EMD Technical Publications and History PDF

CHAPTER EMD Technical Publications and History History The General Motors Locomotive Group as we know it today was founded in 1922 with the creation of the Electro-Motive Engineering Company (EMC) in...

CHAPTER EMD Technical Publications and History History The General Motors Locomotive Group as we know it today was founded in 1922 with the creation of the Electro-Motive Engineering Company (EMC) in Cleveland, Ohio. EMC produced gasoline-electric railcars suited to light freight and passenger service as an alternative to steam powered engines. These 35 ton rail cars proved to be quite successful, and as a result approximately 500 were built between 1926 and 1932. EleCtreMotive The demand for more power resulted in the use of “Winton” gasoline engines wasfounded ranging from 175 to 400 horsepower. A limited number of units were built using two of in Cleve/cmd the 400 horsepower engines. Two major problems confronted the designers at EMC, Ohio in 7922. those of space constraints due to the large engine size and the high cost of gasoline in comparison to alternative fuels. EMC attempted to develop their own distillate engine but were unsuccessful. In 1930, both the Electro-Motive Engineering Company and the Winton Engine Company were acquired by General Motors. With the assistance of General Motors Research, Winton soon produced their first diesel, the “Type 201” engine. ITS Locomotive Training Series - Student Text 1-1 g c/ c. G G c 6 c, 0 ci G G Q e 0 Figure 1.1 The Winton Type 201 Engine 0 The eight cylinder 201 engine was built with 8" bores and a 10" stroke which 0 developed 75 to 80 horsepower per cylinder at 750 revolutions per minute (rprn). 0 The 201 pioneered many innovative concepts that have been passed on to the engines of today. Among them, the Winton 201 was designed with; 0 e lightweight design welded steel frame G * individual removable power assemblies, and G unit injectors. e In 1933 a 600 horsepower version of the 201 was used to power the Burlington Railroads Pioneer Zephyr to a new speed record between Chicago and Denver. 0 T h e Zephyr completed the trip in thirteen hours and five minutes averaging 77.6 mph 0 ( I 2 5 krnlh). Following this achievement there was considerable interest expressed by the railways in the development of true diesel locomotives. c 0 0 G c c G G 6 e Figure 1.2 The 1933 Burlington Zephyr e ElectreMotive Model 567, 645 & 710 Series Diesel Engines C  3 3 3 Interest was such that in 1935 General Motors undertook the construction of North America’s first Diesel-Electric locomotive plant at LaGrange Illinois. uy1) Design work on the diesel engine continued and a new series of engine, the 567 was ready for installation in 1936. A 567 engine was installed in the first locomotive 3 produced at the LaGrange plant. This 600 horsepower switcher locomotive ran in 3 regular service for the Santa-Fe-Railroad until 1975. d The “567” indicated the number of cubic inches per cylinder and this engine was designed primarily for rail use. The 45” “V” design allowed for installation in narrow 3 car-bodies and the two cycle engine provided a simplicity and ease of maintenance which was recognized as an advantage by the railways. Another significant advantage of 3 the 567 design was the ability to manufacture the engine in 6,8,12 and 16 cylinder 3 models to suit different horsepower demands. 3 3 3 3 3 3 3 3 3 3 3 3 3 Figure 1.3 Typical General Motors ”Switcher”Locomotive 3 By 1938, E M C had assumed responsibility for the manufacture of all locomotive 3 components, and in 1940 oficially became the Electro-Motive Division of General Motors. is 3 In 1949 General Motors of Canada, Diesel Division, established a plant in London, Ontario Canada to assemble locomotives for the Canadian Market. 3 The General Motors Locomotive Group was formed in 1988 in order to pool the resources of the London and LaGrange plants. 3 3 3 3 3 ITS Locomotive Training Series - Student Text 1-3 I L, L3 c c c c c Engine Development c The design of the diesel engine has continued to evolve over the years since the c Winton and has seen the incorporation of many improvements. Many of the changes c were in response to the customers ever increasing horsepower demands. By 1959 the horsepower of the basic 16 cylinder 567 engine had been increased to 1800 Hp. G C c c c c c G G c# Figure 1.4 The 567 Series "Roots Blown" Engine G c Continuing research led to the introduction of the first turbocharged engine in 1959. The 16 cylinder 567D2 engine produced 2000 Hp. The 567 engine design G reached its limit in 1964 with the introduction of the 2500 Hp 567D3A. c Building on the success of the 567 engine, GM designers produced the first 645 series engine in 1966 by increasing the bore of the 567. Design work continued on the c 645 model, still driven by higher horsepower requirements, but also by customer c demands for improved fuel economy. The latest version of the 645 engine was the fuel efficient, 3600 Hp, 16 cylinder 645F3B engine. c c c c c c c c c c Figure 1.5 The Turbocharged 645 Engine c c 1-4 ElectreMotiveModel 567, 645 & 710 Series Diesel Engines G  General Motors introduced the new 710G3 engine in 1984 rated at 3800 horsepower. While this engine is similar to the 645 configuration, the longer stroke of the 710 engine required some redesign to the engine block. This was the first major change to this reliable engine design since 1954. The 710 engine looks almost identical to the 645 model, except that the block is deeper between the air box and the top inspection covers to accommodate the longer stroke of the 710 power gssemblies. L3 3 The durable and efficient design of these engines has been proven over the years not only in locomotive applications but also in marine applications, drilling rigs and vs stationary power plants. 3 The newest addition to the General Motors locomotive line is the SD80MAC and 3 SD90MAC locomotives. The SD80MAC Series unit is powered by a 20-710 turbo- charged engine which is rated at 5000 tractive horsepower. T h e SD90MAC units were Ip released with a 16-710 engine at 4300 tractive Hp, and are being retrofit with the new EMD designed "H" engine which will produce 6000 tractive Hp. These locomotives 3 and the "H" engine are covered in separate training packages. 3 13 Locomotive Development 3 Since the production of the first GM diesel electric switcher locomotive in 1936, locomotive design has kept pace with engine design to effectively deliver the ever 3 increasing horsepower to the rails. Another challenge has been to continually improve 3 the locomotives electrical and mechanical systems so as to provide the customer with the most efficient and reliable locomotive possible. 3 While locomotive design has been a constantly evolving process, there have been 3 several significant milestones, particularly in the technological advances made in the electrical system. 3 3 The earliest models of GM locomotives were the; u4 $ 6lb iW-1, SW-900 and SW-1200 3 F-T, F-3, F-7 and F-9 lg GP-7, GP-9 and GP-18 and 9 SD-9, SD-7 and SD-18 t;s These locomotives are 3 characterized by lower horsepower output and direct current generators. 3 3 4 Figure 1.6 Typical F-PLocomotive blJ 3 ITS Locomotive Training Series - Student Text 1-5 u I L J ' c c G c c The next generation of locomotives developed higher horsepower ratings and c offered greatly improved electrical systems. One important electrical advance was the replacement of the direct current main generator with an alternating current main e alternator. The main alternator offered improved ease of maintenance and increased c control over the electrical system. This generation of locomotives included models such as, G GP-38AC and GP-40 G SD-38AC. SDP-40, SD-45 and SD-40 e Later models, known as Dash 2 locomotives offered further refinement to the c electrical system. Most of the electrical modules which were mounted throughout the electrical cabinets were incorporated into cards mounted in a cabinet designed for ease e of troubleshooting and change-out. G G G G c1 c G c G e Figure 1.7 Dash-2 Type Electronic Cards e All locomotive systems and component parts have undergone improvements over G the years such as upgraded traction motors, air supply and filtration systems, car-body design, engine protection systems and a vast number of changes all designed to service G the customers needs more effectively and economically. e The design of the SD or GP-60 series locomotives added further technological c advances to the GM locomotive which enhanced fuel economy, improved traction and wheel slip control, provided for self diagnostics and proved to be an extremely c reliable IgGQgmtive. c c e; e e a 1-6 Electro-MotiveModel 567,645 & 710 Series Diesel Engines c  Voltage Regulation And ’ Power Supply Display Equipment Excitation Computer Computer Logic Computer J,1. -.4 \, Figure 1.8 The 60 Series Microprocessor The 60 Series locomotive replaced the Dash-2 type electronic cards nith microprocessor control technology. This eliminated the need for most of the relays in the electrical cabinet and allowed for a far superior control of the excitation and control systems. The microprocessor control allowed for engine crews and maintenance staff to perform much analysis of the 60 Series locomotive from the cab. Also added were many system diagnostic checks that could be run from the display key-pad. The 60 Series locomotive continued successfully to progress the technology demanded by the customer providing again improved fuel economy in an efficient 3800 horsepower locomotive. The 70 Series surpasses the 60 Series in terms of fuel economy, improved tractive effort and control systems in a 4000 horsepower locomotive. Some of the changes to the 70 Series unit are, the faster EM2000 computer system, 4000 tractive horsepower delivered by the 710G3B engine, improved fuel economy, the “steering” HTCR radial truck, higher capacity D-90 traction motors and several technologically.advanced options such as ICE (integrated cab electronics) and the Micro electronic braking system. Figure 1.9 The 70 Series Locomotive ITS LocomotiveTraining Series - Student Text 1-7 a  3 3 3 The EM2000 computer system has also been incorporated into the n e w SD80MAC and SD90MAC locomotives. These units offer AC traction motors 3 and improvements in truck performance with the HTCR-11. Additionally, these units are equipped with EMDEC electronic fuel injection, and further perfornance 4 enhancements. 3 3 3 r03, 3 Ic$ 3 e3 3 cp 3 3 Figure 1.10 The EM2000 Computer Chassis 3 The SD80MAC is equipped with a 20-710 engine which produces 5000 Tractive 3 Hp. The SD90MAC units were put into service with a 16-710 engine at 4300 Tractive Hp and are being retrofit with the new EMD "H" Model engine. An "H" engine cl) equipped SD90MAC will produce 6000 Tractive Hp. b4 3 r3 Y, 3 lir 3 3 kJ 3 4 Figure 1.11 SD8OMAC / SD9OMAC Carbody Design 3 L) m 1-8 Electro-MotiveModel 567, 645 & 710 Series Diesel Engines L) d c; c c c d3 Electro-MotiveTechnical Publications c; General Motors diesel electric locomotives are complex units made up of many u components and sub-systems. To assiit in the proper maintenance of this equipment, technical publications have been produced. These publications contain valuable G procedures and service data. c In this section of the chapter we will examine four of the technical publications c produced by the GM Electro-Motive Division. Technical G Publications Locomotive Service Manual are provided G to assist in the Engine Maintenance Manual maintenance t and repair of Maintenance Instructions EM0 1ocomotives. Service Pointers G This section will demonstrate the types of information contained in each of these c publications, how to find specific information, and provide an opportunity to practice c with this material. c As you are working through the chapter, it is suggested that you have copies of the various publications available to refer to. All of these publications are very useful on G the job. c G Locomotive Service Manual (LSM) c Electro-Motive Division produces Locomotive Service Manuals in "generic" formats and, more commonly, for customer specific locomotive orders. The manual c1 contains most of the service information for the locomotive, with the exception of the c diesel engine, which is covered in its own manual. c When referring to the index at the front of the Locomotive Service Manual you will notice it is divided into sections, each section dealing with a specific subject. 0 Each section title serves as a description of the type of information contained in that ci section. For example, you find information dealing with the Compressed Air System in Section 6. c The most important point to remember when using these manuals is to know c specifically what information you are looking for. If you know what system you are c working on, then it is easy to look in the index for this system, and quickly find the service information. c, c c 2 b G c ITS Locomotive Training Series -Student Text 1-9 1 c  Section "0"- General Information The sections of the LSM can be identified by the page numbers at the bottom. T h e first number identifies the section, the second number is the page number within that section. For example in Section 0 entitled General Information, the pages are numbered 0-1 through 0-9. This section is unique, in that, it does not cover any system in detail, but provides: General information about the locomotive An overall description of the locomotive and its' systems Types of equipment applied to the locomotive The EMD Capacities of systems such as fuel and lube oil Locomotive Service Weights of major components Manual provides technical and The information contained in Section 0 will be used on a daily basis. For example, maintenance you need to know what the cooling system capacity is when refilling after repairs or when data on each calculating water treatment chemicals. specific class of locomotive. Component weights are required when performing repairs or for selecting proper lifting equipment. Sample Section "2" - Fuel System Section 2 is a typical service section, dealing with the fuel system. Each of these sections begins with a system description, which explains the operation of the system, and describes the major components. Generally, a diagram of the system is shown, to aid in understanding how the system functions, and to assist in troubleshooting. From there, the section describes each major component in detail. Specific maintenance requirements, specifications, and procedures are provided. For example, on page 2 of section 2, the cleaning procedure for the fuel suction strainer is given. A brush can be used to clean the element and a wooden dowel is used to spread the pleats. It also states that the engine must be shut down to perform this servicing procedure. Section 2 provides additional information on the proper storage and handling of fuel for the locomotive. The last part of the section provides a list of references that you can consult if you need additional information. Section 2 states that you could look in M.I. 4110 (Maintenance Instruction) to find additional information on maintenance of the fuel pump. If special tools or equipment are required for servicing the system, you can find them listed on these pages. I 1-10 Electro-Motie Model 567, 645 & 710 Series Diesel Engines c c c c c All of the sections in the Locomotive Service manual are arranged the same way: c General system description c System diagram c Specific service requirements and procedures c References, and Special tools and part numbers c Again, if you know the specific system that you require information about, consult c the index for the section of the manual that covers that system. c e Engine Maintenance Manual (EMM) c The Engine Maintenance Manual is prepared for the specific engine in each c order of locomotives. While most information applies to all G M diesel engines, there may be certain items specific to each order. Always ensure that you are using the correct c manual for your engines. c The manual is broken down into sections much like the Locomotive Service c Manual. The page numbers work the same way, the first number refers to the section, the second number is the specific section page. In this manual, however, you can see c that there is a table of contents for each section to help you find the information you need quickly. c c Section ”0”-Table of Contents c Section 0 again provides general service information on the engine and it’s c systems. It also gives a description of engine operation, specifically the operating cycle of the G M engine. c c This information will be covered in more detail elsewhere in the course. c Section 0 gives engine specifications, ratings and speeds, and specific equipment applied to the engine. For example a Woodward PGR governor has been applied to this c engine and at full speed engine RPM should be 904. Also contained in this section is a c weight list for engine components similar to the Locomotive Service Manual. c O n page 0-9 can be found a complete listing of torque values for your engine. The torque specifications also may include special instruction as denoted by an asterisk CI -(*):’The asterisk (*) means that you have to look at the end of the section for more information. G G Refer to the Table of Contents for Section 1. G c c c - ITS Locomotive Training Series Student Text 1-11 I G  3 311 The table of contents serves as a quick guide to the particular information you need. Section 1 is a typical service section that deals with the crankcase and associated parts. As in the L.S.M., the section starts off with a general description, and then deals with specific components one by one. For each component, a detailed description is provided along with specific inspection and repair procedures. To further understand the layout of the manual, refer to the pages dealing with the lower liner bore insert (p. 1-2). Along with a description of the component, removal and application procedures are described. The manual tells us if special tools are required to perform the indicated tasks, and in this case a puller is needed to remove and apply the insert. The special tools, such as dj the puller, are fully described, and drawings provided should it be necessary to fabricate these tools. Section 1 finishes with a list of references, specifications for the assemblies, and a list of special tools required for repair of components covered in this section. All the remaining sections of the Engine Service Manual are organized in a 3 ; similar manner. 31 Review The Locomotive Service Manual deals with systems and components found on the locomotive except for the diesel engine. The diesel engine is covered separately in the Engine Service Manual. Both manuals are arranged in the same manner, sections that deal with a specific subject. Within the section, the first number on the bottom of the page refers to the section, while the second number is the specific page within the section. Each section starts with a description of the system or component. Specific maintenance procedures for each component are dealt with, and at the back of each section may be found: Service references Specifications Special tools and, sometimes part numbers I 1-12 Electro-MotiveModel 567,645 & 710 Serles Diesel Engines c 6 c -.-- c c Maintenance Instructions (MI'S) c Maintenance Instructions, or MI'S, are another form of technical publication c produced by General Motors. MI'S deal with the service and repair of specific systems c and/or components. These documents are produced as required when: c Locomotives are equipped with components or systems not covered by the LSM or ESM c Information in the Service Manuals has been updated c c Or when more detailed information is required for inspection or repair of systems or components c Quite often the EMM or LSM will list one or more MI'S as reference at the back c of a section. Let's look at a typical MI to see how it is laid out, and the type of c information it contains. c Example MI 1520 c The number of the MI can be found on the top right corner of the first page c (MI-1520). Beneath the number sometimes will be found Rev. and a letter signifyirig the c latest update. If you have two versions of an MI, use the version with the latest revision letter. MI-1 520 shows Rev A, meaning that it has been updated once since it was first c published. c The title on the top of the first page describes the subject dealt with by the MI, c in this case, the inspection and repair of traction motor gear cases. c While each MI deals with a different subject, they all follow a similar layout. The subject of the MI is first reviewed, followed by a brief description of the component c or system involved. For example, M.I. 1520 explains the functions of the traction motor gear case (Protects the traction motor gears from dirt and/or damage, and contains the 6 gear lubricant). c Next, the procedures for removal, inspection, repair, and application are covered c in detail. Detailed drawings are provided as required to explain the procedures, fabricate tools, or modify components. The MI also lists other references when required, part c numbers for original and replacement parts, and special tools or equipment needed to c perform the task. G There are numerous MI'S on a great variety of subjects and an index of current MI'S has been prepared to assist in finding information. This index allows you to find MI e numbers by subject, number, or application. c G c c c - ITS Locomotive Training Series Student Text 1-13 a e  Ls 3 3 Review u) MI’Sare used to provide additional service data on components and/or systems. 3 They are also used to update information contained in the ESM or LSM. 3 MI’Swill also be used to provide service data on additional locomotive equipment 3 or systems. 3 Revisions to MI’Sare indicated by a revision letter under the MI number on the 3 first page. 3 MI’Sare organized similar to the sections of the ESM and LSM: d Beginning with a general description of the system or components involved 4 3 Continuing with service data on inspection, repair, or replacement 3 And finishing with a listing of references, specifications, and tools or special equipment required 3 3 Service Pointers 3 Refer to the sample GM Pointer. 3 3 GM Pointers are produced to update procedures or specifications of engine or locomotive systems/components. 3 They are issued to customers as required, and are designed to get the information 3 distributed as quickly as possible. 3 GM Pointers are also used to provide customers with notice of changes to EMM, 4 LSM, or MI’S. 3 LI Review 3 Pointers are used to get information to the customers fast. They may contain changes to inspections, repair procedures, or specifications. Q They may also be used simply to advise customers of revisions to technical 3 documents. 3 Pointers may deal with one or more subjects. kill G h Ls 1-14 Electro-MotiveModel 567,645 & 710 Series Diesel Engines