WDG4D Final Speed Certificate

CCB INDIAN RAILWAYS LOCOMOTIVE
MAINTENANCE MANUAL
CHAPTER 1
SYSTEM DESCRIPTION AND OPERATION
1.1 AIR BRAKE EQUIPMENT
The Computer Controlled Brake (CCB) equipment, arranged for dual cab, multiple-unit operation,
is used on this locomotive. The principal parts are as follows:
1.1.1 AIR BRAKE EQUIPMENT LOCATION
See Figure 1-1 for location of equipment in the Brake Bay Rack.
See Figure 1-2 for the Brake Valve Controller (BVC) handle positions.
See Figure 1-3 for the Pneumatic Control Unit (PCU) Valve locations.
See Figure 1-4 for the Computer Relay Unit (CRU) Component locations.
1.1.2 BRAKE VALVE CONTROLLER (Figure 1-2)
1.1.2.1 OPERATING - AUTOMATIC HANDLE
The Brake Valve Controller Automatic handle operates through five detented positions: Release
(REL), Running (RUN), Minimum (MIN), Full Service (FS), and Emergency (EMER). There is
also a non-detented Service Zone that utilizes the area between the MIN and FS detented notch
positions. An indicating plate is provided denoting the five detented operating positions.
When charging a train or releasing an Automatic brake application, the automatic Brake Valve
Controller handle must be placed in RUN or RELEASE position.
When a Service brake application is made, the Automatic Brake Valve Controller handle is moved
away from the engineer against the second detent position of the quadrant. This is a minimum
2
reduction position which will provide a 0.3 - 0.4 kg/cm reduction. If it is necessary to increase
the reduction, the handle is moved progressively away from the engineer, bearing in mind that the
further the handle is moved into the service zone, the greater the reduction will be. The brake
valve will self-lap at any point where movement of handle is stopped in the service zone and
automatically maintain NORMAL equalizing reservoir and full service brake pipe leakage.
Full service brake application is obtained by moving the Brake Valve Controller handle to the
FULL SERVICE position against the fourth detented position of the quadrant. Brake Cylinder
2
pressure at Full Service is 4.4 kg/cm . In this position overspeed control and vigilance penalty
applications are suppressed.
Placing the handle in EMERGENCY, the fifth detent position, reduces equalizing pressure to
2
zero. Brake pipe reduces rapidly to zero kg/cm . Equalizing Reservoir reduces to zero at a
2
slower rate. BC pressure is maintained at the Full Service setting of 4.4 kg/cm .
Release of an Automatic locomotive brake while retaining the train brake cylinder pressure can
be accomplished by lifting upward on the Direct handle bailoff (quick release) ring. Locomotive
brakes will remain released unless the Automatic handle is in Emergency. In this case brakes will
reapply when the bailoff (quick release) ring is released. Bailoff (quick release) does not affect a
Direct application. The locomotive brake cylinder pressure will be reduced to the value
corresponding to the position of the Direct handle.
IP-165-C 1-1 DECEMBER/98

MAINTENANCE MANUAL
1.1.2.2 OPERATING - INDEPENDENT BRAKE
When applying the locomotive Direct brake, move the Direct BVC handle away from the engineer
(Full Direct application is the extreme forward position), and when releasing, move the handle
toward the engineer. The brake valve will self-lap at any point in the application zone where
handle movement has been stopped. Brake cylinder pressure is maintained against leakage in
any service position.
The Direct Brake Valve Controller handle should always be in RELEASE position (closest to
engineer) when the locomotive is a trailing unit in a multiple-unit consist or is being towed DEAD.
1.1.2.3 AIR BRAKE SET-UP
The function of conditioning the Locomotive for LEAD IN, LEAD OUT or TRAIL is accomplished
through the panel switch located in the lower right corner of the brake valve controller.
A. For Set-Up as Lead or Single Unit
If unit is in MU with other locomotives, ensure all units are in TRAIL before attempting to set up
locomotive in LEAD.
1. Move Lead/Trail selector switch to “LEAD OUT”.
2. Move Automatic BVC handle to “RUN” position and charge equalizing reservoir to 5.2
2
kg/cm .
3. Move Lead/Trail selector switch to “LEAD IN” position and charge brake pipe.
4. Move Direct brake handle to Release position.
B. For Set-Up as Trail Unit
1. Fully apply Direct Brake and place Automatic BVC handle in Full Service (FS).
2. After Brake Pipe exhaust ceases, select “TRAIL” position on the Lead/Trail selector
switch. Move the Direct BVC handle to “RELEASE”.
3. Automatic and Direct Brakes are now cut-out.
NOTE: DO NOT turn off breaker for Computer Controlled Brake (CCB).
1.1.3 LOSS OF POWER MODE
When loss of power occurs to the CCB system, such as an “Open” AB circuit breaker, the MVER
2
default magnet valve de-energizes to directly reduce equalizing reservoir (ER) to zero kg/cm at a
service rate through a #60 drill choke. This causes brake pipe (BP) to reduce at a service rate to
2
0.7 kg/cm . Brake cylinder pressure is developed by a pneumatic back-up system to a maximum
2
pressure of 3.8 kg/cm . Trailing units will receive pressure via the brake cylinder equalizing pipe
2
(BCEP) to 3.8 kg/cm .
If power cannot be restored to the brake system, the unit must be used as a ‘Trail’ or ‘Dead’
locomotive. If operated as a ‘Trail’ locomotive, all MU pipes must be connected and the unit set
to ‘Trail’ position. Brake cylinder pressure will be developed from the lead unit via the BCEP.
DECEMBER/98 1-2 IP-165-C

MAINTENANCE MANUAL
If the unit is operated as a ‘Dead’ unit. The dead engine cut off cock (COC) located at the lower
left corner of the pneumatic control unit (PCU) must be ‘opened’. Both BCEP and main reservoir
equalizing pipe (MREP) cut-off end cocks must be opened. The brake pipe angle cock and the
brake pipe hose must be opened and connected to the train. Bogey brake cylinder cocks must
be opened, and Air Brake Circuit Breaker (ABCB) must be opened.
Brake cylinder pressure will be developed similar to the train brakes through the operation of the
KE distributor valve and pneumatic interlocks on the PCU. In this mode of back-up operation, a
slight blow at the BCEP end hose will occur. This is normal and does not effect the development
of brake cylinder pressure.
1.1.4 POWER UP PENALTY
Whenever the Air Brake circuit breaker is first closed in a 'LEAD' mode, the CCB system applies
2
a PENALTY service brake. BC and BCEP are pressurized to 3.57 kg/cm . The Brake Valve
Controller handle should be placed into FULL Service detent position to reset the system. The
Brake Valve Controller handle must remain in FULL Service detent position for 10 seconds to
2
reset the system (in addition to the original 30 seconds). When BP charges to 2.9 kg/cm , move
the Brake Valve Controller handle to RUN position to fully recharge the brake system.
2
Brake cylinder pressure must reduce to zero kg/cm before the computer regains control of the
brake cylinders. This function assures that a Penalty brake application will occur should the
power be lost for any reason.
1.2 SYSTEM OVERVIEW
Refer to Figure 1-5
The Computer Controlled Brake (CCB) Equipment is a complete microprocessor Air Brake
Control System for main line locomotives and switchers. The equipment is fully compatible with
locomotives having single pipe MU brake control. All logic is computer controlled. Emergency
applications are also initiated pneumatically in parallel with computer initiated emergency
applications.
The operator commands the computer through the CCB brake valve controller. The brake valve
controller is mainly electronic and signals the computer as to the position for Automatic and Direct
braking. Lead/Trail and Brake Pipe Cut-Out modes are set up through the Three-Position
selector switch. The Feed Valve setting is factory set by the computer software. The only
pneumatic valve contained in the brake valve is the mechanically actuated emergency vent valve.
The vent valve is open in emergency position.
The Computer interprets the signals of the brake controller and controls the Pneumatic Control
Unit for the actual development of pressure. All control pressures are developed in this manner:
brake pipe, brake cylinder equalizing pipe, and brake cylinder. The Computer also controls the
locomotive power knock down cut-off relay (PCS). The voltage conditioning circuitry isolates the
locomotive battery supply from the CCB system as well as providing 24 VDC to operate the CCB
equipment.
The KE Valve provides #16 control volume pressure to the BC relay control that operates to
provide ‘Service’ automatic brake whenever “Loss of Power” of the consist occurs.
Computer Controlled Brake (CCB) equipment is compatible with conventional brake systems in

MAINTENANCE MANUAL
basic function and operation. Handle positions, locomotive set-up, and pressure development
flow rates, remain the same. The changes from conventional AAR/UIC systems occur in how the
air pressure is controlled and the type of equipment used to control the brakes. Also, a major
enhancement is the ability to diagnose problems.
1.2.1 SYSTEM OPERATING PRESSURES
A. AUTOMATIC BRAKE PRESSURES

2
Main Reservoir = 8 - 10 kg/cm .
2
Release - BP = 5.6 kg/ cm Maximum
2
Running - ER and Brake pipe = 5.2 kg/cm , BC = 0
2 2
Minimum Service - ER/ BP reduce to 4.7 kg/cm , BC = 1.1 kg/cm .
2 2
Full Service - ER/BP reduce to 3.4 kg/cm , BC = 4.35 kg/cm .
2 2
Emergency - ER reduces to 0 kg/cm , BC = 4.35 kg/cm .
2
BP reduces to less than 1 kg/cm .
2
BCEP = 3.57 kg/cm .
1.2.2 AUTOMATIC BRAKE SYSTEM FEATURES
As with conventional brake systems the CCB system controls the locomotive and train brakes
through control of trainline brake pipe pressure. Control of brake pipe pressure permits the
development of brake cylinder pressure on both locomotive and train.
Control of brake pipe pressure is accomplished by control of a smaller volume called Equalizing
Reservoir (ER). ER pressure is reduced to apply brakes, and increased to release brakes. Brake
cylinder pressure develops at a controlled rate roughly 2.6 times the amount of brake pipe
reduction.
The CCB system utilizes 2 distinct control circuits to apply and release an automatic brake. I.e.:
Brake pipe control circuit increases or decreases the brake pipe pressure according to the
pressure commanded by ER control. Brake cylinder control circuit controls the increase or
decrease of brake cylinder pressure commanded by #16 Control.
1.2.3 INDEPENDENT (DIRECT) BRAKE

2 2
Independent Brake = Maximum brake position BC = 5.2 kg/cm . BCEP = 3.7 kg/ cm .
2
Release Position BC = 0 kg/cm
1.2.4 INDEPENDENT BRAKE SYSTEM FEATURES
The Independent brake, when operated with a forward motion, develops brake cylinder on the
locomotives only. Pressure is developed much faster than with an Automatic application. At the
same time BC is supplied pressure, air also flows to the Brake Cylinder Equalizing Pipe at the
same charging rate as the Brake Cylinder pressure.
The Independent brake valve is also used for a faster release of the Automatic brake. When the
bailoff (quick release) ring on the Independent handle is lifted, both BC and BCEP pressures are
vented at the Lead Unit releasing the Automatic brakes on the LEAD and all TRAILING units. If
an Independent brake was also applied, these brakes would remain applied.

MAINTENANCE MANUAL
1.2.5 LEAD UNIT AUTOMATIC BRAKE OPERATION - BRAKE RELEASE
Once the brake system is powered-up, equalizing reservoir default magnet valve (MVER)
energizes and remains energized until power is removed for any reason.
1.3 BRAKE PIPE CONTROL SUBSYSTEM
1.3.1 EQUALIZING RESERVOIR ELECTRICAL CONTROL - RUNNING
Refer to Figure 1-6
MVER is energized when commanded by the CPZ via EPA1 and DB1 PCB’s. 24 VDC is
supplied by the VCU through the DB1 output driver circuit. When the Automatic Brake Valve
Controller handle is in Run position, a frequency is generated by the internal electronic circuitry of
the Brake valve controller and transmitted to the FOR PCB via a fiber optic cable. This frequency
is decoded by the FOR board and sent to the CPZ (Central Processor) board where the handle
position is identified. The computer reads this input and calculates the Equalizing Reservoir
pressure for that handle position. The CPZ commands the EPA1 board to the level of output
pressure required.
The EPA1 board outputs a PWM signal to the ER Analog Converter that opens the normally
closed supply magnet valve connecting main reservoir supply air to the equalizing reservoir circuit
at a controlled rate determined by the computer. The ER transducer (ERT) feeds back a voltage
proportional to the ER pressure. When ER pressure reaches the commanded pressure, the
EPA1 de-energizes the supply magnet valve and maintains the pressure level constant through
control of the Analog Converter's magnet valves and feedback from the ER Transducer (ERT).
The Equalizing Reservoir pressure pilots the BP relay which connects main reservoir supply air to
the brake pipe circuit. When Brake Pipe Pressure reaches the pressure dictated by the
Equalizing Reservoir, the BP relay moves to "LAP" position.
In RUN position, 15 VDC is supplied by the SS9 PCB output circuit, through the brake valve
controllers’ contacts ‘AR’, back through the SS9 data output to the CPZ PCB. This circuit assures
the handle position is calibrated to the proper frequency.
1.3.2 EQUALIZING RESERVOIR AND BRAKE PIPE PNEUMATIC CONTROL - RUNNING
Refer to Figure 1-7
Main Reservoir air flows through the open Analog Converter (AW4-ER) Supply Magnet Valve to
the Equalizing Reservoir Transducer (ERT) and to the closed Analog converter (AW4-ER)
Exhaust Magnet Valve. Air then passes through the open Equalizing Reservoir Magnet Valve
(MVER), in Lead position, to charge Equalizing Reservoir (ER). ER pressure pilots the high
capacity Brake Pipe Relay Valve (KR-5EO).
2
Equalizing reservoir (ER) pressure will be increased to, and maintained at 5.2 kg/cm . ER
pressure is maintained automatically by use of the ER Transducer’s commands to AW4-ER’s
Supply and Exhaust magnet valves to either ‘open’ or ’close’ when leakage is detected by the ER
Transducer.
When ER pressure rises slightly above brake pipe pressure, the brake pipe relay valve (KR5-EO)
detects the pressure difference and its internal supply valve opens. This allows MR air to pass

MAINTENANCE MANUAL
through KR5-EO, to magnet valve MV53 cutoff pilot valve, and to the brake pipe cut-off valve
2
(BPCO). If brake pipe air pressure is below 1.5 kg/cm , it is contained at the BPCO valve. Air
flow continues through the de-energized MV53 pilot valve, thus developing pressure at the BPCO
2
pilot port (A4). When this pressure exceeds 1.8 kg/cm , the BPCO valve shuttles to ‘open’
position allowing pressure to flow to the trainline brake pipe through the brake pipe filter.
1.3.3 BRAKE PIPE CHARGING CUT-OFF
Refer to Figure 1-8
MR air flows to the trainline brake pipe via the brake pipe cut-off valve (BPCO). For the purpose
of brake pipe leakage testing of locomotive or train or during Emergency Applications, the flow of
air from the brake pipe relay (KR5-EO) must be stopped. This is accomplished by closing the
high capacity BPCO. This valve automatically closes when the brake pipe pressure on the
2
valve’s pilot port is less than 1.8 kg/cm .
Normally when brake pipe increases at the output of the brake pipe relay (KR5-EO), air flows
through deenergized MV53 magnet valve to the pilot port of the BPCO valve. The BPCO valve is
2
forced to its ‘open’ position when pressure is above 1.8 kg/cm , thus permitting brake pipe
pressure to develop in the trainline brake pipe.
When the Lead/Trail selector switch is placed to either ‘Lead-Out’ or ‘Trail’ positions, the CPZ
PCB commands MV53 magnet valve to energize via EPA1 and DB1 PCB’s. 24 VDC is applied to
the MV53 coil. When energized, MV53 vents the pilot port of the BPCO valve allowing an internal
spring to move the valve to the closed position. Brake pipe pressure flow to the trainline brake
pipe ceases.
When the Lead/Trail selector switch is placed to the ‘Lead-In’ position, voltage is removed from
the MV53 magnet valve by the combination of CPZ, EPA1, and DB1 PCB’s. The pilot port of
BPCO is pressurized by brake pipe exiting at the MV53 magnet valve supply port. MV53 is also
energized and brake pipe cut-off occurs via CPZ, EPA1, and DB1 whenever an emergency
application is detected by the CPZ PCB for the following conditions:
A. Brake valve controller handle in ‘Emergency’ position.

2
B. Brake valve controller handle not in ‘Emergency’ but brake pipe is less than 3 kg/cm .
In parallel with the CPZ, EPA1, and DB1, MV53 is simultaneously energized by a path through
the AE-2 brake valve controller contacts. In ‘Emergency’, 24 VDC is delivered to MV53 through
the AE-2 closed contacts.
1.3.4 FLOW DETECTION
Refer to Fig. 1-9
This circuit includes two flow indicators, one for each control stand piped across an orifice. The 8
mm orifice is in series with a 4 mm orifice restricts the main reservoir flow to the Brake Pipe relay
and thus to the trainline brake pipe in RUNNING position.
Whenever an excessive flow of air occurs across the 8 mm/4 mm orifice, a pressure drop is
developed which is sensed by the flow meters, causing the hands to rotate clockwise giving the
Driver an indication that the train may be experiencing loss of pressure due to a train separation. The
flow is created when the Brake Pipe relay opens in an attempt to maintain the brake pipe leakage.

MAINTENANCE MANUAL
An indicator light on the Flow Meter illuminates whenever the flow exceeds the preset flow
indication.
1.3.5 FAST RECHARGE AND ASSIMILATION - RELEASE
Placing the BVC handle in the Release (REL) position closes the ‘AR’ microswitch. A 15 VDC
signal generated by the SS9A PCB returns to the SS9A PCB as input from the AR switch to tell
the computer that the handle is in the Release position.
Placing the BVC handle in the release (REL) position provides two functions.
A. FAST RECHARGE
Refer to Figure 1-10
MR air flow to the trainline brake pipe increases because the size of the main reservoir
charging orifice increases from approximately 4 mm to 8 mm. This allows faster charging of
the train. The faster charging rate will only be maintained while the handle is held in the
release position against the tension of the brake valve controller’s return spring.
MR air flows from the second main reservoir through a ball valve, locomotive final filter, and
PCU MR filter, to an 8 mm orifice. The restricted air flow then continues on to the by-pass
pneumatic valve (PVBP). The CPZ outputs a command with a data message to the EPA1
PCB. This information is converted by the EPA1 PCB into a 24 VDC command voltage to
energize the brake pipe magnet valve (MVBP). MVBP connects MR air pressure to the pilot
port ‘A4’ of the PVBP causing it to open, thus allowing MR air to bypass the 4 mm charging
restriction orifice to deliver pressure directly to brake pipe at a much faster rate. This permits
the train brake distributing valves to release brake cylinder pressure sooner.
B. OVERCHARGE AND ASSIMILATION
This feature is provided to allow the manual initiation of an automatic overcharge cycle
2
(assimilation) to the maximum overcharge level of 0.5 kg/cm . This feature is initiated
whenever the Automatic brake valve controller handle is placed in the spring-loaded Release
(REL) position.
Once an overcharge cycle is initiated, the brake pipe will charge to the normal brake release
2
pressure of 5.1 kg/cm (plus any previous unassimilated overcharge) at the normal service
2
rate. Brake pipe pressure will continue to increase at a constant rate of 0.05 kg/cm per
2
second to the maximum level of 5.7 kg/cm and will remain at that level for a time period of 60
seconds. After the 60 second time period expires, the brake pipe pressure will slowly bleed
2
off or “assimilate” at the UIC specified rate of 0.002 kg/cm per second down to the normal
2
release pressure of 5.1 kg/cm . To reinitiate an overcharge cycle, it is required that the
Automatic BVC handle be moved to a service position and then back to Release.
If the Automatic BVC handle is moved into a service position at any time before a overcharge cycle
is complete, normal brake pipe control will be resumed with the exception that all subsequent
pressure requests will be adjusted upward by the amount of overcharge in effect at the time the
handle is first moved out of the ‘RUN’ position. This adjustment will remain in effect until the
Automatic BVC handle is placed in the ‘RUN’ position and the existing overcharge is allowed time
to assimilate or the handle is placed in the ‘Release’ position and a new overcharge cycle is
initiated. The overcharge cycle will automatically complete with the BVC handle in the ‘RUN’
position.

MAINTENANCE MANUAL
1.3.6 BRAKE CYLINDER PRESSURE CONTROL SUBSYSTEM - RELEASE OR RUNNING
The brake pipe pressure is monitored by the brake pipe transducer, BPT, which outputs a voltage
proportional to brake pipe pressure to the CPZ board via the EPA1 and ADZ boards.
The computer calculates the #16 control pressure based on the level of brake pipe pressure.
When brake pipe increases, the CPZ calculates the appropriate pressure to be released from the
#16 control volume. This command is sent to the EPA2 PCB to release pressure in the #16
control volume at approximately 2.6 to 1, brake cylinder to brake pipe pressure ratio. The rate of
change for #16 control volume is controlled by an algorithm residing in the computer program
which ramps the command to the EPA board up or down at a predetermined rate until the target
pressure is reached.
The Analog Converter (AW4-16) Supply Magnet Valve closes and the AW4-16 Exhaust Magnet
Valve opens exhausting the #16 Control Volume from the open Control Pipe Magnet Valve
(MV16T). This exhausting of air allows the BC Relay Valve piston to move and vent the brake
cylinder air to atmosphere.
1.3.7 BRAKE CYLINDER EQUALIZING PIPE PRESSURE CONTROL - RELEASE OR RUNNING
A. AUTOMATIC RELEASE
The Brake Cylinder Equalizing Pipe is used to supply air to and from all trailing units of the
locomotive consist to control application and release of both Automatic and Independent
(Direct) brakes. The only exception to this operation is locomotive consist separation. This
function will be discussed under ‘Break-in-Two’ protection.
In Release or Running positions the Automatic Brake Valve transmits a frequency of 10.8 -
11.2 and 9.95-10.3 respectively to the FOR PCB. The fiber optic frequency is converted to a
data message that is received by the CPZ PCB. This information is used to calculate the
pressure level in the BCEP valve’s EXH magnet to energize. This valve will remain energized
until the BCEP pressure level commanded is attained.
Pressure in the 20 Reservoir which serves as a control pressure for the BCEV relay valve
vents at a rate similar to brake cylinder release rate. This rate is controlled by the variable
orifice of the EXH magnet valve.
You can see from Figure 29 that the #20 reservoir flows to exhaust through pneumatic piston
valve PVLT1 and Brake cylinder pipe pressure flows through PVLT2 before exiting the BCEV
relay exhaust. These piloted pneumatic cut-off valves are opened when the locomotive Lead/
Trail switch is in Lead position. Both valves are simultaneously operated by air pressure from
the magnet valve MVLT which is energized by the Lead/Trail switch via the SS9A, EPA2,
CPZ, DB1 PCB’s.
When the pressure in the #20 reservoir reduces lower than the brake cylinder pressure, the
BCEV is forced to move to its exhaust position. Brake cylinder pressure can now vent through
the BCEV exhaust port to atmosphere at the same rate as the #20 control reservoir. With the
brake valve handle in Running or Release position, the BCEP pressure reduces to zero.

MAINTENANCE MANUAL
B. BAILOFF (QUICK RELEASE)
When the brakes are bailed off as previously described, the BCEP is exhausted the same as
described under automatic release of BCEP. However, the rate of release is faster.
1.3.8 LEAD UNIT AUTOMATIC BRAKE OPERATION-BRAKE APPLICATION
1.3.8.1 BRAKE PIPE CONTROL SUBSYSTEM
A. SERVICE APPLICATION
Refer to Figure 1-16, 1-17, 1-18
There are several positions of the Brake Valve Controller handle that control locomotive and
train brake applications. When the automatic Brake Valve Controller handle is moved from
Running to any of the service detent positions from Minimum Service to Full Service,
Equalizing Reservoir and Brake Pipe will be reduced by an amount proportional to handle
movement. In each position of the Automatic Brake Valve a different frequency is generated
by the electronic circuitry identifying the level of Equalizing Reservoir pressure commanded.
This frequency is transmitted through a fiber optic cable isolated from electrical interference
to the Fiber Optic Board (FOR) in the computer rack. As explained in "RUNNING" the computer
reads the FOR, calculates the ER pressure and commands the EPA1 board to energize the
Exhaust Magnet Valve of the ER Analog Converter. The supply magnet valve remains
closed. The flow rate of Equalizing Reservoir to exhaust is controlled by the computer by
changing the command pressure to the EPA1 relative to elapsed time. Since the Analog
Converter magnet valves are soft seat type, the valves need not be fully open or fully closed.
As the pressure approaches the commanded level of pressure, the EPA compares pressure
demand with the output voltage of the Equalizing Reservoir Transducer (ERT) located on the
Analog Converter. The EPA slowly closes the Supply Magnet Valve until the desired
pressure is reached. This action avoids undesired valve chatter and pressure fluctuations
normally inherent to digitally controlled systems.
ER reduces through the energized magnet valve (MVER) and the open exhaust magnet of
the analog converter (AW4-ER) at a controlled rate. With ER reducing, ER air is removed
from the control port of the BP Relay Valve (KR-5EO). The piston in the relay valve moves
and BP reduces through the exhaust port of the Relay Valve (KR-5EO) at a controlled rate by
the relay exhaust choke from the brake pipe volume of the locomotive and train consist. This
action is totally pneumatic. When brake pipe pressure is equal or slightly less than equalizing
Reservoir pressure acting on the Relay diaphragm, the valve slowly moves to a "LAP"
position closing the exhaust port. Since the Relay is a maintaining type valve, brake pipe
pressure will be maintained to the level of Equalizing Reservoir for acceptable train brake
leakage conditions.
B. EMERGENCY APPLICATION
An Emergency Application means to apply brakes at the maximum rate. When the Brake
Valve is placed into Emergency position several actions take place to insure an Emergency
Application occurs. As with Service braking a frequency is generated that is read by the

MAINTENANCE MANUAL
computer via the Fiber Optics board. The analog converter operates the same as described
2
under Service Application - Lead unit; ER reduces at a faster rate and reduces to 0 kg/cm
2
instead of 3.4 kg/cm . This causes the KR-5EO brake pipe relay to open brake pipe to
exhaust assuring no rise in brake pipe can occur even if the cut-off valve leaks. In addition,
the brake controller AE1 switch opens sending an emergency input signal to the computer via
the SS9A or SS9B circuit board. In Emergency position the brake valve mechanically opens a
vent valve that exhausts brake pipe, directly venting BP throughout the entire length of the
train.
Refer to Figure 1-21 & 1-22
In addition, the brake controller AE1 switch opens sending an emergency input signal to the
computer via the SS9A or SS9B circuit board. Both of the above signals tell the computer to
energize the Emergency Magnet Valve (MVEM) via the EPA1 board and Driver Board (DB1).
The opening of the Emergency Magnet Valve (MVEM) vents the pilot port of the high capacity
pneumatic valve (PVEM).
C. TRAIN SEPARATION EMERGENCY APPLICATION
To insure an Emergency rate of brake pipe reduction brake pipe charging must be
suspended. With the handle in Emergency position, or from a train or locomotive separation,
or driver’s Emergency valve, the brake pipe cut-off Magnet Valve (MV53) energizes. A
second switch AE2 also provides 24 VDC, via wires, to energize MV53 in Emergency
position. With a brake valve emergency the Analog Converter (AW4-ER) exhaust magnet
valve, Brake Pipe Cut-Off Magnet Valve (MV53) and Emergency Magnet Valve (MVEM) are
commanded to energize. The opening of the analog converter exhaust magnet valve allows
ER air from the BP relay valve (KR-5EO) and ER reservoir to flow through the open ER
magnet valve (MVER) and to open analog converter exhaust magnet valve to vent to
atmosphere. With BPCO Magnet Valve (MV53) open, the BPCO valve pilot port vents,
forcing the valve to lose communication between Brake Pipe Relay (KR-5EO) and trainline
brake pipe.
A Brake Valve emergency application provides immediate power or dynamic brake knock
down by de-energization of the cut-off Relay (COR) through the computer program logic. If a
2
train separation occurs, BP level and flow are monitored. If BP level drops 2.5 kg/cm below
release pressure, emergency logic is initiated. If during this time BP exceeds 1200 L/min, the
brake pipe flow indicators will alert the operator. An emergency application is also initiated if
an emergency rate of brake pipe reduction is achieved.
With a Break-in -Two in affect Power Knockdown is delayed for 20 seconds or whenever the
Brake Valve Controller is moved to emergency position.
1.3.8.2 BRAKE CYLINDER CONTROL SUBSYSTEM
A. SERVICE APPLICATION
The Brake Pipe Transducer (BPT) detects the reduction of brake pipe, which is read by the
central processor (CPZ) via the Analog/Digital circuit (ADZ). The computer calculates the
required brake cylinder pressure and commands the #16 Analog Converter via the EPA2
board to the desired rate and pressure level.

MAINTENANCE MANUAL
Refer to Figure 1-25, 1-26, 1-27 & 1-28
The EPA2 board responds by controlling the Analog Converter's magnet valves to develop
#16 pipe volume pressure from MR supply. In this closed loop system #16 pipe pressure is
monitored by the Analog Converter's Transducer (16T). When #16 pressure equals the
demand pressure, the EPA2 board slowly closes the Supply Magnet Valve. Again #16 control
pressure will be maintained by the Analog Converter by comparing the 16T Transducer
feedback to the EPA2 output. Main Reservoir air flows through the open supply magnet valve
of Analog Converter (AW4-16) and through open magnet valve (MV16) to the #16 Reservoir
and the pilot port of the high capacity Relay Valve.
The #16 Reservoir air acting on the Relay Valve piston allows Main Reservoir air to pass
through the Relay Valve and supply air to the Brake Cylinders. Brake cylinder pressure
increases until it matches the #16 pipe control pressure. Similar in operation to the KR-5EO
relay, the BC Relay Valve moves to LAP position closing off the supply of MR pressure to the
brake cylinders. The application is complete and brake cylinder pressure will be maintained
at the level commanded until the Brake Valve Controller handle is again moved.
At this point the engineer can make a further reduction by moving the Automatic Brake Valve
2
controller handle toward Full Service position where a 1.6 kg/cm brake pipe reduction is
2
attained and maximum service brake cylinder pressure of 4.37 kg/cm is achieved.
The Service position provides for nullification or reset of penalty applications created by
Alerter systems, power-up penalties, or diagnostic penalties.
B. EMERGENCY APPLICATION
As in a Service brake application the Brake Pipe Transducer (BPT) detects the reduction of
brake pipe which is read by the central processor (CPZ) via the Analog/Digital circuit (ADZ).
The computer calculates the required brake cylinder pressure and commands the #16 Analog
Converter supply valve via the EPA2 board to the desired rate and pressure level.
The EPA2 board responds by controlling the Analog Converter's magnet valves to develop
#16 pipe volume pressure from MR supply. In this closed loop system #16 pipe pressure is
monitored by the Analog Converter's Transducer (16T). When #16 pressure equals the
demand pressure, the EPA2 board slowly closes the Supply Magnet Valve.
Again #16 control pressure will be maintained by the Analog Converter by comparing the 16T
Transducer feedback to the EPA2 output.
So far as this system is concerned, the #16 control circuit works the same as in SERVICE
application except that the rate of pressure increase is slightly faster. The maximum
2
pressure of 4.37 kg/cm is identical.
Main Reservoir air flows through the open supply magnet valve of Analog Converter (AW4-
16) through open magnet valve (MV16) to the #16 Reservoir and the pilot port of the high
capacity BC Relay Valve. The #16 Reservoir air acting on the Relay Valve piston allows
Main Reservoir air to pass through the Relay Valve and supply air to the Brake Cylinders. Brake
cylinder pressure increases until it matches the #16 pipe control pressure. Similar in operation
to the KR-5EO relay, the BC Relay moves to LAP position closing off the supply of MR pressure
to the brake cylinders. The application is complete and brake cylinder pressure will be
maintained at the level commanded until the Brake Valve Controller handle is again moved.

MAINTENANCE MANUAL
Again the brake cylinder pressure rise is slightly faster than a Service application, but the
pressure level is the same as for Full Service.
C. BAILOFF (QUICK RELEASE) - AUTOMATIC APPLICATION
When an Automatic brake is applied, depressing the Independent brake handle in any
position will release BC.
Depressing the brake valve Independent handle closes a microswitch, sending a signal input
to CPZ via the SS9 PCB’s. An isolated output is fed by computer (CPZ) PCB via the EPA2
PCB to the AW4-16 analog converter.
On the LEAD UNIT the central processor commands the EPA2 PCB to release the #16 pipe
pressure through the Analog Converter Exhaust magnet valve which in turn drives the BC
relay to release (Refer to Automatic Brake Release for operation). BC will remain exhausted if
the brake was applied as a SERVICE application. If an EMERGENCY brake had been made,
the brake would reapply to maximum as soon as the bailoff (quick release) ring was released.
NOTE: If the bailoff (quick release) continues for longer than 50 seconds, the brake
cylinder pressure is restored and a fault will be displayed. This prevents
tampering with the bailoff (quick release) button.
1.3.8.3 BRAKE CYLINDER EQUALIZING PIPE CONTROL SUBSYSTEM
A. APPLICATION-SERVICE OR EMERGENCY
In Service positions the Automatic Brake Valve transmits a frequency to the FOR PCB. The
fiber optic frequency is converted to a data message that is received by the CPZ PCB. This
information is used to calculate the pressure level in the BCEP. The BCEV’s supply valve will
energize and remain energized until the BCEP pressure level commanded is attained.
increases at a rate similar to brake cylinder application rate. This rate is controlled by the
computer controlled variable orifice of the EXH magnet valve.
The #20 reservoir flows through normally open pneumatic piston valve to pilot the BCEV
relay valve.
When the pressure in the #20 reservoir increases slightly above brake cylinder pressure, the
BCEV is forced to move to its apply position. Main Reservoir is now ported through the open
supply valve to the BCEP of the Lead locomotive. Air flows through BCEP and on to the
Trailing Units where it will be used to develop brake cylinder pressure on those locomotives.

MAINTENANCE MANUAL
When BC pressure equals BCEP the BCEV relay moves to LAP position, terminating flow of
air to the brake cylinders. Since the BCEV relay valve is a self-lapping pressure maintaining
type of pneumatic valve, BCEP will be maintained at a constant pressure should leakage
develop to either increase or decrease BCEP pressure.
B. BAILOFF (QUICK RELEASE) - SERVICE AND EMERGENCY
When an Automatic brake is applied, depressing the Independent brake handle in any
position will release BCEP as a result of BP reduction.
Depressing the brake valve Independent handle closes a microswitch, sending a signal input
to CPZ via the SS9 PCB’s. An isolated output is fed by computer (CPZ) PCB via the EPA2
PCB to the AW4-16 analog converter.
On the LEAD UNIT the central processor commands the EPA2 PCB to release the BCEP
pipe pressure through the #20 Analog Converter Exhaust (part of the BCEV) magnet valve
which in turn drives the BC relay to release (Refer to Automatic Brake Release for operation).
BCEP will remain exhausted if the brake was applied as a SERVICE application. If an
EMERGENCY brake had been made, the brake would reapply to maximum as soon as the
bailoff (quick release) ring was released.
NOTE: If the bailoff (quick release) continues for longer than 50 seconds, the BCEP pressure
is restored and a fault will be displayed. This prevents tampering with the bailoff
(quick release) button.
1.3.9 TRAIL UNIT AUTOMATIC BRAKE OPERATION - BRAKE RELEASE
1.3.9.1 BRAKE PIPE CONTROL SUBSYSTEM
A. ER Control
In Trail operation the Brake Valve controllers are set up with the Automatic handles in Full
Service position and the Independent handles in Release. The Lead/Trail switch of each
controller is set to TRAIL. The handle positions of the controllers have no affect on system
operation except in Emergency. However, it is a good idea to position the handles as
described should a failure occur.
In Trail, once the brake system is powered-up, equalizing reservoir default magnet valve
(MVER) energizes as in Lead unit operation. However, the CPU is programmed to command
the AW4-ER to energize the AW4-ER analog converter Exhaust magnet valve and reduce
2 2
the ER pressure to zero kg/cm . Equalizing reservoir pressure remains at zero kg/cm in all
Trail operation. MVER remains powered to enable the CPU to determine the output of the
ERT transducer.
The Trail Unit has no control over brake pipe, but does monitor brake pipe through the BPT
transducer. The purpose for BPT on a Trail Unit will be discussed under Locomotive
separation.

MAINTENANCE MANUAL
B. BRAKE PIPE CUT-OFF
When the Lead/Trail selector switch is placed in Trail position, the CPZ PCB commands
MV53 magnet valve to energize via EPA1 and DB1 PCB’s. 24 VDC is applied to the MV53
coil. When energized, MV53 vents the pilot port of the BPCO valve allowing an internal
spring to move the valve to the closed position. Brake pipe pressure flow to the trainline
brake pipe ceases. Brake Pipe pressure cannot flow either way through the valve.
C. BRAKE CYLINDER AND BRAKE CYLINDER EQUALIZING PIPE CONTROL SUBSYSTEM
Brake Pipe pressure increases on the Trail Unit when charged by the Lead Unit. Although the
brake pipe pressure is monitored by the Trail Units’ CPU, brake cylinder pressure is not
reduced because of this action, but rather by the fact that brake cylinder equalizing pipe is
being vented by the Lead Unit’s Brake Cylinder Equalizing Valve.
The venting of BCEP at the Trail Unit is sensed by the 20T transducer located on the Brake
Cylinder Equalizing Valve on the Trail Unit. The output voltage from this transducer is fed
back to the CPU via the ADZ PCB. The computer calculates the pressure required in the
Brake Cylinders based on the BCEP pressure. At this point the CPU commands the AW4-16
to reduce the #16 Control volume at the same rate as BCEP. The BC pressure vents via the
BC Relay valve which moves to release position when #16 pressure is lowered at the BC
Relay pilot port.
D. BAILOFF (QUICK RELEASE)
When the brakes are bailed off at the Lead Unit, the BCEP is exhausted and in turn causes
the Trail unit’s brakes to release as described above but at a faster rate.
1.3.10 TRAIL UNIT AUTOMATIC BRAKE OPERATION-BRAKE APPLICATION
1.3.10.1 BRAKE CYLINDER CONTROL SUBSYSTEM
A. ANY AUTOMATIC APPLICATION
As previously mentioned Automatic application at the Lead Unit reduces brake pipe to apply
the train brakes. With the Brake Cylinder Equalizing Pipe type of control system on the GT 26
MAC locomotives the trail units normally do not respond to reduction of brake pipe to apply
brakes. The Trailing Unit instead receives BCEP pressure during an Automatic application.
The increase of BCEP at the Trail Unit is sensed by the 20T transducer located on the Brake
Cylinder Equalizing Valve. The output voltage from this transducer is fed back to the CPU via
the ADZ PCB. The computer calculates the pressure required in the Brake Cylinders based
on the BCEP pressure. At this point the CPU commands the AW4-16 to increase the #16
Control volume via the Supply Valve at the same rate as BCEP. The BC pressure rises via the
BC Relay valve which moves to apply position when #16 pressure increases at the BC Relay
pilot port. BC pressure increases to the level of BCEP and is maintained against leakage.

MAINTENANCE MANUAL
The maximum brake cylinder pressure that can be obtained on the Trail Unit for Automatic
2
application is the same as the Lead Unit or 4.37 kg/cm . This calculated by the computer and
2
is based on 1.25 x the BCEP pressure of 3.5 kg/cm .
B. TRAIN SEPARATION-EMERGENCY APPLICATION
The Trail Unit does nothing different in this circumstance. The brakes are applied as
described above.
1.3.11 DIRECT APPLICATION AND RELEASE - LEAD MODE
A. SERVICE POSITION
As its name implies, Independent (Direct) Braking applies and releases locomotive brakes
independent of the Automatic Brake. The CCB system uses an Analog Converter to
accomplish this. This Analog Converter is (AW4-20) located on the BCEV and controls
pressure to and from the brake cylinder equalizing pipe.
Similar to the operation of the Automatic Brake, the Direct Brake Handle on the CCB Brake
Valve outputs a frequency to the computer proportional to handle position. The Direct Brake
is a closed Loop system. The EPA3 responds by controlling the analog converter’s magnet
valves for developing BCEP pressure from MR supply. Moving the handle between Release
2.
position to Maximum brake produces a variable pressure output from 0 to 5.2 kg/cm The
system is pressure maintaining at all pressure levels. The BCEP pressure will be maintained
by the analog converter by comparing the 20T transducer feedback to the EPA3 output.
In Service positions the Independent Brake Valve transmits a frequency to the FOR PCB.
The fiber optic frequency is converted to a data message, which is received by the CPZ PCB.
This information is used to calculate the pressure level in the BCEP. The BCEV’s supply
valve will energize and remain energized until the BCEP pressure level commanded is
attained.
increases at a rate similar to brake cylinder application rate. This rate is controlled by the
computer controlled variable orifice of the EXH magnet valve.
The #20 reservoir flows through normally open pneumatic piston valve to pilot the BCEV
relay valve.
When the pressure in the #20 reservoir increases slightly above brake cylinder pressure, the
BCEV is forced to move to its apply position. Main Reservoir is now ported through the open
supply valve to the BCEP of the Lead locomotive. Air flows through BCEP and on to the
Trailing Units where it will be used to develop brake cylinder pressure on those locomotives.
When BC pressure equals BCEP the BCEV relay moves to LAP position, terminating flow of
air to the brake cylinders. Since the BCEV relay valve is a self-lapping pressure maintaining

MAINTENANCE MANUAL
type of pneumatic valve, BCEP will be maintained at a constant pressure should leakage
develop to either increase or decrease BCEP pressure.
Brake Cylinder pressure is developed as described under Automatic Brake Application via
the AW4-16 and BC Relay circuits except that the BC pressure is greater and the build-up
rate is faster.
2
Maximum BC = 5.2 kg/cm
Build-up Rate 0 to 4.94 = 4-6 seconds
2
BCEP 3.7 kg/cm (Same as Automatic)
B. RELEASE POSITION
As the Direct handle is moved to “Release”, the computer reads the updated fiber-optic
frequency information and sends new “set point” data to the EPA3 board which works with
the 20T transducer to reach the new command pressure. The supply MV remains closed
while the exhaust MV opens to vent BCEP pre-control pressure to atmosphere. In turn, the
BCEP relay reduces BCEP pressure to match the pre-control pressure.
C. INDEPENDENT (DIRECT) BRAKING - TRAIL UNIT
The Independent brake on the Trail Unit works the same as the Automatic Brake except for
the pressures and rates. Refer to Section on Trail-Automatic. The Brake Controller
Independent handles are inactive on the trail Unit and cannot be used to apply a brake.
D. INDEPENDENT (DIRECT) BRAKING - HELPER (BANKING) SERVICE
When a locomotive is to be used to push a train, the Lead/Trail switch should be positioned to
Lead-Out. This allows operation of the Independent brake while keeping the Automatic brake
cut-out.
E. LOCOMOTIVE CONSIST SEPARATION-LEAD UNIT
When the consist is accidentally separated all the end hoses immediately begin exhausting
pressure. Within a few seconds Main Reservoir Equalizing Pipe reduces to nearly zero.
2
When the pressure reduces to less than 4.2 kg/cm the CPU detects the drop in pressure via
the MRET transducer voltage feed back through the AD board. The CPU commands the
BCEV valve via the EPA2 board to revert to Trail mode. The BCEP pipe is now isolated from
the brake system preventing any pressure from venting out the open BCEP end hose.
With the brake pipe hose severed brake pipe reduces to zero at a rapid rate. Brake cylinder
pressure begins to increase as if an emergency application is in affect. Since the second
main reservoir is captivated by a one way check valve to the 1st main reservoir, main
reservoir is preserved for use in the brake cylinders. Pressure develops from the operation of
the computer brake system not the backup system in this case.

MAINTENANCE MANUAL
F. LOCOMOTIVE CONSIST SEPARATION-TRAIL UNIT
Since the development of brake cylinder pressure on a Trail Unit normally is derived from the
Lead Unit BCEP pressure, BC pressure must now be controlled by the AW4-16/BC circuit.
The Trail Unit also detects the loss of MREP through it’s own MREP transducer. On the Trail
Unit detection of low MREP causes AW4-16/BC circuit to operate the same as a Lead Unit.
Brakes are applied by the computer controlled system to an emergency level.
2
In both cases above MREP must be restored to above 8.4 kg/cm to restore normal brake
operation.
G. LOSS OF POWER BRAKE APPLICATION-LEAD UNIT
With no voltage to CRU no components can be energized to apply brakes. The normally
energized MVER, MV16T and MVLT deenergize. Equalizing reservoir begins reducing
through MVER to atmosphere through a calibrated orifice at a rate equal to a normal service
brake rate. Pressure is internally ported to the pneumatically actuated PVERI valve. ER
pressure at the pilot port of this valve temporarily moves the valve to its applied position. In
this position the valves internal porting connects the MREP at the PVBIT pilot port to exhaust
causing the valve to move to its open position. In this position, pre-control volume from the
KE distributor backup valve is connected to the BC relay valve via the double throw check
valve and deenergized MV16T magnet valve.
As Equalizing Reservoir pressure decreases at the brake pipe relay, the relay in turn begins
to vent brake pipe pressure at a service rate starting an automatic brake application. With the
brake pipe reducing at the KE valve, pre-control pressure develops and flows to the BC relay
through the PVBIT valve just activated, double check valve and MV16T.
2
Pre-control pressure continues to increase at a service rate until approximately 3.8 kg/cm is
attained. The KE valve will not maintain pressure against leakage
To keep the backup circuit activated pre-control pressure is directed to the PVERI valves pilot
port through a double check valve. ER pressure on the opposite side of the same check valve
bleeds to zero.
BCEP normally developed by the closed BCEV now comes from the PVBC valve. This valve
was initially opened by the same equalizing pressure that triggered PVERI. With ER at the
pilot port of PVBC, the valve opens allowing BC pressure to flow through into the BCEP pipe.
2
This pressure will increase to 3.8 kg/cm and pressurize the trail units.
H. POWER LOSS BRAKE APPLICATION-TRAIL UNIT
On the trail unit MV16T deenergizes. MVER and MVLT are already deenergized. With
MV16T deenergized, a path is created from the BCEP to the BC relay pilot port via the
double check valve. When brake application is made by the Lead Unit the BC relay will be
pressurized by the BCEP pipe and Brake Cylinder pressure will develop on the Trial Unit. BC
pressure will be limited to the maximum pressure in the BCEP pipe.

MAINTENANCE MANUAL
INPUT/OUTPUT ELECTRICAL AND COMMUNICATION INTERFACE
LOCOMOTIVE OUTPUT INTERFACE

NAME LINK PRINTED CIRCUIT CCB TO EM2000 OR LOCOMOTIVE
WIRING
BOARD
CUT OFF RELAY COR SS9A/DBI POWER KNOCKDOWN
COMMUNICATIONS RS485 CPZ PCB CALL PRESSURE VALID-PASSENGER
COMMUNICATIONS RS485 CPZ PCB NO EMERGENCY BRAKE ACTIVE
COMMUNICATIONS RS485 CPZ PCB BRAKE FAIL INDICATION
COMMUNICATIONS RS485 CPZ PCB BRAKE CYLINDER FEEDBACK VALID
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE ACTIVITY
COMMUNICATIONS RS485 CPZ PCB PENALTY BRAKE INDICATION
COMMUNICATIONS RS485 CPZ PCB PTCA -PASS BLENDED BRAKE
COMMUNICATIONS RS485 CPZ PCB BRAKE CYLINDER PRESSURE
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE MODE-GOODS/PASS
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE SETUP
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE CUTOUT
COMMUNICATIONS RS485 CPZ PCB BRAKE PIPE PRESSURE VALID
COMMUNICATIONS RS485 CPZ PCB EQUALIZING PRESSURE VALID
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE TEST RESPONSE
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE TEST SETUP STATUS
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE FAULT CODE
COMMUNICATIONS RS485 CPZ PCB BRAKE PIPE PRESSURE
COMMUNICATIONS RS485 CPZ PCB EQUALIZING RESERVOIR PRESSURE

MAINTENANCE MANUAL
INPUT ELECTRICAL AND COMMUNICATION INTERFACE
LOCOMOTIVE INPUT INTERFACE

NAME LINK PRINTED CIRCUIT CCB TO EM2000 OR LOCOMOTIVE
WIRING
BOARD
COMMUNICATIONS RS485 CPZ PCB VEHICLE SPEED ACTIVE
COMMUNICATIONS RS485 CPZ PCB PENALTY BRAKE REQUEST
COMMUNICATIONS RS485 CPZ PCB BLENDED BRAKE ACTIVE-PASSENGER
COMMUNICATIONS RS485 CPZ PCB DYNAMIC BRAKE ON REQUEST
COMMUNICATIONS RS485 CPZ PCB BCP REQUEST
COMMUNICATIONS RS485 CPZ PCB VEHICLE SPEED
COMMUNICATIONS RS485 CPZ PCB AIR BRAKE SELF-TEST REQUEST
1.4 FIGURE NUMBERS AND TITLES
FIGURE 1-1 BRAKE BAY RACK ASSEMBLY
FIGURE 1-2 BRAKE VALVE CONTROLLER
FIGURE 1-3 PNEUMATIC CONTROL UNIT
FIGURE 1-4 COMPUTER RELAY UNIT
FIGURE 1-5 CCB CONFIGURATION
FIGURE 1-6 EQUALIZING RESERVOIR ELECTRICAL CONTROL-RUNNING
FIGURE 1-7 EQUALIZING RESERVOIR AND BRAKE PIPE CONTROL-RUNNING

MAINTENANCE MANUAL
FIGURE 1-8 BRAKE PIPE CHARGING CUT OFF - LEAD OPERATION
FIGURE 1-9 FLOW DETECTION
FIGURE 1-10 FAST RECHARGE
FIGURE 1-11 OVERCHARGE AND ASSIMILATION
FIGURE 1-12 BRAKE PIPE TRANSDUCER CIRCUIT
FIGURE 1-13 #16 PIPE CONTROL CIRCUIT - BRAKE RELEASE
FIGURE 1-14 AUTOMATIC RELEASE BRAKE CYLINDER PRESSURE CONTROL
FIGURE 1-15 BRAKE CYLINDER EQUALIZING PIPE CONTROL - RELEASE OR RUN - LEAD UNIT
- LEAD IN / LEAD OUT
FIGURE 1-16 ER CONTROL CIRCUIT - MINIMUM SERVICE POSITION- LEAD-IN
FIGURE 1-17 ER CONTROL CIRCUIT - FULL SERVICE POSITION - LEAD-IN
FIGURE 1-18 ER CONTROL CIRCUIT - SERVICE POSITION/LAP - LEAD-IN
FIGURE 1-19 ER/BP PNEUMATIC CONTROL CIRCUIT - LEAD-IN - RUNNING POSITION
FIGURE 1-20 ER CONTROL CIRCUIT - EMERGENCY POSITION - LEAD-IN
FIGURE 1-21 EMERGENCY CIRCUIT - ANY EMERGENCY
FIGURE 1-22 PNEUMATIC EMERGENCY CONTROL CIRCUIT - EQUALIZING RESERVOIR AND

BRAKE PIPE
FIGURE 1-23 BRAKE PIPE CUTOFF - BRAKE VALVE IN EMERGENCY - LEAD-IN
FIGURE 1-24 #16 PIPE CONTROL CIRCUIT - MINIMUM SERVICE POSITION
FIGURE 1-25 #16 PIPE CONTROL CIRCUIT - FULL SERVICE POSITION
FIGURE 1-26 #16 PIPE CONTROL CIRCUIT - EMERGENCY POSITION
FIGURE 1-27 #16 PIPE CONTROL CIRCUIT - LAP POSITION
FIGURE 1-28 AUTOMATIC APPLICATION AND LAP - BRAKE CYLINDER CONTROL
FIGURE 1-29 EMERGENCY APPLICATION - BRAKE CYLINDER CONTROL
FIGURE 1-30 AUTOMATIC BAILOFF (QUICK RELEASE) - SERVICE OR EMERGENCY - #16

CONTROL - LEAD UNIT
FIGURE 1-31 BCEP - AUTOMATIC APPLICATION - SERVICE OR EMERGENCY - LEAD UNIT
FIGURE 1-32 BCEP - BAILOFF (QUICK RELEASE) - SERVICE OR EMERGENCY - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-33 AUTOMATIC BRAKE - BRAKE RELEASE - TRAIL UNIT
FIGURE 1-34 BRAKE PIPE CHARGING CUT OFF - TRAIL OPERATION
FIGURE 1-35 AUTOMATIC BRAKE RELEASE - TRAIL POSITION
FIGURE 1-36 AUTOMATIC APPLICATION - TRAIL POSITION
FIGURE 1-37 DIRECT BRAKE - BCEP APPLICATION - LEAD UNIT
FIGURE 1-38 DIRECT BRAKE - BCEP RELEASE - LEAD UNIT
FIGURE 1-39 DIRECT BRAKE - TRAIL POSITION
FIGURE 1-40 LOCOMOTIVE CONSIST SEPARATION - LEAD UNIT
FIGURE 1-41 LOCOMOTIVE CONSIST SEPARATION - TRAIL UNIT
FIGURE 1-42 LOSS OF POWER BRAKE APPLICATION - LEAD UNIT
FIGURE 1-43 LOSS OF POWER BRAKE APPLICATION - TRAIL UNIT

MAINTENANCE MANUAL
FIGURE 1-1 BRAKE BAY RACK ASSEMBLY

MAINTENANCE MANUAL
FIGURE 1-2 BRAKE VALVE CONTROLLER

MAINTENANCE MANUAL
FIGURE 1-3 PNEUMATIC CONTROL UNIT

MAINTENANCE MANUAL
FIGURE 1-5 CCB CONFIGURATION

MAINTENANCE MANUAL
FIGURE 1-6 EQUALIZING RESERVOIR ELECTRICAL CONTROL - RUNNING

MAINTENANCE MANUAL
FIGURE 1-7 EQUALIZING RESERVOIR AND BRAKE PIPE CONTROL - RUNNING

MAINTENANCE MANUAL
FIGURE 1-8 BRAKE PIPE CHARGING CUT-OFF - LEAD OPERATION

MAINTENANCE MANUAL
FIGURE 1-9 FLOW DETECTION

MAINTENANCE MANUAL
FIGURE 1-10 FAST RECHARGE

MAINTENANCE MANUAL
FIGURE 1-11 OVERCHARGE AND ASSIMILATION

MAINTENANCE MANUAL
FIGURE 1-12 BRAKE PIPE TRANSDUCER CIRCUIT

MAINTENANCE MANUAL
FIGURE 1-13 #16 PIPE CONTROL CIRCUIT - BRAKE RELEASE

MAINTENANCE MANUAL
FIGURE 1-14 AUTOMATIC RELEASE BRAKE CYLINDER PRESSURE CONTROL

MAINTENANCE MANUAL
FIGURE 1-15 BRAKE CYLINDER EQUALIZING PIPE CONTROL

RELEASE OR RUN - LEAD UNIT - LEAD IN / LEAD OUT

MAINTENANCE MANUAL
FIGURE 1-16 ER CONTROL CIRCUIT - MINIMUM SERVICE POSITION - LEAD-IN

MAINTENANCE MANUAL
FIGURE 1-17 ER CONTROL CIRCUIT - FULL SERVICE POSITION - LEAD-IN

MAINTENANCE MANUAL
FIGURE 1-18 ER CONTROL CIRCUIT - SERVICE POSITION/LAP - LEAD-IN

MAINTENANCE MANUAL
FIGURE 1-19 ER/BP PNEUMATIC CONTROL CIRCUIT - LEAD-IN

RUNNING POSITION

MAINTENANCE MANUAL
FIGURE 1-20 ER CONTROL CIRCUIT - EMERGENCY POSITION - LEAD-IN

MAINTENANCE MANUAL
FIGURE 1-21 EMERGENCY CIRCUIT - ANY EMERGENCY

MAINTENANCE MANUAL
FIGURE 1-22 PNEUMATIC EMERGENCY CONTROL CIRCUIT - EQUALIZING

RESERVOIR AND BRAKE PIPE

MAINTENANCE MANUAL
FIGURE 1-23 BRAKE PIPE CUTOFF - BRAKE VALVE IN EMERGENCY - LEAD-IN

MAINTENANCE MANUAL
FIGURE 1-24 #16 PIPE CONTROL CIRCUIT - MINIMUM SERVICE POSITION

MAINTENANCE MANUAL
FIGURE 1-25 #16 PIPE CONTROL CIRCUIT - FULL SERVICE POSITION

MAINTENANCE MANUAL
FIGURE 1-26 #16 PIPE CONTROL CIRCUIT - EMERGENCY POSITION

MAINTENANCE MANUAL
FIGURE 1-27 #16 PIPE CONTROL CIRCUIT - LAP POSITION

MAINTENANCE MANUAL
FIGURE 1-28 AUTOMATIC APPLICATION AND LAP - BRAKE CYLINDER

CONTROL

MAINTENANCE MANUAL
FIGURE 1-29 EMERGENCY APPLICATION - BRAKE CYLINDER CONTROL

MAINTENANCE MANUAL
FIGURE 1-30 AUTOMATIC BAILOFF (QUICK RELEASE) - SERVICE OR

EMERGENCY - # 16 CONTROL - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-31 BCEP - AUTOMATIC APPLICATION - SERVICE OR EMERGENCY -

LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-32 BCEP - BAILOFF (QUICK RELEASE) - SERVICE OR EMERGENCY -

LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-33 AUTOMATIC BRAKE - BRAKE RELEASE - TRAIL UNIT

MAINTENANCE MANUAL
FIGURE 1-34 BRAKE PIPE CHARGING CUT OFF - TRAIL OPERATION

MAINTENANCE MANUAL
New Drawing 5/24/2000
FIGURE 1-35 AUTOMATIC BRAKE RELEASE - TRAIL POSITION

MAINTENANCE MANUAL
FIGURE 1-36 AUTOMATIC APPLICATION - TRAIL POSITION

MAINTENANCE MANUAL
FIGURE 1-37 DIRECT BRAKE - BCEP APPLICATION - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-38 DIRECT BRAKE - BCEP RELEASE - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-39 DIRECT BRAKE - TRAIL POSITION

MAINTENANCE MANUAL
FIGURE 1-40 LOCOMOTIVE CONSIST SEPARATION - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-41 LOCOMOTIVE CONSIST SEPARATION - TRAIL UNIT

MAINTENANCE MANUAL
FIGURE 1-42 LOSS OF POWER BRAKE APPLICATION - LEAD UNIT

MAINTENANCE MANUAL
FIGURE 1-43 LOSS OF POWER BRAKE APPLICATION - TRAIL UNIT

CH 16
FCF2 AB
X
X
CH 88
SPARE-17
CH 91
SPARE-19
CH 95
SPARE-22
Annexure-I
HAULAGE CAPACITY ( Freight )

LOCO:- WDG4D (4500 HP) GAUGE :- B.G. WT OF LOCO : 130.2 t
Trailing load in tonnes at Km/h on tangent track and other casnub bogie air brake stocks
BOXN/BCN
GRADE START 20 30 40 50 60 70 80 90 100
LEVEL 5385 5385 5385 5385 5385 5385 5385 5385 4515 3570
500 5385 5385 5385 5385 5385 4255 3420 2750 2290 1895
400 5385 5385 5385 5385 4760 3715 3005 2430 2035 1690
300 5385 5385 5385 5060 3890 3055 2490 2025 1705 1425
200 5385 5385 5085 3660 2835 2245 1840 1510 1280 1080
150 4990 *5385 3950 2855 2215 1760 1450 1190 1015 855
100 3775 4130 2720 1965 1530 1215 1000 820 700 590
50 2145 2090 1365 975 750 590 480 390 325 270
NOTE :
 Both starting and hauling of trailing tonnages given in the chart are the maximum permissible values. i.e.* On a ruling
grade of 1 in 150, the BOXN load should not exceed 4990 tonnes.
 The values are applicable for straight track only. On a curved section actual permissible load will be less than the
values specified above. Actual permissible loads should be fixed based on load trial.
 Trailing loads fixed by load trail should be confirmed by load factor trial also and the loads recommended should be
such that the load factor does not exceed 60%.
 The load chart is based upon maximum load of 59 BOXN (CC+8+2t) which is the limitation imposed by loop length.
D Sudhakar Kumar
C Sudhakar Kumar
RDSO
APPD. Vivek Khare (MP) DE/T - 414
BY Director/MP/EM
MAINTENANCE INSTRUCTION
M.I. 1517
Revision A
Service Department
ELECTRO-MOTIVE DIVISION
GENERAL MOTORS CORPORATION
November, 2002
SCHEDULED MAINTENANCE
AND OVERHAUL INSTRUCTIONS
HTSC and HTSC-B1 BOGIES
Equipped With
AC Traction Motors
SAFETY PRECAUTIONS
Please refer to the EMD Safety Precautions in appendix to the Locomotive Service Manual
whenever routine service or maintenance work is to be performed on any AC traction equipped
locomotive.
The maintenance procedure as outlined in this instruction is specific to the HTSC and HTSC-B1 type bogies and is offered for
planning purposes only. As written, this document reflects current EMD product design and service experience for the
HTSC/HTSC-B1 design type of locomotive bogie with AC traction motors. The content of this M.I. reflects maintenance
requirements based on time from delivery, kilometers, or megawatt-hours in service. This recommendation is consistent with
present fleet performance and remains within the EMD experience envelope.
This Maintenance Instruction is intended to serve as a guide when establishing maintenance
schedules to meet the particular requirements of individual operations and planned economic
life of the locomotive bogie. It provides average recommendations, which should ensure
satisfactory locomotive operation, and economical maintenance costs where average load
factors and climatic conditions are encountered.
The scheduled inspection and maintenance items defined herein are specific to the HTSC and
HTSC-B1 bogies. Component renewal provisions are consistent with traditional overhaul
procedures.
For planning purposes, EMD has established the following overhaul interval
recommendations for the HTSC and HTSC-B1 bogies. These overhaul interval
recommendations are based on whichever event occurs first: time, kilometers, or megawatt
hours.
HTSC / HTSC-B1 Bogies:
High Speed Service: 6 years / 1,400,000 kms / 23,000 MWHRS.

Heavy Haul Service: 6 years / 1,000,000 kms / 23,000 MWHRS.
NOTE
Kilometer and MWHR values referenced above are defined by Microprocessor Archive Data
as accumulated by the locomotive control computer system.
As always, when specific operating conditions severely impact locomotive performance and
or reliability, maintenance schedules must be adjusted accordingly.
© Copyright 2002
Electro-Motive Division, General Motors Corporation.
All rights reserved. Neither this document, nor any part thereof, may be reprinted without the expressed
written consent of the Electro-Motive Division. Contact EMD Service Publications Office.
HTSC/HTSC-B1 Trucks 2 11/11/02

TABLE OF CONTENTS
1.0 GENERAL DESCRIPTION .............................................................................. 8

2.0 GENERAL MAINTENANCE .......................................................................... 15
2.1 BOGIE CLEANING............................................................................................... 15
2.1.1 UNDER LOCOMOTIVE ............................................................................... 15
2.1.2 TANK IMMERSION...................................................................................... 15
2.2 LUBRICATION ..................................................................................................... 16
2.3 WHEEL AND AXLE INSPECTION..................................................................... 16
2.4 JOURNAL BEARINGS ......................................................................................... 17
2.5 DAMPERS.............................................................................................................. 18
2.6 RUBBER SECONDARY SPRINGS...................................................................... 21
2.7 BRAKE BLOCK GUIDES..................................................................................... 23
2.8 SLACK ADJUSTERS ............................................................................................ 24
2.8.1 GENERAL DESCRIPTION........................................................................... 24
2.8.2 ADJUSTMENT .............................................................................................. 24
2.8.3 GENERAL PHYSICAL INSPECTION ......................................................... 26
2.9 HAND BRAKE ...................................................................................................... 26
2.9.1 DESCRIPTION OF OPERATION................................................................. 26
2.9.2 INSPECTION OF HAND BRAKE CHAIN AND LEVER........................... 26
2.9.3 ADJUSTMENTS & TROUBLE-SHOOTING............................................... 27
2.9.4 MAINTENANCE & LUBRICATION ........................................................... 28
2.9.4.1 Quarterly ..................................................................................................... 28
2.10 GEAR CASES (AC TRACTION LOCOMOTIVES) ............................................ 28
2.10.1 GENERAL DESCRIPTION........................................................................... 28
2.10.2 GEAR CASE REMOVAL.............................................................................. 29
2.10.3 GEAR CASE APPLICATION ....................................................................... 30
2.11 TRACTION MOTOR REPLACEMENT............................................................... 31
2.12 BOGIE REMOVAL................................................................................................ 33
2.12.1 INSPECTIONS BEFORE BOGIE REMOVAL............................................. 33
2.12.2 BOGIE ASSEMBLY REMOVAL ................................................................. 33
2.13 BOGIE APPLICATION ......................................................................................... 39
2.13.1 INITIAL INSTALLATION............................................................................ 39
2.13.2 VERTICAL STOP CLEARANCE ................................................................. 40
2.13.3 FINAL INSTALLATION............................................................................... 41
M.I. 1517A 3 11/11/02

3.0 BOGIE OVERHAUL....................................................................................... 42
3.1 BOGIE DISASSEMBLY........................................................................................ 42
3.1.1 REMOVING VERTICAL DAMPERS .......................................................... 42
3.1.2 REMOVING TRACTION RODS LOCK BOLT COLLARS........................ 43
3.1.3 REMOVING TRACTION MOTORS/WHEELSETS ASSEMBLY ............. 44
3.1.4 DISCONNECTING TRACTION RODS AND REMOVING BEARING
ADAPTERS AND PRIMARY COIL SPRINGS ........................................... 46
3.1.5 REMOVAL OF SECONDARY RUBBER SPRINGS................................... 47
3.1.6 REMOVAL OF LATERAL THRUST PADS................................................ 47
3.1.7 REMOVAL OF YAW DAMPERS ................................................................ 47
3.1.8 REMOVAL OF CARBODY PIVOT ASSEMBLY ....................................... 48
3.1.9 REMOVAL OF BRAKE RIGGING COMPONENTS .................................. 49
3.2 COMPONENT QUALIFICATION........................................................................ 50
3.2.1 BEARING ADAPTERS ................................................................................. 50
3.2.2 BRAKE RIGGING COMPONENTS ............................................................. 50
3.2.3 TRACTION ROD BUSHING REPLACEMENT PROCEDURES ............... 51
3.2.3.1 Traction Rod Bushing Removal.................................................................. 52
3.2.3.2 Traction Rod Bushing Installation .............................................................. 52
3.2.4 CARBODY PIVOT ASSEMBLY.................................................................. 54
3.2.4.1 Carbody Bushing Removal Procedures ...................................................... 54
3.2.4.2 Carbody Rod Bushing Installation Procedures ........................................... 55
3.2.5 TRACTION MOTOR NOSE SUPPORT LINKS .......................................... 58
3.2.6 PRIMARY COIL SPRING SUSPENSION.................................................... 59
3.3 BOGIE FRAME INSPECTION AND RECONDITIONING ................................ 60
3.3.1 BOGIE FRAME TRAMMING ...................................................................... 60
3.3.2 BENT, BROKEN, OR CRACKED MEMBERS ........................................... 61
3.3.3 WORN SPOTS ............................................................................................... 63
3.3.4 ELONGATED OR OVERSIZE HOLES........................................................ 63
3.3.5 WORN BUSHINGS ....................................................................................... 64
3.3.6 DAMAGED THREADS................................................................................. 64
3.3.7 BROKEN OR BENT STUDS ........................................................................ 64
3.3.8 MISSING PARTS........................................................................................... 64
3.4 BOGIE RE-ASSEMBLY........................................................................................ 64
3.4.1 INITIAL BOGIE ASSEMBLY ...................................................................... 64
3.4.2 BRAKE CYLINDER PIPING........................................................................ 68
3.4.3 ASSEMBLY OF BRAKE RIGGING COMPONENTS................................. 68
3.4.4 TRACTION MOTOR AND WHEELSET (COMBO) APPLICATION........ 72
3.4.5 PRIMARY VERTICAL DAMPER APPLICATION..................................... 73
3.4.6 SECONDARY YAW DAMPER APPLICATION......................................... 74
3.5 BOGIE APPLICATION TO LOCOMOTIVE ....................................................... 74
4.0 SPECIAL PROCEDURES ............................................................................. 77
4.1 LOCK BOLTS ........................................................................................................ 77
4.1.1 REMOVING LOCK BOLTS ......................................................................... 77
4.1.2 LOCK BOLT INSTALLATION .................................................................... 78

5.0 SERVICE DATA - BOGIE ASSEMBLY ......................................................... 81
5.1 REFERENCES ....................................................................................................... 81
5.1.1 MAINTENANCE INSTRUCTIONS ............................................................. 81
5.1.2 TYPICAL PARTS CATALOGUES............................................................... 81
5.1.3 DRAWING NUMBERS................................................................................. 81
5.1.4 OTHER REFERENCES ................................................................................. 81
5.2 WEIGHTS............................................................................................................... 82
5.2.1 COMPONENT WEIGHTS............................................................................. 82
5.2.2 ASSEMBLY WEIGHTS ................................................................................ 83
5.3 SPECIAL TORQUE VALUES .............................................................................. 83
5.4 SCHEDULE OF MAINTENANCE ....................................................................... 84
5.4.1 TRIP / MONTHLY INSPECTION ................................................................ 84
5.4.2 QUARTERLY INSPECTION ........................................................................ 84
5.4.3 SEMI – ANNUAL / ANNUAL INSPECTION.............................................. 85
5.4.4 BOGIE OVERHAUL ..................................................................................... 85
5.5 MAINTENANCE AND WEAR LIMITS .............................................................. 86
5.5.1 WHEEL LIMITS ............................................................................................ 86
5.5.1.1 Wheel Size Variation Limits....................................................................... 86
5.5.1.2 Wheel Size Minimums................................................................................ 86
5.5.2 WEAR LIMITS ON BOGIE COMPONENTS .............................................. 86
5.5.2.1 Total Free Lateral Axle Clearances Between Lateral Thrust Pads And
Bearing Adapters ...................................................................................... 86
5.5.2.2 Wear of Nylon Pivot Liners (Split Half-Cylinder) ..................................... 87
5.5.2.3 Secondary Vertical Stop Clearances........................................................... 87
5.5.2.4 Secondary Lateral Stop Clearances ............................................................ 87
5.6 ROUTINE MAINTENANCE EQUIPMENT AND SPECIAL TOOLS................ 89
5.6.1 FIXTURES ..................................................................................................... 89
5.6.2 GEAR RATIOS .............................................................................................. 89
5.6.3 SPECIAL LUBRICANTS .............................................................................. 90
5.6.4 COMMON PART NUMBERS....................................................................... 90
M.I. 1517A 5 11/11/02

LIST OF FIGURES
Figure 1 HTSC Bogie................................................................................................ 8
Figure 2 HTSC – B1 Bogie ....................................................................................... 9
Figure 3 Typical Carbody Pivot Assembly ............................................................... 9
Figure 4 HTSC Bogie (side view)........................................................................... 10
Figure 5 HTSC – B1 Bogie (side view) .................................................................. 10
Figure 6 Secondary Springs and Lateral/Vertical Stops ......................................... 11
Figure 7 Journal Adapter and Retaining Pins.......................................................... 12
Figure 8 Typical Traction Motor Nose Link (Dogbone)......................................... 12
Figure 9 Lateral Thrust Wear Pads.......................................................................... 13
Figure 10 Typical Air Brake Cylinders..................................................................... 14
Figure 11 Roller Type Journal Bearing..................................................................... 17
Figure 12 Typical Vertical Damper........................................................................... 20
Figure 13 Typical Yaw Damper................................................................................ 20
Figure 14 HTSC Secondary Springs (Frame not to scale) ........................................ 21
Figure 15 HTSC – B1 Secondary Springs (Frame not to scale) ............................... 22
Figure 16 Typical Brake Block Rigging and Guides ................................................ 23
Figure 17 Slack Adjusters ......................................................................................... 24
Figure 18 Hand Brake ............................................................................................... 27
Figure 19 Typical AC Gear Case .............................................................................. 28
Figure 20 Traction Motor Gear Case ........................................................................ 30
Figure 21 Gear Case Sealant Beads .......................................................................... 31
Figure 22 Typical Locomotive Jacking Pad Locations ............................................. 34
Figure 23 Typical Jack Alignment ............................................................................ 34
Figure 24 Typical Brake Cylinder Air Piping ........................................................... 35
Figure 25 Secondary Spring Pins (shown with unit lifted) ....................................... 35
Figure 26 Typical Traction Motor Connections (AC motor shown)......................... 36
Figure 27 Typical Secondary Interlock Carbody/Bogie Shackles ............................ 36
Figure 28 Removal of Typical Carbody Yaw Dampers............................................ 37
Figure 29 Lock Wire and Bolt Removal ................................................................... 37
Figure 30 Pivot Plate and Wear Ring........................................................................ 37
Figure 31 Secondary Spring / Underframe Separation ............................................. 38
Figure 32 Typical Bogie........................................................................................... 38
Figure 33 Alignment of Typical Pivot Pin ................................................................ 39
Figure 34 Vertical Stop Clearance ............................................................................ 40
Figure 35 Application of Safety Wire ....................................................................... 41
Figure 36 Vertical Damper Removal ........................................................................ 43
Figure 37 Typical Traction Motor Nose Link Removal (HTCR shown).................. 44
Figure 38 Lifting of Bogie......................................................................................... 45
Figure 39 Carbody Pivot Assembly .......................................................................... 48
Figure 40 Typical Journal Bearing Adapter Bore ..................................................... 50
Figure 41 Removal of Traction Rod Bushing ........................................................... 51
Figure 42 Installation of Traction Rod Bushing........................................................ 52
Figure 43 Typical Carbody Pivot Assembly ............................................................. 54
Figure 44 Carbody Pivot Rod Traction Bushings ..................................................... 55
Figure 45 Carbody Pivot Rod Traction Bushing Alignment..................................... 56
Figure 46 Carbody Pivot Rod Traction Bushing Installation.................................... 56

Figure 47 Carbody Pivot Rod Traction Bushing Retaining Ring Installation .......... 57
Figure 48 Completed Carbody Rod Bushing ............................................................ 57
Figure 49 Typical Traction Motor Nose Support Link (HTCR Shown)................... 58
Figure 50 Bushing Orientation .................................................................................. 58
Figure 51 Primary Coil Springs and Journal Adapter ............................................... 59
Figure 52 Typical Tramming Points ......................................................................... 60
Figure 53 Critical Frame Areas ................................................................................. 61
Figure 54 Preparing Joints For Welding ................................................................... 62
Figure 55 Bogie Frame Straightening ....................................................................... 63
Figure 56 Typical Orientation of Nose Links (HTCR Shown) ................................ 66
Figure 57 Bogie Lifting Connections........................................................................ 67
Figure 59 Brake Lever Assembly Application - Live ............................................... 69
Figure 60 Brake Lever Assembly – Dead ................................................................. 69
Figure 61 Brake Lever Assembly Application - Dead .............................................. 70
Figure 62 Brake Shoe Application ............................................................................ 70
Figure 63 Application of Brake Cylinder Lever Cross-Over Assembly 47360 ........ 71
Figure 64 Typical Carbody Pivot Pin Installation (HTCR Shown) .......................... 74
Figure 65 Typical Secondary Spring Alignment (HTCR Shown) ............................ 75
Figure 66 Typical Carbody Pivot Pin Lock Wire (HTCR Shown) ........................... 75
Figure 67 Typical Carbody Interlock Links (HTCR Shown)................................... 76
Figure 68 Typical Air Brake Piping (HTCR Shown)................................................ 76
Figure 69 Lockbolt Installation ................................................................................. 78
Figure 70 Final lock Bolt Assembly.......................................................................... 79
Figure 71 Lockbolt Finished Dimensions ................................................................. 79
Figure 72 Schematic of Secondary Lateral Stop ....................................................... 87
Figure 73 Procedure to measure Secondary Lateral Stop Clearances....................... 88
Figure 74 Measuring Secondary Lateral Stop Clearance.......................................... 89
M.I. 1517A 7 11/11/02

1.0 GENERAL DESCRIPTION
The HTSC (high traction/speed-three axle) bogie assembly, Figure 1, and HTSC-B1
(high traction/speed-three axle, two traction motor/one idler axle) bogie assembly,
Figure 2, support the weight of the locomotive and provide the means for
transmission of power to the rails. The HTSC series truck is applied to AC
transmission locomotives used in freight service, while the HTSC-B1 is applied to
AC transmission locomotives used in passenger service. There are minor differences
in specifications between the two types of bogie, however the basic design is similar.
Figure 1 HTSC Bogie
Like conventional three axle bogies, the axles are held parallel to each other,
however the HTSC series bogie is designed as a powered “bolster-less” unit. The
locomotive carbody weight is transferred directly to the bogie frame through four
rubber “secondary“ spring pad assemblies, which also provide yaw stiffness for
tracking stability. The relatively stiff “secondary” suspension and uniform traction
motor orientation improve weight transfer within the bogie for optimal adhesion
performance. A soft “primary” suspension, consisting of twelve single coil journal
springs (two at each journal bearing), is designed to provide good ride quality and
equalization of wheelset loads for operation over track irregularities.

Figure 2 HTSC – B1 Bogie
Traction loads are transmitted from the bogie to the locomotive underframe through
a carbody pivot pin assembly, Figure 3.
Figure 3 Typical Carbody Pivot Assembly
Although the bogie frame itself is rigid, the soft spring design allows the end axles
“yaw” freedom within the frame to position the wheelset axles to the curves center
for reduced wheel and rail wear. A “traction rod” and collar/bushing attached to the
journal bearing adapters and bogie frame helps control movement of the end axles
and transfers driving force to the bogie frame.
The “soft” primary coil spring suspension also allows for a small amount of “angle
of attack” variation, thereby lessening wheel wear in curves.
M.I. 1517A 9 11/11/02
The bogie is designed to provide for extended maintenance intervals via reduced
number of rubbing wear interfaces and improved tracking performance of the
wheels on the rails.
Two (HTSC – B1) or three (HTSC) AC traction motors, mounted in each bogie,
convert electrical energy into locomotive tractive effort. The motors are geared to
the driving axles, which in turn apply force to the rail through the wheels. The
driving force is transmitted to the bogie frame through traction rods attached to the
axle journal bearing adapters and from the bogie frame to the locomotive
underframe through the carbody pivot assembly.
AXLE 1 AXLE 2 AXLE 3
Figure 4 HTSC Bogie (side view)
Figure 5 HTSC – B1 Bogie (side view)

Heavy-duty dampers are used vertically between the journal bearing adapters and
the bogie frame at all axles to damp excessive vertical and roll oscillations of the
locomotive. Two yaw dampers are mounted diagonally between each bogie and the
locomotive underframe to damp the lateral and yaw movements of the bogie for
stability at higher road speeds.
Lateral stops are provided on the bogie frame at the center axle position to limit
lateral movement between the bogie and underframe. Vertical stop clearance is
established between the bogie frame and the underframe using shims at locations
inward of the lateral stops near the center axle position. All vertical shims are
welded to the underframe, as shown on Figure 6.
Figure 6 Secondary Springs and Lateral/Vertical Stops
The bogie vertical stop clearances should be measured at specified intervals as

outlined in Scheduled Maintenance.
Secondary Interlocks are located on either side of the bogie frame at the center axle
location, Figure 6. These two links serve to prevent separation of the bogie assembly
from the locomotive during lifting operations of the locomotive with the bogie(s).
M.I. 1517A 11 11/11/02

Interlocking of the journal bearing adapter to the bogie frame for lifting is
accomplished via a contoured structure on the bearing adapter, and two steel rods
which are installed through the bogie frame structure at each journal adapter location
(journal retainer pins –Figure 7).
Figure 7 Journal Adapter and Retaining Pins
The three traction motors are supported on their respective drive axles and at motor
nose link assemblies, Figure 8, attached to the bogie frame. A main feature of the
HTSC/HTSC – B1 bogie design is the orientation of the traction motors in one
direction. This arrangement provides good motor accessibility and maximizes
adhesion characteristics.
Figure 8 Typical Traction Motor Nose Link (Dogbone)

The journal bearings transmit the vertical load from the springs to the axles.
Resilient wear plates mounted inside the bogie frame limit the lateral thrust
movement of the axles. These renewable resilient wear plates, Figure 9, provide the
means to maintain the free lateral clearances at the center (middle) axle and at the
end (front and rear) axles. Three retainer bolts accessible from the outside of the
bogie frame secure the resilient wear plates. These wear plate bolts also serve to
secure the upper vertical damper bracket on the HTSC bogie. The HTSC-B1 bogie
uses three additional bolts to secure the bracket.
The resilient lateral thrust pads are to be replaced as a set if the free lateral axle
clearances exceed the limits specified in the Service Data section. Otherwise, refer to
the bogie overhaul section in regard to replacement of cracked or excessively worn
thrust pads.
•Measure Axle Lateral

Clearance(s) at location indicated
HTSC Bogie
• Axles 1,3,4,6 - 0.19” per side
•Axles 2,5 - 0.31” per side
HTSC - B1 Bogie
• Axles 1,3,4,6 - 0.12” per side
Axles 2,5 - 0.31” per side
Figure 9 Lateral Thrust Wear Pads
M.I. 1517A 13 11/11/02

Figure 10 Typical Air Brake Cylinders
Air brake cylinders and brake rigging mounted on the bogie are used to apply
retarding forces to the wheels to slow and stop the locomotive. A single block brake
system is used, which utilizes one composition block at each wheel.
Brake cylinders are mounted outboard of the bogie frame transoms and operate the
brake system through a lever arrangement. Manual slack adjusters are fitted to allow
for periodic adjustment of brake cylinder travel and brake block renewal.
A manually operated ratcheting type hand brake is fitted to the right rear side of the
locomotive, and operates the brake rigging on the #2 bogie position through a
mechanical chain linkage.

2.0 GENERAL MAINTENANCE
2.1 BOGIE CLEANING
2.1.1 UNDER LOCOMOTIVE
Bogie(s) should be periodically cleaned while under the locomotive to eliminate any
accumulation of oil and road dirt. An oily accumulation presents a fire hazard and
tends to increase wear of moving parts on the bogie, as well as detract from the
general appearance of the equipment.
CAUTION
When cleaning bogies under the locomotive, the engine should be kept running to
supply air under pressure to the traction motors. Discharged air will help prevent
over-spray from entering the motors. Care should be taken to direct spray away from
any motor openings.
A wetting agent and an alkaline solution type cleaner can be used on the bogie.
Spray wetting agent over bogie surfaces and let it remain for 10 to 15 minutes. Then
using steam and an alkaline solution in a mixing gun, thoroughly spray entire truck
assembly. Rinse assembly with hot water.
2.1.2 TANK IMMERSION

When the bogie assembly is removed from the locomotive, the traction motors,
traction rods, traction rod bushings, carbody pivot and bushings, wheels, axles,
bearing adapters, rubber suspension springs; dampers, and brake cylinders should be
removed if the bogie is to be immersed in a cleaning tank containing an alkaline
solution. In addition, non-metallic wear components such as the carbody pivot pin
liners should not be immersed. After a sufficient time to assure removal of all
foreign material, remove the assemblies and rinse thoroughly with hot water remove
all cleaning solution.
M.I. 1517A 15 11/11/02

2.2 LUBRICATION
Periodic lubrication on the bogie assembly is not required. However, depending on
the type of traction motor gear and support bearing assemblies used, reference Table
1 lists the lubrication intervals required for their maintenance.
The carbody pivot pin assembly cylinder is lined with nylon alloy bushing halves.
The pivot pin is to be coated with a bonded dry spray lubricant at time of overhaul or
re-trucking only. Details about the dry spray lubricant are specified in the Section
5.6.3 (Special Lubricants). No additional oil or grease is needed during operational
service.
NOTE
Special care should be taken with all rubber components, the axle lateral wear plates
on the bogie frame, dampers, and brake rigging in order to keep them free of oil or
grease.
Roller support 400,000 kms, or at

bearings (BTR), wheel change
grease lubricated: (whichever comes first)
Oil lubricated gear 92 days or as required
case: by locomotive service
demands.
Table 1 Traction Motor Gear and Axle Lubrication
2.3 WHEEL AND AXLE INSPECTION
Wheels should be inspected for any visible defects before and/or after each trip.
Wheels should be periodically checked for wear, sharp flanges, shelling, cracks, flat
spots, and other injurious defects. Corrective action should be taken immediately, if
unacceptable defects are found.
REFERENCE
Wheel and axle defects, which typically require the removal of any particular
wheelset are well defined and illustrated in the “Wheel and Axle Manual” published
by the Association of American Railroads (AAR), 50 “F” Street, North West
Washington, D.C. 20001.

Further wheel and axle component inspections and wear limit information is
provided in M.I. 1519, entitled: “Wheels, Axles, Axle Gears and Pinions” and at the
end of this publication. Use the following guidelines in conjunction with M.I. 1519
when determining wheel and axle condition.
See Service Data for wheel size variation limits.
• Minimum wheel diameter after last truing operation.
• Maximum diameter mismatch of two wheels on a common axle.
• Maximum diameter mismatch between wheels on one axle compared to
those of any other axle. These include wheels on the same bogie.
• Minimum rim thickness.
• Axle longitudinal limits.
• Circumferential defects on or below the axle surface.
• Axle Run-out.
2.4 JOURNAL BEARINGS

Under normal operating conditions, running temperatures of approximately
56° C (133° F) above ambient temperatures may be expected. If the bearing
appears noticeably warmer than other bearings on the locomotive, the bearing
should be checked on the outside face of the adapter with a temperature-
indicating crayon 93 ° C (200 ° F), or with a direct pyrometer. If the bearing
temperature is in excess of 93° C (200° F), the bearing should be removed
from service for further examination.
Figure 11 Roller Type Journal Bearing
M.I. 1517A 17 11/11/02

In the event that one or more axle end cap bolts are found to be loose or missing
from the bearing - the wheel, gear, axle, and journal bearing assembly should be
removed from the bogie. The bearing should then be removed from the axle and a
full inspection made to determine the cause and possible resultant damage.
A small amount of grease leakage around the seals may be expected during an initial
run-in period. This leakage will eventually be reduced to normal “weepage.”
However, if a bearing appears to be leaking excessively, check for seal damage.
Carefully wipe the area around the seal to allow inspection for a displaced or torn
seal. Do not use solvents to clean the seal area or a probe to try to displace the seal.
Both of these actions will damage the seal and may lead to premature bearing
failure.
Distorted, cracked, or damaged axle end caps should be replaced, and the damaged
caps should be scrapped.
When locomotives equipped with cartridge-type roller bearings are placed in

storage, the hand brake should be set or the wheels chocked to prevent the
equipment from moving. It is necessary to periodically move the locomotive to
distribute lubricant over the bearing surfaces.
For the checking, removal and installation of journal bearings refer to M.I. 1553.
After the installation of the end cap the end cap bolts should be torqued. See Service
Data for torque information.
2.5 DAMPERS
There is rarely a partial failure of a damper. When it fails there is no resistance to
movement in compression, in rebound or in both directions and a simple manual test
can detect the failure.
NOTE
If a damper is new or has not been used for some time, it must be stroked to obtain
consistent motion before being checked for control. Resistance developed during
testing is proportional to velocity of the test stroke.
Dampers contain a reserve of hydraulic fluid, and allow seepage to lubricate the
piston rod. A light film of oil / dust is normal and is not cause for rejection. A failed
seal is recognizable by an excessive accumulation of fluid (wet) on the damper.
However, it is not possible to ascertain the amount of reserve fluid in the damper and
predict remaining life.

Periodic inspection or when loss of damping action is suspected:
1. Check for leaking fluid. Make certain that oil has not been deposited from
some other source and check damper per Manual Qualification Procedures
before condemning.
2. Perform manual qualification tests to detect gross loss of control.
3. Inspect bushing integrity. Bushings should not permit uncontrolled vertical
or lateral movements of the damper.
4. If a failed vertical primary damper is detected, inspect journal springs, lateral
thrust pads and wear plates at each journal bearing location as well.
5. If a failed yaw damper is detected, check the items noted in the above step as
well as all traction rods and bushings, carbody pivot and rod assembly and
bushings, and secondary springs (rubber pads).
Use the following steps to qualify vertical dampers.
1. Remove the damper from the journal bearing adapter and bogie frame.
NOTE
Vertical dampers must be tested in the normal vertical position. Precautions must be
taken to avoid damaging the damper bushings during the testing or wheel
maintenance. The HTSC bogie has stud mounted primary vertical dampers; the
HTSC-B1 bogie uses bar mounted vertical dampers.
2. Manually stroke the damper while retaining the normal vertical position.
Smooth, controlled movement should be felt through both extension and
compression.
3. Inspect the end rod to damper body connections for any cracking. Inspect all
end connection components, such as washers, rubber bushings and nuts.
Replace any components that are cracked chipped or deformed. Renew
damper if necessary.
4. If damper tests good, reapply the damper and torque the fasteners. See
Service data for torque values.
M.I. 1517A 19 11/11/02

Figure 12 Typical Vertical Damper
Figure 13 Typical Yaw Damper
Use the following steps to qualify yaw dampers:
1. Remove the yaw damper from the bogie and underframe.

2. Manually stroke the damper in the horizontal position. Smooth, controlled
movement should be felt through both extension and compression.
3. Renew damper if necessary. Inspect bolts, washers and nuts for signs of
cracking or damage. Replace as necessary. Reapply damper as per bogie
assembly instructions in later section. Torque as per specifications in Service
Data.

It is essential that dampers be replaced with the correct type to ensure proper
adhesion characteristics and ride quality.
NOTE
Whenever a damper is tested or replaced, the mounting lock nuts, which are
removed in the process must be discarded and replaced with new lock nuts of the
same type. (HTSC)
2.6 RUBBER SECONDARY SPRINGS

Thoroughly inspect the springs, Figure 14 and Figure 15, for signs of degradation.
Grease and dirt accumulations on the rubber spring, resulting from normal service,
will not cause deterioration of the rubber material; however, continuous exposure to
lubrication and fuel oils has a detrimental effect on the life of the rubber. Take care
to keep such oil deposits off the rubber springs. In addition, cleaning the rubber
spring will facilitate visual inspection.
Figure 14 HTSC Secondary Springs (Frame not to scale)
M.I. 1517A 21 11/11/02

Figure 15 HTSC – B1 Secondary Springs (Frame not to scale)
To clean the rubber spring, wipe excess grease, oil, and dirt from the spring with a
clean cloth soaked in a mild alkali solution. Do not wash the spring in paraffin de-
greasing agents (such as trichloro-ethylene), caustic soda, or diesel fuel oil.
Check the unloaded spring for degradation. A certain amount of superficial cracking
(crazing) of the rubber surface is not unusual or detrimental to performance. Replace
any spring if any layer has a tear or cut, which exceeds 25mm (1”) in length and
6.25 mm (1/4”) in depth, or if the accumulated tears in any layer exceed 100mm
(4”).
NOTE
Rubber and Nylon components on the bogie do not specifically have any inspection
criteria. They have to be visually inspected for any damage or presence of
equipment. However, instructions regarding specific Rubber and Nylon components
as indicated in the respective sections have to be adhered to for optimum
performance and life of these components.
Lifting of rubber from bonded metal surface is limited to a depth of 12.5 mm (1/2”)
and/or a total length of 100 mm (4”) on any one rubber/metal interface. If separation
exceeds either of these specifications, the rubber spring should be replaced.

Metal plates separating the rubber layers are covered with a thin layer of rubber on
the exposed edges. This is to protect the metal from corrosion. Due to physical
contact with foreign objects, in time, it is expected that some of the protective rubber
covering at the edges and corners of the metal plates will become split, torn, and
ripped away. This is not bonding separation. This condition will not affect the
performance of the part, and is not cause for replacement.
Overhanging edges of metal parts are occasionally bent or burred through

mishandling or excessive service conditions. This is of no consequence, as the
rubber is not trapped and there is no sharp metal edge to come into contact with the
free rubber surface. Any excessive burrs should be filed off without touching the
rubber.
2.7 BRAKE BLOCK GUIDES

Brake block stabilization guides, Figure 16, are provided on the underside of the
bogie frame at the “live” and/or “dead” block lever location. A 6.4mm (0.25”) thick
X 87.5 mm (3.5”) diameter Nylon alloy wear plate is bolted to each brake lever
which mates to a spring steel stabilizing bar. Each brake lever uses a guide bracket
which straddles the stabilizing bar to maintain brake shoe to wheel alignment. The
“dead” brake lever uses a safety hanger, which is a “U” shaped bracket that straddles
the lever pivot bracket at the top side of the truck frame to maintain brake shoe to
wheel alignment. The stabilizing bars are bolted to brackets under the truck frame.
The long bars used between the “live” and “dead” brake levers are further supported
by a tie bar assembly connected laterally from the bar on one side of the truck to the
other. The wear plates should be replaced when the thickness is half of the original,
or 3.2mm (0.125”).
Figure 16 Typical Brake Block Rigging and Guides
M.I. 1517A 23 11/11/02

2.8 SLACK ADJUSTERS
2.8.1 GENERAL DESCRIPTION
The brake slack adjuster, Figure 17, is a manually adjusted pin type assembly
designed for single block brake locomotives.
Figure 17 Slack Adjusters
2.8.2 ADJUSTMENT
Piston travel is set by the placement of a pin into one of the available adjustment
holes in the slack adjuster. A spring-loaded clip that is positioned over the pin in
service retains the pin. For adjustment, the clip is lifted and simultaneously rotated
out of position to enable the pin to be removed. A ring and cable lanyard provides a
means to pull the pin to perform an adjustment. The slack adjustment procedure is as
follows:
CAUTION
This procedure must be conducted with the locomotive parked on tangent track. If
conducted with the locomotive in a curve, error in setting the piston travel will
result.

1. With the brakes fully applied, measure the piston travel. Piston travel must not
exceed 165 mm (6.5”) nor less than 50 mm (2”).
2. If the piston travel exceeds 165 mm (6.5”), the slack adjuster must be reset to
reduce the piston travel. It is prudent to limit the piston travel allowed to some
lower value to allow continued brake block wear and resulting piston travel
increase such that the piston travel will not exceed limits prior to the next
inspection and adjustment. The operating Railroad must determine these
amounts based on their operation and experience.
WARNING!
To avoid potential injury, be certain the locomotive will not roll if the brakes are
released before performing the next step. Take measures such as chocking the
wheels if necessary. It is strongly recommended that this procedure only be
conducted on level track.
3. Release the air brakes on the bogie to be adjusted using the brake cylinder cutout
cock on the underframe above the center of the bogie. This will vent all air from
this BOGIE, on both sides, so be certain other persons in the immediate area are
aware the brake levers will move. Keep hands and feet away from the brake
equipment!
4. Lift and turn the pin retainer clip on the slack adjuster to be adjusted and remove
the pin.
5. Using a suitable pry bar, work through the pinholes to extend the slack adjuster
toward the wheel. When it is judged that the block release is at least 19 mm
(3/4”) to 32mm (1.25”) away from the wheel tread, total for two block position,
16 mm (5/8”) to 25 mm (1”) away for single block position, reapply the pin in
the hole where it best fits.
6. Turn the bogie air cutout cock to apply the brakes. This will apply air to all brake
cylinders on this BOGIE, on both sides, so be certain other persons in the
immediate area are aware the brake levers will move. Keep hands and feet away
from the brake equipment!
7. With the brakes applied, measure the piston travel. It must be a minimum of
50mm (2.0”) at the single block positions (axles #1 and #6) and a minimum of
57mm (2.25”) at the two block positions (axles #2, 3, 4, and 5). It is desirable to
set the piston travel as near to these values as possible, without going less than
them, to obtain the greatest interval of time before readjustment is necessary.
M.I. 1517A 25 11/11/02

2.8.3 GENERAL PHYSICAL INSPECTION
It is recommended that a periodic visual inspection should be performed to find out
if there is any damage, e.g. loose or missing lock pins or a bent or damaged
assembly. Replace or repair the adjuster as required.
A more detailed description of brake rigging and guides is given in 3.0 BOGIE
OVERHAUL.
2.9 HAND BRAKE

2.9.1 DESCRIPTION OF OPERATION
The hand brake, Figure 18, used on HTSC and HTSC – B1 equipped locomotives, is
connected by means of a chain and pulley arrangement to a specially designed brake
horizontal cross over lever on the rear (#2) bogie. The lever, with a pulley at one
end, applies the parking brake to axles #4 and #5 at the rear end of the unit.
Caution should always be exercised when using the hand brake, because brake
component damage, obstruction (such as debris or severe icing), or improper
adjustment may result in an improper application and little or no brake capability.
After setting the hand brake, it is good practice to visually check the brake
application.
2.9.2 INSPECTION OF HAND BRAKE CHAIN AND LEVER

The hand brake, chain, and lever should be inspected on a periodic basis, to check
for unusual wear. The hand brake chain should not rub against the wheel or bogie
during operation. The HTSC-B1 bogie has a special spring pre-tensioning
arrangement to prevent this, Figure 18.

Figure 18 Pre-tension Spring Arrangement on HTSC-B1 Bogie
2.9.3 ADJUSTMENTS & TROUBLE-SHOOTING

If the hand brake appears to need adjustment, check for wear in the chain, pins, and
shackles. Replace any items that have extensive wear. If the parking brake linkage
isn’t worn, check the service brakes for proper adjustment by referring to 2.8 Slack
Adjusters Section of this M.I. before making any adjustments to the hand brake
linkage. The hand brake linkage is adjusted by varying the number of links in the
chain. Once this dimension has been established, it should not have to be re-done.
Check the brake cylinder piston travel with the parking brake applied. If the travel is
greater than 165 mm (6.5”), readjust the slack adjuster until the desired travel of less
than 165 mm (6.5”) is achieved.
M.I. 1517A 27 11/11/02

2.9.4 MAINTENANCE & LUBRICATION
2.9.4.1 Quarterly
• Check that all fasteners (nuts & bolts), clamps, and brackets are secure.
• Verify condition of chain, shackles, and pins for corrosion, wear and
damage. Replace as required.
• Check that the pulley on the brake handle assembly is in good condition and
properly secured. Replace if required.
• Chain and other components should be lightly oiled to prevent corrosion.
2.10 GEAR CASES (AC TRACTION LOCOMOTIVES)

2.10.1 GENERAL DESCRIPTION
The Gear Case, which is an integral part of the Traction Motor Assembly, is
mounted on support arms at the traction motor.
As illustrated in Figure 19, the gear case is comprised of two close fitting halves to
provide a complete oil-tight enclosure. The oil in the gear case is used to lubricate
the pinion / bull gear mesh as well as the traction motor rotor support bearing at the
pinion end of the motor.
Figure 19 Typical AC Gear Case

Located on the inboard side of the gear case are three hex head pipe plugs. These
plugs cap the openings used for oil fill, oil level), and oil drain as illustrated. When
filling the gear case, both the oil fill and oil level plugs must be removed. Lubricant
should be added until oil flows from the level plug. Do not use the oil fill hole as a
reference for a full gear case.
Overcharging the gear case with lubricant will cause leakage through the seals into
the traction motor and will also result in increased oil and bearing temperatures.
On other models there is a fill cap located on the inboard face of the gear case.
Proper oil level is maintained by adding lubricant until the level is even with the lip
of the fill opening.
When a gear case is removed from the traction motor/wheel axle assembly, the case
should be checked for possible damage such as cracks, perforations, or deformation.
The case should be cleaned and the old seal assemblies must be discarded. Seal
retainers and parting lines must be free of dirt, oil, gasket compound, or any other
foreign material.
2.10.2 GEAR CASE REMOVAL

The gear case, Figure 20, is mounted to a support arm on the traction motor, thereby
becoming an integral part of the traction motor assembly. The case is made up of
two close fitting halves with seals to provide a complete oil-tight enclosure. Both
halves are equipped with access plugs or caps to fill and/or drain lubricant.
When a gear case is removed from the traction motor/axle-wheelset assembly, the
case should be thoroughly cleaned and the old seals and/or sealing material removed
completely and discarded. Seal retainers and all parting lines should be free of dirt,
gasket sealing compound, or any foreign material. The material used to form the seal
between the case halves is a silicon based RTV liquid sealant. It is imperative that:
• The mating surfaces to which the sealant is applied is thoroughly cleaned;
• The sealant material is not allowed to plug or restrict drain passages in the
axle seal area.
Visually inspect the case halve for damage such as cracks, perforations or
deformities. Reapply gear case halves, seals and/or sealing compound.
M.I. 1517A 29 11/11/02

Figure 20 Traction Motor Gear Case
2.10.3 GEAR CASE APPLICATION

1. Prepare gear cases for application by thoroughly cleaning interior and exterior of
chips, loose weld spatter, oil, dirt, or old sealing material. Ensure that all traces
of oil have been removed from all gear case sealing surfaces on gear case halves
and mating motor seals.
2. Install breather pipe (if removed) into top case half, using “Loc-tite” type thread
locking compound. Install the filter and vent cap assembly on breather pipe.
3. Check to see that the three drain holes in lower half bores are unobstructed, clean
as required.
4. Wipe all seal surfaces on the gear case halves and the motor axle assembly with
a lint-free cloth, to remove all traces of oil. Apply three continuous 6.25mm (¼”)
beads of RTV sealant to the motor and axle assembly adjacent to the seal
tongues as shown in Figure 21.
5. Apply additional 6.25mm (¼”) diameter sealant beads at each of the half bores
in the upper and lower case halves as also shown in Figure 21. Note that these
sealant beads are always placed outboard of the tongue or groove.
6. Apply a 3.125mm (1/8”) diameter sealant bead on either the upper or lower gear
case parting line flange segments. Form the beads continuously and surround
each bolt hole with a ring of sealant. See Figure 21.

Figure 21 Gear Case Sealant Beads
7. Install the lower half gear case to the motor assembly, and using Thread-Tex
3202 on threads and washer surfaces, hand tighten the two 1-1/8-7” bolts and
washers.
8. Install the upper gear case half to the motor. Apply the 3/8-16” parting line bolts
and dry torque to the value indicated in the Service Data Section.
9. Torque the two 1-1/8-7” bolts to the value indicated in the Service Data Section.
10. With the motor in the normal operating position, fill the gearcase with lubricant
to the level inside the fill opening on the lower gear case half side. Use only
EMD approved synthetic gear lubricant.
2.11 TRACTION MOTOR REPLACEMENT
CAUTION
Journal bearing adapters at both ends of the motor-wheelset being removed must be
restrained in such a manner that prevents them from rotating or dropping clear of the
bogie frame. Prior to removal of the wheelset, inspect the primary interlock rods
(journal adapter retainer pins) to ensure they are secure. This is necessary in order to
prevent the journal springs from dropping out of the spring pockets in the bogie
frame - which could endanger maintenance personnel.
M.I. 1517A 31 11/11/02

Whenever a traction motor-wheelset assembly needs to be replaced, the following
basic procedures should be used:
1. While supporting the rear of the traction motor with a suitable lift device such as
a hydraulic jack, disconnect the nose link (dog bone) rod assembly from the
traction motor. If locking bolts were used in the assembly, they will have to be
removed with a locking bolt collar splitter or cutting torch.
CAUTION
Use care when removing any locking bolts with a torch in order to avoid damage to
the surrounding truck frame, linkages, and bushings. Make sure that all bearing
adapter interlock chains are in place, secure and not worn.
2. Remove the bearing adapter cap from the bottom of the journal-bearing adapter.
3. Disconnect the traction motor leads and any other hardware attached to the
motor / wheelset or bogie frame that would interfere with the removal –
including the wheel flange lubricator nozzles and sanding nozzles, if equipped.
4. Undo the brake slack adjusters and back the brake blocks away from the wheels.
Secure all cables and hardware in a manner that places them safely out of the
way during removal.
5. Hold the nose link assembly away from the motor. Lift the locomotive or lower
the drop table, tilting the traction motor in a manner that will disengage the
motor from the bogie frame interlock. Remove the motor / wheelset from
beneath the locomotive.
6. Move the replacement wheelset assembly beneath the locomotive. Re-assemble
in the reverse order of disassembly and note that the journal bearings seat
properly in the adapters before supporting the weight of the locomotive.
7. Using new hardware, apply the journal bearing adapter caps (binders) at all
locations, and torque. Refer to Service Data for proper torque limits. Bend the
tabs on the lock plate to fully engage one side of the bolt head.
8. Note that as the motor is placed in its’ final position, the traction motor/bogie
frame interlock (safety bracket) is properly engaged. Reconnect all hardware.
Re-adjust the brake slack adjusters.

2.12 BOGIE REMOVAL
2.12.1 INSPECTIONS BEFORE BOGIE REMOVAL
The following items should be inspected before the bogies are removed from the
locomotive. In addition, these inspections should be part of a routine inspection
schedule, to indicate worn parts before they fail.
The list is to be used as a guideline. Each item to be inspected has a reference to a

section in this Maintenance Instruction where the inspections to be performed are
detailed.
NOTE
Perform inspections with the locomotive on straight level track.
• Yaw Dampers – Reference Section 2.5 DAMPERS.

• Primary Suspension Springs - Reference Section 3.2.6 PRIMARY COIL
SPRING SUSPENSION.
• Secondary Suspension Springs – Reference Section 2.6 RUBBER
SECONDARY SPRINGS.
• Carbody pivot pin clearance – Reference Section 3.2.4 CARBODY PIVOT
ASSEMBLY.
• Brake rigging – Reference Section 3.2.2 BRAKE RIGGING COMPONENTS.
• Wheel condition – Reference M.I. 1518 and 1519, Wheels, Axles, Axle Gears
and Pinions, and Service Data section.
• Axle lateral clearances – Reference Section 5.5.2 WEAR LIMITS ON BOGIE
COMPONENTS.
• Vertical stop clearances – Reference Section 5.5.2 WEAR LIMITS ON BOGIE
COMPONENTS .
2.12.2 BOGIE ASSEMBLY REMOVAL

The bogie(s) may be removed from the locomotive by using an overhead crane or
jacks to raise the locomotive, or by use of a drop table of sufficient capacity to
handle one entire truck assembly. Figure 22 indicates typical jacking pad locations
on a GT46MAC locomotive. It may however be noted that the locations may vary
with the carbody design.
NOTE
If working on a locomotive equipped with AC traction equipment, it is required
without exception that all appropriate discharge procedures be performed prior to
commencing work on the trucks or related components.
M.I. 1517A 33 11/11/02

1. Secure locomotive and follow discharge procedures before disconnecting any
traction motor electrical cables.
2. Align jack stands or drop table as per local requirement, Figure 22.
CAUTION
When jacks are used to raise the locomotive, ensure that all jacks are raised
simultaneously in equal amounts. Failure to keep the locomotive level may result in
excessive stress on the underframe and carbody structure, or in a failure of the jacks.
After the lift is completed, the locomotive should be supported with safety blocking
located under the center sills near the jacking pads.
Figure 22 Typical Locomotive Jacking Pad Locations
Figure 23 Typical Jack Alignment

3. Disconnect brake piping; Figure 24, handbrake connections, sanding
equipment, and flange lube equipment (if equipped). Secure loose parts and
fittings.
Figure 24 Typical Brake Cylinder Air Piping
4. Apply penetrating lubricant to secondary spring pins; Figure 25, (HTSC type
shown).
Figure 25 Secondary Spring Pins (shown with unit lifted)
5. Remove traction motor lead boots/heat shrink tubing and disconnect traction
motor leads, ground cables, and unplug lead/s to junction box (if equipped),
Figure 26. Also disconnect speed pick-up cable going to #1 Traction motor.
M.I. 1517A 35 11/11/02

NOTE
Secure cables, hoses, and all other hardware in a manner that places them safely out
of the way during the bogie removal.
Figure 26 Typical Traction Motor Connections (AC motor shown)
6. Remove cotter pins and disconnect secondary interlock shackles from bogie,
Figure 27.
Figure 27 Typical Secondary Interlock Carbody/Bogie Shackles
7. Disconnect yaw dampers from carbody, Figure 28, and secure to bogie. Note
that the carbody bolts are 5/8-11 x 3-3/4”, while the truck end bolts are 5/8-
11 x 2-3/4”. Note also that the bolts are fitted with special washers, 1-5/16”
OD x 21/32” ID x .105”. Retain all washers. Inspect hardware for damage,
discard and replace all locknuts, 5/8”-11.

Figure 28 Removal of Typical Carbody Yaw Dampers
8. Remove and discard lock wire from carbody pivot pin bolts, Figure 29, and
remove 3/4-10 x 2-1/2” bolts, pivot plate and wear ring, Figure 30. Wear
ring should be discarded and a new one fitted on reassembly.
Figure 29 Lock Wire and Bolt Removal
Figure 30 Pivot Plate and Wear Ring
M.I. 1517A 37 11/11/02

9. Ensure all physical connections between carbody and bogie are removed or
disconnected. Lift carbody or lower bogie, ensuring separation of secondary
springs from carbody, Figure 31.
Figure 31 Secondary Spring / Underframe Separation
10. Remove bogie from under locomotive and locate it right side up in the
disassembly area, Figure 32.
WARNING!
When lifting the HTSC-B1 bogie ensure that chains, slings, or other lift devices art
NOT connected to the rear cross member (transom) of the bogie frame. These bogies
have a thinner cross section than the HTSC bogie in this area and may be damaged
by the lifting forces. The frame has cast markings identifying the areas that are not to
be used for lifting.
Figure 32 Typical Bogie

2.13 BOGIE APPLICATION
2.13.1 INITIAL INSTALLATION
The bogie(s) may be applied to the locomotive by using an overhead crane or jacks
to raise the locomotive, or by use of a drop table of sufficient capacity to handle one
entire bogie assembly.
CAUTION
When jacks are used to raise the locomotive, ensure that all jacks are raised
simultaneously in equal amounts. Failure to keep the locomotive level may result in
excessive stress on the underframe and carbody structure, or in a failure of the jacks.
1. Install nylon alloy wear cylinders in carbody pivot on bogie. Note that the
split lines of the two nylon pieces should be positioned towards the sides of
the bogie. Ensure carbody pivot has been cleaned of dirt and corrosion.
Spray pivot pin with moly lube (Refer to Section 5.6.3 for more details).
Clean the pads on the underframe of any rust, grease and oil prior to bogie
application.
2. Roll bogie assembly under raised locomotive, or if using drop table, install
bogie on table and raise under locomotive.
3. Verify alignment of the carbody pivot pin with the carbody yoke and the
secondary spring pins with the holes in the underframe. Slowly lower the
locomotive until the carbody pin enters the nylon insert on the pivot
assembly, Figure 33.
Figure 33 Alignment of Typical Pivot Pin
M.I. 1517A 39 11/11/02

CAUTION
Great care must be taken during this portion of the application process to prevent
damage to the carbody pivot assembly and secondary suspension springs. The pivot
pin and alignment dowels should slide into place easily. If this is not the case, slight
movement of the bogie will be required to aid in assembly.
Note that the carbody pivot will engage before the tapered pins on the secondary
springs. It is permissible to apply anti-seize lubricant to the secondary spring pins,
but the flat surfaces must remain dry for operational friction purposes.
2.13.2 VERTICAL STOP CLEARANCE

With the weight of the locomotive fully resting on the bogies, verify the vertical
clearance at all four side locations, two per bogie at the center axle location. The
vertical stop surfaces on the side of the bogie frame are designed to mate with
similar vertical stops (shims) welded beneath the carbody underframe, as indicated
in Figure 34.
Clearance is provided between the bogie frame vertical stops and the carbody
underframe vertical stops (shims) during normal operation. The vertical stops are
designed to prevent excessive tilting or leaning of the locomotive, but are not
designed to carry a continuous load.
Vertical stop clearance on a new assembly should be at 16 +/-3.2 mm

(0.62” +/- 0.12”)
Figure 34 Vertical Stop Clearance

2.13.3 FINAL INSTALLATION
1. Connect diagonal carbody dampers at carbody bracket using 5/8-11 x 3-3/4”
bolt and 1-5/16 OD x 21/32 ID x .105” thick washer. Note that the dust
cover end must be attached to the carbody with the label facing up. The
bogie end must have the label facing down. Torque to required specifications
listed in Service Data.
2. Apply the pivot pin lock plate and new wear ring using 3/4-10 x 2-1/2 drilled
head bolt and ¾” hardened washer. Use thread-locking compound on bolt
threads and torque to required specifications listed in Service Data.
3. Install 14-gauge lockwire (approximately 2 meters or 6 feet), Figure 35,
through the holes in all the bolt heads and safety wire in place.
Figure 35 Application of Safety Wire
4. Connect traction motor leads and traction motor temperature / speed probes
or speed cables as required.
5. Attach carbody links to bogie flanges using shackle assembly and new cotter
pins.
6. Connect carbody air piping to bogie air piping.
7. Connect truck flange lube equipment if equipped.
8. Connect and adjust handbrake chain.
9. Check and confirm that all bogie and carbody inter-connections have been
completed.
M.I. 1517A 41 11/11/02

3.0 BOGIE OVERHAUL
This section details the procedures required to perform a complete overhaul of the
HTSC / HTSC – B1 Bogie Assembly.
NOTE
While the overhaul procedures are similar for the two types of bogies, it is
imperative that the correct assembly drawing be used to ensure correct dimensions
are achieved.
Following removal from the locomotive (as outlined in the previous section), all
traction motor/wheelsets by lifting the bogie off of the traction motors. It is
recommended that all overhaul procedures be carried out with the bogie in a normal
orientation.
During re-assembly, qualified wheelsets / motors should be applied to the bogie

assembly.
3.1 BOGIE DISASSEMBLY

With the bogie assembly removed from the locomotive, the assembly may be
disassembled (stripped) to facilitate component inspection, repair, and replacement.
The bogie should be located in a suitable work area in a normal orientation. Take
care to identify and properly store all components as they are removed to aid in re-
assembly. Proceed as follows to disassemble the bogie:
3.1.1 REMOVING VERTICAL DAMPERS

1. Vertical dampers on the HTSC bogie may be removed without
disassembly of the mounting brackets. At lower end of damper
assembly, hold the damper-mounting stud with an Allen wrench in
center while loosening the clamping nut. Remove the retaining bolt
and nut from the lower U-connection. While supporting the damper,
repeat this procedure for the top clamping assembly, then slide the
damper out.

Figure 36 Vertical Damper Removal
2. Figure 36 shows the configuration on the HTSC-B1 bogie. Here, the damper
is removed by loosening the bolts and nuts holding the bar mounts at each
end. After all retaining hardware is removed, gently pry the lower portion of
the damper away from the lower damper bracket and drop the damper free of
the upper bracket on the bogie.
NOTE
Do not remove the bolts that secure the upper bracket to the bogie frame, as these
bolts also secure the journal adapter lateral thrust pads.
3. Qualify the unit as per the section on Dampers in this M.I. Inspect all rubber
mounting components, replace as required on re-assembly.
4. Loosen all bolts holding the upper and lower damper brackets, and remove
both brackets. Inspect both brackets and discard in case of excessive wear,
damage due to ballast or object impact, or other damage.
3.1.2 REMOVING TRACTION RODS LOCK BOLT COLLARS

Using the proper size lock bolt splitting tool or cutting torch, cut the collars at both
ends of each of the traction rods, taking special care not to damage nearby rubber
bushings or the bogie frame. Do not attempt to remove the traction rod lock bolts
yet.
M.I. 1517A 43 11/11/02

3.1.3 REMOVING TRACTION MOTORS/WHEELSETS ASSEMBLY
Follow this procedure when removing traction motors from a locomotive where the
bogies have not been removed, or during disassembly after the bogies have been
removed from the locomotive:
WARNING
Journal bearing adapters at both ends of the motor-wheelset being removed must be
restrained in such a manner that prevents them from rotating or dropping clear of the
bogie frame. Prior to removal of the wheelset, inspect the primary interlock rods
(journal adapter retainer pins) for securement. This is necessary in order to prevent
the journal springs from dropping out of the spring pockets in the bogie frame -
which could endanger maintenance personnel.
1. Support the rear of each traction motor assembly with a portable lift device or
blocking, which remain in place after the rest of the bogie assembly has been
lifted away.
2. Disconnect the traction motor nose link (Figure 37) assembly from the traction
motor. Lock bolts may be removed using a proper sized splitting tool or burned
off using a cutting torch (Refer to section on removal and installation of lock
bolts for greater details).
Figure 37 Typical Traction Motor Nose Link Removal (HTCR shown)
3. Use care when removing any lock bolts with a torch in order to avoid damage to
the surrounding bogie frame, linkages, and bushings.
4. Unbolt the journal adapter plates and remove this and bearing adapter spacer from
either side of the motor being removed.
5. Disconnect the cables and any other hardware attached to the motor/wheelset or
bogie frame that would interfere with removal - including the wheel flange lube
nozzles (if used) and sanding nozzles.

WARNING!
When lifting the HTSC-B1 bogie ensure that chains, slings, or other lift devices art
by the lifting forces. The frame has cast markings identifying the areas that are not to
be used for lifting.
6. Shorten brake slack adjusters and back brake blocks away from the wheels.
Secure all cables and hardware in a manner that places them safely out of the
way during motor removal.
7. Hold the nose link assembly away from the motor. Lift the bogie frame (Figure
37), rolling the traction motor in a manner that will disengage the motor from the
bogie frame supplemental interlock (limit stops).
NOTE
In case of a locomotive carbody that has still not been separated from the bogie
frames, lift locomotive or lower the drop table to remove the traction motor
/wheelset assembly from locomotive.
Figure 38 Lifting of Bogie
8. For a bogie that has been removed from locomotive, lift the bogie frame with
all remaining components still attached to it. Lift a small amount and check
that all wheelset/motor assemblies separate completely from the bogie
assembly. Also ensure that the coil springs are still being retained between
the bearing adapters and the bogie frame.
M.I. 1517A 45 11/11/02

9. Continue to lift the bogie assembly until clear of the traction motor
assemblies.
10. Position the bogie assembly with a wooden block beneath all six bearing
adapters. The blocks must be of a height sufficient to accommodate the
brake rigging, traction motor nose link and other components hanging from
the remaining bogie assembly.
CAUTION
The bogie frame with remaining components should be lifted, right side up, with
four chains that are anchored properly and securely to the bogie frame at four
locations on the outside of the frame.
The selected chains must enable the bogie frame to be lifted level when all chains
are tight.
Before proceeding with the lift, tighten ensure that all chains are tight, all lift
connections to bogie frame are secure, and all components still attached to frame are
not in the way of a clean lift.
Primary coil springs should be secured with ropes or straps to their bearing adapters
or to mating coil paired coil springs so that they do not roll away when the bogie
frame assembly is lifted.
3.1.4 DISCONNECTING TRACTION RODS AND REMOVING

BEARING ADAPTERS AND PRIMARY COIL SPRINGS
1. After placing supports under each of the traction rods to support them when
are loosened, remove all lock bolts at each end of the traction rods by
hammering them out, being careful not to damage the remaining rubber
traction bushings in the bogie frames, bogie frames and bearing adapters.
2. Loosen the bolts on the upper damper bracket holding the interlock retainer,
swing out the retainers, and remove the primary interlock rods.
3. Secure all hanging nose links with straps. Remove the lock collars at the
upper connection of each nose link. Lock bolts may be removed using a
proper sized splitting tool or burned off using a cutting torch (Refer to
section on removal and installation of lock bolts for greater details).
4. Using small sized crane, lift the nose links out and store for reuse.
NOTE
Check coil springs to ensure that they will remain in place and will not roll away,
either by the use of ropes or straps attached to the mating springs or the bearing
adapter on which each set of springs sit.

5. Lift the bogie frame, leaving the journal adapter assemblies resting on the
wooden support blocks. When lifting, ensure that components such as the
springs do not fall out. Note the position of the journal adapter support
blocks as this will aid in re-assembly.
6. Position the bogie frame on four wooden blocks, with the flat under surfaces
of the bogie frame resting on these blocks. As before, the blocks should be
high enough to accommodate any components like brake rigging that are still
hanging from beneath the bogie frame.
7. The six bearing adapters and coil spring sets are now sitting separated from
the bogie frame. Non-metallic straps should be used with a small crane to lift
each coil spring and place it on one of its flat end surfaces for later
inspection.
8. Disconnect the sander guide brackets by unbolting from bearing adapter and
removing. Store for re-use.
3.1.5 REMOVAL OF SECONDARY RUBBER SPRINGS

Unbolt the four secondary springs from the bogie frame. Lift up using the lower
steel plate of the rubber spring, by slightly raising it and then hooking on all four
corners. Store flat for later inspection.
3.1.6 REMOVAL OF LATERAL THRUST PADS

Lateral thrust pads are located on the inside of the bogie frame adjacent to the
primary springs at each journal bearing location. To remove a pad, the vertical
damper must have been removed using the procedure previously outlined. Unbolt
the three retaining bolts and remove the upper damper bracket and the pad assembly
from the bogie frame, holding on to both together. Qualify and renew as required.
Replace if the lateral free axle clearance exceeds the limits specified in the Service
Data section of this M.I..
3.1.7 REMOVAL OF YAW DAMPERS

Yaw dampers are mounted diagonally between the bogie frame and the locomotive
underframe. There are two damper assemblies per bogie. To remove the yaw
damper, secure the damper with straps so as to prevent it from dropping. Remove
the two remaining mounting bolts and self-locking nuts, and Lift the yaw damper
using a small crane and store for later inspection. Discard all self-locking nuts.
Qualify the unit as per the section on Dampers in this M.I.
M.I. 1517A 47 11/11/02

3.1.8 REMOVAL OF CARBODY PIVOT ASSEMBLY
Apply a lifting device to the carbody pivot assembly to support it. The pivot Yoke
(Figure 39) is first released by removing the yoke end lock bolts, flanged bushing,
and washer.
Lock bolts may be removed using a proper sized splitting tool or burned off using a
cutting torch (Refer to section on removal and installation of lock bolts for greater
details).
The lock bolts are now removed from the bogie frame end, located on the transom.
Inspect the carbody pivot yoke, and carbody traction rods for cracks or excessive
wear, replace if either condition exists.
Figure 39 Carbody Pivot Assembly
Use care when removing any lock bolts with a torch in order to avoid damage to the
surrounding rod, pivot assembly, bushings and bogie frame.

3.1.9 REMOVAL OF BRAKE RIGGING COMPONENTS
This process is done with the bogie frame supported on blocks with motor sets and
wheelsets already removed. Proceed as follows:
1. Remove all Brake Blocks from the brake lever assemblies by popping out the
brake block key in each.
2. Remove the Slack Adjuster Assemblies by unbolting the Pin Assembly at each
end. Also remove the clip. Lay the pieces on clean floor or board for later
inspection.
3. Remove “Dead” Brake Lever Assembly by unscrewing bolt from the bogie
frame. Also remove washer. Lift the assembly with a hoist high enough to clear
the bogie frame and lay it on the side.
a). Detach Brake Head Assembly by removing the Pin Assembly.
b). Remove the Mounting Block Assembly by unbolting Pin Assembly.
4. Disconnect the clevis end of the “Live” Brake Lever Assembly from the
Cylinder Lever Assembly by removing the clevis pin assembly. Remove the
three Bolts and Washers that mount the brake lever bracket assembly to the
bogie frame. With a hoist, lift the whole “Live” Brake Lever Assembly high
enough to clear the bogie frame and lay it down on its’ side.
a). Detach the Clevis from Live Lever Assembly by removing the Pin
Assembly.
b). Remove the Brake Lever Bracket Assembly from the two Hanger
Assemblies by unscrewing Bolt and Nut and the Washer. Also remove
the two headless Pins by pushing them out.
c). Remove the Brake Head Assembly by unbolting the Pin Assembly.
5. Disconnect the Cylinder Lever Assembly from the Brake Cylinder Assembly by
removing the cotter pin and pin, respectively. Pull out the Ring-Retainer that
secures the Pin at the lever fulcrum to the bogie frame. Pull out the Pin to
retrieve the Cylinder Lever Assembly.
NOTE
Items 1 to 5 are typical to the Brake Rigging Application on an non-handbrake-
equipped bogie. In the Brake Rigging Application with a handbrake, one of the
Cylinder Lever positions becomes the handbrake hookup. Note the position of this
lever relative to the bogie frame to aid in re-assembly. To disassemble, apply steps 4
and 5 above.
M.I. 1517A 49 11/11/02

3.2 COMPONENT QUALIFICATION
3.2.1 BEARING ADAPTERS
Journal bearing adapters, Figure 40, should be given a thorough visual inspection for
signs of overheating, cracks, or evidence of excessive wear in the journal bore and
the spring seat area. Welding may repair worn or cracked areas. Grind off excess
material and thoroughly clean the adapter before re-assembly.
Figure 40 Typical Journal Bearing Adapter Bore
3.2.2 BRAKE RIGGING COMPONENTS

All brake rigging components should be thoroughly cleaned and examined for
damage and wear. The wear surfaces of the brake rigging are equipped with
replaceable hardened bushings, pins, and bolts. Any of these connecting parts that
are worn more than specified below should have both parts replaced. Never use a
new pin with an old bushing or vice versa.
Cylinder levers, brake levers, and brake rods that are bent may be re-used if they are
restored to their original shape. Bolts and nuts that are not subject to wear may be re-
used if they are not damaged, but cotter pins must always be renewed.
Qualification and repair procedures for the brake rigging are as follows:
1. Make a visual inspection of the Bar-Stabilizers, which are still attached to

the bogie frame for straightness. Out of straight of 0.125” from the clamped
portion of the bar necessitates replacement or repair of the part.
2. All bushings must be measured for out of round condition. If a bushing is out
of round by 0.094” or more on the diameter, press it out and replace it with a
new one. Likewise, if the bushed hole is apparently egg-shaped, build it up
with weld and re-drill it to appropriate size before pressing in the new
bushing.

3. The Wear Plate on each Brake Lever Assembly must be inspected for
considerable wear. Total wear for this part must not exceed 0.19”.
4. All pins must be examined for significant deterioration such as cracks, wear
and/or bends. If the condition of any pin is enough to jeopardize its function,
replace it with a new one. Replace a pin if it is worn out more than 0.063”.
5. The Brake Hanger Assemblies of the “live” Brake Lever Assembly should
be inspected for twist and shift. The existence of one or both of these
deformations will adversely affect the angle of contact between brake shoe
and wheel. Repair or replace the part accordingly.
3.2.3 TRACTION ROD BUSHING REPLACEMENT PROCEDURES

The following procedure is to be followed when removing traction rod bushings
from a bogie frame. A similar procedure will be followed for removing a traction
rod bushing from a bearing adapter. See Figure 41for the tooling components and
procedure needed.
Figure 41 Removal of Traction Rod Bushing
NOTE
The threaded stud bolt should be made of heat-treated alloy steel like SAE 4140 with
hardness of 30-36 HRC (Rockwell C).
M.I. 1517A 51 11/11/02

3.2.3.1 Traction Rod Bushing Removal
1. Position stud bolt (E) with flat washer (A) and nut (G) from inside of bogie, so
that the stud bolt will protrude through bushing to outside of bogie frame.
2. Install large tube (B) to contact the welded in traction tube sleeve.
3. Install end cap (C) into end of tube (D) so that the counter bore goes into the
tube.
4. Install the hydraulic puller (F- hollow hydraulic cylinder) on stud bolt with the
ram against the end cap.
5. Install the spacer (D) on the stud bolt and, if necessary, add one or more of the
spacer washers, so as to fill the stud bolt leaving enough for the (2) nuts (G) to
have a minimum of two threads through the nuts.
6. Install the acme nut on the end of the stud.
7. Connect the hydraulic hoses to the cylinder, keeping fingers clear of the entire
load train, and pump to apply pressure until everything has become snug and has
made contact.
8. Check to make sure that entire assembly is properly aligned. If not, loosen, re-
position components and apply pressure again until all components are in
contact, and re-check alignment.
9. Apply ample force to pull bushing out. A small amount of P-80 lubricant may be
applied as bushing is coming out. Support the hydraulic cylinder from falling
when the rubber bushing is about to come out.
CAUTION
Do not stand behind hydraulic cylinder (puller) – stand to the side away from the
force.
3.2.3.2 Traction Rod Bushing Installation

If the traction tube is new, then no cleaning may be needed. However, after removal
of a bushing, the inside of the traction tube may have some remaining rubber pieces
or debris. These should be cleaned out with a rotary wire brush until all debris has
been removed.
Figure 42 Installation of Traction Rod Bushing

CAUTION
P-80 lubricant must be used for bushing assembly. Do NOT use soap, oil, or any
other unapproved type of lubricant as this may lead to deterioration of the bushing
material.
1. Apply P-80 lubricant to inside of traction tube sleeve and funnel (H) as well as
the new traction rod bushing to be installed.
2. Install stud bolt (E) through traction tube sleeve and put end cap [C] on with
counter bore facing away from the traction tube sleeve. This will seat against the
end of tube.
3. Install small spacer and acme nut (G) with two threads through nut.
4. Install funnel (H) to outside of bogie to seat in traction tube sleeve as per Figure
42.
5. Slide on the traction bushing and slide into the funnel as far as possible.
6. Slide on the spacer (D) against the traction bushing.
7. Slide on the hydraulic cylinder (puller) with the ram against the spacer.
8. Install nut (G) with a minimum of two threads through the nut. If needed, add
more spacer washers.
9. Hold up the hydraulic cylinder so that it is in proper position, keeping all hands
and fingers clear of the load train components) and apply hydraulic pressure
enough so as to align everything. If necessary, apply more P-80 lubricant to the
rubber and funnel.
10. Apply more pressure to pull in bushing through funnel into traction sleeve. Stop
when the bushing is a little past slot in sleeve. Check bushing to see if it is
centered in sleeve slots (equal amounts sticking out on both sides). This should
be about 25mm (1”) from edge of slots in sleeve, to allow for bushing spring-
back. If not, pull a little more. If the bushing has gone too far, use a pry or crow
bar to move back to proper spacing. Note: Once the lubricant is dry, the bushing
will take a set and will be hard to move. So all adjustments should be done soon
after bushing is inside the traction tube sleeve.
11. Remove the hydraulic cylinder (puller) and funnel.
M.I. 1517A 53 11/11/02

3.2.4 CARBODY PIVOT ASSEMBLY
Qualification of the carbody pivot assembly (Figure 43) includes inspection of the
pivot; wear sleeves, yoke and carbody traction rods. During a bogie overhaul, it will
be required to renew the bushings in the carbody traction rods.
Figure 43 Typical Carbody Pivot Assembly
Thoroughly clean all components and inspect for damage or fatigue. Carbody rods
are equipped with both different special washers at the bogie end and carbody pivot
yoke end. All must renewed prior to re-assembly.
3.2.4.1 Carbody Bushing Removal Procedures

There are two bushings per bogie and two bushings per carbody end. Refer to the
appropriate print for part numbers and orientation. See Figure 44. These bushings
may be removed using a procedure similar that used for removing traction rod
bushings.

Figure 44 Carbody Pivot Rod Traction Bushings
3.2.4.2 Carbody Rod Bushing Installation Procedures
1. Place the installation funnel on top of the hole. Figure 45.
CAUTION
P-80 lubricant must be used for bushing assembly. Do NOT use soap, oil, or any
other unapproved type of lubricant as this may lead to deterioration of the bushing
material.
2. Apply P-80 rubber lubricant to the inside of the hole and funnel, and on the
outside of the carbody bushing.
3. Apply the ram at the end of a hydraulic cylinder to the inner metal part of the
bushing. During installation, the steel inner member of the bushing must be
pushed beyond the 0.605/0.645” dimension to accommodate spring-back
(will need about 5,000 lb force). See Figure 45. If the carbody bushing is not
in position, it must be repositioned before the lubricant dries. Once the
lubricant dries it becomes much more difficult to move the bushing (it
requires a larger force to move) and the danger of bushing tearing is present.
M.I. 1517A 55 11/11/02

Figure 45 Carbody Pivot Rod Traction Bushing Alignment
CAUTION
Do not stand behind hydraulic cylinder (puller) – stand to the side away from the
force.
Figure 46 Carbody Pivot Rod Traction Bushing Installation

4. Using the ram tool shown, see Figure 47 apply P-80 lubricant to the retaining
ring (2 per bushing), and push the retainer ring into position with about 6,500 lb.
force.
Figure 47 Carbody Pivot Rod Traction Bushing Retaining Ring Installation
5. Apply the opposing retaining ring. Finished bushing assembly should resemble
Figure 48.
Figure 48 Completed Carbody Rod Bushing
M.I. 1517A 57 11/11/02

3.2.5 TRACTION MOTOR NOSE SUPPORT LINKS
Qualification of the traction motor nose support links (dogbones) includes a visual
inspection of the links and replacement of the bushing assemblies, Figure 49.
Figure 49 Typical Traction Motor Nose Support Link (HTCR Shown)
Thoroughly clean all components and inspect for straightness, damage or wear.
Note that the metal supports that protrude from the sides of the bushing have a wider
contact surface on one side. This wider surface is the contact area between the
support and the bogie or traction motor. Ensure bushings are installed with these
wider surfaces facing each other, Figure 50.
Figure 50 Bushing Orientation

3.2.6 PRIMARY COIL SPRING SUSPENSION
Locomotive bogie frame-to-axle journal primary suspension is provided by steel
helical coil springs. Two single coils per journal adapter are utilized that generally
provide for large amounts of deflection. This assists in wheel load equalization, and
improves the ride quality over rough sections of track.
In the event that a primary spring is found to be broken, it should be renewed along
with the remaining spring on the same adapter. In addition, the two springs on the
opposite adapter on the same axle should be thoroughly inspected. Periodically in
normal service, the coil springs shall be thoroughly inspected for signs of fatigue or
degradation.
a) Inspect the coils for breaks or surface cracks. Springs with any indication of
surface cracks should be scrapped. Deep sharp surface nicks can cause
failure of a spring, and their presence is cause for rejection.
b) Hand wash or shot blast the coil to remove surface rust. “Pickling” the spring
is to be avoided. If the cleaning operation removes all indications of surface
rust, and does not reveal corrosion pits, the spring is acceptable for
qualification. If corrosion pits are visible after the cleaning operation, scrap
the affected coil.
c) Smooth worn spots on a coil caused by rubbing - do not condemn the coil.
However, it must still pass the other qualification criteria.
d) For spring identification and qualification, refer to M.I. 1512.
Figure 51 Primary Coil Springs and Journal Adapter
M.I. 1517A 59 11/11/02

In order to secure the coil springs on the journal bearing adapters, spring pilot tubes
are used along with pilot (wear) plates between the springs and the adapter, Figure
51. Spring pilot tubes and shims (spacers) are also located in the truck frame spring
pockets to perform the same function.
3.3 BOGIE FRAME INSPECTION AND RECONDITIONING

Make a thorough inspection for the following and recondition if necessary.
3.3.1 BOGIE FRAME TRAMMING

Tramming of the bogie is done from the spring pocket holes. Clean off the surface
(carefully) and locate the tram points. If necessary, insert rods of same sizes in the
four opposing holes. Measure the distances between the reference points or between
the centers of the rods (if used). The differences between the two distances should be
less than the tramming tolerance specified (See Service Data).
Refer to Figure 52 for identification of tram points (spring pocket holes).
Figure 52 Typical Tramming Points

Measure the distance between diagonal pairs of tram points. For example, the
distance between the left front tram point and the right rear tram point will be
considered “LA” while the distance between the right front and left rear tram points
will be considered to be “LB”. If “LA” is within +/- .06” of “LB”, the tram is
considered to be within specification. See Figure 52.
If the tramming dimensions are not within specification, contact your EMD Service
representative for corrective procedures.
3.3.2 BENT, BROKEN, OR CRACKED MEMBERS

Inspect all bogie members and weldments for breaks or cracks. The critical areas of
the bogie are identified in Figure 53 and require closer attention when inspecting,
than other areas of the bogie frame. Perform magnetic particle inspection at any
areas suspected of being cracked. Before performing any weld repairs to major
structural areas, contact your EMD Service Representative for corrective procedures.
Figure 53 Critical Frame Areas
Breaks or cracks are repaired by welding, using AWS E-7016 electrode. It is

permissible to remove a broken or bent section for straightening if it can be welded
back into place after preparing the joint to obtain a 100 percent section of weld with
reinforcement as shown in Figure 54.
M.I. 1517A 61 11/11/02

To minimize localized stressing when several welds are required, allow sufficient
time for frame to cool to the touch between welding passes. Water soaked rags or air
fans may be used to cool the welding area. Make certain that area to be welded is dry
before welding. To further minimize localized stress distortion, each welding pass,
except the root pass, should be 100% needle peened. Peen immediately after each
pass, except for the final pass. Peen final pass after it has cooled to below 66° C
(150° F). Use a needle-peening gun with a minimum of twenty-eight 3-mm wires
with rounded end. Avoid excessive peening that will impair the quality of the welds.
Figure 54 Preparing Joints For Welding
All welds should be magnetic particle inspected after welds have cooled to below
204°C (400°F)
Bent sections may be straightened either cold or after application of heat, Figure 55.
Before straightening any bent section, determine what effect the straightening will
have on the adjoining sections. If necessary, the affected section should be removed
from the frame assembly, and rebuilt provided the welding criteria described above
is complied with.
NOTE
Temperature to which the bogie frame needs to be heated for straightening depends
on the severity of the damage caused to the frame and the mechanical process used
for straightening. However the bogie frame may not be heated beyond 1000°F
(538°C). It is recommended that a Non-Destructive Inspection be performed after
the frame has been straightened.

Figure 55 Bogie Frame Straightening
Jacks, turnbuckles or fixtures designed for straightening members will expedite the
straightening of bent sections.
3.3.3 WORN SPOTS

The HTSC bogie frame is designed to have a minimum number of wear surfaces to
reduce maintenance. However, it should be periodically checked for worn areas.
Worn spots can be repaired by building up the affected area(s) with weld as outlined
in the above paragraphs. After the welding operation is complete, grind the area(s)
smooth to match its original form. This applies to any area on the frame, machined
or otherwise such as the lateral and vertical stop surfaces, or the primary and
secondary spring seats.
NOTE
Necessary precautions as indicated in Section 11.2 of the Locomotive Service
Manual should be complied with when carrying out welding processes on the truck,
when the truck is beneath the locomotive.
3.3.4 ELONGATED OR OVERSIZE HOLES

Drilled holes elongated by wear due to loose bolts; screws, sleeves, or bushings can
be re-conditioned by either ring or plug welding. Holes that are too small to permit
proper manipulation of the welding electrode should be drilled oversize to permit
proper access for the electrode. The hole should be re-drilled to proper size after
completion of the welding.
M.I. 1517A 63 11/11/02

3.3.5 WORN BUSHINGS
All bushings should be pressed out and replaced at each bogie overhaul. After the
bushing is removed, inspect the drilled hole in the frame for wear or an out-of-round
condition. Holes found unsuitable for a new bushing can be reconditioned by ring
welding and then drilling to accept the new bushing. Applying a band of heat
parallel with the drilled hole may shrink holes that are slightly oversize.
3.3.6 DAMAGED THREADS

All threaded holes should be checked and re-tapped if required. If the threaded holes
cannot be reconditioned by re-tapping they should be plug welded, re-drilled and
tapped. An alternate method of reclaiming unsatisfactory threaded holes is to re-tap
them to accommodate an oversize bolt.
3.3.7 BROKEN OR BENT STUDS

Replace any broken or bent studs with studs that are in satisfactory condition.
3.3.8 MISSING PARTS

Make a thorough inspection to see that all the necessary parts are intact. Special
attention should be given to wear plates, cotter keys, washers, bushings, studs, brake
guides, and brake pins.
3.4 BOGIE RE-ASSEMBLY

The bogie is assembled in the upright position (normal running position). Reference
the appropriate prints for the specific bogie being assembled.
3.4.1 INITIAL BOGIE ASSEMBLY

Unless specifically noted, all bolts are to be torqued to the appropriate values as
shown in the Service Data Section. Self-locking nuts with nylon locking inserts are
installed satisfactorily when the end of the bolt is either flush with the top of the nut
or is protruding through the nut. Lock bolts are to be applied using only the correct
lock bolt installation equipment with pressures adjusted to levels recommended by
the equipment manufacturer. Refer to the assembly instructions in 4.1.2 LOCK
BOLT INSTALLATION. New cotter pins are to be applied, oriented with the split
portion downwards and the long leg bent back sufficiently to ensure security of the
pin. When applying components with machined mating surfaces, ensure that all
grease or preservative has been removed from both surfaces.

1. Place the bogie frame upright on top of four wooden blocks to support the bogie
at four locations under the traction rod bushing holes. As per section 3.2.3
TRACTION ROD BUSHING REPLACEMENT PROCEDURES, the bushings
should be inspected and replaced as necessary. Traction rod bushings in bearing
adapters should also be inspected and replaced as needed. Remove plastic pugs
from threaded holes.
2. Lateral thrust pads are to be inspected and replaced only if the metal frame or the
nylon rubbing surfaces are cracked, or if the lateral axle clearances exceed the
limits shown in the Service Data section at the end of this M.I. If needed, a new
lateral thrust pad is to be installed together with the upper damper bracket using
the same bolts. The bolts and special spring washers are applied from the outside
and thread into the lateral thrust pads. The bolts are to be tightened as per the
Service Data Section.
3. Secondary rubber springs are to be inspected and replaced, if needed, as per
section 3.1.5 REMOVAL OF SECONDARY RUBBER SPRINGS. Note that if
it is required to renew a secondary spring assembly, they should be renewed as a
set (all four on the affected bogie). It will not be required to renew the secondary
spring assemblies on the other bogie. Before installing a new spring ensure that
the secondary spring mounting surfaces on the bogie frame are clean. Install the
secondary spring on the bogie frame with four bolts, with the upper pins aligned
in the longitudinal direction as per bogie assembly drawings.
4. Apply carbody traction rods to bogie frame as per view H in the appropriate
bogie assembly drawing. The flanged bushing is to be applied from the bottom,
and the 1 3/8” lock bolt is to be applied from the top (i.e. collar on bottom).
Thick hardened washers are required at both ends. Do not swage the lock bolts at
this time.
5. Apply the carbody pivot assembly to the carbody traction rods. The flanged
bushing is to be applied from the top as is the 1” lock bolt.
6. Center the pivot assembly to within 1/8” relative to a machined surface on the
bogie frame, such as the drilled drain hole for the primary coil spring, or the
secondary lateral stop. Swage the collars of both the 1” and 1 3/8” lock bolts.
Apply pivot pin wear liners with the split line parallel to the axles.
7. The upper ends of the traction motor nose links are next applied to the bogie
frame at each traction motor location. The end rubber bushings are at four (4)
degree angles perpendicular to the body of the link. See to note the proper
orientation of the link when it is assembled to the bogie frame. Install the 1” lock
bolts that attach the nose link to the bogie frame, noting the proper orientation of
the lock bolts.
M.I. 1517A 65 11/11/02

Figure 56 Typical Orientation of Nose Links (HTCR Shown)
8. At a separate location, place bearing adapters on stands located at the appropriate

width and wheelbase, as shown on the bogie assembly drawings. Since there are
three each of two part numbers of bearing adapter, ensure that are in the right
locations. All tapping pads sticking out from the side must be pointing in the
outward direction. Also, in the HTSC bogie #1, the U-shaped openings on axles
#1 and #2 bearing adapters face towards the open end of the bogie, and axle #3
bearing adapters face towards the rear of the bogie or towards the end transom.
In the same way, in bogie #2, the bearing adapters in axles # 4 and #5 face
towards the open end of the bogie, and the bearing adapters for axle #6 face the
other way. Another point to note is that the four-hole joints on the bearing
adapters for the sander brackets should be pointing outwards for both end axle-
bearing adapters.
9. Apply coil spring shims onto the bearing adapters (one shim per spring location).
Place the primary journal coil springs on the bearing adapters, and on top of each
shim, with the bottom tip of the spring oriented so as to be visible from the
outside of the bogie. The coil spring placed on top of the spring can be held in
place with a 1/8 – 1/4” bead of silicone applied to the top of the spring.
10. Position, prop up and block all axle traction rods in preparation for the lowering
of the bogie frame. Pick up the bogie frame (as per Figure 57) as assembled up
to item #5 above, and lower it slowly onto the bearing adapter spring
combinations, making sure that the bogie is oriented properly.
WARNING!
When lifting the HTSC-B1 bogie ensure that chains, slings, or other lift devices are
by the lifting forces. The frame has cast markings identifying the areas that are not
used for lifting.

NOTE
During the lowering of the bogie frame, ensure that the axle traction rods slip into
the traction tube slots and engage the inner member of the traction rod bushing in the
bogie frame. Remove the block supports for the axle traction rods and continue
lowering. Ensure the bogie frame does not contact any traction rod or bearing
adapter during lowering. Confirm that all coil springs have engaged the spring pilot
tube attachments on the inside of the bogie frame at the spring pocket locations, If a
coil spring is not engaged, a rubber sledge hammer can be used to pop the spring
into the proper engagement.
Figure 57 Bogie Lifting Connections
11. Insert the 1 3/8” lock bolts from the inside of the bogie into each traction rod
bushing location in the bogie frame, so that all pintails of the lock bolt are facing
outwards. Center axle traction rod bolts slide in when the bogie frame is almost
down. Next slide in the remaining 1 3/8” lock bolts into the traction rod bushings
in the bearing adapters, so that the lock bolt head is on the inside and the pintails
are pointing outwards.
12. Lower the bogie frame completely until all its weight is being borne by the coil
springs, and disconnect the lifting hooks and shackles. By means of a wrap
around chain and hydraulic jack combination to depress the spring at each spring
pocket, until the traction rod is horizontal as monitored with a spirit level (within
+/- 0.5 °). While holding the traction rod level, swage the lock bolts at both the
bogie frame and bearing adapter ends of the traction rods, so that the lock bolts
are fully installed.
M.I. 1517A 67 11/11/02

13. Insert the two primary interlock rods into the bogie frame holes for the purpose,
so that the interlock rods are now on either side of the tower of the bearing
adapter (part of bearing adapter that sticks up and has an I-beam like section).
Bolt the retainer interlocks, with one on each side of the upper damper bracket.
Slide the inner flange type end into the slots in the primary interlock rods, so that
both interlock rods are held in place and cannot slide out. Release the applied
compression on the springs at that pocket, and move to another spring pocket
location for assembly of the next traction rod lock bolt combination in the same
manner. Again, apply the primary interlock rods and engage with the interlock
retainer pins.
3.4.2 BRAKE CYLINDER PIPING

Apply the piping as shown on the appropriate application drawing. When securing
unions, ensure that mating surfaces are clean. Adjust piping, hoses and pipe clamps
such that any moisture in the pipes will drain into the brake cylinders. Piping may be
heated for bending so as to align the piping without being sprung. Apply piping so as
to avoid kinking hoses. Air test piping for leaks with air and water solution.
3.4.3 ASSEMBLY OF BRAKE RIGGING COMPONENTS
1. Assemble Brake Lever Assembly - Live as shown in Figure 58.
Figure 58 – Brake Lever Assembly – Live

2. Lift each assembly in step 1 with portable hoist onto the bogie frame positioning
the cluster bracket assembly on top of the mounting cluster bracket of the bogie,
shown in Figure 58. Line up the three holes of the cluster bracket assembly with
those of the bogie frame cluster bracket and apply 3 bolts with 3 new washers.
Figure 59 Brake Lever Assembly Application - Live
3. Assemble Brake Lever Assembly-Dead using Figure 60 as a guide.
Figure 60 Brake Lever Assembly – Dead
M.I. 1517A 69 11/11/02

4. In the same manner, lift each assembly in step 3 onto the bogie frame laying up
the mounting block assembly on top of the dead lever mounting bracket as
shown in Figure 61. Apply 2 new bolts with 2 new washers.
Figure 61 Brake Lever Assembly Application - Dead
5. With all the Brake Lever Assemblies in place, apply Offset Brake Shoe in each
location with Brake Shoe Key, as in Figure 62.
Figure 62 Brake Shoe Application

NOTE
The offset side of the brake shoe is to be on the outboard side of the wheel.
6. Apply the Cylinder Lever Assembly by introducing the brake side arm through
the lever cap fulcrum, drop the Pin into the fulcrum hole and secure it with Ring-
Retainer. Pin the cylinder arm to the Brake Cylinder with the vendor pin and
cotter pin. See Figure 63. The Handbrake Lever Assembly is applied into the
bogie in same fashion. See the appropriate Brake Rigging Application drawing.
Figure 63 Application of Brake Cylinder Lever Cross-Over Assembly 47360
7. Apply Slack Adjuster Assembly on the 1-shoe position by attaching the rod end
to the Brake Lever Assembly and the tube end to the anchor bracket with Pin
Assembly. Apply Clip before putting the Pin Assembly. Apply the same Slack
Adjuster on the other side of the bogie, except that the adjuster has to be flipped
180° about the horizontal.
8. Apply the other Slack Adjuster Assembly on the 2-shoe position by orienting the
rod end with the Brake Lever Assembly-Live and tube end with the Brake Lever
Assembly-Dead, respectively. Remember to apply the Clip before applying the
Pin Assembly. Similarly, apply the same adjuster to the other side by flipping it
180° about the horizontal.
M.I. 1517A 71 11/11/02

3.4.4 TRACTION MOTOR AND WHEELSET (COMBO)
APPLICATION
This assembly assumes that three traction motor/wheel-axle-gear assemblies are
available. Position the three motor wheelset combos in line and spaced properly for
lowering the bogie assembly. The capability for adjusting the motor vertically but
rotating about the wheelset axle while the bogie assembly is being lowered onto the
combos, will be required. Begin with each of the motor assemblies at a high angle.
Lift the bogie assembly connected as shown on Figure 57. Lower the bogie frame
onto the three traction motor combos slowly. As the bogie frame lug passes the
motor’s upper secondary support lug, begin lowering the traction motor
simultaneously, or alternate lowering the bogie assembly and motor. Ensure that the
motor nose link (with upper end already attached to bogie frame) becomes properly
positioned, and that the bearing adapters are fully and properly seated on each of the
journal bearings.
NOTE
Motor nose link bushings are installed in links rotated 4 degrees off center. Make
sure the nose links are installed to motors and frame with tilt of bushing down in
direction of traction motor and up in direction of truck.
1. Apply the 1” lock bolts so as to join the lower end of the nose link to the
traction motor nose lug at the lower end. Orient the lock bolts properly, and
swage the lock collars in order to complete the installation of the nose
link/traction motor lock bolts.
2. Apply the bearing adapter cap plate assembly and the urethane bearing
adapter spacer. Note proper orientation of the plate, since the plate can be
applied backwards. The portion of the plate assembly that engages one end
of the journal bearing race is to be on the wheel side of the journal bearing.
When applied between the journal bearing and the plate assembly, the spacer
will be slightly loose. If the spacer is snug or appears deformed, check to
ensure that the bearing adapter is fully seated onto the bearing at both the
front and back.
3. Bolt on the sander guides to the bearing adapters on both end axles. Apply
the step assemblies on both sides of bogie #1 only. Apply traction motor air
ducts to the tops of each traction motor. Over the opening of the air duct
assembly, place a flat board and tape the opening shut so that no foreign
matter or debris falls in.

3.4.5 PRIMARY VERTICAL DAMPER APPLICATION
Vertical dampers can be applied during bogie assembly, or later after the bogies
have been mated with the locomotive carbody. If installed on the bogie before the
locomotive carbody is lowered on it, the dampers will need to be extended (HTSC
bogie only).
1. Bolt on the lower damper brackets to the tapping pads sticking out on the side of
the bearing adapter. Ensure that the brackets fit well and do not have to be forced
into position.
2. Verify that the thickness of the primary vertical damper mounting locations on
the bogie frame and on the bearing adapter are 1.00 +/- 0.06”, on the upper and
lower damper brackets.
3. Apply the top of the primary vertical damper to the bogie frame by removing
nut, thick washer, rubber pieces, thin formed washers, and conical nylon sleeve
supplied with each damper, then passing the stud through the hole in the upper
damper bracket already bolted to the bogie frame.
4. With the lower thin formed washer engaged in the hole in the upper damper
bracket, apply the nylon sleeve and the upper thin formed washer. Both upper
and lower thin-formed washers are to sit flat and flush against the horizontal
plate of the upper damper bracket. Apply rubber, thick washer, and nut on the
end of the damper. Use a 3/8” Allen wrench to hold the stud of the damper while
the nut is tightened. Torque to 110 ft. lbs. Do not attempt to tighten or torque if
the Allen wrench is not sized or seated sufficiently.
5. Apply the lower end of the damper to the lower damper bracket after sliding the
vertical damper stud into the U-shaped fork end on the lower damper bracket.
Apply the lower connection in a manner similar to the top. Tighten the lower end
of the damper to the bracket only when the damper is in the free state.
NOTE
Do not hold the damper to one side while tightening. To check if the damper is in its
free state, examine the larger diameter upper tube and the clearance to the smaller
diameter lower tube. This clearance should be equal all around the damper.
6. After the lower nut has been torqued, apply the retainer bolt across the U-
opening so as to secure the lower end of the damper. This bolt does not need to
be torqued. Tighten to a snug fit.
M.I. 1517A 73 11/11/02

3.4.6 SECONDARY YAW DAMPER APPLICATION
The yaw dampers should be installed with the right side up (as marked on the yaw
damper), with the smaller end of the yaw dampers attached to the bogie at the yaw
damper bracket, as shown in the appropriate bogie assembly print.
3.5 BOGIE APPLICATION TO LOCOMOTIVE

1. Install nylon-alloy wear cylinder halves in carbody pivot on bogie. Place
cylinder halves so that separation line faces sides of bogie. Ensure carbody pivot
has been cleaned of dirt and corrosion. Spray pivot with moly lube.
2. Roll rebuilt bogie assembly under raised locomotive, or if using a drop table,
install bogie on table and raise bogie up under locomotive. Ensure contact areas
are cleaned of dirt and corrosion.
3. Align carbody pivot pin with pivot and secondary rubber spring pins with
appropriate holes in carbody underframe, Figure 64, and Figure 65. Note that the
carbody pivot will meet the bogie before the secondary spring pins meet the
carbody. Anti-seize lubricant is permissible on the pins only of the secondary
rubber springs. The flat plate surface must remain dry for friction purposes.
Figure 64 Typical Carbody Pivot Pin Installation (HTCR Shown)

Figure 65 Typical Secondary Spring Alignment (HTCR Shown)
4. Connect diagonal carbody dampers at carbody bracket, using bolt (5/8-11 x 3-

3/4”) and washer (1-5/16 OD x 21/32 ID x .105” thick). Torque to specification.
See Service Data.
5. Install new carbody pivot pin wear ring and plate using drilled head bolts (3/4-10
x 2-1/2”) and washers (3/4” hardened). Torque to specifications. See Service
Data. Install 14-gauge lock wire, Figure 66, (approximately 2 meters or 6 feet)
through the holes in the bolt heads and safety wire them in place.
Figure 66 Typical Carbody Pivot Pin Lock Wire (HTCR Shown)
6. Connect traction motor leads, traction motor temperature probe plug, and
traction motor speed plug, as equipped.
7. Attach carbody links to bogie flanges, Figure 67, using shackle assembly and
new cotter pins.
M.I. 1517A 75 11/11/02

Figure 67 Typical Carbody Interlock Links (HTCR Shown)
8. Connect carbody air piping to bogie air piping, Figure 68.
Figure 68 Typical Air Brake Piping (HTCR Shown)
9. Connect bogie flange lube equipment if equipped.

10. Connect and adjust handbrake chain.
11. Check bogie and carbody to ensure all loose ends have been accommodated.

4.0 SPECIAL PROCEDURES
4.1 LOCK BOLTS
There are four locations at which lock bolts are used in the HTSC and HTSC B-1
bogie (Ref. Prints 40075078 and 40075079 – views and sections in this paragraph
refer to these drawings): (1) Carbody traction rods at the bogie end (Section F-F and
View H exploded), (2) Carbody traction rod connection at pivot pin end (Section G-
G and View H), (3) Axle traction rod connections (both ends), and (4) Traction
motor nose link connections (both ends).
The first two connections normally should not need to be disassembled or re-
assembled, except at bogie overhaul, as needed. The axle traction rod and nose link
assemblies will need to be disassembled and re-assembled each time the traction
motor/wheelset combination is removed or re-installed. The general instructions
given here apply to all the lock bolt connections, although the hardware set and
orientation of each fastener is different. Since the lock bolt does not use threads, but
instead makes use of locking grooves, there are no nuts needing to be torqued.
Instead, there is a collar that is swaged (cold formed) onto the locking grooves that
holds the connection secure.
4.1.1 REMOVING LOCK BOLTS

Lockbolt removal is accomplished by either cutting the collar with a cutting torch or
with a mechanical cutting tool. The cut collar and loose lockbolt are waste and must
be discarded.
Before removal of lockbolt, ensure that mating parts are secure and that when the
lockbolt (pin) comes loose, the lockbolt either remains in position, falls safely, or
will be held securely.
Note that all mating components should be blocked, held up by straps or secured as
needed.
CAUTION
All safety precautions and procedures of the lockbolt and lockbolt tool manufacturer
should be strictly adhered to. Ensure that hose connections are tight, and that hand
tool and power rig connections are secure and proper. Do not stay directly in line
with the lockbolt during installation. Push the tool as far as possible onto the collar
before pulling trigger. Keep hands clear from connection before pulling trigger.
When the collar is cut, release trigger. Keep hands and fingers out of nose openings,
and hold hand tool only below hand guard. Stop tool operation in case of breakage
or wrong adjustment, or if hoses are leaking or cables damaged.
M.I. 1517A 77 11/11/02

If using a cutting torch, cut the collar longitudinally (in the same direction as the axis
of the pin) along its entire length. Be careful to not damage other components,
rubber bushings or bogie frame with the cutting torch flame, placing a steel sheet or
protection as necessary between working area and adjacent components.
4.1.2 LOCK BOLT INSTALLATION

The pin or lockbolt is inserted into the prepared hole together with all the washers,
bushings and other components that are to be joined in the connection, Figure 69.
Figure 69 Lockbolt Installation
Then, the mating smooth bore locking collar is slipped on to the pin, with its bevel
end towards the outside.
The lockbolt installation tool (which is hydraulically operated, and is connected to

its power source) is applied to the pintail (end of lockbolt that is opposite to the
head).
When the trigger of the lockbolt tool is activated, see Figure 70, the chuck jaws in
nose of the tool assembly pull on the pintail, inducing an initial clamp load, and the
nose anvil pushes on the collar to remove any gap.
As the tensile load is increased, the nose anvil of the tool overcomes the resistance
of the beaded collar and begins to move over the collar toward the work pieces, thus
swaging the collar onto the annular locking grooves of the pin, and locking in the
full clamp load.

Figure 70 Final lock Bolt Assembly
After the swaging of the collar is complete, the tensile force on the pintail continues
to increase until fracture occurs at the breakneck groove separating the pintail from
the installed fastener. The collar is automatically separated from the tool and the
remaining fractured pintail containing the pull grooves is ejected. Note that the
installed lockbolt collars must within dimensions shown in Figure 71.
Figure 71 Lockbolt Finished Dimensions
M.I. 1517A 79 11/11/02

CAUTION
All safety precautions and procedures of the lockbolt equipment manufacturer
should be strictly adhered to. Never install a lockbolt without a lock collar, as the
lockbolt may be forcefully ejected. Ensure that hose connections are tight, and that
hand tool and power rig connections are secure and proper. Do not stay directly in
line with the lockbolt during installation. Push the tool as far as possible onto the pin
and collar before pulling trigger. Keep hands clear from connection before pulling
trigger. When the pin snaps, release trigger. Keep hands and fingers out of nose
openings, and hold hand tool only below hand guard. Stop tool operation in case of
breakage or wrong adjustment, or if hoses are leaking or cables damaged.

5.0 SERVICE DATA - BOGIE ASSEMBLY
5.1 REFERENCES
5.1.1 MAINTENANCE INSTRUCTIONS
Coil, Elliptic, and Rubber Bogie Spring, Qualification and
Replacement……… ........……………………………………………...M.I. 1512
Wheels, Axles, Axle Gears and Pinions ........ …………………………..M.I.1519
Grease Lubricated, Cartridge-Type Journal Bearings……………......... M.I. 1553
Lubricant Specifications…………………………………………......... M.I. 1756
AC Traction Motor Maintenance - ITB2622-ØTAØ2……….…......... .M.I. 3907
Traction Motor Roller Support Bearing………….…………….........…M.I. 3912
Handbrake……………………………………………………… ........ ..M.I. 1577
5.1.2 TYPICAL PARTS CATALOGUES

GT46-MAC..........................................................................................................E26
GT46-PAC ..........................................................................................................E35\
5.1.3 DRAWING NUMBERS

Bogie Assembly #1 (HTSC) .................................................................... 40075078
Bogie Assembly #1 (HTSC-B1) .............................................................. 40087064
Bogie Assembly #2 (HTSC) .................................................................... 40075079
Bogie Assembly #2 (HTSC-B1) .............................................................. 40087065
Bogie Application (HTSC) ....................................................................... 40075354
Bogie Application (HTSC-B1) ................................................................ 40087066
Traction Motor Mounting (HTSC) .......................................................... 40077463
Traction Motor Mounting (HTSC-B1) .................................................... 10662933
Traction Motor (HTSC)............................................................................ 40075420
Traction Motor (HTSC-B1) ..................................................................... 40086754
Gearcase Upper and Lower (HTSC)........................................................ 40076186
Gearcase Upper and Lower (HTSC-B1) ................................................. 40076352
Traction Rod Assembly............................................................................. 40072213
Carbody Rod Assembly............................................................................. 40074009
Brake Rigging Application (non-handbrake) .......................................... 40080256
Brake Rigging Application (handbrake).................................................. 40075357
5.1.4 OTHER REFERENCES
“Wheel and Axle Manual” - Association of American Railroads (AAR)
M.I. 1517A 81 11/11/02

5.2 WEIGHTS
5.2.1 COMPONENT WEIGHTS
COMPONENT UNIT WEIGHTS (approx)

Lbs. Kg.
TM - 1TB2622-0TB02 4,685 2125
Pinion 85 39
Wheel - 43" 980 445
Axle - Broad Gage (driver) 1,360 617
Axle – Broad Gage (idler) 1,300 590
Support Bearing Housing 382 173
Gear (GT46MAC) 490 222
Gear (GT46PAC) 445 203
Gearcase (Upper & Lower) 228 104
Journal Bearings 108 49
Bearing Adapter Assembly 270 123
Bearing Adapter Bot. Plate 39 18
Sander Brackets 48 22
Spring - Single Coil 80 36
Spring Pads - Steel 2.5 1
Primary Interlock 10 5
Damper - Primary Vertical 18 8
Traction Rod - Primary 39 18
Bogie frame Assembly 12,440 5643
Brake Rigging 1,332 604
Brake Cylinders 122 55
Brake Piping 100 45
Pivot Assembly 135 61
Carbody Rod w/bushing, bolts 106 48
Rubber Spring Assembly - Sec. 130 59
Secondary Interlock 27 12
Yaw Damper - Secondary 75 34
TM Nose Link 100 45
TM Air Duct 86 39
Misc. Pins, Bolts, Etc. 200 91
Bogie Mounted Steps 27 12
Primary Damper Brackets 30 14

NOTE
All weights provided are estimates to assist in lifting and moving tasks. If accurate
weights are needed, then the components and sub-assemblies should be weighed.
5.2.2 ASSEMBLY WEIGHTS
Assembly Lbs. Kgs.

Wheel/Axle/ Gear Assembly (WAG)
(includes 2 journal bearings) 4,446 2,017
Traction Motor Assembly with WAG
(includes pinion, gearcase, and 2 journal adapters) 10,046 4,558
HTSC Bogie Complete 47, 986 21, 772
HTSC-B1 Bogie Complete 41,350 18,761
5.3 SPECIAL TORQUE VALUES
Yaw Damper (5/8-11)............................................................. 156 N.m. (115 ft.lbs)

Carbody Pivot Plate (3/4-10).................................................. 278 N.m. (205 ft.lbs)
Lower Damper Bracket (3/4-10)............................................ 156 N.m. (115 ft.lbs)
Upper Damper Bracket/Thrust Pads -
HTSC (5/8-11) ........................................................................ 156 N.m. (115 ft.lbs)
Vertical Damper – HTSC-B1 (5/8-11) .................................. 156 N.m. (115 ft.lbs)
Journal Adapter (3/4-10) ........................................................ 278 N.m. (205 ft.lbs)
Secondary Spring Base (5/8-11) ............................................ 156 N.m. (115 ft.lbs)
AC Gearcase – Parting (3/8-16).................................................. 48 N.m (35 ft.lbs)
AC Gearcase - Mounting (1-7/8- 7)..................................... 1342 N.m. (990 ft.lbs)
M.I. 1517A 83 11/11/02

5.4 SCHEDULE OF MAINTENANCE
5.4.1 TRIP / MONTHLY INSPECTION
HTSC / HTSC – B1 Bogie Inspection
Component Inspection
Axle Lateral Thrust Inspect for any missing or damaged pads. Replace with new if missing or
Pad Assembly severely damaged as per MI.
Dampers (Shock Inspect for any leaking dampers. Refer Section 2.5 for more details.
Absorbers)
Secondary Rubber Inspect for tearing or delaminating of rubber. Refer Section 2.6 for more
Springs details.
Brake Rigging & Brake Inspect for any impact damage, loose bolts. Ensure brake shoe slack
blocks adjustment is set properly. Refer Sections 2.7 & 2.8 of the MI for more
details.
Hand Brake Check for operation.
Sander Assemblies Check for any damage and proper alignment of the sander hoses and
nozzle assemblies.
Gear Case Check for any damage to gear case.
Traction Motor Cables Check for any signs of damage / rubbing on the TM cables & cleats.
& Cleats
Wheel Condition Visual check for wheel flats, gouges etc.
5.4.2 QUARTERLY INSPECTION

Component /Location Inspection
Axle Lateral Thrust Inspect for any missing pads. Measure Axle Lateral clearances. Refer
Pad Assembly Section 5.4.2 for service data as per M.I.
Absorbers)
Coil Springs Inspect for any broken springs. Replace with new if broken springs are
found.
Springs details.
Brake Rigging Inspect for any impact damage, loose bolts. Ensure brake shoe slack
adjustment is set properly. Refer Sections 2.7 & 2.8 of the MI for more
details.
Primary Interlock Rod Inspect the interlock rods for any damage to the rods or interlock retainers.
Secondary Interlock Inspect the shackle, link and pin assembly for any loose pins and damage.
(Chain)
Gear Case Oil Level Check gear case oil level. Refer to Section 2.2 for details.
Wheel measurement Measure wheel diameter, flange wear and tread wear.

5.4.3 SEMI – ANNUAL / ANNUAL INSPECTION
Component Inspection
Axle Lateral Thrust Inspect for any missing pads. Measure Axle Lateral clearances. Refer
Pad Assembly Section 5.4.2 for service data as per M.I.
Absorbers)
Coil Springs Inspect for any broken springs. Replace with new if broken springs are
found.
Springs details.
Brake Rigging Inspect for any impact damage, loose bolts. Ensure brake shoe slack
adjustment is set properly. Refer Sections 2.7 & 2.8 of the MI for more
details.
Primary Interlock Rods Inspect the interlock rods for any damage to the rods or interlock retainers.
Secondary Interlock Inspect the shackle, link and pin assembly for any loose pins and damage.
(Chain)
Gear Case Oil Level Check gear case oil level. Refer to Section 2.2 for details.
Truck Frame Casting Visually inspect the truck frame for any cracks. Refer to Section 3.3 for
details.
Wheel measurement Measure wheel diameter, flange wear and tread wear. Take wheel profiles
Vertical and Lateral Measure as per M.I., Refer Section 5.4.2 for Service data
Secondary Clearances
Hand Brake Lubrication by recommended grease
5.4.4 BOGIE OVERHAUL

Follow all the instructions as laid out in the M.I. 1517 for the truck and the truck
components specified.
M.I. 1517A 85 11/11/02

5.5 MAINTENANCE AND WEAR LIMITS
5.5.1 WHEEL LIMITS
5.5.1.1 Wheel Size Variation Limits
The following limits apply to wheel diameters. The “new” values listed below are to
be used when turning (truing or profiling) wheels in the shop. The “worn” values are
to be used when inspecting locomotives to determine need for wheel turning.
Between two wheels on the same axle: New: 0.020” (0.5 mm)
Worn: 0.063” (1.6 mm)
Between axles within a bogie: New: 0.125” (3.2 mm)
Worn: 0.25” (6.4 mm)
Between bogies: New: 0.56” (14.2 mm)
Worn: 1.25” (31.8 mm)
5.5.1.2 Wheel Size Minimums
Minimum wheel diameter (approximately) ................................40.0” (1,016 mm)

Minimum rim thickness.................................................................... 1.0” (25.4 mm)
5.5.2 WEAR LIMITS ON BOGIE COMPONENTS

5.5.2.1 Total Free Lateral Axle Clearances Between Lateral
Thrust Pads And Bearing Adapters
These are shown below as axle left and right totals, which can be measured on both
sides with feeler gauges (Axle #1 is lead locomotive axle at cab end).
HTSC Bogie
Axles 1, 3, 4, and 6 – (Bogie end axles)
Nominal is 0.38” total (9.6 mm) ............................................0.62” total (15.7mm)
Axles 2 and 5 – (Bogie middle axles)
Nominal is 0.62” total (15.7mm) ...........................................1.00” total (25.4 mm)
HTSC-B1 Bogie
Axles 1, 3, 4, and 6 – (Bogie end axles)
Nominal is 0.24” total (6.1 mm) ............................................0.50” total (12.7 mm)
Axles 2 and 5 (Bogie middle axles)
Nominal is 0.62” total (15.7 mm) ..........................................1.00” total (25.4 mm)

5.5.2.2 Wear of Nylon Pivot Liners (Split Half-Cylinder)
The thickness of the liner should be measured with a micrometer with round end tips
or with a caliper.
New liner thickness................................. 0.365 +/- 0.010” (9.27 mm +/- 0.25 mm)
Liner set to be replaced if thickness is less than 0.300” (7.6 mm)
5.5.2.3 Secondary Vertical Stop Clearances

This is measured between the bogie and the underframe on each side of the bogie at
the center axle position.
Minimum gap at any location
Nominal is 0.63” +/- 0.12” (16 mm +/- 3.1 mm) ........................... 0.25” (6.4 mm)
5.5.2.4 Secondary Lateral Stop Clearances
Figure 72 Schematic of Secondary Lateral Stop
M.I. 1517A 87 11/11/02

Figure 73 Procedure to measure Secondary Lateral Stop Clearances
• Measure the following distances while the unit is on a tangent and level track
• Measure Lateral stop clearances at two locations, one at each end of the stop
and take the average.
This would be the Lateral clearance (L1) on one side (say left side) at a
location.
• Measure the lateral stop clearance with the same procedure on the opposite
side- say right side (L2).
• The criteria is L1+L2 ≥ 3”(Minimum) and L1 + L2 ≤ 4.5”(Wear Limit).

Figure 74 Measuring Secondary Lateral Stop Clearance
5.6 ROUTINE MAINTENANCE EQUIPMENT AND SPECIAL

TOOLS
5.6.1 FIXTURES
Lifting Fixture
(Traction Motor, Axle and Wheel assembly) ....................................* File No. 288
Wall Mounted Fixture To Test Dampers............................ * Work Sketch #41089
5.6.2 GEAR RATIOS

HTSC................................................................................................................. 90:17
HTSC-B1........................................................................................................... 77:17
* Note: File Drawings and Work Sketches are available from the EMD
Service Department. These drawings include construction details of tooling
that can be manufactured.
M.I. 1517A 89 11/11/02

5.6.3 SPECIAL LUBRICANTS
P80 Rubber Lubricant.................................................................................. 8251651
Moly Lube Dry Bonded Spray Lubricant................................................... 9339834
5.6.4 COMMON PART NUMBERS

COMPONENT HTSC HTSC - B1*
Traction Motor and Pinion Asm 40075428 40086754
Wheel 43” 40077314 10662497
Axle – Broad Gage 40076350 Idler Axle – 10662499
Support Bearing Housing 40075563
Spacer 40076798
Gear – Axle 40074148 10662230
Gearcase (Upper & Lower) 40076186/40076352
Journal Bearings 40077969 40050656
Bearing Adapter Asm 40074918/10664372 40089242
Bearing Adapter Bottom Plate 40082305
Sander Brackets 40082928 40092266
Spring – Single Coil 40075318 40090911
Spring Pad – Steel 40025675
Spring Pad – Polyurethane 40087273
Primary Interlock 40074621
Damper – Primary Vertical 40082318 40090983
Traction Rod – Primary 40072213
Bogie frame Asm 40074880 40087063
Brake Rigging 40080256
Brake Cylinders 40080262/40080263
Brake Piping 40075358
Pivot Asm 40075080
Carbody Rod – with 40074009
Bushing/Bolts
Rubber Spring Asm – Sec. 40075328 40090677/40090678
Secondary Interlock 40083646/40083645
Primary Damper Brackets 40090385/10664581 40089946/40089920
Yaw Damper – Secondary 40057722 40090992
Tm Nose Link 40075326
TM Air Duct 40058521
*Where different

Document Number MM001001 (DE-LP)
Electro-Motive Division of General Motors Corporation

La Grange, Illinois 60525 USA
Telephone: 708-387-6000
Website: www.gmemd.com
©2002
Electro-Motive Division, General Motors Corporation. All rights reserved. Neither
this document, nor any part thereof, may be reprinted without the expressed written
consent of the General Motors Locomotive Group. Contact EMD Customer
Publications Office.

(For official use only)
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION FOR SUPPLY OF AC - AC

TRACTION SYSTEM FOR DUAL CAB 4500HP WDG4D/WDP4D
DIESEL - ELECTRIC LOCOMOTIVES
SPECIFICATION NO. MP. 0. 2400.67 (REV.- 03)

March, 2013
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RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW - 226011.
Specification No. MP. 0. 2400.67 (REV. - 03)
TECHNICAL SPECIFICATION FOR SUPPLY OF AC - AC TRACTION SYSTEM FOR

DUAL CAB 4500HP WDG4D/WDP4D DIESEL - ELECTRIC LOCOMOTIVES
1.0 INTRODUCTION
1.1.1 Indian Railways have introduced 4000 HP Diesel-electric locomotives GT46MAC

(heavy haul freight version renamed as WDG4) and GT46PAC (high speed passenger
version renamed as WDP-4B) equipped with 3-phase AC-AC transmission system
employing propulsion based on GTO technology under TOT agreement with M/s
General Motors, USA, a few years ago. Indigenous manufacture of both these types of
locomotives has been planned by the Indian Railways and Production has already
started.
1.1.2 In these systems, overall loco operation is controlled by Locomotive Control

Computer, which is tightly integrated with microprocessor based traction control and
braking systems. 4000 HP locomotives employ EM – 2000 as the main Loco control
computer, which controls:
I) Traction Control Computers

II) CCB of KNORR BREMSE
III) Excitation of main Generator through SCR unit.
IV) All the associated electrics housed in three electrical cabinets viz. ECC #1,
ECC #2 & ECC #3.
1.1.3 EM-2000 and its peripherals along with proprietary embedded software of M/s
EMD are being used presently on 4000 HP locomotives. These locomotives employ the
Traction Control Computer, which controls the GTO/IGBT based Traction Inverter. Each
Traction Inverter provides power for three Traction Motors. The Traction Inverter along
with its Traction Control Computer is housed in a cabinet called Traction Control Cabinet
(TCC). Two such TCCs are provided for each locomotive.
1.1.4 With the successful development of IGBT based traction control converter and
testing of existing engine to deliver 4500 hp power, it is decided to manufacture Dual
Cab locomotive with 4500 GHP. This specification governs requirements for supply of
AC-AC Traction System consisting of loco control computer system (hardware &
software), IGBT based traction inverters cum hotel load inverters system, ECC panels
and allied equipment to be used on 4500hp WDG4D/WDP4D dual cab locomotives.
1.2 OBJECTIVES OF THE SPECIFICATION
It is proposed to develop an AC-AC Traction system and electrics for Dual Cab 4500 HP
WDG4D/WDP4D locomotives with following broad objectives:
1.2.1 To take care of increased horsepower requirements up to 4500 hp. The equipment
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supplied shall be deemed to have met the 4500 GHP by ascertaining the alternator
output which shall not be less than:
(a) 2915 KW (minimum) in site conditions with both radiator fans at full speed and
compressor loaded condition
(b) 2975 KW (minimum) in site conditions with both radiator fans at half speed and
compressor unloaded
Note: Some of the auxiliaries are specific to the equipment to be offered and therefore
the auxiliary load may vary to some extent from the present load. There may be some
situations where the engine gross power shall go above 4500 hp; in such a situation a
clamping protocol shall be provided by the locomotive microprocessor such that the
power never exceeds 4525 hp for more than 3 minutes and clamping of excitation is
done in such a situation. This shall be achieved through an excitation software and not
LCP. Exact details of the clamping software proposed by the manufacturer can be
decided mutually at design approval stage.
1.2.2 To take care of increased tractive effort requirements on different notches.
1.2.3 To develop a flexible, user configurable, traction inverter system preferably with six
independent traction inverters common for both WDG4D and WDP4D locos. Complete
details of user programmable parameters are listed at clause no. 7.2.4.
1.2.4 Hardware including Traction converters, loco control computer and ECC panels
shall be common for both WDG4D and WDP4D locos and only the software configuration
shall be different for the two applications, these equipment shall be fully interchangeable.
The modified microprocessor based loco control system (hardware & software) shall
completely integrate with the proposed IGBT based traction invertors, existing power
pack, traction alternator, traction motors, Auxiliaries and braking system.
1.2.5 To provide for Hotel Load capability, option to be offered if the tender calls for a
quote for the hotel load equipment.
1.2.6 To accommodate distributed power control concept, option to be offered if the

tender calls for a quote for the same.
1.2.7 To provide blended brake feature on both WDG4D and WDP4D locos. Tractive
effort limiting feature to limit the tractive effort whenever required shall be provided in
both the locomotives. This shall be a user settable parameter.
1.2.8 It is proposed to provide a flexible and user configurable traction inverter system
either with six independent traction inverters or with twin inverters, user configurable
hotel load provision, and other features proposed in this spec. Loco Control Computer
(LCC) controls will require to be substantially modified. In the new system an exhaustive
range of User Settable Parameters shall be provided in LCC as well as TCCs for
flexibility and ease of future upgrades in the control system/Traction equipment. State of
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the art technologies like optical fibre communication, automatic engine start-stop/
Auxiliary power unit, provision for control of distributed power consist etc. shall be
provided.
1.2.9 The LCC along with associated electrics shall completely integrate with existing
power pack, traction alternator, traction motors, auxiliaries and braking system.
1.3 HOTEL LOAD FACILITY
1.3.1 At present, hotel load requirement of passenger carrying trains on IR is met through
two diesel-alternator (DA) power cars, one at either end of the rake (Rajdhani and
Shatabdi type trains) or through self generating equipment provided on each of the
coaches (Normal Mail/Express trains).
1.3.2 In order to cater to the hotel load requirement of entire rake, alternative system with
centralised hotel load power supply from the locomotive diesel engine itself is being
envisaged by Indian Railways. This shall result in higher overall efficiency, passenger
comfort and improvement in overall system reliability with reduced maintenance.
For the purpose of Hotel load an additional inverter shall be provided if asked for in the
tender. The additional inverter shall preferably be housed in the existing TCC cabinet, if
housed separately, the envelop dimensions to be indicated with proposed lay out/
mounting arrangement.
1.3.3 The output of the hotel load inverter on WDP4D locos will be 750 V +5%, 3-phase
4-wire, 50 Hz, 500KVA sine wave supply to make it fully compatible with the existing
hotel load supply arrangement of EOG power cars. In the proposed system, one of the
power cars will be removed, as the power will be provided by the hotel load inverter from
the locomotive itself.
1.4 CREDENTIALS OF THE TENDERER
1.4.1 This specification governs requirements for successful manufacture, testing and
supply of IGBT based traction inverter system along with an integrated hotel load module
and microprocessor based loco control computer system (hardware & software) with
allied equipment to be used on 4500 hp WDG4D/WDP4D locomotives.
1.4.2 Performance of 3-phase microprocessor controlled locomotives largely depends

upon design of traction inverter and loco control system. Therefore, it may be noted that
irrespective of whatever has been stated in this specification, complete integration
(electrical, mechanical as well as software controls) of the offered traction inverter, loco
control and hotel load systems with the other existing equipment of the WDG4D/WDP4D
loco, such as alternator, motors, computer controlled brake system etc. shall be sole
responsibility of the successful tenderer. Successful tenderer shall also be fully
responsible for proper mounting, installation and commissioning of all the offered
equipment as well as satisfactory performance of the locomotive in the field.
1.4.3 Since this specification calls for major design changes in the existing locomotive in
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hardware as well as software, tenderers are expected to sufficiently familiarize
themselves with the functioning of existing EM2000 and other LCC make controls and
traction inverter controls with other allied equipment on WDG4D/WDP4D locomotives
along with hotel load system on existing Rajdhani / Shatabdi and other Mail/Express
trains in order to get clear understanding of requirements for optimum design of the
complete system.
1.4.4 Offers from only those tenderers who have sufficient experience in manufacture
and integration of IGBT based traction control system for 4000/4500HP 3-phase AC-AC
diesel electric locomotives shall be accepted. The tenderer shall have prior experience of
supplying IGBT based traction system for 4000HP and above Diesel Electric
Locomotives.
1.4.5 Tenderers shall submit the evidence of successful track record of manufacture &
integration of IGBT based traction invertors along with their offer. The tenderer shall also
submit a detailed indigenization plan with the offer.
1.4.6 It may be noted that complete details regarding functioning of EM2000, TCC and
their interaction / communication protocol are not available with RDSO/DLW and
therefore only limited information, to the extent available with RDSO/DLW, can be shared
with the successful tenderer. It may also be noted that such information, at any detailed
level including communication protocol between EM2000 and TCC controls, is not a part
of TOT agreement between M/s General Motors and Indian Railways and therefore is not
available with RDSO/DLW.
1.4.7 Some proprietary information of the TOT (between M/s General Motors and Indian
Railways) of WDG4/WDP4 technology cannot be passed on to / shared with the
international competitors of M/s General Motors. Therefore, in order to design a
technically optimum alternative to existing inverter and loco control systems fully
compatible with each other, tenderers are required to have sufficient expertise and
experience in the design of traction control systems.
1.4.8 Change in performance and functionality, if any with the proposed system, shall be
brought out clearly in the offer. However, complete system shall be designed to improve
the performance and functionality.
2.0 DESCRIPTION OF THE EXISTING SYSTEM
2.1 The existing 4000hp locomotive control computer EM-2000 controls overall
locomotive operation. Traction converters are controlled by traction control computer &
braking system is controlled by CCB with interface from EM-2000. The traction control
computers also provide failure detection and protection for inverters and also provide
EM2000 with fault information to be displayed and archived in the memory for further
analysis.
2.2 EM2000 is a 32-bit computer based on Motorola 68020 microprocessor running at 16

MHz with a math coprocessor and communication through RS-232 serial cable/port. The
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traction control computer receives data from EM2000 via RS-485 serial link. The bi-
directional bus carries data such as how much power for traction the inverter shall
develop as well as other information to control activation of devices like blowers and
heaters. In addition to the data via RS-485 link, traction control computers continuously
provide feedback information to monitor various parameters such as status of relays and
temperature of various components, voltages and currents. Based on this feedback data
and information received via RS-485 serial link, the programs stored in the traction
control computers work, to drive the inverter as well as to protect it in the event of faulty
operating conditions.
2.3 Diesel engine drives the traction alternator. Three phase output of the traction
alternator type TA17-CA6 is rectified and fed to two inverters through DC link. Each
inverter supplies three phase controlled output to traction motors mounted on a bogie.
Motors are four pole three-phase squirrel cage induction motors. Inverters are voltage
source PWM type employing GTO/IGBT as basic switching device. Two traction control
computers are used, one for each inverter, to directly control the firing of GTO/IGBT and
thereby controlling the voltage and frequency output from inverters as per the traction
requirement indicated by EM2000 locomotive control system. EM2000 controls overall
locomotive operation. Traction converters are controlled by traction control computer and
braking system by CCB with interface from EM2000. The traction control computers also
provide failure detection and protection for inverters and also provide EM2000 with fault
information to be displayed and archived in the memory for further analysis.
2.4 General arrangement diagrams showing side and top views of the WDG4D and
WDP4D locomotives are attached at annexure-A and annexure-B respectively.
2.5 The characteristic curves for 4500HP loco application are attached at annexure nos.
C & D (for WDP4D loco) and annexure nos. G & H (for WDG4D loco).
2.6 The locomotive is equipped with KNORR/NYAB CCB 1.5 (computer controlled
braking) system. This is an electro-pneumatic microprocessor based system with 30A
CDW type desktop controls.
2.7 End On Generation (EOG) and Self-Generating (SG) type hotel load supply systems
are used on Indian Railways at present. On Rajdhani/Shatabdi trains, hotel load is met
through EOG power cars wherein two power cars are provided one at either end of the
rake. Each power car is a Diesel-Alternator set with associated power contactors and
control / protection circuits. On other Mail/Express trains, the coaches are SG type and
hotel load requirement of these coaches is met through axle-mounted alternator-rectifier-
inverter system. In EOG system, hotel load power from power car to coaches is fed
through two feeders running parallel along the rake (at 750 V, 3-phase, 50 Hz).
2.8 Inter Vehicular (IV) couplers are used to connect the feeders between adjacent
coaches. Each coach has step down transformer which converts the 750 V feeder supply
to 415 V output to be fed to the air conditioning equipment in the coach. Automatic
interlocking and feeder selection system is used such that at a time only one power car
can supply hotel load power to either feeder or both the feeders. Through proper
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interlocking between the power cars, simultaneous hotel load supply from both the power
cars to a feeder is prevented. Inter vehicular couplers on Locomotive shall be in tenderer
scope of supply. Tenderer shall provide adequate details on the type selected together
with a data sheet. Proven, reputed make of inter vehicular coupler is to be offered.
Interlocking and associated circuitry on the Locomotive shall also be in tenderer scope of
supply.
2.9 The complete electrics of the locomotive is housed in three different cabinets named
as ECC #1, ECC #2 & ECC #3. The ECC #1, ECC #2 & ECC #3 shall be as per relevant
DLW/RDSO specification. The various switches, contactors, circuit breakers, indicators,
transducers and sensors presently being used are categorized in the following three
categories:
1 a. Items only from OEM.

2 b. Items from authorised Indian sources of OEM.
3 c. Items from indigenous sources.
3.0 GOVERNING SPECIFICATIONS
This specification is based on the following references :
1. IEC-61287 : Electronic Power Converter mounted on board rolling stock.

2.IEC-60571 : Specific rules concerning the electronic control part of converters.
3. IEC - 34.1 : Auxiliary Electrical machines. (CENELEC) (Part 3-2, Rolling
Stock – Apparatus)
4. EN : 50121-2: Railway Applications – Electromagnetic Compatibility
(CENELEC) (Part 2, Emission of the whole railway system to the
outside world)
5. IEC-61375-1 :Electric Railway Equipment - Train bus – Part 1 : Train
Communication Network
4.0 DEFINITIONS
4.0.1 ‘RDSO’ means Research Designs and Standards Organization, Ministry of

Railways, Manak Nagar, Lucknow-226 011.
4.0.2 ‘DLW’ means Diesel Locomotive Works, Varanasi-221 004.
4.0.3 ‘BG’ means 1676 mm gauge, referred to as Broad Gauge.
4.0.4 ‘IEC’ means International Electro-technical Commission.
4.0.5 ‘IS’ means Indian Standard.
4.0.6 ‘AAR’ means Association of American Rail-roads.
4.0.7 ‘UIC’ means Union International Des Chemins defer (International Union of
Railways)
4.0.8 ‘IRS’ means Indian Railway Standard.
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4.0.9 ‘IR’ means Indian Railways.
4.0.10 Throughout this specification the words:
.1 Horse Power (HP) shall be taken as metric horse Power, i.e. 75 kg metre/sec.
.2 Tonnes (T) shall be taken as metric ton i.e. 1000 kg.
5.0 SCOPE OF SUPPLY
Following equipment are within the scope of supply of the tenderer. It is being attempted
to have a common platform on the locomotive for fitment of various makes of
equipments. In case any particular make requires fitment of equipment over and above
the scope defined in this specification, the same shall be supplied by the tenderer
(including cables, pipes, ducting etc) and the cost shall be borne by the tenderer and not
DLW.
5.1 Electrical Control Cabinet ECC #1 consisting of Locomotive Control Computer (LCC)
system (hardware and software) along with all control, protection and indication
equipment like sensors, relays, breakers, indicators etc., along with other sub-systems
required for proper functioning of the locomotive. The location of the DC link terminals at
ECC#1 shall be as per the sketch placed at annexure - N. Functional equivalents of all
the existing components in this cabinet are within the scope of supply. The LCC may be
located at an alternate location also. In this case, the tenderer shall have to supply any
uncommon item arising out of this alternate location. All communication cables between
LCC and TCC / ECC#1 are in the scope of supply of tenderer.
5.2 ECC#1, ECC#2, ECC#3 shall be as per relevant DLW/RDSO specification. DLW
specification nos. are as follows-
(i) ECC #1 as per DLW specification no WDG4/EL/PS/17(Latest version).
(ii) ECC #2 as per DLW specification no WDG4/EL/PS/20(Latest version).
(iii) ECC # 3 as per DLW specification no WDG4/EL/PS/21(Latest version).
Electrical Control Cabinets ECC #2 and ECC #3 consisting of all the additional protection
and indication equipment, sensors, relays etc., along with other sub-systems required for
proper functioning of the locomotive. ECC#1, ECC#2, ECC#3 shall be as per relevant
DLW/RDSO specification. Functional equivalents of all the existing components in these
two cabinets are within the scope of supply. The system shall be designed in such a way
so as to eliminate the requirement of copper reactor that has been fitted in the ECC#2 of
these locomotives up till now. In case the tenderer is not meeting this requirement, then
all related equipments including the extra cables required shall be in the scope of supply
of tenderer and not in the scope of DLW. Cost implications of such equipment shall be
borne by the tenderer.
5.3 Two traction control cabinets TCC#1 and TCC#2 (or TCC#1 and TCC#2 housed
together in one cabinet); each TCC shall house IGBT based inverters for traction motor
control. The traction control computer(s) can be housed in this cabinet or can be
separately located in ECC1. The inverter configuration can be either for single motor
control or for bogie control. In this case, the tenderer shall have to supply any uncommon
Page 8 of 92
item arising out of this alternate location. In case of motor control, each motor shall be
controlled by separate inverter and there will be a total of 6 inverters. In case of bogie
control 3 traction motors of a bogie will be controlled by a single inverter and there shall
be a total of 2 inverters. The location of the DC link terminals and traction motor terminals
shall be as per the sketch placed at Annexure - N. Separate cables for each traction
motor shall be used from TCC to traction motors. All cooling requirements of the TCC
shall be met by inbuilt blower within the envelope of TCC, any additional cooling
requirement (including blower, motor and ducting) shall be in the scope of supply of
tenderer and not in the scope of DLW. Cost implication for such equipments shall be
borne by the tenderer.
5.4 Crow bar Resistor and Damper Resistor: Crow bar Resistor and Damper resistor or
any other protection device required for proper functioning of IGBT TCC as per DLW
specification No. WDG4/EL/PS/28 mentioned at annexure - L.
5.5 Speed & Temperature Sensors shall be supplied along with TCC as a set i.e. 6
sensors for each TCC ordered. The sensors shall be compatible with the traction motors
being used on the locomotive. The details of the traction motor are furnished in para 9.0
of the specification.
5.6 A TFT LCD display for driver’s cab called DIALS (Digital Into Analogue LCD - based
System) shall be provided as per RDSO specification no. MP.0.0400.10 (Latest version).
Two DIALS shall be located on the operators control console and one DIALS unit on the
assistant’s desk. (total of 3 display units per cab, 6 per locomotive).
5.7 Industrial type electronic notebook complete with communication data analysis
software and configuration software for giving to the nominated shed. Notebook shall be
industrial type (Panasonic tough book CF-53 or equivalent) so that it is sufficiently robust
for handling on the locomotive and maintenance shed. The quantity of notebook shall be
calculated as 0.05 per set of AC-AC system supplied.
5.8 Three years AMC of IGBT based TCC and LCC (beyond warranty period), as per
terms and conditions placed at annexure - M. The firm shall quote its offer for AMC as
per tender SOR/Spec.
5.9 Documentation & Information required: covered under clause 10.
5.10 In the present design, the locomotive is having 3 Electrical Control cabinets i.e.,
ECC#1, #2 and #3. While ECC#1 is installed in the drivers cab, the ECC#2 is under
slung from the locomotive under frame and ECC#3 is located near radiator compartment.
It is preferable that the manufacturers shall eliminate the ECC#2 from their design while
quoting against this specification and suggest alternative locations for the equipments
currently contained in ECC#2.
5.11 ECC#4 – cab 2 shall have a miniature electronic control panel named as ECC#4.
More details are given in clause no. 7.1.1.2.
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5.12: Cable harnesses between TCC and ECC1 shall be as per DLW specification no
WDG4/EL/PS/25 Rev-02 mentioned at annexure-P.
5.13 Control cable harness from ECC4 to ECC1 or any other location as required by
system manufacturer shall be in the scope of supply of successful tenderer.
5.14 To make ease of stocking, control of inventory and ease of withdrawal from store for
production, a comprehensive packing list for items covered under scope of supply for
AC-AC traction system for dual cab should be provided and it should be in the format as
shown in annexure-Q.
5.15 OPTIONAL FEATURES:
Following are the optional features in the scope of supply:
5.15.1 Distributed Power Control

5.15.2 Auto Creep Control
5.15.3 Hotel Load
5.15.4 Remote Monitoring Of Locomotive (REMMLOT)
5.15.5 End Of Train Telemetry (EOTT)
For more details on optional features, clause no. 7.3 (Optional Features) of this
specification may be referred.
The Tenderer shall supply above items to DLW and fitment of these equipment along
with testing and commissioning of the complete locomotive will be done at DLW under
the supervision of successful tenderer. Tenderer shall arrange for special instruments,
tools etc. required for installation and commissioning of the locomotive which are not
available at DLW.
6.0 ENVIRONMENTAL CONDITIONS
6.1 The complete microprocessor based loco controls and inverter systems shall be
required to work continuously at full load under following atmospheric conditions :
Maximum temperature (i) 55 ºC (under sun).

(Atmospheric)
(ii) 47 ºC (in shade)
(Temperature inside locomotive may reach 60

ºC.)
Minimum temperature -20 ºC.
(Atmospheric)
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Humidity 90 % (Up to 100% during rainy season as per
IEC 60721-3-5.
Altitude Max. 1200 meter above mean sea level
Refernce site conditions (i) Ambient temp. 47 ºC
(ii) Temp. inside engine compartment 55 ºC

(iii) Altitude 160 m.
Annual rainfall Between 1750 mm to 6250 mm. The locomotive

shall ve designed to permit it’s running at 5 Km/h
in a flood water level of 10.2 cm above the rail
level.
Dust Extremely dusty and desert terrain in certain
areas. The dust content in air may reach as high
a value as 1.6 mg / m³.
Atmospheric conditions in coastal All the equipment shall be designed to work in
areas in humidity salt laden and coastal areas in humidity salt laden and
corrosive atmosphere corrosive atmosphere.
(a) Maximum PH value : 8.5

(b) Sulphate : 7 mg / liter.
(c) Max. concentration of chlorine : 6 mg / liter
(d) Maximum conductivity : 130 micro siemens /
CM.
6.2 Complete system shall be suitable for rugged service normally experienced for rolling
stock where locomotives are expected to run up to a maximum speed of 130 km/h in
varying climatic conditions existing throughout India.. Complete loco control and inverter
systems with their controls and gate drive electronics shall be protected from dusty
environment by providing well sealed enclosures. Necessary precaution shall be taken
against high degree of electromagnetic pollution anticipated in the locomotive. The
cooling system shall be designed to take care of tilting and centrifugal forces which shall
normally be encountered in service.
6.3 The equipment and their mounting arrangements shall satisfactorily withstand the
vibrations and shocks normally encountered in service as indicated below:
a) Max. Vertical acceleration - 1.5 g

b) Max. Longitudinal acceleration - 2.5 g
c) Max. Transverse acceleration - 1 g
(‘g’ being acceleration due to gravity)
All the equipment and their mounting arrangement shall be designed to withstand
Page 11 of 92
vibrations and shocks as specified in IEC-61287 and IEC-60571 for the inverters and
electronic equipment respectively
7.0 MAIN FEATURES OF THE PROPOSED SYSTEM
The AC Traction system shall consist of Locomotive Control Computer, IGBT based
Traction Inverters, various sensors for Current, Voltage, Temperature, Pressure, Speed
and other allied equipment like relays, breakers, indicators, etc for WDG4D/ WDP4D
locomotives. For WDP4D locomotives, in addition to these, additional IGBT converter will
be required for hotel load requirement (optional)
7.1 DUAL CAB FEATURE:
The proposed twin cab WDG4D locomotive shall have six traction motors with 21.7 tonne
axle load and speed potential of 100 km/h.
The proposed twin cab WDP4D locomotive shall have six traction motors with 20.5 tonne
axle load and speed potential of 105 km/h on mail line & 130 km/h on Rajdhani standard
track.
Existing designs of WDG4 / WDP4 locomotives shall be suitably modified for Dual Cab
Operation. The general arrangement and equipment layout of the WDG4D locomotive
shall be to RDSO drawing no. SKDL- 4762 Alt- nil and that of WDP4D locomotive shall
be to RDSO drawing no. SKDL- 4686 Alt- nil.
Dual CAB Locomotive WDG4D & WDP4D Control Philosophy
Dual locomotive control is based on BL Key concept of Electric Locomotives. Each CAB
will have a BL Key. Existing CAB (SH side) is named as CAB#1 and new CAB (LH side)
is named as CAB#2. Outline details of the BL key switch with handle is placed at
annexure-R.
7.1.1 Changed Assemblies of Dual Cab
7.1.1.1 Following changes shall be done in ECC #1 for dual cab purpose:
1. BL KEY: In each CAB provision shall be given to insert BL Key. If BL key is ON in

any one CAB, that is treated as active CAB. If BL key is inserted in both the CABs
or BL key is not inserted in both the CABs then system will be isolated and
corresponding CREW Message will be given. In ECC1, the BL key and RAPB
switches shall be mounted near Loco Start Switch.
2. Three units of TFT displays (two units for Driver and one unit for Asst Driver -
Total 6 Displays per Loco) shall be provided in each control stand in place of
existing VFD display. The details to be displayed on each screen shall be as per
RDSO specification no. MP.0.0400.10 (Latest version).
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3. The headlight shall be operated from ECC#1 for cab1 and ECC#4 in cab2.
7.1.1.2 Electrical control cabinet #4: CAB#2 shall have a miniature electric control
panel named as ECC#4. Drawings showing mounting holes of ECC#4 and location of
ECC#4 in the cooling hood assembly are attached at annexure-S and annexure-T
respectively. The ECC#4 shall have following controls:
1. Isolation Switch: It shall be provided in both the Cabs. In any CAB if the switch
is kept in Isolate position then Brake contactors will get energised. So in
inactive CAB it shall be kept in RUN position. If any switch is kept in Isolate
position then MCC gets Isolate digital input, If both the switches are kept in
RUN position then only MCC gets RUN digital input.
Note: From any cab system can be isolated
2. Emergency Fuel Cut Off/ Engine Stop Switch (EFCO Switch): It shall be
provided in both the CABs in series and shall be of non-locking type (without
locking arrangement). If any switch is pressed MCC will get NOEFCO
(EMERGENCY FUEL CUTOFF ACTIVATED) digital input.
Note. From any CAB engine can be made shutdown.
3. Classification Light Switch: It shall be provided in both the CABs. In any CAB,
if the switch is kept in CE position then CE (Cab End) side White light, HE
(Hood End, i.e. other cab) side Red light becomes ON. In any CAB if the
switch is kept in HE position then HE side White light, CE side Red light
becomes ON.
4. Memory Freeze Switch: It shall be provided in both the CABs in parallel. In

any CAB, if it is ON then MCC will get Memory Freeze digital input. Suitable
type of switch shall be provided for memory freeze operation which is used for
freezing the event recorder data as and when required specially in accident
case. Normally this switch is sealed. A similar switch already exists in the
event recorder of WDG4/WDP4 locomotives provided by different vendors.
5. Alerter Alarm: It shall be provided in both the CABs. Whenever MCC makes
Alerter Alarm digital output ON, in both cabs alarm will sound.
6. TELM Switch: It shall be provided in both the CABs in parallel through BL key
interlock. It can be activated from any active CAB.
7. RAPB (Restricted Air Penalty Brake) Switch: This is similar to AEB (Automatic
Emergency Brake) which already exists in WDG4/WDP4 locomotives and
fitted in ECC#1, supplied by different vendors including EMD. It shall be
provided in both the CABs in parallel through BL key interlock. It can be
activated from the active CAB. Drawing of the RAPB switch is placed at
annexure-U.
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8. Fuel Prime/Engine Start Switch: It shall be provided in both the CABs in
parallel. If any switch is kept in prime position MCC will get PRIME digital input
if any switch is kept in START position MCC will get START, PRIME digital
inputs.
Note: From any CAB Engine can be started.
9. BL Key: Same as ECC#1.
10. Computer Control Circuit Breaker (CB): This Circuit Breaker shall be provided
in both the cabs. These two are connected in series. If both the switches are
closed then only LCC gets supply.
Note: It shall be provided in both the cabs to recycle AC/AC Traction System
from any CAB.
11. Micro Air Brake Circuit Breaker (MAB CB): It shall be provided in both the
CABs in series. If both are closed then only CCB system will gets power
supply. MCC monitors these circuit breakers status through MABCB1,
MABCB2 digital inputs. If MAB CB2 is open and MAB CB1 is closed then MCC
does not get MAB CB1 digital inputs.
12. CAB Fans and Lights Circuit Breaker (for CAB#2 Fans and Lights): It shall be
provided in both the CABs. In CAB1 it provides supply to CAB fans only, in
CAB2 it provides supply to both Cab Fans & Cab Lights. If the CAB fan CB is
ON in CAB2 then Left & Right CAB fans and CAB lights gets supply
(corresponding switch shall be ON).
Note: Here in CAB 2, CAB Light CB is not available. CAB Fans CB itself gives
supply to CAB Lights.
13. Generator Field CB: It shall be provided in both the CABs in parallel (Parallel
connection as it is found that this CB sometimes trips On line). In active CAB,
CB shall be closed and in inactive CAB this CB shall be open. At a time if both
are made ON, the excitation will be cut off and Locomotive will be in “No Load”
condition with appropriate message. Only one shall be made ON.
14. GRNTCO SW: This switch shall be provided in both the cabs. If both the
switches are closed then only system gets the digital input and treats GR
protection scheme is enabled.
15. Indicative drawing for OGA of ECC#4 (DLW drg. No. 18002389 (Alt-a)) is
placed at annexure-O. The successful tenderer shall adhere to this drawing
and submit the drawing of the proposed ECC#4 for approval to RDSO/DLW
7.1.1.3 Control Stand for CAB1&2: Control stand of Dual cabs shall have following
features:
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1. Alerter Light: It shall be provided in both the CABs. Whenever MCC makes ON
both lights will become ON.
2. Head Lights Switches: In dual CAB loco, in each CAB we have only two rotary
switches to select CAB end / hood end headlights.
Note: (i) Head Lights CB shall be provided only in CAB1 it shall be ON.
(ii) Head Light related “dim resistor” shall be shifted from ECC#1 to
corresponding CAB.
3. GF request Switches: It shall be provided in both the CAB. If corresponding BL

key is inserted, throttle is kept in any notch, GF request switch is closed then
MCC will gets this digital input.(Through BL Key)
4. Engine Run Switch: It shall be provided in both the CABs in parallel. In any
CAB if it is closed then MCC will get TL16 input.
5. Dyn.BRK CB: It shall be provided in both the CABs in parallel. In any CAB if it
is closed then MCC will get TL24 analog input.
6. C&FP Switch: It shall be provided in both the CABs. If this switch is ON and
corresponding BL key is inserted then only Reverser, throttle, sand switch will
gets supply in that CAB. This is already exist in WDG4/WDP4 locomotives and
fitted on control console 2, when C&FP switch is on it provides power to low
voltage control circuit and it enables the loco computer to pickup Fuel Pump
Control Relay FPR and it enables Diesel Engine starting.
7. Flasher Switches: In each CAB, two switches shall be provided (total 4).If any
switch is ON flasher will come.
8. Alerter RST Switches: It shall be provided in both the CABs in parallel through
BL key. In any CAB if it is pressed and corresponding BL key is inserted then
MCC will get Alerter reset digital i/p.
Note: BL key interlock shall be provided for alerter reset digital i/p, to not to
reset the alerter cycle when alerter reset is pressed from inactive CAB.
9. MU Engine Stop: It shall be provided in both the CABs in parallel through BL

key. In any CAB if it is pressed and corresponding BL key is inserted then
SDR relay gets supply, MCC will get corresponding train lines TL3 i/p ON and
TL7,TL12,TL15 i/ps OFF.
10. Attendant Call Push Button: It shall be provided in both the CABs in parallel. In
any CAB if it is pressed then local alarm gong will come and MCC will get TL2
i/p.
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11. Manual Sand: It shall be provided in both the CABs in parallel. In any CAB if it
is pressed and corresponding CPSW is ON and BL key is inserted then MCC
will get TL64 i/p.
12. AEB Reset: It shall be provided in both the CABs in parallel through BL
interlock. In any CAB if it is pressed then MCC will get AEB reset digital i/p.
13. Horn switches: In each CAB 4 switches shall be provided. If any switch is
pressed and corresponding horn will sound. Only for if BL key is inserted then
MCC will get Horn Digital input (VCD reset).
14. TFT Displays: 3 sets of displays (2 for driver & another for assistant driver)
shall be provided in each CAB. Only the Active CAB (BL Key inserted) shall
display system related settings (Test modes, Crew reset, Fault Reset, trip data
settings driver settings etc).
Note: The LCC shall provide all parameter values as required to be displayed on the
DIALS displays on the locomotive control desks. (DIALS specification may be referred for
details).
Control console shall be procured separately by DLW as per relevant DLW drawings.
Supplier shall follow the DLW drawings of the control consoles for cab#1 and cab#2 for
the outer dimensions and design the control stand structure within the envelope as per
the drawing maintaining the overall layout of the control stand as defined.
Some Points to explain working of the system with Dual CAB:
7.1.1.4 For Control Console in CAB#2, all train Line wires shall be terminated through
Terminal Board or suitable connectors. Other wires shall be connected to ECC#1 through
Terminal Board or suitable connectors.
7.1.1.5 In the Control Console; Master Control and Switches shall be active only after
insertion of BL key.
7.1.1.6 Computer Control CB of CAB#1 and CAB#2 shall be connected in series.
7.1.1.7 Locomotive working, both shall be made ON. This is required to avoid
application of Penalty Brake by CCB as BL Key shall be removed while changing from
CAB#1 to CAB#2 and vice versa. Recycling required by Driver can be done from any
CAB.
7.1.1.8 Micro Air Brake CB CAB#1 and CAB#2 shall be connected in series. For
Locomotive operation, both shall be made ON. This is to be done to avoid application of
Penalty Brake by CCB as BL Key shall be removed while changing from CAB#1 to
CAB#2 and vice versa. Recycling required by Driver can be done from any CAB.
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7.1.1.9 Battery Ammeter shall not duplicated in CAB#2 as this information is available on
TFT LCD display.
7.1.1.10 CAB#2 shall have combined Fans and Lights CB.
7.1.1.11 Head Lights CB shall be provided in CAB#1 only. However Head Light
Switches shall be available on both Control Consoles for both CAB#1 and
CAB#2 end Head Lights.
7.1.1.12 Alerter Reset Push button, RAPB, and TELM Switches shall be interlocked
through BL Key of respective CAB. This will ensure that they are not activated from
inactive CAB.
7.1.1.13 MU Eng. Stop shall be active from both CABs simultaneously. Any Switch
can be used to shut down the Engine.
7.2 LOCOMOTIVE CONTROL COMPUTER (LCC)
The offer shall include an LCC, which shall be totally compatible in respect of hardware
and software for achieving the 4500 GHP requirements set out in this specification. The
tenderers can either offer the current 4500 hp LCC in use on IR, viz.., the EM 2000 family
LCC or an LCC of his own design. In case the former is offered, the tenderer shall
establish that they have entered into an agreement with M/s EMD/USA for sourcing and
integration of the EM 2000 family LCC with the TCC offered by the tenderer.
Alternatively, if the offer is for their own LCC, the said LCC shall be of such a design that
it can be fitted in the ECC1 without any major mechanical modification.
7.2.1 LCC HARDWARE REQUIREMENTS
The Locomotive Control Computer (LCC) shall consist of following types of modules:
7.2.1.1 Digital Input Interface
All the locomotive digital signals of Switches, Relay Contact Feedbacks, Contactor
Feedback contacts, etc shall be electrically isolated before being given to the Locomotive
Control Computer through a Digital Input Interface. All such Digital Inputs interfaces shall
be provided with reverse polarity and surge protection to prevent damage to the LCC
circuits against inadvertent wrong connection. LEDs indications shall be provided for
On/Off Status of these inputs on the facia of the module, for ease of maintenance/
troubleshooting. These LED indications shall be made visible without opening the cover
of the LCC unit. If indication of ON/OFF status of individual digital inputs is not provided,
the status of the channels shall be visible on the display screen without opening the LCC
cover.
7.2.1.2 Digital Output Interface
All driving signals for the Relays, Contactors, Lamps, etc shall preferably be driven
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through a MOSFET based circuit of adequate rating. These outputs shall be electrically
isolated from LCC circuits and shall be provided with protection against short circuit and
reverse polarity. LEDs indications shall be provided for On/Off Status of these outputs on
the facia of the module, for ease of maintenance/troubleshooting. These LED indications
shall be made visible without opening the cover of the LCC unit. If indication of ON/OFF
status of individual digital outputs is not provided, the status of the channels may be
shown on the display screen without opening the LCC cover
Note: Alternatively, combined DIO cards for digital input and digital output signals may
also be provided as fitted in existing ECC circuits of M/s EMD, in place of separate digital
input / output cards as described in para 7.1.1.1 and 7.1.1.2 above.
7.2.1.3 Analog Input Interface
All the Analog Signals that are received from the various Sensors e.g. Voltage, Current,
Temperature, Pressure etc, shall be conditioned and electrically isolated with Isolation
Amplifiers before being used by LCC.
7.2.1.4 Analog Output Interface
The LCC shall drive the Load Ammeter and Speedometer mounted on the Driver’s
control Desk. These outputs shall be electrically isolated from CPU and shall have short
circuit protection.
7.2.1.5 Speed Sensor Interface
All RPM signals to LCC shall be electrically isolated and converted to signal levels
required by the LCC. The inputs shall be surge protected.
7.2.1.6 Communication Interface
In view of the electrically noisy environment inside the locomotive, it is preferable that an
optical fiber based communication system be provided between LCC and TCCs.
Preferably dual redundant optical fiber communication link with adequate redundancy
shall be provided to improve the reliability of the system. Communication interface shall
also communicate with the Computer of Knorr Air Brake System (CCB) and Display Unit.
7.2.1.7 Gate Drive Interface
The Companion Alternator output shall be controlled to give the desired Field current to
Main Alternator Field Circuit. The Drive Interface shall interface the driving signal of CPU
with the firing modules of SCRs.
7.2.1.8 Power Supply
These shall provide electrically isolated power supplies for functioning of the various
circuits of the LCC. This shall be designed to accept wide variation in input voltage
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supply and shall continue to function even during the Engine Cranking when the power
supply is expected to dip to a very low voltage for a short time. The Power Supply Input
shall be protected against Reverse Polarity and Surge. The EMI/EMC filtering shall be
provided at the inputs to prevent noise from power supply switching going back to
source.
7.2.1.9 CPU
This is the heart of the system. It shall consist of a 32 bit micro controller running at
minimum 25MHz, along with its programmed software, various peripheral and interface
circuits e.g. Real Time Clock, Non Volatile Memory, etc. All other circuits that are meant
for processing either input or output signals shall be controlled through commands from
this card. The CPU shall continuously monitor all the inputs and control all the out puts of
the system based on the software program. It is preferable that provision shall be made
to configure the control system through Laptop for using the system with different types
of traction equipments/locomotives, through user programmable parameters, loaded in
Non Volatile Memory of CPU. The details shall be finalised in consultation with
DLW/RDSO.
7.2.1.10 Non Volatile Memory
A memory module (removable type memory module is desirable) shall be provided for
storing the Event Data. This data shall be logged during running of the locomotive. It is
desirable that the removable memory module (if provided) shall be prevented from
unauthorised access by a Lock and Key arrangement. The details of the data to be
stored shall be finalised in consultation with DLW/RDSO.
7.2.1.11 General requirements

• The system design shall be made modular in construction to the extent
possible with provision of visual indications by means of LEDs for easy trouble
shooting by maintenance staff.
• Various cards used in the design shall have polarized connections to prevent
inadvertent insertion into wrong slot and possible damage resulting due to this.
• The system hardware design shall have provision to carry out self diagnostics
at Driver’s Instruction and at Power ON.
• The Electronic components used shall be of Industrial Grade.
• It shall be preferable to have the entire control system hardware so optimized
that, the component count is kept as low as possible, without sacrificing the
overall system performance and reliability.
• Password protection shall be provided for configurable parameters.
• Voltage, Current, Temperature, Pressure, Speed, etc parameters shall be
monitored through sensors of adequate rating. The sensors used in the
system shall be provided, wherever necessary, with regulated power supplies.
• Sensors used in the system shall be based on the latest technology prevalent
for the Rolling Stock application in the world.
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7.2.2 LCC FUNCTIONAL REQUIREMENTS
The major functions of the proposed LCC shall be
• Engine starting; in both WDG4D and WDP4D locomotive, cab engine starting
shall be provided and the control system wiring shall be done accordingly in
the electrical control cabinet.
• Engine Control through Governor,
• Propulsion Control,
• Excitation control of Main Alternator,
• Traction Control
• Dynamic Braking Control,
• Wheel Slip Control,
• Control of Auxiliaries,
• On line Fault Diagnostics
• Display of operating status, faults in the traction equipment/electronics.
• Communication with Traction Control computers
• Communication with Knorr CCB Microprocessor
• Other user settable parameters as detailed elsewhere in the specification.
7.2.2.1 ENGINE CONTROL
The LCC shall receive driver’s operating requests through throttle handle and drive the
solenoids in Woodward governor (not in tenderer scope of supply, to adjust the diesel
engine RPM to specified level. LCC shall apply restrictions in case of any faults in
Traction machines. In case of WDP4D loco when Hotel load supply is configured, even
when throttle handle is at Idle also, engine shall be run at sufficient speed to maintain
Hotel load power supply.
7.2.2.2 AUXILIARY GENERATOR CONTROL
The Auxiliary Generator rectified output shall be maintained constant at 74VDC,

irrespective of the variation in engine speed.
7.2.2.3 PROPULSION CONTROL
The LCC functions shall include loco operational control and protection of assemblies &
circuits. Protective actions may include automatic action to isolate defective assembly,
request to driver for manual corrective action, or shutting down or idling engine in
emergency situations. Loco operational control includes sensing of master controller
settings and implementation, including direction, motoring/ braking, level settings, loading
controls of engine etc.
7.2.2.4 TRACTION ALTERNATOR CONTROL
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Traction Alternator field shall be driven by the Companion Alternator output through an
SCR bridge. The LCC shall provide control signals for SCRs controlling the Traction
Alternator field.
7.2.2.5 TRACTION CONTROL
The LCC shall compute engine power capability, kilowatts reference, DC Link voltage
reference, locomotive torque reference, torque reference for individual traction motor (or
traction motors on one bogie) and Traction Alternator field current reference, depending
upon various operational limits of the equipment on the locomotive and operating
requests of the driver through the throttle handle on the control console. At lower speeds
of locomotive, the tractive effort limitation shall decide the operating point on the tractive
effort versus speed curve. At higher speeds, the horse power limitation shall decide the
operating point. Based on this, torque references shall be generated and sent to Traction
Inverters.
7.2.2.6 DYNAMIC BRAKING CONTROL
When the throttle handle is in dynamic braking, the LCC shall measure the BKCP voltage
through an appropriate voltage sensor, compute the braking effort level and send it to the
Traction Computers. The LCC shall energise the BR relays to connect the Dynamic
Braking Grid resistors across the DC Link. The power generated by the Traction Motors
acting as generators shall be dissipated in DB Grids. The LCC shall protect DB Grids
and their cooling blowers against over current, by measuring their currents. In case of
WDP4D locos, the power generated by Traction Motors shall be fed to the Hotel Load
Power Supply through DC Link, to save fuel.
7.2.2.7 WHEEL SLIP CONTROL
To maximize the adhesion performance, creep control philosophy shall be used. Speed
sensors mounted on the Traction Motors provide the speed signals. Wheel diameter
calibration shall be done periodically, whenever loco is under coasting in a specified
band of speed range and dynamic brake/pneumatic brake is not applied. Sand shall be
applied automatically. Conservation of Sand shall be given due importance. During
dynamic braking the controlled creep shall be used for wheel slide control.
7.2.2.8 AUXILIARIES CONTROL
The LCC shall measure the air pressure through an appropriate pressure transducer and
control air compressor loading and unloading. The LCC shall measure Turbo speed and
protect it from over speeding, by reducing the power. The LCC shall control other
auxiliaries like starter motors, fuel pump motors, turbo lube pump motors, TCC blowers,
radiators fan motors etc. LCC shall drive indicators such as Speedometer and Load
meter on both control consoles. LCC shall transmit data to the Event Recorder for
recording, through serial communication. The LCC shall control wheel flange lubricators.
The LCC shall provide vigilance control.
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7.2.2.9 FAULT DIAGNOSTICS
The LCC shall monitor the temperatures, pressures, currents, and voltages of various
traction equipment and identify the faulty equipment. Whenever a fault is identified, the
LCC shall take appropriate action to restrict the operation of the locomotive depending
upon the fault, and to save the other equipment from consequential damage. The system
shall preferably have a built-in feature to ensure that in case of failure of a component,
locomotive operation, if feasible, is either not vitiated at all or downgraded only in such a
manner that the locomotive is enabled to complete the trip safely. A set of data packs
and an appropriate fault message shall be recorded in a non-volatile memory. It shall be
possible to download the faults through a Laptop PC by the maintenance shed staff. An
application software shall be provided for use on Laptop PC. It shall be menu driven and
easy to use by maintenance shed staff without any requirement for much computer
literacy.
7.2.2.10 DISPLAY UNIT
A display unit shall be provided for drivers information display. The display shall be menu
driven. It shall display operational status of loco, fault messages and data packs, running
totals etc. It shall be possible to conduct self tests on various equipment by using a key
pad to be provided on the display unit. It shall be possible to cut out Traction Motors,
through keypad when required. It shall also be possible to conduct self-load test on the
engine and Traction Alternator through the keypad, wherein the Dynamic Braking Grid
Resistors shall be used as load on Alternator.
7.2.2.11 MU OPERATION
The system shall be capable to multiple unit operation in consist of upto four
locomotives.
7.2.2.12 COMMUNICATIONS
The LCC shall provide communication with the Traction Computers, Knorr CCB system
and Display Unit.
7.2.3 INTEGRATION OF SUBASSEMBLIES
Fully assembled Electrical control cabinets ECC #1, ECC #2 and ECC #3 shall be
supplied. The functional equivalents of all the existing components in these three
cabinets like sub assemblies, sensors, relays, contactors, breakers, switches, panels,
etc, shall be properly accommodated in these cabinets. The existing mechanical sizes
and mounting dimensions of these cabinets shall be maintained. Depending upon the
requirement, some of the sub assemblies/ components may be re-arranged or integrated
with others. However it is essential that overall functionality shall be either improved or
maintained same as the existing system. It shall not be degraded in any way due to such
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modifications in design.
For all external temperature/pressure/speed sensors mounted on the engine etc,

compatibility of mounting dimensions shall be maintained.
7.2.4 USER SETTABLE PARAMETERS
For flexibility of operation and future upgrades in the traction equipment, it is desirable to
provide user configurability for various control parameters like currents, voltages, horse
powers, temperatures, pressures, tractive effort on both WDG4D & WDP4D locomotives
and speed (AEB feature) of the traction equipment. It shall be possible to configure these
parameters through a laptop PC. A menu driven easy to use application software shall be
provided for loading on the Laptop PC for this purpose. Password protection shall be
provided to safeguard against misuse.
Details of user settable parameters are listed as below:
(a) Selection /Setting through keyboard on the display unit
• Traction motors /bogie cut in and cut out as and when needed by loco pilot.
• Self load testing.
• Tractive effort limit (settable through keyboard on the display unit or
hardware).
• Self test for the following:
I. Air brake
1 II. DC link shorting
2 III. Excitation / SCR test
3 IV. Wheel slip light test
4 V. Auto test for contactor / Relay
5 VI. Cooling fan test
6 VII. Radar and meter test
7 VIII. TCC blower test
8 IX. Auto test for digital input and digital output
(b) Selectable / Settable through laptop with configurable software
• Loco no.
• Date and time
• Shed Name
• GHP at all notches; to be adjustable in the band of + 5%. GHP at 6th notch
to be adjustable by only; +5% while that at 8th notch to be adjustable by; –
5%.
• Power ground leakage current limits
• Temperature Limits for Radiator Fan on/off and slow and fast speed control;
to be adjustable to upto; –10 °F.
• AEB enable/disable
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• TM derating protocol.
It shall be preferable to design the Loco Control Computer software to enable application
on the following locomotives through menu selection:
• WDG4D locomotive
• WDG4D locomotive with distributed power consist arrangement
• WDP4D locomotive
• WDP4D with hotel load
7.3 OPTIONAL FEATURES
Provision shall be made for the following optional features, which shall be made available
at an extra cost, when the user requests. The tenderer shall quote for these optional
features separately.
7.3.1 CONTROL OF DISTRIBUTED POWER CONSIST
To accommodate distributed power control concept, option to be offered if the tender

calls for a quote for the same.
Load and length of trains in conventional mode with locomotives at the head get limited
by coupler capacity and adequate brake pipe pressure on the last vehicle. For operation
of heavier and longer trains it becomes necessary that additional locomotives be placed
either in the middle or at the end of the train formation. Effective communication between
two locomotive consists placed away from each other in train formation is of paramount
importance for safe operation. In this case all the control and operating signals from the
lead loco shall be transmitted to the distributed trailing locomotives through radio
transceiver, so that all of them are run in synchronization with a single driver control from
the lead loco. Encryption shall be provided for commands sent from the lead loco and
feedback messages from the trail locos for security purpose. The display shall indicate
the status feedbacks received from the trailing units. At any time it shall be possible to
view the status of all trailing locos from the leading loco by the driver. In the trailing locos
Train Lines shall be driven based on the commands received from the leading loco.
Interface shall be provided for Air brake control in the trailing locos, from the commands
from leading loco. It shall be possible to use any loco fitted with this system in leading or
trailing position.
Control of distributed power consist shall be done in accordance with RDSO specification
No. MP.0.400.02 (Rev.-03). Successful tenderer shall prepare the design of distributed
power control based on the above specification and submit the design details for
approval to RDSO /DLW
7.3.2 AUTO CREEP CONTROL
This facility will be required for automatic loading and unloading of coal, iron ore,
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minerals etc. The locomotive shall be made to run at a constant low speed set by driver
irrespective of the load, gradient, curvature of track etc. It shall be possible to set the
desired speed in the range of 0.4 to 30 kmph by the driver. It shall be possible to change
from Auto Creep mode to Normal mode and vice versa by the driver depending upon his
requirement. Equipment shall be suitable for operation of the locomotives in multiple
consist upto four locomotives under auto creep control. Suitable arrangement shall be
provided for switching “ON” and “OFF” operation of the auto creep control, in all the
locomotives in multiple consist, from the leading loco only. The overall functionality shall
be similar to the pace setting equipment supplied by M/s VAPOR, which is in use by IR at
present.
7.3.3 OPERATION AS HOTEL LOAD INVERTER
For the purpose of Hotel load an additional inverter shall be provided, if asked for in the
tender schedule. The additional inverter shall preferably be housed in the existing TCC
cabinet. If housed separately, the envelope dimensions to be indicated with proposed lay
out/ mounting arrangement. The proposed inverter for hotel load shall be accommodated
in the existing over all dimension of the locomotive. All inter-vehicular couplers and
associated electrics shall be within the scope of supply.
The output of the hotel load inverter will be 750 V, 3-phase, 50 Hz, 500KVA supply to
make it fully compatible with the existing hotel load supply arrangement of EOG power
cars. In the proposed system, one of the power cars will be dispensed with.
Hotel load power from the inverter on the loco to various coaches shall be fed through
two feeders (one at left and other at right side of the coaches) running parallel to the rake
at 750 V, 3-phase, 50 Hz supply. Feeders of the adjacent coaches are connected
through standard IV (Inter Vehicular) plug/socket arrangement.
Automatic interlocking and feeder selection system shall be used such that at a time only
one power car can supply hotel load power to either feeder or both the feeders. Thus,
through a feeder, simultaneous hotel load supply from both the power cars is prevented.
Required changes in the speed settings from idle to full speed of engine to get the 500
KVA rated power for hotel load at all notches (even at idle) shall be informed to
RDSO/DLW.
7.3.3(a) The DC link voltage shall be used as input to the hotel load inverter. Major
operating parameters of the hotel load module are listed as below:
Maximum input voltage 3200 VDC

Nominal input voltage 300 VDC to 2600 VDC
DC link voltage ripple Less than 200 V
Output voltage 750 V + 5%, 50 Hz, 3-phase, 4-wire sine
wave
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Maximum rated output power
500 KVA at 0.8 – 1.0 inductive P.F.
Efficiency More than 93% at full load
Total Current Harmonics Maximum 5% up to 20th harmonics
Power factor 0.8 or better (at full load)
7.3.3(b) Hotel load controls shall preferably be designed such that regenerated dynamic
braking power is fed back to hotel load inverter. During dynamic brake, the system shall
be able to use dynamic brake power to the extent possible for hotel load and any short
fall shall be met from traction power. The system shall also be designed such that when
hotel load is not required or partly required, full engine output is diverted for traction
purpose.
7.3.3(c) Additional equipment such as feeder contactors, 4-pole switches, GP relays,

interlocking circuit, hotel load ON/OFF switch, Junction boxes etc shall be required for
proper functioning of the hotel load system and also to make it compatible with the
existing arrangement on EOG trains. These shall be at least similar to or better than the
existing equipment used in Indian Railways.
7.3.3(d) Feeder ON indications for each of the two feeders shall be provided in the
driver’s cab.
7.3.3(e) Following minimum operating controls shall be provided in the driver’s desk:
a) Hotel load supply ON/OFF
b) Hotel load feeder selection
7.3.3(f) The feeder selector switch will have four positions for selecting left feeder, right
feeder, both feeders or OFF condition and will be located at driver’s cab.
7.3.3(g) Following safety devices, in addition to safety devices for hotel load system,
shall be provided:
a) Adequate protection shall be provided against electrical overloads.

b) Train parting condition / PCS operation resulting in power cut off & engine
idling.
7.3.3(h) Interlocking circuit, compatible with the new arrangement, shall also be provided
in the hotel load supply circuit to enable hotel load supply from loco only when hotel load
supply from power car on the same feeder is OFF and vice versa. This circuit shall also
provide safety against train parting/accident by making the hotel load supply OFF.
To ensure proper interlocking and interchangeability of power car and hotel load
locomotive, indicative interlocking scheme for hotel load system is given at annexure–K.
Since these are safety requirements, final interlocking scheme shall be decided in
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consultation with RDSO. Supplier shall submit a copy of the proposed interlocking
scheme to RDSO for approval.
7.3.3(i) One IV socket, one IV plug with dummy socket and two junction boxes will be
provided at each end of the locomotive for hotel load supply to coaches.
7.3.3(j) PROTECTIONS FOR HOTEL LOAD MODULE

a) Line to line short circuit at load
b) Earth fault (input as well as output side)
c) Shoot through fault
d) Heat sink over temperature
e) Gate drive fault
f) High and low DC link voltage
g) DC link short circuit
h) Input and output over current
i) Transient discharge current
j) Reverse polarity
7.3.3(k) INDICATIONS ON LED PANEL
a) Input ON
b) Inverter ON
c) Inverter fault
d) Earth fault
e) Over load
7.3.3(l) INDICATIONS ON DISPLAY PANEL
a) Voltages of all three phases
b) Currents in all three phases
c) Line to line short circuit
d) Earth fault
e) Shoot through fault
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f) Heat sink over temperature
g) Gate drive fault
h) Over load
i) Inverter failure
7.3.3(m) Preferably display for fault diagnosis and trouble shooting for hotel load inverter
shall be common to the fault diagnosis system of traction inverter module. Relevant
parameters of the fault will be stored such that they can be easily read later. Fault
diagnosis system shall preferably have diagnostic software to help in fault analysis and
give tips for trouble shooting indicating area of fault, circuit etc.
7.3.3(n) All the hardware for hotel load interlocking including contactors (except selector
switch) shall be housed at suitable locations.
7.3.4 REMOTE MONITORING OF LOCOMOTIVE
Remote Monitoring and Management of Locomotives and Trains (REMMLOT) system

shall be offered by the tenderer. To have a system of making locomotive health data and
other important parameters along with GPS location information available to shed staff or
any authorised personnel of IR on the internet in real time, it is required to transfer the
data from the microprocessor control system at regular intervals to a central database
using commercially available CDMA or GSM cellular networks. Complete control system
offered shall be compatible with this Remote Monitoring and Management of
Locomotives and Trains system as per RDSO Specification no. MP.0.04.02.04 (Latest
version).
A small antenna shall be provided on the locomotive and the information shall be
transmitted through a commonly used internet protocol to the central monitoring station
through the service providers. This information shall be hosted on an internet web server
by the service providers (ISP).
It shall be possible to view this information through internet connection by concerned

Railway officials and maintenance staff at various sheds. In case of any faults in the
locomotive, the fault data message and data pack shall be transmitted to the central
monitoring station. Automatic generation of alerts depending upon the level of fault shall
be possible, for different levels of Railway Officers through SMS. All the available data on
the LCC like operational data, fault data, running totals etc, shall be transmitted, when
requested. It shall be possible to identify the location of the locomotive using GPS. Fuel
level data shall also be transmitted. Based on the data, it shall be possible to generate
work orders for loco sheds in advance, for maintenance of the locomotive. In case of any
failure of loco online, an expert sitting in the centralised monitoring station shall be able
to guide the driver by an interactive communication through text/voice mails.
The tenderer shall quote for the hardware and software to be provided on locomotive for
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this purpose in his offer. IR will tie up with the service providers for satellite
communication and/or commercial cellular networks like GSM/CDMA and Internet
service providers. The technical data required by these service providers shall be given
by the successful tenderer at the required time. If this feature is opted by IR, the
successful tenderer shall also provide his technical advice in setting up the centralised
monitoring station.
7.3.5 End of Train Telemetry (EOTT) Equipment
This system envisages a standalone EOTT comprising a Communication Display Unit

(CDU) (locomotive unit / front unit) and Sense and Brake Unit (SBU) (rear unit).
The EOTT system shall include the following:
 Front Unit (Locomotive Unit) interfaced with the loco controls (LCC) System with
Antenna for communication with SBU.
 Sensor Brake Unit (SBU) including antenna for communication with Front Unit
 Battery charger with 220V main power supply.
Rear unit: The rear unit shall be capable of determining the brake pipe pressure on the
rear vehicle and transmitting that information to the front unit for display to the locomotive
driver.
Unique code: Each rear unit shall have a unique and permanent identification code that
is transmitted along with the pressure message to the font train unit. A code allotted by
IR shall be deemed to be a unique code for purposes of this Specification.
Front unit: The front unit (Locomotive Unit) shall be integrated with Microprocessor
based Locomotive Control System, so as to share power supply, display unit etc. and
receive pressure sensor information. All data entry requirements of the Front Unit shall
be done through the Microprocessor display unit.
7.3.6 The optional locomotive systems such as Distributed Power System, EOTT and
Remote monitoring of locomotive need to be compatible with various makes of AC/AC
traction systems and interoperable with various makes of the optional systems, which is
essential for rationalization of design, procurement and operation of these systems.
In order to achieve this, the suppliers of the AC/AC system shall give an undertaking to
share the interface architecture & protocol of their system to enable integration with the
third party systems for the above mentioned features as and when the need arises.
Complete responsibility of integration of these optional systems however lies with

suppliers of respective optional system provided that all the interface protocols have
been shared by the AC/AC supplier.
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7.4 TRACTION INVERTER
7.4.1 The traction inverter shall be IGBT based with following configuration:
7.4.2 In the existing WDP4D/WDG4 locomotives, one inverter per three motors
configuration is used. Proposed inverter system may have six inverters and use one
inverter individually for each motor. In this case, three inverters shall be housed in each
TCC. It shall be possible to use the same TCC for either WDG4D or WDP4D loco
through simple configuration change through software by the user. Alternatively, a
configuration of two traction inverters may also be offered. In this case each traction
inverter shall drive 3 traction motors on one bogie as provided in existing GM
locomotives.
Inverter cubicles shall be mechanically and electrically identical for both WDG4D and
WDP4D locomotives. In other words, it shall be possible to use same inverter either on
WDG4D or WDP4D locomotive without any structural changes on the existing
locomotive.
Input supply for all the traction inverters and for hotel load inverter shall be the same DC
link. In case of alternate configuration of IGBT converters for traction and hotel load the
same shall be got approved from RDSO/DLW.
The hotel load configuration is detailed in para 7.3.3.
7.4.3 The basic control philosophy for the induction motor shall be such as to achieve
best suited results for traction application like minimum device losses, high dynamic
response, stable constant speed operation, fast acting slip/slide control etc. Direct
Torque Control, Vector Control, Slip Frequency Control etc. are some of the popular
control strategies used for traction drives. Vector control system is used in the existing
locomotives. The tenderer shall furnish the details of control strategy duly describing its
merits.
7.4.4 The software of the inverter control system shall be fully compatible with the LCC
software including closed loop propulsion control, slip slide control, exchange of
temperature data, fault diagnosis etc. The inverter system shall have its own protection
and control logic, which it shall also be able to communicate with the LCC in the event of
a fatal failure to initiate a protective shutdown of the locomotive. Damage to IGBT
devices of the inverter shall be prevented in case of a short circuit at the load end.
7.4.5 Existing WDP4D/WDG4 locomotives use two traction control cabinets (TCC)
installed in parallel. The dimensions of each cabinet is 1790 mm x 1061 mm x 1527 mm.
The weight of each cabinet is 1420 Kgs. The proposed inverter system may consist of
two cabinets (each housing three inverters in case of axle control) or single cabinet
(housing both the inverters in case of bogie control). Overall envelope dimensions and
total weight of the complete system including traction inverters and hotel load inverter
shall generally conform to the existing overall envelope dimensions and total weight
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respectively. If transformers are required for hotel load application, they may be
considered to be installed outside the TCCs depending upon availability of space. Details
of available space shall be worked out mutually between DLW and successful tenderer.
Redesign and engineering work required at DLW to adapt the carbody interface to
accommodate proposed traction inverter cum hotel load inverter system and loco control
system shall be minimized. Complete details of mechanical and electrical modifications
along with part list and detailed drawing changes required to accommodate the proposed
system shall be submitted to RDSO/DLW, before installation.
7.4.6 The TCC consisting of the inverters with their control systems, transducers and
protection circuits shall be supplied as a complete frame with doors and covers.
However, traction control computer may also be provided as separate circuit module that
can be integrated with proposed microprocessor based loco control system.
7.4.7 Motor cut out facility shall be provided to isolate defective traction motor(s) in case
of any fault. In case axle control philosophy is followed, each defective traction motor can
be isolated individually. In the event of bogie control system and in case of inverter cut
out, inverter control system shall be designed to automatically reduce locomotive power
adequately so that remaining inverters and motors are not overloaded and the
locomotive is able to reach up to destination with reduced power. Locomotive power shall
be reduced in proportion to the number of traction motors cut out at that time.
7.4.8 The proposed traction inverter and loco control computer system shall be designed
to use the traction motor speed sensors and temperature sensors to be supplied along
with the system for the motors of WDP4D/WDG4D locomotives. Temperature sensors
and speed sensors are connected to control cabling by a 5-pin VEAM connector
mounted on the motor frame.
The traction motor speed and temperature sensors shall be compatible with TCC & LCC
and shall also be mechanically compatible with the traction motors i.e. it shall be possible
to fit these sensors in the existing traction motors without any alteration in the traction
motor. The tenderers shall educate themselves regarding the type of traction motors and
fitment provisions. Presently M/s Siemens make traction motors type 1TB2622 0TA02
(MAC version) and 1TB2622 0TB02 (PAC version) are used on these locomotives.
Drawings indicating the mounting dimensions of traction motor speed and temperature
sensors are attached at annexure-V and annexure-W respectively.
7.4.9 In the existing locomotives, a system called IPS (Inverter Protection System) is
used to protect the inverter from over voltage and over current conditions on supply as
well as load side. Current and voltage values are continuously monitored and protection
is achieved by short circuiting the source with a medium crowbar resistor and turning
OFF the main alternator excitation by EM2000 control system in case current or voltage
exceeds a pre-set value. Resistance and inductance values of this IPR (Inverter
Protection Resistor) are 0.18 – 0.23 ohm and 20 – 50 mH respectively. An alternative
proven and reliable protection system may be offered by the tenderers. Since IGBT
based inverters do not have problem of device failing to turn-OFF, a soft crowbar resistor
of suitable value may alternatively be used for each traction inverter to protect the
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inverter from over voltage. However, it is preferable to use the existing IPR mounted
external to the inverter cabinet in the DBR hatch assembly.
7.4.10 The proposed traction inverter system shall be capable of withstanding dielectric
test voltages as per following standards:
(a) Power circuit : As per IEC-61287.

(b) Control circuit : As per IEC-60571.
The inverter system shall be subjected to the above test voltages only once during
prototype/routine testing.
7.4.11 The traction inverter system shall be designed for following protection class:
(a) For phase modules : IP20

(b) For electronic compartments : IP54
7.4.12 The main power semiconductor device used for switching shall be Insulated Gate
Bipolar Transistor (IGBT). The PIV rating of device shall not be less than 4.5 kV. The
IGBT module may contain external or internal protection circuits and gate drive circuits.
The complete system shall be designed as simple as possible with reduced number of
components without compromising reliability and efficiency. The devices offered shall be
field proven. The detailed characteristics of the devices along with details of gate drive
circuits and protection circuits used shall be furnished in the offer.
7.4.13 Suitable temperature sensors shall be provided so that temperature of phase

modules / IGBT modules can be continuously monitored by the control system. In case of
over temperature, traction motor torque shall be gradually reduced to keep phase
modules / IGBT modules at safe operating conditions. Additionally, IGBT modules shall
preferably be provided with a built-in self-protection function to avoid failure on over
temperature, in case of failure of temperature sensor.
7.4.14 COOLING SYSTEM
In the existing 4000 HP GTO locomotives, evaporation bath cooling is used for phase
modules of the traction inverters. Air for the secondary cooling of phase modules of each
inverter and cabinet cooling comes directly from the ambient supply by a forced air
inverter-cooling blower located in the cabinet itself. Therefore two blowers are used, one
in each inverter cabinet. These are dual speed 3-phase AC induction motor blowers with
power supply taken from locomotive’s companion alternator at 24–120 Hz, 40–220 V for
nominal engine speeds. The EM2000 control system of the locomotive exercises control
of the blowers at the request of traction control computers via RS-485 serial link.
In the proposed system, secondary cooling shall be forced air cooling only. It is
preferable that cooling requirement of complete TCC be met by blowers that are located
inside the TCC itself. Power supply for these blowers may be taken from locomotive
companion alternator.
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7.4.15 GENERAL POINTS OF GUIDANCE FOR TRACTION INVERTER DESIGN
(i) Inverter shall be of PWM type with high switching frequency to obtain near
sinusoidal waveform and reduce current harmonics even in the lower speed
region of traction motor.
(ii) The harmonics of the output waveform of inverter shall be controlled to minimise
the traction motor torque pulsations, traction motor heating and also to provide
constant and high adhesion between wheel and rail throughout the operating
speed range of the locomotive.
(iii) The dv/dt on the inverter output shall be minimised to reduce motor winding
stresses and prevent corona breakdown / insulation damage to the windings. It
shall be designed considering motor cable length to reduce over voltage
transients on motors.
(iv) The components and technology used shall ensure very high efficiency of the
inverter system. Typical efficiency of about 98% is preferred. Manufacturer shall
furnish the expected efficiency with respect to locomotive load/speed.
(v) In the design of IGBT based inverter and associated control equipment,
reliability and maintainability shall be of paramount importance. Adequate
margin shall be provided to take into account ambient conditions prevailing in
India. Freedom from dust and protection from surges shall be ensured.
(vi) For semi conductor devices a safety margin of 25% on the ratings for current
and voltage under worst operating conditions shall be provided and established
through calculations.
(vii) Appropriate warning labels and safety provisions shall be made in the inverter
system to prevent direct human contact to any electrical live part.
(viii) Inverter system shall be provided with following features to minimise possibility
of trains being stalled on the section:
(a) In case of axle unit system, one axle can be cut-out in the event of major
faults with the inverter. Similarly in case of bogie control, traction motors
of a bogie may be cut out in the event of an inverter fault. In either case, it
shall be ensured that journey is completed with defective equipment
isolated.
(b) Suitable margin shall be provided in the equipment rating such that under
emergency conditions with isolation of single traction unit such as
inverter, traction motor(s), etc., there is no necessity to reduce trailing
load on level track and the journey can be completed at reduced speeds,
if adhesion conditions are satisfactory. The one-hour ratings of the
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equipment shall not be exceeded under such operations. For this
purpose, short-time ratings of the major equipment shall be furnished by
the manufacturer.
7.4.16 Inverter design shall be modular in construction to facilitate ease of replacement

preferably with the use of interchangeable phase module assemblies. As far as possible,
standard sub systems and modules shall be used. In case of any fault, removal and
replacement of phase modules shall be easy. Complete inverter system shall be
designed such that it requires minimum maintenance. Easy access for all sub-
assemblies / components shall be provided for inspection and maintenance. Tenderer
shall confirm support for obsolescence of all semi conductor devices for a minimum
period of 15 years.
7.4.17 Inverter electronics shall be TCN compatible. All communication interfaces shall
be TCN compatible as per IEC-61375-1. However, if it is not possible to design TCN
compatible inverter control system having proper functional interface with locomotive
control system, then the alternative communication interface offered shall be got
approved. In this case, the tenderer shall submit details of the alternative protocol to
RDSO/DLW for approval.
7.4.18 Features of data logging for monitoring fault conditions. Facility for interfacing PC /
laptop for upload / download of data for fault diagnostics and further analysis shall be
provided. A real time clock unit is to be provided along with the fault logs so that tripping
time can be co-related with the operating conditions of the locomotive. The fault codes
shall be in text format which shall be comprehensible for the operating and maintenance
personnel. Faults shall be stored in permanent memory with a buffer battery. Minimum
fault log size shall be 50 faults with ring buffer. It shall be possible to download the fault
log using a lap top computer and interpret it through a separate common PC application
such as MS EXCEL etc. Important parameters of the equipment at the time of
occurrence of the fault shall be recoverable for fault analysis and shall include the
following:
a) Identification of the fault and its brief description in text and coded form.
b) Identification of components and sub assemblies involved.
c) Time and date of fault occurrence.
The programme download shall preferably be through an online connected PC platform

without the need to remove the memory chips. A FLASH EPROM based program
memory is preferred.
Optionally, a facility for standalone testing may be offered, through which, it shall be
possible to offline test the inverter by inserting a test EPROM or by downloading a test
program in FLASH.
Features to take corrective action in case of certain critical recognizable faults. The
inverter system shall have its own protection and control logic, which it shall also be able
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to communicate with the loco control system in the event of a fatal failure to initiate a
protective shutdown of the locomotive.
The protective shutdown in case of defined fatal conditions shall be based on a

predictable logic preferably implemented in the hardware of inverter electronics. Damage
to IGBT devices of the inverter shall be prevented in case of a short circuit at the load
end.
7.4.19 Proper shielding against electric and magnetic interference shall be provided.
Cable length for gate drive timing signals transmitted from traction control system shall
be kept minimum to minimise losses and prevent loss of data. Actual firing pulses shall
be generated by gate drive units mounted in the phase modules. Proper electrical
isolation for low voltage gate drive signals and high voltage gate drive power supplies
shall be provided. Proper creepage distances between high and low voltage circuits as
well as to the ground shall be maintained.
7.4.20 All cables used in the TCC & ECC shall be E-Beam cables. All control cables of
size up to and including AWG size 3 (25.59 mm²) shall be governed by EDPS-179 and all
power cables of size AWG1 (46.6 mm²) and larger shall be governed by EDPS-304.
7.5 AEB and Blended Brake Operation
7.5.1 Both WDG4D and WDP4D locos shall be provided with Auto Emergency Brake
system (AEB). AEB by default initiates braking in the event of train/loco crossing the
permissible set speed. AEB operation and reset procedure shall be as follows:
Parameters Method of operation
Enable/Disable Through toggle switch/key switch on ECC #1
AEB operating Operating and reset speed shall be user settable through
speed/reset speed software.
AEB reset Automatic (through software), after achieving reset speed. A

speed/procedure manual reset push button shall also be provided on ECC #1
Event after AEB Air Brake & dynamic brake by system. PCS “ON” indication
activation and message on DID.
7.5.2 Both WDG4D and WDP4D locos shall be provided with blended brake feature.
For train braking, dynamic brake effort shall be used to the extent possible to reduce
wear and tear of wheels and rails. Existing CCB shall be retained and its compatibility
with the complete system shall be the responsibility of the tenderer.
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Blended brake operation process shall be as follows:
Parameters Method of operation
Enable/Disable Through toggle switch on ECC #1
Blended Brake indication Indication lamp on ECC #1
* * In case a penalty brake application is imposed on the driver through the VCD, the
same shall be reset as per extant procedure defined for VCD resetting.
7.6 EVENT RECORDER AND VIGILANCE CONTROL
7.6.1 EVENT RECORDER
This shall generally meet the requirement as per RDSO specification No. MP.0.3700-01,
(Latest version). with the ordering specification for GT46MAC speed recorder interface,
Nov’98. Successful tenderer shall prepare the design of event recorder based on the
above specification and submit the design details for approval to RDSO /DLW. The
system shall be able to record the following events in a separate (take out type) memory
unit:
a. Train Brake pipe pressure (kg/cm2)
b. Loco Brake Cylinder pressure (kg/cm2)
c. Status of penalty application (through PCS)
d. Notch position (idle, 1st to 8th)
e. Status of power application (motoring/braking)
f. Direction of movement of loco (FOR/REV)
g. Locomotive speed (Kmph)
h. Status (ON/OFF & Dim/Bright) of headlight
i. Status (ON/OFF) of flasher light
j. TE limit switch ON/OFF
Note: (optional)
.1 The system shall have provision for two additional digital and two analog
signals processing and recording over and above the specified these ten
parameters.
.2 An alphanumeric data entry keyboard is to be provided in the display unit itself
for entering Driver’s code / token number / Driver’s name in 16 digits, Train
number/Name in 8 digits, Section name in 9 digits by the locomotive operator.
7.6.2 MULTI-SETTING VIGILANCE CONTROL
This shall generally meet the requirements as per RDSO specification No.
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MP.0.34.00.04 (Latest version). Successful tenderer shall prepare the design of event
recorder based on the above specification and submit the design details for approval to
RDSO /DLW. Vigilance Control Device (VCD) is provided to enhance the safety of
locomotive operation by ensuring alertness of the crew all the time. The system shall be
of multi - resetting type i.e. acknowledgement of the system is not only by means of
pressing push button but by the other normal driving activities (i.e. throttle handling,
dynamic brake application, operation of horns, sanders or application of brakes), of the
driver during the train operation. This reduces the strain on the driver, as he is not
required to press the push button always when operating other controls of the
locomotive.
a. VCD shall normally require the presence of the driver near the control stand
from which the locomotive is being operated.
b. The electrically operated magnet valve of the device shall be designed to work
on the normally de-energized principle.
c. The device shall be capable of being worked off batteries, and / or auxiliary
generator provided on the locomotive.
d. The device shall ensure that the locomotive is brought to a halt if the driver
were incapacitated at the controls.
7.6.2.1 ACKNOWLEDGEMENTS
Any of the following activities of the driver/crew occurring during vigilance cycle period T0
i.e. 60 seconds will serve as an acknowledgement of the Vigilance Control Device and
the timer will be reset automatically to its initial position.
a. Vigilance cycle reset button pressed

b. Change of throttle handle position
c. Application of dynamic brakes
d. Operation of horns
e. Operations of sanders
f. Application of brakes
The Vigilance cycle reset button shall be located in the control stand in such a position
that it is easily accessible to the driver without leaving his seat. In case of locomotive with
two control stands/cabs, the reset button shall be provided on both control stands/cabs
and connected in series
7.6.2.2 SYSTEM OPERATION
The time sequence of system operations are summarized in the table below:
Operating cycles Time Indications Whether VCD can be

periods in reset or not by push
seconds button /
acknowledgements
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Vigilance cycle (T0) 60 None Yes
Warning cycle (T1) Level I 8+2 Yellow flashing Yes

light
Warning cycle (T2) Level 8 + 2 Yellow flashing Yes
II light and alarm
sounds
Penalty brake (T3) Level I, 34 + 2 Yellow flashing No
Engine idling light remains
but alarm stops
Penalty brake (T4) Level II Until reset None Yes, Only by reset
button
i. Counter shall be provided which shall increase by one unit whenever penalty
brake application takes place. This counter shall be visible to the driver
through display unit so that reading can be noted whenever crew changes
takes place.
ii. If the Vigilance control re-sets button remains in press/release position for
more than 60 sec, the vigilance cycle shall start again.
iii. The device shall ensure that the locomotive comes to halt in case driver is
incapacitated at the control stands.
7.6.2.3 FAIL SAFE FEATURE DURING FAULT IN THE VIGILANCE CONTROL SYSTEM
The system shall be fail safe i.e. penalty brake shall initiate for any fault in the Vigilance
control system and a fault indication given to the driver. The fault cycle period shall be set
at 34 sec, during which the brake application cannot be cancelled. Only after the expiry of
the fault cycle, and the throttle handle has been set to idle position, an attempt can be
made by the driver to reset the fault condition, and resume normal vehicle operation using
the Vigilance Control Reset push button. In case it is not possible to reset the fault
condition, the Vigilance control system shall be isolated.
7.6.2.4 ISOLATION OF VIGILANCE CONTROL (optional)
The vigilance control shall be provided with an arrangement by the tenderer through
which it can be isolated in case it becomes defective/malfunctions. This arrangement shall
be accessible only on breaking of a seal or a glass cover.
7.6.2.5 VIGILANCE SUPPRESSION
a. There shall be a provision to suppress the operation of Vigilance control when

continuous proof of driver’s vigilance is not required. Such suppression shall take
place if Brake cylinder pressure is minimum 2.3 kg/sq cm.
b. Vigilance suppression shall not function during T1, T2 and T3 periods, as well as
during Fault cycles.
C. Vigilance control system during MU Operation
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The Vigilance control system shall be disabled on a slave locomotive in multiple

operations. The vigilance shall also be automatically suppressed whenever both control
stands are set to the OFF position.
7.7 ECC PANELS
Layout and mounting arrangement of ECC #1, ECC #2 and ECC #3 panels shall be such
that it shall be possible to accommodate these in the existing envelopes and as far as
possible mounting arrangement shall also be same as that of existing panels.
These shall be designed and manufactured generally conforming to DLW / RDSO

specifications.
Following points shall be considered for proper design of ECC #1, ECC #2 and ECC #3
panels:
1 a) Ventilation engineering of the each cabinet shall be done based on the

cooling requirement of major components of the cabinet.
1 b) Design of the cabinets shall be modular to facilitate quicker assembly.
1 c) The cabinets shall be pressurised to avoid ingress of dust and other

contaminates inside the cabinets. A pressure of 2 to 3 inches of water gause
shall be maintained in the cabinets.
1 d) No electro pneumatic contactors shall be used.
1 e) Components and cables of common electrical circuits shall be grouped

together to reduce EMC interference.
1 f) Cooling requirements of existing ECC #1, ECC #2 and ECC #3 cabinets

are 200 CFM, 250 CFM and 75 CFM of fine filtered cooling air respectively.
1 g) The cabinets shall be designed to permit its welding with the under frame.
The functional equivalents of all the existing components in these three cabinets like sub
assemblies, sensors, relays, contactors, breakers, switches, panels, etc, shall be
properly accommodated in these cabinets. Depending upon the requirement, some of the
sub assemblies/ components may be re-arranged or integrated with others. Such
modifications shall be clearly brought out in the schematics and approval of DLW/RDSO
shall be taken at design review stage.
It is essential that overall functionality shall be either improved or maintained same as the
existing system. It shall not be degraded in any way due to such modifications in design.
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8.0 PERFORMANCE REQUIREMENTS
8.1.0 TRACTION INVERTER
The proposed traction inverter system shall be designed to operate with following input
/output voltage and current variations under specified site conditions:
Nominal input supply voltage 300 VDC to 2600 VDC (with

ripple less than 100 V).
Maximum continuous input current 1250 ADC per bogie
Maximum input voltage 3200 VDC
Output rms voltage (phase to phase), 3- 0 V to 2030 V

phase AC variable (fundamental wave)
Maximum output rms phase current 900Amps per bogie

Output frequency 0 Hz to 160 Hz
8.2 TRACTIVE EFFORT/ BRAKING EFFORT CHARACTERISTICS
8.2.1 Traction Motor torque vs. speed characteristics (for existing motor) and loco TE &
BE characteristics of WDP4D and WDG4D locomotives are attached with this
specification as listed below:
Traction motor characteristics:
(i) Traction motor torque vs. speed curve (driving operation) - Annexure-E
(ii) Traction motor torque vs. speed curve (braking operation) - Annexure-F
(a) WDP4D LOCOMOTIVES
(i) Loco Tractive Effort vs. speed curve (driving operation) - Annexure-C
(ii) Loco Braking Effort vs. speed curve (braking operation) - Annexure-D
(b) WDG4D LOCOMOTIVES
(iii) Loco tractive Effort vs. speed curve (driving operation) - Annexure-G
(iv) Loco Braking Effort vs. speed curve (braking operation) - Annexure-H
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8.2.2 Tenderer shall try to improve upon the current starting TE values and submit the
proposed TE vs. speed characteristics along with the offer. These will have to be worked
out based on the cooling air available for traction motors and ventilation requirements of
traction motor.
The control system shall have such a provision that, at any time, not-in-use hotel load
power (residual from allocated 500 KVA) shall be used for traction.
Tenderer shall submit Tractive effort versus speed curves without hotel load and tractive
effort versus speed curves with hotel load. The curves shall be drawn for all the notches
8.2.3 The proposed inverters and LCC with existing or equivalent traction motors shall
also be used for generating dynamic braking for the locomotive. Any change in the BE
(Braking Effort) vs. speed characteristics of the locomotive, due to additional hotel load
power, shall be fully explained and justified by the tenderer. Revised BE vs. speed curve
shall be furnished with the offer. The existing DBR (Dynamic Braking Resistance) value
may also undergo a change, which shall be specified. However, outside interface of the
DBR (with other equipment on the locomotive) shall be maintained as existing. The DBR
and blower assembly will be provided by the DLW. The details of the existing DBR
assembly will be provided to the successful tenderer.
8.2.4 Typical data for existing WDG4D/WDP4D locomotives for 4500HP application is
given as below:
 Starting tractive effort shall not be less than 400KN for WDP4D and 540KN for
WDG4D.
8.2.5 The traction inverter system shall use the existing traction motors and retain the
existing gear and pinion ratio. The gear and pinion ratio for WDP4D locomotives is 77:17
and for WDG4D locomotives it is 90:17. The vehicle gauge is 1676 mm broad gauge and
axle load permissible is 21.7 tonnes +2% -4% (for WDG4D) and 20.5 tonnes +2% -4%
(for WDP4D). The curves given above shall be applicable for the half worn wheel
diameter of 1054 mm +0.5 mm and shall be ensured.
8.2.6 In the existing system under normal operating conditions there is no reduction in
tractive effort and not any continuous speed limitation exists. However, temperature
sensors in the traction equipment are continuously monitored and inverter control system
reduces the tractive effort suitably to protect the equipment from overheating during any
abnormal condition such as loco operation over long gradients for prolonged periods etc.
The de-rating protocol to be adopted to protect the major equipment such as traction
motor, inverter etc., in case of such abnormal conditions, shall be furnished by the
successful tenderer.
8.2.7 The supplier will state the value of maximum starting tractive effort, continuous
tractive effort and speed values that will be developed under dry rail conditions and also
under all weather conditions, which will be demonstrated during testing.
Page 41 of 92
8.3 ADHESION REQUIREMENTS
Microprocessor shall be provided with state of the art adhesion improvement system.
The system shall be able to optimize the adhesion for all other weather conditions - dry
rail, wet rail conditions- and all track conditions - mainline, branch line and station yards-
and operating conditions (starting, running, braking).
Tenderers are required to indicate the expected level of adhesion improvement in various
conditions. The proposed inverter and LCC shall achieve better or at least same
adhesion performance compared to the existing WDG4D and WDP4D locomotives.
Starting adhesion on WDG4D loco in fair weather condition with sanding shall not be less
than 42% and shall deliver starting tractive effort of at least 540 KN. The starting
adhesion on WDP4D loco in fair weather condition with sanding shall be adequate to
obtain a minimum of 400 KN starting tractive effort.
8.4.1 The locomotive shall be working under 25 kV, 50 Hz, OHE system also. Electronic
signals generated inside the traction inverters and loco control systems shall not be
affected by this and locomotive shall work without any adverse performance.
8.4.2 The tracks over which the offered system will work may be equipped with DC track
circuits, 83-1/3 Hz track circuits as well as track circuits at higher frequencies. Harmonics
generated by the inverter system shall not affect signalling gears like audio frequency
track circuits and axle counters which work in the range 0-5 kHz with a limit of 400 mA.
On the communication network, control circuits, teleprinter circuits, as well as VHF/UHF
and microwave circuits are employed. The psophometric voltage induced on
communication circuit running by the side of track shall not exceed 1 mV.
8.4.3 Compatibility with Signal & telecommunications installations
a). The design of the power electronics provided on the locomotive/ propulsion
system will be such as not to cause levels of interference exceeding the levels
specified below at any point in the operating envelope of the locomotive:
S.N. Interference current Limit

1.0 Psophometric current 10.0 A
2.0 DC component 4.7 A
3.0 Second Harmonic component (100 Hz) 8.5 A
4.0 1400 Hz to 5000 Hz 400 mA
5.0 More than 5000 Hz upto 50000 Hz
270 mA
b). Locomotive shall comply European Standards EN 50238 for Railway

Page 42 of 92
applications Compatibility between rolling stock and train detection systems
and EN 50121 for Railway applications-Electromagnetic compatibility, as
applicable.
8.4.4 Acoustics noise level generated shall not exceed 80 dB at a distance of 1 meter.
8.5 OTHER REQUIREMENTS
8.5.1 It shall be possible to use the proposed locomotive control computer, and traction
inverters along with the traction computers for WDG4D or WDP4D locomotives
interchangeably through configuration of user settable parameters and some jumper
settings, without any change in software or hardware.
8.5.2 Major existing equipment such as alternator, motors etc. shall be used without any
change. Complete system shall be designed such that there are minimum changes
required in the existing arrangement.
8.5.3 To ensure integration with existing equipment and good locomotive performance,
extensive simulation / systems testing of proposed LCC with traction inverters and
existing motors shall be performed by the manufacturer before prototype approval.
9.0 DETAILS OF TRACTION MOTOR
Main technical data of traction motor for both WDP4D/WDG4D locos for 4500HP loco
application is given as below:
Parameter Value
Nominal starting torque 9500 Nm

Maximum continuous power according 630 KW min at 1460 rpm
to IEC 60349-2 at motor shaft with DC
link voltage = 2600V.
Maximum continuous power according 485 KW min at 685 rpm
to IEC 60349-2 at motor shaft at rated (20% additional for bogie cut out)
voltage.
Maximum current 270A
(RMS value of fundamental wave)
Maximum permissible speed 3320 rpm min
Inverter Frequency Maximum 120 Hz
Circuit Y
Supply conductor 70 sq.mm
Thermal class Class 200N2
Page 43 of 92
Electrical characteristics Shall match the existing traction motor type
Siemens make 1TB2622-0TA02 or
1TB2525-0TA02 such that there is
complete compatibility with the existing
locomotive and traction equipment,
particularly the computers and there is no
need for any change in the relevant OEM
software.
The speed & temperature sensors for

Traction Motor shall be in the scope of
supply of the tenderer. The sensors supplied
shall be compatible with the existing AC
traction motor.
Gear ratio WDP4D: 77/17, WDG4D: 90/17
10.0 DOCUMENTATION
10.1 All the information which shall be required to evaluate the suitability of the offer
vis-vis this specification shall be submitted along with the offer. Following documents
shall invariably be submitted by each tenderer along with the offer for evaluation:
(a) Functional description of the complete system, including salient features and
advantages of the offered system
(b) Clause by clause compliance with the specification.
(c) .Details of technical support and training offered.
(d) All characteristics curves, including the proposed notch-wise TE Vs Speed,
notch-wise DC link V-I, efficiency numbers and ventilation characteristics of
the equipment offered, parasitic load of the auxiliaries used in the system, BE
Vs Speed, basic design data like ratings and temperature capability, envelope
and mounting drawings etc. shall be submitted with the offer.
10.2 Following documents shall be submitted by the successful tenderer, in hard and soft
copies, before commissioning of the equipment on loco.
(a) Technical documentation explaining the complete system including

characteristic curves, inverter output curves and efficiency, diagnostics,
and protection circuits etc.
(b) Locomotive control circuit schematics.
(c) Lay out and mounting drawings of all the equipment offered
(d) Drawings of each sub-system with interface details.
(e) Cooling system details.
(f) Details of enclosures provided.
(g) Details of lubricants.
(h) Procedure for user settable parameter alteration, fault data downloading
and analysis etc.
(i) Maintenance and troubleshooting manual for all the equipment offered.
(j) Recommended list of spares for 3 years.
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(k) List of special tools, jigs and fixtures needed for testing, commissioning,
maintenance and repair.
(l) Modifications needed in the existing locomotives to adopt the offered
system.
Irrespective of the details brought out here, all information and documentation which are
essential for manufacture and maintenance of the locomotive with the equipment
supplied shall be submitted on request of IR.
11.0 TESTING & INSPECTION
11.1 The details of tests and trials to be done on each electronic equipment/sub
assembly of the AC Traction System and on the complete system after installation on
locomotive are indicated at annexure - I
11.2 Type and routine tests on other equipment related with loco control and traction
inverter system offered shall generally be conducted in accordance with IEC-60571, IEC-
61287 and other relevant IEC standards separately. However, if the tenderer proposes a
different test scheme, the same can be examined by DLW/RDSO on provision of
alternative test procedures submitted by the tenderer.
11.3 The supplier shall submit detailed type and routine test programs to DLW/RDSO
for its approval. RDSO/DLW may also decide to carry out some special tests on the
equipment, which are not covered by relevant IEC specifications. Tests shall be carried
out as per mutually agreed test program and the total cost shall be borne by the
manufacturer.
11.4 The prototype unit will be tested by RDSO/DLW representative(s) at the

manufacturer’s premises where all the facilities shall be made available for carrying out
the prototype test.
11.5 Validation test: A final validation test shall be conducted at DLW on the load box
by IR, in which all the performance requirements, which can be determined in static
condition, shall be established by the manufacturer, particularly the power requirement
as per para 1.2.1. Any adjustment required on the Woodward Governor or fuel rack for
achieving the performance requirements shall be arranged by IR, if necessary.
11.6 Instrumentation for type/routine and Validation tests
(a) All the instruments used for testing shall be duly calibrated. The calibration
certificates are to be shown to RDSO/DLW representative(s) on demand.
(b) Value of the fundamental component and THD of traction inverter output
will be measured by power analyzer during the prototype test at various
mutually decided pre-set points in traction and braking mode. True RMS
value of output voltage is also to be measured for record.
11.7 QAP: The successful tenderer shall also be required to submit a detailed Quality
Page 45 of 92
Assurance Plan (QAP) along with the inspection plan for the equipment supplied for
approval by IR before the same is adopted.
11.8 Rating and performance trials: These tests may be done on one prototype
locomotive built with the equipment prototypes supplied by successful tenderers by IR at
their own cost covering the following:
 Dynamometer car test to ascertain starting and rolling resistance of the

locomotive and to prove “tractive effort-speed” characteristics and “dynamic
braking effort/speed” characteristics.
 Adhesion test to prove adhesion capability.
The successful tenderer shall be permitted to associate with the tests as these tests are
one of the means to determine clearance for series manufacture. If either the
microprocessor data obtained after the prototype locomotive has been put in commercial
service is considered adequate by RDSO or similar test/trial data is already available with
RDSO, to establish the performance requirements of the locomotive, these tests may be
waived.
11.9 Field trials: One prototype locomotive each shall be subjected to field trials on IR
for at least three month. The manufacturer shall depute a team of engineers for
commissioning, testing and field trials of the locomotive and its equipment in service. The
manufacturer shall associate in the field trials jointly with IR. The manufacturer shall
ensure availability of typical tools & spare parts in adequate quantity for field trials, to be
done as part of commissioning.
11.10 All the modifications required due to defects noticed or design improvements
found necessary as a result of the field test / trials shall be carried out by the tenderer in
the least possible time. Total cost of such modifications/design changes shall be borne
by the manufacturer.
11.11 Type test will be performed on one prototype unit of given design to verify that
product meets the specified design requirements. However, routine tests shall be carried
out on each equipment.
11.12 If mutually agreed between manufacturer and RDSO/DLW, witnessing of routine

test may be waived for sets manufactured after the prototype. The routine test of
equipment, for which witnessing has been waived, shall be accepted after successful
scrutiny of test results submitted to RDSO.
11.13 Subject to agreement between RDSO/DLW and manufacturer, some or all the
type tests shall be repeated on sample basis so as to confirm the quality of the product.
This will be part of revalidation of vendor approval. In addition, the manufacturer shall
repeat all the type tests after 5 years without any additional cost. Type test may also be
repeated in any of the following cases:
 Major modification of equipment, which is likely to affect its functionality or

Page 46 of 92
performance.
 Failure or major performance variations established during type or routine
testing.
 Resumption of production after an interruption of more than two years.
11.14 To obtain additional information regarding performance and functionality of any

equipment or sub-system, investigation tests may be specially requested by RDSO/DLW.
12.0 WARRANTY
The complete system with controls shall be warranted for satisfactory and trouble free
operation in conformity with the standard IRS conditions. All aspects of workmanship and
design shall be covered by this warranty. The supplier shall immediately provide
arrangement for rectification of failures reported under warranty.
Warranty period of any equipment of the system may be extended as per mutual
agreement between RDSO/DLW and supplier if the equipment has undergone major
design modifications during the warranty period.
13.0 FAILURES DURING WARRANTY PERIOD UNDER MAINTENANCE

CONTRACT
13.1 In case of any failures, the details of failure and action taken to arrest re-
occurrence of similar failure in future with failure analysis report etc. is to be submitted to
RDSO/DLW.
13.2 In case of repeated failures, necessary changes in design on the units put in
service or in production line are to be made by the manufacturer. Investigation tests, if
considered necessary, are to be arranged/conducted by the manufacturer.
14.0 MARKING AND PACKING
14.1 Each equipment shall bear for identification DLW order number, batch/lot number,
serial number, type, year of manufacture, manufacturer’s name as well as important
nominal and short time ratings.
14.2 All equipment of the complete system shall be suitably packed in strong water
proof boxes to prevent any damage during transit and handling.
15.0 INFRINGEMENT OF PATENT RIGHTS
Indian Railway shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, components used in design, development
and manufacturing of complete system and any other factor, which may cause such
dispute. The responsibility to settle any issue lies with the manufacturer.
Page 47 of 92
ANNEXURE-A
Page 48 of 92
ANNEXURE-B
Page 49 of 92
ANNEXURE-C
Tractive Effort Vs Speed characteristics(AAR Condition)

4500 GHP WDP4D (Dual Cab) Diesel Electric Locomotive
One Traction Alternator type TA17
Six Traction Motor type ITB 2525 or equivalent
Gear ratio : 17:77, Wheel Dia. : 1054mm (Half Worn)
Starting Tractive Effort : 400 KN.
450
400
350
300
Tractive effort (KN)
250
200
150
100
50
0
0 20 40 60 80 100 120 140
Speed (Km/h)
Page 50 of 92
ANNEXURE –D
Page 51 of 92
ANNEXURE - E
Page 52 of 92
ANNEXURE- F
Page 53 of 92
ANNEXURE – G
Tractive Effort Vs Speed characteristics (AAR condition)
4500 GHP WDG4D (Dual Cab) Diesel Electric Locomotive
One Traction Alternator type TA17
Six Traction Motor type ITB 2525 or equivalent
Gear ratio : 17:90, Wheel Dia. : 1054mm (half Worn)
Starting Tractive Effort : 540 KN
550
500
450
400
350
Tractive Effort (KN)
300
250
200
150
100
50
0
0 20 40 60 80 100
Speed (Km/h)
Page 54 of 92
ANNEXURE-H
DYNAMIC BRAKING CHARACTERISTICS OF 4500 GHP

WDG4D (Dual Cab) Diesel electric locomotive
OneTraction Alternator: TA17 at 950 rpm
Six Traction Motor: 1TB2525 or Equivqlent
Gear Ratio: 90:17, Wheel Dia: 1054 mm(HW)
280
270
260
250
240
230
220
210
Dynamic Braking Effort (Kilonewtons)
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Speed (Km/h)
Page 55 of 92
ANNEXURE -I
TESTS AND TRIALS
1.0 Type and routine tests shall be conducted on the individual equipment of AC
traction system separately. Complete inverter system shall also be tested after its
installation on the locomotive.
1.1 In general, traction inverter shall be tested in accordance with IEC-61287 & the
control electronics of inverter and LCC shall be tested as per IEC-60571. Individual
equipment, system and sub-system as may be necessary, shall be type and routine
tested in accordance with relevant IECs. In case LCC is part of TCC, no separate type /
routine testing is required to be carried out specially for LCC.
2.0 The list of tests to be carried out on the inverter system is as follows:
Tests on TCC Assembly

Sub Reference clause of IEC Nature of Test Type Test Routine
Assembly 61287-1 Test
Name
Traction IEC 61287-1-4.5.3.1 Visual Inspection √ √

Control
Cabinet IEC 61287-1-4.5.3.2 Dimensions and Tolerances √
with
IEC 61287-1-4.5.3.3 Weighing √
Traction
Inverter IEC 61287-1-4.5.3.4 Marking inspection √ √
IEC 61287-1-4.5.3.5 Cooling system performance tests √
IEC 61287-1-4.5.3.5.3 Check of effectiveness of air filters √
IEC 61287-1-4.5.3.5.4 Leakage test √ √
IEC 61287-1-4.5.3.6 Tests of mechanical and electrical √ √

Protection & measuring equipments
IEC 61287-1-4.5.3.7 Light Load Test √ √
IEC 61287-1-4.5.3.8 Test of the degree of protection √
IEC 61287-1-4.5.3.9 Commutation test √
Page 56 of 92
IEC 61287-1-4.5.3.10 Acoustics Noise Measurement √
IEC 61287-1-4.5.3.11 Temperature Rise Test √
IEC 61287-1-4.5.3.12 Power Loss determination √
IEC 61287-1-4.5.3.13 Supply overvoltage and transient energy √
IEC 61287-1-4.5.3.14 Sudden Variation of Load √
IEC 61287-1-4.5.3.15 IR Test √ √
IEC 61287-1-4.5.3.16 Dielectric Test √ √
IEC 61287-1-4.5.3.17 Partial Discharge Test √
IEC 61287-1-4.5.3.18 Safety requirements as per IEC 61991 √
IEC 61287-1-4.5.3.19 Vibration and Shock (on Sub-assemblies) √
IEC 61287-1-4.5.3.20 Electromagnetic compatibility √
IEC 61287-1-4.5.3.21 Step change of line voltage test √
IEC 61287-1-4.5.3.22 Short-time supply interruption test √
IEC 61287-1-4.5.3.23 Current-sharing test √
Tests on LCC cards, TCC Cards PCBs & Display Unit
Sub Reference Standard Test Details Type Test Routine

Assembly Test
Name
LCC cards, IEC 60571 – 10.2.1 Visual Inspection √ √

TCC cards,
PCBs & IEC 60571 – 10.2.2 Performance Test with simulation √ √
Display
 Voltage variation
unit  Reverse Polarity
IEC 60571 – 10.2.3 Cooling Test(low temp. storage) √
IEC 60571 – 10.2.4 Dry Heat Test √
IEC 60571 – 10.2.5 Damp Heat Test √
Page 57 of 92
IEC 60571 – 10.2.6.1 Supply over voltages √
IEC 60571 – 10.2.6.2 surges √
IEC 60571 – 10.2.6.4 Electrostatic Discharge Test √
IEC 60571 – 10.2.7 Transient Burst Susceptibility test √
IEC 60571 – 10.2.8 Radio interference Test √
IEC 60571 – 10.2.10 Salt Mist Test √
IEC 60571 – 10.2.11 Vibration and Shock Test √
IEC 60571 – 10.2.12 Water tightness test √
IEC 60571 – 10.2.13 Equipment stress screening √
IEC 60571 – 10.2.14 Low temperature storage test √
annexure - J Burn-In test * √
Tests on ECC#1, ECC#2, ECC#3 & ECC#4 Panels

Sub Reference Standard Test Details Type Test Routine
Assembly Test
Name
ECC#1, IEC 60571 – 10.2.1 Visual Inspection of marking & √ √

safety requirements
ECC#2,
Page 58 of 92
ECC#3 IEC 60571 – 10.2.2 Performance Test with simulation/ √ √
Functionality tests
&
ECC#4 On ECC#1
 Functionality
Panels  Continuity
 Operation Test for Relays,
Contactors and Breakers
 Power supply test for
output voltage for variation
in input voltage range (55
VDC to 110VDC)
On ECC#2
 Battery Charging Ass.

 Operation Test of ST & STA
Contactors
 Continuity
On ECC#3
 Functionality
 Continuity
 Operation Test for
contactors & Breakers
On ECC#4
 Continuity
 Operation Test for switches
& Breakers
RDSO spec Pressure Test √
Torque Test (H/W tightness) √
Weight √
Verification of Dimension & √

tolerances
IEC 60571 – 10.2.9 IR Test √ √
IEC 60571 – 10.2.9.2 HV Test √ √
Page 59 of 92
* The cards used in the equipment will be subjected to burn-in test as per the
temperature cycle defined at annexure - J. The cards will be kept energized during the
test. Functional test of each card will be carried out after the burn-in test. (Pl. refer
Clause 10.2.13 of IEC-60571). This will be part of internal test by the manufacturer and
results will be submitted during routine testing.
2.3 OTHER TESTS
After installation and commissioning of loco with the new traction inverter and loco
control system, it will be subjected to certain tests conducted by Indian Railways with
supplier’s representative mainly to satisfy the Railways regarding operational
performance, capability and safety. The following tests may be conducted in this
connection on one or more locomotives with new system:
2.3.1 RATING AND PERFORMANCE TESTS
Dynamometer car tests to ascertain following:
a) Starting and rolling resistance of the locomotive.

b) Tractive effort vs. speed characteristics of the locomotive.
c) Braking effort vs. speed characteristics of the locomotive.
d) Adhesive capability of the locomotive.
2.3.2 SIGNALLING AND INTERFERENCE TESTS
Tests to determine the levels of interference with the Signal and Telecommunication
equipment and facilities to prove that these are within acceptable limits (see clause 7.4)
Page 60 of 92
ANNEXURE - J
BURN-INTEST
Temperature
in Degrees T
emperature Cycle
0
+70C
0
+25C
0
0C
0
-25C
1.4 2.1 5.2 5.5 9.1 9.4 12.5 13.2 15
Time (Hrs)
0.1=10 Min
1.55 5.27 5.42 9,17 9.32 12.57 13.12 14.41
On
Off
Page 61 of 92
ANNEXURE – K(a)
Page 62 of 92
ANNEXURE – K(b)
Page 63 of 92
ANNEXURE – K(c)
Page 64 of 92
ANNEXURE – K(d)
Page 65 of 92
ANNEXURE – K(e)
Page 66 of 92
ANNEXURE – K(f)
Page 67 of 92
ANNEXURE – L
INDIAN RAILWAYS
DIESEL LOCOMOTIVE WORKS SPEC. No.
VARANASI WDG4/EL/PS/28
dlw PURCHASE SPECIFICATION
FOR SUPPLY OF CROW BAR RESISTOR & CROW BAR/DAMPER REVISION: 0.0
RESISTOR REQUIRED FOR IGBT BASED TCC EQUIPPED
WDG4/WDP-4D LOCOMOTIVES ISSUE DATE : 19.09.2008
1. FOREWORD: With the successful development of IGBT based TCC by different sources,
the requirement of Crow Bar Resistor and Damper Resistor has also under gone changes.
This specification covers supply of Crow Bar and Damper Resistor required for proper
functioning of different make of IGBT based TCC.
2. SCOPE OF SUPPLY: Includes supply of any one of Crow Bar and Damper Resistor
combinations to following specifications:
 Resistor Crow Bar of 0.22 Ω to EMD Drg No. 40082110 and Resistor Crow
Bar/Damper 0.22 Ω to EMD Drg. No. 40082111
OR
 Resistor Crow Bar of 2.94 Ω to EMD Drg No. 40047781 and Resistor Crow
Bar/Damper 2.94 Ω to EMD Drg. No. 40053020
OR
 Any other protection device of IGBT TCC designed by TCC manufacturer. The
proposed protection device should be accommodated in existing envelope dimension of
Resistor Crow Bar as per EMD Drg. No.40082110/40047781 and Resistor Crow
Bar/Damper as per EMD Drg. No. 40082111/40053020. Over all dimensions must be
strictly followed.
3. Condition for Tenderer: . these resistors should be procured from DLW approved sources
only.
Appd. By Dy. CPM/EL-EMD Checked by SSE/EL/D Prepared by
Page 68 of 92
Annexure-M
SPECIAL CONDITION FOR ANNUAL MAINTENANCE CONTRACT OF

IGBT BASED TRACTION CONTROL CONVERTERS AND LOCOMOTIVE
CONTROL COMPUTER FOR WDG4D & WDP4D CLASS OF
LOCOMOTIVES
Page 69 of 92
1. GENERAL
This annual maintenance contract agreement is required to be entered between OEM of IGBT
technology based TCC & LCC and Diesel locomotive Works for and on behalf of President of
India for use and operation by the Zonal Railways at Headquarter/ Divisional level under the
supervision of Zonal Railways. The above contract covers the comprehensive maintenance
requirement of IGBT technology based TCC (Traction Control Converter) & LCC (Locomotive
Control Computer) fitted on WDG4D and WDP4D class locomotives.
2. DEFINITIONS
Throughout this document, the terms:
1 a) TCC (Traction Control Converter): means the IGBT technology based TCC.
1 b) LCC(Locomotive Control Computer): means the locomotive control computer.
c) 'IR' means Government of India, Ministry of Railways, Railway Board, New Delhi or its
nominees.
1 d) ‘DLW' means Diesel Locomotive Works, Varanasi - 221004.
1 e) 'Tenderer' means the firm/company submitting the offer for annual maintenance of
Traction Control Converters fitted on WDG4D and WDP4D locomotives.
f) ‘Contract’ means the contract for annual maintenance of IGBT technology based TCC
& LCC fitted on WDG4D and WDP4D locomotives at sheds of Indian railways proposed
to be entered into between IR and the firm, against the tender.
1 g) 'Contractor' means the firm / company or its wholly owned subsidiary in India on whom
the order for annual maintenance of IGBT technology based TCC & LCC fitted on
WDG4D and WDP4D locomotives is to be placed.
1 h) 'Sub-contractor' means any person, firm or company from whom the contractor may
obtain any services for maintenance of IGBT technology based TCC & LCC
1 i) User Railway - means the Zonal Railway or Divisional Railway which has placed the
contract on firm in terms of this agreement.
j) Designated Shed - shall be the shed so designated by the user railway, within the
zone of that user railway, where the locomotives shall be brought for maintenance
including the maintenance of IGBT technology based TCC & LCC.
1 k) 'Nominated Officer' means the person nominated by user Railway for the purpose of
execution of contract.
l) 'Loco Hours' is the total number' of hours in service/breakdown for any locomotive . i.e.
maximum 24 hours per day per loco.
Page 70 of 92
m) ‘Locomonth’ is the unit of measurement of availability of a locomotive over a period of

one month.
n) "RDSO" shall mean Research, Design and Standards Organization of Lucknow

for the purpose of consultation regarding up gradation.
o) "GCC" shall mean General Conditions of Contract (Works) contract, of the

concerned zonal railway.
3. SCOPE
3.1 Annual Maintenance for OEM make IGBT technology based TCC & LCC fitted on WDG4D
and WDP4D locomotives as suggested by OEM/Railway in which the TCC’s & LCC’s are
in working condition to be jointly certified by the Contractor & user Railways to be covered
in the aforesaid AMC. For this purpose AMC contract shall begin when:
a) In case of WDG4/ WDP4B locomotives made at DLW, immediately w.e.f .next day when
the warranty period expires.
b) In case of a) if the AMC is awarded beyond the warranty period, the joint inspection &
OEM recommended rectification, if any, at the cost of IR shall be required before the
commencement of the AMC.
3.2 The contract shall be comprehensive in nature wherein preventive as well as Breakdown
Maintenance of TCC & LCC is to be attended by the contractor including the arrangement
of spares, tools, consumables, technical expertise and manpower. The replaced
consumables, tools, items will be contractor’s property. Contractor shall remove the same
from the shed’s premises with due authority.
The respective firm shall submit the maintenance schedule as per their design to the
zonal railways for approval and all maintenance activity shall be carried out as per the
schedule approved by railways. Loco shall be made available to the contractor within + 7
days.
3.3 The maintenance and support by the contractor shall consist of 4, “three monthly
preventive checks as per the preventive maintenance schedule of the TCC & LCC for
trouble free services of the locomotives as prescribed by the OEM. The scope of
maintenance by the contractor shall be largely as per preventive maintenance schedule of
the equipment but shall include all the extra and out of course attentions including
breakdown, if any required, to ensure trouble free operation of the locomotive.
3.4 Based upon the experience gained by the contractor in the first year of the contract & the
fleet size, it shall be possible to improve upon the above referred levels of availability and
downtime.
3.5 The locomotives going out of the manufacturers' warranty for TCC & LCC shall only be
included under the annual maintenance contract. The warranty period for the equipment
shall be governed by the original supply contract against which the equipment are
supplied to Indian Railways. True copies of such documents shall be furnished by the
contractor.
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3.6 The filter for clean air supply to TCC, clean air compressor, duct for clean air, IPR inlet
panel cables and accessories are excluded from the scope of this contract.
3.7 Annual maintenance contract (AMC) shall not cover the failures due to external
circumstances such as fire, accident, explosion, floods etc. Breakdown arising due to
reason external to the TCC & LCC such as TM failures, TM cable short-circuit are also
excluded from this contract.
3.8 Availability and Downtime
3.8.1 The contractor shall ensure that during the billing period (three months), combined
downtimes of all the locomotives covered under the contract, on account of out of course
repair and online failures of equipment under AMC covered under the scope of work,
does not exceed 1.5% of total loco hours for the locomotives covered in the contract.
Downtime accountal shall be carried out every month and the contractor has to ensure
not less than 98.5% availability on account of equipment under AMC.
3.8.2 The contractor shall ensure that downtime on account of out of course repairs and online
failures of equipment under AMC covered under the scope of work, does not exceed an
amount equivalent to 5% of individual loco hours for each of the locomotives covered in
the contract. Downtime accountal shall be carried out by the contractor every month and
the contractor shall ensure not less than 95% availability of each loco on account of
equipment under AMC.
The down time calculation for para 3.8.1 and 3.8.2 above shall be as under:
a. Downtime on out of the course repair shall start from the time when the stipulated
maintenance schedule of the locomotive is completed but waiting for the repair of
the loco exclusively on account of equipment under AMC.
b. Downtime on account of online failures shall be from the time the loco fails on line
and reported to the contractor till the loco is given ready for service.
If the loco involved in line failure cannot be attended at site, same should be informed to
the shed authorities immediately and then if required the loco shall be moved to the
nearest shed (including the trip sheds) for further attention. Such dead loco/ light engine
movement may take time and is beyond the control of the contractor. Hence, if the time
taken from the reporting of inability to repair at site till handling over of the locomotive to
the contractor at nearest shed (including trip shed) is more than 24 hours, the time above
24 hours shall not be considered for calculating the downtime occurred due to that
failure.
If the locomotive breakdown complaint is given for online failure, the service engineer
shall proceed by road or rail from designated shed with necessary spares & tools within
two hours of receipt of complaint and attend to the loco at the earliest opportunity. If the
contractor confirms in writing after checking the loco that the problem cannot be attended
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online, loco may be moved to the nearest maintenance shed/trip shed for repair. If the
loco is not handed over to contractor within 24 hours from the time contractor has
expressed inability to repair/attend online or at failed site, the extra time taken is beyond
the contactor scope and hence shall not be taken as down time till the loco is handed
over to contractor for repair/attention.
3.8.3 In addition, the number of locos under breakdown repair at 0.0 hours daily shall not
exceed 3% (arithmetically rounded off to nearest integer) of the locomotive under
contract. However, if the total locos under AMC in a shed are less than 100, the locos
under breakdown repair at 0.0 hrs. daily shall not be more than 3 locos.
3.8.4 All the penalties shall be calculated on the entire fleet covered under this contract.
3.8.5 In case any loco is held up in shed for repairs / want of material (other than related to
equipment under AMC) for more than 15 days, the same shall be communicated to the
contractor in writing and the complete held-up period shall be excluded from the
availability figures and hence no payment shall be made for that period. The contractor
shall not remove any material from the loco without prior written consent from Railway
authorities.
4.0 PLACE OF WORK
WDG4D and WDP4D Microprocessor based locomotives are based / proposed to be

based at Diesel Sheds under various Zonal Railways like, Hubli(SWR), Siligudhi(NFR),
Gooty (S.C.R.), Erode (SR), Krishnarajpuram (SWR), Vatwa (WR), Etarsi (WCR), Jhansi
(NCR), Lucknow (NR), BandaMunda (SER), Gonda (NER), Undaal (ER), Kalyan (CR),
Patratu (ECR), Ludhiana (NR), New Katni Junction (WCR), Tughlakabad (NR), Guntkal
(SCR), Bhagat ki kothi (NWR), Raipur (SECR), Kazipet (SCR), Vishakapattnam (ECR),
Pune (CR), etc.. However, contract shall cover any other shed/place nominated during
the currency of the contract. The contractor shall arrange required men and material at
the designated sheds with immediate effect.
The maintenance / breakdown repairs shall normally be carried out by the contractor
through its nominated Service Engineers at designated shed only. However, in case of
failure on equipment under AMC, at any location within that zonal railway the
maintenance / breakdown repair may be carried out at trip sheds also. If it is not possible
to bring the loco to the designated sheds, the contractor’s service engineer shall reach
the spot immediately by any means of transport on receiving the advice from the shed.
Necessary travel authorizations for the service engineer to undertake such travel as
applicable would be provided by the respective zonal railways. After examination of the
loco at out station, in case, the loco cannot be repaired / attended the locomotive can be
moved to shed for further attention. Necessary support and resources required shall be
provided by that shed.
Power failures such as but not limited to GTO, IGBT, Crowbar module, DCL reactor,
Blower motors shall be attended at base sheds only.
5.0 AUTHORITY FOR OPERATION OF CONTRACT
This contract is for trouble free operation of TCC & LCC by the user diesel sheds. Based
upon this agreement, the contract shall be signed by the user diesel shed at Zonal HQ
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and shall be executed under the overall supervision of Zonal Railway.
The User Railway shall nominate an officer who shall operate the contract for
maintenance of the equipment and who shall be responsible for making the contract
(Liaison) with the firm at the defined address by telephone/telex/ fax or in person
immediately when the preventive maintenance breakdown is to be attended to as
required.
The nominated Railway Officer shall also be responsible for supervision of the
contractor's works for the verification of contractor's bill for payment.
6.0 RESPONSIBILITIES OF PARTIES
Following are the responsibilities of Railways and the Contractor.
6.1 RAILWAYS
6.1.1 The Railway authority shall permit the contractor to work on TCC & LCC fitted on the
locomotives under preventive maintenance or break down.
6.1.2 User Railways shall nominate the Officer/ Supervisor for supervision of the work done by
the contractor under the contract.
6.1.3 The User Railway shall issue the necessary identity card (even if temporary) to the
working staff/service engineer for their entry on the platform and other railway premises.
However this Identity Card shall not be taken as a travel authority to travel in any train/s.
Necessary documents to facilitate movement of material shall be given by the shed.
6.1.4 The necessary space, electricity, and water connection shall be provided by Railway free
of cost as required for at the nearest possible point of the site. In addition, a lockable room
to store the tools and tackles shall be provided free of cost by the IR to the contractor.
However, there shall be no separate exclusive security systems for the space/facility
provided to the contractor by Railway. This shall be applicable at all designated base
sheds.
6.1.5 The user Railway shall make the locomotives available for the maintenance.
6.1.6 Railway shall mention the details of the locomotives including the locomotive nos. covered
under Annual Maintenance Contract for the reference of both the parties. In case the base
maintenance designated shed of the locomotive is shifted to any other location, than
those specified in the scope, the scope of AMC shall accordingly shifted to new site/base.
6.1.7 The nominated railway officer shall intimate the firm by Telephone/ Fax or in-person
mentioning the loco numbers and location of the locos along with the time of call. He shall
maintain the register of such calls made for reference of both the parties.
6.1.8 In case the failure of equipment is attended by the contractor at a station other than the
base maintenance shed, the service engineer shall give a declaration indicating the
attendance and clearance time to the concerned Railway official at the location, which
shall be countersigned by the Railway official. The same shall be submitted to the
designated shed along with the site report for records.
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6.1.9 The owning shed and the firm shall jointly arrive at the no. of locos that are falling due for
AMC at the start of every month and a record shall be kept for this purpose.
6.2 CONTRACTOR
All the work including checks shall be carried out on the stable conditions at the
designated shed.
6.2.1 The contractor shall post adequate no. of qualified service engineers /backup engineers
and arrange required materials exclusively for the execution of this contract at the
designated shed/sheds with immediate effect.
6.2.2 Service Engineer shall carryout preventive maintenance on locos at all days and times
including Sundays and Gazetted holidays depending upon availability of locomotive in the
shed.
6.2.3 Normally Service engineer shall be available in the shed during normal working hours to
attend breakdown calls/ preventive maintenance.
A backup engineer shall be located at one of the contractor’s office and shall be available
at the designated shed if required to attend the complaints in case of absence of service
engineer at the designated shed.
6.2.4 The service engineer shall report within one hour at the designated shed to the nominated
officers of Railway if breakdown call is given during normal working hours (06:00 – 22:00)
and within two hours after normal working hours on all days of the week.
6.2.5 The contractor shall keep all the necessary tools, testing equipment / Spare Parts, Sub-
Assemblies & Consumables in the ready stock in the firm's premises at the location of the
designated shed of maintenance or their workshop or in the nearest office. IR shall,
however, provide a lockable room to the contractor at the designated shed.
6.2.5.1 All components/materials required for effective and timely execution of this AMC contract
may have to be moved by “Contractor” from their warehouse or any other location. Risk of
loss or damage during such movement will be to the account of the “Contractor”.
6.2.5.2 “Contractor” must keep adequate stocks of the components/materials received from their
warehouse or any other location in order to ensure minimize down time in the execution
of this AMC contract. Materials kept in the stock-point for the AMC relating to a particular
engine/bogie cannot be removed by the “Contractor” from the stock point except for use
in this AMC or in the case of emergencies/unavoidable circumstances in any other AMC
entered into by the “Contractor” with any other loco sheds.
6.2.5.3 Subject to Clause-6.2.6.2 above, title in the components used in the AMC will remain with
“Contractor” until it passes to the Railways by accretion in the execution of the AMC.
6.2.5.4 Documents for movement of components/materials from Contractors warehouse or any

other location to the stock-points: The documents employed for the inter-state movement
of the components/materials required for the execution of the present AMC must make
explicit reference to the particular AMC contract apart from the locomotive reference for
which the AMC is entered into.
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6.2.6 The contractor shall furnish the standard (OEM recommended) list of spares, consumable
& tools to be stocked by the contractor at the designated shed
6.2.7 It shall be responsibility for contactor to keep the adequate spares, consumable and tools
(that may be required to service the AMC) to avoid any delay in repair time. The Railway
official can check the stock of spares if so desired.
6.2.8 The service engineer nominated for the repair on the shed duty shall observe all safety
and security rules prevailing at the place of work.
6.2.9 Some maintenance spares for the equipment under AMC may be available at the
contractors premises at the location of the designated shed of maintenance or their
workshop or in the nearest office of the diesel Loco sheds. These can be utilized by the
contractor. (The assessment is to be made by the contractor before quoting). However
any such spares used by the contactor from the stock is the IR property and shall be
replaced by new / repaired ones within 3 months of their uses at no extra cost. However,
if such spares are used for correcting damages caused by external reasons (e.g.
accident, cattle over run etc.), the same need not be replenished.
6.2.10 The contractor shall maintain all such records/ log-books prescribed by the Railway &
produce for inspection by the Railway whenever required.
6.2.11 The contractor shall arrange required men and material at the designated sheds with
immediate effect. However, for new service locations a reasonable time frame of 3
months shall be provided.
6.2.12 Whenever any locomotive has had an adverse incident/unusual occurrence or failure
online or in shed, the contractor has to submit a detailed repair report to the user railway
official within a week from the date of completion of repairs. Failure investigation report
based on troubleshooting, data analysis and primary failure analysis shall be provided by
the contractor within 60 days from the date of completion of repairs.
It is the duty of the contractor to ensure that the components/spares used by him are of
highest quality and reliability. If any component is failing frequently and a trend is visible,
necessary preventive action should be taken by the contractor to arrest the failures and
make modifications to the system/component with the prior approval of the user railway in
writing. Any modifications required to improve reliability shall be carried out free of cost by
the contractor. Performance up gradation to locos shall be done after consultation with
OEM, Supplier and RDSO and with additional charges on case to case basis.
7.0 PROGRESS REPORT
The regular observations and monthly progress report of the user railways shall be sent to
DLW by the user railway for future centralized reference.
8.0 VALIDITY OF CONTRACT
The above contract (with rates and terms & conditions) shall be valid for 3 years (from the
date of issue of the contract or from the date of expiry of warranty of the Locomotive
whichever later) unless otherwise extended or terminated by Railway. Both the parties
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shall take up jointly the inventory of eligible locomotives to be maintained under this
contract.
For the purpose of billing and payment, AMC takes effect with signing of agreement
between Railway and Contractor and taking up of joint inventory of eligible locomotives to
be maintained.
9.0 RATES
The rates to be quoted for comprehensive AMC covering both the break down & preventive
maintenance (including spares and service) per Locomotive per year consisting of TCC & LCC in
figures and in words. The rates under this contract shall be in INR.and exclusive of all applicable
taxes and will be charged at actulas during the execution of the contract. As the components/
materials will have to be moved by the “Contractor” from their warehouse or any other location to
their stock-points only for the execution of this AMC contract, the “Contractor” will have to ensure
appropriate payment of central sales tax in the respective state where the material to be used for
the AMC is initially kept. The “Contractor” will have to keep the Railways indemnified for any
consequences that the Railways may be exposed to as a result of the omission on the part of the
“Contractor” to discharge such liability. The gross amount paid by the Railways to the
“Contractor” for the execution of the present AMC contract will be inclusive of such central sales
tax and exclusive of applicable service tax.
10.0 OWNERSHIP OF THE REJECTED & OLD COMPONENTS
The ownership of the rejected or defective replaced components/parts vests with the
Contractor against the replacement made by them on equipment supplied to make it
operative.
11.0 PENALTY: FOLLOWING PENALTIES SHALL BE IMPOSED:
The cumulative maximum penalty shall be limited to 20% of the billing amount.
11.1 PENALTY FOR DELAY IN ATTENDING THE BREAKDOWN CALLS BY RAILWAY ON

THE CONTRACTOR
Problems / failures reported would be advised to the contractor's representative at

the designated shed on contact phone no. (which contractor shall apprise at the
time of award of contract). The contractor and he shall attend such
problems/failures within stipulated time starting from time of intimation failing which
penalty as described hereunder shall apply.
Any delay by the firm in completing the above activities shall affect the running of the train
services and may cause loss of revenue to the user Railway. Therefore, the user Railway
shall recover from the contractor as agreed damages and not by way of penalty a token
sum of Rs.5,500/- in each case of delay stipulated in Clause 6.2.4.
11.2 PENALTY FOR COMBINED DOWNTIME OF ALL THE LOCOMOTIVES (ref. clause 3.8.1):
For this purpose, downtime shall be calculated as percentage of total downtime hours for
the month to the total loco hours of all the locos covered under the AMC. In case the
contractor fails to maintain the contracted availability requirements, a penalty shall be
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levied as under
Down Time Penalty

1.5% or less Nil
> 1.5% - 3% 2% of the total monthly proportionate bill
> 3% - 5% 5% of the total monthly proportionate bill
> 5% - 10% 10% of the total monthly proportionate bill
> 10% 20% of the total monthly proportionate bill
11.3 PENALTY FOR DOWNTIME OF INDIVIDUAL LOCOMOTIVE (ref. clause 3.8.2):
For this purpose, downtime shall be calculated as percentage of individual downtime

hours for the month of a loco to the individual loco hours of the same loco covered under
the AMC. In case the contractor fails to maintain the contracted availability requirements,
a penalty shall be levied as under
Individual Loco Penalty Rate

downtime %
5% or less Nil
> 5% - 8% 5% of the individual loco’s monthly proportionate bill
> 8% 10% of the individual loco’s monthly proportionate bill
11.4 PENALTY FOR LOCOMOTIVE UNDER REPAIR (ref. clause 3.8.3):
For this purpose the number of locomotives under repair everyday at 0.0. hrs on account
of equipment under AMC shall not exceed 3% (rounded off to the next highest integer
number) of the total no. of locomotives under maintenance contract during the particular
month or else penalty shall be levied as under:
Max number of Locos Down Penalty

3% or less Nil
> 3% - 5% 2% of the total monthly proportionate bill for the day
> 5% 10% of the total monthly proportionate bill for the day
12.0 PAYMENT
12.1 For the purpose of contract, the AMC for any locomotive shall begin immediately from the
date of entering into the contract after the warranty cover of the locomotive to be covered
under the AMC is over.
12.2 The total yearly payment shall be made in four equal instalments and such instalments of
the payment shall be made against the bill by the contractor every quarterly which is
certified by the nominated officer for completion of maintenance and after calculation of
penalties as stipulated in para 11.0, 12.0, 13.0, 14.0, 15.0 & 16.0. On account of penalty or
non-performance of a planned scheduled maintenance, such dues, if any shall be
deducted as above.
12.3 The bills submitted by the firm for payment must accompany:
12.3.1 The certificate of maintenance of the locomotives issued by nominated Officer.

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12.3.2 The above bill shall bear the individual locomotive number of the locomotives maintained
by the firm for each quarter covered under this AMC.
13.0 THE RECORDS TO BE MAINTAINED BY NOMINATED OFFICER.
13.1 The user Railway & the contractor shall jointly sign the list of locos to be covered under this
contract. Any modification shall also be jointly signed, as proposed by the user Railway.
13.2 The user railways shall maintain records of maintenance contract stating the locomotive
numbers to be maintained under this AMC along with the date of inclusion of the
locomotive under AMC. .
13.3 The nominated officer shall keep the register/ record for the previous bills paid for each
locomotive to avoid duplicity of payments at any time.
14.0 PAYING AUTHORITY
The payment against this contract shall be made by the Sr. Divisional Finance Manager
of the user Diesel Shed. Any taxes including Income tax required to be deducted at
source shall be deducted and a certificate to that effect shall be issued to the contractor
as prescribed under the rules;
15.0 CONTRACT PERFORMANCE GUARANTEE
The contractor shall submit Performance Guarantee for amount equivalent to 5% of

contract agreement for 36 months. This performance guarantee shall be in the form of
Bank Guarantee.
The user railway may forfeit the B.G. in case of the failure of firm in execution of the
contract or in the event of breach of any terms and conditions of contract by the
contractor.
16.0 FORCE MAJEURE CLAUSE
Force majeure shall comprise the occurrence beyond the control of the railways and the
firm as the case may be. This shall include, but not limited to the events such as
explosion, flood, fire, major power failure, accident, breaches, act of God, act of public
enemy, wars, riots, sabotage or any law of state or Ordinance or the order or regulation of
Govt. or local public authority. In such situation, either party shall promptly notify the other
party in writing about such event with evidence of happening, where possible and
mentioning that it is beyond their control to carry out obligation of this contract and agree
for mutually acceptable course of action.
The liquidated damages shall also not be applicable during this period.
17.0 COST OF THE TENDR FORM
Cost of the tender form and mode of payment shall be decided by the concerned user
Railway.
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18.0 ARBITRATION
18.1 In the event of any question, dispute or differences arising under the condition of this
contract which cannot be resolved by mutual discussions, such dispute can be referred to
the sole arbitrator nominated by the General Manager of user railways. The sole arbitrator
appointed by the General Manager in this case shall be Gazetted Railway officer. However
the person shall not be one of those who have dealt with the matter related to or who in the
course of their duties as railway servant have expressed view on all or any of the matter
under dispute or differences. The award of the sole arbitrator shall be final and binding on
both the parties to this contract.
Subject as after said, the arbitration act ,1996 & the rule of their under and any statuary
modifications thereof for the time being inforce shall be deemed to apply to the arbitration
proceeding under this clause.
18.2 Where the arbitral award is for the payment of money, no interest shall be payable on whole
or any part of the money for any period till the date on which the award is made.
18.3 The arbitral award shall state item wise, the sum and the reasons upon which it is based.
20.0 LAWS GOVERNING THE CONTRACT.
The contract shall be governed by the Laws of India for the time being enforced irrespective
of the place of performance or payment under the contract.
21.0 JURISDICTION OF THE COURTS
The courts of the place where the contract has been entered into by the user railway and
the firm shall alone have the jurisdiction to decide any dispute arising out of or in respect of
the contract.
22.0 FAILURE
If the contractor fails in the performance of the contract (except in case of force majeure &
having been allowed a reasonable time to complete the obligation), the user Railway may
without prejudice to his other rights, cancel the contract or a portion thereof and if it so
desires, to enter into another contract for fulfilment of the obligation for the remaining
period, at the risk and cost of the contractor.
23.0 SUBLETTING AND ASSIGNMENT
The contractor shall not, save with the previous consent in writing of the user Railway,
sublet, transfer or assign the contract or any part thereof or interest therein or benefit or
advantage thereof in any manner whatsoever.
In the event of the contractor's subletting or assigning this contract or any part thereof
without any such consent, this shall be deemed as the breach of contract and the user
railways shall be entitled to cancel the contract without prejudice to Railways right to
recover damages and taking any action including legal action as deemed fit by Railways.
24.0 LOCAL CONDITIONS
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It shall be the responsibility of the contractor as he deems necessary to acquaint himself

with all the local conditions and factors which would have any effect on the performance of
the contract and the cost of the stores. In his own interest the contractor may familiarise
himself with the Income Tax Act, 1961, The Companies Act, 1956, The Customs Act, 1962
and related laws in force in India amended from time to time.
25.0 RULING LANGUAGE
The ruling language shall be English.
26.0 OTHER CONDITIONS
In the proposed contract, for the condition not specified therein, General Conditions of
Contract with the latest amendments shall apply. The execution of works covered by the
tender shall be governed by the General Conditions of Contract (GCC) of lndian Railways
with all the latest amendments up to date. By signing the contract, it would be deemed that
the contractor has kept himself informed of the provisions of the "General Conditions of
Contract" including all corrections and amendments issued up to date. A copy of GCC shall
be enclosed to the agreement and which shall form part and parcel of the agreement.
27.0 CONTRACT ISSUING AUTHORITY
27.1 This contract is issued on M/s Firm & shall remain valid for a period of one/two/three years
from the date of issue of the contract unless otherwise mutually agreed to for extension or
terminated.
.
27.2 For the conditions not covered in this document, General Conditions of contract shall
apply.
This concludes the contract and is issued for and on behalf of the president of India.
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Annexure - N
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Annexure – O
OGA OF ECC#4
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Annexure – P
Page 84 of 92
Annexure – Q
Packing List
Items of AC-AC traction system as per RDSO specification to be supplied with its
different constituents packed in boxes as listed below and the boxes should be clearly
marked with alpha-numeric markings listed below.
These markings should be in letter size of minimum 15 cms and provided on at least
three sides of the boxes.
Part-A
SN Description Part No. Packing Boxes
1. ECC#3 18000897 In one box marked A1
2. TCC 18000940 In one box marked A2
3. Resistor Crow Bar In one box marked A3
4. Resistor crow bar damping In one box marked A4
Part-B
1. ECC#2 18000022 In one box marked B1
2. Temperature & speed sensor for TM-1 In one box marked B2

to TM-6
Part-C
1. ECC#1 18000885 In one box marked C1
Page 85 of 92
Part-D
1. Cable harness for power (18010234 &

grounding sensor signal to TCC 18010246) or
40142778
2. Cable harness for 3 phase (18010258 &

power supply from ECC# 1 to 18010260) or In one box
TCC blower 40142778 marked D1
containing all
3. Cable harness 74 V supply from 40133598 & 40133600
these cable
ECC#1 to TCC#1 Only for M/s EMD
harnesses
4. Cable harness 74 V supply from 40133599 & 40133601
ECC#1 to TCC#2 Only for M/s EMD
Part-E
SN Description Part Packing Boxes

No.
1. LCC with modules IN one box containing all the

module cards marked E1
2. Electronic note books as per In one box marked E2

respective clause of RDSO
specification
3 DIALS and associated cable harness. In one box marked E3
Part-F
1. ECC4 and uncommon items if any, related In one box marked F

to respective AC-AC traction system
Control cable harness from ECC4 to ECC1 or any other location as required by system
manufacturer shall be in the scope of supply of successful tenderer.
Page 86 of 92
Annexure – R
MODEL NO: 3LA0250 5YW 108W
6 NAME PLATE BL KEY SWITCH 1 -
5 PANEL 1 -
4 HANDLE FOR BL KEY SWITCH 1 SKDP - 4124

3 NUT FOR LEVER HUB 1 SKDP - 4122
2 HUB - BL KEY SWITCH 1 SKDP- 4121
1 BL KEY SWITCH (PROGRAMMABLE)- 10 AMPS 1 SKDP- 4123
ITEM DESCRIPTION QTY. MATL. SPEC.
D A.K.TALUKDER
APPLICABLE FOR
C P.K.RAI OUT LINE DETAILS OF BL KEY
WDP4D
APPD WDG4D SWITCH WITH HANDLE
B-C460D-19061
NTS
INDIAN RLYS DRG. SUPERSEDES
Dt. NOV. - 2012 ALT
NO. OF
PLACES
REF.
NO. DESCRIPTION
ALT.NOTE
NO. SIGN DATE RDSO (MP) NO. SKDP- 4119 SUPERSEDEDBY
Page 87 of 92
Annexure – S
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Annexure – T
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Annexure – U
Page 90 of 92
Annexure-V
Page 91 of 92
Annexure-W
Page 92 of 92
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m / T e l e :+91 (522) 246 5733 (PBX) 3 F p m 3 l f 3 ? * ~ ~ . 3 t h +JRzT m
- 226 011
mflelegram :'RAILMANAK', Lucknow Government of India - Ministry of Railways
MIFAX
:+91 (522) 245 3916 (RDSO) Research Designs & Standards Organisation
$-&TI E-mail ID: [email protected] LUCKNOW - 226 011
--
No. SD. Schedule.EMD Dated 13.08.2012.
CMPE/Diesel-All Zonal Railways.

CWE-All Zonal Railways.
CME/DMW/PTA.
CME/DLW.
Sub: Document No MP. Misc - 285, August 2012 on Schedule of Standard Examinations for HHP (EMD)
Diesel Electric Locomotives of 4000/4500/5500HP.
---
Subject document No MP. Misc - 285, August 2012 on Schedule ofstandard Examinationsfor HHP (EMD)
Diesel Electric Locomotives of 4000/4500/5500HP is herewith circulated to the Railways for
implementation.
Copy of the same has also been uploaded on the website: http://irdieselpower.in for easy
availability. The same may be downloaded after having accessed to as: http://irdieselpower.in 3
Motive Power 3 Informatory Letters.
DA: As above
Copv to:
DME/Tr/Rly Bd.
AN IS0 9001 CERTIFIED ORGANIZATION

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SCHEDULE OF STANDARD EXAMINATIONS

FOR
HHP (EMD) DIESEL ELECTRIC LOCOMOTIVES OF 4000/4500/5500 HP
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MP.MISC - 285 (Revision – 00)

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RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011
PREFACE
This is the standard schedule of examination for HHP (EMD) Diesel Locomotives. M/s EMD has specified a scheduled maintenance program in Maintenance
Instruction (MI) 1746. Over the years, IR has gained experience about running of these locomotives. In the course of time, many components have been indigenised.
HHP (EMD) 4000 HP locomotives have also undergone the phase of up-gradation resulting in locomotives of 4500 HP. Further, WDG5 (5500HP) locomotives have also
been developed.
In the process of finalisation, this document, in draft form, was repeatedly circulated vide letter Nos: SD.Schedule.EMD dated: 16.05.2012, 29.06.12 etc for inviting
comments from the Railways. In addition, the same was uploaded on website irdieselpower.in for easy availability.
This document is based on EMD MI 1746 and field experience.
SCOPE
This schedule is applicable for HHP (EMD) Diesel Locomotives of 4000/4500/5500 HP of IR.
STANDARD EXAMINATION/REPAIR SCHEDULE OF DIESEL LOCOMOTIVES:
Schedule Periodicity
Schedule code Periodicity

Trip/Monthly Trip/30 days
90/180 days 90/180 days
Yearly/Two yearly 1 year/2 years
Three yearly 3 years
Six yearly/Twelve yearly 6 Years/12 years
Eighteen yearly 18 years
NS Non-scheduled
Following points are mentionworthy in regard to the maintenance attention, scheduled or otherwise, given to the locomotives before releasing the same for service:
1. It may be noted that the service periods of locomotives specified in this schedule for maintenance attention are the maximum allowable between the
successive examinations from reliability point of view.
2. Though uniformity is expected in the implementation of major schedules (Three Yearly and above), variation in operating condition in different regions may
make it necessary to carry out lower schedules more frequently or to introduce examination of items not mentioned herein. Such changes are to be
authorized by an official not below the rank of Shed in-charge ie Sr DME / DME. This shall be done under intimation to RDSO.
3. While carrying out out-of-schedule attention of locomotives, all missing nuts, bolts, set screws, cotters, split pins etc must be made good. Also, items found
defective must be replaced/renewed. Split pins and cotters once removed must not be used again. All loose nuts, set screws etc must be properly tightened.
Cotters/split pins, to be fitted on the locomotives, must be of correct size, and, fitted in such a manner as to bear against the nut/washer properly.
4. Examine and ensure that all locking devices, wherever provided, are secure.
5. There are certain fundamental requirements that are important for any successful maintenance programme. These are:
a) Adequate provision of well-trained supervisors and quality workmen.
b) Adequate provision of proper maintenance facilities and tools.
c) Adequate time for completion of schedule maintenance work before release of the locomotive for service.
d) Provision of adequate quantity of the consumables like fuel, lubricating oil, treated water etc.
e) A well planned maintenance programme including an adequate system of maintenance records.
6. Further, following general instructions are common for all types of locomotives and must always be kept in mind by the maintenance staff of the running
Diesel Shed:
a) All measuring devices such as torque wrenches, electric meters, lubricant dispensers etc, which require calibration, should be checked on at
least quarterly basis for accuracy, or, sooner if required.
b) All tools, parts etc should be accounted for and removed from the locomotive after any maintenance work has been performed.
c) All work done including methods, tools etc used for maintenance should be in accordance with the guidelines like manufacturer’s
instructions, maintenance manual, technical orders etc.
d) Use of waste cotton on diesel locomotives is prohibited. Use lint-less rags /wiping towels for improving the appearance, exterior and interior,
of the locomotives. Exterior of locomotives including roof, body, bogies etc are to be washed on each trip. Spraying water directly on the
electrical equipments like traction motors etc should be avoided. The interior of engine room, including power pack should be properly
wiped and cleaned. Proper cleaning should be ensured on: Interior of driver cabin, all the windows- inside and outsides, headlight lens,
interior of the nose compartment etc.
e) Measures of safety including those for fire prevention in locomotives should be in accordance with the existing instructions.
7. Items of maintenance schedules are telescopic in nature, that is, items of lower schedules get covered in higher schedule.
LEGENDS/ABBREVIATIONS
1. Documents pertaining to M/s EMD:
 LOM means Locomotive Operators Manual: GT46 (MAC/PAC)
 LSM means Locomotive Service Manual: GT46 (MAC/PAC)
 EMM means Engine Maintenance Manual: 710G3B
 MI means EMD Maintenance Instruction (Includes Nos 1515, 1519, 1746, 3317 etc)
 PC means Parts Catalogue: GT46 (MAC/PAC)
 ETI means EMD Engineering Test Instructions (Includes 892, 904 etc)
2. Documents pertaining to RDSO:
 MP.IB (or IB)
 MP.MI (or MI)
3. Others:
 M-Mechanical items
 E-Electrical items
 NS-Non Scheduled attention
REMARKS
1. Items for 90/180 day schedule are not much different. However, wherever applicable, items specific to 180 day schedule have been distinguished by
mentioning in brackets (alongside the items). Similar is the case with yearly/two yearly schedules.
2. In case of 5500HP locomotive (WDG5):
2.1 Electrical locker (E-locker) has taken the place of cabinets for ECC1, ECC2, ECC3, TCC1, TCC2 etc collectively, retaining the functionality of equipments at the
same time. E-locker, which effectively comprises control cabinets and inverter cabinet is supplied as single welded unit, pre-wired and tested. Therefore,
much difference is not envisaged in the maintenance schedule of E-locker. Schedule periodicity as applicable to ECC1, ECC2, ECC3, TCC1, TCC2 of
WDG4/WDP4 locomotives is therefore applicable to E-locker also.
2.2 Maintenance Instruction MP.MI-33 (Rev.00) March 2012 issued by RDSO shall be followed for attention to under-truck (Bogie). Moreover, efforts have been
made for indicating the same against the applicable items in the standard schedule of examination.
3. Effort has been made to list out the items for attention against schedules. Also, mention has been made about documents like MI etc alongside. In some
cases, MIs may contain maintenance details which are not applicable to lower schedules but are still mentioned alongside. This has been done for better
understanding of the item of maintenance.
GENERAL:
The schedule of standard examination has been prepared in view of existing equipments, parts, components etc of the locomotives. There is scope for changes in
these equipments, parts, components etc in future which may arise due to changes in technology or otherwise. There is need to keep the schedule of standard
examination updated in view of such changes. In addition, Diesel Sheds/Railways may have better experience, ideas etc regarding locomotive maintenance. Benefits
of such better experience, ideas etc may be exploited. Further, Railways may share experience regarding addition/deletion of items of maintenance schedule.
Accordingly, Railways are advised to send their suggestions.

Standard Schedule of Examination: Details
Item E/ Parts Schedule Stopped/ Work to be done Remarks

no M Periodicity Running
1. E All interior and Trip/Monthly Stopped Inspect and test working of the following:
exterior lights, alarms, Flasher lamp auto & manual; Head light & inputs to DIO; Classification lamp,
fans etc Horns & inputs to DIO; Sanders & direction; Cab light & maintenance lights,
AEB reset switches and indicators; Alerter lamp, alarm & reset; Flasher light
switch panel; GR, DB cutout & B/B cutout seals; Indication panel PTT
switches, Attendant call bell, Cab fans and air brake fans, cab AC unit.
2. E TCC blower, Cooling Trip/Monthly Stopped/ Conduct the following self tests:
fan, Wheel slip, DCL, Running Load test, TCC blower test, Cooling fan test, Meter test, Wheel slip test, DCL
Excitation, Contactor shorting, Excitation test, Contactor & relay test, Radar test, Load regulator
& relay, Radar, Load test.
regulator FIRE
Screens, FIRE power Check working of FIRE Screens and FIRE power supplies (WDG5).
supplies etc.
3. E ECC 1, ECC 2, ECC 3, E- Trip/Monthly Running Ensure all components are working and are in good condition inside:
locker and Control ECC 1, ECC 2, ECC 3, E-locker (WDG5) and Control stands.
stands
4. E Dynamic brake Trip/Monthly Running i. Check functioning of both dynamic brake controllers.
controllers, fuel pump ii. Record fuel pump motor current, DVR voltages, Rad fan 1 and 2 currents
motor, DVR, Rad fan, iii. Check & ensure the following items:
Event recorder/ Crash a. Event recorder/ Crash Hardened Memory function (WDG5).
Hardened Memory b. Cleanliness of driver cabinet.
Event recorder, Driver c. Check cab roof sealing and provide sealant if necessary.
cabinet, AEB, EBT, d. Check AEB function with AEB switch turned ‘on’
Radar, MVCC, AEB e. PT phone & jumper cable
etc. f. EBT operation.
h. Radar air blow operation.
i. MVCC operation.
j. Check low voltage grounds from Aux. Gen & Comp. Alt and attend if
any.
k. Check for ‘AEB’ operation at all settings. If AEB unit exists in
locomotive.
5. E Main Alternator (MA), Trip/Monthly Running a. Check for any unusual sounds from main and companion alternator. Refer MI 3317-1,
Companion Alternator b. Check carbon brushes, springs, slip rings, slip ring bolts and brush holder Rev E/H.
(CA) etc. for any abnormality.
c. Clean inspection glass windows and visually inspect fuse indicators.
d. Check TG output cables and ensure clean air chamber is cleaned.
e. Check CATB cover and CA enclosures (covers) are intact and ensure not
rubbing against TG coupling disc mounting bolts.
f. Check for any water entry into CAC and arrest with RTV sealant.
6. E Auxiliary generator/ Trip/Monthly Running a. Check for any unusual sounds from auxiliary generator. Refer MI 3707,
TM blower b. Check Aux Gen covers are properly fitted and not rubbing against the Rev B /C.
shaft.
c. Check the condition of TM blower and MA blower.
7. E Dynamic brake motor/ Trip/Monthly Running a. Check for any unusual sounds from motor during computer self test. Refer MI 4104,
radiator cooling fan b. Check for any water traces on DB motors and ensure RTV sealant on DB Rev D.
motor fan mounting bolts.
c. Check for any arcing on commutator of DB motor during self test Refer MI 4105,
d. Visually inspect the condition of radiator fan motor power supply cables. Rev A.
8. E TCC electronic blower Trip/Monthly Running a. Check for any unusual sounds from motor and blower assembly during
motor, dust bin engine run.
blower motor etc b. Check the condition of connector and receptacles and ensure proper
locking.
c. Check condition of air ducts and clamps.
9. E Motors (fuel pump Trip/Monthly Running a. Check and ensure normal functionality of FPM/ TLPM and governor
motor/TLPM/ /stopped booster pump motor (in PAC locos).
governor booster b. Check for any unusual sounds from FPM/TLPM/Gov. Booster pump motor.
pump motor/ starter c. Check starter motors for pinion /ring gear damage, intactness of mounting
motor etc) bolts.
d. Check for motor guard whether intact.
10. E Traction motor and Trip/Monthly Stopped a. Inspect all cables (Power, sensor and earthing) for insulation damage or Refer MI 1517A
cables cut marks.
b. Inspect all cable cleats for broken studs, excessive tightness and rubber Refer traction
cleat damage. motor operating
c. Inspect all sensor (Speed &Temp) plugs for correct locking. instruction
d. Inspect all air ducts (TM Bellows) and fixing bolts for damage. A1A25110E/01.20
e. Inspect all motors for any hit marks, physical damage and presence of all 01/Version 1.
end shield cover bolts.
f. Inspect cable junction plates and umbrella boots for signs of damage or
overheating.
g. Ensure all cables are routed properly and there is no excess/short cable
over hangs.
h. Apply insulation/spacers at all locations where cables are rubbing each
other and with locomotive body.
i. Blow all the traction motors with dry compressed air.
11. E Radar Trip/Monthly Stopped a. Ensure Radar mounting Angle is not disturbed and mounting bracket bolts
are tight and intact.
b. Inspect and clean Radar face plate with soap water
c. Ensure Radar Safety Guard is intact and no damages.
d. Ensure Radar connector is properly locked
e. Conduct Radar Self Test and verify
f. Ensure Radar Air Blast Pipe nozzle is directed to Radar faceplate and air
blast is working
12. E Battery Trip/Monthly Stopped a. Ensure all vent plugs are intact.
b. Check the lock assembly of Covers.
c. Blow out all the dust.
d. Clean with water thoroughly.
e. Check for low voltage grounding.
f. Visual check-up of Cables / Terminals for tightness.
g. Check for Leakages from cells
h. Ensure adequate packing between batteries against rubbing.
i. Check battery containers for damage.
j. Check & Record Specific Gravity.
k. Record Electrolyte level. (Before water topping)
l. Record Cell voltages (Engine dead & On load)
m. Record details of water added in each cell. (Add water when Engine is
running
n. Record make, Sl No.
o.Provide terminal guard plates for all lead acid batteries.
13. M Air brake system Trip/Monthly Running a. Check functional operation of CCB 1.5 and CCB II-IR and Auto & Refer ETI 0991 for
CCB 1.5 Independent brake valves. CCB 1.5 & NYT
CCB II-IR b. Check fault archive of CCB. 1794-C for CCB II-
c. Conduct air brake self test from both control stands. IR.
d. Check CRU (CCB 1.5)/LRU (CCB II-IR) all connectors for proper locking.
e. Check working of Asst. Driver emergency valve.
f. Check brake pipe pressure from both Control stands i.e. S/H and L/H 5.2
kg/ cm².
g. Check feed pipe pressure 6 kg/ cm².
h. Check brake cylinder pressure during application from both control stands
i.e. S/H and L/H.
i. Check MR pressure, to be within 8.5 to 9.8 kg/ cm² (120 to 140 psi).
j. Check working of airflow indicator from and in both control stands.
k. Conduct blended brake test from both control stands. (PAC Locos only).
l. Check working of horns, wipers, sanders & ABD valves. Drain condensate
from both reservoirs.
m. Check electrical connection of air dryer and their tightness. Refer RDSO
n. Check humidity indicators condition. MP.MI-18 Rev. -
o. Check for any leakages in control stands, CCB System, pipelines. 02, April – 2008
p. Clean CCB rack to remove dust. Amendment 1
q. Check BP and FP hose pipe rubber washer condition & continuity of May 2009 for air
pressure at Hose ends. dryer.
14. M Air compressor Trip/Monthly Stopped/ a. Check compressor oil levels.
running b. Check. Breather valve for proper working /breathing
c. Check leakages in compressor compartment i.e for Air, Water and oil
leakages.
d. Check compressor oil drain, COC handle position & Bottom dummy for
Intactness / tightness.
e. Check compressor extension shaft hub Rubber-Bushes
f. Check for any unusual sound in Compressor compartment
g. Check and ensure unusual sound during loading and unloading
h. Open intercooler drain cock both ends and ensure no engine cooling
water is leaking out
i. Check air compressor efficiency test with 7.14 mm choke at 8th notch.
15. M Fuel system, governor Trip/Monthly Running Check and properly attend for:
and valve lever i. Fuel line leakage.
ii. Fuel header leakage.
iii. Fuel return pipeline leakage.
iv. Rubbing of suction pipe to Strainer /any puncture in pipe
v. Leakages in fuel return sight glass.
vi. Bubbles in return sight glass
vii. Fuel in bypass sight glass.
viii. Check the fuel primary housing vent cock for leakage.
ix. Fuel tank sight glass condition.(Glow rod gauge).
x. Fuel tank filling strainer condition.
xi. Check the fuel tank for any leakage / swetting of fuel at the bottom
welded joint.
xii. Check proper securing of fuel tank /tank Securing nuts.
xiii. Fuel pump love-joy coupling condition.
xiv. Fuel pump oil leakage.
xv. Governor oil level.
xvi. Condition of adaptor and hose pipe of governor booster pump.
xvii. Check the air box pressure pipe and its connection to governor. Check
free movement of the rack.
xviii. Open the fuel pump cover and clean the Idler Gear bush. If found
defective, Replace the pump. (Horizontal pump only).
xix. Top deck Inspection.
i. Valve lever mechanism for proper lubrication and unusual sound.
Pinching of lash adjusters.
ii. Cam rollers rotation (any sliding mark or unusual sound).
iii. Any leakages or vibration in governor oil pressure sensing Pipeline &
clamp intactness.
xx. Latch & stopper’s inspection. Condition of the top deck latches and
stoppers.
xxi. Check for any pipe line rubbing to the by-pass gauge of the fuel.
16. M Radiators Trip/Monthly Running/ a. Visually examine proper seating of Radiators and tightness of securing
stopped bolts.
b. Blow both radiators with compressed air in the opposite direction of
normal air flow.
c. Perform cooling system pressure test
d. Visually inspect all joints for leakages
e. Check operation of EPD
i. Low water
ii. Low crankcase vacuum
f. Check condition of water level gauge and clean.
g. Check the condition of lube oil filters and change if warranted.
h. Check for water pump leakages through tell-tale hole.
i. Any unusual sound from water pump/lube oil pump.
j. Irrespective of the schedule attention on due date, renew the filters and
‘O’ rings, if any.
k. Check for any vibration at:
i. Radiator
ii. Equipment rack
l. Check all safety brackets/clamps in lube oil and cooling water system.
17. M Power pack Trip/Monthly Stopped/ a. Top deck inspection.
running i. Valve lever mechanism for proper lubrication and unusual sound,
pinching of lash adjusters.
iii. Injector linkages and fuel rack; EUI (WDG5).
iv. Sensors to determine crankshaft speed and position, system pressures
and temperatures (EMDEC WDG5)
v. Pin retainers.
vi. Any leakages or vibration in governor oil pressure sensing pipeline &
clamp intactness.
b. Check for leakages:
i. Water leakages.
ii. Lube oil leakages.
iii. Air box and sump cover leakages.
c. Visual check exhaust manifold:
i. Any missing bolts.
ii. Gasket leakages.
iii. Any bolt head cut.
d. Condition of expansion bellows.
e. Check for any water level reduction.
f. Check for unusual vibration/leakages from cam gear housing.
g. Remove and tap baggie filters & refit.
(Pressure drop across baggie filters (5”-14” H2O)).
h. Check for any lube oil/ water entry in clean air compartment.
i. Check and record exhaust gas temperature of each cylinder.
j. Turbo inlet temperature
k. Auxiliary Generator shaft checking Engine side and Gen. side
i. Condition of couplers.
ii. Condition of shaft.
l. Record CC- Vacuum (2”-8” H2O).
m. Record vibration levels at Aux. Gen end at Cam Gear end and OST Cover
end.
18. M Turbo Trip/Monthly Running Engine running:
a. Check for oil leakage
b. Check for water leakage
c. Check air leakage
d. Whether spin on pipe line touches to the engine block or starting motor
Stopped Engine stopped: Check for:

a. Condition of A.G. Shaft Couplers & Shaft
b. Condition of A.G. Shaft Guard
c. Condition of A.G. Drive housing
d. Check Partition plate rubbing to Baggie filter housing adjust if necessary
e. Check rubber air intake boot , clamps in correct position adjust if
necessary
f. Remove the 16th oil pan hand hole cover and visually check lube oil
draining from turbo charger gear train.
19. M Under truck, Under- Trip/Monthly Stopped a. Buffer:
frame and allied Check and attend:
parts/sub-assemblies i. Any crack or bolt found slack.
etc. ii. Any buffer rotating.
iii. Clean all buffers properly & lubricate.
iv. Free movement/functioning of the buffer during compression and
release shall be ensured and repaired if necessary following the
guidelines contained in MP.MI-116/82 (Rev. 02) Nov 2000.
b. CBC & screw coupling:

i. Clean both CBC & Screw couplings & lubricate.
ii. Check and attend any damages found in CBC & screw coupling
iii. Check CBC & its working condition.
iv. Check whether CBC safety locking pin available
v. Check for proper working of screw coupling & locking.
vi. Check CBC draw bar for any dropping.
vii. Check for any missing components.
c. Cattle guard & Rail guard:

i. Check for condition, missing bolts, slackness etc and attend as
required.
ii. Adjust the height of cattle guard (6½”) & Rail guard(4½”) as required.
d. Hand brake & brake cylinder:

i. Brake piston travel length/ Adjust if required.
ii. Any air leakage, Bolts slack in brake cylinder.
iii. Check Hand brake, Pinion, Ratchet, releasing pin, Pulley and chain. Refer RDSO
iv. Check proper functioning of Hand brake. MP.IB.VL-18.82.09
v. Clean Hand brake assembly & lubricate. (Rev.00).
vi. Check hand brake assembly for proper working and adjust if necessary.
vii. Any air leakage, Bolts slack in brake cylinder.
viii. Brake piston travel length/ Adjust if required.
e. Brake and Brake hanger assembly: Check and attend for:

i. Any slackness found in brake hanger assembly.
ii. Any location slack adjuster pin missed or without split pin.
iii. Any location B/B rubbing on the Wheel flange area.
iv. Any location brake head drooping.
v. Any location B/B damaged or worn out more than limit
vi. Any location slack adjuster giving problem to adjust.
vii. Any location B/B cotter pin missed or damaged or rubbing on wheel.
f. Sanders brackets, hoses & Nozzles: Check and attend for:

i. Any puncture found in hose pipe or nozzle.
ii. Nozzle direction, adjustment etc.
iii. Any damages found in sander brackets.
g. Axle Lateral Thrust Pad Assembly:

Inspect for any damaged pads. Replace with new if severely damaged.
h. Trucks (visual examination)

i. Inspect the truck frame for any crack.
ii. Vertical dampers top & bottom bracket condition.
iii. All spacer rubber available.
And, check and attend for:
iv. Any rubbing marks
v. Any location TP bracket broken found or bolts slack.
vi. Any centre pivot bolts slack in unsealed condition.
vii. Any breathing mark found in car body assembly.
viii. Any breathing mark found in centre Pivot carrier assembly.
ix. Any stay plate bolts found slack.
x. Any damages found in TM Nose link.
i. Wheel & Axle:

Check and attend for:
i. Any pitting, wheel-binding marks or skidding found.
ii. Any cracks found in wheel by visual or Hammer checking.
iii. Any location axle Allen screw slack, greasing dummy missing found.
iv. Record wheel diameter & wear parameters.
j. Gear case mounting:

Check and attend for: Refer MP.IB.EM
i. Any damages, cracks & leakages found in Gear case mounting. 03.12.10, dated
ii. Any dummies found slack or missed condition. 05-03-2010.
iii. Any Allen screws found in slack or missed or broken condition.
iv. Gear case oil level. Add if required.
k. Bearing Adapter Assembly with journal Bearing: Refer MI 1517 Rev

Journal Bearing should be visually inspected for the followings: A and MP.MI -33.
0
i. Sign of overhearing (Temperature should not exceed more than 56 C
above ambient).
ii. Excessive lubricant leakage from the grease seals.
iii. Broken, loose or missing parts (such as loose cap screws, etc.)
iv. Loose or defective seals.
v. Cracked or broken cups, end caps or adapters, etc.
Note: If above problems are noticed, the journal bearings should be
removed from service for detail investigation and subsequent overhauling of
the bearings. Refer EMD MI
Remark: During Wheel Change, Journal bearings must be removed from 1553.
service for overhauling.
l. Suspension: Refer MP.IB.VL.

i. Inspect for any leaking dampers & check for any slack bolts in Vertical 01.02.12 (Rev.00)
dampers Yaw dampers & torque.
ii. Any coil springs for damages/ breakage/crack.
iii. Inspect for any broken/damaged happy pad. Replace with new if any
broken happy pad is found.
iv. Inspection of secondary rubber spring.
Remark: If any damper has become due for overhauling/ renewal, the same
should be replaced by an overhauled / renewed/new damper.
Refer RDSO
m. Tread Brake Unit (TBU) ( WDG5): MP.MI - 33
a. Inspect for any impact damage, loose or broken bolts. (Rev.00) March
b. Poke out the breather hole with a rod-like tool. 2012
c. Inspect the tread brake unit, especially the bellows, for damage.
d. Check the unit for ease and freedom of movement, and re-grease as
required.
e. Check the dust filter (if included) for dirt.
n. Traction Motor Cables & Cleats

Check for any signs of damage / rubbing on the TM cables & cleats.
20. M Toilet (WDG5) Trip/Monthly Stopped Clean the toilet. Check and attend any deficiency etc.
21. E Control stand covers, 90 days Stopped a. Attend the bookings
ECC1, ECC2 and ECC3 b. Open control stand covers and blow out all the dust.
cabinets, E- c. Blow out all the dust in ECC1, ECC2, ECC3 and E-locker (WDG5) cabinets
locker(WDG5), Head d. Open head light resistance covers and blow.
light resistance e. Blow out all the dust inside the IPRS
covers, IPRS, grids, f. Blowout dust inside the grids and remove any waste f. Refer MI 1601.
ECC1 cabinet, EM g. Thoroughly clean ECC1 cabinet, E-locker (WDG5), EM2000 chassis and
2000 chassis and power supply chassis.
power supply chassis, h. Clean all electrical cabinets with moist cloth.
all electrical cabinets i. Clean both the control stands and cab thoroughly.
and both the control
stands and cab.
22. E Control stands 90 days Stopped a. Check for any loose or overheated connections in all the terminal boards.
b. Check all the switches for loose connections and free operation.
c. Check indication panels for loose or improper connections.
d. Check slide switches for correct operation.
e. Provide missing screws, nuts and bolts.
f. Renew defective switches or any other components
g. Open bezel assembly of controllers check for missing springs, screws,
damaged sleeve, readout drum etc and attend.
h. Check bezel for free wipers movement, damage etc.
i. Replace missing or damaged latches.
j. Check Parking Brake Pressure Switch (PBPR) (WDG5)
23. E ECC1, E-locker(WDG5) 90 days Stopped a. Check all circuit breakers for loose or overheated connections.
b. Check all panel mounted modules for broken connecting plugs, missing
jackscrews etc.
c. Check power supply modules for damaged pins and screws.
d. Inspect power supply chassis for signs of bent pins, loose connectors and
pushed back pins from the back.
e. Inspect EM2000 chassis for damaged module slots, bent pins. Check for
loose plugs and missing jackscrews from the back.
f. Inspect power supply ribbon connector for tight fitment and insulation for
prevention of rubbing.
g. Check all the contactors and switchgears for loose connections, sparking
and correct fitment of arc chutes.
h. Check SCR bridge for loose connections and overheating marks.
i. Check all the relays, resistors and other components for loose or
oveheated connections.
j. Inspect MUTB for loose connections and foreign material
k. Check all terminal boards and ensure all plugs are properly locked.
l. Check gaskets, latches and hinges of all the doors and covers.
m. Inspect all EM2000 modules for jack screw threads damage and correct
application.
n. Provide missing bolts and nuts.
o. Ensure cab roof sealing is well applied.
p. Renew filter.
q. Check all switches and meters on engine control panel
24. E ECC2 90 days Stopped a. Check battery charger for loose or overheated connections.
b. Check ST and STA contactors for loose connections, signs of distress and
mechanical damage.
c. Check both terminal boards and aux gen breaker.
d. Check DCL reactor and ensure back side clearance is adequate.
e. Check for damaged or missing latches bolt and nuts and hinges.
f. Blow filter with air and clean.
g. Renew filter (180 days).
h. Check hose pipe for damage and clamps.
25. E ECC3 90 days Stopped a. Check all the connections of contactors and terminal boards.
b. Check all bus bars for overheating and cracks.
c. Ensure free travel of plunger of all contactors.
d. Check busbar support welding.
e. Replace damaged or missing latches, bolt and nuts and hinges.
f. Blow filter with air and clean.
g. Renew filter (180 days).
h. Ensure backside cleat sealing is intact and no water leaks into the cabinet.
i. Provide spacer for outgoing cables wherever rubbing.
j. Check all connectors for damage and correct locking.
k. Check hose pipe for damage and clamps.
26. E Miscellaneous 90 days Stopped a. Check terminal board behind head light assemblies
(Electrical) b. Check IPRS for damage and overheating.
c. Provide spacers for IPR cables wherever touching to metal body and
looming bars.
d. Check battery knife switch and connections for slackness.
e. Check headlight resistances and connections for slackness.
f. Check grid cables for damage, rubbing and overheating.
g. Check grids for displaced resistor element and flash marks on insulator
and cracked insulators.
h. Check EPU, TPU, MRPT and other sensors for clearance and connector
locking
i. Inspect VCU and connectors
j. Clean cab light assembly & provide all maintenance room and exterior
lamps.
k. Inspect MU receptacles on both ends
l. Renew dyna cell filters (180 days)
m. Replace Condenser filter, Return air filter & Fresh air filter of AC unit
(WDG5)
27. E Main alternator & 90 days Stopped a. Open cover and blow off dust from TA, Aux. Gen. DB motors FPM, TLPM &
companion alternator GBPM at low pressure.
b. Brush condition & brush arm assembly
c. Pig tail overheating
d. Spring tension
e. Slip ring fixing bolts
f. Condition of fuse indicators f. Refer MI 3317-1
g. Slip ring condition, cabling. Rev. H
h. Clean companion alternator O/P TB and ensure connections are intact. Refer MI 3317-2
i. Open TG O/P bus bar guards and clean with dry cloth. Rev. D
j. Inspect diode fuse indicators and ensure diode bank is cleaned. Refer MI 3317-3
k. Reversal of CA field polarity once in every 90 days. Rev. nil
l. Reversal of CA and MA field polarity once in every 180 days.
28. E Auxiliary generator/ 90 days Stopped Auxiliary generator: Refer MI 3707
radiator fan motor a. Inspect diode plate and clean with cleaning solvent for electrical machines Rev. C
if necessary. Refer MI 4105
b. Check for intactness of covers with bolts. Rev. A
c. Check for any unusual sound & rubbing marks
Running Radiator fan # 1 & 2:
Check for any unusual sounds and intactness of cables.
29. E Dynamic brake motor 90 days Stopped/ a. Check for proper function of DB motors/record currents Refer MI 4104
running b. Check for any sparks during DB self test at stabling. Rev. D
c. Condition of brush arm assembly
d. Ensure the RTV sealing on fan mounting bolts
e. Rotate fan by hand and check for free rotation
f. Check carbon brush, spring tension by hand and condition of commutator
(scoring/ over-heating marks etc)
30. E Fuel pump motor / 90 days Stopped/ a. Ensure the intactness of terminal box & cable conduit
TLPM/governor running b. Check for loose base bolts.
booster pump motor c. Check for any unusual sounds from motors
d. Measure FPM current & TLPM current
31. E TCC electronic blower 90 days Stopped/ a. Check for proper operation of motors and any unusual sounds from
motor/ dust bin running motor and blower assembly.
blower motor b. Check foundation bolts, connectors and receptacles.
c. Check hose pipes & clamps.
32. E Traction motor blower 90 days Stopped/ a. Intactness of fasteners, intake ring, guard.
running b. Check for any unusual sound during engine run.
33. E Starting motor 90 days Stopped a. Check the condition of drive gear and ring gear.
b. Check for intactness of cables and clean.
c. Check intactness of motor guard.
d. Lubricate bushes with SAE 20/40 oil
e. Clean starter motors & cables
34. E Sizes brush and spring 90 days Stopped Note down sizes brush and spring tension
tension TA, TM and
TLPM.
35. E/ Fault archive 90 days - Verify fault archive and driver repair books for following faults:
M a. Ground relay power/dynamic brake.
b. Speed sensor or locked axle faults.
c. Temperature sensor or hot traction motor faults.
d. Radar feedback and DC link over voltage faults.
e. Inverter output over current and GTO/IGBT monitoring faults.
f. Unusual sounds from under truck and jerks on run in power or DB or in
both.
If any of these faults are recorded a thorough inspection of cables, bellows,
connectors, cleats, IR value and motor winding resistance measurements
may be required.
36. E Traction motor and 90 days Stopped a. Thoroughly clean and Inspect all cables (Power, sensor and earthing) for Refer MI 1517A
cables insulation damage or cut marks. Refer traction
b. Inspect all cable cleats for broken studs, excessive tightness and rubber motor operating
cleat damage. instruction
c. Inspect all sensor (Speed &Temp) plugs for correct locking. A1A25110E/01.20
d. Inspect all air ducts (TM Bellows) for damage and fixing bolts. 01/Version 1.
e. Inspect all motors for any hit marks, physical damage and presence of all
end shield cover bolts
f. Inspect cable junction plates and umbrella boots for signs of damage or
overheating.
g. Ensure all cables are routed properly and there is no excess/short cable
over hangs.
h. Apply insulation/spacers at all locations where cables are rubbing each
other and with locomotive body.
i. Open inspection covers, inspect windings for any damage and presence of
foreign material and blow with light compressed air
j. Open motor and car body connection umbrella boots and inspect cable
lugs for signs of overheating.
37. E Radar 90 days Stopped/ a. Verify Radar mounting Angle with inclinometer and record.
running b. Inspect and clean Radar, face plate and bracket with soap water
c. Ensure Radar Safety Guard and mounting bracket are intact, all fasteners
are tight and no damages.
d. Ensure Radar connector is properly locked
e. Conduct Radar Self Test and verify
f. Ensure Radar Air Blast Pipe nozzle is directed to Radar faceplate and air
blast is working
g. Verify Radar status flag is ‘Zero, while moving the locomotive at speed
above 4 kmph.
38. E Battery 90 days Stopped/ a. Ensure all vent plugs are intact.
running b. Check the lock assembly of Covers.
c. Thoroughly Blow out all the dust.
d. Clean with Washing Soda & water.
e. Apply petroleum jelly to terminals
f. Check for low voltage grounding.
g. Visual checkup of Cables / Terminals for tightness.
h. Check for Leakages from cells
i. Ensure adequate packing between batteries against rubbing.
j. Check battery containers for damage.
k. Put oil to all latches and hinges.
l. Check & Record Specific Gravity.
m. Check & Record Electrolyte level. (Before water topping)
n. Record Cell voltages (Engine stopped & on load)
Battery bank 1
Battery bank 2
Charging voltage (Eng running)
o. Record details of water added in each cell. (Add water when engine is
running)
39. M Air brake system 90 days Stopped/ a. Check MR pressure (120 to140PSI) & normal cut-in/cut-out
CCB 1.5 running b. Conduct blended brake test from the both control stand (PAC locos).
CCB II-IR c. Check working of horns, wipers, sanders & ABD valves
d. Check cyclic operation & Memory Feature of air dryer. Refer RDSO
e. Examine the drain valve. MP.MI-18 Rev. -
f. Charge the system from zero pressure and check that dryer does not 02, April – 2008
cycle immediately. Note the pressure when the dryer starts cycling. Amendment 1
g. MRPT pipe to be cleaned/Drain moisture. May 2009 for air
h. Open and clean PVERI, PVBIT & PVBC valves and fit. (CCB 1.5) dryer.
40. M Air compressor 90 days Stopped/ a. Both compressor air filters condition to be checked, change if required.
running b. Grease L.P & H.P. Unloaders.
c. Record compressor oil pressure & Inter cooler pressure during load test
(oil pressure –15 psi min at 600C in low Idle after load test).
(Inter cooler pressure –40 psi min)
d. Flush compressor oil with fresh oil (180 days).
e. Renew compressor spin on filter (180 days).
41. M Fuel system, governor 90 days Stopped Check and properly attend the following:
and valve lever a. Fuel line leakage.
mechanism b. Fuel header leakage.
c. Fuel return pipeline leakage.
d. Rubbing of suction pipe to Strainer/Any puncture in pipe.
e. Leakages in fuel return sight glass.
f. Bubbles in return sight glass.
g. Fuel in bypass sight glass.
h. Check the fuel primary housing vent cock for leakage.
i. Fuel tank sight glass condition. (Glow rod gauge)
j. Fuel tank filling strainer condition.
k. Check the fuel tank for any leakage/swetting of fuel at the bottom welded
joint
l. Check proper securing of fuel tank /tank Securing nuts
m. Fuel pump love joy coupling condition.
n. Fuel pump oil leakage.
o. Governor oil level.
p. Condition of Adaptor and hose pipe of Governor booster pump.
q. Check the air box pressure pipe and its connection to Governor.
r. Check free movement of the rack.
s. Open the fuel pump cover and clean the Idler Gear bush. If found
defective, Replace the pump. (Horizontal pump only).
t. Top deck Inspection.
i. Valve lever mechanism for proper lubrication and unusual sound
pinching of lash adjusters.
iii. Any leakages or vibration in governor oil pressure sensing pipe line &
clamp intactness.
u. Latch & stopper’s Inspection.
Condition of the top deck latches and Stoppers.
v. Renew the Suction Strainer ‘O’ ring & clean the Strainers. Give the oil
sample to the lab.
w. Renew the Primary filter (180 days) and its ‘O’ ring and Clean the inner
side of the Primary filter housing.
x. Close the vent cock and drain cock of the primary filter.
y. Prime the fuel and check for any bubbles in return sight glass.
z. Renew engine mounted spin-on fuel filter elements.
42. M Heat Exchangers 90 days Stopped a. Visually examine proper seating of radiators and tightness of securing Refer MI 549.
bolts.
b. Blow both radiators with compressed air in the opposite direction of
normal air flow.
c. Perform cooling system pressure test at 20 psi.
d. Visually inspect all joints for leakages.
e. Check operation of EPD
i. Low water
ii. Low crankcase vacuum
f. Check condition of water level gauge and clean.
g. Check the condition of lube oil filters and change if warranted.
h. Renew lube oil filters (180 days). h. Refer MI 926.
i. Clean all lube oil strainer all elements & renew ‘O’rings.
j. Clean eductor & oil separator mesh.
43. M General 90 days Stopped/ Initial run check:
running a. Check the Engine repair book and record any important remarks and
bookings.
b. Check the fault archive data and record any significant faults up to
previous schedule.
c. Inspect all under frame air pipelines for leakages.
d. Visually inspect CBC, Side buffers, Air hoses, Cattle guard, Rail guard,
Shock Absorbers etc and record any unusual.
e. Drain the moisture from both Main Reservoirs.
f. Inspect the fuel tank for leakages, check the filling strainer and glow rod
gauges.
g. Check the levels:
i. Engine oil (at 720C)
ii. Governor oil
iii. Cooling water
h. Inspect Engine top deck at engine idling. Check for proper lubrication, fuel
leaks, cam roller rotation etc.
i. Check the air pressure readings of MR, BC, BP and MREQ gauges.
j. Inspect spring loaded water pressure cap/Expansion tank pressure relief
valve for proper working.
k. Conduct self load test and check for leakages (Air, Fuel oil, Lube oil,
Coolant water, and exhaust gas leakages) and any unusual noise and
odors. Record findings.
Final run check Final run check

Cleaning and general attention jobs Ensure that the
Ensure : locomotive is
a. Cab cleaning. ready from all
b. Interior cleaning including Engine, Generator and compressor pits. sections including
c. Cleaning of air chamber aspirator hole. renewal of filters.
d. Exterior cleaning. Crank the Engine
e. Under frame items cleaning. as per cranking
d. Check and ensure no water leakage into the cabin. procedures.
Ensure Pre-lube of
Inspect : lube oil system if
a. Cab for Misc. holders and sun visors. engine is shut
b. Doors / hinges / windows down for more
c. Driver seats than 48 hours.
d. Air brake compartment covers
e. Window and door glasses.
Component check
i. Check the following levels and top up if required.
a. Engine oil (at 720C)
b. Governor oil
c. Cooling water
d. Fuel level
ii. Check the operation of
a. Sanders
b. Horns
c. Wipers
d. ABD valves
iii. Inspect Engine overhead at engine idling. Check for proper
lubrication, fuel leaks, cam roller rotation etc.
iv. Check for correct air pressure settings.
a. Main Reservoir (130-140psi)
b. Brake pipe (74psi)
c. Eq reservoir (74psi)
d. Brake cylinder (74psi)
e. Compressor control (130-140psi)
v. Inspect all under frame air pipelines for leakages.
vi. Visually inspect CBC, Side buffers, Air hoses, Cattle guard, Rail guard,
Shock absorbers etc and ensure that all are in proper condition.
vii. Inspect the fuel tank for leakages, check the filling strainer and glow
rod gauges.
viii. Inspect spring loaded water pressure cap/Expansion tank pressure
relief valve for proper working.
ix. Conduct self load test and check for leakages (air, Fuel oil, Lube oil,
Coolant water, and exhaust gas leakages) and any unusual noise and
odours. Ensure that all the IRC bookings are attended.
x. Provide Safety spares:
a. Wooden wedges
b. BP hose
c. FP hose
d. Spare sand bags
e. Fire extinguishers (ensure the due dates)
f. U-Clamp for PAC locos only.
xi. Provide Driver Repair Book after indicating relevant details therein
including details of next schedule due date etc. Provide new trip
card/sheet.
44. M Power pack 90 days Running/ i. Conduct load test and record readings:
stopped ii. OSTA Tripping RPM (1035-1050) 4000/4500HP Engine
iii. Differential Pressure across After Cooler Inches of H2O (25”Max—
15”Max for New) (4000/4500 HP Engine/WDG5)
iv. Compression Pressure readings in PSI: (275-350psi)
v. Check exhaust screen for debris/foreign material
vi. Check piston crown
vii. “Pee” Pipe alignment
viii. Following Filters to change.
a) Turbo spin on
b) Soak back lube oil
c) Baggie filters
ix. Impeller condition (Visually).
x. Check operation of engine protector. Refer MI 260
45. M Turbo 90 days Stopped/ The following items are to be checked and recorded: ii g. With the
running engine shut down
i. Engine running: and soak back
a. Check for oil leakage pump running,
b. Check for water leakage. remove left rear
c. Check for Air leakage. hand hole cover
d. Whether spin on pipe line touches to the engine block or starting and check oil flow
motor. through gear
trains. Observe
ii. Engine stopped: camshaft
a. Condition of AG Shaft Couplers & Shaft. bearings. If lube
b. Condition of A.G. Shaft Guard oil flow from
c. Condition of A.G. Drive housing camshaft bearings
d. A.G. Shaft bolts torque checking with soak back
e. Checking of A.G. Shaft alignment, thrust clearance and backlash pump running
f. Soak back filter changing while the engine is
g. Turbo lube oil filter shut down,
h. Engine air filters inspect spin-on
i. Condition of Turbo impeller turbo lube filter
j. Inspection of loose/ missing bolts outlet check valve
for proper
operation.
46. M Under truck, Under- 90 days/180 Stopped 1. Buffer:
frame and allied days a. Check for crack or bolt slack.
parts/ subassemblies b. Check for buffer rotating.
etc. c. Clean all buffers properly and lubricate.
d. Free movement/functioning of the buffer during compression and
release shall be ensured and repaired if necessary following the
guidelines contained in MP.MI-116/82 (Rev. 02) Nov 2000.
2. CBC & screw coupling:

a. Clean both CBC & Screw couplings & lubricate.
b. Check and attend any damages found in CBC & screw coupling
c. Check CBC & its working condition.
d. Check whether CBC safety locking pin available
e. Check for proper working of screw coupling & locking.
f. Check CBC draw bar for any dropping.
g. Check for any missing components.
3. Cattle guard & Rail guard:

a. Check for general condition, slackness, missing bolts etc and attend
as required.
b. Adjust the height of cattle guard (6½”) & Rail guard (4½”) as
required.
4. Suspension:
a. Inspect for any leaking dampers & check for any slack bolts in Refer MP.IB.VL.
Vertical dampers Yaw dampers & torque. 01.02.12 (Rev.00)
b. Any coil springs for damages/ breakage/crack.
c. Inspect for any broken/damaged happy pad. Replace with new if any
broken happy pad is found.
d. Inspection of secondary rubber spring and necessary attention.
Remark: If any damper has become due for overhauling /renewal, the same
should be replaced by an overhauled / renewed/new damper.
5. Hand brake & brake cylinder:

a. Brake piston travel length/ Adjust if required.
b. Any air leakage, Bolts slack in brake cylinder.
c. Check Hand brake, Pinion, Ratchet, releasing pin, Pulley and chain.
d. Check proper functioning of Hand brake.
e. Clean Hand brake assembly & lubricate.
f. Any air leakage, Bolts slack in brake cylinder.
g. Check Brake piston travel length/ Adjust if required.
6. Brake and Brake hanger assembly:

i. Any slackness found in brake hanger assembly.
ii. Any location slack adjuster pin missed or without split pin.
iii. Any location B/B rubbing on the Wheel flange area.
iv. Any location brake head drooping.
v. Any location B/B damaged or worn out more than limit
vi. Any location slack adjuster giving problem to adjust
vii. Any location B/B cotter pin missed or damaged or rubbing on wheel.
7. Sanders brackets, hoses & Nozzles:

a. Any puncture found in hose pipe or nozzle.
b. Nozzle direction to check & adjust.
c. Any damages found in sander brackets.
8. Trucks (visual examination)
i. Inspect the truck frame for any crack.
ii. Vertical dampers top & bottom bracket condition.
And, check and attend for:
iii. All spacer rubber available.
iv. Any rubbing marks
v. Any location TP bracket broken found or bolts slack.
vi. Any centre pivot bolts slack in unsealed condition.
vii. Any breathing mark found in car body assembly.
viii. Any breathing mark found in centre Pivot carrier assembly.
ix. Any stay plate bolts found slack.
x. Any damages found in TM Nose link
9. Wheel & Axle:

Check and attend: Refer MI 1517
a. Any pitting, wheel-binding marks or skidding found. Rev. A & MP.MI -
b. Any cracks found in wheel by visual or Hammer checking. 33
c. Any location axle Allen screw slack, greasing dummy missing found.
d. Record wheel dia & wear parameters.
e. Any T.M mounting bolts found in slack condition.
10. Bearing Adapter Assembly with journal Bearing: Refer EMD MI

Journal Bearing should be visually inspected for the followings: 1553.
i. Sign of overhearing (Temperature should not exceed more than 560C
above ambient).
ii. Excessive lubricant leakage from the grease seals.
iii. Broken, loose or missing parts (such as loose cap screws etc.) Refer RDSO
iv. Loose or defective seals. MP.IB.EM.03.12.1
v. Cracked or broken cups, end caps or adapters, etc. 0, dated 05-03-
Note: If above problems to be noticed, the journal bearings should be 2010.
removed from service for detail investigation and subsequent overhauling of
the bearings.
During Wheel Change: Journal bearings must be removed from service for
overhauling.
11. Axle Lateral Thrust Pad Assembly:
Inspect for any damaged pads. Replace with new if severely damaged
12. Gear case mounting:

a. Any damages, cracks & leakages found in Gear case mounting.
b. Any dummies found slack or missed condition.
c. Any Allen screws found in slack or missed or broken condition.
d. Gear case oil level. Add if required.
13. Brake and Brake hanger assembly:

a. Any slackness found in brake hanger assembly.
b. Any location slack adjuster pin missed or without split pin.
c. Any location B/B rubbing on the Wheel flange area.
d. Any location brake head having drooping.
e. Any location B/B damaged or worn out more than limit
f. Any location slack adjuster giving problem to adjust
g. Any location B/B cotter pin missed or damaged or rubbing on wheel.
h. Measure and record buffer length & height.
i. Measure and record rail guard & cattle guard heights
j. All locations gear case oil sample to be tested in lab.
14 Tread Brake Unit (WDG5): Refer RDSO

a. Inspect for any impact damage, loose or broken bolts. MP.MI - 33
b. Poke out the breather hole with a rod-like tool. (Rev.00) March
c. Inspect the tread brake unit, especially the bellows, for damage. 2012
d. Check the unit for ease and freedom of movement, and regrease as
required.
e. Check the dust filter (if included) for dirt.
180 days
Attend all items of 90 days and following additional items:
a. Inspect primary interlock chain arrangement visually for securing Refer MI 1517A
(WDG5 loco). and MP.MI-
b. Axle Lateral Thrust Pad Assembly: Inspect for any missing pads. 33(WDG5).
Measure Axle Lateral clearances. Refer MP.IB.VL.
c. Measure secondary vertical and lateral stop clearances. 01.08.11 (Rev.00)
d. Measure primary vertical clearance (WDG5). and MP.MI-33
e. Inspect Secondary Interlock (Chain) including shackle, link and pin (Rev.00) March
assembly for any loose pins and damage. 2012(WDG5).
f. Inspect primary interlock rod(for WDG4/WDP4)
47. E Control stand covers, Yearly Stopped a. Remove the controller to overhauling section.
ECC1, ECC2 and ECC3 b. Remove EM2000 display, all modules from EM2000 and power supply
cabinets, E-locker, chassis and hand over to module room in anti static covers.
Head light resistance c. Blow out all the dust inside the ECC1, ECC2 and ECC3 cabinets, or, E-
covers, IPRS, grids, locker (WDG5).
ECC1 cabinet, EM2000 d. Open control stand covers and blow out all the dust.
chassis and power e. Open head light resistance covers and blow.
supply chassis, all f. Blow out all the dust inside the IPRS
electrical cabinets and g. Blowout all the dust inside the grids.
both the control h. Handover speedometers & TE/BE meters to calibration section.
stands and cab. i. Remove DBGR, FLSHR and GR and handover to overhauling section.
j. Remove ST contactor and handover to overhauling section.
k. Remove headlight resistor clean, check the value and refit.
l. Take megger readings [ensure all modules, x-plugs, breakers & knife
switch open] of grid path 1, 2; TCC1, TCC2 I/P cables, TA, TM1, TM2, TM3
and same for truck 2.
48. E Control stand Yearly Stopped a. Clean both the control stands thoroughly.
b. Inspect all components and connections for signs of overheating and
stress and replace if necessary.
c. Check all the switches for loose connections and free operation.
d. Check indication panels for loose or improper connections.
e. Check slide switches for correct operation.
f. Provide missing screws, nuts and bolts.
g. Load the overhauled controller given by section.
h. Check controller for free movement, power and DB operation etc.
i. Replace missing or damaged latches.
j. Ensure sealant applied around BP pipe is intact.
k. Provide calibrated speedometers and TE/BE meters.
49. E ECC1 Yearly Stopped 1. Thoroughly clean the cabinet with soap water
2. Check and tighten all circuit breakers connections.
3. Check all panel mounted modules connectors for damage, missing
jackscrews, guide pins etc and replace.
4. Ensure insulation provided for module wire bunch against rubbing is
intact.
5. Load tested DBGR, FLSHR and GR.
6. Check power supply chassis connectors for pushed back pins, damage,
missing jackscrews, guide pins etc and replace.
7. Check EM2000 chassis connectors for pused back pins, damage, missing
jackscrews, guide pins etc and replace..
8. Inspect EM2000 chassis for damaged module slots, bent pins and
damaged threads of module jack screw nuts etc.
9. Inspect flat power supply cables for correct locking and application of
insulation to prevent rubbing.
10. Check all the contactors and switchgears for loose connections, sparking
and correct fitment of arc chutes.
11. Inspect tips of GFC, GFD, DCL switches and braking contactors.
12. Check SCR bridge for loose connections and overheating marks.
13. Check all the relays, resistors and other components for loose
connections and overheated symptoms.
14. Check all the circular, CMU, PD and dip plugs and connectors for pushed
back pins, damage and correct locking.
15. Check all terminal boards.
16 Check gaskets, latches, hinges bolts and nuts of all the doors and covers.
17. Renew filter.
18. Ensure cab roof sealing is in proper order.
19. Remove platform at the back of ECC1, thoroughly clean and refit.
20. Check all switches and meters on engine control panel.
21. Unload PCR, MCB, AR, CMPSYN relays for checking.
22. Check 3G2A plug for signs of overheating, poor crimping of cables etc.
2. Check battery charger rectifier for loose or overheated connections.
3. Load overhauled ST contactor and make connections
4. Check contactors for loose connections, signs of distress and mechanical
damage.
5. Check terminal boards and aux gen breaker connections
6. Check DCL reactor and ensure adequate air gap at the backside
7. Check for damaged or missing latches, bolt and nuts and hinges.
8. Renew filter
9 Check hose pipe for damage and clamps.
2. Check all the connections of contactors and terminal boards.
3. Open all the contactors front cover, inspect tips and tighten.
4. Ensure free travel of plunger of all contactors.
5. Check all bus bars for overheating and cracks.
6. Ensure busbar support welding is intact.
7. Check and replace damaged or missing latches, bolt and nuts and hinges.
8. Renew filter.
9. Ensure backside cleat sealing is intact and no water leaks into the
cabinet.
10. Provide spacer for outgoing cables wherever rubbing.
11. Check all connectors for damage and correct locking.
12 Check hose pipe for damage and clamps.
13 Ensure no water seepages inside the cabinet from the weld joints etc.
14 Check rad. fan cable harness for rubbing and damages to insulation.
52. E Miscellaneous Yearly Stopped 1. Check terminal board behind head light assembly and clean.
(Electrical) 2. Check IPRS for damage and overheating.
3. Check and tighten all connections and plugs of VCU. Ensure gasket is
intact.
Ensure wiring harness above VCU is not rubbing to body.
4. Provide spacers for IPR cables wherever touching to metal body and
looming bars.
5. Check battery knife switch and connections for slackness & tighten.
6. Check EPU, TPU, MRPT and other sensors for clearance and connector
locking
7. Check cabling inside the clean air chamber for damage.
8. Clean cab light assembly & provide all maintenance room and exterior
lamps.
9. Open MU receptacles and clean on both ends
10. Ensure MU cable support rod is intact.
11. Check settings of EFS and FVS switches (Two Yearly Sch).
53. E Dynamic brake grids Yearly Stopped 1. Remove grid covers and clean all the grid insulators with soap water.
2. Check insulators for cracks and flashover marks.
3. Check the ribbon resistor for displacement from the slots and poor
brazing.
4. Ensure heat shrink is applied for all cable ends near the lugs.
5. Tighten all the connections.
6. Provide insulation sheet over the cables at all locations where the cables
are rubbing to body, sharp edges, bolt and nuts.
7. Ensure all mounting bolts are intact.
8. Renew dynacell filters.
54. E Main alternator & Yearly Stopped 1. Air blowing of TG/CA, Aux. gen, DB motors, FPM, TLPM at low pressure Refer MI 3317-1
companion alternator and clean TG components with cleaning solvent for electrical machines Rev. E
and dry cloth. Refer MI 3317-2
2. Pig tail overheating. Rev. D
3. Spring condition and its locking. Refer MI 3317-3
4. Slip ring fixing bolts. Rev. Nil
5. Condition of fuse indicator assembly.
6. Slip ring condition & cabling.
7. TG diodes continuity check.(10 to 20 Ω-fwd; 30000 Ω- rev.)
8. Condition of brushes and brush arm assembly
9. Check MG terminal board connections.
10. Check any slackness in the connections of diode bank and measure
resistance of ct’s (12 Ω approx).
11. Slip ring bolt torque check (10 Nm)
12. Reversal of CA/ MA field polarity.
13. Out of roundness check of slip rings (ovality check) and record the Refer ETI 982 &
readings (max. limit 0.15 mm) 904
14. Ensure cleanliness of clean air chamber.
15. Clean companion alternator O/P cable TB and ensure connections are
intact.
16. Check IR value and record (min. 1 MΩ) Refer ETI 385
17. Measure field circuit resistance of CA and MA at slip ring (in ohms):
CA (between 1 & 2)
MA (between 3 & 4)
55. E Auxiliary generator/ Yearly Stopped 1. Auxiliary generator:
radiator fan motor a) Check diode plate and clean with cleaning solvent for electrical Refer MI 3707
machines. Rev. C
b) Check for intactness of covers with bolts. Refer MI 4105
c) Check for any unusual sound & rubbing mark on shaft. Rev. A
d) Check aux. gen o/p cables, its routing.
2. Radiator fan # 1 & 2:
Check for any unusual sounds from motor and intactness of cables and
clean.
3 Check RTV sealant on rotor to stator mounting bolts.
56. E Dynamic brake motor Yearly Stopped 1. Check for proper function of DB motors. Refer MI 4104
2. Condition of commutator & terminal posts. Rev. D
3. Condition of brush arm assembly.
4. Ensure the RTV sealing on fan mounting bolts.
5. Rotate fan by hand and check for free rotation-cracked blades, loose
bolts etc.
6. Check carbon brushes, spring tension and replace if necessary.
7. Check IR value and record (min. 1 MΩ)
57. E Fuel pump motor / Yearly Stopped 1. Replacement of fuel pump motor with over hauled motor.
TLPM / governor 2. Ensure the intactness of terminal box & cable conduct.
booster pump motor 3. Check for loose base bolts.
4. Check for any unusual sounds from motors
5. Measure FPM current.
6. Check inverter and clean heat sinks.
58. E TCC electronic blower Yearly Running/ 1. Check for proper operation of motors and any unusual sounds from
motor/ dust bin stopped motor.
blower motor 2. Check foundation bolts.
3. Check air ducts & clamps.
4. Check for any unusual sounds during initial run check.
5. Check connectors and receptacles and replace if found damaged.
6. Clean blower and motor.
59. E Traction motor blower Yearly Stopped 1. Intactness of fasteners, intake ring, guard and housing mounting bolts.
2. Ensure and record gap between intake ring and blower (above 3 to 5
mm.)
3. Check for any unusual sound during IRC.
4. Intactness of TM blower housing to aux.gen bracket mounting bolts.
5. Remove blower guard and clean dust from blower coupling sleeve.
60. E Starting motor Yearly 1. Check drive gears and ring gear for any damages.
2. Check for intactness of cables, routing and tightness of mounting bolts
and clean cables & motor.
3. Lubricate bush.
4. Check intactness of guard.
5. Special drive: check for proper engagement of starter motor pinions with
ring gear and measure clearance between pinion tooth and ring gear slot
(3 to 4 mm).
61. E Sizes brush and spring Yearly Stopped Note down sizes of brush and spring tension.
tension TA, TM, GBPM
and TLPM
62. E Slip rings Yearly Stopped Check ovality of slip rings & record. Refer ETI 904 &
ETI 892.
63. E CA and MA Yearly Stopped Measure IR value at 1000 V. Refer ETI 904, ETI
892 & ETI 385.
64. M Painting Yearly/Two Stopped Paint locomotive exterior and interior, including machinery, whenever Painting may be
Yearly necessary (Two yearly Sch). done more
frequently, if
desired by the
Railways
65. E Carbody plates, Yearly Stopped 1. Open all carbody and junction plates
carbody cables etc. 2. Clean and paint all the plates
3. Check the condition of carbody cables
4. Check and ensure proper colour code and availability of heat shrinks.
5. Check and ensure the condition of cable supplying cleats and replace if
necessary.
6. Check and ensure the condition of umbrella boots.
7. Check and ensure the condition of terminal lugs both at carbody side and
motor side for any overheating or discolourisation.
8. Disconnect all the traction motor connections
9. Ensure cable support holding plates for continuous welding. Provide
additional clamps if necessary.
66. E Radar Yearly Stopped 1. Open Radar and Radar safety guard.
2. Clean Radar, Radar safety guard, face plate and base of Radar and paint
guard and base of Radar.
3. Check and ensure the condition of Radar base fixing bolts.
4. Check and ensure Radar angle 37.5°
5. Check and ensure Radar back plate
6. Check and ensure condition of Radar safety guard
7. Check and ensure Radar plug condition and clean thoroughly.
8. Check and ensure the position of Radar air blast pipe nozzle to Radar face
plate.
9. Refix the Radar and conduct Radar self test.
67. E TM and cables Yearly Stopped 1. Provide all carbody and junction plates. Refer MI 1517A.
2. Record IR and winding resistance of all TMs. Refer traction
3. Replace defective items if necessary (like heat shrinks, colour code, lugs, motor operating
cleats etc.) instruction
4. Reconnect all the TM cables. A1A25110E/01.20
5. Check terminal connections of TM for overheating and loosening. 01/Version 1.
6. Check that car body cable and TM cable is properly secured.
Cable routing
1. Check all TM sensors (speed & temperature) and locking plugs
2. Check all TM cables for any excessive hanging and improper routing
3. Check Sensor cables and earthing cables.
4. Provide cable cleats and spacers wherever necessary.
5. Secure cables with cable ties.
Bellow attention
1. Check and ensure the condition of TM bellows.
2. Check all the bottom side fixing bolts for proper tighten and missing of
bolts provide if necessary.
3. Renew the bellow if necessary.
4. Record all bellow Sl. No. and make.
TM inspection
1. Open all the TM inspection covers and ensure no foreign body present
inside the TM.
2. Blow with dry compressed air (4.5-5 kg/cm sq.) from inspection window
and gear case end opening.
3. With a hand lamp, check the motor winding for any foreign body entry
and broken/burnt winding insulation etc.
4. Check all TMs for any hit marks and external damage.
5. Check all TMs for any gear case oil entry or grease oozing.
6. Provide back all the inspection covers.
Torquing and cleaning

1. Check and torque NDE end shield cover bolts (18mm) with a value 70
Nm.
2. Check and torque both DE and NDE side bolts (36mm) with a value of
680 Nm.
3. Scrap all motors with wire brush.
4. Clean all the power cables, sensor cables and earth cables by surf water.
5. Record all TM serial Nos. and make.
68. E Battery Yearly Stopped 1. Ensure all vent plugs are intact.
2. Clean all terminals with spray, examine support plates and tighten
connections
3. Remove covers and thoroughly blow out all the dust inside the cabinet.
4. Clean with washing soda & water.
5. Clean covers, lubricate latches & hinges
6. Ensure free operation of latch assemblies
7. Check battery containers for damage and leakages from cells
8. Ensure adequate packing between batteries against rubbing.
9. Check battery box mounting bolts and torque.
10. Apply battery terminal coating spray.
11. Check for low voltage grounding.
12. Check & record specific gravity.
13. Record cell temperature (when engine is running)
14. Check & record electrolyte level (before water topping)
15. Record cell voltages (engine dead & on load)
Battery bank 1 volts -
Battery bank 2 volts -
16. Charging voltage (eng running)-
17. Record details of water added in each cell.
(add water when engine is running)
69. M Air brake system Yearly Stopped 1. Renew MR1 & MR 2 final filters. Refer RDSO
CCB 1.5 2. Renew DL filter element. (CCB 1.5) MP.MI-18 Rev. -
CCB II-IR 3. Clean BCEP, BP, MREP & 20 pipe filters or replace if damaged. (CCB 1.5) 02, April – 2008
4. Remove and replace MR, BP, MREP and 20 pipe filters. (CCB II-IR) Amendment 1
5. Replace consumables as per respective air dryer manufacturer’s May 2009 for air
recommended replacement kit. dryer.
6. Overhaul Horns, sanders, MVCC & EBT Magnet Valves & refit.
7. Overhaul both ABD valves & refit.
8. Clean external muffler connected with purge valves & check condition of
each pipe assembly and their tightness.
70. M Air compressor Yearly Stopped LP & HP Suction/Discharge valves to change with new Copper washers (Two Refer operating
yearly) and service
manual no. 13-3-
615 of M/s
Gardner Denver.
71. M Fuel system, governor Yearly Stopped 1. Flush the Governor oil.
and valve lever 2. Remove two Injectors and check for its Valve opening pressure.
3. Set the Injector Rack length to 1.00″.
4. Set the TDC pointer.
5. Perform Engine timing.
6. Check the Top deck cover seal.
7. Check the latches and stoppers.
8. Renew the Sight glass Spin-on ‘O’rings
9. Renew the Primary ‘O’ring
10. Renew the Spin-on filters.
11. Renew the Suction Strainer filters.
12. Re-torque Control shaft retainer plate bolts.
13. Overhaul the diesel tank sight glass.
14. Check the fuel filling strainer tightness.
15. Flush the fuel tank and re-new the Manhole gasket and tight the drain
dummies.
16. Fit overhaul fuel pump and check for any leakages.
17. After crank, check for any pinching and lube oil leakage.
18. After conducting load test, conduct black light test.
72. M Heat exchanger Yearly Stopped 1. Visually examine proper seating of radiators and tightness of securing
bolts
2. Blow the radiators with compressed air
3. Perform cooling system pressure test (20 psi).
4. Visually check all joints for leakages
5. Check operation of EPD.
a. Low water.
b. Low Crankcase vacuum.
6. Check condition of water level gauge and clean.
7. Renew lube oil filters.
8. Renew all rubber hoses
9. Inspect condition of rubber packing under the radiator cores and change
if damaged or compressed.
10. Clean radiator header screen
11. Inspect water tank pressure cap and replace if necessary.
12. Remove and test hot oil detector on test stand & re-fit (Two yearly sch).
13. Blow inertial filters opposite to normal air flow.
14. Renew Expansion tank water level gauge glass ‘O’ rings.
15. Re-torque both water pump impeller nuts (80 ft Lbs).
16. Re-torque both lube oil pump gear nuts (340 ft Lbs) & seal.
17. Remove, EPD replace repair kit test on test stand & refit (Two yearly
sch.).
18. Renew Expansion tank pressure cap (Two yearly sch).
19. Clean coarse mesh & fine mesh lube oil strainer elements & renew ‘O’
rings & gasket.
20. Clean educator & oil separator mesh.
21. Renew dresser couplings on cooling water system.
73. M Power pack Yearly Stopped/ Initial Run Check (IRC) For IRC i to iii,
running i. Conduct load test and record readings. Engine will be in
ii. OSTA Tripping RPM. running condition.
iii. Compression Pressure readings in PSI: (275-350psi).
iv. Check exhaust screen for debris/foreign material.
v. Check piston crown.
vi. “Pee” Pipe alignment.
vii. Conduct lead wire measurement.
viii. Clean Air box & covers.
Power Pack Fasteners Torquing Refer EMD EAI

2127.
Water adding, pre lube and cranking
Perform during scheduled load test, the following:
1. Final run check.
2. Take load test readings.
3. Check temperature differential between lube oil and cooling water
into engine. (Two yearly sch).
4. Clean oil cooler, if necessary. Refer MI 927 and
MI 928.
Engine protector Refer MI 260.

Renew or recondition engine protector and re-qualify on test stand after
renewing springs, “O” rings, and diaphragms. (Two yearly sch).
74. M Turbo Yearly The following items are to be checked and recorded:
Running i. Engine running condition:
a. Check for oil leakage
b. Check for water leakage.
c. Check for Air leakage.
d. Whether spin on pipe line touches to the engine block or starting
motor.
e. Temp. Across after coolers and radiators to be recorded.
Stopped ii. Engine stopped condition:

a. Condition of A.G. Shaft Couplers & Shaft.
b. Condition of A.G. Shaft Guard
c. Condition of A.G. Drive housing
d. A.G. Shaft bolts torque checking
e. Checking of A.G. Shaft alignment, thrust clearance and backlash
f. Soak back filter changing
g. Turbo lube oil filter
h. Engine air filters
i. Condition of Turbo impeller ii i. Refer MI 1753
j. Inspection of loose/ missing bolts Rev. F
k. After coolers to be removed and wash
l. Turbo impeller clearance to be record
m. Inspection of loose/ missing bolts
n. Exhaust valve timing to be record
75. Under-truck, under- Yearly/Two Stopped Attend all items of 180 days and following additional items:
frame and allied yearly 1. Ultrasonic testing of axles. Refer procedure
parts/subassemblies no MC-71 for UST
of axles issued by
M&C/RDSO.
2. TBU to be dismounted, opened and inspected initially along with OEM Refer MP.MI-33.
after two years in order to assess the overhauling periodicity (WDG5).
76. M Toilet (WDG5) Three yearly Stopped Renew pipes, toilet seat etc.
77. E Control stand covers, Three yearly Stopped 1. Refer IRC sheets and attend to all the bookings.
ECC1, ECC2 and ECC3 2. Remove and overhaul the controller.
cabinets, E-locker, 3. Remove EM2000 display, all modules from EM2000 and power
Head light resistance supply chassis and keep them in anti static covers.
covers, IPRS, grids, 4. Blow out all the dust inside the ECC1, ECC2, ECC3 cabinets, or, E-
ECC1 cabinet, EM2000 locker (WDG5).
chassis and power 5. Open control stand covers and blow out all the dust.
supply chassis, all 6. Open head light resistance covers and blow.
electrical cabinets and 7. Blow out all the dust inside the IPRS
both the control 8. Blowout all the dust inside the grids
stands and cab. 9. Calibrate speedometers, TE/BE meters & BC ammeter.
10. Remove DBGR, FPR, FLSHR, TLPR, SPR1 &2, all DIPs, GFC, GFD AND
GR and handover to section.
11. Remove EM 2000 Display, Power supply & EM2000 chassis..
12. Remove SCR bridge, GTO power supplies, DCL motor, TCC
contactors.
13. Remove ST, STA contactor, battery charger assembly.
14. Remove headlight resistor clean, check the value and refit.
15. Remove spike suppressors for all magnet valves, TCC contactors, rad
fan small contactors, GFC, GFD AND DCL switchgear motor.
16. Remove both side head light, flasher light assemblies and
classification covers.
17. Remove cab fans, air brake fans and arc chutes of braking
contactors.
78. E ECC1 Three yearly Stopped 1. Load tested DBGR, FPR, FLSHR, TLPR, SPR1 & 2, all DIPs, GFC, GFD AND Refer MI 5389 for
GR. auxiliary relay.
2. Fit back EM 2000 display, power supply & EM2000 chassis, SCR bridge,
GTO power supplies, DCL motor and TCC contactors and make
connections.
3. Inspect MUTB for loose connections and for any foreign material
4. Inspect tips of DCL switches and braking contactors.
79. E ECC2 Three yearly Stopped Fit back ST, STA contactor and battery charger assembly and make
connections
80. E ECC3 Three yearly Stopped Fit back DIP 80 and make connections
81. E Miscellaneous Three yearly Stopped 1. Install spike suppressors for all magnet valves, TCC contactors, rad
(Electrical) fan small contactors, GFC, GFD and DCL switchgear motor.
2. Install head light, flasher light assemblies and classification covers
3. Provide cab fans, air brake fans and arc chutes of braking contactors
4. Renew governor Amphenol plug.
82. E Dynamic brake grids Three yearly Stopped 1. Ensure sheet is applied to the cables at all locations where the cables
are rubbing to body, sharp edges, bolt and nuts.
2. Ensure all mounting bolts are intact.
3. Paint all the rusted surfaces and grid body.
83. E Main alternator & Three yearly Stopped 1. Clean diode bank assembly with cleaning solvent for electrical Refer MI 3317-1
companion alternator machines. Rev.H
2. Check spring tension with push-pull gauge Refer MI 3317-2
3. Ensure intactness of covers and fasteners. Rev. D
4. Torque all TG diode tails at 15 Nm. Refer MI 3317-3
5. Check & record MA bearing temperature Rev. Nil
6. Check pressure difference across MA bearing on special drive basis
if needed.
84. E Auxiliary generator/ Three yearly Stopped 1. Auxillary generator: Refer MI 3707
TM blower a) Open covers and blow off dust at 50 psi. Rev. C
b) Check aux. Gen o/p cables and exciter field cables for any insulation
damage.
2. TM blower:
Check unusual sound from TM blower during engine run. Check intactness
of fasteners of impeller & housing mounting bolts and torque at 278 Nm.
3. Record the gap between intake ring and blower wheel on both sides of
wheel assembly i.e. MA/TM ( 3.5 to 5 mm)
85. E Dynamic brake motor Three yearly Stopped 1. Unload the both motors and load over hauled motors. Refer MI 4104
& radiator fan motors 2. Rotate fan by hand and check for free rotation of fan. Rev. D
3. Torque mounting bolts (140 Nm) for radiator fan & DB motors to 100 Refer MI 4105
Nm. Rev. A
4. Ensure silicon sealant (RTV) is applied on fan mounting bolts.
86. E Fuel pump motor / Three yearly Stopped 1. Replace fuel pump, TLP motor with over hauled motors.
TLPM / governor 2. Check for any slackness of foundation bolts.
booster pump motor 3. Ensure proper connections to the motor.
4. Note: horizontal FPM is polarity dependant i.e. +ve and –ve supply
cables should be connected +ve and –ve terminals on motor.
5. Measure FPM current and TLPM current during FRC.
87. E TCC electronic blower Three yearly Stopped 1. Unload motors and load over hauled motors.
motor/ dust bin 2. Check for proper direction of rotation of motors in FRC.
blower motor 3. Check fixing bolts and connections
4. Check the condition of hose pipes & clamps.
5. Check for any unusual sounds from & blower assembly in FRC.
6. Check intactness of blower guard.
88. E Starting motor Three yearly Stopped 1. Unload motors and load over hauled motors.
2. Tighten mounting bolts.
3. Check cables for any insulation damage & intactness of cable tags.
4. Check for proper engagement of motor pinion with ring gear after
disconnecting “STC” wire from motor
89. E TM and cables Three yearly Stopped Renew all carbody side lugs.
90. E Battery Three yearly Stopped 1. Remove covers and unload all the batteries.
2. Check cabinet mounting bolts and torque.
3. Inspect cabinet bottom surface for corrosion and erosion of metal
surface and repair.
4. Thoroughly scrape all corroded surfaces and bottom flooring, blow with
compressed air and clean with water.
5. Paint the cabinet and the covers completely.
6. Inspect cover latches and repair.
7. Load batteries and apply suitable wooden packing in between batteries.
8. Apply battery connections taking care of polarities.
9. Apply battery terminal coating spray for all connections.
10. Provide covers back and ensure proper closing and opening.
11. Lubricate all the latches and hinges.
91. M Air brake system Three yearly Stopped 1. Replace the elements of BCEP, BP, MREP filters (CCB 1.5) Refer RDSO
CCB 1.5 2. Both Horn bells overhauling kit to renew. MP.MI-18 Rev. -
CCB II-IR 3. MRPT hose pipe line to renew. 02, April – 2008
4. Wiper Motor hose pipe to renew. Amendment 1
5. Overhaul air dryer completely & test. Replace consumables as per May 2009 for air
respective air dryer manufacturer’s recommended replacement kit. dryer.
92. M Air compressor Three yearly Stopped 1. Compressor sump examination to do. Refer operating
2. Inter cooler safety valve to overhaul. and service
manual no 13-3-
615 of M/s
Gardner Denver.
93. M Main reservoir Three yearly Stopped 1. Visually inspect general condition of the reservoirs and attend as All pressure
& control reservoir of required. Visually inspect the threads meant for inlet/outlet connection vessels to be
Air Brake System. for any cut mark, pit mark, dent mark etc. tested and
2. Measure thickness of MR using ultrasonic equipment. certified
3. Keeping 1.5 times working pressure conduct the hydraulic test. periodically by a
4. Conduct final leakage test with soap water. qualified Boiler
Inspector at a
periodicity to be
specified by the
CME’s office.
Certification on
every 48 months
is recommended
but a shorter
period may be
followed, if so
necessary, based
on local
conditions.
94. M Fuel system, governor Three yearly Stopped 1. Renew top deck cover gasket and overhaul it.
and valve lever 2. Check the front and back latches tightness.
3. Check Governor sensing pipeline clamps.
4. Renew the Governor and mounting gasket.
5. Renew the Injectors, EUIs (WDG5).
6. Renew overhauled Valve levers.
7. Renew the Valve bridges with lash adjusters.
8. Renew the Spin-on filters and Sight glass ‘O’rings.
9. Renew the Primary filter and its ‘O’rings.
10. Renew the Fuel pump.
11. Fix the fuel lines with new copper washers and nut.
12. Check for any fuel leakage in fuel lines and fuel pipelines.
13. Remove the fuel filling strainer and re-fit by using thread sealant.
14. After load test, conduct the Black light test by LAB and re-torque the
fuel lines.
95. M Heat exchanger Three yearly Stopped 1. Visually check all joints for leakages Refer MI 549, MI
2. Check lube oil filter Bypass valve 550
3. Inspect water tank pressure cap and replace if necessary
4. Remove and blow inertial filters
5. Remove and overhaul water pumps
6. Remove radiator cores and clean & refit
7. Renew rubber packing of radiator core
8. Renew all cooling system pipe line Gaskets
9. Remove and clean lube oil strainers renew ’O’ Rings
10. Clean educator & oil separator mesh
11. Renewal of R/s Radiator
12. Renewal of L/s Radiator
96. M Power pack Three yearly Stopped/ 1. Lube oil draining and water draining
running 2. Cylinder Head to be overhauled If any cylinder is having less compression
pressure
3. Renew all top connecting rod bearings (No 1 to No 8)
4. Main bearing bottom changing
5. Inspect crankshaft gear damper for free movement.
6. Cylinder head to liner nut torquing.
7. Exhaust manifold gasket changing if any leakages.
8. Top deck, Air box and sump cleaning
9. All air box and sump cover gasket & nylon washers changing
10. System flushing and draining
11. Lube oil topping
12. Water topping up, pre-lube and crank the engine
13. All bearings temperature recording after cranking. Repeat same at 10
mints before and after load test.
14. Renew sensors to determine crankshaft speed and position, system
pressures and temperatures (EMDEC WDG5)
97. M Turbo Three yearly Stopped 1. Turbo removal for renewal and overhauling of clutch assly.
2. AG Drive housing overhauling
3. AG Shaft zyglo testing
4. AG Shaft Couplers to renew
5. Measure and record turbo impeller clearance after turbo fit at following
locations:
i. Right bank housing
ii. Left bank housing
98. M Under truck, under- Three yearly Stopped 1. Measure and record buffer length & height.
frame and allied 2. Measure and record rail guard & cattle guard heights. Check for condition
parts/components and attend as required.
3. Test all location gear case oil samples in lab.
4. Remove all knuckles and screw coupling and send to workshop for stress
relieving process.
All items of Yearly schedule.
Additional Items Refer MI 1517.

1. Bogie assembly to be run out. Refer MP.MI-33
2. Measure and record Thrust pad lateral, Secondary vertical and, lateral for WDG5 loco.
stop clearances
3. Remove dust accumulated on bogie components by compressed air
before visual examination.
4. Inspect bogie frame thoroughly for any cracks, in case fabricated bogie
frame is employed then all but and critical areas to be checked by
suitable NDT tools (DPT/MPT)
5. Remove hydraulic dampers and check for its functionality if any doubt
then check for capacity as per IB issued by RDSO.
6. Inspect helical coil spring for crack.
7. Inspect secondary rubber spring and measure free height and record
8. Replace spring pad (condition basis)
9. Inspect bearing adapter and taper roller bearing for any abnormality
10. Inspect traction rod bushing, nose link and car body rod bushing for
damage, it is preferable to replace NL bushing if preferable to replace
damaged bush in this schedule if proper tooling and fixture is available
with shed.
11. Replace centre pivot packing ring, tighten bolt with torque and lock
with wire
12. Replace brake block and stopper (lateral) condition basis. Lubricate all
pin joint with solid grease. Adjust slack as per wheel diameter if
required.
13. Measurement of wheel profile and record as per RDSO format.
14. Remove and overhaul all brake cylinders (WDG4/WDP4).
99. E Control stands Six yearly Stopped Renew horn, sand and alerter reset switches and indication panels.
100. E ECC1/ E-locker(WDG5) Six yearly Stopped 1. Renew head light dim resistor
2. Check all wirings for loose connections and overheated symptoms.
3. Paint the cabinet at all the locations wherever paint has peeled off and
rusted. Paint all backside covers.
101. E ECC2/ E-locker(WDG5) Six yearly Stopped 1. Renew hose pipe and clamps.
rusted.
102. E ECC3/ E-locker(WDG5) Six yearly Stopped 1. Remove all contactors inside ECC 3 and overhaul them.
2. Fit back overhauled contactors and make all the connections
3. Renew hose pipe and clamps.
rusted.
103. E Miscellaneous Six yearly Stopped 1. Paint knife switch covers.
(Electrical) 2. Renew head light resistors
3. Renew AC unit (WDG5)
104. E Dynamic brake grids Six yearly Stopped 1. Unload DB grids
2. Paint all the DB grids mounting surface area
3. Load reconditioned grids and make connections
105. E Main alternator & Six yearly Running Initial run Check: Refer MIs (Latest
companion alternator 1. Check for any unusual sounds from CA/MA. version):
2. Check air pressure differential across main alternator bearing (spl drive) Refer MI 3317-1,
3. Check MA bearing temperature after load test Rev H.
Refer MI 3317-2,
Stopped 1. Open TG air box covers, CA enclosures and dust off main and companion Rev D.
alternator with dry compressed air. Refer MI 3317-3,
2. Clean CA/MA with compressed blow of cleaning solvent for electrical Rev Nil.
machines. Refer ETI-892 &
3. Unload diode banks and clean thoroughly. ETI-904.
4. Torque diode at 45 to 47 Nm and diode tail at 15 Nm. Refer MI 3317-1H.
5. Unload slip ring assembly, outer seal and bearing cover.
6. Inspect main alternator bearing for any damages.
7. Remove old grease and apply new Unirex N-2 grease.
8. Assemble bearing cover, shaft seal, outer bearing cover and slipring
assembly.
9. Check eccentricity of slip rings (Max. Limit – 0.15 mm).
10. Install carbon brushes and hardware and renew CA/MA springs.
11. Fit back overhauled (cleaned and tested) diode bank assembly.
12. Provide connections as per schematic diagram.
13. Clean and check CATB connections.
14. Check CA filed poles, bus bars and CA filed cables terminal crimp.
15. Fit back CA enclosures and CATB cover after inspection.
16. Measure field circuit resistance of CA and MA at slip ring (in ohms).
CA (1.48 to 1.54 ohm between slip ring 1 & 2),
MA (1.384+ 4% at 75°C between slip ring 3 & 4).
17. Fit back all the covers and ensure no foreign body left inside the TG air
box.
18. Renew TG o/p cable cleats
19. Torque TG o/p cables to rectifier bus bars and fit back guards.
20. Renew/ replace the following assemblies/ sub assemblies with
new/reconditioned machines and assemblies.
a. Auxiliary generator and TM blower wheel assembly.
b. DB motor
c. TCC # electronic and dust bin blower motor.
d. Small motors (starter motor, fuel pump motor, turbo lube pump
motor and gov. Booster pump motor (if available).
21. Torque all the foundation and mounting bolts of rotating machines as
per the torque chart.
22. Check and torque starter motor bracket mounting bolts and align the
bracket with respect to ring gear (special drive).
23. Replace TM/MA blower air ducts (TM Bellows) with new ones after 6
years of service life.
24. Replace TCC electronic and dust bin blower hose pipes.
25. Provide RTV sealant on BNF cover mating joint, lagin (hood) joint to
avoid water entry into CAC.
26. Ensure cleanliness of CAC.
27. Check for normal functionality of rotating machines in FRC and ensure
no unusual sounds from rotating machines.
28. Measure phase to phase (group) resistance of CA and MA.
106. E Traction motors and Six yearly Stopped All traction motors to be overhauled.
allied components
107. M Air Brake System Six yearly Stopped Overhaul all the pneumatic and magnet valves of the complete system & Refer Manual No
CCB 1.5 Brake Controller. IP-165-C issued by
CCB II-IR M/s Knorr-
Bremse.
108. M Air compressor Six yearly 1. Recondition air compressor Refer operating
and service
manual no 13-3-
615 of M/s
Gardner Denver.
109. M Fuel system, governor Six yearly Stopped 1. Remove top deck cover gasket and overhaul it.
and valve lever 2. Check the latches and repair it.
3. If top deck frame oil leakages found, remove and re-make the gasket
joint.
4. Remove Injector linkage Assembly and overhaul it.
5. Remove Valve lever Assembly and overhaul it.
6. Remove Valve bridges and overhaul it.
7. Renew lash adjusters.
8. Remove the Camshafts, clean and inspect.
9. Remove Injectors, EUIs (WDG5) and overhaul these.
10. Remove the Governor and Governor base and overhaul it.
11. Remove the Primary housing, clean and fit it back.
12. Remove the Primary filter drain cock, overhaul and fit it back.
13. Renew Governor Layshaft support bearing and seal kit.
14. Re-torque Control shaft retainer plate bolts.
15. Renew Governor Linkage Bearings.
16. Flush the diesel tank and renew all joint sealants.
17. Overhaul the fuel tank sight glass.
18. Overhaul the Spin-on filter housing.
19. Remove the Primary filter by-pass gauge and test it for any leakage and
re-fit it back
20. If required remove the OSTA housing and overhaul it.
21. Renew the Governor Lube oil connection pipeline adaptors at the both
end
22. Remove the fuel Headers and its rubber hose assembly and overhaul
it.
23. Re-fit the Camshaft by using new Bearings.
24. Check for free movement of the Camshaft segment before fitment of the
studs.
25. Fix the stud with New Nylock nut and torque it.
26. Fix the Injectors, EUIs(WDG5).
27. Fix the fuel Headers by using new end gaskets.
28. Fix the linkages and check for its free movement.
29. Fix the Rubber hose and connect to the fuel Header by using new
gaskets.
30. Connect new fuel line with new copper washer to the Injectors.
31. Connect the overhauled fuel pump and test for any fuel leakage in
the system.
32. Fit back the top deck covers and check for any gap after locking the
latches.
33. Set the TDC pointer.
34. Perform Engine timing.
35. After cranking, Check the top deck for any unusual.
36. After load test, conduct the black light test by LAB and re-torque the
fuel lines.
110. M Heat Exchangers Six yearly Stopped 1. Remove left side water Pump inlet pipe Refer MI 549, MI
2. Remove right side water pump inlet pipe 550.
3. Remove left side water pump.
4. Remove right side water pump.
5. Renewal of left side water pump
6. Renewal of right side water pump
7. Remove left side water pump out let pipe
8. Remove right side water pump outlet pipe
9. Remove main lube oil pump outlet pipe
10. Remove elbow piston cooling pipe.
11. Remove elbow Strainer pipe.
12. Remove Governor drive pipe
13. Renewal of hot oil detector.
14. Remove Engine Protective Device and hose pipe connections
15. Remove Piston Cooling Pump.
16. Remove Scavenging Pump to lube oil filter drum copper pipe.
17. Remove Scavenging Pump.
18. Remove Elbow Scavenger.
19. Remove strainer to Scavenging Pump pipe.
20. Remove strainer housing
21. Remove filter drum to lube oil cooler pipe.
22. Remove lube oil cooler to strainer 4” pipe & 4” dresser gasket.
23. Remove lube oil filter drum to Strainer 1” pipe & 1” dresser gasket
24. Remove left side ‘T’ joint pipe.
25. Remove right side ‘T’ joint pipe.
26. Remove left side lube oil cooler 3” pipe.
27. Remove right side lube oil cooler 3” pipe.
28. Remove expansion tank Top ¾” dresser gasket.
29. Remove radiator vent to lube oil cooler hose pipe.
30. Remove lube oil cooler.
31. Over hauling of Lube oil cooler.
32. Loading of lube oil cooler
33. Remove left side radiator inlet connection.
34. Remove left side radiator outlet connection.
35. Remove left side radiator outlet 3” dresser gasket & renewal
36. Remove left side radiator
37. Remove right side radiator inlet connection
38. Remove right side radiator inlet connection.
39. Remove right side outlet 3”dresser gasket & renewal.
40. Remove right side radiator.
41. Renewal of Radiator shim R/S & L/S
42. Gasket change over of right side radiator
43. Gasket change over of left side radiator.
44. Remove water drain cock
45. Remove cross over pipe
46. Cleaning of all pipe lines.
47. Renewal of pressure relief valve & fitment
48. Renewal of lube oil filters & ‘O’ ring.
49. Renewal of by-pass Valve.
50. Renewal of strainer & loading.
51. Cross over pipe fitment
52. Renewal of water drain cock & fitment.
53. Strainer to Scavenging Pump pipe line.
54. Scavenging pump renewal & fitment
55. Main lube oil pump renewal & fitment.
56. Governor drive pipe fitment.
57. Elbow scavenger pipe fitment.
58. Main lube oil pipe outlet pipe fitment.
59. Elbow piston cooling pipe fitment.
60. Elbow strainer pipe fitment.
61. Left side water pump outlet pipe fitment.
62. Right side water pump outlet pipe fitment.
63. Left side water pump fitment
64. Right side water pump fitment.
65. Scavenging pump to filter drum copper pipe fitment & 3” dresser gasket
66. Left side ‘T’ joint with 2 1/2” dresser gasket fitment
67. Right side ‘T’ joint with 2 ½” dresser gasket fitment
68. Lube oil filter drum to lube oil cooler pipe line with 3” dresser gasket
fitment.
69. Lube oil cooler to strainer 4” pipe with 4” dresser gasket fitment.
70. Lube oil filter drum to strainer 1” pipe line with flange gasket & 1”
dresser gasket.
71. Lube oil cooler inlet 3” dresser gasket & flange gasket fitment.
72. Lube oil cooler connections fitment.
73. Left side radiator loading ,inlet, outlet,vent hose connections.
74. Right side radiator loading, inlet, outlet, vent hose connections
75. Renewal of Test valve.
76. Renewal of hot oil detector
77. Renewal of hot oil detector
78. Check condition of Neck assembly
79. Renew Valve assembly ball cock relief
80. Renew Expansion tank Sight glass
81. Renew Valve assembly By-pass.
82. Comp. Inlet ‘O’ Ring Renewal
83. Renewal of Comp outlet ‘O’ Ring
84. Both side water pump inlet to expansion tank hose pipe connection
85. Remove and blow inertial filter
111. M Power pack Six yearly Stopped Remove, completely dismantle and recondition:
1. Renew or recondition crankshaft damping device.
2. Renew all exhaust manifold gaskets, Expansion joint gaskets & all
hardware.
3. Renew, qualify expansion joint assemblies.
4. Install all new lower main bearing & No.6 upper main bearing thrust
collars, check & record crankshaft thrust.
5. If necessary change upper main bearing.
6. Renew all lower liner inserts
7. Provide all crab bolts and torque
8. Renew all upper & lower conrod. Bearing & fork rod hardware’s Check,
qualify, clean both engine water discharge ‘Y’ flange & renew Gaskets.
9. Check & renew accessory drive end coupling centre bonded rubber
bushes.
10. Renew accessory drive end felt seal oil.
11. Renew both side water manifold seals
12. Check, qualify water manifold brackets, straps if necessary renew strap
nuts.
13. Check & ensure torque of crankcase to oil pan & engine bed bolts.
14. Check, qualify & blow piston cooling pipe manifold.
15. Renew power pack assemblies, replacement components should be new
or unit exchange.
a. Apply new cylinder heads liners, pistons & rings.
b. Apply new wrist pin & bearings
c. Apply new head seat rings.
d. Check, qualify or renew inlet tubes & piston cooling pipes.
e. Renew all outlet elbows & seals.
16. Renew all inlet tubes, pee pipe seals & gaskets.
17. Top up fresh engine lube oil & cooling water.
18. Check, qualify, renew all hand hole covers.
19. Renew all handhole covers gaskets & hand wheel nylon washers.
20. Keep engine in running without giving any load for 24hrs, check & record
all bearing temperature.
21. Conduct load test, record FRC reading.
22. Check & record all main bearing & Con rod. Bearing temperature before
& after load test
23. Re-torque all power assemblies, fasteners at engine temperature 70
degree Celsius or after load test.
24. Refit engine cover with new cushioning hose & torque the bolts
25. Re-torque the power pack fasteners after 100 hrs of running
112. M Turbo Six yearly Stopped 1. Renew turbocharger. Refer MI 277
2. Renew turbocharger clutch assy.
3. Renew or Recondition A.G. drive assy
4. Renew or overhaul after cooler cores
5. Soak back filter assy. Overhauling
6. Turbocharger lube oil filter assy. Overhauling
7. Cam shaft stub shaft bearing changing
8. Cam shaft drive gear changing if necessary
9. Soak back pump assly - Renew or Recondition.
10. Engine Air filters housing to be cleaned and check the condition of inner
mesh.
113. M Under truck, Side Six yearly Stopped (WDG4/WDP4):
Buffers, CBC etc. Trucks to be run out from locomotive, dismantled, cleaned. Refer to MI 1517
All the components of bogie assembly should be inspected separately as laid Rev. A
out in the maintenance instruction provided by EMD for HTSC and HTSC-B1
bogies.
WDG5:
Trucks to be run out from locomotive, dismantled, cleaned. Refer RDSO
All the components of bogie assembly should be inspected separately. MP.MI -33.
Overhaul the truck assembly and components, and assemble as per the
details given in MP.MI-33.
And, following attention common to WDG4/WDP4/WDG5:
1. Suspension:
a. All Vertical dampers to be renewed.
b. All Yaw dampers to be renewed.
c. All Single Coil springs to be renewed.
d. All Happy pads to be renewed.
e. All secondary rubber springs to be renewed.
f. Centre pivot wear half to be renewed
g. Centre pivot rubber bush’s to be renewed.
h. Centre pivot car body Assembly to be renewed
i. All traction rod rubber bushes to be renewed.
j. All Nose link assembly rubber bush’s to be renewed.
k. Thrust pads to be renewed
l. Thrust pad and vertical stop clearance to be checked and recorded
2. Tread Brake Units to be overhauled:

Refer M/s Knorr Overhaul Instructions: U-BG10.22-en_Rev 04 and U- Refer Document
BH10.24-en_Rev 02 (WDG5). no B- B000.25
Rev 12 titled
‘Tread brake unit
PEC7’ issued by
M/s Knorr
Bremse.
Side Buffer etc:

a) To be renewed.
b) Buffer length and heights to be checked and recorded
c) Rail guard and cattle guard heights to be checked and recorded.
CBC and Screw coupling:

a. Screw coupling to be renewed on condition basis
b. CBC uncouples assembly to be renewed
c. Knuckles to be renewed on condition basis
Hand brake and brake cylinder

a. Hand brake assembly to be overhauled
b. All Brake cylinders to be removed and overhauled.
c. All Brake lever bushes to be renewed and brake head bolts to be
renewed.
d. Slack adjuster barrels to be renewed.
114. M Under-frame and Eighteen Stopped Completely dismantle locomotive frame and body panels. Inspect for
allied parts/sub- yearly corrosion, fractures etc. Replace or repair as necessary.
assemblies.
115. M Engine Eighteen Stopped Renew engine.
yearly
116. E Electrical equipment Eighteen Stopped a. Renew main traction alternator and companion alternator.
and systems yearly b. Renew traction motors.
117. E Electrical components NS Stopped High voltage cabling - Renew. Refer MI 5406
Low voltage wiring - Renew. Rev B, MI 5421-2
Rev A.
High voltage cabinet (ECC 1)/ E-locker (WDG5):
i. Replace control system computer modules as required.
ii. Inspect connectors and cables for signs of fatigue at the times of
component replacement.
iii. Replace DC Link contactors, braking contactors, and motors modules as
required.
iv. Clean inside of TCC Cabinets/Low Voltage Cabinets as required. Remove
dust etc.
118. M MECHANICAL NS Stopped The following work is to be performed at wheel change time or when one or
COMPONENTS more truck assemblies are removed for reconditioning.
i. PINION- Check for involute profile wears.
ii. AXLE GEAR - Carry out Magnaflux.
119. M WDG5 brake blocks NS Stopped Replace upon reaching the specified minimum thickness values. Refer Document
No B-B000.25 Rev.
12 - 16.06.2011
titled ‘Tread brake
unit PEC7’ issued
by M/s Knorr
Bremse.
The brake blocks
must be replaced
upon reaching the
specified
minimum
thickness values.

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CCB INDIAN RAILWAYS LOCOMOTIVE

SYSTEM DESCRIPTION AND OPERATION

1.1 AIR BRAKE EQUIPMENT

1.1.1 AIR BRAKE EQUIPMENT LOCATION

1.1.2 BRAKE VALVE CONTROLLER (Figure 1-2)

1.1.2.1 OPERATING - AUTOMATIC HANDLE

IP-165-C 1-1 DECEMBER/98

1.1.2.2 OPERATING - INDEPENDENT BRAKE

1.1.2.3 AIR BRAKE SET-UP

A. For Set-Up as Lead or Single Unit

1. Move Lead/Trail selector switch to “LEAD OUT”.

4. Move Direct brake handle to Release position.

B. For Set-Up as Trail Unit

3. Automatic and Direct Brakes are now cut-out.

1.1.3 LOSS OF POWER MODE

DECEMBER/98 1-2 IP-165-C

1.1.4 POWER UP PENALTY

1.2 SYSTEM OVERVIEW

Refer to Figure 1-5

IP-165-C 1-3 DECEMBER/98

1.2.1 SYSTEM OPERATING PRESSURES

A. AUTOMATIC BRAKE PRESSURES

1.2.2 AUTOMATIC BRAKE SYSTEM FEATURES

1.2.3 INDEPENDENT (DIRECT) BRAKE

1.2.4 INDEPENDENT BRAKE SYSTEM FEATURES

DECEMBER/98 1-4 IP-165-C

1.2.5 LEAD UNIT AUTOMATIC BRAKE OPERATION - BRAKE RELEASE

1.3 BRAKE PIPE CONTROL SUBSYSTEM

1.3.1 EQUALIZING RESERVOIR ELECTRICAL CONTROL - RUNNING

Refer to Figure 1-6

1.3.2 EQUALIZING RESERVOIR AND BRAKE PIPE PNEUMATIC CONTROL - RUNNING

Refer to Figure 1-7

IP-165-C 1-5 DECEMBER/98

1.3.3 BRAKE PIPE CHARGING CUT-OFF

Refer to Figure 1-8

A. Brake valve controller handle in ‘Emergency’ position.

1.3.4 FLOW DETECTION

Refer to Fig. 1-9

DECEMBER/98 1-6 IP-165-C

1.3.5 FAST RECHARGE AND ASSIMILATION - RELEASE

Refer to Figure 1-10

B. OVERCHARGE AND ASSIMILATION

Refer to Figure 1-11

IP-165-C 1-7 DECEMBER/98

1.3.6 BRAKE CYLINDER PRESSURE CONTROL SUBSYSTEM - RELEASE OR RUNNING

Refer to Figure 1-12

Refer to Figure 1-13

1.3.7 BRAKE CYLINDER EQUALIZING PIPE PRESSURE CONTROL - RELEASE OR RUNNING

Refer to Figure 1-15

DECEMBER/98 1-8 IP-165-C

B. BAILOFF (QUICK RELEASE)

1.3.8 LEAD UNIT AUTOMATIC BRAKE OPERATION-BRAKE APPLICATION

1.3.8.1 BRAKE PIPE CONTROL SUBSYSTEM

Refer to Figure 1-16, 1-17, 1-18

Refer to Figure 1-19

Refer to Figure 1-20

IP-165-C 1-9 DECEMBER/98

Refer to Figure 1-21 & 1-22

C. TRAIN SEPARATION EMERGENCY APPLICATION