DEMU

The DPC (Driving Power Car) has a single power pack consisting of a diesel engine, model KTA-50-L
(Kirloskar Cummins Ltd).

1.4 SPECIFICATION
01 Exact description and Model of the engine : Cummins KTA-50-L
02 Rated output : 1400 BHP
03 Maximum intermittent traction rating at site condition
given below : 1600 BHP @ 2100 RPM
04 Site conditions
Ambiant température : 55Deg. C
Altitude above mean Sea level : 1000M
Relative Humidity : Above 40%
05 Rated speed at continuous rating : 1800 RPM
06 Type of cycle : Four stroke
07 Method of pressure charging : Turbo charging
 Pressure ratio of the compressor
at the rated output : 2.4
 Single stage/ Two stage : Single stage
 No. of Turbochargers used : Two
 Make and model of Turbocharger : Cummins
08 Type of exhaust system : Pulse type
09 Cooling method of the charge air : By engine coolant.
10 Type of combustion chamber : Direct injection chamber
11 Fuel Injection equipment : Unit type FIP and injector
12 Fuel pump : PT-fuel pump
13 Number of cylinders : 16 Cylinder (8 cyl. per bank)
14 Arrangement : “V”-Type 60 degree
15 Cylinder bore : 159mm
16 Piston Stroke : 159 mm
17 Total displacement : 50 Lts
18 Cubic capacity/ Cylinder : 3.13 Lts./ Cyl.
19 Compression Ratio: : 13.8: 1
20 Firing Order : 1R-1L-3R-3L-7R-7L-5R-5L-
8R-8L-6R-6L-2R-2L-4R-4L
21 Mean piston speed at the rated speed : 9.5 m/s.
22 Brake mean effective pressure : 12.58 Kg/Cm2
23 Maximum combustion pressure at the
rated output : 141 Kg/Cm2 (2000 PSI)
24 Compression pressure at No load at
Minimum idling speed : 350 PSI
25 Minimum No-load idling speed : 700 RPM
(A low idle features is provided on the Engine)
26 Max. no load RPM under steady conditions : 2070 RPM
27 Minimum firing speed : 150 RPM.
28 Piston
 Piston cooling method : By engine Lube oil.

1
29 Cooling System
 Cooling system type : Pressurized
 Water tank capacity : 153 Litre
 Treatment recommended for water : Borate base compound
30 Lube Oil System
 Sump Capacity : 151 Liters
 Brand of oil recommended : Multi grade CF4 15-W-40
31 Lube oil Consumption at the rated output : 0.14 Lit / Hr
32 LOC % of fuel consumption : 0.14% of fuel consumption
(Max. is 0.25% of fuel consumption)
33 Lubricating oil pressure at the rated speed
at the normal operating temperature : 3.4 to 6.16 Kg/Cm 2
34 Maximum pressure of charge air in the intake
manifold at the rated output : 1.278 Kg/Cm 2 ( 37” of Hg)
35 Maximum pressure of gases in the exhaust
manifold at the rated output ( At output of TSC) : 3” of Hg
36 Maximum RPM of turbocharger at the
rated output : 63600 RPM
37 Maximum permissible RPM of the
turbocharger : 100000 RPM
38 Temperature of exhaust gases at Turbo
Inlet at the rated output : 600 to 630 Deg.C.
39 Maximum permissible temperature for
Which the turbocharger components have
been designed : 735 Deg. C.
40 Heat balance of the engine:
Useful output : 38.6%
Exhaust :35.3%
Coolant : 24.4%
Ambient : 1.7%

41 Weight of the engine complete with all items

excluding water and lubricating oil : 4858 Kg.
42 Weight of the water contained in the engine : 155 Kg. approx.
43 Weight of the oil contained in the engine : 150 Kg. approx.
44 Specific fuel consumption.
 Indicate the lower heating value of the
fuel used in arriving at the specific fuel : 10000Kcal/Kg.
consumption figures (154.17gm/BHP/Hr)
45 Fuel oil consumption at idle in L/H : 4.16 Lit/ Hr.
46 Type of governor : LCC CGA Make
47 Safety devices provided on the engine.
 Over speed trip safety device
 Low lubricating oil pressure safety device
 High water temperature safety device
 Low water level safety device
48 Transmission System
 Alternator type : BHEL TA 7003 BX
C. Greaves C1012 TA
 Maximum speed : 1800 rpm
 Maximum voltage : 900 V
2
  Maximum current : 2145 A
 Continuous rating low voltage : 550 V, 1660 A, 1800 rpm
 Continuous rating high voltage : 900 V, 990 A, 1800 rpm
 Weight with accessories (Approx.) : 4400 Kg
 Traction motor type : BHEL TM 4303 AZ
C. Greaves C1005 TM
 Maximum speed : 2772 rpm
 Number of TM per DPC : Four
 Continuous voltage : 550 V
 Continuous current : 415 A
 One hour rating : 455 V, 550 A,
 Weight per unit (Approx.) : 2200 Kg
 Gear ratio : 20: 91
 Suspension : Axle hung, nose suspended
 Auxiliary generator : KEL A 18122 FM
 Rating : 110A DC, 135V DC, 18.5KW
 Unit weight : 445 Kg.

Leading Particulars of1400 HP DEMU Power Car

1. Length over headstock : 21417 mm

2. Distance between bogie centers : 14783 mm
3. Bogie wheel base : 2896 mm
4. Wheel diameter : 952 mm (New)
5. Tread wear : 37.5 mm
6. Overall width : 3245 mm
7. Height from rail level to top of roof : 3886 mm
8. Height from rail to floor level : 1282 mm
9. Maximum height of center line of centre buffers above : 1104 mm
rail level for unloaded vehicles.

3
DIESEL ENGINE AND ITS RELATED SUB –ASSEMBLIES
INTRODUCTION
One diesel engine, model KTA-50-L (Kirloskar Cummins Ltd) is provided in each DPC which
produces required power to drive the DEMU. During run, both the engines in both DPC works
together.
SYSTEMS OF DIESEL ENGINE
The various systems of the Diesel engine used in DEMU are as follows:
Air Intake and Exhaust system
Fuel system
Lube oil system
Cooling water system
Hydraulic oil system

1. AIR INTAKE AND EXHAUST SYSTEM

The main components of the air intake and exhaust system are :-
i. Air filter :- It is fitted in the air intake side of engine air manifold at both sides ( RHS & LHS) ,
which cleans the engine air intake from air dust and foreign particles.
ii. Vacuum indicator :- This unit is mounted on the air filter outlet , it indicates a red band when
the accumulated dust is beyond the permitted level.
iii. After cooler :- This unit is mounted to cool the compressed air , supplied from rotary
compressor of Turbo Supercharger unit . It increases the density of air.
iv. Supercharger :- This is a combined unit of Rotary compressor & Turbine which is separated by
a seal . The turbine unit is driven by the hot flue gases from the exhaust of engine cylinder,
which in turn drives the rotary compressor. The Rotary compressor unit is provided to supply
compressed air to air manifold and then finally to the engines cylinder.
v. Exhaust manifold:-This unit is fitted to collect the exhaust hot flue gas coming out from
engine which in turn is utilized for driving the turbine.
vi. Silencer:- This unit is fitted at the exhaust outlet of turbine to reduce noise of hot flue gases

DESCRIPTION :-
Air is drawn through the supercharger portion of the turbo supercharger which compresses and
feeds the compressed air to the cylinders via an after cooler which cools the air. The cooling of air
helps in increasing the density.
The air filter is provided to remove harmful dust, abrasive particles from the air. If these particles
are permitted to enter the engine, the particles will mix with the
lubricating oil to form an abrasive paste which will quickly wear out piston rings, cylinder
liners, pistons, valve guides etc. causing high lubricating oil consumption and blow by.
A vacuum indicator is fitted at the air filter outlet that indicates a red band when the accumulated
dust is beyond the permitted level, so it is necessary to clean the air cleaner element. Air cleaner
element can be cleaned with pressurized air at not more then 30 PSI.
The exhaust air from the cylinder drives the turbine portion of the turbo super charger, which
helps in utilisation of residual heat of exhaust gases.
The exhaust gases are exhausted through a silencer kept on the dished rooftop of the DPC.
Flexible stainless steel connection between the turbo supercharger & silencer allows for expansion
due to heat of the exhaust gases.

4
2. FUEL OIL SYSTEM

The main components of the fuel system are :-

i. Fuel tank :- It is a storage tank having capacity of fuel oil 3000 Lts .
ii. Fuel filter :-This unit is fitted to remove foreign particles suspended in fuel oil
iii. Fuel Oil Pump (Gear type):- The fuel oil pump is driven by accessory drive gear shaft rotates
at engine speed which draws fuel oil from the tank & supplies oil to the system.
iv. Pulsation damper:- During engine running as the fuel oil pump teeth mesh and unmesh ,
considerable turbulence is created in the fuel . To eliminate this roughness a pulsation damper is
fitted.
v. Magnetic filter screen:- Pressurized fuel flows into the centre of the filter screen , which is
located at the top of the fuel pump. Dirt and other materials are removed at by this filter.
vi. Pressure regulator :- It regulates the fuel oil pressure in the system.
vii. Governor :- Governor controls engine speed by varying the supply of the fuel oil, as per
throttle position.
viii. Injector Assembly :- This assembly consists unit type FIP and injector , which supplies
pressurized fuel oil in the form of spray . There are 10 injector assemblies , one for each
cylinder.

5
 GEAR PUMP LCC GOVERNOR SET

DESCRIPTION :-

The fuel oil system is designed to introduce fuel oil into the engine cylinders at the correct time, at
the correct pressure, at correct quantity and correctly atomised. The system injects metered amount
of fuel into the engine cylinder correctly in highly atomised form at a stipulated time in the four
stroke cycle operation of the engine. Metering the fuel to correct required quantity is important
because the engine has to work in a variable speed and with variable load .Timing the injection of
fuel is also important to enable fuel to burn completely for maximum benefit out of it.

6
This system consists of a fuel tank of capacity 3000 Lts .Oil is drawn from the tank by gear pump
via a fuel filter . The gear pump is driven by the accessory drive gear shaft and rotates at engine
speed. To eliminate turbulence of the liquid fuel , pulsation damper is provided in pump outlet .
Fuel then flows through the filter screen to pressure regulating valve , from regulating valve fuel is
supplied to the fuel injector equipment as per throttle position through engine governor. Fuel
injector equipment consists unit type FIP & injector . Shut down valve is provided in injector inlet
line which has final control of fuel oil from the pump to injector . Timing the injection of fuel is
carried out by cam mechanism. Fuel return line from the injector unit is connected to tank.

How Auto Governor controls engine speed :-

During cranking of an engine the engine speed should reach 190 to 250 RPM. At 150 RPM, a good gear
pump will be able to pick up fuel, at these speeds, the idle spring and weight assist spring will hold the
governor plunger and idler plunger together, but fuel pressure is not height.
As engine fires and speed increases, gear pump delivery also increases. But governor weight force also
increases. Fuel pressure continues to rise and increase fuel flow to the engine.
As engine speed reaches 800 to 1000 RPM approximately, resistance to governor weight force increases, as
idle spring and torque spring start getting compressed.
The high resistance presented by these two springs keeps the plunger surfaces very close together and
continually increases fuel to engine- raising engine speed or torque.
Fuel flow continues to increase, as the throttle comes to full open, until the high speed governor spring is
compressed enough that its resistance will balance the force exerted on the governor plunger.
At this point the engine’s governor cut off speed has been reached, and unless position is changed to reduce
it, fuel flow will continue at this ‘governed’ rate.
A wide open throttle will soon allow engine speed to increase beyond a safe speed in order to save the engine
from such a damaging high speed and consequent failure (particularly valve and injector train damage,
governor plunger is provided with small four holes through which fuel is dumped and speed decreases.
As the throttle is closed, the engine speed reduces to idle speed. Reduced governor weight speed moves the
plunger back until it aligns idle port.

7
3 LUBRICATING OIL SYSTEM
Diesel engine is fitted with force-feed lubricating oil system with low lube oil protection device.
The lube oil system has the following characteristics:-
1. To lubricate all the moving parts of the engine.
2. To help in sealing the combustion chamber from the crankcase.
3. To clean the engine by picking up foreign particles.
4. To cool the parts that it contacts.
The main components of the lube oil system are : -
i. Lube oil sump :- It is a storage tank having capacity of 151 Lts .
ii. Lubricating oil Pump :- It is a gear type positive displacement pump which supplies lube oil
to the system.
iii. Lube oil Full Flow Filters :- The purpose of lube oil filter is to remove foreign particles
suspended in the oil, so that it cannot harm the engine.
iv. Bypass Filter :- The function of by-pass filter is to assist the full flow filter by trapping the
finer dirt particles that get through the full flow filter.
v. Lube Oil Cooler :- The purpose of lube oil cooler is to cool the lube oil so that it can again
absorb heat while lubricating the parts.
vi. Pressure regulating valve :- It maintains lube oil pressure in the system between 3.4 to
6.2 kg/cm².
vii. Pressure relief valve :- It is fitted at the discharge side of the pump which protects the pump
from high pressure and controls the discharge pressure bypassing a portion of the oil back to the
sump.
viii. By pass valve :- It is a differential pressure valve to hold a relatively constant pressure across
the filter.

8
DESCRIPTION :-
The lubricating oil pump, mounted on the free end side of the engine sump, draws the lubricating
oil from the engine sump and feed it into the system. A relief valve fitted at the discharge side of the
pump which protects the pump from high pressure and controls the discharge pressure by passing a
portion of the oil back to the sump. The remainder of the oil flows through the regulating valve and
then passes through full flow filter, which is equipped with a differential pressure by-pass valve to
hold a relatively constant pressure across the filter. From the filter the oil flows through the lube oil
cooler and then into the main lubricating oil header of the engine to provide pressure lubrication to
the bearing surfaces. A pipe connection from lube oil cooler goes to the both turbo super charger for
cooling and lubricating the TSC and drain in the sump. A branch line of the lube oil goes for by pass
filter for filtration of lubricating oil. Branch lines leading from the main header supply lubricating
oil to the main bearings, connecting rods, cylinder heads, piston cooling jets and return to the sump.
Another branch feeds the oil to camshaft bearings & cam follower. Sub header supplies oil to
accessory drive like fuel pump & water pump etc. A small line leads to the pressure gauge and the
low lube oil pressure switch for engine safety. The normal lube oil pressure of the engine is 3.4 Kg/
cm2 to 6.2-kg/ cm2 at the rated speed and normal temperature.

Checking of Lube Oil level by dipstick.

Oil gauge dipstick is located on the engine. For accurate readings, oil level should not be checked
for approximately 15 minutes after engine shutdown.
Dipstick should be kept with the pan with which it was originally fitted. Keep oil level as near "H"
(high) mark as possible.

9
 4. COOLING WATER SYSTEM

The main components of the cooling water system are :-

i. Expansion tank :- The capacity of expansion tank is 85 liters. It collects vent out air from
engine and radiators.
ii. Water pump :- Water pump is the main part of water cooling system. It is used to circulate the
cooling water in the system .
iii. Radiators :- Four radiators ( two on each side) are provided in radiator compartment . The
water is cooled while passing through the radiator.
iv. Hydraulic oil coolers :-Hydraulic oil cooler is located in the radiator compartment . It is
situated at the right hand side of the engine . before the RHS radiator , it receives cold air first
for cooling the hydraulic oil.
v. Radiator Fans:- Two nos. of radiator fans are located on top at the centre of the radiator
compartment . The fans are driven by hydraulic motors. Radiator fans suck relatively cold air
from atmosphere through the radiators and throw out the hot air to the atmosphere.
vi. Ventilation fan :-Ventilation fan is located on top of the engine compartment .Like radiator fan
it is also driven by hydraulic motor. As the engine is mounted in closed compartment ,
ventilation is required to keep the compartment cool.

10
 DESCRIPTION :-

After combustion of fuel in the engine, a portion of heat produced inside the cylinder is absorbed by
the components surrounding the combustion chamber i.e. Piston, Cylinder, Cylinder head etc.
Unless the heat is taken away from them and dispersed elsewhere, the components are likely to fail
.All internal combustion engines are provided with a cooling system designed to cool the
excessively hot components, distribute the heat to other surrounding components to maintain
uniform temperature through out the engine and finally dissipate the excess heat to atmosphere to
keep the engine temperature within suitable limit. The engine of DEMU (provided in DPC) is also
provided with closed circuit pressurised water cooling system .
A centrifugal pump driven by the engine crank shaft through a gear, draws water from the
system and delivers through the outlet under pressure. From the outlet about 25% is utilised for
cooling after cooler & rest is utilised for cooling oil cooler. Both the water outlet is connected to
engine block , where it cool down cylinder liner & cylinder head & then the hot water get inside the
radiator core for further cooling by radiator fan & the same water is recirculated by the water pump.

11
5. HYDRAULIC OIL SYSTEM
The purpose of hydraulic system is to transfer the required power from engine to radiator and
ventilation fans.

The main components of hydraulic system are : -

Hydraulic tank
Hydraulic pump
Hydraulic Motor
Hydraulic oil cooler
Manifold block
Pressure relief valve
Thermatic valve
Return line filter
Return block
Hydraulic oil level indicator
Remote Pressure Regulating Valve
Shut-off valve
Hydraulic pressure gauge
Hydraulic temp gauge

12
DESCRIPTION :-

The purpose of hydraulic system is to transfer the required power from engine to radiator and
ventilation fans.
Variable displacement pump is mounted on the engine. It is directly driven by engine gear drive
with 1: 1: 1 drive ratio and is used to drive the radiator fan . The hydraulic pump which is used to
drive ventilation fan is of fixed displacement type. It is mounted on engine and driven by belts from
left accessory drive of the engine. Both the pumps run simultaneously to draw hydraulic oil from
the hydraulic tank after passing through the strainer.
The hydraulic oil is then delivered to individual hydraulic block for running the radiator fan
hydraulic motor as well as ventilation fan motor .The excess hydraulic oil is vent back to hydraulic
tank .The hot hydraulic oil from the tank is allowed to pass to hydraulic oil cooler for cooling and
after filtration through strainer the hydraulic oil is then recirculated in the system .

Hydraulic System Maintenance:

Hydraulic Oil for hydraulic system is expected to give a very long life, if maintained properly. One should be
careful to monitor these factors, which are detrimental to oil life.

 Hydraulic oil temperature should be within the best operating. range i.e. 20°C to 60°C.
 A variation of 10° below or above this range reduces the oil life to half of the recommended period.
 Dirt entry into the system because of poor handling, transportation gasket leakage etc. is not
desired.
 Viscosity of the oil should not be outside the range (74.5 to 167 mm2/second) measured within 20°
C to 80 °C temperature range.
 Avoid mixing of water with the oil, which may occur during rainy season.
 Check presence of water during every 300 hours of engine maintenance by draining the bottom
plug.
 Check if cloudiness is observed in the oil. Presence of water will destroy the lubricating properties
of oil and cause fast wear.
 Avoid foaming of the oil, which normally occurs due to heavy churning of oil or suction of air by
hydraulic pump.

13
Hydraulic System Do's & Don'ts:

Do's Don'ts
Do not exceed oil change interval more than
Change oil after every 2000 hours of operation.
one year or 2000 hours, whichever is earlier.

Filter Element should be changed immediately

Do not clean and re-use filter element
after restriction indicator shows" RED" mark.

Replace Hoses & 'O' rings after every 6000

Do not re-use any "O" ring or Dowty washers
hours of operation or 2 years, whichever is
during re-assembly.
earlier.

Oil contamination level should be checked every Do not use oil with contamination level exceed
month. the limits.

Do not repair the thermatic valve. Do not reuse

Do check the thermatic valve in hot water temp
the thermatic valve in case flow does not seize
bath. It should close hydraulic flow at 90 Deg. C.
at 90 Deg. C.

During re-fitting carefully align and route the Do not apply force or twist the hoses for
houses. alignment and tightening.

14
 Important Trouble Shooting for 1400 HP DEMU

S.No Problem Cause Remedy

1 Engine not cranking.  24 V knife switch in OFF - Put it ON.
position.
 Starting panel MCB in OFF - Put it ON.
position.
 Selector switch knob not set - Put selector switch in correct position if:-
in correct position. 1. Engine start by control panel, put knob on
No. 1 (In this method only local engine will
start)
2. Engine start by Driver cabin, put knob on
No. 2 (In this method all engines will start at
time)

2. Engine cranking but Any shutdown safety device in

not starting operative position-

1. L.C.W.L in operative Check all safety devices (L.H.O.L, L.C.W.L,

condition. Over speed trip, H.O.F.F etc.) if any safety
device found in operative condition put it
right as follows-
Check water tank level, if any leakage found
tries to stop it and reset the L.C.W.L then
start the engine.

2. O.P.S. in operative Check lube oil level and O.P.S. connections if

condition. found lube oil in correct level. Reset the O.P.S
then start the engine and record the LOP.

3. L.H.O.L sound with Check hydraulic oil level if found necessary

indication on ECP and top up it.
L.H.O.L in operative Check hydraulic oil tank cutout cock it should
condition. be in fully open position.
If hydraulic oil level is correct reset the
L.H.O.L and start the engine.

4. Over speed indication on Reset it on ECP by reset switch.

ECP.
Governor MCB in OFF position Put it ON
Air lock in Fuel oil system. Remove air lock in the system
3. Engine cranking but Empty fuel tank. Top up fuel in tank.
suddenly stopped
Obstruction in fuel supply or Put it ON and check priming pump cutout
main cutout cock close. cocks both should be in close position.

Air lock in Fuel oil system. Remove air lock in the system

Any rubber pipe crack Replace defective pipe.

15
 Actuator linkage in maximum Check actuator position and correct it.
position.

Governor MCB in OFF position. Put it ON

Any shutdown safety device in

operative position- Check and correct as describe in S.No. 1 & 2

4. Engine not D.I.R not picking up. Manually operate DIR relay.
responding
according to Driver’s key not properly fitted. Driver’s key fit properly.
throttle.
ECS in OFF position. Put it ON.

Master controller not works Check interlocks.

properly.

5. Engine over speed Actuator linkage at maximum Check actuator linkage if stick up, put it in
during start. level. right position.
Check Magnetic pickup coupler for open if
open then tight properly

6. Engine shut down Any shut down safety device in Set shut down device on ECS and-
and not starts operate position. Check lube oil level and OPS. If engine not
again. cranking, smoothly strike on OPS by wooden
piece.

Over speed trip. Set over speed trip

LCWL operate. Check water level in the tank, top up if

require.

LHOL operate. Check Hydraulic oil level and inspect hose

pipes.
Check Hydraulic tank COC they are in OPEN
position and micro switch not loose.

Fuel tank empty. Top up Fuel in fuel tank.

Restrict fuel supply or COC Check main suction line and manually fuel
closed. priming pump.
Check and correct as describe in S.No. 3
7. Engine Hunting Engine not notch up properly. Engine notch up properly and wait for RPM
setup.

Restrict fuel supply Check for air locks and leakage, if found put it
right.

Any idling device in operate Re set operate device.

condition.

16
8 Alarming Hot Water temperature above 960 C. Check water leakage from water pump,
Engine radiator room and engine block.
Get fast pumping by put GF off for reducing
temp.
Water pump not working Check temp. of suction & outlet by hand, if
properly. temp. deference observes then water pump
may not be work.
Observe water pressure through vent valve.

Radiator fan not working Ensure radiator proper fan RPM and radiator
properly. room door in closed.

Hydraulic pressure less. Check pressure in Hyd. Pressure gauge if

found less , adjust it by pressure adjusting
knob.

ETS defective. Check temp. in temp. gauge and check

manually water level.
Remove load and get fast pumping by put GF
off for reducing temp.

9 Engine shutting Low water level. Check water level if found less fill water.
down with LCWL If water level is correct then disconnect LCWL
signal. connection.
Water leakage from SMR Check water level if found less fill water.
radiator.
10 Wheel skid / Wheel Brake jam Check brakes for proper opening.
jam Release brake by Distributor valve, close
brake cylinder pipe COC.
Traction motor Bearing seized. Isolate seized motor.

Smoke coming form Traction Use fire extinguishers, Isolate seized motor.
motor.
Defective Axle box bearing. Check axle box bearing for over heating.

DPC Traction motor pinion jam. Release brakes. Check wheel movement in
reverse & forward direction.
11 Air spring D- flat Air spring air hose cracked or Isolate defective air spring.
brushed.
Broken Air spring. Check for hanging parts, if not then Isolate
defective air spring.
12 MR pressure not Air compressor defective Check air compressor – Check Oil level
building up or MR Check V belts for broken
pressure zero. Crack compressor pipes
Check compressor pipe seat

Unloader valve defective. Close isolating valve. Check pressure switch

and off MCB if required.
17
 ABD valve defective. Tapping ABD valve.
Close all drain cocks and isolate ABD valve.

Any flexible pipes crack or Check all flexible pipes for leakage and repair
brushed. it.
13 Feed pipe pressure MR pressure not charges Prevent air leakages and charge MR pressure
not building up properly. upto 8 kg/cm2

Leakage from Feed pipe Prevent air leakages from Feed pipe.
14 Brake pipe Compressor defective Check air compressor – Check Oil level
pressure/ Feed pipe Check V belts for broken
pressure not Crack compressor pipes
building up or zero. Check compressor pipe seat
Check intercooler for leakages.

BP/FP angle cocks in wrong Put it right in position.

position.
Any drain cocks in open Put it close position.
condition
BP/FP pipes palm end in open Refit with new rubber washers.
condition

18
RECIPROCATING AIR COMPRESSOR
(MODEL –TRC 2507 OF M/S . ELGI)

TECHNICAL SPECIFICATION

MODEL TRC 2507

Type Reciprocating, Air cooled, Splash lubricated
Displacement 3292 Lit./min (116.252 cft/min) (3.292 M 3 /min)
Free air delivery 2600. Lit./min (91.818 cft/min) (2.600 M 3 /min)
Working pressure 7 Kgf/cm2
Type of configuration ‘V’
Compression stage 2 stage
Cylinders 2 No. ( 1 LP & 1 HP)
Cylinder size (dia) & stroke LP-197 mm, HP-127 mm, stroke - 90 mm

Type of valve (Suction & Delivery) Individual Disc valves LP & HP

Volumetric Efficiency 79%

Compressor speed 1200 rpm
Type of lubrication Splash
Type of cooling Air cooled
Type of fan Forced draught
Oil fill capacity Max. 3000 ml. Min 2500 ml
Grade of oil Servo Press 150
Direction of rotation Clockwise - viewed from non driving end

Inter cooler Safety valve set pressure 5 kgf/cm2

Overall dimensions L x B x H 670 mm x 820 mm x 855 mm

Net Weight 650 kg
Type of drive V belt

INTRODUCTION :-
Compressed air is required for Braking system , operation of Electro pneumatic contactors, Air
suspension, operation of Wind shield wipers & Horns. To get constant supply of compressed air at
required pressure, a belt driven compressor at the free end of the engine is provided to supply
compressed air at a required rate of 8 kg/cm² at idling speed of the engine.

The air compressor is a reciprocating type two stage, two-cylinder compressor. The compressor
has splash type lubricating oil system and its cooling is done by air. The compressor consists of two
cylinders arranged in a 'V' form on a crankcase, with the low pressure (LP) cylinder at the one side
and the high pressure (HP) cylinder on the other side of the crankcase.

19
 RECIPROCATING AIR COMPRESSOR

The main components of air compression system are :-

i. Air suction filter :- It is a dry type air filter and fitted at the suction side of the LP ( Low
Pressure) cylinder . While passing through the filter element , all dust particles in the air will be
absorbed by the filter . So the suction air will be dust free.
ii. Low pressure (LP) cylinder :- Atmospheric air is initially compressed at low pressure inside
this cylinder
iii. Inter cooler :- An inter cooler is provided to cool the low pressure compressed air which will
be compressed further in high pressure cylinder.
iv. Inter cooler safety valve :- A safety valve is fitted in the intercooler for protection of the inter
cooler and low pressure cylinder.
v. High pressure (HP) cylinder :- After cooling in the intercooler , the air is further compressed
at high pressure inside this cylinder.
vi. Crank case :- The crankcase houses the crankshaft assembly . It also acts as the sump for the
lubricating oil and is provided with an oil level indicator , a draining plug and a breather valve.
vii. Main air reservoir (MAR) :- it is mounted in the under frame of DPC . High pressure
compressed air is accumulated inside this reservoir. One drain cock is provided in MAR which
is used for draining out of moisture from the compressed air when required.

RECIPROCATING AIR COMPRESSOR

DESCRIPTION :-
Atmospheric air initially enters through air suction filter to low pressure cylinder and get
compressed at low pressure. The compressed air from low-pressure cylinder manifold enters into
the inter cooler manifold and passed through the inter cooler tubes. The inter cooler is of radiator
type consisting tubes with fins which cools the low-pressure compressed air before compression in
the high-pressure cylinder. In the high pressure cylinder, it is further compressed to attain the
specified pressure. The discharge side of high-pressure cylinder is connecred to the main air
reservoir.

20
TROUBLE SHOOTING CHART FOR COMPRESSOR

Sl. No. DEFECT LIKELY CAUSES REMEDIES

1 Compressor over  Dirty oil  Change oil.
heats  Oil level low  Fill correct grade of oil up to
maximum level in the dipstick.
 Cylinder and inter cooler tube  Blow with compressed air or
fins dirty clean manually.
 Breather valve not working  Open, clean and refit after
 Wrong direction of rotation checking.
 Interchange correct direction
2 Compressor dose  Blocked unloader pipes  Open and clean pipes
not unload  Defective suction unloader  Remove the suction unloader,
clean and refit
3 Oil carryover in  Chocked air filter.  Clean or renew the air filter
Compressed air element.
 Oil level high  Drain to correct level
 Oil viscosity too low  Change to recommended grade
 Breather not working  Open, clean and refit after
checking
 Piston rings stuck in grooves  Loosen the piston rings, if broken,
or broken. change the rings as a set. Check
all related parts for wear before
 Piston to cylinder clearance fitting.
excessive  Check and change as required
4 Unusual wear of  Inadequate air filter  Increase frequency of cleaning
cylinder, piston maintenance  Increase frequency with more
and piston ring  Oil change frequency periodic check of oil
insufficient  Change to correct grade as given
 Incorrect grade of oil in recommended lubricants chart.
5 Water or rust  Faulty breather valve.  Check and replace the breather
formation in valve if necessary.
crankcase
6 Oil leak through  Breather valve is not working.  Open and refit the breather.
breather valve  Piston rings stuck in Grooves
or broken.  Loosen the piston rings. If broken.
Change the rings as a set. Check
all related parts for wear before
 Piston to cylinder clearance fitting.
excessive.  Check and change as required.
7 Abnormal noise  Loose compressor pulley and  Remove pulley and examine
and key. keyway and key for wear, Change
Compressor the key I pulley as required
Knocking  Worn out piston, cylinder,  Overhaul compressor unit.
crankshaft and connecting rod Replace the related components.
bearings.

-contd-

21
Sl. No. DEFECT LIKELY CAUSES REMEDIES
8 Pressure built up  Chocked air filter.  Renew new one.
time excessive  Loosen belts.  Adjuster or replace, if elongated.
 Leak joints in pressure lines.  Open and re-tighten with Teflon
 Defective seating of inlet and tape or jute and shellac.
delivery valve plates.  Open, clean and refit after careful
 Worn out piston rings. check.
 Replace after checking the related
components.
9 Excessive belt  Incorrect engine and  Check and adjuster using a
wear compressor pulley alignment. straight edge or string across the
 Incorrect belt tension diameter of bolt the pulleys.
 Check belt adjustments
frequently.
10 Compressor  Uneven surface level.  Check the surface with spirit level
package vibration and correct the surface level.
 Mounting bolts and nuts  Tighten bolts and nuts.
loose.

22
SCHEDULE OF STANDARD EXAMINATION OF 1400 hp BG HHPDMU

Periodicity of maintenance of CIL engine, Electrics & Controls, Brake equipments:

i) Trip Schedule. - At end of each trip (maximum 7 days)

ii) Monthly Schedule. - 1 month ± 3 days
iii) Quarterly Schedule. - 3 months ± 3 days.
iv) Half-yearly Schedule. - 6 months ± 5 days.
v) Eighteen monthly Schedule. - 18 months ± 7 days.

Type and periodicity of schedules of Coach body, Under frame, Bogie assembly,
Brake rigging:

i) Primary . - Daily
ii) Schedule ‘A’ - 1 month ± 3 days
iii) Schedule ‘B’ - 3 months ± 7 days.
iv) Schedule ‘C’ - 6 months ± 15 days.
v) POH - 18 months ± 15 days.

Schedules of Periodical Overhauling(POH) of Major Items :

i) CIL Engine : After 18,000 hrs based upon performance parameters.
ii) Traction motors : 18 months.
iii) Traction Alternators : 36 months.
iv) Compressor : 18 months.
v) Coach body & Under-gear : 18 months.

23
 Part - I
Schedule for Engine, Brake Power, Compressor etc.
SCHEDULE OF STANDARD EXAMINATION OF 1400 hp BG HHPDEMU
SCHEDULE OF STANDARD EXAMINATION OF 1400 HP BG HHPDEMU
(CIL Engine, Brake power, Compressor etc.)

TRIP SCHEDULE

DPC/DTC No: Cumulative km.

Date : Cumulative hrs.
S.No Details of work to be carried out Condition/action Remarks
A. CONDITION: DIESEL ENGINE STOPPED

1. Oil & Water filling

Check and top-up if necessary:

a) Lube oil

b) Fuel oil

c) Coolant

d) Hydraulic oil

e) Compressor oil

2. Drain residue from :

i) Air reservoirs.

ii) Intercooler of compressor.

iii) After cooler of pneumatic circuit.

3.
Engine fuel system
Drain sediments from water separator.

4. Check and clean fuel tank level gauge.

5. V-Belts

Check the belts for correct tension and

serviceability:

a) Compressor

b) Water pump.

c) Hydraulic ventilation fan pump drive

24
6. Engine air intake system

a) Remove and clean dust pan.

b) Check for complete red band on

vacuum indicator. Clean outer element
only with dry compressed air from inside
to outside.

Note: Replace outer element after 4/5

cleanings or as soon as red band appears
immediately even after cleaning.

7. Clean the following items with dry

compressed air.

a) Panel filter (engine room).

c) Outer body of engine air intake filters.

8. Check for red indication on return line

filter on hydraulic tank. If red, change the
filter.

9. Check and ensure proper fitment of hose

securing clamp and hose end fittings.

25
B. CONDITION : DIESEL ENGINE RUNNING
10. Mechanical (General examination)

a) General visual checking to be madeto

detect loose, defective, missing orleaky
parts in the following systems:

i) Cooling water

ii) Lube oil

iii) Fuel oil

iv) Air intake & exhaust

v) Hydraulic

vi) Pneumatic

b) Ensure proper working of all

gauges. (DPC & DTC)
11. Check and ensure that hydraulic valve is
fully open.

12. Check radiator fan Hydraulic oil pressure Pressure Temp.

& temperature

Pressure : 150- 180 bar

Temperature : Not more than 70°C

13. Check operation of compressor to ensure that

there is no noise and vibration.

14. Check and record: Idle 1800 rpm

Engine lube oil pressure: Permissible values;
2
*1-2 kg/ cm. for idle

*3-7 kg/ cm.2 for 1800rpm

Lube oil temp: Should lie between 75°C - 105°C .

Cooling water temp : Not more than 95°C

26
SCHEDULE OF STANDARD EXAMINATION OF 1400 hp BG HHPDEMU
S.No Details of work to be carried out Condition/action Remarks
15. Pneumatic system (DPC ,DTC)

a) Time for charging the 10 min.

main air reservoir from 0 to 7 kg/cm2.

b) MR cut in pressure. 6 ± 0.1 kg/cm2

c) MR cut out pressure. 7 ± 0.1 kg/cm2

d) MR safety valve starts 7.75 kg/cm2

blowing off at.

16. Check and record the following :

a) Brake Cylinder Pressure.

2
DPC – 1.6 kg./cm.
2
DTC – 3.5 kg./cm.
2
b) BP pressure : 5.0 kg./ cm.
2
c) Feed .Pipe Pressure 6.0 kg./ cm.
2
d) Parking Brake pressure 3.5 kg./ cm.

17.
Functional Test : (DPC & DTC)
a) A9 valve : Apply & Release

Satisfactory

b) SA9 valve : ---do----

c) Guard’s valve : ---do---

d) Deadman’s device : ---do----

18.
Check working of wiper
19.
Check working of horn.

Repairs booked by driver

1.

2.

SSE (DEMU) Name & Sign SUP Name & Sign

27
EXAMINATION OF 1400 hp BG HHPDEMU
SCHEDULE OF STANDARD EXAMINATION OF 1400 HP BG HHPDEMU
(CIL Engine, Brake power, Compressor etc.)

MONTHLY SCHEDULE
DPC/DTC No.: Cumulative km.
Date : Cumulative hrs.
Repeat all checks of Trip Schedule

S.No Details of work to be carried out Condition/action Remarks

A. CONDITION : DIESEL ENGINE STOPPED

1. General check :

Check tightness of foundation/

mounting bolts of the following :

a) Engine,

b) Radiators,

c) Compressor

d) Radiator & Ventilation fan .

e) Inlet & Exhaust manifolds.

2. Change the following filters (after 300

hrs / monthly, whichever is earlier) :

a) Engine lube oil system :-

i) Full flow filter

ii) By-pass filter

b) Engine fuel filter

3. Change Engine Oil (after 300 hrs /

monthly, whichever is earlier) .

4. Fuel inlet connection screens :

Check and clean magnetic filter

screens in fuel system.

5. Check throttle linkages with hand for

freeness.

28
6. Clean and inspect. Replace if
damaged.

a) Crank case breather,

b) Compressor breather,

c) Fuel Tank breather,

d) Hyd. Tank breather.

7.
Coolant :

Engines provided with Borate

base coolant(i,e. Coolant
Additive Concentrate-CAC)

- Check coolant for CAC with

Test strip.

- Add CAC if value per litre <

0.6.

- If coolant colour is pink, pH

is within limit (8.5to 10.0).

- If colourless, add CAC to

maintain concentration.
8. i) Hydraulic oil to be checked for
water contamination by draining
sample from the bottom plug and see
if cloudiness is observed in the oil.

ii) Hydraulic oil & filter to be changed

(only during first monthly and then
during Half-Yearly schedule)

9. Compressors;

i) Remove and clean the oil bath air

filter.

ii) Change oil in oil bath air filter.

iii) Change crank case oil.

29
EXAMINATION OF 1400 hp BG HHPDEMU
S.No Details of work to be carried out Condition/action Remarks
10. Check air piping. Visually inspect
hoses, pipes for damages/cracks and
clamps for looseness.

11. Test and refill the fire extinguishers if

necessary.

B. CONDITION : DIESEL ENGINE RUNNING

12 Cooling water system

Check that vent pipes in the system

are open.

13. Check working of radiator fan:

Radiator fan RPM should be

measured by inserting tachometer at
fan shaft.

Side mounted Min. : 750

Radiator Max. : 1600

Vent Fan Max. : 1200

14. Check safety valve operation of

compressor.

(9.0 kg/cm2)

Repairs booked by driver

1.

2.

SSE (DEMU) Name & Sign SUP Name & Sign

30
 SCHEDULE OF STANDARD EXAMINATION OF 1400 HP BG HHPDEMU
(CIL Engine, Brake power, Compressor etc)
QUARTERLY SCHEDULE
DPC/DTC No.: Cumulative km.
Date : Cumulative hrs.
Repeat all checks of Trip & Monthly Schedule
S.No Details of work to be carried out Condition/action Remarks
CONDITION : DIESEL ENGINE STOPPED
1. Compressors
a) Open crankcase door and check
all connecting rod nuts and bolts.
b) Remove, dismantle and clean
the disc valves. Assemble with new
packings.
c) Clean the intercooler.

2. A-9 & SA-9 brake valves for DPC &

DTC.

Lubricate brake valve cams.

3. Pneumatic System :
i) Clean aftercooler externally by
blowing compressed air.
ii) Blow down air reservoirs with
compressed air and clean.

4. Fuel injectors and valves ( only

during first quarter and then
during POH)
a. Adjust fuel injectors.
b) Check and ensure valve
clearance as :
- Inlet : 0.36 mm
- Exhaust : 0.69 mm.
Replace Rocker cover gasket &
tighten the cover capscrew to 45
Nm.
5. Check water pump for free rotation.
A. CONDITION: DIESEL ENGINE RUNNING
5. Check for leakages in all the
systems.

Repairs booked by driver

1.

2.

SSE (DEMU) Name & Sign SUP Name & Sign

31
SCHEDULE OF STANDARD EXAMINATION OF 1400 HP BG HHPDEMU
( CIL Engine, Brake, Compressor etc.)
HALF-YEARLY SCHEDULE
DPC/DTC No.: Cumulative km.
Date : Cumulative hrs.
Repeat all checks of Trip, Monthly & Quarterly Schedule

S.No Details of work to be carried Condition/action Remarks

out
CONDITION : DIESEL ENGINE STOPPED
1. Hydraulic system
A. Change oil.
B. Change return line filter element.
C. Clean and check strainer for
external damage. Change if
necessary.
CONDITION : DIESEL ENGINE RUNNING
2. Check for leak-offs from pumps in
the hydraulic systems. Remove
leak-off hose and collect oil in
measuring jar for one minute.
i) Radiator pump leak-off :
Variable Displacement < 6.300
litres/min.
Fixed Displacement < 5.600
litres/min.
ii) Vent pump leak-0ff < 1.900
litres/min.
3. Check for leakages in the system.
REPAIRS BOOKED BY DRIVER
AND REPEATED BOOKING

SSE (DMU)'s SIGN. SUP. SIGN

NAME
NAME

32
STANDARD SCHEDULE EXAMINATION OF 1400 HP HHPDEMU
( CIL Engine, Brake , Compressor etc.)
EIGHTEEN MONTHLY SCHEDULE
DPC/DTC No.: Cumulative km.
Date : Cumulative hrs.
Repeat all checks of Trip, Monthly, Quarterly & Half-yearly Schedule
S.No Details of work to be carried Condition/action Remarks
out
Air Intake & Exhaust System
1. Turbocharger
i) Check oil leakages through
intake & exhaust seals.
ii) Check turbocharger shaft end
clearance with a dial depth
gauge ( value: 0.05mm to 0.13
mm ).
iii) Repair the turbo with repair
kit.
2. Check for leakage in air intake
system, if any, rectify the same
with necessary parts.
3. Replace air cleaner inner &
outer filter elements
4. Check vacuum indicators for
functioning of reset button &
external damages and replace if
necessary
5. Check for leakage from exhaust
system, if any, rectify the same
with necessary parts.
6. Check & replace hoses &
clamps of air intake pipings on
condition basis.
7. Check air intake and exhaust
piping supports. Take corrective
action accordingly.
8. Clean the engine room panel
filters by dry compressed air
and replace if necessary.
Fuel System
1. Clean water separator
assembly.
2. Replace fuel filter element.
3. Replace all fuel line hoses.
4. Calibrate the injectors after
replacing the cups and O-rings.
5. Calibrate the PT pump by
replacing the necessary parts
need to be changed for
calibration ( magnetic filter,
gasket set, etc.)
33
S.No Details of work to be carried Condition/action Remarks
out
6. Adjust valve. Check the
conditions of push rods,
adjusting nut & screws, if
necessary replace.
7 Check fuel lines & connections
for leakage.
8 Check fuel pump linkages.

9 Check actuator functioning.

10. Clean thoroughly fuel tank with

steam and detergents and dry
the tank with air blast.
Lubricating Oil System
1. Replace engine oil.

2. Replace full flow & bypass filter

elements.
3. Replace all oil line hoses &
clamps.
4. Check external oil leakage from
head gasket/rocker housing
gasket, seals, etc. If necessary,
replace the same.
Cooling System
1. Flush cooling water tank.
Replenish with CAC and water .
Replace CR element of system
with CAC for DPCs having CR
element.
Check for concentration.
2. Replace water pump drive belts.

3. Replace all hoses, clamps &

coupling O-Rings of cooling
system pipe lines and radiator
assembly.
4. Remove radiator assembly
(RMR) from the mounting &
clean the radiator assembly.
5. Check all radiator Anti Vibration
Mountings and replace if
necessary.

34
Hydraulic System
1. Replace hydraulic oil. Ensure
that oil cleanliness level is of
NAS1638 Class 9 or better
2. Replace hydraulic oil return line
filter.
3. Replace vent pump belts.
4. Clean hydraulic system strainer.
Check for external damage,
replace if necessary.
5. Check thermatic valve operation.
6. Externally clean & check leak-
offs from main hydraulic &
ventilation pump at rated speed.
Radiator fan pump :
Variable Displacement < 6.300
litres/min.
Fixed Displacement < 5.600
litres/min.
Vent fan pump : < 1.900
litres/min
Externally clean & check leak-
offs from main hydraulic &
ventilation motor at rated speed.
Radiator fan motor : < 2.550
litres/min.
Vent fan motor : < 0. 8 litres/min
7. Externally clean & check radiator
fan operation
8. Externally clean & check vent
fan operation
9. Hoses:
i) Replace all hydraulic pressure
line hoses.
ii) Replace all hydraulic leak-off
& return line hoses on condition
basis.
10. Clean hydraulic oil cooler
externally.
11. Check & set hydraulic system
pressure at 170 bar
12. Compressor :
i) Dismantle and overhaul
ii) Replace worn out parts.
iii) Replace all ‘O’ rings, gaskets,
oil seals.
iv) Assemble and run the
compressor to evaluate its
performance.

35
13. Brake valves :
i) Dismantle and overhaul all
brake valves.
ii) Replace all ‘O’ rings seals and
gaskets.
iii) Assemble and test to
evaluate their performance.
14. Check Vibration damper, replace
if necessary.
15. Carry out repairs advised by
Shed in Pre-Shopping report.
CONDITION : DIESEL ENGINE RUNNING
16. Carry out the load box test to
check the performance of
engine.
17. Check for the leakages in
various systems.

36
37