ELECTRICAL

OPERATION &

MAINTENANCE

MANUAL

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 PREFACE
This manual has been prepared to enable TECHNICALLY skilled personnel to
maintain electrical equipment and comprises OPERATION, SAFETY
CONTROLS, MAINTENANCE, TROUBLE SHOOTING & OVERHAUL
INSTRUCTIONS.

For ease of reference, divider cards section the books, with an index to each
section, which lists the particular groups of equipment or topics covered.

The manual has been prepared to enable skilled personnel to maintain and
overhaul the locomotive. The information contained in this manual is based upon
standard workshop practice and every effort has been made to ensure accuracy.
The maintenance and inspection periods are based upon standard Railway
practice and may be varied as operating experience dictates.

Before any examination is started, all safety precautions must be carried out in
accordance with instructions.

For any Service enquiry, please contact:

SAN ENGINEERING & LOCOMOTIVE CO. LTD.

SERVICE DEPARTMENT
WHITE FIELD ROAD
MAHADEVAPURA POST
BANGALORE – 560 048
KARNATAKA
TELEPHONE: 080 – 42449200-6
FAX: 080 – 28452260
E-MAIL: service@[Link]
Web Site: [Link]

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 CONTENTS
CHAPTER DESCRIPTION PAGE No.
Chapter – 1 General Description 7
Layout Description of Electrical
Chapter – 2 15
Equipment
Chapter – 3 Operator Instructions 27
Chapter – 4 Circuit description 35
Chapter – 5 Safety Devices 59
Chapter – 6 Auxiliary Power & Control Equipment 69
Chapter – 7 Maintenance of Auxiliary System 75
Inspection Sheets of Maintenance
Chapter – 8 83
Schedule
Chapter – 9 Trouble Shooting 97
Chapter – 10 Encyclopedia of Locomotive Electrics 115
Chapter – 11 Annexure – Additional Controls (If Any) 155

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 CHAPTER – 1
GENERAL

DESCRIPTION

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 CHAPTER 1
1.0 GENERAL DESCRIPTION
Electrical System of Locomotive constitutes Controls and Instrumentation which
are used for logic control, monitoring & Audio-Visual warnings, Switching and
Safety.

The electrical circuit is designed for 24volts DC two-wire system for operating the
starter motor, controls, lighting and other electrical loads of the locomotive.

The twin power pack locomotive has separate front and rear diesel engines and
must be started independently. The cranking (starting) of the engine is by means
of an axial throw type of electrical starter motor. The primary power supply for
cranking draws heavy current from three 8-volts batteries of sufficient ampere-
hour capacity, which are connected in series to get 24 volts DC power source.

The charging of the batteries is done by an engine mounted belt driven alternator,
which consists of an inbuilt rectifier regulator unit and does not require any
maintenance. The correct charging of the batteries is achieved by the voltage
regulator. Apart from charging, the alternator also serves auxiliary electrical loads
of the locomotive.

The discharging of the battery is indicated through an Indication lamp on the

instrument panel and it should be off during normal operation, to ensure the
charging condition.

Engine "ON" lamps are provided independently for both the engines on the
instrument panel to indicate start and run condition of engines separately.

All conductors are of copper, which have adequate current carrying capacity.

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Separate engine mounted Auxiliary Alternators, with in-built rectifier & voltage
regulator units of ample power capacity provide power simultaneously for charging
the batteries, control circuits, fans, lights and other electrical loads.

Independent ammeters are connected in the alternator circuit to indicate the

charging condition of the system. The battery charging and discharging is
indicated by the pointer. Positive (+) side indicates battery charging and Negative
(-) side indicates battery discharging.

Low brake pressure indication lamps for each engine are provided on the
instrument panel to caution the driver and are also automatically controlled with
appropriate interlocks before moving the locomotive.

Electronic water level indicators (switch relay) are provided on the instrument
panel to indicate low water level in the radiator tank, which is sensed by water
level sensor which is mounted on the radiator tank. It also cautions the driver
while initially moving the locomotive. A capacitor is used to suppress the surge
voltage through electro magnetic interference and is connected across the sensor
terminals of switch relay.

Fuel inlet to the engine is controlled by a fuel solenoid. The supply to this has
three automatic shutdown devices to protect the engine against normally closed
contact of low water level, normally closed contact of engine over speed and
closed normally open contact of low lubrication oil pressure. The emergency
engine stop push button and safety devices, which are connected in series with
engine safety relay, the contact of engine safety relay is connected in series with
fuel solenoid.

Air inlet to the transmission and engine throttle is controlled by driver's valve,
which is connected with a main magnet valve in series with closed normally open
contacts of engine safety relays, normally closed contact of water temperature
switches, normally closed contacts of transmission oil temperature switches, and
normally closed contacts of transmission control relay. The electric supply to main
magnet valve will cut off when any of above safety devices or switches exceeds

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and operates above the pre-set limits which bring the engine to idle, thus cutting
off the transmission.

Electro pneumatic governor is used in the pneumatic circuit to unload the

compressor delivery of air to atmosphere and actuate the auto drain valve when
the system pressure reaches the maximum preset level.

Main magnet valve is used as a safety valve during actuation of safety controls
and thus the engine comes to idle and transmission cuts off.

Transmission Magnet valve is provided to interlock the transmission to prevent the

locomotive movement, when there is low brake pressure in the reservoir as it is
connected in series with brake air pressure switch and power cut off air pressure
switch.

Power cut off air pressure switch is used as a safety device during full or
emergency brake application. It acts as a safety switch to cut off traction power to
the locomotive by opening its normally closed contact, which is connected in
series with transmission magnet valve and thus the engine comes to idle and
transmission cuts off.

Transmission control relay is used as one of the safety devices to inter lock the
transmission as a precaution measure. If driver has forgot to bring the engine
throttle to zero/neutral position when oil or water temperature or loco over speed
exceeds above the pre set limit, the locomotive should not move by its own when
temperature comes to its normal condition. To move the locomotive switch "OFF"
and then switch "ON" transmission circuit breaker, which is provided on the
instrument panel.

Starter timers are provided to prevent the long cranking of the starter motors and
cuts off the starting circuit after reaching set time delay and has to be started once
again.

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Hooter timers are provided to cut off the hooting of the hooter after set time delay
to protect the hooter and avoid hooting for long period.

The voltmeter is provided on the instrument panel to indicate battery/alternator

voltage.

HMI (Human Machine Interface) is provided on the instrument panel to indicate

the speed and distance travelled of the locomotive.
Proximity switch is provided on the front bogie of rear final drive axle box (right
side) for sensing the speed of locomotive.

Locomotive over speed system is provided in the locomotive to prevent the loco
over speed if exceeds above the preset limit. Locomotive over speed lamp is
provided on the instrument panel to indicate the over speed of the locomotive.
Loco over speed relay is used to interlock the loco over speed indication lamp till
the reset operation is done by switching ON and OFF the Transmission circuit
breaker. Locomotive brakes are applied automatically on the occurrence of Loco
over speed.

Forward & reverse indication lamps are provided on the instrument panel to
indicate the travel direction of the locomotive.

Transmission "ON" indication lamp is provided on the instrument panel to indicate

the driver, loco is ready for movement.

Lamp test push button is provided on the instrument panel to check the
healthiness of all the indication lamps.

Two sets of Emergency engine stop push buttons are provided on the either side
of the Driver desk to shut "OFF" the engines during emergency/abnormalities in
the system.

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Electronic engine RPM meter and Hour meter is provided on the instrument panel
to indicate engine rpm and to counts number of engine running hours. Magnetic
pick up unit is provided on the flywheel housing for sensing the engine rpm.

Electrical gauges such as lube oil pressure gauge, lube oil temperature gauge,
water temperature gauge and transmission oil temperature gauge are provided on
the instrument panel. Sensors are provided in respective places of engine &
transmission, to sense the temperature and pressure.
The driver's cabin is equipped with two fans and two cabin lights which are
provided in the roof. The cabin lights are directly connected to the battery through
a circuit breaker to provide illumination before entering the cabin. They are
independently controlled by two sets of two way switches which are mounted on
instrument panel and near the door to operate similar to a stair case lighting
operation. Two gauge lights are also provided for easy reading of gauges on the
instrument panel during night driving.

The locomotive is fitted with two headlights in the front, and two in the rear. Two
taillights and two parking lights are provided at the four corners of the locomotive.
There are six lights in the each hood for easy maintenance. In addition a portable
inspection lamp unit is provided with sufficient length of wire to reach any part of
the locomotive without any difficulty. The power source for inspection lamp unit is
available through any of three plug points provided in the hoods, between the
bogies in the under-slung of the locomotive.

The headlights switches are conveniently provided on the instrument panel.

The switches for taillights, parking lights, fans, cabin lights, sockets, gauge lights
and hood lights are grouped in a convenient position on the instrument panel. The
operation of headlight, taillight and parking lights can also be visualized by parallel
operation of indication lamps, which are provided on the instrument panel.

All branches of the circuits are protected by circuit breakers of thermal over load
type to isolate the system under any over load or short circuit conditions.

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Adequate facilities are provided for easy access, maintenance and replacement of
the electrical control equipment.

When the locomotive is not in use, the starter lines should be isolated, by battery
isolating switch and main circuit breaker in the driver's cabin should be in "OFF"
condition.

For safe and satisfactory operation of the locomotive adequate controls are
provided including gauges, indicating lights and safety devices in the driver's
cabin and are arranged within easy reach and sight of the driver from both the
driving positions.

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CHAPTER – 2
LAYOUT
DESCRIPTION
OF
ELECTRICAL
EQUIPMENT

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 CHAPTER - 2
2.0 LAYOUT DESCRIPTION OF ELECTRICAL EQUIPMENT
The Layout description facilitates the easy identification of the Electrical items
mounted over and under frame.

The Locomotive is made of rigid frame. The length of the locomotive is divided
into three distinct profiles. The driver’s cabin is sandwiched centrally between front
& rear hoods of the locomotive. Fuel tank is into two parts and each part is
mounted on either end of the locomotive. Walking platforms are provided on all
four sides of the loco for ease of inspection and maintenance.

The Driver’s cabin is equipped with a Driver desk on which all the driver controls
are mounted, Driver’s brake valves, Hand brake, Driver’s seats and Instrument
panel. It offers double operating position with throttling wheels on both sides of
Driver’s desk.

The hood is divided into two compartments viz., Power pack equipment
compartment and Radiator compartment. These two compartments are separated
by a metallic partition, mainly to avoid intermixing of air circulation.

The Auxiliary & Control wires terminate on the terminal blocks mounted inside the
Main Control Box. They are all logically grouped according to maintenance
aspect. It is mounted to the cabin wall inside the hood. All the pressure &
Temperature switches are mounted on a panel with prior wired to a terminal
connector.

All the Electrical equipment is located as shown in the Drawing of “Electrical

Equipment Layout Diagram” and Item location list Table.

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 I. LOCOMOTIVE ASSEMBLY

SL. LEGEND DESCRIPTION LOCATION

NO.
1. AA11/21 AUXILIARY ALTERNATOR ENGINE-PP1/2
DRIVER’S DESK
2. BIS31 BATTERY ISOLATING SWITCH
(RIGHT SIDE)
BRAKE
3. BRAKE PANEL DRIVER’S CABIN
PANEL -1, 2
4. CF31, 32 CABIN FAN DRIVER’S CABIN

5. CL31, 32 CABIN LIGHT DRIVER’S CABIN

6. DD31 DRIVER’S DESK DRIVER’S CABIN

7. DS31, 32 DOOR SWITCH DRIVER’S CABIN

8. EOSS11/21 ENGINE OVER SPEED SWITCH ENGINE-PP1/2

FRONT/REAR
9. ETB11/21 ENGINE TERMINAL BOARD
HOOD (INSIDE)
ENGINE- FRONT/REAR
10. POWER PACK1/2 ENGINE
PP1/2 HOOD (INSIDE)
FRONT HOOD
11. FHL31, 32 FRONT HEAD LIGHT
(OUT SIDE)
BUFFER PLATE
12. FPL31, 32 FRONT PARKING LIGHT
(FRONT SIDE)
BUFFER PLATE
13. FTL31, 32 FRONT TAIL LIGHT
(FRONT SIDE)
14. FS11/21 FUEL SOLENOID ENGINE-PP1/2
FRONT HOOD
15. HLF31 – 36 HOOD LIGHT (FRONT)
(INSIDE)
16. IP31 INSTRUMENT PANEL DRIVER’S CABIN
INSPECTION LAMP SOCKET FRONT HOOD
17. ILSF31
(FRONT) (INSIDE)
INSPECTION LAMP SOCKET REAR HOOD
18. ILSR31
(REAR) (INSIDE)
INSPECTION LAMP SOCKET
19. ILSU31 UNDER SLUNG
(UNDER SLUNG)
20. LOPS11/21 LUBE OIL PRESSURE SWITCH ENGINE-PP1/2
LUBE OIL PRESSURE SENSOR
21. LOPSU11/21 ENGINE-PP1/2
UNIT

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 LUBE OIL TEMPERATURE
22. LOTSU11/21 ENGINE-PP1/2
SENSOR UNIT
FRONT/REAR
23. MCB11/21 MAIN CONTROL BOX
HOOD (INSIDE)
24. MPU11/21 MAGNETIC PICK UP UNIT ENGINE-PP1/2

25. MS11/21 MAGNETIC SWITCH ENGINE-PP1/2

AXLE BOX-
FRONT BOGIE OF
26. PS31 PROXIMITY SWITCH
REAR FINAL
DRIVE (R.H.S)
PRESSURE AND TEMPERATURE FRONT HOOD
27. PTSP31
SWITCH PANEL (INSIDE)
REAR HOOD
28. RHL31, 32 REAR HEAD LIGHT
(OUT SIDE)
BUFFER PLATE
29. RPL31, 32 REAR PARKING LIGHT
(REAR SIDE)
BUFFER PLATE
30. RTL31, 32 REAR TAIL LIGHT
(REAR SIDE)
31. SM11/21 STARTER MOTOR ENGINE-PP1/2
TRASMISSION OIL REAR HOOD
32. TOTS21
TEMPERATURE SWITCH (INSIDE)
TRANSMISSION OIL TRASMISSION-
33. TOTSU11/21
TEMPERATURE SENSOR UNIT PP1/2
TRANSMISSI FRONT/REAR
34. POWER PACK1/2 TRASMISSION
ON-PP1/2 HOOD (INSIDE)
REAR HOOD
35. HLR31 – 36 HOOD LIGHT (REAR)
(INSIDE)
36. WLSU11/21 WATER LEVEL SENSOR UNIT RADIATOR TANK

37. WTS11/21 WATER TEMPERATURE SWITCH ENGINE-PP1/2

WATER TEMPERATURE SENSOR
38. WTSU11/21 ENGINE-PP1/2
UNIT

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 II. MAIN CONTROL BOX – MCB11/21
SL.
LEGEND DESCRIPTION
NO.
1. ACB31 AUXILIARY CIRCUIT BREAKER

2. BCB31 BRAKE CIRCUIT BREAKER

3. CCB11/21 CONTROL CIRCUIT BREAKER

4. ESR11/21 ENGINE SAFETY RELAY

5. FPLD11/21 FIRE PROTECTION LINK DIODE

6. GCB11/21 GAUGE CIRCUIT BREAKER

7. HLD31 – 38 HEAD LIGHT DIODE

8. HT11/21 HOOTER TIMER

9. HTCB31 HEAD LIGHT TAIL LIGHT CIRCUIT BREAKER

HTD11 – 13, 21 –
10. HOOTER TIMER DIODE
23, 31
11. LCB31 LIGHTING CIRCUIT BREAKER

12. LOSR31 LOCO. OVER SPEED RELAY

13. MCLD31 MULTIPLE CONTROL LINK DIODE

14. ST11/21 STARTER TIMER

15. TCR31 TRANSMISSION CONTROL RELAY

16. TLD31 - 36 TAIL LIGHT DIODE

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 III. INSTRUMENT PANEL – IP31
SL.
LEGEND DESCRIPTION
NO.
1. AM11/21 AMMETER

2. BDL11/21 BATTERY DISCHARGE LAMP

3. CFS31, 32 CABIN FAN SWITCH

4. CLS31, 32 CABIN LIGHT SWITCH

5. EHM11/21 ENGINE HOUR METER

6. EOL11/21 ENGINE ‘ON’ INDICATION LAMP

ENGINE OVER SPEED WARNING INDICATION
7. EOSL11/21
LAMP
8. ERM11/21 ENGINE RPM METER

9. FHLDBS31 FRONT HEAD LIGHT DIM, BRIGHT SWITCH

10. FHLOL31 FRONT HEAD LIGHT ‘ON’ INDICATION LAMP

11. FHLS31 FRONT HEAD LIGHT SWITCH

12. FL31 FORWARD INDICATION LAMP

13. GL31, 32 GAUGE LIGHT

14. GLS31 GAUGE LIGHT SWITCH

15. HLSF31, 32 HOOD LIGHT SWITCH – FRONT

16. HLSR31, 32 HOOD LIGHT SWITCH – REAR

17. HMI31 DISPLAY UNIT (PV480)

HIGH TRANSMISSION OIL TEMPERATURE
18. HTOTL11/21
WARNING LAMP
19. HWTL11/21 HIGH WATER TEMPERATURE WARNING LAMP

20. ILSS31 INSPECTION LAMP SOCKET SWITCH

21. LBPL31 LOW BRAKE PRESSURE WARNING LAMP

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 22. LLOPL11/21 LOW LUBE OIL PRESSURE WARNING LAMP

23. LOPG11/21 LUBE OIL PRESSURE GAUGE

24. LOSL31 LOCO. OVER SPEED INDICATION LAMP

25. LOTG11/21 LUBE OIL TEMPERATURE GAUGE

26. MCB11/21 MAIN CIRCUIT BREAKER

27. PLOL31 PARKING LIGHT ‘ON’ INDICATION LAMP

28. PLS31 PARKING LIGHT SWITCH

29. RHLDBS31 REAR HEAD LIGHT DIM, BRIGHT SWITCH

30. RHLOL31 REAR HEAD LIGHT ‘ON’ LAMP

31. RHLS31 REAR HEAD LIGHT SWITCH

32. RL31 REVERSE INDICATION LAMP

33. SPARE INDICATION LAMP – SPARE

34. TCB31 TRASMISSION CIRCUIT BREAKER

35. TCLL31 TRASMISSION CONTROL LOCK LAMP

36. TLS31 TAIL LIGHT SWITCH

37. TOL31 TRASMISSION ‘ON’ LAMP

38. TOTG11/21 TRASMISSION OIL TEMPERATURE GAUGE

39. VM31 VOLTMETER

40. WH11/21 WARNING HOOTER

41. WLSI11/21 WATER LEVEL SWITCH CUM INDICATOR

42. WTG11/21 WATER TEMPERATURE GAUGE

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 IV. DRIVER’S DESK – DD31
SL.
LEGEND DESCRIPTION
NO.
1. DKS11/21 DRIVER’S KEY SWITCH

2. EBMV31 EMERGENCY BRAKE MAGNET VALVE

3. EESPB11/12 EMERGENCY ENGINE STOP PUSH BUTTON

4. GMV31 GOVERNOR MAGNET VALVE

5. LTP11/21 LAMP TEST PUSH BUTTON

6. MMV31 MAIN MAGNET VALVE

7. SPB11/21 STARTING PUSH BUTTON

8. TMV31 TRASMISSION MAGNET VALVE

V.
PRESSURE & TEMPERATURE SWITCH PANEL –PTSP31
SL.
LEGEND DESCRIPTION
NO.
1. BAPS31 BRAKE AIR PRESSURE SWITCH

2. FAPS31 FORWARD AIR PRESSURE SWITCH

3. GAPS31 GOVERNOR AIR PRESSURE SWITCH

4. PCS31 POWER CUT-OFF AIR PRESSURE SWITCH

5. RAPS31 REVERSE AIR PRESSURE SWITCH

6. TAPS31 TRASMISSION AIR PRESSURE SWITCH

7. TOTS11 TRASMISSION OIL TEMPERATURE SWITCH

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 CHAPTER – 3

OPERATOR

INSTRUCTIONS

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 CHAPTER - 3
3.0 OPERATOR INSTRUCTIONS
PREPARATORY CONTROLS
a) Close the main battery-isolating knife switch located near the front right
hand side of the driver's desk.
b) Close Main circuit breaker of both power packs, which are provided on the
Instrument panel and Control circuit breaker, Gauge circuit breaker, Brake
circuit breaker, Head & Tail light circuit breaker, Auxiliary circuit breaker
and Lighting circuit breaker located inside the Main Control box (Behind
the driver's desk).
 Voltmeter indicates the voltage of the Battery.
c) Insert driver's key switch and turn to "ON" position of both power packs.
 Low lubricating oil pressure warning lamp glows of respective power
pack.
 Battery discharge warning lamp glows of respective power pack.
 Warning hooter hoots and shuts off after set time delay of respective
power pack.
d) Ensure Throttle cum Direction Handle is in “NEUTRAL” position.
e) Ensure both Drivers’ Brake valve handles are in “APPLIED” position.

INDICATION LAMP TEST

Press “LAMP TEST” Push button, which will switch “ON” all the following
Indication lamps and indicates its healthy condition:
 Engine ON
 Low lube oil pressure
 High water temperature
 Engine over speed
 Low water level
 High Transmission oil temperature
 Forward
 Reverse
 Transmission ON

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  Transmission control lock
 Front head lights ON
 Rear head lights ON
 Tail lights ON
 Parking lights ON
 Loco over speed
 Battery discharge
 Low brake pressure

GAUGE LIGHT
Switch ‘ON’ “GAUGE LIGHT” Switch, which will switch “ON” two Gauge
lamps on Instrument panel.

ENGINE STARTING
a) Press the start push button of fuel supply and turn Driver's key switch to
start position simultaneously.
 Fuel solenoid gets energized.
 Fuel passage to engine throttle is open by fuel solenoid.
 Magnetic switch coil is energized through the normally closed contact of
engine safety relay, normally closed contact of starter motor timer and
closes magnetic switch contact, which in turn energizes starter motor
solenoid and closes main contact in the starter motor, The starter motor
cranks the engine and engine sustains running in low idle rpm.
 Lube oil pressure builds up.
 Engine "ON" Lamp glows.

b) As soon as the engine is started release the driver's key switch.

 “START” position of driver's key switch is spring returnable and will
come back to "ON" position once released.
 Magnetic switch is de-energized and supply to starter motor is cut off.
 Low lube oil pressure warning lamp extinguishes.

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 c) Release the fuel start push button switch of fuel supply only after the lube
oil pressure builds up which is indicated by the extinguishing of low lube oil
pressure warning lamp and low lube oil pressure gauge should indicate
more than 0.5 bar (kg/cm²).
d) Fuel solenoid is continuously energized by closing of normally open contact
of Engine safety relay.
e) Engine safety relay is energized through normally closed contact of
emergency engine stop push buttons, normally closed contact of water
level switch cum indicator, normally closed contact of engine over speed
switch and closing of normally open contact of low lube pressure switch.
 Low lube oil pressure warning lamp extinguishes.
 Low brake pressure warning lamp glows and extinguishes after pre-set
brake pressure builds up.
 Engine "ON" lamp glows.
 Battery discharge warning lamp extinguishes.
 Auxiliary alternator starts generating the voltage.
 Auxiliary alternator takes over control supply and starts charging the
battery.
 Battery ammeter indicates charge current (pointer on +ve side).
 Electronic engine rpm meter and engine hour meter starts indicating the
engine RPM and clock time.

CHARGING OF RESERVOIRS
After starting the engine, it is necessary before movement of vehicle that air
pressure in the reservoirs has to be built to the required level. Ensure that
Transmission control valve on the Driver desk is in OFF position. As the
pressure is built at slow rate during low idle speed of engine, raise the
engine to high idle so that build up of air can be faster. Now Engine speed
rises to high idle and thus the compressor runs at higher speed to fill
reservoirs at high rate. Charging of reservoirs continues till Governor Air
pressure switch cuts-out when system pressure reaches 7 bar (kg/cm²) and
hence auto drain valve is actuated to unload compressor delivery of air to
atmosphere. As the system pressure drops below cut-in pressure of

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 Governor Air pressure switch which is set to 6 bar (Kg/cm2), the
compressor starts charging the reservoir and the cycle repeats.

VEHICLE PROPULSION
Close the Transmission circuit breaker, which is provided on the instrument
panel.
 Main magnet valve is energized by closing of normally open contact of
engine safety relay, normally closed contact of transmission oil temperature
switch, normally closed contact of water temperature switch, normally
closed contact of transmission control relay.
 Transmission magnet valve is energized by closing of normally open
contact of Brake air pressure switch (after air brake pressure builds up and
opening the isolating valve/cock, which is mounted on the Driver’s desk)
and normally closed contact of Power cut off air pressure switch.
 Transmission air pressure switch operates after opening the isolating
valve/cock, which is mounted on the Driver’s desk.
 Transmission "ON" lamp glows.

NOTE:
For more details regarding the engine throttle, change of direction, engage and
disengage of transmission refer pneumatic circuit.

SELECTION OF DIRECTION
Depending on the travel direction, the Driver’s Throttle wheel will be rotated
to either Forward or Reverse direction. Correspondingly “Forward
Indication lamp” or “Reverse Indication lamp” glows and vehicle will start to
move according to the direction selected.

WARNING & INDICATION

 If any of the following faults occur, the engine comes to idle condition,
respective fault indication lamp glows, warning Hooter hoots.
 High Engine water Temperature
 High Transmission oil Temperature

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  Transmission Control Lock
 Low Brake Pressure
 Locomotive Over Speed

 If any of the following faults occur, the engine shuts OFF, respective
fault indication lamp glows, Warning Hooter beeps.
 Low Engine lube oil pressure
 Engine over speed
 Low Radiator water level

 If any of the following faults occur, it only warns the operator but doesn’t
interrupt the operation. Respective fault indication lamp glows, Warning
Hooter hoots.
 Battery discharge due to failure of Auxiliary Alternator

 The following features are meant only for its indication through their
respective Indication lamps.
 Engine ON
 Forward
 Reverse
 Transmission ON
 Front Head Light ON
 Rear Head Light ON
 Tail Light ON
 Parking Light ON

BRINGING ENGINES TO IDLE

Bring the Driver’s Throttle Wheel to “Neutral” position.

STOPPING THE VEHICLE

Initially bring the Driver’s Throttle Wheel to “Neutral” position. Apply the
brakes (Service / Standby) and then the vehicle comes to halt according to
braking distance.

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 SHUTTING OFF THE ENGINES
Ensure Driver’s Throttle Wheel is in “Neutral” position. Press Engine stop
push button to mechanically latch or turn Driver key switch to OFF position,
which shuts OFF the engine. Engine “ON” indication lamp extinguishes.

SETTINGS OF SAFETY CONTROLS

Timer Relay
1. ST11/21 - Starter Timer Relay : 8 Seconds
2. HT11/21 - Hooter Timer Relay : 5 Seconds

Pressure Switch
1. GAPS31 - Governor Air Pressure Switch
Cut Out : 7 bar (Kg/cm2)
Cut In : 6 bar (Kg/cm2)
2. FAPS31 - Forward Air Pressure Switch : 1.5 bar (Kg/cm2)
3. RAPS31 - Reverse Air Pressure Switch : 1.5 bar (Kg/cm2)
4. TAPS31 - Transmission Air Pressure Switch : 1.5 bar (Kg/cm2)
5. BAPS31 - Brake Air Pressure Switch : 4 bar (Kg/cm2)
6. PCS31 - Power Cut-Off Air Pressure Switch : 0.3 bar (Kg/cm2)
7. LOPS11/21 - Lube oil Pressure Switch : 0.5 bar (Kg/cm2)
(Factory Set)
Speed Switch
1. EOSS11/21 - Engine over speed Switch : 2352 RPM
(Factory Set)

Temperature Switch
1. TOTS11/21 - Transmission Oil Temperature Switch
Cut Out : 110ºC
Cut In : 87ºC
2. WTS11/21 - Water Temperature Switch : 93ºC

Electrical Operation & Maintenance Manual – TPP Page 34 of 144

 CHAPTER – 4

CIRCUIT

DESCRIPTION

Electrical Operation & Maintenance Manual – TPP Page 35 of 144

Electrical Operation & Maintenance Manual – TPP Page 36 of 144
 CHAPTER 4
4.0 CIRCUIT DESCRIPTION
1) Three 8 Volts Batteries [BA 31, 32 & 33] are connected in series to get 24 volts
output voltage for cranking the engine and other control loads in case of
alternator failure, during operation of the locomotive.

2) Close the door light circuit breaker [LCB31 (1:2)] (Always should be in "ON"
condition) which is located in the main control box behind the driver's desk.

3) Two cabin lights [CL31 and CL32] are directly connected to the battery through
a protective lighting circuit breaker [LCB31 (1:2)] capable of being switched
ON/OFF by either of the two door switches [DS31(1:2, 1:3)] and DS32 (1:2,
1:3) of two way switch] located by the sides of each cabin doors diagonally and
two cabin switches [CLS31(1:2, 1:3) and CLS32(1:2, 1:3) of two way switch]
which are mounted on the instrument panel.

a) Switch 'ON' the two-way cabin light/door switch [CLS31 (1:2, 1:3) OR DS31
(1:2, 1:3)], which is located on the instrument panel and near the left door.
 Cabin lamp left [CL31] lights. This cabin light is independently controlled
by two switches [CLS31 (1:2, 1:3) and DS31 (1:2, 1:3)] of two-way
switch) and operates like a staircase lighting operation.

b) Switch 'ON' the two-way cabin light/door switch [CLS32 (1:2, 1:3) OR DS32
(1:2, 1:3)], which is located on the instrument panel and near the right door.
 Cabin lamp right [CL32] lights. This cabin light is independently
controlled by two switches [CLS32 (1:2, 1:3) and DS32 (1:2, 1:3)] of
two-way switch) and operates like a staircase lighting operation).

4) Close the battery-isolating switch [BIS31 (1:2, 3:4)] which is located on the
front right side of the driver's desk.

Electrical Operation & Maintenance Manual – TPP Page 37 of 144

5) Close the Main circuit breaker [MCB11 (1:2) / MCB21 (1:2)], which is provided
on the instrument panel.
 Ammeter [AM11 (B: L) / AM21 (B: L)] shows the discharge current.

6) Insert driver's key switch [DKS11 (OFF: IGN) / DKS21 (OFF: IGN)] and turn to
"ON" position.
 Battery supply flows to all the circuit breakers.

7) Close the control circuit breaker [CCB11 (1:2) / CCB21 (1:2)], which is located
in the junction box (behind the driver's desk).
 Voltmeter indicates the voltage of the battery.
 Low lubricating oil pressure warning lamp [LOPL11 / LOPL21] lights up.
 Battery discharge lamp [BDL11 / BDL21] lights up.
 Hooter [WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes off after
set time delay.

8) Press the start push button [SPB11 (3:4) / SPB21 (3:4)] of fuel supply and turn
driver's key switch to start position [DKS11 (IGN: STA) / DKS21 (IGN: STA)]
simultaneously.
 Fuel solenoid [FS11 (A1:A2) / FS21 (A1:A2)] gets energized.
 Fuel passage to engine throttle is open by fuel solenoid [FS11 (A1:A2) /
FS21 (A1:A2)].
 Magnetic switch [MS11 (A1:A2) / MS21 (A1:A2)] coil is energized,
through normally closed contact of engine safety relay [ESR11 (81:82) /
ESR21 (81:82)] and normally closed contact of starter timer [ST11
(15:16) / ST21 (15:16)] to close its (magnetic switch) contact, which in
turn energizes motor solenoid and closes main contact of starter motor
and thus the battery supply is fed to the starter motor. The starter motor
cranks the engine.
 Lube oil pressure builds up.
 Low lube oil pressure warning lamp [LOPL11 / LOPL21] extinguishes.

Electrical Operation & Maintenance Manual – TPP Page 38 of 144

9) As soon as the engine is cranked, release the driver's key switch [DKS11
(IGN: STA) / DKS21 (IGN: STA)].
 Start position of driver's key switch [DKS11 (IGN: STA) / DKS21 (IGN:
STA)] is spring returnable and will come back to "ON" position after
releasing the switch.
 Magnetic switch [MS11 (A1:A2) / MS21 (A1:A2)] coil is de-energized.
 Supply to the starter motor [SM11 / SM21] is cut off.

10)Release the fuel start push button [SPB11 (3:4) / SPB21 (3:4)] only after the
lube oil pressure builds up which is indicated by extinguishing of low lube oil
pressure warning lamp [LOPL11 / LOPL21].
 Fuel solenoid [FS11 (A1:A2) / FS21 (A1:A2)] is continuously energized
and maintained through closed normally open contact of engine safety
relay [ESR11 (13:14) / ESR21 (13:14)]. Engine safety relay [ESR11
(A1:A2) / ESR21 (A1:A2)] is energized by normally closed contact of
emergency engine stop push button [EESPB11(1:2) & EESPB21(1:2)],
normally closed contact of water level switch cum indicator [WLSI11(C:
NC) / WLSI21(C: NC)], normally closed contact of engine over speed
switch [EOSS11(C: NC) / EOSS21(C: NC)], and by closing of normally
open contact of low lube oil pressure switch [LOPS11(C: NO) /
LOPS21(C: NO)] which are all connected in series with engine safety
relay [ESR11 (A1:A2) / ESR21 (A1:A2)].
 Auxiliary alternator [AA11 / AA21] starts generating voltage.
 Battery discharge lamp [BDL11 / BDL21] extinguishes.
 Auxiliary alternator [AA11 / AA21] takes over control supply and starts
charging the battery.
 Ammeter [AM11 / AM21] shows charging current.
 Voltmeter [VM31] shows system/charging voltage.
 Engine 'ON' lamp [EOL11 / EOL21] lights up.

11)Starter timer [ST11 (A1:A2) / ST21 (A1:A2)] is provided to prevent the long
cranking of the starter motor, which is set to 8 seconds. Normally closed
contact [ST11 (15:16) / ST21 (15:16)] of this timer is connected in series with

Electrical Operation & Maintenance Manual – TPP Page 39 of 144

 magnetic switch. During starting of the engine if driver holds the driver's Key
switch for more than 8 seconds the timer gets energized & cuts off the power
to the magnetic switch. In turn avoids driver from cranking the engine once
started.

12)Hooter timer [HT11 (A1:A2) / HT21 (A1:A2)] is provided to cut off the hooting
of the hooter after set time, to protect the hooter and avoid hooting for long
period. Normally closed contact [HT11 (15:16) / HT21 (15:16)] of this timer is
connected in series with hooter and opens after set time delay.

13)Water level sensor unit [WLSU11(C: NC) / WLSU21(C: NC)] is fitted on the
radiator water tank to sense the level of water.
 Water level sensor unit [WLSU11(C: NC) / WLSU21(C: NC)] is connected
in parallel with water level switch cum indicator [WLSI11 / WLSI21].

14)Water level switch cum indicator [WLSI11 / WLSI21] is used to monitor the
water level. When the level of water in the radiator tank goes below the level it
shows "LO".

15)A Capacitor [EMISC11 / EMISC21] is used to suppress the surge voltage

(electro magnetic interference) and connected across the water level switch
(sensor) and provided on the electronic water level switch cum indicator or
inside the main junction box across the signal terminals.

16)Close the transmission circuit breaker [TCB31 (1:2)], which is provided on the
instrument panel.
 Low brake pressure warning lamp (LBPL31) lights up.
 Select the transmission control (selector) switch (TCS31) to various
positions shown on the label plate of the switch, which enables correct
selection of the transmissions as per the following sequence.

Position “0" - OFF

Electrical Operation & Maintenance Manual – TPP Page 40 of 144

 Position “1" - Engage front and rear transmission.
 Main magnet valve [MMV31 (A1:A2)] is energized by closing of normally
open contact of front and rear engine safety relays [ESR11 (33:34))] &
(ESR21 (33:34)], normally closed contact of front and rear transmission oil
temperature switches [TOTS11(C: NC)) & [TOTS21 (C: NC)], normally
closed contact of front and rear water temperature switches [WTS11(C:
NC)] & [WTS21(C: NC)], normally closed contact of transmission control
relay [TCR31 (31:32)].
 Transmission magnet valve [TMV31 (A1:A2)] is energized by closing of
normally open contact of brake air pressure switch [BAPS31 (2:3)] (after air
brake pressure builds up and opening the isolating valve/cock, which is
mounted on the instrument panel) and normally closed contact of power cut
off air pressure switch [PCS31 (2:1)].
 Transmission air pressure switch [TAPS31 (2:1)] operates after opening the
isolating valve/cock, which is mounted on the instrument panel.
 Transmission "ON" lamp [TOL31] lights up

Position "2" - Engage front transmission.

 Main magnet valve [MMV31 (A1:A2)] is energized by closing of normally
open contact of front engine safety relay [ESR11 (43:44)], normally closed
contact of rear engine safety relay [ESR21 (61:62)], closing of normally
open contact of front engine safety relay [ESR11 (33:34)], normally closed
contact of front water temperature switch [WTS11(C: NC)], normally closed
contact of front transmission oil temperature switch [TOTS11(C: NC)],
second contact (B2) of transmission control switch (TCS13), closing of
normally open contact of front engine safety relay [ESR11 (53:54)],
normally closed contact of transmission control relay [TCR31 (31:32)].
 Transmission magnet valve [TMV31 (A1:A2)] is energized by closing of
normally open contact of brake air pressure switch [BAPS31 (2:3)] (after air
brake pressure builds up and opening the isolating valve/cock, which is
mounted on the instrument panel) and normally closed contact of power cut
off air pressure switch [PCS31 (2:1)].

Electrical Operation & Maintenance Manual – TPP Page 41 of 144

  Transmission air pressure switch [TAPS31 (2:1)] operates after opening the
isolating valve/cock, which is mounted on the instrument panel.
 Transmission "ON" lamp [TOL31] lights up.
 Position "3" -- Engage rear transmission.
 Main magnet valve [MMV31 (A1:A2)] is energized by closing of normally
open contact of rear engine safety relays [ESR21 (43:44)] , normally closed
contact of front engine safety relay [ESR11 (61:62)], normally closed
contact of rear water temperature switch [WTS21(C: NC)], normally closed
contact of rear transmission oil temperature switch [TOTS21 (C: NC)],
normally closed contact of transmission control relay [TCR31 (31:32)].
 Transmission magnet valve [TMV31 (A1:A2)] is energized by closing of
normally open contact of brake air pressure switch [BAPS31 (2:3)] (after air
brake pressure builds up and opening the isolating valve/cock, which is
mounted on the instrument panel) and normally closed contact of power cut
off air pressure switch [PCS31 (2:1)].
 Transmission air pressure switch [TAPS31 (2:1)] operates after opening the
isolating valve/cock, which is mounted on the instrument panel.
 Transmission "ON" lamp [TOL31] lights up.

17)Transmission control relay [TCR31 (A1:A2)] is used as a safety device to

interlock the transmission as a precautionary measure. If by chance driver has
forgot to bring the engine throttle to zero/neutral position when water or oil
temperature or Loco over speed exceeds above the pre set limit.

18)Transmission control relay [TCR31 (A1:A2)] will be energized through the

closed normally open contact of transmission oil temperature switch [TOTS11
(2:3)/ TOTS21 (2:3)] or closed normally open contact of water temperature
switch [WTS11(C: NO)/ WTS21(C: NO)] or Loco over speed relay contact
[LOSR31 (13:14)] and at the same time relay will be self locked with its own
contact [TCR31 (13:14)] and will open its normally closed contact [TCR31
(31:32)] which is connected in series with main magnet valve [MMV31
(A1:A2)]. Hence the locomotive will not move by its own when oil or water
temperature or Loco over speed comes down to its normal condition.

Electrical Operation & Maintenance Manual – TPP Page 42 of 144

  Transmission control lock warning lamp [TCLL31] lights up.
 To move the locomotive, when the temperature or Loco over speed comes
down to normal condition, SWITCH "OFF" and then SWITCH "ON" the
transmission circuit breaker [TCB31 (1:2)], which is provided on the
instrument panel.
 Transmission control relay [TCR31 (A1:A2)] will de- energize and contact
will come back to its normal position.
 Main magnet valve [MMV31 (A1:A2)] will energize back and allow the
locomotive to move.
 Transmission air pressure switch [TAPS31 (2:3)] operates after opening the
isolating valve, which is mounted on the instrument panel.
 Transmission “ON" lamp [TOL31] lights up
 Transmission control lock warning light [TCLL31] extinguishes.

19)Loco over speed relay [LOSR31 (A1:A2)] gets energized by closing of normally
open contact when loco speed exceeds above 1.25 times of rated loco
maximum Kmph. Loco over speed warning lamp [LOSL31] lights up and will
remain ON till reset operation is done through switching OFF and ON
Transmission Circuit Breaker [TCB31 (1:2)].
 Loco over speed warning lamp [LOSL31] lights up and warning hooter
[WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes after set time delay.
 Locomotive comes to idle as Transmission control relay [TCR31 (1:2)] gets
energized when normally open contact of [LOSR31 (13:14)] closes and at
the same time relay will get self locked with its own contact [TCR31
(13:14)] and opens its normally closed contact [TCR31 (31:32)] which is
connected in series with magnet valve [MMV31 (A1:A2)] and cuts off air
supply to engine throttle and transmission, so that locomotive will not move
by its own, when loco speed comes below 1.25 times of rated loco
maximum speed.
 Transmission control lock warning lamp [TCLL31] lights up.
 Emergency brake magnet valve [EBMV31 (A1:A2)] will gets energized
through the closing of normally open contact of locomotive over speed

Electrical Operation & Maintenance Manual – TPP Page 43 of 144

 relay [LOSR31 (43:44)] and opens its port, air supply goes to brake cylinder
to apply the brakes and hence loco comes halt.
 Engine comes to idle and transmission cuts off.
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when air
pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3)/RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31/RL31] extinguishes.
 To move the locomotive, SWITCH OFF and then SWITCH ON the
transmission circuit breaker (TCB31), provided on the instrument panel.

20)Close the brake circuit breaker [BCB31 (1:2)], which is located inside the Main
Control box (behind the driver's desk).
 Transmission air pressure switch [TAPS31 (2:3)] operates after opening the
isolating valve/cock, which is mounted on the instrument panel.
 Transmission “ON" lamp [TOL31] lights up

21)Electro pneumatic governor air pressure switch [GAPS31 (2:3)] operates by

closing of normally open contact when system pressure reaches the maximum
pre set level.
 Electro pneumatic governor magnet valve [GMV31 (A1:A2)] is energized.
 Unload the compressor delivery of air to atmosphere.
 Actuate the auto drain valve to remove the water accumulation from the
reservoir.

22)Forward air pressure switch [FAPS31 (2:3)] operates, by rotating the driver's
wheel in forward direction.
 Forward lamp [FL31] lights up.

23)Reverse air pressure switch [RAPS31 (2:3)] operates, by rotating the driver's
wheel in reverse direction

Electrical Operation & Maintenance Manual – TPP Page 44 of 144

  Reverse lamp [RL31] lights up.

24)Close the Gauge circuit breaker [GCB31 (1:2)] which is located inside the Main
Control box (behind the driver's desk).

a) Engine RPM meter (ERM11/ ERM21) & engine hour meter [EHM11/
EHM21] is provided on the instrument panel to indicate engine rpm and
number of hours used. The supply to the engine rpm and hour meter is fed
through the closing of the normally open contact of the engine safety relay
[ESR11 (23:24)/ ESR21 (23:24)].
 Magnetic pick up unit [MPU11/ MPU21] which is provided on the
flywheel housing for sensing the engine RPM

b) Lube oil pressure gauges [LOPG11/ LOPG21] are provided on the

instrument panel to indicate the engine lube oil pressure and is sensed by
pressure sensor [LOPSU11/ LOPSU21].

c) Lube oil temperature gauge [LOTG11/ LOTG21] are provided on the

instrument panel to indicate the engine lube oil temperature and is sensed
by temperature sensor [LOTSU11/ LOTSU21].

d) Water temperature gauge [WTG11/ WTG21] is provided on the instrument

panel to indicate the engine water temperature and is sensed by
temperature sensor [WTSU11/ WTSU21].

e) Transmission oil temperature gauge [TOTG11/ TOTG21] is provided on the

instrument panel to indicate the transmission oil temperature and is sensed
by temperature sensor [TOTSU11/ TOTSU21].

f) The speed of the vehicle along with distance travelled in kilometers is

shown on odometer in (Human machine interface).

Electrical Operation & Maintenance Manual – TPP Page 45 of 144

 g) Proximity switch [PS31] is provided on the front bogie rear final drive axle
box (right side) for sensing the speed of locomotive. Proximity Switch
[PS31 (Pin No.B)] senses speed of vehicle and send frequency signal to
HMI [12 pin connector (Pin no.11)].

25)Close the head and tail light circuit breaker [HTCB31 (1:2)], which is located
inside Main control box (Behind the driver's desk).

a) Switch “ON” the front headlight switch [FHLS31 (1:2)].

b) Switch “ON” the front headlight dim- bright switch [FHLDBS31 (1:2)] to
bright position.
 Front headlights [FHL31 & 32] Bright “ON”.
 Front headlight “ON” indication lamp [FHLOL31] lights up
 Rear tail lights [RTL31, 32] will “ON”.
 Rear taillights "ON" indication lamp [TLOL31] lights up

c) Switch "ON" the front headlight dim- bright switch [FHLDBS31 (1:3)] to Dim
position.
 Front headlights [FHL31 & 32] will glow Dim.
 Rear tail lights [RTL31, 32] will “ON”.
 Rear taillights “ON” indication lamp [TLOL31] lights up

d) Switch “ON” Tail light switch [TLS31 (1:2)].

 Front & Rear tail lights [FTL31, 32 & RTL31, 32] will "ON".
 Front tail lights and rear tail lights will "ON" and indication lamp
[TLOL31] lights up.

e) Switch “ON” the rear headlight switch [RHLS31 (1:2)].

f) Switch “ON” the rear headlight dim- bright switch [RHLDBS31 (1:2)] to
Bright position.
 Rear headlights [RHL31 & 32] Bright “ON”.

Electrical Operation & Maintenance Manual – TPP Page 46 of 144

  Rear headlight “ON” indication lamp [RHLOL31] lights up.
 Front tail lights [FTL31, 32] will “ON”.
 Front taillights “ON” indication lamp [TLOL31] lights up.

g) Switch “ON” the rear headlight dim- bright switch [RHLDBS31 (1:3)] to Dim
position.
 Rear headlights [RHL31 & 32] will glow Dim.
 Front tail lights [FTL31, 32] will “ON”.
 Front tail lights “ON” indication lamp [TLOL31] lights up.

h) Switch “ON” parking light switch (PLS31 (1:2)).

 Front and rear parking lights (FPL31, 32 & RPL31, 32) will “ON”.
 Front parking lights and rear parking lights “ON” indication lamp
(PLOL31) lights up.

26)Close the auxiliary circuit breaker [ACB31 (1:2)], which is located inside Main
control box (Behind the driver's desk).

a) Switch “ON” the cabin fan switch [CFS31-LH (1:2)].

 Cabin fan [CF31] will “ON”.

b) Switch “ON” the cabin fan switch [CFS-RH (1:2)].

 Cabin fan [CF32] will “ON”.

c) Switch “ON” inspection lamp socket switch [ILSS31 (1:2)].

 Cabin Inspection lamp sockets [ILS31, 32 & 33] are powered.

d) Switch “ON” the cabin light switch [CLS31 (1:2)].

 Cabin lamps [CL31 & 32] lights up.

e) Switch “ON” the hood light switch [HLSF31 (1:2)].

 Hood lamps [HLF31, 32, 33] lights up.

Electrical Operation & Maintenance Manual – TPP Page 47 of 144

 f) Switch "ON" the hood light switch [HLSF32 (1:2)].
 Hood lamps [HLF34, 35, 36] lights up.

g) Switch “ON” the hood light switch [HLSR31 (1:2)].

 Hood lamps [HLR31, 32, 33] lights up.

h) Switch "ON" the hood light switch [HLSR32 (1:2)].

 Hood lamps [HLR34, 35, 36] lights up.

i) Switch “ON” the gauge light switch [GLS31 (1:2)].

 Gauge lamps [GL31 & 32] lights up.

j) Lamp test push button [LTP31 (2:3)] is provided on the instrument panel to
check the healthiness of indication lamps.

Electrical Operation & Maintenance Manual – TPP Page 48 of 144

 ELECTRICAL

CIRCUIT

DIAGRAM

Electrical Operation & Maintenance Manual – TPP Page 49 of 144

Electrical Operation & Maintenance Manual – TPP Page 50 of 144
 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 5) * INDICATES NO SEPARATE DRAWINGS. DRG. NO. 34180250
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
3) WORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS WITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A 300 A
K
TO 'A'

PD11
TO SHEET 3 A
MCB11

109
DKS11 60 AMPS
TO SHEET 3 IGN 2 1 OFF 104 103 100
109 L B 2 1
A
TO SHEET 3 3 TO SHEET 2
AM11

323
312

308
STA
1 105
CCB11

105A
5 AMPS
A A 2
3
HTD11 HTD12
K K
T

110

110
4 SPB11a

104
450
110
110

110

110

110
NO

105
323 71 1 EESPB11a
ESR11 (PART) ACCR11 R BDL11
72
113B 81
B B

111A

111A
NC 2

114
123
323

NC +VE - 13 3 ESR11

100
113A 82
A 1 -VE +
ESR11
14 4 NC
A HTD14 NO SPB11
NC WLSI11 NO 3 1
HTD13 K 2 EESPB21b a 4 2

106
K (PART)

115

111
LTP31

112

112
K A EMISC11
C (PART) 15 3
WLSI11 +VE C
125 HTD15 124 NC C NC ST11
WL

116
-VE 18 16
NO NC
C
EOSS11 AA11
(2352 rpm)
WLSU11
NO
NC
117

C
LOPS11
(0.5 Bar)
NC
NO

112
125

112

112
15 2
119

C S G
C HT11 C
BAT MTR
18 16

102
A
NO NC
FPLD11
118

120

K
126

T T T 3 4 100
121

-
A1 A2
450

450

450
A1 A1 R R A1 G A1 A1 MS11 SM11
1 8 1 2
2 8 2
A2 A2 A2 A2 A2
HT11 WH11 EOSL11 LLOPL11 ESR11 EOL11 FS11 ST11
1 NC 5 NO 1 NC
(5 sec) 3 NC (8 sec)

TO 'B'
2

2
D D
FRONT ENGINE (FRONT POWER PACK) CONTROLS DRN. SUNDAR.V ELECTRICAL CIRCUIT
SCALE
NTS
TRCD. DIAGRAM SAN ENGG. AND LOCOMOTIVE
COMPANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 1 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 51 of 144

 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE.
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
5) * INDICATES NO SEPARATE DRAWINGS. DRG. NO. 34180250
3) WORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS WITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A
300
FROM 'A' TO 'A'
K

PD21
MCB21 A
60 AMPS
DKS21
203
200 1 2 B L 204 OFF 1 2 IGN 209
A

209
FROM SHEET 1 2 4 3
BIS31 AM21
STA 1
1 3
CCB21
5 AMPS

205A
2
3

1
T 210
1 4 SPB21a

210

210

210

210

210

210
LCB31 NO

450
5 AMPS 71

205
2 1 ESR21
R ACCR21 EESPB21a 72

3
NC

3
B 2 2 BDL21
213B
(PART) NC
B

223
2
DS32

211A

211A
DS31 3 13 - +VE

214
200
1 3 1 3 ESR21 213A 1 A
81 + -VE
ESR21 4 14 EESPB11b
82 SPB21 NO WLSI21 NC HTD24
NC
(PART)

7
8

204
K

4
5
1 3 2
c

224
215
2 4

206

212
1 3 1 3
LTP31 EMISC21 A K

211
C
2 2 (PART) C WLSI21
CLS32 NC
BA31 CLS31 +VE
NC HTD25 TO SHEET 3

216
1A

WL

9
6

-VE
C
+
WLSU21 EOSS21
V AA21 (2352 rpm)
BA32 NC NO
- CL32

217
VM31 CL31
2A

15
3 C
2
2

ST21 C
LOPS21
16 18 (0.5 Bar)

212

212

212
NO NO NC
BA33 NC

C C

219
G S

MTR BAT
202

220

218
A
207

FPLD21
K

4 3 T T T
- 200

221
A2 A1

450

450

450
SM21
MS21 A1 A1 G A1 R R
2 1 7
2 8
A2 ST21 A2 FS21 EOL21 A2 ESR21 LLOPL21 EOSL21
1 NC 4 NO
(8 sec) 3 NC

FROM 'B' TO 'B'

2

2
D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
REAR ENGINE (REAR POWER PACK) CONTROLS DIAGRAM
NTS
TRCD. SAN ENGG. AND LOCOMOTIVE
COMPANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 2 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 52 of 144

 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERW ISE.
2) CO DE O F PRACTICE, ABBREVIATION ETC., TO IS : 696.
5) * INDICATES NO SEPARATE DRAW INGS. DRG. NO. 34180250
3) W ORK TO CO ARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS W ITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SAN ENGG . AND LOCOMOTIVE
COMPANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 3 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 53 of 144

 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN m m UNLESS STATED OTHERW ISE. 5) * INDICATES NO SEPARATE DRAW INGS. DRG . NO. 34180250
2) CODE O F PRACTICE, ABBREVIATION ETC., TO IS : 696.
3) W O RK TO COARSE/MEDIUM /FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS W ITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SA N ENGG . AND LOCOM OTIV E
COM PANY LTD.
DIESEL HYD. LOCO. BANGALO RE - 560 048
CHKD.
T.P.P-SHEET 4 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG . NO . 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 54 of 144

 1 2 3 4 5 6
1) ALL DIM ENSIO NS ARE IN m m UNLESS STATED OTHERW ISE. 5) * INDICATES NO SEPARATE DRAW INGS. DRG. NO. 34180250
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
3) W ORK TO CO ARSE/MEDIUM /FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS W ITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SAN ENGG. AND LOCOMOTIVE
COM PANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 5 OF 8 DATE REV
Electrical
ECN. [Link].
Operation & Maintenance
DESCRIPTION DATE
Manual
INTL.
– TPP
ECN. NO. REV. DESCRIPTION DATE
Page 55 of 144
INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6
 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERWISE. 5) * INDICATES NO SEPARATE DRAW INGS. DRG. NO. 34180250
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
3) W ORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS W ITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SAN ENGG. AND LOCOMOTIVE
COMPANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 6 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
Electrical
1 Operation & Maintenance2Manual – TPP 3 Page 56 of4 144 5 6
 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERW ISE. 5) * INDICATES NO SEPARATE DRAWINGS. DRG. NO. 34180250
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
3) W ORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS WITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SAN ENGG. AND LOCOMOTIVE
COMPANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 7 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 57 of 144

 1 2 3 4 5 6
1) ALL DIMENSIONS ARE IN mm UNLESS STATED OTHERW ISE.
2) CODE OF PRACTICE, ABBREVIATION ETC., TO IS : 696.
5) * INDICATES NO SEPARATE DRAWINGS. DRG. NO. 34180250
3) W ORK TO COARSE/MEDIUM/FINE TOLERANCES OF IS : 2102 FOR DIMENSIONS W ITHOUT TOLERANCE.
4) DO NOT SCALE, IF IN DOUBT PLEASE ASK.

A A

B B

C C

D SCALE D
DRN. SUNDAR.V ELECTRICAL CIRCUIT
NTS
TRCD. DIAGRAM SAN ENGG. AND LOCOMOTIVE
COM PANY LTD.
DIESEL HYD. LOCO. BANGALORE - 560 048
CHKD.
T.P.P-SHEET 8 OF 8 DATE REV
ECN. NO. REV. DESCRIPTION DATE INTL. ECN. NO. REV. DESCRIPTION DATE INTL. APPD. 30-05-2013 DRG. NO. 34180250 06
1 2 3 4 5 6

Electrical Operation & Maintenance Manual – TPP Page 58 of 144

 CHAPTER – 5
SAFETY

DEVICES

Electrical Operation & Maintenance Manual – TPP Page 59 of 144

Electrical Operation & Maintenance Manual – TPP Page 60 of 144
 CHAPTER 5
5.0 SAFETY DEVICES
It is essential that the locomotive should be self-protecting in operation & should
be provided with certain protective safety devices to protect the engine &
transmission against operational hazards during faulty conditions.

1) Engine lube oil pressure drops below the safe limit (0.5kg/cm2)
 Low lube oil pressure switch [LOPS11 (C: NO) / LOPS21 (C:NO)] operates,
which is fitted in the engine lube oil line.
 Engine safety relays [ESR11 (A1:A2) / ESR21 (A1:A2)] is de-energised by
opening of closed normally open contact of low lube oil pressure switch
[LOPS11 (C: NO) / LOPS21 (C: NO)] and cuts off electric supply to fuel
solenoid.
 Fuel solenoid [FS11 (A1:A2) / FS21 (A1:A2)] is de-energized by opening of
closed normally open contact of engine safety relay [ESR11 (13:14) /
ESR21 (13:14)] and cuts off fuel supply to the engine.
 Main magnet valve [MMV31 (A1:A2)] is de-energised by opening of closed
normally open contact of engine safety relay [ESR11 (33:34) / ESR21
(33:34)] and cuts off air supply to engine throttle and transmission.
 Low lube oil pressure warning lamp [LLOPL11 / LLOPL21] lights up.
 Engine comes to shut down and transmission cuts off.
 Engine "ON" light [EOL11 / EOL21] extinguishes.
 Battery discharge warning lamp [BDL11 / BDL21] lights up.
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when air
pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 Warning hooter [WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes off
after set time delay.

Electrical Operation & Maintenance Manual – TPP Page 61 of 144

NOTE:
Return driver's wheel back to off or neutral position before restarting the engine.

2) Engine cooling water temperature exceeds above pre-set safe value

(93ºC).
 Water temperature switch [WTS11 (C: NC) / WTS21 (C: NC)] operates
which is installed on the water manifold.
 Main magnet valve [MMV31 (A1:A2)] is de-energised by opening of
normally closed contact of water temperature switch [WTS11 (C: NC) /
WTS21 (C: NC)] and cuts off air supply to engine throttle and transmission.
 High water temperature warning lamp [HWTL11 / HWTL21] lights up.
 Engine comes to idle & transmission cuts off.
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when air
pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 Warning hooter [WH31 (A1:A2)] gives sound and goes off after set time
delay.
 Transmission control relay [TCR31 (A1:A2)] will energized through the
closed normally open contact of water temperature switch [WTS11 (C: NO)
/ WTS21 (C: NO)] and same time relay will self locked with its own contact
[TCR31 (13:14)] and opens its normally closed contact [TCR31 (31:32)]
which is connected in series with main magnet valve [MMV31 (A1:A2)], so
that locomotive will not move by its own when water temperature comes
down to its normal condition. Transmission control lock warning lamp
[TCLL31] lights up.
 To move the locomotive, switch "OFF" and then switch "ON" the
transmission circuit breaker [TCB31 (1:2)], which is provided on the
instrument panel.

Electrical Operation & Maintenance Manual – TPP Page 62 of 144

NOTE:
Return driver's wheel back to off or neutral position once fault occurs.

3) Engine maximum speed exceeds more than predetermined safe value

(2352 rpm).
 Engine over speed switch [EOSS11 (C: NC) / EOSS21 (C: NC)] operates
which is installed near the engine governor.
 Engine safety relay [ESR11 (A1:A2) / ESR21 (A1:A2)] is de-energised by
opening of normally closed contact of engine over speed switch [EOSS11
(C: NC) / EOSS21(C: NC)] and cuts off electric supply to fuel solenoid.
 Fuel solenoid [FS11 (A1:A2) / FS21 (A1:A2)] is de-energized by opening of
closed normally open contact of engine safety relay [ESR11 (13:14) /
ESR21 (13:14)] and cuts off fuel supply to the engine.
 Main magnet valve [MMV31 (A1:A2)] is de-energised by opening of closed
normally open contact of engine safety relay [ESR11 (33:34) / ESR21
(33:34)] and cuts off air supply to engine throttle and transmission.
 Engine over speed warning lamp [EOSL11 / EOSL21] lights up.
 Engine comes to shut down and transmission cuts off.
 Engine "ON" light [EOL11 / EOL21] extinguishes.
 Battery discharge warning lamp [BDL11 / BDL21] lights up.
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when air
pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 Warning hooter [WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes off
after set time delay.

NOTE:
Return driver's wheel back to off or neutral position before restarting the engine.

Electrical Operation & Maintenance Manual – TPP Page 63 of 144

4) Transmission oil temperature exceeds above preset value (110 deg C).
 Transmission oil temperature switch [TOTS11 (2:1) / TOTS21 (2:1)]
operates which is located behind the driver's desk fitted to the transmission
output pipe (oil) line.
 Main magnet valve [MMV31 (A1:A2)] is de-energized by opening of
normally closed contact of transmission oil temperature switch [TOTS11
(2:1) / TOTS21 (2:1)] and cuts off air supply to engine throttle and
transmission.
 Transmission oil temperature warning lamp [HTOTL11 / HTOTL21] lights
up.
 Engine comes to idle and transmission cuts off.
 Battery discharge warning lamp [BDL11 / BDL21] lights up /blinks (low
engine idle rpm)
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when air
pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 Warning hooter [WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes off
after set time delay.
 Transmission control relay [TCR31 (A1:A2)] will energized through the
closed normally open contact of transmission oil temperature switch
[TOTS11 (2:1) / TOTS21 (2:1)] and same time relay will self locked with its
own contact [TCR31 (13:14)] and opens its normally closed contact
[TCR31 (31:32)] which is connected in series with main magnet valve
[MMV31 (A1:A2)], so that locomotive will not move by its own when oil
temperature comes down to its normal condition.
 Transmission control lock warning lamp [TCLL31] lights up.
 To move the locomotive, switch "OFF" and then switch "ON" the
transmission circuit breaker [TCB31 (1:2)], which is provided on the
instrument panel.

Electrical Operation & Maintenance Manual – TPP Page 64 of 144

NOTE:
Return driver's wheel back to neutral position once fault occurs.

5) Water level drops below the safe limit.

 Water level sensor unit [WLSU11 (C:NC) / WLSU21 (C:NC)] operates,
which is fitted on the top of radiator water tank
 Engine safety relay [ESR11 (A1:A2) / ESR21 (A1:A2)] is de-energised by
opening of normally closed contact of water level switch cum indicator
[WLSI11(C: NC) / WLSI21 (C: NC)] and cuts off electric supply to fuel
solenoid.
 Fuel solenoid [FS11 (A1:A2) / FS21 (A1:A2)] is de-energized by opening of
closed normally open contact of engine safety relay [ESR11 (13:14) /
ESR21 (13:14)] and cuts off fuel supply to the engine.
 Main magnet valve [MMV31 (A1:A2)] is de-energized by opening of closed
normally open contact of engine safety relay [ESR11 (33:34) / ESR21
(33:34)] and cuts off air supply to engine throttle and transmission.
 Water level switch cum indicator [WLSI11 / WLSI21] starts blinking "LOW"
 Engine comes to shut down and transmission cuts off.
 Engine "ON" light [EOL11 / EOL21] extinguishes.
 Battery discharge warning lamp [BDL11 / BDL21] lights up.
 Transmission air pressure switch [TAPS31 (2:3)] opens its contact when
air pressure drops by de- energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)]
opens its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 Warning hooter [WH11 (A1:A2) / WH21 (A1:A2)] gives sound and goes off
after set time delay.

NOTE:
Return driver's wheel back to off or neutral position before restarting the engine.

Electrical Operation & Maintenance Manual – TPP Page 65 of 144

6) Locomotive speed exceeds above the pre-set limit (1.25 times the rated
maximum locomotive speed).
 Locomotive speed is sensed by proximity switch [PS31] and at the same
time electrical signal is sensed by HMI [HMI31]
 Loco over speed sensing relay gets energized when loco speed exceeds
above 1.25 times the rated maximum locomotive speed.
 Loco over speed warning lamp [LOSL31] lights up and extinguishes after
reset only.
 Warning hooter [WH11 / WH21] hoots and goes off after set time delay
 Transmission control lock warning lamp [TCLL31] lights up
 Emergency brake magnet valve [EBMV31 (A1:A2)] will gets energized
through the closing of normally open contact of locomotive over speed
relay [LOSR31 (43:44)] and opens its port, air supply goes to brake cylinder
to apply the brakes and loco comes halt.
 Engine comes to idle and transmission cuts off.
 Transmission air pressure switch [TAPS31] opens its contact when air
pressure drops by de-energizing of the main magnet valve [MMV31
(A1:A2)].
 Transmission "ON" light [TOL31] extinguishes.
 Forward/Reverse air pressure switch [FAPS31 (2:3) / RAPS31 (2:3)] opens
its contact depending on the direction of loco.
 Forward/Reverse "ON" light [FL31 / RL31] extinguishes.
 To move the locomotive, SWITCH “OFF” and then SWITCH “ON” the
transmission circuit breaker [TCB31 (1:2)], which is provided on the
instrument panel.

NOTE:
Return driver's wheel back to neutral position once fault occurs.
 IF ANY ONE OF THE ABOVE FAULTS OCCURS. INVESTIGATE AND
SEE THEIR POSSIBLE CAUSES. REPORT MAINTENANCE
PERSONNEL.

 START THE ENGINE STRICTLY AFTER INVESTIGATION ONLY.

Electrical Operation & Maintenance Manual – TPP Page 66 of 144

7) A removable driver's key switch [DKS11 (OFF: IGN: START) / DKS21 (OFF:
IGN: START)] is provided on the driver's desk to prevent un-authorized
persons starting the engine or operating the locomotive.

8) Brake Air pressure switch [BAPS31 (2:3)] is provided for low brake pressure
until sufficient brake pressure develops to the safe value, a visual indication
will indicate on the panel [LBPL31] and transmission magnet valve [TMV31
(A1:A2)] will not energize till brake pressure builds up.

9) Transmission Magnet valve [TMV3 (A1:A2)] is provided to interlock the

transmission to prevent the locomotive movement when there is low air
pressure in the reservoir.

10)Main magnet valve [MMV31 (A1:A2)] is used as a safety valve during failure of
safety controls and thus the engine comes to idle and transmission cuts off.

11)Hooter timer [HT11 (A1:A2) / HT21 (A1:A2)] is provided to cut off the hooting
of the hooter after set time delay to protect the hooter and avoid hooting for
long period.

12)Starter timer [ST11 (A1:A2) / ST21 (A1:A2)] is provided to prevent the long
cranking of the starter motor, which is set for 8 seconds. During starting of the
engine if driver holds the engine starter push button for more than 8 seconds
the timer gets energized and cuts off the power to the magnetic switch and in
turn avoids driver from cranking the engine once started.

13)Power cut off air pressure switch [PCS31 (2:1)] is used as safety measure
during a full/emergency brake application which serves to cut off traction
power to the locomotive and thus the engine comes to idle and transmission
cuts off.

14)Electro Pneumatic governor consists of governor air pressure switch [GAPS31

(2:3)] & governor magnet valve [GMV31 (A1:A2)] and are provided in the

Electrical Operation & Maintenance Manual – TPP Page 67 of 144

 pneumatic circuit to unload the compressor delivery of air to atmosphere and
actuate the auto drain valve when the system pressure reaches the maximum
preset level.

15)Transmission control relay [TCR31 (A1:A2)] is used as a safety device to

interlock the transmission as a precautionary measure. If by chance, driver has
forgot to bring the engine throttle to zero/neutral position when water or oil
temperature exceeds above the pre set limit, so that locomotive will not move
by its own when water or oil temperature comes to its normal condition. To
move the locomotive, switch "OFF" and then switch "ON" the transmission
circuit breaker [TCB31 (1:2)], which is provided on the instrument panel.

Electrical Operation & Maintenance Manual – TPP Page 68 of 144

 CHAPTER – 6
AUXILIARY
POWER
&
CONTROL
EQUIPMENT

Electrical Operation & Maintenance Manual – TPP Page 69 of 144

Electrical Operation & Maintenance Manual – TPP Page 70 of 144
 CHAPTER 6
6.0 AUXILIARY POWER & CONTROL EQUIPMENT
AUXILIARY ALTERNATOR
The Auxiliary Alternator has been specially designed for use on mobile diesel
locomotive. The alternator is a three-phase machine of the revolving field and
stationary armature type. Alternator is a self-rectifying, self-excited air-cooled. A
separate current regulator is not required as the alternator itself is self-regulating
in this respect built in diodes in the alternator to prevent the reverse current flow
from battery into the alternator through the stator when the machine is stationary
or when generating less than the battery voltage. Hence, a cutout is not required.
As the alternator is self-limiting in current output, the regulator has only to control
output voltage, which it does by regulating the alternator field current.

The alternator consists of field coil, stator, rotor, bearings, voltage regulator unit
and diode rectifier. When a current path to the field coil is established by the
voltage regulator, a magnetic flux is created which flows through a small air gap to
the rotor and alternately from pole to pole of the stator, inducing a magnetic field
in the stator coil winding. As the rotor is turned, these magnetic lines of force are
completed and inducing alternating three phase voltage and amperage in the
stator coil winding. The alternating current output from the stator is supplied to a
three-phase full wave bridge rectifier, which provides a direct current to the load.

The alternator and rectifier unit is having ample capacity at continuous rating, to
provide power simultaneously for fans, controls, loco lighting, battery charging and
other D.C loads of locomotive.

The six rectifier diodes of the full wave bridge rectifier circuitry embedded in two
circular mounting plates, which form a heat sink assembly at the front of the
alternator next to the front, end cover. This provides effective diode heat
dissipation and cooling.

Electrical Operation & Maintenance Manual – TPP Page 71 of 144

VOLTAGE REGULATOR
The voltage regulator is an electronic control device, which provides long life,
reliability and performance stability of the system.

The voltage regulator is fully transistorized with no moving parts and does not
require any service attention and is non-repairable.

The voltage regulator consists of transistors, diodes and resistors, which are fixed
on a printed circuit base in a seated moulded case. The regulator senses the
voltage requirement of the load and supplies the necessary field current to the
alternator for accurate control of the alternator under all loading conditions to give
automatic voltage regulation.

Thus the voltage regulator is capable of maintaining the output voltage of the
alternator for controls, auxiliary loads and battery charging voltage throughout the
full range of alternator load and speed.

STARTER MOTOR
The starter motor is of axial design. Axial starters are used on engine, where
because of the high inertia of flywheel and crankshaft, it is necessary for the
starter pinion to engage with the engine flywheel before it develops full torque.
Engagement between starter pinion and engine flywheel is affected by an axial
movement of the complete armature assembly. The field winding of the starter
Motor consists of a main series winding, an auxiliary sensing winding and start
winding. A solenoid operates two-stage switch forms an integral part of the starter
and is used to control the starting cycle, so that only a small switch to handle the
solenoid current is required externally.

AMMETER
It is provided on the instrument panel, which is always connected permanently in
series with alternator circuit. It indicates the condition of the battery through the
direction of current flow as charge or discharge. The center of the dial is the point

Electrical Operation & Maintenance Manual – TPP Page 72 of 144

of zero current flow and the two extremes indicate maximum charge and
discharge.
VOLTMETER
It is provided on the instrument panel, which is always connected permanently
across the battery to indicate the load voltage.

AIR PRESSURE SWITCH

It is single pole double throw, electro pneumatic pressure switch, is designed for
starting or stopping or indicating of equipment when pressure in the system drops
or exceeds the pre set limits.

Electrical Operation & Maintenance Manual – TPP Page 73 of 144

Electrical Operation & Maintenance Manual – TPP Page 74 of 144
 CHAPTER – 7

MAINTENANCE
OF
AUXILIARY
SYSTEM

Electrical Operation & Maintenance Manual – TPP Page 75 of 144

 CHAPTER 7
7.0 MAINTENANCE OF AUXILIARY SYSTEM
For an efficient and satisfactory performance of the locomotive a proper periodical
maintenance of the various items is necessary in the electrical system as per
instruction given in the standard maintenance schedule

Electrical Operation & Maintenance Manual – TPP Page 76 of 144

STARTER MOTOR

CHAPTER 7
7.0 MAINTENANCE OF AUXILIARY SYSTEM
For an efficient and satisfactory performance of the locomotive a proper periodical
maintenance of the various items is necessary in the electrical system as per
instruction given in the standard maintenance schedule

STARTER MOTOR
a) Checking and lubricating the starter motor: Regularly lubricate the plain
friction bearings on the pinion side of the starter motor, through the oil hole
(remove the counter sunk screw). The bearing on the commutator side does
not require regular lubrication. When over hauling the starter motor the bearing
should be cleaned and checked properly. The pinion of the starter motor and
the flywheel ring should be cleaned of dirt and to be greased sparingly.

ALTERNATOR
Maintenance of the charging system is limited to simple tasks designed to keep
the system in tiptop shape by eliminating the build up of dirt and corrosion. The
diodes in the alternator function as one way valves and the transistors in the
regulator operate as fast switches both are accurate and sensitive they do not
wear and never require adjustment but because they are sensitive to voltage
change and high temperature the following precautions are vital to prevent them
being destroyed.

a) Keep the alternator clean with a cloth moistened in kerosene (paraffin) or white
spirit and ensure that ventilation slots or air spaces are clear and unobstructed.

b) Keep the regulator housing clean and ensure that cooling air pass freely over
the housing.

Electrical Operation & Maintenance Manual – TPP Page 77 of 144

c) Ensure that the driving belt on the alternator has correct tension as too slack a
belt will cause slip and too tight a belt will shorten the life of the belt.

d) Check the mounting bolts for tightness.

e) Always identify a lead to its correct terminal when disconnecting or

reconnecting any lead. A short circuit or wrong connection giving reverse
polarity will immediately and permanently ruin the transistors and diodes.

f) Never connect a battery into the system without checking for correct polarity
and correct voltage. Short Circuiting or reverse polarity no matter how brief will
cause immediate and permanent damage to transistors and diodes, besides
possible damage to the loads.

g) Never disconnect a lead without first stopping the alternator and turning any
switches in the circuit to the "OFF" position.

h) Never disconnect the battery while the alternator is running. This will cause a
voltage surge in the charging system that will immediately ruin the diodes or
transistors.

i) Always ensure that the regulator is mounted with the terminals vertically down.

j) Always ensure that the regulator mounting is such that it is not subjected to
direct water splash.

k) Always ensure that the alternator is not mounted close to the exhaust manifold
without any protection.

BATTERY
a) Keep naked flames away from the battery at all times, particularly during
and after a charge.

Electrical Operation & Maintenance Manual – TPP Page 78 of 144

 b) Keep the cells and containers dry and clean, if there is any corrosion of the
metal work clean the affected parts and neutralise any remaining acid with
a solution of sodium carbonate to protect from further corrosion by covering
with acid proof paint.
c) Smear all metal inter cell and terminal connectors with petroleum jelly.

d) Add nothing to the cells but distilled water to top up the level never allows
the acid level to fall below the level of the plates. Acid should never be
added to the cells except by properly trained technician about batteries
handling.

e) Keep vent plugs and connection tight.

f) Specific gravity at 27deg C for batteries operating in tropical climate, where

ambient temperature is frequently about 20 deg C.

 Normal charged specific gravity - 1.255

 Initial falling in specific gravity - 1.21
 Specific gravity below which battery
should not be discharged - 1.13
 Battery received charged needs equalizing
charge is specific gravity is below - 1.24
 Maximum electrolyte temperature during charging - 52 deg C

HOW TO HANDLE CHARGED BATTERY FILLED WITH ACID?

a) If the battery has been given a first charge and the specific gravity is near
the fully charged value it can be put into service immediately.

b) If the specific gravity is below 1.24 the battery should be given an

equalizing charge/bench charging.

HOW THE CHARGED BATTERY IS PUT INTO OPERATION?

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Charged batteries can be put into operation immediately after filling with
chemically pure sulfuric acid with a specific gravity of 1.24 (1.28 in temperate
climate). Of course it is important that a battery put into service by means receives
the charge from the generator of the vehicle. This can be obtained only while
driving the vehicle without idling; otherwise it is necessary that the battery should
receive some regular full charge. Especially during very cold climate a short
additional charge or boost charge is recommended. It serves for warming up, as a
cold battery accepts the charging current of the generator only with reluctance.
Correct way of activating is important for the service life of a battery. Some hints
for filling and charging are given below.

1) Unscrew the vent plugs.

2) Chemically pure sulfuric acid with a specific gravity of 1.24 (in temperate
climate 1.28) to be filled. Fill the acid to the level of 5mm above the upper edge
of the separator. This level of acid can be checked with a clean wooden stick.

3) After lapse of time the level of the acid to be checked. If there is not enough
acid it should be filled up to the mark. If there is any surplus acid it should be
drawn off. A temperature control is important; the maximum temperature
during the charging should not exceed 50C

4) The maximum normal charge rating of a battery is shown in the battery

guarantee card supplied with each battery. If the suitable current is not
available with the charging circuit, the next lower one is to be chosen it must
then be charged for a little longer period.

5) Connect the plus terminal of the charging line to the plus terminal of the battery
and the minus terminal of the charging line to the minus terminal of the battery.

6) The charging instruments to be switched “ON” check correct contact and

polarity.

Electrical Operation & Maintenance Manual – TPP Page 80 of 144

7) After 12 hours the specific gravity of the acid in each cell is to be tested by
means of the hydrometer. The battery is fully charged when the specific gravity
remains constant during 3 hourly readings at 1.24 (in temperate climate 1.28)
and the voltage measured with charging current still flowing in between 2.56 to
2.70 volt per cell. If these conditions are met the charging can be
disconnected.

8) After charging is completed the battery should cool down to the room
temperature. After that the level of the acid is tested again and adjusted.

9) The average time of charge is about 9 to 14 hours (for normal batteries it is

about 50 hours). If the temperature exceeds 50 degree centigrade the process
of charging has to be interrupted until the temperature is dropped below 40
degree centigrade.

10)Vent plugs are screwed and terminals are greased properly. Batteries are
washed and cleaned. The battery is now ready for installation in the vehicle.

GENERAL INSTRUCTIONS TO HANDLE BATTERY

1) After arranging the Batteries, inter unit connections shall be firmly tightened
and checked.

2) All inter unit connections shall be given a thin coat of Vaseline or Petroleum
jelly on the external surfaces.

3) If any container is broken, the groups shall be removed and kept immersed in
distilled water till container replacement.

4) Care must be taken not to short circuit the cells while using spanner etc.

5) Records are to be maintained perfectly & if any cells show weakening, it

should be intimated to the manufacturer.

SAFETY PRECAUTIONS DURING OPERATION WITH BATTERIES

Electrical Operation & Maintenance Manual – TPP Page 81 of 144

1) Always use protective safety items viz., goggles, rubber gloves, shoes /
gumboots & aprons while handling acid.

2) Never add water to concentrated acid as it will cause splash and result in
severe injury.

3) In case of acid splash to eyes or skin wash immediately with large quantity of
cold water and contact near by doctor for treatment.

4) Do not bring open flame or lighted cigarettes etc., near the batteries as it may
cause explosion and result in severe injury.

Electrical Operation & Maintenance Manual – TPP Page 82 of 144

 CHAPTER – 8

INSPECTION
SHEETS
OF
MAINTENANCE
SCHEDULE

Electrical Operation & Maintenance Manual – TPP Page 83 of 144

Electrical Operation & Maintenance Manual – TPP Page 84 of 144
 WEEKLY INSPECTION SHEET

VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILIARY ALTERNATOR

General Examination

Examine belt drive

BATTERIES

General examination

Electrical Operation & Maintenance Manual – TPP Page 85 of 144

FORTNIGHTLY INSPECTION SHEET

VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILLIARY ALTERNATOR

General examination

Examine belt drive

BATTERIES

General examination

Top up and check connections

Record specific gravity of all cells

Check charging rate

Electrical Operation & Maintenance Manual – TPP Page 86 of 144

MONTHLY INSPECTION SHEET

VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILLIARY ALTERNATOR

General examination

Examine belt drive

Check connections

BATTERIES

General examination

Top up and check connections

Record specific gravity of all cells

Check charging rate

LIGHTING CIRCUITS

Check illumination lights

CONTROL CUBICLE

Electrical Operation & Maintenance Manual – TPP Page 87 of 144

General Examination

DRIVER DESK

General Examination

Electrical Operation & Maintenance Manual – TPP Page 88 of 144

 QUARTERLY INSPECTION SHEET
VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILLIARY ALTERNATOR

General examination

Examine belt drive

Check voltage regulation

Check connections

BATTERIES

General examination

Top up and check connections

Check cleanliness & grease coating of terminals

Record specific gravity of all cells

LIGHTING CIRCUITS

Check lamp holders, lamps & fittings

Electrical Operation & Maintenance Manual – TPP Page 89 of 144

CONTROL CUBICLE

General Examination

Check for loose connections

Examine relay contact tips

Check operation of all relay coils manually

Check operation of all Circuit Breakers manually

Check operation of all Switches manually

DRIVER DESK

General Examination

Check for loose connections

Examine Switch contact tips

Check operation of all switches manually

Check all pneumatic operated equipment manually

Electrical Operation & Maintenance Manual – TPP Page 90 of 144

 HALF YEARLY INSPECTION SHEET
VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILIARY ALTERNATOR

General examination

Examine belt drive

Check that the rotor turns freely

Check voltage regulation

Check connections

BATTERIES

General examination

Give equalizing charge

Top up and check connections

Check cleanliness & grease coating of terminals

Record specific gravity of all cells

LIGHTING CIRCUITS

Check lamps & fittings

CONTROL CUBICLE

Electrical Operation & Maintenance Manual – TPP Page 91 of 144

General Examination

Check for loose connections

Examine relay contact tips

Check operation of all relay coils manually

Check operation of all Circuit Breakers manually

Check operation of all Switches manually

DRIVER DESK

General Examination

Check for loose connections

Examine Switch contact tips

Check operation of all switches manually

Check all pneumatic operated equipment manually

Electrical Operation & Maintenance Manual – TPP Page 92 of 144

 MAJOR OVERHAUL INSPECTION SHEET
VEHICLE No. : ____________ DATE : ____________

ENGINE RUNNING HOURS : ____________

AUXILIARY ALTERNATOR

Dismantle & repack bearing with grease and examine all components. Replace
appropriate components if required.

BATTERIES

General examination and replace if required

LIGHTING CIRCUITS

Check lamps & fittings. Replace if required.

CONTROL CUBICLE

General Examination

Check connections

Examine condition of Relays, Circuit Breakers & Switches. Replace if required.

DRIVER DESK

General Examination

Check connections

Examine condition of Electrical and Pneumatic equipment. Replace if required.

Electrical Operation & Maintenance Manual – TPP Page 93 of 144

Electrical Operation & Maintenance Manual – TPP Page 94 of 144
 CHAPTER – 9

TROUBLE

SHOOTING

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Electrical Operation & Maintenance Manual – TPP Page 96 of 144
 CHAPTER 9
9.0 TROUBLE SHOOTING
Troubleshooting is an organized study of the problem and planned method of
procedure for investigation and correction of the difficulty. Trouble shooting
guidelines are provided to help in minimizing the time required to find out & correct
any trouble, which may occur during operation.
These guidelines do not include the trouble caused by the normal maintenance.

STARTER MOTOR
Failure of the engine to start may be attributed (treated) not only to the faulty
starter motor but also to other system faults such as battery, switches, wiring
connections, ignition systems or fuel supply etc.

Make sure that the trouble does not lie elsewhere before attempting to test the
starter motor.

The following are some useful hints for dealing with trouble limited to starter
motor, such as

SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION

No. DEFECTS
1. When starter Discharge/defective Recharge
motor is operated battery. battery/substitute a fully
its shaft fails to charged battery. If starter
rotate or rotates motor now cranks the
slowly and the engine, then the battery
starter motor must be attended.
does not crank Loose Tighten all connections.
the engine even connections/defective
though pinion has earth connections
engaged with ring Dirty, oily or badly burnt Remove the starter for
gear. commutator. further inspection.

Electrical Operation & Maintenance Manual – TPP Page 97 of 144

 Starter terminal or brush Remove the starter for
box having an earth fault. further inspection.
Defective solenoid Remove the starter for
switch. further inspection.
Defective armature/field Remove the starter for
coils. further inspection.
2. Armature rotates Pinion improper Clean it.
but pinion fails to engagement.
engage Burr formation on pinion Deburr it by filing.
or ring gear.
Defective auxiliary coil Change auxiliary coil.
Loose mounting. Tighten mounting/units.
Worn commutator Change the bush.
end/drive end bush.
Commutator bearing pin Check the tightness of
loose. bearing pin fixing screws.
3. Starter motor Sticky starting key switch. Disconnect starter cable
continues running immediately at battery or
after release of starter, repair/ replace
starting key switch.
switch. Short in wiring harness. Repair fault in wiring.
Dry - drive end bush. Trace cause and lubricate.
Sticky solenoid switch Remove the starter for
contacts. solenoid inspection.
Bush in pinion seized on Remove the starter from
shaft. the vehicle for inspection.
Pinion/ring gear fouled or Clean thoroughly,
damaged. deburring of pinion & ring
gear by filing.
4. Pinion engages In-sufficiently charged Recharge the battery /
but starter motor battery/corroded clean terminal & smear
does not crank terminals. petroleum jelly.

Electrical Operation & Maintenance Manual – TPP Page 98 of 144

 the engine In sufficient pressure on Change the brush springs/
(whining noise is carbon brushes or worn brushes.
heard). out brushes.
Shorted/earthing Change armature.
armature.
Slipping clutch assembly. Change clutch assembly.
Partially earthing field Change field coil.
coil.
Solenoid contact is not Re-set solenoid and
making. replace spring.

Using of the starter motor

The following points should be strongly observed while starting the engine.
1) Make sure that all engine controls are correctly adjusted.

2) Press the starter push button and turn the starting key switch in to start
position firmly and release it immediately after the engine fires.

3) If the engine does not fire at once, allow it to come to rest before another
attempt to start.

4) Do not run down the battery by keeping the starter motor push button pressed
and turning the starting key switch when engine refuses to start. Ascertain the
cause of failure to start.

5) On no account should the starter motor be operated when engine is running,

otherwise serious damage would occur both to starter motor and to flywheel
teeth.

Caution: Do not operate the starter motor more than 8 seconds.

If any of above defects found, please report maintenance personnel

immediately.

Electrical Operation & Maintenance Manual – TPP Page 99 of 144

BATTERY
The following are some useful hints for dealing with trouble limited to Control &
Charging circuit, such as

SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION

No. DEFECTS
1. Excessive gassing and Voltage setting is too Reduce voltage setting
progressive increase in high to lower value and check
Sp. Gr during charging accuracy of voltmeter in
charger.
2. Progressive decline in Voltage setting is too Increase the Voltage
the value of Sp. Gr. low setting and check the
accuracy of voltmeter in
charger.
3. Cell getting discharged Leakage of current Check for leakage of
through grounded electrolyte or grounding
circuits of current carrying
conductors in charger or
Battery circuit.
4. Rapid fall in cell Loose connections or Clean corroded parts
voltage Corroded terminals with dilute Alkaline
solution and water. After
drying coat with vaseline
or petroleum jelly.
5. Continuously low 1. Leakage of 1. In case of leakage,
electrolyte level electrolyte replace the
Container.
2. Loss of water in 2. Add distilled water to
electrolyte due to Maintain electrolyte
evaporation by very level & ensure
high floating correct setting of
voltage or Voltage regulator
excessive charging.

Electrical Operation & Maintenance Manual – TPP Page 100 of 144

 6. Continued low reading Internal short circuit 1. Disassemble the cell
of Sp. Gr. loss of 2. Examine the plate for
capacity after full accidental contacts,
charge, low open missing or sheared
circuit voltage separators.
3. Wash out the
accumulated
sediment. Replace
the old and sheared
separators with new
ones.
4. Assemble the cell,
adjust electrolyte
level and put on
charge before
placing it for service.
7. Premature gassing Sulphation due to low Pour out the electrolyte.
electrolyte level, over Fill with distilled water
discharging and under and allow to stand for
charging and one hour. Charge at the
unwarranted addition half the initial charging
of acid when only current specified, till the
water should have Sp. Gr attains constancy
been added. over three consecutive
hourly readings.
Pour out the electrolyte.
Fill with acid of final Sp.
Gr to 1.255 after a rest
period of one hour
charge at normal
charging rate till
Constancy of Sp. Gr is
attained.

Electrical Operation & Maintenance Manual – TPP Page 101 of 144

 8. Cells overflowing Increase in electrolyte Adjust electrolyte level to
level correct height.
9. Reverse polarity in Particular cell may be Give equalizing charge
cells lagging from healthy every month to bring the
cells. lagging cells on par with
the healthy cells.
Equalizing charge shall
be given at normal
charging rate and
continued till 3 hourly
constant reading for cell
voltage and Sp. Gr are
obtained

RELAY
The following are some useful hints for dealing with trouble limited to starter
motor, such as
SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION
No. DEFECTS
1. Relay does not Low control voltage. Check the control voltage.
operate
Large voltage drops. Check the loose
connection.
Control circuit incorrectly Check and correct the
wired. control circuit and coil
connection.
2. Relay chatters Low control voltage. Check the control voltage.
Large voltage drops. Check the loose
connections
Broken shading ring on The mechanical life of
the magnet pole. contactor is over. Replace
the relay.

Electrical Operation & Maintenance Manual – TPP Page 102 of 144

 3. Humming of iron Rust, dust or other Rub off rust with fine emery
core or noise substance is on contact paper or clean the surface
magnet surface of iron core. with cloth.
Broken shading rings. Mechanical life of contactor
is over. Replace the relay.
Magnet faces not mating. Mechanical life of contactor
is over. Replace the relay.
Dirt or rusts on magnet Clean lightly with fine
faces. emery paper or dry cloth or
use compressor air.
4. Over heating of Low voltage preventing Check and correct the
contacts or magnet from closing control voltage.
welding of the properly.
contacts Abnormal in rushes of Check the cause of
current. excessive load current or
use higher size of
contactor.
Foreign matter preventing Remove the foreign matter
contact closing. and clean with per chloro-
ethylene or white petrol.
Rapid inching. Install larger contactor or
caution operator.
5. Relay failure to Low voltage. Check control voltage.
pick up and close
Coil open or shorted Replace the coil.

Mechanical obstruction. Clean and check the free

movement of contact
assembly.
6. Relay fails to drop Coil not disconnected Check wiring of the coil
out (open) from supply. circuit.
Worn or rusted parts Replace such parts.
causing binding.

Electrical Operation & Maintenance Manual – TPP Page 103 of 144

 Residual magnetism due The mechanical life of
to lack of air gap in contactor is over. Replace
magnet path. the relay.
7. Over heating of Over voltage or under Check and correct the
coil voltage. control voltage.
Inter turns short circuit Replace coil
caused by mechanical
damage in coil.
Dirt or rusts on pole faces Clean pole faces with very
increasing the air gap. fine emery paper or dry
cloth.

GAUGE
The following are some useful hints for dealing with trouble limited to Gauges,
such as

SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION

No. DEFECTS
1. Gauge indicates Sensor connection Check and correct the
maximum disconnected sensor terminal.
pressure /
temperature even
though the
temperature /
pressure are not
high.
2. Gauge indicates Gauge negative Check and correct the
less than zero connection disconnected negative connection.
value of

Electrical Operation & Maintenance Manual – TPP Page 104 of 144

 temperature / Sensor body grounded / Check and isolate the
pressure even shorted ground fault / short.
though the
temperature /
pressure is
greater than zero.

AUXILIARY ALTERNATOR & CHARGING CIRCUIT

The following are some useful hints for dealing with trouble limited to Auxiliary
Alternator, such as
SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION
No. DEFECTS
1. Battery Discharge Stop engine driven
Warning alternator.
Indication lamp
does not glow Short terminal "F" and
when start switch negative terminal of
is "on" regulator by a jump lead.

If Indication lamp glows,

the cause is

(i) Faulty regulator Replace the regulator.

Electrical Operation & Maintenance Manual – TPP Page 105 of 144

 Short terminal "A" of
regulator to Ground by a
jump lead.

If Indication lamp glows,

the causes are
(i) Jammed brushes Free brushes or replace if
or lead adrift. necessary.

(ii) Dirty slip ring. Clean the slip ring.

(iii) Rotor open circuit. Check that the ends of the

rotor winding are soldered
properly to the slip ring
terminals. Re-solder or
replace rotor assembly if
necessary.
If the indication lamp
does not glow even after
grounding terminal "A",
the causes are

(I) Fused Indication Replace Indication Lamp

Lamp unit. unit.
2. Battery Discharge Loose belt Tighten belt. There should
Warning be 1/2" - 3/4" play when
Indication lamp normal hand pressure is
does not glow & applied on the longest side.
ammeter shows Auxiliary diode, lead "A" Check the connections and
no charge. open. repair.
Shorted rotor. Trace short, rectify if
possible or replace rotor
assembly.

Electrical Operation & Maintenance Manual – TPP Page 106 of 144

 Stator open/shorted. Replace stator assembly.
3. Battery Discharge Faulty rectifier bridge. Check the heat sink
Warning assembly, if necessary
Indication lamp replace.
does not glow but
ammeter shows
charge.
4. Battery Discharge Fault rectifier bridge. Check heat sink assembly
Warning replace if necessary.
Indication lamp Stator winding short. Rectify or replace stator
does not glow but assembly.
battery shows low
output.
5. Battery Discharge High resistance in Check and tighten all
Warning warning lamp circuit. connections.
Indication lamp
glows dim
6. Battery Discharge High resistance in the Check for loose
Warning negative line. connections and ensure,
Indication lamp use of recommended wire.
and ammeter
flickers heavily.

CONTROL CIRCUIT

General checks
a) 24V D.C. supply shall be available & indicated by voltmeter on instrument
panel.
b) All the miniature circuit breakers shall be switched to ‘ON’ position.
c) Press Lamp Test Push Button LTP31 on Driver’s Desk to check the
healthiness of all Indication Lamps on Instrument panel.

Electrical Operation & Maintenance Manual – TPP Page 107 of 144

The following are some useful hints for dealing with trouble limited to Control
circuit, such as

SL. SYMPTOMS / PROBABLE CAUSES REMEDIES / ACTION

No. DEFECTS
1. Engine starts but Check the position of If mechanically latched
stops immediately Emergency engine stop rotate & release
push button
Faulty lube oil pressure Check & replace if
switch. necessary.
Faulty Engine Safety Check and replace if
Relay necessary.
Low Engine lube oil level Check Engine lube oil level
and top up appropriately.
Faulty water level switch Check and replace if
on Radiator necessary.
Faulty water level switch Check and replace if
cum Indicator necessary.
Loose electrical Check for loose
connections connections and tight
appropriately.
2. Engine does not Faulty stop switch. Check & replace if
stop. necessary.
3. Even though lube Faulty driver's key switch Check & replace if
oil pressure is necessary.
more, engine Faulty low water level Check & replace if
stops after relay necessary.
releasing the start Faulty over speed switch Check & replace if
push button. necessary.
Faulty lube oil pressure Check & replace if
switch. necessary.
4. Transmission is Faulty transmission Check and replace if
not engaging to circuit breaker necessary.

Electrical Operation & Maintenance Manual – TPP Page 108 of 144

 forward / reverse. Faulty transmission oil Check and replace if
temperature switch necessary.
Faulty high water Check and replace if
temperature switch necessary.
Faulty power cut off Check and replace if
switch. necessary.
Faulty Main magnet Check and replace if
valve. necessary.
Faulty transmission Check and replace if
magnet valve. necessary.
Problem in pneumatic Check and replace if
lines or system pressure necessary.
Faulty transmission ON / Check and replace if
OFF Valve necessary.
Faulty transmission Check and replace if
control switch necessary.
5. Direction Faulty Braking System Check and adjust or
engaged but replace if necessary.
locomotive does
not move
6. Locomotive Faulty Main magnet Check and replace if
speed drops valve. necessary.
immediately or Faulty transmission Check and replace if
slows down magnet valve. necessary.
during travel Problem in pneumatic Check and replace if
lines or system pressure necessary.
Faulty Engine Safety Check and replace if
Relay necessary.
7. Engine does not Faulty Driver’s key switch Check and replace if
start necessary.
Faulty Magnetic switch Check and replace if
necessary.

Electrical Operation & Maintenance Manual – TPP Page 109 of 144

 Faulty Starter motor Check and replace if
necessary.
Low Battery voltage Check condition of
batteries and has to be
replaced if necessary.
Loose electrical Check for loose
connections connections and tight
appropriately.
8. Engine speed Faulty Main magnet Check and replace if
does not increase valve. necessary.
Faulty transmission Check and replace if
control switch. necessary.
9. Loco over speed Faulty Loco over speed Check and replace if
indicating but Relay necessary.
engine does not Faulty HMI Output Check for proper signal
come to idle and / output from HMI
or automatic loco Faulty transmission Check and replace if
brakes are not control relay. necessary.
applied Faulty Brake magnet Check and replace if
valve necessary.
Loose electrical Check for loose
connections connections and tight
appropriately.

Electrical Operation & Maintenance Manual – TPP Page 110 of 144

CHAPTER – 10

ENCYCLOPEDIA

OF

LOCOMOTIVE

ELECTRICS

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Electrical Operation & Maintenance Manual – TPP Page 112 of 144
 CHAPTER 10
10.0 ENCYCLOPEDIA OF LOCOMOTIVE ELECTRICS
The Electrical Equipment required to control the Locomotive is suitably located for
convenience of maintenance and inspection. The detailed descriptions for each
equipment are briefly explained below.

AMMETER
Battery charge and discharge
current is indicated through the
Ammeter. This ammeter shows
the condition of battery by
indicating the direction of current
flow as charge and discharge. The
pointer at center of the dial
indicates no current flow and on
either side indicates charge (Right
AMMETER – BATTERY
side) and discharge (Left side).
DISCHARGE
(AM 11/21) Ammeter is mounted on the
SAN CODE: 97501590 instrument panel, which is always
connected permanently in series with alternator circuit to indicate the condition of
the Battery and the direction of current flow (charge or discharge). The center of
the dial is the point of zero current flow and the two extremes indicate maximum
charge and discharge. [Pointer on plus (+) side indicates battery charging and on
minus (-) side indicates battery discharging].

SPECIFICATION
Range : 50 - 0 - 50 Amps
Control circuit Voltage : 24 Volts DC
System : Moving magnet type
Negative terminal : Insulated
Case size : 52 mm Diameter
Sweep Angle : 72 ° C

Electrical Operation & Maintenance Manual – TPP Page 113 of 144

 AUXILIARY ALTERNATOR

ALTERNATOR
The alternator has been specially designed for use on diesel locomotive. It is a
three-phase machine with revolving field and stationary armature type. Alternator
is a self-rectifying, self-energizing (self-excited) air-cooled. A separate current
regulator is not required as the alternator itself is self-regulating in this respect
built in diodes in the alternator to prevent the reverse current flow from battery into
the alternator through the stator when the machine is stationary or when
generating less than the battery voltage. Hence, a cutout is not required. As the
alternator is self-limiting in current output, the regulator has only to control output
voltage, which it does by regulating the alternator field current.
The alternator consists of field coil, stator, rotor, bearings, voltage regulator unit
and diode rectifier. When a current path to the field coil is established by the
voltage regulator a magnetic flux is created which flows through a small air gap to
the rotor and alternately from pole to pole of the stator, inducing a magnetic field
in the stator coil winding. As a rotor is rotated these magnetic lines of force form a
closed loop inducing alternating three phase voltage and amperage in the stator
coil winding. The alternating current output from the stator is supplied to a three-
phase full wave bridge rectifier, which provides a direct current to the load.
The alternator and rectifier unit is having ample capacity at continuous rating to
provide power simultaneously for fans, controls, loco lighting, battery charging and
other D.C. loads of the locomotive.
The six rectifier diodes of the full wave bridge rectifier circuitry embedded in two
circular mounting plates form a heat sink assembly at the front of the alternator
next to the front end cover. This provides effective diode heat dissipation and
cooling.

VOLTAGE REGULATOR
The voltage regulator is an electronic control device, which provides long life,
reliability and performance stability of the system. The voltage regulator is fully
transistorized with no moving parts and does not require any service attention and
is non-repairable.

Electrical Operation & Maintenance Manual – TPP Page 114 of 144

The voltage regulator consists of transistors, diodes and resistors that are fixed on
a printed circuit board in a sealed moulded case.
The regulator senses the voltage
requirement of the load and
supplies the necessary field
current to the alternator for
accurate control of the alternator
voltage under all loading
conditions to give Automatic
voltage regulation.
Thus the voltage regulator
AUXILIARY ALTERNATOR
WITH INBUILT VOLTAGE is capable of maintaining the
REGULATOR output voltage of the alternator for
(AA11/21) controls, auxiliary loads and
SAN CODE: 91512290
battery charging voltage through
out the full range of alternator load and speed. Refer separate Auxiliary Alternator
Manual supplied with Engine.

ALTERNATOR CHARGING CORRECTION RESISTOR

The Alternator Charging
Correction Resistor is a Fusible
Wire Wound Ceramic Resistor.
The “WL” terminal of Auxiliary
alternator serves dual purpose for
charging indication and initial
excitation which requires a
minimum load of 3 Watts. As the
ALTERNATOR CHARGING
CORRECTION RESISTOR Indication lamp provided is of LED
(ACCR11/21) type which consumes negligible
SAN CODE: 91533890 power and hence a substitute
Resistor to compensate the required load is connected in parallel with Battery
Discharge Warning Indication Lamp.

Electrical Operation & Maintenance Manual – TPP Page 115 of 144

 AIR PRESSURE SWITCH (RT 5x / RT 116 / RT 200)
GOVERNOR / BRAKE / POWER CUT-OFF
Pressure Switch is single
pole double throw, electro
pneumatic pressure switch
designed for operation of
the system when pressure
in the system drops or
exceeds the pre set limits.
Pressure switches are
diaphragm-actuated
devices, designed for
applications requiring
PRESSURE SWITCH
(RT 5X / RT116 / RT200) sensitive response to small
(GAPS31 / BAPS31 / PCS31) pressure changes at low-
SAN CODE: 91509310 / 91509420 / 91502280 pressure ranges. A
seamless metal bellows actuated control is used for pressures as high as 2000
p.s.i and the piston operated hydraulic switches are suitable for pressures up to
15000 p.s.i. The range and differential (difference between “cut-in” and “cut-out”
pressures) can be changed any time in the field.
All the above shown pressure and temperature switches are of Indfos make.
RT series (RT 116 & RT 200) pressure switches used in the Locomotive utilizes
seamless stainless steel bellows as the sensing element. The simplicity of design
and ease in installation are well suited for applications where shocks and
vibrations are present.

Electrical Operation & Maintenance Manual – TPP Page 116 of 144

 AIR PRESSURE SWITCH (IPS 100)
TRANSMISSION/FORWARD / REVERSE “ON” INDICATIONS
IPS (Industrial Pressure Switch) (IPS 100) is a single pole double throw electric
pressure switch, designed for starting or stopping of equipment when the pressure
in the system drops or exceeds the pre-set limits.

All the above RT &

IPS pressure switches
perform well and are
suitable for corrosive
media, viscous fluids and
slurries, or any hazardous
areas. The enclosure is
weatherproof to IP: 66 as
per IS: 2147. One set of
change over switch
(Common-2, NC-1, and
NO-3) is provided for
PRESSURE SWITCH (IPS100) control logic.
(TAPS31 / FAPS31 / RAPS31 / LBPS31)
SAN CODE: 91502020

Battery Isolating Switch is

used to make and break the
control circuit of locomotive.
It is a double pole single
throw type switch. The
continuous current carrying
capacity of the contacts is
400 Amps.

BATTERY ISOLATING SWITCH

(BIS31)
SAN CODE: 91514390

Electrical Operation & Maintenance Manual – TPP Page 117 of 144

 BLOCKING DIODE
Semi-conductor Diodes are used
in our circuit for logic application to
block the DC current flow in one
direction and allows in the other
direction. These diodes are of
1N5408 type with Axial / Flying
Leads and can carry Average
Forward current of 3 Amps with a
maximum Peak Inverse voltage
BLOCKING DIODE
(HLD 31-38/HTD11-13, 31 / capacity of 1200 Volts.
TLD31 36/MCLD31/FPLD11/SSD31 - 34)
SAN CODE: 91520790

CABIN FAN

The fan used inside the cabin is rugged

and can be tilted in all the four directions
according to the requirement. It operates
at a nominal operating voltage of 24 volts
DC and consumes 20 watts. The overall
diameter of the fan unit is 225 mm.

FAN – CABIN
(CF 31, 32)
SAN CODE:

CIRCUIT BREAKER
This is an automatic device, which opens during over current or short circuit
condition in the circuit. The whole Locomotive is grouped according to function
into many circuits and is protected by different ranges of miniature Circuit
Breakers. This circuit breaker is most reliable and rugged in construction.
This is the only circuit breaker in India, which has successfully short circuit
tested by the prestigious ASTA Short circuiting Authority in U.K. It is also only

Electrical Operation & Maintenance Manual – TPP Page 118 of 144

 miniature circuit breaker in India,
which is tested for short circuit at
regular intervals on proving its
performance regularly. The MCBs
embodies both thermal over-load and
magnetic short-circuit tripping devices.
The trip free mechanism ensures that
contacts cannot be held closed against
a fault and the thermal element
prevents continuous rapid enclosing of
a circuit when fault or over load
persists. MCBs are tested at CPRI in
accordance with test duty sequence

CIRCUIT BREAKER – 6/10/16/25/ 63 AMPS requirements to comply with IS 8828

(LCB31, TCB31, BCB31, GCB11/ CCB11, and BS 3871 part 1.
ACB31 / HTCB31 / MCB11)
SAN CODE: 91535460 / 91535500 /
91535470 / 91535480 / 91535490

ELECTRICAL & MECHANICAL CHARACTERISTICS

Model : L 431XX RO (XX – Rated Current)
No. Of Poles : Single
Breaking Capacity : As per IS : 8828 / BS 3871 - Part 1
(5 to 60 Amps – 3 K Amps)
Maximum Operating Voltage : 250 Volts DC
Ambient Temperature Range : - 25 to + 55 °C
Vibration Resistance : 5 g at minimum of 30 minutes
Shock Resistance : 20 g @ minimum 20 impacts
duration of shock 13 m Seconds
Mechanical Service life : 20,000 Operation Cycles
Electrical Endurance at Rated Load : 20,000 Operation Cycles

Electrical Operation & Maintenance Manual – TPP Page 119 of 144

 DRIVER KEY SWITCH
The key switch in the locomotive is used
for three functions (Engine OFF,
IGNITION & START). This key switch is
provided with a cylinder lock. It can only
be operated with the appropriate key.
The actuator is provided safety, with
lockable in the "IGNITION" position. The

DRIVER KEY SWITCH current carrying capacity of the contacts

(DKS11/21) is 26 Amps.
SAN CODE: 91502330

ENGINE RPM CUM HOUR METER

ENGINE RPM METER MAGNETIC PICK UP UNIT

(ERM11/21) (MPU11/21)
SAN CODE: 97504200 SAN CODE: 97503130
The Engine RPM & Hour meters are two
different devices, which measures the
engine speed in Revolutions per minute
(RPM) and records total engine running
time in hours. This is supplied by
Cummins along with Engine. The pulses
can be obtained from the ring gear of an
engine by means of an electromagnetic
pick up unit (sensor). These magnetic
ENGINE HOUR METER
(EHM11/21)
SAN CODE: 97503270

Electrical Operation & Maintenance Manual – TPP Page 120 of 144

pickup units are exclusively designed for flywheels having 118/142 numbers of
teeth.
ELECTRICAL & MECHANICAL CHARACTERISTICS
Operational Voltage : 24 Volts DC
Temperature Range : - 20 °C to + 85 °C
RPM Input signal Voltage : 1.5 V rms min. from a Magnetic pick up
RPM meter Range : 0 - 3000 RPM
Hour meter Range : 1,00,000 Hours in 0.1 increments
Case size (RPM Meter) : 96 mm x 96 mm
Case size (HOUR Meter) : 60 mm ø
Case Material (RPM Meter) : Plastic
Case Material (HOUR Meter) : Aluminum

ENGINE OVER SPEED SWITCH / FUEL SOLENOID

ENGINE OVER SPEED SWITCH FUEL SOLENOID – ENGINE

(EOSS11/21) (FS11/21)
SAN CODE: 91512330 SAN CODE: 91503990
Refer separate Engine manual for detailed description.

ELECTRO MAGNETIC INTERFERENCE SUPPRESSOR - CAPACITOR

Electrical equipment of inductive load, generate electromagnetic interference

emission during the course of their operation and also switching equipment due to
periodic electrical transients generated by automatic or manual switching
operations. The interference may be both generated from the equipment itself and

Electrical Operation & Maintenance Manual – TPP Page 121 of 144

also conducted back through the A.C. signal line to other equipment with the
connections serving to further generate the interference. It is always the

conducted interference which

appears to be most objectionable.
One prior art technique for
suppressing common mode
interference is connecting a
capacitor across A.C leads to
short or by-pass the interference.
The required capacitance values
vary over a wide range (0.001-

ELECTRO MAGNETIC 0.047 mfd) and are empirically

INTERFERENCE SUPPRESSOR determined by the type of
CAPACITOR
equipment, suppression standard
(EMISC11 / 21 SSC31 - 34)
SAN CODE: 91516720 to be met and the value of the
differential mode suppression

capacitor. Thus, with this suppression technique, a Metal Oxide Polyester type
capacitor with a value of 0.01 mfd of Thermax make is connected across the
Sensor signal terminals of Water Level Sensor cum Indicator. These capacitors
provide relatively low radio frequency impedance but a relatively high frequency
impedance path for current between the signal lines and the equipment case. The
suppression of electromagnetic interference is thus defeated.

HMI31 – HUMAN MACHINE INTERFACE

(PV380)

HUMAN MACHINE
INTERFACE
(HMI)
SAN CODE:91518400

Electrical Operation & Maintenance Manual – TPP Page 122 of 144

 INSPECTION LAMP - PLUG & SOCKET

INSPECTION HAND LAMP PLUG & SOCKET – INSPECTION LAMP

SAN CODE: 91501220 ILSU31/ILSF31/ILSR31
SAN CODE: 91509380 / 91509370

The Plug and Socket for Inspection lamp application in the locomotive are made
of pressure cast aluminum alloy casing. The plug pins are fully shrouded and the
cable guard is tapered with rigid plastic cable grip for plug. Extra finger grips are
provided for plug with interiors covered with glass-filled polyester material. Socket
contacts are recessed and self-aligned. The casing is of stove enamel finished.
The current carrying capacity of the plug & socket are 10 Amps. The Inspection
Lamp is handy and is provided with 10 meters cable with plug unit.

LIGHT UNITS
HEAD LIGHT

HEAD LIGHT UNIT HALOGEN BULB

TYPE: HL-130 PAS TYPE: P45T, H4
(FHL31, 32 /RHL31, 32) SAN CODE: 91532480
SAN CODE: 91532470

Electrical Operation & Maintenance Manual – TPP Page 123 of 144

Semi-sealed type headlight consists of lens, reflector, bulb, socket, cover frame
and adjustment screw of light center. For adjustment of the light center, loosen the
bottom screw, take off the front cover and turn the three screws reasonably.
For replacement of the bulb, take off the front cover and turn the lens to anti-
clockwise, then the whole assembly of lens, reflector, bulb and socket can be
pulled out forward. After which the bulb can be removed from the socket.
The bulb has two filaments. If any one filament is fused, then change the
connection of wire to the other side, and hence bulb can be used twice. If
brightness is decreased, clean the lens, bulb and reflector by soft and clean cloth.
The system voltage is 24 Volts DC.

CABIN & HOOD LIGHT UNITS

These lamps are based on well-developed solid-state Power L.E.D illumination
technology. These are made of fabricated steel body finished Black & White
colour outside and inside. The transparent Acrylic sheet is fixed type, held in
position and fitted by tropicalised rubber gasket. The rating of the Light unit is 24
Volts DC, 6 Watts. There are 6 [Link] and each consumes 1 Watt. The power
[Link] are naturally cooled as the heat generated by them are dissipated through
aluminium heat sink and vent holes of the cabinet.

CABIN / HOOD / VALVE / COMPARTMENT

LIGHT UNIT
CL31, 32/HLF31-36/VCL31
SAN CODE: 91516930

Electrical Operation & Maintenance Manual – TPP Page 124 of 144

 MARKER LIGHT UNIT – L.E.D. TYPE
[TAIL LIGHT (RED) & PARKING LIGHT (WHITE)]

MARKER LIGHT UNIT

(FTL31, 32 / RTL 31, 32 /
FPL 31, 32 / RPL 31, 32)
SAN CODE: 91516990

These lamps are based on well-developed solid-state L.E.D illumination

technology. These are made of fabricated steel body finished in sand stone colour
outside and inside. The glass is fixed type, held in position and fitted by
tropicalised rubber gasket. The operational voltage is 24 Volts DC.

GAUGE LIGHT UNIT

These lamps are meant for Control
cubicle illumination. They are made of
steel body. The operational voltage is 24
Volts DC. These lamps are based on
well-developed solid-state LED Light
Emitting Diodes and specially designed
electronic circuitry to give many
advantages over the conventional bulb
type indicators used for illumination on
GAUGE LIGHT UNIT control panels.
(GL 31, 32)
SAN CODE: 91525800

Electrical Operation & Maintenance Manual – TPP Page 125 of 144

 INDICATION LAMPS

INDICATION LAMP – GREEN INDICATION LAMP – AMBER

(EOL11 / 21, TOL31) (RL31 / RHLOL31 / PLOL31)
SAN CODE: 91525770 SAN CODE: 91525780

INDICATION LAMP – RED INDICATION LAMP – BLUE

(BDL11/21 / LLOPL11/21 / EOSL11/21 / (FL31/FHLOL31/TLOL31)
HWTL11/21 / HTOTL11/21 / TCLL31 / SAN CODE: 91525810
LBPL31 / LOSL31)

These lamps are based on well-developed solid-state LED technology. It consists

of cluster of Light Emitting Diodes and specially designed electronic circuitry to
give many advantages over the conventional bulb type indicators used for pilot
indication on control panels.
ELECTRICAL & MECHANICAL CHARACTERISTICS
Operating Voltage : 24 Volts DC
Operating Range : - 30 % or +20 % of operating
voltage
Power Consumption : 0.5 Watts at 230 Volts AC
Indication Colors : Red, Green, Blue and Amber
Life expectancy : 1,00,000 Hours

Electrical Operation & Maintenance Manual – TPP Page 126 of 144

Housing Material : Flame-retardant ABSTRYNOL
with ribbed Polycarbonate Lens
Enclosure : IP 65 as per IS 13947 – (1) 1993
Rated Insulation Voltage : 500 Volts
Insulation Above : 500 Mega Ohms
H.V Test : 2.5 KV for 1.5 Minutes
Termination : Totally enclosed / finger touch
proof glass filled nylon. Suitable
for 2.5 Sq. mm cable (By M3
Brass Screws)
Lamp Test Lead : 2 Mts Long Yellow Cable

PROXIMITY SWITCH
Proximity switch is one among the
speed sensing devices. They are
ideally suitable for non-contact
sensing of metallic objects. As
inductive sensors work on
electromagnet principle, they are
inherently resistant to dust
humidity and oil in industrial
environment.
PROXIMITY SWITCH
(PS31)
SAN CODE: 91542130
An alternating electromagnetic field is developed at the sensing face of proximity
switch. When a metallic object enters this field, energy is absorbed. The amplitude
of the oscillations of the electromagnetic field is consequently reduced. The
reduction in amplitude is processed internally and an output stage is switched on
(or off). For DC switches this out put stage is either NPN or a PNP transistor and
for AC switches it has a thyristor.
The proximity switch used in the Locomotive is protected to IP 67 grade. Housings
are made of Nickel coated brass barrel as they can widely be used in non-
corrosive atmospheres. The normal atmospheric temperature range is between -
15 to +65 °C.

Electrical Operation & Maintenance Manual – TPP Page 127 of 144

 ELECTRICAL & MECHANICAL CHARACTERISTICS
Model Size : PE - C2
Housing Diameter & Pitch : M18 x 1.5 mm Pitch
Minimum Target size : 8 mm x 8 mm
Rated Operating Sensing Distance : 2 mm
Actuation Distance : 1.6 mm
Repeat Accuracy : 0.2 mm
Hysterisis : 0.3 mm
Mounting : Bolt type self mounted

Voltage Range : 5 – 40 Volts DC

Transistor Type : NPN - Current Sinking
Switching Type : Normally Open (NO)

Maximum Load Current : 300 mA

Switching Frequency : 450 Hz
Wire Gauge of Cable : 3 x 0.22 mm²
Length of Cable : 2 Mts

LUBE OIL PRESSURE SWITCH / SENSOR / GAUGE – ENGINE

LUBE OIL PRESSURE SWITCH LUBE OIL PRESSURE

– ENGINE (LOPS11/21) SENSOR – ENGINE (LOPSU11/21)
SAN CODE: 91507710 SAN CODE: 97504090

The Pressure sensor is a sender unit of variable resistance type, which senses
the Engine Lube oil pressure. It operates at a nominal 24 Volts DC system
voltage. It is a completely sealed unit.

Electrical Operation & Maintenance Manual – TPP Page 128 of 144

It is of Insulated type and designed for two-wire system. The range of
measurement is from 0 to 100 psi (6.9 Bar). The thread is of standard 1/8” BSP.
The Pressure switch is a diaphragm type. The range of pressure is between 0.5 to
7 bar. The nominal power rating of the switch is 24 Volts Dc and 0.5 Amps. It is of
Insulated type and designed for two-wire system. It consists of one set of potential
free change over contacts. The thread is of standard 1/8” BSP.

The Pressure Gauge monitors the

pressure of Engine lube oil. These
gauges use cross coil movement,
which compensates for small
voltage fluctuations, normally
experienced in automotive circuits.
The nominal operational voltage is
24 Volts DC. It is of Insulated type
and designed for two-wire system.
LUBE OIL PRESSURE The sweep angle is 80° and the
GAUGE – ENGINE
case size is 52 mm diameter. The
(LOPG11/21)
SAN CODE: 97504080 range of measurement is 0 to 7
Bar.
LUBE OIL TEMPERATURE SENSOR / GAUGE - ENGINE

TEMPERATURE SENSOR TEMPERATURE GAUGE -

ENGINE ENGINE LUBE OIL
LUBE OIL (LOTG11/21)
(LOTSU11/21) SAN CODE: 97503370
SAN CODE: 97503380
Electrical Operation & Maintenance Manual – TPP Page 129 of 144
The Temperature sensor is a sender unit of variable resistance type, which
senses the Engine Lube oil temperature. It operates at a nominal 24 Volts DC
system voltage. It is a completely sealed unit. It is of Insulated type and designed
for two-wire system. The range of measurement is from 40 to 120 °C. The thread
is of standard 1/2” BSP.
The Temperature Gauge monitors the temperature of Engine lube oil. These
gauges use cross coil movement, which compensates for small voltage
fluctuations, normally experienced in automotive circuits. The nominal operational
voltage is 24 Volts DC. It is of Insulated type and designed for two-wire system.
The sweep angle is 80 ° and the case size is 52 mm diameter. The range of
measurement is 40 to 120 °C.
LUBE OIL TEMPERATURE SWITCH - TRANSMISSION
Temperature switches are designed for automatic control of temperature
maintaining equipment. Gas vapor or liquid pressure expands a metal bellows
against the force of a spring to give a motion to an operating pin, which snaps a
precision switch to its operating position when the setting is reached. The
precision switch snaps back to its normal position when the pressure in the
bellows drops enough to allow the main spring to compress the bellows.
Electrically, the thermostat is a two-wire control pilot device (switch) that is
temperature actuated.
RT series (RT 107) temperature
switches used in the Locomotive
has a vapor filled thermostatic
element. The thermostatic element
consists of sensing bulb, capillary
tube and a bellows element. The
entire element contains a charge,
which reacts to temperature
variations at the sensing bulb, so
that pressure on the bellows
TEMPERATURE increases on rising temperature.
SWITCH (RT107) – TRANSMISSION The bellows movement due to this
(TOTS11/21)
SAN CODE: 91501820 increase in pressure is utilized to
operate the switch.

Electrical Operation & Maintenance Manual – TPP Page 130 of 144

The above RT series Temperature switch perform well and are suitable for
corrosive media, viscous fluids and slurries, or any hazardous areas. The
enclosure is weatherproof to IP: 66 as per IS: 2147. Their coils operate at a
nominal voltage of 24 Volts DC each of that consumes power of 12 Watts. One
set of change over switch (Common-2, NC-1, NO-3) is provided for control logic.

MAGNET VALVE
MAIN / GOVERNOR / TRANSMISSION
Magnet valves are a convenient
form of remote control. The relay
type of magnet valve reduces
electrical power consumption and
size and size and weight of the
valve, but gives high pneumatic
capacity.
The Magnet valve consists of two
main parts, the valve portion and

MAGNET VALVE – MAIN / the electro-magnet portion. The

GOVERNOR / TRANSMISSION / valve can be operated manually
EMERGENCY BRAKE by a spring-loaded plunger located
(MMV31 / GMV31 / TMV31/EBMV31)
SAN CODE: 94712950 below the electro-magnet portion.
The nominal operating voltage is
24 Volts DC.
PUSH BUTTONS

LAMP TEST EMERGENCY ENGINE STOP

PUSH BUTTON (LTP31) PUSH BUTTON (EESPB11, 21)
SAN CODE: 91509320 SAN CODE: 91521680

Electrical Operation & Maintenance Manual – TPP Page 131 of 144

 Push Button is one among the
master switch, manually operable
plunger or button for actuating any
device. It has built in independent
double break contactor with one
set of normally open (NO) and
normally closed (NC) contacts.
ENGINE START
PUSH BUTTON (SPB11/21) The above shown push buttons
SAN CODE: 91502060 are for different applications. They
are robust in material and construction and are made dust and vermin proof with
flame retardant housings, which leads to higher mechanical and electrical life. The
advantages of these types of push buttons are positive contact opening through
double break contacts. The contacts do have adequate terminal capacity with self-
wiping contacts.

ELECTRICAL & MECHANICAL CHARACTERISTICS

Rated Insulation Voltage : 500 Volts
Rated Thermal Current : 10 Amps
Contacts Operation : Self Wiping, Slow Break, NO or NC
Make & Break Capacity : DC 11: 1 Amps, 220 Volts DC
(ISS 6875(1)-1973)
Terminal Capacity : Max. : 2 x 1.5 mm² or 1 x 2.5 mm²
Min.: 1 x 0.5 mm²
Short Circuit Protection : 10 Amps Fuses
Ambient Temperature : -25 °C to +70 °C
Altitude : < 3000 mts
Operating position : All positions
Degree of operation : IP 65
Mechanical Life : Over 1 Million operations

Electrical Operation & Maintenance Manual – TPP Page 132 of 144

 RELAY – ELECTRO MECHANICAL
Electromechanical Relay is a device, actuated by electromagnetic means, for
establishing and interrupting an electric power circuit repeatedly. The Relays
confirm to the latest IEC: 337-1, IS: 6875 standards. They are suitable for use in
any climate and has unmatched performance and reliability with high electrical
and mechanical life as are made of superior quality material. It has finger touch-
proof terminals, which protect against accidental contact with live parts.

Both relay models 3 TH30 40-OB (5 NO + 3 NC) and 3 TH80 22-OB (2 NO + 2

NC) are snap mounted on to a common 35 mm Din rail. They both operate at
nominal terminal voltage of 24 Volts DC.

RELAY – 2NO + 2NC RELAY – 5NO + 3NC

TYPE : 3TH 80 22 – 0B TYPE : 3TH 30 40 – 0B
(TCR31/LOSR31) (ESR11/21)
SAN CODE: 91503910 SAN CODE: 91503920

ELECTRICAL & MECHANICAL CHARACTERISTICS

Rated Continuous Current : 10 Amps
Mechanical Endurance : 30 Million Operation Cycles
Insulation Rating : 660 Volts
Duty Cycle / Hour : 3600
Ambient Temperature Range : -25 to + 55 °C
Coil Voltage Tolerance : 0.8 to 1.2 Times of Rated Operational
Voltage
Power Consumption : 6.5 Watts

Electrical Operation & Maintenance Manual – TPP Page 133 of 144

 STARTER MOTOR / MAGNETIC SWITCH

STARTER MOTOR MAGNETIC SWITCH – ENGINE

(SM11/21) (MS11/21)
SAN CODE: 91525400 SAN CODE: 91507720
The starter motor is of axial throw type is used on engine. Because of the high
inertia of flywheel and crankshaft, it is necessary for the starter pinion to engage
with the engine flywheel before it develops full torque engagement between
starter pinion and an axial movement of the complete armature assembly affects
engine flywheel. The field winding of the starter motor consists of a main series
winding, an auxiliary sensing winding and start winding. A solenoid operates two-
stage switch, forms an integral part of the starter and is used to control the starting
cycle so that only a small switch to handle the solenoid current is required
externally.
Refer separate Engine manual.
TOGGLE SWITCHES
These toggle switches are basically binary “ON-OFF” isolators, which can be used
to isolate power to a particular area of operation.

TOGGLE SWITCH – 6 AMPS,

TOGGLE SWITCH – 15 AMPS SINGLE POLE,
SINGLE POLE 2 WAY WITHOUT ‘OFF’
(FHLS31, RHLS31) (DS31, DS32, CLS31, CLS32)
Electrical Operation & Maintenance Manual – TPP Page 134 of 144
SAN CODE: 91507960 SAN CODE: 91521440
 TOGGLE SWITCH – 6 AMPS TOGGLE SWITCH – 15 AMPS
SINGLE POLE SINGLE POLE,
(CFS31, 32, PLS31, TLS31, 2 WAY WITHOUT ‘OFF’
VCLS31, ILSS31, HLSF31, 32, (FHLDBS31, RHLBS31)
GLS31) SAN CODE: 91533520
SAN CODE: 91514400

TIMER RELAY - ELECTRONIC

ELECTRONIC TIMER
(ST11/21, HT11/21)
SAN CODE: 91521530 EXPLODED
VIEW
The Timer Relay used is a pre-programmed on-delay timer with four different time
ranges. A Time range selector switch is provided in the side with visual indicator in
the front as shown. Two sets of change over contacts are provided.

Electrical Operation & Maintenance Manual – TPP Page 135 of 144

Initially the contacts will be in neutral position. After giving supply to A1 & A2
terminals the pre-set time begins. At the end of set timing the contacts will change
over and remains in the same position until the supply is removed.
We have selected the time delay range of 3 seconds to 30 seconds and the dial is
set to 8 seconds maximum for engine cranking application. The operational
voltage is 24 Volts DC.
These Electronic Timers are snap mounted on to a common 35 mm Din rail. They
operate at nominal terminal voltage of 24 Volts DC.

ELECTRICAL & MECHANICAL CHARACTERISTICS

Model : A1D1-X
Type : On Delay Timer
Rated Voltage : 24 – 220 Volts AC / DC
Time Range : 3 – 30 Seconds Adjustable
Contacts : 2 NO + 2 NC change Over type
Repeat Accuracy : ± 0.5 % Maximum (Including initial value)
Setting Error : ± 10 % Maximum with respect to full
scale
Resetting Time : 0.1 Seconds Maximum
Variation due to Voltage change : ± 1 % Maximum
Variation due to Temperature : ± 0.5 % Maximum
Insulation Resistance : 100 Mega Ohms Min. (@ 500 Volts DC)
Ambient Temperature : Operating – 10°C to +55°C ;
Storage – 25°C to +80°C
Humidity : 45 to 85 % RH
Service Life : Mechanically: 20,000,000 minutes
operations (Under No Load & at
operating frequency of 1800 operations
per hour)
Electrically: 100,000 operations at 250
Volts AC, 5 Amps Resistive Load
Weight : Approximately 110 grams

Electrical Operation & Maintenance Manual – TPP Page 136 of 144

 TRANSMISSION OIL PRESSURE GUAGE AND SENSOR

TRANSMISSION OIL PRESSURE TRANSMISSION OIL PRESSURE

SENSOR – ENGINE GAUGE – ENGINE (TOPG11/21)
(TOPSU11/21) SAN CODE: 97504770
SAN CODE: 97504780

The Pressure sensor is a sender unit of variable resistance type, which senses
the Transmission oil pressure. This is supplied by Murphy, It operates at a
nominal 24 Volts DC system voltage. It is a completely sealed unit.
It is of Insulated type and designed for two-wire system. The range of
measurement is from 0 to 200 psi (13.5 Bar). The thread is of standard 1/8” NPT.

The Pressure Gauge monitors the pressure of Transmission oil. This is supplied
by Murphy. These gauges use cross coil movement, which compensates for small
voltage fluctuations, normally experienced in automotive circuits. The nominal
operational voltage is 24 Volts DC. It is of Insulated type and designed for two-
wire system. The sweep angle is 80° and the case size is 52 mm diameter.
The range of measurement is 0 to 200 psi (13.5 Bar).

Electrical Operation & Maintenance Manual – TPP Page 137 of 144

 TRANSMISSION OIL TEMPERATURE SENSOR / GAUGE

TEMPERATURE SENSOR TRANSMISSION OIL

ENGINE, TRANSMISSION TEMPERATURE GAUGE
(TOTSU11/21) (TOTG11/21)
SAN CODE: 97504760 SAN CODE: 97504750

The Temperature sensor is a sender unit of variable resistance type, which

senses the Transmission oil temperature. This is supplied by Murphy. It operates
at a nominal 24 Volts DC system voltage. It is a completely sealed unit. It is of
Insulated type and designed for two-wire system. The range of measurement is
from 60 to 150 °C. The thread is of standard 1/2” NPT.
The Temperature Gauge monitors the temperature of Transmission This is of
Murphy make. These gauges use cross coil movement, which compensates for
small voltage fluctuations, normally experienced in automotive circuits. The
nominal operational voltage is 24 Volts DC. It is of Insulated type and designed for
two-wire system. The sweep angle is 80 ° and the case size is 52 mm diameter.
The range of measurement is 60 to 150 °C.

Electrical Operation & Maintenance Manual – TPP Page 138 of 144

 VOLTMETER
The condition of battery voltage is
indicated through Voltmeter. This
Voltmeter shows the state of
charge of the battery during open
circuit and on-load in the form of
voltage.
Voltmeter is provided on the
instrument panel, connected
permanently across the battery, to
indicate the voltage of the system.
VOLTMETER – BATTERY
(VM31)
SAN CODE: 91528430
ELECTRICAL & MECHANICAL CHARACTERISTICS
Range : 0 - 30 Volts DC
System : Moving coil type
Earthing : Insulated
Case size : 65 mm Diameter
Sweep Angle : 120 ° C

WARNING HOOTER
The Warning Hooter is
used to beep during
selective faults in the
control system. It operates
at voltage of 24 Volts DC.
The sound level is between
80 to 125 db. The overall
size of the Hooter is 96 mm
x 96 mm with panel cut out

WARNING HOOTER size of 92 mm x 92 mm.

(WH11/21) The duty operation is
SAN CODE: 91509390

intermittent and hence is protected by an external Electronic Hooter Timer Relay.

Electrical Operation & Maintenance Manual – TPP Page 139 of 144

 WATER LEVEL SENSOR & WATER LEVEL SWITCH CUM INDICATOR
The Water level sensors provided in the radiator tank are magnetic float switches,
which are equipped with hermetically sealed reed switches. The reed switches are
actuated by the magnetic field of magnet inside the float. The only moving part of
the float switch is the float, which will be reliable floating on the water surface.
These switches have one normally closed contact, which are potential, free.
The Electronic level indicator is a digital device, which constantly monitors the
level of water in the radiator. It gives binary output as “LO” or “HI” depending on
the level of water. It has in- built timer to avoid wrong analysis of water level
during travel or rail condition due to super elevation, up & down gradients. The
time is pre-set to 15 seconds. It has one set of potential free change over
contacts.

WATER LEVEL SENSOR WATER LEVEL SWITCH

(WLSU11/21) CUM INDICAOR
SAN CODE: 91522860 (WLSI11/21)
SAN CODE: 91523880

Electrical Operation & Maintenance Manual – TPP Page 140 of 144

 WATER TEMPERATURE SWITCH / SENSOR / GAUGE – ENGINE COOLING

WATER TEMPERATURE WATER TEMPERATURE

SWITCH – ENGINE SENSOR – ENGINE
(WTS11/21) (WTSU11/21)
SAN CODE: 91507700 SAN CODE: 97503380

The Temperature sensor is a sender unit of variable resistance type, which

senses the Engine cooling water temperature. It operates at a nominal 24 Volts
DC system voltage. It is a completely sealed unit. It is of Insulated type and
designed for two-wire system. The range of measurement is from 40 to 120 °C.
The thread is of standard 1/2” BSP.

The temperature switch is a bi-

metallic type, which senses the
Engine cooling water temperature.
This is supplied by Cummins India
Ltd. The range of temperature is
between 40 to 100 °C. The
nominal power rating of the switch
is 24 Volts Dc and 0.5 Amps. It is
of Insulated type and designed for
WATER TEMPERATURE
two-wire system. It consists of one
GAUGE – ENGINE
(WTG11/21) set of potential free change over
SAN CODE: 97504390 contacts. The thread is of standard
1/2” BSP.

Electrical Operation & Maintenance Manual – TPP Page 141 of 144

The Temperature Gauge monitors the temperature of Engine water. These
gauges use cross coil movement, which compensates for small voltage
fluctuations, normally experienced in automotive circuits. The nominal operational
voltage is 24 Volts DC. It is of Insulated type and designed for two-wire system.
The sweep angle is 80 °C and the case size is 52 mm diameter. The range of
measurement is 40 to 120 °C.

Electrical Operation & Maintenance Manual – TPP Page 142 of 144

Electrical Operation & Maintenance Manual – TPP Page 143 of 144
CHAPTER – 11
ANNEXURE

ADITIONAL

CONTROLS

(IF ANY)

Electrical Operation & Maintenance Manual – TPP Page 144 of 144