Chapter IV: Part 4

A. The Vauclain has one valve on each side, distributing steam to the high and low-pressure cylinder on that side. The four-cylinder tandem has two valves on each side, one for each of the two cylinders. A Baldwin balanced compound has two valves the same as the Vauclain. The American balanced compound has four valves, one for each cylinder, the two valves for one side of the engine being connected to one valve rod. A Mallet compound has a separate valve for each cylinder the same as a simple locomotive.

28. Q. How do you test for blow in high and low-pressure cylinder packing for each type of compound engine?

A. Simple the engine if a cross compound, then make test the same as for a simple engine. For Vauclain four-cylinder compounds, test low pressure first. A blow past the low-pressure piston will show the same as on a simple engine; a blow past the high-pressure piston will make the engine stronger on that side when working a full throttle and the exhaust from the low-pressure cylinder will be heavier. To test the valve on either side, cover the ports. Broken packing rings in the steam valve will show a blow in one position and be tight in another. For tandem compound, to test high-pressure piston packing, stand engine on the top quarter, lever in back gear, drivers blocked and starting valve closed; remove back indicator plug or open back cylinder cock of high-pressure cylinder. Steam coming from the back cylinder cock must get by the piston packing or by-pass or starting valve. Now put reverse lever ahead and try the other indicator plug or cylinder cock. If a leaky by-pass valve in the front end is the trouble, no steam will come through. To test the low-pressure piston packing, place the engine in the same position, lever in position to admit steam into the front end of high-pressure cylinder. Open starting valve, remove back indicator plug of low-pressure cylinder and give engine steam; if steam comes from the indicator plug opening or open back cylinder cock, either packing or by-pass is leaking. To determine which one, put reverse lever in another position, close back indicator plug and open forward one; if blow still continues, the packing rings are leaking or else both by-pass valves. Would then inspect the by-pass valves.

29. Q. How can the blow through sleeve packing between high and low-pressure cylinder of the tandem compound be located?

A. Place the engine as before on the top quarter, put reverse lever in forward gear, see that starting valve is closed, block the drivers or set the brakes solid and open the throttle. Until the engine moves, unless there is a leak, no steam can get into the front side of the low-pressure cylinder. Remove the indicator plug in front end of the low-pressure cylinder for this test.

30. Q. How test for piston packing blow with balanced compound?

A. For a Baldwin balanced compound to test the high-pressure piston packing, place the engine with the outside main pin on that side of the engine on the bottom quarter, the reverse lever in the forward notch, starting valve closed, set the brakes solid or block the drivers, remove the indicator plug in the front end of either the high or low-pressure cylinder. With throttle open this will admit steam to the back end of high-pressure cylinder. Steam coming out of this plug opening, will indicate a leak past the piston or the high-pressure valve. If uncertain, next test the high-pressure valve by moving the reverse lever to the center notch. This should cover the ports and if the valve is tight the blow will stop. To test the low-pressure piston, place the engine in the same position with wheels blocked, starting valve open, back indicator plug out; when throttle is opened, the leaky packing will be shown by steam issuing from the plug opening. If uncertain, the valve can be tested by bringing reverse lever to the center of quadrant, which will spot valve over port and if it is tight the blow will stop. In any compound engine a blow past the high-pressure packing tends to increase the pressure in the low-pressure cylinder. A blow past the low-pressure packing can always be heard at the exhaust, and is usually on both forward and back strokes, while a blow past the by-pass valves or valve bushings occurs at a certain part of a complete revolution only.

31. Q. In case it was necessary to disconnect on one side of a compound engine, how would you cover ports and hold valves in position?

A. The easiest way is to clamp the valve stem to hold valve in mid position; this should cover all ports. It may be necessary to take off head of piston valve chest and block in there.

32. Q. Is it a disadvantage to work a compound engine in short cut-off? Why?

A. Yes. If cut-off is too short the proper proportion of steam passing the throttle will not get to the low-pressure cylinder. The work should be divided between the two cylinders on same side.

33. Q. In what way do the Mallet or articulated compounds differ from other steam locomotives in the distribution of the steam?

A. Mallet compounds have two separate and complete engines under one boiler. The rear engine has a rigid connection to the back end of the boiler; this engine works boiler steam direct the same as a simple locomotive. Under the front end of the boiler is another engine so constructed that the entire front engine can move from side to side under the boiler, having a hinged connection at the front end of the rear engine to allow the locomotive to pass curves more easily. The front engine takes the exhaust steam from the rear engine through a flexible pipe or receiver and works it through a larger set of cylinders and thus compounds the steam. From the low-pressure cylinders the steam is exhausted to the atmosphere through the stack.

34. Q. How do you get the use of both engines when starting a train?

A. To get steam into the low-pressure cylinders before the high-pressure engine has exhausted, some types of the Mallet compound have a live steam pipe with a valve in the cab to admit boiler steam to the receiver pipe and thus get the use of the front engine in starting a train. The American Locomotive Company articulated compounds have an intercepting valve similar to the one used in the Richmond cross compound, located between the exhaust passage of the rear engine and the flexible receiving pipe of the front one. This intercepting valve when in SIMPLE position, allows the high-pressure cylinders of the rear engine to exhaust directly to the stack instead of into the receiver, and feeds boiler steam at a reduced pressure into the receiver pipe for the low-pressure cylinders without giving any back pressure on the high-pressure pistons. This increases the power of the complete locomotive about 20 per cent. When in compound position, the intercepting valve cuts off the supply of live steam to the receiver pipe and forces the exhaust steam to go to the low-pressure engine ahead.

35. Q. How is the American articulated compound changed from compound to simple, and back to compound again?

A. To work the locomotive simple, place the handle of operating valve in the cab to point toward the rear. This admits steam against the piston that operates the emergency exhaust valve and opens it. Exhaust steam from the high-pressure engine can pass to the exhaust nozzle instead of to the low-pressure engine. The intercepting valve then moves over so that live steam reduced to 40 per cent. of boiler pressure goes through the receiver pipe to the low-pressure engine. To work compound, place the handle of the operating valve to point forward. This will exhaust the steam, holding the emergency exhaust valve open; a spring and the pressure of the steam exhausted from the rear engine will close the emergency exhaust valve and build up a pressure against the intercepting valve that will open it so exhaust steam from the rear engine will go to the forward one and at the same movement close the reducing valve so no more live steam goes to the receiver.

36. Q. When is it necessary to use the operating valve to change the locomotive from compound to simple, or from simple to compound?

A. When giving the engines steam to start, the intercepting valve should automatically go to simple position until exhaust steam from the rear engine builds up a receiver pressure that shifts the valve to compound; if it does not, use the operating valve. When moving less than four miles an hour or when about to stall on a grade, set the engines working simple; changing to compound when the danger of stalling is over or the speed is more than four miles an hour. If there is no intercepting valve to furnish live steam to the forward engine, open the starting valve to admit live steam to the receiver pipe and low-pressure engine.

37. Q. If in starting the locomotive the forward engine does not take steam, what is the trouble?

A. The reducing valve may be stuck shut on account of being dirty or stuck on the stem of the intercepting valve. In case the reducing valve is stuck shut, the head of the dash-pot can be taken off and the valve worked back and forth to loosen it. The intercepting valve should be liberally oiled just before starting and occasionally during long runs to keep it free from sticking.

38. Q. Why does the Mallet compound have more power when working simple than compound?

A. If a starting valve is used to admit live steam to the receiver pipe and thence to the low-pressure engine, this gives a higher pressure to the low-pressure cylinders. If an intercepting valve is used, the open emergency exhaust valve allows exhaust steam from the rear engine to go direct to the stack; this takes away the back pressure of the receiver steam from the high-pressure pistons, about 30 per cent. of the boiler pressure, and thus adds to the power of the rear engine. The reducing valve when feeding live steam gives about 40 per cent. of boiler pressure to the low-pressure engine instead of the 30 per cent. it gets from the receiver; the added power of both engines working simple is about 20 per cent. over the compound operation.

39. Q. What is the duty of the by-pass valves on the sides of the low-pressure cylinders? Should they be kept clean of gum and grit?

A. These valves are connected to the steam ports at each end of the cylinders and open to allow air and steam to pass from one end of the cylinder to the other; away from the moving piston when the engine is drifting. If not kept clean they may stick open; when working steam the engine will blow badly; if they stick shut the engine will pound when drifting.

40. Q. In what position should the reverse lever be when the steam is shut off and the engine drifting?

A. Below three-quarters of full gear, so the valves will have nearly full travel.

41. Q. Why should the power reversing gear of the Mallet compound always have its dash-pot cylinder full of oil?

A. To prevent the too rapid movement of the reverse gear piston and its damage.

42. Q. In what position should the engines stand to test for blows in valves and piston packing?

A. Put the operating valve, or starting valve, in simple position. Spot the engine in the proper position and test each engine for blows the same as for a simple engine.

43. Q. What power is used with Ragonnet or Baldwin power reverse gear?

A. Air pressure.

44. Q. Can and should steam pressure be used?

A. Yes. However, steam should never be used except in an emergency when air is not available.

45. Q. What precaution should be taken regarding steam check and throttle?

A. That they are tight and check working properly, to insure that steam is kept from entering main reservoir, for if it should do so it would burn out the gaskets in the air brake equipment, allow moisture to accumulate, which would result in freezing and bursting of equipment as well as being dangerous.

46. Q. What would cause the gear to fail to hold links in intended cut-off, and allow them to raise and lower without operating valve in the cab being changed?

A. Leaks in main valve and piston packing.

=WALSCHAERT AND BAKER-PILLIOD VALVE GEARS=

1. Q. Give a brief explanation of the Walschaert valve gear.

A. The Walschaert gear has an eccentric crank attached to the end of the main pin on each side of the locomotive, with an eccentric rod from this pin to the connection at the bottom end of the link. This eccentric is located so it serves for both forward and back motion. The link swings on a center trunnion and cannot be moved up and down as the Stephenson link, but the link block can be moved from one end of the link to the other to reverse the engine; or part way toward the center of the link to change the cut-off. A radius rod connects the link block to the valve stem. There are two motions given to the valve stem, one from the link block which regulates the travel of the valve for the cut-off and reversing; the other motion is from a connection with the cross-head which gives the valve a positive motion to take care of the lap and lead. To give this motion there is used a combination lever or a lap and lead lever connected to a cross-head arm by the union link.

2. Q. Is the Walschaert gear direct or indirect?

A. It is direct when the link block is below the center of the link; it is indirect when the link block is above the center of the link.

3. Q. What are the principal differences in the location of the Stephenson and Walschaert gears, and what advantages does this give the Walschaert?

A. The Stephenson gear is placed between the main frames and employs two eccentrics, with straps and rods on each side of the locomotive; one for forward and one for backward motion. The Walschaert gear is placed outside the driving wheels and frame, has but one eccentric, which is a simple arm connected to the outside end of the crank pin for both forward and back motion. The links are set above the wheels on a level with the steam chest, the combination lever next to the cross-head. This gives it an advantage of a better chance to inspect all parts, the eccentric connections are much lighter and direct, which makes them less liable to wear or breakdown, and the valve has a constant lead.

4. Q. How is the lead affected by movement of the reverse lever with the two gears?

A. With the Stephenson gear the lead increases as the reverse lever is hooked toward the center in both forward and back motion. With the Walschaert gear the lead is the same in all positions of the lever, so that the lever is used to reverse the engine or adjust the cut-off.

5. Q. In reversing, how do the two gears differ as to the movement of the link and link block?

A. With the Stephenson gear, when reversing, the link is raised and lowered, bringing the block which is not moved by the reverse lever under control of either the forward or back-up eccentric as is desired to move the engine the proper way. With the Walschaert gear the link is not moved by the reverse lever, but the link block is raised and lowered in the link; the position of the block above or below the center of the link controlling the direction of motion.

6. Q. What would you disconnect if the eccentric crank, eccentric rod, or the arm at the bottom of the link should break?

A. Would remove the broken parts, disconnect the link lifter from the radius rod and block the link block in the center of the link; the combination lever would then move the valve twice the amount of its lap and lead, which would be sufficient to provide for lubricating the cylinder.

7. Q. If the main crank pin was broken?

A. Take down eccentric rod, eccentric crank, main rod and all connecting rods, block cross-head, disconnect from end of radius rod, chain it to running board and block steam valve to cover ports.

8. Q. Broken cross-head pin, main rod, strap or brasses?

A. Take down main rod, block cross-head, disconnect front end of radius rod and chain to running board and block the valve to cover ports.

9. Q. With a broken combination lever, union link or cross-head arms, what would you do?

A. Would disconnect the forward end of the radius rod and secure it to the running board with a small chain, wire or rope, remove all broken parts, take off the combination lever, even if not broken, secure the valve in its central position, loosen cylinder head to provide for lubrication, leave up main rod and proceed on one side. If valve was blocked to open rear port slightly, this would provide for lubrication and the cylinder head need not be loosened.

10. Q. If the radius rod on Walschaert gear is disabled, what should be done?

A. If broken in front of the link block, take off the broken part by disconnecting from combination lever, take down eccentric rod, fasten valve to cover ports and proceed on one side. If broken back of the link block, block the link block in the desired position and proceed with both sides.

11. Q. What would you disconnect with a Walschaert gear if a valve yoke should break?

A. Disconnect the forward end of the radius rod, suspend it from running board, block the valve, provide for lubricating the piston and proceed.

12. Q. How proceed with a broken reach rod?

A. Remove the reach rod, block links on lower side to hold them in running position for proper direction. Unless radius rod lifters can be uncoupled, leave a little slack in the blocking.

13. Q. How can you tell without opening the steam chest if the valve covers the port with Stephenson gear? With Walschaert gear?

A. Place the rocker shaft vertical with Stephenson gear. Place the combination lever vertical with reverse lever in mid gear so the link block is in the center of Walschaert link.

14. Q. What is the Baker-Pilliod valve gear?

A. It is an outside gear with an eccentric crank, similar to the Walschaert gear, but without a reversing link. The motion is reversed by means of a reversing yoke instead of a link; the cut-off is changed in the same manner. It uses a combination lever connected with a union link to its cross-head arm. In case of breakdown remove the broken parts the same as described for Walschaert gear, blocking the reversing yoke, if necessary, in the proper position.

15. Q. Is the Baker gear a direct or an indirect motion?

A. It is direct, going ahead for an inside admission and indirect backing up, and just the opposite for the outside admission type.

16. Q. What parts of the Baker gear take the place of the link which is used by the Stephenson or Walschaert motion?

A. The radius bars and reverse yoke.

17. Q. What relation to the main pin is the eccentric crank set to?

A. The eccentric crank always follows the main pin.

18. Q. Should the eccentric rod or eccentric crank break how is the engine put in condition to proceed?

A. The disabled side can have lap and lead travel and a port opening equal to the lead for all cut-offs. First block the bell crank by using a "U" bolt (which should be provided) in the holes placed in the gear frame for this purpose. Throwing reverse lever in mid-gear will help to get bell crank in position to block. Second, take down broken parts. Third, knock out back pin of short reach rod and throw reverse yoke in forward motion against gear frame.

19. Q. What is to be done should a gear connection rod break?

A. Do the same as for a broken eccentric or crank.

20. Q. What is to be done should the upper part of gear connection rod break?

A. If break is close to the middle pin, do the same as for a broken eccentric rod and also tie lower end of gear connection rod to keep it from swinging. If break is near the top and below the jaw, first block the bell crank and wire the connection rod fast to radius bars. If break is through top jaw, do the same as for broken eccentric rod.

21. Q. What is to be done should a radius bar break?

A. Do the same as for broken eccentric rod.

22. Q. If the horizontal arm of bell crank should break?

A. Same as broken eccentric rod.

23. Q. What is to be done should the vertical arm or bell crank break?

A. Take down union link combination lever and valve rod, then block valve over ports by using set-screw in valve stem cross-head provided for that purpose.

24. Q. Should you break cross-head arm or union link, what would you do?

A. If rod be provided to secure lower end of the combination lever to guide yoke, remove broken parts and proceed with full train, working engine at long cut-off. Otherwise would remove broken parts, combination lever and valve rod, cover ports, and proceed on one side.

25. Q. What do you do if a union link should break?

A. Same as for a broken cross-head arm.

26. Q. What is to be done if a combination lever should break?

A. Tie combination lever plumb, same as for a broken cross-head arm, if it is possible. If not possible, take down the combination lever and valve rod and cover the ports.

27. Q. What is to be done if a valve rod breaks?

A. Take down the broken parts and cover ports, leaving the rest of the gear intact.

28. Q. What is to be done if a reverse yoke breaks?

A. If lugs for holding reach rod breaks, block yoke securely at whatever cut-off you wish to work the engine and take down the short reach rod. If break is below the lugs, do the same as for broken eccentric rod.

29. Q. What do you do if reach rod should break?

A. If short reach rod breaks, block the yoke at cut-off desired and wire fast so it cannot move. If main reach rod breaks, block between tumbling shaft arm and cross-tie brace, wiring same securely.

30. Q. What is to be done if the engine breaks down other than valve gear?

A. In this case do the same as for any other valve.

=SOUTHERN VALVE GEAR=

1. Q. If the eccentric crank or eccentric rods fail?

A. Disconnect the eccentric rod from crank, radius hanger and transmission yoke, tie up the hanger and yoke, clamp valve central position and proceed.

2. Q. If radius hanger fails?

A. Disconnect the hanger from rod and take down eccentric rod, clamp valve in central position and proceed.

3. Q. If transmission yoke fails?

A. Disconnect from the eccentric rod and clamp valve in central position and proceed.

4. Q. If horizontal arm of bell crank fails?

A. Disconnect the yoke from the eccentric rod, tie up to clear, clamp valve in central position and proceed.

5. Q. If vertical arm to bell crank breaks?

A. Clamp valve in central position and proceed. Take the broken arm down if necessary.

6. Q. If one auxiliary reach rod or reverse shaft arm fail?

A. Block both link blocks in same position of links, and in such a position as to give port opening enough to start train and control speed by throttle.

7. Q. If main reach rod, or middle arm to reverse shaft fail? If both auxiliary reach rods fail?

A. Block link blocks in full valve travel, controlling power and speed with the throttle.

=LUBRICATION=

1. Q. What produces friction, and what is the result of excessive friction?

A. Friction as considered in locomotive service is produced by one body being rubbed across the surface of another when they are held in contact by pressure, and the result of excessive friction is heat more or less intense and the destruction of the journal and its bearing or the roughening of the sliding surfaces.

2. Q. What is lubrication and its object?

A. The object of lubrication is to interpose a film of oil, grease or some lubricant between the two surfaces that will prevent these rubbing surfaces from coming into too intimate contact.

3. Q. What examinations should be made by the engineer to insure successful lubrication?

A. See that all oil holes are open, cups filled and in good working order, the packing in cellars evenly put in and in contact with the journal. That waste on top of driving or truck boxes is in proper shape, also that grease cups are filled, and the plugs and jam nuts in good shape, and that the grease cellars contain sufficient grease for the next trip.

4. Q. How should feeders of all oil cups be adjusted?

A. To feed as small a quantity of oil as possible and regularly to give perfect lubrication.

5. Q. Why is it bad practice to keep engine oil close to boiler in warm weather?

A. The oil is thinned to such a degree by the heat of the boiler that it runs off as soon as applied, and very often a hot bearing is the result.

6. Q. In what manner would you care for a hot bearing if discovered on the road?

A. Use as much time as available in cooling the same, making sure that all moving parts are free and carefully lubricated before proceeding.

7. Q. What kind of oil should be used on hot bearings?

A. Use engine oil unless the temperature of bearing consumes it, when a small quantity of valve oil may be used while the bearing is warm enough to make this oil flow. The valve oil must be removed as soon as the bearing cools to prevent reheating.

8. Q. At completion of trip what is necessary?

A. Close all adjustable feeds and examine all lubricated parts by contact with the hand to determine that they are not above running temperature.

9. Q. How would you determine what boxes to report examined? Why not report all boxes examined?

A. By placing the hand on driving box, on hub of engine truck wheel and on top of tender truck boxes nearest the brass, and would not report them examined unless the temperature of same was above running heat. It is not necessary to report all boxes examined, because they do not all give trouble at the same time. If this report was made, it would appear that a proper inspection had not been made and would result in unnecessary work and waste of material.

10. Q. Why is it bad practice to disturb the packing on top of driving and engine truck boxes with spout of oil can when oiling engine?

A. This packing is put on top of boxes to assist in keeping dirt and dust out of oil holes, also to aid in gradual lubrication from the top. If this packing is disturbed it will permit dirt and grit to work into oil holes and on the bearings as well as feed the oil away too rapidly.

11. Q. How do you adjust grease cups as applied to rods?

A. Screw down plug until you feel a slight resistance from the grease, stop when grease shows between brass and pin; this should be sufficient over the division.

12. Q. Is it usual for pins to run warm when using grease?

A. Yes; grease does not work properly until it gets warm enough to flow readily over the bearing.

13. Q. What effect does too much pressure produce?

A. Wastes grease and increases the friction until the surplus amount is worked out so the bearing runs free on its journal.

14. Q. Is it necessary to use oil with grease on crank pins?

A. No.

15. Q. When an engine is equipped with Elvin driving box lubricator, how can you tell whether a sufficient amount of lubricant is in the grease receptacle?

A. The indicator wire fastened to the bottom of the grease cellar indicates the amount of grease left in the cellar.

16. Q. Why should engine oil not be used on valves and cylinders?

A. Engine oil loses its lubricating qualities before it gets up to the temperature of the valves and cylinders when they are working steam.

17. Q. At what temperature does engine oil lose its lubricating qualities? At what temperature for valve oil?

A. Engine oil begins to separate and give off gas at 345 degrees F. The temperature of steam at 120 pounds is 350 degrees F., while valve oil has a flash test of 520 degrees F. The temperature of steam at 235 pounds is 431 degrees F., much lower than the flash test of valve oil.

18. Q. How and by what means are valves, cylinders and the steam end of air pumps lubricated?

A. By a sight-feed hydrostatic lubricator.

19. Q. What is the principle on which a lubricator operates. How does the oil get from the cup to the steam chest?

A. The lubricator is located in the cab so there is a gradual descent in the oil pipe from the lubricator to the steam chest. Above the oil reservoir is a condenser that is kept filled with water condensed from steam fed from the boiler. The pressure of this water comes on the oil in the oil tank below it, forcing oil through the sight-feed valves; it then passes up by the sight-feed glasses to the oil pipe and steam chest. The use of the glasses is to make the drop of oil visible as it leaves the sight-feed nipple so the amount of oil fed can be regulated. Steam from the boiler fed to the lubricator at boiler pressure through the equalizing tubes balances the pressure which comes from the steam chest when the engine is working steam.

20. Q. How should the lubricator be filled?

A. First close all valves connected with the lubricator, open drain plug and remove filling plug, allowing water to escape until oil appears with it. Drain plug should then be closed. Fill the oil tank in the usual way, being careful not to overflow it; then replace filling plug. If the supply of oil is insufficient to fill the lubricator, water can be used to finish it, as the lubricator will begin feeding sooner when filled full.

21. Q. After filling lubricator, what should be done?

A. Open the steam throttle to the lubricator wide, then carefully open the water valve, but do not open the feeds until sure the chamber in the glass is filled with water.

22. Q. How long before leaving terminal should the feed valves be opened? Why?

A. About fifteen minutes; this time is necessary to allow oil to feed through the oil pipe and reach the steam chests.

23. Q. How many drops should be fed per minute?

A. From one to seven, timed by the watch, depending on conditions. Cylinders of large size require more oil than smaller ones.

24. Q. If lubricator feeds regularly when working steam and too rapidly after shutting off, what is the trouble?

A. The opening in the choke plug at the lubricator or through the steam valves at the steam chest is too large and should be reduced to the proper size by applying new chokes or valves.

25. Q. When valves appear dry while using steam and the lubricator is working all right, what would you do to relieve these conditions?

A. Ease off throttle for a few seconds to reduce the steam chest pressure and drop the reverse lever a few notches to give the valve a longer travel; oil held in the pipes will then flow down.

=FEDERAL REGULATIONS=

=For Inspection of Locomotive Boilers and Safety Appliances=

1. Q. What is the purpose of the federal rules and regulations for inspection of locomotive boilers?

A. So that all railroads operating under the laws of the United States government, would be obliged to maintain their boilers in a safe working condition.

2. Q. What is the purpose of the quarterly and monthly interstate inspection cards placed in the cab of the locomotive?

A. So that the federal inspector or engineer may see that the locomotive boiler has received its monthly or quarterly inspection.

3. Q. What constitutes a safety appliance, as applied to a locomotive?

A. Any appliance that is placed on a locomotive for the purpose of protecting the employees from personal injury.

4. Q. Name some of the safety appliances found on a locomotive?

A. Shield for tubular glass lubricators, also shields for water glass, automatic couplers, with lever attachments, air brakes, etc.

5. Q. In what condition should safety appliances be maintained?

A. They should be maintained in first class condition.

6. Q. What should be done in event of any of the safety appliances being damaged while engine is in service so as to render it unsafe?

A. Warn all employees whose duties require them to work around the locomotive of its unsafe condition, then make report to those in authority so that it may be taken out of service until repairs are made.

7. Q. What effort should be made on the part of the engineer to prevent persons using a safety appliance which he knows is damaged and unsafe?

A. He should use such precaution as in his judgment would protect from injury all persons who are on or around the locomotive.

8. Q. What is the duty of the engineer in event of his discovering a safety appliance which is in an unsafe condition when taking an engine from roundhouse territory?

A. He should report at once to the person in authority so that necessary repairs may be made before engine goes into service.

=PYLE-NATIONAL ELECTRIC HEADLIGHT=

1. Q. Why are electric headlights applied to locomotives?

A. Electric headlights are applied to locomotives so that the engineer may have a clear view of the track for enough ahead of the train to enable him to protect the company's property in his charge.

2. Q. How far ahead of the engine should the arc headlight illuminate the track?

A. Not less than from fifteen to twenty telegraph poles.

3. Q. State how you would focus the lamp.

A. First, would adjust back of the reflector so front edge of reflector will be parallel with front edge of case. Second, adjust the lamp to have point of copper electrode as near the center of reflector as possible with carbons as near the center of the chimney holes as you can set them. Third, have the locomotive on straight track. Now move the base of the lamp around until you get a parallel beam of white light straight down the center of the track, then tighten the lamp down.

4. Q. If the light throws shadows upon the track, is it properly focused?

A. No.

5. Q. If the light is properly focused, that is, if the rays are leaving the reflector in parallel lines, but the light does not strike the center of the track, what should be done?

A. When the light rays are thrown out in parallel lines and they do not strike the center of the track, it denotes that the headlight case is not set straight with the engine, and the entire case on base board must be shifted until the shaft of light strikes the track as desired.

6. Q. What can you do to insure a good and unfailing light for the entire trip?

A. By carefully inspecting the entire equipment before departing on each trip, and know that there are no wires with insulation charred or worn off, that all screws and connections are tight, commutator clean and brushes set in brush holder in proper manner. Carbon in lamp of sufficient length to complete trip, and that the carbon will feed through the clutch freely and rests central over the copper electrode. Copper electrode cleaned off, oil in both bearings and see that steam does not blow at stuffing box gland.

7. Q. What kind of oil and how much would you use in the bearings of the electric headlight equipment?

A. Would use the best grade of black or engine oil furnished for both bearings and only enough oil in oil cellar that the revolving loose oil ring may trail through the oil. When bearings are supplied with oil cups, use a heavy oil such as good engine or valve oil.

8. Q. Why should you not use valve oil in these bearings?

A. Valve oil cannot be used successfully in the main bearing because of its heavy body. Valve oil could not be carried up to shaft by the oil ring in cold weather, as the ring will not revolve.

9. Q. What is the most vital part of the dynamo?

A. The commutator.

10. Q. What care or attention should be given the commutator?

A. The commutator must be kept clean, free from dirt, and the mica must be kept filed a trifle below the surface of the copper bars.

11. Q. What kind of a bearing should the brush have on the commutator?

A. Brushes should be fitted to have a bearing with the same contour as the commutator.

12. Q. How are the brushes fitted?

A. Brushes are fitted by cutting a strip of No. 0 sandpaper about the width of the commutator surface (have the dynamo idle), place the strips of sandpaper under the brush, then pull the sandpaper from left to right; continue this process until the brush has been fitted to a true smooth bearing. Then trim about one-eighth inch off of the front edge of the brush.

13. Q. Is it advisable to ever try to fit a brush with a file or knife?

A. Most emphatically no. You could not get a bearing across the brush no matter how hard you might try with either a file or a knife.

14. Q. Why is it important to clean the scale off of the point of the copper electrode each trip?

A. The scale on the copper electrode after it has cooled off is a non-conductor of current, and acts as a blind gasket between the carbon and the copper electrode. Unless this scale is removed, the current cannot pass between the points of carbon and electrode and you cannot, therefore, have a light. When the dynamo fields are compound wound, it is unnecessary to clean scale from copper electrode oftener than once a week, at which time copper electrode should be removed from holder and all scale cleaned off. (With compound wound dynamo fields the cab lamps will continue to burn when head-lamp is extinguished by lifting carbon by hand.)

15. Q. How should the copper electrode be trimmed at the point?

A. The copper electrode should have about one-eighth inch surface on the contact point.

16. Q. How far should the copper electrode project over the holder?

A. About one inch.

17. Q. Should the electrode be raised up to one and one-half inches, what might happen?

A. If the copper electrode was run at a point so near the clutch, the intense heat of the arc might do damage to the top carbon holder and clutch.

18. Q. What regulation should be given to the tension spring No. 93 of the lamp, and why?

A. This tension spring, No. 93, should be regulated when the current is off the lamp and should be adjusted only tight enough to pull the magnet yoke up against the top stop lug on the side of lamp column.

19. Q. If this tension spring was tightened too tightly, what might happen?

A. At usual speed between stations, the movement of the engine would impart an added resistance against the pull of the solenoid by the tension spring, which would shorten up the arc and dim down the light.

20. Q. Is there anything else that could cause the light to dim down when the engine is running fast?

A. Yes; if the spring No. 92-A that hold the heel of the clutch should be too weak, the heel of the clutch would be forced up by the motion of the locomotive; this would release the carbon which would fall to the point of the copper electrode, causing the light to dim down, or, if the clutch should be used until the sharp edge that grips the carbon should have become worn smooth or round, the same would occur.

21. Q. If the light burns satisfactorily while the engine is in motion, but goes out when engine is stopped, where would you find the trouble?

A. This trouble is most always found to be caused by the tension spring No. 93 being too weak, though if the dash-pot plunger has become corroded until it sticks in the dash-pot, the light will act the same as if the tension spring were too weak.

22. Q. If the dash-pot should be found stuck, would you put oil in it?

A. Coal oil could be used to clean and cut the dirt out of the pot and from off the plunger, but after the dash-pot and plunger have been cleaned, all oil must be wiped off, for oil would cause the plunger to stick as well as collect dirt.

23. Q. If the carbon of lamp should "jig or pound", what can be done to stop it?

A. If the carbons pound the electrode, it is evidence that the iron armature No. 64 may be too far out of the solenoid, or the speed of the turbine engine may be too slow. This trouble can be remedied by adding another link to the suspension link, which has one end connected to the magnet yoke, the other end being connected to the iron armature No. 64. If, however, when the arc is formed, it is found that the bottom end of iron armature No. 64 measures one-half inch from bottom of solenoid, the pounding is caused by the speed of turbine engine being too slow.

24. Q. If the copper electrode was fusing, how would you know it?

A. When the copper electrode is fused, a green light is always given off.

25. Q. What should be done when a green light is seen?

A. Immediately close off on the steam throttle until a white light re-appears.

26. Q. What is the cause of the fusing of the copper electrode?

A. Usually too high speed of the armature, although should you connect the wires up wrong that the current flowing from the dynamo to the lamp should enter the lamp at the electrode instead of passing through the carbon first, you would get a green light and fuse the electrode.

27. Q. What arrangements have been made so that you cannot connect the wires wrong?

A. The positive binding posts, both at the dynamo and the lamp, have been provided with a much larger hole to receive the wire than has been made in the negative binding posts, and the ends of the positive wire should always be bent or doubled back, so that they will just enter the receptacle in the positive binding posts, but cannot be connected at the negative binding posts.

28. Q. Should the copper electrode and holder become fused until no longer serviceable while on the road, what would you do?

A. Would remove the damaged holder from the lamp and substitute either an iron bolt of sufficient length or a carbon, securing the improvised electrode in the bracket of lamp same as the electrode holder is held, only being sure that the end of the bolt or carbon comes up into the center of the reflector and did not rest on the base of reflector or lamp.

29. Q. What is the difference between a series wound equipment and a compound wound equipment, and what advantages are obtained from the use of the compound equipment.

A. With the series wound equipment, the incandescent cab lights burn only with the arc lamp, while with the compound machine the incandescent lamps are independent of the arc and can be used as desired.

30. Q. If you were running along with your light burning steadily and nicely, then suddenly the light began to flash badly and kept it up, where would you look for the trouble?

A. Trouble would usually be found at one of the binding posts, where one of the binding post screws would be found loose.

31. Q. If you were running along with light burning satisfactorily and suddenly it went out, where would you be likely to find the trouble?

A. You would find that either the carbon had burned out, one of the lead wires had broken between the dynamo and the lamp, or one of the wires had gotten loose at the binding post and fallen out.

32. Q. If the light goes out while you are between stations, what course should an engineer pursue?

A. If the light goes out while you are between stations and an investigation cannot be made within a few minutes thereafter to determine the cause, the steam should be shut off from the turbine and the dynamo stopped until such time when the cause of failure can be determined.

33. Q. Why is it essential to shut off steam and stop the equipment?

A. For the reason that if the failure was due to a short circuit, damage might be done to the coils or armature by overheating.

34. Q. How does the equipment act when short-circuited?

A. When there is short circuit, the engine will labor heavily, run slow with a large volume of steam blowing at the exhaust, there will be no light shown either at the arc or cab lamps, and the carbon point and cab lights will only show a dull red or go entirely out.

35. Q. How will the equipment act when the circuit is broken, either by a broken disconnected wire or a burned-out carbon?

A. With a broken circuit the engine will run noiselessly and fast with very little steam blowing at exhaust and no light will be seen at the arc or on cab lights.

36. Q. If the insulation on the cab wires is worn off until your two wires can come together either directly or through the medium of some metallic substance, what would occur?

A. A short circuit would result that would put out all of your lights.

37. Q. What should be done?

A. Wrap the exposed wire, if you can locate it, with a piece of waste, or if you cannot locate the short circuit, disconnect one of your cab wires from the dynamo. This would give you the benefit of the arc lamp and you can look for the trouble at your leisure.

38. Q. If the light goes out when steam drops back fifteen to twenty pounds, what is the trouble?

A. Either one of the governor valves is stuck shut, short bushing No. 18 in engine cab is worn badly, allowing wheel to drop away from the governor stand so steam passes around wheel to exhaust, or governor springs are too weak.

39. Q. In this case what should be done?

A. Report of the action of the dynamo should be made upon the work book at the terminal.

40. Q. If clutch rod No. 78-B should break while on the road, what could be done to get use of the lamp?

A. A piece of wire could be used by fastening one end around the end of top lever No. 59, the other end being attached to clutch through eye.

41. Q. If you should lose the clothespin holder or top carbon clutch, what could be done to get the light?

A. Would fasten a wire around the carbon and top holder to keep carbon in line, being careful not to get the wire either too tight or too loose.

42. Q. If you should lose the iron armature No. 64 in solenoid, what could be done to get use of light?

A. Would use a common iron bolt and suspend same by wire in magnet.

43. Q. What would be the result if any of the levers of the lamp should bind?

A. All levers of the lamp must work absolutely free and must not drag, for if they are not perfectly free the carbon cannot feed properly.

=Pyle-National Electric Incandescent Headlight=

44. Q. What is meant by an incandescent headlight equipment?

A. A headlight having an electric incandescent lamp in the reflector in place of the usual oil or acetylene gas flame, and electric instead of oil cab lamps, the electricity being generated by a small combination steam-turbine and electric generator. Suitable wiring distributes the electric current.

45. Q. In what manner does the incandescent headlight differ from the arc headlight?

A. It is not so powerful. An incandescent or bulb type of lamp takes the place of the arc lamp in the headlight reflector. The current being less than is required for an arc, is supplied by a smaller turbine.

46. Q. What type of incandescent lamp is used in the reflector?

A. A low voltage, gas filled bulb, containing a very compact or concentrated fillament.

47. Q. Why cannot a standard or house type of lamp be successfully used in the reflector?

A. Because the fillament or light-giving wire inside the bulb is not sufficiently compact or concentrated to reflect the light in the form of a beam. The voltage of the house lamp is also too high to be used on a locomotive installation.

48. Q. How is the lamp held in place in the reflector?

A. By the usual socket, into which the lamp screws. The socket is a part of the focusing device, one type of which holds the lamp in a horizontal position, while in the other the lamp is held vertically or upright.

49. Q. Before turning the steam into the turbine, what precautions should be observed?

A. The turbo-generator should be lubricated by a small amount of black or engine oil, placed in the cup on the turbine or steam end. On the generator end, the oil should be maintained within one-half inch of the top of the hinge-cover cup; using black oil. The drainage of the steam end is cared for automatically by a three-eighth inch drain pipe without a valve. The pipe should be kept open.

50. Q. How do you proceed when you wish to use the light?

A. Open the globe valve in the steam pipe to the turbo-generator, at least two turns. The water-glass, steam and air gauge lamps in the cab, and the number indicator lamp in the headlight case should light up as soon as the turbo-generator reaches full speed. A double-throw knife switch in the cab controls the headlight. In one position the switch gives the full brilliancy of the headlight. The opposite or "dimmer" position reduces the brilliancy about one-half. When the switch bar is in neither position the headlight is entirely out, and only the number lamp is burning. The classification lamp, lubricator and order or reading lamp, are controlled by a small switch on the socket of each lamp.

51. Q. For what purpose is the dimmer, and how does it operate?

A. It is to reduce the intensity of the headlight when locomotive is in yards or around stations. It consists of a small resistance tube in the wiring circuit, and with the cab switch in dimmer position, a portion of the current is converted into heat instead of light.

52. Q. How is an incandescent headlight focussed?

A. By moving the lamp in its position in the reflector until the most brilliant and compact beam of light is obtained. If the beam does not strike the track centrally, or as high or low, the headlight case must be moved on its platform until the beam is properly directed. It is often necessary to raise the front or back of the case by shimming between the case and its platform in order to direct the beam of light the proper distance ahead of the locomotive.

53. Q. What provision is made for moving or focussing the lamp in the reflector?

A. When the lamp is mounted horizontally there are thumb screws by which the lamp may be moved sidewise, up and down, and forward and backward. This mounting is called the "micrometer" device, because of the accuracy of adjustment. With the vertical mounting, a flat head thumb screw at the base of the lamp support releases the ball joint so that the lamp may be easily moved sidewise or forward and backward. To raise or lower the lamp, the thumb screw higher on the lamp stand must be loosened.