LOCO DIESEL SHED , PHULERA

About Indian Railways

 Indian Railways has one of the largest & busiest rail networks
in the world.
 It comes under the Ministry of Railways.
 It is the world’s largest commercial employer, with more than
105 million employees.
 The fleet of includes over 200,000 wagons, 50,000 coaches,
8,000 locomotives.
 It also owns locomotives & coaches production facilities.
 Indian Railways transporting over 20 million passengers.
 Indian Railways are divided into 16 zones. & each zones is
made up of a certain no. of divisions. There are 67 divisions.
 The total length of the track used by Indian Railways is about
108,805 KM (67,608miles.)
 About 50% of the total track KM is Diesel .
 It also operates the Kolkata, Delhi metro.
WHAT IS DIESEL SHED
 Diesel locomotive shed is an industrial – technical setup, where
repair & maintenance works of diesel of diesel locomotives is
carried out, so as keep loco working properly.
 It contributes to increase the operational life of diesel
locomotives
 Minimize the line failure
 The technical manpower of a shed also increases the efficiency
of the loco.
 Diesel shed usually has -;
 Berths & plate for loco maintenance
 Pits for under frame maintenance.
 Heavy cranes, lifting jacks.
 Fuel storage & lube oil storage, water treatment plant & testing
labs etc.
 Sub-assembly overhauling 7 repairing sections.
 Machine shop & welding facilities.
SHED INFRASTRUCTURE
SHED AREA ----------------------------------------------------------- 2261 sq.m .

M.G SETELITE SHED----------------------------------------------- 1965- 1997.

M.G HOME SHED---------------------------------------------------- FROM 1997

HOLDINGS ------------------------------------------------------------- 64.

SHEDULES------------------------------------------------------------FOUR(TI1,TI2,M3,M9 )

STAFF CADER----------------------------------------------------------- 100

BEARTHING SPACE---------------------------------------------- 9 LOCO SHEDULE PIT

2 LOCO LOAD PIT

MANUFACTURER----------------------------------------------------- ALCO/ DLW

SHED LAYOUT
MAIN STORE RUNNING STORE ELECTIRCAL INJETION & FUEL BRAKE ROOM
CONTROL ROOM ROOM

PIT WHEEL LATHE CLEANING & WASHING

PLANTS

LIGHT REPAIR BAY MAIL

OVER HANDLING SECTION

LAB / TESTING

HEVRY REPAIR BAY / SMALL PART OF CRANE

DEMINERALISED WATER
PLANTS
OFFICE BLOCK

VEHICLE STAND
CANTEEN
THREE GENERAL CLASS OF LOCOMOTIVES
Freight locomotive – For designed with
slower speed, acceleration and have
capacity to pull heavier load as
compared to another.
Ex. (WDG2, WDM4)

Passenger locomotive-- For designed

with high speed, fast acceleration &
light loads. Ex. (WDP2, YDP4)

Shunting locomotive-- For designed

with slower speed, low HP and suitable
for shunting purpose onl.
Ex. (WDS4, WDS6)
CLASSIFICATION OF LOCOS
 The first digit [gauge]
 W= Broad Gauge
 Y= Meter Gauge
 Z= Narrow Gauge WDM3

 The second digit [power]

 D= Diesel
 C= DC traction
 A= AC traction
 CA= Dual-power AC/DC traction
 B= Battery electric (rare) YDM3

 The third digit [load]

 M= Mixed Traffic
 P= Passenger
 G= Goods
 U= Multiple Unit ( EMU/ DEMU) ZDM3
 R= Railcar
How to start LOCO

 Compression ignition engine

 Firing order - 1,4,2,6,3,5
 Cycle of operations – suction, compression, power,
exhaust
Sections view of Diesel Engine
LOCO Specification YDM4
 Engine Model:- YDM4
 Engine Company:- ALCO
 No. of Cylinder:- 6
 Cylinder Arrangement:- Inline
 Cylinder Shape:- I shape
 Engine BHP:- 1200
 Max. Weight:- 72 tone
 Traction HP:- 1200HP
 Gross HP:- 1280HP
 Starting Speed: 100-150 r.p.m
 Compression Ratio:- 12:1
 Full Speed:- 400-1100 r.p.m
 Max. Speed:- 1200 r.p.m
 Fuel Tank Capacity:- 3000 lit.
 Wheel Arrangement:- co-co
 Radiator Fan:- 41HP
 Firing order is:- 1-4-2-6-3-5
 Dia. Of Wheel:- 965 mm
 Compressor:- 1100 r.p.m
 Battery:- Series Compound Shunt
SIX MAIN COMPONENTS OF ENGINE
NOSE – It consists head light, sand box, resistance grid.

DRIVER’s CAB – It consists long hood, short hood, control stand, air brake control stand,
booster air pressure , indicating lube oil, pressure gauges, mechanical control &
electrical speedometer and load meter.

MAIN GENERATOR COMPARTMENT – It consists traction motor, excitation

generator, auxiliary generator, front traction motor blower and housed in this
compartment.

ENGINE ROOM - It consists after cooler, turbocharger governor, fuel injection pump,
fuel oil filters, lube oil filters, water pump, extension shaft, expressor spline
coupling.

EXPRESSOR COMPARTMENT – It produces a vacuum compressed air which is used

for braking purpose, pump for hydraulic governor fuel booster pump & fuel booster
pump motor are also kept.

RADIATOR - Radiator fan, radiator panel, lube oil, right angle gear box, driving radiator
fan, eddy current clutch which converts right angle gear box to diesel engine’s
extension shaft.
Parts of loco
ARRANGEMENT OF WHEELS IN THE LOCO
 Wheels are first
arranged into bogies.
 It provides greater
flexibility.
 They are represented in
two blocks separated by
(-) sign.
 This type of bogies are
called CO-CO.
Function of components
 Main Generator
The diesel engine drives the main generator which provides the
power to move the train. The alternator generates DC
electricity which is used to provide power for the traction
motors mounted on the trucks (bogies).
 Auxiliary Generator
This provides DC power for lighting, heating, air conditioning,
dining facilities etc. on the train.
 Motor Blower
Motor blower provides air which is blown over the traction
motors to keep them cool during periods of heavy work.
 Air Intakes
The air for cooling the locomotive's motors is drawn in
from outside the locomotive. It has to be filtered to remove
dust and other impurities
 Batteries
The diesel engine needs a battery to start it and to provide electrical power for
lights.
 Traction Motor
Traction motors are provided on the axles to give the final drive. These motors
were traditionally DC
 Fuel Tank
The fuel tank is normally under the loco frame and will have a capacity of 3000
lts.
 Air Reservoirs
Air reservoirs containing compressed air at high pressure are required for the train
braking and some other systems on the locomotive. These are often mounted next
to the fuel tank under the floor of the locomotive.
 Drive Shaft
The main output from the diesel engine is transmitted by the drive shaft to the
generators at one end and the radiator fans and compressor at the other end.
 Radiator and Radiator Fan
Water is distributes around the engine block to keep the temperature within the most
efficient range for the engine.
Air brake
 Air Brake System (Loco Brake System)
 SA-9 Valve : for loco brakes only
 Release position :-running loco is in released position
 Application position :- stopped pressure of 3.5kg/cm2

 Vacuum Brake System:-

 A-9 Valve : for loco & train brake system
 1. Release position: - pressure to 5.0kg/cm2of MR. vacuum is about 55-60 cm.
 2. Minimum position:- pressure in brake pipe= 4.5 kg/cm2, vacuum =50-55 cm
 3. Service application:- Brake pipe pressure = 3.5 kg/cm2 , Vacuum =25-30 cm
 4. Over reduction:- Brake pipe pressure = 2.5 kg/cm2, Vacuum =20 cm
 5. Emergency:- Brake pipe pressure = 0.0kg/cm2, engine is in idle condition
EXPRESSOR
 Expresser is made with combination of EXhauter +
comPRESSOR.
 It is located at free end of the engine block and driven through
the extension shaft attached to the engine crank shaft.
 Exhauster suck air from train pipe to create required amount of
vacuum to brake system.
 There are 6 cylinder are arranged in a W type, 2 cylinder in
vertical, 4 in V shaped.
Turbo Supercharger
 It is used increase the amount
of air pushed into cylinder.
 Pressure of air is 3-6 kg/cm2
 It gives a 50% increase in
engine power.
 Advantage is that it gives more
power with no increase in fuel
cost because it uses exhaust gas
as driving power.
 It also increase the air pressure,
better ignition & efficiency.
 CAUSES OF TURBO
CHARGER
 Intermediate casing, turbine
casing, nozzle failure.
FUEL OIL SYSTEM
WATER COOLING SYSTEM
Failure Analysis
 Ultra sonic test
 In ultrasonic testing very short ultrasonic pulse – waves
with center frequencies ranging from 0.1 – 15 MHz.
 US testing is performed on steel ,metals and alloy.
 It is a form of non destructive testing.

 Zyglo test
 Zyglo test is a of non destructive testing
 It is quick & accurate process for locating surface flaws
such as shrinkage cracks, fatigue cracks, grinding cracks
etc.
 Zyglo test is performed on metals & non metals materials
like Al, Mg, Cu, brass, bronze, sintered carbide, non –
magnetic alloys, ceramics, plastic & glass.
 Schedule Examination
Minor Schedule
 Trip -1 & Trip -1
 Fuel oil, lube oil& filter are checked.
 Expressor discharge valve.
 Record oil level in the axle caps for suspension bearing.
 Turbo super charger is checked.
 Under frame are checked.
Major Schedule
 Run engine; check operation of air system safety valves & expressor crank
case lube oil pressure.
 Stop engine; carry out dry run operational test, check FIP timing &
uniformity of rack setting & correct if necessary.
 Engine crankcase cover:- remove crankcase cover and check for any foreign
material, renew gasket.
 Clean strainer & filters, replace paper elements.
 Compressor air & vacuum system:- check, clean and recondition rings,
intake strainers, & inlet, exhaust valve, lube oil relief valve. Drain, clean &
refill crankcase.
 Roller bearing axle boxes. Check for loose bolts, lose of grease. sign of
overheating. Remove covers,. Carry out ultrasonic test of axles.
 Renew airflow indicator valve.
SPECIAL PLANT
 To provide pollution free environment, an ETP is
installed.
 Various effluents emitted from diesel shed are passed
through the plant.
 Pollution free water is collected & Water is used for non
drinking purposes – gardening & washing of the
locomotives.
Thanking you