WDG4/P4 LOCOMOTIVES The 4000 HP computer controlled GM locomotive has a large

number of special and improved features like two stroke, EM 2000 computer etc. The models are GT46 MAC/PAC for Goods and Passenger trains.

DTTC/GTL/SCRly

COMPARTMENTS & MECHANICAL PARTS

• NOSE COMPARTMENT• DRIVER/ENGINEERS CAB• ELECTRICAL CONTROL COMPARTMENT• TCC COMPARTMENT• CLEAN AIR CHAMBER• GENERATOR COMPARTMENT• ENGINE COMPARTMENT• ENGINE EQUIPMENT RACK• COMPRESSOR ROOM• RADIATOR COMPARTMENT

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ENGINE ROOM SUMP DOOR

AIR BOX COVER

DE-COMPRESSIONADOPTERS

VALVE LEVERS COVER

ENGINE ROOM

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EXHAUSTMANIFOLD

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GENERATOR ROOM

TURBO

AFTER COOLER

OIL SEPERATOR

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VALVE LEVER MECHANISM

CAM SHAFT

VALVE LEVER MECHANISM

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ENGINE ACCESSORIES FROM LEFT SIDE

ENGINE PROTECTINGDEVICE

LOW WATER

LOW CRANK CASE VACUUM

LWS COCDTTC/GTL/SCRly

ENGINE ACCESSORIES FROM RIGHT SIDE

ENGINE GOVERNOR

OSTA RESET

HANDLE

CAM SHAFT VIBRATION

DAMPER HOUSING

FUEL SIGHT GLASS

LLOP

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ENGINE ACCESSORIES FROM RIGHT SIDE

SECONDARY SPIN ON FUEL

FILTER

RIGHT BANK WATER PUMP

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TURBO SOAK BACK PUMP & FILTER

SOAK BACK PUMP

SOAK BACK FILTER

L/O DIPSTICK GAUGE

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ENGINE EQUIPMENT RACK FROM RIGHT SIDE OF LOCO

ENGINE START SWITCH

PRESSURE CAP

RELIEF VALVE

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ENGINE EQUIPMENT RACK FROM LEFT SIDE OF LOCO

ENGINE EQUIPMENT RACK/COMPRESSOR COMPARTMENT

EXPANSION TANK

COMPRESSOR

LUBE OIL COOLER FUEL OIL

PRIMARY FILTER

LUBE OIL FILTER DRUM

Lube oil filtercondition gauge

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RADIATOR COMPARTMENT

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VERTICAL SHOCK ABSORBERS

UNDER TRUCK

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LOCO LIFTING PAD

SIDE LOAD PAD

SAFETY LINK

CHAIN

BRAKE CYLINDER

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HAND BRAKE

HAND BRAKE

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SIDE BUFFERS

CBC

BP

FP

JUMPER RECEPTACLE

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FUEL TANK

EMERGENCY FUEL CUT OFF

SWITCH

FUEL GLOW ROD GAUGE

AIR BOX DRAIN (BAP)

FUEL TANK

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FUEL SYSTEM IN WDG4/WDP4 FUEL OIL SYSTEM CONSISTS OF FOLLOWING COMPONENTS:-• Fuel tank of 6000 Liters capacity• Fuel suction strainer • Fuel oil pump (AC motor driven constant RPM fuel pump)• Fuel primary filter• Fuel secondary (Engine mounted spin – on filters)• Fuel headers• Unit fuel injectors. THE TOTAL FUEL SYSTEM DIVIDED AS:• Fuel feed system and • Fuel injection system

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FUEL SYSTEM IN WDG4/WDP4

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LUBE OIL SYSTEM OF WDG4/WDP4 LOCOS Lubricating of Oil system in WDG4/WDP4 consists of the

following:• Engine sump• Scavenging oil pump • Lube oil filter tank• Lube oil cooler • Lube oil strainer• Main Lube oil and piston cooling oil pump• Soak back oil pump• Oil separator and • Hot oil detector

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AIR INTAKE SYSTEM OF WDG4/WDP4 LOCOS Diesel Engine in WDG4/WDP4 locomotive is a super charged

fuel-efficient and two stroke engine. Since the locomotive is provided with two-stroke engine, the inlet air requirement for proper combustion of the fuel is high. To fulfill the requirement of the engine a special turbo super charger is provided in this locomotive to supply required quantum of air in each notch according to load and speed condition.

Air intake system consists the following parts -• Inertial air intake/cyclonic type air intake filters • Clean air chamber • Baggy type engine air intake secondary filters. • Turbo super charger.• After coolers.• Air boxes.

DTTC/GTL/SCRly

DTTC/GTL/SCRly

THANK YOU

DTTC/GTL/SCRly

COMPUTER CONTROLLED BRAKE SYSTEM (CCB)

1.WIPER CONTROL KNOBS

2.MR(RED) , ER (WHITE)GAUGE

3.BP(WHITE) , BC (RED)GAUGE

4.AIR FLOW INDICATOR (WHITE NEEDLE-INDICATOR, REDNEEDLE- SETTING)5.SPEEDO METER

6.TRACTIVE EFFORT METER7.INDICATING PANEL

8.ALERTOR LIGHT9.HORN BUTTONS

213 4 5

6 7

8

910

10.ALERTOR RESET BUTTON

CONSOLE

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BRAKE CONTROL UNIT

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BRAKE CONTROL UNIT (BCU) :

I)Automatic Brake valve (Auto Brake) : Having 5 positions.

a) Release/over charging (spring loaded): BP = 5.7 kg/cm2 max.

b) Running : Equalizing reservoir (ER) and BP = 5.2 kg/cm2 BCP=0

c) Minimum service : ER/BP reduce to 4.7 kg/cm2, BCP = 1.1 kg/cm2

d) Full service : ER/BP reduce to 3.4 kg/cm2, BCP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2)

e) Emergency : ER reduces to 0, B.P reduces to < 1 kg/cm2 BCP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2), BCEP = 1.8 kg/cm2 (1.82 +/- 0.14 kg/cm2)

DTTC/GTL/SCRly

II) Independent Brake Valve (Direct Brake) : It is having following positions

a) Release Position : BCP = 0 b) Application zone : Maximum brake position, BCP =5.2 kg/cm2 (5.1 +/- 0.14 kg/cm2),

BCEP=5.2 kg/cm2 (5.1 +/- 0.14 kg/cm2) c) Bail off : When an automatic brake is applied, lifting the bail-off ring which is provided in the independent brake valve handle , in any position will release BC pressure. Independent brake handle bail-off ring is spring loaded and by lifting it, the bail of function will be activated. III) Selector Switch or Air Brake Lead/Trail set up switch:

The Lead/trail air brake set up switch is located on brake control next to independent brake handle.

This switch has the following positions: HLPR: Used during Banking loco in the working console.

Trail : In Leading Loco non-working Console and also for Trailing loco both the consoles. Lead : Used with loco in lead or controlling .Test : In working console used during brake pipe leakage-testing and also during attaching of locomotive on formation.

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ITEM WORK CONSOLE

NON-WORKING CONSOLE

1. REVERSOR NEUTRAL NEUTRAL2.THROTTLE/SELECTOR

IDLE IDLE

3.AUTOMATIC BRAKE HANDLE

RUN FULL SERVICE

4.DIRECT BRAKE HANDLE

FULL APPLICATION

RELEASE

5.LEAD/TRAIL (SELECTOR) SWITCH

LEAD TRAIL

PROCEDURE FOR MAKING CONSOLE IN WDG4/WDP4 LOCOMOTIVES.

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ITEM WORKING CONSOLE CHANGING IN TO NON-WORKING CONSOLE

1. REVERSOR NEUTRAL NEUTRAL

2.THROTTLE/SELECTOR IDLE IDLE

3.AUTOMATIC BRAKE HANDLE

RUN FULL SERVICE

4.DIRECT BRAKE HANDLE

FULL APPLICATION RELEASE

5. LEAD/TRAIL (SELECTOR) SWITCH

LEAD TRAIL

PROCEDURE OF CHANGING CONSOLE

• Keep isolation switch in START/STOP/ISOLATE position.

CONVERTING THE WORKING CONSOLE AS NON-WORKING CONSOLE.

DTTC/GTL/SCRly

ITEM NON WORKING CONSOLE CHANGING IN TO WORKING CONSOLE

1. REVERSOR NEUTRAL NEUTRAL

2.THROTTLE/SELECTOR

IDLE IDLE

3.AUTOMATIC BRAKE HANDLE

FULL SERVICE RUN

4.DIRECT BRAKE HANDLE

RELEASE FULL APPLICATION

5. LEAD/TRAIL (SELECTOR) SWITCH

TRAIL LEAD

CONVERTING THE NON-WORKING CONSOLE AS WORKING CONSOLE.

DTTC/GTL/SCRly

SAFETY PRECAUTIONS/CONDITIONS BEFORE CONDUCTING AIR BRAKE SELF TEST

Air brake self test is to be conducted on WDG4 and WDP4 locomotive under following conditions.1. Failure of console selection( Change of console if wrongly done)2. During any Air brake failure on run.Step. 1Following safety precautions are to be strictly followed before conducting air brake self test.•Stop the locomotive/train.•Apply “Hand brake” on locomotive.•Secure the formation, which should not roll during self test.•Close BP and FP angle COC’s on locomotive and on formation.•Close MR and BC equalizing COC’s on both ends of locomotive.•On working console :

1.Keep reversor handle in ”Neutral” position.2.Keep automatic brake handle in “Run” position.3.Keep independent brake handle in “release” position.4.Lead/Trail switch in “Lead” position

•On non working console :1.Keep automatic brake handle in “Full service” position.2.Keep independent brake handle in “Full application” position.3.Lead/Trail switch in “Trail” position.

On fulfilling .,safety precautions, Air Brake self test is to be conducted.•Ensure minimum MR pressure of 110 PSI.

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AIR BRAKE SELF TEST PROCEDURE

• Press “Main menu” key.• Using down arrow key, bring curser to “Self Test” and press ‘F3’

to select.

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• Press “F2” key to go to “Next” page.

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•Using down arrow key, bring cursor to “Air Brake Test” and press F3 to select.

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• Entry conditions for Air Brake Test will be displayed on the screen, which are already fulfilled. •Press “F1” key to continue test.

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•Air brake test in progress display will come.

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• EM-2000 initiates Air Brake Self test. •On completion of test, ‘SUCCESSFUL TEST COMPLETED, NO DEFECTS FOUND’ will be displayed on EM – 2000 screen. • Then press F4 key to ‘END TEST’.

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•Crew message display will come as below

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•After keeping Automatic brake handle to emergency position the following Crew message display will come . •Then keep A/brake handle to ‘RUN’ position and press F4 key to exit.

•Keep independent brake handle to ‘Full application’ position in workinconsole and ‘Release’ position in Non-working console.

DTTC/GTL/SCRly

Note: If Air brake self test failed, then note the defect code digital number on CRU display. And make working console to non-working and non-working to working console. Again conduct Air brake self to that console . If succeeds then work with that console and if fails note the number and inform to concern shed.

G/P SWITCH

CRU DISPLAY

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CUT OUT COCKS IN BRAKE SYSTEM

Locomotive short hood end & long hood end --•FP coc•BP cocRight side of the Locomotive below the chasis – ( near front truck & near rear truck ):•BC equalizing coc•BP additional coc•FP additional coc•MR equalizing coc

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•Bogie isolation coc- for front & rear truck

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•MR1 & MR2 with ‘J’ filter (system) coc’s – In between front truck and fuel tank (Right side of the loco)

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• F2 feed valve coc – In between front truck and fuel tank (Right side of the loco)

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• Dead engine coc – (Nose compartment) : It should be kept in open condition to get brakes in Dead WDG4/P4 locomotive when only Brake pipe connected .

DEAD ENGINE COC

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MOVING OF WDG4/P4 LOCOMOTIVESS.No. LEAD LOCO CONNECTIONS TRAIL LOCO

1 ANY AIR BRAKE LOCO MU JUMPERBP/(FP), MR EQ. &BC EQ.

WORKING WDG4/P4 LOCOKEEP BOTH CONSOLES AS NON WORKING

2 ANY AIR BRAKE LOCO BP/(FP), MR EQ. &BC EQ. DEAD WDG4/P4 LOCOKEEP BOTH CONSOLES AS NON WORKING & COMPUTER BREAKERS IN ON POSITION

3 ANY AIR BRAKE LOCO ONLY BP/(FP)MU JUMPER IF

REQUIRED

WORKING WDG4/P4 LOCOON WORKING CONSOLE KEEP AUTO BRAKE - FULL SERVICEDIR. BRAKE - RELEASEL/T SWITCH - HLPR KEEP OTHER CONSOLE AS NON WORKING

4 ANY AIR BRAKE LOCO ONLY BP/(FP) DEAD WDG4/P4 LOCOKEEP BOTH CONSOLES AS NON WORKING-OPEN DEAD ENGINE COC-OPEN MR EQ. &BC EQ. COC AT ONE END OF LOCO.

DTTC/GTL/SCRly

THANK YO

UDTTC/GTL/SCRly