1455167359126-Maintenance Manual for Diesel Locomotives (1)

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES Annexure 14.2 DIESEL LOCOS ON INDIAN RAILWAY – ALCO LOCO PARAMETERS SN Description WDM1 WDM4 WDM3 WDM7 WDP1 WDP3A 1. Name given Chetak 1957 1962 1970 1987 1995 1998 2. Induction in IR No No No No No 0 0 0 14 No 40 3. Production continuing as Mixed Mixed Mixed Mixed Coaching on 31.03.2013 18047 18540 16208 62 19182 4. Number of locos as on 2845 3088 Coaching 31.03.2013 16092 5. Service 6. Length in mm (over Buffers) 7. Width in mm 2914 3016 3000 4185 4162 4185 8. Height in mm 3994 4087 1690 1728 1068/ 1090 1090 1090 9. Top of U/Frame from R/L --- --- 96.0 80.0 117 96.0 80.0 117.0 10. Buffer height from Rail 1066 1066 (mm) 111.6 112.8 111.6 112.8 11. Weight in working order (t) Adhesive wt. in working 12. order (t) 13. Axle Load in (t) 18.6 18.8 16 20 19.5 14. Adhesion in % --- --- --- 25 25 15. Wheel Dia. New / Cond. In 1016 1092 1092 1092 1092 mm 1016 1016 Single centre H design bogie Trimount Bolster less BO-Bo CO-CO type, flexi pivot on to a bolster CO-CO type, type, Flexi coil (side coil MK-V bogies, cast steel supported by & double bolster helical springs 2side bearers, spring groups, centre 1centre pivot, 16. Type of bogie attached with 1centre pivot pivot) secondary springs Wheel arrgt. swing links to the bogie frame. 2 stage, Primary & 2 stage, Primary & secondary springs secondary springs with hyd.dampers in with vertical & 17. Suspension arrgt. primary & lateral hydraulic secondary stage. dampers in primary & secondary stage. 18. Bogie Structure Cast steel Fabricated Cast steel 19. Weight transfer C.P 60% Side spring group CP/side springs S.B 40% 100% 29250 Tractive effort in Kgs - 27900 28200 20000 Max. 19300 20600 25920 104 20. 19.0 120 24 21. Tractive effort in Kgs - DC/DC: 18900 16400 19950 Cont. AC/DC: 21500 120 160 29 32 22. Maximum Rated speed DC/DC: 105 105/140 KMPH AC/DC: 100 105/120 23. Min. continuous speed in DC/DC: 21.7 KMPH AC/DC: 18.1 24. Speed cleared by RDSO 25. Fuel oil capacity in Liters, 6060 5000 3200 3000 5000 1-No/Loco 756 830 756 760 1270 26. Lube oil capacity in Liters 27. Cooling water capacity in 1210 1210 Ltrs Revised 2013 Printed: 2015/03/08 Ch-14 Page 296 of 303 Home

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES SN Description WDM1 WDM4 WDM3 WDM7 WDP1 WDP3A 0.40/4 0.34/ 8 0.4/4 Sand cap.(cu.m)/ No.of 28. boxes 29. Rated HP of Eng Standard: 1977 Standard: 2600 UIC 1977 hp, UIC condition: 2300 UIC condition: hp. hp. At site: 1856 hp, At site (47C- 3100 hp, At site: 1856 At site: 2400 hp 600m): 2231 hp At site (47C- hp hp 600m): 3007 hp 2000 2750 30. HP available for traction DLW 251B GM 567D3 DLW- 251 B DLW-251B DLW-251B (uprated)FE Weight (uprated) FE, 31. Make, type of Engine, 1 (dry): 14982 kg Weight (dry): per loco 19026 kg 32. No. of Cylinders & 12-45 deg V, 4 16-45 deg V, 2 12 – 45 deg V 12-45 deg.V 4 16-45 deg.V arrangement stroke stroke stroke 4 stroke 22/61 33. Gear ratio 94/17 61/16 94/17 18/65 LH LH 34. Loco drive - left/right hand Available Available Not Available Not Available Not Available 35. Dynamic brake facility Revised 2013 Printed: 2015/03/08 Ch-14 Page 297 of 303 Home

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES DIESEL LOCOS ON INDIAN RAILWAY - ALCO LOCO PARAMETERS SN Description WDM2 WDM3A WDG3A WDM3D WDM3F 1. Name given Gajraj Shakthi With Equal beam Without Equal Without Equal 2. Induction in I R 1962 1994 1995 2003 2009 2009 No Yes Yes No Yes No 3. Production continuing as on 31.03.2013 642 1119 1133 350 Mixed 4 18632 4. Number of locos as on Mixed Mixed Freight Mixed Mixed 31.03.2013 17120 17145 19132 18632 19920 5. Service 6. Length in mm (over Buffers) 7. Width in mm 3010 3010 3016 3090 3090 3084 4185 4185 4162 4265 4265 4265 8. Height in mm 1600 1600 1654 1735 1735 - 9. Top of U/Frame from R/L 10. Buffer height from Rail 1090 1090 1090 1090 1090 1090 (mm) 112.8 112.8 123.0 117 118.2 120 112.8 112.8 123.0 117 --- 11. Weight in working --- order (t) Adhesive wt. in working 12. order (t) 13. Axle Load in (t) 18.8 18.8 20.5 19.5 19.7 20 14. Adhesion in % 27 27 33 33 33 --- 15. Wheel Dia. New / Cond. 1092 1092 1097 1092 1092 1092 In mm 1016 1016 1012/1008 1016 1016 1016 Trimount CO- Trimount CO- Bolsterless high Bolsterless high Bolsterless high Bolsterless high adhes CO type, 2side CO type, 2side adhesion adhes HAHS Co- adhes HAHS Co- HAHS Co-Co type, Type of bogie & bearers, bearers, HAHS Co type, Co type, 4 side load pads, Wheel arrgt. 1centre pivot 1centre pivot 1center pivot 16. Co-Co type, 4 side load pads, 4 side load pads, 4 side load 1center pivot 1center pivot pads, 1cent pivot 4 group of 4 group of 2 stage, Helical 2 stage, Helical 2 stage, Helical 2 stage, Helical springs, springs, springs in springs in primary springs in springs in primary & 2 outer and 2 2 outer and 2 primary & & Rubber primary & Rubber sandwitch inner helical inner helical Rubber sandwitch springs Rubber sandwitch springs in secondary coils with coils with sandwitch in secondary, springs in with Vertical & friction friction springs in Equalizer & secondary with Lateral hydraulic snubbers and snubbers and secondary, compensating Vertical & Dampers in Primary & Equaliser Equaliser Equalizer & beams with Lateral hydraulic Secondary stage. 17. Suspension arrgt. beams (Long & beams (Long & compensating Vertical & Lateral Dampers in Short) Short) beams with hydraulic Primary & Vertical & Dampers in Secondary stage. Lateral Primary & hydraulic Secondary stage. Dampers in Primary & Secondary stage. 18. Bogie Structure Cast steel Cast steel Fabricated Fabricated Fabricated Fabricated 19. Weight transfer C.P 60% C.P 60% Side load pads Side load pads Side load pads Side load pads 100% S.B 40% S.B 40% 100% 100% 100% 30450 30450 Tractive effort in Kgs - 40600 38610 38610 38500 Max. 24600 20. 120 Tractive effort in Kgs - 28050 31920 25950 25950 Cont. 18 21. 105/120 Maximum Rated speed 120 100 120 120 120 KMPH 22. Min. continues speed in 22.8 20 26.1 26.1 KMPH 23. 24. 105/120 105 105/120 105/120 80 (Prov) Speed cleared by RDSO Revised 2013 Printed: 2015/03/08 Ch-14 Page 298 of 303 Home

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES SN Description WDM2 WDM3A WDG3A WDM3D WDM3F 5000 5000 6000 5000 Fuel oil capacity in 5000 5000 Liters, 1-No/Loco 1270 25. 1210 Lube oil capacity in 1070 1270 1270 1270 1270 0.04m3/8 Liters 26. 3600 hp 27. Cooling water capacity 1210 1210 1210 1210 1210 3300 in Ltrs 0.40/4 0.16m3/4 0.16m3/4 0.16m3/4 0.16m3/4 DLW-251B 28. Sand cap.(cu.m)/ No.of (uprated)FE boxes 16-45 deg.V 2600 UIC condition: UIC condition: UIC condition: UIC condition: 4 stroke 2400 3300 hp, 18/65 29. Rated HP of Eng 3100 hp, At site 3100 hp, At site 3300 hp, LH At site (47C- (47C-600m): (47C-600m): At site (47C- 600m): 3152 hp Available 3007 hp 3007 hp 600m): 3152 hp 2950 Annexure 14.3 HP available for 2750 2750 2950 traction 30. ALCO/DLW DLW-251B DLW-251B DLW-251B DLW-251B (uprated) FE (uprated)FE, (uprated)FE, 31. Make, type of Engine, 1 251-B . Weight (uprated) FE Weight (dry): Weight (dry): Weight (dry): Weight (dry): per loco (dry): 14682 kg 19026 kg 19026 kg 19026 kg 16-45 deg.V 16-45 deg.V 16-45 deg.V 19026 kg 4 stroke 4 stroke 4 stroke 32. No. of Cylinders & 16-45 deg.V 16-45 deg.V 18/74 18/65 18/65 arrangement 4 stroke 4 stroke LH LH LH 33. Gear ratio 18/65 18/65 Loco drive - left/right RH LH hand 34. 35. Dynamic brake facility Available Available Available Available Available DIESEL LOCOS ON INDIAN RAILWAY - HHP LOCOS PARAMETERS SlNo Description WDG4 WDP4 WDG5 1 Induction in I R 2000-01 2001-02 2012-13 2 Freight Freight 3 Service 21240 Coaching 22262 4 Length in mm (over 3070 21240 3250 5 Buffers) 4220 4357 6 Width in mm 1090 3070 1090 7 126 t 4220 134 t 8 Height in mm 126 1090 Buffer height from Rail (mm) 117 t 22.3 9 21 78 10 Weight in working order (t) 42 1092/1016 11 1092/1016 19.5 High Tensile Cast Fabricated 12 Adhesive wt. in working order Bolsterless high adhes 42 (t) HTSC CO-CO type, 4 side 1092/ 1016 (HTCF) bogie frame Axle Load in (t) load pads, 1centre pivot Bolsterless high adhes assemblies Co-Co HTSC A-A-1, 1-A-A type, Adhesion in % 2 stage, Helical springs in 4 side load pads, 1centre bolster-less secondary primary & Rubber sandwich pivot suspension system Wheel Dia. New / Cond. In mm 2 stage, Helical springs in springs in secondary with primary & Rubber sandwich High Strength Low Alloy Type of bogie & Wheel Vertical & Lateral hydraulic springs in secondary with steel Vertical & Lateral hydraulic arrgt. Dampers in Primary & Dampers in Primary & Side load pads 100% Secondary stage. Secondary stage. 560 KN 13 Suspension arrgt. Cast steel (HTSE) Cast steel (HTSE) 405 KN 105 14 Bogie Structure Side load pads 100% Side load pads 100% 30.6 105 15 Weight transfer 53000 27550 7500 16 Tractive effort in Kgs - Max. 17 Tractive effort in Kgs -Cont. 40774 20377 18 Maximum Rated speed KMPH 19 Min. continuous speed in KMPH 100 160 20 Speed cleared by RDSO 20 22.5 21 Fuel oil capacity in Liters, 1- 105 105/160 No/Loco 6000 6000 Revised 2013 Printed: 2015/03/08 Ch-14 Page 299 of 303 Home

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES SlNo Description WDG4 WDP4 WDG5 22 Lube oil capacity in Liters 950 1073, 1596 lube oil pan, bottom to top 23 Cooling water capacity in Ltrs 1045 dipstick: 371 1235 24 Sand cap.(cu.m)/ No.of boxes 1045 10 Cu ft/ 25 Rated HP of Eng 0.04/8 5500 hp 0.028/8 26 HP available for traction AAR condition: 4132 CV, 5332 At site (47C-600m): 4012 AAR condition: 4132 CV, Input to traction under site 27 Make, type of Engine, No per At site (47C-600m): 4012 Loco CV condition : 3726, CV 710-G3B-ES 28 No.of Cylinders & arrangement Input to traction: 3780 CV 3726, 29 Bore and Stroke Input to traction: 3780 CV 20- 45 Deg V, 2 stroke 30 Compression Ratio GT 46 MAC 710 G3B, 230.19 X 279.4 31 Engine RPM idle Weight (dry): 17963 kg GT 46 MAC 710 G3B, 16:1 32 Engine RPM Max 16-45 deg.V, 2 stroke Weight (dry): 17963 kg 200 33 Engine RPM during OSTA 16-45 deg.V, 2 stroke 904 230.19 x 279.4 --- trapping 16:1 230.19 x 279.4 34 Firing Order 269/200 16:1 35 Mean Piston speed M/sec 904 269/200 36 B.M.E.P (Kg/Sq.cm) 37 Type of Transmission (Electric) 990-1045 904 38 Type of Turbo & make 990-1045 39 Type of Engine Governor 40 Fuel injection system, Type of 1,8,9,16,3,6,11,14, 1,8,9,16,3,6,11,14, 1,19,8,11,5,18,7,15,2,17, 4,5,12,13,2,7,10,15 4,5,12,13,2,7,10,15 10,12,3,20,6,13,4,16,9,14 pump & Injector 8.38 8.38 --- 41 Cooling water system, pump 11.23 11.23 --- type, & capacity AC/DC AC/DC AC/DC 42 Engine cooling Electronic fuel injection with EMD Model G. EMD Model G EMDEC, Displacement/ cyl: 43 Lube oil system Weight: 953 kg 44 Engine air intake system WW 11635 cm2 WW 45 Creation of Air and vacuum Direct Unit injection system, One radiator fans drive with 46 Cooling compressor/ Exhauster Direct Unit injection system, Displacement/ cyl: 11635 AC motor of 100 hp Displacement/ cyl: 11635 cm2 47 Traction motor isolation cm2 Two water pumps, engine 48 No. of transitions Two water pumps, engine driven, Centrifugal, 3785 l/m 49 Traction motor arrangement driven, Centrifugal, 3785 l/m @ 900 rpm No.of T.M's @ 900 rpm 50 Gear ratio Two radiator fans drive with 51 Engine cranking done by Two radiator fans drive with AC motor of 113.4 hp AC motor of 113.4 hp 4 Lube oil pumps 4 Lube oil pumps Inertial with baggy type Inertial with baggy type Compressor secondary filters (cyclonic) secondary filters (cyclonic) Compressor Compressor Water cooled KNORR Water cooled KNORR (NYAB) (NYAB) Full truck to be isolated in Full truck to be isolated in which defective motor is which defective motor is available available 0 0 LLL/RRR LL/RR 6 (3 in parallel per bogie) 4 (2 in parallel per bogie) 90/21 2 Air starting motors 17/90 17/77 2 DC Starter motors 2 DC Starter motors 52 Master controller model Reversor handle,throttle Reversor handle,throttle LH handle,DB handle handle,DB handle 53 Loco drive - left/right hand LH LH 54 Min.radius of curvature in 64.92 73.2 meters CCB (Electro pneumatic 55 Brake system type), Air/Hand brake, CCB (Electro pneumatic KNORR/NYAB-CCB1-IR, Train: pure air brake type) Air/Hand brake, Train: Microprocessor controlled 56 Brake effort in tonnes 57 Dynamic brake facility 27.534 pure air brake air brake. 58 Dynamic brake working in case Available Available of traction motor isolation Effective for one truck Effective for one truck Revised 2013 Printed: 2015/03/08 Page 300 of 303

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES Date Issued: dd/mm/yyyy SlNo Description WDG4 WDP4 WDG5 59 Dynamic braking force 26.25t 16.3t 60 Traction control computer SIBAS 16, Siemens. SIBAS 16, Siemens. EM2000 Ch-14 61 Loco computer Home 62 Traction inverters EM 2000 EM 2000 1GE 420 050 9010.00MB74, 1GE 420 050 9010.00MB74, Voltage source inverter with Voltage source inverter with gate turn-off thyristors, gate turn-off thyristors, rating: 1430 KW, Qty: 2 rating: 1430 KW, Qty: 2 (one per bogie) (one per bogie) Annexure 14.4 PARTICULARS OF DIESEL LOCO WEIGHTS (in KGs) SN Description WDM2 WDM3A WDG3A WDM3D WDG4 126010 1 Loco with Supplies 112795 112795 123600 123600 17963 105853 105853 114645 114645 2 Loco Light 953 19026 19026 19026 19370 - 3 Diesel Engine (Dry) 1816 1816 1816 1816 39 - 64 39 - 64 49 4 Engine Base 59 59 21773 5 Governor - Crank Shaft and - - 6 Extension Shaft 1725 1725 1725 1725 8709 - Assembly 3016 2631 7 Cylinder Block 5584 5584 5584 5584 111.23 111.23 102 102 8 Cylinder Head Assembly 41 41 41 41 23 23 9 Cylinder Liner - - 55 55 10 Piston 66 66 243 545 11 Piston and Connecting 243 243 73 73 Rod Assembly 70.4 70.4 545 545 613 613 12 Camshaft 282 282 282 282 13 Camshaft Gear 14 Turbo-Supercharger 15 Turbo-Supercharger Support 16 Exhaust Manifold (Single 227 227 148 148 Pipe) 17 Exhaust Manifold 795 795 - - (4 Pipes) 136 136 136 136 17 Turbo Air Aftercooler 134 134 134 134 152 152 152 152 18 Water Pump 23162 23162 25000 25000 13015 13015 - - 19 Lubricating Oil Pump - - 5600 5600 20 Truck, Complete 6075 - - - 21 Truck without Motor - 6400 6400 - 22 Truck Frame with BK. Rigging 22 Traction Generator 22 Traction Alternator with accessories 23 Traction Motor without 3382 - -- Pinion 24 Traction Motor with - 3690 3650/3750 3680 Pinion,Gear & gear case 22.7 22.7 22.7 24 1946 - 2150 25 Traction Motor Pinion 2150 26 Wheel and Axle Assembly with Gear Revised 2013 Printed: 2015/03/08 Page 301 of 303

Document No: Chapter –14 Locomotive Data Version No: 1.0-d0 Draft Date Issued: dd/mm/yyyy Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES SN Description WDM2 WDM3A WDG3A WDM3D WDG4 27 Wheel, Motor Truck 483 - - - - 113.4 - - - - 28 Equalizer - 81.6 80 80 - - 29 Traction Motor Blower, 1043 Ch-14 Front 1089 105 Home - - 30 Traction Motor Blower, 2019 - 105 - - Rear - 850 1134 - - - - 31 Expresser (6CD4UC) 2010 850 1089 788 - 2019 408 32 Compressor 2019 - - - - - 33 Hood over Engine - - 788 - 34 Driver Cab Hood 788 647 788 647 35 Radiator Compartment - Hood - 36 Radiator(1) Radiator fan, Right angle 37 Box & Eddy Current 360 360 360 360 Clutch 38 Radiator fan, 53.5 53.5 53.5 53.5 314 - - - 39 Auxiliary Generator 5 GY 27 40 Auxiliary Generator 278 - -- AG 51 196 - -- 41 Exciter 5 GTA 6A1 Auxiliary generator 42 GM, 5A – 814 & blower -- -- assly 43 Exciter, GM, CA - 6B -- - - - 435 435 435 44 Auxiliary Generator & Exciter AG 3101AY 45 Auxiliary Generator & - 365 365 365 Exciter AG 2702 AZ 46 Cattle Guard (2 per 300 300 300 300 Loco) wt. Each 47 CBC (2 per Loco) wt. 527 527 527 527 each 48 Side Buffer (4 per 166 166 166 166 Loco) wt. Each 49 Cattle Guard Support (2 350 350 350 350 per Loco) wt. Each Revised 2013 Printed: 2015/03/08 Page 302 of 303 Ch-14 Home