Power Pack of Diesel Locomotive & its components By- G.N.

Singh,AP(D)

POWER PACK WDM2

Power Pack Assly WDM2

ENGINE DATA
            

CYCLE:

4 STROKE CYCLE

ASPIRATION: TURBO SUPERCHARGED WITH CHARGE AIR COOLING MODEL:ALCO 251 B ,( V SHAPED, 16 CYL) BORE: STROKE: 9 INCHES (228 mm) 10.5 inches (267 mm)

Compression Rtio : 12.5:1 (conv),11.75:1(mod) HORSEPOWER (GROSS): 2600 BHP ENGINE SPEED:1000 RPM (FULL LOAD) 400 RPM (IDLE) PISTON SPEED (MEAN): 9.89 m/sec SWEPT VOLUME PER CYLINDER: 10.5 ltrs. WEIGHT (DRY ENGINE): 19026 kg

POWER PACK WDM1

Cut Section of Engine

READYPOWER PACK WDM2

In Complete Power Pack WDM2

BEARING PORTION IN ENGINE BLOCK

16 CYLINDER

POWER PACK COMPONENTS

ENGINE BLOCK AND ENGINE BASE ARE OF STRUCTURAL STEEL DESIGN WHEREIN PISTONS, CYL LINER, CON ROD ASSEMBLY, CRANKSHAFT ASSEMBLY AND CAMSHAFT ASSEMBLY ARE ASSEMBLED TO MAKE A COMPLETE POWER PACK. ENGINE BLOCK STRUCTURE CONSISTS OF SADDLE FORGINGS AND MICRO ALLOYED STEEL PLATES UPTO 75 MM THICKNESS.

ENGINE BLOCK

ENGINE BASE

ENGINE BLOCK


Engine Block , Fitted following important items :

Crankshaft Cam shaft Cylinder Head Cylinder Liners Piston Con. Rods Fuel Injection Pumps Fuel Pump Cross head Turbo Support Governor etc. Crankcase Exhauster

Provides mounting surface:- Turbo supercharger support

- Exhaust Manifold - Air intake elbow - Water elbow - Traction Generator / Alternator - Replaceable Liner Sleeve (fitted into lower liner bore of Cylinder Block.)

Integral part of Block:-

-Crankshaft Main Bearing Saddles

-Camshaft bearing supports -Air intake manifold -Cooling water, a passage on Cylinder Block -Water from Block is conducted to Cylinder Head by Water Jumper.

Power Pack free end

CRANK SHAFT

16Cylinder Engine Crankshaft: No of Main Bearings : 9 Location of Centre Journal: 5 No. of Crankpins : 8 Lift Crankshaft at Crankpin Nos. : 2 and 7 Support Crankshaft at :Main Journals: 3 and 7

Cam Shaft

Conventional Camshaft

Unit Camshaft

Camshaft performs vital role of opening and closing Inlet and Exhaust valves and timely injection of fuel in Cylinder. 3 Cams are provided for each Cylinder. 2 Outer Cams for Exhaust and Air inlet valves and central Cam for fuel injection.

Fabrication :-

Basic building elements of Block.

a) Saddle (Inter/Centre) Forging mfd. from Steel (Specification IS : 1875.) b) Spline Fabricated form Low Carbon Steel Plates (IS:2062)Top Deck : 75 mm thick Plate Side Sheet : 22mm thick Plate Middle deck : 45 mm thick Plate Inside Wall : 16 mm thick Plate

Spline Air intake manifold

Saddles

1
E N G I N E

Saddle Portion
Spline portion

3
B L O C K

WELDINGa) welding by process of Submerged Arc Welding (SAW) undertaken for critical joints.

b) Radiographic testing of critical welded joints

c) After fabrication, stress relieving of Engine Block is undertaken at 640 C (14 hours Heating 4 hours Soaking and 10 hours Cooling) in Stress Relieving Furnace.

Machining : 1) Marking Table- Marking of Engine Block is undertaken on maintaining required dimensions. 2) Planning Machine- Engine Block is placed on for machining inclined sides and top faces. 3) Milling Machine- Generator end and Free end of Block are for maintaining required length of Block. 4) Angular Boring Machines (M/s XLO and M/s HMT) - Upper and lower Liner bores of Blocks are machined on Special purpose

Note : *2 Bores are inclined at 22 with vertical axis. Concentricity of upper and lower bore ensured due to simultaneous machining. 5) Drilling Machine. Different size of holes drilled and tapped to UNC and UNF Drilling / Tapping of holes on Generator end and Free end undertaken on Horizontal End

6) Serration Milling Machine - Serration Milling

of Saddle Faces of Engine Block along with Main Bearing Caps ( Accuracy and furnish of serrations milled is 0.0002 )

Note :  Each Bearing Cap is marked for location so that Bearing Cap cannot be pooled or wrongly fitted.


After inspection Bearing Caps are assembled and MB Studs tightened to 0.040 Elongation.

Cam and Crank Boring :

7) CNC Horizontal Boring Machine.Boring bars used for boring Cam bore and Crank bore

Note: Weight of Block at stage is 25.2T. 8) Hydraulic Test -Cylinder Block to check for leakages from welding , Liner seat etc. (110 psi for 30 min.) Note : Engine Blocks are found to show signs of distortion after life of 12 to 15 years of service. Reclamation of Engine Block is undertaken at DMW/Patiala.

Maximum possible misalignment permitted in Main Bearing Bore is :

(a) Horizontal Misalignment :

Between 2 adjacent Bores : 0.002 Between 2 Non adjacent Bores : 0.004

(b)Vertical Misalignment :
Between 3 adjacent Bores Between 2 Non adjacent Bores
Note : * Above alignment of MB bores is checked with the help of Mandrel and Feeler Gauge. * Optical Collimator is also used at DLW for checking above alignment.

: 0.0015 : 0.003

LINER BORE WITH SLEEVE

Liner

Improved Design Liner

HONEY CHROME LINER Surface hardened with chrome layer. Layer thickness 6-8 thou. Surface hardened to 1000 VHN. Surface finish to 50-100 RMS

OPEN GRAIN LINER Surface hardened with chrome layer. Layer thickness 7.5-9.5 thou. Surface hardened to 1000 VHN. Surface hardened with chrome layer. Low manufacturing cost. Plating surface finish to 40-80RMS. Advantages: Longer life, Lower LOC

LINER SLEEVE

Overhauling of Engine Block:1) Drain Engine and strip Block of all attaching parts, preparatory to its removal from Engine Base. 2) Remove two Nos. Block to Base dowels located at each end on right side of Engine. 3) Working through openings in Base, remove Cap screws and Lock washer between Block and Base. 4) Apply Lifting hooks to Eye Bolt at power take-off end and Lifting plate bolted to free end and lift Block from Base.

Inspection of Block : 5) Clean and inspect Engine Block (by Magna flux process) for cracks , signs, leaks and other damages.

Removal of Cylinder Liner Sleeve: 6) When inside diameter of sleeve exceeds maximum specified limit , Sleeve shall be replaced. (Liner sleeve tool is required for removal of Liner Sleeve) 7) Hydrostatic Testing - 2.5kg/cm2 at normal temps.

1.


CHECKING MAIN BEARING BORES OUT OF ROUNDNESS

1.

MB Bore diameter :- Checked at planes A, B and C and D, E and F ( from edge). Diameter (New) : 9.0355 - 9.0370 Diameter (Worn) : 9.0350-9.0395 Out-of-Roundness : 0.0035

A c B

2. Taper : Check vertical taper between planes A and D and Taper at 45 from vertical between Planes B and F and C and E . Vertical Plane 45 from Vertical 3. Horizontal Misalignment : Two adjacent Bores Two Non-adjacent Bores 4. Vertical Misalignment : Three Adjacent Bores Two non-adjacent Bores: : : 0.001 0.003

: :

0.002 0.004

0.0015 0.003

*No compensation allowed for out-of-roundness ,taper or difference in diameter.

Checking Vertical and Horizontal Misalignment of Main Bearing Bores

5. Bore Camshaft Hauling Diameter (New) : Condemning Diameter :

4.7500 4.7515 4.7525

LINER SLEEVE TOOL

OF CAMSHAFT BORE AND CYLINDER LINER SEAT

ENGINE BASE
Description :
Engine Base is a welded steel structure ,Fabricated from Steel (Specification IS:2062 with 0.2% Carbon). Lubricating Oil Pump (LOP) Water Pump (WP) 4 nos.Engine Mounting Pads - Traction

Generator Magnet Frame Foundation bolt fitted on Main Base.

bottom

Acts as a Lubricating oil reservoir (Sump)

* Screens fitted across the Base at each Cylinder location. to prevent foreign matter.
Accommodates Lube Oil Main Header Baffle Plates provided for strengthening structure and

arresting splash of Lube Oil. -Lub oil carried in Base below the Base Screen ,Sump capacity enhanced from 910 Liters to 1050/1270 Liters -Lub oil drain plug, -Bayonet Gauge (with high/low level markings) -Filler Pipe are located in the Base.

CRANKCASE INSPECTION DOOR

- Removable Door ,Openings on each side of Base gives

access - Con. Rod bearings, Crankshaft and Main Bearings inspecting oil lines, piston skirts and Cylinder Liners..

CRANKCASE EXPLOSION DOOR

Explosion doors mounted on right and left side of Base at the Power take-off end.

CRANKCASE EXPLOSION DOOR

CYLINDER HEAD
251 Plus Cyl.hd 251Cyl.hd

Piston & Connecting Rod

Steel cap Piston

Aluminum alloy Piston

Connecting Rod Assembly

Improved Piston Ring Design

CONVENTIONAL FE RING 1. 2. 3. 4. Plasma filled top ring 2nd Taper ring 3rd Taper ring 4&5 Oil conformable ring

Square, taper, taper, oil Barrel taper, taper, oil conformable and oil scraper scraper and oil configuration conformable configuration.

Fuel efficient piston rings Advantages

Reduced piston / ring and liner wear Reduced lube oil consumption. Reduced fuel oil consumption.

Assembly of Engine Base &Block

A sealing compound is applied before fitting the block to Base make the crank case air tight so that crank case vacuum can be maintained.

2.while assembling ,block and base should be perfectly aligned within the limit(Gen end:0.000.Side ways:0.002 max.)

3. Apply and tighten several cap screws and lock washer between base& block.

THANK YOU