CAMTECH Troubleshooting Guide for WDP4 and WDG4

(Govt. of India)
(Ministry of Railways)
TROUBLE SHOOTING GUIDE
ON
WDP4/WDG4 LOCOMOTIVES
FOR LOCO PILOTS AND MAINTENANCE STAFF
(For official use only)
IRCAMTECH/2013/M/GM/TSG/1.0
May, 2013
Centre
for
Advanced
Maintenance
TECHnology
Excellence in Maintenance
MAHARAJPUR, GWALIOR – 474005
egkjktiqj, Xokfy;j & 474005
TROUBLE SHOOTING GUIDE
ON
WDP4/WDG4 LOCOMOTIVE
FOR
LOCO PILOTS AND MAINTENANCE STAFF
FOREWORD
GM locomotive was introduced in Indian Railways services
in the year 1999-2000. Due to new version of locomotive,
there
are
various
locomotives
hence
differences
proper
from
conventional
knowledge
of
this
technologically upgraded locomotive is necessary to Loco
pilots and staff involved in operation and maintenance of
these locomotives. The failure of GM Locomotives has a
great impact on the reliability of the diesel locomotive. This
trouble shooting guide is prepared for assistance to the
staff who are involved in the maintenance and operation of
WDP4/WDG4 locomotives.
This hand book contains important trouble shootings
repeatedly experienced on line by the loco pilots as well
as by shed maintenance staff.
I am sure that the Trouble shooting Guide will be very
much useful to the concerned staff, to ensure trouble free
service.
23rd May, 2013
CAMTECH, GWALIOR
( A R Tupe )
Executive Director
PREFACE
Proper knowledge of trouble shooting of faults in GM
locomotive
is
availability
of
necessary
WDP4/WDG4 GM
to
locomotives.
ensure
reliability
and
This
handbook
on
locomotives has been prepared by
CAMTECH with the objective that those involved in
operation and maintenance of diesel electric locomotives,
must be aware of sufficient knowledge of trouble
shootings.
Technological Up gradation and learning is a continuous
process. Hence feel free to write to us for any addition /
modifications or in case you have any suggestion to
improve the handbook. Your contribution in this direction
shall be highly appreciated.
23rd May, 2013
CAMTECH GWALIOR
(K.P.Yadav)
Director/Mech
CORRECTION SLIPS
The correction slips to be issued in future for this handbook will
be numbered as follows:
CAMTECH/M/2012/GM/TSG/1.0/C.S. # XX date --------------Where “XX” is the serial number of the concerned correction
slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. of
C.Slip
Date of
issue
Page No. and Item
no. modified
Remarks
CONTENTS
Sr. No.
A1.0
1.1
Description
Page No.
Foreword
Preface
Contents
Correction Slips issued
CHAPTER 1
Introduction of the GM Locomotive
Description of Locomotive computer Display
Panel
i
ii
iii
iv
1
2
i.
Display Panel Keypad
3
ii.
Display Panel Screen
4
iii.
Navigating the Menus
5
iv.
Computer Display Operation
v.
Display Power Up
vi.
Crew Messages
7-8
vii.
Main Menu
8-9
viii.
Traction Inverter Cutout
10-11
ix.
Cutting-out or Cutting-In a Traction Inverter
or Bogie (Truck)
11-12
5-6
6
x.
Maintenance Menu
13
xi.
Meter Menu
13
xii.
Blanking the Screen
14
List of the important Crew messages with
Code.
Indicator Light Messages
Checking of the Loco by loco Pilots
CHAPTER 2
Trouble Shooting of faults on WDP4/ WDG4
HHP Locomotives.
15-16
2.0
Engine Shuts Down Automatically.
21-23
2.1
Reduced Power/ power not coming as per Notch.
23-25
2.2
Tractive effort meter not responding (Load meter is
not responding).
25-26
1.2
1.3
B-
16-19
20
21
Sr. No.
Description
Page No.
2.3
Ground Relay Tripping
27
2.4
TCC related problems
27-28
2.5
Locked wheel speed sensor fault
2.6
TCC Blower contactor problem
28-29
2.7
Experiencing jerks in under trucks
29-30
2.8
Digital input system failure
30-31
2.9
Air brake system problems
31-32
2.10
MR pressure dropping on Run
32-33
2.11
Simultaneous Forward / Reverse request
33-34
2.12
Simultaneously power / DB request
2.13
Head light not working
2.14
Flasher light not working.
35
2.15
Flasher light working continuously
35
2.16
White smoke in exhaust
35
2.17
Water level reducing
35
2.18
Engine is not cranking
36-37
2.19
Throttle not responding
37
2.20
Engine cranking but not starting
2.21
PCS Knocking off
2.22
Continuous wheel slip
2.23
34
34-35
37-38
38
38-39
Air Brake Trouble Shooting
39
1.0 MR pressure dropping
39
2.0 Unusual sound from compressor
39
3.0 Improper loading
compressor
2.24
28
and
unloading
of
air
39-40
4.0 BP dropping and PCS Knocking out
40
5.0 Air brake failure with crew message.
Air brake failure- use loco in trail only.
41
Air Brake System - Trouble Shooting in Ghat
41
1.0 MR pressure dropping with EM-2000 – Crew
message “Low Main Reservoir Equalizing
Pressure use Loco in trail only” FC 2977 in lead
working loco.
41
Sr. No.
2.25
C-
Description
Page No.
2.0 If MR pressure dropping other than Leading
Loco
41
3.0 BC EQ – Hose pipe burst causing MR pressure
dropping
42
4.0 “Air brake failure use Locomotive in Trail only”
FC 2975 in Lead / HLPR loco if experienced
with BP leaking.
42
5.0 Air brake failure other than lead / HLPR modes
locos in MU’s (or) TLC.
42
6.0 Air brake failure in the MU / HLPR mode loco
(down the ghat) (or) TLC (up the Ghat).
42
7.0 Air brake penalty not getting reset even after
keeping auto brake handle 10 seconds in FS or
60 seconds in emergency position.
42-43
8.0 At any situation 2 control stands in one MU
consists the L/T switch should not be kept in
LEAD/ HLPR Mode.
43
9.0 To make Lead mode MU consists to couple with
another MU consist any one control stand to be
kept in HLPR Mode only.
43
Important DO’s and DON’T’s for Loco Pilots & Shed
maintenance staff.
43-44
CHAPTER – 3
Trouble Shooting by shed maintenance
staff
45
3.0
Ground Relay
45-46
3.1
Ground relay dynamic brake, Load test
46-47
3.2
No dynamic brake (OR) Load Test, Grid resistance
path-1 (OR) 2 are too low
47
3.3
No dynamic brake (OR) Load test – Grid resistance
path1 (OR) 2 is too high
47-48
3.4
Locked wheel (OR) speed sensor fault
48-49
3.5
Speed sensor disabling procedure
49
3.6
Cutting out of Trucks
49
3.7
Computer turn off or Reset while Reverser is not
centered (OR) computer is loading
49-50
Sr.
No.
Description
Page
No.
3.8
TCC # GTO power supply under voltage or no Aux.
Gen. Output.
50-51
3.9
No Companion Alternator Output
3.10
DC link under voltage problems
3.11
DC link over voltage Faults
3.12
Excitation test Failing
3.13
Low horsepower problems
53
3.14
Automatic Shutting down of the Locomotive
53
3.15
Engine speed Failure
3.16
TCC # 1 or 2 communication link failure
54
3.17
Procedure for recycling of circuit breaker
54-55
3.18
Communication Link Failure – MAB
3.19
Load meter not responding
3.20
Load meter fluctuations
56
3.21
Load meter not responding beyond first Notch
57
3.22
Experiencing jerks from Trucks
57
3.23
Head Light problems
58
3.24
Digital input system Failure
58
3.25
Flasher light not working or continuously working
58
3.26
Engine not Cranking
59
3.27
Filter Blower Motor breaker is not closed
3.28
Fuel pump motor breaker is tripping
60
3.29
No Grid Blower Motor current or Grid Blower Motor
current is too high
60
3.30
Radiator fan Motor not working
60-61
3.31
Fuel Pump motor is not working
61
3.32
Turbo Lube pump motor is not working
61
3.33
DCOP failed to pickup / DCCL failed to drop out
3.34
Battery charging Ammeter showing discharge side
62
3.35
TCC # failed to acknowledge direction request
62
3.36
Horn continuously working
62
3.37
Event recorder communication failure
63
51
51-52
52
52-53
53-54
55
55-56
59-60
61-62
Sr.
No.
Description
Page
No.
3.38
TCC computer or TCC blower circuit breaker not
closed
63
3.39
TCC blower contactor failed to pick up
63
3.40
Air dryer malfunctioning
3.41
Water level reducing
64
3.42
Water Siphoned out
64
3.43
Unusual sound from turbo end
64
3.44
3.45
Low compression pressure in cylinder
LR not matching
65
65
3.46
LLOB Tripping
3.47
Pinching of Lash Adjuster
66
3.48
Smoke from top Deck
66
3.49
Less CC Vacuum
66
3.50
More CC Vacuum
67
3.51
Engine shutdown Automatically
67
3.52
Piston Crack
3.53
Black thick Smoke from Turbo
3.54
OSTA Tripping
68
3.55
OSTA not Tripping
68
3.56
OSTA not Re-setting
68
3.57
Fuel Header vibration
68
3.58
High Lube oil consumption
69
3.59
Lube oil leakage from Air box drain pipe
69
3.60
Water leakage from Air box drain pipe
69
3.61
Oil throw from Turbo
69
3.62
Water throw from Turbo
69
3.63
Crank shaft not Rotating
70
3.64
Loss of Horse power
70
3.65
Engine Hutting in load test – 2 condition and rack
length above 0.82
70
3.66
Engine is cranking in cold condition, but engine
RPM is less and not holding
70-71
3.67
LR% is not matching in higher notches
63-64
65-66
67
67-68
71
Sr.
No.
Description
Page
No.
3.68
Abrupt increase in engine speed before getting
stabilized as and when engine is notched up/down
71
3.69
If the LR% is less in all Notches
71
3.70
RPM dropping in Load
72
3.71
Bubbles at returns sight glass
72
3.72
th
Bubbles at 8 notch only in return sight glass
rd
th
72
3.73
Bubbles at return right glass after 3 or 4 notch
72
3.74
MR pressure dropping on Run & PCS Opening
3.75
MR pressure dropping
73-75
3.76
Brake pipe (BP) pressure not creating
75-76
73
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |1
A- CHAPTER – 1
INTRODUCTION OF THE GM LOCOMOTIVE
The WDG4 & WDP4 series of DLW make locomotives are
GM (General Motor) locomotives. GM locomotive models
are GT46 MAC for goods service and GT46 PAC for
passenger service. GM locomotive is fitted with engine
model No. 710G3B.
The GM locomotives are also fitted with equipments like
Engine, Turbo super charger, Compressor, Alternator,
Traction motors etc. like those in ALCO locomotive but their
designs are different. GM locomotive are provided with Fuel
oil system, Lube oil system, Cooling water system, Charged
air system, Compressed air system, Air brake system,
Electrical system and various safety devices like those
provided in ALCO locomotive but their designs are different.
GM locomotive power pack is 16 cylinders, Two strokes,
‘V‘–arrangement,
internal
combustion
engine.
GM
locomotive is highly fuel efficient having 11% better fuel
efficiency compared to the ALCO design locomotive. GM
locomotive is a 4000 BHP locomotive. GM locomotive is
having highly improved maintainability compared to ALCO
locomotive.
This
locomotive
is
equipped
with
a
microprocessor based computer control system- referred to
as EM- 2000 locomotive computer.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
1.0. DESCRIPTION OF
DISPLAY PANEL
P a g e |2
LOCOMOTIVE
COMPUTER
The locomotive computer display panel, consists of a 6line, 40-column vacuum fluorescent display with a 16key back-lit keypad.
Figure 1.0 – Computer Display Panel
Panel with key pad:
This display panel is an interactive device that is an
interface between the locomotive computer (EM2000)
and the locomotive operating crew. The crew can read
the display and input information to EM-2000 through
the keypad. EM-2000 messages further instruct the
crew.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |3
i. Display Panel Keypad
The locomotive computer display panel is equipped
with a keypad. The keys are:
• F1, F2, F3, F4 Keys are function keys. The functions
may vary on each screen. Pressing a function key
typically requests the loco computer to perform a
function- reset a fault, cut out an inverter, display
stored data, etc.
The function keys are directly below the display
screen. The bottom line on the screen names the
function that each function key can perform. If no
function appears above a function key, it has no
function on that screen.
F1
F2
F3
F4
ON
OFF
Main
Menu
SELECT
CREW
Bright
DIM
HE
Power
SLOW
SPEED
HELP
Figure 1.1 – Display Panel key pad
• ON / OFF Key controls display panel operating power.
• MAIN MENU Key returns screen to main menu.
• BRIGHT/DIM Key controls screen intensity.
• HE POWER Key Not used.
• Arrow Keys ↑, →, ↓, ← ) move the screen cursor.
• SELECT Key selects the item at the cursor location.
• CREW Key returns screen to crew messages display.
• SLOW SPEED Key Not used.
• HELP Key Not used.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |4
ii. Display Panel Screen:
The display screen has 06 horizontal lines which
are designated for reference as shown below.
Display Screen Layout
. . . . . . . . . . line 1 . . . . . . . . . .
. . . . . . . . . . line 2 . . . . . . . . . .
. . . . . . . . . . line 3 . . . . . . . . . .
. . . . . . . . . . line 4 . . . . . . . . . .
. . . . . . . . . . line 5 . . . . . . . . . .
. . . . . . . . . . line 6 . . . . . . . . . .
There are three major locomotive computer display
screen classifications:
• Crew Message Screens replace annunciator
module and local engine indicator lights used
on previous model locos.
Note: Crew Messages describe normal operating
conditions and various locomotive problems.
Examples of conditions and problems described by
crew messages:
– Engine speeds-up because water temperature is
too low.
– Locomotive is not properly set up for the
requested mode of operation.
– Traction power is being limited for some reason.
– Some locomotive equipment or system has
failed, and a protective function is active.
• Menu Screens offer choices such as various
service functions routinely performed by the
operating crew: fault reset, system cut out, etc.
• Blank Screens reduce annoying screen
illumination when screen is not in use.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |5
iii. Navigating the Menus:
The locomotive computer display has a cursordriven menu system.
The cursor consists of two inward-pointing
arrowheads:
............
Menu items appear between the two cursor
arrowheads, in the “. . . . . . . . .” space shown
above.
Move the cursor with the keypad arrow keys:
Press the key to move the cursor from the bottom
of one column to the top of the column to the right.
To select a menu item, move the on-screen cursor
to the item, then press the SELECT function key.
Selecting one menu item causes a sub-menu to
appear on the display. To activate certain menu
items, it is necessary to press a function key, such
as CUT OUT.
iv. COMPUTER DISPLAY OPERATION
The locomotive computer display performs both
loco operation and loco service functions. Loco
operation functions include some service-related
procedures, such as traction motor cutout and
fault reset.
1. Operation - Loco crew members use only Crew
Message screens to monitor unusual operating
or fault conditions and cut out motors or reset
faults.
2. Service- Maintenance personnel use two types
of screens:
• Crew Message screens to examine fault
conditions.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
•
P a g e |6
Main Menu screens to load test the
locomotive, self-tests for certain locomotive
systems, meter screens, and other trouble
shooting data.
Note: The GT46PAC locomotive is equipped for
traction inverter cutout. Cutting out traction
inverter #1 cuts off power for both bogie #1
traction motors. Cutting out traction inverter #2
cuts off power for both bogie #2 traction motors. If
a traction inverter or its blower fails, the fault
causes bogie power lockout and a crew message.
To continue operation, cut out the traction inverter
for that bogie.
v. Display Power Up:
When the locomotive computer and its display
panel initially power up after a shutdown, the
computer displays the following on the screen:
1. Fault messages that occurred since the fault
annunciator was last reset are stored in
locomotive computer archive memory.
The
“MAINTENANCE
INFORMATION
STORED” message appears at the top of the
screen for ten seconds after power-up if there
are any messages in the annunciator.
2. If there are not any stored (archived) fault
messages, but there are active crew messages,
then the computer will display the active crew
messages on the Crew Message screen.
Note: Only one message is displayed on the
screen at a time.
Each message includes a specific priority
number.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |7
EM2000 displays messages in order by priority
number.
The priority numbers have been assigned
based on urgency.
3. If there are no active crew messages, then the
locomotive computer displays the Main Menu
screen,
vi. Crew Messages:-The Crew Message screen,
displays fault conditions that require immediate
attention - important crew messages interrupt the
other display functions.
Crew Message # x of y
alarm status
crew message line 1
crew message line 2
| - - - - - function key assignments - - - - - |
F1
F2
F3
F4
Line 1 -x = Message Number
y = Number of Available Messages
Line 2 - Blank or ALARM (if message caused alarm)
Lines 3 & 4 - Crew Message
Line 5 - Blank
Line 6 - Function Key (F1, F2, F3, F4) assignments:
- RESET: Resets faulted/locked out functions.
- CUTOUT: Cuts out devices.
- NEXT: Displays
next lower
priority
message.
Fig. Crew
Message
Format
- PREVIOUS: Displays next higher priority message.
Fault Reset
Pressing function key F3, resets this fault, provided
that the fault condition is not still present.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |8
.
Crew Message #1 of 3
ALARM
REDUCED DYNAMIC BRAKE
GRID OVER CURRENT
F1
F2
RESET
F3
F4
Fig. 1.2 Typical Crew Message
vii. Main Menu
To bring up the Main Menu screen, press the
MAIN MENU key once, or press the EXIT key on
other screens as many times as necessary.
The Main Menu screen is the starting point for
access to the EM2000 for locomotive service and
service-type driver functions. Starting at the Main
Menu screen, service personnel have multiple
screen
options
available
for
evaluating
performance,
testing
subsystems,
and
troubleshooting equipment and circuitry.
The cursor in is set at Data Meter. If the SELECT
function key is pressed, the displayed screen
changes to the meter menu screen,
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e |9
Main Menu Screen
- Main Menu 1:2
Data Meter
Self Tests
Unit Information
Traction cutout
NEXT
F1
Fault archive
Fig,Running totals
English/metric
Lock Wheel Detect
SELECT
EXIT
F2
F3
F4
Fig. 1.3
If the NEXT function key is pressed while the Page 1
Main Menu screen displays,
- Main Menu –
Maintenance
PREVIOUS
F1
EXIT
SELECT
F2
F3
F4
Fig. 1.4 Main Menu Screen
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 10
viii. Traction Inverter Cutout
The traction inverter cutout function replaces the
engine control panel traction motor cutout switch
on previous EMD locomotive models. This
function enables the locomotive crew to view the
status of both traction inverters on the EM2000
display, and enables them to cut out or cut in
either traction inverter with the display.
This locomotive has separate cooling air blowers
for each traction inverter. If one of the blowers
fail, then it is advantageous to cut out the
traction inverter associated with that blower,
enabling the locomotive to be powered by the
other traction inverter. The entire bogie (truck)
can be electrically disabled or enabled through
the display.
- Traction Status Truck 1:
Truck 2:
F1
aaaaa
bbbbb
Key Stat
F2
F3
TRACTION
TRACTION
EXIT
F4
aaaaa and bbbbb = DISABLED or ENABLED
or FAIL DSBL or FAIL ENBL
or TRANSFER
Key Stat = DISABLED or ENABLED
or FAIL DSBL or FAIL ENBL
Function Key F3 definition:
- If cursor is on a truck (bogie) with FAIL DSBL
(cut out failed) or DISABLED status, F3 is ENABLE.
- If cursor is on a truck (bogie) with FAIL DSBL
(cut in failed) or ENABLED status, F3 is DISABLED.
Figure 1.5 Truck (Bogie) Electrical Status
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 11
Traction inverter disable/enable functions can be
performed from the Traction Status display screen,
Figure given above.
Note: The locomotive must be unloaded while
attempting to disable/enable a traction inverter.
Access the Traction Status screen in either of two
ways – Select TRACTION CUT OUT on the Main Menu.
– Operate the CUTOUT function key on a Crew
Message screen indicating a faulted device.
Note: In order to continue operation after a fault
causes power lockout (crew message appears), it is
necessary to disable a truck (bogie).
ix. Cutting-out or Cutting-In a Traction Inverter or
Bogie (Truck)
Changes in traction status usually must be made
because of a fault condition that is indicated by a
crew message on the locomotive computer
display. The following are traction status changes:
• Disabling a bogie (truck): all motors on a bogie
and the associated blower motor are cut out.
• Enabling a bogie (truck): all motors on a bogie
and the associated blower motor are cut back
in.
For each fault condition, a crew message is
displayed that identifies the fault and assigns it
to a bogie.
A failure of the a traction inverter blower produces
a crew message TRACTION INVERTER BLOWER #1 IS NOT
TURNING, for example. If the CUT OUT key on
Crew Message screen is pressed, the screen
changes to the Traction Status screen, Figure
given above, to enable the bogie to be cut out.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 12
Proceed as follows to cut out an inverter or
bogie:
1. The CUT OUT designation is above the function
key on the Crew Message screen having the
fault message.
2. Isolate the locomotive. (Set isolation switch in
START/STOP/ISOLATE.)
3. Press the CUT OUT function key to bring up
the Traction Status screen.
Note: The Traction Status screen is also accessible
directly from the Main Menu screen by selecting the
Traction Cut Out option.
3. On the Traction Status screen the Key Stat
function key (F3) is designated ENABLE or
DISABLE for a faulted bogie blower. Moving the
cursor to the faulty bogie causes the function key
designation to indicate the status of that device.
5. The status of the bogie (truck) displays.
4. If the cursor is at Truck 1, and bogie 1 is
ENABLED, only the DISABLE and EXIT
functions are available because this bogie is
already enabled.
7. Press DISABLE key to cut out the #1 bogie.
• During cutout process, truck (bogie) status
changes to TRANSFER.(No function keys are
designated during cutout process.)
• If cutout process is successful, Truck 1 (bogie
1) status changes to DISABLED on the
display.
Note: If just interrogating computer for bogie status, be
sure both bogies are cut in before operating locomotive.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 13
x. Maintenance Menu
Pressing NEXT key on Main Menu page 1 brings
up Main Menu page 2.
-Maintenance Menu Air Test Setup
SELECT
F1
F2
EXIT
F4
F3
Fig. 1.6 Maintenance Menu Screen
xi. Meter Menu :
Selecting DATA METER on the Main Menu brings
up the Meter Menu screen, Setting the cursor at
any of the meter menu items, then pressing the
SELECT key brings up a screen that displays
information about the selected subject.
Program Meter
Dynamic brake
Starting system
Digital I/O
- Meter Menu Power Data
Creep Control
Cooling System
Speed Meter
NEXT
F1
Fig. 1.7
F2
SELECT
F3
EXIT
F4
Meter Menu Screen Format
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 14
xii. Blanking the Screen
Screen blanking eliminates all screen text from the
EM2000 display when it is not needed. Screen
blanking actuates when either of the following
conditions is true:
• OFF key on keypad is operated.
• There has been no keypad usage for the past 30
minutes provided that:
– There are no active crew messages, and
– No locomotive system self-test or device cut-out
process is running.
To return to the previous screen after the screen has
been blanked, press the ON key (on display panel
keypad) no later than 10 minutes after the screen was
blanked.
During locomotive operation, the display screen is
blank most of the time because there are no loco fault
conditions & the locomotive crew has not used the
keypad for 30 minutes.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 15
1.1. LIST OF THE IMPORTANT CREW MESSAGES WITH
CODE
Following are some common potential crew messages.
CODE
241
309
14
0
73
206
322
76
77
311
240
512
96
281
124
61
319
302
15
494
172
600
174
176
178
192
179
CREW MESSAGES
DYNAMIC BRAKE GRID OVERCURRENT
ENGINE AIR FILTERS DIRTY
ENGINE AIR FILTERS DIRTY-THROTTLE 6 LIMIT
ENGINE DEAD - UNIT NOT ISOLATED
ENGINE DIED WHILE ISOLATED
ENGINE IS NOT RUNNING
ENGINE PROTECTION SHUTDOWN
ENGINE SPEED INCREASE – Turbo COOL DOWN
CYCLE
ENGINE SPEED INCREASE - LOW AIR PRESSURE
ENGINE SPEED INCREASE - LOW WATER
TEMPERATURE
ENGINE SPEED INCREASE - TRACTION MOTOR
COOLING
FILTER BLOWER MOTOR CIRCUIT BREAKER IS
OPEN
FORCED IDLE - ENGINE RUN SWITCH DOWN
FUEL PUMP IS NOT RUNNING
GENERATOR FIELD OVEREXCITATION
GROUND RELAY - DYNAMIC BRAKE
GROUND RELAY - POWER
HOT ENGINE - THROTTLE 6 LIMIT
#n LOCKED WHEEL
#n LOCKED WHEEL DETECTION DISABLED
NO ACTIVE CREW MESSAGES
NO DYNAMIC BRAKE - DYNAMIC BRAKE CUTOUT
NO DYNAMIC BRAKE - GROUND RELAY LOCKOUT
NO LOAD - ENGINE TEMP FEEDBACK FAILURE
NO LOAD - GENERATOR FIELD SWITCH DOWN OR
SDR RELAY IS PICKED UP
NO LOAD - GROUND RELAY CUTOUT
NO LOAD - IMPROPER B CONTACTOR STATUS
NO LOAD - IMPROPER GFC STATUS
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
200
CODE
453
456
221
131
125
8
4
2
10
11
7
59
127
22
130
133
149
222
521
P a g e | 16
NO LOAD - IMPROPER GFD STATUS
CREW MESSAGES
NO LOAD - NO COMPANION ALTERNATOR OUTPUT
NO LOAD - PCS OPEN
NO LOAD - SIMULTANEOUS FORWARD/ REVERSE
REQUEST
NO LOAD - SIMULTANEOUS POWER/SLOW SPEED
REQUEST
NO LOAD - UNIT IS ISOLATED
NO LOAD TEST, DYNAMIC BRAKE - EXCESSIVE GRID
BLOWER #n CURRENT
NO LOAD TEST, DYNAMIC BRAKE - GRID BLOWER
#n GRID FAILURE
NO LOAD TEST, DYNAMIC BRAKE - GRID CURRENT
IMBALANCE
NO LOAD TEST, DYNAMIC BRAKE - GRID OPEN
CIRCUIT
NO LOAD TEST, DYNAMIC BRAKE - GRID
OVERCURRENT
NO LOAD TEST, DYNAMIC BRAKE - NO GRID
BLOWER #n CURRENT
NO POWER - GROUND RELAY LOCKOUT
REDUCED DYNAMIC BRAKE - ENGINE SPEED UP
FAILURE
REDUCED POWER, DYNAMIC BRAKE - TRACTION
MOTOR BLOWER #n FAULT
SIMULTANEOUS
POWER/DYNAMIC
BRAKE
REQUEST
STARTER MOTOR OVERLOAD
TRAINLINE ALARM BELL
TURBOCHARGER CIRCUIT BREAKER OPEN
TURBOCHARGER LUBE PUMP NOT RUNNING
1.2. INDICATOR LIGHT MESSAGES:
The control consoles each incorporate a six-indicator
light assembly. Each indicator is imprinted with a word
or phrase that conveys a message for the locomotive
driver.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 17
BB C/O Light On:
Conditions: Engine control panel BLENDED BRAKE
switch is set in CUT OUT (slider Down). Setting AUTO
brake handle in SERVICE ZONE causes air braking
alone to apply - without any dynamic braking.
Action Required: To regain use of blended braking,
set BLENDED BRAKE switch slider in CUT IN (Up).
SAND Light On:
Conditions: This light indicates locomotive sanding is
active on this locomotive and on train lined locomotives
for any of various reasons (SAND switch operated,
automatic sanding initiated for wheel creep
enhancement, etc.)
Action Required: None.
WHEEL SLIP Light, Continuous or Flashing
Regularly
Locked Powered Wheel Condition:
Note: follow prescribed instructions concerning Locked
Wheel faults.
Locomotive computer immediately lights WHEEL SLIP
indicator and drops load when Siemens system detects
locked wheel. After 10 seconds delay, (20 sec.if air
brakes are applied), locomotive computer sets fault,
sounds alarm bell, continues WHEEL SLIP light, and
displays following message: #n LOCKED WHEEL STOP TRAIN AND THEN CHECK IF THE WHEELS
TURN FREELY. Fault indications above continue until
driver uses loco computer display panel to reset fault.
WARNING
Locked wheels on moving locomotives are very
dangerous. If locked wheel is indicated, do the
following:
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 18
Action Required: Stop the train and set the throttle
handle in IDLE. Then follow the procedure provided for
Locked Wheel Condition.
WHEEL SLIP Light, Flashing Irregularly or
Occasionally
For any locomotive connected to any loco by train
jumpers, the conditions given below can activate the
control console WHEEL SLIP light.
Startup/Slow Conditions: Speed under 2.4 km/h (1.5
MPH); normal startup wheel slip correction operation.
Action Required: No action required. Do not reduce
throttle unless slipping threatens to break the train.
Normal Running Conditions: Speed over 2.4 km/h
(1.5 MPH); backup of Super Series wheel creep control
operation. Possible failure of Super Series. May also
indicate normal wheel slip detection/control on train
lined non-Super Series units.
Action Required: No action required. Do not reduce
throttle unless slipping threatens to break the train.
Over speed Conditions: Wheel over speed detected
by computer. The indicator light flashes- 3 seconds
“On”/
3 seconds “Off” - to indicate wheel (and
traction motor)
over speed, and locomotive
computer displays WHEEL OVER SPEED message.
Cause may be excessive track speed or simultaneous
slipping of all locomotive wheels. In either case, the
system automatically corrects by regulating traction
alternator output (power drops out until speed drops,
then picks up again). Locomotive computer message
and indicator light flashing automatically cancel after
recovery.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 19
Action Required: Reduce throttle setting.
FLSHR LAMP Light:
Conditions: This light flashes On/Off when either
outside flasher lamp (at cab end or at long hood end) is
flashing, provided that outside flasher lamp is not
burned out and LIGHTS breaker is closed. Flashes at
same rate as outside flasher lamp.
Action Required: Open flasher light switch when
flasher light operation is no longer required.
PCS OPEN Light On:
Conditions: Penalty or emergency brake application
and loss of power. Computer displays NO LOAD - PCS
OPEN message, motoring/Diesel engine will come into
throttle idle however dynamic braking can be availed.
Action Required: Set throttle in IDLE. Set automatic
brake in EM (Emergency), wait 60 seconds, then set in
REL (Release). For the recovery of penalty is always
gets displayed on EM 2000 screen. For example: EM
2000 displays “keep auto brake handle in full service for
10 seconds to recover normal air brake”.
BRAKE WARN Light On:
Conditions: Excessive dynamic brake current on this
loco or on a train lined locomotive.
Action Required: Reduce dynamic brake handle
setting immediately. If light stays On, set DYN BRAKE
cutout switch on engine control panel in CUT OUT
(slider Down). Computer then displays NO DYNAMIC
BRAKE-DYNAMIC BRAKE IS CUT OUT message.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 20
1.3. Checking of the Loco by Loco pilots:
1. Before starting the train, ensure good quality sand is
available in all sand boxes.
2. Check water level in loco dead condition and after
cranking condition.
3. Keep 10 seconds gap for power to DB and DB to
power mode.
4. If loco is not cranking 2/3 times, wait to cool down the
starting motors for 2-3 Minutes.
5.
If required for raising the Engine, put A. Engine Run Switch to run.
B. Isolation switch to run.
C. Reverser in natural
6. Don’t reverse the loco operation while in moving.
7. For enroute, if loco shut down, first secure the loco
before cranking.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 21
B- CHAPTER – 2
TROUBLE SHOOTING OF FAULTS ON WDP4/WDG4
HHP LOCOMOTIVES
Some of the important trouble shootings of WDG4/WDP4
locomotives are given in this chapter for assistance to loco
pilots.
S
No
2.0
Fault
Engine
Shuts
Down
Automati
cally
Items to be
Action to be taken by
checked
Loco Pilot
Check
for RESET LLOB
LLOB tripping
Check
for a. If EPD found tripped,
EPD tripping
RESET button and also
RESET LLOB button.
b. Bottom button (crank
case button) tripped,
inform shed, do not try to
re-crank.
Note: Whenever EPD button trips, it will
always be accompanied with the tripping
of LLOB button.
OSTA tripping
RESET OSTA
If OSTA tripping, LLOB & EPD may also
trip. Check LLOB & EPD buttons for
tripping if found trip. RESET them.
Check
for Checks throttle position
malfunctioning in the EM 2000 display.
of
master If it shows "STOP”,
controller
change control stand
and work If the problem
is not rectified, check for
tightness of the couplers
543A, B,C in SH control
console.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
P a g e | 22
Items to be
Action to be taken by
checked
Loco Pilot
Check
MU If found pressed, RESET
stop button
it.
Note: In this case, computer shall display
"MU STOP REQUEST”
Check tighten- If the lay shaft is not
ess of rack by moving at all, or is tight.
physically
Try to re-crank the loco
moving
lay and Clear the section.
shaft
Note: If rack stuck up, EM 2000 shall
display the message "GTO POWER
SUPPLY 1 UNDER VOLTAGE" AND
"GTO POWER SUPPLY 2 UNDER
VOLTAGE",”ENGINESPEED FAILURE"
AND "DC LINK UNDER VOLTAGE"
Check
for If return sight glass Is
bubbles
In having bubbles, tighten
return
sight the spin-on-filter and
glass, i.e., fuel strainer and re-crank the
sight
glass loco. If the bubbles are
nearer to the still present, try to clear
engine block section and ask relief
while priming. loco. If by pass sight
Also check for glass is full of oil & return
oil in by pass sight glass has no oil,
sight glass.
nothing can be done.
Demand for loco.
Check for red Inform shed and seek
LED indication advise
in PRG, PSM
modules
Check for red Inform shed and seek
indication
in advise
any of the EM
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.1
P a g e | 23
Fault
Items to be
Action to be taken by
checked
Loco Pilot
2000 modules
Check
for RESET slide switch and
tripping
of re-crank the locomotive.
slide switch for
fuel pump
Note: if any of the above problems are
noticed and engine is shutting down with
speed bogging down, disconnect the
AMPHENOL plug and try to re-crank, if
loco is not cranked after removal of
AMPHENOL plug, nothing can be done
and consult shed.
Reduced Check
for • Ensure tightness of
Power/
bubbles
in
filter, fuel. Strainer &
sight
fuel primary drain cock
power not return
coming
glass, i.e., fuel
should be in closed
as
per sight
glass
condition.
Notch
nearer to the • Ensure that minimum
engine
1500 liters of diesel is
available in tank.
Check
for • RESET radiator fan
breaker if provided.
radiator fans
not working
• Check for any visible
loose connection in
radiator fan circuit in
ECC3.
• Swap 010 1 and 3.
• Radiator fan fuse might
have blown, nothing
can be done, work in
lower notches if the
train
load
permits,
Inform Shed
Note: If radiator fans are not working, EM
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
P a g e | 24
Items to be
Action to be taken by
checked
Loco Pilot
2000 shall display "REDUCED POWER –
THROTTLE 6 LIMIT
Check for TCC Work in lower notches if
over
possible; else wait for a
temperature
while and allow TCC
temp.to come down,
and then work further.
If the message appears
only in one TCC, that
particular TCC can be
isolated, if the train load
permit
Check for
Work in lower notches if
Traction Motor possible; wait to cool
over
down Traction Motors,
temperature
and then start again.
Note: In case of TCC over temperature
and TM over temperature, message shall
be logged in EM 2000 showing
"REDUCED
POWER
TCC
OVER
TEMPERATURE" or REDUCED POWER
HOT TRACTION MOTOR"
Check
for If EM 2000 does not
throttle
display the same throttle
position in EM position as the actual
If EM 2000
throttle position, change
the control stand and
work further.
Check
for Ensure
tightness
of
speed
and AMPHENOL plug of
power
Governor. If the problem
fluctuation.
persists, seek advice
from shed.
Note: Full ENG HP will not be achieved at
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.2
Fault
Tractive
effort
meter not
respondin
g
(Load
meter is
not
respondin
g)
P a g e | 25
Items to be
Action to be taken by
checked
Loco Pilot
Lower speeds since load regulation is
based on Tractive Effort. Full HP will be
achieved at about 25 KMPH.
Check
PCS Recover PCS as per the
knocked out
message displayed in
EM 2000
Check
for Tighten the AMPHENOL
governor
plug
AMPHENOL
plug tightness
Check Engine Switch on the engine run
Run
Switch switch (It should be UP)
position
Check
for If TH position is not in
throttle
actual throttle position,
position in EM change the control stand
2000 display
and work further.
Check
Tighten the couplers in
couplers
control stand.
543A. B & C
tightness
Check for DIO Swap DIO cards 1, & 3
card
failure or 2 & 3. If the problem
(there will be sets right work further;
no indication else seek advice from
In EM 2000)
the shed.
Check
for Ensure free movement
locked
axle of that particular axle
message
in physically. If the wheel is
EM
2000 rotating freely, disable
display
the
speed
sensor
through EM 2000 and
work further.
Check
for Check AG drive shaft is
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
Items to be
checked
message "NO
COMPANION
ALTERNATOR
OUTPUT-NO
AUXILIARY
GENERATOR
OUTPUT"
Check for AG
field/ feedback
breaker
tripping
in
panel.
Check for AG
circuit breaker
in ECC2.
P a g e | 26
Action to be taken by
Loco Pilot
intact. If shaft is broken,
Inform Shed.
DVR may be defective,
nothing can be done and
ask for relief locomotive
& INFORM SHED.
If tripped, RESET and
work further.
a. If tripped RESET and
work further.
Check
for Keep in ON position
position
of (UP)
isolation
switch
Check
for Put in ON Position (UP)
position of GF
switch.
Check for GF Put in ON Position (UP)
breaker
Check
for Act according to the
crew message crew message
Check
for If OPMODE does not
reverser Input show PROP, change
in power data control stand
in
data
meters. This
will be shown
"PROP"
in
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
2.3
Ground
Relay
Tripping
2.4
TCC
related
problems
Items to be
checked
OPMODE'.
Check
crew
message. If it
shows
“GRPOWER”
P a g e | 27
Action to be taken by
Loco Pilot
Isolate TMS one by one
& locate in which TM GR
is tripping.TM causing
GR tripping may be
isolated & work further.
If the crew Isolate DB by DB slide
message
switch
provided
in
shows
“GR- engine control panel and
DB,
Load work further.
Test”
Check
crew It
causes
automatic
message. TCC reset of TCC & Loco
internal
Pilot need not do
anything. Loco can work
RESET……
further
without
any
problem.
TCC commun- Recycle that particular
-ication
link TCC computer breaker
failure.
along with EM 2000
TCC failed to computer breaker.
acknowledge
DB request.
TCC failed to
acknowledge
LOAD request.
TCC failed to
acknowledge
DIRECTION
request.
TCC internal Nothing is required to
RESET-No
be done and train will
Speed
work normally.
detectable
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
2.5
Locked
wheelspeed
sensor
fault
2.6
TCC
Blower
contactor
problem
P a g e | 28
Items to be
checked
TCC # lock out
………
Action to be taken by
Loco Pilot
Recycle
the
TCC
computer breaker. If the
message
disappears,
work further. If the
message continues to
appear,
isolate
the
particular truck, if the
train loads permits.
Verify
free If it freely rotates,
rotation of the disable that particular
wheel
by speed sensor and work
moving loco.
further
Note: If the message does not disappear
even after disabling the speed sensor,
dis-engage the speed sensor connector
on the TM. After disabling the speed
sensor computer will show "TCC# n
speed sensor disabled for locked wheel
detection. Ignore the message & work
further.
In case for any reasons, recycling of
computers is done, speed sensor
becomes enabled automatically. Hence it
is required to be disabled again after
recycling.
Also the speeds of Traction Motors in
terms of RPM can be checked in ” Speed
Meter” screen in data meters. There
should not be any abnormal variation.
Check crew Check for tripping of TCC
messagecomputer breaker or TCC
Reduced
blower breaker. If tripped,
Load TCC#n RESET.
blower
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.7
Fault
Items to be
checked
breaker/
computer
breaker is not
closed.
If
blower
breaker
is
repeatedly
tripping
TCC#n
blower
contactor
failed to pick
up
Experienc Check
for
eing
speed sensor
Jerks
fault on EM
In under- 2000 display
truck
TCCproblem,
indicated in
EM2000
screen.
Select creep
control
in
data meters
and check for
the value of
Trouble Shooting Guide for WDP4/WDG4 locos
P a g e | 29
Action to be taken by
Loco Pilot
Open the circuit breaker
panel and by pass the
feedback interlock wires
(Wire Nos. MULA7 &
MULAX
for
TCC1,
MULB7 & MULBX for
TCC2). The wires are to
be removed from the
interlock terminals and
joined
together
&
insulated. Inform shed.
Isolate that particular
truck and work further. If
the load does not permit
to work on single truck,
contact the shed.
Isolate defective speed
sensor duly ensuring free
rotation of the wheel and
work further.
Isolate that particular
truck as indicated in EM
2000 display screen &
work further.
Check for cleanliness of
Radar face plate. If it is
dirty clean ft. Also check
for
tightness
and
intactness of the Radar
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
P a g e | 30
Items to be
checked
N+dN during
run.
If
it
indicates
3600 on free
run.
Check
for
proper
working
of
sanders
Check
for
Traction
Motor cables
in the under
gear.
Jerk during
DB.
2.8
Digital
input
system
Check
crew
message
for
-
Trouble Shooting Guide for WDP4/WDG4 locos
Action to be taken by
Loco Pilot
cable and plug.
If sand is not coming,
check for availability of
.sand in sand boxes. If is
sand is available in the,
boxes, close the nozzle
by hand' and operate the
sander manually to clear
any blockage and ensure
free flow of sand.
If any of the cable is
found
cut
or
dis
connected, disable that
particular truck and work
further - INFORM SHED.
Stop the locomotive,
select DB in data meters
and
check
uniform
increase
of
TL24T
voltage from 0 to 74.
Volt, as the throttle
handle is moved in DB
zone from set up to 8111
notch. If it is not uniform
& it suddenly increases
to maximum voltage,
isolate DB and work.
Swap DIOs 1 or 2 with 3
duly
putting
OFF
computer breaker and
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.9
Fault
P a g e | 31
Items to be
checked
failure
Digital input
system
failure. check
mux circuit.
Air brake Check for crew
system
messageproblems Communicatio
n link failure
MAB.
Action to be taken by
Loco Pilot
ensure usage of anti
static wrist band.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
Recycle micro air brake &
computer
control
breakers
Check for tightness of
COM card of EM 2000
Check for tightness of
CPZ card in CCB system.
Check for tightness of
VCU connectors and CRJ
connector.
Air
brake INFORM SHED and work
failure-use
further.
loco in LEAD
only.
Air
brake Check for availability of
failure - use MR pressure. If available,
loco in TRAIL recycle micro air brake
only
and computer control
breakers - conduct air
brake self test. If MR
pressure is not available,
consult shed.
Air brake fault Check for tightness of
– BC control EPA2 front connector and
failure.
conduct air brake self
test.
Air brake fault Check for tightness of
– BP control EPA1 front connector and
failure.
conduct air brake self
test.
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
Items to be
checked
Air brake fault
–BC
equalizing
control
failure.
No blended
brake – Lock
out.
2.10
MR
Pressure
dropping
on Run
Loco Brake
not releasing
Check for any
external
leakage in air
flow indicator.
Check
for
unusual
sound from
compressor
valves
Check
for
normal
operation of
air dryer.
Trouble Shooting Guide for WDP4/WDG4 locos
P a g e | 32
Action to be taken by
Loco Pilot
Check for tightness of
EPA3 front connector and
conduct air brake self
test.
Check for tightness of BC
equalizing
valve
connector.
Conduct blended brake
self test. Even if it does
not pass, work further
and INFORMED SHED.
Conduct self test
Arrest the leakage
CONSULT SHED.
If it is continuously
purging – put OFF air
dryer breaker and work
further -INFORM SHED.
If after putting OFF AD
breaker
also,
it
is
continuously
purging,
shut down loco. Drain
MR1 and plug the
defective purge valve
using a coin and then recrank the loco.
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.11
P a g e | 33
Fault
Items to be
Action to be taken by
checked
Loco Pilot
Check ABD Bring the plunger in
valve working manual position and drain
continuously. MR manual at every train
stoppage.
Pneumatic
Close the cut out cock
pipe
and drain moisture from
connecting
test plug. Open the cut
MRPT
in out cock and again give
compressor
blow down. Finally open
compartment cut out cock and work
may
be further.
clogged with
moisture.
Any sanders Close MR1 cut out cock
working
and drain out trapped
continuously
pressure through MR1 J
Any
horns filter. Open MR1 cut out
cock and work further.
working
continuously
Simultane Check
for Check for position of
ous
crew
reverse handle in control
Forward / message -No stand. Also check for
Reverse
load
reverser input in program
request
simultaneous meter or in power data. In
Forward
/ power data, the reverser
Reverse
input is indicated as
request with OPMODE - PROP When
alarm
it is in Forward or
Reverse.
Keep
the
reverser in neutral and
see that reverser input
will show Idle and in
program meter RHSF &
RHSR shall show OFF. If
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.12
2.13
Fault
P a g e | 34
Items to be
checked
Action to be taken by
Loco Pilot
it is not so, operate the
reverser
handle
in
Forward
/
Reverse
directions till such time it
correctly shows.
Note: When Reverser is in centre, RHSF
& RHSF will show "OFF" in program
meter 8S soon as it is in Forward RHSF
will be "ON" &RHSR will be "OFF". If
reverse is kept in Reverse, then "RHSF
will be "OFF" and RHSR will show "ON".
Simultane Check
for Check throttles position in
ously
crew
EM 2000. It should show
power
message
– Idle whenever throttle is
No
load kept in Idle. If it is not SO,
/DB
simultaneous operate the throttle in
request
both the control stands
power/DB
request.
and see that throttle
position comes to idle. If
it does not set take
throttle in DB zone and
again bring to Idle. Check
throttle position on both
the controllers In Idle.
Head light Check
for If one bulb is fused.
not
working
of INFORM SHED and work
working
both
the If both the bulbs are not
bulbs.
glowing in Long hood
side, check the tightness
of 623C, 823D plugs in
ECC3.
If both the bulbs on Short
hood
side
are
not
working, check for any
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.14
2.15
2.16
2.17
Fault
Items to be
checked
Flasher
Check
for
light not flasher light
working
switch
position.
It
should
be
ON. Also all
the breakers
in
breaker
panel should
be ON
Flasher
light
working
continuously
P a g e | 35
Action to be taken by
Loco Pilot
loose cable connection in
head light dim resistance
inside ECC1 top right
comer.
If the breakers are ON,
and problem persists,
Swap 010 1 & 3 and
check for the entire
flasher switches in 'ON'
position In both the
control stands.
Check for flasher working
by applying emergency
brake. If flashers are
working, start train.
If they are in ON position,
put OFF the switches.
If the switches are in OFF
& problem persists, Swap
DIO3 with1
Check for the
flasher switch
position
in
both
the
control
stands.
Check
for Recover PCS
PCS knocked
out.
White
Checks lube If lube oil level is
smoke in oil level.
increased, consult shed.
exhaust
Water
Check for any Open Pressure relief
level
external
valve by pulling the
reducing leakages.
handle and tie it. Clear
the section and consult
shed.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
2.18
Fault
Engine is
not
cranking
P a g e | 36
Items to be
checked
Action to be taken by
Loco Pilot
1.No Fuel oil
1.Check fuel oil level
2.No Lube oil
2.Check lube oil level
3.No water
3.Check water level
4. Gov. LLOB 4.Reset it if tripped
may be in
tripped
condition
5.OSTA may
be tripped
6. Low water
switch button &
crank
case
pressure
button of EPD
may
be
tripped.
7. Battery knife
switch may be
open
or
starting
fuse
glown up.
8. EFCO may
be in pressed
condition.
9. MUSD may
be in pressed
condition.
10.Fuel pump
and
switch
may be in off
condition
11.
Circuit
breaker
on
control circuit
panel may be
in off position.
12.
Engine
Trouble Shooting Guide for WDP4/WDG4 locos
5.Reset it if tripped
6.Reset if tripped
7. Check battery knife
switch
8.Check EFCO
9.Check MUSD
10. Check fuel pump and
switch
11.
Check
breakers
circuit
12.Put ECS on Idle
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
S
No
Fault
Items to be
checked
isolation switch
may be in RUN
position
13. Improper
sequence
of
switches
in
working & non
working control
stand
2.19 Throttle
not
respondi
ng
1.Check
isolation
switch in run
position
2. any one
control circuit
breaker may
be tripped
3. Check PCS
may
be
knocked off
4. Check WW
Gov.LLOB
5.
After
putting ONTLPR & main
control circuit
breaker, wailt
for
35
minutes.
2.20 Engine
1. Check
cranking
starting
but not
motor, gear
starting
may
be
Trouble Shooting Guide for WDP4/WDG4 locos
P a g e | 37
Action to be taken by
Loco Pilot
13.Check sequence
1.Put it on RUN
2. Reset it if tripped
3.Check it
4.Reset LLOB if tripped
5.Ensure the same
1.Check motor
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
slipped
2. TLPR
in
ON
condition
2.21 PCS
Knockin
g off
P a g e | 38
Check TLPR
1.L/T
switch 1.Check position
may be in
wrong position
2.
Control 2.Put them in correct
stand A-9 & position
SA-9,
Reverser
&
throttle
may
not
be
in
correct
position
2.22 Continuo 1.Recycle
us wheel TCC1or TCC2
slip
circuit breaker
2.If
required
isolate
TCC1or TCC2
alongwith
ACGTO1&
ACGTO2
3.After
isolation
for
goods
train
work with 60%
load
4.If wheel slip
indication
flashing,
it
means there is
Trouble Shooting Guide for WDP4/WDG4 locos
1. Follow
procedure
recycling
2.Isolate TCC1 or TCC2
if required
3.Follow the instructions
4. Check
indication
accordingly
wheel
and
slip
act
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 39
a possibility of
slipped
pinion,comput
er will detect
concerned
traction motor
2.23 AIR BRAKE TROUBLE SHOOTING
SNo.
Defect
Action to be taken by Loco Pilot
1.
MR Pressure 1.Check air leakages from FP,BP,
Dropping
BC, Auto Drain, Air Dryer, Radar
Blow, Sanders & cooling coils
2.After attending ensure engine
RPM coming to idle (During air
leakages, engine RPM will
increase due to AIR Compressor
operation)
3.If Air dryer purge valve, or drain
valves are blowing continuously it
may be plugged with a threaded
plugged.
4.If MR1 and MR2 ABD (Auto blow
down) valves are blowing then
close ABD valves to manual side
2.
Unusual
1.Check for correct compressor oil
sound from
level if found less than low mark
compressor
shut down the loco & inform shed
2.If any unusual sound from LP &
HP cylinder, inter coolers and
safety valve or any air leakage
inform shed to confirm whether to
continue working or not.
3.
Improper
1. Close MR1 ‘J’ filter COC and
loading and
drain out the trapped moisture in
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 40
unloading of
air
compressor
4.
MR1 system, when MR safety
valve starts blowing keep MRI
COC to normal open position.
2.Close MRPT COC drain and
trapped moisture by pressing the
spring loaded MRPT quick
connector stem, ensure increase
in ENG RPM with blowing of MR
safety valve and then close MRPT
COC to normal open position.
3.If the trouble still continues close
MRPT COC and take advice from
shed for further movement.
4.Recycle computer control circuit
breaker the trouble very set right.
5.MVCC struck up, Improper
loading. Press and release the ‘T’
handle on the MVCC unit.
BP dropping 1.Check AIR FLOW indication for
and PCs
needle shooting.
Knocking
2.Check the leakages on the
out
formation and arrest the same.
3.Check for any air leakage from
both control stands. This may be
due to stuck up A9 or Fireman
Emergency air valves.
4.If A9 emergency valve in stuck up
in open position, throw A9 handle
to emergency sharply 2 or 3 times
& then bring to Run position to
RESET.
5.If A9 emergency valve air leakage
still continues. Dummy the air
passage with dummy cap of BC
equalizing pipe.
6.Check if AEB circuit breaker in
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
5
Air brake
failure with
crew
message
Air brake
failure use
loco in trail
only
P a g e | 41
wrongly put ON
1.Recycle MICRO AIR BRAKE.
2.Conduct Air Brake self test
3.If problem still continues, apply
hand brake provide skids shut
down loco and drain MR1 and
MR2 completely close COCs
properly. crank the loco again and
conduct self test.
4.If no further improvement use this
loco as an MU trailing unit taking
full power of the loco.
5.Open CCB cover & inform shed
the fault code number on display
screen of CCB for further action.
Note: At time SELF TEST may fail but Air Brake system
works normally. In such case give message and work up to
destination.
2.24 AIR BRAKE SYSTEM-TROUBLE SHOOTING IN
GHAT
SNo.
1.
2.
Cause/Defect
MR
pressure
dropping with EM
2000-Crew message
“LOW
MAIN
RESERVOIR
EQUALISING
PRESSURE USE
LOCO IN TRAIL
ONLY” FC 2977 in
lead working loco.
If
MR
pressure
dropping other than
LEADING loco.
Remedial action
If unable to attend. Close
MREQ COC in both LEAD
and TRAIL loco MU end.
Keep LEAD TRAIL switch in
lead loco from LEAD mode
to TRAIL mode, and keep
TRAILING loco TRAIL mode
to LEAD mode.
The loco where the MR is
dropping both end
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 42
MREQ COC to be closed.
3.
BC EQ –Hose pipe Close the BCEQ COC in
burst causing MR both end of the MU coupled
pressure dropping.
locos. The TRAILING loco
4.
“AIR
BRAKE
FAILURE
USE
LOCOMOTIVE
IN
TRAIL ONLY” FC
2975 in LEAD /
HLPR
loco
if
experienced with BP
leaking.
5
Air brake failure
other than LEAD /
HLPR mode locos in
MU’s (or) TLC.
6.
Air brake failure in
the MU HLPR mode
loco(down the ghat)
(or) TLC (up the
ghat)
7.
Air brake penalty
not getting reset
even after keeping
auto brake handle
10 seconds in FS or
60
seconds
in
emergency position.
which is disconnected from
BCEQ towards the train end
LEAD TRAIL switch to be
moved from TRAIL mode to
HLPR mode.
Keep LT
switch
from
LEAD/HLPR mode to TRAIL
mode and keep TRAILING
loco LEAD TRAIL switch
from
TRAIL
mode
to
LEAD/HLPR mode duly
ISOLATING BP TO LEAD
loco to avoid BP leaking
Permitted
to
work
continuously from LEAD/
HLPR loco. Whenever the
failed loco required working
LEAD/HLPR AB self test to
be conducted to clear the
fault.
Keep L/T switch from HLPR
mode to TRAIL mode and
keep L/T switch in MU/TLC
loco from TRAIL mode to
HLPR mode.
Keep auto brake handle in
run position and keep L/T
switch from LEAD mode to
TRAIL mode for 10 seconds
again keep from TRAIL
mode to LEAD mode. If
problem still exists recycle
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
8
At any situation 2
control stands in
one MU consist the
L/T switch should
not be kept in
LEAD/HLPR MODE
9
To
make
LEAD
MODE MU consists
to
couple
with
another MU consist
any one control
stand to be kept in
HLPR MODE only
P a g e | 43
MICRO
AIR
BRAKE
BREAKER with COMPUTER
CONTROL BREAKER.
If both control stands L/T
switch by mistake happened
in LEAD/HLPR MODE then
A/B self test to be conducted
to clear the fault to work in
LEAD/ HLPR
BCEQ pipe should not be
connected between LEAD
MODE MU/TLC and HLPR
MODE MU/TLC.
2.25. IMPORTANT DO’s AND DONT’s FOR LOCO
PILOTS & SHED MAINTENANCE STAFF
DO’s
1 DO-Let the locomotive warm up properly to the
desired temperature of 125ºF(55ºC) before
attempting to move the locomotive. (The locomotive
raises engine speed to 3rd notch RPM automatically
till the temperature is obtained).
2 DO-Ensure cranking of the locomotive at least once
in 24 hours to make sure that there is no hydraulic
lock up if the engine has not been cranked for more
than 24 hours by barring the crankshaft manually.
3 DO-Ensure pre-lubrication of the engine (to be done
by maintenance staff) if the engine has not been
cranked for more than 48 hours.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
4
P a g e | 44
DO- Follow correct cranking and shut
procedures to enhance engine and turbo life.
down
5 DO- Ensure all brakes are released properly before
moving the locomotive.
Dont’s
1 DON’T – Raise the engine beyond 4th notch without
load.
2 DON’T– Spill tea / coffee or other eatables on control
stand or cab. (The sensitive air brake equipment in
control stand and air brake compartment may
malfunction)
3 DON’T– Permit incorrect lube oil, governor oil or
coolant water to be added in the locomotive.
4. DON’T- Permit bad quality sand or wet sand to be
added in the sand boxes.
5. DON’T– Stable the locomotive without applying the
hand brake.
6. DON’T– Move your train unless you physically check
that the brakes are active.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 45
C- CHAPTER – 3
TROUBLESHOOTING BY SHED MAINTENANCE STAFF
3.0 GROUND RELAY
1. If the message of Ground Relay tripping experienced,
confirm fault is in Power or Dynamic Braking mode. If
fault recorded as ‘Ground Relay’ in Power mode, first
isolate the Trucks one by one to confirm the Faulty
truck and disable faulty truck.
- Ground Relay Power:
2. To start with, conduct Excitation Test. If GR trips
check TA for failed Diodes & Fuses, spring loaded
indicator in “Popped out” condition indicates a failed
fuse indicating the failed diode connected to the fuse.
3. Check MGTB for cracks, melted connections, wire
rubbing with covers.
4. Check AC cables for insulation damage below
MGTB.
5. Check surge suppression Resistor for damage,
capacitors for grounding, bulging, leakage etc.
6. Check cabling up to ECC1, & high voltage areas
(Red painted) inside ECC1.
7. Check GRT,T2 & phase imbalance circuit resistor &
diodes. Conduct load test & verify is GR operating.
8. Check Traction motor cabling for any damage of
insulation; mostly at the cleats where car body
cables and motor cables are joined and secured
inside umbrella boot. Release both Top & Bottom
cleats, check for damaged insulation, carbon
deposits etc.,
9. Check Traction Motor cable supporting cleats for any
flash marks/ burnt marks and insulate with high
voltage insulation tape.
10. Check TCC outgoing Terminal post cable connection
for burnt connections and touching to body.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 46
11. Check Traction Motor by removing inspection cover
of the motor for any metal pieces - usually, flash
marks in the stator windings, molten copper pieces,
broken bellow pieces, damaged rotor bar end rings
etc.,
12. Check Damping Resistor cables & IPR cables inside
the central air compartment (Gen. room) particularly
where it is tied with the looming bar. IPR bus bars
should not be rubbing with Mica insulator which can
cause GR to trip. Ensure that there is no tracking
above insulator.
13. Check for water falling over IPR1 from top hood.
14. ECC2 should be free of water & dust.
15. Check visually any insulation damages and
Grounding of cables in ECC2, ‘62A Terminal Board’
and decoupling reactor.
16. Check back side clearance for DCL reactor it should
be more than 5 mm.
17. Check 3G2A plug connections and Pins for proper
locking and for proper harness. Check for any flash
marks inside the plug.
18. Check the L1,2,3 reactor inside inverter cabinets
supporting insulator for breakages. If again GR Trips
measure IR of power circuit.
3.1 GROUND RELAY DYNAMIC BRAKE, LOAD TEST
1. For “Ground Relay Dynamic Brake, Load test”,
Check all Grids for Flash marks near ribbon element
or any damage to the insulator.
2. Check for any foreign metal pieces, which are
connecting element to Ground.
3. Inspect for water entry inside the DB motor (Grid
Blower Motor) through the top bolts of blower.
4. Check both Grid Blower Motors for flash marks on
Terminal connections, commutator marks & heavy
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 47
carbonization, Hanging of Brushes, damaged
winding and internal cabling.
5. Check Grids ribbon holding insulators at the Top &
Bottom for Flash marks, tracking, cracks etc,
` Note: If Grounding Problem is experienced in
Dynamic Brake mode only & unable to find the cause
enroute, Dynamic Brake function can be disabled by
Dynamic Brake cut out switch provided in ENG
control panel. Loco will work Normal in Power but no
Dynamic Brake is available.
3.2 NO DYNAMIC BRAKE (OR) LOAD TEST, GRID
RESISTANCE PATH 1 (OR) 2 ARE TOO LOW:
1. Observe DCLV Feedback on EM 2000 screen while
conducting Load test, if it changes according to
notches, it is OK, if not, check REVDCL continuity
and Resistance value (200 K ohms+/-2%).
2. Check VDCL connections continuity from “B1 and B2
Grid contactors” through REVDCL and connections
at VDCL (RD, WH, BK).
3. Check VDCL transducer if faulty Renew.
4. Check VDCL connector at “PDP” plug, connectors
connecting the “ADA” module, at the rear side of EM
2000 chassis. Replace ADA module.
5. Check Gen field winding for open circuit, worn out
brushes, damaged springs.
6. Check for defective GFC or GFD contactors.
3.3 NO DYNAMIC BRAKE (OR) LOAD TEST – GRID
RESISTANCE PATH 1 (OR) 2 IS TOO HIGH :
1. Check REVDCL for continuity and for Resistance
value 200 K ohms +/-2% and VDCl connections.
2. Check “Grid 1A & Grid 2A” current transducer
feedback while conducting Load test. It should not be
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 48
‘Zero’ (or) -ve value, if so, check current transducer
of faulty path and the connector in “PDP plug”.
3. Check “ITCC current transducer” feedback while
locomotive loading, it should not be Zero (or) -ve, if
so check “ITCC transducer connections (RD, BK &
WH)” and connector at “PDP plug”.
4. Check all the grids for open or burnt connections and
resistor ribbon element for open circuit.
3.4 LOCKED WHEEL (OR) SPEED SENSOR FAULT:
(In case of accompanying the loco or receiving
message from line)
1. Stop train and verify for free rotation of wheels.
2. Select “speed meter screen” from EM 2000 and
observe TMs feedbacks by moving locomotive. All
TM RPMs should be in same direction and values
are to be near equal.
3. If any one of the sensor feedback is less than the
others (or) Zero; Check for unusual sounds from
wheel axle bearing, motor & Gear case and ensure
free rotation of wheel.
4. If wheel is rotating freely, Check “speed sensor plug”
pins for pushback and for any damage to insulation.
5. Check ‘X’ plug (XA, XB & XC) connections of faulty
speed sensor.
6. If it is speed sensor fault, which cannot be attended
enroute, disable speed sensor feedback in EM 2000
computer by selecting “Lock wheel detect” in Main
menu. If possible disconnect the defective speed
sensor plug from its position (located at the top of the
Traction Motor). Secure the plug properly.
7. If any of the TCC cards C075, C083, G059 & G067
are found to be faulty, replace faulty TCC card.
If TM1 & TM2 or TM4 & TM5 speed sensor feedback
is wrong, then G059 or C075 may be defective. One
by one, the defective card is required to be identified.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 49
If TM3 or TM6 speed sensor feedback is wrong, then
replace G067 or C083 card.
8. Conduct stall test and observe speed meter screen
to check TM RPM are Zero. If any of the Motor is
showing speed and the locomotive is standstill, it can
be case of slipped or broken pinion.
9. Ensure No hand brake application and brake cylinder
are releasing fully.
3.5 SPEED SENSOR DISABLING PROCEDURE
1. Select main menu on computer display.
2. Take cursor to lock wheel detect and select.
3. Take cursor to the axle which is to be disabled and
press disable.
4. Crew message appears for correct disabling.
Note: Whenever computer control breaker is
recycled it
is necessary. Follow the above
procedure again.
3.6 CUTTING OUT TRUCKS
1. Press main menu on computer display.
2. Take cursor to traction cutout and select.
3. Disable the required truck.
Note: Keep isolation switch in isolate, throttle in idle
and reverser center before cutting out truck.
3.7 COMPUTER TURNED OFF OR RESET WHILE
REVERSOR IS NOT CENTERED (OR) COMPUTER IS
LOADING:
1. Ensure power supply modules are functioning
properly. (PRG, PSM 300, PSM 310 & PSM 320)
from its ‘GREEN’ indication on face plate of module.
2. Check for PRG connection plug (Back panel to
power supply chassis) loose connection (or) poor
locking of pins.
3. Check for flat Ribbon cable which carries +5V &+/12V power supply to EM 2000 chassis from power
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 50
supply charries for rubbing to metal body insulation
damage & improper locking etc.
4. Check for any overloading of power supply module
PSM 320 by opening plugs of ‘BAROMETER’
‘RADAR’ unit and MRPT With this, the red LED fault
signal should go off and Green LED signal should
glow. Under such circumstances, that particular
component can be assumed as faulty. If the Red
Light signal is still ON, then PSM is defective.
5. Check Computer control breaker connections.
3.8 TCC # GTO POWER SUPPLY UNDER VOLTAGE OR
NO AUX. GEN OUTPUT:
1. Is GTO power supply under voltage recorded in both
TCC’s at same time. If yes;
2. Check Aux. Gen output. FCD Green LED Indication
should be ON.
3. Check Aux. Gen drive shaft and coupling for any
damage.
4. Check Battery charger assembly and Aux. Gen
output
breaker position and for any loose
connections.
5. Confirm “PS GTO output OK (Green LED in on
condition).
6. Check DVR plug connection and change DVR
module if malfunctioning.
7. Check Aux. Gen field & Diode rectifier for bad
soldering and burnt diode plate etc,
8. ECC1 back panel “33C TB connections” and “3G2A
plug connector” for loose connections or burnt plug.
9. Check all X-Plugs for pushed back pins melted pins
and damaged wire loop inside the X-plugs.
10. Check ‘RE AG FLD’ connections & the Resistance.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 51
11. If the problem is in only one TCC, check GTO power
supply circuit breaker, GTO PS unit, connectors, XPlugs and TCC cards of that TCC.
12. Check AUX. GEN field & feedback breaker &
connections
3.9 NO COMPANION ALTERNATOR OUTPUT
CHECK AUXGEN FIELD BREAKER :
1. Check any additional Message like “NO AUX. GEN
OUT PUT- Check Aux. Gen. Field breaker” is
figuring. If ‘Yes’ follow Trouble shooting procedure
for No. Aux. Gen output.
2. Programme ‘CAV’ and ‘CA full’ in computer & 116
check for a minimum of 40 volts and 26 Hz in idle
condition.
3. With millimeter, check the Companion Alternator
output at test points in Circuit Breaker panel & at Bus
bars in ECC3 cabinet.
4. Shut down engine and check Companion Alternator
slip rings, brushes, connections, springs etc., for
scoring, condemned brushes, broken connections
etc.,
5. Open Companion Alternator output Terminal Board
cover and check for any loose connection, burnt
terminals etc.,
6. Check connections near Bus bar inside ECC1, GF
Breaker, AC control Breaker.
7. Check CA field connections inside ECC2 & at MGTB.
8. Change FCF Module and then CPU.
9. Check CA field winding resistance.
3.10 DC LINK UNDER VOLTAGE PROBLEMS:
1. Check ENG rpm feedback as per throttle position in
Load Test.
2. Conduct Excitation Test.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 52
3. Programme DCLV, T1 DCLV & T2 DCLV in
programme meter and conduct stall test. All the three
should be near equal.
4. If anyone is Zero or less, It’s circuit is required to be
checked by qualifying Wiring, Resistance value,
transducer, connectors and the feedback module.
5. If DCLV is at fault check ‘REVDCL’ VDCL transducer
and ADA card 6. Check VDCL plug at PDP.
7. Conduct excitation self test and attend if test fails.
8. Check GF breaker - If tripped, the following aspects
are to be checked:a) Current transducer (IMGF) may be at fault.
b) GF contactor may be defective.
c) Governor may be defective as its Load regulator is
not functioning.
d) Breaker itself is defective.
9. Check for radar feedback problems.
10. If fault is in DB, check DB gride.
11. Check for ground relay tripping faults.
3.11 DC LINK OVERVOLTAGE FAULTS :
1. Check Eng rpm is as per notch position.
2. Conduct excitation test.
3. Check speed sensors feedback and fluctuation.
4. Check radar functioning.
5. If fault is only in DB check DB gride and motor.
6. Check sanders and direction of operation.
7. Check REVDCL, VDCL,ADA and associated wiring.
8. Check TA bearing and alignment with engine.
If fault is in only one TCC
a) Check TCC voltage transducer
b) Gate units
c) Output voltage and current transducers
3.12 EXCITATION TEST FAILING:
1. Check GF breaker and correct 3 phase supply from
comp. Alternator.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 53
2. Check GFC, GFD and IMGF.
3. Check FCF, FCD, ADA and FC distribution box.
4. Check SCR bridge for loose diode connections
shorted diodes or SCRS.
5. Check MA slip rings brushes and field connections
and resistance.
6. Check for correct phase rotation and gating signals.
3.13 LOW HORSE POWER PROBLEMS
1. WDG4/WDP4 locos will achieve full horse power
only above 25 KMPH.
2. At Eng temp above 95 C the HP starts dropping
gradually and at 100 C it drops to 6 th notch HP.
Check Radiator fan working and check for tripped
circuit breaker/blown out fuses inside ECC3 cabinet.
3. Check Engine Air filter dirty message is active isolate
EFS and FVS switch inside ECC1. Ensure baggy
filter are not cyclonic filter are not clogged and dust
bin blower is working OK.
4. Ensure both truck are in enabled condition & are
working.
5. Check for TCC over temp or hot traction motor fault.
Allow TCC/TM to cool down by raising engine rpm
with reverser center.
6. Check for radar malfunctioning sanders not
operating.
7. Check bar pressure feedback, it should be above 90
on computer display.
3.14 AUTOMATIC SHUTTING DOWN OF THE
LOCOMOTIVE
1. Check for controller feedbacks in EM 2000 screen by
programming required parameters.
2. Check supply to governor Amphenol plug.
3.15 ENGINE SPEED FAILURE:
1. Conduct Load test and Ensure Eng rpm is as per
throttle position.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 54
2. Program EPU rpm & Engine rpm and ensure both
are same.
3. Check “FCF Module”, “ADA” and “CPU”.
4. Check governor amphenol plug.
5. Check companion alternator output AC control
breaker.
6. Check proper fuel supply to engine/fuel system.
7. Check stuck up racks.
8. Check the function of turbo clutch.
9. Check governor. Check fuel oil return sight glass for
bubbles in load test ‘TH 8’
3.16 TCC # 1 or 2 communication link failure:
1. Keep throttle in idle, reverser in centre, and isolation
with in isolate position.
2. Recycle the related TCC computer breaker and EM
2000 computer breakerfaulty TCC
and check
front plug and connections of C003 card and change
C003 card if faulty.
4. Ensure communication wires continuity from C003
front plug thought XD plug to 10A and 10B
connections to COM card and Signal Distribution
BOX.
3.17 Procedure for recycling of circuit breaker:
1. Stop the locomotive.
2. Secure the loco by
(i)
Apply SA9/hand brake.
(ii)
Keep throttle handle.
(iii)
Keep reverser neutral.
(iv)
Isolation switch on isolate.
(v)
ER off.
(vi)
GF off.
3. Switch off computer circuit breaker
4. Switch off concerned circuit breaker (TCC1, TCC2,
MAB, auxiliary generator, breakers etc.).
5. Wait for 20 to 30 seconds.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 55
6. Switch on concerned circuit breaker.
7. Switch on computer circuit breaker.
8. Recover air brake penalty by keeping A9 on FS for
10 seconds.
3.18 COMMUNICATION LINK FAILURE - MAB:
1. Recycle Micro ‘Air Brake’ and computer control
breaker by stopping train and keeping Isolation
switch to isolate position, Reverser in centre and
throttle in idle position.
2. Ensure continuity of communication cable from “CRJ
10 plug” to SIG Distribution Box through “314A plug”
(underneath DCL with gear). Ensure the tightness of
communication cable connector CRJ-10 with CRU
assembly through single white cable. (Location:
inside the driver cab near the CCB right hand bottom
corner)
3. If everything is OK, then change ‘COM’ card with
another Good ‘Com’ card. Keep computer control
breaker in OFF while changing the COM card and
put ON after changing.
4. If problem repeats renew CPZ card of CCB.
3.19 LOAD METER NOT RESPONDING:
1. Check for crew Message on EM 2000 screen and
attend accordingly.
2. Ensure “GF Req” input feedback ON while moving
throttle 1 through 8.
3. Ensure energizing of GFD and GFC contactor and
for input feedbacks to EM 2000 with isolation switch
in RUN and Reverser in either direction respectively.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 56
4. Check for MGFLDA current transducer feedback
from EM 2000 screen according to the notches.
5. Check “MGTB” for loose or open Traction Alternator
field connections.
6. Check slip ring brushes & Traction Alternator Field
coil connection brass bolts for any damage.
7. Check field coil Resistance & continuity.
8. Ensure VPC contactor has picked up.
9. Check MG Fld. Breaker position and ensure it is in
ON position.
10. Check LR% max. input in computer and it should be
100%. If less or Zero, fault could be with Governor,
Engine, and Fuel system.
11. Change ASC & ADA Module and see LR changes.
12. Check Governor Amphenol plug.
13. Ensure Eng rpm is raising according to throttle
position and governor request.
3.20 LOAD METER FLUCTUATIONS
1. Conduct Load Test and verify Horse power, Eng.
RPM & LR% are within the prescribed limit.
2. Check Crew message and Fault Archives for any
ACTIVE messages.
3. Conduct RADAR test and check Radar feedback
while moving with load.
T1+dN - Not to be 3600
T2+dN - Not to be 3600
and Radar status flag ‘O’ when speed is beyond
4KMPH,
4. Check for any wheel slipping.
5. Conduct Radiator Fan Self Test and Verify fan
rotation.
6. Check operation of Sanders and direction of
operation, it should match with that of the Reverser
direction.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 57
3.21 LOAD METER NOT RESPONDING BEYOND 1ST
NOTCH
1. Check for Amphenol plug of Governor for correct
locking. Open AMPHENOL plug (When reverser is in
centre and throttle in Idle, ENG isolation switch in
isolate position and Computer OFF)
2. Check Male & Female Pins of the plug and provide.
3. Check controller switches feedback and governor
valve operation according to notches.
4. Check power supply for Amphenol plug.
3.22 EXPERIENCING JERKS FROM TRUCKS
1. Observe speed sensor feedback of Traction Motor
from Speed Meter screen. If any of the speed sensor
direction is opposite change speed sensor if possible
or disable speed sensor and open plug at Traction
Motor and secure.
2. Check Radar feedback, conduct self test and check
sanders operation.
3. If jerks are experienced only in DB, check “TL 24T”
voltage feedback from controller, voltage should
gradually increase from ‘O’ volts to 72volts in steps
with DB handle position movement from setup to DB
8th position.
4. Check TCC#1(or) 2 outgoing connections for
slackness.
Note: Do not touch any power cable without following
discharging procedure (conduct DCL shorting test
and Isolate isolation switch).
5. Check all Traction Motor connections;
6. Check TCC down loads for GTO Monitoring or output
low frequency faults and act accordingly.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 58
3.23 HEADLIGHT PROBLEMS:
1. If only one headlight is not glowing first swap
connections of the fused H/L with that of other Good
Headlight, if problem is shifted to adjacent one, then
probably the headlight Resistor is defective; change
it. If the problem is not shifted to other headlight,
change fused lamp.
2. If both the headlights are not working from L/H side
first check 823-C plug in ECC3 compressor side for
any slackness of plug and melting of pins.
3. If plug is alright; trace out for supply to H/L
4. Check for switch problem and the breaker defect.
3.24 DIGITAL INPUT SYSTEM FAILURE:
1. Check in EM 2000 Main menu - Data meter screen
select multiplexer and see.
2. All MUXON should be ON. All MUX OFF should be
OFF. All MUXSEL should be ON. If anyone is not
correct, check that input.
3. Try out swapping DIO-1 with DIO-3 or DIO-2 with
DIO3.
4. Check for multiple low voltage grounds.
5. Check CMU, DIP and PD plugs.
3.25
FLASHER
LIGHT
NOT
CONTINUOUSLY WORKING:
WORKING
OR
1. Check Flasher switches are “ON Position” in control
stands.
2. All Breakers in “Circuit breaker” panel should be ON.
3. If both side not working, swap DIO-3 with any other
DIO.
4. Check Flasher light and wiring.
5. Check Flasher resistance.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 59
3.26 ENGINE NOT CRANKING:
1. Check Crew message.
2. Check LLOB button, OSTA, Low water & Low
crankcase buttons.
Note: Do not crank if low crank case button is in
tripped condition.
3. Check for Fuel pump running & clear fuel oil in return
sight glass.
4. Check Engine for free crankshaft rotation by barring
with crank over tool.
5. Check ST & STA operation in starting system menu
while cranking.
6. Check Battery voltage & measure voltage drop while
cranking. It should not drop below 25 volts.
7. Try changing out PRG module if computer goes
blank while cranking.
8. Check “knife switch” connections, contacts, starting
fuse and battery connections, starter motor
connections and ST contactor connections.
9. Check ST contactor tips by opening cover.
10. Ensure both start motors are engaging with ring gear
and cranking.
11. Check baggy filters and turbo.
3.27 FILTER BLOWER MOTOR BREAKER IS NOT
CLOSED:
1. Ensure filter blower motor breaker is closed if the
breaker is tripping.
2. Check and ensure proper locking of connector on the
filter blower motor.
3. Check for free rotation of impeller through inspection
window.
4. Check for any unusual sound (rubbing or hitting
sounds).
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 60
5. Check motor current with clamp meter for “Full load
current of the motor”. It should be max of 21 A@200
VAC.
6. Check for correct “Three phase supply” is available
at motor connector.
7. If not check “322A plug”, Filter blower circuit breaker
and proper companion Alternator output supply.
NOTE: Connector on the motor can be disconnected
and worked further after putting ON the breaker.
3.28 FUEL PUMP MOTOR BREAKER IS TRIPPING:
1. Check fuel pump motor current (Should not be more
than 10.1A @ 74 VDC)
2. Check for any unusual sound due to bearing seizure
or pump over loading. Check any shorting of input
supply cables inside the terminal box.
3. Check fuel pump inverter for internal failure.
3.29 NO GRID BLOWER MOTOR CURRENT OR GRID
BLOWER MOTOR CURRENT IS TOO HIGH :
1. Check DB motor supply connections at terminal
board (Both inside & outside). Check grid blower
motor connections tapping at DB grids.
2. Check carbon brush, brush holders and commutator
condition.
3. Check grid blower current transducer and feedback
plug in PDP.
4. Rotate DB motor fan by hand & see motor is rotating
freely and bearing is not seized.
NOTE: First visually check whether motor is working
(if rotating check feedbacks).
3.30 RADIATOR FAN MOTOR NOT WORKING
1. Conduct Fan Test and check for proper function of
contactors.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
2.
3.
4.
5.
P a g e | 61
Check continuity of Fan Fuses in ECC3 cabinet.
If Circuit breakers are provided reset if tripped.
Check Companion alternator output is available.
Check for “intactness” of supply cables inside ECC3
cabinet as well as motor side.
3.31 FUEL PUMP MOTOR IS NOT WORKING
1. Check whether fuel pump relay has picked up
(Ensure by seeing RED Flag indication in Relay unit
at Right top).
2. Check for 64/74VDC at fuel pump motor
Connections.
3. Check and ensure that FPR < ON & FPR > ON
signals from EM 2000 starting system menu.
4. Check & ensure that FP & control switch is ‘ON’ in
L/H C/S EFCO switch is Not in closed condition &
MU button Red colored ‘STOP’ button is not in
pressed condition.
5. Check Fuel pump inverter.
3.32 TURBO LUBE PUMP MOTOR IS NOT WORKING
1. Check for 64/74VDC supply available at TLPM
terminals.
2. Check for TLPR breaker and computer breaker are’
ON’.
3. Check the TLPR whether it is picking up or not.
4. Check TLPM brushes and springs (DC motor). (Pick
up ‘Red Flag on Relay’, Drop out - ‘Green Flag on
Relay’)
3.33 DCOP FAILED TO PICK UP/DCCL FAILED TO
DROP OUT:
1. Conduct DCL switchgear test in contactor & relay
test. Also visually inspect operation of switchgear.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 62
If it is continuously operating, DIO output channel is
shorted, SWAP‘DIO2’ with other DIO preferably DIO3.
2. Check connections on the Terminal block of DCL
switch assy.
3.34
BATTERY CHARGING
DISCHARGE SIDE
AMMETER
SHOWING
1. Check & confirm that there is no Message like “No
Aux. Gen output - Check Auxiliary Generator Field
Breaker”.
2. Check for any loose battery connections. If
everything alright, then meter is defective.
3. Measure battery charging voltage if less than 68 V
check BC ARM DVR renew accordingly.
4. Renew BC Am meter
5. Check for glowing of green LED on FCD module
3.35 TCC # FAILED TO ACKNOWLEDGE DIRECTION
REQUEST
1. Check for communication cards of EM 2000 and the
TCC.
2. Check all the X-plugs of TCC.
3. Check the connector at signal distribution box and
EM 2000 mother board for any loose connection &
pin not mating properly.
3.36 HORN CONTINUOUSLY WORKING:
1. Check whether magnet valve stuck up in ON
condition.
2. Check Horn Button stuck up in ON condition.
3. Disconnect Magnet valve coil wires & check.
4. Check for Low voltage grounds.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 63
3.37 EVENT RECORDER COMMUNICATION FAILURE
1. Recycle event recorder circuit breaker
2. Check the unit for communication with EM 2000 for
display of software ID in unit information.
3. Check the power supply connector & RS 485
connector in the unit.
4. Check RS 485 connector at the Signal Distribution
Box.
5. Renew COM card, Event recorder accordingly.
3.38 TCC COMPUTER OR TCC BLOWER CIRCUIT
BREAKER NOT CLOSED
1. Check for tripped TCC blower or TCC computer
breaker, reset if tripped.
2. Check backside interlock for open wire connection.
3. Check wiring as per schematic.
4. Change DIO module.
3.39 TCC BLOWER CONTACTOR FAILED TO PICK UP
1. Check whether contactor physically picked up or not.
2. If picked up feedback problem check interlock
connection and wiring.
3. If contactor not picking up check coil supply coil
resistance.
4. If supply not available check DIO output, wiring, PD
plug etc.
5. Change DIO module.
Note: Feedback wire may be temporarily bypassed
and loco can be worked until the section is cleared.
3.40 AIR DRYER MALFUNCTIONING
1. Air dryer should purge only when DCR relay is
picked up.
2. Above 485 rpm DCR permanently remains in ON.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 64
3. Below 485 rpm the DCR should get ON whenever
MVCC is OFF and compsyn relay is ON.
4. DCR Plug should get supply in following sequence.
A Pin - + 72 V
B Pin - + 72 V
Whenever DCR is ON
C Pin - - 72 V
3.41 WATER LEVEL REDUCING :
1.
2.
3.
4.
5.
6.
Head to Liner gasket joint leakage in engine.
Water inlet tube to power assembly joint leakage.
Radiator/Radiator vent leakage.
Head to liner gasket joint leakage in Air Compressor.
Water drain cock leakage.
Engine water ‘Y’ manifold bottom gasket joints
leakage.
7. Any crack/damage in power assemblies.
8. External leakage from dresser & flange joints or
external piping system.
9. Water outlet elbow leakage, After- cooler tube
leakage & pipelines joint leakage.
10.Water leakage from water pump seal.
3.42 WATER SYPHONED OUT
1. Radiator Fans not working.
2. Damaged Power assembly.
3.43 UNUSUAL SOUND FROM TURBO END
1. Defective Turbo making humming sound.
2. Defective planetary gear train in Turbo.
3. Rubbing of impeller with main casing.
4. AUX.GEN drive unit back lash not adjusted properly.
5. Improper seating of exhaust valve, broken exhaust
valves, injector dribbling, defective power assembly.
6. Defective Injector.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 65
3.44 LOW COMPRESSION PRESSURE IN CYLINDER
1.
2.
3.
4.
5.
6.
7.
Improper exhaust valve timing adjustment.
Improper exhaust valve seating.
Crack/damage in exhaust, valve disc.
Worn out piston rings.
Exhaust valve bent, defective cylinder heads.
Improper seating of valve guide.
Cracked piston.
3.45 LR NOT MATCHING :
1.
2.
3.
4.
5.
6.
Defective injector.
Fuel racks not adjusted properly.
Injector output less.
Defective Governor.
Chocked Air filters.
Defective OSTA trip pawl (Injector rocker arm lifted
condition)
7. Defective clutch.
8. Improper working of fuel pump.
9. Less Fuel in Fuel tank.
10. Improper adjustment of injector timing & exhaust
valve timing.
11. Engine inlet air leaking from After- cooler/Housing
joint.
3.46 LLOB TRIPPING
1. Malfunctioning of Turbo Clutch.
2. Engine oil pressure sensing pipe to Governor
damaged / leaking.
3. Fuel contamination in lube oil.
4. Defective hot oil detector.
5. Defective Governor.
6. Clogged Turbo supercharger spin on filter.
7. Defective pressure relief valve.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 66
8. Heavy oil leakage from cam shaft bush bearings.
9. Heavy oil leakage from Stub shaft, rocker arm rollers.
10. Leakage in lube oil dust bin blower manifold.
11. Defective main lube oil pump.
12. Manifold connecting to turbo spin on dummy missing.
3.47 PINCHING OF LASH ADJUSTER:
1.
2.
3.
4.
5.
6.
Defective Lash adjuster.
Defective valve bridge.
Damaged exhaust valve locks.
Improper exhaust valve timing.
Exhaust valve disc breakage.
Exhaust valve spring cut, or valve bridge spring
broken
7. Inadequate lube oil supply to lash adjuster.
3.48 SMOKE FROM TOP DECK:
1.
2.
3.
4.
Crack in piston crown.
Drilled through threaded hole on piston crown.
No oil supply to Aux. Gen. drive.
Exhaust valve guide breakage.
3.49 LESS CC VACUUM
1. Top deck covers not closing properly.
2. Defective sump covers.
3. Defective top deck cover sealing.
4. Clogged eductor.
5. Clogged eductor flexible hose/damaged eductor.
6. Wrong choke provided in eductor.
7. Worn out piston rings.
8. Worn out felts in free end oil seal.
9. Power assembly liner seal hardened.
10. Exhaust valve guide broken.
11. Piston cracked.
12. Head seat ring damage.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 67
3.50 MORE CC VACUUM:
1. Wrong choke provided in Eductor.
2. Larger dia flexible pipe connected to Eductor.
3.51 ENGINE SHUT DOWN AUTOMATICALLY:
1. Turbo clutch failure.
2. OST Tripping.
3. Fuel pump not working properly.
4. Low water.
5. Low crank case vacuum.
6. Low lube oil pressure.
7. Defective lube oil pumps (Main).
8. No Fuel in fuel tank.
9. Defective Turbo.
10. Defective Governor lube oil sensing pipe.
11. Injector rack stuck up.
12. Defective Governor.
3.52 PISTON CRACK
1.
2.
3.
4.
5.
Improper alignment of piston cooling pipe.
Defective piston cooling pipe.
Wrong Exhaust valve timing.
Reverse fitment of piston carrier.
Improper fitment of piston holding tool during
maintenance.
6. Defective piston cooling pump.
7. Blocked piston cooling oil manifold.
3.53 BLACK THICK SMOKE FROM TURBO
1. Chocked air filters.
2. Defective clutch.
3. Turbo air inlet rubber boot worked out and blocking
the turbo air inlet passage.
4. Defective injectors.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
5.
6.
7.
8.
9.
P a g e | 68
Improper supply of fuel oil.
Turbo malfunctions.
Improper adjustment of rack
Malfunction of Governor.
Slippage of injector linkage.
3.54 OSTA TRIPPING:
1.
2.
3.
4.
Improper adjustment of OSTA
Injector struck up.
Defective OSTA assembly and linkages.
Improper adjustment of fuel rack.
3.55 OSTA NOT TRIPPING
1. Improper adjustment of tripping pawl.
2. Stuck up throw weight.
3. Defective OSTA trip lever.
3.56 OSTA NOT RESETTING:
1.
2.
3.
4.
Defective OSTA trip lever key.
Defective OSTA lock.
Defective OSTA linkages.
OSTA trip pawl defective.
3.57 FUEL HEADER VIBRATION :
1.
2.
3.
4.
5.
Cam gear vibration.
Faulty injectors.
Improper engine timing.
Improper rack setting.
Improper fitment of counter weights (OSTA+cam
gear end).
6. Improper Engine alignment & compressor alignment.
7. Cam shaft breakage.
8. Gear train components failure.
9. Slack Engine foundation bolts.
10. Defective power assemblies.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 69
3.58 HIGH LUBE OIL CONSUMPTION
1.
2.
3.
4.
5.
6.
7.
External leakages.
Engine additional drain dummy leakage.
Leakage in lube oil drain pipe.
Worn out piston rings & valve guides.
Main lube oil header leakage.
Engine block leakage.
Sump covers leakage.
3.59 LUBE OIL LEAKAGE FROM AIR BOX DRAIN PIPE
1. Punctured air box drain pipe in sump.
2. Main lube oil header crack.
3. Worn out piston rings.
3.60 WATER LEAKAGE FROM AIR BOX DRAIN PIPE :
1.
2.
3.
4.
5.
Defective water inlet tube.
After cooler tube leakage.
Head to liner gasket & joint leakage.
Damaged power assembly.
Improper fitment of water inlet tube.
3.61 OIL THROW FROM TURBO
1. Damaged power assembly.
2. Damaged valve guide.
3. Low crank case vacuum.
4. Clogged eductor.
5. Oil separator oil collecting wire meshes missing.
6. Improper fitment of piston rings, head seat ring (worn
out).
3.62 WATER THROW FROM TURBO :
1. Cylinder Head crack.
2. Head to Liner gasket leaking.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 70
3.63 CRANK SHAFT NOT ROTATING:
1. Obstruction to the movement of crank shaft due to
external materials.
2. Defective power assembly.
3. Improper Exhaust valve timing.
4. Defective gear train components.
5. Hydraulic locking of power assembly due to any
water/oil collected on piston crown.
6. Defective turbocharger.
3.64 LOSS OF HORSE POWER :
1. Clogged air filters.
2. Stuck up injectors.
3. Improper adjustment of fuel racks.
4. Blocking of air inlet duct.
5. Exhaust manifold expansion joint puncture.
6. Malfunction of Governor.
7. Defective clutch.
8. Defective fuel return relief valve 15 psi.
9. Defective Turbo.
10. Improper supply of air.
11. High engine temperature due to fans not working.
12. Insufficient supply of fuel.
13. OSTA pawl stuck in tripped condition.
3.65 ENGINE HUNTING IN LOAD TEST – 2 CONDITION
AND RACK LENGTH ABOVE 0.82 :
1. Improper setting of Governor.
2. Low engine output.
3.66 ENGINE IS CRANKING IN COLD CONDITION. BUT
ENGINE RPM IS LESS AND NOT HOLDING :
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 71
1. Improper adjustment of Governor Compensation
needle valve.
2. Worn out Teflon seal of power piston.
3.67 LR% IS NOT MATCHING IN HIGHER NOTCHES :
1. Choked Baggie filters.
2. Rack demand; (Ensure rack position shall be
corresponding to the request of Governor).
3. Exhaust manifold leakage.
4. Boost air pipe connection to Governor may be
broken/ disconnected.
5. Defective Fuel injector (will be known by measuring
individual cylinder exhaust temperature).
6. Injector rocker arm for free movement & ensure
OSTA trip pawl is not obstructing the rocker arm
movement & timing of the injector.
7. Defective governor setting.
8. Defective fuel relief 15 psi return side value.
3.68 ABRUPT INCREASE IN ENGINE SPEED BEFORE
GETTING STABILISED AS AND WHEN ENGINE IS
NOTCHED UP/DOWN:
1. Defective buffer piston spring & buffer piston of the
governor.
2. Sluggish movement of the injector rack.
3.69 IF THE LR% IS LESS IN ALL NOTCHES:
1. Select load test mode in EM 2000 & remove
AMPHENOL plug, then check the LR% if it is less
than 100%, it is due the electrical problem.
2. Ensure proper functioning of the booster air
pressure. As the notch varies, sensor piston position
also varies. It should not stuck up.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 72
3.70 RPM DROPPING IN LOAD :
1. Ensure the LR scale of the Governor is activating. If
it is activated, ensure the LR reading in EM 2000 as
well as in Governor LR scale should be same. If not,
it is the probe of resistor pack of the Governor or
Electrical connections connecting the ‘AMPHENOL’
plug.
3.71 BUBBLES AT RETURN SIGHT GLASS :
1. Leakage in the suction pipeline or injector.
3.72 BUBBLES AT 8TH NOTCH ONLY IN RETURN
SIGHTGLASS:
1. Suction pipe adapter & pipeline leakage.
2. Leakage in the injector.
3.73 BUBBLES AT RETURN RIGHT GLASS AFTER 3RD
OR 4TH NOTCH :
1. Less Fuel pump pressure (25 to 32 psi)
2. Any foreign material in suction strainer and in fuel
tank suction pipe.
3. Condition of the primary filter drain cock. It should
always be in closed condition.
NOTE : FINDING OUT OF LEAKY/DEFECTIVE
INJECTOR :
1. By closing the rack of individual injector under engine
in idle condition, the bubbles in the return sight glass
used to disappear for that particular injector.
2. Check exhaust temperature at exhaust manifold
raises.
3. By opening test plugs individually under engine idle
condition & check for white smoke through the test
plug.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 73
3.74 MR PRESSURE DROPPING ON RUN & PCS
OPENING
1.
2.
3.
4.
Check for continuous operation of Sanders, Horn,
ABD Valve, MVCC, Radar- Air Blast etc.,
Conduct MR efficiency test.
Check for correct operation of Air Dryer.
Check correct operation of EBT, Sander, MVCC.
3.75 MR PRESSURE DROPPING
When MR Pressure is dropping rapidly on loco with
formation attached (observe flow indicator). Close
the BP angle COC of loco and check the MR
pressure. If MR pressure is building up and
loading/unloading is taking place in idle, formation
leakage to be checked.
Note: In case of train of twin pipe - Close FP first
ensure AFI indication for BP leakage.
-
CHECK AIR DRYER OPERATION
a. If Air dryer towers (i.e., inside and outside) blowing
continuously switch off air dryer breaker.
b. After switching off air dryer CB even then air is
blowing continuously then shut down the engine by
securing hand brake and providing wheel skids.
Drain MR completely to dummy the purge valve (on
tower) by providing 2 Rupee coin for the tower which
is blowing continuously.
c. If Pre-coalescer drain valve blowing continuously
switch off air dryer CB.
Note: If Air dryer function is isolated for malfunction.
Additional care to be taken to drain moisture from
ABD valves periodically. Before draining MR
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
-
P a g e | 74
completely, air brake circuit breaker to be put off
while re-cranking when MR full then put ’ON’.
CHECK AUTOMATIC BLOW DOWN VALVE
FUNCTION
Check the proper function of MR1, MR2, ABD
valves.
If any one of the valves operating for longer time,
close the defective (i.e, brass spindle ‘IN’ only) ABD
Valve from AUTO position to OFF position.
-
CHECK THE EM 2000 MR PRESSURE ON DISPLAY /
MRGAUGES
a. Check the MR Pressure in EM 2000 Screen and
MR gauge in control stands. If both reading are
shown more than 4 to 5 kg/cm2 difference, it
indicates defective MRPT or choked pipelines
connected to MRPT. (ensure eng. RPM increasing
properly for air comp. operation)
b. MRPT is located inside ECC3 compartment. Close
the MRPT COC and drain the moisture from test
plug duly pressing. Open the MRPT COC for
normal operation which is provided in compressor
room behind ECC3 cabinet.
-
DEFECTIVE MVCC VALVE
a. Magnet Valve of compressor control (MVCC) is
located inside compressor compartment mounted
on unloader panel. It controls the compressor
loading
and unloading cycle according to EM
2000
commands through DIO.
b. If MVCC valve stem has stuck up, MR pressure
continuously act on unloader assembly and
compressor will go on unloading the compressor
causing low MR pressure even though MVCC is in
de-energize condition.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 75
c. Press the MVCC valve ‘T’ handle 3 to 4 times
which is located in MVCC (over riding manual
handle.)
d. If MVCC is not having ‘T’ handle, close the MR ‘J’
filter COC, drain the trapped pressure and dose.
Ensure MR safety valve blowing. If not, defect still
existing because of comp. valves or pipeline
leakage.
-
DEFECTIVE LP SUCTION VALVE
a. Check unusual sound from compressor LP (Low
Pressure) suction valves. If unusual sound is
observed from LP suction valve, it indicates
suction valves are defective.
b. Conduct MR Efficiency Test.
i. Engine to be kept in Load Test mode (i.e., 8th
notch).
ii. 7.14 mm orifice choke to be provided in MR2 ‘J’
filter and open ‘J’ filter COC fully.
iii. MR pressure should maintain a min of 136 PSI
or normal loading &unloading should take place
iv. If MR Pressure is dropping below 7 kg/cm2 it
indicates LP suction valves are defective, renew
suction valves.
3.76 BRAKE PIPE (BP) PRESSURE NOT CREATING
1. ON RUN BP PRESSURE DROPPED :
a Check the air flow indicator, if flow indicator shoots
up, it indicates BP pressure leaking on formation,
(Chain pulling or parting between coaches/
wagons).
b. Check crew message.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
NO: IRCAMTECH.2012.M.GM.TSG.1.0
P a g e | 76
c. If EM 2000 displays penalty, keep auto handle(A9)
in FS for 10 seconds. (OR) emergency for 60
seconds according to EM 2000 request.
d. After penalty time is over, and still BP pressure not
restored, keep L/T switch in trail then after 10
seconds again keep in lead if problem still exist
then recycle the MAB circuit breaker for 20
seconds.
e. Even after recycling the breaker also, BP is not
building, conduct Air brake self test.
f. If self test also failed, Open the CCB compartment
and check the fault code on the CCB that is
displayed.
g. If the fault code is displayed 60 or 70 series put off
MAB CB in control panel & gently press Air Brake
computer modules, i.e., EPA1, EPA2, EPA3, and
CPZ face connectors.
h. Check the BCEV connector tightness.
i. Close the formation BP angle COC and check the
BP gauge and air flow indicator in loco, if it is
showing 5.2 and 0 respectively, It indicates
formation leakages.
j. After checking BCEV connector tightness and AB
modules put on MAB breaker and once again
conduct air brake self test.
k. If air brake self test passed, restore BP and work.
2. HORN & SANDER WORKING CONTINUOUSLY
i. If Horn blowing continuously close MR1 filter COC
& drain the Trapped pressure and open the COC
duly closing drain COC of J filter.
ii. If Sanders working continuously, follow the above
same procedure used for horn.
iii. Check whether Electrical switches are in pressed/
struck up position.
Trouble Shooting Guide for WDP4/WDG4 locos
CAMTECH/Gwalior
OUR OBJECTIVE
To
upgrade
maintenance
technologies and methodologies and
achieve improvement in productivity
and performance of all Railway
assets and man power which interalia
would
cover
reliability,
availability, utilization and efficiency.
If you have any suggestions and any specific comments,
please write to us.
Contact person
: Director (Mech.)
Postal address
: Indian Railways,
Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior.
Pin code - 474 0050
Phone
Fax
0751- 470890, 0751-470803
0751- 470841
:
:
Download PDF
Similar pages