diesel engine and fuel oil system of alco

8/17/2019 Diesel Engine and Fuel Oil System of ALCO

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A PROJECT REPORT ON

ALCO DIESEL ENGINE & ITS MAINTANANCESCHEDULE

FOR

RITES LTD.

BY

ADITYA SRIVASTAVA

IN PARTIAL FULFILMENT OF SUMMER TRAINING FOR THEREWARD OF THE DEGREE OF

BACHOLOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

FROM

DELHI COLLEGE OF TECHNOLOGY ANDMANAGEMENT

(2014-2015


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CONTENTS

o DIESEL ENGINE DATA

o DIESEL ENGINE COMPONENTS• ENGINE BASE• ENGINE BLOC! • CRAN! SHAFT• CAM SHAFT• CYLINDER HEAD• VALVES• PISTON• PISTON RINGS• CYLINDER LINER • CONNECTING ROD• MAIN AND CONNECING ROD BEARING

o FUEL OIL SYSYTEM• FUEL FEED SYSTEM• FUEL OIL SYSTEM• PRIMARY FILTER • FUEL TRANSFER PUMP• FUEL RELIEF VALVE• FUEL SECONDARY FILTER • FUEL REGULATING VALVE• FUNCTIONING OF FUEL FEED SYSTEM

o FUEL INJECTION PUMP & ITS FUNCTIONING

o

FUEL OIL INJECTION SYSTEM

o CONCEPT OF MECHANICAL MINOR SCHEDULES• T " 1 SCHEDULE (20 DAYS• T " 2 SCHEDULE (40 DAYS• M-2 SCHEDULE (#0 DAYS• M-4 SCHEDULE• M-$ SCHEDULE• M-12 SCHEDULE


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o CONCEPT OF MECHANICAL MAJOR SCHEDULE M24

ALCO 251B DIESEL ENGINE DATAIn Diesel electric locomotive the source o !o"er is # Diesel en$ine% InWDM& cl#ss locos% AL'O (esi$n &)*+ mo(el *, c-lin(er .v. sh#!e/ tur0osu!erch#r$e(/ close( circuit "#ter coole(/ me(ium s!ee( our stro1eDiesel en$ine is use(%

The En$ine2s $ener#l ch#r#cteristics #n( r#tin$s #re $iven 0elo"34

Cycle 4 stroke cycle

Aspiration Tur o super c!ar"e# $it!c!ar"e air syste%

Bore 22& %%

'orse po$er 2()) B'*

En"ine spee# 1))) rp% +,ull loa#-4)) rp% +i#le-

*iston spee#+%ean- ./&. %0sec

Stroke 2( %%

ei"!t +#ry en"ine- 1.)2( k"

E5!l#n#tion o terms

FREE END 4 The Tur0o su!erch#r$er en( o the en$ine%

GENERATOR END 4 The !o"er t#1e o6 en( o the en$ine%

RIGHT AND LEFT SIDE 4 The ri$ht or le t si(e o the en$ine (etermine( 0-vie"in$ the en( rom the !o"er t#1e o6 en( i%e vie"er2s ri$ht si(e #n( le tis le t si(e o en$ine%

'7LINDER LO'ATION 4 The en$ine c-lin(er #re num0ere( rom the reeen( No% * ri$ht #n( le t 8IR 9IL: #re the c-lin(er ne#rest to the tur0o%


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DIESEL ENGINE COMPONENTS

I% ' ) *'+, + /, '+) % /+ 3 % ' )) % +6 + 6) % ), * ) 3%7* %) 8* %7 9 : %3 ' D ) 6 E%3 % C /, % % ). T' )*8)) % '+) % : ,* % % ) +% + ALCO 6 * ) I% +% R+ 69+;) '+ )


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ENGINE BLOCK

2.1. T' %3 % 6 *: ) ' / ) /, +% +% ; ' 3'6; ) )) ) 8* 8 % 9' *'+ + %8/ /, +% %3) 6 : * +%: )'+ 7 *+/ )'+ 7 *;6 % ' + )7 *;6 %6 % )7 , ) % * %. 7 8 6 %> * % ,8/,) +% * ))' + 7 8 )8,, 7 3 % *.

2.2. L : %3 % +) ' ) ) 8* 8 ( % *+) ALCO L * ) ) +6) + *+ / 6 9*+ % ) 6 ), * *+ % IS 20#2. T' )+ 6 7 ' 9 7 ) + 3 %3 8 ) 6 ), * *+ % IS-1$@5.

T' M+ % + %3 *+,) + 3' % ' ), * 8 +68 .

2.= T' /+ /8/ , )) 6 / )+6 3%/ % , / % /+ % + %3 ' 8) %3 + +)66 9)?-

H % +6 / )+6 3%/ % ? 1 B 9 % + >+* % ). 0.0022 B 9 % +%; +%; . 0.004

V *+6 / )+6 3%/ % ? 1 B 9 % + >+* % 0.0015

2. B 9 % +%; +%; . 0.00=

T' ) ) / )+6 3%/ % *+% *' *: 9 ' ' ' 6, /+% 6 +% 6 3+83 . B8' ) ) * %) + ' * 8 / ' . I ) + )+ 6 /+: )8*' *' *:) 9 ' ' 6, , *+6 %) 8/ % ) 6 : * 66 /+ ) 3 +**8 + )86 ).

2.4 A ' %3 * +%: +% *+/ )'+ + %3 ' 8) %37 ' 9 : /+*' % %3 , &/ 6 *:) *;6 % 6 % ) ) +: % 8,. T' 9 )7 ' *'+/ ) +% +* %3 ' ,

+* + +66 % ) /86 +% 8)6; 9 ' ' ' 6, * 6- %3 /+*' % 9 ' 9 %3 + ) + +% +%36 450.

2.5 T' %3 % 6 *:) '+ % 8% )' 9 ) 3%) ) % + + 6 12 15

; + ) +) +% + * * +%:)'+ ) 8 /+> +** % . I% * , 9 ' )8*'* )7 *+,+* ; '+) % * + % DL< *6+/+ % 6 *:).

= CRANKSHAFT

=.1 T' %3 % * +%:)'+ ) , + 6; ' ) %386+ * ) 6 ) / % ' ) 6 %3 % . I )' / 8/ +%) / %3 * , *+ %3 / % + ; / %. T' * +%:)'+ /+;

+)) / 6 ;, 9 , * 6 ;, /+; ) %36 , * 3 %3. B+6+%* 9 3' ) *+% ' 6 8, 9 6 . T' ) +% + L * ) I% +% R+ 69+;) + 9 ' ) %36 , ** +%:)'+ 9 ' 9 6 * 8% 9 3' ).

T' ALCO * +%:)'+ ) + /+%8 +* 8 / *' / -/ 6; %8/ ) 6 8 +6 %

SAE 4140. T' , * )) 3 %3 ) )8*' '+ * % %8 8) 3 + % 6 9 ) /+ % + % . I%/+%8 +* 8 * +%:)'+ 7 66 9 %3 ) 8 %* , + % ) 3 % +66; 66 9 ?-


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+ F 3 %3 +% / %3 , + % R 83' /+*' % %3* D 66 6 ' 6 ).

U6 +) % * & M *'+% *+6 ) %3. < 6 %3 * 8% 9 3' ) & )' 6+) %3.

S )) 6 %3 & S' 6+) %3.3 F %+6 /+*' % %3 & + 8) ) %3 * +%: > 8 %+6 * % ) +% 6 ' 6 ).' N %3

G % %3 L+,, %3 > S + * & ;%+/ * +6+%* %3: F %+6 %), * %

A , ) % HEC R+%*' ) /+%8 +* 8 %3 * +%:)'+ ) + 8) ;, ) %*68 %3 ' % )8 ALCO L * ) I% +% R+ 69+;).

=.2 T' + 9 , * )) ) )8 +* '+ % %3 9 ' + 6) 3 % 6 9?-

M ' '+ % %3 H+ % )) N8/ D , ' *+)+. I% 8* % '+ % %3 C-40 0.124

. D %3 C-#0 0.012 0.015

G % +66; 6 9 HP %3 % ) ' ) , * )) ) , +) , ' *+) ) /+% ' * +%: > 8 %+6) +% /+% + %3 > 8 %+6) *+% 3 8% 9% % ) , ) . I% *+)

' 3' +% ' 3' ), %3 % ) , %* ) ' ) * % , * )) +) 3 ) 6 %3 6 7 '+ 9 + %3 % 36 3 6 .

=.= C' *: %3 * +%: )'+ 6 * % ) % ' ) +% + / ' ) 8) ; %3 %/+%8 +* 8 ) +% /+ % + % %)8 %3 * * +6 3%/ % * +%:)'+ +) +6) %3 %

+ %3 ' 8) %3 * % +6 6 % . T' +) ) % 6 % ' ) ) '+ ' * +%: )'+ ) % / )+6 3% '+ /+ %3 % 6 *: ) 8 +6 3%/ % ' % ' ) +%* 9 % ' 6+ * +%: 9 +* )7 9 66 + ; 9' % ' * +%:)'+ ) + . T'

+ + % + )/+66 3 9 66 % +%; *+) ' . B8 9' % ' ) + + % /'+% , )* 6 / /+; % '+ ' * +%:)'+ ) % 6 *: * % +6 6) / )+6 3% . I% ALCO %3 % ) ' * +%:)'+ 6 * % ) / +)8 + ' * +%: 9

% + ) ' 3 % + .

A) +,+ / * +%: )'+ +% %3 % 6 *: / )+6 3%/ % ' 6+ , ) % '3 % + 66 + %3 9 ' ), * ' %3 % /+ % + %3 *+8) ) 8 '6 * %. I% ' ) L * ) + /+ /8/ 6 * % 0.00$ ) , / )) 6 . T' * * %

' * )) 6 * % ) % ; + %3 / %3 )' % ) 9 % /+3% +/ ) +%* , * +% %3 % 6 *:.

4. CAM SHAFT

4.1 I% ) 6 %3 % ' *+/ )'+ , /) ' +6 6 , % %3 +% *6 ) %3 %6 +%'+8) +6 ) +% +66 9 %3 / 6; %> * % 8 6 %) ' *;6 % . U)8+6 , +* * )

, = *+/) +*' *;6 % ' 9 8 *+/) %3 '+8) +% %6 +6 ) +%' * % +6 *+/ %3 8 6 %> * %.


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%3 % ) 9 ' + 8 +68 550 L ). T' *;6 % ' + ) + / +6 / +6 > % % *;6 % .

5.= T' *;6 % ' + *+) %3) + /+ / ), * +6 +66 ; *+) % +) , ), * *+ %3 % 6 9?-

ALCOT +6 *+ % =.00 =.40S 6 * % 1.$0 2.20S86,' 0.12 M+ .P' ),' 8) 0.15 M+ .M+%3+% ) 0.#5 0C' / 8/ 0.20 0.40S 6 * %

N *: 6 0.1 M %.M 6; %8/ 0.=5 0.45

#. VALVES:

#.1 T' +6 ) + ' / ) /, +% ' )/+66 * /, % % ) ' D ) 6 %3 % .


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* /, ) 8% . T' +6 ' + /+ +6 %3 +8) % * ) 6 '+) ' 3' 6 6 ) *') ) +%* +% ) *+,+ 6 '+ % %3 + R *:9 66 C-=4.

T' ) / ) 5 $ '. %*' % +/ +% /+ SAE 4140. T' ' + ) /+ ), * +6 ' + ) ) +% +8) % * /+ +6 (21-4N % ' 66 9 %3 * /, ) %.

ALCO VALVE HEAD ALCO VALVE STEMC+ % 0.45 0.#0 0.=$ 0.4=M+3+% ) $.00 10.00 0.@5 1.00P' ),' 8). 0.04 M+ 0.040 M+ .S86,'8 0.04 0.040S 6 * % 0.25 0.25 0.=5C' / 8/ 20.00 22.00 0.$0 1.10M 6; %8/ =.25 4.50

N 3 % 0.=5 0.50

@. PISTONS

@.1 T' , ) % ) ' / ) /, +% * /, % % % ' ) 6 %3 % +) +: ) * ,+ %+%)/ )) % , 9 . I )7 ' 7 % * ))+ ; '+ ' ) 3% ) +% 8) ) /8) :% 9 '

)) % +6 + 6) + 8 ' , ) %. T' * / 8) % 8 6 )86 ) % 6+ 3 +/ 8% ' + %3 6 , . O8 ' ) + 8 1$ ' ' + ) + ) ; , ) % %6;.

7.2 Type of P !"o#!: B + 6; ), +: %37 ' , ) % + 9 ) %* ;, ) . . T 8%: ;, +% C )) H + ;, .


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rin$ c#rrier #n( 0o(- #re o hi$h (ensit- #luminum #llo- or$in$% Theinter erence 0et"een rin$ c#rrier #n( !iston 0o(- "#s incre#se( rom


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there is no uestion o (is4lo#(in$ o the rin$ c#rrier #n( to th#te5tent these !istons #re trou0le ree% The (is#(v#nt#$e o this t-!eis th#t no recl#m#tion 0- ch#n$in$ rin$ c#rrier #s in AL'O !iston c#n0e (one% These !istons h#ve Niresist rin$ inserts ;tte( to t#1e the

to! rin$% The- h#ve si5 !iston rin$s%Met#llur$ic#l com!osition o the M#hle !iston m#teri#l is $iven

0elo"3 4

Silicon * %<

'o!!er *%<

Nic1el *%<

M#$nesium *%<

A68/ % 8/ /+ %

&/ *ISTON INGS

&/1 Piston rin$s #lon$ "ith c-lin(er liner !resent the m# or "e#r #n(m#inten#nce !ro0lem or # (iesel en$ine% The m#in unction o !istonrin$s #re3 4

a- Preventin$ 0lo" 0- #ir #n( hi$h tem!er#ture com0ustion $#ses 9!revent s#me rom $ettin$ #ccess to cr#n1 c#se%

- Preventin$ e5cessive #mount o lu0e oil rom re#chin$ com0ustion

ch#m0er%

&/2 The "#- the !iston rin$s se#l the $#s #n( the techni ue o se#lin$ is$iven in the s1etch #tt#che(% It "ill 0e seen th#t the to! rin$ $ets them#5imum #ssist#nce rom the hi$h !ressure $#sses to !revent !#ss#$e o $#ses rom the com0ustion ch#m0er to the cr#n1 c#se%

&/6 T7*ES O8 *ISTON INGS


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There #re m#n- v#rieties o !iston rin$s #s sho"n in S1etch%

a- 'om!ression rin$s 8i: s u#re #ce

8ii: T#!er #ce

8iii: Insi(e 0evel

8iv: e- stone%

- Oil P scr#!er rin$s or oil rin$s

8i: Wi(e ch#nnel (ou0le li!

8ii: S!eci#l 0evel sin$le li!%

8iii: 'om orm#0le rin$s%

&/4 The rin$ #rr#n$ements #s #!!lic#0le to our st#n(#r( cl#ss o m#inline locos #re $iven over le# 8S % I4*&:

&/5 Pre erre( !iston rin$ m#teri#l is c#st iron "ith o!en $r#!hitestructure #n( # h#r( !e#rlitic m#tri5% The !iston rin$ o!er#tes (urin$ #!#rt o its li e un(er con(itions o m#r$in#l lu0ric#tion% In #((ition to theo!en oil ret#inin$ structure o c#st iron/ the $r#!hite urther !rovi(es oremer$enc- sel 4lu0ric#tion%

The !iston rin$s $ener#ll- h#ve ollo"in$ t"o t-!es o co#tin$s3 4

#: Scu6 resistin$ #n( uic1 se#tin$ co#tin$ 9

0: We#r #n( corrosion resist#nt co#tin$s%


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8,, +% 6 9 *:). I% + % ' ) );% ' * 8 ) +6) )8 + 6 8+6 ) + 8) 7 % % ' 8,, *: 3 +% 9 % / 6 *: % %* * %3+): ) /+; )86 % 9+ 6 +:+3 *+8) %3 9+ * % +/ %+ % * +%: *+) 6. T' 6 %

'+) *' / ,6+ )8 +* +% ) ' % ; *' / ; 6 * 6; * , * )). ALCO 6 % )'+ % ) , ) % ' . I '+) 3 %6; % ) +% + ) , / %3 + 9 + 0.00

%*'.MA! *;6 % 6 % ) % % %* 8 ) >8) + )6 %3 % ' *;6

*:) +% ' 6 +:+3 ) , % %6; 9 ' ' ' 6, 3+): ). T' *;6 % 6 % )K 8 .

G % +6 M *;6 % 6 % ) + + *+ ;, / ; %3 ' 9+ >+*: . I%G % +6 M L * ) %) + 6 % %3 *' / ,6+ ' , ) % %3) + *' /

,6+ ..1 ' ALCO *;6 % 6 % ) + /+ ' 3' ) %3 ' *6 ) 3 + % +66 ; *+) % ' +

+ 6 ) )) ). T' 6 % / +6 * /, ) % ALCO %3 % ) 3 % 6 9? -

AL'O

'#r0on B%


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the c#vit- is more th#n *@ > (ee! then the liner h#s to 0e t#1en out ouse%

+, CONNECTIING ROD

*


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Sul!hur


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F%EL OIL S7STE3 T' 8 6 6 );) / ) ) 3% % 8* 8 6 6 % ' %3 % *;6 % ) + ' * *

/ 7 + * * ' 3' , ))8 7 + * * 8+% ; +% * * 6; + / ) . T' );) / %> * )% ' *;6 % * * 6; / +/ 8% 8 6 % ' 3'6; + / ) / + + ) ,86+/ % ' 8 ) : *;*6 , + % ' %3 % . H 3' , ))8 8 6 ) 8

6 %3 ' % 6 +6 +% , % + % 8 6 % ' , ))8 ) * / 8) % *'+/ .H 3' , ))8 +6) ' 6,) % , , + / + % ) '+ ' )/+66 ,6 ) * / % * % +* 9 ' ' )' + % * / 8) % *'+/ +% '8) '+ * / 8) %. M %3

' 8 6 * * 8 8+% ; ) /, +% *+8) ' 6 * / %3 % ) + + + 6), +% + + 6 6 + %3 % 9 ' + + 6 8 / % 8 6 9 ' % + ,+ *86+ +%3 .T / %3 ' %> * % 8 6 ) +6) /, +% %+ 6 8 6 8 % * /,6 6; /+ /8/

% 8 .

T' 8 6 6 );) / /+; )*8)) % 9 , %) ) ,+ + 6;7 +6 ' 83' ' + + ,+ +% % 3 + );) /? -

( F8 6 );) /

( F8 6 %> * % );) /

FUEL FEED SYSTEM

T' 8 6 );) / %*68 ) ' 66 9 %3? -

(1 F8 6 6 +%:

(2 F8 6 , /+ ; 6

(= F8 6 +%) ,8/, 8 6 ) ,8/,

(4 F8 6 6 +6

(5 S * % + ; 6


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(# F8 6 386+ %3 +6

(@ F8 6 6 ' +

T' 8 6 );) / , ) ' +*: %3 8, )8,, ' 8 6 %> * % ,8/,) ;/+ % + % %3 ) + ; )8,,6; 8 6 ' / + + , ))8 =.00 !3 */ ) .- =.5 !3 */ ) . )

'+ ' 8 6 ,8/,) % 8 % *+% / +% 6 ' 6 ' *;6 % ) + * * , ))8+% / .

FUEL OIL TAN!

T' 8 6 6 +%: 5000 6 ) *+,+* ; ) + *+ 8% ' )8, ) 8* 8 '6 * / +% 6 *+ % 9 % 9 3 ). B+ 6 9+66) + ' %) + ) )8 3

6 9' % ' 6 * / ) / %3. A ) + % 6 + ' 66 %3 ,6837 +% % * % 7+ % ,683 +% 36 - ;, 6 6 % *+ ) + +6) , .

PRIMARY FILTER

A 6 ) , % ' )8* % ) ' 8 6 +%) ,8/, +66 9 %6; 6 63 %3 % ' ,8/,. T' ) ) % % %'+%* ' 6 ' F8 6 +%) ,8/,. T'

6 ) / ) % + % 9+ 6 6 +*' * % 9+) ,+*: 6 * // %6; :% 9% +)) *:) ;, 6 6 / % . T' ) ) *:) ;, 6 ) + * + ) ;, 6 ) +% '+ 3 ++ 6 ; + ) / ) 8 +% % * ) *' +, . H 9 % * + % ,6+* ) ' ) '+) %

,6+* ; ,+, ;, 6 ) 9' *' '+ 6 %3 ) * 6 .

FUEL TRANSFER PUMP BOOSTER PUMP

T' 8 6 6 );) / '+) + +%) ,8/, ) ,8/, 6 ' 8 6 / ' +%: 6 9 ' );) /. T' 3 + ;, ,8/, 8) ) % ; + D.C. / 9 ' *8 %+ + 6+ 6 / ' ) +3 + ) ' 83' + )8 + 6 * *8 . T' ,8/, *+,+* ; ) 146 ). , / %8 + 1@25 ,/ + , ))8 4 4.$ :3 */. ) .

FUEL RELIEF VALVE

T' ), %3 6 + 6 +6 ) / +% ;-,+)) %3 * )) 6 +*: ' 8 6 +%:7 '8)

6 +) %3 * )) 6 + % ' ,8/, +% ' / %)8 ' )+ ;. I ) + >8) + , ))8 5-:3 */. ) . +% ;-,+)) ) ' * )) 8 6 +*: ' +%:. I +6) %)8 ) ')+ ; ' ) * % + ; 6 +% ' , , 6 % )..


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FUEL SECONDARY FILTER

T' 8 6 ) * % + ; 6 ) 6 *+ + ' ) ,8/, % ' 8 6 );) /. T'6 8) ) + ,+, ;, 6 *+ 3 % 8+6 ;7 % 9+ 6 + 386+ % +6). 6 + ) ) ' % ,+ *6 ) 6 ; ' , /+ ; 6 +% %)8 6 %3 6

8 6 %> * % 8 ,/ % ).

FUEL REGULATING VALVE

T' 8 6- 386+ %3 +6 ) + ), %3-6 + +6 ) / 6+ ) 3% 6 : ' 8 6 6+6 8 6 *+ + ' ) * % + ; 6 % ' 8 6 );) /. T' ) +6 ) + >8)

=-:3 */. ) . (40 45 ,) , ))8 +% +69+;) /+ % + %) ' )+/ , ))8 % ' 8 6 );) / ; 6 +) %3 ' * )) , ))8 7 +%;7 +*: ' 8 6 6 +%:. T' ) % ;-

,+)) %3 6 ' , ))8 ) 6 )) '+% ' + >8) 6 6.

FUNCTIONING OF FUEL FEED SYSTEM

T' 8 6 ) ,8/, +%) ,8/, ) )9 *' % +% ' ,8/, ) + ) )8*: %3 6/ ' 8 6 6 +%:7 6 ' 83' ' , /+ ; 6 . B *+8) + + 6 * %)8/, % ;

' %3 % 7 ' 6 ; , ))8 ' ,8/, /+; ) %* +) %3 6 + % ' ,8/, +% ) / . * % ,8/,) % ' 3' +%: ' 83' >8/, , , ). T' 386+ %3 +6 /+ % %3

+ ' 3' ) 8 6 ' + 7 +: ) *+ * )) , ))8 = :3 */. ) (40 -45 ,) ; ;-,+)) %3 ' + 6 +*: ' +%:. A 3+83 * %% * % ) +: % / ' 6 + %3

' ) *+ % % *+ %3 ' 8 6 6 , ))8 . T'8) ' 8 6 );) / : ,)8 6 * % %8 8)6; + + 6+ 6 ' 8 6 %> * % ,8/,)7 9' *' ' ,8/,) /+; 8) 8)

, % %3 % ' /+% ' %3 % .

FUEL INJECTION SYSTEM

8#: FUEL IN E'TION PUMP

The uel in ection !um! use( is # const#nt stro1e !lun$er t-!e !um! "ithv#ri#0le u#ntit- o uel (eliver- to suit the (em#n( o the en$ine% This t-!e o !um!s #re commonl- 1no"n #s +OS'H t-!e !um!s (esi$ne( #n( !#tente( 0-Dr% +osch o Germ#n-%

The !um!in$ stro1e o the !lun$er is controlle( 0- the uel c#m% The len$th o stro1e o the !lun$er #n( the time o stro1e is (e!en(ent on c#m !ro;le #n( c#m#n$le% The return stro1e o the !lun$er is (ue to the !lun$er s!rin$%


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The 0#rrel insi(e "hich the !lun$er moves/ m#(e rom nitr#llo- steel !ro!erl-tre#te( h#ve ver- close toler#nce "ith the !lun$er #n( #re $roun( ;nishe(to$ether to hi$hest (e$ree o #ccur#c-% When the !lun$er rece(es to +D' the

s!ill !orts in the 0#rrel "hich #re o!en to the uel ee( s-stem h#vin$ oil #t B1$%!ressure #v#il#0le there #re o!en% Oil then rushes to ;ll u! the em!t- s!#ceinsi(e the 0#rrel% At the correct time in the (iesel c-cle the uel c#m !ushes the!lun$er or"#r( #n( the s!ill !orts #re then covere( u! 0- the movin$ !lun$er%

The oil thus tr#!!e( into the 0#rrel is orce( out throu$h the (eliver- v#lve to 0ein ecte( into the com0ustion ch#m0er throu$h the in ection noKKle% The !lun$erh#s t"o i(entic#l helic#l $roves or heli5 cut #t the to! e($e "ith # relie slot% Atthe 0ottom o the !lun$er there is # lu$ to ;t into the slots o the control sleeve%When the rot#tion o the en$ine moves the c#msh# t #n( the uel c#m moves the!lun$er to m#1e the u!"#r( stro1e% it m#- #lso rot#te sli$htl-/ i necess#r-/throu$h the en$ine $overnor / control sh# t/ control r#c1 #n( control sleeve%

This rot#r- movement o the !lun$er #lon$ "ith reci!roc#tin$ stro1es ch#n$esthe !osition o the helic#l relie in res!ect to the s!ill !ort #n( oil inste#( o 0ein$(elivere( throu$h the !um! outlet esc#!es 0#c1 to the lo" !ressure ee(s-stem% The $overnor or en$ine s!ee( control/ sensin$ the re uirement o the

uel controls the rot#r- motion o the !lun$er/ "hile it is #lso h#vin$ reci!roc#tin$!um!in$ stro1es% Thus #li$nment o heli5 relie "ith the s!ill !orts sooner orl#ter "ill m#1e the stro1e more or less e6ective% The heli5 const#ntl- rem#inin$in #li$nment "ith the s!ill !orts 0-4!#sses the entire #mount o oil #n( nothin$ is

0ein$ (elivere( 0- the !um!% The en$ine sto!s 0ec#use o no uel in ection #n(this is 1no"n #s NO FUEL POSITION% When #li$nment o heli5 relie "ith s!ill !ortis (el#-e(/ th#t "oul( me#n !#rtl- e6ective stro1e #n( en$ine runs #t lo" s!ee(#n( !o"er out!ut is !#rti#l% When heli5 is not in #li$nment "ith the s!ill !ortthrou$hout the stro1e/ th#t is FULL FUEL POSITION/ 0ec#use the entire len$th o the stro1e is e6ective #n( en$ine out !ut #n( s!ee( is #t the !e#1% The !ositiono the !lun$er #n( its rel#tion 0et"een s!ill !ort #n( heli5 is (etermine( 0- the!osition o the control r#c1 $r#(u#te( in mm% Line#r movement o the uel r#c10- the $overnor #n( the movement o the control sh# t h#s rel#tive rot#r-movement o the !lun$er/ there0- #li$nin$ the heli5 #n( the s!ill !ort sooner or

l#ter m#1in$ the stro1e ull- e6ective/ !#rtl- e6ective or ull- ine6ective%

The oil then !#ss throu$h the (eliver- v#lve% The (eliver- v#lve is # s!rin$lo#(e( v#lve "hich o!ens #t the oil !ressure (evelo!e( 0- the !um! !lun$er%

This hel!s incre#se the (eliver- !ressure o oil/ unction #s # non4return v#lve/ret#inin$ oil in the hi$h !ressure line% This #lso hel!s in sn#! termin#tion o uelin ection to #rrest the ten(enc- o (ri00lin$ (urin$ uel in ection% The s!eci#ll-(esi$ne( (eliver- v#lve moves u! to o!en/ (ue to the !ressure 0uilt u! 0- the!um!in$ stro1e o !lun$er #n( "hen the oil !ressure coll#!se insi(e the 0#rrel/the l#n(in$ on the v#lve moves 0#c1"#r( to incre#se the s!#ce #v#il#0le in the


23/53

hi$h !ressure line #n( thus the !ressure insi(e the hi$h !ressure line coll#!sehel!in$ in sn#! termin#tion o uel in ection% This re(uces the ch#nces o (ri00lin$ #t the 0e$innin$ or en( o uel in ection throu$h the uel in ectionnoKKles%

80: FUEL IN E'TION NO LE

The uel in ection noKKle or the uel in ector rem#ins ;tte( in the c-lin(er he#("ith its ti! !ro ecte( insi(e the com0ustion ch#m0er% It rem#ins connecte( tothe res!ective FIP "ith # shim less steel tu0e 1no"n #s uel hi$h !ressure line%

The multi hole nee(le v#lve t-!e uel in ection noKKle/ v#lve o!er#tin$ #t hi$herh-(r#ulic !ressure #$#inst s!rin$ tension #re ver- commonl- use(% The nee(lev#lve closes the oil holes 0- 0loc1in$ them (ue to s!rin$ !ressure% Pro!er #n$leon the v#lve #n( the v#lve se#t #n( !er ect 0e#rin$ ensures !ro!er closin$ o thenoKKle v#lve%

Pressure o uel in the uel (uct #n( the !ressure ch#m0er insi(e the noKKle(ue to (eliver- 0- the FIP/ su((enl- shoots u! ver- hi$h/ #s hi$h #s


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A!#rt rom re$ul#r m#inten#nce #ctions #ccor(in$ to the l#i( (o"n ins!ectionsche(ule to 1ee! the uel ee( s-stem in $oo( "or1in$ or(er # test 1no"n #s

ori;ce test is (one uite o ten% This test is # rou$h #n( re#(- metho( to#scert#in the e cienc- o the uel ee( s-stem un(er ull lo#( con(ition% The!roce(ure o testin$ is #s un(er3

1. A% * ,6+ 1 $ %*' ) % ' );) / ' 386+ %3 +6 .

2. A * % + % ,6+* 8% ' * * 66 * ' 6 '+ 9 86 6 +: ' 83' 8 %3 ' ) .

=. T' 8 6 ) ,8/, )9 *' % #0 ) * % ).4. T' + 6 +:+3 )' 86 + 8 L ). 8 6 , / %8 ' 83' ' * (9 '

' %3 % % ) ,, * % % . T' );) / )' 86 + 6 /+ % + % = !G */ , ))8 9 ' ' ) + 6 +:+3 9' *' ) /86+ ) +,, . ' 866 6 +* %)8/, % ; ' %3 % . I% ' % , % , ))8 ' + 6 +:+3 9 86+6) 6 )) % *+ %3 ) / * % ' );) / 8* %3 ) * %*; / ' 866

8 / % 8 6 8 %3 , +: 6 + .

The #0ove test is e#s-/ reli#0le #n( #lso s#ves time #n( costl- uel #n( isme#nt or the uel ee( s-stem onl-% This is more im!ort#nt 0ec#use (urin$norm#l testin$ o the en$ine in she( "ithout lo#(/ the r#te o consum!tion 0ein$ver- lo" even in ull s!ee( o the en$ine/ there is h#r(l- #n- (ro! in uel oil!ressure/ #lthou$h !ressure m#- (ro! on lo#( in c#se there is some (e ect in the

s-stem% A trou0le shootin$ ch#rt is #lso #nne5e( "ith this ch#!ter or $ui(#nce%

F%EL IN ECTION P%MP

The uel in ection !um!s #re su!!ose( to 0e ins!ecte( once in ever- *&months in norm#l course #n( e#rlier i re uire(% It is essenti#l to chec1 the

ollo"in$ items (urin$ the ins!ection o the !um! #ssem0l-%

1. S 8 )6+*:% )) % ,68%3 +% + 6

2. S* + *' )7 )*8 /+ :) +% 866 +,, + +%* % ' ,68%3 +% + 6 )8 +* 8 + +) ) % 8 6 6.

=. E ) % ' 6 3 ) % ' ,68%3 ; % ) ,86+ 6 / )


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4. C ) % +% , %3 /+ :) % ,68%3 + 6.

5. D )* 6 8 ' + %3 % ,68%3 +% + 6.

#. D 6 ; +6 ), %37 ' +6 +% ' +6 ) + % *+ 86 *' *: %3. G % %3 '

+6 +% ' +6 ) + , , +%36 +% 6+,, %3 /+; '+ % % * ))+ ; %)8 , * * % +* 9 % ' +6 +% ' ) + .

@. S6+*:% )) 9 % * % 6 +*: +% 8)' %37 * % 6 +*: +% * % 6 )6 7 '* % 6 )6 +% ,68%3 683 , 8* ) 6 ) / % +% /+: ) *86 + >8) '

+*: / / % +**8 + 6;.$. < + % , / ) ' 38 *8, % ) *' *: %3.

. L+,, %3 )8 +* 9 % ' + 6 +% 6 ; +6 ; +% +6) 9 %6 ; +6 ; +% ' 6 ) 8 '+ 6 +: , > % ).

10. P68%3 ), %3 ) *+ 866; *' *: * +*:) 6 )) %) %.While #ssem0l- c#re must 0e t#1en to m#tch the !osition 0et"een the 0#rrel

#n( the !um! 0o(- #n( #lso the uel r#c1 #n( the control sleeve% Theserel#tions #re e5tremel- im!ort#nt #n( in(ic#te( 0- (o"el !in #n( !unch m#r1res!ectivel-%

Durin$ ins!ection #n( re#ssem0le/ com!onents #re to 0e in !er ectcle#nliness #n( rinse( in cle#n uel oil%


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8I* cut 3o#el : *arts


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PLUNGER 9 SLEEQE


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A plun"er is # t-!e o !ositive (is!l#cement !um! "here the hi$h4!ressure se#l isst#tion#r- #n( # smooth c-lin(ric#l !lun$er sli(es throu$h the se#l% Thism#1es them (i6erent rom !iston !um!s #n( #llo"s them to 0e use( #thi$her !ressures% This t-!e o !um! is o ten use( to tr#ns er munici!#l#n( in(ustri#l se"#$e

http://en.wikipedia.org/wiki/Piston_pumphttp://en.wikipedia.org/wiki/Piston_pump


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8I* O;E 'A


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• Disconnection the uel 0#n o oint%

'le#nin$

• FIP 0o(- is cle#n in uel oil

• Stri!!in$ FIP com!onents cle#n in !ure uel oil% 8 Plun$er/ Plun$er0#rrel/ 'ontrol sleeve/ +# e rin$/ Deliver- v#lve 0o(-/ Deliver-v#lve/ Deliver- v#lve s!rin$ 9 Deliver- v#lve hol(er nut:

Ins!ection

• All FIP com!onents chec1 or cr#c1s

• 'hec1e( com!onents #re $oo( con(ition/ s#me is ;tte(/ i #n-cr#c1e( con(ition re!l#ce ne" one%

Assem0lin$

• +e ore #ssem0lin$ #$#in cle#n the !#rts FIP 0o(- is !rovi(e( in #;5ture in #n u!ri$ht !osition%

Testin$

• FIP is ;tte( in the c#li0r#tion test st#n(%

•

Me#surin$ #r !rovi(e un(er the FIP (eliver- !i!e%• Horse shoe !iece !rovi(e( in the uel r#c1% Fuel r#c1 is Bar is 45 cc/


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8I* TEST STAND


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IN?ECTO NO@@LE C


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• 'hec1 the v#lve li t is "ithin the limit or not limit or ne"v#lve is


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• Pum! the tester h#n(le slo"l- #n( recor( the o!enin$!ressure o the noKKle v#lve% The o!enin$ !ressure or ne"noKKle is B=


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TESTING OF NO LE

Openin" *ressure 6.)) 4)5) psi +Ne$- 6 )) 6&))psi +Ol#-

Spray *attern0 Blotter test


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CONCE*T O8 3EC'ANICAL 3INOSC'ED


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• Q#cuum +r#1e Pi!e ,) cms/ HS4 'ontrol Air Pressure *%? $@ cm&%

• 'ontrol #ir !ressure ) $@ cm & #n( v#cuum 0r#1e !i!e!ressure on test !l#te mm )& cm 9 ,) cm "ith ?%* mm(i# hole /

o En"ine Stop Ite%

• En$ine coolin$ s-stem%%• F#n Drive univers#l oints #n( $re#se them%• Sen( s#m!le or testin$%• W#ter 9 oil le#1#$es rom tell t#le hole o "#ter !um! 9

# ter cooler%• Don t !lu$ tell t#le hole%• To! u! "ith tre#te( "#ter%

o En"ine 8uel Oil Syste%• To! u! oil i necess#r-%• Sen( s#m!le or testin$%• 'h#n$e P@ Sec% Filter # ter B< (#-s or on con(ition 0#sis%

o E pressor

• 'hec1 oil level 9 to! u! i necess#r-%• H% P% (isch#r$e v#lve ch#n$e%• 'hec1 con(ition o As0estos ro!e on H%P% !i!e line%• A ter cooler%• 'hec1 0olts/ i necess#r-%• 'hec1 #n- le#1#$e rom # ter cooler tell t#le hole%• Tur0o vent !i!e s# et- cl#m!s 9 0r#c1ets

o Traction 3otor Blo$in" c!eck

• 'on(ition 9 tension o Q40olts #n( #( ust i re uire(%


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• Gre#sin$ o 0e#rin$s%• Pulle- #li$nment%• Pro!er ti$htness o #(o!ter nut%• Im!eller or shi tin$%

o ust

• +r#1e c-lin(er !iston trimmin$ 8,%,* cm m#5%:• Set sl#c1 #( uster or =%) mm shoe rele#se%• Ti$htness o nuts on 0r#1e he#(%• '+' or r#cture #n( "e#r%• '#ttle $u#r(s/ +u6ers/ Pull ro( s# et- !in/ U 'l#m!s%

o 3iscellaneous Ite%s

• Fire E5tin$uishers se#l 9 (ue (#te%• Dr#in moisture rom MR t#n1• 'om!% E5t% intercooler (r#in con(ens#te%

o En"ine o=er spee# control linka"es c!eck/

• Free movement o r#c1/ lu0ric#te r#c1 #ssem0l-/ chec1$#! 0et"een OST coll#r 9 uel control sh# t%

Free movement o uel control sh# t /


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o E#4 #e

• R ,6+* 8 6 , /+ ; 6 6 / % & ) 3+): 8 +) , 6+ * .(F8 6 )+/,6 * 66 * & *' *: ; L+ ) +

R ,6+* T8 S8, C'+ 3 L8 O 6 6 6 / % +% % 9 3+): .

o A ) B)(5e

• C6 +% GD " $0 D 6 ' 8) %3) +% ) 6 / % *6 +% ; 6 9 %3% ) * %.

o C/e05 L6S ope)(" o#

o C/(#4e TSC f *"e)

3 F 2 Sc!e#ule +() #ays-

o Loco unnin"/

• 'hec1 #ll the items o T4* 9 T4& sche(ules%

• 'hec1/ LWS o!er#tion 9 reset time%

• OST RPM/ TRD 9 m#in 0e#rin$ tem!er#ture%

• E5!ressor Lo! 9 Q#cuum%

• Air le#1#$es 9 #n- housin$ le#1#$es%

o En"ine Stoppe#/


47/53

• Fuel s-stem T#1e s#m!le o uel rom !rim#r- ;lter #n(sent to l#0%

• 'h#n$e Prim#r- @ secon(#r- ;lters 9 its $#s1ets%• Lu0e oil s-stem / cle#n lu0e oil str#iner 9 re!l#ce its to! 9

0ottom $#s1ets% Ensure ;tment o s!rin$%• 'h#n$e lu0e oil ;lters element in * < (#-s 9 =< (#-s i

centri u$e ;tte( in loco%• 'h#n$e ;lter element

o Cylin#er =al=e

•

Ins!ect v#lve lever mech#nism 9 lu0ric#te%• 'hec1 e u#liKin$ -o1e #n( v#lve s!rin$%

• Re!l#ce !ush ro( i 0en(%

En$ine cr#n1 c#se e5#min#tion 4

• 'hec1 or orei$n m#teri#ls%

• 'hec1 lu0e oil he#(er/ um!er !i!e 9 S4!i!e%• 'onnectin$ ro( 9 m#in 0e#rin$ nuts 9 securin$ s!lit !ins%

• 'hec1 ti$htness o the nut "ith co!!er h#mmer%

o E pressor

• 'le#n e5!ressor #n( #ir int#1e ;lter 9 str#iners%

• 'h#n$e e5!ressor L%P% 9 H%P% (isch#r$e v#lve re!l#ceco!!er shims%

• 'hec1 e5!ressor sum! or orei$n m#teri#l #n( cle#n%

• 'hec1 lu0e oil !um! ch#in #n( ch#n$e i oun( loose%


48/53

• Ensure !ro!er lo#(in$ #n( unlo#(in$/ e5!ressor lo! /v#cuum # ter com!letion o sche(ules%

o a#iator

• Air 0lo"in$ shoul( 0e (one in the reverse (irection to thenorm#l #ir Co"%

• Ste#m 0lo"in$ #n( 9 r#(i#tor $#! shoul( 0e chec1e(%

E5h#ust m#ni ol( 9 tor ue

• Tor ue #ll inlet / e5h#ust 0olts 9 stron$ 0olts%

• Tor ue #ll FIP su!!ort 9 FIP 9 +enKo c#! scre"%

• Tor ue #ll um!er !i!es/ W#ter riser !i!es 9 0olts%

• Tor ue TS' oun(#tion 0olts/ e5!ressor/ lu0e oil cooler/

E'' 9 R#(i#tor #n 0olts%• 'hec1 ''E motor oun(#tion 0olts%

o Traction %otor Blo$er

• 'hec1 #ll the Tri! sche(ule items 9 +@ si(e loc1 nut%

o Traction %otor suspension earin"

• O!en "ic1 !#( #ssem0l- #n( ch#n$e i oun( (e ective 9chec1 "hite m#teri#l on "ic1 !#(%

• 'h#n$e oil i oun( (irt-%

•

Tor uin$ the unse#le( 0olt to B) l0s% #n( 0olts shoul( 0ese#le(%


49/53

• To! u! oil throu$h ;lin$ c#! onl-%

• 'hec1 "ic1 !#( #ssem0l- 0- !ressin$/ there shoul( 0eree movement o the "ic1 !#( #ssem0l-%

• '#re shoul( 0e t#1en/ "hite ;ttin$ "ic1 !#( #ssem0l- in"in(o"s%

• or < mm "i(e "ic1 "in(o" o s @ 0e#rin$ c#! ,)mm%

• &) mm "i(e "ic1 "in(o" o s @ 0e#rin$ c#! )&mm%

o C!eck uni=ersal s!a,t "reasin" : ECC,oun#ation olts/

o Bo"ie F Lu ricate slack a#>uster c!eck oil le=elo, centerin" castin" : si#e %ountin" pa#/C!an"e ? lter ele%ent// GD &)D oil s!oul# ec!an"e#/

3 4 Sc!e#ule ite%s

• All ite% o, 3 2 sc!/ : its a##itional ite%s are

• Tappet clearance an# p!asin" to e #one a#>uste#an# Blo$ Bye test is #one/

•

A le o e a%ination an# its "reasin" to e #one/

3 & Sc!e#ule ite%s

• All ite% o, 3 4 sc!/ : its a##itional ite%s are

• In>ectors are to e c!an"e#/• C!an"e cyclonic lter : c!eck its all ru er !oses/• ick pa# cleanin"/


50/53


51/53

A,ter co%pletin" t!e 3 F 12 sc!e#ules loa# o is #onean# para%eters are recor#e# as

• Co%pression : rin" pressure/

• TSC E !aust "as te%p/at Tsc inlet : TSC out let

te%p/ : $ater te%p/ is c!ecke#/• E p LO* : =acuu% : its loa#in" : unloa#in"/

• BA* an# openin" o, ,uel rakes/

• 8O* : LO*/

• ;olta"e : A%pere are recor#e# : '* calculate#/

• En"ine crank case =acuu% c!ecke#/

• 3ain Bearin" te%p/ a,ter loa# o /

• T D L S OST *3 are c!ecke#/

• Any leaka"es : repairs are note#

• LC c!ecke#/

Concept o, 3ec!anical 3a>or Sc!e#ule 324

T!e un#er %entione# ite%s are to e o=er!aule#

• '-lin(er he#(s•

Po"er Assem0lies• Tur0o su!erch#r$e


52/53

• E5!ressor@'om!ressor• Lu0 oil cooler• A ter cooler• W#ter !um!• Lu0 oil !um!• Roc1er #rm #ssem0lies• R#(i#tor F#n• E((- current clutch• RTTM 0lo"er• Fuel in ection !um!s• In ectors• R#(i#tors• OST Assem0l-• S!ee(ometer @ All $#u$es• Lu0e oil@ Fuel oil v#lves• Air 0r#1e Q#lves• Univers#l sh# t• +oth 0o$ies• A5le 0o5es

C!eck an# a#>ust• '#m sh# t/ c#m $e#r #n( s!lit $e#r #n( #( ust thrust

#n( 0#c1l#sh%• 'r#n1 sh# t/ cr#n1 !in #n( m#in 0e#rin$ ourn#l #n(

#( ust cr#n1 sh# t thrust• 'r#n1 sh# t (eCection• E5!ressor #li$nment•

) Ecc #li$nment• , All cle#r#nces o 0o$ies/ #5le 0o5es/ tr#ction motors#n( $e#r c#ses%

eplace ,ollo$in" ite%s

• All c-lin(er liners• All Ce5i0le hoses• Lu0e oil/• All G#s1ets #n( ru00er O rin$s


53/53

Clean an# inspect ,ollo$in" ite%s e,ore t%ent

• W#ter um!er !i!es/ riser !i!es /e5h#ust m#ni ol(s #irinlet el0o"s

• 'r#n1 c#se covers/ E5!losion covers/

• Fuel s-stem #n( lu0e oil s-stem co!!er !i!es

• Lu0e oil ;lter housin$/ Fuel !rim#r-9 Secon(#r- ;lter

housin$s #n( Str#iner housin$• +oth M#in Reservoir t#n1s cle#nin$/ testin$ #n( over

h#ulin$

• +oth 0o$ie r#mes #n( "heels or r#cture/ "e#r #n(cr#c1s

• Ultr#sonic testin$ o A5les #n( "heels

diesel engine and fuel oil system of alco

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