LOCOMOTIVE WORKSHOP NORTHERN RAILWAY, CHARBAGH LUCKNOW
An INDUSTRIAL TRAINING REPORT On "Cylinder Head"
SUBMITTE TO!
SUBMITTE BY!
Mr. V.K. Sonkar
Devyanshu Kumar Kumar
Senior Se!ion En"ineer
#.Teh $Mehania%& SRM'EM( LU'KNO)
A'KNO)LEDGEMENT
In*us!ria% !rainin" is very essen!ia% +or suess+u%%y om,%e!in" !he #ahe%or o+ Tehno%o"y. Tehno%o"y. I -as very %uky !ha! I "o! an o,,or!uni!y !o *o an In*us!ria% !rainin" in Loomo!ive )orksho,( Lukno-. I am sinere%y !hank+u% an* ,%ease* !o sho- my *ee, "ra!i!u*e !o my ,roe! hea* Mr. V.K Sonkar +or his oo,era!ion *urin" !he !rainin" ,erio*. This ,roe! -ou%* no! have /een ,ossi/%e -i!hou! -i!hou! his kin* su,,or! an* an* a/%e "ui*ane. I -ou%* a%so %ike !o !hank mi"h! Go* an* my ,aren!s( -i!hou! !heir he%, i! -ou%* have /een very *i++iu%! *i++iu%! +or me !o om,%e!e om,%e!e !he ,roe! suess+u%%y suess+u%%y 0 a%so !o !o a%% my o%%ea"ues o%%ea"ues 0 !he em,%oyees o+ Loomo!ive )orksho, )orksho, -i!h -hom I1ve *eve%o,e* a s,eia% /on*. $Devyanshu Kumar&
1.INTRODUCTION 1. INTRODUCTION TO INDIAN I NDIAN RAIL RAI LWAY Indian Railay# is !he s!a!e2o-ne* en!er,rise( o-ne* an* o,era!e*
/y !he Governmen! o+ In*ia !hrou"h In*ia !hrou"h !he Minis!ry o+ Rai%-ays. Rai%-ays . In*ian Rai%-ays has one o+ !he %ar"es! an* /usies! rai% ne!-orks in !he -or%*( !rans,or!in" over 34 mi%%ion ,assen"ers an* more !han 5 mi%%ion !ons o+ +rei"h! *ai%y. I!s revenue is Rs.367.88 /i%%ion. I! is !he -or%*9s %ar"es! ommeria% em,%oyer( -i!h more !han 3.: mi%%ion em,%oyees. I! o,era!es rai% !rans,or! on 8(;6; s!a!ions over a !o!a% rou!e %en"!h o+ more !han 8<(<57 ki%ome!ers$<;(<=6 mi%es&.The +%ee! o+ In*ian rai%-ay in%u*es over 566(666 $+rei"h!& -a"ons( =6(666 oahes an* 4(666 %oomo!ives. I! a%so o-ns %oomo!ive an* oah ,ro*u!ion +ai%i!ies. I! -as +oun*e* in 34=< un*er !he Eas! In*ia 'om,any. In*ia In*ian n Rai% Rai%-a -ays ys is a*mi a*mini nis! s!er ere* e* /y !he !he Rai% Rai%-a -ay y #oar #oar*. *. In*ia In*ian n Rai%-ays is *ivi*e* in!o 38 >ones. Eah >one rai%-ay is ma*e u, o+ a er!ain num/er o+ *ivisions. There are a !o!a% o+ si?!y2seven *ivisions. I! a%so o,era!es !he Ko%ka!a me!ro. There are si? manu+a!urin" ,%an!s o+ !he In*ian Rai%-ays. The !o!a% %en"!h o+ !rak use* /y In*ian Rai%-ays is a/ou! 364(46= km $87(864 mi& -hi%e !he !o!a% rou!e %en"!h o+ !he ne!-ork is 8<(:8= km $<;(:<= mi&. A/ou! :6@ o+ !he !o!a% !rak ki%ome!er is e%e!ri+ie* 0 a%mos! a%% e%e!ri+ie* se!ions use 5=(666 V A'. In*ian rai%-ays uses +our rai% !rak "au"es In*ian Rai%-ays o,era!es a/ou! ;(666 ,assen"er !rains an* !rans,or!s 34 mi%%ion ,assen"ers *ai%y .In*ian Rai%-ays makes 76@ o+ i!s revenues an* mos! o+ i!s ,ro+i!s +rom !he +rei"h! se!or( an* uses !hese ,ro+i!s !o ross2su/si*ies !he %oss2makin" ,assen"er se!or. The Ra*hani E?,ress an* Sha!a/*i E?,ress are !he +as!es! !rains o+ In*ia.
2.DIESEL LOCOMOTIVE SHED CHARBAGH, LUCKNOW
Diese% %oomo!ive she* is an in*us!ria%2!ehnia% se!u,( -here re,air an* main!enane -orks o+ *iese% %oomo!ives is arrie* ou!( so as !o kee, !he %oo -orkin" ,ro,er%y. I! on!ri/u!es !o inrease !he o,era!iona% %i+e o+ *iese% %oomo!ives an* !ries !o minimi>e !he %ine +ai%ures. The !ehnia% man,o-er o+ a she* a%so inreases !he e++iieny o+ !he %oo an* reme*ies !he +ai%ures o+ %oo. The she* onsis!s o+ !he in+ras!ru!ure !o /er!h( *isman!%e( re,air an* !es! !he %oo an* su/sys!ems. The she* -orkin" is heavi%y /ase* on !he manua% me!ho*s o+ *oin" !he main!enane o/ an* very %ess au!oma!ion ,roesses are use* in she*s( es,eia%%y in In*ia. The *iese% she* usua%%y has2
#er!hs an* ,%a!+orms +or %oo main!enane.
Pi!s +or un*er +rame main!enane
Beavy %i+! ranes an* %i+!in" aks
Cue% s!ora"e an* %u/e oi% s!ora"e( -a!er !rea!men! ,%an! an* !es!in" %a/s e!.
Su/2assem/%y overhau%in" an* re,airin" se!ions
Mahine sho, an* -e%*in" +ai%i!ies.
DIESEL SBED( 'BAR#AGB( LU'KNO) o+ nor!hern rai%-ay is %oa!e* in LU'KNO). The she* -as es!a/%ishe* on 55 n* A,ri% 34=7. I! -as ini!ia%%y ,%anne* !o home 7= %oomo!ives. The she* a!er !he nee*s o+ Nor!hern rai%-ay. This she* main%y ,rovi*es %oomo!ive !o run !he mai%( "oo*s an* ,assen"er servies. No *ou/! !he re%ia/i%i!y( sa+e!y sa+e!y !hrou"h ,reven!ive an* ,re*i!ive main!enane is hi"h ,riori!y o+ !he she*. To mee! ou! !he ua%i!y ua%i!y s!an*ar* she* has !aken various s!e,s an* o/!ainin" o+ !he ISO2;6632566O0 ISO 3:663 OBSAS 'ERTICI'ATION is amon" o+ !hem. The Diese% She* is eui,,e* -i!h mo*ern mahines an* ,%an! reuire* +or Main!enane o+ Diese% Loomo!ives an* has an a!!ahe* s!ore *e,o!. To ,rovi*e ,rovi*e ,o%%u!ion +ree a!mos,here( Diese% She* has ons!ru!e* E++%uen! E ++%uen! Trea!men! P%an!. The mora%e o+ su,ervisors an* s!a++ o+ !he she* is very hi"h an* -ho%e she* -orks %ike a -e%%2kni! !eam.
3.DIESEL ELECTRIC LOCOMOTIVE
PARTS O$ THE LOCOMOTIVE %$IG& ' &
SAND #O RADIATOR RADIATOR CAN TUR#O SUPER'BARGER #OGIE$5 SETS&$
'FLINDER BEAD 'ROSS BEAD CUEL INE'TION PUMP #ATTERIES $4 OC 4.84 VOLTS& CUEL TANK ACTER 'OOLING 'ORE UN'TION #O
4.CYLINDER HEAD (PROJECT STUDY)
4.1 INTRODUCTION In an in!erna% om/us!ion en"ine ( !he (ylinder )ead $o+!en in+orma%%y a//revia!e* !o us! )ead& si!s a/ove !he y%in*ers on y%in*ers on !o, o+ !he y%in*er /%ok . I! %oses in !he !o, o+ !he y%in*er( +ormin" !he om/us!ion ham/er . This oin! is sea%e* /y a hea* "aske!. "aske!. In mos! en"ines( !he hea* a%so ,rovi*es s,ae +or !he ,assa"es !ha! +ee* + ee* air an* +ue% !o !he y%in*er( an* !ha! a%%o- !he e?haus! !o esa,e. The hea* an a%so /e a ,%ae !o moun! !he va%ves( va%ves( s,ark ,%u"s( ,%u"s( an* +ue% ine!ors . Key *ea+re# -* Cylinder Head!
I! is su/e!e* !o hi"h shoks( s!resses an* om/us!ion !em,era!ure. 'oo%in" ,assa"es are ore* +or hea! ree!ion. r ee!ion. I! a%so ,rovi*es ,assa"es +or in%e! air( e?haus! "ases( +ue% ine!ion no>>%es( va%ve "ui*e( va%ve sea!s e!.
4.2 Common Common com comon! on!n"# n"# $#!% $#!% &n &n In%&'n In%&'n R'&( R'&()' )'* * C*(&n%!+ H!'%#
Part No.
DESCRIPTION
22200215
CYLINDER HEAD WITH VALVES
2231129
AIR VALVE
2231129
EXHAUST VALVE
2461082-1
AIR AND EXHAUST VALVE SPRING
2231231
SPRING SEAT
2231152
SPRING SEAT LOC
22200115
CYLINDER HEAD WITH INSERTS! LESS VALVE
2221082
PLUG! SPL ! "OR NO##LE CLA$P STUD
2221092-1
NO##LE OPENING SLEEVE
2221093-1
STUD OPENING SLEEVE
2221 222109 0944-1 1
IN%E IN%EC CTION TION TU&E OP OPENING SLEEVE EEVE 'RE 'RE(UR (URED "O "OR EA EARLY RLY DES DESIGN HE HEADS ADS ONLY
2461083
SNAP RING "OR VALVE SEAT INSERT
2241024-1
VALVE LEVER YOE GUIDE
2221081-2
PLUG! INDICATOR CONNECTION
2151119
GASET! INDICATOR PLUG
54021A
PLUG! THER$OCOUPLE CONNECTION! 1)2 IPS! HEX. H.
215142*9-3
STUD! IN IN%ECTION TU&E TO CYLINDER HEAD
21516311
NUT. SPL.! IN%ECTION TU&E STUD
2151313-1
LOCWASHER!1)2
2151429-5
STUD! NO##LE CLA$P! 5)8-11 X 5-5)16
21516310
NUT NO##LE CLA$P 5)8-11
2241294-1
PUSH ROD SLEEVE
2153403
GRO$$ET! PUSHROD SLEEVE
2500 250002 0286 86
WAT WATER EL&O L&OW IT '3 PC. PC.+ HEAD EAD TO &LOC LOC 'LOC LOCO$O O$OTIVE! IVE! $ARINE INE AND STATIONARY+
25000288
WATER EL&OW I IT '3 PC.+ HEAD TO &LOC 'DUAL "UEL+
4.3 Com$( Com$(#o+ #o+* * comon comon!n" !n"# # "o ! ! !-c' !-c'n/! n/!% % &n C*(&n%!+ H!'% S!c"&on S.NO. 1. 2.
DESCRI0TION Valve Guide L!"
0.L. NO. 10124639 102104##
4.4 C+&"& &"&c'( '+ '+"# S.No. 1. 2. 3. 4. .
D!#c+&"&on E$%au&' Ga& Valve le' Valve L!" Valve Sea' &e,' 30 S-,i.
0.L. No. 10244334 1024*+0# 102104## 102492*4 1016011*
4. C*(&n% C*(&n%!+ !+ H!'% H!'% #!c"&on #!c"&on )o )o+& +&n/ n/ +oc +oc!%$ !%$+! +! 1/ 2/ 3/ 4/ */ 6/ #/ +/
O,enin" o+ Bea* $va%ve( s,rin"( va%ve inser! sea!s( e!.&. Sra!hin" !he y%in*er hea* !o remove ar/on. S,rin"( sea!( %ok( +%an"e( e!. are %eane* -i!h *iese% an* sur+ -a!er. Removin" ar/on +rom o%* Va%ves. Grin*in" !he +ae o+ o%* va%ve -i!h "rin*in" mahine. Per+ormin" R.D.P. !es! +or hekin" !he a,s o+ y%in*er hea*. Va%ve( s,rin"( a"e an* va%ve %oks are Hy"%o Tes!e*. Va%ve Va%ve "ui*e( va%ve sea! inser!( s,rin"( om,ression sea! e!. are measure*. Ree!e* ,ar!s are re*2rosse*1 an* an* remove*. ;. Dama"e* Dama"e* va%ve sea! sea! inser!( inser!( va%ve "ui*e( "ui*e( no>>%e( no>>%e( oo%in" oo%in" s%eeve s%eeve e!. are re,%ae* /y ne- ones. 36.Per+ormin" hy*rau%i !es!in" $+or in!erna% raks&. 33.A+!er reor*in" eah *imensions( hea* is !ie* /ak. 35.Per+ormin" #%o-2#y !es! +or /%o-2/y "asses.
4. T!#"& !#"&n/ n/ o o C*(& C*(&n% n%!+ !+ H!' H!'% % •
RED-DYE PENETRATION TEST (RDP) Dye ,ene!ran! ins,e!ion $DPI&( a%so a%%e* %iui* ,ene!ran! ins,e!ion $LPI&( is a -i*e%y a,,%ie* an* %o-2os! ins,e!ion me!ho* use* !o %oa!e sur+ae2/reakin" *e+e!s in a%% non2 ,or , or ou s ma ! er i a% s $ me !a % s( ,% as !i s ( or e ra mi s & . Pe ne !r an ! may /e a,,%ie* !o a%% non2+errous ma!eria%s( /u! +or ins,e!ion o+ +errous om,onen!s ma"ne!i ,ar!i%e ins,e!ion is ,r e +e r r e* +o r i !s su /s u r +a e * e! e !i on a ,a /i % i!y. i! y. LP I is us e * !o *e!e! as!in" an* +or"in" *e+e!s( raks( an* %eaks in ne ,r o* u !s ( a n* +a !i "u e r a k s on in 2s er vi e o m,o m, o ne n! s .
•
Zyglo test: The >y"%o !es! is a non*es!ru!ive !es!in" $NTD& me!ho* !ha! he%,s !o %oa!e an* i*en!i+y sur+ae *e+e!s in or*er !o sreen ou! ,o!en!ia% +ai%ure2,ro*uin" *e+e!s. I! is uik an* aura!e ,roess +or %oa!in" sur+ae +%a-s suh as shrinka"e raks( ,orosi!y( o%* shu!s( +a!i"ue raks( "rin*in" raks e!. The HFGLO !es! -orks e++e!ive%y in a varie!y o+ ,orous an* non2,orous ma!eria%s ma!eria%s a%uminum( ma"nesium( ma"nesium( /rass( o,,er( !i!anium( /ron>e( s!ain%ess s!ee%( sin!ere* ar/i*e( non2 ma"ne!i a%%oys( eramis( ,%as!i an* "%ass. Sine Sine y%in* y%in*er er hea* hea* is ui!e ui!e heavy heavy !here+ !here+ore ore y%in* y%in*er er hea* hea* is no! *i,, *i,,e* e* in >y"% >y"%o o so%u so%u!i !ion on ins! ins!ea ea* * o+ *i,, *i,,in in" " in !he !he so%u so%u!i !ion on i! is heke* /y s,rayin" ,o-*er on !he y%in*er hea* /y !he +o%%o-in" ,roe*ure.
•
'%ean !he sur+ae an* in!erna% areas o+ !he y%in*er hea* -i!h -a!er.
•
•
A,,%y ,ene!ran!( !hrou"h s,ray. No- a soure o+ %i"h! is use* i.e.( u%!rasoni %i"h! is ma*e !o +a%% on !he sur+ae o+ !he y%in*er hea* i+ !here is any rak is ,resen! !hen a "reen %i"h! -i%% a,,ear -i!h a >i"2>a" ,a!!ern.
•
I+ i! is %ess !han 56 miron !han i! is re,aira/%e /y sur+ae +inishin" or remova% o+ u,,er %ayer o+ !he *e+e!ive sur+ae.
•
I+ !he in!ensi!y o+ !he %i"h! is more !han 56 miron !hen i! is on*emne*.
•
d,auli! 'e&' A )ydr-#+a+i( +e#+ is a -ay /y -hih y%in*er hea*s( ,ressure vesse%s suh as ,i,e%ines as ,i,e%ines(( ,%um/in"( ,%um/in"( /oi%ers an* /oi%ers an* +ue% !anks an /e !es!e* +or s!ren"!h an* %eaks. The !es! invo%ves +i%%in" !he vesse% or ,i,e sys!em -i!h a %iui*( usua%%y -a!er( -hih may /e *ye* !o ai* in visua% %eak *e!e!ion( an* ,ressuri>a!ion o+ !he vesse% !o !he s,ei+ie* !es! ,ressure. Pressure !i"h!ness an /e !es!e* /y shu!!in" o++ !he su,,%y va%ve an* o/servin" -he!her !here is a ,ressure %oss. The %oa!ion o+ a %eak an /e visua%%y i*en!i+ie* more easi%y i+ !he -a!er on!ains a o%oran!. S!ren"!h is usua%%y !es!e* /y measurin" ,ermanen! *e+orma!ion o+ !he on!ainer. S!e,s
o
Run !he en"ine !o a!!ain norma% o,era!in" !em,era!ure$8= 6'&
o
S!o, runnin" !he en"ine a+!er a!!ainin" i!s o,era!in" !em,era!ure
o
#rin" !he ,is!on in!o i!s om,ression s!a!e
o
Ci! !he hy*rau%i "a*"e! in!o !he y%in*er hea* %ose a%% !he o,enin"s
o
C%o- !he -a!er in!o !he om/us!ion ham/er ham/er
o
'u! o++ -a!er su,,%y a! 76 ,si. Throu"h s!o, ok an* reor* !he !ime -hen i! omes omes !o >ero. 7 !o 36 seon*s are ok.
•
l 5 Te&' Bl-./y re+ers !o !he %eaka"e o+ "as ,as! !he ,is!on o+ an en"ine a! ma?imum ,ressure.
Cause Cause oversi>e* /ore( /a* rin" ,ro+i%e( *en! on ,is!on rin"s( more "a,s in ,is!on rin"( %a!e o,enin" an* %osin" o+ e?haus! va%ves( e!. Effect Genera%%y( a ne- en"ine has hi"h /%o-2/y -hih re*ues onsi*era/%y -i!h runnin" as !he hi"h ,oin!s o+ /ore honin" -ears a-ay an* !hus im,rovin" ,is!on rin"s sea%in". #u! i+ i! is *ue !o any manu+a!urin" *e+e!s or e?essive -orn ,ar!s( !hen i! -i%% sure%y re*ue en"ine ,er+ormane. In -ors! ase i! -i%% inrease %u/ria!in" oi% onsum,!ion ausin" hi"h smoke an* ,ar!iu%a!e emission. e mission. Blow2 Blow2by Test I! is !du!'ed ' !%e!" '%e &eali.
e!ie! 7 '%e !85u&'i !%a85e, a ,ui. e.ie a& -e, '%e 7lli. -,!edu,e:
Ru '%e e.i e.ie e ' a''ai a''ai ,8 ,8al al -e,a -e,a'i 'i. . 'e8-e 'e8-e,a' ,a'u, u,e e (6*;C)
S'- ,ui. a7'e, a''aii. ,8al -e,a'i. 'e8-e,a'u,e/
,i. ,i. '%e -i&' -i&' 7 '%e !,, !,,e& e&- -d di i. . !li !lid de, e, a' TDC TDC i !8-,e&&i &',"e/
C%a,.e '%e !85u&'i !%a85e, i'% !8-,e&&ed ai,/ ai,/
Cu' = ai, &u--l a' #0 -&i/ T%,u.% &'- !!" ad ,e!,d '%e 'i8e %e i' !8e& d ' >e,/# ' 10 &e!& i& O?/
Vari-# i01-r+an+ 1r-(e## and (-01-nen+# +- /e re1la(ed VALVESJVALVE SEAT INSERTS AND VALVE GUIDES Un%ess e?!reme au!ion is use* -hi%e "rin*in" !he va%ve sea! inser!s va%ve sea! rakin" an* hekin" may resu%!. A maor ause +or !his on*i!ion is ei!her !he use o+ im,ro,er s!rokes or !he a,,%ia!ion o+ !oo muh ,ressure /y !he *river. I+ i! is neessary !o remove a va%ve sea! inser! use a va%ve sea! e?!ra!or !oo%. MA'BINING INSERT #ORES The ,roe*ure +or mahinin" /ore are as +o%%o-s 3. Remove Remove a%% va%ve va%ve "ui*es( "ui*es( eua%i>in" eua%i>in" yoke yoke "ui*es "ui*es an* s!u*s. s!u*s. 5. Cor s!an*ar* s!an*ar* oversi>e* oversi>e* va%ve va%ve sea! sea! inser!s inser!s mahine mahine y%in*er y%in*er hea* hea* /ore is in*ia!e*. <. #%o#%o- ou! ou! hi hi,s ,s.. :. Press nene- va%ve va%ve "ui*es( "ui*es( usin" usin" inser!in inser!in" " s%eeve s%eeve !oo%. !oo%. =. Press ne- va%ve va%ve eua%i> eua%i>in" in" yoke yoke "ui*es. "ui*es. 8. A,,%y nene- no>>%es no>>%es s!u*s s!u*s or rea,,%y rea,,%y o%* s!u*s s!u*s i+ in "oo* on*i on*i!ion. !ion. APPLI'ATION OC VALVE GUIDES A%% va%ve "ui*e /ores shou%* /e %eane* usin" =J4 inh -ire /rush. The /rush has a s,in*%e -hih may /e a!!ahe* !o a han* *ri%% or some o!her han* mahine. VALVE AND VALVE SEAT GRINDING S!e%%i!e inser!s may /e ,rone !o "rin*in" raks. In suh a ase !hese shou%* /e "roun* usin" a %i!!%e %i!!%e mahine so%ven!s.
The ,roe*ure +or "rin*in" va%ve sea! inser!s an* reon*i!ionin" va%ves are as +o%%o-s 3. Remo Remove ve "%a> "%a>ee on va%v va%vee sea! sea! /y usin usin" " ,ie ,ieee o+ san* san* ,a,e ,a,err un*e un*er r "rin*in" s!one an* !hen s,in i!. 5. Grin* !he !he sea! an* use use *ia% in*ia! in*ia!or or !o hek hek !he !rueness. !rueness. <. 'hek 'hek ou! va%ve va%ve sea! run ou!. ou!. The va%ve va%ve "ui*e "ui*e /ore mus! /e -i!hin -i!hin !o%erane %imi!. :. 'hek !he sur+ae sur+ae o+ !he va%ve va%ve sea! inser! +or raks. raks. =. I+ va%ves va%ves sho-i sho-in" n" rak rak shou%* shou%* /e sra,,e sra,,e*. *. 8. Va%ves %ves shou%* shou%* /e ,ro,er% ,ro,er%y y +ae* +ae* $e?haus! $e?haus! "as va%ve va%ve a! := o( air in%e! va%ve a! <6 o&. 7. To hek va%ve va%ve -i!h -i!h sea! /%ue va%ve va%ve inser! is use*. use*. Cine %ine %ine mus! sho- aroun* en!ire irum+erene on %ar"e *iame!er o+ sea! on!ra!in" area. 'OMPRESSION SEAL Sine !he y%in*er hea* %iner oin! is me!a% !o me!a% !he sea!in" area mus! /e in "oo* on*i!ion. These sur+aes shou%* /e heke* an* i+ neessary( %a,,e* usin" a %a,,in" rin". Sea!in" sur+aes mus! /e smoo!h an* in one ,%ane. Usin" /%uin"( a on!inuous on!inuous /%ue mark no! %ess !han !han 3J38 inh -i*e mus! mus! sho!hrou"hou! !he irum+erene. NOHHLE BOLE SLEEVE A s%eeve is a,,%ie* -i!h Ti!e sea% in !he no>>%e ho%e o+ eah y%in*er hea* !o ,rovi*e a -a!er ake! ake! +or no>>%e oo%in" an* !o +urnish a sea! +or !he no>>%e. no>>%e.
4.5 N!) N!) G!n! G!n!+' +'"&o "&on n C*(&n C*(&n%! %!+ + H!'% H!'% AL'O 5=3 y%in*er hea*s are !he %a!es! "enera!ion y%in*er hea*s( use* in u,*a!e* en"ines( -i!h !he +o%%o-in" +ea!ure
Cire *ek !hikness re*ue* +or /e!!er hea! !ransmission.
Mi**%e *ek mo*i+ie* /y inreasin" num/er o+ ri/s $su,,or!s& !o inrease i!s mehania% s!ren"!h. The +%yin" /u!!ress +ashion o+ mi**%e *ek im,roves !he +%o- ,a!!ern o+ -a!er e%imina!in" -a!er s!a"na!ion a! !he orners insi*e y%in*er hea*.
)a!er ho%*in" a,ai!y inrease* /y inreasin" num/er o+ ores $3: ins!ea* o+ 33&
Use o+ +ros! ore ,%u"s ins!ea* o+ !hrea*e* ,%u"s( arres! !en*eny o+ %eaka"e.
Ma*e %i"h!er /y 4 k"s $A% s,aer is use* !o make "oo* !he "a, /e!-een ru//er "romme! an* y%in*er hea*.&
Re!ainin" rin"s o+ va%ve sea! inser!s e%imina!e*. #ENECITS
#e!!er hea! *issi,a!ion
Cai%ure re*ue* /y re*uin" rak an* e%imina!in" sa""in" e++e! o+ +ire *ek area.
.VARIOUS OTHER COM0ONENTS O6 RAIL LOCOMOTIVE .1 The *iese%
TURBO SU0ERCHAR S U0ERCHARGER GER en"ine ,ro*ues mehania% ener"y
/y
onver!in" hea! ener"y ener"y *erive* +rom
/urnin" o+
+ue% insi*e !he y%in*er. y%in*er. Cor e++iien!
/urnin" o+
+ue%( avai%a/i%i!y o+ su++iien! su++iien! air in
,ro,er ra!io
is a ,rereuisi!e.
A
+r/-()ar2er( or +r/-( is a "as
om,ressor
use* +or +ore*2in*u!ion o+ an
in!erna% om/us!ion en"ine. Like a su,erhar"er( !he ,ur,ose o+ a !ur/ohar"er is !o inrease !he *ensi!y o+ air en!erin" !he en"ine !o rea!e more ,o-er. Bo-ever( a !ur/ohar"er !ur/ohar"er *i++ers in !ha! !he om,ressor is ,o-ere* /y a !ur/ine *riven /y !he en"ine9s o-n e?haus! "ases. MAIN 'OMPONENTS OC TUR#O2SUPER'BARGER
Tur/o2 su,erhar"er onsis!s o+ +o%%o-in" main om,onen!s.
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Gas in%e! asin". Tur/ine asin". In!erme*ia!e asin" #%o-er asin" -i!h *i++user Ro!or assem/%y -i!h !ur/ine an* ro!or on !he same sha+!.
*esi"ne* !o in!ro*ue +ue% oi% in!o !he en"ine y%in*ers a! !he orre! !ime( a!
orre! ,ressure( a! orre! uan!i!y an* orre!%y a!omi>e*. The sys!em ine!s in!o !he y%in*er orre!%y me!ere* amoun! o+ +ue% in hi"h%y a!omi>e* +orm. Bi"h Bi"h ,res ,ressu sure re o+ +ue% +ue% is reu reuir ire* e* !o %i+! %i+! !he !he no>> no>>%e %e va%v va%vee an* an* +or +or /e!! /e!!er er ,ene!ra!ion o+ +ue% in!o !he om/us!ion ham/er. Bi"h ,ressure a%so he%,s in ,ro,er a!omi>a!ion so !ha! !he sma%% *ro,%e!s ome in /e!!er on!a! -i!h !he om,re om,resse sse* * air in !he om/us om/us!io !ion n ham/e ham/er( r( resu%! resu%!in" in" in /e!!er /e!!er om/us om/us!io !ion. n. Me!eri Me!erin" n" o+ +ue% +ue% uan!i uan!i!y !y is im,or! im,or!an! an! /eaus /eausee !he %oomo %oomo!iv !ivee en"ine en"ine is a varia/%e s,ee* an* varia/%e %oa* en"ine -i!h varia/%e reuiremen! o+ +ue%. Time o+ +ue% ine!ion is a%so im,or!an! +or /e!!er om/us!ion.
.3 BOGIE
A /-2ie is a -hee%e* -a"on or !ro%% ey. In mehanis !er ms( a /o"ie is a hassis or +rame-ork arryin" -hee%s( a!!ahe* !o a vehi%e. I! an /e / e + i? e* in ,% a e ( a s on a a r"o r" o !r u k( mo un !e * o n a s -i ve %( as on a rai%-ay arria"e or %oomo!ive( or s,run" as in !he sus,ension o+ a a!er,i%%ar !rake* vehi%e. #o"ies serve a num/er o+ ,ur,oses2
T T
&u--,' '%e ,ail ve%i!le 5d
T T
,u &'a5l 5'% &',ai.%' ad !u,ved ',a!"
T T
e&u,e ,ide !87,' 5 a5&,5i. vi5,a'i ad 8ii8i>i. !e',i7u.al 7,!e& %e '%e ',ai ,u& !u,ve& a' %i.% &-eed/
T T
8ii8i>e .ee,a'i 7 ',a!" i,,e.ula,i'ie& ad ,ail a5,a&i/
U&ua U&uall ll ' ' 5.i 5.ie& e& a,e a,e A''e A''ed d ' ea!% ea!% !a, !a,,ia. ,ia.e e a. a. , l!8'ive e a' ea!% ed/
.4 GENERATOR This "ian! en"ine is hooke* u, !o a n eua%%y im,ressive "ener a!or. I! is a/ou! 8 +ee! $3.4m& in *iame!er an* -ei"hs a/ou! 37(766 ,oun*s $465;k"&. A! ,eak ,o-er !his "enera!or makes enou"h e% e!rii!y !o ,o , o- er a ne i "h /or /o r ho o* o + a/ ou ! 3( 66 6 ho us e s . So( -here *oes a%% !he ,o-er "o I! "oes in!o si?( massive e%e!ri mo!ors %oa!e* in !he /o"ies. The en"ine ro!a!es !he rank sha+! a! u, !o 3666r,m an* !his *rives !he various i!ems nee* !o ,o-er !he %oomo!ive. As As !he !ransmission is e%e!ri !he en"ine is use* as !he ,o-er soure +or !he e%e!rii!y "enera!or or a%!erna!or.
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Pe, Pa Pa!"
The -ork o+ ,o-er ,ak se!ion is !o *o !he overhau%in" an* re,airin" -ork. They !ake ou! !he hea* +rom !he en"ine an* assem/%es i! a+!er neessary re,air. In !he ,o-er ,ak se!ion !he assem/%y o+ ,is!on an* onne!in" ro* is *one. The !horou"h hekin" o+ ,is!on is *one in !his se!ion. The ,is!on is sen* + or >y"%o !es! !hen i! is heke* +or a%% !he %earanes. I! is heke* -he!her !he ,is!on is sei>in" or no!. There are !-o !y,es o+ ,is!on use*( mo*i+ie* an* unmo*i+ie*. In mo*i+ie* ,is!on( ,is!on hea* is ma*e u, o+ s!ee%( !he ,is!on skir! is ma*e u, o+ a%uminum. Unmo*i+ie* ,is!on is !o!a%%y ma*e u, o+ s!ee% on%y. The -ei"h! o+ !he assem/%y is o+ ;6k". There are "enera%%y = rin"s use* in !he y%in*er( +irs! < are om,ression rin" ne?! 5 are oi% rin"s. The +irs! one is ma*e u, o+ s!ee% an* has suare +ae. The seon* one is a%so o+ s!ee% an* has !a,ere* +ae. The !hir* one is o+ '.I. an* is +ue% e++iien! !a,er +ae. The +our!h an* +i+!h are a%so o+ '.I. an* are a%%e* oi% sra,,er rin"s. PARTS PARTS OC TBE PO)ER PA'K PA'K • • • • • • • • • • • • • • • •
EBAUST MANICOLD )ATER 'BANNEL PGEV GOVERNOR 'RANK 'ASE MOTOR 'FLINDER $MA. 38 'FLINDER& PISTON CUEL OIL INE'TOR RO'KER ARM FOKE LU#E OIL BEADER PIPE 'AM SBACT 'RANK SBACT 'ROSS BEAD CUEL INE'TION PUMP 'ROSS PIPE CIP 'OVER
• • • • • • • • • • • • • • •
CUEL OIL #ENHO LU#E OIL SUMP GEAR 'ASE 'FLINDER BEAD INLET 0 EBAUST E BAUST VAULVE VAULVE TUR#O SUPER 'BARGER ACTER 'OOLING 'ORE OVER SPEED TRIP BOUSING OIL SLEEVE RING )ATER PUMP LU#E OIL PUMP OIL SLEEVE DRAINE PIPE CUEL 'ONTROOLING SBACT
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In!erna% om/us!ion En"ine Cun*amen!a%s1( C un*amen!a%s1( Bey-oo*( Ta!a Ta!a MGra- Bi%%s.
In!erna% om/us!ion En"ine1( V Ganeshan( Ta!a Ta!a MGra- Bi%%s. In!erne! soures %ike
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/i"i-edia/!8 /,ailal!e.ie/!8 /,d&/idia,aila&/.v/i
C'e'& 3.
BTRODUCTOB TO BDB RL RLY///////////////////// Y//////////////////////////////////////////////////// ////////////////////////////////////////////// ///////////////// 3
5.
DESEL LOCO@OTVE SED CRG LUC?BO///////////////////////////////////////////// LUC?BO/////////////////////////////////////////////4 4
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DESEL ELECTRC LOCO@OTVE////////////////// LOCO@OTVE////////////////////////////////////// /////////////////////////////////////// ////////////////////////////////////// ///////////////////6 6
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CYLBDER ED/////////////////////////////////////////////// ED////////////////////////////////////////////////////////////////// /////////////////////////////////////////// ///////////////////////////////// ///////// +
=.
8.
4/1
BTRODUC BTRODUCTOB/ TOB////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ///////// ///////// ////////// ////////// ////////// ////////// /////////// ///////////////// //////////////////+ ///////+
4/2
C88 C88 !8- !8-e'& e'& u&ed i dia dia Rail Raila a Cli Clide, de, ead&////// ead&/////////// ///////////// ////////////9 ////9
4/3
C8-ul C8-ul& &, , !8- !8-e' e'& & ' 5e e$!%a e$!%a.ed .ed i Cli Clide de,, ead Se!' Se!'i///// i//////////10 /////10
4/4
C,i'i!al C,i'i!al -a,'&/ -a,'&////// ///////// ///////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// //////////// ///////////////// ///////////////////// ///////////////////10 ////////10
4/*
Clide, Clide, ead ead &e!'i &e!'i ,"i. ,"i. -,! -,!edu, edu,e///// e////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ///////11 //11
4/6
Te&'i. e&'i. 7 Clide, Clide, ead/////// ead//////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ///////////// /////////////////// //////////////////12 ///////12
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Be Gee,a Gee,a'i 'i Clide, Clide, ead// ead/////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// //////////// ////////////////1# /////////1#
VROUS OTER CO@POBEBTS O< RL LOCO@OTVE/////////////////// LOCO@OTVE///////////////////////////////// ///////////////////1+ /////1+ */1
TURO TURO SUPER SUPERCRGER// CRGER/////// ////////// ///////// ///////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// //////////////// ///////////// //1+ 1+
*/2
*/3
OGE/// OGE//////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ///////// ///////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// /////19 19
*/4
GEBER GEBERTOR/ TOR////// ///////// ///////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////////// //////////////////// //////////////////20 ///////20
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Pe, Pe, Pa!"// Pa!"/////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ////////// ///////// ///////// ////////// ////////// ////////// ////////// ////////// ////////// //////////// ///////////// //////20 20
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