EMD (HHP) ENGINE TESTING SHOP:

Main Parts of EMD Engine:

OIL PAN CRANK CASE CRNAK SHAFT LINEAR PISTON ASSEMBLY ALTERNATOR

Complete Assembly Of Power pack:

Testing Arrangements:

Testing Procedure of EMD Engine:

Preparation of Test Bed & Placement of Engine

Crane Connection

Alignment (Radial=+,-.020”&Angular=+,-.010”) & Torquing of foundation Bolts (Engine coupling Bolts-295 foot-pound,engine mounting bolt= Front-650,&Rear-450&Alternator Mounting Bolt=1400 Foot Pounds .

Water Circulation(100+-10 psi)for15 min.

Fuel Oil Circulation(60-70 psi for 15 min.)

Filling of Lube Oil (Multgrade Servo RR520MG 300 Gallon)& Circulation.

All Connection of Test Bed

First Inspection:

Ensure Lube Oil In Cam Shaft Bearing & Check the free rotation of the Engine with the help of Crank Over Tool

Maintain 100 to 110 PSI Pressure in Trolley Bellows

Fill Water & Lube Oil

Ensure Proper level of Lube Oil

Loose Cylinder test Valve & Rotate 2 Rounds the Engine for Blow out & Close test Valve

Break in & Full Load Test:

Start Soak back Pump Before 10 Min. starting of Engine & Run the 20 min after the Engine shut down

Start the Engine for 10 min without load check for any unusual sound and leakages

Now start the Load testing as per given schedule at different notches

Notch wise Load:

Notch 4000 HP Engine 4500 HP Engine Duration in Minutes

RPM BHP(AAR) RPM BHP(AAR)

Low Idle 200 +4 - 200 - -

1 269 +4 300 270 259 25

2 343 +15 530 354 607 35

3 490 +15 1110 486 1148 5

4 568 +4 1440 572 1573 5

5 651 +15 1840 675 1916 25

6 730+4 2290 764 2960 25

7 820 +15 3680 863 3822 25

8 904 +4 4080 954 4500 80

Over Load

10

60

Check OST Operation & Adjust 1035-1050 RPM

Check Turbo Run Down (50 sec. min )

Check LWS Operation (35 sec. min)

Final inspection:

Checking of Scoring & Leakages:

TOP Deck

Air Box

After Cooler Core

Piston Top

Cylinder Liner Valve

Piston Cooling Tube

Cam Roller

Turbo Charger

Disconnection & Dispatch: