Beruflich Dokumente
Kultur Dokumente
DIESEL LOCOMOTIVE
A PROJECT REPORT
Submitted by
R.KUMARESAN
95307114309
S.SIRUMURUGAN -
95307114318
S.SIVASANKAR
95307114319
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
SIGNATURE
SIGNATURE
SUPERVISOR
Levengipuram-627114
Levengipuram-627114
INTERNAL EXAMINER
EXTERNAL EXAMINER
SOUTHERN RAILWAY
(CENTRAL WORKSHOP)
THIRUCHIRAPPALI 620014. INDIA.
CERTIFICATE
This is to certify that the project work entitled A STUDY OF
CRANKSHAFT FAILURES ANALYSIS IN DIESEL LOCOMOTIVE is the
bonafide project work submitted by the following students in 2011 at SOUTHRN
RAILWAY.
Name
Register Number
R.KUMARESAN
95307114309
S.SIRUMURUGAN -
95307114318
S.SIVASANKAR
95307114319
Mr.B.RAJAMANI.,
PRINCIPAL.
Date
Place : Trichy
ACKNOWLEDGEMENT
First and foremost, we would like to express our thanks to our
beloved principal Dr.N.AZHAGESAN, M.E., Ph.D., and we would like
to express our tanks to our Head of the Department
Prof.M.S.RAGAVAN, M.E., and other staff members for undertaking
this project and encourage for completing our project successfully.
We would also like to express our thanks to our Ass
Prof.K.RAJKUMAR, M.E., who guided us by providing the study
materials, related to our project and helped us for completion of our
project.
We take the immerse pleasure in expressing Our hearty thanks to
Mr.D.SHANMUGANATHAN IR SME (Chief Workshop Manager) for
permitting us to this project work. I thank Mr.B.RAJAMANI
(Principal/BTC) and Mr.B.GANESH (CI/BTC) for helping me to great
extent in visiting the shop and getting enormous information about the
workshop.
I also take this opportunity to thank Mr.KASINATHA
BOOBATHI (TRADE INSTRUMENTATION) coordinator of project
work (BTC) helped me to a great extend in visiting the shops and
gathering enormous information about the workshop. Finally we would
express
our
sincere
thanks
to
our
technical
advisor,
Mr.CHANDRASEKAR, B.Com.,
We take this opportunity to thanks all teaching and non teaching
staffs for their kind co-operation in completing our project.
Last but not Least, we are grateful to everybody for encouraging
and helping us to complete our project as a part of our academic course.
ABSTRACT
In basic PONMALAI RAILWAY YARD is the maintenance oriented
company. So spare utilization can be decides organization efficiency. So reducing
of spare failures can be increasing the organization efficiency. In our project
analyzed failures of crankshaft in diesel locomotive.
This project deals with the analysis about the various causes of failures of
the Crankshaft of the diesel locomotive engine. It is found that the cost for the
crankshaft is very high whereas the lifecycle is not satisfactory. The causes for the
failure of the crankshaft and the possible ways of minimizing the failure effects
were briefly studied from the past failure specimen. The load bearing capacity of
the crankshaft is theoretically calculated and compared with the actual load acting
on the crankshaft. The remedy for maximizing the lifecycle for the crankshaft was
found and suggestions were made to reduce the frictional forces acting on the
shaft. This prevents excessive wear and deformation of the crankshaft. Thus the
lifecycle of the crankshaft is increased and the cost for the maintenance is reduced.
LIST OF CONTENTS
CHPTER NO
TITLES
INTRODUCTION
1 SOUTHERN RAILWAY
2 GOLDEN ROCK PROFILE
DIESEL LOCOMOTIVE
1 DIESEL ENGINE
2 DIESEL ENGINE TYPES
PARTS OF DIESEL ELECTRIC LOCOMOTIVE
3
4
7
8
9
10
11
12
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60
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70
72
SOUTHERN RAILWAY
The Southern Railway Company, which operated in England from 1923 to
1947. For the modern UK train operating company, see Southern (train operating
company). For the US railroad merged into Norfolk Southern, see Southern
Railway (U.S.).For other uses, see Southern Railway (disambiguation).
The Southern Railway (SR) was a British railway company established in
the 1923 Grouping. It linked London with the Channel ports, South West England,
South coast resorts and Kent. The railway was formed by the amalgamation of
several smaller railway companies, the largest of which were the London & South
Western Railway (LSWR), the London, Brighton and South Coast Railway
(LBSC) and the South Eastern and Chatham Railway (SECR). The construction of
what was to become the Southern Railway began in 1838 with the opening of the
London and Southampton Railway, which was renamed the London & South
Western Railway.
The railway was noted for its astute use of public relations and a coherent
management structure headed by Sir Herbert Walker. At 2,186 miles (3,518 km),
the Southern Railway was the smallest of the "Big Four" railway companies and,
unlike the others, the majority of its revenue came from passengers rather than
freight. It created what was at that time the world's largest electrified railway
system and the first electrified InterCity route (London--Brighton). There were two
Chief Mechanical Engineers; Richard Maunsell between 1923 and 1937 and Oliver
Bulleid from 1937 to 1948, both of whom designed new locomotives and rolling
stock to replace much of that which was inherited in 1923. The Southern Railway
played a vital role in the Second World War, embarking the British Expeditionary
Force, during the Dunkirk operations, and supplying Operation Overlord in 1944;
because the railway was primarily a passenger network, its success was an even
more remarkable achievement.
The Southern Railway operated a number of famous named trains, including
the Brighton Belle, the Bournemouth Belle, the Golden Arrow and the Night Ferry
(London - Paris and Brussels). The West Country services were dominated by
lucrative summer holiday traffic and included named trains such as the Atlantic
Coast Express and the Devon Belle. The company's best-known livery was highly
distinctive: locomotives and carriages were painted in a bright Malachite green
above plain black frames, with bold, bright yellow lettering. The Southern Railway
was nationalised in 1948, becoming the Southern Region of British Railway.
26 Acres
Track Length:
67KMS
No of Quarters:
3807
and can be operated by the same drivers. It differs principally in that it carries its
own generating station around with it, instead of being connected to a remote
generating station through overhead wires or a third rail. The generating station
consists of a large diesel engine coupled to an alternator producing the necessary
electricity. A fuel tank is also essential. It is interesting to note that the modern
diesel locomotive produces about 35% of the power of a electric locomotive of
similar weight.
The UK Class 47 is typical of the general New SD90MAC 6,000 hp heavy freight US
diesel-electric locomotives with AC drive first
purpose diesel-electric locomotives
built in 1998
introduced in the 1960s.
caused by air being suddenly compressed in the cylinder. At this stage, the air gets
compressed into an area 1/25th of its original volume. This would be expressed as
a compression ratio of 25 to 1. A compression ratio of 16 to 1 will give an air
pressure of 500 lbs/in (35.5 bar) and will increase the air temperature to over 800
F (427 C).
The advantage of the diesel engine over the petrol engine is that it has a
higher thermal capacity (it gets more work out of the fuel), the fuel is cheaper
because it is less refined than petrol and it can do heavy work under extended
periods of overload. It can however, in a high speed form, be sensitive to
maintenance and noisy, which is why it is still not popular for passenger
automobiles.
Diesel Engine Types
There are two types of diesel engine, the two-stroke engine and the fourstroke engine. As the names suggest, they differ in the number of movements of
the piston required to complete each cycle of operation. The simplest is the twostroke engine. It has no valves. The exhaust from the combustion and the air for
the new stroke is drawn in through openings in the cylinder wall as the piston
reaches the bottom of the down stroke. Compression and combustion occurs on
the upstroke. As one might guess, there are twice as many revolutions for the twostroke engine as for equivalent power in a four-stroke engine.
The four-stroke engine works as follows: Down stroke 1 - air intake,
upstroke 1 - compression, down stroke 2 - power, upstroke 2 - exhaust. Valves are
required for air intake and exhaust, usually two for each. In this respect it is more
similar to the modern petrol engine than the 2-stroke design.
In the UK, both types of diesel engine were used but the 4-stroke became the
standard. The UK Class 55 "Deltic" (not now in regular main line service) has a
two-stroke engine. In the US, the General Electric (GE) built locomotives have 4stroke engines whereas General Motors (GM) always used 2-stroke engines until
the introduction of their SD90MAC 6000 hp "H series" engine, which is a 4-stroke
design.
The reason for using one type or the other is really a question of preference.
However, it can be said that the 2-stroke design is simpler than the 4-stroke but the
4-stroke engine is more fuel efficient.
Size Does Count
Basically, the more power you need, the bigger the engine has to be. Early
diesel engines were less than 100 horse power (hp) but today the US is building
6000 hp locomotives. For a UK locomotive of 3,300 hp (Class 58), each cylinder
will produce about 200 hp, and a modern engine can double this if the engine is
turbocharged.
The maximum rotational speed of the engine when producing full power
will be about 1000 rpm (revolutions per minute) and the engine will idle at about
400 rpm. These relatively low speeds mean that the engine design is heavy, as
opposed to a high speed, lightweight engine. However, the UK HST (High Speed
Train, developed in the 1970s) engine has a speed of 1,500 rpm and this is
regarded as high speed in the railway diesel engine category. The slow, heavy
engine used in railway locomotives will give low maintenance requirements and an
extended life.
There is a limit to the size of the engine which can be accommodated within
the railway loading gauge, so the power of a single locomotive is limited. Where
additional power is required, it has become usual to add locomotives. In the US,
where freight trains run into tens of thousands of tons weight, four locomotives at
the head of a train are common and several additional ones in the middle or at the
end are not unusual.
To V or not to V
Diesel engines can be designed with the cylinders "in-line", "double banked"
or in a "V". The double banked engine has two rows of cylinders in line. Most
diesel locomotives now have V form engines. This means that the cylinders are
split into two sets, with half forming one side of the V. A V8 engine has 4
cylinders set at an angle forming one side of the V with the other set of four
forming the other side. The crankshaft, providing the drive, is at the base of the V.
The V12 was a popular design used in the UK. In the US, V16 is usual for freight
locomotives and there are some designs with V20 engines.
Engines used for DMU (diesel multiple unit) trains in the UK are often
mounted under the floor of the passenger cars. This restricts the design to in-line
engines, which have to be mounted on their side to fit in the restricted space.
An unusual engine design was the UK 3,300 hp Class 55 locomotive, which
had the cylinders arranged in three sets of opposed Vs in an triangle, in the form of
an upturned delta, hence the name "Deltic".
Tractive Effort, Pull and Power
Before going too much further, we need to understand the definitions of
tractive effort, drawbar pull and power. The definition of tractive effort (TE) is
simply the force exerted at the wheel rim of the locomotive and is usually
expressed in pounds (lbs) or kilo Newtons (kN). By the time the tractive effort is
transmitted to the coupling between the locomotive and the train, the drawbar pull,
as it is called will have reduced because of the friction of the mechanical parts of
the drive and some wind resistance.
over the main engine. In older locomotives fitted with DC generators instead of
AC alternators, the generator was used as a starter motor by applying battery
power to it.
Governor
used to operate the fuel rack lever controlling the amount of fuel supplied to the
engine by the injectors.
Fuel Injection
Ignition is a diesel engine is achieved by compressing air inside a cylinder
until it gets very hot (say 400 C, almost 800 F) and then injecting a fine spray of
fuel oil to cause a miniature explosion. The explosion forces down the piston in
the cylinder and this turns the crankshaft. To get the fine spray needed for
successful ignition the fuel has to be pumped into the cylinder at high pressure.
The fuel pump is operated by a cam driven off the engine. The fuel is pumped into
an injector, which gives the fine spray of fuel required in the cylinder for
combustion.
Fuel Control
In an automobile engine, the power is controlled by the amount of fuel/air
mixture applied to the cylinder. The mixture is mixed outside the cylinder and then
applied by a throttle valve. In a diesel engine the amount of air applied to the
cylinder is constant so power is regulated by varying the fuel input. The fine spray
of fuel injected into each cylinder has to be regulated to achieve the amount of
power required. Regulation is achieved by varying the fuel sent by the fuel pumps
to the injectors. The control arrangement is shown in the diagram left.
The amount of fuel being applied to the cylinders is varied by altering the
effective delivery rate of the piston in the injector pumps. Each injector has its
own pump, operated by an engine-driven cam, and the pumps are aligned in a row
so that they can all be adjusted together. The adjustment is done by a toothed rack
(called the "fuel rack") acting on a toothed section of the pump mechanism. As the
fuel rack moves, so the toothed section of the pump rotates and provides a drive to
move the pump piston round inside the pump. Moving the piston round, alters the
size of the channel available inside the pump for fuel to pass through to the injector
delivery pipe.
The fuel rack can be moved either by the driver operating the power
controller in the cab or by the governor. If the driver asks for more power, the
control rod moves the fuel rack to set the pump pistons to allow more fuel to the
injectors. The engine will increase power and the governor will monitor engine
speed to ensure it does not go above the predetermined limit. The limits are fixed
by springs (not shown) limiting the weight movement.
Engine Control Development
So far we have seen a simple example of diesel engine control but the
systems used by most locomotives in service today are more sophisticated. To
begin with, the drivers control was combined with the governor and hydraulic
control was introduced. One type of governor uses oil to control the fuel racks
hydraulically and another uses the fuel oil pumped by a gear pump driven by the
engine. Some governors are also linked to the turbo charging system to ensure that
fuel does not increase before enough turbocharged air is available. In the most
modern systems, the governor is electronic and is part of a complete engine
management system.
Power Control
The diesel engine in a diesel-electric locomotive provides the drive for the
main alternator which, in turn, provides the power required for the traction motors.
We can see from this therefore, that the power required from the diesel engine is
related to the power required by the motors. So, if we want more power from the
motors, we must get more current from the alternator so the engine needs to run
faster to generate it. Therefore, to get the optimum performance from the
locomotive, we must link the control of the diesel engine to the power demands
being made on the alternator.
In the days of generators, a complex electro-mechanical system was
developed to achieve the feedback required to regulate engine speed according to
generator demand. The core of the system was a load regulator, basically a
variable resistor which was used to very the excitation of the generator so that its
output matched engine speed.
The control sequence (simplified) was as follows:
1. Driver moves the power controller to the full power position
2. An air operated piston actuated by the controller moves a lever, which
closes a switch to supply a low voltage to the load regulator motor.
3. The load regulator motor moves the variable resistor to increase the main
generator field strength and therefore its output.
4. The load on the engine increases so its speed falls and the governor detects
the reduced speed.
5. The governor weights drop and cause the fuel rack servo system to actuate.
6. The fuel rack moves to increase the fuel supplied to the injectors and
therefore the power from the engine.
7. The lever (mentioned in 2 above) is used to reduce the pressure of the
governor spring.
8. When the engine has responded to the new control and governor settings, it
and the generator will be producing more power.
On locomotives with an alternator, the load regulation is done
electronically. Engine speed is measured like modern speedometers, by counting
the frequency of the gear teeth driven by the engine, in this case, the starter motor
gearwheel. Electrical control of the fuel injection is another improvement now
adopted for modern engines. Overheating can be controlled by electronic
monitoring of coolant temperature and regulating the engine power accordingly.
Oil pressure can be monitored and used to regulate the engine power in a similar
way.
Cooling
Like an automobile engine, the diesel engine needs to work at an optimum
temperature for best efficiency. When it starts, it is too cold and, when working, it
must not be allowed to get too hot. To keep the temperature stable, a cooling
system is provided. This consists of a water-based coolant circulating around the
engine block, the coolant being kept cool by passing it through a radiator.
The coolant is pumped round the cylinder block and the radiator by an
electrically or belt driven pump. The temperature is monitored by a thermostat and
this regulates the speed of the (electric or hydraulic) radiator fan motor to adjust
the cooling rate. When starting the coolant isn't circulated at all. After all, you
want the temperature to rise as fast as possible when starting on a cold morning
and this will not happen if you a blowing cold air into your radiator. Some
radiators are provided with shutters to help regulate the temperature in cold
conditions.
If the fan is driven by a belt or mechanical link, it is driven through a fluid
coupling to ensure that no damage is caused by sudden changes in engine speed.
The fan works the same way as in an automobile, the air blown by the fan being
used to cool the water in the radiator. Some engines have fans with an electrically
or hydrostatically driven motor. An hydraulic motor uses oil under pressure which
has to be contained in a special reservoir and pumped to the motor. It has the
advantage of providing an in-built fluid coupling.
A problem with engine cooling is cold weather. Water freezes at 0 C or 32
F and frozen cooling water will quickly split a pipe or engine block due to the
expansion of the water as it freezes. Some systems are "self draining" when the
engine is stopped and most in Europe are designed to use a mixture of anti-freeze,
with Gycol and some form of rust inhibitor. In the US, engines do not normally
contain anti-freeze, although the new GM EMD "H" engines are designed to use
it. Problems with leaks and seals and the expense of putting a 100 gallons (378.5
liters) of coolant into a 3,000 hp engine, means that engines in the US have
traditionally operated without it. In cold weather, the engine is left running or the
locomotive is kept warm by putting it into a heated building or by plugging in a
shore supply. Another reason for keeping diesel engines running is that the
constant heating and cooling caused by shutdowns and restarts, causes stresses in
the block and pipes and tends to produce leaks.
Lubrication
Like an automobile engine, a diesel engine needs lubrication. In an
arrangement similar to the engine cooling system, lubricating oil is distributed
around the engine to the cylinders, crankshaft and other moving parts. There is a
reservoir of oil, usually carried in the sump, which has to be kept topped up, and a
pump to keep the oil circulating evenly around the engine. The oil gets heated by
its passage around the engine and has to be kept cool, so it is passed through a
radiator during its journey. The radiator is sometimes designed as a heat
exchanger, where the oil passes through pipes encased in a water tank which is
connected to the engine cooling system.
The oil has to be filtered to remove impurities and it has to be monitored for
low pressure. If oil pressure falls to a level which could cause the engine to seize
up, a "low oil pressure switch" will shut down the engine. There is also a high
pressure relief valve, to drain off excess oil back to the sump.
Transmissions
Like an automobile, a diesel locomotive cannot start itself directly from a
stand. It will not develop maximum power at idling speed, so it needs some form
of transmission system to multiply torque when starting. It will also be necessary
to vary the power applied according to the train weight or the line gradient. There
are three methods of doing this: mechanical, hydraulic or electric. Most diesel
locomotives use electric transmission and are called "diesel-electric" locomotives.
Mechanical and hydraulic transmissions are still used but are more common on
multiple unit trains or lighter locomotives.
Diesel-Electric Types
Diesel-electric locomotives come in three varieties, according to the period
in which they were designed. These three are:
DC
DC
(DC
generator
supplying
DC
traction
motors);
Diesel Engine
This is the main power source for the locomotive. It comprises a large
cylinder block, with the cylinders arranged in a straight line or in a V. The engine
rotates the drive shaft at up to 1,000 rpm and this drives the various items needed
to power the locomotive. As the transmission is electric, the engine is used as the
power source for the electricity generator or alternator, as it is called nowadays.
Main Alternator
The diesel engine drives the main alternator which provides the power to
move the train. The alternator generates AC electricity which is used to provide
power for the traction motors mounted on the trucks (bogies).
In older
the motors through flexible ducting. The blower output also cools the alternators.
Some designs have separate blowers for the group of motors on each truck and
others for the alternators. Whatever the arrangement, a modern locomotive has a
complex air management system which monitors the temperature of the various
rotating machines in the locomotive and adjusts the flow of air accordingly.
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 and its flow
regulated by temperature, both inside and outside the locomotive. The air
management system has to take account of the wide range of temperatures from the
possible +40 C of summer to the possible -40 C of winter.
Rectifiers/Inverters
The output from the main alternator is AC but it can be used in a locomotive
with either DC or AC traction motors. DC motors were the traditional type used
for many years but, in the last 10 years, AC motors have become standard for new
locomotives. They are cheaper to build and cost less to maintain and, with
electronic management can be very finely controlled.
To convert the AC output from the main alternator to DC, rectifiers are
required. If the motors are DC, the output from the rectifiers is used directly. If
the motors are AC, the DC output from the rectifiers is converted to 3-phase AC
for the traction motors.
In the US, there are some variations in how the inverters are configured.
GM EMD relies on one inverter per truck, while GE uses one inverter per axle both systems have their merits. EMD's system links the axles within each truck in
parallel, ensuring wheel slip control is maximized among the axles equally.
Parallel control also means even wheel wear even between axles. However, if one
inverter (i.e. one truck) fails then the unit is only able to produce 50 per cent of its
tractive effort. One inverter per axle is more complicated, but the GE view is that
individual axle control can provide the best tractive effort. If an inverter fails, the
tractive effort for that axle is lost, but full tractive effort is still available through
the other five inverters. By controlling each axle individually, keeping wheel
diameters closely matched for optimum performance is no longer necessary.
Electronic Controls
Almost every part of the modern locomotive's equipment has some form of
electronic control. These are usually collected in a control cubicle near the cab for
easy access. The controls will usually include a maintenance management system
of some sort which can be used to download data to a portable or hand-held
computer.
Control stand
This is the principal man-machine interface, known as a control desk in the
UK or control stand in the US. The common US type of stand is positioned at an
angle on the left side of the driving position and, it is said, is much preferred by
drivers to the modern desk type of control layout usual in Europe and now being
offered on some locomotives in the US.
Batteries
Just like an automobile, the diesel engine needs a battery to start it and to
provide electrical power for lights and controls when the engine is switched off and
the alternator is not running.
Cab
Most US diesel locomotives have only one cab but the practice in Europe is
two cabs. US freight locos are also designed with narrow engine compartments
and walkways along either side. This gives a reasonable forward view if the
locomotive is working "hood forwards". US passenger locos, on the other hand
have full width bodies and more streamlined ends but still usually with one cab. In
Europe, it is difficult to tell the difference between a freight and passenger
locomotive because the designs are almost all wide bodied and their use is often
mixed.
Traction Motor
Since the diesel-electric locomotive uses electric transmission, traction
motors are provided on the axles to give the final drive. These motors were
traditionally DC but the development of modern power and control electronics has
led to the introduction of 3-phase AC motors. There are between four and six
motors on most diesel-electric locomotives. A modern AC motor with air blowing
can provide up to 1,000 hp.
Pinion/Gear
The traction motor drives the axle through a reduction gear of a range between 3 to
1 (freight) and 4 to 1 (passenger).
Fuel Tank
A diesel locomotive has to carry its own fuel around with it and there has to
be enough for a reasonable length of trip. The fuel tank is normally under the loco
frame and will have a capacity of say 1,000 imperial gallons (UK Class 59, 3,000
hp) or 5,000 US gallons in a General Electric AC4400CW 4,400 hp locomotive.
The new AC6000s have 5,500 gallon tanks. In addition to fuel, the locomotive will
carry around, typically about 300 US gallons of cooling water and 250 gallons of
lubricating oil for the diesel engine.
Air reservoirs are also 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.
Air Compressor
The air compressor is required to provide a constant supply of compressed
air for the locomotive and train brakes. In the US, it is standard practice to drive
the compressor off the diesel engine drive shaft. In the UK, the compressor is
usually electrically driven and can therefore be mounted anywhere. The Class 60
compressor is under the frame, whereas the Class 37 has the compressors in the
nose.
Drive Shaft
The main output from the diesel engine is transmitted by the drive shaft to
the alternators at one end and the radiator fans and compressor at the other end.
Gear Box
The radiator and its cooling fan is often located in the roof of the
locomotive. Drive to the fan is therefore through a gearbox to change the direction
of the drive upwards.
Radiator and Radiator Fan
The radiator works the same way as in an automobile. Water is distributed
around the engine block to keep the temperature within the most efficient range for
the engine. The water is cooled by passing it through a radiator blown by a fan
driven by the diesel engine.
Turbo Charging
the diesel-electric locomotive but there are some variations in design mentioned
below.
Fluid Coupling
In a diesel-mechanical transmission, the main drive shaft is coupled to the
engine by a fluid coupling. This is a hydraulic clutch, consisting of a case filled
with oil, a rotating disc with curved blades driven by the engine and another
connected to the road wheels. As the engine turns the fan, the oil is driven by one
disc towards the other. This turns under the force of the oil and thus turns the drive
shaft. Of course, the start up is gradual until the fan speed is almost matched by
the blades. The whole system acts like an automatic clutch to allow a graduated
start for the locomotive.
Gearbox
This does the same job as that on an automobile. It varies the gear ratio
between the engine and the road wheels so that the appropriate level of power can
be applied to the wheels. Gear change is manual. There is no need for a separate
clutch because the functions of a clutch are already provided in the fluid coupling.
Final Drive
The diesel-mechanical locomotive uses a final drive similar to that of a
steam engine. The wheels are coupled to each other to provide more adhesion.
The output from the 4-speed gearbox is coupled to a final drive and reversing
gearbox which is provided with a transverse drive shaft and balance weights. This
is connected to the driving wheels by connecting rods.
Hydraulic Transmission
Hydraulic transmission works on the same principal as the fluid coupling but
it allows a wider range of "slip" between the engine and wheels. It is known as a
"torque converter". When the train speed has increased sufficiently to match the
engine speed, the fluid is drained out of the torque converter so that the engine is
virtually coupled directly to the locomotive wheels. It is virtually direct because
the coupling is usually a fluid coupling, to give some "slip". Higher speed
locomotives use two or three torque converters in a sequence similar to gear
changing in a mechanical transmission and some have used a combination of
torque converters and gears.
Some designs of diesel-hydraulic locomotives had two diesel engines and
two transmission systems, one for each bogie. The design was poplar in Germany
(the V200 series of locomotives, for example) in the 1950s and was imported into
parts of the UK in the 1960s. However, it did not work well in heavy or express
locomotive designs and has largely been replaced by diesel-electric transmission.
Wheel Slip
Wheels slip is the bane of the driver trying to get a train away smoothly.
The tenuous contact between steel wheel and steel rail is one of the weakest parts
of the railway system. Traditionally, the only cure has been a combination of the
skill of the driver and the selective use of sand to improve the adhesion. Today,
modern electronic control has produced a very effective answer to this age old
problem. The system is called creep control.
Extensive research into wheel slip showed that, even after a wheel set starts
to slip, there is still a considerable amount of useable adhesion available for
traction. The adhesion is available up to a peak, when it will rapidly fall away to
an uncontrolled spin. Monitoring the early stages of slip can be used to adjust the
power being applied to the wheels so that the adhesion is kept within the limits of
the "creep" towards the peak level before the uncontrolled spin sets in.
The slip is measured by detecting the locomotive speed by Doppler radar
(instead of the usual method using the rotating wheels) and comparing it to the
motor current to see if the wheel rotation matches the ground speed. If there is a
disparity between the two, the motor current is adjusted to keep the slip within the
"creep" range and keep the tractive effort at the maximum level possible under the
creep conditions.
Diesel Multiple Units (DMUs)
The diesel engines used in DMUs work on exactly the same principles as
those used in locomotives, except that the transmission is normally mechanical
with some form of gear change system. DMU engines are smaller and several are
used on a train, depending on the configuration. The diesel engine is often
mounted under the car floor and on its side because of the restricted space
available. Vibration being transmitted into the passenger saloon has always been a
problem but some of the newer designs are very good in this respect.
There are some diesel-electric DMUs around and these normally have a
separate engine compartment containing the engine and the generator or alternator.
These weights ensure an even (balance) force during the rotation of the moving
parts.
2.Engine
block
3.Crank
shaft
5.Cylinder
head
and
Valves
6. Liner
CRANKSHAFT
4.Cam shaft
The engine crankshaft is probably the singular costliest item in the diesel
engine. It is the medium of transforming reciprocating motion to rotary motion. The
crankshaft may be assembled type or two pieces bolted type or may be single piece
forging. Balance weights can be either bolted up or welded. The standard
Locomotives of Indian Railways are with single-piece crankshaft with welded
counter weights. In case of CLW/MAK engines the counter weights are bolted.
The ALCO crankshafts are manufactured from chrome-molybdenum steel
equivalent to SAE 4140. The process of forging is such that continuous grain is
maintained. In manufacture of crankshaft, following sequence of operation is
generally followed: a) Forging and forming operation
b) Rough machining
c) Drill of oil holes.
d) Ultrasonic & Mechanical testing
e) Welding of counter weights & their X-ray test.
f) Stress relieving & shot blasting
g) Final machining & for giving fillet radius at crank journal corners and making
oil holes.
h) Nitriding
i) Grinding Lapping
j) Static & dynamic balancing
k) Final inspection
There are two processes of surface hardening with details given below:Method of hardening
Hardness
Depth of hardness
Induction hardening
C-40
0.124"
Nitriding
C-60
0.012 to 0.015"
Generally for low HP engines the first process is preferred, as depth of case is more
and the crank journals and man bearing journals can be ground down to next step
size. In case of high HP and high-speed engines, the preference is for the second
process as it gives long life, the rate of wear being negligible.
Maintenance & Inspection
After cleaning thoroughly, Dye penetration / Magnaflux test is conducted to
detect surface crack. Measure the following dimensions:
Crank pin: Positioning it vertically check dimension at two locations just
beside two oil holes (at two right angular planes in each location) to check ovality
and taperness.
Nominal Dia: 6", Limit upto 5.996"
Ovality: .002"(max) Taperness: .001"(max)
Main journal: Position the crankshaft, keeping No 1 crankpin in vertical
location, measure the dimension as that of crank pin.
Nominal Dia: 8.5", Limit upto 8.496"
Ovality: 002" (max) Taperness: .001" (max)
Fillet Radius: Checked through a special gadget. (.0005" filler gauge should
not pass between the gadget and the fillet)
Eccentricity checking: Eccentricity is checked between any three
consecutive main journals (1,2,3) is given by the distance between the center points
of journal 2 and the mid point of the line joining the center points of journals 1 & 3.
The limit of eccentricity is .001". Eccentricity is checked by the following way:
Place the crankshaft horizontally on a "V" block supported at No3 and No 7 Main
Journals, keeping No 1 crank pin in vertical position.
Mark Dial of a clock at the free end flange in this position, to understand angular
location of the maximum deviated zone.
Record the readings of maximum deviation of every main journal along with their
angular location.
An example of calculating the eccentricity (For No 1,2,3 Main Journals) is
given below:
- Highest total indicator reading (TIR) for:
No 1 M.J.0.0015" at 3 o'clock location.
No 2 M.J. 0.004" at twelve o'clock
No 3 M.J. 0.0015 at 1-30 o'clock
- Plot the graph according to deflection and o'clock location, with suitable scale.
- Connect TIR position of No1 and No3 with a straight line.
- Mark the midpoint of the above straight line and connect it with the TIR of No 2.
This is the relative runout of No 1,2,and 3 main journals.
- Divide the runout by 2. This is the eccentricity and must not exceed .001". (This
case it is .00175" and not acceptable.)
Repeat the above case for each group of three consecutive main journals
12 0'CLOCK
2
.0035 TIR
3
1
3 O'CLOCK
Crank web deflection: Checking of crank web deflection is one of the major
works while assembling engine.
Main generator is coupled at one end of the crankshaft, whose other end is
supported on a bearing housed at the magnet frame. As such, due to mislocation of
magnet frame, if axis of armature does not completely align with the axis of the
crankshaft, the unbalanced mass of armature will cause uneven loading on crank
web at different angular positions during rotation. This causes deflection on crank
web, which will be changing at various positions of crankshaft during rotation.
Such kind of continuous cyclic variation of load leads to main bearing seizure and
breakage of crankshaft.
The crank web deflection can be measured by fitting a deflection gauge at the
located punch mark on the 8th crank web, nearer to TG and rotating the crankshaft
in both the directions
The permissible limit of deflection on each side is . 0008", TIR . 0016".
Correction is made by adding or subtracting shims at the mountings of magnet
frame with engine block. The magnet frame is mounted at two locations with the
engine block and at two locations at the base. Adjustable shims are provided at the
mountings of the magnet frame with the block. The shims of the magnet frame with
the base are fixed and normally not disturbed during crankshaft deflection.
1. Crankshaft
Power from the burnt gases in the combustion chamber is delivered to the
crankshaft through the piston, piston pin and connecting rod. The crankshaft
(fig.3.62) changes reciprocating motion of the piston in cylinder to the rotary
motion of the flywheel. Conversion of motion is executed by use of the offset in the
crankshaft. Each offset part of the crankshaft has a bearing surface known as a
crank pin to which the connecting rod is attached. Crank-through is the offset from
the crankshaft centre line. The stroke of the piston is controlled by the throw of the
crankshaft. The combustion force is transferred to the crank-throw after the
crankshaft has moved past top dead centre to produce turning effort or torque,
which rotates the crankshaft. Thus all the engine power is delivered through the
crankshaft. The cam-shaft is rotated by the crankshaft through gears using chain
driven or belt driven sprockets. The cam-shaft drive is timed for opening of the
valves in relation to the piston position. The crankshaft rotates in main bearings,
which are split in half for assembly around the crankshaft main bearing journals.
Both the crankshaft and camshaft must be capable of withstanding the
intermittent variable loads impressed on them. During transfer of torque to the
output shaft, the force deflects the crankshaft. This deflection occurs due to bending
and twisting of the crankshaft. Crankshaft deflections are directly related to engine
roughness. When deflections of the crankshaft occur at same vibrational or resonant
frequency as another engine part, the parts vibrate together. These vibrations may
reach the audible level producing a "thumping" sound. The part may fail if this type
of vibration is allowed to continue. Harmful resonant frequencies of the crankshaft
are damped using a torsional vibration damper. Torsional stiffness is one of the
most important crankshaft design requirements. This can be achieved by using
CRANKSHAFT
Because of the additional internal webs required to support the main
bearings, the crank case itself is very stiff. The disadvantages of this type of
bearing arrangement are that it is more expensive and engine may have to be
slightly longer to accommodate the extra main bearings. Counter weights are used
to balance static and dynamic forces that occur during engine operation. Main and
rod bearing journal overlap increases crankshaft strength because more of the load
is carried through the overlap area rather than through the fillet and crankshaft
web. Since the stress concentration takes place at oil holes drilled through the
crankshaft journals, these are usually located where the crankshaft loads and
stresses are minimal. Lightening holes in the crank throws do not reduce their
strength if the hole size is less than half of the bearing journal diameter, rather
these holes often increase crankshaft strength by relieving some of the crankshaft's
natural stress. Automatic transmission pressure and clutch release forces tend to
push the crankshaft towards the front of the engine. Thrust bearings in the engine
support this thrust load as well maintain the crankshaft position. Thrust bearings
may be located on any one of the main bearing journals. Experience shows that the
bearing lasts much longer when the journal is polished against the direction of
normal rotation than if polished in the direction of normal rotation. Most
crankshaft balancing is done during manufacture by drilling holes in the
counterweight to lighten them. Sometimes these holes are drilled after the
crankshaft is installed in the engine.
CRANKSHAFT NOMENCLATURE
Crank-throw
This is the distance from the main-journal centers to the big-end-journal
centers. It is the amount the cranked arms are offset from the center of rotation of
the crankshaft. A small crank-throw reduces both the crankshaft turning-effort and
the distance the piston moves between the dead centers. A large crank-throw
increases both the leverage applied to the crankshaft and stroke of the piston.
Crank-webs
These are the cranked arms of the shaft, which provide the throws of the
crankshaft. They support the big-end crankpin. They must have adequate thickness
and width to withstand both the twisting and the bending effort, created within
these webs. But their excessive mass causes inertial effect, which tends to wind
and unwide the shaft during operation.
Main-bearing Journal
Main-journal is the parallel cylindrical portions of the crankshaft, supported
rigidly by the plain bearings mounted in the crankcase. The journals diameter must
be proper to provide torsional strength. The diameter and width of the journal
should have sufficient projected area to avoid overloading of the plain bearing.
Connecting-rod Big-end (Crankpin) Journals
These journals have cylindrical smooth surfaces for the connecting-rod bigend bearings to rub against.
To increase the fatigue life of the shaft, the fillet radius between journals and
webs should be as large as possible but not less than 5% of the journal diameter.
The overlap between the diameters of the big-end crankpin and the main-end
journal depends on the length of the stroke i.e. the crank-throw. A long-stroke
engine has very little overlap, requiring thicker web sections, and a short-stroke
engine has considerable overlap which strengthens the shaft.
INTEGRAL CRANKSHAFT
Collars are machined on the webs adjacent to the journals to accurately align
the crankshaft and the bearings with the correct amount of side-float and, if
manufactured from steel either by forging or casting. The main bearing and connecting rod
bearing liners are made of babbitt, a tin and lead alloy. Forged crankshafts are stronger than
the cast crankshafts, but are more expensive. Forged crankshafts are made from SAE 1045
or similar type steel. Forging makes a very dense, tough shaft with a grain running parallel
to the principal stress direction. Crankshafts are cast in steel, modular iron or malleable
iron. The major advantage of the casting process is that crankshaft material and machining
costs are reduced because the crankshaft may be made close to the required shape and size
including counterweights. Cast crankshafts can handle loads from all directions as the metal
grain structure is uniform and random throughout. Counterweights on cast crankshafts are
slightly larger than counterweights on a forged crankshafts because the cast metal is less
dense and therefore somewhat lighter.
Generally automobile crankshafts were forged in past to have all the desirable
properties. However, with the evolution of the nodular cast irons and improvements in
foundry techniques, cast crankshafts are now preferred for moderate loads. Only for heavy
duty applications forged shafts are favored. The selection of crankshaft materials and heat
treatments for various applications are as follows.
(i) Manganese-molybdenum Steel
This is a relatively cheap forging steel and is used for moderate-duty petrol-engine
crankshafts. This alloy has the composition of 0.38% carbon, 1.5% manganese, 0.3%
molybdenum, and rest iron. The steel is heat-treated by quenching in oil from a temperature
of 1123 K, followed by tempering at 973 K, which produces a surface hardness of about
250 Brinell number. With this surface hardness the shaft is suitable for both tin-aluminium
and lead-copper plated bearings.
(ii) 1%-Chromium-molybdenum Steel
This forging steel is used for medium-to heavy-duty petrol- and diesel-engine
crankshafts. The composition of this alloy is 0.4% carbon, 1.2% chromium, 0.3%
molybdenum, and rest iron. The steel is heat-treated by quenching in oil from a temperature
of 1123 K and then tempering at 953 K. This produces a surface hardness of about 280
Brinell number. For the use of harder bearings, the journals can be flame or induction
surface-hardened to 480 Brinell number. For very heavy duty applications, a nitriding
process can produce the surface to 700 diamond pyramid number (DPN). These journal
surfaces are suitable for all tin-aluminum and bronze plated bearings.
(iii) 2.5%-Nickel-chromium-molybdenum Steel
This steel is opted for heavy-duty diesel-engine applications. The composition of this
alloy is 0.31% carbon, 2.5% nickel, 0.65% chromium, 0.55% molybdenum, and rest iron.
The steel is initially heat-treated by quenching in oil from a temperature of 1003 K and then
tempered at a suitable temperature not exceeding 933 K. This produces a surface hardness
in the region of 300 Brinell number. This steel is slightly more expensive than manganesemolybdenum and chromium-molybdenum steels, but has improved mechanical properties.
(iv) 3%-Chromium-molybdenum or 1.5%-Chromium-aluminium-modybdenum Steel
These forged steels are used for diesel-engine crankshafts suitable for bearing of hard
high fatigue-strength materials. The alloying compositions are 0.15% carbon, 3%
chromium, and 0.5% molybdenum or 0.3% carbon, 1.5% chromium, 1.1% aluminum, and
0.2% molybdenum. Initial heat treatment for both steels is oil quenching and tempering at
1193 K and 883 K or 1163 K and 963 K respectively for the two steels. The shafts are casehardened by nitriding, so that nitrogen is absorbed into their surface layers. If the nitriding
is carried out well in the journal fillets, the fatigue strength of these shafts is increased by at
least 30% compared to induction and flame-surface-hardened shafts. The 3%-chromium
steel has a relatively tough surface and hardness of 800 to 900 DPN. On the other hand the
1.5%-chromium steel casing tends to be slightly more brittle but has an increased hardness,
of the order of 1050 to 1100 DPN.
(v) Nodular Cast Irons
These cast irons are also known as speroidal-graphite irons or ductile irons. These
grey cast irons have 3 to 4% carbon and 1.8 to 2.8% silicon, and graphite nodules are
dispersed in a pearlite matrix instead of the formation off fake graphite. To achieve this
structure about 0.02% residual cerium or 0.05% residual magnesium or even both is added
to the melt due to which the sulphur is removed and many small spheroids in the as-cast
material are formed. The surface hardness of as-cast nodular iron is greater than for steel of
similar strength, their respective hardnesses being 250 to 300 and 200 to 250 Brinell
number. The flame or induction hardening can produce a surface with Brinell numbers of
550 to 580, and also a form of nitriding can be applied if necessary.
Nodular cast iron has the advantageous properties of grey cast iron (that is, low
melting point, good fluidity and cast ability, excellent machinability, and wear resistance) as
well as the mechanical properties of steel (that is relatively high strength, hardness,
toughness, workability, and harden ability). Now-a-days a large number of crankshafts for
both petrol and diesel engines are made from nodular cast iron in preference to the more
expensive forged expensive forged steel. To support the slightly inferior toughness and
fatigue strength of these cast irons, larger sections and the maximum number of main
journals are used.
HEAT TREATMENT
(a) Flame and Induction Surface-hardening
These are the surface hardening methods for steel having 0.3 to 0.5% carbons
without the use of special compounds or gases. The basic principle is to rapidly apply heat
to the surface followed by only water quenching. As it is heated locally instead of heating
the entire mass, the hardening is greatly reduced and distortion of the journal is avoided.
Flame hardening is carried out by oxyacetylene flame at the surface layer
temperature between 993 and 1173 K. The surface temperature depends on the carbon
content equivalent of the different alloying elements in the steel. The heating process is
followed by a water-jet quenching operation. Since the actual period for heating and
cooling is critical, it is predetermined and is mostly automatically controlled.
Induction hardening is carried out by inducting heat electrically into the surface to be
hardened. This case eliminates the danger of either overheating or burning the surface of
the metal as with a flame hardening. An induction coil surrounds the journal and carries a
high-frequency current. This induces circulating eddy currents in the journal surface
thereby raising of its temperature and heat is mostly confined to the outer surface of the
journals. In this process the higher the frequency of the current, the closer the heat is to the
skin. The current is automatically switched off when the required temperature is attained
and the surface is simultaneously quenched by water jet, which passes through holes in the
induction block.
(b) Nitriding Surface-hardening Process
In this process the journals are heated to 773 K for a predetermined time in an
ammonia gas atmosphere, so that the nitrogen in the gas is absorbed into the surface layer.
The alloying elements such as chromium, aluminium, and molybdenum, present in the
steel, from hard nitrides. Aluminium nitrides form an intensely hard shallow case.
Chromium nitrides diffuse to a greater depth than aluminium nitrides. The molybdenum
increases hardenability, gives grain refinement, and improves the toughness of the core.
This process can use directly the journals ground to their final size as there is no
quenching after nitriding thereby avoiding distortion unlike other surface-hardening
processes. The slow rate of penetration of the surface makes the cost of the process high for
example, it takes 20 hours to produce a case depth of about 0.2 mm.
(c) Carbonitriding Surface-hardening Process.
Tufftride' is the best-know salt-bath carbonitriding process. The crankshaft is
immersed in a bath of molten salts at a temperature of about 853 Kfor a relatively short
cycle time of two to three hours. In the process both carbon and nitrogen dissociate from
the salts and diffuse into the surface. Since nitrogen is more soluble than carbon in iron, it
diffuses further into the material. Hard iron carbides and tough iron nitrides are formed on
the surface thereby resistance to wear, galling (surface peeling), seizure, and corrosion are
greatly increased.
Depending on the steel used, this outer layer is 6 to 16 jam deep with hardness
varying from 400 to 1200 DPN. Underneath this outer layer, the excess nitrogen goes into
solid solution with the iron due to which it is strengthened. This inner diffusion zone forms
a barrier which prevents spreading of cracks leading to fatigue failure.
This surface-hardening treatment, also known as soft FLYWHEEL nitriding, is
becoming increasingly popular for both steels the cast irons, and is expected to replace
other more expensive processes for the components using plain carbon steels requiring
surface hardness and corrosion resistance. This process is much quicker and cheaper and
produces similar properties to nitriding, but the depth of hardness is normally less, which
can be a problem if the shaft is to be reground.
CRANKSHAFT SERVICING
1. Condition
The crankshaft is one of the most highly stressed engine components. The stress
increases four times as the engine speed doubles. The crankshaft is rejected if there is any
sign of a crack, because a cracked crankshaft may break if continues in service. Crankshaft
cracks in high production passenger car engines can be detected with a close visual
inspection. High-rpm racing crankshafts should be checked with Magnaflux to detect any
minute crack that may lead to failure.
CRANKSHAFT LUBRICATION
1. Crankshaft Oil-hole Drillings
Oil from the main oil gallery reaches each individual main-journal and bearing. Oil is fed
through a central circumferential groove in the bearing and it completely surrounds the
central region of the journal surface. Diagonal oil hole drills are provided in the crankshaft
which pass through the webs between the main and big-end journals for lubrication of the
big-end journal. For effective lubrication of the big-end, these oil holes emerge from the
crankpin at about 30 degrees on the leading side of the crank's TDC position. The drilled oil
passages should not be close to the side walls of the webs or near the fillet junction between
the journal and the webs to avoid high stress concentration, which may cause fatigue
failure. Also the oil holes on the journal surfaces must be chamfered to reduce stress
concentration, but excessive chamfering can destroy the oil film.
In its simplest form, the oil passage is a diagonal drilling running from the main journal to
the big-end journal. Normally the diagonal hole is drilled at an angle to the crank-web
centre-line so that, when the crank-pin is in the TDC position and combustion force pushes
the connecting rods downwards, some oil still enters between the journal and the bearing. It
is because if the exit of the diagonal hole is exactly at the top of the big-end journal, oil can
not enter between the bearing and the journal in the TDC position. Additionally the
effective projected bearing area is also reduced by chamfered oil hole.
To have an improvement in oil delivery, a cross-drilling runs straight through the
big-end journal and a diagonal drilling from the main-bearing journal intersects the big-end
cross-drilling. Another hole is also drilled diametrically opposite the diagonal-hole's entry
in the main journal, so that when the bearing is loaded at the top or the bottom of the stroke,
the other side of the bearing permits oil to enter.
B. Crankshaft with diagonal web passage and right-angled cross-drilling in the bigend journal.
FAILURES OF CRANKSHAFT
FAILURES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Thermal cracks
Breaking f Journal Bearing.
Enlarged Keyway .
Cracks in Thrust collar.
Second main journal Thermal Crack.
Excess run out at 915 main Journal.
Fourth crankpin having cracks at both end.
Bearing size is enlarged.
Fifth crankpin has dart mark.
Z type crack.
8th and 9th main journal excess run out.
PROBABLE CAUSES
1. Thermal cracks
th
enough.
43.1%
13.6%
Misalignment
10.0%
Overloading
8.4%
Corrosion
4.7%
Other
5.3%
the oil supply to the bearing is shut off and the bearing is wiped and burned.
illustrates bearing damage resulting from lack of lubrication. A lack of oil supply to
the bearings causes burned and extruded bearings linings. If the bearings do not
have the proper crush fit, they may move and turn with the crankshaft. If that
happens the back of the bearings is burned when it turns in the connecting rod. If a
rear main bearing seal is too tight it causes excessive heat build-up on the rear
crankshaft journal so that the back half of the rear main bearing is burned. If the
main bearing bores are misaligned, the centre main bearings and adjacent main
bearings burn and seize. Beaning-edge burning results if the main beaning housing
or connecting rod housing is tapered.
Fatigue
The crankshaft may become ridged in the journal area directly below the oil
grooves in the upper halves of the main bearings. When such ridges occur, the
crankshaft ridge causes a fatigue strip in the lower half of the main bearings. Figure
20.37 shows bearing fatigue failure.If a connecting rod is misaligned, a V-shaped
fatigue occurs at the edge of the connecting rod bearings. Fatigue at the adjacent
parting faces on the bearings takes place if the bearing housing is out of round.
Bearing edge fatigue is caused by an hourglass-shaped crankshaft-bearing journal.
The heaviest loading area in a bearing is a 120 degrees arc of the bearing due
to the specified oil clearance space. The load is applied to the upper half of the
connecting rod bearings and the lower half of the main bearings. If the bearing oil
clearance exceeds specifications, the bearings are overstressed in a 30 to 45 degrees
arc due to the excessive movement of the crankshaft or connecting rod.
Heavy engine load causes bearing fatigue in the upper connecting rod bearings,
especially at low engine speeds. Also excessive engine speed causes bearing fatigue
in the upper and lower connecting rod bearings.
Corrosion
Corrosive acids may contaminate the engine oil because of excessive piston
ring "blow-by", internal antifreeze leaks or the use of high-sulpher fuels. Infrequent
oil change intervals also cause oil contamination by corrosive acids. These corrosive
acids convert the lead in the bearing material to a lead soap, which is subsequently
washed out of the bearing so that the other bearing materials are exposed.
Erosion
This is the uncommon type of bearing failure. When erosion occurs, there
exists a gradual irregular deterioration of the bearing surface, which is caused by the
hitting of surface by oil at high velocity and pressure.
Year of mfg-09.06.76
2.
3.
1.
Year of mfg-26.09.75
2.
3.
1. Year of mfg-22.06.93
2. Date of inspection-10.09.04 to 16.02.2010
3. Nature of defect-split gear journal thermal undersize/Thrust collar crack
1. Year of mfg-14.04.97
2. Date of inspection-11.09.07 to 18.02.2010
3. Nature of defect-9th main journal thermal crack, 3rd crank pin damage
1. Year of mfg-10.01.78
2. Date of inspection-09.10.07 to 19.02.10
3. Nature of defect-counter weight damaged, 8th crankpin undersize
1. Year of mfg-26.10.96
2. Date of inspection-09.10.03 to 18.02.10
3. Nature of defect-Thrust collar crank excessive run out.
1. Year of mfg-13.03.65
2. Date of inspection-30.07.07 to 19.02.10
3. Nature of defect-Location no.2, crankpin broken into two pieces.
1. Year of mfg-02.02.98
2. Date of inspection-21.08.07 to 16.02.2010
3. Nature of defect-Broken into two pieces at 6th crank pin.
1. Year of mfg-25.08.82
2. Date of inspection-06.06.07 to 22.01.10
3. Nature of defect-Thrust collar crack keyway oblong.
1. Year of mfg-23.01.96
2. Date of inspection-19.06.08 to 23.01.96
3. Nature of defect-8th main journal thermal crack and bearing seizure.
1. Year of mfg-14.04.97
2. Date of inspection-27.06.08 to 23.01.10
3. Nature of defect-5th main journal bearing seizure.
1. Year of mfg-24.04.97
2. Date of inspection-27.06.08 to 22.01.10
3. Nature of defect-6th crankpin badly damaged.
1. Year of mfg-17.11.83
for
cracks and repair as required.
Remove all engine power assemblies.
Clean and inspect oil separator screen, ejector assembly, and educator tube
assembly.
Remove exhaust stack manifolds and replace exhaust manifold gaskets.
Inspect manifolds and advise VRE of cracks, etc to determine disposition of
the
manifolds; inspect top deck exhaust manifold bolt holes to allow for proper
torquing of stack manifolds - repair holes as required with Key locking thread
repair inserts.
Thoroughly clean the air boxes, oil pan, crankcase, and Michiana tank and
remove
dirt, debris, and chips.
Inspect the engine for structural cracks and advise VRE of inspection results
to
determine disposition of material.
Replace all Michigan lube oil filters.
Clean the ice cream box strainer housing assembly.
Remove clean and re-install inertial air filters.
Replace engine air filters.
Replace all fuel filters.
Install new lower main bearings and main bearing thrust collars.
Inspect and qualify the piston cooling tubes (P-pipes); replace as required.
Power assemblies shall be rebuilt as follows:
o Completely disassemble, clean, and inspect each power assembly.
o Clean and inspect connecting rods for length, twist, piston pin surface
and
bore parallel.
o Pistons shall have tin plated skirts and ring sets with chrome faced no.
1,
2, and 3 compression rings for 645E3C engines. Carriers shall be checked
visually and dimensionally, inspected, and reassembled with new thrust
washer and snap ring.
o Cast iron cylinder liners with hardened upper bore shall be used.
o Rebuild cylinder heads with new Inconel valves, valve guides, valve
springs, and valve retainers installed in rebuilt cylinder head. Heads shall
be Diamond 5 or newer.
o Install new liner seals and head gaskets.
o Install new lower liner inserts.
o The completed assembly shall be hydrostatic pressure tested.
o Record the old and the new head, liner, and rod serial numbers by
location.
o Plate-type crabs and new head seat rings shall be used when installing
the
Power Assembly in the engine.
Inspect cams and replace as required, inspect cam followers, valve bridges,
rocker
HOW TO AVOID CRANKSAFT FAILURES
To check the OST (over speed tripper) equipment has properly working. There is
any fault that is must be replaced.
Properly check the lubrication oil viscosity.
Periodically change the high quality lubrication oil.
Engine can be operated by rated RPM (1110 to 1140)
Journal can be properly polished.
To check the lubrication oil hole. There is any foreign particles. That is must be
removed.
Engine can be operated limited load (or) torque.
Periodically replaced the lubrication oil filter.
Engine Overheats
The probable causes include lack of coolant; defective radiator hose ;
defective water pump ; clogged water jackets or radiator core ; thermostat stuck
closed ; loose or broken fan belt ; insufficient oil; ignition timing late ; high-altitude,
hot-climate operation ; defective fan clutch; and valve timing late.
Engine Back Fires
The reasons are engine overheats; carbon in engine; excessively rich or lean
mixture; spark plugs of wrong heat range ; ignition timing off; valves hot or stuck ;
cracked distributor cap ; inoperative anti-backfire valve ; and across-firing plug
wires.
Engine Run-on or Dieseling
The causes include timing advanced ; hot spots in cylinders ; engine overheats
; incorrect idle solenoid adjustment; and in diesel engine due to injection-pump
solenoid not turning off fuel valve.
Smoky Engine Exhaust
If blue smoke then excessive oil consumption ; if black smoke then
excessively rich mixture; and if white smoke then steam in exhaust are expected.
Engine Exhaust Contains too much HC and CO
The causes include ignition missing ; faulty air injection ; carburetor troubles ;
incorrect ignition timing ; defective catalytic converter ; and defective TCS system.
CONCLUSION
CONCLUSION
Normally maintenances in PONMALAI RAILWAY YARD is planned very well but
they invest lot of every maintenance because lot of spare must be replaced. We analyzed
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