The Diesel Locomotive

Introduction
The modern diesel locomotive is a self contained version of the
electric locomotive. Like the electric locomotive, it has electric
drive, in the form of traction motors driving the axles and
controlled with electronic controls. It also has many of the same
auxiliary systems for cooling, lighting, heating, braking and
hotel power (if required) for the train. It can operate over the
same routes (usually) 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.

Parts of Diesel Locomotive

The following diagram shows the main parts of a US built
Diesel electric locomotive .Click on the part name for a
description

This is the main power source for the locomotive.

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 handheld

computer.

Power Assembly Section D Shop

C.C 7026
In this section we are repair engine and its parts we also washing
different parts. Different basic parts name are given below;
Engine block
Pistons
Rings
Connecting rods
Crankshaft
Cylinder heads
Valves and related components
Valve train
Harmonic balancers
Balance shafts.

Engine Block
The engine block is the basic support and
attaching point for all other engine parts. Engine
blocks are made by pouring molten cast iron, steel,
or aluminum into molds. After the metal cools, the
molding sand is washed out and the block is
machined to allow other parts to be installed or
attached. The major parts installed in or on the

block are the pistons, crankshaft, camshaft,

cylinder heads, and manifolds. As shown in fig.

Pistons and Rings

Pistons transfer the force of expanding
combustion gases to the connecting rods. They are
made of aluminum to reduce weight. Most
automotive pistons have two compression rings
and one oil ring, as shown in figure.
Compression rings seal in the pressure created
during the compression and power strokes. If this
pressure is allowed to leak out, the engine will not

start or will have severe power and drive ability

problems. The compression rings are installed at
the top of the piston. A film of oil between the
compression ring and cylinder wall seals pressure
in the cylinder. This oil film is only about 0.0025
mm thick, but if it is removed, the engine will not
develop enough compression to start. The oilcontrol ring is installed below the compression
rings to prevent excessive oil consumption. During
the pistons intake stroke, vacuum in the cylinder
tries to pull oil from the cylinder wall. To reduce oil
loss, the oil-control ring scrapes most of the oil
from the cylinder wall when the piston is moving
down in the cylinder. A small amount of oil passes
by the oil-control ring to seal the compression rings
against the cylinder wall.

Connecting Rods and Crankshaft

The connecting rods are forged steel rods that
connect the piston to the crankshaft. They transfer
the force from the piston to the crankshaft. Each
connecting rod is connected to a piston by a piston
pin. The rod is attached to the crank-shaft by a
bearing cap and bearing inserts that surround the
crankshaft journal. The piston pin and crankshaft
bearings allow the rod to move in relation to both
the piston and crankshaft. The crankshaft
converts the straight-line force from the piston and
connecting rod into rotary force. It is attached to
the engine block by bearing caps and bearings that
surround the crankshaft journal. This design allows
the crankshaft to rotate inside of the bearings with
minimal friction. The bearing caps are held to the
engine block by two, four, or six bolts torque to
specifications.

Crank-Shaft

Connecting rods

Cylinder Heads
The cylinder head contains the combustion
chamber for each cylinder and forms the top of the
cylinder. Cylinder heads contain the intake and
exhaust valves and, in some cases, the camshaft
and lifters. They also contain oil galleries, coolant
passages, and openings to allow the flow of intake
and exhaust gases. Cylinder heads are made from
either cast iron or aluminum. A sheet metal, cast
aluminum, or plastic valve cover is installed over
the upper valve train components. We show a
typical cylinder head. Coolant passages between
the cylinder heads and engine block must be
sealed to prevent coolant leakage.

Also, the pressure of expanding combustion gases

must be contained within the cylinder. Head
gaskets are used between the head and engine
block for these purposes.
They are thin and made from steel, copper, and
fibers.
The cylinder head and head gasket are secured to
the block with head bolts. These must be torque to
specifications. A few engines have studs and nuts,
rather than head bolts.

Wood WARD Governer

The PGE governor is basically a standard PG
hydraulic governor to regulate engine speed with a
number of special adaptations for locomotive and
train operation. It includes an electro-hydraulic
speed setting mechanism for remote control of
engine speed, a mechanical-hydraulic load control
device for automatic regulation of engine load to
maintain a specific power output at each speed
setting, and a 12 ft-lb (16 J) single acting spring

return hydraulic power servo with tail rod. The

power servo may have either a reciprocating
(linear) or rotary output.
The governors may be arranged for use with a
remote vane servomotor to adjust the generator
exciter rheostat or they may include both
servomotor and rheostat as integral parts of the
governor. There are different type of governer are
given below.
36600, PG Governor Basic Elements 36692, PG Power
Cylinder Assemblies 36693, PG Base Assemblies,

Machine shop C.C 7005

In machine shop there are different types of machine are
working properly.
1-Center Lathe Machine
2-Capstone Lathe Machine

3-Turret Lathe Machine

4-Drilling Machine
5-Boring Machine
6-Grinding Machine
7-Shaper Machine
8-Planer Machine
9-Milling Machine
10-Screwing Machine
Different types of operations performed in machine shop
e.g. turning operation, facing operation, drilling operation,
Boring operation, and cutting operation, are performed in
machine shop.

TURNING OPERATIONS
In this operation we can reduce the diameter of the job
along the bed.

FACING OPERATION
In this operation we can reduce the length of the job
across the bed.

CUTTING OPERATION
In this operation we can cut the material in different ways
e.g. length, depth and diameter.

DRILLING OPERATION

In this operation we make drill in different types of material

e.g. in bearing, cylinder, bearing housing and suspension
bearing.

PLANNING OPERATION
In planning operation we plane the rough surface of
material e.g. we plane the surface of motor cab.

TOLL SHOP C.C 7019

In tool shop we made all types of tool used in making
different parts of engine and used in Pakistan railway
engine. Different types of tool are given below;
1-MILLING TOOL
2-TWIST DRILL TOOL
3-BRIDGE REAMERS
4-TAPS SET
5-MILLING CUTTERS

FOR CAST IRON

6-CEMENTED CARBIDE TIPPED TOOL
7-HIGH SPEED STEEL TIPPED TOOL
All types of tool are used for cutting different types of
material according to the name of tool of tool.
MILLING TOOL

TWIST DRILL

CARBIDE TIPPED TOOL

TAPS SET & DIES

Tool shop is a place where fitting or assembling

work is carried out. Some repair / maintenance and
Die punch work is also carried out in Fitting shop.

FOUNDRY SHOP C.C 7001

Foundry is one of the manufacturing process by
which a desired shape of metal is obtained by
heating up to its molten state (liquid state), and
pouring into mould cavity. After some time metal is
allowed to cool and solidify. The solidified piece of
metal is known as casting. Foundries produce
castings that are close to the final product shape,
i.e., near-net shape components. Castings are
produced by pouring molten metal into moulds,
with cores used to create hollow internal sections.
After the metal has cooled sufficiently, the casting
is separated from the mould and undergoes
cleaning and finishing techniques as appropriate.
There are a number of documents in the public
domain that provide detailed descriptions of
foundry processes (Defray 2003a, b; European
Commission 2004; Chartered Institute of
Environmental Health 1997). A brief description of
foundry processes is provided below for those who
may not be familiar with the industry.

Sand mould and core making

Sand casting is the most common production
technique, especially for ferrous castings. Sand is
mixed with clay and water or with chemical binders
and then packed or rammed around the pattern to
form a mould half. The two halves are joined
together to make the mould - a rigid cavity that
provides the required shape for the casting.
Variations on this technique include the use of
plaster in place of sand and the recently invented

Pattern less process (CDC 2000), where the mould

is machined directly out of a sand block without the
need for a pattern.

BLACK SMITH SHOP

ROUGH SECTION
Different types of hammer used in black smith
shop for making different links of train.
1-Pnaumetic Hammer No.61
It is used for link forming (PL W-402). It is also used
for making T-Nut (DG-647 LR) and also making
safety pin (DG-647).
2-Pnaumetic Hammer No.44

By the help of this hammer we made hanger (PL V1684) and making shekel (W-401).And also made
safety pin.
It also made break beam end (V-724).

TRIMMING PRESS
In this section press trim the extra material from
the required shape and required shape is obtained
in this process roughly.

DROP STEMP
To draw dots on the t-nut to drill screw in it;

MACHINE SECTION
PUNCHING MACHINE (PS-08)
This machine doing some operation;
1-Punching operation
2-Cutting operation
3-Angle cutting operation
FORGING MACHINE (DF-04)

These machine are making buffer spindle, w-401

shekel and different size of head are formed.
It also making truss bar end, break beam end,
revote forming, pin head and AC 400v.
HYDRAULIC PRESS SYSTEM
This section made different shapes e.g. to bend, vshape and different types of bend.

SPRING SHOP
Principle of a spring
In distinction to a rigid beam, a spring, regardless
of its form or shape, will exert a changing force as
it deflects its horn block. This relationship is linear,
with maximum force being applied when the spring
is fully compressed (to take the example of a
compression spring), and zero force being applied
when the spring is in its fully relaxed state this
principle is shown in figure 7. The actual deflection
of the spring is directly proportional to a property,
the 'spring rate' (or 'spring constant') of the
particular spring. If a spring relaxes to depress a
wheel onto the rail, the reduction in the force
applied to the horn block will be counterbalanced
by a distributed increase in the force the loco

applies to its other suspension points. Springs

absorb and discharge potential energy, and
decouple the vertical forces between the wheels
and the body.
Viability of springs in small-scale models
A prototype loco is suspended, being held up by
the strength of the springs. It is generally accepted
as being difficult to reproduce the characteristics of
prototype springs in small-scale models because:
1.the mass to momentum relationships in the
prototype do not scale linearly to models; 2.with
the exception of the use of commercial music wire
strings as beam springs, it can be difficult to
provide the range of model springs appropriate for
all the different weights of model locomotives; 3.it
can be difficult to adjust the springs so that the
loco is both level and at the correct buffer height;
4.it is difficult to assess what the design value of
the deflection of a spring should be; 5. Model rail
does not deflect under the weight of a model loco
like prototype rail does.

LIFTING SHOP C.C 7121

ROLLER BEARING SECTION
In this section there are three types of bearing are
greased and ungreased.
1-spherical bearing
2-taper bearing
3-cylindrical bearing
PARTS OF BEARING
1-outer ace
2-inner ace
3-roller
4-cuage

DIFFERENCE BETWEEN SPHERICAL & TAPER

BEARING
1-Spherical bearing has no clearance but
cylindrical bearing has clearance from 0.002 to
0.012 thousand.

2-The inner ace of cylindrical bearing is 130mm

and the inner ace of taper bearing is 120mm.
3-Both bearing are heated about 120*C.
4-For mounting the cylindrical bearing is heated
from the inner ace but for mounting the taper
bearing is heated as a whole.

BOGIE ASSEMBLY
Set the frame on the bolster and then fitted the
suspension link and then fitted the bolster tray
finally. Now fitted the under gear and then fit the
shock absorber then paint it and then change the
damage part of bogie. The parts of bogie are given
below:
1-pivoit pin
2-pull road
3-Under frame section
4-safety bracket
5-shock absorber
6-spring (k 64, 65, 66)

7-head stock
8-cross bar
9-longitudnal bar
10-side barrier
And also different parts are used in the Pakistan
railway bogies.

MECHANICAL ENGINEERING
WORK SHOP ASSIGNEMENT

FROM: THE UNIVERSITY OF

LAHORE
NAME: MUHAMMAD QAMER
ROLL NO: BSME01143044