Ge 7s12
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G EK - 301 50 SE CTI O NX11
CO N TEN TS Page
IN TRO D U CTI O N TRO U B LE-S - SH O O TI N GP R O C E D U R E SAFETYN O TI CE TRO UB LE-S - SH O O TI N GG UD E O W N PR ELI MN A R YCH E CK EN GN ESH U TD PR ELI MN A R YCH E CK EN GN ERU N NN G PR ELI MN A R YCH LDWA E CK CO TH ER NCH EN GN E RU E CK LO A DN GUN T O A DCH RSELF- LO E CK H O R SEPO W ER TRO UB LE TU RB O C H A RG E R TRO UB LE M O D ULATI NGC O N TRO LG UB LE O V ERN O RTRO CH EC EX C TA TI O NSYSTEMTR O U B LE
XI I -1
M n a a
N
W
X C7
W
XI 1 2 XI 1 2
XI I - 3 XI I - 3 XI I - 9
XI I -9 XI I -1 -10 0 XI I -1 -11 1 XI I -12 -12 XI I -1 -14 4
H EELSLI LI PSYSTEMTR O U B LE CM RW
XI I -1 -14 4 XI I -17 -17
IN TRO D U CTI O N
Thi Thi s s ec e c t i o n p r e ssee n t s t roub roubl e- sho shooti ng procedure a s an f or corr corr ecti ng l o co co mo t i ve pr o bl ems t o keep t he l ocomot i ves on t he l i n e I t l i s t s som e of t he t r o uubb l e s whi ch m ay o c c u r al ong obab abll e c a u s e s and ong w t h mo s t pr ob c or o r r e c t i o ns ns whi ch w i l l r e s t o r e nor mal wor ki ng order ai d
The Th e i nf ormati on con contt ai ne nedd i n t h i s gui ea l s w t h those gui de d ea pr obl ems whi ch c oouul d be c or r e cctt eedd on t he road o r a t a t e r m n al a l w t h a mni m an d r e p aiai r equi pment umof t i me and
FI G XI I -1
C e r t a i n pr obl ems ar e r e l a t e d t o v i s ua ua l and a uudd i b l e war ni ng i n d i c a t i o n s recei ve vedd by t he op operat erat or Causes of s o me of t h e s e i n d i c a t i o n s a r e com m on operati operati ng f a i l u r e s nor mal t o op operati erati on of a road l ocomot i ve, yet e a s i l y overl overl ooked ooked
T U R O O M P R E S S O R E N D D ETA LS, C
These i n s t r u c t i o n s a r e i ntended ntended f or t he general gui dance dance a r e s t aatt eedd a s s i g n ne e d s u g g e s t e d c o or r r e c t i o n ns s pers onn onnel el Th of Thee b r i e f l y t o enabl e an expe experr i enced enced mai nt a i ner t o r a p i d l y scan t he l i s t s and pi npoi nt t he necessary c o r r e c t i o n f or a s p e c i f i c t r o uubb l e They ar e not i ntend ntended ed t o p r o v i d e an exh exhau austi sti ve t r eat ment of s a f e t y pr e ca caut i ons or procedures f or any i n d i v i d u a l expe experr i enced enced or i nexp nexperi eri enced enced,, w t h r e g a r d t o i n s t a l l a t i o n r emoval , operati operati on on,, mai nt enance or r e p ai ai r of t he equi pment I n a l l i n s t a n c eess l o ccaa l s a f e t y r u l e s sho shoul ul d
These c or or r ec t i on pro c eeddure s s hhooul d be pe perr f or med by q u a l i f i e d personnel ha havi vi ng a worki ng kno know w edge edge of t he o ve v e r a l l l ocom ocomot i ve s yst ems F a m l i a r i t y w t h t he nec eceessary te st equi pment r eq equi r eedd t o p e r f o r m t h e s e t e s t s and adj ust ment pr oced ocedur ur es i s a l s o necessary
These i n st st r u ct ct i o nnss do not pur por t t o cover al l det a i l s or v aarr i a t i o nnss i n equi pm ent nor t o pr ovi de f or ever y po s ssii b l e cont i ngency to be m et I n connect i on w t h I n s t al al l at i on, oper at i on or m at i on be d eess i r e d or shou ai nte nt enance Shoul d f u r t h e r i nf or m probl obl em s shoul d pa r t i c uull a r pr a r i s e wh ch ar e not cover ed s u f f i c i e n t l y f or t he p ur ur c h a s eerr s pu r p ooss e s , t he m at t er shoul d be r e f e r r e d t o t heGener al El e ct ct r i c Com pany
V e r i f y num number ber s f or p a r t s t o ol o l s or ma t e r i a l by u s i n g t he Renewal P a r t s or Tool Ca t a l o ggss or c o n t a c t your Gener al E l e c t r i c r e pr p r e s e nntt a t i v e f or a s s i s t a n c e Do not order f r o m t h i s publ i cati cati on
8- 78 5000
T
GENERAL
ELE LEC CT RI C
PR N TE D IN US A E
TRO U BLE- SH O O TI N G SEC -30150 TI O NXI I , GEK-3
TRO U BLE- SH O O TI N GG UD E
The f ooll l ow ng pr oced ocedur ur es a r e not a l l - c o n c l u s i v e and shou shoull d not be used as a s uubb s t i t uutt e f o r no norr mal r a i l r o a d t roubl roubl e- sh shoo oott i ng procedures These procedures ar e a g e n e r a l gui de d e t o be used i n a d d i t i o n t o t he nor no r mal r a i l r o a d ocedur ur es as a f u r t h e r ai d t o t he t roubl roubl e- sh shoo oott i ng pr oced mai nt ai ner ner I t sh shou oull d a l s o be noted t h a t an o ve ve r a l l v i s u al al procedure ure s not i nc l u de ded but s i nspe specti on and check proced
b
he c yl yl i nder v al a l v e covers and i n s ppee c t Rem em ove t he oken each c y l i n ddee r f or br oken oken or stuck v a l v e s , br oken rocker l e ve ve r s or push r oodd s , l o os o s e or m s s i ng v a al l v e k e e p e r s , l oo oose se l ocknu ocknuts ts t appe appett n u t s , l o o s e or any unusual con condi ti on t h a t m ay be e v i d e nntt
c
I f no nott hi ng i s f ou ound nd up t o t h i s p o i n t , open t he c y l i n ddee r r e l i e f v a l v e s an andd man anua uall l y bar t he eng ngii ne over t wo compl et e r e v o l u t i o n s Whi l e b a r r i n g
covered i n Secti on I I , I nspe nspecti ons ons and Checks .
o v e r , l o ok ok f o r wat er comng out of t he r e l i e f v a l v e s , l i s t e n f o r unusual n ooii s e s , and f e el el f o r ndi ng i n t he engi ne I f no nott hi ng i s observed any bi ndi up t o t h i s p o i n t , c l o s e t he c y l i n ddee r r e l i e f v a l v e s and c a r e f u l l y t r y t o crank t he engi ne Do not t r y t o hel p t he eng ngii ne t o s t a r t by movi ng t he l a ys y s h aaff t
PR ELI MN A RY C H EC K EN GN E SH U T D O W N
W hen a uni t i s s i t t i n g on t he i nco nco mng t r a c k r eady t o be br ough oughtt i n t o t he shop, check t he f ol l owi ng
1 Al l a va va i l a blbl e e ng ng i n ee e e r s r e ppoo r t s f o r t r o ub ub l e
N O TE f an engi n ne e
2 Check l i n e - o f - r o a d r e p o r t s f o r reported t r o ub ub l e s
1
L uubb ee-- o i l pum e a r i n g hou ousi si ng f o r s i g ns ns of p b ea heat
2)
Oi l i n t he crankcase f o r v i s c o s i t y out of l i m t s
3)
Wat er l e vvee l i n t he s i g h t g l a s s on t he wat er tank
4)
Fuel p r e s s u r e by s t a r t i n g f u e l pum p
To avoi d r unni ng t he b a t t ery down,
I f t he eng ngii ne s shut down on a r r i v a l , check t he ys , Annunci nnunci ator Panel and t he t wo hol di ng r e l a ys Engi Engi ne Tem Temper perat at ur e Hol di ng Rel ay ETH THR) and Gover over nor Sh Shut ut Down Ho l di ng Rel ay GSDHR) , f o r t i n d i c a t o r l i g h t s and c h he ec k a l l s a f e t y s hu hutt dow downn d e vvii c e s Cl os e the the b a t t e r y swi swi t ch i f t s open I f any i n d i c a t o r l i g h t s a r e t or s a f e t y s hu hutt dow downn d e vvii c e s a r e f ou ound nd t r i p p eedd , determne t he reason and c o r r e c t I f no l i g h t s a r e t and none of t h he e d ev e v i c e s a r e f ou ound nd t r i p ppee d, d, m ake a t hor ou ough gh crankcase i nsp spe ecti on i n a l l doors l oo ki ki ng f o r d r i p p i n g wat er , broken c y l i n de de r s k i r t s , scored l i n e r s , t r a c e s of f i n e me t aall l i c p a r t i c l e s on i n t e r n aall s u r f a c e s and l edg dge es of t he ns of heat on any of t he crankcase or s i g ns he mai n or beaar i ng caps I f any of t h e s e cond condii ti on onss ar e r od be f ound ound,, not onl y the p a i r s on t h e s e the appr o pprr i ate r e pa i t em em m ay be n e c e s s a r y , t w i l l a l s o r e q u i r e che checki ng i t e em m such as t he f ol o l l ow ng :
wat er
11- 13 hi l e c ra n ki ki n g, g, i t pr obabl y i s not goi ng t o
do not co con nt i nue cranki ng t he engi engi ne I f per mt t ed by r aaii l r o ad ad rul es, pul l t he racks on t wo ( o nnll y ) i n j ec t i o n pum ps ack whi l e cranki ng f th the e engi ne s t i l l out t o f ul u l l r ack
Then go t o t he u nini t a
does not f i r e w thi thi n s i x t y
seconds and f uel pum p racks do not com e out t o
start
3 Check past work or k r e p o r t s on t he u nini t f o r r e p e a t s
manu anual al l y
and/ and/ or
does not start, l ea ve proceed oceed t o i n ve ves t i g at at e ve i t dead andpr t he po ss ss i b l e cause
abll e X I I - I l i s t s t he mo s t com 5 Tab m on c a u s e s of engi ne cranki cran ki ng pr ob obll ems and eng ngii ne shut down down pr obl ems Tab abll e X I I - I I p r e s e n t s a mor e d e t a i l e d l i s t i n g of eng ngii ne c ompo ponent nent mal f un unct ct i ons, e l e c t r i c ala l mal f unct unct i ons ons and l oc ocom omoti ve syste system ms mal f un unct ct i ons i n c l u d i n g s o me nl y occurrences I t sh one t i me o nl shou oull d be not ed t h a t i n som e c a s e s i n Tab abll e X I I - I I , mor e t han one s h u t down d ev e v i c e i s shown as be beii ng a c t i v at at e d f o r a p a r t i c ul u l a r cause Al t hou ough gh t wo d e vvii c e s m ay be a c t i v a t e d , on onll y one s r equ quii r ed f o r engi ngi ne shut dow downn A l s o , t shou shoull d be not ed t h a t t he POSSI BLE CAUSE
Tbab abl l e X I I - I l i s t s tthehe f icras ut s ce as u si en l descendi de scendi ng co l um or de der r nof i pnr oob abi l i t y Thus, i s t e d i s t he mo s t pr obab obabll e cause of t he pr obl obl emand t he l a s t cause as t proba l i s t e d i s t he l e as probabl bl e cause PR ELI MN A RY C H EC K ENGI N E RU N NN G
I f t he l oco ngii ne runni runni ng a t i d l e , ocom moti ve a r r i v e s wi t h t he eng check t h e f ooll l ow ng
Oper per at or s Cab
Engi Engi ne l u b e - o i l p r e s s u r e sh shou oull d be 20 ps i ( m ni mum
2 F u e l - o i l p r e s s u r e shou shoull d be 40 ps i ( m ni mum
XII-3
NX11, TRO GEK- 30150 SECTI O U BLE SH O O TI N G
T BLEX I I - I , ENGI NE TRO U BLES
Probll em Prob
Corr ect i on
P ooss s i b l e Cause
O N T START ENGI NE W Fuel pum p won t r un
GSD SD HR s t ri pped CO P i s t ri ppe pped
Shut Shut down down s i g na na l has been sent t o
engi ngi ne
Engi Engi ne won t crank cont a c t o r s do donn t ope perat rat e)
Fuel pum p i s not ope perat rat i ng B a r r i n g Over Sw t c h BOS) i s open
Engi Engi ne won t crank cont a c t o r s op operat erat e)
S t a r t c i r c u i t i s mal f unc nctt i oni ng
En Engi gi ne won t s t a r t govemor gap i s g r e a t e r t han
St op s i g na na l i s bei ng sent t o governor
1 i n
engi ne s hut down down de One or mor e engi v i c eess t ri ppe pped
En Engi gi ne won t s t a r t govapproxi mat el y ernor gap i s approxi 3/ 4 i n rack s e t t i n g i s l e s s t han 10 nun)
Engi Engi ne won t s t a r t governor gap i s app apprr oxi oxi mat el y 3/ 4 i n ; rack s e t t i n g i s 11 t o 13 m m
unct ct i on Ove vers rs pee peed systemmal f un
M s -a dj dj us te tedd overspeed gove goverr nor Fuel sup probll emw t h f u e l suppl pl y l ow, prob l i n e or very l ow f u e l p r e s s u r e
Ti m n g i s i n ccoo r r e cctt Cranki ng speed speed i s t oo sl ow
Reset a f t e r a n a l y s i s of f a u l t Reset a f t e r a na na l y s i s of f a u l t s ee Crankcase Overver Shut Shut dow downn Devi ces pCheck r e s s u r ael lt rot i p he p erd dunder En her ev e v i c e sEngi i ngiclne udi ng con contacts on Emer genc y f u e l s h u t - o f f and and Eng ngii ne St op push-- but t on push onss Reset a f t e r a n a l y s i s of f a u l t Repl epl ace cover on b a r r i n g over d r i v e or connect c a bl bl e Check brus hes and c ommut at or s i n a u x i l i a r y generat generat or and e x c i t e r ; check c a bbll e s and s t a r t c i r c u i t Al so, so, check f or 74 vdc battery v o l t age
Move T h r o t t l e handl andl e f r o m SHUTDO W Nt o
ID LE p o s i t i o n t o c l e a r stop s i g na na l t o t he governor speed sol sol enoi noi d DV DV)) Det erm ne whi ch d ev ev i c e s i s t ri pp ppe ed and t he cause See Engi Engi ne Sh Shut ut down down Devi ces ppe ed Check overspeed governor Reset i f t ri pp crankii ng Pressure ou outt put p r e s s u r e du duri ri ng crank sh sho oul d no nott be l e s s t han 95 ps i f p r e s s u r e i s and// or l e s s t han 95 p s i , r e p l a c e overspeed l i n k and go gover ver nor r e g u l a t i n g v ala l v e overr speed speed go governor vernor Adj ust ove Check f u e l sup suppl pl y and f u e l l i n e I f needed, add f u e l Deter m ne and c o r r e c t t he cau cause of l ow f u e l p r e s s u r e Reset t i m n g conndi t i on Check battery co
ENGI NE SHUTDO W ND EVI CES LowOi l P r e s s u r e LO LOP t ri pped Thi Thi s i s an aauut o-
ve l Lowoi l l e ve Di r t y oi l f i l t e r s
Add oi l Repl ace f i l t e r s
mat i c r e se t
n-back ck v a l v e Open f i l t e r tank drai n-ba
al v e Cl ose v al
H Rw l l NO TE GSD a l s o be t r i p ppe ed Reset a ft er a na na l ys i s of
f a ul t
C) Di r ty t u bbee - o i l c o ooll e r oi l s i d e D i r t i n crankcase oi l s t r a i n e r or l oose cover Fauul t y t u bbee - o i l r e l i e f v aall v e Fa Di r ty f u e l f i l t e r or s t r a i n e r p F a i l e d s l i p p i n g bonded pum drive Hot o i l because of l ow v i s c o s i t y F a i l e d oi l pum p
XII-4
Repl ace coo cool er t ube bundl undl e Repl ace s t r a i n e r s e c u r e cover Repl epl ace v aall v e Repl epl ace f i l t e r o r s t r ai a i n er er Repl epl ace bonded pum p drive
Det erm ne and c o r r e c t t he cau cause of l ow v i s c ooss d be - o i l i t y such a s d i r t y o i l f i l t eerr s i r t y t u be c oo o o l e r s , and d i r t crankcase o i l s t r a i n e r Repl epl ace o i l pum exam m ne engi p Al so, so, exa engi ne b e a r ousi ngs f or s i g ns i ng caps and housi ns of e x ccee s s i v e heat ; i n v e s t i g a t e and c o r r e c t cause
TRO UBLE LE SHO O TI NG SECTI O NX I I , G EK 30 01 15 50 0
T
Probll em Prob
LEXI I
Cont d - I Cont
Corr ect i on
P ooss s i b l e Cause
engi gi ne beari ngs Exce Excessi ssi ve vell y wor n en
W or n governor d r i v e gear
b e aarr i n ggss Wong d i p s t i c k
LWP) LowWat er P r e s s u r e LW t r i p p e d Thi Thi s i s an au autotomat i c r e se t
box s h a f t
Repl ac ace e w th prop proper d i p s t i c k and recheck oi l l e ve ve l
her , oi l i n t he deadDuri ng co coll d weat her, gove vern rno or s l ow l u b ee-end end pipe to the go o i l p r e s s uurr e d e v i c e bec omes very
Modi odi f y t he deaddead- end end pi pi ng t o bypass See GEMS Vol um e V, I s s u e 2 dat ed Sept 30 , 1977
B o i l i n g wat er at pum p inlet
Repl epl ace di aph aphrr agm cool i ng Add wat er A l s oo,, i n s ppee c t l ocom ocomoti ve coo ak s Rem em ber t h a t t he r a d i a t o r s system f or l e ak nl e s s enerr al E l e c t r i c l oco on Gene ocom moti ves ar e dry u nl t he wat er t emperat ur send ure e i s hi gh enough to sen unni ng) wat er t o t he r a d i a t o r s w th engi ne r unn w at er l e ak ak s I nspect spect t he crankcase f or c y l i n d er er check f or wat er i n o i l ve l or mal f un unct ct i oni ng Check f or l ow wat er l e ve
thick aphr ag agm m i n governor Def ecti ve di aphr ve l Lowwat er l e ve
Cool i ng systemno nott pressuri pressuri zed
cooll er wat er s i d e D i r t y l u b e - o i l coo L u bbee - o i l coo cooll er wat er i n l e t s c r e e n i s pl ugg ugged ed D i r t y f u e l f i l t e r or s t r a i n e r p F ai ai l e d s l i p p i n g bonded pum drive De f e c t i v e di aph aphrr agmi n t he governor p r e s s u r e s w t c h
Crankcase Overpressure
ence ce Duri ng crankcase i nspecti specti on l ook f or evi den l l crankcase l e d g ge e s C a r eof beari ng met al on f u l l y i n s pe pe c t beari ng cap capss f or s i g ns ns of d i s t r e s s Repl epl ace b e aarr i n ggss
Oi l l e ve ve l t oo hi gh
ppe ed COP) tr i pp
t hermost at p eell l e t Examne t he i l l cap f or a good g a s k e t , good pp l i c at at i o n e, and f or proper a pp i t t o t he i l l p i p e, of t he he i l l cap A l s o , check f or cracked wat er tank or s i g hhtt g l a s s Repl ace c o ol ol e r tube bund bundll e em em ove d eb eb r i s and cl ean s c r e e n Repl ace f i l t r or s t r a i n e r Repl ace bonded pum p drive
Check f or wat er l e a kkaa g e t t he l ow wat er p r e s s u r e s w t c h on t he governor r e p l a c e di aph aphrr agm P u l l t he d i p s t i c k and and che check ck f or o i l l e vvee l bei ng to oo o hi gh Perf orm t e s t t o check f or presence of wat er i n crankcase
Cyl i nder bl ow by
Pl ugg ugged ed or i n v eerr t e d crankcase breather s c r e e n CO P s w t c h out of c a l i b r a t i o n Def ecti ve sw tch
ay be caused by Excess l e ve ve l i n crankcase m ak i n g wat er ake crankcase c y l i n d er er s e alal s l e ak ppii ng f r o m i nspe specti cti on t o l ook f or wat er dri pp e i t h e r t he i n s i d e of t he c y l i n ddee r bore t op seal l e ak ak or f r o m t he bottom o uutt s i d e p a r t of t he c y l i n d er er s k i r t l ower l i n e r seal l e ak ak Perf orm bl ow by t es e s t t o d e t e c t d ef ef e ct ct i v e c y l c om popo d e f e c t i v e i n ddee r or p i s t o n r e p l a c e nent s Cl ea ean n s c r e e n ; check f or proper i n s t a l l a t i o n Recal i brate s w t c h Repl epl ace s w t c h XI I - 5
GEK-3 30150
O U B LE SH O O TI N G SEC TI O NXI 1, TR
T B LE XI
Pro bl bl em
I - 1 Cont d. )
P os o s s i b l e Cause
Cor recti on
OTHER ENG NE TROUBLES Hot en engi gi ne Seve vere re coo cool i ng wat er systemrel ated ated probll em prob
Check coo cool i ng wat er system s ee i t ems l i s t e d under LowWat er P r e s s u r e LLW WP ) Tri pp pped ed ound nd w t h th e c oo no f a u l t i s f ou ool i ng wat er syst em t e s t s t he LOTS s w t c h I t m ay not be i nbe - o i l t emper per at ure has d i c at at i n g t h aatt a hi gh l u be occurred Check t h a t f an i s r unn unni ng On a General ener al E l e c unss whi l e th e t r i c l oco ocom moti ve, ve, t hhee f a n al ways r un unni ng en engi gi ne i s r unn Cl ea ean n r a di di a t o r s Cl ea ean n screens Rep epll ace coo cooll er tube bun bundl e norr l i n k pi n and check c o n t r o l Rem ove gover no l i n kkaa g e f or bi ndi ng Rep epll ace over ver speed speed gover ver nor , or r es e s et i n pl a c e shoul ul d be s et f o r 1150 on en engi gi ne Over speed sho en engi gi ne r pm 1708 r pmat tach d r i v e) e) Reset r a c k s or reduce l i n kkaa g e bi ndi ng If
F ai ai l e d f an d r i v e
O// S) En Enggi ne Over ver speed speed O
t r i pped
Di r t y r a ddii a t o r a i r passages Pl ugge uggedd a i r i n l e t s c r e e n s Di r t y l u b e - o i l coo cooll er ei e i t h eerr s i de d e) St uck c o n t r o l rack l i n ka k a ge ge
De f e c t i v e overspeed gover no norr o r s et
t oo l ow
p r a ck cks s t uc uc k I n j e c t i o n f u e l pum
open
De f e c t i v e en engi gi ne gover governo norr No f u e l Di r t y f u e l s t r a i n e r Suc uctt i on l eak i n l i ne ne Di r t y f u e l f i l t e r Def ect i ve f u e l t r a n s f e r pum p mot or Reg egul ul ati ng v al al v e s et t oo l ow Rel i ef s aaff e t yy)) v alal v e l e aakk s Rel i ef s aaff e t yy)) v alal v e s et t oo l ow Def ecti ve nozzl e
Lowf u e l p r e s s u r e
governo norr Rep epll ace gover Check f ue ankk add f u e l u e l i n t an Cl ea ean n str ainer Locate l e ak ak and r e p aiai r Cl ea ean n filter Rep epll ace mot or al v e t o 40 ps i Reset v al Rep epll ace v al al v e Reset v al al v e t o 75 ps i P o p - t e s t each c y l i n ddee r t o check f o r weak and/ or not f i r i n g c y l i n ddee r Repai r or r e p l a c e noz
Fuel d i l u t i o n
zl e
Rep epll ace f u e l pum p Rep epll ace t hermost at Cl ea ean n o r i f i c es i n p i l o t
Def ect i ve f u e l i n j e c t i o n pum p Col d en engi gi ne
valve
3 Al l c i r c u i t b r e a k e r s on Engi ontt r ol Pa Pan nel cl osed sed o r Engi ne Con ON
9 Power L i m t 7t h Not ch) OPERATI ONp o si si t i o n
4 No i n d i c a t i n g l i g h t s
10 Rever Rever se han handl dl e i n NEUTRAL p o s i t i o n
l t or
a l ar m b e l l s r i n g i n g
Battery s w t c h cl osed
11
6 Ope perr at or s c o n t r o l con consol sol e sw t che ches s e t - u p f o r pr oper oper ope perr ati on
perr ati on 7 Ai r br a ke kes s e t - u p f o r proper ope 8 Al l a i r p r e s s u r e gages at nor mal
XI I - 6
Swtch i n
N O R ML
Gener ener at or F i e l d s w t c h i n OFF p o s i t i o n
12 Pop-test l l c y l i n ddee r s , and l i s t e n c a r e f u l l y f or any unusual n o i s e s com ng f r o m t he engi ne
Engi ne
R o o m
ak s S i d es es of en engi gi ne f or f u e l , o i l o r wat er l e ak
TRO UBLE SHO O TI NG SECTI O NXI G EK 30 01 15 50 0
TABLE X11-11,
S U M MR Y CAUSES FO REN G NE SH U TD O W N
Low Oi l Pressure
Cause
Item
LOP)
Low Wat er Pressure
LLW WP)
Resul esul t Crankcase Engi Engi ne Over Ove r Speed Pressure COP) O/ O/ S)
Fuel
Pr obl em F uuee l
one
EN GN E oi l
2 3 4 5 6 7 8 9 10 11 12 13
14
15
16 17
18
19
20
21
22 23 24 25
26
27
28 29 30 31
32
33
34
35
l erviel eng l / bea L F aoi w l e d bear ea ng/ earr i ng ngss Lu Lub be- oi l pum pfailed Over s peed governor l ow out put p r e s s u r e Over s peed l i n k f a i l e d aphragm f a i l e d Lowo i l di aphragm Lowwat er di aph aphr agmf a i l e d engi en gi ne Low speeds St uck r a c k s Def ec t i ve l oad pot ka ge ge Engi Engi ne bog due t o s t i c k y f u e l l i n ka Lowl u b e - o i l v i s c o s i t y f u e l d i l u t i o n BondedBonded- r ubb ubber er pum p d r i v e sheared Pi pe pl ug m s s i n g f r o m c av av i t y i n t o op p of f o r war d- end cover Pl ugged ugged crankcase br eat her her b r eat her he r screen i nve vert rt ed l a r g e Crankcase mesh up) Br oken crankcase educt educt or Hi gh o i l l e v elel Wat er pum pfailed Wench on l a yyss h af af t gover er nor d r i v e F ai ai l ed gov Faul Faul t y go gove verr no norr Engi Engi ne ove overr speed t r u e over over speed speed)) F al a l s e eng engii ne overspeed cover o r adj ust ment screw l o ooss e F u e l - i n j e c t i o n pum ge p rack or f u e l l i n kkaa ge stuck overr speed governor F au aul t y ove F ai ai l ed t ur boch ochar ar ger
X X X X X X
X
X
Pl ugged ugged i n t e r c o o l e r s I n l e t po porr t car bon Cracked p i s t o n St uck r i n g s or s c ore ore d l i n e r s Dr y pi st on r i n g s a f t e r ext end ended ed s hut down) Cracked p i s t o n cr own ong pi st on r i n g s a pp pp l i e d Cyl i nd nder er wat er l e ak ak s i n t o crankcase c a uuss i n g el t o be t oo hi gh) oi l l e v el
X X
X X
X X X X X X
X X X X X X X
X
X
X
X X
X X X
X X
X
X
X
X X
X
X
X X
X X X
X
X
X
ELECTR CAL
Dynam c braki ng f o r l ong peri od and at hi gh
2
ambi ent t emper per at ur e Engi Engi ne won t crank F au aul t y CO Pswtch
X X
X XII- 7
UBLE SHOOTI NG NX11, TRO GEK 3 30 0150 SECTI O
T
LEX I I -
II C Cont ont d
Low
Oi l P r eess s u r e
Cause
Item
LOP)
Low Wat er P r es es s u r e
LLW WP)
Resul esul t Engi ne Cr ankcase ankcase Engi Ov er Over Pressure Speed COP) O O// S)
F uel
Pr obl em Fuel Fuel )
None
Cont d ELECTR CAL Cont 4 5 6 7 8
9 10 11 12
GSDHRtr i pped
c h or ENGI NE I ntermt tent tent f u e l c u t - o f f s w t ch STOPp P push- butt on down on t h r o t t l e Emer gency s hut dow ENGI NE STOP push- butt on has been pressed Excessi xcessi ve e x c i t a t i o n Cont r ol gr ou oun nds ns i e nntt s Tran Transi ti on t r a ns Fuel pum p r e l a y c oioi l f a i l e d pmot or f a i l e d Fuel pum
X X X
X X X X
X
X X
X
X
X
X
LOCO M OTI VE SYS YSTE EM M S
3
5 6 7
8 9 10 11 12 13
14
15
16 17 18 19 20
21
22 23 24 25 26 27
XII-8
Bl ocke ocked d o i l pan s t r a i n er er pan s t r a i n e r or d eeff e cctt i v e cover Cover of f oi l
X
a l v e C) open F i l tgasket e r dr ai n- back v al l u b e o i l cool coo l er oi l s i d e Pl ugged ugged coool er water s i d e Pl ug ugged ged l u b e - ooii l co Lowwat er l e v elel Water - t ank ank f i l l cap m s s i ng or l o ooss e i t or d e f -
X X
ec t i v e ef e cctt i v e b a f f l e or s p l i t Wat er s t o r a g e tank d ef ocked ed s c r e e n s , cracks i n tank t e r , bl ock Wat er l eak eak Hot wat er c a u s e s hot a nd l ow v i s c o s i t y o i l e- o i l v al R e l i e f l u b ea l v e s et t oo l ow f u e l f i l t er Pl ug ugged ged Pl ug ugged ged en engi gi ne ai r f i l t e r s v e l t oo hi gh Lu Lub be- oi l l e ve Wong l u b e-e- o i l d i p s t i c k Bl ocked breather pi pe at t he exhaust stack Ai r bl ow down at l ub ee-- o i l i l t r change) etween O/ S gover gover no norr and l i n k Leak i n oi l l i n e between
Fuel tank em pt y Lowor no f u e l p r e s s u r e eakag agee i n f u e l sucti sucti on l i n e or i n seal E xxcc e s s i v e l eak p of f u e l t r a n s f e r pum r a i n er er , o r waxed- up I c e i n f u e l tank or f u e l s t ra
f u e l s t r a i ne r Pl ugged ugged l u b e - o i l f i l t e r Wong exhaust stack Br oken oi l pi pe Hot oi l coool i ng d i r t y r ad a d i a t or or , Lowor no r a d i a t o r co opped ped,, et c f an st op
X X
X X
X
X
X X
X
X X
X X X X
X
X X X
X
X
X X
X
X
X X
X
X X
X X
X
- 30150 TRO UBLE- SHOOTI NG SECTI ONX11, GEK-3
r pm A l s o , a s s u r e r pma t I DLE i s c o r r e c t See Not e
v e l a t or near f u l l mar k) 2 Oi l l e ve
3 Wat er t emperat ur e gage 150 t o 170 F)
apprr oxi mat el y 170 F , 4 The wat er s i gghh t l e v e l g l a s s a t app water shou shoull d be near H GHa t I DLE mar k) 5 Wat er pum p f o r s e a l l ea eakk check f o r wat er d r i p onto pl at f or m 6 Wat er f i l l p r e s s u r e cap i s i n p l a c e 7 Ai r compr es sor f o r o i l l e a k s
be bell ow
NOTE
cause r oad shut dow n r p m w hen r e t u r n i n g t o I D LE Corr orr ect speed i s 450 t ach dr i v e i s 668 r pm
10 Assure v o l t a ggee r e g u l a t oorr 74 74 v ddcc a t I DLE)
8 The r a d i a t o r f a n i s turni ng
PREL ELII MNARY CH LD W EC K CO EA TH ER
The f o l l ow ng c hec ks ks sh shou oull d be per f or med t o hel p p r e coll d we at at h hee r t r o u b l e and an d p o s s i b l e road shut down down vent co These ch checks ecks a r e i n addi t i on t o t h e nor mal r a i l r o a d checks ol d weat her s e r v i c e and procedures f o r c ol Assure t h e r e a r e no br eaks eaks i n t h e t r a c t i o n mot or a i r ducts t h a t woul d permt moi st ure t o ent e r 2 Assure t h e r e a r e no br eaks i n t h e s e a l s on th thee co conntr ol c ompar t ment en t doors t h a t woul d permt moi st ure t o enter 3 Assure wi nt er / summer doors a r e i n proper p o s i t i o n
Assure f u e l heat er i f i n s t a l l e d
i s op opeerati ng prop ropeerl y
5 Assu ssurr e prop roper er o i l f o r c ol ol d weat her s e r v i c e i s used i n goverr nor 5W t he gove 5W 30 or I OW 30 dep dependi endi ng on r a i l r o a d c ol ol d weat her s e r v i c e r equi equi r ement)
6 Assure f u e l f i l t e r s a r e cl ea eann 7 Assure f u e l s t r a i n e r i s cl ea eann
NOTE :
The f uel oi l p r es s u r e gage m ust i ndi c aatt e 25 ps i m ni m um i n Notch ot ch 8 w hen checked on s el el f - l o a d or t he Load Box I f not, r echeck c l e aann l i n es es s of f uel f i l t e r s and s t r a i n e r
8 Assure sh shou oull d occurs, replace
hor sepower sepower i s pr ope operr f o r each notch Ther e be no eng engii ne bo bogg ggii ng f governor modu odull at i on check l u b e - o i l f i l t e r s f o r c l e a n l i n e s s I f d i r t yy,, f i l t e r s I f hor sepower sepower i s l ow, ow, check eng engii ne
ondi ti o n and i s f u l l y i s i n good c on
9 Assure b a t t e r y charged
11
9 Dynam c brak brakii ng g r i d s f o r burned or open ri bbon bbonss and an d br oke okenn i n s u l a t o r s or b a r r i e r s
Lowi d l e speed w l l
is
operl erl y operati operati ng pr op
I f permtted by r a i l r o a d r u l e s , add a l c o h ooll t o f u e l tank t o pr eevvent f r e e z i n g u s ua u a l l y one g a l l o n of al co coh hol per 1000 g a l l o n s of f u e l
outt s t a r t i n g , check t h e 12 I f engi ne c r aannks w t hou overspeed l i n k The overs pee peedd governor p r e s s u r e becc omes f u l l y m ay reach 200 ps i I f t h e l i n k be compr es sed a t a g r e a t e r ps i t han 120 or does not f u l l y compr ess , r e p l a c e t h e overspeed l i n k I f t h e p r e s s u r e i s l e s s than 95 p s i , r e p l a c e overs pee peedd governor r e g u l a t i n g v a l v e wt t hout cra anki ng w NOTE: O l p r es s u r e dur i ng cr si st ) shoul d not be l e ss ss t ha han n 95 psi or m anua all ra c k a sssi l e s s t han 175 ps i w hen engi ne r ea each ches es I D LEspeed A n oi l p r es s u r e of 200 ps i , or hi gh gher, er, i s consi der ed
See GE M S
st stan andar d
Vol um eIII,
I s s uuee dat date ed
Dece cem be err 10, 1974
NOTE
If
t he
equi pm ent
has
been pr oper l y
m ai nt ai ned and t he above 12 s t e p s have been an s ta r t f rom romt he per f or orm m ed s at at i s f a cctt o r i l y, a s i n g l e m
o p e r a t o r s cab cab w l l be po ss ss i b l e
ENG NE RU NC H EC K
After t h e P r el el i m na nar y Check s) have been compl et ed and i f everyt everyt hi ng appears t o be nor no r mal up t o t h i s p o i n t , proceed w t h t h e f ol o l l ow ng l
Run t h hee engi ne up t o t h hee ei ght h T h r o t t l e no nott c h no an and d read a l l s e t t i n g s Return l oa oad) d) g a g e s f o r nor mal th hee Thr o t t l e hand andll e t o I DLE
2 I f everyt everyt hi ng s t i l l appear appear s t o be nor mal , s e t l ocomoti ve b r a kkee s , s et e t - u p f o r pow power er , open t h r o t t l e t o Not ch and check t h a t l oadmet er r e a d s up s c a l e t o nor mal Not ch c u r r e n t approxi approxi mat el y 300 a mp s Return t h e T h r o t t l e hand andll e t o I DLE I f r eason easonab abll y s u r e t h a t t h e r e a r e no mal f un unct ct i ons ons w t h t h e e n ggii n e , pr oocc e ed w t h t h e e l e c t r i c a l an andd l ocomoti ve
system checks
XII- 9
E C T O N G E K 3 0 1 5 0S
T R O U L E S H O O T N G
T
LEX I I
M O K E N EX HU S TS
Corr ecti on
One or mor e d efef e cctt i v e i n j e c t o r s
Reco econd ndii t i on or change t he d ef ef e c t i v e i n j e c -
Fuel pum p rack i s st uck Fuel pum p rack s s et t oo hi gh Fuel pum p i s out of t i me bocharr ger W or n or damag ed t ur bocha Broken or l ea eak ki ng mani ani f ol d pi pe pess boggi ng down Engi Engi ne speed i s boggi
Adj us t t i m nngg Repai r or r e ppll a ccee t he t ur bocharger bocharger Repai r or r e ppll a ccee t he man anii f ol d Check t he engi and d c i r c u i t s f or engi ne ope perat rat i on an
Turbocharger s s uurr g i n g
ok e puffs Whi t e s moke
an d oi l Bl ue s mok okee exhaust and
St ead eadyy sm ok ky y exhaust s t r eam Wat er ou outt of stack Bl ow i n exhaust system
LO D N G
UN T
Turbocharger rotor s st uck Fuel pum p i s ou outt of t i me Cyl i nder nder w t h v al al v es es burned or st uck open Engi Engi ne i s t oo c ol ol d Cyl i nder nder w t h l ow compr essi on Fuel system s a i r bound F ai a i l e d t ur bo bocharger charger b eeaa r i n g s and s e aall s gs W or n or broken p i s t o n r i n gs Cracked p i s t o n crown
out t he he s t a ck ck
O R SELF
LYSI S
P o ssss i b l e Cause
I ndi cati cati on
ok e puffs Bl ack s moke
- 1 1 1, 1,
t or Free t he rack or change t he pum p ad j u s t Locate t he hi gh rack and r e ad
f a ul ul t I n l e t p o r t s p a r t i a l l y bl ock ocked ed or turbo m sand d diffuser ass embl ed che check ck nozzl e r i n g an Cl ean i n l e t p o r t s , i f d i r t y
Repl ace t ur bocharger bocharger Ad Adjj ust t i m n g Repl ace c y l i n ddee r
arm up Wai t u nntt i l engi engi ne warm Repl ace c y l i n ddee r Bl eed eed t he f u e l sys systt em bocharger Repl ace t ur bocharger gs Repl ace r i n gs and d rings Repl ace p i s t o n an Repl ace c y l i n ddee r and r i n gs gs an and d Load engi engi ne con condi t i on sho shou ul d c l e a r - u p
Scored l i n e r engi ne at perat rat i on of t he engi Prol ong ong ope ID LE W or n or l e aakk i n g i n j e c t o r s L a t e pum p t i m n g on a l l c y l i n ddee r s Cyl i nder nder seal l e ak ak s , cracked t ur bo bo,, et c Broken exhaust man anii f ol d s e c t i o n
Change t he i n j e c t o r s ps Ti me t he engi engi ne pum Loc Loc aatt e a nd nd c o r r e c t Repai r or r eepp l a c e t hhee mani f ol d or mani f ol d
Val ve t appet appet c l e ar a r a nc nc e i s i n s u f f i c i e n t Cyl i nder nder v alal v e i s st uck open Cyl i nder nder v alal v e s eeaa t i s gu gutt t ered
s ec ec t i o n Readj ust Repl ace c y l i n ddee r Repl ace c y l i n ddee r
3 Sm oke f r o m s t a c k Ta Tabl bl e X I I - I I I
LO D CH EC K
as s umed l l control control s and d e vvii c e s ar e pro propperl y s et and an i nspec t i on of i t ems such as wat er l ev elel , o i l l e v e l s and battery v ol o l t a ge ge , have been per f ormed It is
NO TE For det ai l ed i ns t r uc uc t i ons , Secti on X of t h i s com posi t e m anual al
r efer
to
4 Sound f r o m engi engi ne such a s heavy pound, r a p , knock or c l a t t e r au au d i b l e i n d i c at a t o r s of t r o uubb l e 5 P o p - t e st and d observe exhaust s t c yyll i n de de r s an Ta Tabl bl e X I I - I I I
ok e f or s moke
an d check S t a r t e n ggii n e, e, r un at I D LEand 25- 35 ps i w t h wat er at nor mal p r e s s u r e 25t emperat ur e)
1 L uubb ee- o i l
2 Fuel p r e s s u r e aapproxi pproxi mat el y 40 p s i XII- 0
age r e g ul 6 Vol t age ul a t o r v olol t s 73 . 5 - 7 4 . 5 vdc)
and d o i l l e ak 7 Wat er , f u e l an ak s ve l and c l e an an l i n eess s 8 Gover nor o i l f or proper l e ve
9 Rack r e a ddii n g s of f uuee l i n j e cctt or o r pum ps
T R O U B L E S H O O TN G S E C TO NXI
Sl ow y m ove T h r o t t l e hand handll e t o Not ch 8 and check L uubb ee- o i l p r e s s u r e 90- 11 1155 p s i , or hi gher i f o i l i s col col d)
Fuel p r e s s u r e 2525- 36 p s i
Tur bo a i r p r e s s u r e 203 Tur 20- 32 ps i ; p r e s s u r e w i l l vary w t h atmospher ospher i c p r e s s u r e and t emper per atur e) 170- 180 F) Wat er t emperat ure 1705
Engi Engi ne a i r f i l t e r s e r v i c e i n d i c a t o r not tr i pped
6 Br ake c y l i n de de r p r e s ssuu r e 45 ps i mni m um 7 Cycl ycl i ng of
a i r compr ess or
8 Exhaust s mok okee Ta Tab bl e X I I - I I I 9 Ai r f l o w out of r a d i a t o r s no d eb eb r i s or d i r t i n a i r passages 10 Ai r man anii f ol d l e a ks k s i n c l u di d i n g turbo el bo bow ws 11 Exhaust man ak s anii f ol d l e ak
12 Wat er tank s i gh g h t g l a ssss f or t r a c e s of o i l or car bon 13 Gover nor l oad pot p o s i t i o n a t m ax xii m um i e l d 14 Power Power , v o l t a g e and current f r o m CHEC Panel te st poi nt s t o check l oad adii ng and e x c i t a t i o n
Move T h r o t t l e hand handll e t o I DLE, then m ove i t t o Not ch 8 and observe Exhaust s mok okee TTab abll e X I I - I I I 2 Ti me r equ quii red f or f u l l hor sepow sepower er 3 Engi hunti nti ng ng)) Engi ne speed s t a b i l i t y hu 1
I, G EK-3 - 30150
no i d s a r e operati ng prope 2 Check t h a t gover nor s o l e no roperl y
3 Check t h a t gover nor pl ug i s pr operl y s e a t e d I f the the engi ne r espon esponded ded t o t he he t h r o t t l e but but no l o a d, d, shut t he engi engi ne down and check
E x c i t e r br ushes
2 Al ter na nator tor s l i p r i n g b r u s h e s , or g e n e r a t o r br ushes
Control a i r p r e s s u r e
Contactor and r e l a y sequence 5 Assure Gener at or F i e l d , b r e a k e r s a r e cl osed osed
Control
and Exci tati on
ank t he engi ne and, under no l oad cond Then cr ank condii ti on, on,
check t he output f r o m t he a l t e r n a t o r / r e c t i f i e r c i r c u i t G A and G N i r e s w t h the the engi ne a t I DLE and a t Not ch 1 thru Not ch 8 p os os i t i o nnss
NO TE Ref er
t o t he R e c t i f i e r s , E x c i t e r , and Al ternator ternator s e c t i o n s of t he a p p l i c a b l e l oc ocom omoti ve schemati c f or l o c a t i o n of te st poi nts t o meas ur e G AI G Nv ol o l t a g e A 1500 vdc met er i s needed f or t h i s d, w i l l v a r y te st Vol tage r e a d i n ggss at Not ch no l o a d, from1200 vdc t o 1500 vdc dep depend endii ng on model of es t i n g, g, Secti Secti on XI , f or l oc ocom omoti ve Ref er t o Load T es v o l t a g eess f or each model of l oc ocom omoti ve Exci tati on panel cards
Move T h r o t t l e hand engi ne handll e t o I DLE and then per for m engi ocedure ure shutdown pr oced
A qu quii ck check here i n vo v o l v e s s e t t i n g l ocom ocomoti ve up t o l oad and open t h r o t t l e t o Not ch 1 W t h a vol t meter check s i g na na l f r o m t h r o t t l e s t a n d , gove goverr nor nor , et c t hrough hrough t he nt i l t he s i g na na l i s l o s t ; then go bac e x c i t a t i o n system u nt ackk one s t e p and f i n d t he t r o uubb l e
H O R S EPO WR T R O U B LE N o Hors r sepower Engi ne Runni ng
Open t h r o t t l e t o s ee t h a t en engi gi ne r espo esponds, contactor contactor s andd l oa oadm dmeter i n d i c a t eess u p - s c a l e I f engi p i c k - u pp,, an engi ne does not respond t o notch s p e e d s , check engi engi ne c oonn t r o l s t o e n s u r e t h a t a l l br eaker eaker s and sw tch tches es a r e i n pr op oper er op operati erati ng p o s i t i o n A l s o , check t he output of t he v ooll t a ggee r e gguu l a t oorr panel f or 74 vdc battery chargi chargi ng v o l t a g e Shut t he engi engi ne down
I n s ppee c t t h r o t t l e contr contr ol w i r i n g f or conti nui ty
rs sepower Engi ne Runni ng LowHor
Check 1
Power L i m t s w t cchh i s i n
N O R M A Lp o s i t i o n
2 Mot or cut - o uutt s w t cchh f or ALL ALL-- I N p o s i t i o n 3 En Engi gi ne i s not smoki smoki ng and sounds nor mal 4 Reduced exc exci tati on i n d i c a t o r l i g h t on EC panel and on Annu Annunci nci ator Panel i s not l i t
GEK 3015 50 0 SECTI O NX I I ,
TR O U B LE S H O O T I N G
Shut t he engi engi ne down
crew r e p o r t s or on t he b aass i s of s ym ympt pt oms oms noted whi l e t hhee specti ti on process l ocom ocomoti ve i s be beii ng operated du duri ri ng t he i nspec Whi l e t he sym pt ptom om noted m ay i d e n t i f y a d ef ef e ct ct i v e t he s ame ame t h a t turbocharger, i t has f requ requentl entl y happened sym pt ptom oma pp pp l i e s t o other f a u l t s on a l ocom ocomoti ve, so m any turbochargers ar e r e pl pl aced unneces sa sar i l y Ref er t o s ym ympt pt oms om s sh show ow ng mul ti pl e Tabl e XI I - I V f o r exampl es of
Check t h a t rack l i n k aagg e i s not bi ndi ng
ani f ol d dent nt d e f e c t s mani 2 V i s u a l l y i n s pe pe c t engi engi ne f o r evi de l e ak ak s , di scon sconne nected cted f u e l pum p c o n t r o l l i n k s , et c 3 Check paper ai r f i l t e r Re Red F l a ggss
f o r d i r t y ai r f i l t e r s
faults
S t a r t t he engi onee- hal f engi ne and advance t h r o t t l e t o about on speed no l oad and check
overr speed l i n k i s f u l l y compr es sed That ove
I ns nspe pecti cti on O n Locom oti ot i ve
The p r e f e r r e d met hod of qual i f yi ng a turbocharger f o r co conti nti nued nued s e r v i c e i s t o observe i t and i t s e f f e c t s ) whi l e l o a d - t e s t i n g t he l ocom ocomoti ve Load-t esti ng r e f er er t o Load perf or m ed after f i r s t XI T es e s t i n g, g, Secti ecti on shou sho ul d onl y be establishing t h hee f ol ol l oow w ng n g i t ems ar e f uncti oni ng and
Turr bo d i s c h aarr g e pi pi ng and f i t t i n g and t he i n t a k e 2 Tu mani ani f ol d f o r l e ak a k s you w i l l be a b l e t o fe e l and, p e r h ap s , s ee or hear them
3 Re em move pl ug f r o m bottom of t he t ur bo- compres sor outt of t he hol e c a s i n g and f e e l t h a t t he a i r i s p u l s i n g ou w t h no o i l or wat er present i f okay, r e ppll a c e pl ug i f not, f u r t h e r i n v e s t i g a t i o n of t he turbo w i l l be necessary thee eng engi ne r unn nnii ng t op speed no l o a d ) , check f u e l W t h th p r e s s u r e assum assum ng th thee gage i s not d eeff e c t i v ee)) I f t h e r e i s mor e than a t h r e e pound d i f f e r e n c e bet ween I DLE and top probab abll y not r e c ei speed r e a ddii n gs gs , t h hee engi ne i s prob ei v i n g s u f f i c i e n t f u e l under l oad co cond ndii t i on onss Deter m ne why ; e . g d i r t y fue l f i l t e r or s t r a i n e r , l ow r e g ul ul a t o r s eett t i n g s , et c
I f t he pr ob obll em deve devell ops ops bet ween 20 t o 30 mph, check t r a n s i t i o n s e t t i n ggss w t h t e s t s et I f no nott hi ng i s f ound ound up t o t hhii s p oio i n t , th thee uni t sho shou ul d be connected t o t hhee l oad box or s e l f - l o a d f o r f u r t h e r checks Ref er t o Load T e s t i n g, ect i on XI One t h i n g t o r e me mbe r g, Sect conndi ti ons ons i s t h a t under l oad co
I f t he l oad pot i s bel bel ow m ax xii m um i e l d , t he pr obl obl em i s u s ua u a l l y mechani cal
correct
2 3
4 5
6
Fuel pum p r a c k s c o r r e c t l y s et and equal Fuel pum roperl y t i med ps properl F u e l - i n j e c t i o n pum ps and nozzl nozzl es a l l mus t f uncti on exh haust aust man anii f ol ds f r e e of l eak eakage Ai r- i ntake take and ex Val ve tappet c l e ar a r a n c e c o r r e c t l y s et Fuel f i l t e r and engi engi ne a i r f i l t eerr s cannot be pl ugged
7 Fuel l i n k aagg e f r e e movi ng 8 Exci xci tati on c i r c u i t s mus t be i n good order and capa capabl bl e of be beii ng adj adj ust ed
W hen under FULL LO AD and i n Not ch 8 observe turbocharger ai r p r e s s u r e , c ooll o r of exhaust gases, governor l oad pot a c t i o n, n, and check t he turbocharger f o r o i l and wat er l eakag eakagee an andd mechan echanii cal d i s t r e s s Us e Tabl e XI I - I V t o i d e n t i f y a f a u l t y t ur bo boch char ar ger or other l oc ocom omoti ve
compone com pone nt
ocomoti ve, W hen i t i s not p o s ssii b l e t o l oad t e s t t he l ocom p erf orm t hhee f ol o l l ow ng t u urr bo bochar ge ger check, w t h t he l ocom ocomoti ve shut down
Wor ki ng down t hhrr u t hhee s t a c k , us e a f l a s h l i g h t and a es , m r r or o r pos i t i oned t o observe serve th thee t u r b i n e - d i s k b l a d es Fi g XI I - 2 Whi l e obs er er v i ng th thee b l a d es es , us e a hook tool, m ade f r o m 1 / 8 - i n di amet er s t a i n l e s s s t e elel , t o l i f t and r o t a t e rotor t h r u one compl et e revo revol uti on Exam Exa m ne a l l bl ades ades f o r p o s ssii b l e da dam mag agee caused by f o r e i gn g n ma t e r i a l , and check rotor f o r f r e e r o t a t i o n P erf orm ng t h i s operati operati on w i l l often break up carbon educed r ot bui l d-up w whi hi ch causes r educed ot or or s pe peed and al l ow conti conti nu nued ed use of th thee tu turbo rboccharger rger
axi m um i e l d , t he pr ob 2 I f at m obll em i s u s uuaa l l y e l e c t r i c a l g h , t hhee r e m 3 I f t he hor s epower epower i s h i gh ay be both mechani cal and e l e c t r i c a l pr obl ems TU R B O C HR G E R TR O U B LE
Gener al
W hen m ount ed i n t he l ocom turbocharge rger, r, ocomoti ve, the turboc Fi g X I I - 1 , i s a d i f f i c u l t p i e c e of equi pment t o check qui ck ckll y and q u a l i f y f o r co e r v i c e The turbocharger conti nti nu nued ed s er i s f req dged ed t o be f a u l t y on t he b as requ uentl entl y j udg as i s of operati operati ng XII- 2
2 Remov ove e t he cl amps, f l e x i b l e d u c t , and ai r duct f r o m urr bo bochar ge ger , F i g XI I - 3 t he compr es s or end of t he t u Man anua uall l y tu turr n th thee r o t o r , and note t hhaa t r o t o r i s f r e e t o r o t a t e Set up a d i a l i n d i c a t o r and m ove t he r o t o r , as
r e qu qu i r e d, d, t o check t he a x i a l and r a d i a l c l e a r a nncc e
TRO UBLE- SHO O TI NG SECTI O NX
T
Cr ew Rep Repor or t Or
V, TRO ETU RO C HR G ER UBLE- SHO O TI NGTH
Act ual Tu Turr boch bochar ar ger Fa Fau ul t
Sym pt om
Bl ack s mo ke out stack
LE X1111- I
Ro t o r no t
r educed educed speed
Ot her P ooss s i b l e Locomot i ve F a u l t s
P ooss s i b l e Cause O Faull t Tu Turr bochar bochar ger Fau
turning Rot or t ur ni ng a t
s t e ad a d yy- s t a t e
objj ect Rot or damag aged ed by f o r e i g n ob E xxcc e s s i v e carbon bui l d- up bet ween t u r b i n e seal an and d di s k F ai a i l e d b eeaa r i n ggss F a i l u r e of r o t o r t urbi ne d i s k or compr esso es so r wheel Compr es s or wheel or t u r b i n e d i s k r ubbi bbi ng
ps not pr ope oper l y t i med I n j e c t i o n pum ps an and d/ or Fau Faul t y f u e l i n j e c t i o n pum noz z l es
E xc xc e s s i v e carbon bui l d- up i n a i r i n t a k e ports D r t y i n t e r c oooo l e r s Pl ugged gged engi engi ne a i r f i l t e r s ani f ol d Leakage i n a i r - i n t a k e mani Fau Faul t y e x c i t a t i o n c i r c u i t ad adjj ust ment ent s or
Not l oad oadi ng or l ow on power
Ro t o r no t
turning Rot or t ur ni ng a t r edu educed spe speed ed
Bl ue s mo ke, and o i l out s t a c k
e a r i n gs gs F a i l e d b ea and and/ or s eeaa l s
Seal a i r p a s s a g e pl ugge gged d wi t h
carbon Lab Labyr i nt h i n t ur bi ne-end e-end seal pl ugge gged d wi t h carbon Rot or t urni ng a t , r edu educed spe speed ed
G EK-3 - 30150
Rot or damag aged ed by f o r e i g n o b j e ct ct E xxcc e s s i v e car bon bui l d- up bet ween t u r b i n e seal an and d disk a r i n gs gs F a i l e d b e ar F a i l u r e of r oott oorr t ur u r b i n e d i s k or
co com mponent s
D r t y or pl ugge gged d fuel f i l t e r Fuel pum p r a c k s s et i n c o r r e c t l y a r a n c e s et i n c o r r e c t l y Val ve t ap appet pet c l e ar Leak i n man anii f ol d l i nnee t o governor A l s o , s ee f a u l t s l i s t e d above f or B Bll ack s mo ke out st ack
compr ess es s or wheel Compr es s or wheel or t urb rbii ne d i s k r ubbi ng Pi pe pl ug m s s i n ngg i n upper c a v i t y of f or wardard- end end cover Wong s i z e o r i f i c e i n l u bbee - oi o i l suppl y pi pe Rot or un unbal bal ance ance opeer at i on of engi Prol onge onged d op engi ne i n i d l e an and d l ower spee speed d notch otches es
W or n or broken p i s t o n r i n ggss Cr acked pi ston cr own) own) Scored l i n e r
Lowt ur boch ocharger arger a i r p r e s s u r e At Not ch 8 FULL LO AD
Exc Excessi essi ve carbon bui l d- up bet ween seal an and d disk a r i n ggss Defecti ve b e ar Compr es s or wheel or t ur u r b i nnee d i s k
r ubb bbii ng
Lowt ur boch ocharger arger a i r p r e s s u r e At l e s s t han han Not ch 8, FULL LO AD
Leakage a t a i r d i s c hhaa r g e el bows bows or i n anii f ol ds a i r - i n t a k e man Leakage i n ex exhhaust mani f ol d Fau Faul t y gage
A l s o , s ee f a u l t s l i s t e d above f or Lo Low power er on pow P os os s i b l y , no f a u l t Tu and above, and under Turr bocha bocharr ger a i r p r e s s u r e i s not i ndi cat cat ed u n t i l i n Not ch 6, and l oa oad d Ther Ther e i s no i n d i c a t i o n when i n dyna ynam m c br ak akii ng
and d Tor que Val ues s e c t i o n f or Ref er t o Dat a s e cctt i o n an
limts
3 Check f or pl ugged s e a l - a i r p a s s a g e s D scon sconn nect t he s e a l - a i r p i p es hoo p a i r i n t o t he s e a l - a i r es and appl y s h passages i n t he h e t ur ur b bii ne c a s i n g I f p a s s a g e s a r e c l e a r , t he sound of escap escapii ng a i r wi l l be hear hear d a t t he st ack pee r at at i o n can o f t e n c l e ar ar a ou outt l et Thi s o p p a r t i a l l y - b l o c k e d passage
an i n g u s i n g compr es s ed a i r f or c l e an pur p poos es es , an envi r onment p o t e n t i a l l y hazardous t o pers onn onnel el i n t he i mmedi at e area i s created To pr even eventt physi cal cal i n j u r y by f l yi ng d eebb r i s , observe a l l Rai l r oa oad d and O SHAs a f e t y r e gguu l a t i o n s W R NN GW hen
Check v i s u a l l y f or evi den ence ce of mechani echani cal dam damage, e x ce c e s s i v e heat and wat er l e ak ak s
XII- 1 3
NX11, TRO GEK- 30150, SECTI O UBLE- SHOOTI NG Torqu or que Val ues
ount i ng Bol ts , t urb urbochar arge ger m
Bol ts , stack cl am pi ng Bol ts , exhaust m ani f ol d t o t urb urbocharge ar ger
Lb - Ft 1500-16 165
Nm
203- 224
55- 60
75- 81
70- 75
95- 102
Nut uts, s, stud stud-- l ocki cki ng and ea earr - cl ampi ng ng,, ai r- di scha scharge el bows
ange t o i nt ercoo rcooll er Bol ts, f l ang
E S ET BLAD FI G X I I - 2 I NSPECTI NG TURB NE- BUCKET
Dat a W ei ght ght , t urb urbocharge ar ger Rotor otor,, end- pl ay
N e w
M a x
wor n
Engl i sh
Met r i c
14701b
667 kg
0, 330330-
0. 013 13-0. 021 i n
0, 533
m m
0. 025 i n
0, 635
m m
Rotor otor,, di am earr an ance ce etr et r al cl ea
i n be beari ari ng ngss
0. 003-
N e w
M a x
wor n
0. 0055 i n 0. 0065 i n
0, 0760760, 140
m m
0, 165 m m
Speed pi ck ck-- up pr prob obe t o
cap, cl ea earance rance
0. 028 28-0. 090 i n
0, 7117112, 286
N X
55- 60
75- 81
35- 40
47- 54
O N T R O L G O V ER N O R TR O U B LE M O D U LA TI N GC
ydraull i c The m odul at atii ng co con nt r ol gover nor i s an el ectr o- hydrau egul ate speed and hor hors sepower out put of t he devi evi ce used t o r egu n u m b e er r of auxil i ary de devi vi ces engi ne I t al so i ncl ud udes es a di esel esel engi at er Pressure Sw t ch W PS and an O l Pressure such as a W
rovii de t he power pl ant ant w t h Sw t ch O PS t o pr otect and prov oti ve servi servi ce rabl e f or rai l way l ocom cha charac racteri teri sti cs desi rabl events nts ar e Thes se e cha operat i onal onal eve charac racteri teri sti cs, de devi vi ces and operat shown i n Fi g X I I - 4 Thi s f i gure con consi sts of f our our tr acki cki ng event nt s and charts t hat shownor m al oper at i ng eve al and abnor m al what acti on shoul d be t aken t o correct t he abnor m events events The f our our t rack rackii ng charts ar e
ow wer Nor m al Condi t i ons - Po 2 Engi ne Start Nor m al Condi t i ons Dynam ynamc c B ake
4 Hot Engi ne Cont r ol s
CHEC EXC TATI ON SYSTEMTRO U B LE LE
at nor m al operati erat i ng
ci tati on syst em s EC ex ci The m aj or com pon ponent i n t he CH phasi s has been t he FL138 Exci t at i on Panel Theref ore, em pl aced on t he tr oubl e- sho shoo oti ng of t he panel
t em per at atur ure e of 160- 190 F
71- 88 C , w th engi ne at I D LE w t h engi ne at N8
W
m m
Oi l - sup suppl y pressure, m easur asur ed casi ng i nl et, w t h at t urbi ne- casi oi l
N M M N
10- 20 psi
69- 139 kPa
15- 40 psi
103- 276 kPa
card rds s i n t he panel and the theii r Tabl e X I - V l i s t s t he ten ca pane nell s f or f uncti on The f i r s t ni ne cards ar e t he he sam e i n al l pa
oti oti ves The odel s of Gener al El ectri c l ocom t he di f f erent rent m odel of err en ent f or or each m tenth, or Refer ar d, i s di f f e eferen ence Card, Excc i t at i on odel of t he FL138 Ex l ocom ot i ve and f or each m
Panel
-VII Tabl e XI I -V
NO TE
ai nt ntai ai ner shoul d not as ss sum e, f or The m al l C 30-7 307 Lo com oti ot i ves w l l have t he exam pl e, that odel of t he FL138 panel and, thus, t he sam sam e m e t ype of Ref efer eren ence Car odel of t he FL138 ard d The m L ocom oti ot i ve depends on Panel i ns t al al l ed on t he C30- 7
aa
N
c
t he type type of t urb urbocharge ar ger i nstal stal l ed C U TO N Power
FI G X I I - 3
TU R B OI
NSTALLATI ON DETA LS,
C O M PR E SSO REN D
XII- 4
shoul d be r em ov oved ed when pul l i ng
oni c car ds , t o pr or repl repl aci aci ng el ectr oni preve event el ectri ca call da am m age t o t he cards or the p a n el theii r co con nt ac actt s i n t he
T R O U B LE -S -S H O O T IN GS E C T IO NXI I , G E K -3 0 1 5 0
N O R M A L CO ND TI O N S - PO W E R
N O R M A L CO R A K E N D TI O NS - D YN A MCB
FU L L T H R O T TLE FU L L S P E E D FU W E R L L PO LU R E> A T E R> 6 PSI ; W 2 PSI
S T A R T H E R E
FU LL E N GN E SPEED N O R M A L D Y N A MCB R A K E LURE >46 PSI ; W A T ER> 2 PSI
S T A R T H E R E
N O
N O
IF
IF PR E S S U R ED R O PS TO 46 PS LURE O R A T E 12 PSI W
R OS PR E S S U R ED 70 46 PSI LU B EO R A T ER 2PSI W
YE S
YE S
L U B EW A T E RG O VE R N O R SWTCH CLOSES
E C O N D 19 S TM E RR U N S
G O V. S WTC HOE N S
PO W E RR E D U C E S E V E L ( EG T O 3/ 4 L R)
A N N U N LT O N ( LUBE O R
E S S U R E SR S R SE W H E NPR B E= 50 W T OLU A T E R = 15
T H E N
PR E S S U R E G O E S
W A T E R
B R E A KSEAL, KS M A N U A L R E S E T LT U T G O E SO
M O D U LA T E LO A D A N DS P E E DT O HG H E RL RL E V E L
UP
I F LU B E< PSI A T ER< O RW PSI
A FT E R19 SEC ECOND S E N E R GZ E G O V S P E E D S O LE N OD S
W H E NG O V RESETS
F
S T A R T N O R M A L E S E T G O V R
TO P
Z
R
a
i
R E PO R T
ID LE
0
C R A N KN G LO C K E DO DO U T U N TL G S D H R IS R E S E T
G O V
R E S E T
W H E NG O V RESETS SWTC H E SOE SO N E S T A R T T H E NR
S D H R R E S E T T H E NM A N U A L G
FU L L SPEED FU W E RO RD Y N A MCB R A K E L L PO LU B EA N DW A T E R< 35 F
S T A R T
?O
20
30
W A T E R0
3
6
9
H E R E
40
12
50
60
15
18
PR E S S U R E-
PSI
70
80
90
100
2
24
27
30
IF
IF N O
N O
W A T ER H E A T ST O 235 F
LU B E
H E A T ST O 235 F
S T A R T
`
S T A R T N O R M A L
H O T EN G NE C O N T R O LS
10
YES
( LO TS
H NTS) YES
PUSH A N GN ES N DH O LDE T A R TB U T T O N I F G S D H R IS R E S E T
S T A R T H E R E
R E S E T
G O VE R N O RS T A R T S FA E S E T S TR
T H E NR E S T A R T
C E P
EN G NE
I F LUBE < PSI O RW A T ER
O N
ROL W AT FO
OC T O O L
O W R R M A LO A N D D YNB R A K E
IF IF LU R E >10 PSI
A N DW A T E R> PSI
PR E S S U R E S SR R SE
LU B EA N DW A T ER
YES
B R E A KS E A L M A N U A L R E S E T
LUBE H E A T S TO 245 F
N O
T H E N
L U B EW A T E RG O V E R N O RS WT C HCLO LO SES
YES
R E S E T
1
S E C O N D TM ERR U N S
G O VE R N O RS H U T SD O W NE N GN E L IG H TO NE C PA N E L G S D H R L A T C H E SU SU N TL M E S E T A N U A L R
A N N N LT O N ( LUBE O R W A T E R
A FT E R19 S E C O N D S E N E R GZ E G O V. S PEE D S O L E N OD S
S T A R T N O R M A L
G O V
R E S E T
B R E A KSEAL, G O VE R N O RS T A R T S M A N RESET FA S TR E S E T LT G O E SO U T
W H E NG O V RESETS
C R A N KN G LO C K E DO U T U N TL G S D H R IS R E S E T
R E PO R T
S Y S T E M R E S TO R E D
N O
W H E N
IH O TS
R E S E T
W H E NC O O LE D
10 F
T H E N
H O TEN G NE R E L A YL A T C H E SU SU N T LM A N U A LR E S E T (ET R AD A L A R MB R30 S E C E L L FO G OT ON ON OLO
FT E R R3 30 S E C O N D S ID LE S P E E DA
E TH R L IG H TO N
W AT FO RC O O LD O W N
R E S E T
SWTC H ES O PE N
T H E N
M A N U A L ET H R R E S E T T H E NM A N U A L G S D H R R E S E T
T H E NR NR E S T A R T
R E PO R T
L E G E N D
> R E A T E R RT T H A N
ESS T H A N < ~ PPR O A C H E S
FI GXI I - 4
E N GN EM G O V E R N O R C H A R T S T R A C KN G O D U L A T TN N G XI I - 15
UBLE- SHO O TI NG GEK- 30150, SECTI O NXI I , TRO
T
Position Lef Lef t t o Ri gh ghtt )
Car d
Car d
Sy mbo boll
Title
TC
Test
LE XI
I - V,
NCTI N DFU
C R DD T
Car d No FD732
O N
Car d Functi Functi on epll acement by Car d r e s e r v e s t he l e f t contact s t r i p i n panel f o r r ep CH ECKI T pl ug duri ng system t e s t s or checks No component s a r e mount oun t ed on i t ; how however ever , t ha hass i n t e r l o c k wi r i n g and mus t be i n ECKI T i s pl ugge ugged d in p l a ccee u nl nl e s s CH
2
FT
F i e l d Contr ol *
4
M P
Mu l t i p l i e r
Modul odul at or
M D
FD733 FD734 FD735
xc i t e r GY27) Pro Provvi des a v a r i a b l e current t o t h hee shunt f i e l d of t he e xc Contr ol s t hhee v a r i a t i o n i n t he shunt f i e l d current Generat es t he power s i g nnaa l by mul ti pl yi ng t he v o l t a g e and c u r r e n t s i g n a l s su supppl i ed t o i t ropoort i onal nal to t urbo-r ot or speed Gener enerat at es a s i g nnaa l prop ocom moti ve controll th the e l oco Determ nes nes whi ch of t hhee v a r i o uuss s i g n a l s wi l l contro braki ng e f f o r t de devel vel ope oped d ounn t of dynam c braki out put put or t h hee amou power out Rand VCRr e a c t o r s and f u r Smoot hs s i g n a l s f r o mACCR BCCRand n i s h es es t wo s i g n a l s t o compar at or card Generat es a 4 Hz s i g nnaa l t o e x c i t e t he t h r e e r e a c t o r s ACCR he e RGcard VCR BCCR and s u pppp l i e s power t o t h n eg e g a t i v e 15 v o l t power f o r c e r t a i n Su Supp ppll i es r e gguu l a t eedd p o s i t i v e and m and on cards and has has f our r e l a yyss whi ch r e p e a t t he T h r o t t l e com M U r a i n f n e wi r e s P r e s e t s t he pow power er , c u r r e n t and v o l t a ggee l i m t s f or each T h r o t t l e and modi odi s i g nnaa l when s p eecc i f i e d f u r ni n i s h es e s a notch, power m at ch f i e s turbo speed s i g na na l
Turbo Speed Compar at or
TS CP
5 6
FD736 FD737
FL
7
Filter
FD738
8
Oscillator
O S
FD739
9 10
R G
Re Regul gul ator
FD740
RF
Re Reff erence
FD- Se S X IeIe- VTIa)bl e
*The FD733 Card FT) FT)
s
ar d, F i e l d Sw t c h Car d, or F i e l d Cont r o l Car d ransii stor Card, s omet i mes r e f e r r e d t o as t hhee Fi el d Trans
Tabl e XI I - VI V I I p r e s e n t s a procedure f o r qual i f ying t he Thi s pr oced ocedure ure i s a v i s u aall check l ocom ocomoti ve f o r s e r v i c e Thi whi ch can be per per f or med w t hout t e s t equi pment
t
haat t h he e mai nt ai ner use a CH ECKI T i s sugge suggest st ed t h
checkii ng of t h hee conveni ni ent check d i a g n o s t i c an anal al yzer f o r t h e conve ECKI T xci tati on system W t h t he CH o v e r a l l e l e c t r i c a l exci
c or d pl ug i n s er e r t e d i n t he FL138 panel i n p l a c e of t he ve t h he e FD732 Test Car d TC TC)) , t he mai nt ai ner can obs eerr ve norr mal ope oper ati on of t h EC exci xci tati on system duri ng no hee CH t e s t i n g o r d u r i n g l o a d D e t ai l ed perr at i on l ocom ocomoti ve road ope ECKI T t e s t i n s t r u c t i o n s a r e i ncl uded w t h t he CH
However owever , i f a CHECKI T i s not a v a i l a b l e r e f e r t o pt omand Thii s t a b l e l i s t s t he t r o u b l e sym Tabl e XI I - VI VI I I Th asss umed good card f o r bsti ti tuti ng an as t he p o s s i b l e cause Subs et hod of m a l f u nc nct t i o ni ng card i s t he f a s t e s t m a suspected ca cann no not b e t roubl roubl e- sh shooot i ng t he panel I f t he probl em s t r e s o l v e d a f t e r check checkii ng t he p o s s i b l e cause i n Tabl e X I I V I I I ocom moti ve i s so o ad box check or i f t he l oco perf orm a l oa equi pped, pped, a s el el f l o aadd check For d e t a i l e d i n s t r u c t i o nnss r e f eerr t o Load T es es t i n g Secti on XI
T
LEX I I - V I
SSI R E FE R E N C EC R DA
Locomot i ve
Model B18B18- 7 B23- 7 B23- 7 C23- 7 B28- 7 C28- 7 B30B30- 7 C30- 7 C30- 7 C30- 7 B33- 7 C33- 7 B36- 7 C36- 7 XII
6
Re Reff erence
Car d
FD894 FD867 FD897 FD868 FD895 FD896 FD862 FD741 FD1146
FD1202 FD864 FD863 FD866 FD865
GNM ENTS Panel
Model
17FL138K2 17FL FL138H 8H 2
17FL138T2 17FL138J 7FL138J 2
17FL138L2 17FL FLI 38M 2 17FL FL138B2 17FL FL138A2 17FL FL138N 8N 2 17FL138X2 17FL138D2 17FL FL138C2 17FL138F2 17FL138E3
Tabl e XI I - I X i s presented a s an a d d i t i o n a l a i d t o t he mai nt ai ner The t a b l e s t s t he t e s t poi nts on t he c a r d s i n t he FL138 CH EC Exci xci tati on Panel These t e s t p o i n t s a r e co coll or- code coded a s f o l l o wwss :
2 3
4 5 6 7
Bl ack - Com om m on Bl ue - D Cs i g nnaa l v ol o l t a g e f r o m measur easur i ng d ev ev i c e suppll y Or ange - +15 vdc power supp Whi t e - - 15 vdc power sup suppl pl y Brow Brown - T h r o t t l e notch Yel l ow - A- C, u s u a l l y f o r o s c i l l o s c o p e use Gr een - D C r e f e r e n c e v o l t a ggee
NXI G EK-3 - 30150 TRO UBLE- SHO O TI NG SECTI O
T
CO M O TI VE FO RSERV CE LEX I I - V I I , PR O C ED U R E FO RQ UALI FYI NGLO
Engi En gi ne
Shut down
Step
Event
Check l ocom ocomoti ve ECpanel f or a l i t REDUCED EXC T i n d i c a t i n g l i g h t ontt r ol Com a I f l i t t he l ocom ocomoti ve i s i n t he reduced exc xcii tati on m ode Open t he Con D ar d t o RESET par t ment door and p r e s s t he Toggl e s w tc h on t he M b I ndi ca operati on of Reset Sw tc h on M Dcard cati ti ng l i g h t wi l l go out w t h operati c To v e r i f y whet her f a u l t r emai ns or has c l e a r e dd,, l ocom ocomoti ve mus t be s e t f or or
2 3
4
motor i ng, ng, a i r brakes se t, r e v e r s e r t hr own, G Fi n O Np o s i t i o n , ECs w t c h i n RUN p o s i t i o n and i s o l a t e a l l other u n i t s handl dl e t o Not ch u n t i l uni t s t a r t s t o l oad d M ove T h r o t t l e han ocom moti ve, r e t u r n adii ng i s observed on l oadmet er of t he l oco e Wen i ndi ca cati ti on of l oad handl dl e t o I DLEand note whet her i ndi ca Throttl e han cati ti ng l i g h t i s now i t I f t he l i g h t not l i t t he f a u l t has been c l e a r e d i s not ontt r ol Compa r t ment and check a l l c a r d s f or prof I f i n d i c a t o r r e l i g h t s , go t o t he he Con per l o c a t i o n and a s s u r e they a r e s e cu c u r e l y pl ugged gged i n t he panel The t wo r ed LEDl i g h t s on t he RGcard FFD shouul d be O Nwhen t he +15 vdc D740 sho and -1 and// or t he O -15 5 vdc power s u pppp l i e s a r e f uncti oni ng I f not, chan change ge out out t h i s and S card FD739 oggl gl e s w t c h on M D ar d FD734 t o TESTp o s i t i o n t o si mul ate a f a u l t , Move t he Tog ca cauusi ng the panel t o go t o t he r educed educed e x c i t a t i o n m ode The r ed LEDon t h i s card shouul d come on and s t a y l i t u n t i l Toggl e s w tc h i s m F i e l d Sw tc h L i g h t sho oved t o t hhee RESETp o s i t i o n As t he s w t c h i s moved, oved, you sho shouul d hear t he EFr e l a y operate Check term nal s f or l o ooss e con conne nect ct i ons ons and w r es f or ch charre arredd or di sc scool ored i n s u l a conne nect ct i on onss t i o n Repl ace any dam damag ag ed w r es or hardware an andd t i g h t e n any l o o s e con
Engi En gi ne
Runni unni ng X Run
X X
X Start or Run
X
Start
or Run
X
X
Start
CU TI O N The ei g ht mt ers ar e f acto ctory ry sea seal ed and ount ed pot ent i omters ht panel - m sho shoul d not be t am pered per ed w t h , ot her w se equi pmnt m ay be da am m age ged
5
Check that c a r d s a r e i n t h e i r a s s i g ne n e d l o ccaa t i o nnss and t h a t card number s a g r e e w t h panel number s
X
6
Check t h a t t he RF t e n t h card i s t he proper one f or t he model of l ocom ocomoti ve on whi ch i n s t a l l e d
X
U LE C M RW HEELSLI P SYSTEM TRO
I ntr oducti on I f a l oc ocom omoti ve has a r ep epor t of CM R wh eeee l s l i p system t r o uubb l e , t h i s gui gui de wi l l a s s i s t i n l o c a t i n g and corr corr ecti ecti ng t he probll em The gui prob o n s i s t s of Tabl gui de c on abl e XI I - X X,, F i g X I I - 5 , Fi g XI I - 6 and s p e c i f i c t roub roubl e-s hoo hoot i ng procedures
Tabl abl e XI I - X p r e s e n t s a l i s t i n g of s p e c i f i c pr ob obll ems t h a t a r e f a i r l y com m on I f t he system tr oubl e i s not s pe pe c i f i c o r i t cannot be l ocat eedd i n Tab abll e XI I - X, proceed t o Fi g X I I - 5 Thi s f i g u r e p r e s e n t s a pr ogr am amm med approach t o t r o ub ub l e - s hhoo oott i n g t he prob probll em Observe t he i n i t i a l co conndi t i on onss s p e c i f i e d i n Step of Fi g X I I - 5 and proceed s t e p by s t e p t o probll em Wen abnor mal operat i s o l a t e and c o r r e c t t he prob perat i on o c cu c u r s , t he h e hori hori zon zontt al l i n e shown by t he ap apppl i ca cabbl e s t e p on Fi g X I I - 5 wi l l r e f e r e n c e a s p e c i f i c t roub roubl e-shoo e-shoot i ng
X
Start
or Run X Start
or Run
perat i on Fi g X I I - 6 procedure f o r r e s t o r i n g nor mal operat c o n s i s t s of a graph f or p l o t t i n g a x l e a l t e r n a t o r output
f r eque equency ncy o r a x l e r pmv e r s u s t r a i n speed
NO TE
R s) eact ors s CM ur r ent M easur i ng Reactor The Curr used on Se r i es - 7 Locom otii ves ar e col or - coded r ed or ot whi t e f rom romt wo di f f e r en ent vendors Thes hese e CM R s ar e erchangea eab bl e and mchani cal l y and e l e c t r i c a l l y i nt erchan ot i ve m ay be mxed on any l ocom
The cust omr
R s w t h any sh sho oul d not r e pl pl a ce ce t he red or whi t e CM R s that he m bl ack CM ay have i n st ock These bl ack
CM R s ar e _not e l e c t r i c a l l y i nt e rcha rchann ge ge ab abl e w t h red or whi t e ones
Procedures
A Pr obl ems W t h Step
I
The prob probll em i s w t h t r a n s i s t o r Q O n a six-axle F D 1 1 5 4 l o catt ed i n t he l oco ocom moti ve, r eepp l a c e t hhee Card ca XII- 7
NX11, TRO GEK- 30150, SECTI O UBLE- SHOOTI NG TAB LE XI I - V VII I I CHECEXC TATI O NSYSTEMTRO U BLE
VI I I Cont Cont d TABLE XI I - VI se e Possi ossi bl e Caus
Possi bl e Caus se e
Exci t ati on Panel
Sym pto t om
Ext ernal Ci rc u uii ts
N opow power i n
RG M D
ot ch any notch
Ope en n exci xci t er shunt f i e l d
FT, or RF
ci rcu rcuii t
card
broken ex exci ci t er brushes
def def ecti ve
Governor over nor pl ug not i n pl ace ace GF, G FAopen
Wrn Wr n- out or
Ver ery yl i t t l e
FT or TS
Open exci xci t er shunt f i e l d
pow ower
card
o si gnal gnal of ci rcu rcuii t N
notch ot ch
in
any
def def ecti ve
Less t han nor or m al pow ower in m ost or l l
TS or card def ecti ve
not ches
Exci t a t i on Panel
Sym pt to om
Ext er nal Ci rc u uii ts
Dynamc ynam c br ak-
Rever ser not com pl et etel el y t hr ow ng, perha perhaps due
i ng wor ks i n one di rec recti ti on of l ocom oti ot i ve
t o l eaki ng ai r l i nes or
def def ecti ve m ag gn ne ett val val ves
m ovem ovement , but ot her not i n othe
t ur bo speed Fuel
filter
par t i al l y
bl ocked or f uel uel su sucti cti on
l eak LCP w l l be at m ni m um Low
oti ot i ve, FL80 CM RW heel sl i p Pa Pan nel O n f our- axl e l ocom F L 8 4 CM R r epl epl ac ace e t he FD cat ed i n t he 1155 Car ard d l ocat
W heel sl i p Pa Pan nel
bat t er y v ooll t a ge ge One m ag gn ne ett mssi ng f rom rom
t ur bo rotor
Nor m al power and cu curr r ent i n
RF or RG
Ope en n ci rcu es t o rcuii t i n w r es
card
coi coi l of rel ays RLA
ot ches ; som e notche
def def ecti ve
hi gher or l ow
RLB RLC or RLDon RGcard F a aii l ur e of
er t han nor others rs m al i n othe
t hes e rel ays t o operate pr oper l y
O S or CP
re en nt i n
card
l l
def def ecti ve
Open O VR esi stor Ope en n sec secon ondar y i n CR ACCR Short or t ed V N o f eedback f ro rom m
ACCRand/ or V CR
Load Cont r ol
M Pcard
Pot ent i om eter et er
def ecti ve
br aki ng cur-
def ecti ve Ope en n P5 or P6 pot en-
i t i v e end of br aki ng po-
t i om eter et er i n adj ust m ent
or t ed RFC3 or nal Short A M C 1 ca cap pac acii t or Open m ot or f i el d ci r c ui ui t Ope en n gr i d ci r c ui ui t w t h C M R Wong CP2
m odul e
Pr Proceed oceed t o Fi g X I I - 5 , Step tep 3
C Pr Probl obl em s Wth St ep 4
is
l oc ocated ated
ace t he Al t er nat or handl e and pl ace Gener era at or or)) Fi el d GF) ci rcu breaker t o O FF rcuii t breake
Return et urn t he Thrott l e handl e t o I DLE, cente terr th the e
Rever everse se
Ope en n f ee eed d w r e t o EX P-A - ABt e r m t ent i om et eter er
2
cont act or sequence
romt he CM Rs Equal i ze t he wheel sl i p panel i nput s f rom by j um e r m na nal s t oge per i ng t he f o l l ow ng t er ogett her her
a
handl e pos osii t i on
b
pot ent i om et eter er
curr r ent Br aki ngcu
O S or CP
Open BCCRcontrol
i n red zone of
car d def ecti ve
w ndi ng
O n t he
FL80 Panel
ssii x- axl e l ocom oti ve) , j um per t e r mnal mnal s C D E- F- G- H
Ope en n connecti ect i on t o ne nega gatt i ve end of br aki ng
br aki ng i n any
1
M axi m um
FL84 Panel f our- axle mnal s C D E j um per t e r mnal E-- F O n t he
Pum p- up
t he
i r
l ocom oti ot i ve br brake akes
l oco ocom moti ve ,
br brake ake syst ste em and set
t he
Dynam ynamc c
ard
br aki ng cu curr r ent
def ecti ve
XII- 1 8
circui t s I f none ar e f ound, rep circui repll ace ace WXrel ay l ocat cat ed on CM Rwheel sl i p panel
her e t he faul tes testi ti ng t o determ et ermn ne where faul t
Ope en n f eed w res res to pos-
hunt nts s
grounds or short not pi cki cki ng- up Look f or ground
CP card
l oadm et er
is
N o or ver ver y l ow
rent
WXrelay
hi s poi nt , several pos ssii bl e t hi At t hi hi ngs cou coul d be t he cau cause of t h he e tro ou ubl e Theref ore, i t i s necessary f or further
r eads eads t oward mn m umi el d
B Pr Probl obl em s Wth St ep 2
Exce xcessi ssi ve curnot ches
Pr Proceed oceed t o Fi g XI I - 5 5,, St ep 2
Open ci rcu rcuii t t o L2 reactor i n exc i t ati on
panel
4
Pl ace ace G F brea reaker to ON m ove Rever ever se handl e t o FO RWRD or REVERSE and advance Thrott l e handl e t o Not ch 1
TROUBLE- SHOOTI NG SECTI ON XI I , G EK-3 - 30150
TABLE X I I - I X , Card ar d Sym ym bol
TC FT
Card ar d No
Test Poi Poi nt
FD732 FD733
None TPI
M D
FD734
TP2 TPI
M P
FD735 FD736
TS
CP
FD737
FD738
FL
OS R G
RF
Test Po Poii nt
Rem ar ks
Title
Meas ur es Q4 out put
SWTCHO U T PU T
C O M M O N M O D U L TO RO U T PU T
TP2 TPl TP2 TPl TP2 TP3 TP4 TP5 TP6 TP1 TP2 TP3 TP4 TP5 TP6
C O M M O N PO WR300 K WV O LT
TP1 TP2
C C R 600 A/ V VCR BCCR, M O TO RN G15
TP3 None TPI TP2 TP3 TP4 TP5 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10
FD739 FD740
Tabl e See Tabl XII-VI
NOTE
C H ECC R D STEST PO NTS
Negat egat i ve vo voll t age age ; see Not ote e
C O M M O N
A-C vol vol t ag agee ; t urbo urbo spee speedd si gnal nal
SO R TU R B OSEN
PMV V TU R B O2150 RPM C O M M O N FER E N C E PO WRRE
TU R B O I R E FER E N C E M OTOR NG
R E FER E N C E M OTOR
NG RAKI NG GR DREFEREN C E B C E BRA FI ELDREFEREN KI NG M O D U L TO RB AS
Al t er nat nat or current voll t ag agee Al t er nat nat or vo Br ak akii ng g r i d current Br ak akii ng f i e l d current Com pari pari son j unc t i on
C O M M O N
B RK E1
A/ V
s ee
V/ V
; A nnat ot2e 2 All tt er er nat nat at or or current vol t s ; see NotNe br ak akii ng current
C O M M O N
Reg egul ul at ed sup supp pl y Reg egul ul at ed sup supp pl y
+15 VD C
- 15 VD C C O M M O N
Not used
Gover overnor nor l o a d po t vo voll t ag agee
LO DPO TB R U S H R M N O TC H N O TC H2 N O TC H3
N O TC H4 N O TC H5 N O TC H6 N O TC H7 N O TC H8 PO WR
C O M M O N
al c ul ul at e d a s f o l l o ws TP1 v ooll t s x 424 = Hor sepower i nt o al t e r na nat o r f or t r ac t i on ca can n be c al
hors hor sepower NOTE 2
cal cu cull at ed Hor sepower i nt o al t e r na nat o r f or t r ac t i on ca cann be cal TPI v ol ol t s x TP2 v ol ol t s =
78
NOTE 3
as
f o l l o ws :
hor se power
Al l m eas easur urem ement s ar e 15 vdc or l e s s except FD736Tur urbo bo Speed Car ard d t e s t poi nts TP1 and er , o r hi ghe r ohm per vo voll t me t er TP2 whi ch ar e a- c Use 1 XII
9
GEK-3 30150
SEC TI O NXI
I,
TR O U B LE S H O O TI N G
H E E LS LI P SYSTEM TR O U B LE T BLE XI I - X C M RW
Sy ym m pt om
P os os s i b l e Cause
Correcti on
At s t a n d s t i l l , f a l s e wh e eell s l i p i n didi c a t i o n when T h r ot o t t l e handl andl e i s m oved f r o m I DLEt LE t o Not ch
Bad w r i n g a t CM R Wong mot or contactor sequence Sl i pped pi ni on Open c i r c u i t i n t r a c t i o n mot or conne nect ct i on i n one of Hi gh r e s i s t a nncc e con t he power c i r c u i t s Di sc onnect onnect ed mot or c a blbl e Locked t r a c t i o n mot or I mpr oper mot or conne connect ct i ons ons ea r i n g on one or mor e a x l e s Wong g ea W de v a r i a t i o n i n wheel di amet er mor e t han i n . Compress i on b o l t s not r emov ed f r o m t r a c t i o n mot or nose mount s
Look f or l o o s e j o i n t s or con conne necti cti on ons, s,
Cont i nu nuou ouss wh ee ee l s l i p i n d i c a t i o n when speed r each eaches es a l i t t l e over ph one m
ee l s l i p i ndi ca Cont i nu nuou ouss wh ee cati ti on a t or above c er e r t a i n l ocom ocomoti ve speed ph or h i g he he r u s ua u a l l y 50 m
Cont i nu nuou ouss wh e eell s l i p i n d i c at at i o n dyna nam m c br ak akii ng but not duri ng dy duri ng mot ori ng
Over s pee peedd det ect i on s et t oooo l ow Car d) FD FD406 Car W de v a r i a t i o n i n wheel di amet er mor e t han i n . akii ng g r i d c i r c u i t Open br ak
ee l s l i p i ndi cati B r i e f wh ee cati on a t t r a n s i tion
S e n s i t i v i t y s et s l i g h t l y t oooo l o w Cont ont act or acti on i s a l i t t l e s l o w
B r i e f wh e e l s l i p i ndi cati cati on a t l ow spee spe eds whi l e i n dy dyna nam m c br ak akii ng
akii ng c ont ac t or s Ext ende endedd range br ak c o om m n g not i n a t t he s am ame e t i me
St ead eadyy wh e eell s l i p i n d i c at a t i o n a t c eerr t a i n speed whi l e i n dy dyna nam m c br ak akii ng
Ext ende endedd range contactors di d not
No wh ee e e l s l i p i ndi cati cati on w t h s l i p s known t o e xix i s t
ansf ormer CT) f a i l u r e Cur r ent t r ansf W SXd e f e cctt i v e
5
op ope er at e pr ope oper l y
ed on t h e FL80 Panel The FD406 Car d l oc at ed s i x - a xl x l e l ocomot i ve) ve) and on t he FL84 Panel four-axle l ocomot i ve ve)) ha hass f i ve ve t e s t p ooii n t s number ed 2 , 3 , 4 and Com m on The FD408 Car d a x l e l ocomot i ve) ve) ha l o ca c a t e d on t he FL80 FL80Panel Panel s i x - ax hass m on t h r e e t e s t p o i n t s num number ber ed 5 6 and Com
Check v ol o l t a ge g e bet ween t e s t p o i n t s 2 3 4 and Com m on on t he FD406 Card and 5 6 and Com m on on t he FD408 Car d, i f a pp p p l i c a bbll e w t h a shou ul d be s e l e c t e d t o vol t met er The met er s c a l e sho r ead d- c v o l t s bet ween 24 and 30 v o l t s 4 v o l t s f or ev every ery 100 amper es on t he l oadmet er i n t he cab) axi m um i f f e r e n c e sho shou ul d not not exce xcee ed 3 v o l t s , The m per cent v a r i a t i o n f r o m h i g hhee s t t o l owest or 7 per XI I - 2 0
6
es other p o s s i b l e c l u es s mo ke, heat or othe ep p 4, Ot her w se s t a r t w t h St e Fi g X I I - 5
Check mot or r o t a t i o n Check mot or con conne nect ct i on onss ea r i n g Check g ea Compar e wheel di amet er
Check f or compr ess i on b o l t s ep p 4, Ot her w se s t a r t w t h St e Fi g XI I - 5 S t a r t w t h St ep 4, Fi g XI I - 5
Compar e wheel di amet er
bur ned open or d i s c o n-nLook f or g r i d bur
ne nect ct ed c a bbll e
Ot her w se beg egii n w t h St e ep p 9, Fi g XI I - 5 ondi ti on Thi s i s not an abnor mal c on provi de dedd i t does not get get wor s e I f i t d o e s , s t a r t w t h Step 4, Fi g X I I - 5 Thi s i s not abnor mal pr ovi ded i t does not ge t wor s e I f i t d o e s , s t a r t w t h St ep 4, Fi g XI I - 5 Check contactors Ot her w se s t a r t w t h Step 9, Fi g XI I - 5 S t a r t w t h Step Fi g XI I - 5
P r ooce cee ed w t h Cas e No
NOTE
Seve vera ra l pos s i bl e t hi ngs ngs cou coul dbe t he cause of roubl e- sh shoo oott i ng, ng, t he fa u ull t roub bl e To s i mpl i f y t roub t he t rou Case s i t ua uat i o n has been pr es es en en t ed ed i n t hree Cases No 1, Case N o 2 and Case No 3
Case No
Rwh ee ee l s l i p system a ct ct i v a t e s W I f t he CM SL l i g h t i s l i t reducti on of e xc xc i t a t i o n , san sandi ng oc occu curs rs and t h e r e i s a red t hen pr oceed t o Case No 2 I f t he CM R wheel sl i p system does not a cctt i v a t e,e, t he pr obl obl em i s l o c a l i z e d t o t he M Rsystem P r o ce ceed w t h t he e x t e r n a l por t i on of t he he C f ooll l ow ng
TRO U BLE SH O O TI N G SEC TI O NXI I
STEP 1
GEK-3 30150
C M RW HEELSLI LI P
I NT AL CO ND TI O NS 1 EN G NE AT I DLE 2 REVERSE H A N D LE CENTERED 3 G F BREAKER O FF
SYSTEMO MO PERATES CO NTI NUO USLY
AG OTO PRO C ED U R EA
N OC M RW HEELSLI LI P SYSTEMACTI VATI O N
STEP
J UM PER LEVEL TEST PON O NT O N FD1154 O R 11551 O NT O C A R D TOT O TH E CO M M O N TEST PON EC ARD F SAM
C O M E O N
NO T CEDURE O TOPRO
B
O M ES O SX I S G OOD W SL C N W
STEP 3
R EM O V E J UM PER
G O TO STEP 4
0
a
STEP 4
N
1 3
PUM P UP LO CO A R BRAKE SYSTEM SET BRAKES PLACE G F BREAKER TO O N
O V E REVERSE H 4 M R W AR DO A N D LE TO FO R REVERSE O V E THRO TTL LE E H 5 M A N D LE TO N O TC H1
W v7
C M RW HEELSLI LI P
SYSTEMO MO PERATES
AG OTOPRO C ED U R EC
RW NO CM HEELSL LII P SYSTEM ACTI VATI O N
X O
CAUTI O N TO AVO D M O TO R DAM AGE, D ON O TH O LD M O TO RC N G ER T U TE U R R E N T LO H A N 1 MN
STEP 5
G G LE SWTCH O PLACE TEST TO R PAN EL TO N CM TEST AN DH O LD FO R 5 TO 10 SECONDS
TH ER NO O RO RESPO PO NSE
C E D U R E O O PRO
D
NTI NUO USL LY Y, SAND NG OCCURS, W SL FL LA ASH ES CO
A D M E TE R DRO AN D LO WR LEVEL AS LO PS TO LO N G AS SWTCH I S HELD LEVEL C RCU T I S G O O D D
STEP 6
R E T U R N TH TT TL LE H E THRO A N D LE TO I DLE CENTER THE REVERSE H AN D LE AN D PLACE G F
BREAKER TOO OO FF
2 APPLY TEM PO R A R Y J UM MTH HEELSL LII P PER FRO EW AR D TERMN PAN EL TERMNAL BO ALS AP TO AR O N 6-A 6- AXLE LO CO M O TI VES 4- AXLE LO AC TO AD O N 4-A CO M O TI VES
M PER N ULLI FI ES TH NO TE TH EJU E LEVEL CO NNECTI O N I N THE EXC TER SH U N T FI ELD C RCU T RATE REM A NS
UP 3 ab P U M PBR LS O CO A R BRAKE SYSTEM SE T AKE C PLACE G F BREAKER TO O N d M A N D LE TOFO R W AR DO O V E REVERSE H R e f
REVERSE M O V E THRO A N D LE TO N O TC H1 TTL LE E H A D M E TE R TO B W A T FO R LO EC O M E STEADY
CAUTI O N TOAVO DM O TO R DAM AGE, D ON O T
H O LD M O TO RC N G ER TH A N MN U TE U R R E N T LO
g
N OREACTI O NO R RESPO PO NSE, SAM E AS FO R STEP 5 O C E D U R EE G OTO PR
PLACE TEST TO G G LE SWTCH TO TEST AN D HO LD FOR 5 TO 10 SECONDS
NTI NUO USL LY Y, SAND NG OCCURS, W SL FLASHES CO AN D LO AD M ETER DRO WR LEVEL, BU PS TO TOA A LO T N O T AS LO H EN J U WAS I N STEP 5 W AS O M PER W FF 03 AN D RATE C RCU T AR E G OOD N TI N U ED AT TO P O STEP 6 CO F NEXT PAG E
FI G XI I 5 CM RW H EELSLI P SYSTEMFLO W CH ART XI I
21
GEK-3 30150, SEC TI O NXI I
TR O U B LE S H O O TI N G
FR O MSTEP 6
STEP 6 CONT D
1
2
STEP 7
THROTTLE H ND LE TO I DLE DPLACE G F LE N CENTER THE REVERSE H ND B R EK ER TO OFF R EM O V E TEM PO RR Y JU M PER APPLI ED I N STEP NO 6 R E TU R N TH E
U NIN HOSTLE THE LOCOM OTI VE LLO W T TO R R WR D N DREVERSE BOTH FO
HEELSL SLI P C M RW
SYSTEM OPER ERATES
CE ED DURE F vv--G O TO PRO
RW HEELS SL LI P NO CM ACTI VATI ON
STEP 8
E SET TH OTI VE BRAKES N D D VN C ETH E LOCOM NTI L TH E LOCOM OTI VE PULLS D LE U TH R O TT LE H N
HEELSL SLI P C M RW SYSTEMOPER ERATES
TH R O U G H TH E BR KES
GO TO PROCEDURE G
HEELS SL LI P SYSTEM RW NO CM ACTI VATI ON STEP 9 DAT A WTH THE LOCOM OTI VE I N I DLE N STANDSTI LL, G M C BRAKI NG I F OI NTO DYNA LOCOM OTI VE DOES NOT H VE DYNAM C BRAKI NG PROCEED TO STEP N O 10
W HEELS SL LI P SYSTEMO M OPERATES C M R
O C ED U R E o G OTO PR
H
RW HEELSL SLI P SYSTEM NO CM ACTI VATI ON
STEP 1
WTH THE LOCOM DAT A OTI VE I N I DLE N R E XLE LTERN TO STANDSTI LL, D SCONNECT TH WRES FRO MTH DMPANEL STU E L N DS 6-A - AXLE LOCOM OTI VE) O R TH DP STUDS 4- AXLE E N N LOCOM OTI VE)
CONTI NU E C M RW HEELSL SLI
STEP
E N C YG CONNECT A FREQU ENER ERATOR SUCH AS AN O R R EC T 14 TEST KI T TO TH E C M M 37 M M 26, O R TM R TERMNALS I N PLACE OF TH E AXLE LTERN TO OBTA N THE FREQU E E D E D TO G VE E N C YN MG R PH I N FI G XI I - 6 OVERSPEED DETECTI ON FRO SPEED VAR ES WTH RA LROAD
P
LS TO S SR TE OY PE AM TEFA OR OPERATES AT D FFERENT SPEED
P SYSTEM ACTI VATES AT PROPER SPEED C M RW HEELS SL LI
STEP 12 E Q U E N C YG E N E RT O R TEST KI T N D R EM O V E FR N TO R R EC O N N EC T XLE LTER
M RW H EELSLI P SYSTEMFLO W C HR T CONT D FI G XI I 5 C
XI I - 22
O C ED U R EJ ow GO TO PR
TRO UBLE- SHO OTI N G SECTI O NX I I , GEK- 30150
good Check t he CM R t e r m n a l s f or d i r t or condu con duct ct i ng ma t e r i a l Cl ean t e r m n a l s i f n e c e s s a r y
300
8
/
a
/
/ r1 w 250
y
IO Q
F
I LL
w
Check f o r l oos e bol t eedd j o i nt n t s e i t h e r i n t he t r a c t i o n mot or conn connect ect i ons ons w t h i n t h e mot or i t s e l f or i n t he ns of acc ompanyi panyi ng busbars and c a bbll e s Look f o r s i g ns heat and/ and/ or s mok e
800
X
900
700 AXLE R PM
ope erat i on 9 Check t he mot or contactor sequence op Assure l l t i p s ar e op ope erat i ng and ar e i n good con condi ti on Al so c a r e f u l l y check t he t r a c t i o n mot or
z oo
so o
/ /
PQ
10 Check f o r an open c i r c u i t w t hi hi n t hhe e traction mot or Check t o s ee i f a pi ni on has c o me of f of a t r a c t i o n mot or
/
z
shun shu nt conn connect i on onss
150
400
100
50
60
70
300
100
90
80 PH TR A N SPEED - M
11 Check t r a c t i o n mot or conn connecti ecti ons ons t o a s s u r e mot or s wi l l r o t a t e i n proper d i r e c t i o n and t h a t t h e r e ar e no l ocke ocked a x l e s 12 C a r e f u l l y i n s pe p e c t wheel s i z e s I f t h e r e i s a d i f f e r e nc nc e of g r e a t e r than one i n di amet er bet ween t he l a r g e sstt and s ma ma l l e s t whe heel el s t he C M Rwh eeee l s l i p system wi l l
FI G XI I - 6 AX LE A LTE RN A T O RO U T PU T FR E Q U E N C YO RAX LE R PMVS
det det ect i t Change whee heell s i f n e c e s s a r y , t o s a t i s f y t he tolerance
TRA NSPEED
Retur n Thro ttl e han handl dl e t o I DLE c e nntt e r t he Reverse FF ace t he GF breaker t o O han handl e and pl ace
2
Rem ove t he j umper s f r o m t he panel t e r m n a l s and
then r ep epeat St ep eps 4 and 5 of Procedure C noti ng whi ch t e s t po poii nt g i v es es t he abno r mal r ead adii ng
13 Check t o a s s u r e l l t r a c t i o n mot or s have t he s a me g e ar ar i n g Al so check t he nose mounti ount i ngs of t he t r a c t i o n mot or s t o a s s u r e they ar e f i r m y s e a t eedd i n t he r ubber ubber mount s
14 Check t he CMR s ar e e f f e c t i v e l y s h i e l d e d f r o m nearby c a bbll e s
3
cent er t he Reve everr se Retur n Thro ttl e ha han ndl e t o I DLE center FF han handl e and p l a c e t he GF breaker t o O
4
Usi ng t he l ocom hem mat i c and t he a pp ocomoti ve sc he pp l i c aabb l e CM R Whe hee el sl i p Panel schemat atii c t r a c e t he c i r c u i t contt ai ni ng t he t e s t poi con poi nt i n que quest i on Deter m ne whi ch wi r e s on t he panel termnal s t r i p ar e i n t he s ame c i r c u i t as t he t e s t poi poi nt
Th Thii s i s t he end of Case N o I f t he f a u l t has not been corrected proceed t o Case No 2 I f t he f a u l t has been c o r r e c t e d , proceed t o Fi g X I I - 5 , Step 5
5
6
R s by r emovi ng t he Check t he w r i ng ng t o t he CM Term rm nal s C D E F , G and Hon t he wi r e s f r o m Te heeel sl i p Panel s i x - a xl CM R Whe x l e l ocomoti ve o r Te Term rm nal s C D E and F f o u r - a x l e l ocomoti ve
Usi ng a Si mpson 260 met er o r e qquu i v al a l e nntt , meas ur e t he resi stanc stanc e bet ween t he w r e and i t s cor respondi respondi ng t e r m n a l stud I f a d i f f e r e n t r e s i s t a nncc e i s noted as c ompar ed w t h t he o t h e r s , epl ace t he wi r e s t he prob probll em i s i n t h a t c i r c u i t Repl when f i n i s h e d
Case N o 2 I f t he CM R wh ee ee l s l i p system a ct c t i v at a t e s and t h e r e i s no poii nts on s i g n i f i c a n t v ol o l t a ge g e d i f f e r en e n c e bet ween t he t e s t po t he c a r d s , proceed t o Case N o 3 I f there i s a s i g n i f i c a n t v ooll t a g e d i f f e r e n c e , t he prob probll em i s mo s t l i k e l y i n t he c u r r e n t measur i ng c i r c u i t t r a n s f o r me r s on t he panel pan el or t he v ol o l t a g e compari son c i r c u i t FD FD409 or FD 410 10 Card Not e t he t e s t p ooii n t s g i v i n g t he en pr o cce eed w t h t hhee f ooll l ow ng abnorr mal read abno readii ng and t h en
Retur n t he Thro ttl e han handl e t o I DLE c e n t e r t he Reverse ha han ndl e and p l a c e t he GF breaker t o OFF
7
Check f o r an o p en o r shorted CM R Compar e r e s i s t a nncc e meas ur ement s w t h a CM R know own t o be
2
Rem emove j umper s f r o m panel t e r m n a l s
XI I - 2 3
UBLE- SHOOTI NG NXI I TRO GEK- 30150, SECTI O
3
Assure ssur e
w re ess on t he panel
al l
t er mnal mnal s t r i p are
3
f i r m y f astene astened d
4
Usi ng
a
Re em m ove
Pum p up t he
a
ai r
br brake ake syst em eman and set t he
l ocom ot otii ve brakes brakes
equi va vall ent ent , check Sm pson 260 mter or equi
con nt i nui ty of t he panel t r ansf or mrs t he w ndi ng co circuii t w t h Esp spe eci all y check t he t r ansf or mr i n t he circu t he abnor ml r eadi ng 5
Per f or mthe the fol fol l ow ng
b
ove Rever evers se handl e Pl ace ace G F breake br eaker t o ON m EV ER S E and advance R W A R D or R t o FO Thrott l e handl e t o Not ch 1
c
ecom e st eady eady Wi t f or l oadmt mter er t o bec
al l
romt he panel and vi su sua al l y t he ca cards rds f rom damge amged d com ponent s f or bur ned or 49 Esp spe eci al l y check t he f i l t er cap pac acii t ors on t he FD er ca check
ot or damge, do avo oi d t r act i on m CA U TI O N To av
or t he FD 4 Car d check t he pl u Al so, ug g
ot otii ve Car ard d s i x - axl axl e l ocom
f ourour- axle
l ocom ot otii ve
ut e ongerr t han one mnute curr r ent l onge ot or cu not hol d m
connect ectii on pi ns on each card t o assure t hey ar e not bent or br brok oken Rep ace any def ect i ve card
6
4
slots and t he cir cu proper slots cuii t cards i n t hei r prop secu r ed i n t he panel assure t hey ar e Repl ace
al l
T and Pl ace ace t est Toggl e swtch on t he panel t o TES hol d f or 5- 10 seconds
a
t he end of Case N o 2 I f t he faul faul t has not se eN o 3 I f t he faul faul t ected,, pr oceed t o Cas been corr ected ected, pr oceed t o Fi g XI I - 5 , St ep 5 has been corr ected,
Thi s
is
as l ong as t he Toggl e swt ch
a
If
1
rence i ndi ca catt es t he si gni f i can cant vo voll t age di f f erence
circuii ts Level Level , Rat e pr obl em s i n one of the det ecti on circu
Retur et urn n the the Throttl rottl e handl e t o I DLE, cente terr th the e
2
Re em m ove j um per s f r ompanel t erm nal
3
Repe ea at Step 2 of Fi g XI I 5 t o doubl e- check WX rel ay i s oper at i ng pr oper l y I f i t i s not , rep repll ac ace e it
4
If
pr oceed w t h t he
3
is
ng condi t i on i n w r i ng circuii t con Check f or open circu
Check di ode rectifier bri dge 513R1 whi ch i s
road Rest estart art t he engi engi ne ; observe st andard rail road pr ocedur ure e and preca precauti uti on onss
5
Per f or m t he i ni ti al con condi t i ons of St ep 1 of
Fi g XI I - 5
and t hen return t o Step 4 of
Fi g XI I - 5
E
Pr obl em Wth St ep 6
D Pr obl em Wth St ep 5
centt er t he Retur et urn n t he Thrott l e handl e t o I DLE, cen to O FF p l ac a c e t he h e G F break br eak er Rever evers se handl e and
2
ot otii ve or x-axle xle l ocom Rep ace t he FD 54 Car d ssii x-a ot i ve w t h an t he FD 55 Car d f our- axl e l ocom
assumd good card
l ocom ot otii ve
l ocat cat ed on t he si de of t he panel 4
centt er t he Retur et urn n t he Thr o t t l e handl e t o I DLE, cen FF ace t he G F br breake eaker t o O Reverse evers e handl e and pl ace
p etel etel y Shut dow ot otii ve com n l ocom
betw bet ween panel and current t r ansf or mr
no faul faul ts have been f ound t o t h i s point, repl repl ac ace e ar d s i x - axl t he FD 54 Card axl e l ocom ot otii ve or t he ot i ve w t h an FD 55 Car d f our- axl e l ocom assumd good card Proc Pr oceed t o Fi g XI I - 5 , St ep 5
XI I - 24
esponse, se, no r espon
Thi s
2
2
is
gerous ous vo voll t ag ages es avoi ds pot en e nt i al l y danger seri ri ou ouss or fatal i nj ur y whi ch coul d cause se
dead
ace G Rever ever se handl e and pl ace F break FF breaker t o O
there
unl ess W A R NN GDo not pr oceed unl
ver speed Pr Proc oceed w th t he f ol l ow ng or Overs
hel hel d, pr oceed t o
f ol l ow ng
The l ack of
is
Fi g XI I - 5 , St ep 6
b o Case N
shes cont i nuousl y, sandi ng I f t he WL l i ght f l ashe evel el rops to a l ower l ev occur s and t he l oadmt mter er drop
ot otii ve or ar d ssii x-a x-axle xle l ocom Rep ace t he FD 54 Card our- axle l ocom oti oti ve w t h an ar d f ourt he FD 55 Card
assumd good card
3
Repea eat St eps 4, 5 and 6 of Fi g XI I - 5
TR O U B LE S H O O TI N G SEC TI O NX I I
F Pr obl ems W t h Step 7
Ret ur n t he Throttl ent eerr t h hee Throttl e ha hand ndll e t o I DLE c en Reverse ha hand ndll e and p l a c e t he GF breaker t o OFF
2
3
C a r e f u l l y check t he c ab a b l i n g t o t he r e v e r s e r Look f o r s h o r t s gr oun ounds ds o r l o o s e con conn nect i ons ons bet ween busbar s t he c a bbll e s and busbar
f ou oun nd i n i t i a l l y 4
G
H
Repeat Step 7 of F i g X I I 5 I f t he pr obl ems s t l l e x i s t r e t u r n t o Step 4 of Fi g X I I - 5 t o l o c a t e t he t r o u b l e I f t h e r e s no CM R system a c t i o n a f t e r r ep epea eatt i ng Step 7 proceed t o Step 8 of Fi g X I I - 5
Pr obl ems W th Step 8
Return t he T h r o t t l e ha hand ndll e t o I DLE c e n t e r t he Reverse ha hand ndll e and p l a c e t he GF br ea eak er er to O FF
2
C a r e f u l l y check t he CMR s E i t h er er one or mor e of t hem ar e not g i v i n g t he proper s i g n a l s at hi gh gher er m ot or currents traction
3
probll em s t l l Repeat St ep 8 of F i g X I I - 5 I f t he prob e x i s t s return t o Step 4 of F i g X I I 5 t o l o c a t e t he t roub roubl e I f t h e r e s no CM R system a c t i o n a f t e r r e p ea e a t i n g Step 8 proceed t o Step 9 of Fi g X I I - 5
Pr obl ems W t h Step 9
2
Ca r ef e f u l l y check t he c ab a b l i n g and busb sbaar s of t he dynam dyn am c braki ng c i r c u i t s t o t he t r a c t i o n mot or s conn necti ons ons ounds and l o o s e bol t ed con Look f o r gr ounds
3
Check t he ext ended aki ng contactors ar e ended r ange ange br aki
4
Check t he c o n t a c t s
of t he r e v e r s e r Assure l l per l y when t he r e v e r s e r contacts ar e pi cki ng- up pr oper operates Leave t he r e v e r s e r i n t he p o s i t i o n t was
Return t he T h r o t t l e hand handll e t o I DLE c en ent eerr t h hee Reverse hand handll e and p l a c e t he GF breaker t o OFF
G EK 3 15
operati operati ng prop properl erl y
Check f o r an open c i r c u i t i n t he braki ng g r i d s e i t h er er a g r i d s bur bur ned open open or a c a bbll e s burned of f Proceed t o F i g X I I 5 Step 10
Pr obl ems W t h Step 11
hand ndll e t o I DLE c e n t e r t he Return t he Throttl e ha Revers e hand handll e and pl ace t he GF breaker t o OFF
2
ender and ext en endd t he Use a 44- pi p i n c ar ar d ext ender Car d f r o m t he pan panel
3
W t h t he f r eq equ uen ency cy gener at at oorr Tes t Ki t s t l l equ uen ency cy t o t h hee pr prope operr v a l u e as connect conn ect ed s et t he f r eq i ndi cated cated on Fi g X I I - 6
4
FD4 6
CM R
n t i l t he card a cpotent A whdjee e eulst s l i pt hesystem t i v a t e si om w et t hera usm smal al l i n ccrr e a s e i n f r eq equ uen ency cy ab abov ovee t he pr ope operr v a l u e
5
ns i v e t o any I f t he wh ee ee l s l i p system i s not r e s p o ns pott ent ent i ometer r e pl s e t t i n g of t h hee po p l a c e t he FD4 6 Car d w t h an ass as s umed good card Set t he pot pot ent ent i omet er on t he r epl acement card a s s p e c i f i e d i n Steps 3 and 4 above
6
D scon sconn nect th thee card card exten tendder Car d i n t he pan panel Proceed t o F i g X I I 5 Step 12
r ep e p l a ce c e t hhee FD4 6
G KK-61 61301
T R O U B L ES H O O TN G
LOCOMOTI VE SYSTEMS I NTERFACES
I n t e r f a c i n g Syst ems
ocom moti ve sys Many of t he l oco systt ems com e i n a cctt u a l , or near, contact w t h other l oco ocom moti ve e r f a ce c e s a r e by d es es i g n, n, whi l e o t h e r s occur as a sys t ems T hi hi s i s t er med an i n t e r f a c e Som om e i n t er xi s t uncti on The Tabl r e s ul ul t of a mal f uncti Tabl e bel bel ow p r e s e n t s som e of t he N O R M ALi n t e r f a c e s t h a t e xi on l ocomoti ves ves W hen one system i s at a hi gher gher p r e s s u r e than t he o t h e r , t he hi gher gher p r e s s u r e i s i ndi ndi ca cated ted by a c i r c l e d X
3 op
O
ILI
C a x y
a
Q
ti
U
X
w
U
UU
X X X X X
X
X X X
X X
X
X
X
X
X
X X
X X
X X X
X X
X
X
X
X
X
X X
X X X
X X
X
X X X X
X
Remar ks
Locati on I n t e r f a c e Locati Lu Lubbe-oi l coo cool er Lu Lubbe-oi l coo cool er Wat er pum p Cyl i nde nder s
W t h en engi gi ne r unn nnii ng W t h en engi gi ne shut dow n Obser ve open t e l l - t a l e hol e acked d c y l i n ddee r - j a c kk-Def ecti ve l ower l i ne r s ea ea l , or por ous or cr acke casti ng et casti
L u bbee - o i l coo Radi at or cooll er Wat er- t ank f i l l cap
hol es Obser ve t e l l - t a l e hol
Depe ependi ndi ng on wat er f l o w e i t h er er systemca n be at hi gher gher p res sure
ab heat heat er X X
X X
I n t eerr c o ol ol e r s F u e l - o i l heater Cyl i nde nder s
Gover nor Engi ne temper per atu ature re sw tch Cyl i nde nder s t op l i n e r s e alal Cyl i nde nder s t op l i n e r s e alal Cyl i nde nder s l i n e r wa l l Cyl i nde nder s f u e l - o i l d r a i n L u bbee - o i l coo cooll er Turbochar ger s e alal s Tur Tur bo bochar char ge gerr s e alal s Gover nor Cyl i nde nder s p i s t o n r i n gs gs Bl ower ower f a i l u r e p r e s s u r e s w t c h BFPS) Engi ne f i l t e r pressure s w t c h EFPS) Ove verr t emper per at ure senso sensorr s O OTSTS- 1, - 22,, - 3 E l e c t r i c a l con contr ol s E l e c t r i c a l r o t a t i n g machi nes bust i on cham Cyl i nder nder c ombust ber Fuel tank vent) Fuel oi l d r a i n s p Fuel t r a n s f e r pum Overs pee peedd- der der at er l i n k
F u e l - o i l pressure i s n eg eg aatt i v e Cracked c y l i n de de r j ack ackeet at f u e l - o i l d r a i n LW W P) Lowwat er p r e s s uurr e d e viv i c e L
ETS) W t h en nnii ng engi gi ne r unn W t h en engi gi ne shut dow n
Obser ve t e l l - t a l e hol hol es W t h good seal ai r p r e s s u r e W t h poor seal ai r p r e s s u r e ev i c e LOP) Lowi l pressure d ev
I n power r e c t i f i e r panel panel s I n control com co mpar t ment generr at or or a l t e r n aatt o r , a u x i l i a r y Tracti Trac ti on mot or s, t r a c t i o n gene ge gene nerr ator s
One on each s i d e of en engi gi ne
These i n s t r u c t i o n s do no t purport t o cover al l d e t a i l s or v ar provii de f or eve everr y p os os s i b l e conti ngency ngency t o be ar i a t i o n s i n equi equi pment ent nor t o prov on n e cctt i o n wi t h i n s t al a l l a t i o n , ope enance ce Sh Shou oull d f u r t h e r i nformati on be desi r ed or shoul shoul d p aarr t i c ul u l a r pr obl ems met i n c on oper ati on or mai nt enan coverr ed s u f f i c i e n t l y f oorr t he he pur ar i s e whi ch ar e no t cove pur chase chaserr s purposes, t he mat t er shoul shoul d be referred t o t he Gener al E l e c t r i c om ompany pany
BUSI SI NESS DI VI SI ON, GENERAL ELEC ELECTR TRII C CO TRA TR ANSPO SPOR RTATI ON SYSTEMS BU M PANY, RM 4
E RRII E , P
16531
PR NTED IN V. S . A
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