8 WHEELER DETC/DHTC

ELECTRICAL
TRD

TROUBLE SHOOTING DIRECTORY

DESIGNED BY:-
SSE/TRD/RRD/KGP
ELECTRICAL TRD
 Troubeshootings:-
ITEM DEFECT What to do
Put on 24v/110v circuit breakers on control
panel. Ensure 24v knife switch is on
Check for glowing of engine off/ON indication
lamp Ensure indication lamp “ON” local remote panel
Electrical side
Check Local remote switch It should be at “LOCAL POSITION”.

Check Emergency stop switch on control panel . It should be in run position

Check 24V Battery supply
Out of fuel or fuel shut off closed
1. Engine not
Poor quality of fuel / grade fuel
cranking/self starter
not responding Air leaks in suction lines
Restricted fuel lines
Broke fuel pump drive shaft
Mechanical side Scored gear pump or worn gears
Cracked injector body or cup
Water in fuel and/or waxing
AFC calibration incorrect
Gasket blow by or leakage
Incorrect valve and injection timing
*****Tightened the mechanical screw at shut down valve and start manualy.
If not , Refer to Elect Case-1
Ensure opening of fuel shut off
Ensure good quality during filling of fuel, for dust and other
sediments filters may be used.
Proper tightening of joints and remove defective gasket.
Fuel pipes and jammed filters to be cleaned
Replace
Replace
Replace
leakage to be arrested and deffective fuel should be replaced.
To be caliblated
Replace
Timing adjustment to be done.

Check 110v Supply on LCC Ensure Supply on LCC or Reset

Electrical side Check supply on fue solenoid ( Shut down valve) Tightened the screw and make it direct
Relay/electro pneumatic valve does not operate If not , Refer to Elect Case-1
2.Engine Cranking Relay chatering If not , Refer to Elect Case-1
but Not Firing Check the Actuator Reset it

Mechanical side Fuel Injection not proper Check fuel filters and pipes, clean if required

Air cleaner chocked Check and clean if required

 Check 110v Supply on LCC
a) Faulty low water level switch
Electrical side b) Faulty low water level relay
c) Faulty over speed switch
d) Faulty lub oil pressure relay
e) Faulty low hydraulic oil level
Poor quality of fuel / grade fuel
3. Engine Cranking, Air leaks in suction lines
Firing but Not Holding Restricted fuel lines
Plugged injector spray holes
Cracked injector body or cup
Mechanical
Damaged injector O-ring
side
Water in fuel water/or waxing
Injector flow incorrect
Long idle periods
Gasket blow -by or leakage
Broken or worn piston rings
Injectors valve and injection timing
Reverser Swith not properly PUT ON
Loose connection of 12 pin connector on LCC
Ensure that the DIR relay is in energized
Electrical side condition
Safety relay (SR) should be in de-energized
condition
4. Engine RPM is Not
Temperature indication lamp glowing on ECP
Raising panel in engine room
Dirty fuel filters
Dirty water Separator
Mechanical
side Dirty in Baby filter.
Check MR Pressure
Ensure Supply on LCC or Reset
Check, Reset /replace if necessary.
Check, Reset /replace if necessary.
Check, Reset /replace if necessary.
Check, Reset /replace if necessary.
Check, Reset /replace if necessary.
Ensure good quality during filling of fuel, for dust and other
sediments filters may be used.
Proper tightening of joints and remove defective gasket.
Fuel pipes and jammed filters to be cleaned
Clean the same / replaced if necessary
Replace
Replace
leakage to be arrested and deffective fuel should be replaced.
clean the same / Adjust if necessary
Check and normal maint of fuel and air ckt to be done
Replace
Replace
Timing adjustment to be done.
PUT ON in desired direction properly.
Check and connect properly.
if not pack DIR in energized condition
If not reset it.
if so press reset button
Clean filters.
Clean filters.
clean.
It should be more than 3.5kg/cm2
 a) Faulty low water level switch Check, Reset /replace if necessary.
b) Faulty low water level relay Check, Reset /replace if necessary.
c) Faulty over speed switch Check, Reset /replace if necessary.
d) Faulty lub oil pressure relay Check, Reset /replace if necessary.
Electrical side e) Faulty low hydraulic oil level Check, Reset /replace if necessary.
5. Engine
If OST indication is found on ECP panel press the reset button
Shutdown If OST indication found on LCC press the reset button
Automatically On Observe 1st notch led lamp glowing on LCC control
module if not glowing check LCC circuit breaker for proper closing
Run ****Note: Even after checking all the above if unable to overcome the problem Put OFF 24VOLTS KNIFE SWITCH AND
CLOSE and try for re-cranking

Air leakage in Fuel System Check and tightened.

Mechanical
side

Check Supply of Voltage at PT pump If not available then tightened the screw from AUTO to MANUAL

Over load protection device is tripped condition Check and reset

Open circuit in exciter field. Check and replace if necessary.
Short circuited alternator output leads Check and rectify
Open circuit in rotating rectifier Check and replace if necessary.
6. No output from the Open circuit in alternator field coils Check and replace if necessary.
Electrical side Shorted rotating diodes Check and replace if necessary.
Traction Alternator
Shorted exciter armature Check and replace if necessary.
Shorted surge protector Check and replace if necessary.
Open circuit between excitation control system and
exciter stator Check and replace if necessary.
Malfunctioning of excitation control system Check and replace if necessary.
 a)Open the Cover of Rectifier Unit and check the
Forward/Reverse Fuse
b)Check Motor Over Load Relay
c) Defective ADD ON block CT1 (CT2) power
contactor.
7.Tower car is d) Check 02R relay for its operation. Power to this
relay comes from signal converter.
Moving only in Electrical side
e) Defective SIGNAL CONVERTER
One Direction f) Defective FORWARD/REVERSE solenoid
irrespective of g)Remove the ‘A’cable from the leading DPC and
try to work further if succeeds
Reverser Position h)Remove the ‘A’ cable of trailing DPC also and
set the reverser handle and move to required
direction and move the train.
a) Check the Air Presure should be more than 3.5
Mechanical
kg/cm2
side
b) if pressure not raising to sufficient
Check the BCH handle in released position
MR pressure to be more than 5.0 kg/cm2
8. BP Pressure Mechanical Emergency brake valve handles in closed condition
side in both cabs
Not Building Up Ensure proper closing of angle cut out cocks of
BP pipe on either ends of the formation.
Cheeck for any Air leakage at joints
Check the condition of Compressor and belts for
proper working
Check for air leakages at compressor delivery pipe
Check for air leakages atafter cooler joints
Check for air leakagesMR tank inlet elbow joint.
9. MR Pressure Mechanical Check the un-loader/ABD if continuously blowing
side
Not Building Up Ensure proper closing of MR and auxiliary reservoir
drain cocks and emergency valve handle in proper
position
Check for air leakages on BP & FP pipeline on
formation
Check the NRV for proper working
Check and replace
Reset if dropped.
Check and replace Refer to Electrical defect-20
Check and replace Refer to Electrical defect-20
Check and replace Refer to Electrical defect-20
Check and replace Refer to Electrical defect-20
If not moving leave the ‘A’ cable in removed condition
Remove the ‘A’ cable of trailing DPC also and set the reverser
handle and move to required direction and move the train.
If not then raise the pessure more than 3.5kg/cm2
Tightened the bottom screw of control valve of the unit.
Ensure if not then do it in release position.
Check
Check and close if not
Check and close if not
If so then tighten same properly.
If not overhouling may done
If so then arrest air lekage.
If so then arrest air lekage.
If so then arrest air lekage.
close the relevant COC
If so then do it accordingly.
If so then arrest air lekage.
Check and replace if necessary.
 Check the SD valve screw in Mechanical position on
Keep it in mechanical position.
PT pump

10. Removing Air Check for Closing of the COC on pipeline connected
Mechanical from fuel tank to primary filter. Then open auxiliary
Lock in Fuel Oil side cocs (two numbers) and disconnect the pipe line
connection on to actuator. Then operate the
System priming pump plunger till such time the oil flows
Do accordingly
out through the disconnected pipeline. Reconnect
the pipe at actuator and close two auxiliary cut out
cocks and open the main COC and crank the engine.
 ELECTRICAL TROUBLESHOOTINGS
Defect 1: When starter motor is operated its shaft fails to rotate or rotates slowly and the starter motor does not crank the engine through pinion has engaged with
ring gear.

Cause Action - Remedy

a) Discharge/defective battery Recharge battery/substitute a fully charged battery.
Defective/loose connections. Tighten all connections.
c) Dirty, oily or badly burnt commutator Remove the starter for further inspection.
d) Starter terminal or brush box having an earth fault. Do
e) Defective, solenoid switch. Do
f) Defective armature field coils. Do

Defect 2: Engine is not cranking

Cause Action - Remedy
a) Weakened battery Check the voltage of the battery charge it if required.
b) Inoperative ENGINE START switch Check and replace if necessary.
c) Faulty fuel solenoid Check and replace if necessary.
d) Faulty magnetic switch Check and replace if necessary.
e) Faulty starting motor solenoid Check and replace if necessary.
f) Faulty starter motor Check and replace if necessary.
g) Faulty ER1 (ER2) relay or Faulty FSR relay Check and replace if necessary.
*** Tightened the mechanical screw at shut down valve and start manualy.

Defect 3: Armature rotates but pinion fails to engage.

Cause Action - Remedy
a) Improper pinion engagement Clean it.
b) Burr formation on pinion or ring gear Deburr it by filling
c) Defective auxiliary coil. Change auxiliary coil.
d) Loose mounting. Tighten mounting/units
e) Worn commutator end/drive end bush Change the bush
f) Commutator bearing pin loose. Check the tightness of bearing pin fixing screw.
Defect 4: Starter motor continuous running after release of ENGINE START switch.
Cause Action - Remedy
a) Sticky starting switch. Open starter motor isolating knife switch immediately and repair/replace switch.
b) Short in wiring harness Replace faulty wiring.
c) Dry-drive end bush Trace cause and lubricate
d) Sticky solenoid switch contacts. Remove the starter for solenoid inspection.
e) Bush in pinion seized on shaft. Remove the starter for inspection.
f) Pinion/ring gear fouled or damage. Clean thoroughly, deburring of pinion and ring gear by filling.

Defect 5: Pinion engage but starter motor does not crank the engine (whining noise is heard)
Cause Action - Remedy
a) In sufficiently charged battery/corroded terminals. Recharge the battery/clean terminal and smear petroleum jelly.
b) In sufficient pressure on carbon brushes or worn out brushes. Change the brush springs/brushes.
c) Shorted/earthing armature Change armature
d) Slipping clutch assembly Change clutch assembly.
e) Partially earthing field coil. Change starter motor

Defect 6: RELAYS ER1\ER2/TRC/FSR DOES NOT OPERATE.

Cause Action - Remedy
a) Low control voltage Check the control voltage
b) Large voltage drop Check the loose connection
Check and correct the control circuit and coil connection. Check the marking of cables and connect
c) Control circuit incorrectly wired. accordingly.

Defect 7: RELAY CHATTERS ER1/ER2/TRC\FSR

Cause Action - Remedy
a) Low control voltage Check the control voltage

b) Large voltage drop Check the loose connections. Clean the contact tips of main and auxiliary contacts.

Defect 8: HUMMING OF IRON CORE OR NOISE MAGNET

Cause Action - Remedy
a) Rust or dust or other substance is on contacting surface of iron
core. Rub off rust with fine emery paper or clean the surface with cloth.
b) Broken shadding rings Mechanical life of contactor is over.
c) Magnet faces not mating Mechanical life of contactor is over.
d) Dirt or rust on magnet faces Clean lightly with fine emery paper or dry cloth or use compressor air.
Defect 9: RELAY FAILURE TO PICKUP AND CLOSE ER1/ER2/TRC/FSR
Cause Action - Remedy
a) Low voltage Check control voltage
b) Coil open shorted Replace the coil
c) Mechanical obstruction Clean and check the free movement of contact assembly.

Defect 10: RELAY FAILURE TO DROP OUT (OPEN) ER1/ER2/TRC/FSR

Cause Action - Remedy
a) Coil not disconnect from supply. Check wiring of the coil circuit
b) Worn or rusted parts causing binding Replace such parts.
c) Residual magnetism due to lack of air gap in magnet path The mechanical life of relay is over.

Defect 11: OVERHEATING OF COIL

Cause Action - Remedy
a) Over voltage or under voltage Check and correct the control voltage.

b) Inter turns short circuit caused by mechanical damage in coil. Replace coil
c) Dirt or rust on pole faces increasing the air gap. Clean pole faces with very fine emery paper or dry cloth.

Defect 12: OVERCHARGING BATTERY GASES

Cause Action - Remedy
Action - Remedy
a) Sensing lost Check circuitry and restore sensing connections.
b) Faulty regulator Check the regulator, replace if necessary.
c) Rotor shorted to earth on negative side. Rectify and replace rotor assembly

Defect 13: ENGINE DOES NOT STOP

Cause Action - Remedy
a) Faulty ENGINE/START-STOP switch Check and replace if necessary.

Defect 14: EVEN THOUGH LUB OIL PRESSURE IS MORE, ENGINE DOES NOT SUSTAIN (STOPS AFTER RELEASING THE START PUSH BUTTON)
Cause Action - Remedy
a) Faulty low water level switch Check and replace if necessary.
b) Faulty low water level relay Check and replace if necessary
c) Faulty over speed switch Check and replace if necessary.
d) Faulty lub oil pressure relay Check and replace if necessary
e) Faulty low hydraulic oil level Check and replace if necessary.
Defect 15: ENGINE THROTTLES IN HIGH RANGE BUT CAR DOES NOT MOVE (TRANSMISSION DO NOT ENGAGE)
Probable Cause Remedy
a) Defective timer relay TCE1 Check and replace.
b) Defective clutch cut off valve Check and replace

Defect 16: BRAKE APPLIED INDICATION DOES NOT EXTINGUISH EVEN AFTER ALL THE BRAKES ARE RELEASED.
Probable Cause Remedy
a) Defective service brake pressure switch Check and replace
b) Defective parking brake pressure switch Check and replace
c) Disturbed pressure settings in pressure switch Check and verify for proper settings.

Defect 17: EMERGENCY RAISE OF ENGINE DOES NOT TAKE PLACE I.E. ENGINE REMAINS IDLE WHEN EMERGENCY RAISE PUSH BUTTON IS RAISED.
Probable Cause Remedy
a) Defective push button switch Check and replace
b) Defective ERR relay Check and replace

Defect 18: ENGINE THROTTLE DOES NOT TAKE PLACE EVEN AFTER THE THROTTLE HANDLE IS MOVED TO DIFFERENT NOTCH POSITIONS
Probable Cause Remedy
a) Defective ET1 (ET2) relay Check and replace
b) Defective timer relay TCE2 Check and replace
c) Defective MUTC solenoid Check and replace
d) Defective speed relays (NRA-NRD) Check and replace

Defect 19: CAR DOES NOT MOVE WHEN SELECTED "LO" IN THE "RANGE SELECTOR" EVEN AFTER DIRECTION ENGAGED INDICATION IS CONFIRMED
Probable Cause Remedy
a) Defective LRR relay Check and replace
b) Defective TCE1 timer relay Check and replace
c) Defective GEAR1 solenoid Check and replace
d) Defective clutch cut off valves Check and replace
Defect 20: FORWARD/REVERSE SOLENOID FAILS TO GET ENERGISED EVEN AFTER DIRECTION IS SELECTED.
Probable Cause Remedy
a) Defective ADD ON block CT1 (CT2) power contactor. Check and replace

b) Check 02R relay for its operation. Power to this relay comes from signal converter. Check and replace
c) Defective SIGNAL CONVERTER Check and replace
d) Defective FORWARD/REVERSE solenoid Check and replace

Defect 21: CABIN DOES NOT GET INITIALISED

Probable Cause Remedy
a) Defective RESET AND INITIALISATION push button. Check and replace
b) Defective cabin relay - ………..
CR1 - CABIN1 a) Check and replace.
CR2 - CABIN2 b) Use stand by relay by switching on cabin BY-PASS switches in control cubicle.
c) Defective DRIVERS KEY SWITCH Check and replace

Defect 22: HEAD LIGHT DOES NOT GLOW

Probable Cause Remedy
a) Defective head light switch Check and replace
b) Defective diode stack unit Check and replace diode in that particular fault line.
c) Defective relay contact Check and replace relay/and on block.
TROUBLE SHOOTING OF TRANSMISSION
S.No CAUSE REMEDY

I. LOW CONVERTER OUT PRESSURE

1 Low oil level Add oil to proper level
2 Oil line leakage Check for leaks
3 Clogged oil strainer Clean oil strainer
4 Defective oil pump Rebuild oil pump assembly
5 Aerated oil Leaks in suction passages

II. HIGH OIL TEMPERATURE

1 Low Or High Oil Level
2 Low Coolant Level
3 Low Convertor out pressure
4 Cooler line kinked or clogged
5 Operating in too high for eqpt. Speed
6 Torque convertor starter locked
7 Engine overheating
Restore oil to proper level
Add coolant. Check for leaks
Refer "A"
Clean or replace cooler lines
Downshift to lower range
Check converter components
Refer engine manual

III. HIGH STALL SPEED

1 Oil level low Add oil to proper level
2 Low conv. Out pressure Refer to "A"
3 High oil temperature Refer to "B"
4 Clutch slipping Overhaul transmission

IV. LOW STALL SPEED

1 Low engine output Refer engine manual
2 Broken convertor parts Replace convertor assembly
3 Stato reversed or rollers Assembly stator correctly
DERRICK TROUBLE SHOOTING
 Emergency Lowering In case the platform does not come down in-spite of pressing 'DOWN'
button
due to any reason, such as power failure, fault in the hydraulic or
electrical circuit etc.
proceed as follows:
(a) Open the shut-off valve fitted between the cylinder outlet and hand
pump.
(b) Open the release valve on hand-pump. Oil from the cylinder returns
back to
reservoir through hand pump while ram lowers by gravity.

 Emergency Lifting (a) Open the shut-off valve fitted between the cylinder outlet and hand-
pump.
(b) Close release valve on the hand pump.
(c) Operate the hand-pump. Ram moves up very slowly to raise the
platform in
loaded condition as well
 Emergency Swivelling In case there is any fault in the system when platform is raised and
swivelled
out, proceed as follows :
(a) Lower the platform (as explained above) such that the pinion fitted
on the gear
box comes within the reach of the person standing on the roof.
(b) Unscrew hex bolt and grub screw fitted with pinion assembly.
Remove the pinion
from gear box shaft.
(c) Now the platform is free to rotate in any direction. Manually rotate the
working
platform to normal position.
(d) Lower it completely to bring to its normal retracted position.
 INSTRUCTIONS
DAILY CHECK BY DRIVER BEFORE STARTING THE ENGINE
(DAILY CHECKS OF TOWER CAR REDUCES FAILURES)

 Check fuel oil level &leakage if any

 Check engine oil level & leakage if any.

 Check radiator water level and leakage if any

 Check tension of ‘V’- belts of alternator

 Check oil level in hydraulic tank

 Check air cleaner indicator
 Check all under frame equipments for any defect/ deficiency
 Ensure parking brakes are in applied condition & wooden wedges/ skid are placed at
front wheels on both ends.
CABIN INITIALIZATION
 Ensure all switches/ driver’s controls are in ‘OFF’/ ‘0’ / ‘STOP’ position.
 Insert driver’s control switch (DCS) key in BL box and keep it in ‘OFF’ position.

 Insert the master controller switch key and operate reverser handle in ‘FORWARD’ & ‘REVERSE’ and keep it in the ‘OFF’ position.
 Switch on 24V DC Battery.
.

 Switch on both battery voltmeter switches and check for

i) Starting battery voltage reads 24V.
ii ) Control battery voltage reads above 88V.
  Switch ‘ON’ all MCBs (control and auxiliary ) including rectifier blower motor ‘MCB’.
i )Switch on 110V MCB and 24V MCB in the engine control panel.
ii ) Select the local/ remote selector switch in the engine control panel to remote side.

 Insert ‘DCS’ key in the BL box turn it‘ON’.

 Switch ‘ON’ control switch in the BL box.
 Control ‘ON’ indication will come on ‘LED’ indication panel.
 Press ‘LAMP TEST’ switch to ensure healthy condition of all ‘LED’ indication.
 Ensure all brake valve handles are in release and running position.
 Check for the function of HEAD LIGHT,
 TAIL LIGHT, MARKER LIGHT and FLASHER LIGHT from both cabins.

STARTING OF ENGINE
 Keep Engine Control Switch (ECS) in ‘IDLE’ position.
 Press ‘Engine-ON’ switch.
 Engine ‘ON’ indication will come as soon as Engine is started.
 Once Engine started, auxiliary alternator rectifier set will generate supply and auxiliary alternator failure indication will go ‘OFF’.

CHARGING OF RESERVOIRS
 Keep the test sequence switch in ‘ON’ condition and ECS continue to be in ‘IDLE’ position.
 Allow the engine to run in ‘IDLE’ position till feed pipe pressure reaches 6.0 kg/cm2.
 For fast build up of the pressure engine can be notched up and accordingly press the dead-man’s handle.
CHANGING OF DIRECTION
 Keep the master controller handle in ‘OFF’position.
 Selection of direction shall be done only in stationary condition.
 Select the required direction by operating reverser handle in ‘FORWARD’ or ‘REVERSE’ direction.

DRIVING THE CAR

 2
Ensure the feed pipe pressure is built up to 6 kg/cm .
 Ensure that brake pipe pressure is 5 kg/cm
2

 Ensure that parking brake is released by pressing the parking brake release switch.
 Remove wooden wedges/ skids from wheels.
 Put test sequence switch in ‘OFF’ position and ECS switch in ‘RUN’ position.
 Switch ‘ON’ Excitation switch in BL box. Alternator Excitation ‘ON’ indication will come.
 Move the master controller key in clockwise direction by 90° & set the reverser handle of master controller to the ‘FORWARD’ position from ‘OFF’
position.
  Press dead-man’s handle and move it in the ‘Notch-1’ position.
 Move the master controller handle to higher notches, notch by notch.
 Observe the Load Ammeter Current. The car will move as soon as current starts building up.

SHUTTING OFF THE CAR

 Bring the master controller handle to ‘OFF’ position & release the dead-man’s knob & remove master controller key.
 Switch ‘OFF’ the Excitation.
 Apply parking brakes and provide wooden wedges/ skids on front wheels on both sides.
 Put ECS switch in ‘IDLE’ position. Switch ‘OFF’ the engine.
 Switch ‘OFF’ the Control switch in BL box.
 Bring DCS key in ‘OFF’ position and remove it from DCS box.
 Switch ‘OFF’ all MCBs.
 Switch ‘OFF’ control battery and starting battery isolating switches.
 Close all the doors and windows of both cabs.
PHOTOS, DIAGRAMS AND CIRCUITS