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    Failure Report of 4730 GMU-30 - 14.06.2022

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    alam zeb
    The crankshaft of locomotive 4730 GMU-30 became jammed after failures in power assembly numbers 06 and 14. Upon examination, it was found that the swept volume of cylinders 05 and 13 was less than required. Using thicker cylinder head seat rings resolved the issue and freed the crankshaft. The crank case had undergone six rehabilitations previously and requires remachining of bearing caps and serrations to ensure adequate performance. Initial starting of the engine was successful but further trials are requested from the shed.

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    Failure Report of 4730 GMU-30 - 14.06.2022

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    alam zeb
    26 views3 pages
    The crankshaft of locomotive 4730 GMU-30 became jammed after failures in power assembly numbers 06 and 14. Upon examination, it was found that the swept volume of cylinders 05 and 13 was less than required. Using thicker cylinder head seat rings resolved the issue and freed the crankshaft. The crank case had undergone six rehabilitations previously and requires remachining of bearing caps and serrations to ensure adequate performance. Initial starting of the engine was successful but further trials are requested from the shed.

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    Failure Report of 4730 GMU-30- 14.06.2022

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    The crankshaft of locomotive 4730 GMU-30 became jammed after failures in power assembly numbers 06 and 14. Upon examination, it was found that the swept volume of cylinders 05 and 13 was less than required. Using thicker cylinder head seat rings resolved the issue and freed the crankshaft. The crank case had undergone six rehabilitations previously and requires remachining of bearing caps and serrations to ensure adequate performance. Initial starting of the engine was successful but further trials are requested from the shed.

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    © All Rights Reserved
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    Download as docx, pdf, or txt
    26 views3 pages

    Failure Report of 4730 GMU-30 - 14.06.2022

    Uploaded by

    alam zeb
    The crankshaft of locomotive 4730 GMU-30 became jammed after failures in power assembly numbers 06 and 14. Upon examination, it was found that the swept volume of cylinders 05 and 13 was less than required. Using thicker cylinder head seat rings resolved the issue and freed the crankshaft. The crank case had undergone six rehabilitations previously and requires remachining of bearing caps and serrations to ensure adequate performance. Initial starting of the engine was successful but further trials are requested from the shed.

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    © All Rights Reserved
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    Download as docx, pdf, or txt
    of 3

    PAKISTAN RAILWAYS

    DIESEL WORKSHOP KARACHI CANTT

    No: 12/1-Shop/KC/Rebuilding/ Dated: 13.06.2022

    The General Foreman


    Diesel Workshop Karachi Cantt.

    Sub: Failure Report of 4730 GMU-30


    It is stated that subjected DE Loco received from shed in jammed condition along
    with comments that after failure of Power Assembly No# 06 piston and valves seized
    (broken) we changed Power Assembly no. 06 & 14 but after tightening of crab nut of
    cylinder head ,Crank Shaft become jammed different steps are taken by them but Crank
    Shaft is still jammed at same position.
    DE loco is thoroughly examine and it is concluded that swept volume of
    Cylinder no. 05 & 13 is less although Cylinder Head seat Ring of 0.038” over size (i-e
    0.230”thick) were already installed under Cylinder Head which is last Limits.
    On further examination it also point out that Power Assy. no. 05 Piston were
    touch Cylinder Head at 191° degree of fly wheel while the actual top dead center is at
    202.5° degree of fly wheel. So as per calculation it was 11.5°degree advance and the total
    advance for same piston was 0.319” so to solve the problem we use (2 two Cylinder
    Head seat rings of Combined thickness 0.354" keeping in view lead reading of 0.020” to
    0.068” on both Cylinder Head 5 & 13.after tightening all crab nuts of cylinder head
    Crank shaft now became free of any abstraction.
    All other parameter was examined and following finding is observed.
    Piston at both locations slightly came out from liner but piston ring is still inside
    the piston.
    Piston did not touch pie pipe of piston cooling.
    Cylinder head elbow seals are not leaked after water filling as well as after
    starting.
    Water inlet jumper pipe properly fit and not leaked pre and after starting.
    High Pressure tube properly seated not leakage found after fuel pressure is
    checked.

    Page 1 of 3
    Test cock seated properly no leakage found after starting.
    As per history of Crank Case of DE Loco 4730 GMU-30 having Sr no. 75-D1-1116 (6) six
    times Rehabilitation is carried out in MGPR.
    Crank Case which requires line bore much have the main bearing caps
    reworked to obtain machining stock and to upgrade the serration quality.
    A minimum of 0.040"must be cut off the crest of serration during remachining o ensure
    adequate cleanup.
    Furthermore during normal engine operation the Cylinder Head retainer surface is also
    subject to wear in head seat ring and contact area this wear is also reduce the swept
    volume of power assembly. Which can be re machine in Block shop C.C No. 7028
    MGPR LHR.

    COUCLUSION
    Lead reading of Power assembly no. 05 & 13 could not be maintain using
    over size ring 0.230” which is last limits as per MI (MI 316 page no. 16.) Cat no 9803.
    2 cylinder head seat Rings instead of one are installed for trial purpose Only .
    initial Starting of engine is safe but further trial and close watch is requested from KC
    Shed .
    Report is submitted for your further disposed please.

    CRANK CASE
    Crank Case Serial No. 75-D1-1116
    1st Rehabilitated from MGPR LHR Loco Shop on Dated: 16.05.1996
    2nd Rehabilitated from MGPR LHR Loco Shop on Dated: 20.03.2001
    3rd Rehabilitated from MGPR LHR Loco Shop on Dated: 28.07.2008
    4th Rehabilitated from MGPR LHR Loco Shop on Dated: 25.02.2010
    5th Rehabilitated from MGPR LHR Loco Shop on Dated: 12.02.2016
    6th Rehabilitated from MGPR LHR Loco Shop on Dated: 11.02.2017
    CRANK SHAFT
    Crank Shaft Serial no:-

    Page 2 of 3
    ACC. End GEN. End
    8031642 8034722
    CK-3017 DK-2158
    8034708
    06-M1-4336 06-M1-4336

    Life earned before last fitment on 4730 07 Years -09 Months -21 Days
    Total life after Fitment on 4730, 12 Years – 11 Months – 14 Days

    FOREMAN DIESEL
    WORKSHOP KC

    Page 3 of 3

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