Diesel Locomotive Shed Alambagh Lucknow This provides the correct info about tell tale sign.

1. DIESEL SHED LOCOMOTIVE
ALAMBAGH, LUCKNOW (U.P)
SUMMERTRAININGREPORT
AMBALIKA INSTITUTE OF MANAGEMENT AND TECHNOLOGY
MOHANLALGANJ, LUCKNOW (U.P)
SUBMITTED BY-
NAME – DHEERAJ PAL
COURSE – B.TECH (1736340907)
BRANCH – MECHANICAL ENGINEERING

2. Tell-tale
Sign
Of
Diesel

3. Locomotive
INDEX
1. PREFACE
2. ACKNOWLEDGEMENT
3. INDIAN RAILWAYS
4. INTRO TO DIESEL SHED
5. TELL-SIGN
6. OBJECTIVES
7. CLASSIFICATION
8. VARIOUS TELL-TALE SIGNS
9. CONCLUSION

4. 10. REFERENCES

5. PREFACE
The objective of the Summer Training is to learn
something about industries practically and to be familiar
with the working style of a technical person to adjust
according to the environment.
It is rightly said practical life is far away from theoretical
one. We learn in the class room can give the practical
exposure real life experience no doubt they help in
improving the personality of the student but the practical
exposure in the field will help the student in long run of
life and will be able to implement the theoretical
knowledge.
As a part of academic syllabus of four year degree course
in Mechanical Engineering every student is required to
undergo a practical training.
I am student of mechanical and this report is written on
the basis of practical knowledge acquired by me during
the period of summer training taken at Diesel Shed
Locomotives, LUCKNOW.

6. ACKNOWLEDGEMENT
We take this opportunity to express our sincere gratitude
to the peoples who have been helpful in the successful
completion of our summer training and this project.
We would like to show our greatest appreciation to the
highly esteemed and devoted technical staff of the Shed.
We are highly indebted to them for their tremendous
support and help during the completion of our training
and project.
Despite their busy schedules, they took time out for us
and explained to us the various aspects of the working of
the plant from the production shops.
Submitted to:
DME (Diesel Shed Locomotive)
Alambagh, LUCKNOW

7. INDIAN RAILWAYS
Indian Railways is an Indian state-owned enterprise,
owned and cooperated by the Government of India
through the Ministry of Railway.
Railways was first introduced to India in the year 1853
from Bombay to Thane. In 1951 the systems were
nationalised as one unit, the Indian Railways, becoming
one of the largest network in the world. IR operates both
long distances and suburban rail systems on a multi-
gauge network.
IR is divided into 16 zones. Each zone railway is made up
of a certain number of divisions (67 divisions). There are
six manufacturing plants of the Indian Railways.

8. DIESEL SHED
Diesel Locomotive Shed is an industrial-technical setup,
where repair and maintenance works of diesel
locomotives is carries out, so as to keep the loco working
properly. It contributes to increase the operational life of
diesel locomotives and tries to minimize the line failures.
The technical manpower of a shed also increases the
efficiency of the loco and remedies the failures of loco.
The shed consists of infrastructure to berth, dismantle,
repair and test the loco and subsystem. The shed
working is heavily based on the manual methods of doing
the maintenance job and very less automation processes
are used in sheds, especially in India.
The diesel shed usually has:
Berths and platforms for loco maintenance
Pits for under frame maintenance
Heavy lift cranes and lifting jacks
Fuel and Lube oil storage
Sub-assembly overhauling and repairing sections
Machine shop and welding facilities
Testing Labs

9. TELL-TALE SIGNS
•The symptoms of an existing abnormality or defect in a
component or a system.
•The equipment/ component exhibits its distress & never
fails instantaneously, without giving any distress signals.
• If these distress signals could be identified, understood
and due attention is paid, then failure rate could be
brought down.
• Indicators like gauges, meters, alarm gongs , LED
display panel etc have already been provided in
locomotives for monitoring the condition of the various
systems of the locomotives.
• Apart from above there are certain signs/symptoms
which could be observed during running/testing of locos
during maintenance schedules, by interpretation of
which defects/faults with subassembly/systemscould be
known.
• TELL TALE SIGNS can be understood by our eyes, ears,
nose, and by feeling with our hands.

10. OBJECTIVES
It helps in :-
• Predictive maintenance
• Controlling failures
• Reliability of locomotives
Classification
Classified into four Categories :-
• VISUAL
• AUDIO
• TOUCH /FEEL
• SMELL

11. POWER PACK
 BY VISUAL INSPECTION :-
1. Black Smoke from chimney
2. Bluish white Smoke from chimney.
3. White Smoke from chimney.
4. Water coming from tell tale hole of Water pump.
5. Water coming from after cooler tell tale hole.
MECHANICAL ELECTRICAL
1 POWER PACK ROTATING MACHINES
2 EXPRESSOR RELAYS CONTACTORS
3 UNDER TRUCK CABLES WIRING

12. 6. C/Case Examination
7. Pink marks on water cooling system joints
8. Water is coming from Cylinder head leak off pipe.
9. Smoke from Cylinder head leak off pipe.
10. Oil throw from CC exhaust
11. Intermittent smoke from engine exhaust
12. Lube oil mixed in cooling water
13. Radiator compartment Oily
14. Copper particles near ECC drum
15. Oil throwing TSC chimney
16. Hyd. motor Indicator of Moatti filter
 BY AUDIO/HEARING
1. Unusual sound from Cylinder head assembly.
2. Unusual sound near cam gear cover.
3. Unusual sound from FIP base
 BY TOUCH/ FEEL
1. Excessive Vibration in Lube oil , water
cooling or charged air system pipe lines.
2. Excessive Vibrations in FIP housing.
3. Excessive Vibrations/shocks in HP line

13. EXPRESSOR
 BY VISUAL INSPECTION
1. Discoloration (Overheating marks) in HP
cylinder as well as joining pipes.
2. Smoke emitting through expresser exhaust & oil
throw.
3. Wobbling of Kooper coupling
4. Expresser shivering as a whole while cranking the
engine.
5. Expresser Breather Valve Worked Out.
6. Efficiency spindle not projecting
 BY AUDIO/HEARING

14. 1. Unusual beating sound from expresser cylinder
2. Inter Cooler Safety Valve / MR safety valve blowing.
3. Unusual sound from fast coupling.
 BY TOUCH/ FEEL
1. Efficiency spindle projecting – but going
inside while pressing it.
UNDER TRUCK
 BY VISUAL INSPECTION
1. Hot axle box cover plate
2. Brass particles over suspension bearing cap
3. Discoloration of gear case cover
4. Equalizing Beam Sagging
5. Spreading of grease over rim back of Axle Box
6. Battery box resting on br. Cyl. Foundation
7. Compressed Outer coil spring
8. Shine marks on Washer
Rotating Machines

15.  BY VISUAL INSPECTION
• Loose fasteners
• Commutator condition
• Carbon condition.
• Leakage of oil
 By TOUCH /FEEL
1. Temperature of Rotating machine
 BY HEARING
1. Unusual Sound from machine
Relays Contactors
 BY VISUAL INSPECTION
1. Flashing on Tips Contacts & shunts
2. Over Heating Mark

16.  By Touch
1. Excessive Temperature.
2. Loose connection.
 By Hearing
1. Leakage of Air
Cables wiring
 BY VISUAL INSPECTION
• Punctured insulation
• Discoloration of cable insulation & Lugs
 By Smell
1. Burning smell of insulation.
2. Smell of acid fumes.

17. Thick black smoke from TSC White smoke
Bluish white smoke Crankcase Examination
Pink marks on water Water coming from
coolingsystem joints Cylinder head leak off pipe

18. Smoke from Cylinder Copper particlesnear
head leak off pipe ECC drum
Intermittent smoke Inter CoolerSafety Valve /
from engine exhaust MR safety valveblowing.
Unusual sound from Unusual sound from fast
FIP base coupling

19. Unusual beating sound Brass particles over
from expresser cylinder suspension bearing cap
Hot axle box cover Temp. of rotating m/c
Loose Fasteners Looseconnection

20. Cable rubbing Punctured Insulation
Flashing / over heating Discoloration & broken
marks on strands insulation
Leakage of air Excessive vibration in FIP
HSG

21. Water pump Tell-tale Hole
The centrifugal water pump has two seal i.e. water
seal and oil seal. There is the cylindrical shaped hole
in the pump which is called Tell-tale hole.
This helps in checking the water pump. If the oil
leaks from the hole then the oil seal is to be
changed and if water leaks from the hole then the
water seal in damaged and it is changes.
On changing both if it leaks again the whole water
pump is changed.

22. After cooler tell tale Hole
It also had tell-tale hole for checking of water.
Radiator room dirty
Radiator room should be cleaned regularly on time
for overcoming the accident in the engines.

23. Leakage of oil from TG gear case
Discoloration of HP discharge Pipe
Wobbling of Kooper Coupling

24. Reasons for thick black smoke from
engine exhaust are:
• After coolergasket cut
• Leaky air inlet elbow
• Leaky exhaust manifold
• Choked air filters and carbody filters
Reasons for Bluish White Smoke From
Exhaust:
Entry of lubeoil into the combustion chamber.
The reasons for the entry of lube oil are
1) Excess bore of the cylinder liner.
2) Worn out piston rings.
3) Excessive piston ring gap.
4) Excessive side clearance.
5) Excessive Exhaust Valve Guide Clearance
6) Piston Rings Gap comes in one line
7) Turbo also contributesfor this defect
Reasons for White Smoke From Engine
Exhaust
Mainly due to water contamination in fuel oil.

25. Sources of contamination are
• Fuel filling depot.
• Cracked cylinder heads.
• Defective nozzlesleeves
• After Coolertube puncture
Smoke from Cylinder head leakoff pipe
 Injector not seated properlyin cylinder head sleeve
Intermittent Smoke from engine exhaust
Injectors dribbling

26. Oil throwing from CC exhaust
Less Engine sump vaccum
Defective CC Exh. motor
Choked drain pipe
UNUSUAL NOISE FROM CYLINDER HEAD
Excessive tappet clearance.
Less tappet clearance
a) Defective yoke, yoke-guide and springs.
b) Bent push rods.

27. Oil throwing from TSC chimney
1) Excess bore of the cylinder liner.
2) Worn out piston rings.
3) Excessive side clearance.
4) In line position of all piston ring gap.
5) Excessive clearance in the turbo and oil seal.
Discoloration (Overheating marks) in HP
cylinder as well as joining Pipe
1.Carbonized, stuck up or broken HP discharge valve.
2. Oil throw due to worn out LP piston rings & liner. oil
will burn in the HP discharge pipe resulting in
discolouration.
3.Continuousloadingdue to mal-functioning of
compressor governor followed by oil throw
Crank case examination
Siezure of main Bearing
Siezure of conn rod bearing
Broken/unlocked snap ring

28. Wobbling of Kooper coupling
DEFECTIVE RUBBER WORN BUSH
ROLLERS
Discoloration of Gear Case
Grease on Rim

29. Vibration on HP Pipe Line
Breather valve
FLASHED REVERSER CONTACT

30. Conclusion
The signs shown in the report
may be helpful in judging the
indication of faults.
Further efforts should be made
in the direction of upgrading
the skills of the technicians
through training in sheds.

31. REFERENCE
www.google.com
www.scibd.com
www.indianrailways.com