1400_HP_DEMUs

Trouble Shooting for 1400 HP DEMU S.No Problem Cause Remedy 1 Engine not • 24 V knife switch in OFF - Put it ON. cranking. position. • Starting panel MCB in - Put it ON. OFF position. • Selector switch knob not - Put selector switch in correct position if:- set in correct position. 1. Engine start by control panel, put knob on No. 1 (In this method only local engine will start) 2. Engine start by Driver cabin, put knob on No. 2 (In this method all engines will start at time) 2. Engine cranking Any shutdown safety device Check all safety devices but not starting in operative position- (L.H.O.L, L.C.W.L, Over speed trip, H.O.F.F etc.) if any safety device found in operative condition put it right as follows- 1. L.C.W.L in operative Check water tank level, if any condition. leakage found tries to stop it and reset the L.C.W.L then start the engine. 2. O.P.S. in operative Check lube oil level and condition. O.P.S. connections if found lube oil in correct level. Reset the O.P.S then start the engine and record the LOP. 3. L.H.O.L sound with Check hydraulic oil level if indication on ECP and found necessary top up it. L.H.O.L in operative Check hydraulic oil tank condition. cutout cock it should be in fully open position. If hydraulic oil level is correct reset the L.H.O.L and start the engine. 4. Over speed indication on Reset it on ECP by reset ECP. switch. Governor MCB in OFF Put it ON position Air lock in Fuel oil system. Remove air lock in the system Maintenance Manual for 1400 HPDEMU Page 1 of 5

3. Engine cranking Empty fuel tank. Top up fuel in tank. but suddenly stopped Obstruction in fuel supply or Put it ON and check priming main cutout cock close. pump cutout cocks both should be in close position. Air lock in Fuel oil system. Remove air lock in the system Any rubber pipe crack Replace defective pipe. Actuator linkage in maximum Check actuator position and position. correct it. Governor MCB in OFF Put it ON position. Any shutdown safety device Check and correct as describe in operative position- in S.No. 1 & 2 4. Engine not D.I.R not picking up. Manually operate DIR relay. responding Driver’s key fit properly. according to Driver’s key not properly throttle. fitted. ECS in OFF position. Put it ON. Master controller not works Check interlocks. properly. 5. Engine over speed Actuator linkage at maximum Check actuator linkage if during start. level. stick up, put it in right position. Check Magnetic pickup coupler for open if open then tight properly 6. Engine shut down Any shut down safety device Set shut down device on ECS and not starts in operate position. and- again. Check lube oil level and OPS. If engine not cranking, smoothly strike on OPS by wooden piece. Over speed trip. Set over speed trip LCWL operate. Check water level in the tank, top up if require. LHOL operate. Check Hydraulic oil level and inspect hose pipes. Check Hydraulic tank COC they are in OPEN position Maintenance Manual for 1400 HPDEMU Page 2 of 5

and micro switch not loose. Fuel tank empty. Top up Fuel in fuel tank. Restrict fuel supply or COC Check main suction line and closed. manually fuel priming pump. Check and correct as describe in S.No. 3 7. Engine Hunting Engine not notch up properly. Engine notch up properly and wait for RPM setup. Restrict fuel supply Check for air locks and leakage, if found put it right. 8 Alarming Hot Any idling device in operate Re set operate device. Engine condition. Check water leakage from Water temperature above 960 water pump, radiator room and engine block. C. Get fast pumping by put GF off for reducing temp. Water pump not working Check temp. of suction & properly. outlet by hand, if temp. deference observes then water pump may not be work. Observe water pressure through vent valve. Radiator fan not working Ensure radiator proper fan properly. RPM and radiator room door in closed. Hydraulic pressure less. Check pressure in Hyd. Pressure gauge if found less , adjust it by pressure adjusting knob. ETS defective. Check temp. in temp. gauge and check manually water level. Remove load and get fast pumping by put GF off for reducing temp. 9 Engine shutting Low water level. Check water level if found down with LCWL less fill water. signal. If water level is correct then disconnect LCWL connection. Water leakage from SMR Check water level if found Maintenance Manual for 1400 HPDEMU Page 3 of 5

10 Wheel skid / radiator. less fill water. Wheel jam Brake jam Check brakes for proper opening. Release brake by Distributor valve, close brake cylinder pipe COC. Traction motor Bearing Isolate seized motor. seized. Smoke coming form Traction Use fire extinguishers, Isolate motor. seized motor. Defective Axle box bearing. Check axle box bearing for over heating. DPC Traction motor pinion Release brakes. Check wheel jam. movement in reverse & forward direction. 11 Air spring D- flat Air spring air hose cracked or Isolate defective air spring. brushed. Broken Air spring. Check for hanging parts, if not then Isolate defective air 12 MR pressure not Air compressor defective spring. building up or MR Check air compressor – pressure zero. Check Oil level Check V belts for broken Crack compressor pipes Check compressor pipe seat Unloader valve defective. Close isolating valve. Check pressure switch and off MCB if required. ABD valve defective. Tapping ABD valve. Close all drain cocks and isolate ABD valve. Any flexible pipes crack or Check all flexible pipes for brushed. leakage and repair it. 13 Feed pipe pressure MR pressure not charges Prevent air leakages and not building up properly. charge MR pressure upto 8 kg/cm2 Leakage from Feed pipe Prevent air leakages from Feed pipe. 14 Brake pipe Compressor defective Check air compressor – Check Oil level pressure/ Feed Check V belts for broken Crack compressor pipes pipe pressure not Check compressor pipe seat building up or zero. Maintenance Manual for 1400 HPDEMU Page 4 of 5

Check intercooler for leakages. BP/FP angle cocks in wrong Put it right in position. position. Any drain cocks in open Put it close position. condition 15 Brake pipe BP/FP pipes palm end in Refit with new rubber pressure not open condition washers. building up FP pressure not building up. Check FP pressure and correct as describe in S.No.13 A-9, C-2 Relay valve may be Adjust BP through A-9 valve defective Tapping C-2 relay valve Check both direction cocks for proper position. Leakage in BP pipe line Check BP pipe line for leakage and prevent leakage. Check both ends BP angle cocks for closed position. Intermediate cocks in open position 16 Brakes are not A-9, C-2 Relay valve may be Tapping A-9, C-2 relay valve applying in train defective Brake pipe pressure not Correct as describe in building up S.No.15 17 DPC brakes are DV may be defective Check position of R charger not applying. handle of DV it should be in open position. Isolate the Bogie Brake cylinder pipe/ Isolate the defective brake diaphragm defective cylinder. 18 TC/DTC brakes DV may be defective Check position of R charger are not applying handle of DV it should be in open position. Isolate the Bogie Brake cylinder pipe/ Isolate the defective brake diaphragm defective cylinder. Maintenance Manual for 1400 HPDEMU Page 5 of 5

REFERENCES The following documents are referred for information. 1) Operation and maintenance manual for Air Brake equipments of DMU/DPC coaches By Stone India Limited. 2) Electro-Pneumatic Brake Controller Type E.D. 6 (Westinghouse) 3) Electro-Pneumatic Brake Unit (Modified Type ) (Westinghouse) 4) E.P. Brake equipments for HHP DMU/DPC & TC coaches. (Westinghouse) 5) Descriptive and maintenance manual ESCORTS Parking Brake system EMU’S, MEMU’S, DMU’S and self- propelled vehicle’s. (Edition 02.08) 6) Operational and maintenance manual ESCORTS Modular brake Controller Esbc- III M (2000 & 2006) (Edition 08.08) 7) Descriptive and maintenance manual ESCORTS Electro- Pneumatic Brake Unit Kbr VIIIc1 (Edition 01.04/05/06) 8) Semi Permanent Coupler (Westinghouse Saxby Farmer Limited) 9) Maintenance Instructions on Air Suspension for DC, AC & AC-DC EMU/HHP DMU coaches (RDSO/CMI- 9802 Rev. 2 February 2008) 10) Maintenance manual of bogie, Brake, Brake Gear and coupler for HHP DMU stock (1400 hp) fitted with Air suspension (BG – 1676 mm) RDSO/CMI-K401 Rev. 0 11) Operation & maintenance manual (Bulletin No. 3243773-06 (September 2004) Cummins India limited 12) (ELGI) Operation, maintenance manual and parts list of Reciprocating Air Compressor for diesel locomotive 2 stage 2 cylinder (Model TRC 2507) 13) Hydraulic system manual (Cummins India Limited) 14) Guide for Layout of DMU Car Shed CMI No. RDSO/2008/CG/CMI-05 Maintenance Manual for 1400 HPDEMU

15) Diagram Book of 1400 HP DEMU (report No. MP- MISC. -111 Rev. 0.00 March 2001 16) Schedule of standard Examination of 1400 hp HHP DEMU (MP- MISC- 157 Rev. 0 , Oct 2004 17) Maintenance Manual for BG HHP (1400 HP) diesel Electrical Multiple Units (Electrical Equipment) of Integral coach factory, Chennai (BHEL) Maintenance Manual for 1400 HPDEMU