02 - WAG12 - Loco Pilot Handbook - (English)

WAG12 LOCOMOTIVE
LOCOPILOT HANDBOOK
This document is the property of Alstom Transport and the recipient hereof is not
authorised to divulge,distribute or reproduce this documentor any part thereof
without prior written authorisation from Alstom Transport.
CONTENTS
1. Instructions for Loco Pilot ........................................................ 4
1.1. Do’s ............................................................................. 4
1.2. Don’ts.......................................................................... 6
2. Technical Data of WAG12 Locomotive ..................................... 8
3. General Description ............................................................... 10
4. Driver Cab ............................................................................. 12
4.1. Left Panel .................................................................. 12
4.2. Master Controller ....................................................... 13
4.3. Brake Gauges Panel ................................................... 14
4.4. Central Panel ............................................................. 15
4.5. TCMS, DDU (Train Control & Monitoring System, Driver
Display Unit) ............................................................................. 17
4.6. Indication Panel ......................................................... 18
4.7. Line Indicator............................................................. 19
4.8. Right Shelf................................................................. 20
4.9. Pedal Switches .......................................................... 21
4.10. Assistant Panel .......................................................... 22
4.11. Cab Cabinet Right ...................................................... 23
5. Electrical System Description ................................................. 24
5.1. Pantograph................................................................ 24
5.2. HV Cubicle ................................................................. 24
5.1. Main Transformer ...................................................... 26
5.2. E-Block (Traction Convertor) ...................................... 26
5.3. Traction Control Unit (TCU) ........................................ 26
5.3.1. Tractive/Braking Effort Limitation .............................. 27
5.3.2. Traction Isolation ....................................................... 27
5.4. H-OM (Earthing Switch) ............................................ 27
5.5. Auxiliary Loads ........................................................... 27
WAG12 - Loco Pilot Handbook [1] NRD0000572585

5.6. Battery Unit & Charging System................................. 28
6. Pneumatic System ................................................................ 29
6.1. MASU (Main Air Supply Unit) .................................... 29
6.2. Main Compressor Regulation ..................................... 29
6.3. Auxiliary Compressor Regulation ................................ 30
7. Brake System ....................................................................... 30
7.1. Types of Brakes ......................................................... 30
7.1.1. Regenerative Brake ................................................... 30
7.1.2. Types of Pneumatic Brakes ........................................ 30
7.2. Brake Control Module (BCM)..................................... 31
7.3. Brake Pressure (Nominal) ......................................... 34
7.4. Different Types of Brake Blending Logics ................... 35
7.5. Parking Brake Manual Release Plunger ..................... 36
8. Locomotive Operating Modes ................................................ 37
9. General Procedures ............................................................... 38
9.1. Locomotive Energisation Procedure ........................... 38
9.2. Loco Shutdown Procedure ......................................... 38
9.3. Cab Change Procedure .............................................. 39
9.4. Loco Grounding Procedure......................................... 39
9.5. Dead Engine Brake Configuration .............................. 40
9.6. EB Reset Procedure ................................................... 41
9.7. Penalty brake Reset Procedure in case of EBV Failure 42
9.8. Vigilance Management .............................................. 42
9.9. Back-Up Brake (PTDC) .............................................. 43
9.10. Coupling Two Locomotives ........................................ 44
9.11. BP leak test procedure ............................................... 44
9.12. Single Pipe Loco Configuration (with load) ................. 45
9.13. Charging BP on first power Up (i.e. Loco Charging).... 46
9.14. Helper Mode ............................................................. 46
9.15. Wired Multiple Unit configuration .............................. 47
9.16. Main Compressor Oil level check................................ 47
Loco Pilot Handbook - WAG12 [2] NRD0000572585

10. Troubleshooting .................................................................... 49
11. Haulage Chart ....................................................................... 61
11.1. Axle Weight 22.5 ton/axle, Normal Mode (8 Motors
Working) & Dry Track ................................................................ 61
11.2. Axle Weight 22.5T, Degraded Mode (6 Motors Working)
& Dry Track ............................................................................... 63
11.3. Axle Weight 22.5 T, Normal Mode (8 Motors Working)
& Wet Track .............................................................................. 65
11.4. Axle Weight 22.5 T, Degraded Mode (6 Motors
Working) & Wet Track ............................................................... 67
Reference Documents
Reference No. Document Title
NRD0000572523_1 WAG12B Driver Training Manual
NRD0000572572_0 Dead Locomotive Operation
NRD0000258515_8 Operational Context Document

1. INSTRUCTIONS FOR LOCO PILOT
1.1. Do’s
1 Loco pilot shall enter proper details in DDU regarding Pilot
ID, Hauling Load and No. of Wagons attached while taking
charge. Ensure load attached is as per hauling chart.
2 Check for any active IOS in DDU page and follow
troubleshooting steps before movement of locomotive.
Inform HELPLINE/OCC in case of any failure IOS and follow
the Helpline instructions.
3 Prior to giving VCB close command, ensure Master
Controller (Throttle) is at neutral Position.
4 In case of repeated VCB tripping contact Helpline.
5 Above 10Kmph prefer regenerative braking as primary
brake.
6 While Cab change /Loco Shutdown, put CCB mode Selector
Switch to TRAIL position.
7 Ensure VCB open and Zero speed before isolating/normalise
TCU.
8 In case of continuous glowing of LSAF indicator, physically
check for no leakage in BP line of wagons and Loco.
9 Automatic Bail-Off feature is available in locomotive,
manual bail off to be avoided. It shall be used on need basis.
10 In case of any abnormal sound from underframe,
immediate stop the Loco and inspect the underframe.
11 Ensure all the CBs are always closed in both sections, unless
explicitly recommended by TCMS on DDU.
12 In the event of axle blocking IOS6107 will appear, loco Pilot
should stop and inspect the locomotive before restarting.
13 In the event of loss of control on Traction or Braking
command, Loco Pilot should blow horn and trigger an
Emergency Brake.
14
15 Loco Pilot should ensure proper release of the brakes during
operation to avoid inefficient Tractive Effort or sometimes
fire hazard.
16 Loco Pilot should apply the Parking Brake before proceeding
for brake pipe leak test.
17 Parking Brake should be applied while the cabin is active
and loco is in standstill condition. Also, after application of
PB, Loco Pilot should confirm the application from DDU &
Gauge before leaving the cabin.
18 Ensure parking brakes are in “Released condition” prior to
hauling the loco in “Dead Mode”,and confirm by gap
between wheels and brake shoe.
19 In train configuration, ensure the brakes on wagons are
manually released before starting the train.
20 Ensure the isolation cocks (Z01/1, Z01/2, B40.09, N55.05,
Flap isolation slider), bypass switches (Vigilance Isolation
Switch, Fire Detection Bypass Switch, Zero Speed Bypass
Switch) are in normal position, unless explicitly
recommended by TCMS on DDU.
21 In the event of unintended traction after application of
Emergency Brake, immediately lower the pantograph by
moving the pantograph switch to EMERGENCY position.
22 In case of false alarm due to smoke detectors, contact
Helpline and follow the instructions.
23 Before leaving the locomotive after making the loco dead,
loco pilot must ensure closure of rear-view mirror.
24 While leaving locomotive in dead condition, ensure parking
brakes are applied and wedge blocks are placed.
25 Use wiper control knob carefully, as overtightening might
lead to damage of knob and loss of wiper control

26 For EBV fault code 153, always check that all TCU’s are
healthy and compressor(s) is/are in running condition.
27 Any command activated through DDU or hardware shall be
deactivated from same means.
28 Before Loco shutdown, ensure to make active cab as non-
working.
29 Keep the gadgets like tablet, its charger, torch at their
designated location after use to avoid damage or theft.
30 Whenever CP oil level is observed at below minimum level
please perform CP oil level procedure and check the CP oil
again. Even then any abnormality inform Helpline.
1.2. Don’ts
1 Don’t break seal of any isolating cock or bypass switch
unless required and authorised by TLC/Helpline.
2 Do not Leave locomotive unattended with electronic in
“ON’ condition.
3 Do not Use Direct Brake (SA9) + Regenerative braking
simultaneously when loco attached with load and running
above >10kmph.
4 Do not Shutdown the locomotive directly from battery box
when electronics are in “On” condition.
5 Do not Operate “Direction Selector Switch (Reverser)”
while locomotive is in running condition.
6 Do not change position of Panto Selector Switch, when
Panto is in raised condition.
7 Should not Lower the Pantograph without opening the
VCB.
8 After power-up of the locomotive and activating the cab, the
Loco Pilot should NOT release the parking brake of the
locomotive until the main pipe pressure reaches 6 bar.

9 Do NOT operate the locomotive at speeds greater than 100
km/h when operating locomotive without wagons.
10 Do NOT leave the locomotive without placing the wheel
wedges when the locomotive is parked for maintenance or
for longer duration.
11 Sanding operation is NOT recommended when locomotive
is operating without wagons.
12 Bail-OFF mode is prohibited when locomotive is operating
without wagons.
13 Avoid the presence of staff in gangway during locomotive in
motion. Be cautious while passing through the gangway
while locomotive in motion.
14 Do not switch Off HVAC manually in non-active cab.
15 Do not Operate locomotive with Cab Windows, Machine
room/Gangway door in open condition
16 Do not operate “Fire Extinguisher Switch” unless there is
an actual fire/smoke found inside machine room as
complete CO2 gas cylinder will get exhausted. Inform
HELPLINE/OCC if operated.
17 Do not operate any isolation/ cut-out cocks partially. Ensure
its complete operation.
18 Do not operate wiper without water.
19 Don’t enter machine room immediately after CO2 fire
extinguisher is operated.
20 Don’t allow to spray sanitizer directly on DDU, EBV or any
electronics part.
21 Don’t operate the oil filter cock available on Air Dryer.
22 Do not paste anything on mic like paper, tape, chewing gum
etc.

2. TECHNICAL DATA OF WAG12 LOCOMOTIVE
Description Specification
Type of vehicle Freight locomotive
Horsepower 12000 Hp
2 (Section-1, Section-2)
No. of Sections
(Section-A, Section-B)
Axial arrangement BoBo
Number of axles 8
Rail gauge 1,676 mm
180 t for 22.5 Tonne/axle
Mass of locomotive
200 t for 25 Tonne/axle
Length 38,400 mm
Width 3,058 mm
Height 4,150 mm
1,250 mm (New Wheel)
Diameter of Wheel 1,207 mm (Half Worn)
1,164 mm (Fully Worn)
Maximum speed 100 km/h (upgradable to 120 km/h)
Gearbox ratio 110/23
Nominal: 22.5 kV, 50 Hz, single phase
AC
OHE Voltage
Maximum:31kV
Minimum: 17kV
Traction power in continuous
9,000 kW
rating mode
Maximum starting tractive
706 kN
effort at 22.5 t/axle load
Maximum starting tractive
785 kN
effort at 25 t/axle load

Tractive effort at maximum
270 kN
operating speed 120 km/h
Maximum tractive effort 115.149 kN/motor
Maximum braking effort 79.315 kN/motor
Low voltage supply 110 V DC
Auxiliary voltage supply 415 V, 3–phase AC
DC Link voltage 1800 V DC± 3%
Multiple unit operation 2 Locomotives
Suitability for remote multiple
2 Locomotives
unit operation
Cattle Guard 196 mm above rail level
Stone Deflector 40 mm above rail level
Side Buffer 968 mm above rail level

3. GENERAL DESCRIPTION
WAG12 locomotive is composed of two sections (Section 1 and Section 2). Each section of locomotive consists of two traction E-
blocks located inside the machine room which contains the power converters for propulsion and auxiliaries. Two traction motors
are installed on each bogie for propulsion and braking. The locomotive is fed by a 25 kV AC, 50 Hz overhead catenary.
Figure 1: WAG12 Single Section

Figure 2: Main Components of WAG12 Locomotive
Note: Signalling Cabinet and Toilet Module are future provision, not available in current locomotive.
4. DRIVER CAB
The WAG 12 locomotive cabin consists of Loco Pilot desk, Loco Pilot seat, Assistant Loco Pilot seat, Cab Cabinet Right & Toolbox
Cubicle.
4.1. Left Panel
Figure 3: Left Panel

4.2. Master Controller
Figure 4: Master Controller

4.3. Brake Gauges Panel
Figure 5: Brake Gauge

4.4. Central Panel
Figure 6: Central Panel-01
S. No Description S. No Description
1 Pantograph Toggle Switch (ZPT) 4 Headlight Control Toggle Switch (ZPRD)
2 VCB Open/Close Toggle Switch (BLDJ) 5 Parking Brake Toggle Switch
3 Headlight Toggle Switch (BLPR)

Figure 7: Central Panel-02
1 Emergency Stop Push Button (BPEMS) 6 Fire Alarm Reset Push Button (BPFR#)
2 Main Compressor Forcing Switch (BLCP) 7 Voice recorder microphone
3 Constant Speed Control Push Button (BPCS) 8 Tractive Effort Limit Switch (ZTEL#)
4 VCD ACK/RESET Push Button (BPVR#) 9 Speed Freeze Push Button
5 Flasher Light Latched Push Button (BPFL#) 10 Speed Indicator
4.5. TCMS, DDU (Train Control & Monitoring System, Driver Display Unit)
Figure 8 TCMS DDU

TCMS DDU displays the status of locomotive and its sub-systems, it provides soft key commands.
4.6. Indication Panel
Figure 9 Indication Panel

4.7. Line Indicator
Line indicator displays the traction effort, line voltage and battery voltage.
Figure 10 Line Indicator

4.8. Right Shelf
Figure 11 Right Shelf

4.9. Pedal Switches
Figure 12 Pedal Switches

4.10. Assistant Panel
Assistant panel consists of following control equipment:
Figure 13 ALP Desk

4.11. Cab Cabinet Right
The cab cabinet right is located behind the assistant Loco Pilot seat.
Figure 14 CAB Cabinet Right

1 Fire detection bypass switch(sealed) 6 Zero Speed Bypass Switch (sealed)
2 Internal Lights Push Button 7 Vigilance Isolation Switch (sealed)
3 Machine Room/Gangway Lighting Switch 8 TBC Bypass Switch (Sealed)
4 Panto Selector Switch 9 Circuit Breakers
5 Battery Connect Switch (S.BAC#) 10 Fire Extinguishing Override Switch
11 It is issued for 230v AC supply.
5. ELECTRICAL SYSTEM DESCRIPTION
5.1. Pantograph
Figure 15 Pantograph
The pantograph can be used for normal contact wire and high reach contact
wires with heights ranging from 4.58 to 7.52 m from top of the rail.
5.2. HV Cubicle
between the pantograph and primary winding of main transformer.
a) Potential Transformer
b) Current Transformer
c) Vacuum Circuit Breaker (VCB)
d) H-HT (High Voltage Disconnector)
e) Surge Arrestor

Figure 16: Electrical Schematic

5.1. Main Transformer
The AC catenary voltage is connected to the primary winding of the main
transformer of the same section via the single-phase main circuit breaker ‘VCB’
and to the main transformer of the other section via a 25kV line between the
sections and the 2 automatic switches.
Figure 17: Traction Power Electric Scheme

5.2. E-Block (Traction Convertor)
For each E-block, the input AC from the transformer secondary is rectified and
regulated to feed an 1800 V DC link
Traction Invertor is used Convert 1800 V dc to 3 Phase VVVF as demanded.
Each traction E-block drives two traction motors (for 2 axles)
5.3. Traction Control Unit (TCU)

In each E-Block there is one Traction Control Unit (TCU) for the driving of
traction and auxiliary converters. Each TCU is an electronic control rack.
Tractive Effort
No. of Healthy Bogies
22.5 T Axle Load 25 T Axle Load
4 706 kN 785 kN
3 529 kN 588 kN

5.3.1. Tractive/Braking Effort Limitation
DDU has a provision to limit tractive/braking efforts in two ranges as given
below,
When limit is not selected, locomotive applies default traction curve, as per axle
load configuration.
Traction Effort Limits: Limit can be activated through DDU home page.
a 300 kN
b 529 kN
5.3.2. Traction Isolation
In order to ensure the Service continuation in case of traction isolation (one
bogie isolated) with the maximal haulage load as declared, in any gradient up
to 1/150, the approaching speed of the locomotive shall be
maintained above 15 kmph.
If, in such a situation, the Locomotive comes to very low speed, the train may
not be able to re-start, a Banking Engine would be needed to continue the
Service.
5.4. H-OM (Earthing Switch)
H-OM is used to earth the high voltage system while performing any
maintenance or emergency scenarios such as panto entanglement, VCB Failure
etc.
5.5. Auxiliary Loads
S. No Description Quantity Per Section
1 E-Block Blower 2(1 in each E-Block)
2 E-Block water pumps 2(1 in each E-Block)
3 Traction Motor Blower 2
4 Machine Room Blower 2
5 Punction Blower 2
6 MASU 1
7 HVAC 1
8 230v Socket 1
9 Battery Charger 1
10 MTr Oil Pump 2
11 Crew Fans 2

5.6. Battery Unit & Charging System
The battery charger is fed from a 3 phase 415 V AC output from an auxiliary
transformer.
The function of charger is to feed the entire DC load of the locomotive and to
maintain the charging of the battery unit. The battery system supplies the
load during the unavailability of catenary.
Figure 18:Battery Charger Schematic
Battery in each section
Battery Type Ni-Cd
Number of Cells 80 (40 Cells in each Battery box)
Battery Capacity 100Ah
Nominal Voltage 110V DC
Battery Charger
Input Voltage 415 V AC, 3 phase, 50 Hz
Output Voltage 110V DC
Maximum Power Rating 14 kW
Maximum Output Current 100 A
Battery charging current 20 A
Battery Level Monitoring: At 89v, Alarm on DDU.

Note:
When Battery voltage is detected as <= 85 Volts, Loco enters shutdown mode
to protect excess draining of batteries.
6. PNEUMATIC SYSTEM
Each section of the WAG 12 locomotives is equipped with a Main Air Supply
Unit (MASU) of 2430 ± 6% LPM capacity (before dryer). Location of MASU is in
the machine room. Oil level can be checked through Spy Glass on Main
compressor.
Synthetic oil Anderol 3057M is used for lubrication. Oil capacity at Max. Level
is 7Ltr and at Min. Level is 6Ltr.
6.1. MASU (Main Air Supply Unit)

i. Air filtration and inlet arrangement
ii. Main compressor with filtration system
iii. Air Dryer
iv. Main Reservoir
v. Auxiliary compressor
6.2. Main Compressor Regulation
Compressor Management done by TCMS
Pressure Effect
MR-10 Kg/cm2 Both compressor Off
MR-8 Kg/cm2 One compressor Starts
MR-6.5 Kg/cm2 Both compressors start
MR-5.5 Kg/cm2 Penalty applied, Traction Cut Off
Safety Valves
Pressure Effect
MR-10.7 Kg/cm2 MR safety valve blows
CP-12.2 Kg/cm2 Compressor Safety Valve Blows
- For machine room temperature less than 50°c, the MASU shall operate
on ODD / EVEN day basis
- For machine room temperature between 50°c and 55° the MASU shall
operate on HOURLY basis.

6.3. Auxiliary Compressor Regulation
Pressure Effect Pressure Effect
6 Kg/cm2 Compressor Start 7 Kg/cm2 Compressor Stop
7. BRAKE SYSTEM
7.1. Types of Brakes
7.1.1. Regenerative Brake
Regenerative braking starts above 10Kmph and cuts off at 5Kmph.
Maximum Regenerative effort is available between 10Kmph and 60Kmph.
Regenerative Braking Effort

No. of Healthy Bogie
22.5 T Axle Load 25T Axle Load
4 514Kn 563Kn
3 385Kn 422Kn
7.1.2. Types of Pneumatic Brakes

i. Auto Brake- Applies brake in complete trainline.
ii. Direct Brake- Applies Brake only on Locomotive.
iii. Emergency Brake- Applies Brake in complete trainline.
iv. Back Up Brake- Applies brake in complete trainline.
v. Parking Brake- Parking Brake in Locomotive only.

7.2. Brake Control Module (BCM)
Figure 19: BCM

Figure 20: Auxiliary Panel

Figure 21: EPCU

7.3. Brake Pressure (Nominal)
i. Auto Brake
BP pressure BC pressure
Position
Kg/cm2 Kg/cm2
Release 5.5 ± 0.1 0
Run 5 ± 0.1 0
Minimum 4.6 ± 0.1 0.81 ± 0.1
Full Service 3.3 ± 0.1 3.8 ± 0.15
Emergency 0 3.8 ± 0.15
ii. Direct Brake

DBP pressure BC pressure
Position
(kg/cm2) (kg/cm2)
Release 0 0
Full 3.8 ± 0.15 3.8 ± 0.15
iii. Emergency Brake

BP pressure BC pressure
Condition
Kg/cm2 Kg/cm2
Applied 0 3.8 ± 0.15
iv. Parking Brake

BC pressure PB pressure
Position
(kg/cm2) (kg/cm2)
Release 0 5.67 ± 0.2
Apply 0 0
Note:
Parking Brake Gauge indicates pressure value of service brakes,
if service brakes are applied during PB applied condition.

Figure 22: Pneumatic Flow in Brake System
7.4. Different Types of Brake Blending Logics

Pneumatic
Master Auto Brake ED Brake Pneumatic Brake
Brake
Controller Handle (Locomotive) (Locomotive)
(Wagon)
YES
Activated NO NO NO
(Max 514KN)
YES YES
Activated Activated (Max of ED or NO (Accor. to BP
FB) Pr. Drop)
YES YES
NO Activated (Accor. to BP Pr. NO (Accor. to BP
Drop) Pr. Drop)
Loss of ED
YES
Activated
NO NO (Direct Brake as NO
Demand<90%
per demand)
YES YES
Activated
NO NO (BP drop- (BP drop-
Demand>90%
Penalty Brake) Penalty Brake)

7.5. Parking Brake Manual Release Plunger
Parking Brake cylinder is available on wheel number 1, 4, 5 & 8 in each
section with Manual Release Plunger. Parking Brake of individual wheel
can be released of by pulling this plunger.
Figure 23: Parking Brake Manual release plunger

8. LOCOMOTIVE OPERATING MODES
Mode Description
Both batteries are isolated from low voltage
distribution circuits through isolation device in
Dead Mode each battery boxes.
Low voltage (110V DC) is not available in the
locomotive
Low Voltage (LV) (110V DC) is available for
Locomotive to energize.
Shutdown In this mode LV is available for:
Mode a) Machine room and Cab Lighting with time
out (15 min).
b) Horn
Stand-by mode is activated by closing battery
Contactor through the Battery Connect Switch.
The locomotive is operational with all sub-
Standby Mode systems ready but no cabin is active in the train.
If locomotive remains in this mode for more
than 10 minutes, then Locomotive will change
over to Shutdown mode.
This mode can be activated from Standby mode
by activating any one of the Cabins.
VCB, panto and driver desk commands are then
Cab Active
available.
Mode Do not leave the cabin active for long durations
with VCB in open condition, as battery gets
discharged.

9. GENERAL PROCEDURES
9.1. Locomotive Energisation Procedure
i. Operate Battery Isolation CB (CB.100) to normal position in
both sections.
ii. Check Battery Voltage on Voltmeter at LV Cubicle in both
sections.
iii. Move battery connect switch to Start-up position to switch
ON control electronics.
iv. Turn, Key Switch (BL Key) to ON Position in Master
Controller.
v. Move Pantograph toggle switch to raise position.
vi. Check the line voltage value is within range from Line
Indicator located on Driver Desk.
vii. Close the VCB
viii. Put EBV Mode selector to “LEAD” position.
ix. Place Direct Brake Handle (SA9) at FULL position
x. To release penalty brake, place the EBV Auto Brake Handle
(A9) at FS position for minimum 10 seconds.
xi. Once “OKAY TO RUN” message appears on EBV screen,
ensure to charge BP up to 5kg/cm2.
xii. Release Parking brakes from Central Panel
xiii. Select the direction from Reverser (Direction Selector) on
Master Controller.
9.2. Loco Shutdown Procedure

i. Place the EBV handle in FS position and lock with pin.
ii. Move the VCB open/close switch to Open position.
iii. Move Pantograph toggle switch to lower position.
iv. Ensure pantograph is lowered.
v. Apply the parking brakes on Locomotive.
vi. Turn, Key Switch (BL Key) to OFF Position in Master
Controller.
vii. Move battery connect switch to “Stop” position.

viii. Ensure all loads are shutdown.
ix. If the loco stays dead mode for more than 24 Hours, Operate
Battery Isolation CB to OFF position.
9.3. Cab Change Procedure

i. Place the EBV handle at FS position and lock with pin.
ii. Place the Direct Brake Handle (SA9) at “REL” position.
iii. Change EBV mode selector to “TRL” position.
iv. Move the VCB open/close switch to Open position.
v. Move Pantograph toggle switch to lower position.
vi. Ensure pantograph is lowered.
vii. Turn MASCON Key Switch (BL Key) to OFF Position in Master
Controller.
viii. Change the Cab within 10 Mins
(If other cab is not activated within 10 Mins, Locomotive will
enter shutdown mode)
ix. Turn, Key Switch (BL Key) to ON Position in Master
Controller.
x. Move Pantograph toggle switch to raise position.
xi. Check the line voltage value is within range from Line
Indicator located on Driver Desk.
xii. Close the VCB.
xiii. Change EBV mode selector to “LEAD” position.
xiv. Place Direct Brake Handle (SA9) at FULL position
xv. To release penalty brake, place the EBV Auto Brake Handle
(A9) at FS position for minimum 10 seconds.
xvi. Once “OKAY TO RUN” message appears on EBV screen,
ensure to charge BP up to 5kg/cm2.
xvii. Select the direction from Reverser on Master Controller.
9.4. Loco Grounding Procedure

i. Open the VCB by using the VCB open/close toggle switch.
ii. Lowered the Pantograph by using the Pantograph toggle
switch.

(Physically verify that pantograph is lowered)
iii. Isolate Pantograph Cut-out Cock available on PCU in machine
room. This process Releases the pressure available in
pantograph pipe (In Both Sec.)
iv. Ensure Workshop/Shore supply CB in off position (In both
Section)
v. Operate the Z-SEC key to “HV disconnection” position.
Release the Z-SEC key by rotating Clockwise. Z-SEC key is
attached by a welded ring with the H(O-M) input key (Blue
Key-KABA) and with workshop plug box key (used for the
workshop plug function).
vi. Insert the Blue KABA key inside the input barrel, rotate the
key and turn the input barrel.
vii. Rotate the H(O-M) in grounding position through the switch
gear handle.
viii. When the switch gear handle of H(O-M) is in grounding
position, turn the output barrel clockwise direction and the
output key (green) handle linked with the H(O-M).
9.5. Dead Engine Brake Configuration

i. Put EBV mode switch in ‘TRL’ position in both sections.
ii. Put Auto handle in both the section should be kept in FS
position & secure using lock pin and put Direct brake Handle
on REL position.
iii. Locomotive shutdown is in Dead Mode (batteries isolated),
iv. Close (horizontal position) SIFA Cock (N55.05), on Auxiliary
Panel of Brake System in both sections
v. Connect BP Hose to another loco or train and Open BP angle
cock so that BP can be charged on dead loco.
vi. DER (Dead Engine Regulator) cock at ERCP in Brake Panel
shall be operated in ‘IN’ position (rotate anti-clockwise
position) in both sections (Rotate anti clockwise to “IN”
position written on ERCP) and allow to charge BP & 150 Litre
Reservoir through brake pipe air up to 5 kg/cm2.

vii. Close (vertical handle position) FP cock (B50.01), on Auxiliary
Panel of Brake System in both sections.
viii. Charge BP to normal level, verify brake are released and BC
pressure is zero. If BC is not reducing to zero, then give brief
pulls to quick release lever at bottom of distributor valve (KE
Valve) Ensure BC reduces to zero.
ix. If loco Brake remains applied, press 20TP (Test point) of 20CP
on Pneumatic Panel to Release BC to Zero.
x. Open one end of DBP & MREP angle cock at one end of dead
Loco.
xi. Release Parking Brakes by Pressing Plunger (red colour on
apply/ release solenoid") on BCM panel of both the sections
and ensure pressure on the parking brake gauge is more than
4.8 kg/cm2.
xii. Release Parking Brakes by Pulling Manual Release Pins on
Parking Brake Unit of each axles in both the sections. Ensure
Parking brakes are released by looking into the gap between
brake shoes and wheel.
9.6. EB Reset Procedure

i. Move the auto brake handle to EMER position once
intimation on EBV comes.
ii. Clear the reason for EB application if any. For example:
a) Normalise EB push button in the section from where EB
was applied.
b) Reset the Assistance Driver Emergency Cock in the section
from where EB was applied
c) Put the auto brake handle in FS, if EB applied from non-
active cab.
iii. Give a VCB close triggered pulse.
iv. Move the Auto Brake handle to FS position once intimation of
"Safety Penalty Keep in FS" comes on EBV.
v. Wait for 10 seconds and move the Auto brake handle to RUN
to charge BP once intimation of "Okay to Run" comes on EBV

9.7. Penalty brake Reset Procedure in case of EBV
Failure
Note: - In case Loco cannot run from the section due to failure of
EBV Back-up brake to be used or for rear cab driving.
(Electronic Brake Valve)
i. Move Auto Brake Handle (A9) of failed EBV to FS position
and lock.
ii. Put selector switch on LEAD of the healthy EBV.
iii. Move the auto brake handle to EMER position once
intimation on EBV comes.
iv. Move the Auto Brake handle to FS position once intimation of
"Safety Penalty Keep in FS" comes on EBV
v. Wait for 10 seconds and move the Auto brake handle to RUN
to charge BP once intimation of "Okay to Run" comes on EBV.
9.8. Vigilance Management

Vigilance control is operative in all driving modes except inching mode,
it is also operative for locomotive speeds beyond 5 km/h.
The logic of vigilance is different for driving modes and logic is explained
below:
Loco pilot must perform any of the following actions every 60 seconds
(acknowledgement):
i. Movement of master controller handle (displacement of
more than 5 degree
ii. Movement of auto brake handle
iii. Tap vigilance pedal switch
iv. Press the VCD Ack/Reset push button
If none of the above actions are performed for 60 seconds, an alarm is
triggered and vigilance warning indication lamp is lit on indication panel
along with buzzer.
To reset, Loco Pilot must press and release the vigilance foot pedal.
If alarm is not reset within 16 seconds, then penalty brake is initiated.
To reset vigilance function, Loco Pilot must:
i. Bring traction brake controller handle to “Neutral”

ii. Wait for 32 seconds
iii. Press “VCD Ack/Reset” push button on central panel.
iv. Give VCB close command
v. The reset is recorded in event recorder.
To reset the penalty brake, move auto brake handle to Full Service (FS)
position for 10 seconds and then to RUN position.
Indication is provided when vigilance alarm is active.
a. Visual alarm on Indication Panel
b. Audio alarm through Buzzer Alarm
9.9. Back-Up Brake (PTDC)

The following sequence will be applied to switch over from normal brake
to back-up brake:
i. Trip the Circuit breakers 62Q06 (present in LVC) of BCM in
both the sections.
ii. Operate the PER-COS cock present in BCM of active section
to Cut - in position (horizontal).
iii. Ensure Back-Up Brake handle in Position ‘III’ (lap position).
iv. Ensure VCD bypass switch is in normal position.
v. Charge Brake Pipe pressure by moving the Back-Up Brake
handle to position II/RELEASE in active cab.
vi. BC pressure will reduce to zero. If not, briefly pull the quick
release lever at the bottom of the ‘KE’ (Distributor) Valve
present in BCM panel. Thereafter Loco Pilot can operate
with back-up brake.
vii. Still Emergency Brake can be applied with Auto Brake
Handle(A9) handle.
Note:
During Backup-Brake operation, moving handle slightly in between
position III and Position V, BP drops in same ratio and brakes will
applied accordingly.
Moving handle completely to Position V leads to emergency brake

application.

Follow Indian Railways speed restrictions while operating locomotive
with Backup-Brake
9.10. Coupling Two Locomotives

i. Bring the two locomotives near to each other at slow speed
(approximately 2 - 3 km/h) and stop them approximately at
a distance of 1 - 2 meters
ii. Check the alignment and position of coupler centres.
Couplers must stand within the gathering range as given
above.
iii. Ensure that both coupler head knuckles are in open
condition or one open and the other in closed condition.
iv. If required adjust the coupler head position manually
towards each other and make sure that they are in the
gathering range of the coupler geometry.
v. Now bring one locomotive slowly (approximately 3-5 km/h)
towards the stationary locomotive for coupling.
vi. Connect end pipes; feed pipe (white), brake pipe (green),
MREP (red) and DBP (yellow) by operating the respective
cocks.
vii. Before starting to move the loco, ensure that the parking
brakes are released. If not, use the manual release lever in
the parking brake cylinder.
Note:
Pull the locomotives and ensure proper coupling.
9.11. BP leak test procedure

i. Apply Parking Brake before starting BP leak test.
ii. In non-working cab ensure EBV in TRAIL position and EB is
not applied before attempting to set up in TEST.
iii. Set Auto brake handle is lock in FS position in non-active
cab.

iv. Put selector switch on LEAD in active cab.
v. Set Auto brake handle in RUN and Direct brake handle in
Full position in active cab (charge BP)
vi. Set EBV Automatic Handle - MIN
a) ER reduces to approximately 4.6 ± 0.10
b). BP reduces to approximately 4.6 ± 0.10
vii. Set EBV Mode switch in TEST, BC develops to approx. 3.8 ±
0.15
viii. Set EBV (SECTION-I) Automatic Handle - FS
a) ER reduces to approximately 3.3 ± 0.10
b) BP remains approximate 4.6 ± 0.10
ix. Wait one (1) minute. Then Monitor brake pipe pressure for
two (2) minutes. Leakage should not exceed 0.07
x. Set EBV Automatic Handle - RUN
a) ER increases to approx. 5.0 ± 0.1. Wait one (1) minute
b) BP must not increase.
xi. Set EBV Mode Selector Switch - LEAD
a) BP increases to ER +/-0.1
b) BC reduces to < 0.2
9.12. Single Pipe Loco Configuration (with load)

i. Apply the parking brake.
ii. Connect the BP hose pipe in the formation.
iii. Release the parking brake.
iv. Put auto brake handle on FS with lock, direct brake handle on
REL and Put selector switch on TRAIL in non-active cab.
v. Put selector switch on LEAD in active cab.
vi. Move the ABH to EMER position once intimation on EBV
comes.
vii. Move the Auto Brake handle to FS position once intimation of
"Safety Penalty Keep in FS" comes on EBV
viii. Wait for 10 seconds and move the Auto brake handle to RUN
to charge BP once intimation of "Okay to Run" comes on EBV.

9.13. Charging BP on first power Up (i.e. Loco
Charging)
i. Keep Auto/A9 handle in FS, wait until “Okay to Run” message
displayed on EBV.
ii. Place Direct Brake Handle (SA9) at REL position
iii. Move Auto Brake Handle (A9) to RUN position and verify that
BP is charged to 5 kg/cm2, BC drops to 0 kg/cm2.
iv. To overcharge the BP to 5.5 kg/cm2, Hold Auto Brake Handle
(A9) at REL position for minimum 3 seconds.
v. Once BP starts increasing, place Auto Brake Handle (A9) at
RUN position.
vi. BP will charge to 5.5kg/cm2 and then drops back to 5 kg/cm2.
(this process takes approximately 270 +/- 10 seconds)
Note: The overcharge cycle should not be interrupted by any means i.e.
EB, penalty, Cab change etc. If interrupted, initiate the overcharge cycle
again and allow it to complete.
vii. Quick release of Auto Brake in Loco either can be by lifting
Bail-Off ring provided on Direct Brake Handle (SA9) or by
pressing Bail-Off foot pedal switch.
9.14. Helper Mode

i. Connect Brake pipe of helper unit to the leading units to apply
brakes in helper loco based on BP drop from lead locomotive.
Other pipe connections can be done based on configuration to
which helper loco is to be connected.
Note: Banker loco is generally placed at the end.
ii. Ensure that the mode selector switch on the EBV in the
inactive section is set to ’TRAIL’, and the auto brake handle is
in ’FS’. The auto brake handle in the inactive cab should be
locked by inserting the provided lock pin into position.
iii. In the active section, place Auto handle in ’FS’ (Full Service)
and Independent (Direct) handle in ’FULL’ application.
iv. Place Reverser Handle in ‘Neutral’.

v. Turn Mode selector switch on EBV to HLPR.
vi. The EBV screen displays the following message: “MODE
CHANGE; MODE = HLPR".
vii. Auto brakes are not available except ‘Emergency’ application
and Independent (Direct) handle operation is still available.
9.15. Wired Multiple Unit configuration

i. Couple the locomotives mechanically as per coupling process.
ii. Shutdown both the locomotives.
iii. Connect all the 4 end pipes of Main Reservoir Pipe, Feed Pipe,
Brake Pipe and Direct Brake Pipe by operating the respective
cocks.
iv. Connect the 4 electrical jumpers to electrically couple both the
locomotives.
v. Both locomotive battery MCBs (CB-100) shall be in ON
condition.
vi. Both intermediate cabs are disabled: it’s not possible to
activate them. Only end cabs of the consist can be activated.
vii. Energise the locomotives and activate any of cab at either
end.
Note: Electronics of Follower locomotive can be switched ON from lead
locomotive itself by operating battery connect switch. It is not required to operate
the cab activation key in follower locomotive.
Once any one of the cabs is activated, that locomotive becomes Lead locomotive
and the locomotive connected to it becomes Follower locomotive.
Only one BCM will be ON out of 4 BCMs in two locomotives.
9.16. Main Compressor Oil level check

i. Oil level of main compressors should be checked using the
sight glass provided at MASU.
ii. The compressor should be made to RUN for 5 minutes either
by draining the MR below 8 kg/cm2 using the MR drain cock

A10 and by forcing the compressors via the forcing toggle
switch (BLCP) present on the Driver desk.
iii. Wait for 5 mins once compressor stops.
iv. Now, check the oil level in the sight glass.
v. If the level is below MIN, then oil level is considered as LOW
and if it between the MIN and MAX marking then it is OK.
vi. The observed value is not between MIN & MAX level, inform
Helpline.

10. TROUBLESHOOTING
S. No Fault Help
1.Put auto brake handle on FS with lock, direct brake handle on REL and Put selector
switch on TRAIL in non-active cab.
2. Put selector switch on LEAD in active cab.
3. Apply the parking brake.
Service Brakes not
1 4. Put the Auto brake handle on RUN and Direct brake handle on REL.
releasing
5. Ensure that BP is charged to 5 kg/cm2.
6. Release the BC by using lever on distributor valve. If still not released, then release
the BC by pressing test points 20TP and 16TP on the LRU’s or by opening the front DBP
angle cock.
1.Apply the Autobrake or Direct Brake in Active Section.
2. Ensure the BC pressure is showing in gauge.
Parking Brakes not 3. Release the parking brake by pressing PB solenoid valve (B40.05) on BCM panel of
2
releasing both the section, if not releasing proceed to the next step.
4. If PB not released, release the PB by pulling manual handle from all TBU.
5. Call OCC to Rescue the Loco.
1. Normalise the EB push button present on Driver Desk, If not possible.
EB push button
3 2. Operate PER-COS located on BCM Panel & Use Back-Up Brake by following Back-Up
being pressed
Brake procedure.

S. No Fault Help
1.Check that EBV Auto Handle is in RUN position, and EB push Button is in released
condition, and ALP Emergency cock should be closed position.
2.Put auto brake handle on FS with lock, direct brake handle on REL and Put selector
switch on TRAIL in non-active cab.
3.Put selector switch on LEAD in active cab.
4. Ensure MR Pressure on gauge is > 8kg/cm2.
5. Check the Display of EBV if it is showing target pressure “0.00 kg/cm2” or “xxxx”,
then check the leakage in BP line, otherwise follow the displayed instruction.
6. Ensure the no leakage from Assistant driver emergency cock and cock is fully closed
4 BP Not Charging in both section (by hearing sound).
8. Close the BP angle cocks (front and intersection) of the locomotive and charge BP by
placing auto brake handle in RUN position.
9. Check the leakage from 821 vent valve (N98, underframe) if yes, close the SIFA
emergency cock (N55.05) on BCM of respective section.
10. Check for no leakage from both the BCMs.
11. If leakage is arrested by closing the cock, then charge BP by following the EBV
display instruction (follow the EB reset instruction).
12. Open the BP angle cock (intersection) to supply BP to formation slowly.
13. After opening the cock if again BP is dropping check the formation leakage.

S. No Fault Help
1.Check EBV mode in Non-active cabin, it should be in TRAIL, if not put it in TRAIL.
2.Check EBV mode in Active Cab it should be in LEAD if not put it in LEAD.
5 EBV mode mismatch 3.Switch over the BCM and check the functionality.
4.Still fault message appears in EBV Display use Back-Up Brakes. (Follow the Back-Up
Brake procedure)
Ensure that ZSEC is not in HV disconnection Position in both cabins.
6 Panto not Raising Ensure that not CB on LV cubical of both sections is in tripped condition.
Ensure that pantograph switch in other section is not in “EMERGENCY” position.
7 BCM Failures Switch to another BCM by following the General Procedure of changing BCM.
Vigilance Pedal
8 Put VCD switch present in CCR to Bypass position.
Failure
VCB Open/Close
9 Use DDU to Open/Close VCB.
switch failure
Emergency Brake
10 Request relay 1 Isolate Emergency COC (SIFA) in faulty Section.
and/or 2 failure
Both Headlights not 1. Try to operate Headlight from DDU.
11
working 2. If Head light is not glowing, Inform to OCC.

S. No Fault Help
1. Break the seal of VCD isolation switch located in CCR panel

12 VCD isolation
2. Turn the VCD isolation switch to 'isolated' position.
Cab not getting 1. Turn OFF the master controller key and remove the key.
13
deactivated 2. Trip the CB 74Q01 located in the LVC.
1. Verify that the Flasher Control is in ON position and Mode selector toggle switch in
Main or Standby.
2. Press Flasher Light push button located in Driver Desk and check Flasher Light is
working or not. If it is not working proceed to the next step.
3. Switch the mode to (STANDBY/MAIN) .Still It is not working proceed to the next
Flasher Light not
14 step.
working
4. Try to activate the flasher light using DDU .If it is not working perform the next step.
5. Put the fuse in MAIN/STANDBY by taking from SPARE fuse and check the operation
by following above steps .
6. Flasher light still does not work Complete failure of the flasher control unit. No
controls will work.

S. No Fault Help
1. Put the throttle at Neutral.
2. Put the Direction switch in OFF position then put in FWD/REV as per requirement
TBC (Throttle) not
15 then put throttle to Traction if still it is not responding proceed to next step.
responding
3. Remove the sealing of TBC bypass switch and Turn the switch to Bypass.
4. Use the virtual Master controller on DDU for throttle operation.
1. OPEN the VCB (Ensure throttle is in Neutral ).
2. Go to Motor screen by pressing the key '4' or touch the (...) icon.
16 TCU Isolation 3. Touch the 'Isol.' icon below the TCU which you must isolate.
4. Ensure the TCU isolated by seeing the (...) icon.
5. Close the VCB.
1. Check the OHE voltage from Line Indicator/DDU. If available Ensure the throttle
position in Neutral else proceed to the next step.
2. Check the Panto status from DDU. If Panto is down, stop the Loco.
VCB not closing after 3. Raise the panto
17
neutral section 4. Wait for voltage indication in Line Indicator/DDU & Close the VCB.
5. Still VCB not closing change the panto selector switch to other section and wait for
voltage indication in Line Indicator/DDU.
6.Close the VCB.

S. No Fault Help
1. Put the panto toggle switch to emergency position (Ensure the VCB is open and loco
18 Panto failed to lower speed is zero) still panto is not lowering proceed the next step.
2. Put the panto isolation cock in cut out position.
For 110 V CB: - 1. Reset once the CB (Don’t hold the CB while resetting).
2. Inform to OCC if it trips again.
CB resetting in 1. Open the VCB.
19 For 415 V CB: -
LVC/E-Block/HVC 2. Down the panto.
3. Reset the CB.
4. Do not reset if trips again.
1. Check the CB 74Q01 located in the LVC if it is in tripped reset it else proceed to the
next step.
20 Cab activation
2. Insert Master controller key and make ON/OFF 2 to 3 times still cab not activate.
3. Call OCC for Rescue of the Loco.
1. Open the access door located adjacent to ALP by using square key lock to isolate
21 Horn Isolation affected Horn.
2. Put the respective horn isolation cock to closed position.
22 Horn failure 1. If the horn is not working (LP/ALP), use the other horn available (ALP/LP)

S. No Fault Help
1. Check the Compressor is running or not.
2. Check the leakage from Auto drain valve under Main Reservoir, if yes put the auto
drain valve (B60.01) in closed position of respective section.
3.Check Drain cock (A-10, Under MR) of both sections is in Open/Close position, if
found Open, then Close it.
MR Pressure not
23 4.Check the Drain Cocks (A11/1,A11/2,A11/3) located in BCM of both sections. If any
building up
of them are in open position, then close it.5. Check the leakage from MASU (i.e. safety
valve, air dryer etc.) if there is leakage then Cut out the MASU Isolation cock (A13) of
the respective section.
6. Check the leakage from MREP, DBP & FP angle cocks.
7.Check the leakages in load side.
Fire Alarm
24 continuously Put the Fire detection bypass switch to bypass mode.
triggered
25 Line Indicator failure Operate the loco by using DDU
26 Speed display failure Operate the loco by using DDU

S. No Fault Help
1.Check the CB 91Q01 present in LVC . If found tripped , reset it.
Marker light not
27 2.Check the taillight(RED Light) switch position which should be in OFF.
working
3.Operate the Marker Light switch 2 to 3 times in Driver Desk.
CAB light or 1. Check CB 23Q04 present in LVC. If it is tripped then reset it, else
28 Spotlight not 2. Operate cab light switch/Assistant's Reading Light/Driver's Reading Light present in
working Driver desk 3-4 times.
Bail-Off Pedal not
29 Use EBV Bail off ring on Direct Brake Handle (SA9).
working
1. Check CB 23Q04 present in LVC. If it is tripped then reset it, else
2. Ensure that if Machine Room/Gangway light switch present in CCR is in ON position
Machine room light then Gangway light switch present in machine room should be in OFF position. And if
30
not working Gangway light switch present in CCR is in OFF position then Gangway light switch
present in machine room should be in ON position.
3. If the switch orientation is fine try operating the switch 3-4 times.
VCD pedal not
31 With OCC confirmation Operate VCD Bypass switch present in CCR.
working

S. No Fault Help
1. Check CB 63Q01, if it is tripped then reset it. Else
Sanding pedal not
32 2. Check Sanding Isolation Cock (SAND-COC, F41.01) present on BCM panel and if
working
isolated put it in OPEN position (vertical).
Indicator Panel Check the status of CB (23Q05) on LV Cubicle, If Tripped try to reset once.
33
failure If CB trips again, DDU to be used.
Air Leakage:
Operate isolation COC present in driver desk for wiper and isolate it. Manually operate
the wiper.
34 Wiper failure Motor Failure:
Manually operate the wiper.
Blade failure:
Isolate wiper and do not operate.
1. Reset CB 72Q21 located in LVC. If still not working then
35 DDU failure
2. PRT will intervene.
Check the CB 23Q03, if tripped reset it
36 Gauges failure
Else PRT intervention needed.
Check the CB 74Q04, if tripped reset it
37 Cab Buzzer failure
Else PRT intervention needed

S. No Fault Help
Throttle failure:
1. Remove the sealing of TBC bypass switch and Put the switch to Bypass.
2. Use the virtual TBC on DDU for throttle operation.
Key switch failure:
Master Controller
38 Loco can only be run from other section.
failure (mechanical)
If not possible, PRT intervention needed.
Direction Selector Switch Failure.
Loco can only be run from other section.
If not possible, PRT intervention needed.

S. No Fault Help
Driver detects a continuous leakage sound from the underframe even after the
emergency brake is reset.
1. Isolate EMERGENCY Isolation (SIFA - N55.05) located in BCM to close position. If
the venting continues, driver shall identify the section in which the leakage is
happening.
2. In case the section identified is the leading cab (cab away from the wagons):
a. Isolate BP venting by operating the BP isolation cock (N95) to close position, located
BP not Building up. adjacent to the BCM.
821 Vent valve
39 b. Isolate the BP line using the Inter-car end cock B82; first on the trailing cab and then
(N98, underframe)
on the leading cab.
failure.
c. Isolate Z01/1,Z01/2 located in BCM.
d. Put Panto Selector switch in Both Position.
e. Charge the BP from the leading cab EBV and continue service till end of trip with 50%
braking.
3. In case the section identified is the trailing cab (cab connected with the wagons).
Failed BCM shall be isolated by operating respective N95 Cock.
Continue service till end of trip with 50% braking.

S. No Fault Help
PANTOGRAPH TOGGLE SWITCH: Use DDU for panto.
VCB OPEN/CLOSE SWITCH: PRT Intervention needed. Otherwise run the loco from
other section.
CONSTANT SPEED CONTROL PB: Use DDU.
VIGILANCE RESET PB:
1. Put VCD bypass switch present in CCR to bypass position.
Any of the Haulage
2. Restart the loco.
Chart FLASHER LIGHT LATCHED PB: Use DDU.
40 switches/push FIRE ALARM RESET PB: Use fire detection bypass switch present in CCR. And physically
button (Driver Desk check for any presence of fire.
/CCR) failure EMERGENCY PB: Use backup brake. PRT intervention needed.
CAB LIGHT CONTROL SWITCH:
If lights are not OFF trip the CB 23Q03.
If lights are not ON operate the switch 3-4 time if still it is not working, then RPT
intervention needed.
SPEED FREEZE PB: PRT intervention needed.

11. HAULAGE CHART
11.1. Axle Weight 22.5 ton/axle, Normal Mode (8 Motors Working) & Dry Track
a. 0° Curve
Speed Level Slope Slope Slope Slope Slope Slope Slope
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 6471 6000 4651 3764 2704 2221
30 6000 6000 6000 6000 4651 3764 2704 2221
60 6000 6000 6000 6000 4312 3348 2288 1835
b. 1° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 6471 5844 4524 3679 2659 2189
30 6000 6000 6000 5844 4524 3679 2659 2189
60 6000 6000 6000 5734 4169 3259 2245 1805

c. 2° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 6471 5648 4404 3597 2614 2158
30 6000 6000 6000 5648 4404 3597 2614 2158
60 6000 6000 6000 5489 4035 3175 2203 1777
d. 3° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 6318 5464 4289 3519 2571 2128
30 6000 6000 6000 5464 4289 3519 2571 2128
60 6000 6000 6000 5264 3910 3095 2162 1749
e. 4° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 6090 5291 4180 3444 2530 2098
30 6000 6000 6000 5291 4180 3444 2530 2098
60 6000 6000 6000 5056 3791 3018 2122 1723

f. 5° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 5878 5129 4077 3372 2489 2070
30 6000 6000 5878 5129 4077 3372 2489 2070
60 6000 6000 5777 4863 3679 2945 2084 1697
11.2. Axle Weight 22.5T, Degraded Mode (6 Motors Working) & Dry Track
a. 0° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7318 5282 4489 3439 2774 1981 1618
30 6000 6000 5282 4489 3439 2774 1981 1618
60 6000 6000 5282 4489 3439 2774 1979 1582

b. 1° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 7251 5068 4332 3344 2711 1946 1594
30 6000 6000 5068 4332 3344 2711 1946 1594
60 6000 6000 5068 4332 3344 2711 1941 1557
c. 2° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 6860 4871 4185 3253 2649 1913 1571
30 6000 6000 4871 4185 3253 2649 1913 1571
60 6000 6000 4871 4185 3253 2649 1904 1532
d. 3° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7462 6509 4687 4048 3168 2591 1881 1549
30 6000 6000 4687 4048 3168 2591 1881 1549
60 6000 6000 4687 4048 3168 2591 1869 1508

e. 4° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7050 6191 4517 3918 3086 2535 1850 1527
30 6000 6000 4517 3918 3086 2535 1850 1527
60 6000 6000 4517 3918 3086 2535 1834 1484
f. 5° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 6680 5902 4358 3797 3008 2481 1819 1505
30 6000 5902 4358 3797 3008 2481 1819 1505
60 6000 5902 4358 3797 3008 2481 1801 1462
11.3. Axle Weight 22.5 T, Normal Mode (8 Motors Working) & Wet Track
a. 0° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7600 6468 4436 3766 2878 2316 1646 1340
30 6000 6000 4436 3766 2878 2316 1646 1340
60 6000 6000 4436 3766 2878 2316 1646 1340

b. 1° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 7109 6099 4255 3633 2798 2263 1617 1319
30 6000 6000 4255 3633 2798 2263 1617 1319
60 6000 6000 4255 3633 2798 2263 1617 1319
c. 2° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 6669 5769 4088 3509 2721 2211 1589 1300
30 6000 5769 4088 3509 2721 2211 1589 1300
60 6000 5769 4088 3509 2721 2211 1589 1300
d. 3° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 6278 5473 3933 3393 2649 2162 1562 1281
30 6000 5473 3933 3393 2649 2162 1562 1281
60 6000 5473 3933 3393 2649 2162 1562 1281

e. 4° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 5930 5204 3789 3283 2580 2114 1535 1262
30 5930 5204 3789 3283 2580 2114 1535 1262
60 5930 5204 3789 3283 2580 2114 1535 1262
f. 5° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 5617 4960 3655 3181 2514 2069 1510 1244
30 5617 4960 3655 3181 2514 2069 1510 1244
60 5617 4960 3655 3181 2514 2069 1510 1244
11.4. Axle Weight 22.5 T, Degraded Mode (6 Motors Working) & Wet Track
a. 0° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 5560 4718 3221 2727 2073 1659 1165 940
30 5560 4718 3221 2727 2073 1659 1165 940
60 5560 4718 3221 2727 2073 1659 1165 940

b. 1° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 5191 4446 3088 2629 2014 1620 1144 925
30 5191 4446 3088 2629 2014 1620 1144 925
60 5191 4446 3088 2629 2014 1620 1144 925
c. 2° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 4866 4203 2965 2538 1958 1582 1123 910
30 4866 4203 2965 2538 1958 1582 1123 910
60 4866 4203 2965 2538 1958 1582 1123 910
d. 3° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 4578 3985 2850 2452 1904 1545 1103 896
30 4578 3985 2850 2452 1904 1545 1103 896
60 4578 3985 2850 2452 1904 1545 1103 896

e. 4° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 4322 3787 2744 2372 1854 1510 1084 883
30 4322 3787 2744 2372 1854 1510 1084 883
60 4322 3787 2744 2372 1854 1510 1084 883
f. 5° Curve
(kmph) Track 1/500 1/200 1/150 1/100 1/75 1/50 1/40
START 4091 3607 2645 2296 1805 1477 1065 869
30 4091 3607 2645 2296 1805 1477 1065 869
60 4091 3607 2645 2296 1805 1477 1065 869
Note: For complete details refer Chapter -19 of ‘NRD0000572523_Driver Training Manual - WAG12B’

02 - WAG12 - Loco Pilot Handbook - (English)

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02 - WAG12 - Loco Pilot Handbook - (English)

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WAG12 LOCOMOTIVE

WAG12 - Loco Pilot Handbook [1] NRD0000572585

Loco Pilot Handbook - WAG12 [2] NRD0000572585

Loco Pilot Handbook - WAG12 [3] NRD0000572585

Loco Pilot Handbook - WAG12 [5] NRD0000572585

Loco Pilot Handbook - WAG12 [6] NRD0000572585

Loco Pilot Handbook - WAG12 [7] NRD0000572585

Loco Pilot Handbook - WAG12 [8] NRD0000572585

Loco Pilot Handbook - WAG12 [9] NRD0000572585

Figure 1: WAG12 Single Section

4.1. Left Panel

Figure 3: Left Panel

Figure 4: Master Controller

Loco Pilot Handbook - WAG12 [13] NRD0000572585

Figure 5: Brake Gauge

Figure 6: Central Panel-01

Loco Pilot Handbook - WAG12 [15] NRD0000572585

Figure 8 TCMS DDU

Figure 9 Indication Panel

Loco Pilot Handbook - WAG12 [18] NRD0000572585

Figure 10 Line Indicator

Loco Pilot Handbook - WAG12 [19] NRD0000572585

Figure 11 Right Shelf

Figure 12 Pedal Switches

Figure 13 ALP Desk

Loco Pilot Handbook - WAG12 [22] NRD0000572585

Figure 14 CAB Cabinet Right

Loco Pilot Handbook - WAG12 [24] NRD0000572585

Loco Pilot Handbook - WAG12 [25] NRD0000572585

Figure 17: Traction Power Electric Scheme

5.3. Traction Control Unit (TCU)

Loco Pilot Handbook - WAG12 [26] NRD0000572585

Loco Pilot Handbook - WAG12 [27] NRD0000572585

Figure 18:Battery Charger Schematic

Loco Pilot Handbook - WAG12 [28] NRD0000572585

6.1. MASU (Main Air Supply Unit)

Loco Pilot Handbook - WAG12 [29] NRD0000572585

Regenerative Braking Effort

7.1.2. Types of Pneumatic Brakes

Loco Pilot Handbook - WAG12 [30] NRD0000572585

Figure 19: BCM

Loco Pilot Handbook - WAG12 [31] NRD0000572585

Loco Pilot Handbook - WAG12 [32] NRD0000572585

Loco Pilot Handbook - WAG12 [33] NRD0000572585

ii. Direct Brake

iii. Emergency Brake

iv. Parking Brake

Loco Pilot Handbook - WAG12 [34] NRD0000572585

7.4. Different Types of Brake Blending Logics

Loco Pilot Handbook - WAG12 [35] NRD0000572585

Figure 23: Parking Brake Manual release plunger

Loco Pilot Handbook - WAG12 [36] NRD0000572585

Loco Pilot Handbook - WAG12 [37] NRD0000572585

9.2. Loco Shutdown Procedure

Loco Pilot Handbook - WAG12 [38] NRD0000572585

9.3. Cab Change Procedure

9.4. Loco Grounding Procedure

Loco Pilot Handbook - WAG12 [39] NRD0000572585

9.5. Dead Engine Brake Configuration

Loco Pilot Handbook - WAG12 [40] NRD0000572585

9.6. EB Reset Procedure

Loco Pilot Handbook - WAG12 [41] NRD0000572585

9.8. Vigilance Management