STC-GS-3a Operation and Troubleshooting in TL and AC Coaches

Phase II- Module no.
STC-GS-3
ACCA AC Coach Attendant ACCI AC Coach Mechanic
Ah Ampere hour Alt Alternator
Amp Ampere CD1 Condenser Motor1
CD2 Condenser Motor2 CP1 Compressor motor1
CP2 Compressor motor2 DP Double pole
Emergency Feeding Earth Leakage
EFT ELD
Terminal Detector
Electronic rectifier Fuse distribution

ERRU FDB
cum regulator unit board
Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

HP High pressure HRC High rupturing
capacity
INV Inverter IR Insulation resistance

LED Light Emitting Diode LP Low pressure
MCB Miniature circuit MCCB Moulded case circuit
breaker breaker
–VE Negative NPP Non Power panel

OHP Over heat protection OP Oil pressure
OVP Over voltage OVR Over Voltage Relay
protection
+VE Positive PP Power panel

Roof mounted
PVC Poly Vinyl chloride RMPU
package unit
Rectifier cum Regulator
RRU RSW
unit
Sealed
SG Self generating SMF
Maintenance Free
Special Maintenance Temporary
SMI TC
Instructions connection
TDR Time delay relay TP Triple pole
Valve Regulated
VR Vane Relay VRLA
Lead Acid battery
Water Raising
WRA
Apparatus.
DUTIES OF AC COACH ATTENDANT
 To appear in prescribed uniform and have his badge fixed
on it so as to easily identify by the passengers.
 To be present one hour before the schedule departure of

the train.
 To check that all internal electrical fittings in the coach

provided for the comfort and safety of passengers are
intact and in working order.
 To monitor electrical/ mechanical defects developing in the

coach and call maintenance staff for attending whenever
necessary.
 To assist the AC coach mechanic in pre-cooling of the
coach well before commencement of the journey.
 Assist AC coach mechanic to take reading of pressure at

panel board, discharge pressure of refrigerant and oil
pressure of compressor and voltage, current of the
alternators and battery etc., from time to time and make
entries in the log book and inform AC coach mechanic
incase of any abnormalities in the readings.
 To assist the AC coach mechanic in the rectification of

minor faults in the AC coach equipment enroute.
 Keep doors closed during run & open at station when train
is stopped.
DUTIES OF AC COACH MECHANIC
 Should be available in the coach one hour before

schedule departure of the train.
 Check logbook of the coach for any entry by the

maintenance staff and act accordingly.
 Check the condition of V-belts in stable condition. It

should be 6+6 from the primary depot.
 Check OFF load battery voltage. It should be 118V.
 Record all parameters of the equipment in the logbook.

 Check whether the coach is pre-cooled or not. If not, pre-cooling
should be done after placement of the train and pre-cooling should
be removed 10 minutes before departure of the train.
 Switch OFF one of the AC plant before removing pre-cooling

cable from external supply.
 Check all the grills inside the coach. These should be in open
condition.
 Check all lights, emergency lights, fans, night lamps, reading

lamps & mobile charging sockets.
 Attend complaint of passengers, if any.
 Should do temporary connection in TL coach also, if required.

 As the coach picks up speed after its commencement of
journey, observe the reading of the voltmeter and
ammeters of alternators, to ensure that they are working
and write down the parameters in the logbook for every
two hours.
 Observe the function of AC plants by noting the load

currents on the inverters and also cooling effect inside the
coach.
 Record temperature in the logbook for every 2 hours.
 If any abnormality is observed, first note down the same

in the logbook and try to solve the problem to the extent
possible.
 Frequently check the AC control panel indicators for
any faults.
 Change the working of WRAs/ monoblock pump for

every 6 hours if AUTO mode is not in service.

1. Be cautious about un-claimed baggage /luggage.
2. Check working of AC plant/light/fans & reading lights

etc.
3. Check cleanliness of compartment.
4. Keep panel shutter closed with latches already provided.
5. Ensure following in the coach:

a) Pre-cooling cable
b) Emergency feed cable.
Carry standard tool kit box.

6. Use fire extinguisher in case of fire.
7. Open emergency window in case of emergency.
8. Troubles shoot line failure immediately.
9. Communicate line failures & Non-AC certification, if

any. Inform to base depot & destination depot
immediately.
10. Fill logbook details properly.

S. No. Description Qty
4 sq mm PVC copper wire in two pieces for
1. 15m
manual operation of the ERRU/RRU
Inter cell connection leads along with nut
2. 2+2
and bolts.
Carbon brushes for blower, condenser &
3. 1 set
compressor motor for under slung coaches.
HRC fuses 400A, 250A, 160A, 125A, 63A,
4. 2 set
40A, 20A, 10A & 6A
5. CFL & choke 2
6. Cotton cloth for cleaning 1m

Size of E-BEAM Copper
S. No. Quantity
Cable
25 meter length with pre-
3 core 70 mm² cables as cooling socket as per
per RDSO‟s specification RDSO‟s drawing No.
1 No. ELRS/ SPEC/ ELC/ RDSO/ PE/ MS/ AC/ 0044-
0019 (Rev-1) issued in July 2008 (Rev-1)
2010. issued vide letter no.EL/
7.1.83 dated 28.05.2010.
2- Core 25 mm² cables as
per RDSO‟s specification 25 meter with proper
2 No. ELRS/ SPEC/ ELC/ crimping lugs on both ends
0019 (Rev-1) issued in July for DC-DC feed extension.
2010.
S. No. Size of E-BEAM Copper Cable Quantity
Single Core 50 mm² cable as per 0.5 meter with

RDSO specification No. ELRS/ proper crimping
3 SPEC/ ELC/ 0019 (Rev-1) issued in lugs on both ends
July 2010. for bypassing the
Note: Only 3 cells can be bypassed. cells.
Single Core 16 mm² PVC/2.5 mm² 1.5 meter with

elastomeric /2.5 mm² e-beam cable proper crimping
4. for Feed extension in TL coaches as lugs for feed
per RDSO‟s Technical circular extension in TL
No.RDSO/PE/TL/TC/0002-(Rev-0) Coaches.

S. No Type Capacity Location
Negative and Positive terminal of cell
1 HRC 315A
bank
2 HRC 250A Both plant negative and positive supply
Incoming supply from alternator
3 HRC 160A
regulator
Positive supply of control panel for
4 HRC 100A
cooling plants
For positive supply of heating control
5 HRC 60A
panel
6 HRC 2A For negative control supply
Bottle type 10A,
7 Blower and condenser motor supply
Cartridge 20A

S. No. Type & No. Capacity Location
1. Main MCB TP 63A Power input to RMPU

equipment
2. MCB TP 1,2,3 6A Blower motor & Condenser
motor
3. MCB TP 4,5 32A Compressor motor
4. MCB TP 6,7 16A Heater
MCB DP 8 2A In coming of Control

5.
transformer
MCB DP 9 4A Out going of Control

6.
transformer
S. No. Type & No. Capacity Location
7. MCB TP 16A For WRA
8. HRC-F3 10A ERRU field fuse
9. HRC-F1, F2 160A ERRU main fuse
10. HRC 400A Positive and negative of battery
11. MCB DP 0.6A Inverter cooling fan
12. MCCB DP 250A Inverter input
13. MCCB DP 300A Inverter input

( Siemens make)
14. HRC fuse 20A In ERRU/ RRU before

capacitor
Sr. RSW No. Capacity Location
At Power Panel
For alt1,alt2 and battery at power
1 RSW1 500A
panel
2 RSW2 300A For Inv-1 & Inv-2 at power panel
For inverter selector of WRA/
3 RSW3 16A
mono block pump at power panel
4 RSW4 16A For Fans circuit at power panel
5 RSW5 10A L1 & L2 circuits at power panel
6 RSW6 2A Night lamps at power panel
7 RSW7 10A For WRA selection at power panel

Sr. RSW No. Capacity Location
At AC Control Panel
8 RSW1 63A Power ON RSW at AC control Panel
9 RSW2 16A For blower ON at AC control Panel
For auto/manual mode selector RSW at

10 RSW3 16A
AC control panel
For compressor selector, bypass RSW at

11 RSW5 6A
AC control panel
COS-1 & Change over switch for selection of

12 63A
COS-2 power supply in change over control box

1. Overload relay (O/L)
O/L – 1 - For evaporator blower motor.
O/L – 2 & 3 - For condenser motor 1 & 2.
O/L – 4 & 5 - For compressor motor 1 & 2.
2. Time Delay Relay
T.D.R. – 1 & 2 - For compressor motor 1 & 2.

3. Contactors
C-1 - For blower motor.
C-2 & 3 - For condenser motor 1 & 2.
C-4 & 5 - For compressor motor 1 & 2.
C-6 - For heater bank 1 & 2.
AC-1 - For auxiliary contactor.

4. Rotary switch
R.S.W. – 1 - For 3 AC, main supply „ON/OFF‟.
R.S.W. – 2 - For control supply „ON/OFF‟.
R.S.W. – 3 - For Vent/ Auto/ Manual Cooling/

Manual Heating.
R.S.W. – 5 - For compressor by pass mode selection.
5. O.H.P. – 1 & 2
For over heat protection of heater 1 and 2.

6. Electronic thermostat
For controlling heating/ cooling.
7. V.R. – 1 and V.R. 2
Vane relay for check air loss in the air supply to both
side blower.
8. Transformer
415V/ 110V, step down transformer for control circuit.

The following precautions should be observed while working
on coach to reduce risk of injury or accident:
1. Keep all covers in place and doors closed during normal

operation.
2. Ensure that the test equipment is in good and safe

operating condition.
3. When working on the connected motor or motor supply

cable, ensure that the input MCCB of the converter is in
„OFF‟ position.
4. If smoke /fire observed anywhere in the coach then

switch „OFF‟ power supply immediately.
 Ensure provision of two numbers of dry powder type fire
extinguishers in A.C. coaches.
 Ensure that no protection is by-passed.
 Proper rating of MCBs / fuses shall be used.
 Look for any overheating sign after putting on all loads.
 Loose or temporary connection, hanging wires/ exposed

joints etc. should not be allowed.
 Check condition of PVC bushes/ glands provided in

junction-boxes.
 Replace worn-out bushes/ glands during schedules.
 Check condition of insulation especially in junction-

boxes.
 Don‟t permit damaged/ broken/ cracked insulation.
 Rubbing of cables shall not be permitted.
 Check physical condition of wire/ cables for external

damage and overheating marks, discoloration of lugs due
to excessive flow of current/ overheating.

GENERAL CHECKS IN AIR CONDITIONED COACH
Before placing the AC coach at starting station, this should be

pre-cooled. The following items should be checked at depot:
1. Visually inspect, both upper and under frame and ensure all
fittings are intact at their places.
2. In under frame check

• Alternator,
• Axle pulley,
• „V‟ belts of alternators,
• Compressor & Condensers (in case of under slung),

• Battery etc.
if any abnormality found arrange for rectification.
3. In upper frame check control & power panels, fan and

light fittings etc..
4. Check the battery voltage. It should be above 118V at

„OFF‟ load & 115V on „ON‟ load.
5. Check the position of „RSW I‟ & „RSW II‟ is normal and

ensure that the mains and LVR indication (U/S) is
glowing in control panel.

Start the control panel and observe the reading of LP, HP,
OP gauges (U/S).
I. Suction pressure gauge reading should be 2.6 – 2.8

kg/cm2.
II. Discharge pressure gauge reading should 12.6 - 15.5

kg/cm2.
III. Oil pressure gauge reading should be 5.6 - 6.3 kg/cm2.
IV. Feel the temperature suction side cold, delivery side hot
and liquid line should be warm.
OPERATING PROCEDURE FOR AC COACHES
 Ensure coach voltage by pressing voltmeter switch (118V

off load).
 Keep 500A RSW1 in ALT 1, 2 position.
 Keep the 300A, RSW2 in power panel on Inverter 1&2

position.
 Latch ON the MCCB in the inverter and keep the

inverter switch in ON position and observe input DC
voltage in the voltmeter (110 V D.C) and AC output
voltage 415V.
 Put ON the main supply by putting rotary switch RSW1
in ON position.
 This will cause the RED, YELLOW & GREEN (Power

supply) indications to glow.
 This rotary switch should be switched OFF only in case

of repairs/servicing of the unit or control panel.
 This is necessary to ensure healthy power supply to crank

case heaters even the unit is OFF.
 Normal ON/OFF operation of the unit is achieved using

RSW2.
 Check that all the MCBs are ON and the „POWER ON‟
(RED) LED is ON.
 Ensure that RSW5 is at position Comp.1 & 2 ON.
 Place RSW3 on AUTO position and ensure the contacts of

CD1 & CD2 close immediately and CP1 & CP2 contactors
close after a time delay of 120 sec &150 sec respectively.
 Observe and ensure that there is no trip indication in the

LED indication panel of AC control panel.
 After closing of CP1 & CP2 contacts check the load current
in the inverter output side ammeters (21-23 Amps).

 Follow the same procedure for the other side AC plant.
 Ensure working of plant on AUTO mode.
 Switch ON the WRA/ Monoblock pump motor and

check for availability of water in the toilets and wash
basins.
 Record the temperature of each unit (PP and NPP side)

at Electronic thermostat display unit.
 If Electronic thermostat is not there, the temperature

may be measured by portable thermometer near the
return air grill.
 Do not operate the alternator rotary switches (300 amps
capacity) on load. This can cause damage to the switch,
electronic components and the V-belts.
 For failure noticed en-route, if any assistance is required

at the en-route station, message should be given to the
SSE/JE of the station concerned in advance with a copy
to the primary and secondary maintenance depots
concerned.
The following interlocks have been provided in the control

panel to ensure sequence of plant operation:
 If blower motor is not ON, other equipment cannot get

switched ON.
 If Vane Relay is not ON, “AIRLOSS” LED will glow
and no other equipment except the blower can get
switched ON.
 One condenser fan is ON, the compressors can get

switched ON.
 However, if either condenser fan is defective, one of the

compressors operation should be disabled by using
RSW5.
 If Heater is ON, compressor cannot be switched ON.
 Heaters can be switched ON only if both condenser fans

are OFF.
 Place 63A change over switch in the AC control panel on
external position.
 Switch „ON‟ one of the AC plant preferably NPP side when

the external power supply is not extended to battery charger.
 Connect Female socket end to the coach and male socket end
to the pre-cooling socket.
 Switch „ON‟ the MCCB at Pre-cooling male socket.
 Ensure the 3-Ph supply in the AC control panel and switch

ON the other AC plant through inverter only.
 Ensure that centre zero ammeter reads charging Amperes

depending upon battery condition.
DC-DC FEED EXTENSION PROCEDURE
A. From Power Panel to Power Panel (RMPU)
 Switch OFF AC plants before extending TC from

DC Power Panel to DC Power Panel.
 Remove 250A inverter +VE, -VE fuses in the power

panel for one of the inverter supply.
 Extend the DC supply from (2514 or 2513) terminals

of power panel of healthy coach to terminals of
(2514 or 2513) power panel of defective coach with
2 core 35 sq. mm copper cable as shown in the next
slide.
Healthy RMPU Coach Failed RMPU Coach

 Remove the battery fuse of the defective coach.
 After ensuring through feeding connections, re-insert

the 250A fuses of the inverters in both the healthy and
defective coaches.
 Switch on AC plant by balancing the load on both

coaches to avoid over loading of healthy coach
alternators and batteries.

B. Power Panel to/from AC Control Panel (U/S Type)
 Switch OFF AC plants before extending TC from

DC Control Panel to DC Power Panel.
 Remove 250A Inverter +VE, -VE fuses in the power

panel for one of the inverter supply.
 Extend the DC supply from (2514 or 2513)

terminals of power panel of healthy/defective coach
to terminals (B +VE, B -VE) of control panel of
defective/healthy coach with 2 core 35 sq. mm
copper cable as shown in the next slide.
 Remove the battery fuse of the defective coach.

Healthy RMPUCoach Failed U/S coach
 After ensuring through feeding connections, ensure no switch

is in ON condition then re-insert the 250A fuses of the
inverters in both the healthy and defective coaches.
 Switch on AC plant by balancing the load on both coaches to

avoid over loading of healthy coach alternators and batteries.
THROUGH FEEDING PROCEDURE
(Non AC Coaches - TL Coaches)
Actions to be taken in healthy coach
o The availability of power supply in the emergency fed
terminal should be ensured.
o Only one dark coach should be extended feed supply

from one healthy coach.
o Before connecting, the polarity of healthy coach as well

as dark coach should be checked.
o L-II circuit of the healthy coach shall be switched off

before connecting supply to the dark coach.
o The rotary switch (socket paralleling main) SPM I & II
shall be kept in ON position.
L1 RSW L2 RSW Fan RSW SPM RSW
16A L1 16A L2 16A Fan 16A SPM 35A -VE

HRC HRC HRC HRC HRC

Actions to be taken in defective coach and feed extension
o The earth fault shall be checked with the help of test lamp. If
earth fault is there then feed extension should not be done.
o The rotary switch (socket paralleling main) SPM I&II shall

be kept in ON position.
o Remove (+ve) fuse from battery box and (-ve) fuse from
main junction box to disconnect the power supply of battery.
o L-II & fan circuits of the dark coach shall be switched off
before connecting supply from healthy coach.

o The feeding shall be
given to L-I circuit only
of the dark coach from
healthy coach.
o The defective coach

shall be attended and
feed cable should be
removed at the first
available opportunity by
TL staff. +VE, -VE EFT Terminals

o The size of cables for feed extension shall be of 16 mm2
PVC aluminum/ 2.5 mm2 elastomeric cable/ 2.5 mm2 e-
beam copper cable.
o The length of the wire for feed extension shall be 2 x 1.5

meter (for both terminals).
o Both ends of the cable shall be provided with suitable

size of lug.
o The cables shall be secured tightly by screws or bolts,

nuts and plain washer. The proper tightness of the
connections should be ensured.
THROUGH FEEDING WHEN AC COACH
IS IN BETWEEN TWO TL COACHES
AC COACH Defective TL Coach.

Healthy TL Coach
TC TC
o Switch off the SPM RSW in healthy coach.
o Remove –VE fuse in failed TL coach and switch off Lights

and fans.
o Extend the TC from healthy coach EFT to AC coach EFT.

o Ensure the connectivity of the EFT cables on both ends
of the AC coach.
o Extend TC from the other end of the AC coach EFT to

failed TL coach EFT.
o Before switching on the SPM RSW, Switch off L-II

circuit in the healthy coach.
o Switch on SPM RSW and ensure the availability of

supply in Junction box of failed TL coach.

o Switch „ON‟ L-I circuit and Fan circuit in the failed TL
coach.
o Always remember that when extending TC from one

coach to other coach, switch off L-II circuit in both the
coaches to avoid over loading of alternator of the healthy
coach.

COACH HISTORY SHEET
Railways:
A. Coach Particulars
Coach Coach Year of POH done POH Coach type Remark

Sr No manufacturer manufa date and due SG/EOG/LHB/
cture place date underslung

B. Equipment Details (Ex- POH)
S. Equipments Make and Sr no. of equipment
No PP Side NPP
1 AC plant- RMPU/under-slung
2 Compressor
3 Blower motor
4 Cond. motor
5 Control panel RMPU/ under-slung
Power panel
6 Thermostat
7 Alternator
8 Pre-cooling Socket
9 I.V. coupler
10 25 KVA inverter
11 ERRU/RRU
12 V-belts
13 60/50 KVA transformer
14 3 KVA transformer
15 (make/lug date)
16 Pre-cooling transformer
17 Fire extinguishers
18 Emergency Light
C. Equipment Replaced/Repaired In Between POH TO
POH
Date of Equipment Make and Sr no. of Reason for

replacement replaced equipment provided replacement
PP side NPP side
D. Telephone/CUG Mobile No. of Important AC/TL Depot
Depot CUG No. Line Railways Auto Phone number

E. Instruction to Escorting Staff
Sr No Instruction
1. Appear in uniform & name badge
2. Join duty one hour in advance from train departure
3. Be cautious about un-claimed/Baggage /Luggage
4. Check working of AC plant/light/fans & reading lights etc.
5. Check cleanliness of compartment
6. Keep doors closed during run & open at station when train is stopped
7. Keep panel shutter closed with latches already provided
8. Carry following
a) Standard tool kit box
b) Pre-cooling cable
c) Emergency feed cable

Sr No Instruction
9. Use fire extinguisher in case of fire
10. Open emergency window in case of emergency.
11. Trouble shoot line failure immediately
12. Communicate line failures & Non-AC etc to base depot immediately
Communicate line failures, non-AC etc to destination depot

13.
immediately
14 Fill log book details properly

F. List Of Tools in Standard Tool Kit for AC Escorting
Staff (Circulated vide RDSO letter No. EL/7.2.2 dated 17.01.2006)
S.No. Description Qty
Tool box of size 325x440x120 mm (Approx.) with fixing

1. arrangement for tools and locking arrangement with 2 no. 1 set
keys
Screw driver set with 8 nos of blade similar to Jhalani P. No.

2. 1 set
830 or equivalent
Combination plier insulated with thick CA sleeve with joint

3. 1
cutter length 205 mm
4. Digital multimeter 1
5. T spanner of sizes 10, 13, 15, 17 1
Panel key square type ¼ size suitable for opening of control
6. 1
panel of AC coaches
7. Key for opening fittings of AC coaches 1

Test lamp holder (brass) fitted with two mtrs. of 2 core flexible
8. 1
copper wire
9. Torch, cells (+2 cell spare) 1
DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 16/17,
10. 1 set
18/19, 20/22
11. Allen key size 4 mm, 3/16, 7/32 1
Heavy duty cable cutting knife adjustable in aluminium casing

12. 1
over all size 140 mm
13. Adjustable spanner length 255 mm 1
14. Thermometer digital 1
15. Nose plier 6” 1

16. Tongue tester A.C. (0-100 A) 1
17. Hammer ½ kg 1
18. Hacksaw frame with blade (+ 1 spare blade) 1
19. Insulating tap 1
20. Wire fuse 1

G. Coach Monitoring Log Sheet For AC Coaches (To
Be Filled By Escorting Staff) RMPU Type Coach
Date------------ Originating/Destination Station------------- Train No. ----------
AC coach Mechanic (Name /Design)…… Attendant (Name/Designation) -----
No load voltage ---
1. Every two hour following details are to be filled
a. Status of battery, alternator , inverter and Temperature
current Temp at return air

Alternator
(A) Inverter-1 Inverter-2 grill/Electronic
Voltage Current (A)
Time (+ /-) thermostat display
(ON
Load)
Alt.1 Alt.2 A V I V I PP NPP

b. WRA Switching (Use WRAs alternately)
0600- 1200- 1800- 0000- 0600- 1200- 1800-

Time
1200 1800 2400 0600 1200 1800 2400
WRA-1
WRA-2
2. Record all line failures and unusual as under
Clearing Brief details of

S.No. Date Time Section
Time unusual

I. Coach Monitoring Log Sheet for AC Coaches
(To Be Filled by Escorting Staff) Under-slung AC coaches
Date--------- Originating/Destination Station -------- Train No. -----
AC coach Mechanic (Name /Design) ……. Attendant (Name/Designation) ----
No load voltage -----–
1. Every two hour following details are to be filled Status of battery,
alternator ,inverter, Temperature
Voltage Alternator Current

Pressure Temp at return air grill/
Time (ON Current (A) Pressure (PP)
(NPP) Electronic thermostat display
Load) (A) (+ /-)
Alt.1 Alt.2 LP HP OP LP HP OP PP NPP
2. Record all line failures and unusual/public complaint on TL&AC system as

under
S.No. Date Time Section Clearing Time Brief details of unusual
Signature of escorting staff

with date & time

J. Format For Maintenance Log Sheet for AC Coaches
(Primary/Secondary Maintenance)
Date ------ Originating/Destination station ----- Train No. ----- From ----- To ----
Following checks to be done
Arrival condition Departure

Sr of coach condition of coach
Item to be checked
No
PP side NPP side PP side NPP side
Temperature (to be taken
1
at Return air grill)
Working of RMPU in Auto
2
mode
Condition of AC control
3
panel of RMPU

Arrival condition of Departure condition of
Sr coach coach
Item to be checked
No
4 Current of compressors
5 Current of condenser motor
6 Current of Blower motor
7 Condition of inverter
8 WRA working
Refrigerant pressures (for under
9
slung AC caches
10 Alternator suspension bush /pin
11 Nos. of V-Belts
V-Belt Tension (Tight/loose)
Vane Relay
Available working Available working
Lap top/mobile charger
Yes/No Yes/No
12 Earth leakage

Arrival condition of Departure condition of
Sr
Item to be checked coach coach
No
13 Test working of emergency light 1 2 3 4 1 2 3 4
Battery box condition/welding/
14 Box-1 Box-1
tightening of fastners
No load Full load No load Full load
15 Battery voltage voltage voltage voltage
2nd 55th 2nd 55th

16 SPG of pilot cells
Emergency Pre- Emergency
Pre-cooling
17 Availability of cable feed cooling feed
Note : Depot mechanic shall ensure the implementation of all the SMIs and modifications issued by
RDSO during primary maintenance. No coach should be given in service until all SMIs &
modification sheets are complied for the coach.
BRIEF DESCRIPTION OF MAINTENANCE CARRIED OUT

1.
2.
3.
4.
Name/Designation & Signature of supervisor with date & time
In the event of accident/ disaster,
escorting staff shall contact train
conductor/guard and shall be
ready for any type of help and
same should be informed to
electrical controller.

1
DERAILMENT/ COLLISION
(INCLUDING LEVEL
CROSSING ACCIDENTS)

 Immediately check lights in the coaches.
 Provide light in dark coaches.
 Provide light at accident site.
 Take necessary actions as a man of common

prudence will take not only to help the stranded
passengers but also to arrange such helps as
would be demanded by the circumstances.
 Help in extricating the trapped passengers/

bodies.
2
FIRE IN TRAIN

 Immediately isolate the affected coach/coaches
electrically.
 Use fire extinguisher to extinguish fire to the

extent possible.
 Immediately check lights in the coaches and

provide light in dark coaches.

 Take necessary actions as a man of common
prudence will take not only to help the stranded
passengers but also to arrange such helps as
would be demanded by the circumstances.
 Help in extricating the trapped passengers/

bodies.

3
CYCLONE/ STORM/
FLOOD

 Immediately isolate the affected coach/coaches
electrically.
 Shall immediately check lights in the coaches and provide

light in dark coaches.
 Take necessary actions as a man of common prudence

will take not only to help the stranded passengers but also
to arrange such helps as would be demanded by the
circumstances.
 Help in extricating the trapped passengers/bodies.

4
REPORTED BOMB IN
TRAIN

 Immediately isolate the coach in which the bomb has
been reported with assistance from C&W staff/Division.
 Immediately check lights in all the coaches including

non-AC coaches and provide light in dark coaches.
 Immediately isolate the power cars in case of Rajdhani/

Shatabdi trains.
 Help the passengers in moving out from the coach.
 Open/ break the emergency window of affected coach.

5
EXPLOSION OF BOMB IN
A TRAIN

 Immediately isolate the coach/ coaches
electrically.
 Use fire extinguisher to extinguish fire.
 Immediately check lights in all the coaches and

provide light in dark coaches.
 Help in extricating the trapped passengers /

bodies.
 Open emergency / break the window of affected

coach.
 Inform the passenger of other coaches to
evacuate to avoid the possibility of casualty due
to bomb explosion in other coaches.
 Take such necessary actions as a man of

common prudence will take not only to help the
stranded passengers but also to arrange such
helps as would be demanded by the
circumstances.

7
OPERATION OF FIRE
EXTINGUISHERS

 Update knowledge on fire extinguisher types and operating them.
Clamp
 Do not become panic when coach catches fire.
 Remove the seal & clamp of the fire extinguishers.
 Find out the base of the fire.
 Hold the nozzle and aim towards near to the base of the fire.
 Hit the operating knob and ensure that the powder is sprayed
properly.
 Ensure the fire is totally extinguished and it is cooled.
 After extinguishing fire, isolate the fired equipment from the circuit.

8
ELECTRIC SHOCK

 Electric shock occurs when an electric current flows
through the body. The human body is made up of 60% to
70% water. This makes it a good conductor of electricity.
Burns, damage to internal organs, heart rhythm
problems, and death can result from electric shock.
 What to do when a person received an electric shock:
 Switch off the current, if possible, by removing the fuse

or switching off the circuit breaker
 Do not touch/ remove the victim from the electric source

until the power source has been shut off.

 Separate the person from the source of electric current
using a dry broom handle or other type of non-
conducting material such as wood or rubber.
 Do not touch the victim with your bare hands, as electric

current will pass through you as well.
 Let his head be slightly lower than the rest of the body,
and raise his legs.
 6. Inform TTE/conductor and call any Doctor, if

available in the coach/train to attend the injured person.
Inform this incidence to electrical control.

 Do keep all the tools, gauges & instruments in
working condition.
 Do tighten nuts & bolts fully by applying proper

torque.
 Do keep all commonly used tools and gauges in

a handy tool box.
 Do ensure that in 3 phase supply system the

neutral is available.
Contd......
 Do check continuity only by using series lights

bulb of 100 W or higher rating and not with
ohm-meter.
 Do work with full confidence.

 Don‟t climb on roof of coach in electrified
sections.
 Don‟t bypass safety devices.
 Don‟t wear loose clothes and chappals.
 Don‟t use defective tools, gauges and

instruments.
 Don‟t use oversize/ improper tools.

Contd......
 Don‟t apply unsafe method of working.
 Don‟t leave tools gauges & instruments at work

place after completion of work.
 Don‟t leave nuts & screw/bolts half tighten.
 Don‟t use nuts & bolts having different pitches

together.
 Don‟t apply excessive pressure for tightening the

nuts, bolts & screws.
Contd......
 Don‟t use Fork lift, lift package unit from top
through hooks only.
 Under no circumstances the plant should be run
in manual mode for prolonged period of time
and without supervision of a qualified
technician.
 Don‟t allow the refrigerant gas to escape to the
atmosphere.
 Don‟t use refrigeration compressor for pulling a
vacuum.
 Do pour cold water immediately on the burn till
the burning sensation stops.
 Do keep an ice or cold water pack on the burn.
 Do make the person roll on the floor, if his
clothes catch fire.
 Do protect burn from dust, dirt, flies, etc. Cover
it with a thin and light cotton cloth.
 Do immediately get the help of doctor, if the burn
is severe.
 Don‟t apply any ointment on the burn.
 Don‟t cover the burn with thick cloth.
 Don‟t wrap a blanket around a person whose

clothes have caught fire.
 Don‟t tie a cloth tightly. Don‟t use a dirty cloth.
 Don‟t get the help from an unqualified person.

 Do Make the victim lie down with his head
in a lower position than the body
 Do pour cold water on the victim‟s head.
 Do put a cold pack on the nose.
 Do immediately get the help of doctor, if the

burn is severe.

 Don‟t put a pillow under the victim‟s head.
 Don‟t allow victim to put finger in his nose.
 Don‟t allow victim to blow his nose too often.
 Don‟t get the help from an unqualified

person.

 Do make the victim lie down in a cool place
 Do keep an ice or cold water pack on the head

of victim
 Do Give water or juice to drink to the victim.
 Do immediately get the help of doctor, if the

burn is severe.

 Don‟t crowd around the victim.
 Don‟t cover the victim with any cloth,

especially woolen cloth.
 Don‟t give hot tea or coffee to the victim.
 Don‟t get the help from an unqualified person.

 Do make the victim lie down in a cool place
 Do wash the wounds with clean water & then

clean the wounds with an antiseptic solution.
 Do give sufficient support to the affected area in

case of sprains or tear in muscles.
 Do immediately get the help of doctor, if the burn

is severe.

 Don‟t crowd around the victim.
 Don‟t apply any oily or greasy ointments.
 Don‟t massage the affected area.
 Don‟t get the help from an unqualified

person.

 Do always connect same make of ERRU with
same make CIP (Coach Indication Panel)
 Do keep rotary switch on CIP, in normal position

i.e. both ERRUs working.
 Do changes switch position in case ERRU-1/

ERRU-2 fails, accordingly for emergency mode
i.e. control circuit of healthy ERRU will drive
both ERRUs. This can be done when train is
stationary.
Contd......
 Do check ERRU status before changing the

switch position, if OVP is tripped, then reset it.
 Do reset CIP and old data cleared, if ERRU is

fitted first time in coach. Do ensure the correct
parameter set.
 Do use only correct rating of HRC fuse i.e. 6A,

10A, 16A and 160A.

Contd......
 Do use controlled supply with maximum output

limited to 130V while charging the coach battery
with external charger.
 Do check connection polarity after attention or

replacement; ensure correct setting through the
display panel.

 Don‟t change the rotary switch position while
alternators are running.
 Don‟t reset ERRU, if OVP is tripping

repeatedly.
 Don‟t by-pass the OVP and fuse.
 Don‟t disturb the setting of ERRUs.

Contd......
 Don‟t test the ERRU without connecting

battery after installing in coach.
 Don‟t touch control IGBT with naked hands.

 Do make separate connection for DC+, BC+
and DC-, BC- in case of 4.5 kW ERRU whereas
25kW ERRU, BC+ shall be used in power
panel.
 Do reset display unit and old data cleared, if

ERRU is fitted first time in coach.
 Do use only correct rating of HRC fuses i.e. 6A,

10A and 32A.

Contd......
 Do use controlled supply with maximum output

limited to 130V while charging the coach battery
with external charger.
 Do check connection polarity after attention or

replacement.

 Don‟t connect/ short DC+ and BC+ in 4.5 kW
ERRU
 Don‟t reset, if OVP is tripping repeatedly.
 Don‟t by-pass the OVP and fuse.
 Don‟t disturb the setting of ERRUs.
 Don‟t touch control IGBT with naked hands.

Ref: Railway Board Letter No.97/Elec.(G)/180/7 New Delhi,
dated: 2.9.1999
CAMTECH, Gwalior Phase II - Module No. STC-GS-3

1. CESEs of the Railways to interact with their counterparts
in other Railways to advise the unusual occurrences and
obtain feed back.
2. All the AC coaches to be pre-cooled before placement of

rakes on platform. This is the time when passengers
require maximum and immediate comfort level. Pre
cooling cum emergency leads should be provided in all
SG AC coaches (1 in each coach) and power cars (2 in
each power car).
3. No train to leave the Primary Depot with EFTs or
equipments in isolated Condition.
4. Defects in the coaches to be noticed immediately after

arrival of train and remedial action taken accordingly.
Escorting staff should report at secondary maintenance
depot and advise the status of coach and should sign the
register with Depot and Depot staff to sign the Log
Book with Escorting Staff.

5. All AC coaches from Primary depot should go with both
Alternators working. If an Alternator cannot be
replaced/repaired at the secondary maintenance depot,
decision to send coach with one Alternator to be taken at
officer's level. Second Alternator to be fully functional with
full generation and the coach/rake to be properly pre-cooled.
6. AC coaches should go from Primary Depot with 6+6 belts on

the Alternators and minimum 5+5 from Secondary Depot
Adequate facilities to be built up for changing the belt on
rake itself
7. The knowledge of all the ACCIs & ACCAs should be
checked regularly regarding operation of the AC coach
equipment as well as handling of the situation in case of
failure of the equipment. ACCIs/ACCAs MUST maintain
the log book and enter all the unusual occurrences.
Training of AC staff of one week duration to be
Standardized by the Railways.
8. Drive system for generation testing and Regulator setting

to be introduced For Alternators at all Primary Depots.

9. Unit Exchange Spares (UES) should be available in all
depots. Each depot should have authorized holding of
UES. Register should be available for each major UES at
all the depots.
10. All the major depots should carry out failure analysis of
major equipments & the information should be sent to
RDSO periodically.
11. The power supply system for pre-cooling to be augmented

in view the increasing number of AC coaches in the
depots. Railways to examine and take corrective action.
12. Railways to revise their Estimated Annual Consumption
of the material because of increasing AC Coach holding.
13. Cleaning of alternator field and phase wires to be

properly checked at primary depot.
14. Full load and no load voltage of each cell of SMF

batteries to be recorded (weeded out weak cell) every
month for subsequent 3 months and if there is no
abnormal variation in voltage, it should thereafter be
recorded once in 3 months.
15. Working of thermostat should be monitored and recorded
in log book. If thermostat is not found in working
condition, the same should be Attended/ replaced by
primary depot.
16. Working of WRA should be checked on arrival of train at

primary/secondary depot and its working should be
ensured before placement of rake at the platform.

Phase II – Module no. STC-GS-3
A : Safety Chain
B : Hanger Pin & Bush
C : Alternator Pulley
D : Alternator Shaft
E : Terminal Board
 Axle pulley & Axle pulley pad
 V-Belt
 Alternator tensioning mechanism
 Rectifier Regulator Box
 Battery box
 Under Frame
 Rotary Junction Box

 Fuse distribution Boards
 Fans
 Light Fitting
 EFT/BCT
 Wiring
 Others
 Existence of eight bolts with flat washers, full tightness
of bolts.
 Proper alignment of axle pulley and alternator pulley.
 Observation of correct belts tension without twist,
 Maintaining gap 3 mm between two flanges, observation

of without worn-out grooves and breakage etc.,
 Dimensions & material

 Full complement of battery box fixing bolts.
 Its tightness, observation of its bottom plate and side

plates for any damage,
 Full tightness of cell packing.
 Proper securing of anti theft arrangement and battery

box cover.
 Full tightness of inter cell connections with double

fasteners.
 Correct size of battery fuse.
 Elimination of earth leakage.
 Maintenance of correct polarity etc.,
 Full tightness of cell packing.
 Proper securing of anti theft arrangement and battery

box cover.
 Full tightness of inter cell connections with double

fasteners.
 Correct size of battery fuse.
 Elimination of earth leakage.
 Maintenance of correct polarity etc.,

 Junction box - provision of correct polarity of
incoming and outgoing cables.
 Full tightness of all cables.
 Proper securing of all cables etc.
Back
 Full complement of RR Box fixing bolts and its
tightness.
 Provision of correct size of HRC fuses.
 Maintenance of correct polarity of field wire.
 DC output terminals and their tightness etc.
 The fuse provided in 4.5 KW RR Box for one of 3

phase AC supply is 32 A HRC.
 The field fuse provided in RR box is 6 A HRC.
 The voltage setting of the 4.5 KW regulators for

passenger train is 128.5 ± 0.5 V DC, when coach is
loaded with batteries.
 Full tightness of all terminal connections.
 Provision of correct size & Rating of HRC

fuses.
 Maintaining correct polarity incoming and

outgoing cables.
 Avoiding earthing and shorting of cables. Back

 Full complement of its fixing bolts and their tightness.
 Proper securing of guards and blade.
 Elimination of single field coil working fan .
 Observation fan hinge for breakage avoiding of

earthing and shorting of fan wires etc.
 Connect Fan lead with fan connector (fixing with coach

body). Back
 Replace fan lead if found in damage condition.
 Replace fan Guard/fan blade if found in damage

condition.
 Provision of correct size of fuses or re-wirable fuses.
 Elimination of loose fuse wires.
 Full tightness of terminal connections.
 Proper securing of its cover etc.

Back
 Proper fitment of above with screws/bolts.
 Avoiding earthing and shorting of lamp

leads.
 Proper securing of wiring.
 Provision of correct size of fuses etc.

Back
 Proper Fitment /provision of these fitting.
 Correct polarity, provision of correct size

of fuses.
 Maintaining correct polarity while charging.

Back
 Securing of wiring through cleats with trough casing.
 Provision of correct size of fuses in wiring circuits.
 Elimination of lower size cables.
 Provision of PVC bushes when ever wires passing

through metal parts.
 Eliminations of temporary wiring, avoiding of

earthing and shorting of cables etc.
Back
 Ensure 35/50 mm barrel bush gap in the bogie bracket
of TL/AC coaches respectively.
 The belts of same length i.e., same grading should be

used as a set.
 Two or more makes of belts should not be used in a set.
 Check tension of V belt after fitment by 4 kg weight..
 Re-tension of newly fitted belts shall be done after 1st

trip or 500 km run, whichever is convenient.
 Check alignment of pulleys whenever alternator is
replaced.
 The field wire should not be reversed; otherwise there

will be no residual magnetism/generation.
 For field wires, the positive is marked as Red and the

negative is marked as Black.
 In RR Box, the DC output terminals should not be

reversed, otherwise the battery fuse will be blown, flash
over occurs.
 The alternator terminals, RR Box terminals are properly
crimped with correct size of Lugs and to be tightened
fully with flat and spring washers.
 The V belts are to be properly aligned.
 Maintain correct belt tension for proper generation.
 The alternator pulley key way and key are to be properly

matched otherwise the key way will be worn-out and
pulley becomes loose.
 Alternator pulley nut and lock nut are to be properly

inspected for tightness in every trip avoid falling of
pulley.
 Alternator and regulator connections are to be inspected
for every trip for tightness.
 Under Frame Junction Box connections are to be

inspected for tightness in every trip for tightness.
 The safety chains should not be infringed in movement

of alternator.
 The safety chains should have originals bolts with split

pins
 Anti-rotating clamp must be provided to stop the
movement of alternator suspension pin to avoid worn-
out of nylon bushes and other parts.
 The V belt should not be twisted if, twisted belts are

found then they should be set right immediately.
 The under frame cables are properly secured to avoid

loose connections & short circuits and fire hazards.
 BCT and EFT terminals are never to be shorted,

otherwise flash over occurs.
 When battery is connected for charging the polarity is to
be maintained i.e., positive of the charger is to be
connected to the positive of the battery, & the negative of
the charger to the negative of the battery.
 The batteries should never be allowed for deep

discharged.
 The battery fuses provided for 120 Ah TL batteries is 40

Amps HRC for positive and negative side separately.
 The capacity of HRC fuses provided in main
distribution board for Fan, Light-1 , Light-2 and EFT
circuits is 16 Amps.
 The capacity of re-wirable fuse in FDB for protection

of fans and lights in 110 V TL system is 35 SWG or 6
Amps.
T.L COACH
 Material Polyurethane Rubber as per IRS-48. Grade “F”
 Shore “A” Hardness 70 ± 5.
 Axle pulley pad as per RDSO Drg. No RDSO/PE/SK/TL

/0084-2005 (Rev. 0)
 Size of Axle pulley pad for TL Coach Axle pulley16.25

Ton is 240x160x18+0 &-1
 Size of Axle pulley pad for TL Coach Axle pulley13
Ton is 230x160x18+0&-1
 Check Rubber quality in each lot from M&C Lab.

Note:
 Manufacturer name in 5 mm letter on side –

Engrave/Emboss & manufacturing month & Year.
 Axle Pulley Pad Should be replaced 100% during

IOH, POH or if found defective during inspection.
 Axle pulley For TL Coach as per RDSO Drg. No
SKEL 3883 Alteration 5 or latest.
 Axle pulley half material as RDSO specification No.

ELPS/ SPEC/ TL/13, March 1998 & IS:210,
Gr. FG260.
 Axle pulley Bore Dia for TL coach is 173mm

(For 13 Ton Axle.)
 Axle pulley Bore Dia for TL coach is 180mm

(For 16.5 Ton Axle.)
 Axle pulley PCD 572.6 ± 0.4 mm.
 Axle pulley V-Groove Angle 38° ± 0.5°.
 The gap between two halves on axle pulley in

assembled condition on axle with axle grip shall be
maintained as 3 ± 0.5mm.
 Nut & studs on axle pulley assembly shall be

tightened with torque of 30 kg-m (maximum)
 Chemical composition as per IS260: Sulphur &

Phosphorus content shall not exceed 0.12% each.
 Tensile Test:-260 N/mm² (min). in accordance with IS-
2078.
 Hardness Test:-180-220.(Brinell hardness ) in accordance

with IS:1500.
 Manufacturer name or trade mark & year of manufacture

to be punched on each Half.
 Distance between two V –groove centre is 31.75±0.5mm.
 Corner of the grooves are to be rounded to 0.5R.
 All stud assembly (stud, nut, lock nut, split pin, plain
washer )should be replaced during IOH &POH.
 Axle pulley Stud size 20Øx2.5x175mm.
 Axle pulley Stud Material IS:2073-70,C45

(Galvanised).
 50mm thread on both side & split pin hole dia 4 mm

at the distance of 9 mm from free end.
 Nut M20x2.5 Material IS:2073,C 20 (Galvanised).
 Lock nut M20x2.5 Material IS:2073, C 20

(Galvanised).
 Punched plain Washer Ø22 , IS: 1997,St32
(Galvanised).
 Split pin Ø4x40 as per IS 549 table 1.
 Dowel pin as per IS 2393.& size 40mm length & dia

16mm+00,-0.027,
 The dowel pin should be press fit in one half &

clearance fit in other half.
 Alternator pulley for TL coaches alternator as per
RDSO Drg.No.SKEL3882 Alt.4.or Latest.
 Alternator pulley material as RDSO specification

No. ELPS/SPEC/TL/13, March 1998 & IS:210, Gr
FG260.
 Life of pulley is approximately 04 years.
 Chemical composition as per IS260: Sulphur &

Phosphorus content shall not exceed 0.12% each. Back
 Tensile test:-260 N/mm² (min) in accordance with IS-
2078.
 Hardness test:-180-220 (Brinell hardness) in

accordance with IS:1500
 No. of V groove in alternator pulley for TL coach = 04

Nos.
 Alternator pulley PCD 200 ± 0.3mm.
 Alternator pulley V-groove angle 34°± 30’

Back
 Mating surface of alternator pulley with shaft not less
than 80%.
 Taper 1 in 8 on dia for TL Coach Alternator pulley:

Bore Dia 41.25mm , Length-102mm, Smaller Dia -
28.5mm,
 Alternator shaft dia at the distance of 97mm from

starting taper 41.25mm.
 Distance between two V–groove centre is 31.75 ± 0.5

mm.
 Corner of the grooves are to be rounded to 0.5R. Back

 Key way width in TL coach alternator pulley = 9.5+
0.018 to 0.040 mm.
 Key length 80 mm.
 Key size 9.5*11*80mm.
 Dynamic balancing of alternator pulley with alternator

rotor shall not be more than 2.5gm-cm per kg.
 Manufacturer name or trade mark & year of

manufacture, month to be punched on each alternator
pulley. Back
 Safety chain for 4.5 kW alternator as per RDSO Drg
No. SKEL 3943 Alt 2.
 Total length of 4.5 kW alternator safety chain is

214+0,-5mm.
 No. of links in 4.5 KW = 03 nos. & dia of Link

alternator safety chain = 10 mm.
 No of shackle in 4.5 kW = 02 nos. & dia of link

alternator safety = 12mm.
 Total length of safety chain = 3x30 + 2x62 = 214mm Back

 Material of link as per IS:2429-70,Pt II.
 Material of shackle & bolt as per IS:6132-71,

Pt I Gr 40.
 Safety factor shall not be less than 4.
 Safety chain for 4.5 kW transom mounted alternator

tested at 1000 Kgf.
 Bolt, nut, plain washer & split pin should be replaced in

every POH.
 Bolt size for safety chain is M16*85mm, split Back

pin
hole dia Ø 3mm.
 Split pin size 3*45 to IS 549.
 Hole at the distance of 06mm from free end.
 Plain washer -17mm I/D, 32mm O/D, & 2mm

thickness. Qty =04 Nos.
 Hex nut M16*12 height. - 02Nos.
 Gap between shackle = 28 mm.
Back
• Suspension hanger pin, split cotter for 4.5 KW
alternator: As per RDSO drg. No.3939 Alt.2.
• Material specification of
(i) Pin:-IS 1875,CL 4 OR BS 970,EN-9.
(ii) Split Cotter: - IS 1079-73 St 42.
Back
• The suspension hanger pin shall be hard Chromium
plated as per IS:1337(Rev-2)
• Split cotter shall be Zinc plated with passi-vation.
• IS-1875 Cl 4.
Carbon - 0.40-0.50.
Silicon - 0.15-0.35.
Manganese - 0.60-0.90.
Sulphur - 0.04 max.
Phosphorus - 0.04 max. Back
Mechanical:
Tensile Strength - 620 N/mm² min.
Yield Strength - 320 N/mm² min.
Elongation-min - 15%
Hardness min - 175 minimum
Normalizing Temp. - 830-860°C

(for information only).
Back
The Suspension hanger bush as per RDSO Drg No.3942 A (Alt 4)
(iii) BUSH:-Nylon-66 As per RDSO’s SPEC .No.
RDSO/PE/AC/0006-99(Rev-o).
• It should be checked in every fortnightly schedule i.e. Head of

Pin & split cotter.
• If found defective replace it.
• Stopper should be match with suspension hanger pin slotted

head.
• If stopper found in worn-out condition , replace the stopper.

Back
RDSO Specification For V- Belts:
RDSO/PE/SPEC/AC/0059-2004 Rev-0) with

amendment No. 1.
Marking on V-BELT C-122 Lp 3155 IR 05/12.
Grading of V-Belt: Between 48 to 52.
Top width of V-Belt - 22±0.5mm.
Height of V-Belt - 14±0.5mm.

Angle of V-Belt - 40°.
Grade Length Between
From To
48 3150 3152
49 3152 3154
50 3154 3156
51 3156 3158
52 3158 3160 Back

 Common Terminal Board for 25kW & 4.5 kW
alternator as per RDSO Drg.No.-
RDSO/PE/SK/AC/0047-2004 (Rev-2).
(RDSO LETTER No-EL/1.6.9.15 Dt 27-02-2006)
 Hardware item replaced in every POH.
Back
 Shaft material –EN-24 as per BS 970.
Carbon - 0.35-0.45.
Silicon - 0.15-0.35.
Manganese - 0.45-0.70.
Sulpher - 0.05 max.
Phosphorus - 0.05 max.
Chromium - 0.90 to1.40.
Nickel - 1.30 to1.80.
Back
Molybdenum - 0.20 to0.35.
 Alternator Shaft shall be tested by ultrasonic
100%.
 Shaft shall be hardened & tampered.
 If bearing fitment found loose on Alternator

Shaft during POH replace the shaft by new
one.
Back
Fits &limits on bearings of alternators, ac/dc motors fitted
on coaches:
As per IS:2709-1964. 1 Micron=0.001mm.
Nominal Shaft Inner race Housing dia Outer race
shaft tolerance bore tolerance bore
Dia in mm K5 micron tolerance hB micron J6 Micron tolerance
hB micron
10 to18 +9 -8 - -
+1 0 - -
18 to 30 +11 -10 -5 0
+2 0 +8 -9
30 to 50 +13 -12 -6 0
+2 0 +10 -11
50 to 80 +15 -15 -6 0
+2 0 +13 -13
80 to 120 +18 -20 -6 +16

+3 0 +16 -15
120 to 150 - - -7 0
- - +18 -18
150 to 180 - - -7 0
- - +18 -25
180 to 200 - - -7 0
- - +22 -30
Bearing Life L-10 not be less than 16 million Km at 1500 rev/min.
 As per RDSO Drg No. SKEL 3940 sheet 1& sheet 2
Alt 5 or latest.(For 4.5 kW Alternator)
 Spring details for TL Alternator 4.5 KW.
 Free Length 345±3.0mm
 Working Length 310mm
 Inner Dia 86mm
 Effective Turns 12Nos Back

 No of Turns 14Nos
 Outer Dia 114±1mm
 Wire Diameter 14±0.1mm
 Material IS 4454 Pt3 975.
 Treatment Oil Hardened &Tempered.
 Clearance -35 mm for TL Alternator.

Back
•
 Electric shocks are generally received by the worker
and can be avoided.
 Switch off immediately if a person in contact with a

live conductor.
 Apply artificial respiration quickly and call the doctor

at once.
 Always connect a switch on live (+ve or phase)

conductor only.
 Do not use wires and tools having poor insulation.
 Use CO2/CTC extinguishers only on electrical fire.
 Do not renew a blown fuse until rectified the fault.
 Do not add water to acid, always add acid to water.
 Do not bring a naked flame near an accumulator.
 Do not throw water on a live conductor or equipment in

case of fire.
 Obtain line block from guard or ASM.
 Keep Danger board on the rake and lock the scotch block.
 Danger board and lock should remove after completion of

work by authorized person only.
 Do not place or drop metal objects on top of the battery.
 Disconnect the supply immediately in case of coach

firing.
 Use box spanners to attend battery connections.
 Remove rings, wrist watches etc. while working with

battery.
 Always follow safety instructions.
 Do not toss tools and materials.
 Do not handle heavy TL equipment carelessly.
 Do not remove/ replace connections in regulators box

when supply is ON.
 Do not try to remove or replace V belts, when it is in full
tension.
 Be caution about 120 V DC supply.
 Use ladder while replacing sidelights.
 Do not adopt short cut methods.
 Hasty makes the man prone to danger.
 Complete your work before few minutes of starting of a

train.
 Do not try to catch or get down from moving train.

 Beware of live conductors, bare or insulated.
 Never tamper with any electrical gear.
 Never disconnect a plug point by pulling the flexible

cable.
 Never touch a conductor unless you have made sure it is

dead and earthed.
 Never energies a conductor unless you are sure all are

clear and there is no one likely to be working on it.
 Always switch off before replacing a blown fuse.
 Do not lift or move portable electrical appliances with

power 'ON'.
 Switch 'OFF' power and earth the frame before shifting

position.
 Check leakage on metallic frame with a neon tester after

switching ON before touching the metallic frame of the
apparatus.
 Cut off supply and earth the point on which you want to
work. If you have to work with power 'ON' keep your self
insulated and see that you are on firm support.
 Do not handle electric switches of appliances with wet
hands. Be more careful in handling electric gear inside
bathrooms and during monsoon weather.
 Do not lean against electrical poles or stay wire.
 Do not play with electricity.
 Use 5- pin plugs and check up earth connections carefully.
Each plug socket to be protected and controlled by a
proper fuse/MCB and a switch on the live side.
 Use inter lock switch plug or keep the plugs located at a

high level not less than 4'-6‘ above floor level i.e. beyond
the reach of children.
Phase II- Module no. STC-GS-3
1. At Power Panel
 RSW 1 in Power panel
should be on Alternator1, 2
& battery position.
RSW1 in power panel
 Check the incoming and
outgoing supply at RSW1. If
RSW1 defective/ burnt, by pass
it and incoming +VE’s of alt1,
Alt1 incoming Alt2 incoming Battery alt2 & battery to be connected
+VE +VE +VE to incoming of RSW2.
2. At Alternator
 Ensure the availability of V-belts.
 Check the continuity of field & phase windings at alternator

terminals for open/ short circuit fault with multimeter and earth
fault with megger of suitable range.
V-belts Tension device

Axle pulley
25 KW alternator
V-belts
Phase wires Field wires
 If the coach was in ideal condition for a long time, to gain the
residual magnetism, check the field winding of alternator with
110V DC in series with test lamp of 25W/ 40W.
3. At RRU/ ERRU
 Check the condition of

OVP. If it is in tripped
condition, reset it.
 Check and ensure the

availability of 110V DC
in RRU/ ERRU at DC
+VE, -VE terminals.
Capacitor OVP Reset
 Check the condition of button
field fuse and its
tightness. Universal Voltage controller
HRC Main Fuse 160A HRC Field Fuse 6,10A
 Check the condition of HRC field fuses (6 Amps) & main fuse
(160 Amps) in the RRU/ ERRU. Replace them, if blown out.
 Check the continuity of field & phase windings for open circuit
with multimeter.
 Excite the field separately. If not succeeded, give external

excitation to alternator.
1. At RRU/ ERRU
o Check continuity of field after disconnecting from

ERRU field terminals
o Check for any loose connections at field terminals.

If loose, tighten them.
o Check the condition of field fuse and its tightness.

2. At Battery
o Check for loose connection at inter-cell

connections and battery end connections. If loose,
tighten them by torque wrench only at
recommended torque.
o Record OFF load/ ON load voltages of each cell.

If any cell found reverse/dead, bypass them.
o Even though if the voltage is not improved,

provide TC from the adjacent coach DC-DC
supply.
1. At Power Panel
 Check for availability of supply at incoming and outgoing

terminals of RSW2 in power panel and check the position, it
should be in INV 1&2 position.
 Check the condition of

RSW2. If found defective,
bypass it.
 Check the 400A, 250A HRC

fuses in power panel. If
blown out, replace them.
HRC Fuses in power panel
2. At Inverter
 Check and ensure the

availability of input 110 V
DC supply at the inverter
MCCB.
 Check 350A HRC fuses and

replace if blown out. 350A HRC Fuse
Input to Inverter MCCB
 Check 4A glass fuses in 24V

control circuit of inverter.
Replace it, if blown out.
4A Glass Fuse
 Check the condition of Earth
Leakage Detector (ELD).
 If it is in tripped condition, reset

it.
 If ELD is not holding, check for 20

earth leakage in the coach. If ELD
is found defective, bypass it by
connecting wire on terminal 18 to
terminal 20 of ELD (On board 18
type Siemens).
1. At AC Control Panel
 Switch off all MCBs of blower, condensers, compressors,
heaters in the control panel (MCB-1 to MCB-6).
 Switch ‘ON’ the inverter again. If
the inverter is working on OFF load,
switch ‘ON’ the AC plant equipment
MCB’s one after other as following:
Over load-1
a. Switch ‘ON’ blower MCB-1. If
inverter not tripped, switch ‘ON’ MCB-1 MCB-7
condenser motor-1 MCB-2. RSW-5
b. If inverter not tripped, switch
‘ON’ condenser motor-2 MCB-3.
RSW1 415/110 T/F
Electronic thermostat Main MCB
c. If inverter not tripped, switch ‘ON’ compressor-1 MCB-4.
d. If inverter not tripped, switch ‘ON’ compressor -2 MCB-5.
 Switch ‘OFF’ faulty equipment MCB on which the inverter trips.
 Check for fault indication in the inverter panel.
 Check for short circuit/ earthing of power cables between

Inverter output and AC control panel terminals.
 If no fault is found, then give message to next major station for

necessary attention.
 Set on emergency mode and use three compressors only.

 Check the individual cell
condition. Isolate/ bypass the
defective cells.
 Check the input DC voltage at

inverter. It should not be less
than 90V to avoid input under
voltage fault.
-VE terminal +VE terminal
 Even though the voltage is not improved, provide TC from the

adjacent coach.
1. Power Indication LED Not Glowing
Check the following at control panel:
 Check the position of 63A

changeover switch. It should
be in Inverter position and
ensure the availability of three
phase supply at incoming and
outgoing terminals of Change
over. If found defective,
bypass it.
63 A CHANGE OVER
SWITCH
 Check the healthy condition and availability of 3-phase supply at
incoming and outgoing terminals (361,362,363) of 63A RSW1 and 63A
Main MCB (358,359,360). If found defective, bypass it.
I/P MCB-8
for T/F
O/P MCB -
RSW1 9 for T/F
Control T/F
Main MCB 63A

 Check the working condition and availability of control supply at
incoming (358,359) and outgoing (370,371) terminals of MCB-8 of
415/110V AC control transformer. If supply is not available, extend the
supply from bus bar to the control transformer bypassing MCB-8 and
record in the logbook for further rectification.
 Check control transformer, if found defective extend the control
supply either from 110V AC fans or adjacent coach AC control
panel temporarily.
 Check working condition of MCB-9 at incoming (36,100) and

out going terminals (10,100).
 Ensure availability of control supply on RSW2 at terminal (10,

12). If found defective, bypass it.
Note: In case of SG AC coaches, control supply to MCB-8 shall be

given from two phases directly from inverter to TC-1 & 2
instead of bus bar.
2. Blower Motor Not Working
(a) Red light of over load ‘ON’
Check the following at control panel:
MCB-1
 Check MCB-1 and ensure

supply voltage of 415V AC, 3-
Ph at outgoing terminals of MCB-1
MCB-1 (343,344,345). If found

defective, bypass it.
 Check Over load relay (OL-1)
a. If it is in tripped condition,
check the over load setting (2.1
to 3.1A) and reset it.
b. Check the supply from RSW2

to Blower OLP NC point wire
No.12 and out going wire
No.13. If supply not available
at wire No.13, short 12 & 13
wires. 12 13
Over Load Relay
Note: Before bypassing OL-1, ensure the 3-ph supply is available at
T1, T2, T3 terminals of blower motor to avoid single phasing.
 Check the incoming (322, 323, 324) 18
and out going (301, 302, 303)
terminals of blower contactor C1. If
found defective, bypass it.
 Check ‘NO’ interlock of Auxiliary

contactor (AC-1). If found defective,
19
bypass by shorting 18, 19 terminals.
Check the following at blower:

Auxilary Contactor (AC-1)
 Check availability of the supply at T1, T2, T3 power terminals of
blower.
 Rotate the blower by hand to check for any jammed bearing or loose
blower runners on the shaft.
Note: If blower motor is still not working and it seems to be defective, give
message to next major station for necessary attention.
(b) Air loss indication red LED glowing
 If blower is ON but indication LED not glowing, check as
per para (a).
 Check the direction of rotation of
blower motor, if it is rotating in
reverse direction, inter change any two
phases of T1, T2, T3 (301, 302, 303)
power terminals.
 Check Vane Relay flapper/ switch
contact/ connection. If found
defective, bypass Vane Relay by
shorting 44, 46 control terminals.
Control Terminal block in AC PANEL Short 44, 46 terminals
Note: Before shorting Vane Relay terminals, ensure that blower is

rotating in right direction. Put off MCBs of Heater circuit.
 Check whether the fresh and return air filters are not clogged. If
clogged, clean the filters.
Note: Put a handkerchief or paper at return air grill inside the

coach. If it is sucked, it means that the blower is running in
correct direction.
Air sucking position
Return Air Grill

(c) Auto/ Manual Indication LED not glowing if mode selector
RSW-3 is put to their respective position
 If air loss indication LED is

glowing, check the cause of air RSW3
loss as per para (b).
RSW2
 Check the condition of RSW-3
incoming supply at wire No.19
and out going wire No. 23 for
cooling mode and wire No. 24
for heating mode. If supply not
available at 23, 24 wires, short
19, 23 for cooling and 19, 24 for
heating. Indication Panel
(d) Cooling Indication LED not glowing in Manual/ Auto mode.
If air loss indication RED LED is glowing when RSW-3 is in

manual/ Auto mode, check causes of air loss and take
remedial action as per para (b) above.
3. Condenser Motors Not Working
CD1 or CD2 over load indication RED LED glowing when
RSW3 is on cooling mode
1. When cooling indication LED is not glowing in manual/ auto mode,
then take remedial action as per para 4.7.2 (b).
2. Check mode selections switch RSW3
as per para 4.7.2 (c).
3. Check over load relay (OL-2, OL-3).
a. Check the incoming supply
from wire No.23 and 40 at
heater contactor (C6). If
found defective, bypass it (by
OL-2 OL-3 C6 Contactor
shorting 23 & 40).
AC Control Panel
Note: Heater MCBs should not be kept ‘ON’
while bypassing.
b. If OL-2 and OL-3 are in tripped condition, check the over load
setting (1.7 to 2.1A) and reset it.
c. If OL-2 and OL-3 are found defective, bypass them by shorting

40 with 41 and 40 with 43.
Note: Before bypassing OL-2 and OL-3, ensure 3-ph supply is

available at T4, T5, T6 for CD1 and T7, T8, T9 for CD2
terminals of condenser motors to avoid single phasing and
measure the load current taken by the condenser motor in
each phase.
4. Check MCB-2 & MCB-3 and ensure supply voltage of 415V
AC, 3- ph at outgoing terminals of MCB-2 (346, 347, 348) of
CD-1 and MCB3 (349, 350, 351) of CD-2. If found defective,
bypass it.
C3 Contactor
C2 Contactor
MCB-3
AC Control Panel MCB-2
5. Check supply at the incoming terminals of contactor (C2) (325,

326, 327) of CD-1, contactor (C3) (328, 329, 330) of CD-2 and
out going terminals of contactor (C2) (304, 305, 306) of CD-1,
contactor (C3) (307, 308, 309) of CD2 respectively. If found
defective, bypass them.
4. Compressor Not Working
a. Compressor-1/ 2 over load red indication LED glowing
i. Ensure both the condenser

motors are working. If not, refer
para 4.7.3.
ii. Check output at TDR 1 &TDR2
iii. Check the working condition of

RSW5. If it is defective, bypass RSW5
it. If supply not available, check
the continuity of wire No. 48 at
outgoing terminal of RSW5
from C2, C3 contactors.
iv. Check over load relays (OL-4, OL-5). If
a. They are in tripped
condition, check the over
load setting (7A -12.5 A)
and reset it.
b. OL-4 and OL-5 are found

defective; bypass them by
shorting 52 with 54 and
63 with 65.
C5Contactor OL-4 OL-5
C4 Contactor
AC Control Panel
Note: Before bypassing OL-4 and OL-5, ensure 3-ph supply is
available at T10, T11, T12 for CP1 and T13, T14, T15 for CP2
terminals of compressors to avoid single phasing and measure
the load taken by the compressors in each phase.
v. Check MCB-4 & MCB-5 and ensure supply voltage of
415V AC, 3- ph at outgoing terminals of MCB-4 (352,
353, 354) of CP-1 and MCB-5 (355, 356, 357) of CP-2.
If found defective, bypass it.
C5Contactor
C4 Contactor
MCB-5
MCB-4
AC Control Panel
vi. Check the incoming terminals of contactor (C4)
(331, 332, 333) of CP-1, contactor (C5) (334,
335, 336) of CP-2 and out going terminals of
contactor (C4) (310,311,312) of CP-1, contactor
(C5) (313, 314, 315) of CP2 respectively. If
found defective, bypass the contactors.
(b) HP1 or HP2 red LED glowing
i. Check the working condition of the condenser

motors as per para 4. 7.3.
ii. Check the condition of HP1/ HP2 cutout

switches. If tripped, reset it manually.(Setting
415 PSI)
(c) LP1 or LP2 red LED glowing
i. Check and clean wire mesh
ii. Check the load of respective compressors with clip

on meter. If current drawn is less than 6.5 Amps,
replenish gas where ever possible.
iii. Ensure that return air filters are clean.
iv. Check and ensure that all the grills are in open
condition.
v. Check the direction of rotation of blower as per para

4.7.2 (b).
vi. Check LP1 or LP2. If defective, bypass by shorting

29, 31 for LP1 and 35, 37 for LP2.
i. Ensure the position of RSW1
in Alternator-I/ Alternator-II/
battery position.
ii. If it is found defective, bypass

it by looping B, Y, R phases to
cable 361, 362, and 363
respectively.
iii. Check the battery fuses. If

blown out, replace it.
400 A Battery fuse
iv. Check the inter-cell connectors
of battery for open circuit.
iv. Check the battery fuse bases for tightness.
v. Check the continuity of Battery +VE, -VE cables in

the power panel extending from the under-gear
junction box.
Inter cell connector
At Battery
1. AC WRA/ Monoblock Motor
RSW for WRA
Selection
RSW for WRA

Selection
a. Check for availability of 3-ph supply at inverter

selector RSW3. If supply not available on output
side of RSW3, bypass it.
OFF button
WRA Overload
contactor cum MCB
ON button
Power Panel
b. Check the incoming (4151, 4152, 4153) and outgoing

(4157, 4158, 4159) terminals of MCCB and ensure
availability of 3-ph supply. If found defective, bypass it.
c. Check for availability of 3-
ph supply at inverter
selector RSW7. If supply
not available on output side,
bypass it.
d. If MCB trips again due to Flushout

internal fault of the motor, Valve
change the position of
RSW7 to the another motor.
Note: WRA motors are working but water not coming in

the toilets, release the air lock by pressing flush-out
valve in the toilets. Ensure proper tightness of the
water filling pipe caps.
Field
+VE
RRU/ERRU
Field
-VE
1. Remove the existing field wires (F +VE, F -VE) at RRU/

ERRU terminal block before extending the separate
excitation.
2. Ensure continuity of the alternator field wires with

millimeter and healthiness of power diode.
3. Extend 6 cell connections (12V supply) from battery as
follows:
a. Connect the wire from first cell positive terminal to

alternator field +VE terminal duly providing switch
control in between at main door handle, for
switching OFF the separate excitation while stabling.
+VE of first cell

1100 AH
Battery
-VE Cell of 9th cell

+VE of first cell
-VE Cell of 9th cell
b. Connect 9th cell –VE terminal to alternator field -VE

terminal.
c. Incoming supply to extension terminal from

RRU/ERRU shall be disconnected.
1. Coach is dark (Lights and fans not working)
Cause Action to be Taken
• Loose contact in rotary • Check and attend the
switches. defective rotary switch.
• HRC Fuses of 16Amps • Replace fuses with 16

(for L1, L2 & Fans) & 35 Amps fuse wires.
and 35Amps negative
may be blown in main
junction box.
• 40 Amps battery fuses • Check battery fuses. If
may be blown near found blown replace with
battery box. 40Amps fuse wire.
• No generation/ belts • Measure the voltage if found

missing. below 90V then remove the
main –ve fuse from main
junction box and then
connect TC from the
adjacent coach.
• Cells defective (Cells • Check the voltage if found

low voltage or/ and below 90 volts then connect
reverse polarity) TC from the adjacent coach.
2. Coach lights and fans in burnt/ smoke condition &
coach is in dark condition.
• Cut the regulator field +ve

& -ve wires which are
• Over generation due
coming from alternator or
to defective regulator.
remove negative main
fuse link and battery fuse
and then connect TC from
adjacent coach.
3. Smoke in individual Fan/ Light
• Burning of fans winding • Disconnect supply wires
or inverter in FTL. to fans/lights.
4. Spark in junction boxes.

• Loose fitment of • Tightened or replace
HRC/ rewirable fuses the fuses.
in main/ distribution
junction boxes.
5. Smoke from battery box.
• Cells sulphation.
• First extinguish smoke/
• Low water level or Dry
fire if found then remove
cell
battery +ve or –ve fuses
• Cell container breakage and connect TC from
adjacent coach.
• Loose connection
6. Belts smoke
• Alternator pulley jam • Cut the belts and connect
TC from Adjacent coach.
जो कार्य तम
ु आज
कर सकते हो,
उसे कल पर कदापप
मत छोड़ो।
Phase II – Module No. STC-GS-3
Fires in coaches could be broadly classified under
two heads viz:
 Overvoltage
 Failure of the insulation due to deterioration/
mechanical damage
 Local heating due to loose / defective joints and loose
connections
 Overheat of fuel pipe line near turbo changer
 Loose connection
 Smoke from mobile charging point
 Ciggerate/bidi butts and gutakha wrapper in
fuse distribution board/ roof openings
 Ciggerate/bidi butts and gutakha wrapper in

fan base
 Carrying of Inflammable material
 Fire in Pantry car

 Electric power is generated by Alternator mounted on
under frame. It is connected to voltage regulator and
rectifier.
 Alternator charges the batteries, which is also mounted on

the under frame, and also supplies power to coach when
the speed of the train is above 19 kmph. Below 19 kmph,
power is supplied by batteries.
 Positive and negative
main wires of DC supply
from battery are taken to
rotary junction panel in
the coach through
separate conduits. 40
Amps fuses are provided
in the positive and
negative main wires as
third level of protection 40 A Battery Fuses in +ve and -ve
In the rotary junction panel
bifurcation of positive mains
into four circuits takes
place. L1 ands L2 for two
light circuits, one fan circuit
and one circuit for
35 A –ve
Emergency feed to adjacent
6 A +ve Fuse
Fuse coaches.
Rotary Junction Panel
 Each circuit is protected by a 16 Amps fuse, which is
second level protection.
 Further to eliminate the possibility of short circuit

positive and negative wires are taken in separate conduits
along the side walls of the coach.
 35 Amps fuse on negative side is also provided for

additional safety.
 Supply to each fan and light is provided from fuse
distribution boards provided on both positive and
negative main wires in each bay.
 Supply to each fan and light is provided from fuse

distribution boards provided on both positive and
negative main wires in each bay.
FDB
 Two 6 Amps fuses are provided on
both positive and negative wire for
each light and fan for protection
against short circuit.
 Thus there is three tier protection

against short circuits.
 All the material used in coach

wiring including conduit, rotary
switches, fuses, cables etc. have
fire retardant properties.
6 A Fuse
MAIN FDB
NEGATIVE
WIRES
6 A FUSE
CFL
FANS
EFT
6 A FUSE
MAIN
POSITIVE
WIRES
L1 L2 F SPM NEG
FDB
COACH FLOOR
COACH UNDERGEAR 40 A +VE MAIN FUSE
4.5 BATTERY 120 Ah

KW RRU 110 Volt
40 A -VE MAIN FUSE
 Commutator is shrouded in metal
Carriage Fan casing and thus sparking inside the
fan can not initiate fire.
 In case of winding getting shorted
slight smoke will come out but it
will result in immediate tripping of
fan fuse and further smoke emission
will be prevented. This can in no
case initiate fire.
Contd…..
 In case of bursting of tube light the path of electricity gets
broken and in such case there is no flow of energy from
tube light to initiate any fire in the surrounding area, which
comprises of fire retardant material.
 With three levels of protection against short circuit, limited

energy that can be dissipated from the battery, separation of
positive and negative mains, use of fire retardant material,
DC electrical supply system in coaches is adequately
designed to ensure safety against electrical fires.
 Multilayer (four layer fuse protection) similar to non AC
coaches.
 Use of e-beam fire retardant cable to prevent propagation

of fire.
 Protection against failure of heating system:
 Regular monitoring of return air temperature by micro

controller.
 Protection against switching ON of heater in case of failure
of flow of air due to failure of blower motor.
 Over heat protection system directly monitors the

temperature of the heating element and switches it off
beyond 135C.
 Use of A-1 safety category refrigerant in HVAC which is

non inflammable and non explosive in case it enters into air
duct.
Contd…..
Further measures taken:
 Manning of AC coaches by trained electrical staff.
 Though it may not be possible to completly eliminate

smoke on account of equipment failure, but protective
system will ensure that it does not lead to fire in railway
coaches on electrical acount.
 Main reasons for initiation of fire identified and both short
term and long term action plan were drawn. Both short and
long term measures have already been implemented in all
power cars.
 Lekages from fuel/ lube oil pipe line.
 Regular cleaning of spill over oil in engine room.
 Continious checking of proper functioning of engines.

Initiation of fire
 Main source- Overheating of cooking oil
 Prone areas- Cooking area near chimney
Steps taken to prevent such fires

 Ensuring switching off of all cooking appliances between 11 PM to
5 AM as per CRS recomendation.
 Locking of electrical panel by electrical staff during night.
 Modification to chimney design.
Suggestions
 Cooking specially deep frying be avoided in pantry cars.
 Pre cooked food to be picked up from base kitchen as in

airlines and stored at sub zero temperature and heated
just before serving in line with new Catering Policy
2010.
 Need to provide a different set of equipment.

AC Control Panel Power Panel
Switch Board cabinet
Microprocessor panel for

control of AC system
 Locate origin of fire
• Look for maximum heat affected zone
 Identification of maximum heat affected zone
• Car body deformation
• Colour of trough floor assembly
• Maximum damage portion

 Condition of fuses
 In yard fire cases, battery fuse remain intact due to load

not ON.
 Try to gather statement of passengers whether lights/ fans

were working at the time of fire.
 In case of minor smoke emission and electrical system is

not affected lights and fan supply to be restored.
 No detachment of coach incase of minor smoke or battery

bursting.
 Preserve ERRU/ Inverter data.

S. No. Description
1. Testing procedure for proper working of over voltage
protection provided in 25 kW/22.75kW alternator in AC
coaches – To prevent generation of Over Voltage in
coaches to avoid busting of lights and sparking in DC fans
which may cause fire.
2. SMI for “V” belts fitted on TL & AC coaches – To check
the condition of V-Belts for proper functioning of self
generating system and avoid smoke emission cases from
V-Belts.
S. No. Description
SMI for checking of pulleys in “V” belt drive - To check
the condition of Pulleys for proper functioning of self
3.
generating system and avoid smoke emission cases from
V-Belts.
Protection of Lead wire of TL & AC Alternator – To
minimise disconnection of lead wire of alternator for
4.
proper functioning of self generating power system in
coaches.
Belt tensioning assembly - To check the condition of belt

5. tensioning assembly for proper tensioning of V-Belts to
avoid smoke emission cases from V-Belts.
S No Description
SMI for VRLA batteries fitted on TL & AC coaches – To

prevent malfunctioning of battery and avoid any smoke
6.
emission due to loose connection or poor battery
condition.
Provision of vane relay in the blower motor circuit of AC

7.
coaches- It stops working of heater in case blower fails
Modification Sheet to prevent fire hazard in canvas duct in

8. under slung type AC coaches- cases of smoke emission
from canvass duct catching fire eliminated
S No Description
Checking the working of Emergency light unit in AC &
Non-AC coaches- It ensures that during every primary
9.
maintenance coach with emergency light in working
condition is given in service.
Modification sheet for the cover for fuse distribution board
used in general second class and 2nd class SL coaches- It
10.
ensures that Cigarette/bidi butts and gutaka wrapper does
not go inside FDB.
Modification in battery charging terminal cum fuse box
11. plate for provision of 40 Amp. HRC fuse instead of re-wire
able fuse.
S No Description
Provision of ICF design chimney with provision of exhaust

12 through side wall in pantry car of LHB Coaches- Chimney
is having all fire retardant material.
Modification sheet for providing cable looping in place of

415 V MCB bus -bar in Switch Board Cabinet of LHB
13
coaches and power cars- It has eliminated cases of smoke
emission from bus bars.
Instructions for locking of pantry equipment during night

14.
hours issued to zonal Railways.
Metallic blade Exhaust arrangement
Lockable
Covers on
the Heater
Switches
Acrylic sheet door fixed with
Nut-Bolt
MCB Accessible only by
opening LOCK
 It is quite difficult to pin point the exact cause of fire in
railway coaches due to extensive damages and only
general observations are available.
 There are variety of reasons which may be a source of

initialization of fire, some of them are mentioned in next
slides.
 Panic has also been noticed to have been caused among

the passengers due to smoke emission due to brake
binding/ hot axle.
 Carrying Inflammable
goods like stove, gas
cylinder, kerosene oil,
petrol, fireworks etc. in
passenger coaches.
Kerosene Stove
 Making fire/ using fire

near paper, wood, petrol
or such other
inflammable articles.
 Throwing waste material out side the dust bin near
door. Non-removal of garbage from pantry
car/coaches
 Malpractices like carelessly thrown lighted match sticks,
cigarette butts, Bidi butts etc.
 Leakages/ Blasts of Pantry Gas Cylinders.
 Careless storage of inflammable materials like news

papers, edible oil etc. in pantry cars.
 Sabotage / Discrepancy.
 Mishandling/ careless use of pantry equipment by pantry

car staff.
 Insertion of cigarette butts, Bidi butts, Gutakha wrapper
etc. in fan base, fuse distribution board, roof openings.
 Insertion of cigarette butts, Bidi butts, Gutakha wrapper etc.
 Insertion of cigarette
butts, Bidi butts,
Gutakha wrapper etc.
FRP mounting Over heat protection
 While investigating fire case in train no 2903 near
Ladhowal station on 15/5/03, CRS Central circle directed
RDSO to simulate various scenarios to asses the
probability of fire due to failure of electrical equipment,
wiring and their safety devices.
 RDSO conducted simulation test trials in coach no.

WGSCN 96204 and test results are given in next slides.
This test was conducted to ascertain the
possibility of fire due to presence of highly
Purpose inflammable material in the vicinity of DC
Railway Carriage Fans due to spark/flash from
its commutator.
Description All the fans of bay number of two were kept in
switched on condition.
A bundle of rags dipped in kerosene was brought
near the fan guard and body of the fan and kept
their for few minutes.
Observation No sign of flash, spark or smoke was noticed
during the test.
To ascertain the working of protection system of
individual branch wiring against short circuits in
fan and light circuits.
Purpose It is also to be seen whether blowing OFF of
branch wiring fuse provided in the fuse
distribution board may cause fire if highly
inflammable material are available in the vicinity
of fuse distribution board.
A dead short circuit was created in the positive

Description and negative supply of fan circuit of bay No.3.
A bundle of rags dipped in kerosene was placed
around the fuse distribution board cover.
As soon as the power supply for the fan,
having short circuit, was switched ON both
the rewirable fuses of 6 amp. (35 SWG)
provided on positive and negative circuits of
Observation
the branch wiring of the fan circuit blew off.
Although the flash was observed while the
fuses were blown, no sign of smoke or fire
from the rags placed on the fuse distribution
board was observed.
To assess the possibility of fire due to spark/
Purpose flash because of loose connection in the fuse
distribution board.
Fuse wire connection of fan circuit in the fuse

distribution board was kept in loose condition
Description and the cover for the same was closed. A
bundle of rags soaked in kerosene was kept
around the fuse distribution board cover.
As the fuse wire was loose it was causing a
small spark when fan circuit was switched
ON but when the fuse distribution board was
Observation
closed and rags soaked with kerosene were
kept around the cover it did not caused any
smoke or fire when the switch was put ON
and OFF repeatedly.
The purpose of the test was to see the effect
Purpose of short circuits in fan or light supply
circuits either at junction box or in the
conduit wiring in the side wall of the coaches
between positive and negative supplies.
A dead short circuit was created in fan

Description circuit between positive and common
negative supply at the output of the rotary
switch board by using a 35mm² cable.
As soon as the fan supply was
switched ON by rotary switch in the
rotary switch board the HRC fuses of
Observation
16 amps at fan positive and 35 amps at
common negative supply blew off
without causing any flash or smoke
in the rotary switch board or cables.
The purpose of the test was to see the effect of
short circuit between positive and negative
Purpose supply in fan circuit or either of the light circuits
with their fuses at rotary switch board in
bypassed condition.
Short circuit was created in fan circuit

between positive and common negative output
Description of the rotary switch board. The fuses of fan
positive and common negative circuit were
bypassed in the rotary switch board by using a
35 mm² cable.
As soon as the rotary switch for fan
circuit was switched ON, next level of
protection with rewirable fuse of 32
Observation
amps (20 SWG) in the battery circuit,
blew OFF as the fan positive and
common negative fuses were in
bypassed condition.
To see the effect of dead short circuit in the
electrical wiring inside the coach with all
Purpose safety devices in bypassed condition and
continuously feeding the short circuit through
the battery supply.
 The rewirable fuses in positive and negative
supply of night light were by passed in fuse
distribution board by using flexible cable
strands of total size of approximately 10 mm²,
in bay No. 9 .
Description
 In rotary switch board HRC fuses in positive
and common negative supply were bypassed
by using 35 mm² cable and battery fuse in the
under-frame was also bypassed by using 35
mm² cable. Dead short circuit was created
across the night light of bay NO.9.
 The night light switch of bay No. 9 was
switched ON. Short circuit current was allowed
to flow continuously as all the fuses i.e. branch
wire fuse, fuse on the positive and negative
circuit in the rotary switch board and battery
fuse were bypassed.
Observation
 The wiring of the night light circuit got over
heated and light grey smoke was observed.
Finally the branch circuit got open circuited
due to over heating & smoke also stopped after
some time. On checking insulation of the cable
was found over heated and burned but no fire
or flame was observed during the test.
PROBABILITY OF FIRE DUE TO ELECTRICAL CAUSE
a) The normal working conditions of electrical equipment in a

coach with all necessary safety devices intact, does not create
any condition resulting in fire even when highly inflammable
material in vicinity.
b) Even if one protection system is by passed , the next level of

protection system is able to protect the electrical equipment
without creating an unsafe condition resulting in fire, with
highly inflammable material in vicinity.
c) With all safety devices bypassed , a fault with dead
short circuit , resulted in over heating of cables and
damage to cable insulation with smoke which finally
results in breaking of conductor ,causing the open
circuit.
Though smoke is generated but

situation did not resulted in fire.
(Ref: Annexure to Board’s DO No. 2003/Elect.(G)/
113/2 pt. New Delhi dated 30.12.2009)
1. Use of standard size of fuse wire for the individual
branch light & fan circuit of individual bays in TL
coaches .Use of standard size of fuse /MCB in main
control panel and other circuit/equipment.
2. Use of standard size cables in different circuit of the

coaches as per specification.
3. Ensuring minimum clearance of 10 mm between live

part & the coach body & 4 mm between opposite
polarities in coach wiring
4. Regular checking of earthing on positive & negative
wire of the coach following standard procedures
prescribed by R.D.S.O.
5. Use of protective grommet of PVC as per B.S.1765 or

I.S.5861 grade VI with noninflammable property to
avoid damage to the cable insulation from metallic sharp
edge.
6. Provision of cable sleeve near terminal to avoid shorting

of cable where clearances between live part and metallic
body are critical.
7. Proper sealing of fuse distribution board in T. L. coach to
prevent of foreign material like bidi, cigarette, paper etc.
by passengers. Regular checking in inspection schedule
to be ensured.
8. Use of flush type light fitting in luggage compartment of

SLR.
9. Provision of Rotary switch panel with fuse in lieu of

MCB in T.L Coaches.
10. Provision of suck through arrangement type evaporators

unit in AC coaches with under slung A.C. equipment.
11. Ensuring provision of over heat protection in heater circuit of
S.G/E.O.G. AC Coaches.
12. Ensuring proper working of Vane relay in AC Coaches.
13. Proper training to staff for feed extension from adjacent
coach in emergency condition.
14. Use of non metallic fire retardant blades in chimney blowers
of Pantry car.
15. Use of fire retardant, non-toxic, low smoke canvas cloth for
ducting of AC Coaches.
16. Use of low smoke , fire retardant low halogen E-beam cable
in TL & AC Coaches.
17. Use of rubber ferrules at cable exit entry points & critical
location to prevent damage to cable.
18. Use of proper cleating of cable as specified in code of

practice of wiring of TL/AC coaches scheme.
19. Proper tightening & cleaning of battery connection.
20. Provision of over voltage protection in RRU of TL coaches

as per R.D.S.O. Specification sheet No.
RDSO/PE/MS/TL/0021-2001(Rev-1) in Aug 2004.
21. 21.Replacement of damage / perished cables in coaches

during POH / Major schedules.
Phase II - Module No. STC-GS-3
 Cable sizes have been standardized and are of fire
retardant type.
 In case short circuit take place the protective device in

circuit should isolate the fault instantly and early. this is
achieved by use of HRC fuses.
 In case electrical fire does break out, spread of fire is
prevented by use of good quality, fire retardant material
for cleats, distribution boards panels and PVC conduit.
Use of proper rating of fuses.
 Positive/negative branch fuses - 6A (35 SWG)
(In DFB) Rewire able fuse
 LI, LII, Fan +ve - 16A HRC
 SPMI,II (EFT) - 16A HRC
 Main Negative - 35A HRC
 Battery Fuses - 40A HRC
 Phase fuse in RR Box - 32A HRC
 Field fuse in RR Box - 06A HRC
 Use of E- beam cable.
 Use of Fire retardant low tension tape.
 If joint is noticed in cable during POH, replace the cable.
 Cable terminating at junction boxes should have proper size
of crimping sockets.
 Crimping to be done by crimping tool.
 Use corrosion inhibiting grease during crimping in case of
Aluminium cables.
 Attend cable whose insulation is damaged.
 All electrical fitting both on super structure and under frame
should be mounted directly on the coach body.
 Air clearance of 10 mm between any live part and coach

body to be maintained.
 Air clearance of 4 mm between any live part of opposite

polarity.
 Rewiring of coaches to be planned on the basis of cable life

as 20 years. However after 15 year coach wiring to be tested
and rewired if necessary.
 FRP trays to be provided in battery
box before providing battery.
 Ventilating grills provided in battery

box should not be blocked. They
should be cleaned.
 Provision of OVP in rectifier

regulator units.
 Coach Insulation to be measured with

500V Megger. It should be minimum
2 mega ohms in case of TL Coaches.
Cable not
provided in
PVC conduit.
USE FLEXIBLE PVC CONDUITS, FOR TOILET

WIRING UNDER WATER TANKS.
DFB covers in TL coaches are to be provided with
strengthening arrangement to prevent inserting Gutka
sachets, etc., by passengers
Rewirable 35 swg fuse should be in
single lead only.
Strengthening
not provided
for cover
PVC grommets and bushes to be provided at
cable entry point.
Provide proper connectors for feeding supply
to fans, berth lights, step lights, FT fittings.
Avoid hanging wires

Provide proper connectors for feeding supply to
fans, berth lights, step lights, FT fittings.
Provide proper sleeves

and avoid improper
twisting of cables
Earth leakage in coaches to be checked with
double test lamp method.
Never allow
coaches with
earth leakage.

STC-GS-3a Operation and Troubleshooting in TL and AC Coaches

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STC-GS-3a Operation and Troubleshooting in TL and AC Coaches

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Phase II- Module no.

Electronic rectifier Fuse distribution

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

INV Inverter IR Insulation resistance

–VE Negative NPP Non Power panel

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

 To be present one hour before the schedule departure of

 To check that all internal electrical fittings in the coach

 To monitor electrical/ mechanical defects developing in the

 Assist AC coach mechanic to take reading of pressure at

 To assist the AC coach mechanic in the rectification of

 Should be available in the coach one hour before

 Check logbook of the coach for any entry by the

 Check the condition of V-belts in stable condition. It

 Check OFF load battery voltage. It should be 118V.

 Record all parameters of the equipment in the logbook.

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

 Switch OFF one of the AC plant before removing pre-cooling

 Check all lights, emergency lights, fans, night lamps, reading

 Attend complaint of passengers, if any.

 Should do temporary connection in TL coach also, if required.

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

 Observe the function of AC plants by noting the load

 Record temperature in the logbook for every 2 hours.

 If any abnormality is observed, first note down the same

 Change the working of WRAs/ monoblock pump for

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

2. Check working of AC plant/light/fans & reading lights

3. Check cleanliness of compartment.

4. Keep panel shutter closed with latches already provided.

5. Ensure following in the coach:

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

7. Open emergency window in case of emergency.

8. Troubles shoot line failure immediately.

9. Communicate line failures & Non-AC certification, if

10. Fill logbook details properly.

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

Single Core 50 mm² cable as per 0.5 meter with

Single Core 16 mm² PVC/2.5 mm² 1.5 meter with

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

1. Main MCB TP 63A Power input to RMPU

3. MCB TP 4,5 32A Compressor motor

4. MCB TP 6,7 16A Heater

MCB DP 8 2A In coming of Control

MCB DP 9 4A Out going of Control

8. HRC-F3 10A ERRU field fuse

9. HRC-F1, F2 160A ERRU main fuse

10. HRC 400A Positive and negative of battery

11. MCB DP 0.6A Inverter cooling fan

12. MCCB DP 250A Inverter input

13. MCCB DP 300A Inverter input

14. HRC fuse 20A In ERRU/ RRU before

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

9 RSW2 16A For blower ON at AC control Panel

For auto/manual mode selector RSW at

For compressor selector, bypass RSW at

COS-1 & Change over switch for selection of

Phase II- Module no. STC-GS-3 CAMTECH, Gwalior

O/L – 1 - For evaporator blower motor.

O/L – 2 & 3 - For condenser motor 1 & 2.

O/L – 4 & 5 - For compressor motor 1 & 2.