27-Aug-20

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.

27-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

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

27-Aug-20
 FUEL OIL SYSTEM
FOS WDG4choked)
WDG4(Primary filer
Primary filter
choke

Primaryfilter choke

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

Primary filter chock

27-Aug-20
 Fuel Tank

F/oil Tank
6000 lts 27-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.

27-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.
27-Aug-20
Fuel Booster Pump(modified)

27-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.
27-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.

27-Aug-20
PRIMARY FUEL OIL FILTER

27-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.

27-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.
27-Aug-20
Secondary filter-layout

27-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

27-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. SG No-2
 When fuel filter choked,
By pass V/v open and
diverts the fuel oil back
to tank.
 In normal condition ,this
“By pass sight glass” is
empty.
27-Aug-20
 Fuel in - out manifold
 The excess fuel is
used to cool &
lubricate the close
tolerence of Injector.

27-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.

27-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

27-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.
27-Aug-20
 Reconditioning/Overhauling
procedure
 Lapping of the following parts may be done-
 Bushing

 Plunger

 Spray tip
 Spring cage

 Spacer

 Flat check valve

27-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.

27-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.

27-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.
27-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

27-Aug-20
Injector calibrating stand

27-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

27-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.

27-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.

27-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.

27-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.

27-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

27-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.

27-Aug-20
Exhaust Valve Tester

27-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.

27-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.

27-Aug-20
Fuel prime /Engine start switch

27-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.

27-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.
27-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

27-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.

27-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.

27-Aug-20
3

CAS

2
4
6
7

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

27-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..
27-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.

27-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.

27-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
27-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
27-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
27-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.
27-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.

27-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
27-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.

27-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
27-Aug-20
 Why TSC requires mechanical
drive?
 Positive pressure of air is required to enter the
chamber

27-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.

27-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
27-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).

27-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

27-Aug-20
Air box inspection

27-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.

27-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
27-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.
27-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
27-Aug-20
27-Aug-20