WDG4/P4 LOCOMOTIVES The 4000 HP computer controlled GM locomotive has a large number of special and improved features like two stroke, EM 2000 computer etc. The models are GT46 MAC/PAC for Goods and Passenger trains.
DTTC/GTL/SCRly
COMPARTMENTS & MECHANICAL PARTS • • • • • • • • • •
NOSE COMPARTMENT DRIVER/ENGINEERS CAB ELECTRICAL CONTROL COMPARTMENT TCC COMPARTMENT CLEAN AIR CHAMBER GENERATOR COMPARTMENT ENGINE COMPARTMENT ENGINE EQUIPMENT RACK COMPRESSOR ROOM RADIATOR COMPARTMENT DTTC/GTL/SCRly
ENGINE ROOM DE-COMPRESSION ADOPTERS
VALVE LEVERS COVER
AIR BOX COVER
ENGINE ROOM SUMP DOOR
DTTC/GTL/SCRly
EXHAUST MANIFOLD
DTTC/GTL/SCRly
GENERATOR ROOM OIL SEPERATOR TURBO
AFTER COOLER
DTTC/GTL/SCRly
VALVE LEVER MECHANISM CAM SHAFT
VALVE LEVER MECHANISM
DTTC/GTL/SCRly
ENGINE ACCESSORIES FROM LEFT SIDE ENGINE PROTECTING DEVICE
LOW WATER
LOW CRANK CASE VACUUM
LWS COC DTTC/GTL/SCRly
ENGINE ACCESSORIES FROM RIGHT SIDE OSTA RESET HANDLE CAM SHAFT VIBRATION DAMPER HOUSING
LLOP
ENGINE GOVERNOR FUEL SIGHT GLASS DTTC/GTL/SCRly
ENGINE ACCESSORIES FROM RIGHT SIDE
SECONDARY SPIN ON FUEL FILTER DTTC/GTL/SCRly
RIGHT BANK WATER PUMP
TURBO SOAK BACK PUMP & FILTER
L/O DIPSTICK GAUGE
SOAK BACK FILTER
SOAK BACK PUMP DTTC/GTL/SCRly
ENGINE EQUIPMENT RACK FROM RIGHT SIDE OF LOCO
PRESSURE CAP
RELIEF VALVE
ENGINE START SWITCH
DTTC/GTL/SCRly
ENGINE EQUIPMENT RACK FROM LEFT SIDE OF LOCO
LUBE OIL COOLER
EXPANSION TANK FUEL OIL PRIMARY FILTER
Lube oil filter condition gauge
LUBE OIL FILTER DRUM
COMPRESSOR
ENGINE EQUIPMENT RACK/COMPRESSOR COMPARTMENT DTTC/GTL/SCRly
RADIATOR COMPARTMENT
DTTC/GTL/SCRly
UNDER TRUCK
VERTICAL SHOCK ABSORBERS
DTTC/GTL/SCRly
SIDE LOAD PAD
SAFETY LINK CHAIN
BRAKE CYLINDER
DTTC/GTL/SCRly
LOCO LIFTING PAD
HAND BRAKE
HAND BRAKE DTTC/GTL/SCRly
SIDE BUFFERS
JUMPER RECEPTACLE
FP BP
DTTC/GTL/SCRly
CBC
FUEL TANK
EMERGENCY FUEL CUT OFF SWITCH
AIR BOX DRAIN (BAP)
FUEL TANK
FUEL GLOW ROD GAUGE DTTC/GTL/SCRly
FUEL SYSTEM IN WDG4/WDP4 • • • • • • •
FUEL OIL SYSTEM CONSISTS OF FOLLOWING COMPONENTS:Fuel tank of 6000 Liters capacity Fuel suction strainer Fuel oil pump (AC motor driven constant RPM fuel pump) Fuel primary filter Fuel secondary (Engine mounted spin – on filters) Fuel headers Unit fuel injectors.
THE TOTAL FUEL SYSTEM DIVIDED AS: • Fuel feed system and • Fuel injection system DTTC/GTL/SCRly
FUEL SYSTEM IN WDG4/WDP4
DTTC/GTL/SCRly
LUBE OIL SYSTEM OF WDG4/WDP4 LOCOS • • • • • • • • •
Lubricating of Oil system in WDG4/WDP4 consists of the following: Engine sump Scavenging oil pump Lube oil filter tank Lube oil cooler Lube oil strainer Main Lube oil and piston cooling oil pump Soak back oil pump Oil separator and Hot oil detector DTTC/GTL/SCRly
DTTC/GTL/SCRly
DTTC/GTL/SCRly
AIR INTAKE SYSTEM OF WDG4/WDP4 LOCOS
• • • • • •
Diesel Engine in WDG4/WDP4 locomotive is a super charged fuel-efficient and two stroke engine. Since the locomotive is provided with two-stroke engine, the inlet air requirement for proper combustion of the fuel is high. To fulfill the requirement of the engine a special turbo super charger is provided in this locomotive to supply required quantum of air in each notch according to load and speed condition. Air intake system consists the following parts Inertial air intake/cyclonic type air intake filters Clean air chamber Baggy type engine air intake secondary filters. Turbo super charger. After coolers. Air boxes. DTTC/GTL/SCRly
DTTC/GTL/SCRly
DTTC/GTL/SCRly
COMPUTER CONTROLLED BRAKE SYSTEM (CCB) CONSOLE 1
3
2
4
5
6
7
8
1.WIPER CONTROL KNOBS 2.MR(RED) , ER (WHITE)GAUGE 3.BP(WHITE) , BC (RED)GAUGE
10
9
8.ALERTOR LIGHT 9.HORN BUTTONS 10.ALERTOR RESET BUTTON
4.AIR FLOW INDICATOR (WHITE NEEDLE-INDICATOR, REDNEEDLE- SETTING) 5.SPEEDO METER 6.TRACTIVE EFFORT METER 7.INDICATING PANEL
DTTC/GTL/SCRly
BRAKE CONTROL UNIT
DTTC/GTL/SCRly
BRAKE CONTROL UNIT (BCU) : I)Automatic Brake valve (Auto Brake) : Having 5 positions. a) Release/over charging (spring loaded): BP = 5.7 kg/cm2 max.
b) Running
: Equalizing reservoir (ER) and BP = 5.2 kg/cm2 BCP=0
c) Minimum service
: ER/BP reduce to 4.7 kg/cm2, BCP = 1.1 kg/cm2
d) Full service
: ER/BP reduce to 3.4 kg/cm2, BCP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2)
e) Emergency
: ER reduces to 0, B.P reduces to < 1 kg/cm2 BCP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2), BCEP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2) DTTC/GTL/SCRly
II) Independent Brake Valve (Direct Brake) : It is having following positions a) Release Position : BCP = 0 b) Application zone : Maximum brake position, BCP =5.2 kg/cm2 (5.1 +/- 0.14 kg/cm2), BCEP=5.2 kg/cm2 (5.1 +/- 0.14 kg/cm2) c) Bail off : When an automatic brake is applied, lifting the bail-off ring which is provided in the independent brake valve handle , in any position will release BC pressure. Independent brake handle bail-off ring is spring loaded and by lifting it, the bail of function will be activated. III) Selector Switch or Air Brake Lead/Trail set up switch: The Lead/trail air brake set up switch is located on brake control next to independent brake handle. This switch has the following positions: HLPR: Used during Banking loco in the working console. Trail : In Leading Loco non-working Console and also for Trailing loco both the consoles. Lead : Used with loco in lead or controlling . Test : In working console used during brake pipe leakage-testing and also during attaching of locomotive on formation. DTTC/GTL/SCRly
PROCEDURE FOR MAKING CONSOLE IN WDG4/WDP4 LOCOMOTIVES.
ITEM 1. REVERSOR 2.THROTTLE/SELECT OR 3.AUTOMATIC BRAKE HANDLE 4.DIRECT BRAKE HANDLE 5.LEAD/TRAIL (SELECTOR) SWITCH
WORK CONSOLE NEUTRAL IDLE
NON-WORKING CONSOLE NEUTRAL IDLE
RUN
FULL SERVICE
FULL APPLICATION LEAD
RELEASE
DTTC/GTL/SCRly
TRAIL
PROCEDURE OF CHANGING CONSOLE •Keep isolation switch in START/STOP/ISOLATE position. CONVERTING THE WORKING CONSOLE AS NON-WORKING CONSOLE.
ITEM 1. REVERSOR
WORKING CONSOLE CHANGING IN TO NONWORKING CONSOLE NEUTRAL NEUTRAL
2.THROTTLE/SELECTOR
IDLE
IDLE
3.AUTOMATIC BRAKE HANDLE
RUN
FULL SERVICE
FULL APPLICATION
RELEASE
LEAD
TRAIL
4.DIRECT BRAKE HANDLE 5. LEAD/TRAIL (SELECTOR) SWITCH
DTTC/GTL/SCRly
CONVERTING THE NON-WORKING CONSOLE AS WORKING CONSOLE. ITEM 1. REVERSOR 2.THROTTLE/SELECTOR 3.AUTOMATIC BRAKE HANDLE
4.DIRECT BRAKE HANDLE 5. LEAD/TRAIL (SELECTOR) SWITCH
NON WORKING CONSOLE CHANGING IN TO WORKING CONSOLE NEUTRAL
NEUTRAL
IDLE
IDLE
FULL SERVICE
RUN
RELEASE
FULL APPLICATION
TRAIL
LEAD
DTTC/GTL/SCRly
SAFETY PRECAUTIONS/CONDITIONS BEFORE CONDUCTING AIR BRAKE SELF TEST Air brake self test is to be conducted on WDG4 and WDP4 locomotive under following conditions. 1. Failure of console selection( Change of console if wrongly done) 2. During any Air brake failure on run. Step. 1 Following safety precautions are to be strictly followed before conducting air brake self test. •Stop the locomotive/train. •Apply “Hand brake” on locomotive. •Secure the formation, which should not roll during self test. •Close BP and FP angle COC’s on locomotive and on formation. •Close MR and BC equalizing COC’s on both ends of locomotive. •On working console : 1.Keep reversor handle in ”Neutral” position. 2.Keep automatic brake handle in “Run” position. 3.Keep independent brake handle in “release” position. 4.Lead/Trail switch in “Lead” position •On non working console : 1.Keep automatic brake handle in “Full service” position. 2.Keep independent brake handle in “Full application” position. 3.Lead/Trail switch in “Trail” position. On fulfilling .,safety precautions, Air Brake self test is to be conducted. •Ensure minimum MR pressure of 110 PSI. DTTC/GTL/SCRly
AIR BRAKE SELF TEST PROCEDURE •Press “Main menu” key. •Using down arrow key, bring curser to “Self Test” and press ‘F3’ to select.
DTTC/GTL/SCRly
•
Press “F2” key to go to “Next” page.
DTTC/GTL/SCRly
•Using down arrow key, bring cursor to “Air Brake Test” and press F3 to select.
DTTC/GTL/SCRly
• Entry conditions for Air Brake Test will be displayed on the screen, which are already fulfilled. •Press “F1” key to continue test.
DTTC/GTL/SCRly
•Air brake test in progress display will come.
DTTC/GTL/SCRly
EM-2000 initiates Air Brake Self test. •On completion of test, ‘SUCCESSFUL TEST COMPLETED, NO DEFECTS FOUND’ will be displayed on EM – 2000 screen. • Then press F4 key to ‘END TEST’. •
DTTC/GTL/SCRly
•Crew message display will come as below
DTTC/GTL/SCRly
•After keeping Automatic brake handle to emergency position the following Crew message display will come . •Then keep A/brake handle to ‘RUN’ position and press F4 key to exit.
•Keep independent brake handle to ‘Full application’ position in workinconsole and ‘Release’ position in Non-working console. DTTC/GTL/SCRly
Note: If Air brake self test failed, then note the defect code digital number on CRU display. And make working console to non-working and nonworking to working console. Again conduct Air brake self to that console . If succeeds then work with that console and if fails note the number and inform to concern shed. CRU DISPLAY
G/P SWITCH DTTC/GTL/SCRly
CUT OUT COCKS IN BRAKE SYSTEM Locomotive short hood end & long hood end -•FP coc •BP coc Right side of the Locomotive below the chasis – ( near front truck & near rear truck ): •BC equalizing coc •BP additional coc •FP additional coc •MR equalizing coc
DTTC/GTL/SCRly
•Bogie isolation coc- for front & rear truck
DTTC/GTL/SCRly
•MR1 & MR2 with ‘J’ filter (system) coc’s – In between front truck and fuel tank (Right side of the loco)
DTTC/GTL/SCRly
• F2 feed valve coc – In between front truck and fuel tank (Right side of the loco)
DTTC/GTL/SCRly
• Dead engine coc – (Nose compartment) : It should be kept in open condition to get brakes in Dead WDG4/P4 locomotive when only Brake pipe connected .
DEAD ENGINE COC DTTC/GTL/SCRly
MOVING OF WDG4/P4 LOCOMOTIVES S.No.
LEAD LOCO
CONNECTIONS
TRAIL LOCO
1
ANY AIR BRAKE LOCO
MU JUMPER WORKING WDG4/P4 LOCO BP/(FP), MR EQ. &BC EQ. KEEP BOTH CONSOLES AS NON WORKING
2
ANY AIR BRAKE LOCO
BP/(FP), MR EQ. &BC EQ. DEAD WDG4/P4 LOCO KEEP BOTH CONSOLES AS NON WORKING & COMPUTER BREAKERS IN ON POSITION
3
ANY AIR BRAKE LOCO
ONLY BP/(FP) MU JUMPER IF REQUIRED
WORKING WDG4/P4 LOCO ON WORKING CONSOLE KEEP AUTO BRAKE - FULL SERVICE DIR. BRAKE - RELEASE L/T SWITCH - HLPR KEEP OTHER CONSOLE AS NON WORKING
4
ANY AIR BRAKE LOCO
ONLY BP/(FP)
DEAD WDG4/P4 LOCO KEEP BOTH CONSOLES AS NON WORKING -OPEN DEAD ENGINE COC -OPEN MR EQ. &BC EQ. COC AT ONE END OF LOCO.
DTTC/GTL/SCRly
DTTC/GTL/SCRly
