested new innovation or Modify design. pump. pressure needle etc. loader unloading assembly. its different parts like safety valve. For how much time the loco remained in the shed. DEMU:- A DEMU or a Diesel. Control Room:- It works as an operating unit and notes the following parameters: Arrival time of the loco in the shed.efficient on almost all railways of the world.braked and enjoy a fast acceleration and reacceleration. AC-DC or AC-AC. How much lube oil the loco has consumed per 100 kilometers. The transmission of the power from the diesel engine to the wheels is done by converting the mechanical energy into electrical energy and feeding the electrical energy to the traction motors on the wheels. They are usually air. (d) To give daily report of each loco to headquarter. Leaving time of the loco from the shed. This controls the fuel supply to the fuel actuator 18 .electric multiple unit is a self powered train set which can move in either direction. The diesel engine is governed by an electronic load and speed control card supplied by Governors America Corp(GAC). How much distance the loco has traveled. 14.(c) It keeps loco holding record & technical report of each schedule perform on particular loco. 15. The conversion of energy may be into DC/AC and hence the transmission may be DC-DC. It is powered by an on-board diesel engine on one of the cars and consists of two or more cars with a provision for the driver on either end of the train set. The DEMU is controlled on either end of the train set. DEMUs are very popular and widespread being energy. The four 19-pin control cables run through the length cf the train and are interconnected from one car to the other using couplers. 8 ( 18.42% Weight in working order (in tonnes) Axle load max. in tonnes) 112.5 KMPH 42500 kg at 20 KMPH Adhesion 0.0 21.and hence controls the supply of fuel into the diesel engine by sensing the load of the train.0 18.0 19 .80 80.27% 0.8 112. FEATURES OF DIESEL ELECTRIC LOCOS Description Year of introduction WDM2 1962 WDM2C 1994 WDP1 1995 WDG4 2000 Tractive effort max (in kg) 30450 45600 21000 53000 Tractive effort cont.8 20.0 126.25% 0.8 KMPH 15050 kg at 31.27% 0. 24600 kg at 18 KMPH 28050 kg at 22. Mount Co-Co Tri-Mount Co-Co Tri-Mount Co-Co High Adhesion Lube Oil sump Capacity (in Ltrs) 910 1270 740(SS) 760(LS) 950 Fuel Oil sump Capacity (in Ltrs) Water Oil sump Capacity (in Ltrs) 5000 5000 3000 6000 1210 1210 1210 1144 20 .Speed potential (in KMPH) 120 120 120 100 Length (in mm) 15862 15862 14810 19964 Distance between Bogie (in mm) Wheel arrangement 10516 10516 8800 13868 Co-Co Tri. 6 X 266. 900T on level gradient at 120KMPH. Ratio 12.19 X 279.7 228.4 Comp.e.6 X 266.Transmission DC-DC AC-DC AC-DC AC-DC Driving Right Hand Left Hand Left Hand Left Hand Hauling Capacity 3600T on level gradient at 75KMPH.7 230.7 228. 1100 Tonnes on level gradient at 100KMPH. of Engine Cylinder /loco Bore & Stroke(mm) DLW 251B DLW 251B 45 degree V-type 12 GM 710 G-3B 45 degree V-type 16 45 degree V-type 16 45 degree V-type 16 228.5:1 13:1 16:1 21 .17 coaches (with2AC/SG) at 100KMPH and 9AC coaches(EOG) at a speed of 120KMPH ALCO/DLW-251B 4700T on load1:500up gradient at balancing speed of 69KMPH.5:1 12. 21 coaches (with2AC/SG) at 100KMPH 17Coaches 58 Box Load i.4700Tonnes in 1:150 up gradient Diesel Engine make and type Cylinder Formation No.6 X 266. UIC condition 2600 3100 2300 4000 4132CV(AAR condition) HP at Site 2400 (55°C-600mm) 3007 (47°C-600mm) 2750 2231 (47°C-600mm) 2000 4012 (47°C-600mm) 3780CV HP input to TM 2250 Type of Injection System Jerk.6 15. direct Jerk.P. (kg /cm^2) 13.Engine RPM rated/idle 1000/400 1050/400 1000/350 904/269 (200low speed) B.89 9. direct Jerk.M.E.041 15.75 11. direct Direct injector Type of Pump Injector Mico-APFICO AKK Mico-APFICO AKK Mico-APFICO AKK Mico-APFICO AKK 22 .38 HP at Std.89 8.23 (at rated output) Mean Piston Speed(m/sec) 8.33 8. 67 EMD model BAP (kg/cm2) 1.97 Engine Governor EDC Wood Ward EDC Wood Ward EDC Wood Ward EDC Wood Ward Engine Water Pump Centrifugal Centrifugal Centrifugal Centrifugal OSTA Tripping Range(RPM) 1120-1160 1120-1160 1180-1220 SFC (gm/bhp/hr.GE GE 7S1716 1. GE 7S1716 ABB VTC-304-VG15.Make & type of Turbo ALCO-720 ABB VTC-304-VG15. NapierNA295IR.6 1.4-1. NapierNA295IR.) 153-155 161-165 (ALCO TSC) 155-157 157-159 Loco Brake System 28LAV-1 IRAB-1 28LAV-1 KNORR/NYAB CCB 23 . 3700A.1690kW Cyli.3400A. Dynamic &Emergency Brake A-9. 760V. 1050rpm/LV. Dynamic(Pure Air Brake System) Expresser/ Compressor KPC-6CD4UC KNORR CCB-W L N A 9B. Parking& Emergency Brake KPC KE-6 ELGI-6CD3UC Air.SA-9. Hand. Gen. Dynamic &Emergency Brake KCW-523/623 ELGI-LG3CDE A-9. Make& Type Of Tr. 1000rpm.1850A.2 Stage. Motor BHEL-TM 165 M/ 4906AZ BHEL-4906AZ BHEL-4906AZ SIEMENSITB-2622 24 . AltGM TA-17 Rating (continuous) 680V. 1000rpm/HV. Hand.Type of Brake A-9. 525V.1760A. Hand.Head Insulation 1100V.2480A. 413V. 1000rpm/LV.SA-9./ Alternator BHEL-TG 10931-AZ/M BHEL-TA10102CW/DW BHEL-TA 10106 AZ Tr.3Cylinder Fan drive Eddy Current Clutch Eddy Current Clutch Eddy Current Clutch AC Motor Make& Type Of Tr. 1000rpm/HV.SA-9. 980A.248kW. Gen/Exictor BHELAG51/M BHELAG3101AY/ AY1 BHEL-AG2702AZ GM-5A-814/ GM-CA6B Rating (continuous) 75V. 950-2620rpm as Exictor Centrifugal multi vane 74V DC at 904rpm Front Tm Blower Centrifugal multi vane Gear Driven Centrifugal multi vane Movable inlet guide vane. 950-2620rpm as AG 95V. 3600rpm. 12kW CLF Insulation 75V. 360rpm.248kW. Cyli. 950-2380rpm as Exictor 75V.Head Insulation 2850V.OTA02 Rating (continuous) 285V.Head Insulation.220A.220A.160A. Cyli.160A. 950-2380rpm as AG 95V.960A.980A. 360rpm.Head Insulation 285V. GFOLR Setting 230-240A 275-285A 230-240A 25 . 850-2380rpm. 500kW Gear Ratio 18:65 18:65 18:65/22:61 90:17 Make& Type of Aux.248kW Cyli.160A. ) Exide4HMFG31KP 74V/450AH (10hr.) Exide4HMFG31KP 64V/500AH (10hr.2.3) Power Contactor FS Contactor 9 (3S+6P) 6 9 (3S+6P) NIL 4 (P1.) Surrette Exide-16H-25 26 .5.2.P2.49& 78KMPH 1 Transition 49KMPH 1 Transition 60KMPH Cranking Contactor 2(CK1.P4) 4 Battery 64V Lead Acid Battery Exide-MGD-19 64V/450AH (10hr.Transition 3 Transition 31.2) 3(CK1.P3.3) 3(CK1. diesel engine of four stroke cycle having an open combustion chamber with solid fuel Injection.W. turbosupercharged. It includes a diesel engine connected to an electric generator creating electricity that powers electric traction motors. 228 mm x 267 mm. 27 . No clutch is required. The engine speed is governed by an electrohydraulic governor (W. Controls are applied for multiple unit operation with all units controlled from one cab. 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. Each locomotive is powered by a 6 cylinder inline.Governor). of vehicles and ship types for providing locomotion.INTRODUCTION Diesel-electric transmission Diesel electric transmission or diesel-electric power train is used by a no. WDS6 AD The six motors WDS6 AD locomotive are designed for shunting service. 36197.36*** No. WR 28 . Ratlam shed. All IR 6***. Incorporates a YDM4 Alco power pack.Series Unit shown 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.Type Gauge Wheel Argmt Brakes Power History & Devpt Railways No. The entire electrical transmission from the MG YDM 4 to make a fine 1200 HP shunter and trip locomotive. 29 . Lubricating oil is cooled by the water in the lubricating oil cooler. Full pressure lubrication on all parts is provided.The loco uses a 6 cylinder inline Alco engine. 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. Lack of Dynamic Brakes has allowed the short hood to be cut down. and the water by fan cooled radiators. Note the 'Alco' inspired cab roofline WDS 6 (Heavy-haul shunters made in large numbers for industrial concerns as well as for Indian Railways Rated at 1200/1350 hp) The diesel engine has an all welded steel frame. AIR & VACUUM BRAKE PANEL 16. RECTIFIER 15.EQUIPMENT LAYOUT 1. AIR RESERVOIR 22. CONTROL DESK (NID) 7. T. TRACTION 3. WATER EXPANTION TANK 21. LUBE OIL FILTER 14. COMPRESSOR 5. LUBE OIL COOLER 13. T. FLEXIBLE COUPLING 25. TURBOSUPERCHARGER 10. HEAD LIGHT 26. GEAR COUPLING 24. BLOWER FRONT 12.M. FUEL TANK 20. 19. MOTOR TRUCK 30 . CONTROL COMPARTMENT 9. ENGINE 2. EDDY CURRENT CLUTCH 18. BLOWER REAR 17. BRAKE VALVES 8. RADIATOR 23. BATTERY BOX ARRGT.M. ALTERNATOR BHEL 4. RADIATOR FAN 6.FILTERS-CYCLONIC 11. ............................. 1350 / 1150 GEAR RATIO......................... 3022 mm LENGTH OVERALL ................................... 0............................................................................ 28LAV .......................................................................................................................... 4027 mm WIDTH (MAX) ... Co-Co ENGINE HORSE POWER ........................................ 17430 mm TRACK CURVATURE (MAX)................................................. 73.............. 114000 Kg 31 ......................GENERAL DATA MODEL NUMBER....................................... 645 litre SAND .....TOTAL CAPACITY : FUEL OIL TANK................... 170-10’ Rad.................................... ...................................................... 530 litre COOLING WATER ........................................................................................................ 3000 litre SUPPLIES ...................AAR.................................... 65 KMPH TRACK GAUGE...1 FUEL OIL TANK CAPACITY .................2 m WEIGHT : TOTAL LOCOMOTIVE............................... 5000 litres LUBRICATING OIL ....................... 1097 mm JOURNAL SIZE ....................... 1676 mm BRAKE EQUIPMENT........................................ 74 / 18 LOCOMOTIVE SPEED MAX............................................ 150 mm PRINCIPAL DIMENSIONS : HEIGHT (MAX) ...40 M 3 WHEEL DIAMETER (NEW) ....................................................................... WDS6AD CLASS ....... Two specific types of construction are used by radiator manufacturers. Brazed construction core have .LOCOMOTIVE SECTIONS 1. the construction is soldered. in turn. Soldered construction cores are made up of . The radiator core is the basic unit of the assembly and is bolted to cast iron or fabricated steel tanks using a gasket seal. while if the metal is harder and has a yellowish hue. it indicates brazed construction. are made up of one or more cores. 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.018 inch wall seamless copper tubes fitted through copper cooling fins and brazed to a copper alloy header. 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. Ceres are constructed of thin walled tubes which are passed through cooling fins and attached to tube sheets or headers at each end. the soldered core construction and the brazed core construction. If the metal uncovered is soft and white. 32 .012 inch wall lock seam soldered copper tubing fitted through copper cooling fins and soldered to a copper alloy header.Radiator assemblies are made up of one or more panels which. 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. diesel engine of four stroke cycle having an open combustion chamber with solid fuel Injection. 33 .W. into a bolting strip. The engine speed is governed by an electrohydraulic governor (W.RADIATORS WITH VERTICAL TANKS Two radiators. Each radiator is hinge-mounted to two angle irons. this gas pressure forces the piston down. Bolts. A tank is flange bolted to each of these header plates. The resulting combustion increases the cylinder pressure and on the third or power stroke. 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. Each cylinder requires two engine revolutions for four strokes of the piston to complete one working cycle. turbo supercharged. DIESEL ENGINE Each locomotive is powered by a 6 cylinder inline. fuel is injected into the cylinder where it is ignited by the heat of the compressed air. 2. one vertically mounted on each side of the radiator compartment. the other an outlet connection. cool the water from the engine. the top angle being secured to the compartment by flat head machine screws and the bottom angle to the floor by welding. Just before the end of the compression stroke. at the rear of the radiator secure the radiator to the compartment bulkhead. one tank having an inlet connection. 228 mm x 267 mm. Each radiator consists of a single core made up of lock seam copper tubing fitted through and soldered to copper fins and end header plates.Governor). On the fourth or exhaust stroke. 34 . 5. the burnt gases are expelled by the piston travelling upwards. The auxiliary generator furnishes power for battery charging. The blower next to the radiator compartment is belt driven from the fan drive shaft and supplies air to the motors in the truck directly below the radiator compartment. lighting and control circuits. TRACTION MOTOR BLOWERS The traction motor blowers supply ventilating air for the traction motors on both front and rear trucks. The traction alternator produces alternating current and rectified to direct current with alternator mounted rectifier for the operation of the traction motors. TRACTION MOTORS Each traction motor is supported by axle suspension bearings and a resilient support spring nest mounted on the truck transoms. A second blower is gear driven from the main alternator shaft and supplies air to the motors in the truck below the cab. 4. Shrunk on to the motor armature shaft is a pinion which meshes with a drive gear pressed onto the wheel axle. The exciter furnishes excitation for the traction alternator. and by scavenging action of the inlet made possible by a large intake and exhaust valve overlap. TRACTION ALTERNATOR AND EXCITER-AUXILIARY GENERATORS The traction alternator is directly connected to the diesel engine crankshaft while the exciter-auxiliary generator is gear driven from the traction alternator shaft. 3. AUXILIARY EQUIPMENT An extension shaft from the diesel engine drives the compressor exhauster through a flexible coupling. Power to drive the compressorexhauster unit comes from the diesel engine through a flexible coupling major components are crankcase. intercooler. A shaft from the compressor exhauster then drives the radiator fan through an eddy current clutch and right angle gear box. COMPRESSOR Locomotives equipped with vacuum brake systems have a compressorexhauster unit. Since these compressors are of the compound type. connecting rods. 7. 35 . crankshaft pistons. which the discharge air from each low pressure cylinder passes to the intake of the high pressure cylinder. exhauster cylinders connected in parallel and fan for cooling. Air passing through the strainer unit enters the compressor intake.6. which furnishes compressed air for purposes of locomotive control and vacuum for the train brakes. The use of an intercooler reduces the temperature of the discharge air and improves the volumetric and overall efficiency of the compressor. 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. each is fitted with an intercooler through. employing finned copper tubing mounted between cast iron headers except on the 6 CD-3UC machine. low pressure and high pressure compressor cylinders. The intercooler is of the radiator type. Gear 8. lifting Arrangement 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. Sanding Arrangement 10. The bogie frame in turn is supported on axles through helical coil spring mounted on equalizer beams. 6 WHEELS. Gear Case Assembly 6. T. Center pivot does not take any vertical load and is used only for transfer of traction and braking forces. 1. No. Bogie Frame Assly 2. Axle & Axlebox Arrangement 4. 4907 7. 3 MOTOR This is a 3-axle type bolsterless with two stage suspension. The equalizing mechanism consists of 36 . Nose Suspension Arrangement 3. Wheel. Suspension Arrangement 5. TRUCK. Bogie frame is of straight and fabricated box type construction with three transoms to carry nose suspension.8. The general arrangement of bogie is shown in fig.M. -floating and uni directional arrangement of axle hung nose suspended traction motors. Brake Gear Arrangement 9. 1. From here. 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. BRAKING SYSTEM Bogies are provided with conventional brake gear arrangement as shown in Fig. the brake shoe comes in contact with the wheels and the brakes are actuated. Compressed air tapped from the compressor is stored in the MI tank. 2. 9. compressed air is extracted and pushed into the pistons as shown in fig 2. 37 . Fig 2 BRAKE GEAR ARRANGEMENT The system is mechanically linked such that when the piston moves out due to the incoming compressed air.equalizers hung directly on end axle boxes and supported on middle axle box through a link and compensating beam arrangement. The other is a full flow pleated 38 . and bacteria from the air. When there is gradual drop in fuel oil pressure. fig 1 attached to the left side of the engine There are two different types of filter cartridges in use. LUBRICATING OIL FILTERS The engine lubricating oil system contains single-unit cartridge type oil filters. It is locatedat the starting of air inlet manifold. mold. check both primary and secondary filters. One is a cotton waste type sock which requires the use of a cage assembly. The primary filter is located between fuel oil tank and suction side of booster pump. it require 7-1/2 pounds of long strand cotton waste packing.FILTERS AIR FILTERS It is a device composed of fibrous materials which removes solid particulated such as dust.Along with the air brakes. pollen. If a sock is not used and is hand packed. 10. The secondary filter is located between engine and discharges side of booster-pump. FUEL OIL FILTERS Fuel oil filters consist of two types of filters Primary Secondary These filters are basically of same construction except in size and filtering element. vacuum brakes may also be used for which the brake compressor-exhauster unit is used as explained above. This type of filter is painted “red” for identification and is marked “DO NOT OIL”. 39 . However. the elapsed time between such necessary servicing will depend on and vary with the severity of dust conditions encountered in operation. PANEL FILTERS Panel filters of the dry impingement type should be cleaned periodically.cotton paper filter cartridge which does not require the use of a cage assembly. Adequate lubrication allows smooth continuous operation of equipment with only mild wear.52 4.0 13.48 9.by interposing a substance called lubricant between the surfaces to carry or to help carry the load between the opposing two surfaces . Brand names of various industrial lubricants (other than engine oil and greases) listed herein are in lieu with International Organization for Standardization (ISO) classification.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 .98 2.14 5.6 61. 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.4 50. Max.0 11. 506 612 748 900 1100 1 350 1 650 40 . The ISO viscosity grade number designates the mid point of kinematics viscosity range in Cs at 40°C.5 16.88 3.8 90 110 135 165 198 242 288 352 414 .2 74.12 7. 1.42 2.06 6.2 41.5 19.8 24.2 28.8 35. 41 .tests for physicochemical properties must se carried out for identification of the product. Before using any branded lubricant.HANDLING OF LUBRICANTS Handling of lubricants must be done carefully. At the time of change over from one brand of lubricant to another. For this purpose. Lubricants container should also be kept under covered condition Use of dirty hands in handling lubricants should be avoided. these are not necessarily compatible with each other. 2. Although different brands of lubricants marketed by different oil companies may have been recommended for the same applications. 4. It must be ensured that the specific brand meets the specification requirement. 3. IMPORTANT Following points should also be kept in mind: 1. the lubricated parts should be thoroughly cleaned and the system flushed before charging the new brand. It should be ensured that no two lubricants are handled in the same service container. In case recommended lubricants are not available. matter should be referred to RDSO (Motive Power Directorate) for suitable advice Lubricating oils used in an engines should be changed semi-annually or more often if indicated by Laboratory analysis. even though these Lubricants may appear to be similar. The hot lubricating oil enters the shell at a flange connection on the top at one end. and leaves the cooler at the bottom flange connection at the other end of the cooler. two removable end covers which contain the inlet and outlet water connections. The oil then passes through the fine mesh screen and out of the strainer shell.Min.. cst 100 deg. The strainer screen is “star shaped” to provide maximum straining area.AN EXAMPLE OF LUB. Cooling water from the water circulating pump flows into the cooler at the end cover connection. During this process Heat is removed from the oil due to its contact with the tubes. LUBRICATING OIL STRAINER The lube oil strainer is of the basket type with oil entering the strainer at the bottom shell connection. 3 Mrs. through which the cooling water is flowing. OIL SERVOCOAT170T Kinematic Viscosity. Mill Timken OK Load kg . circulates back and forth across the tubes. Color Copper Strip Corrosion @ 1000C. Baffles are provided inside the shell to channel the oil flow in the most efficient manner. It consists of a shell with inlet and outlet oil connections. and a tube bundle held by two tube sheets welded to the cooler casing. Flash Point(COC) deg. through the tubes and out of the other end of the cooler. the oil flows up through a hollow tube and flows over the top into the space between the tube and strainer screen. 710-760 280 15 Black 1 LUBRICATING OIL COOLER The lubricating oil cooler is a heat exchanger of the horizontal shell and tube type. 42 . Max. WDS-6 belongs to the category of Diesel-electric transmission and still used for shunting purposes at railway stations where their use is still remains not that significant.4A. The locomotive rated at 1000-1200 hp was majorly used in the sheds such as Ratlam . With the advent of DEMU and battery operated locomotives(in some areas) . ERS.4C.(in abbreviations). it was used as Heavy-haul shunters made in large numbers for industrial concerns as well as for Indian Railways.4D which still exist as broad gauge locos with diesel-hydraulic transmission. Krishnarajapuram(KJM).CONCLUSIONS The locomotive WDS-6 is a yester-year engine which is not being used nowadays. Further improvements and additions to this Engine has led to WDS-6 with electric car as well as Biodiesel being used to run the loco.KGP. 43 . Delhi(Shakur Basti and Tughlakabad). In its years of full functioning .4B. Pune. others being. The use of WDS series is reduced to WDS-4.VTA etc. 44 .