P/ZRTI BSL 1

Index

Sr. no.

Description Page no.

1 Location,general description of diff. loco 2 Location of relays &valves provided in

different loco

3 Current & Voltage of T.M. 4 Name &location of valves & cocks

provided in different loco

5 Procedure & precaution of wedging of

relay / contactor

6 Procedure of fuse replacement

7 MCPA not working ,E.R. pressure not building up & panto not raising

8 CHBA not working ,working when pilot lamp not glowing

9 Impossible to close DJ (ICDJ) ,Q118/Q44 wedging precautions

10 DJ not maintaining 11 Working when DJ lock & unlocking

procedure of DJ

12 Trouble shooting when Safety Relay target drops

13 Defects in TM & trouble shooting of line contactors

P/ZRTI BSL 2

15 Dynamic Braking 16 Auxiliary failureü 17 üProgression & regression trouble 18 Indication / remedies after different fuse

melting on run & CCPT melting

19 MR pressure not building up & BP pressure not building up

20 Loco brake not applied &released by SA9

21 Different pneumatic testing in loco 22 MU Operation 23 Trtain working in abnormal condition 24 Dead loco working 25 üEnergy coservation 26 Safety fitting , Safety device & Safety

item

27 WAG7 loco 28 WAP1 loco 29 WAP-4 loco 30 Bogie (WAG5 & WAG7) 31 Static convertor 32 üMicroprocessor loco 33 Modification 34 O.H.E. 35 Circuit Diagram

P/ZRTI BSL 3

General description of diff. loco Discription WAM4 WAG5 WAG7 WAP1/4

Service Mix Goods Goods Pass.

Gauge mm 1676 1676 1676 1676

Wt. in ton 112.8 118.8 123 108.3/ 112.8

Axle load in

ton

18.8 19.8 20.5 18.05/

18.8

Wheel base

in m.m.

3810 3810 3800 3895

Length

(Buffer to

buffer)ü

19972

mm

19972

mm

20394

mm

18794

mm

Width (max)ÓÓÓÓ 3055 mm 3055 mm 3055 mm 3000/3179

mm

Height (panto

lower)

4162

m.m.

4162

m.m.

4185

m.m.

4235/

4232.5m.m.

Height (panto

raise)

4162

m.m.

4162

m.m.

4185

m.m.

4235 /

4232.5m.m

Horse power

3640 3850 5000 3800/5060

Bogie Costing Costing High Adh. ü Flexi coil

Transformer

rating in KVA

3460 3900 5400 3900/

5400

T.M. H.P. 667

(T) 770 (T)

840 (H)

770(T)/

840(H)

P/ZRTI BSL 4

T.M.(v)

715 700 750 700/750

TE effort(ton)

33.84 33.5 42.0 22.4/30.8

TE (cont.)

17.6 ton 20.5 ton 21 ton 13.6/19 ton

Adhesion 30 T 33.5T 34.8 T 30/30 T

Gear Ratio 15:62

(4.13)

15:62

(4.13)

16:65

(3.61)

21:58/23:58

(2.76/2.52)

Max. speed 120

Km/h

80

Km/h

100

Km/h

130/ 140 Km/h

Cont. speed (km/h)

56

Kmph

50.5

Kmph

50

Kmph

73.5 / 72

Kmph

Setting &location of Relay/Valve in diff. loco Relay WAG5 WAG7 location

QLM 300/6 Amp. 450/9Amp. TR

QRSI-

1/2

3600/4.5 Amp. 4000 / 5 Amp. TR

QLA 2000/5 Amp. 2000/5Amp. TR

QE 900/4.5 Amp. 900/4.5Amp. TR

QF 700 Amp. 750 Amp. HTC

QD 1/2 160A pick upÖ

130A drop

160A pick up

130 A drop

BA1/2

QOP 1/2 50 volt D.C. 50 volt D.C. TR

QOA 50 volt D.C. 50 volt D.C. TR

P/ZRTI BSL 5

QCVAR 157 V pick up 75 V

drop

210 V pick up 170

V drop

TR

Q30 215 V pick up

260V drop

215 V pick up

260 V drop

TR

Q20 865 V pick upú

740 V drop

865 V pick up

740 V drop

BA-3

RGEB-2 Cut in 2.8Kg/Cm2

Cut outü 4.2Kg/Cm2

Cut in2.8Kg/Cm2

Cut out 4Kg/Cm2

TPN2

RGCP

Cut in 8Kg/Cm2 cut

out 9.5 Kg/Cm2

Cut in 8.0Kg/Cm2

Cut out 9.5Kg/Cm2

TPN1

RGAF Cut in3.5Kg/Cm2

Cut out 4Kg/Cm2

Cut in 3.5Kg/Cm2

Cut out 4.0 Kg/Cm2

Behind cab 1û

P-1 close 4.6Kg/Cm2

open 4.8Kg/Cm2

Close 4.6Kg/Cm2

open 4.8Kg/Cm2

-

P-2 Close 4.4Kg/Cm2

Open 4.6Kg/Cm2

Close 4.4Kg/Cm2

Open 4.6Kg/Cm2

-

QPDJ

{ABB}

Cut in5.5Kg/Cm2

Cut out 4.5Kg/Cm2

Cut in 5.5Kg/Cm2

Cut out 4.5Kg/Cm2

HTC

QPDJ

(VCB)

Cut in4.6Kg/Cm2

Cut out ü4Kg/Cm2

Cut in 4.6Kg/Cm2

Cut out 4Kg/Cm2

In VCB box

Note- Except QD1/2 setting of all relays in WAP 4

is same as WAG 7.

P/ZRTI BSL 6

Current & Voltage rating of T.M. StartingCurrent (A) Loco Types

of TM

2 min.

10 Min.

60 Min.

Cont. Current (A)

Max volt (V)

WAP1 Tau 1100 1000 840 750 700

WAP4 Hitt 1250 1150 960 900 750

WAM4(6P) Tau 1100 1000 840 750 700

WAM4 Tau 1100 1000 750 667 715

WAG5 Tau 1100 1000 840 750 700

WAG5 Hitt 1200 1100 840 750 750

WAG7 Hitt 1300 1100 960 900 750

Name &location of diff.valves &cocks in locomotive Equipm

ents

WAG5 WAG7non

mod. Mod.ü

WAM4 WAP1/4

MCPA

drain cock

In TPN1

nearÓ MCPA

In TPN1

nearÓ MCPA

In TPN1

nearÓ MCPA

NearÓ

MCPA

R S drain

cock

In TPN1

belowÓ ER

In TPN1

belowÓ ER

In TPN1

belowÓ ER

TPN1/behind

cab1below ÓER

R1 COC Near wheel

no. 4

Near wheel

no. 6/7

TPN1 TPN1/behind

cab 1

RGCP TPN1 TPN1 TPN1 TPN1

PT drain

cock

Between

MR1 & ÓMR2

Near After

cooler

Between

BA1&BA2

After MR4

before wheel

no.5

P/ZRTI BSL 7

RDJ drain

cock

Near SMGR

PRV

- Near SMGR

PRV

-

MR EQ

drain cock

Below cab1

LP near foot

step

Below cab1

LP near foot

step

Below cab1

LP near foot

step

Below cab1

LP near foot

step

Bobie-1

COC

Near wheel

no.6

Near wheel

no.6

Near wheel

no.6

Near wheel

no.7

Bogie -

2 COC

Near wheel

no.7

Near wheel

no.7

Near wheel

no.7

Near wheel

no.6 Feed valve &iso. cock

Near wheel

no. 8

Near wheel

no.7/Pneu.

pannel

Near wheel

no. 8

Near wheel

no.8/Pneu.

pannel

C2-

Relay

valve

Between

MR3 &

MR4

Between MR3

& MR4

Pneu. pannel/

Between

MR3 & MR4

Between MR3

& MR4Pneu.

pannel/

Ad C2-

Relay

valve

Behind

MR1

Behind MR1

/pneu.pannel

Behind

MR1

Between

MR1&MR2/

Pneu.pannel

L&T

cock

In cab 1 In cab 1/

Pneu.pannel

- In cab 2/pneu.

pannel RGEB2

Iso. cock

In TPN-2 In TPN-2 / Pneu.pannel

In TPN-2 In TPN-2/ Pneu.pannel

P/ZRTI BSL 8

IP&E3W Valve &Ó COC

Behind

cab1

Behind cab1

/pneu.pannel

--- Pneu.

pannel

DJ oil sep.

drain cock

In front of

MR1

----

In front of

MR1

Near MR4

SMGR.Pre.

red.valve

In corr.2

near ZSMS

In corr. 2

near ZSMS

In cor.2 near

ZSMS ú

In corr.2 near

ZSMS ú

SMGR

drain cock

Between SL-

2 & TFP

Between

SL-2 &TFP

Between SL-

2 & TFP

Between

SL-2 &TFP MR4iso.cock After MR-4 After MR-4 After MR-4 After MR-4

Control

reservoir

Near TFP

towards

cab 1

Towards

bogie no.2

Near TFP

towards

cab 1

Between MR4

& wheel no..5

CR.drain

cock

Before

MR1

- Before

MR1

-

NC7 valve & iso. cock

Behind cab

1 near MCP

Behind cab

1 near MCP

Behind cab

1 near MCP

Behind cab

1 near MCP MV4 valve

Behind

cab 1

Behind cab

1/pneu.

pannel

Behind

cab 1

Behind cab

1/pneu.

pannel Air intake cock

Near SL1 Near SL1 Near SL1 Near SL1

MR- 5 - - - Below cab 2

P/ZRTI BSL 9

Wedging Procedure of EM Contactors &

Precautions- A) EM Contactors-

1. Open DJ, lower the Panto and put HBA on 0 before wedging of EMC. 2. Contactor should be wedged by proper wedge & ensure that armature fully operated, all contacts closed properly. Note-1-Only 2 EMC can be wedged at a time but C-118 should not be wedged in any condition. 2- 3 EMC can be wedged at a time in SI loco. B) EP Contactor 1. Before wedging EPC open DJ, lower the panto & put HBA on 0. 2. Ground the loco & open HTC door. 3. Close BA panel COC. 4. Open the cover of defective EP valve.put 1or2 coins on the spindle, tight the llid cover of EP valve.Ensure closing of EPC. Note-1. Max Two line contactor can be wedged at a time. (One L/C can be wedged from one group) Shunting contactor & C145 should not be wedged.

Precaution of relay wedging - 1. Open DJ, lower panto & put HBA on 0 before

wedging of any relay. 2. Operate relay armature plunger 2-3 times before wedging.

P/ZRTI BSL 10

3 To wedge the relay press plunger at proper place & apply wooden wedge.

4. After wedging relay ensure that relay plunger is not loose & all interlocks are operated properly. If loco is working with any relay in wedge condition,follow precautions.

Note -> 1.Manual control of relay can be taken by any bad conductor things in loco energise condition.

2.If relay gets energise after manual control then need not to be wedge.

3.No any relay should be wedged in de energise condition without divisional instructions.

Procedure of fuse replacement- 1. Open DJ, lower panto & put HBA on 0. 2. Remove fuse from holder.

3. Put HBA on 1. 5. Test fuse in ECC socket if LECC is glowing then fuse is ok & if not glowing then fuse is melt . 6. If fuse is melt then take another fuse of same

rating & test it on ECC. 7. Put HBA on 0. 8. Place tested fuse in holder & tight it properly. 9. Put HBA on 1 .

P/ZRTI BSL 11

10. Keep defective fuse in fuse rake. If the same fuse melts again then:- Take other fuse

of same capacity,test it on ECC after that put HBA-0 & HOBA-off and tight the fuse in fuse holder properly.Again put HBA on1 & energise the loco,if fuse maintains then work the train in HOBA

off condition.Check control circuit for smoke,fire smell etc. frequently

If$the same fuse melts again even after HOBA

off it means short ckt. In control ckt. Cable or earth fault in negative cable, in that case fuse will not hold . Note>:-In HOBA off condition 180/210 ohm

resistance adds in complete control circuit as well as in QOP/QOA ckt. In this position QOP/QOA will not work properly, so that in HOBA off condition

take precautions of these also. Trouble shooting when MCPA not working 1- Ensure that battery voltage is more than 85 volt.

2- Check CCBA, replace if melt. 3- Check ZCPA wire terminals, tight it if found

loose. 4- Operate ZCPA switch 2-3 times and short ZCPA

wire terminals for some times if necessary. 5- Check MCPA wire terminals also.

P/ZRTI BSL 12

6-Check MCPA corbon brush, tight it with proper packing if found loose. E.R. pressure not building up- 1- Ensure that RAL cock is open. 2- MCPA, ER, RDJ, DJ oil separator & panto drain cock should be closed.

3- Check for leakage in panto & DJ pneumatic ckt. attend if any.

If not succeed then close RAL & R1 cock , send pressure directly in system by MCPA,energise the loco and open the R1 cock after 6.5 Kg/Cm2 MR pressure. Trouble shooting when Panto not raising 1-Battery voltage should be more than 85 volt 2-Check ER pressure, increase if not sufficient 3-Check CCBA & CCPT, replace if melt 4-Check VEPT wire connection & ensure that its isolating cock is open 5-Press VEPT knob, if still not raising try to raise another panto 6- Ensure that BPEMS is reset.

Battery Charger not Working Indication-LSCHBA will continuously glow in DJ close condition, but DJ trips whenever HBA kept 0. it means battery charger not wkg .if DJ not trips then QV 61 is diffective. Action - If CHBA defective then ensure that HCHBA is on 1 position & ckt breaker is not trip, if CHBA still not wkg then isolate it by HCHBA and work with battery upto 85 volt. If QV 61 deffective then

P/ZRTI BSL 13

ignore LSCHBA glowing & keep watching on CHBA wkg. Note:- Release BLRDJ after 4 sec. while closing DJ, if LSCHBA not extinguish. Action to be taken when all Pilot Lamps are not glowing 1. Check CCLS and replace it if blown out. 2. Check A cong connections for tightness. 3. Check ZLS/HLS, it should be on (if provided on loco). If not succeed then work the train without pilot lamp as following- LSDJ - a) Before raising panto- ensure opening of DJ with the help of auxiliary contact of DJ, energise position of QV60, energising of Q-50 after MPJ F/R etc. b) Ensure closing of DJ by UA meter / sound of Arno & auxiliaries. LSCHBA - by CHBA Ammeter LSGR - by notch repeater & GR drum LSB - by position of J 1, J 2 / CTF/ Q-50 LSRSI - Check T/T fuse or QV 63 LSP - Check Q 48 / Q 51/ Ammeter Fluctuation Note - If CCLS not maintained even after HOBA off then work the train with wedging of QRS in energise condition along with above procedure

P/ZRTI BSL 14

Trouble Shooting Of DJ Impossible to close DJ (ICDJ) 1-BA voltage should be more than 85V. 2-ER pressure should be more than 6.5 Kg/cm2 increase if insufficient.

3-CCBA CCPT CCDJ should be in good condition. A- Q118 is not energising after HBA on,Check & ensure the following-Contactor C118, C105, C106, C107 are open & GR on on 0, If still not energising then- Take manual control of Q118 (close DJ and on BLVMT to start blowers, after starting of blowers release manual control of relay) or wedge Q118 with precautions. B. Q45 is not energising after pressing BLDJ & BLRDJ Check & ensure following - 1. Check CCDJ, replace it if blown out. 2. Press BP1 DJ 2/3 times. 3. Operate BLDJ & BLRDJ 2/3 times. 4. Try by Pressing BP2 DJ. 5. GR should be on 0 & LSGR glowing. 6. Operate ZPT 2/3 times or change position. 7. Take manual control of Q45 to close DJ and release Q45 after LSCHBA extinguish or after 4 second. 8. Try by another cab, if not succeed then ask for assistance.

C. Relay Q44 is not energising - 1. Ensure that GR is on 0. Take 2/3 notch manully & back on 0.

P/ZRTI BSL 15

2. Take Manual control of Q44& try to close DJ. 3. Q44 may be wedged with all preacautions, if permitted by division. 4. Do not take manual control/wedge relay Q45 and Q44 simultaneously. D. Contactor C118 is not picking up. 1. Lower the panto &put HBA on 0. 2. Check LT terminal of C118 coil. 3. Operate C-118 armature 2-3 times manualy. 4. Put HBA on 1, raise panto & Try. 5 Ask for asstt. Engine if not succeed. E. EFDJ & MTDJ Coil not energising- 1. Check relay board. 2. Check QLM (Target should not be drop) 3. Check ER pressure,it should be min.6.5 kg /cm2, increase if insufficient . 4. Put HQPDJ on 0 5. Ask for asstt. Engine if not successful. Wedging precautions of Q118 Before wedging of Q118 - Ensure opening of contactor C118, C105, C106, C107, & GR should be on 0. After DJ closing - 1. C118 should be open after closing DJ 2. If HQCVAR is already on 0, then releae BLRDJ after 4 sec.while closing DJ. 3. Keep watch on working of Arno, MPH, MVSL-1/2, MVRH, MVMT-1/2 .

P/ZRTI BSL 16

4. Take Regression notch by notch and open the DJ by BLDJ, when MP on 0 & GR stuckup on notches. 5. Keep watch on chattering of C105, C106, and C107.

Wedging precautions of Q44 A. Before wedging ensure that, 1. MP on 0, GR on 0. 2. Contactor C118 is open. 3. GR should not be Sluggish. B. After closing DJ ensure that 1. C118 is open. 2. Arno & all aux. are wkg. properly. C. Before taking 1st notch - 1. Send ALP near RGR in coridoor & ensure that no smoke is coming from RGR, after taking 1st notch if so then open DJ immediately. D. While on run 1. Open DJ as soon as UA needle comes to 0. 2. Keep watching on all aux, Arno & RGR. 3. Don not take manual control of GR. 4. Also take all preacaution of wedging Q118. Note - Follow divisional instructions to wedge relay Q 44 .

DJ closing but not maintaining 1) Indication - LSDJ flickering or DJ opens just after closing when BLDJ ON & BLRDJ press. Reason- 1.Target of QLM or QOA may be dropped 2. QPDJ may be defective.

P/ZRTI BSL 17

Remedies-- 1-Check all safety relay target ,if dropped reset as per rule. 2-Check ER pressure. It should be more then 6.5 kg/cm2. 3. Kept HQPDJ on 0 if ER pressure sufficient. 2) Indication- BLDJ-ON,BLRDJ Press,DJ closed ,LSDJ & LSCHBA extinguish, UA needle deviates, starting sound of Arno & Aux. will come. but DJ trips after 0.6 sec. from releasing BLRDJ. Reason - Defect in Q30. Remedies - Wedge Q44 with preacautions as per divisional rules & work under advice of TLC. 3) Indication - BLDJ-ON & BLRDJ Press, LSDJ lamp extinguish,but LSCHBA not extinguish,no any sound of Arno & Aux, UA needle not deviates & DJ trip within 5.6 sec Reason- No OHE tension, or open circuit between OHE to TFWR. Remedies - 1. Lower the panto & raise again by ZPT. 2. If no chattering sound coming while touching panto with OHE wire, means No OHE tension. In that case wait for OHE tension, if it takes more time then work as per traffic rules. 3. If chattering sound coming, means OHE supply available then check open circuit on loco roof if possible. 4. Try to energise the loco with another panto.

P/ZRTI BSL 18

5. If not succeed, ask for assistance. 4)Indication-BLDJ-On,BLRDJ Press, LSDJ extinguish, LSCHBA not extinguish,UA needle deviates, ARNO & AUX sound coming but DJ trips after 5.6 sec. Reason-ARNO or QCVAR defective. Remedies 1.Check Arno for any smell, smoke or abnormality. if noticed then fail the loco.

2.If ARNO is normal then put HQCVAR on 0, and keep watching the working of ARNO.At that time release BLRDJ after 4 sec.while closing DJ.

3.Keep attention on working of CHBA. 5)Indication-BLDJ-ON & BLRDJ Press, LSDJ & LSCHBA extinguish, UA needle deviates, ARNO & Aux. sound coming but DJ trips after 5.6 sec. Reason - QPH/MPH, QVSL1/2, MVSL1/2 or NOI of QCVAR may be defective. Remedies -- 1.Put HPH, HVSL1, HVSL2 on 3 rd, one by one. Try to close DJ. If succed then ensure working of concern auxiliary & work further. 2.If aux. not working, kept concered switch on 0, & work with necessary preacautions. 3. If still DJ trips after putting above switches on 3 or 0 positions,then keep HQCVAR on 0 and work further with keep watching on working of ARNO. 6) Indication - DJ opens after 5.6 sec. from closing of BLVMT. Reason- MVRH or QVRH defective.

P/ZRTI BSL 19

Remedies-1.Keep HVRH on 3rd position, close DJ, and check working of MVRH. 2. If MVRH not wkg. then put HVRH on 0 & work with all preacaution.

7) Indication-DJ opens after 10.6 sec from closing of BLVMT

Reason- MVMT-1 or QVMT-1 defective. Remedies-1.Keep HVMT-1 on 3rd position,close DJ and check working of MVMT- 1 . 2) If MVMT1 not wkg. then put HVMT- 1 on 0 and

work with all preacaution. 8) Indication- DJ opens after15.6 sec. from closing of BLVMT.

Reason - MVMT-2 or QVMT-2 defective. Remedies-1.Keep HVMT 2 on 3rd position, close DJ then check working of MVMT 2. 2) If MVMT 2 not wkg. Then put HVMT-2 on 0 and work with all preacaution. 9) Indication - DJ opens after taking 1st notch Reason- MVSI-1/2 or QVSI-1/2 defective or GR sluggish. Remedies-1.Close DJ & ensure wkg. of MVSI1/2, if any MVSI not wkg then put concerned HVSI on 0 & work with all preacautions. 2. If MVSI 1/2 wkg properly then put HVSI 1/2 on 3rd position one by one, close DJ , take 1st notch if DJ not trips then work with preacaution . 3. If still trping is experienced on 1st notch then GR may be sluggish.

P/ZRTI BSL 20

4. Put both HVSI on 1 and take manual control of GR with all preacautions & clear the section with 30 KMPH. Inform to TLC. 10) Indication- 6th notch tripping. Reason- Any one from Contactor C105, C106, C107 or all are not closing properly or their NOI may be defective. Remedies - 1. Close DJ & on BLVMT ensure that C105, C106, C107 are closing properly. 2. If any contactor found open, then check the reasons & wedge if required. 3. If any contactor wedged,then concerned switch should be kept on 3rd to close DJ. 4. If all contactor closed properly it means defect may be in NOI of C105 or C106 or C107. 5. Put HVMT-1& HVMT-2 on 3rd one by one and try to close DJ. 6. If still DJ trips then fault may be only in NOI of C107, wedge Q118 with all preacautions. 7. If HC-105 is provided in loco and 6th notch tripping comes even after C105,C106,C107 are closed then on it and ensure working of all 3 blowers. DJ Tripping without any apparent cause - Remedies - 1. Put HQPDJ on 0. 2. Put HPH, HVSL1/2, HVSI1/2, HVRH, and HVMT1/2 on 3rd one by one, if succed then ensure wkg. of concerned aux. and work the train.

P/ZRTI BSL 21

3. If not succeed, wedge Q118 & work with all preacautions. 4. Take GR sluggish test, if OK, then wedge Q44 and work with all preacautions. Indications of DJ locking 1-LSDJ will not glow after unlocking BL, do not raise panto and try to unlock DJ. 2- On run, when LP opens BLDJ the pilot lamp LSDJ & LSB should glow , if not glowing then it means DJ is locked in close condition immediately lower the panto & try to unlock DJ. 3-On run,the sound of AUX becomes off or UA needle comes to 0 without glowing LSDJ/LSB then it means DJ is locked in close condition immediately lower the panto & try to unlock DJ.

Procedure of clearing the section

If indications of DJ locking found then lower the panto immediately & work as follows - 1-Wedge Q118 relay. 2-Close VEPT cock & kept ZPT on 1/2 position.ü

3-BLDJ on,BLRDJ press and ensure closing of C-118. 4- Now open VEPT cock.

5- Release BLRDJ after LSCHBA extinguish. 6-Work with all precaution of Q118 & Q44 wedging,check safety relays and clear the section,

P/ZRTI BSL 22

lower panto immediately by ZPT in any abnormality.

Procedure of unlocking DJ - 1)-Create ER pressure to 8 kg/cm2 and try to open DJ,if LSDJ still not glowing then unlock DJ as per following : a) Ground the loco as per procedure. b) Enter in HTC and exhaust all pressure of RDJ through its drain cock. c) Remove cover of DJ box, look the piston of DJ servo motor, if piston is towards out side it means that DJ is open and if piton is towards in side then it means that DJ is closed. d) In DJ locked condition LP will found piston towards inside condition, now operate the piston 2 or 3 times by 32 mm spanner & keep the piston in out side condition i.e. in DJ open condition. e) Close DJ box cover and open /close DJ in LT 2 or 3 times. f) If succesfull then resume normal traction after ungrounding the loco. g) If DJ locked again, then fail the loco and

demand for assistance. Trouble shooting when safety relay target drops DJ opens with target of QLM Check HTC,specially main transformer and graduator for smoke, fire, burning smell, oil spray or any other abnormality before resetting the target. If found such abnormality then fail the locomotive and demand for assistance. If there is a fire or smoke or oil spray, then extinguish the fire.

P/ZRTI BSL 23

If every thing is found normal then QLM may be reset once and close DJ.inform the incidence to TLC. If QLM dropped again then fail the locomotive, whether there is abnormality or not. Note- 1-Oil trap chamber is being provided in loco, generally it is remain empty but during QLM target drop it should also checked for oil particles , if oil found then loco may be failed. 2- If DJ opens with torget of QLM along with target of any other relay- then a) Trouble shooting of QRSI to be done after resetting target of QLM &QRSI. b) Trouble shooting of QOP to be done after resetting target of QLM, QRSI & QOP DJ opens with target of QRSI 1 & 2 a) If target drops even after applied less current than limit , then work with less current. b) If target drops on less Amps.then:-

1. Isolate TM one by one by HMCS till you get success. if not succeed then. 2. Isolate a group of TM by HVSI &work further.If not succeed again then – 3. Work the train on less Amps. If possible

Note -Check power ckt. and TM for any abnormality like smoke, fire, burning smell etc.

DJ opens with target of QOP1 & QOP2

Remedies-1) Check power ckt. For smoke & fire if any abnormality found isolate concern equipment.before resetting QOP1/2.

P/ZRTI BSL 24

2) Isolate TM one by one by HMCS & start traction till you get succeed, if not succesfull then put HMCS normal. 3)Put HQOP1/2 off,reset QOP and before starting traction do following - a)stop the train and apply loco brakes. b)Take 2-3 traction notches. c)Get down & check traction motors for any abnormality like smoke fire, burning smell etc.if found such abnormality then isolate TM by HMCS d)Check HTC for any abnormality. if everything is ok then work the train ahead with HQOP off condition and keep watch on HTC and TM frequently .

e) Enter the incidence in log book & inform toTLC. Permanent QOP Dropping

1) Stop the train and check traction power circuit for smoke, fire and mica out & any other abnormilty. 2) If there is mica out from traction motor then-

* Isolate that particular traction motor from +ve & -ve side. * Clear the section with 15 kmph. 3) If any other abnormilty experienced from traction

power circuit then- * Isolate that particular equipment. * Reset relay target.

P/ZRTI BSL 25

4) If relay target does not reset then- to ensure the trouble from traction motor side or any other

equipment, do the following steps- *Kept HBA off and reset relay target. * Ground the loco and kept particular reversor in neutral position .

* Kept HBA on a) If QOP drops, it means there is no fault from TM side at that time kept particular HQOP in off position and revesor to be kept in desired direction

and work with all precautions. b)-If QOP does not drops, it means there is fault from TM side at that time isolate the particular TM by HMCS from +ve side and place the neumex

paper in particular Rev. from -ve side. In different type of locos, the following procedure to be adopted to isolate the faulty TM by placing neumex paper in J1, J2 REV bits.

(A)WAG5, WAG7, WAM4 (6P),WAP1/4(With DBR& CPU locos)

1)-QOP1 Dropping- There is fault in TM 1, 2, 3 fields. Place neumex paper in J1 reversor bits to isolate the fauly TM.

P/ZRTI BSL 26

There is 12 bits in J1 reversor, 6 no. of bits on top side & 6 no. of bits in down side its shown in

fig (right to left from EP valve)

Procedure of placing neumex paper in revesor bits.

*Ground the loco and reset QOP1 target by putting HBA off.

* Normal HQOP1 & HOBA if it is in off position.

* Ensure the REV is in proper direction.

* Place the neumax paper in J1 Rev. in bits no 7, 8, and 9,10,11,12.

* Kept HBA on.

* Now QOP1 target does not drops.

TM1 bits no1-2,7-8 TM2 bits no 3-4,9-10 TM3 bits no.5-6,11-12

P/ZRTI BSL 27

* Remove neumax paper one by one from reversor bits.

* QOP1 drops after removing neumax paper from any bits it means there is fault in TM again place neumax paper in that particular bits remaining all neumax paper to be removed from revesor bits .

*Then isolate the faulty TM by HMCS1 from +ve side.

* Unground the loco and reset QOP1 target, work with 5 TM if load & road permits.

2)- QOP2 Dropping- There is a fault in TM 4,5,6 place neumax paper in J2 bits to isolate the faulty TM(adopt the above given procedure)

There is 12 bits in J2 reversor, 6 no. of bits on top side & 6 no. of bits in down side its shown in fig (right to left from EP valve)

TM4 bits.no 1-2,7-8

TM5 bits no 3-4,9-10 TM6 bits no 5-6,11-12

P/ZRTI BSL 28

(B) WAP1/4 ( Without DBR & CPU) LOCO-The

figure of J1&J2 bits as above but adopt following

procedure to ensure the faulty TM. a) QOP1 Dropping - To isolate the fauly TM after placing the

neumax paper in J1 bits no 8,10,6 adopt the procedure like WAG5

b)- QOP2 Dropping - To isolate the fauly TM after

placing the neumax paper in J2 bits no 8,10,6 adopt the procedure like WAG5

Note-1)-If LP experienced permanent QOP dropping

in section then try to clear section by putting concern HQOP off with all precaution.After clearing the section trouble shoot as per above procedure. 2) Inform to TLC in detail & enter in log book.

TM1 bits no. 1-2,7-8 TM2 bits no. 3-4,9-10 TM3.bits no.11-12 5-6

TM4 bits no.11-12, 5-6 TM5 bits no. 3-4,9-10

TM6. bits no.1-2,8-7

P/ZRTI BSL 29

3) MPJ should not be operated if any rev. bit packed with neumax paper and rev. handle to be

bounded by rope in desired direction to avoid falling down off neumax paper.

DJ Tripping With Target Of QOA Remedies- Open all BL switches & re close DJ. 1) If QOA target dropped as soon as DJ closes, then earthfault may be in ARNO itself, MPH, MVSL 1/2,MVSI-1/2,RTPR,Cab-heater,Cabfan,TFS&CHBA. 2) Check the above aux. and equipments for any abnormality and isolate particular equipment,if found any abnormality. If everything is found ok then try by isolating each equipment / aux. one by one till you get succeed. 3) If not succed, then put HQOA to 0 & keep watch on all aux. 4) If QOA target is not dropping just after closing DJ then it means earth fault in aux. with contactor a) If target drops after closing BLCP then reset the target & change position of MCP by HCP, if still

QOA target drops then put HQOA on 0. b) If target drops after closing BLPV then reset thetarget & change position of MPV by ZPV, if still QOAtarget drops then put HQOA on 0. C) Target drops after BLVMT close - (i)- If immediate drops then isolate MVRH (ii)- If drops after 5 sec. then isolate MVMT1 (ii)- If drops after 10 sec. then isolate MVMT2 If still target drops then put HQOA on 0.

P/ZRTI BSL 30

REVERSER (J1& J2)

Location- J1 HTC (BA1) and J2 HTC (BA2) J1 for TM 1, 2 & 3 and J2 for TM 4, 5 & 6 Reverser From cab no.1

From cab no. 2

J-1, J-2 J-1, J-2

Upwards (F) Down wards (R)

Upwards (R) Down wards (F)

CTF 1, CTF 2 & CTF 3 Location- -CTF 1 HTC (BA1) CTF 2 HTC (BA2) CTF 3 HTC (BA2) CTF have two positions, traction & braking Traction- All the CTF handles will be in upward direction. Braking- All the CTF handles will be in downward direction.

Action to be taken in case of fire, smoke & abnormal sound from TM.

1) Stop the train. 2) Check the defective TM. 3) Start again and send ALP to walk along with the loco & observe that all the wheel are moving. 4) If any pair of wheel is not moving then stop the train & ask for assistance. 5) If the all wheels are rotating, then try to detect that the falure is due to slipped pinion or metal out or mica out or hot axle or any other abnormality and act accordingly.

P/ZRTI BSL 31

Mica out from T M 1) Smoke may be come out from TM. 2)White fibers of mica will be seen at the cage near gear case of TM in that case, LP will identify and isolate the particular TM & clear the section with speed restriction of 15 KMPH,under advice of TLC. Metal out of TAO- 659 TM- 1) Screeching sound will come. 2) Smoke will come from gear case and suspension bearing. 3) Colour of gear case ring may be changed. 4) Particular TM will slightly jump on first notch. 5) There will be a gape of about 1/2 inch.between gear case and axle at the bottom side wich can be seen from wheel side. 6) Axle box may be running slightly warm. When above indications appears,LP will take following actions- a) Start the train again and send ALP to walk along with loco and see the movement of that particular wheel set. If wheel is moving freely then clear the section cautiously and ask for assistance. b) If wheel is not moving, then fail the loco and ask for assistance. Indications & action to be taken in case of slip pinion 1)-Smoke may come from gear case. 2)-Abnormal sound will come from gear case. 4)-LSP will glow if slip pinion in QD connected motor.

P/ZRTI BSL 32

5) In such case identify the traction motor & isolate it and clear the section, speak to TLC. Indications if line contactors are not closing If all line contactors are not closing 1- Ammeter/Voltmeter will not deviate. 2- Notch repeator will show notches &LSGR will extinguish. Remedies- Check reasons for line contactors are not closing.and trouble shoot.If not succeed wedge max.two line contactors.(only one from each group) Note- While control the train do not bring GR on 0, at least GR should be on 1 notch after dead stop bring GR on 0, when any line contactor is wedged. Indications if any one line contactor is not closing:- L1 Open -- U1 will not deviate L2 Open -- 1st notch regression will come with LSP L3 Open-- 1stnot regression with LSP &1st ammeter

of both cabs will not deviate. L4 Open--1st not regression with LSP&2nd ammeter

of both cabs will not deviate. L5 Open ---1st notch regression With LSP. L6 OPEN--- U 2 will not deviate. To identify the difference between L2 & L 5, kept HMCS 1 on 3rd, if regression not comes that means L 2 is open, if regression occurs means L5 is open. Remedies -Isolate the particular open line contactor by HMCS & work the train if load & road permites.

P/ZRTI BSL 33

Dynamic Braking It is a electric braking which is used with the help

of momentum of train. Train speed can be reduced so much with the help of this braking but train could not be dead stop. Benefits of DBR

1- Train controlling in down gradient is easy. 2- Life of wheels & brake block increased due to less wear. 3-Speed of train can be increased immediately since load is released. 4- Section running time reduced.

5- More energy conservation. DBR should not be taken in following conditions. 1. While taking MP on P, if LSB not extinguish after glowing. (Because it indicates that CTF 1/2/3 are not thrown in braking or C 145 is not close) 2. The speed of train is below 15 kmph. 3. Any TM is isolated. 4. MP is fail. 5. Q50 is in wedge condition. 6. Any RSI block is Unloaded 7. MVRF is not wkg. 8. Any HQOP is off. 9. Any line contactor is wedged. 10. After pressing PVEF loco brakes applied in conjuction.

P/ZRTI BSL 34

11. Repeatedly dropping of QE / QF1/2 12.CTF stuckup while MP kept from 0toP & P to 0.

Procedure of taking DBR 1- MP- 0,GR -0 & LSGR should glow.

2- Bunch the train by A-9 before taking DBR. 3-Put MP from 0 To P & ensure that LSB extinguish just after glowing once, it indicates that all 3 CTF moves towards braking & C-145

contactor closed. 4- Now put MP from P to N and then N to + position .one notch will come in braking side, with the same procedure increase notches one by one

in braking side. 5-Generated current should be less than 700 amps while DBR . Note: In WAG7 generated current should be less

than > 850 Amps. Procedure to return from DBR

1.Operate MP in Braking Side from N to -,one

notch will reduce.In same procedure reduce braking notches$. 2. Put MP on 0 after comming GR 0 & wait some

time. 3.Now put MP from P to 0 & ensure that LSB extinguish after glowing.

P/ZRTI BSL 35

4.Resume normal traction & work the train. Testing of Dynamic braking (DBR) After taking charge of train (a)- Release loco brakes. (b)-Put MP on P, LSB should extinguish after glowing.

In running train a)- Apply train brake slightly by A-9. b)-Take 2-3 notches after putting MP on P,Ammeters will moves towards lower side & show generated current, it indicates that DBR is working. Testing of MVRF/QVRF

a) Use DBR at the speed of 60-65 KMPH. b) Give supply up to 200 volt or 5 notch. c) LSDBR should extinguish if not so,it means

MVRF is not working and if extinguish then MVRF is working. In standing train during testing of QVRF auto regression should come after 5 notch. Trouble shooting concerned with DBR Trouble1-LSB contineus glows when MP kept on P. Reason - CTF1, 2, 3 are not thrown in braking side

or C-145 is not closing. Remedies - Check CTF 1, 2, 3

Trouble 2- LSDBR not extinguish during DBR.

P/ZRTI BSL 36

Reason - MVRF / QVRF defective. Remedies- Generaly LSDBR extinguish after 3-4

notch/200 V, if not so then ensure working of MVRF and put HQVRF on after that 6th notch regression will stop but LSDBR will not extinguish.

Trouble 3 - 6TH notch regression . Reason - QVRF not working.

Remedies - If 6th notch regression comes even after MVRF working then kept HQVRF on. Trouble 4- Regression comes on 600 amps.

Reason - Target of QF 1/2 drops. Remedies - Reset the target & work under current

limit of 600 amps during DBR. Trouble 5- MP/EEC fails with LSB lamp when

moving towards traction after DBR. Reason - CTF 1,2,3 not coming in traction. Remedies- Check handle of all 3 CTF,it should be

upwards. Trouble 6- Loco brake comes along with train brake during DBR.

Reason- Defect in VEF circuit or excessive BP dropping. Remedies- Do not use DBR, if nessesary then use

in PVEF press condition.

P/ZRTI BSL 37

Trouble 7- BP not dropping when DJ tripps in DBR Reason - IP COC & E-3W COC may be closed.

Remedies- Open IP & E-3W COC.

3 Phase MVRF:-In some locos 3-phase AC MVRF is

being provided in place of DC-MVRF, but due to limited capacity of Arno, some changes in ckt. is nessesary,due to change in the ckt. during traction MVRH will work & during DBR MVRF will work &

MVRH will remain stop. Circuit Analysis:-In C107 ckt. one CTF interlock is provided which will be close in traction & open in

DBR so that C-107 will open at the time of DBR and will remain close during traction. One new EMC C108 is provided which will remain open during traction & will close during DBR. In some locos

C108 picks up after taking notch in DBR. IP Magnet valve & E 3W (Auto Emergency)valve- Location-In WAG5&WAG7,provided behind cab 1 and in WAG-7mod.provided behind cab 2 pneumatic panel top rake,one isolating cock provided near it. During DBR if DJ trips due to any reason then IP valve gets de energise&BP pressure exhausted through E3W valve and train brake applied.

During traction it is contineuosly energise,

but in following condition IP valve gets de energise

P/ZRTI BSL 38

& applied emergency train brake- 1- If CCPT melts.

2- If DJ open when Add CCBA & CCBA melted.

Trouble shooting after CCA melting:-Remove

CCLSA,CCAD fuse and off all BL switches and

change CCA . Adopt following procedure for trouble shooting-

Sr no Indication Reason Action

1 When HBA ON

Earth fault in Q119 & NC-7 valve

Wedge any one from C101/C102/C103 and create leakage from E.R.

2 After5sec.

from DJ closing.

Earth fault in

Q1oo relay

Remove +ve wire of

Q100 & wedge it or put HOBA off and replace CCA .

3 When

BLCPD closed.

Earth fault

in 101,C102 or C103

Change HCP position if

not succsessful put HCP 0& wedge MCP cont. as per requirement.

4

When BLCP closed.

Erth fault in RGCP &VEAD valve.

Open BLCP &work with BLCPD,watch MR pressure and operate BLCPD accordingly .

P/ZRTI BSL 39

5

When

BLPV closed.

Earth fault

inC121,C111 as per ZPV.

Put ZPV on 3rd/4th if CCA melt

then open BLPV & wedgeü C121 or C111.

6

When HPV ON.

Earth fault in HPV switch.

HPV should not be used.

7 When BLVMT closed.

Earth fault in C107 or QTD105.

1-Kept HVRH 0 If CCA not melts then work with C107 wedge condition. 2-If CCA melts then earth fault

may be in QTD105, put HOBA off or remove QTD105 +vewire &wedge C105, put HVMT1 on 3.

8 After 5 sec. from BLVMT

closed

Earth fault in C105 or QTD106.

1-Kept HVMT1 0 If CCA not melts then work with C105 wedge condition. 2-If CCA melts then earth fault

may be in QTD106, put HOBA off or remove QTD106 +ve wire &wedge C106,putHVMT2 on 3.

P/ZRTI BSL 40

9 After 10 sec.from

BLVMT closed.

Earth fault in

C106

Kept HVMT 2 on 0 and wedge C106.

10 When MP

kept on P

Earth

fault in VEF

Do not use DBR.

Noteü- If CCA melts after HOBA off when earth fault in Q100, QTDIO5/106 then clear the section with all auxiliary failure trouble shooting,after that try to trouble shoot as per sr.no. 2,7,8 of above table under advice of TLC. Working of train in case of All Aux. Failure A. Check the following. 1. fuse CCA should be in good condition. 2.Relay Q100 should be energise, if required it may be wedged. 3. Ensure tightness of B cong Connection. 4.Operate timer of C118 mannully 2 or 3 times . B. If not succeed ,then wedge max.2 EMC. 1. In case of air brake train, wedge any Two MCP contactors. 2. In case of vac. brake train wedge one contactor of MCP and one contector of MPV. After wedging contactors take following. Preacautions:-

P/ZRTI BSL 41

1. Wedge relay Q118 to avoid 6th notch tripping. 2. Create leakage from ER drain cock to maintain MR pressure between 8 to 9.5 kg/cm2. 3. Give max. 500 amp.current to all TM & work the train if load and road permits. 4.Keep watching on oil level of TFP &MPH working.

Precaution after wedging Q100 - In modified auxiliary control ckt., if Q 100 is to be wedged then

all contactors of blowers will remain close , when DJ will be closed after opening at N/S or any other reason, so that NCI will remain open in Q-118 branch & LP will experienced ICDJ. To avoid the

problem work as per following instructions- 1. Operate MPJ on 0 & off BLVMT in standing train then close DJ. 2. In running train, off BLVMT & kept HBA on 0 or

put MPJ on 0 cautiosly so that blowers contactors will be open. 3. Ensure working of auxiliaries & watch TFP oil level if Q-100 wedged.

4- Open all BL switches before open the DJ & close one by one after closing of DJ. 5. If any other relay wedged along with Q100 then follow precautions of both relays.

6.Inform to TLC & book in repair book.

P/ZRTI BSL 42

Working of train in case of MPH failure. Indication - DJ opens after 5.6 sec. from closing. Remedies - 1. Put HPH on 0. 2. Ensure that MVRH is working. 3.Keep watch of TFP oil,it should not be increased 4.Give max. 500 Amp current to all TM and work further if load & road permits. 5. Inform to TLC. Working of train in case of MVSI 1/2 failure. Indication- DJ trips after taking 1st notch. Remedies - 1. Put HVSI 1/2 on 0. 2. Put HVMT1/2 on 0. 3. Put HVSL1/2 on 0. 4. Group of TM 1-2-3 or 4-5-6 will be isolated. 5. Work the train with remaining group if load & road permits. 6. Contact with TLC after clearing section. Working of train in case of MVSL 1/2 failure. Indication - DJ opens after 5.6 sec. from closing. Remedies - Procedure (1) - 1. Put HVSL1/2 on 0. 2. Give max 500 amp. current to all TM and clear the section if load & road permits & contact to TLC 3. Keep watch on SL1/2 frquently. Procedure (2)-1. Put HVSL1/2 on 0 2. Put HVMT1/2 on 0

P/ZRTI BSL 43

3. Put HVSI 1/2 on 0 4. Group of TM 1-2-3 orTM 4-5-6 will be Isolated. 5.Work the train with remaining group if load & road permits. Keep watch on SL1/2 frequently. 6. Contact TLC after clearing the section. Working of train in case of MVRH failure. Indication-DJ opens after5.6 sec.when BLVMT on. Remedies - 1. Put HVRH on 0, ensure that C 107 is open. 2. Ensure working of MPH. 3. Wedge relay Q118 to avoid 6th notch tripping. 4. Work the train with 500 amps.current if load & road permits. 5. Keep watch on TFP oil level,it should not increase. Note- If C 105 & C106 is not closing then wedge C105 ,C106 will automatically close. Working of train in case of MVMT1 failure. Indication-DJ opens after 10.6sec when BLVMT on. Remedies - 1. Put HVMT-1 on 0. 2. Ensure that C-105 is open. 3. TM 1 2 3 will be Isolate. 4. Put HVSI-1 & HVSL-1 on 0 also. 5. Clear the section with remaining 3 TM (with full current) if load & road permits & inform to TLC. Working of train in case of MVMT2 failure. Indication- DJ opens after 15.6 sec. when BLVMT on.

P/ZRTI BSL 44

Remedies - 1. PUT HVMT-2 on 0. 2. Ensure that C-106 is open. 3. TM 4 5 6 will be Isolate. 4. Put HVSI-2 & HVSL-2 on 0 also. 5. Clear the section with remaining 3 TM (with full current) if load & road permits & inform to TLC. Working of train in case of MVMT1 & MVMT2 failure. 1.Remove +ve wire of C105&C106 coil and tape it. 2.Ensure that C105 & C-106 are open. 3. Keep both HVMT on 1 & wedge Q118 or put both switches on 3. 4. Work the train with max.500 amps.current to all TM, if load & road permits.Contact to TLC after clearing section. Note:-The loco in which TM does not isolate by HVMT, adopt following procedure. 1. Put HVMT1/2 on 0 and ensure opening of C105 & C106. 2. Work the train with max.500 amps.current to all TM, if load & road permits. Contact to TLC after clearing the section. Failure of MCP-1, 2,3 (Any 1 or 2) Indication -MR pressure not build up . Remedies-1.If any MCP is required to be isolated then put HCP in that position in which concern MCP isolates. 2. Ensure opening of concern EMC.

P/ZRTI BSL 45

Failure of MPV-1, 2 (Any 1) Indication- Vac.level will reduce. Remedies- If any one MPV defective then isolate the same by putting ZPV 3 or 4 no. position and ensure opening of concern contactor and inform to TLC. Troubles related with Progression & regression

MP /EEC not working- Check & ensure the following - 1. Q50 should be energised i.e LSB should extinguished, if LSB is not extinguishing then, i) Check J1 & J2 for proper direction. ii) Check CTF 1,2,3 for proper direction. If all above is ok, then relay Q 50 may be wedged in energised condition. 2. Relay Q 51 should be de energise, if not then check QRS ,If QRS is de energise then wedge it in energise condition but if Q51 is energise even after QRS energise then Q51 may be wedged in de energise with precautions.(if PR2 is energised then wedge it in deenergise or remove CCLSA) 3. Relay Q52 should be de energise If energise then wedge Q52 in de enegise condition & take progression notch by notch (Do not stay on + position).

4. SMGR pressure should be between 2.5 to 3.5 Kg/cm2. 5. ZSMGR handle should be in vertical position. 6. ZSMS should be on 1 position.

P/ZRTI BSL 46

7. GR should be on 0 take one notch manually & back to 0 try again by MP if not successful then try by EEC, if still not successful then, take manual control of GR . Emergency Electric Control (EEC) working- 1. Put MP on N in traction side. 2. Rotate ZSMS from 1 to 0. 3. For one notch in progression press BPP once. 4. For one notch in regression press BPR once. 5. For quick regression press BPR contineuously. 6. Whenever DJ trips put MP to 0, then close DJ, again put on N then resume EEC. NOTE:-In some locos it is not necessary to rotate ZSMS. Precautions- 1.BPR Should be release after pressing while regression otherwise notches will regrets continuesoly . 2. MP should not be taken on 0 while GR on notches other wise Q46 will energise. 3. If DJ trips, put MP on 0 before closing DJ and put MP again on N after closing DJ other wise Q50 will not enersise and notches will not come. Procedure of Manual Control of GR:-- 1. Put MP on N in traction side. 2. Remove ZSMGR handle in 3 o clock position by turning it from 6 o clock to 3 o clocks anti clock wise. 3. Ensure that SMGR pressure is exhausted.

P/ZRTI BSL 47

4. Apply ZSMGR handle in 6 oclock position in GR drum shaft. 5. For progression rotate ZSMGR handle to one complete round in clockwise direction within 0.6 sec. For regression rotate ZSMGR handle to one complete round in anticlock wise direction within 0.6 sec. one notch will regress. 6. For further progession and regression adopt the same procedure. 7. If Q 44 is in wedge condition manual control of GR is prohibited. 8. Make codes between LP & ALP for progression and regression. 9. Clear the section with maximum speed of 30 kmph. Precautions-

1. Ensure that Q44 is not in wedge condition before manual control, if so then manual control should not be taken. 2. For progression rotate ZSMGR handle for one

complete round in clockwise direction withen 0.6 sec. otherwise DJ will trip by Q 44. 4. If DJ trips while manual control put MP on 0, and take GR to 0 manually. After that close DJ, put MP on N, and work further with manual control. Note:-If cock provided before GR servomotor in pipe line,then close the cock before manual control.

P/ZRTI BSL 48

Action to be taken in case of Auto Regression- A) Regression comes with LSP glowing-

It may be happened due to QD1/2 & Q48 energise, at that time - 1- If regression comes on higher notches then work

the train on lower notches. 2- a) If regression comes on first notch then ensure closing of line contactor connected with QD, if not so then wedge the particular line contactor.

b) If all line contactors are closing then defects may be in TM at that time isolate the TM by HMCS. c) Check ZQWC in both cab if found in on position,

put it off. Note- Auto regression may be come with LSP if there is axle lock or slip pinion, ensure that all wheels are moving if not so then fail the loco and if

there is slip pinion (axles are free )then isolate the TM by HMCS & clear the section cautiously. B) Regression comes without LSP by Q 51-

It happens due to QRS de energise, check reasons for deenergising of QRS (as-operating of H5, HB5 or CCLS melting) if QRS is de energise even after

everything is OK then wedge QRS and work the train with precautions.

P/ZRTI BSL 49

First Notch Regression without LSP Rear cab BL may be unlocked:-

1) Lock leading cab BL and ensure extinguishing of all pilot lamps, if not extinguishing then it is clear that rear cab BL is in unlocked position . 2) Try to locked rear cab BL properly.

3) If not succeed, wedge Q118 & work with EEC from leading cab. Auto regression with LSB glowing:-

1) Relay Q50 may be in deenergised condition. 2) Check J1/J2 & CTF 1,2,3 are in desired direction. If not, to be kept manually in proper

position. 3) Wedge relay Q50 in energised condition with all preacaution.

Auto Regression on any Notch :-- 1.If with LSP then Q51 may be in energised condition. 2.If with LSB then Q50 may be in de energised condition. Q 50 may be wedge in energized. condition after ensuring position of J1/ J2 & CTF. 3.Check ZQWC it should be in off position in both cabs. 4.Check QRS,it should be energised,it may be wedged in energised condition .

P/ZRTI BSL 50

Indications & remedies after diff. fuse melting in running train

Sr.n fuse Indications Remedies

1

CCPT

a) DJ will open

b) Panto will lower c) Line cont.will open dü) GR will stuck up on notches, LSGR remain

extinguish e) BP will drop due to IP valve deenergise

a) Change fuse as

per procedure b) If melts again then change position of ZPT

2

CCBA

No any indications

received but after DJ tripping or while N/S panto down, pilot lamps will glow,UBA willshow

voltage

Change fuse as

per procedure & work further

3

Add. CCBA

No any indication received but after

Tripping of DJ or while N/S panto comes down & pilot lamps will not glow, UBA will not show

voltage.

Stop the train, change fuse

cautiously & work the train. if circuit breaker provided then made it on.

P/ZRTI BSL 51

4 CCA a) If GR is between 6-32

notch then DJ will be trip b) All aux. having EMC will not work.

Change fuse as per

procedure & work further,if melts again then put HOBA off &

change the fuse.If the fuse melts again then work as all aux. failure.

5 CCDJ

DJ will open immediately,GR comes on 0 if on notches. ICDJ indication recieved.

Change fuse & work further.

6 CCLS

a) Auto regression will come

b) Pilot lamp will not glow c) Ensure by pressing BPT.

Change fuse as

per procedure & work further.

Note-If the above fuse melts repidetly then work

cautiously in HOBA off condition.

7 CCCPU

Screen light in both cab extinguish with the ICDJ problem, pilot lamps will

not glow

Change fuse & work further

8

CC INV

a) Static convertor will not workb) DJ will also trip if GR on notches

Change fuse & work further

P/ZRTI BSL 52

Note- In diff. loco if following fuses are not maintained even after HOBA off then loco should be failed-

1-Loco with Arno conv.-Add CCBA,CCBA,CCPT&CCDJ 2-Loco provided with S.I.-Add CCBA,CCBA, CCPT,

CCDJ & CCINV

3-Loco provided withMicroprocessor- Add CCBA,

CCBA, and CCPT & CCCPU 4-Loco with Micro. & S.I. – Add CCBA, CCBA, CCPT,

CCCPU & CCINV

CCPT Melting – Trouble shoot as per following manner after CCPT melting –

Ind. Reason Remedies 1-After HBA on.

Earth fault or short circuit

in Q-118, IP valve or Q-51.

1-Check IP valve,remove its wire connection & tape it.Isolate the coc. 2- earth fault may be in Q-51 coil, unlock BL in that case & inform to TLC. 3-Earth fault may be inQ-118, keep HOBA off in that case.

2-While raising panto.

Earthfault or short ckt. In concern VEPT.

Check concern VEPT, remove its wire , tape it and isolate coc , work with second panto

3-Immediate after closeDJ.

Earth fault or short ckt. May be in Q-44 or QCVAR.

Put HOBA off.

P/ZRTI BSL 53

4-After operate MPJ .

Earth fault or short ckt. may be in Q-50/ J1, J2 EP valve.

Ground the loco, check J1, J2 if any foreign particle shown then remove it or remove +ve wire ofJ1 /J2 EP valve and tight J1/J2 in desire direction. If fuse melts again then put HOBA off.

5-While keeping MP on N (mod.)

Earth fault or short ckt. may be in L1, L2, L3,L4,L5,L6 coil

Ground the loco & check L1,L2,L3L4,L5,L6,remove foreign parts if any or detect defective line contactor by HVSI1/2, HMCS1/2 and isolate the same

6-After taking first notch.

Earth fault or short ckt. may be in VE 1 or L1, L2, L3 L4,L5,L6 coil.

1- Take 1st notch in HVSI-1/2 0 position if fuse melts then earth fault in VE1 , clear the section by manual control of GR in that case & contact to TLC.

2- Take 1st notch in HVSI-1/2 0 position if fuse not melts then trouble shoot as per sr. no. 5

7-After taking 6th notch.

Earth fault or short circuit may be in EVPHGR.

Remove & tape wire of EVPHGR,work further and keep watching on GR oil level.

8-After taking shunt notch

Earth fault orshort circuit may be in EP valve of shunting cont.

Do not use shunt notch.

P/ZRTI BSL 54

9-On notchby notch regressionü

Earth fault or short circuit may be VE2 coilü

Clear the section by GR manual control & contact with TLC

10-On quick regression (by keeping MP 0)ü

Earth fault or short circuit may be Q-46 coilü.

Do notch by notch regression, put MP on 0 after GR coming on 0.

11-After MP keeping on P

Earth fault/short ckt. may be inCTF1,2,3 bkg./C-145 coil.

Do not use rehaustatic braking.

12-After ZQWC on.

Earthfault/short ckt. may be in QWC& EP valve inconcern shunting cont.

Do not on ZQWC.

13- After pressing PVEFü.

Earth fault or short ckt. may be in PVEF or VEF coil.

Remove & tape VEF coil +ve wire, if necessary then isolate conjuction working.

14-After pressing BPSW

Earth fault or short ckt.in coil of MV-4.

Check MV-4 for any foreign particle or remove & tape +ve wire.

15-With LSP lamp glowing

Earth fault or short ckt. may be in Q-48 coil.

Off HOBA & avoid wheel slip.

P/ZRTI BSL 55

Trouble & Remedies regarding pneumatic Circuit- MR pressure not maintaining 1-Ensure MCP is working, otherwise change MCP.

2- Tap MCP safety valve if blowing. 3- Arrest if leakage from NC-7 or isolate by COC. 4- Tap ABD valve if blowing or close COC. 5- Tap MR safety valve if blowing or close isolating cock if provided. 6- All drain cock including MR & CDC and both end equilising pipe COC should be closed. 7- Check E3W valve , if pressure drained then close its COC & open after 5 kg/cm2 BP pressure. 8- If still pressure not building then start all 3 MCP. 9- Arrest the leakage in system if any . 10- If Air Dryer provided then isolate it. Brake pipe pressure not creating (by A-9) 1- Ensure MR pressure is above 8 to 9.5 kg/cm2. 2- Ensure MR-4 cock is open. 3- Ensure A-9 cocks in working cab are open &

close in non working cab. 4- Ensure RS1/2 are closed 5- Ensure both A-9 handels are in released position. 6- Ensure MU2B is in lead position and L&T cock

in open position. 7- Tap Add. C2 relay valve. 8- Operate MU2B for few times. 9- Change the cab & try.

P/ZRTI BSL 56

10-If still un successful contact with TLC. Loco Brake not applied by SA9.Check following -

1- Ensure that SA 9 cocks of wkg cab are open & in non working cab cocks are closed. 2- Operate MU2B 2/3 times & put on lead position. 3- Ensure that bogie COC is open. 4- Check proper closing of BC equalising pipe COC. 5- If SA9 valve stuckup then tap gently. 6- If C2 relay valve stuckup then tap gently. 7- Check air leakage in system if any leakage found, arrest it. Note:- If loco brake still not applying after checking all things, then use loco brake in conj. wkg. by A9. Loco Brake not releasing by SA9.It may be happen

if SA9 or C2 relay valve stuckup,in that case operate SA9 handle 2/3 times & if not releasing, tap SA9 valve & C2 relay valve gently.If still loco

brake not releasing then close bogie COC and try, if any particular brake cylinder not releasing then loose dummy nut of same cylinder & exhaust the pressure . Different pneumatic testing in loco Vaccum Leak Test (Loco)- 1- Put HCP on 1 or 2 or 3. 2- Ensure that 5 kg/cm2 BP pressure available.

P/ZRTI BSL 57

3- On BLPV & ensure vaccume creation it should be 57 cm on dummy, and in 8 mm test plate vac. should be min. 53 cm within 45 sec. 4- Again create full vac. and open BLPV.

5- Wait upto 30 sec. or up to 45 cm vac.dropping, after that check vac. leakage it should not be dropped more than 5/6 cm/min. BP Leak Test (Loco)-

1) BP pressure should be 5 Kg/cm2 in gauge . 2) Operate A9 to min. reduction and drop BP 0.5 to 0.6 kg /cm2. 3) Close L&T Cock. 4) Check BP pressure leakage it should not be more then 0.7 kg/cm2 in 5 min. 5) Open L&T Cock. & release A9. BP Leak Test (with train)-

1) BP pressure should be 5Kg/cm2 in gauge . 2) Close L&T Cock. 3) Check BP pressure leakage it should not be more than 1.25 kg/cm2 in 5 min. 4) Open L&T Cock. & release A9. MU OPERATION 1. Closing of DJ can be done for both locos

together and seperetly. Similarly opening of DJ can be done for both the locos together or of the rear loco only.

P/ZRTI BSL 58

2. Only rear loco DJ open & panto lower can be done by pressing BLSN in leading loco. 4. Trailing loco DJ can be closed from the trailing

loco by pressing BP2DJ. but can not be opened by BP1DJ . In case of emergency the DJ of trailing loco can be opened by removing its CCPT fuse. Normaly it should not be done 5. Opening DJ of leading loco by trailing loco is

not possible 6. If DJ open & panto lower of rear loco is done

by pressing BLSN then after putting BLSN off only panto of rear loco will raise & for closing DJ pressing of BLRDJ again will be required 7. LSDJ, LSCHBA,LSGR, LSB lamps will glow if DJ trips in any loco 8.Identify as following that in which loco DJ has trip

a.If LSGRT glows,it means leading loco DJ has trip. b. If LSOL glows & LSGRT remain extinguish , it means trailing loco DJ has trip 9. If HOBA of one loco is to be kept off due to

fuse melting then HOBA of the other loco should alsobe kept off otherwise fuse will continue to melt

P/ZRTI BSL 59

10. Whenever it is necessary to work with EEC then keep ZSMS on 0 for both the loco

11. Whenever HQCVAR is kept on 0 in leading loco due to defect in QCVAR,never close DJ separately of any loco. Close DJ of both the locos together.

12. Do not wedge any EMC or relay except Q 100 & QRS in trailing loco. If necessary make the trailing loco dead. Position of Cocs In M.U Loco ITEM LEADING LOCO TRAILING

LOCO

1 A-9 COC Open in wkg. cab

& closed in non wkg. cab

Closed in both cab

2 SA-9 COC open in Wkg cab

closed in Non wkg cab

closed in both cabs

3 MU2B Lead trail 4 L&T coc Open close 5 MTP Open Open

Open Open

6

HB5 COC 1)VAC.BK 2)AIR brake Train Closed Closed

P/ZRTI BSL 60

Open Closed

7

Feed valve coc

1)Twin pipe air brake train 2)Single pipe air brake

train

Closed Closed

Cab Changing in MU In working cab 1) Create MR Pressure up to 10 kg/cm2 by BLCPD 2) Apply loco brake by SA9 & ensure BC pressure in gauge. 3) Apply A9 brake also if train stopped on gradient. 4) Close both cocks of A9 & SA9 5) Open DJ & all BL switches, lower panto, put MPJ on 0,unlock BL and remove all keys

6) Close L&T cock. 7) Go to other loco with all keys.

In other Loco 1) SA9 to be kept in application. 2) Open all cock of A9/SA9 in wkg. Cab 3) Open L&T cock . 4) Kept MU2B on Lead & energises the loco. 5) Release SA-9 & again apply,ensure application & release of loco brake. In previous Loco Keep MU2B on trail & close all doors, windows

P/ZRTI BSL 61

Note-1) Apply hand brake & wooden wedge while cab changing if necessary. 2) Ensure application & releasing of loco brake in both loco by SA9 before starting the train. Procedure for Passing neutral section in MU 1) When train approach before 500 m board in neutral section, create MR pressure to 10 kg/cm2 and back shunting notches. 2) At 500 m board bring MP to 0 & ensure glowing of LSGR. 3) At 250 m board press BLSN & ensure glowing of LSDJ, LSCHBA, LSB, LSOL . 4) At DJ open board open DJ & ensure that UA needle comes to 0 and sound of aux. is off ,if not then lower the panto immediately . 5) At the DJ close board operate BLSN upward. 6) After passing one OHE mast from DJ close board, close DJ & ensure the extinguishing of pilot lamps. Trouble shooting after DJ tripping in M.U.operation When ever DJ trips put MP on 0,MPJ position should not be changed & check glowing of LSOL, LSGRT . 1)Glowing of LSGRT indicates defect in leading loco. 2) When LSGRT not glowing, but LSOL glowing, it means defect in trailing loco Trouble shooting in MU operation- When any defect noticed in leading or trailing loco then LP should try to clear the section and then

P/ZRTI BSL 62

after trouble shoot in defective loco.If required remove jumper cables between loco If defect in leading loco Check relay target, if target dropped then reset & trouble shoot as per WAG5 single loco TSD. If any relay target not drops then check loco for any abnormality & trouble shoot as per WAG5 single loco TSD If not succeed work the train with rear loco as per following instuctions. 1) Remove all keys. 2) Put leading loco HBA on 0. 3) Donot change any cock position. 4)Remove jumper cables between locos & secure it. 5) LP will remain in leading loco for train controlling. 6) ALP will go in trailing loco & operate MP as per instruction of LP by predecided codes as well as responsible for other operations also. 7)Clear the section with max. 40 KMPH & inform to TLC. Note-With vac. brake train kept MU2B in lead & close BC equilising COC bet. loco.

If defect in trailing loco-

1) Press BLSN & ensure that trailing loco DJ is open & panto is down. 2) Cleare the section with single loco when load & road permits. 3) After clearing section, if required check the relay target of trailing loco. 4) If any relay target found dropped, trouble shoot as per single WAG 5 TSD.

P/ZRTI BSL 63

5) If not succeed then made trailing loco dead and work the train with single loco or contact with TLC.

In MU , indications after melting any fuse in rear loco Sr.no fuse In leading loco In rear loco

1 CCDJ No effect No effect

2

CCPT

a) DJ will remain close

b) LSDJ, LSCHBA, LSGR, LSB, LSOL lamps will glow

a) DJ will open b) LSDJ, LSCHBA,

LSGR, LSB, LSGRT lamps will glow

3 CCLS No effect No effect

4 CCA No effect DJ will trip on 6th notch

5 CCBA No effect

DJ will not close after tripping

ABNORMAL WORKING

Train Working With Rear Cab - When electrical control of leading cab failed,

then train may be worked from rear cab as per following procedure. 1. Energise the loco from rear cab. 2. ALP will go in rear cab & will be responsible for all operations. (Prog.&reg. etc.) 3. Do not change any cock position. 4. LP will present in leading cab and will be responsible for train controlling & safe operation. 5. Work the train with 40 KMPH.

P/ZRTI BSL 64

6.LP/ALP will decide code for progression/ regression and DJ opening.

7. Clear the section & inform to TLC. Engine Failure - 1. On Flasher light 2. Apply train brakes by A9 in emergency and donot release it. 3. Apply loco brake by SA9 and kept it applied.

4. Inform to Guard for assisting engine 5. Pass the assisting engine memo with load, location of engine & brake van, types of defect, required type of assistance etc. 6. Depute ALP to protect the train. 7. If train stopped on gradient then secure the train also as per rule. Head light failure Check following things if head light defective- 1. Ensure that ZRT is on. 2. Ensure that HRTPR is on 1(for RTPR) position or on 2 (for DC-DC convertor). 3. Check CCRTPR and other fuse provided on RTPR, change if defective. 4. Change mode switch provided on DC-DC convertor (Main to stand by or convertor position 1 to 2). 5. Check micro fuse on DC-DC convertor, replace if melt. If head light fails during wkg in night, rainy season /foggie weather, then LP will ensure wkg of marker light. Work the train with max. 40 kmph.

P/ZRTI BSL 65

or as per caution order, if caution order is less than 40 kmph through out the the section. Flasher Light Defective Following actions should be taken:-- 1. Change another filament of flasher light. 2. Change the micro fuse of control unit,if melt . 3. Micro fuse is also provided in LED base flasher check it also. 3. If flasher light still not wkg. Then inform to TLC. Note: - In flasher light fails at starting station then inform to TLC immediately and if flasher light fails in mid section then clear the section with preacaution & inform to TLC. Cab light defective 1. Change CCLC fuse, if found melt. 2. Check the cab light bulb, change it if fused. 3. If not succeed then work the train without cab

light & inform to TLC at first opportunity. 4. Enter in loco repair book. Speedometer defective Loco should not be brought out from shed with defective SPM. If defect occurs in mid section, then work the train as per clock, km post & WTT running time. Work the train with 10 % less speed than max. speed in case of defective SPM. Marker light defective 1. Ensure BL key & BLLF should be on. 2. Replace CCLF fuse if found melt. 3. Replace defective bulb. 4. Work the train without marker & Inform to TLC.

P/ZRTI BSL 66

Horn defective 1. Loco should be fail at starting station if horn fails. 2. If horn failed in mid section, then clear the section with max. 25 kmph if visibility is clear & 8 kmph in case of visibility is poor & pass memo to S.M. 3. If TLC permits to work further then proceed with max. 25/8 kmph speed. 4. In that case loco should be change as far as possible at first apportunity. Cattle run over-If LP saw any cattle on his track & the cattle was suppose to hit the loco in higher speed then LP will control the train by A9 ,but if cattle run over then stop the train & act as per following. 1. On flasher light. 2. If track obstructed then remove it with the help

of other rly. emp.&voilenters. 3. If the adjacent line obstructed then secure the

track first & after that remove the obstruction. 4. Check the loco under truck for any damage & act

accordingly. 5. If obstruction could not be clear then stop the

train at next station without clearing the block section & give written memo to SM.

6. Inform to TLC & enter in log book, so that shed staff can check the loco thoroughly.

P/ZRTI BSL 67

Note-1. Do not open DJ while inspection of loco otherwise due to defect in battery / cable loco may be fail. 2. Close add. BP/FP angle cock if leading cock is brocken. Panto Entanglement- Whenever LP experienced for panto entanglement of his engine then he should act as following- 1. On flasher light , open DJ & note the km . 2. Stop the train immidiatly. 3. Try to lower the panto by putting ZPT on 0 4. If panto comes dn, then LP will ensure that- (i) Dammage panto is not touching to loco roof . (ii) Raise another panto. (iii) Isolate damaged panto by closing VEPT isolating cock . (iv) Proceed with wkg. panto & stop the train at

next station without clearing the section. (v)Inform to SM in written,about panto entanglement alongwith OHE mast No./defect in OHE .

If any part of damaged panto is touching to loco /OHE then isolate and secure it if possible otherwise make loco dead & demand assistance.

If damaged panto not comes down then ask assistance from TPC. Action to be taken after wheel skidding. 1. Stop the train at first block station. 2. Ensure that hand brakes&parking brakes are in release condition.

P/ZRTI BSL 68

3. Check wheel skidding parameters, it should be less than 50 mm for engine. 4. Inform to TLC & work accordingly. 5. Proceed with less than 20 KMPH speed.if skidding found more than 50 mm. 6. Check under gear frequently for safe working 7. Enter in log book. Note- If LP experienced wheel skidding in mid section clear the section cautiously with 20 KMPH. Precaution to avoid wheel skidding- 1. Donot use SA-9 to contol the train. 2. Donot use SA-9 While DBR. 3. Check proper position of P&G handle. 4. Before starting the train loco brake should be in

release condition. 5. While working with dead loco ensure that there

is no brake binding. 6. Hand brakes should be in released before

starting 7. Press PVEF while controlling the train. 8. B.C. pressure should not be more than 3.5

kg/cm2 by SA9 and 1.8 kg/cm2 in conjuction wkg.

Precaution for attaching & clearing dead loco - For dead loco movement of WAG 5/WAG 7 locos, following preacaution should be taken- 1. Make the loco dead electrically by putting BL key, ZPT & HBA switch to off positioin .Ensure both reversers are in neutral position.

P/ZRTI BSL 69

2.Couple dead loco with live loco in rear mechanically (CBC). 3 Both cabs A9 and SA9 of dead loco should be kept in released position. 4 close all A15 cut out cocks of A9 /SA9 in both cabs of dead loco. 5. close MTP and L&T(A8) cocks of the dead loco. 6.Kept MU2B of dead loco on trail position. 7.Drain all the air pressure from the main reservoirs of the dead loco & then close the drain cocks , 8.Ensure loco brakes of dead locomotive are in released condition by observing BC pressure gauge , if not then release the same as follows - a) Operate manual handle of distributor valve in pneumatic panel to release control pressure, ensure loco brake release. b) Release through bogie isolating cocks of both bogies. There are two procedure to clear the dead loco- (i) In case MR & BC equilising pipes are available on both locos, then connect them as M.U. & keep their cocks open as M.U.and work normally. (ii)Connect BP pipe between dead & live loco and then open the BP angle cocks of both the locos. The MR-4 in the dead loco will get charge with BP supply through C3W distributor valve of dead loco. BP gauge in the cab of the dead loco

P/ZRTI BSL 70

should show the same amount of pressure as live loco . (in case locos are to be attached on a train having twin pipe i.e. both BP , FP then FP of both the locos should also be connected & its angle cock should be opened ) . keep MU2B on lead position. Drop BP by A9 from wkg. Loco & ensure application /realising of loco brakes in both loco. If MR4 not charged by 5 kg/cm2 then left MU2B on trail & close both bogie COC so that brakes can not be applied in dead loco and clear the dead loco with max. 15 KMPH speed. Energy Conservation- 1- Use maximum DBR while controlling the train in

down gradient ú * 2-Take maximum benefit of coasting without

affecting time. 3-Ensure full releasing of brakes before starting

the train 4-Blowers should be kept off if train stops more

than 15 minutes at station. 5 -If the train is supposed to be detained for a

long period, shut down the loco with the permission of SCOR/TLC.

6 - Follow coasting boards strictly. 7- Achieve booked speed in minimum time & try to work the train with normal speed.

P/ZRTI BSL 71

8 - While controlling the train, when negotiating caution order speed of train should not be dropped than caution speed. 9 -Knowledge of road & load should be updated so that maximum coasting can be used. 10. While working with M.U , keep rear loco shut down if not required. 11. Use head light dimmer at night. Name Of Safty Fittings Safety Device Safety Item

Safety Fittings

Safety Device Safety Item

Cattle guard

Hand brake

Ladder

Rail gaurd

Head light

earthing

pole/cable

Earthing stud with fly nut

Flasher light

Fire extinguser

Brake assembly hanger pin

Speadometer

Wodden wedg

CBC Lock pin

Marker light Spr. coupling.

Equalizing safty braket

Wipers Spr BP, FP

Hose pipe

Tie bolt Horns Spr vac. hose pipe

Nose susp. Pad pin Fuse Detonators

P/ZRTI BSL 72

J - Bracket Relay Fusy

Brake pull rod AFI Gear case bolt Brake cross tie

bar & safty chain Bogi safty chain

WAG-7 loco 1. WAG 7 loco is suitable only for air brake trains. 2. Vaccum hose pipe provided only for contineuty. 3. In some loco 3 MCP provided, which are same as WAG5, but in some loco only 2 MCP provided, do not ON BLCP & BLVMT at a time in that loco because the HP of each MCP is 27.5. and MR charging capacity is 2000 lt/min it means it is double than normal MCP. so that only one MCP should be used at a time. 4. Oil pump is provided in these MCP. Pump should be worked during wkg. of MCP. 5. If there is Elgi MCP then wkg. of pump can be checked by its spindle, if spindle not comes out during wkg. then use another MCP. 6. Pressure gauge is provided in Kirloskar make compressor, to check the wkg. In wkg.condition oil pump pressure should be between 1.4 to 2.4 kg/cm2. if not so ,use another MCP. 7. 3 Shunt Notches are provided in this loco.

P/ZRTI BSL 73

8. Ammeter &volt meter connection are same as WAG5. 9. Isolation of TMs by HMCS are same as WAG 5 loco. 10. During wkg. from EEC, it is not required to change the position of ZSMS. 11. All Electrical & Pneumatic Circuits are same as WAG-5. 12. In this loco only hittachi type TM is used. 13. Conections & setting of QD-1& QD-2 are same as WAG5. 14. Setting of QLM relay is 450 Amps. 15. Setting of QRSI1-2 is 4000 Amps.

Important features of WAP-1 1. WAP-1 loco is fit for vacc. & air brake with high

speed trains 2. Two compressors of 12.6/14 HP are provided 3. L&T cock is provided in cab 2 near A9 coc. 4. Only 6 nos. of roof bars are provided 5. Only one reversor is provided (two rev. provided in WAP-1 6 P like WAG-5) 6. R-1 cock is provided in TPN 1 7. DC-DC convertor & RTPR with HRTPR switch (position 0, 1, 2) provided. 8. 6 nos. of brake cylinder are provided in each bogie 9. All loco before loco no. 22033 are same as WAM-4 2S 3P (only RSI 1&2 are in series) 10. Only one QD is provided bet. TM 1-2& 5-6

P/ZRTI BSL 74

11. In this loco secondary suspension, fabricated flexicoil bogie provided with H type bolestor Note - After loco no. 22033 all loco converted as 6P in which electrical circuits are same as WAG-5 ( 6-P )

Ammeters & volt meters connection

AM 1/1 AM 2/1 U 1 CAB -1 TM - 1,2 TM - 5,6 TM - 3,4 AM 1/2 AM 2/2 U 2 CAB -2 TM - 1,2 TM - 5,6 TM - 5,6

Important Features of WAP-4

1. WAP-4 loco is suitable for only air brake & high speed train.

2. In this loco 2 MCP provided. Each MCP has 12.6/14 HP. and RGCP setting is 8 kg/cm2 to 10.5 kg/cm2.

3. L&T cock, C3W, & other equipment of brake system is provided on pneumatic panel behind cab no 2 (modular loco)

4. Only 6 nos of roof bars provided & ET-2 gap 105 mm.

5. All Electrical circuits are same as WAG-5. 6. DC-DC convertor & twin beam head light provided in this loco. 7. 4 nos. of shunting notches are provided. 8. 6 brake cylinders are provided in each bogie. 9. No provision for MU in this loco .

P/ZRTI BSL 75

10.Relay QLA is provided & its setting is 2000 amps. 11. QLM setting is 450 amps. 12. QRSI setting is 4000 amps. 13. In this loco cast steel, mark 1, secondary suspension, flexi coil bogie provided with H type bolestor. Salient features 1- EP type C-118 provided in this loco. 2- Side lockers converted in front lockers in both

cab. 3- In microprocessor - WAP4 CPU provided in cab

2 relay panel. 4- Hand brake fitted in cab 1 between LP & ALP

in lying condition. 5- MCPA, ER, R1, RAL and drain cock of MCPA &

ER are provided behind cab 1 in this loco. 6- Roof mounted DBR is provided in this loco, in

which RF is fitted on loco roof & cooled by atmosphere air. MVRF is not provided and setting of QF is 850 Amps. In roof mounted DBR loco, auto regression will come on 16th notch during DBR.

Note- About all locations of WAP-4 & WAG-7 modular loco are same.

Ammeter & Voltmeter connection AM 1/1 AM 2/1 U 1 CAB -1 TM - 3 TM - 4 TM - 1 AM 1/2 AM 2/2 U 2 CAB - 2 TM - 3 TM - 4 TM - 6

P/ZRTI BSL 76

LOCOMOTIVE BOGIES

Bogies components: The bogie of a locomotive is an assembly of following component- 1. Bogies frame 2. Wheels 3. Axles 4. Springs 5. Axle boxes 6. Support for traction motors 7. Support for brake rigging and brake cylinder 8. Friction dampers/snubbers.

WAG-5 Bogie 1- The weight of the locomotive body is transferred

to the bogie at the pivot and at the two load bearers to form a three-point support. This type of bogie is called tri-mount bogie. 2- The pivot carries approximately 60% of the

vertical load and also receives and transmits traction and braking forces while the load bearers share the remaining 40% of the vertical load. 3- The load bearers are not designed to transmit

any traction or braking force. 4- This tends to minimise the weight transfer due to tractive effort or braking force and maintains a higher factor of adhesion in service.

5- Total weight of bogie is about 23 tonnes. for TAO motor and about 28.5 tonnes for hitachi motor.

P/ZRTI BSL 77

6-The Loco Pilot should check axle box temperature, the condition of flexible shunt while

taking over charge and on run at every halt. Vertical Load Transmission Body Center pivot 60% + Side bearers (2 box) 20% x 2 - Bogie frame - Helical suspension spring -

Equalising beam - Axle box - Axle - Wheel - Rail - Earth. Horizontal Accelerating Force Transmission Traction motor - Main Gear - Axle - Axle box -

Horn chick - Bogie frame - Center pivot - Loco body Coupler. Oiling Poient

1- Center pivot --02 2 - Side load bearer -- 04 3- Gearcase --06 4- Suspension Bearing sump-- 06(Only in TAO TM)

Bogie of WAG- 7

With increasing demand of heavy freight traffic on Indian Railways, a new high adhesion bogie has been developed by RDSO for high horse power

freight locomotive to achieve higher tractive effort of 42T at start. The bogie exhibits better adhesive characteristics with reduced weight transfer.

P/ZRTI BSL 78

General Arrangement Of Bogie This is a 3-axle bogie with two stage suspension,

floating pivot and uni-directional arrangement of axle hung, nose suspended traction motors. Bogie front is of straight and fabricated box type construction with three transoms to carry nose

suspension. The locomotive body weight is supported on

bogie frame through four - rubber side bearers

directly mounted on bogie side beams. Shims have been provided below outer side-bearers to distribute load on side bearers in a 60:40 ratio, 60% of the load being supported on side bearers

adjacent to center pivot and 40% of the load being at remaining two side bearers. Center pivot does not take any vertical load and is used only for transfer of traction and braking forces.

The bogie frame in turn is supported on axles through helical coil springs mounted on equalizer beams. The equalizing mechanism consists of equalizers, hung directly on end axle

and supported on middle axle box through a link and compensating beam arrangement. The equalizing mechanism enables achievement of

P/ZRTI BSL 79

equal axle loads on uneven track reduces weight transfer at start.

D - Shakle There is two D shackle in each side in each bogies provided which are fitted between bogie & body on the lateral beam. Bogie & body coupled with the help of D-SHAKLE.

WAP 1/ 4 - Bogie Arrangement: Vertical Load Transmision In WAP1/4 Loco:

Loco body - Pivot - yoke - Bolster - Secondary spring - Bogie frame - Primary spring - Axle Box - Axle wheel - Rail.

Horizontol Acceleration Force In WAP1 Loco: Traction Motor pinion - Axle Pinion - Axle - Wheel - Axle box - Bogie frame - Bolster - Pivot - Loco

body - Coupler. WAP1/4 Bogie Details:

1.Suspension springs (Primary and Secondary).

2. Phenolic pivot liners vertical & Horizontal.

3. Friction damper assembly (Phendic) piston in secondary suspension. Bogie frame and bolster:- The bogie frame and bogie bolster of flexi coil bogie mark are of steel casting box type

P/ZRTI BSL 80

construction. The locomotive body weight is transferred to the bolster through the center pivot. The steel cast H type bolster is supported on the steel cast bogie frame at four corners by pair of helical springs placed in spring pockets of main longitudinal member of the bogie frame. The bolster is located with respect to bogie frame by upright pedestals which are integral part of bogie frame. The arrangement serves to transmit force from bolster to the frame and vice-versa. Springloaded snubbing piston 2 Nos per bogie made of Phenolic materials to have high friction between bolster and bogie frame for damping in both vertical and lateral modes or oscillations. The above pedestal arrangement lateral stops are also provided on the bolster as well as on the bogie frame to limit side movement by flexing action of the springs. The bogie frame is in turn supported on the axle by another set of springs resting on the axle boxes. The load of the loco super structure, rest on the center pivot bowl of the bogies. The bowl is fill with Phenolic oil to lubricate vertical and horizontal liners which provide rotational freedom between body and bogie in operation. Two lifting links located diagonally opposite provide the easier accessibility the bogie when installing and removing the bogie.

P/ZRTI BSL 81

STATIC CONVERTOR LOCO In AC locomotive static convertor is being provided instead of Arno convertor.Static convertor provides 3 phase AC supply to all 3 phase auxiliaries. There are following advantages of SI . 1. It gives constant out put voltage 415 +/- 5% volt 3 phase if OHE voltage is between 16.5 KV to 31 kv . 2. SI will trips automatically when OHE voltage becomes less then 16.5 KV & more then 31 kv and saves failures of auxiliaries. 3. Less maint. cost since less maint. 4. Blowers start smoothly at a time. 5. Blowers contactors closing on no load, therefore the life of cont. and concerned aux.is increased 6. SI. will trip automatically in following conditions- a. In put(aux.) windings open circuited b. When in put voltage becomes less then 16.5 KV and more then 31 KV. c. Melting of in put fuse. d. SI over loading. e. Under or over loading of DC link. f. Earth fault in in put / out put. h. Fan not wkg. i. Failure of supply of control elecronics. j. Single phasing or short circuiting in aux. k. Over loading / short circuiting in charger.

P/ZRTI BSL 82

Technical Data 1. Normal in put voltage: 1 AC 760 to 830 volt 2. Cont. in put voltage: 642ê to 1014 volt 3. SI trip.volt (min.) --less then 591volts (16.5 kV) 4. SI trip.Volt.(max) --morethan1150volt (31 kv) 5 Out put power - 180 KVA

6. Out put voltage - 3 415v+5%AC, 110V DC 7. Cooling - Air forced by fan 8. Out put current- 600Amp for 5 second,

300Amps for1 min. and cont. 250 Amps

9. Out put over load - trips on more than 600 Amp in 5 sec.

10. In put fuse rating - 1250 volt, 630Amp. in SI 11. Control supply voltage - 110 V. DC

Equipments removed from loco: - Arno, C-118, R-

118, QCVAR, HQCVAR, QOA, HQOA, Q-100, QTD-105, QTD-106, QLA New equipments provided in SI loco:- SI, QSVM,

Q-CON Q-SIT,QTD-101,LSSIT,CCINV New Equipments Of SI- 1. SI – It is provided in the place of Arno. Types of SI are –üAAL, ABB, SIMENS, MEDHA, HIRECT, GEC STESALIT It is provided behind cab no. 2. Indication panel on its body provided .Rectifire; DC link, Invertor, and CHBA are inbuilt. SI started after 9 to 12 second after DJ closing. It gives 3 phase 415 V-AC supply to all 3 phase Aux.

P/ZRTI BSL 83

2. QCON:- It is provided on relay board. When SI start after 10 to 12 sec. then Q-CON picks up via SI senser. 3. QSIT:-

K3 - Internal fault cont. & K4 - external fault cont

QSIT provided on relay board(PC-8 or Target type). When ever internal and external fault occurs in SI unit or auxiliaries, relay QSIT energises and trips DJ with LSSIT glowing. When ever any defect comes in SI inside or in any Aux. then SI try to rectify the trouble up to 20 sec. & restart after trip, if trouble not rectify then QSIT will energise permanently and make unable to close DJ.

4. QSVM:- It is 2 sec. time delay relay provided on relay board or behind cab no-2 ALP side,to operate blowers cont. on no load. 5) QTD-101:-It is 5 second time delay relay, provided behind cab no-2 to start compressors 5 second late from SI start. 6). CCINV- It is provided on switch board , rating of fuse is 6 amps. for controlling of SI control circuit. SI will not work if CCINV melt. 7). LSSIT :-- It is provided in both cabs on pilot lamp pannel for QSIT relay .

P/ZRTI BSL 84

Noteü:- 1-To reset QSIT , if reset button provided in Siemence & AAL make SI then press it or put HBA on 0, wait for 10 sec . & try again. 2- In ABB make SI, DJ should be closed at least after 3 min from HBA kept 0 to 1.

Circuit Analysis Power circuitü :-1, 830v supply given to SI by connection of two windings a0.a1& a7,a8 each 415v of auxiliary transformer. SI gets supply after closing DJ

and converts it in to 3, 415v Static convertor control circuitü

Conditions to start Static convertor (1) CCINV should be OK. (2) BLVMT open or QSVM should be energise.

P/ZRTI BSL 85

(3)DJ should be closed.If BLVMT is on & then DJ will be closed then after closing DJ, SI will start via

BLVMT NCI. When BLVMT closed, SI will trip due to NCI open and after 2 sec. QSVM will energise,so that NOI of QSVM will close on SI control circuit & SI will restart.

DJ Closing But SI Not Starting

Causes Remidies

Melting

Of CCINV

1) Replace it,if melts again keep HOBA in

off condition & replace the fuse . 2) If fuse melts even after HOBA off then inform to TLC & fail the loco.

Melting

Of CCA

1)Check for reseans & trouble shoot it.

2) Replace if melting , again its melts, then keep HOBA in off condition & replace the fuse . 3) If fuse melts even after HOBA off then

inform to TLC .

QSVM Not Energise

If QSVM not energizing, then wedge in energies condition & close the DJ in BLVMT on condition.

Compressor Control Circuit. Ckt. Description-

1. CCA fuse intact.

P/ZRTI BSL 86

2. BLCP close. 3. RGCP in cut in position.

4. QTD 101 in energise condition. 5. Q-119 should be de- enegise for C-103 Before DJ closing if BLCP on,then SI will start in10-12 seconds after DJ closing. QCON will energise when

SI produced 415v 3-phase.NOI of QCON will closed in the branch of QTD 101. QTD 101 pick up after 5 sec(since time delay). C P 1 & 2, will start after 15-17 sec. (10/12+5=15-17) and C P 3

will start after 5 sec. when Q119 relay gets de energise . MCP Contactor not closing

(1) CCA should be in good condition. (2) QTD 101 relay should be energise.if found de energise then wedge it with all preacaution.

P/ZRTI BSL 87

(3) When Q CON found de energise condition then wedge with Q 118. In this condition close BLCP

after 20 sec of DJ closing. Note--Wedgeing of any MCP contactor is prohibited.

Blowers Control Circuit Ì

(1) CCA fuse should intact.

(2) BLVMT should close. (3) After closing BLVMT C 105, 106, 107 will get energise, QSVM relay also get supply, but it energise after 2 sec. since it is 2 sec. time delay. Operation of blower contactor is in SI off condition.

NOTE-- (1) Normally DJ should be closed in BLVMT closed condition for contactors off load operaton.

(2) If BLVMT closed after DJ closing SI will turn off & C105, C106, C107 will close. (3) All contactors can be wedged if necessary.

CCA Melting after BLVMT on - Open BLVMT,

change the fuse and wedge C105, C106, C107 and work the train. DJü Control Circuit: - Following changes has made in

this circuit- (1)- In Q118 branch- (a) C118 NCI not available

P/ZRTI BSL 88

(b) QCVAR NOI &Ó HQCVAR switch contact not available (c) QCON NCI provided in parrelal to all supervising

relays NOI

(d )C108 NOI is provided in parrelal of C107 (2)-C118 branch removed (3) QSIT NCI provided in place of QLA/QOA in

MTDJ branch ** Initialy Q118 ckt. remain bypass through QCON NCI till SI produced 415 V means up to 11 sec. ** Q118 superwise aux. working after QCON energise

, if any aux. not working then Q118 will de energise after 5 sec. or 11+5 = 16 sec. (from DJ closing) & DJ will open

**If QSIT energise then DJ opens due to its NCI open in MTDJ.If QSIT energise permanentaly then LP experienced ICDJ.

Be Rememberingü :- 1. In DJ control circuit ICDJ or DJ tripping

experienced only due to QSIT energise, with indication of LSSIT lamp. If LSSIT not glowing & ICDJ experienced then do not connect it with SI & trouble shoot as per normal mannerü.

P/ZRTI BSL 89

2. If QCON wedged in energise for trouble shooting of MCP contactor, then Q118 will de energise after 5

sec. so that wedge Q118 also along with QCON 3- Even after SI not started , DJ will remain close but DJ will trip on 1st notch due to MVSI 1/2 not working 4. OHE supply will available in loco if SI not

working & DJ is close but there will no sound in loco so that it may feel like DJ open & any mistake can be happened like- entering in HTC without loco grounding , be careful about that.

5- DJ will remain close up to 20 sec. if SI will trip due to any reason . LP may feel it DJ tripping since there is no any sound . So that difference between SI off & DJ tripping to be define and

trouble shoot accordingly. General Instructionsü- On BLDJ , press & release ü BLRDJ to close DJ

1- LSCHBA will extinguish when SI Will produce 415 V means after QCON energise. 2- 1st notch should be taken after LSCHBA extinguish

3- If DJ trips with LSSIT then pick the indication from SI unit & trouble shoot accordingly. 4- Kept HBA on 0 for at least 5 minute while trouble shooting of ICDJ & again try to close DJ.

P/ZRTI BSL 90

SI will automatically trip when OHE supply out of limit . HTFVT: - If there is earth fault in TFVT in SI loco then TFVT will not bypass only by removing CCVT, so that in some loco this switch is provided to bypass the TFVT , it has two position as following-

1) '0' TFVT isolate 2) '1'ü TFVT working HTFVT switch to be kept on 0 to bypass TFVT

while trouble shooting of QSIT Energising of loco - 1. Close DJ after putting BLVMT, BLCP ON. All

auxiliaries will start with SI (except compressor) after closing of DJ. Compressor will start after 5 sec. from LSCHBA extinguish or 16 (11+5) sec. after DJ closing.

2. Close DJ & then put BLVMT, BLCP ON, SI will start just after DJ closing but immediately off after BLVMT ON and will again restart after 2 sec. after closing of blower contactors and then after CP will

start. DJ opening & closing: - To open DJ, off BLDJ. Let the BLVMT.BLCP be closed so that contactors of

blowers & compressor are remain close. Close DJ

P/ZRTI BSL 91

by BLDJ & BLRDJ, all aux. will start except comp., comp .will start after 5 sec. from LSCHBA

extinguish or 16(11+5) sec. from DJ closing. Working if LED glowing or message received in any make SI

1.If input defect indication received then fail the loco. 2. If fan gets defective then loco may be failed 3. If there is earth fault, over current, over load

single phase or phase fault then any aux. may be defective. identify the defective auxiliary & isolate. 4. If any other indications received the put HBA on

0 and wait for 5 minute, again energise the loco. If succeed then work further otherwise inform to TLC Working of SI while defect- 1.Defect concern with OHE(over/under voltage)-

SI will trip & restart when OHE restore If OHE voltage is less then DJ will also be trip via Q-30 If GR is on notches then DJ will also be trip

due to MVSI not working. 2. Generaly SI will restart in all defects except fuse, fan & temperature concerned defect. 3. If defect not rectify after efforts then DJ will also

trip with SI in external & internal fault. Off battery &

P/ZRTI BSL 92

wait some time ,again on battery and try, if succeed work further otherwise fail the loco.

DJ not maintaining 1-Indication-- BLDJ ON &Ó BLRDJ press, LSDJ extinguish, but UA needle not deviate, DJ tripps

after BLRDJ releasing. Reason- No OHE tension, or open circuit from OHE to TFWR.

Remedies:-Trouble shoot as per conventional Loco. 2-Indication-- BLDJ ON &Ó BLRDJ press, LSDJ

extinguish, UA needle deviate & DJ tripps after BLRDJ releasing.

Reason- defect in Q 30 Remedies-Trouble shoot as per conventional Loco.

3-Indication- BLDJ ON &Ó BLRDJ press, LSDJ extinguish, UA needle deviate but DJ will tripps in

5.6 sec. after releasing of BLRDJ. Reason- Defect may be in NCI of QCON on Q118 branch.

Remedies-Wedge Q118 in energise condition with all preacaution. 4-Indication- BLDJ ON &Ó BLRDJ press, LSDJ

extinguish, UA needle deviate but DJ will tripps

P/ZRTI BSL 93

after 17 sec.ü approx. from releasing of BLRDJ or DJ will tripps in 5.6 sec. after LSCHBA extinguish.

Reason:-QVMT1/MVMT1,QVMT2/MVMT2,QVRH/MVRH, QVSL1/MVSL1, QVSL2/MVSL2,QPH/MPH not wkg.

Remedies:- Trouble shoot as following (1) Close DJ in BLVMT open condition , if DJ trips

after 17 sec. from releasing of BLRDJ or after 5.6 sec. from extinguish of LSCHBA lamp it means QVSL1 or MVSL1, MVSL2 or QVSL2, QPH or MPH not working, put concern switch on 3 one by one .

By keeping which switch DJ not trips then ensure working of concern auxiliary , if aux. not working then switch to be kept on 0 and work the train with precautions.

(2) Close DJ in BLVMT open condition , if DJ not trips after 17 sec. from releasing of BLRDJ or after 5.6 sec. from extinguish of LSCHBA lamp it means

QVMT1 or MVMT1, QVMT2 or MVMT2, QVRH or MVRH not working ,put concern switch on 3rd one by one in BLVMT on condition . By keeping which switch DJ not trips then ensure working of concern

auxiliary , if aux. not working then switch to be kept on 0 and work the train with precautions.

P/ZRTI BSL 94

5-Indication: - DJ trips on 1st notch. Reason:- QVSI1 or MVSI1,QVSI2 or MVSI2 not

working ,or GR is sluggish. Remedies:- Trouble shoot as conventional loco.

6-Indication :- 6th notch tripping. Reason:- C105,C106,C1O7 are not closing or its

NOI defective Remedies:- Trouble shoot as conventional loco .

ICDJ 1- Energising of QSIT.

2- All reasons of ICDJ like ARNO based loco (except C-118 problem) Trouble Shooting when QSIT energise- Put HBA on

0 and de energise QSIT. After that to detect internal fault in SI or external fault , isolate all out put load of SI (put all switch of aux. on 0 , ensure opening of EMC, isolate cab heater,cab fan, RTPR,

NR & W/T charger),put HBA on 1, close the DJ ü- 1- If DJ trips, it means there is internal fault in SI, at that time, put HBA on 0, wait for 5 min. and try again if DJ trips then fail the loco

2- If DJ not trips, then fault may be in out side in SI, at that time put switches of aux. normal one by

P/ZRTI BSL 95

one and wait for 20 sec., by keeping which switch normal DJ trips then again keep this switch on 0

and remaining switches to be kept normal. Clear the section with preacaution and inform to TLC. HRAVT- Now a days this switch is provided in loco on switch board as a modification. Cab heater, cab fan,

notch repeater & walkie talkie charger can be isolated by this switch. This switch has 4 positions as following ü- close --- × working --- √ HRAVT positon

Cab heater

Cab fan Notch repeaterü

W/T chargerü

0 × × × × 1 √ √ √ √ 2 × √ √ √ 3 × × √ ×

HSIV- This switch is provided on switch board in SI loco it has 2 position . 1 is normal position , whenever LP is unable to trouble shoot in case of earth fault in out side of SI , then press by pass push button on SI

panel and put HSIV switch on 0 so that QSIT will not drop due to adding one resistance of 1500 ohm / 500 watt in circuit . Now clear the section and consult with

P/ZRTI BSL 96

TLC. In this condition loco will shut down automatically after 45 minute and SI will be freeze.

Working of Microprocessor based loco

Microprocessor is being used in electrical locomotives. In this loco CPU provided behind cab 2 & display unit provided in both cab infront of ALP, in which current operation & trouble of loco are displayed.

Maximum relays & interlocks are removed due to Microproceesor but reliability of loco is increased ADC makeú (Version-1) or Medha make (Version-2) CPU are provided- 1- In Version-1 Q-44, Q45, Q-118, Q-46, Q-100, QRS, QV-60, QV- 63, Q-48, Q-50, Q-51, QWC QTD105,QTD106,PR1 and PR2 not provided in the loco ,only QV-61, QCVAR & safety relays with target are available In Version-2 Q30, Q20, QV61, QCVAR are also removed alongwith above relays.

2. CCDJ, CCA & CCLSA fuses are removed and one new fuse CCCPU (6 amps in ADC make & 2 amps in medha make) is provided.

3. In SI loco QTD101, QSVM & QCON are also removed

4. If any one fuse from CCBA, CCPT & CCCPU melts then pilot lamp and display unit will not work, because of this loco will also not energise.

P/ZRTI BSL 97

ADC make (Version-1) I- On display unit screen, notch repeater (by LED) ,

& 24 buttons providedü II-If any faults occurs, its message will display on

screen as foolowing Fault Messageü

Fault Time Fault Date current Time current Date Press CLR/FLT button after rectify the fault then message will disappear from screen 1. Total 15 buttons among 24 are important for L.P. 0 to 9 buttons - to set date and time LTF button -to bring display mode in latest

mode CLR/FLT button- to clear fault message from

screen CLR/MEM button-to clear fault memory from screen Date set button - to change the date Time set button - to change the time 2. Procedure to change the date - Press date set button. Enter New Date will display on screen.Now set new date by using 0 to 9 buttons in Date , month , Year formü . 3. Procedure to set the Time - Press time set button , Enter New Time will appear on screen , now set new time by using 0 to 9 buttons in Hour, Minute , Second form.

P/ZRTI BSL 98

Medha Make (Version-2) - Screen, digital type NR & 5 buttons provided on display unit Button PURPOSE ACK For acknowledgement of the fault

displayed on screen MENU For selection of various operation CURS UP To view the next cursor fault in

memory when in cusor fault display mode

CURS DN To view the previous cursor fault in memory when in cursor fault display mode

ENTER Command terminator

P/ZRTI BSL 99

To energise the loco--Energise the loco in normal manner as per message displayed on screen -

MASSAGE OPERATION ADCúMAKE MEDHA

MAKEú HBA ONü WAITING FOR

COMMAND WAITINGFOR COMMAND

UNLOCK TO BLü BLDJ OPEN BL KEY ON CLOSE BLDJ ü ZPT/BV OPEN BLDJ CLOSE PUT ZPTü 1 /2 BLRDJ OPEN PANTO RAISED PRESS BLRDJü REVERSER ON

ZERO BLRDJ ON- DJ CLOSED

MPJê F/Rü MP ON ZERO NO MESSAGE MP on N ü MP ON TRACTION NO MESSAGE

MP on Pü MP On BRAKING NO MESSAGE

Message displayed on screen after DJ tripping If DJ trips on run in ADC make Microprocessor based loco then its message displayed on screen as following .Trouble shoot as per message-

1 DJ TRIPPING VIA QVRH

6 DJ TRIPPING VIA QPH

2 DJ TRIPPING VIA QVMT1

7 DJ TRIPPING VIA QLM

3 DJ TRIPPING VIA QVMT2

8 DJ TRIPPING VIA QOP1

4 DJ TRIPPING VIA QVSL1

9 DJ TRIPPING VIA QOP2

5 DJ TRIPPING VIA QVSL2

10 DJ TRIPPING VIA QOA

P/ZRTI BSL 100

11 DJ TRIPPING VIA

QVSI1 15 DJ TRIPPING VIA

QRSI1 12 DJ TRIPPING VIA

QVSI2 16 DJ TRIPPING VIA

QRSI2 13 DJ TRIPPING VIA

QLA 17 DJ TRIPPING VIA

Q30 14 DJ TRIPPING VIA GR

STUCK UP IN BET. NOTCHES

18 AUTO REGRESSION VIA

WHEEL SLIP Note 1- In medha make Microprocessor based loco, concerned trouble shooting is also displayed along with message. 2- Close DJ atleast after 4 sec. if DJ trips or opened otherwise ICDJ indication will recieved 3- Press ACK. button after trouble shooting. Impossible to close DJ (ICDJ) - 1- Read the reasons for ICDJ on screen & trouble

shoot accordingly. 2- Check Add CCBA, CCBA, CCPT & CCCPU

fuse, change if melt. 3- ER pressure should be 8 Kg/Cm2 4- Battery voltage should be 90 volt or more. 5- GR should be on 0, check on GR drum.ü 6- Try to close by BP2DJ 7- Check that C-118 is closing in ARNO based

loco. 8- Try by putting HQOP1/2 & HOBA off.

P/ZRTI BSL 101

9- Put HBA on 0 forü 5 minutes and try to close DJ again.

10- Try from rear cab. Note - 1. Be remember there will no any message displayed if any one of contactor from C-105 ,C-106, C-107 are not picking up and also DJ will not be trip after 6th notch ,so LP should ensure closing of all contactors after DJ closing. But if all aux. having contactors are not working then DJ will trip after 6th notch. 2. All auxiliaries with EMC will not work if QCVAR is de energise. 3- Auto regression will come along with message on screen if RGEB / QD picks up or DJ trips. 4. Press BPQD if regression comes due to wheel slip, but it works up to 10 notch only . If wheel slip comes more than 10 notch, it means there is defect in any TM, isolate it .ü 5. If LSP is glowing but notches are coming then work the train continuesoly. 6. If LP confused due to ICDJ , DJ tripping or any other abnormal indications in loco then open the DJ, all switches & put HBA on 0 , again try to energise the loco as per sequence.

P/ZRTI BSL 102

Modifications Vigilence Control Device Object:-To keep alert to LP/ALP while working

V.C.D. is being provided in other electrical loco also like ABB loco. Equipments:- Following equipments are provided to operate the system ü- a) Control unit:- This unit is provided in tool box upon hand brake in WAG-5 and in cab 1 pilot desk

towards ALP in WAP-4 loco. One switch is provided on this unit to bypass it. b) Display unit:-This is provided in both cab on

pilot desk towards ALP. LEDs are provided on this panel. c) Aknowledgement push button:-ThÖs is a push

button type switch which is provided in both cab on pilot desk(PC) near BPP and towards ALP near 110 V PCLX. d)QVCD Relay:-This relay is provided in cab-1

TPN 1. Working :- When BL key unlocked , VCD moves in

self test mode & QVCD relay gets energise, so that its NCI on IP valve branch gets open and train brake applied due to IP valve de energise. After

P/ZRTI BSL 103

completion of self check, Power on System OK LED will glow.

Note:- If IP valve COC is in close condition then VCD will continueosly remain in self check mode , in this position notches will not come.so after taking over charge of the loco ensure opening of IP

COC. There are two modes in VCD as following-- 1.Vigilence Mode:- When ever MP kept on N after

releasing A9 & SA9 then VCD moves in vigilence mode and in this mode it is compulsory to

acknowledge it .If not acknowledged then penalty brake will be applied.

P/ZRTI BSL 104

While working the train if LP operates any one of the following equipments then no need to

acknowledge by pressing ACK. Push button .- a) Horn b) SA9 c) sandersü d) Prog. & reg. e) A9 If pilot not operates any one of the above

equipments during train working then he should press ACK. push button within the time interwal of every 60 sec. if he not does so then this unit will be activated & one LED will display on it for next 8

sec.if LP ack. VCD during this time then LED will extinguish but if still not acknowledged then buzzer will sound for next 8 sec.,after hearing this sound LP should ack. by push button but if still not

acknowledged then finally VCD control unit will be operate & QVCD gets energise , so that its NCI on IP valve branch will open, IP valve gets de energise and brakes applied in train, also NOI of QVCD

closed on Q-51 branch and auto regression will come since Q-51 energise. If LP not operates any equipments (as above) and also not ack. by pressing Ack.push button

then penalty brakes will be applied .

P/ZRTI BSL 105

One LED will flash for next 30 sec. after penalty brake applied. To release the brake, press ACK

button,in MP 0 position after the LED extinguish. To isolate the unit, while any defect, one switch is provided on this unit in sealed condition.To isolate the unit break the seal & put it off, so that

LED on main panel & display unit will extinguish . Enter in log book & inform to TLC after isolation. Sleep mode:- When brake applied through SA9 &

A9 then VCD remain in sleep mode , in this mode it is not required to acknowledge . In MU loco this unit is remain in sleep mode in rear loco. Note-Relay Q-51 should not be in wedge condition. Twin Beam Head Light:- Twin beam head light is being fitted on all loco. For this head light DC-DC

Convertor unit provided near RTPR .One change over switch provided on this unit to bring convertor in service or isolate. Ensure glowing of head light in both position of this switch while taking over the

charge of loco. There are two bulb in this head light & each bulb having two filaments, one of 100 watt & another of 90 watt. Benefits of this head light is as following -

P/ZRTI BSL 106

1-Vigibility distance increased due to bright light which is up to 305 meter approx.

2- Bulb life is more. 3- Maintainance cost is less. 4- Bulb replacement is easy. 5- Head light will remain glowing in N/S after DJ

open. 6- If one unit becomes defective then we can work from another unit. 7- Power loss is less.

Check following things if twin beam head light not working-- 1- ZRT switch should be ON. 2- One DC-DC convertor provided & one change

over switch fitted on this, which has main & stand by position . 3- Seperate glass fuses are provided for main & stand by in DC-DC convertor, check them also.

4- If intensity of light is insufficient then it may be possible that only one bulb is glowing , change the bulb with spare if available otherwise remove the bulb from rear head light & replace .

Note%& 1- Incoming & outgoing wire of RTPR made dummy and taped, so that RTPR will not work.

P/ZRTI BSL 107

2--In some loco RTPR & DC-DC convertor both are in working condition. To select them switch HRTPR

is provided. Position of switch is as follows- 0 -- Both are isolated, H/L will not work. 1 -- RTPR in service. 2 -- DC-DC converter in service.

BPEMS: - Its full name is Emergency stop press

button. It is provided on LP desk in both cabs, LP can use it in emergency. One relay QEMS energise

when BPEMS operates & following actions will take place in locoü:- 1- DJ will open & panto will lower

2- Auto regression will come 3- IP valve gets de energise & emergency brakes applied. If switch is operated then to reset the switch,

first put ZPT on 0 , after that rotate the switch towards the arrow marked on the switch . Noteü:- Ensure opening of IP valve COC In the loco

which is fitted with BPEMS while taking over the charge of loco.

OHE Indicatorü:- In some loco OHE indicator fitted

in side the cab . Red & green colour LED provided on this, glowing of green LED indicates availability

P/ZRTI BSL 108

of OHE supply and red LED indicates non availability of supply. Be remembering it is provided

only for indication, do not take decision to climb on roof or to fail the loco on the base of it. Auto Flasher Light - This modification is for the help

of LP & ALP, but no any duties, mentioned in G&SR for the abnormal condition has reduced by this modification.

BP charging & electrical control circuit of AC

loco is modified. Flasher light will automatically ON, LED will glow, buzzer will sound & GR will come on 0 If hose pipe uncoupled, load parted, ACP or emergency brake applied by guard.

Normaly BP charging is done by 5.5 mm dia chock which is located between MR-3 & Addl. C-2 relay valve port no. 1. During initial load charging or after brake application the time for BP charging is

not sufficient, so that in this loco BPSW push button is provided in both cab on pilot desk . Magnet valve (MV4)ú is energise after pressing of BPSW and BP charging started from 19 mm

chock, because increasing of charging rate BP pressure charge very fast. LP should keep press

P/ZRTI BSL 109

this button during initialy BP charging & during recharging after brake application.

SW1 &ú SW2 reset switch is provided in both cabs towards ALP. When flasher light ON automatically & LP wants to off it then he should press this switch, after pressing this button flasher

& buzzer will off but LED will continueosly glowing till BP pressure coming up to 4.6 KG/cm2 .ü If flasher light is to be kept ON & only buzzer to be made off then put FL switch manually on

position. If the system ON automatically while working the train then LP should take it as abmormal indication and should act as per G&SR rule.

During application & releasing by A9 this system should not work, so that PR-1 relay (60sec. time lag) is provided in this circuit. After releasing A9 if BP not comes more than 4.6 kg/cm2 within 60 sec.

then flasher light & buzzer will ON automatically. If magnet valve not energise after pressing BPSW then it will take more time in recharging, at that time LP should wait for complete releasing of

brakes. BPSW should not be pressed during run. Magnet Valve (MV4):-It is provided behind cab 1 & energise after pressing BPSW.BP charging rate will

P/ZRTI BSL 110

be slow in MV deenergise condition(charging via 5.5 mm dia chock)and charging rate will be fast

when MV is energise(charging via19 mm dia chock) BPSW1/2-This push button is provided in both

cabs on LP desk.MV energises after pressing of

BPSW & de energise after releasing. SW1/2(Push Button): This push button type reset

switch is provided in both cab towards ALP to off flasher & buzzer if start automaticaly. P-2 pressure switch:- It is provided in cab 1 on brake pipe. P-2 interlock closed in circuit when BP pressure drops up to 4.4 Kg/cm2 or less and opens when pressure increased up to 4.6 Kg/cm2 or more.

P-1pressure switch: This pressure switch is

provided in cab 1 on control pressure pipe line bet.

A-9 port no. 5 & MU2B valve port no. 3, if operating pressure, going from A-9 to Addl. C2 relay valve is drops up to 4.6 kg/cm2 or less then P1 interlock closed in circuit & opened when

pressure increased up to 4.8 kg/cm2 or more. PR-1(60Sec.)Time Lag Relay:-This relay is connected in the circuit after P-1 in series.PR-1

energise when P-1 closed after application by A-9

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and de energise after 60 sec.from releasing of A-9 handle. PR-2 Relay:-When flasher light ON automaticaly due to load part ,hose pipe uncoupled or ACP then PR-2 relay energise & its NOI on Q-51 branch closed so that GR comes on 0 due to Q-51

energise. RGEB-1:- It is connected in modified circuit after

HB-5 valve directly, double acting check valve & H-5 valve removed. In vac. brake train when load parted or hose pipe uncoupled then RGEB-1 will operate through HB-5 valve.NOI of RGEB will close

in this circuit and flasher light will on automaticaly also LED will glow & buzzer will sound. RGEB-2:-It is directly connected on brake pipe,

when LP applied emergency brake then RGEB-2 operates & GR will come on 0 due to QRS de energise,but flasher light will not glow & buzzer will

not sound. QFL Relay:-NCI of its relay is connected in the

circuit before flasher & buzzer,when flasher on

automatically &LP wants to reset the flasher/ buzzer then QFL energise after pressing SW1/2.NCI of

P/ZRTI BSL 112

QFL will open in circuit and flasher & buzzer will off due to supply of flasher & buzzer will cut off. Testing Switch(TS):-It is provided on relay board or behind cab 2. When MPJ is in F/R position then after pressing TS,flasher light will ON,buzzer will sound & LED will glow . Note:- (1)-Be remembering flasher can be ON

manualy other than automatic system as previous. (2)-Flasher light should not glow automatically while

braking or releasing by A-9, if its happened then

system may be defective, isolate it as following & enter in log book-a- Remove CCLSA fuse (if Addl. CCLSA fuse is provided near PR1/2 then remove it also) .If not

succeed then wedge PR-1 in energise and operate MPJ in F-N-F or put HBA 0-1. Modification of ZLS/HLS :-This switch is provided in

switch board near HBA . While working with MU , LSDJ, LSCHBA, LSGR & LSB are remain glowing in both loco when DJ trips in any loco, it is slight difficult in working . To rectify the problem ZLS/HLS

is provided .In MU which loco is to be kept dead , ZLS/HLS of this loco is also should be kept off so

P/ZRTI BSL 113

that pilot lamp circuit will cut off from battery and pilot lamp of working loco will work as single unit.

Note:-1.In AJJ base loco HLS switch is provided.

Pilot lamp will not glow & also panto will not raise in the loco when HLS is kept off. 2. In BZA base loco ZLS switch is provided, only pilot lamp will remain off when this switch is off.

Modification of LSGRR:-In some loco LSGRR pilot

lamp is provided,generally LSBCR is renamed as

LSGRR. If LSGRR is glowing in leading loco it means trailing loco GR is on 0 & if extinguish it means trailing GR is on notches. Air filter and dryer unit:- Air dryer & filter unit is

being provided in all electrical loco on recomondetion of High Level Committee. Moisture,

oil particles & dust are collected in MR during air charging through compressor, the same air is used in brake system which was dangerous for valves of brake system and may be affecting in efficiency,

also life of equipments may reduced. In some loco this unit is provided between both bogies in under truck and in some loco provided below corridor no. 2 .Inlet of this unit is

connected from MR-2 & outlet is connected from

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MR-3. A & B cocks provided in inlet & outlet pipe respectively,both cocks are green in colour.To

bypass the unit one cross over pipe is provided on which one C cock of red colour is connected. Generaly A & B cock should be open and C cock should be in close condition. If colour code is not

as above then follow the instructions written near Air dryer.This unit works with 110 volt DC control supply.CCAD fuse is provided for safety & HAD switch is provided for isolation of the unit, both are

provided behind cab-2. This unit gets electrical supply through CCAD fuse when HAD ON.To check efficiency of the unit,one indicator is fitted on its body. In normal condition it shows blue colour

but if the unit not works then moisture will come out when drain cock of MR 3 will be open,in this position check that CCAD is intact & HAD is ON.In the following circumstances the unit should be by

passed - 1.When the indicator shows yellow colour. 2.When water comes out while moisture drain by MR-3.

3.When any difficulty in pressure building or maintaining.

P/ZRTI BSL 115

To bypass the unit close A & B cock and open C cock. Enter in log book. OHE OHE Normal voltage - 25 KV Minimum Voltage - 19 KV Maximum Voltage - 27.5 KV Working clearance (Safety Redius)- 1 Meter (in 1500 V DC) 2 Meter (in 25 KV AC) Power Supply Arrangement- 1) Feeding Post (FP) - FP is the switching station from which 25000 volt supply given to OHE through CB & BM. 2) Sectioning and Parralalling Post (SP)- SP is provided Where supply of one FP ends and another FP supply started. Neutral section is provided in front of the SP. 3) Sub sectioning and Parrelaling Post( SSP)- It is provided between FP & SP to reduce the section. 4) Neutral Section ( N/S)- A part of OHE in which no any supply is given, called neutral section. Ac loco will pass through any type of N/S without taking any current.For indication of N/S boards are provided on OHE mast.Before 500m. from N/S,before 250 m. from N/S,DJ open board is just before N/S and DJ close board is after N/S are provided.N/S is provided near TSS, SP & SP. Types of N/S - There are 3 types of N/S.

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1) Over lap type- This N/S is a small part between two insulated over lap, which is always remain in dead condition. To charge this type of N/S, isolator switch is provided near DJ close board towards direction of traffic. It is always kept in open condition. Isolator key is kept in key box with key register under custody of S.M. Its length is 41 meter. 2) PTFE Type-(Poly Tetra Fluro Ethylene)- Length of this type N/S is 3.74 m/5.163 m/9.4 m.It is provided on main line on adequate distant from level crossing & signal. 3) Section Insulator Type N/S- Length of this type of N/S is 5 m or 12 to 14 m and it is provided over yard line. If train stalled in this type of N/S then LP should inform to TPC & work as per his instruction. BOND- It is a electrical connection which connects rail to rail or any structure to rail. It is a iron strip. Bond is used to pass return current easily and to neutralize the voltage which is induced due to matalic construction. Types of Bond- 1) Structure bond 2) Rail bond 3)Inter Rail bond 4) Inter truck bond 5) Z bond (X bond) Duties of LP in case of OHE brake down- Contact

with TPC immediately through emergency phone after OHE brake down and work as per his

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instructions .If any wire is broken then keep him self 2 m. away from the wire and protect as per

traffic rules. Duties of LP while OHE supply failure- LP will inform to guard by any available methods if there is momentary failure & will look back that train is comming safely and work normally. If OHE supply not resumes then LP will reduce speed of the train (not more than 60 KMPH during night ) .If still supply not resumes then LP will on flasher & stop the train near telephone socket, inform to TPC and work as per instructions received. If LP feels that it will take more time to send information to control office then he will depute to ALP to check complete train along with guard, if no abnormality found in train then flasher should be kept off and try to contact with control office. If supply rsumes in between, then clear the section cautiously. Duties of LP in case of Panto Entanglement- When panto entangled with OHE in block section, immediately on flasher light, note the KM and stop the train. Inform to TPC through emergency socket. Further action to be taken as per TPC instruction. Duties of LP in case of adjacent line OHE defective If OHE wire of adjacent line is hanging after brakage or caitilever hanging due to insulator broken or contact wire / jumper wire hanging down

P/ZRTI BSL 118

side or OHE mast projected inside/outside the track more than normal position then LP should immediately on the flasher light , stop the train and protect the adjacent line. Inform to TPC/SCOR through milage phone & further action to be taken as per their instruction. 4)Auto Tentioning Device( ATD)-It is a device which kept height & tention of OHE wire equal in all season.One small & one big pulley provided on it , one 400 kg balance weight is hanging with the help of a stainless steel roap. In summer when length increased due to heat then balance weight comes down & in cold when length is shrinks then weight goes upwards, because of this height & tension of OHE wire will remain equal in all season. If balance weight comes down on earth due to SS roap broken then inform this matter immediately so that proper caution order can be imposed. Reasons for Panto intanglement- 1). Braking of catenary, contact wire.

2). Braking of OHE insulator. 3). Stagger becomes out. 4). Setting of OHE at turn out, cross over is not adequate.

5). Study Arm is hanging after braking. 6). External reasons like- roap hanging on OHE wire. 7). Strips are not fixing properly on panto.

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8). Panto pan broken. 9). Plunger pin not available. ************