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Under the Guidance of Ravi Chandra Submitted by Jerome Leonard. K. J Clement Stephenson . B Susheel Raj .

G 09681A0321 09681A0316 09681A0320

Felix Joshua .G

09681A0317

Fuel Oil System, often referred to as the heart of the Diesel Locomotive.
This system deals with the squirting the proper quantity of fuel into the

cylinder at proper timing.


This system is responsible for helping in generating the required power for

the proper functioning of the locomotive.


In this system, the heat loss is very less and the fuel consumption is also

low.

The fuel oil system is designed to introduce fuel oil into the

engine cylinders at correct time, in correct quantity

,at correct pressure.

CORRECT TIME
Fuel should be introduced into the combustion chamber with

precise defined period of the cycle.

CORRECT QUANTITY

Correct quantity of fuel is important to maintain the variable speed of locomotive at variable load. Usually at equal distribution.

CORRECT PRESSURE
High pressure helps in proper atomization so that better contact is established

between small droplets and fresh air.


High pressure of fuel is also required to lift the nozzle valve and for

better penetration into the combustion chamber

Fuel oil system consists of two integrated systems


Fuel Feed System . Fuel Injection System.

Fuel Feed System The fuel system provides the back up

support to the fuel injection pump by maintaining steady supply of fuel at required pressure.
Fuel Injection System- The fuel injection pump starts

according to firing order. All F.I.P starts & discharge fuel oil at high pressure to their respective nozzle.

Fuel Oil Tank


Fabricated under the super structure of locomotive and

located between two trucks. Capacity5000-6000 Lts

Fuel Primary Filter


Paper type filter

Fuel Relief Valve The spring loaded relief valve.

Adjusted at - 5kg/cm2 (70p.s.i )

Booster Pump (fuel transfer pump)


Pump Capacity - 1414 Lts/ minutes(at 1725 rpm)
Pressure - 4-4.8 kg/cm2 Fuel Regulating Valve
The spring loaded valve. Adjusted at - 4.0 to 4.2kg/cm2 (50 - 55p.s.i)

Fuel Injection Pump


It is single acting constant stroke plunger type pump Function To raise the fuel oil pressure to nozzle which will

efficiently atomize the fuel.


To supply the correct quantity of fuel to nozzle as per

power and speed requirement of the engine.


To accurately time the delivery of the fuel for efficient

economical operation of engine.

Control Rack
Barrel & plunger Control sleeve

Plunger spring
Guide cup Lower spring seat

Snubber valve assembly.

Fuel Injection Nozzle


To inject fuel at a sufficiently high pressure so that the fuel

enters the cylinder with a high velocity. Fuel injection nozzle injects fuel oil to combustion chamber at 4000psi.
Nozzle opening pressure (New) 4000 to 4200 psi.

Nozzle opening pressure (Old) 3700 to 3800 psi.

Purpose:
Good atomization ,correct spray pattern and no leakage or

dribbling are the criteria of a good FIN

The following tests are conducted on a specially designed machine


Spray pattern ( by taking impression on blotting paper)
Spray pressure(3900-4050 PSI for new & 3700-3800 PSI

for reconditioned nozzle)


Dribbling : This occur due to improper pressure setting or dirt

stuck up between the valve & valve seat. Or improper contact between the valve and valve seat.

Opening Pressure: 3900-4050 psi (New), 3700-3800 psi

(Old)
Spray Pattern/ Blotter test: Uniform pattern Dribbling: Holding at 3500 PSI for 10 sec ( No drop) Leak off: 3500 to 1000 PSI drop down time 6-16 sec

Valve Lift: .026"(max), .005 to .007"(New)

Nozzle chatter
This sound creates due to free movement of the nozzle

valve inside the valve body. it should be proper.

Nozzle leak off rate


The process of checking the leak off rate is by

creating pressure in nozzle up to 3500 PSI and hold the pressure till it drop to 1000 PSI.( 5sec)

Fuel oil pressure not building up. Fuel pump motor not working.

Fuel pump contactor not picking up.


Oil leakage from fuel T jumper o ring. T jumper cap screws worked out.

Fuel pump/support cap screw worked out.


Fuel oil primary/secondary filter chocked. Fuel oil cross over pipe burst. Fuel oil hose pipes burst/damaged due to rubbing. Fuel oil leaking from hose pipe joint/union defective. Fuel oil contaminated with water.

Development of technology for improving existing Rail Traction

Diesel Engines for

Better Fuel Efficiency Higher Reliability Increased Availability

Development of technology for increasing power output of existing

Diesel Engines.

Develop capability for designing new Rail Traction Diesel Engines for

meeting future needs of Indian Railways.

To provide effective R&D backup to Railways and Production units to


Maintain Quality Facilitate Indigenization