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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.

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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
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ENGINE ROOM
VALVE LEVERS COVER DE-COMPRESSION ADOPTERS

AIR BOX COVER

ENGINE ROOM SUMP DOOR

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EXHAUST MANIFOLD

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GENERATOR ROOM
OIL SEPERATOR TURBO

AFTER COOLER

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VALVE LEVER MECHANISM


CAM SHAFT

VALVE LEVER MECHANISM

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ENGINE ACCESSORIES FROM LEFT SIDE


ENGINE PROTECTING DEVICE

LOW W ATER

LOW CRANK CASE VACUUM

LWS COC
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ENGINE ACCESSORIES FROM RIGHT SIDE


OSTA RESET HANDLE
CAM SHAFT VIBRATION DAMPER HOUSING

LLOP

ENGINE GOVERNOR
FUEL SIGHT GLASS
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ENGINE ACCESSORIES FROM RIGHT SIDE

SECONDARY SPIN ON FUEL FILTER


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RIGHT BANK WATER PUMP

TURBO SOAK BACK PUMP & FILTER

L/O DIPSTICK GAUGE

SOAK BACK FILTER

SOAK BACK PUMP


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ENGINE EQUIPMENT RACK FROM RIGHT SIDE OF LOCO

PRESSURE CAP

RELIEF VALVE

ENGINE START SWITCH

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ENGINE EQUIPMENT RACK FROM LEFT SIDE OF LOCO


EXPANSION TANK
FUEL OIL PRIMARY FILTER

LUBE OIL COOLER

Lube oil filter condition gauge

LUBE OIL FILTER DRUM

COMPRESSOR

ENGINE EQUIPMENT RACK/COMPRESSOR COMPARTMENT


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RADIATOR COMPARTMENT

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UNDER TRUCK

VERTICAL SHOCK ABSORBERS

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SIDE LOAD PAD

SAFETY LINK CHAIN

LOCO LIFTING PAD

BRAKE CYLINDER

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HAND BRAKE

HAND BRAKE
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SIDE BUFFERS

JUMPER RECEPTACLE

FP BP

CBC

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FUEL TANK

EMERGENCY FUEL CUT OFF SWITCH

AIR BOX DRAIN (BAP)

FUEL TANK

FUEL GLOW ROD GAUGE


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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
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FUEL SYSTEM IN WDG4/WDP4

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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
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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.
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COMPUTER CONTROLLED BRAKE SYSTEM (CCB)


CONSOLE
1 2 3
4 5

1.WIPER CONTROL KNOBS 2.MR(RED) , ER (WHITE)GAUGE 3.BP(WHITE) , BC (RED)GAUGE


4.AIR FLOW INDICATOR (WHITE NEEDLE-INDICATOR, REDNEEDLE- SETTING) 5.SPEEDO METER 6.TRACTIVE EFFORT METER 7.INDICATING PANEL
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10
8.ALERTOR LIGHT 9.HORN BUTTONS 10.ALERTOR RESET BUTTON

BRAKE CONTROL UNIT

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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


: ER/BP reduce to 4.7 kg/cm2, BCP = 1.1 kg/cm2 : ER/BP reduce to 3.4 kg/cm2, BCP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2) : 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)
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c) Minimum service

d) Full service

e) Emergency

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 RUN

NON-WORKING CONSOLE NEUTRAL IDLE FULL SERVICE

FULL APPLICATION LEAD

RELEASE

TRAIL

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PROCEDURE OF CHANGING CONSOLE


Keep isolation switch in START/STOP/ISOLATE position. CONVERTING THE WORKING CONSOLE AS NON-WORKING CONSOLE.

ITEM
1. REVERSOR 2.THROTTLE/SELECTOR 3.AUTOMATIC BRAKE HANDLE 4.DIRECT BRAKE HANDLE 5. LEAD/TRAIL (SELECTOR) SWITCH

WORKING CONSOLE CHANGING IN TO NONWORKING CONSOLE NEUTRAL NEUTRAL


IDLE RUN IDLE FULL SERVICE

FULL APPLICATION LEAD

RELEASE TRAIL

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CONVERTING THE NON-WORKING CONSOLE AS WORKING CONSOLE. ITEM 1. REVERSOR 2.THROTTLE/SELECTOR 3.AUTOMATIC BRAKE HANDLE NON WORKING CONSOLE CHANGING IN TO WORKING CONSOLE NEUTRAL IDLE FULL SERVICE NEUTRAL IDLE RUN

4.DIRECT BRAKE HANDLE


5. LEAD/TRAIL (SELECTOR) SWITCH

RELEASE
TRAIL

FULL APPLICATION
LEAD

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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 COCs on locomotive and on formation. Close MR and BC equalizing COCs 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.
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AIR BRAKE SELF TEST PROCEDURE Press Main menu key. Using down arrow key, bring curser to Self Test and press F3 to select.

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Press F2 key to go to Next page.

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Using down arrow key, bring cursor to Air Brake Test and press F3 to select.

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Entry conditions for Air Brake Test will be displayed on the screen, which are already fulfilled. Press F1 key to continue test.

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Air brake test in progress display will come.

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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.

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Crew message display will come as below

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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.
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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
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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

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Bogie isolation coc- for front & rear truck

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MR1 & MR2 with J filter (system) cocs In between front truck and fuel tank (Right side of the loco)

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F2 feed valve coc In between front truck and fuel tank (Right side of the loco)

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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


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MOVING OF WDG4/P4 LOCOMOTIVES


S.No. 1 LEAD LOCO ANY AIR BRAKE LOCO CONNECTIONS TRAIL LOCO MU JUMPER WORKING WDG4/P4 LOCO BP/(FP), MR EQ. &BC EQ. KEEP BOTH CONSOLES AS NON WORKING BP/(FP), MR EQ. &BC EQ. DEAD WDG4/P4 LOCO KEEP BOTH CONSOLES AS NON WORKING & COMPUTER BREAKERS IN ON POSITION 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 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.

ANY AIR BRAKE LOCO

ANY AIR BRAKE LOCO

ANY AIR BRAKE LOCO

ONLY BP/(FP)

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