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= Front650,&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

RPM

BHP(AAR)

RPM

BHP(AAR)

Low Idle

200 +4

200

269 +4

300

270

259

25

343 +15

530

354

607

35

490 +15

1110

486

1148

568 +4

1440

572

1573

651 +15

1840

675

1916

25

730+4

2290

764

2960

25

820 +15

3680

863

3822

25

904 +4

4080

954

4500

80

Over
Load

Duration in
Minutes

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: