DeIcer/ Flat Car DI - 40

Student Guide

DGMO-OPMS Technical Skills & Maintenance Training Carmen Turner Facility

DeIcer/ Flat Car DI - 40

After completion of the training session the trainee will be able to:

Identify components and cab controls of the Deicer flat car

Perform a standard walk around inspection, using a TRST rolling stock prior to use

inspection form

Perform Operational Procedures

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THIS MANUAL IS WRITTEN BY THE PLASSER COMPANY, A FEW PAGES WERE ADDED BY THE TRAINING STAFF TO HELP EVERYONE STAY FOCUSED. THE PAGES ARE WMATA’s PRIOR TO USE INSPECTION FORM, AND THE REFERENCE TO THE LEFT OR RIGHT SIDE AND FRONT OR REAR OF THE DEICER FLAT CAR.

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OPP-MAN-DI-40 (371-492)

DI-40 Theory of Operation

The DI-40 Deicer machine is used to remove ice from the third rail and to inhibit additional buildup of ice through the application of a deicing solution that is sprayed on to the third rail after scraping it.

The DI-40 is designed and built to be pulled or pushed by a prime mover machine through the work area to perform its functions.

Scraper Blade assemblies are located on each corner of the machine and are attached to the trucks. The Scraper Blade arms float up and down as they make contact with the third rail. The upward movement of the assembly due to contact with the third rail automatically activates the application of the deicer fluid. There are provisions to manually spray the third rail with deicing fluid when needed.

The pressure for the spray equipment is generated by a pump that is driven by an AC motor. The AC power for the motor is created on the DI-40 with an onboard generator and converted into the 3 phase power that the motor uses with a phase converter.

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Any reference to the “Left” or “Right” side of the Deicer flatcar or “Front ” or “Rear” in this manual are referred to as viewed when the flat is coupled to a Prime Mover in the normal direction.

Rear view ofPMC50

Front

Rear

Left side Right side

NEED TO KNOW INFORMATION

Fluid Capacities

Deicing Agent Storage Tank1500 gals

Generator Diesel Fuel 30 gals.

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OPP-MAN-DI-40 (371-492)

Major Component Locations

1. Whisperwatt Generator – 10kw generator and enclosure.

2. Diesel Fuel Tank – 30 gallon diesel fuel tank for the generator.

3. Deicer Fluid Tank – This tank will store 1500 gallons of deicing fluid.

4. AC Motor and Spray Pump – The AC motor and Spray Pump for the deicer system are inside this enclosure.

5. Operator’s Cab – The operator’s cab and controls are at this end of the machine.

6. Manual Brake - The manual brake is located at this end of the machine.

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OPP-MAN-DI-40 (371-492)

Pictures and Switch Descriptions

Manual Conventions The following section shows pictures of control panels and gives descriptions and function of various switches and controls.

For switches labeled “0” and “1”;

“0” = de-energized or “0ff” position

“1” = Energized or “On” position

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OPP-MAN-DI-40 (371-492)

Manual Brake

1. Manual Brake - The Di-40 manual brake is located at the rear end of themachine.

2. Manual Brake Release Lever – Lifting this lever will release the manual brakewhen it’s set.

3. White Chain Links – When the white chain links on the Manual Brake arevisible it is an indication that the Manual Brake is in the released position.

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4. Hand Wheel - Turning this counter clockwise can also be used to release tension on the chain.

B 30 Panel is the circuit breakerpanel. Located on the front of thecab.

Circuit Breakers in the box are:

Heater Rec Generator

Cab Rec B-12

Deicer Pump Power Supply

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OPP-MAN-DI-40 (371-492)

B5 Panel

1. 10 amp Breaker – This breaker is used to protect the S1 cab control circuit foritems such as the wiper motor and the defroster fan.

2. 10 amp Breaker – This breaker is used to protect the S2 circuit for the B5 panel lights and 12V relays for the automatic control of the Deicer System.

3. Fuel Level Gauge – This is a gauge to indicate the level of the fuel for thegenerator.

4. Glycol Level Gauge – This is a gauge to indicate the level of the deicing fluidin the storage tank.

5. Position #2 Auto indicator light – This light will illuminate when the IceScraper Switch for position #2 has the Automatic mode of operation selected.

6. Position #1 Auto indicator light - This light will illuminate when the Ice ScraperSwitch for position #1 has the Automatic mode of operation selected.

7. Ice Scraper Position #2 Auto Switch – This switch is used to select theautomatic or manual mode of operation for ice scraper position #2.

8. Ice Scraper Position #1 Auto Switch - This switch is used to select theautomatic or manual mode of operation for ice scraper position #1.

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OPP-MAN-DI-40 (371-492)

B5 Panel (continued)

9. Position #1 Manual indicator light - This light will illuminate when the IceScraper Switch for position #1 has the Manual mode of operation selected.

10. Position #1 Active indicator light – This light will illuminate when the IceScraper has made contact with the rail and the position is selected at the switch.


12. Position #2 Active indicator light - This light will illuminate when the IceScraper has made contact with the rail and the position is selected at the switch.





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OPP-MAN-DI-40 (371-492)

B5 Panel (continued)





21. Low Glycol Alarm light - This warning light will illuminate when thedeicing fluid tank needs to be refilled.

22. System On Switch – This switch needs to be turned on after the generator isstarted to enable the rest of the functions on this panel.

23. Deck Light Switch - This switch turns on the deck lights24. Alarm Buzzer - This is an audible alarm buzzer.25. Cab Light Switch – This switch turns on the lights in the cab.26. Headlight Switch - This switch turns on the headlights27. Washer Pushbutton - This switch activates the windshield washer.28. Wiper Switch – This switch controls the windshield wipers.29. Voltmeter - This gage indicates the voltage output of the 12V DC power Supply.

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OPP-MAN-DI-40 (371-492)

B5 - 12V Power Supply

1. 12V Power Supply – The power supply for all 12V components is located insidethe B5 panel toward the left side.

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OPP-MAN-DI-40 (371-492)

Manual Control Ball Valves

1. Nozzle Position 1 – This illustration shows the location of Nozzle position #1.2. Nozzle Position 2 - This illustration shows the location of Nozzle position #2.3. Nozzle Position 3 - This illustration shows the location of Nozzle position #3.4. Nozzle Position 4 - This illustration shows the location of Nozzle position #4.5. Manual Control Valve for Nozzle #4 - This valve can be used to manually turn

on the flow of deicing fluid to nozzle #4. Note: This bypasses the function of theproximity switches on the Scraper Blade Assemblies that sense when the arm isresting on the rail. As long as the pump is running, the nozzle will spraycontinuously when turned to the “On” position.

6. Manual Control Valves for Nozzle #2 - This valve can be used to manually turnon the flow of deicing fluid to nozzle #2. Note: This bypasses the function of theproximity switches on the Scraper Blade Assemblies that sense when the arm isresting on the rail. As long as the pump is running the nozzle will spraycontinuously when turned to the “On” position.

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OPP-MAN-DI-40 (371-492)

Manual Control Valves ….Continued

7. Emergency Dump Valve – This valve vents the brake pipe air pressure to set thetrain brakes in an emergency. Normal braking and control of the brake pipe airpressure is done from the Prime Mover machine.



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OPP-MAN-DI-40 (371-492)

Flow Control Valves

1. Flow Control Valves - These valves are set manually to individually control theflow of the deicer fluid to the spray nozzles. Note: Ask a mechanic for help if thespray pattern is not consistant and uniform.

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OPP-MAN-DI-40 (371-492)

B21 Panel

The B21 panel is located in the operator’s cab behind the operator’s seat. Within this panel is the motor controller that accepts input from the single phase AC power created by the generator and outputs the 3 phase AC power that the deicer pump motor uses.

1. Deicer Pump Power Switch2. Deicer Pump Emergency Stop Switch

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OPP-MAN-DI-40 (371-492)

Horn Valve

This view shows the Horn Valve located on the side wall near the door.

1. Horn Valve – Beneath the protective cover is the pneumatic Horn Valve thatcontrols the horn.

2. Horn Pull Cord – This Pull Cord activates the horn.

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OPP-MAN-DI-40 (371-492)

Generator Control Panel

1. Frequency Gauge - This gauge indicates the output frequency in hertz.

2. Current Gauge – This gauge indicates the amount of current that is being drawnfrom the generator.

3. Voltage Gauge – This gauge indicates the output voltage of the generator at theU, O, and V output terminal lugs.

4. Engine Warning Display Module

a. Overheat Lamp – This lamp goes on when the coolant is over 234degrees F.

b. Low Oil Pressure Lamp – This lamp goes on when the oil pressure dropsbelow 7.1 PSI

c. Low Battery Voltage Lamp – This lamp goes on when the battery voltage islow.

d. Pre-Heat Lamp – This lamp goes on when the engine is ready for startingduring cold weather operations. When this lamp flashes, refer to the“Troubleshooting” area in the back of the generator operation manual.

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OPP-MAN-DI-40 (371-492)

Generator Control Panel (continued)

5. Speed Control Switch – This is used to set the engine to idle or operating RPM.

6. Generator Engine Hour Meter – This gauge indicates the number of hours thegenerator has been used.

7. Ignition Switch - This switch is used to start and stop the generator.

8. Voltage Regulator – This control allows the manual adjustment of the outputvoltage of the generator up to + - 15%.

9. Engine Area Work Light Switch

10. Ground Connection for GFCI

11. Main Circuit Breaker – This 45 amp main breaker protects the U, N, and Voutputs from the generator from overload.

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OPP-MAN-DI-40 (371-492)

Generator Right Side

1. Internal Fuel Tank – This fuel tank that is internal to the generator housing isunused on the DI-40 installation. An external tank is provided.

2. Generator Engine Air Filter3. Generator Engine Radiator4. Generator Engine Oil Dipstick - Refer to the Kubota Engine Owner’s Manual

for the proper type of oil to be used for the temperature ranges expected.5. Generator Engine Fuel Filter6. Generator Engine Starter Battery

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OPP-MAN-DI-40 (371-492)

Generator Left Side

1. Internal Fuel Tank – This fuel tank that is internal to the generator housing isunused on the DI-40 installation. An external tank is provided.

2. Whisperwatt 10kw Generator3. Generator Engine Starter Motor4. Generator Engine Alternator5. Generator Engine Exhaust Pipe

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OPP-MAN-DI-40 (371-492)

Generator Top

1. Generator Engine Exhaust - The generator engine exhausts in this area.2. Generator Radiator Fill cap

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OPP-MAN-DI-40 (371-492)

Fuel Tank

1. External Fuel Tank – This 30 Gallon Diesel Fuel tank is used to store the fuelthat powers the Whisperwatt generator.

2. Diesel Fuel Line Shut off Valve

3. External Fuel Tank Fill Cap and Level Gauge - When refueling be aware thatfuel expands as its temperature goes up. Thus a tank that is filled to the top whenit is cool outside may overflow as the temperature warms up.

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OPP-MAN-DI-40 (371-492)

Deicer Pump

1. AC Motor

2. Deicer Pump

3. Drive Coupler – This unit couples the AC Motor to the Deicer Pump.

4. Gear Drive Unit – This is the helical drive gearbox. The oil change frequency isevery 10,000 hours or 2 years, whichever is first.

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OPP-MAN-DI-40 (371-492)

Ice Scraper Arms

The DI-40 has Scraper Blade assemblies installed on both sides of each truck that are used to scrape snow and ice off of the power rail and spray deicing fluid on the rail to prevent ice buildup during winter operations.

1. Deicer Hose Quick Disconnect Fitting

2. Scraper Blade

3. Deicer Spray Nozzle

4. Scraper Blade Assembly Pivot Arm

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OPP-MAN-DI-40 (371-492)

Ice Scraper Blade Tension Components

1. Proximity Switch – Each Scraper Blade Assembly has a proximity switchthat recognizes when the scraper blade arm is riding up on the third rail. Thistriggers the automatic flow of deicer fluid.

2. Scraper Blade Assembly Torsion Shaft – This shaft is contained by anelastomer holding device inside the blue pillow blocks at each end. Theyprovide the torsional spring rate for the scraper blade arm pressure against thethird rail.

3. Spring Clamp Bolts – These bolts clamp the scraper blade arm to the torsionshaft. They assist in the adjustment of the spring tension as necessary. (See theadjustment procedure at the back of this manual.)

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Track Rolling Stock Prior to Use Inspection

T All rolling stock equipment used by TRST personnel shall require a “Prior to Use Inspection Form” be completed each time the equipment is inspected.

T The “prior to use inspection form” shall be turned in to a TRST Supervisor and/orManager when completed.

NOTICE: THE COMPLETED “PRIOR TO USE INSPECTION FORM”

SHALL BE WRITTEN IN SUCH A MANNER SO AS TO BE

LEGIBLE.

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TRST ROLLING STOCK PRIOR TO USE INSPECTION Initials (Operator /Flagman)

_________1. Check for wheel chocks and that the required quantity for unit(s) in the consist is present.

_________2. Check angle cocks, train line seals, air tool and drain valves. (Open or close as required).

_________3. Check main engine for proper oil level.

_________4. Check for any loose, broken, torn, cracked or leaking components as you make your walk

around inspection.

_________5. If using auxiliary components such as cranes, generators and compressors, check all controls,

movements, fluid levels and safety devices.

_________6. Start machine and check all switches, gauges and warning indicators.

_________7. Check for sufficient air pressure and if equipped with A‐9, make sure it is at 90 psi in the release

position.

_________8. Check transmission for correct oil level and any abnormal sounds or functions.

_________9. Make sure that all equipment, tools, supplies and loose debris are secured on decks and not

posing any safety hazards.

_________10. If equipped and scheduled for use, inspect work head assemblies for wear, out of adjustment

and damage. Check oil fill reservoirs and grease all fittings.

_________11. If equipped, inspect E‐couplers, tow bars and revenue train couplers.

_________12. Gas cylinders should be secured and in their proper location.

_________13. Make sure all work heads and components such as crane booms, outriggers, measuring

buggies, clamp frames, plows, turn tables and extension arms are pinned and locked with safety

devices prior to travel.

_________14.Check fuel and hydraulic tanks for proper level.

_________15. Check all wheels, brakes, visable linkage and suspension on all rolling stock vehicles.

_________16. Check for cracked, broken or missing windows. Make sure there are no bent or loose railings,

steps or cabinet enclosures that are missing safety chains, locks or latches.

_________17. Turn on and inspect all lighting on unit(s) in consist for any defects or problems.

_________18. Check that back up alarms and horns sound.

_________19. Fire extinguishers should be charged and secured.

_________20. Radios should be able to transmit and receive clearly.

_________21. Inspect all items in flagman's booth for proper operation and functionality.

_________22. Make sure that loads are secure, evenly distributed and are not hanging over the side or ends

of flat car.

_________23. Check all Flat Car emergency dump valves and hand brakes.

_________24. Depending on unit, perform standing and rolling brake checks on all units in consist.

_________25. Inspect hi‐rail components for thin flanges, leaking cylinders, safety pins, tires, shunts and

proper tuck when on hi‐rail.

_________Note: When transporting units for PMI, make sure that cabs, decks, platforms and operating

stations are clear and free from trash, debris, tools, materials and supplies.

_________Notes/Comments: ____________________________________________________________

Print name (s):________________________________________I.D # (s):________________________________

Signature (s): _________________________________________Equipment # (s) _________________________

Yard or location where inspection performed at: __________________________________________________

Date: ______________________________________________Time of inspection: _______________________

SOP 1.01 Rev 0 07/18/201428

OPP-MAN-DI-40 (371-492)

Operational Procedures

Generator Startup

1. Check the fuel level to ensure that there is an adequate amount for the work to beperformed.

2. Ensure that the fuel shutoff valve is turned on.3. Check the radiator antifreeze level.4. Check the engine oil level.5. Check the generator for loose belts, bolts, wiring, hoses, or other damaged

components that may affect the safe running of the generator.6. Set the speed control switch to the Start/Idle position.7. Insert the key into the ignition switch. Turn the key clockwise to the Pre-Heat

position and observe the Pre-heat lamp. When the Pre-Heat lamp has turned off,continue turning the ignition key clockwise to the Start position. When the enginestarts, release the key. If the engine fails to start within 10 seconds, wait 30seconds and repeat this procedure.

8. Once the engine starts, let it run for 1 to 2 minutes. Listen for any abnormalnoises. If any abnormalities exist shutdown the engine and correct the problem.

9. The generator’s frequency meter should be displaying the 60 cycle outputfrequency in hertz.

10. The ammeter will indicate zero amps until a load is applied.11. Set the speed control switch to the Run position.12. Place the Main, GFCI and auxiliary breakers in the On position.13. The Generator’s AC voltmeter will display the generator’s output in Volts. If the

voltage is not within the specified tolerance, use the voltage adjustment controlknob to increase or decrease the voltage as required.

14. Observe the generator’s ammeter to verify that it reads the anticipated amount ofcurrent considering the load in use.

15. The generator will run until manually stopped or an abnormal condition occurs.

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OPP-MAN-DI-40 (371-492)

Generator Shut-Down

Never stop the engine suddenly except in an emergency.

1. Place the Main, GFCI, and the auxiliary circuit breakers in the OFF position.

2. Set the speed control switch to the Start/Idle position and let the engine cool for 3to 5 minutes.

3. Turn the ignition key counter-clockwise to the Stop position.

4. Close the Generator Panel Door and lock as necessary.

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OPP-MAN-DI-40 (371-492)

De-Icing System

Automatic Mode 1. Start the generator to provide power to all of the De-Icing systems.2. Ensure there is sufficient deicing fluid in the reservoir for the amount of work to be done.3. Switch the ‘Deicer Pump Power Switch’ to the “On” position on the B21 panel

behind the Operator’s seat to activate the deicer pump.4. Turn the “System On” switch on the B5 panel to the “On” position.5. Using the four selector switches on the B5 panel, switch all nozzles to the “Auto”

position.

6. Have the Prime Mover machine move the DI-40 through the work area.7. As the scraper shoes ride up on the power rail which is indicated by proximity

switches on the assemblies, this will signal the DI-40 to switch on the deicer valve forthe spray nozzle on that shoe.

8. Control the flow of the deicing fluid out each nozzle by the manual valvesbehind the “Flow Control Access Door” in the panel to the right of theOperator’s seat.

Manual Mode Follow the instructions for Automatic mode as above with the following exceptions:

1. Using the four selector switches on the B5 panel, switch the desired nozzles to the “Manual” position. (Switch on the intended nozzles instead when working in the rearward direction.) This will bypass the proximity switches and deicing fluid will flow from the nozzles.

2. Using the ball valves to the right of the operator seat can select each individual nozzleto apply deicing

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Spot Deicing or Electrical Malfunction

Bypass Mode (Used For Mechanical Malfunction or Electrical Power Loss)

fluid to the third rail. This will bypass all proximityswitches and solenoids. As long as the pump is running deicing fluid will flow.

This will dispence deicing fluid to only those deicer shoes that are currentlymaking contact with third rail. The other shoes are inactive at this time.

E008639

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E008639

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Documents

DeIcer/ Flat Car DI - 40