8 WHEELER DIESEL ELECRIC TOWER CAR WITH UNDERSLUNG TRANSMISSION. OPERATING & MAINTENANCE MANUAL (2019)

PREFACE

This instruction book covers the operation & maintenance instructions for electric traction

equipment supplied by Compton Greaves Ltd. to Integral Coach Factory, Chennai for DIESEL

ELECTRIC TOWER CAR WITH UNDER SLUNG DUAL POWERPACK & AC/DC

TRANSMISSION SYSTEM for Indian Railways.

The purpose of this instruction manual is to familiarise maintenance personnel with the

procedures for operating and maintaining the electrical equipment.

This manual covers description of electrical circuits, general maintenance and data on control

gear, electrical machines besides other general information. Instructions for auxiliary alternator,

power rectifier are covered in separate manuals.

The instructions contain adequate details/information required for maintenance of equipment.

Nevertheless, it is not practicable to cover all details and every contingency, which is likely to

arise in service. Should any further information be desired or should particular problem arise, the

matter should be referred to: CG POWER AND INDUSTRIAL SOLUTIONS LTD. Industrial

Systems; D-5 Industrial Area, Mandideep, Bhopal - 462 046.

Continuous efforts on improvement in product design may result changes in details, which may

not be covered in this manual. Although efforts are made to furnish all such changes to the user,

it is advisable to consult CG for obtaining necessary assistance.

CG POWER AND INDUSTRIAL SOLUTIONS LTD.

TRACTION MACHINES & SYSTEM DIVISION,

D-5, INDUSTRIAL AREA, MANDIDEEP

BHOPAL - 462 046

POWER PACK ARRANGEMENT

CHAPTER I

INTRODUCTION

This manual covers operation & maintenance instructions of major power & control equipment used in

Broad Gauge Diesel Electric Tower Car with Under slung transmission system (DETC/US). The

equipment meets the requirements of ICF’s spec. No. ICF/M/D/SPEC-300, for supply of complete

electrics of DETC/US. The equipment includes Diesel Engine, Traction Alternator, power rectifier,

traction motors, Auxiliary Alternator, motor switch group cubicle, all protective devices, and instruments

for measurement & indication and auxiliary equipment.

DETC/US is a self-propelled unit used for periodic inspection, patrolling and maintenance of Over Head

Electric Transmission Equipment of Electrified Routes. It is also used for attending sites of break down,

restoration of damaged OHE equipment.

DETC facilitate the breakdown sites by restoring the damaged OHE. It is required to -

a) Reach the breakdown site in shortest possible time,

b) Attend & clear the Traction Over Head Equipment breakdown site,

This whole operation is to be accomplished in shortest possible time with least hindrance to regular rail

traffic.

This is achieved by DETC, with following major facility -

To carry auxiliary equipment to facilitate OHE breakdown.

ii.

Supervisors / attenders seating room and kitchen.

iii.

Installed with high speed Dual Traction Power Pack & its controls.

iv.

Driver desk & control cubicle on either side of the car.

Elevating Platform & Observation Dome.

vi.

Pantograph for testing Over Head Cables.

vii.

Room for OHE testing Equipment & Work shop.

viii.

Tools & tackles to attend / clear the accident site

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

These power packs provide traction power to run the car unit (DETC) at high speeds up to 110 km/h. The

under slung power pack free up the over board floor space for housing supervisory staff & to carry

auxiliary equipment

Each power pack consists of following major components:

Under floor mounted:

•

Diesel engine

•

Traction Alternator

•

Auxiliary Alternator

•

Drive shaft for aux. alternator

•

Exhaust Silencer for diesel engine

•

Water Rising Apparatus for radiator

Equipments installed over board;

•

Control cubicle.

•

Driver's desk.

•

10 KVA capacity Diesel Alternator Unit.

•

Air filters for diesel engine air intake.

•

Hydraulic Oil Tank.

Over the roof

•

Hydro Static Radiator Unit.

•

Elevating platform

•

Pantograph

•

Observation dome

Above equipment with associated accessories are engineered to provide trouble free traction power with

in built safety & protection equipment. The controls are developed to provide regulated traction power to

match the demand from driver's console command while maintaining the safety checks all the time

during traction.

MAINTENANCE MANUAL FOR DETC-US

All the healthy, operation & faults are brought to driver's console as indicating lamps for easy recognition of

sequences happening in the traction system. A fixed time alarm (warning hooter) is also operated to alert the

driver in case of any faulty / warning system activity.

Certain serious system faults not only indicate & warn the driver and also disable the traction power or shut

down the diesel engine depending on the severity of the fault. Under such circumstances, there are certain

"bypass safety" switches provided in the control cubicle. The use of these will enables the driver to run the

traction system for short durations to clear the track for regular traffic.

The bypass safety function is not permitted to use on a regular basis or

for longer periods. Use of bypass safety function for longer periods

could lead to severe damage to the equipment or total failure of the

affected unit connected equipment and severe injury or loss of life,

because the bypass safety function disables systems automatic check

function

User is strictly advised to familiarize about the complete equipment by use of this document provided for the

purpose and follow the driving, operation & maintenance instructions.

The manual contains following information:

System Description

Equipment Description

Circuit Description

Fault Diagnostics

Maintenance Instructions

INTRODUCTION

1.0 PERFORMANCE AND GENERAL DATA

GENERAL DESIGN FEATURES

1. Track Gauge

1676 mm

2. Minimum Radius of Curvature

175 m

3. Maximum Super Elevation

185-mm

4. Maximum Super Elevation Deficiency

100-mm

5. Wheel Arrangement of Power Car

BO-BO(All axles independently Powered)

6. Wheel Diameter

952mm (New), 914.5mm (Half Worn)

877mm (Fully Worn)

7. AXLE Load

20 T (Approx.)

8. Gear Ratio

20/91

9. No. of power packs

Two

10. Input To Traction

2 x 312 HP AT 37°C

2 x 298 HP AT 55°C

11. Diesel Engine type

NTA-855R3 of Cummins

12. Power Transmission

AC / DC Electric

13. Traction Alternator

C1009A1 of CGL

14. Traction Motor

TM2141C of CGL

15. Auxiliary Alternator

8 kW, 122 VDC of KEL

16. Maximum Operating Speed

110 km/h

17. Clearance Above Rail Level

Minimum of 102mm with coaches fully

loaded & wheels in fully worn condition.

18. Reference Site

Ambient = 0 - 55° C

Max. Temperature in sun 70° C

Humidity = 40 to 100 %

Altitude up to 1000 metres above MSL

MAINTENANCE MANUAL FOR DETC-US

INTRODUCTION

2.0 LIST OF ABBREVIATIONS

AAPR1-2

AUXILIARY ALTERNATOR PROVING RELAYS

ASS

LOAD AMMETER SELECTION SWITCH

COR

CUTOUT RELAY

DCS

DRIVER’S CONTROL SWITCH BOX

ECS

ENGINE CONTROL SWITCH

ECR 1-2

ENGINE CONTROL RELAYS

ER 1-2

GOVERNOR CONTROL RELAYS

FC21-22

ENGINE TRIP RELAYS

FLIL

FLASHER LIGHT INDICATION LAMP

FLS

FLASHER LIGHT SWITCH

FOLS

FOG LIGHT SWITCH

HEADLIGHT SWITCH

HLEM

HEADLIGHT EMERGENCY SWITCH

HLS

HAND LAMP SOCKET

IL1

INSTRUMENT LAMPS

LCC

LOAD & SPEED CONTROL SYSTEM

LED

LED INDICATION PANEL

LRR1-2

LOCAL RESET RELAYS

MASTER CONTROLLER

MLS

MARKER LIGHT SWITCH

R11-12

HIGH COOLING WATER TEMP MONITORING RELAYS

R21-22

LOW HYDRAULIC OIL LEVEL MONITORING RELAYS

R41-42

LOW LUBRICATING OIL PRESSURE MONITORING RELAYS

R51-52

ENGINE OVERSPEED MONITORING RELAYS

R61-62

LOW COOLING WATER LEVEL MONITORING RELAYS

R81-82

LOCAL ENGINE ON/OFF RELAYS

R91-92

REMOTE ENGINE ON/OFF RELAYS

RCFR1-2

RECTIFIER COOLING FAILURE RELAY

REG

DC/DC CONVERTER

RR1-2

READY TO START RELAYS

S11-S12

ENGINE ON RELAYS

MAINTENANCE MANUAL FOR DETC-US

INTRODUCTION

SLS

SEARCH LIGHT SWITCH

SR1-2

SAFETY RELAYS

TLS

TAIL LIGHT SWITCH

GFR

GROUND FAULT RELAY

GRCO

GROUND RELAY CUT-OUT SWITCH

MCS1-2

MOTOR CUT-OUT SWITCHES

BIS 110V

BATTERY ISOLATING SWITCH 110VDC

BIS 24V

BATTERY ISOLATING SWITCH 24VDC

RCD1-3

REVERSE CURRENT DIODES

AFP1-3

AUXILIARY FUSE PANELS

EQUIPMENT GOVERNOR BYPASS SWITCH

BPCG

BRAKE PRESSURE CONTROL GOVERNOR BYPASS SWITCH

PBG

PARKING BRAKE GOVERNOR BYPASS SWITCH

AFR1-2

AIR FLOW RELAYS BYPASS SWITCHES

FLS1-CAB

FLUORESCENT LAMP SWITCH-1 CAB

FLS2-CAB

FLUORESCENT LAMP SWITCH-2 CAB

CLS

CENTRE LIGHT SWITCH

FS1-CAB

FAN-1 SWITCH CAB

FS2-CAB

FAN-2 SWITCH CAB

VS1

VOLTMETER (0-150VDC) SWITCH

VS2

VOLTMETER (0-50VDC) SWITCH

S2-3

BATTERY CHARGING LAMP SWITCH

LRS1-2

ENGINE LOCAL/REMOTE OPERATION SELECTION SWITCHES

LOP1-2

ENGINE LUBRICATING OIL PRESSURE GAUGES

LOT1-2

ENGINE LUBRICATING TEMPERATURE GAUGES

WT1-2

ENGINE WATER TEMPERATURE GAUGES

RPM1-2

ENGINE SPEED METERS

BCA1-2

BATTERY CHARGING INDICATION AMMETERS

HM1-2

HOUR METERS FOR ENGINES

BIL1-2

BATTERY CHARGING INDICATION LAMP

TR11,21

DIESEL ENGINE CRANKING SAFETY TIMERS

TR12,22

LUBRICATING OIL PRESSURE SWITCH BYPASS TIMERS

BD1-2

BLOCKING DIODES

MAINTENANCE MANUAL FOR DETC-US

INTRODUCTION

WLI1-2

WATER LEVEL INDICATION GAUGES

HOLI1-2

HYDRAULIC OIL LEVEL INDICATION GAUGES

MCBs

110 VDC

GOV-1 SPLY

GOVERNOR - 1 SUPPLY MCB 15A

GOV-2 SPLY

GOVERNOR - 2 SUPPLY MCB 15A

GOV-1 CTRL

GOVERNOR - 1 CONTROL MCB 5A

GOV-2 CTRL

GOVERNOR - 2 CONTROL MCB 5A

AAPR1

AUX ALTERNATOR-1 PROVING RELAY MCB 5A

AAPR2

AUX ALTERNATOR-2 PROVING RELAY MCB 5A

BM1

BLOWER MOTOR-1 MCB 30A

BM2

BLOWER MOTOR-2 MCB 30A

HEADLIGHT MCB 10A

L+

LIGHTS MCB 10A

EM+

EMERGENCY LIGHTS MCB 10A

VM1

VOLTMETER (0-150VDC) 5A

MARKER LIGHT MCB 5A

TL&FL

TAIL LIGHT & FLASHER LIGHT MCB 5A

FL CAB

FLUORESCENT LAMP CABIN MCB 5A

FL&CL CAB

FLUORESCENT LAMP & CENTRE LIGHT CAB MCB 5A

FAN-1 CAB

FAN-1 CAB MCB 5A

FAN-2 CAB

FAN-2 CAB MCB 5A

SYS CTRL

SYSTEM CONTROL MCB 30A

CTRL

CONTROL MCB 15A

EXC CTRL

EXCITATION CONTROL MCB 10A

ENG CTRL

ENGINE CNTROL MCB 5A

COMP UL

COMPRESSOR UNLOADER MCB

LAMP TEST

LED INDICATIONS LAMP TEST MCB 5A

ALT. EXC

ALTERNATOR EXCITATION MCB 5A

RTS

READY TO START MCB 5A

FAULT IND

FAULT INDICATION MCB

PARKING BRAKE MCB 5A

MAINTENANCE MANUAL FOR DETC-US

INTRODUCTION

24 VDC

ENG-1 PROT

ENGINE -1 PROTECTION MCB 15A

ENG-1 SAF-1

ENGINE-1 SAFETY-1 MCB 5A

ENG-1 SAF-2

ENGINE-1 SAFETY-2 MCB

GOV-1 SPLY

GOVERNOR-1 SUPPLY MCB 5A

ENG-1 GAUGE-

ENGINE-1 GAUGE MCB 5A

ENG-2 PROT

ENGINE -2 PROTECTION MCB 15A

ENG-2 SAF-1

ENGINE-2 SAFETY-1 MCB

ENG-2 SAF-2

ENGINE-2 SAFETY-2 MCB 5A

GOV-2 SPLY

GOVERNOR-2 SUPPLY MCB 5A

ENG-2 GAUGE-

ENGINE-2 GAUGE MCB 5A

SEARCH LIGHT MCB 5A

FOL

FOG LIGHT MCB 5A

VM2

VOLTMETER (0-50VDC) MCB 5A

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

CHAPTER II

POWER PACK ARRANGEMENT

1. Introduction

The Diesel Electric Tower Car (DETC) is equipped with two set of under slung mounted Power packs.

Each Power pack consists of one under slung Engine (NTA-855 R), one Traction Alternator - 230 kW

(C1009A1) & one auxiliary alternator connected by a cardan shaft and flexible coupling. The car consists

of two bogies (4 axles), each axle is powered by the traction motor. The engine flywheel is directly

coupled with Traction alternator with the help of flex plates. These flex plate couplings are used to

compensate Axial, Angular and radial displacement of connected machines. Flex plates are provided to

absorb shocks on torque, by which it will minimize vibration, and transmits the power. The output power

of alternator is rectified to DC & fed to the traction motors.

These two Power pack units are synchronized & regulated to provide total traction power as a single

system when controlled from either cabin. Two cabins one on each end is provided for the purpose.

Provision also exists to isolate any of the power packs and run the vehicle. Driver’s desk mainly consists

of controls for Engine, Alternator and Pneumatic Brakes, Indication lamps, Gauges, switches, speed-

time-distance recorder etc., which will be functioning in conjunction with control cubicles. The complete

power pack is attached beneath the under frame.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

2. Major components of power pack

2.1 Engine

The model of the engine used in the equipment is NTA - 855R manufactured by M/s CIL, Pune. It is a

horizontal version engine suitable for under slung mounting. The specification of the engine is provided

in the specification section. This engine is supported at three points, viz, one support at front end

(vibration damper side) and two supports at rear end (Flywheel side). All the three supports are bracket

mounted with Anti vibration units.

2.2 Traction Alternator

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

The alternator used in the car is C1009A1, manufactured by M/s CG, Bhopal. This alternator caters to

supply electrical power for main Traction. It is under slung mounted with suitable brackets and is driven

from engine directly through the flex plates. The specification of the alternator is provided in the

specification section. This alternator is supported on four points. All the four supports are bracket

mounted, consisting of two Main Brackets which positively holds both the coupled engine and alternator

together. These brackets rest on four Anti vibration units. The AVM’s are pre-compressed in the

assembly position. The mounting fasteners for these AVM are torque tightened and locked with split pin.

2.3 Flexible Coupling

In this power pack, the flexible coupling is used to connect the engine to auxiliary alternator through a

XLO cardan shaft. This coupling is manufactured by M/s.Vulkan. This coupling is selected to suit

maximum torque & speed of Auxiliary Alternator. These highly flexible couplings are guided radially &

axially. All the transmitting parts are arranged without clearance so that no wear will occur during the

rotation. The rubber element is suitable for temperature between

-40°C & +90°C & is internally

vulcanized to the ring. The permissible angular coupling displacement is 0.5°.

2.4 Auxiliary Alternator

Two 8 KW, 110V DC. Brush less, foot mounted Auxiliary Alternator is provided in the DETC, one each

for power pack. These alternators caters to supply electrical power for Battery charging & Control source

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

Supply, coach lights, fans, cab & head lights, tail lights, flasher lights etc. It is under slung mounted with

suitable brackets and is driven from engine vibration damper through a cardan shaft.

A static regulator cum rectifier unit rectifies the three-phase AC alternator output. A constant voltage of

122 Volts DC (65% regulates DC output at a maximum load current of 65 Amps @ idle engine speed of

700 rpm) is utilized.

2.5 Cardan Shaft

Cardan shaft is used to connect the flexible coupling mounted over the diesel engine to the coupling

flange mounted over the auxiliary alternator.

Maintenance and service related procedure for cardan shaft is explained in detail in Annexure 1 of this

document.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

3. Power Pack Mounting

The Engine and Alternator (with the flex plates) are coupled together and positively held by two main

brackets at three points on either side of engine & alternator. Along with this, the auxiliary alternator end

of the Engine is held by a ‘Z’ Bracket. This whole power pack assembly has five suspending points,

which rests over anti vibration mountings, held rigidly by vertical brackets welded to under frame

structural members. This arrangement has low vibration transmissibility to the under frame. For details of

mounting, refer power pack drawing.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

6. RADIATOR MOUNTING & PIPING ARRANGEMENT

Radiator unit is mounted on roof of the coach. A single radiator unit is provided for both the engines. This

radiator unit is mounted on AVM to damp vibrations. The sucker type fan is used in the system; it sucks the

air through the radiator core and blows to the atmosphere to cool the water circulating inside core. The fans

are driven by hydro static motors.

Pipe routings from both the engine passes beneath the under frame at intricate conditions, passing through

the

floor

(suitable

cutouts

are

provided)

and

connects

the

radiator.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

The radiator unit has following pipe connections:

Inlet

Outlet

Vent

Over flow

By pass line

The hot water that is pumped out from the engine is connected to inlet port of radiator. The hot water enters

from the top most point of the core. Hot water flows through the core, gets cooled and comes out through

outlet pipe at bottom most point of the core. This outlet pipe from radiator unit is connected to water inlet

port of Engine and cools the engine, water jackets after cooler, compressor and exhaust manifold while

circulating inside the engine. Water is pumped to the Thermostat housing on the engine; this senses the water

temperature in the system and controls the water flow to the radiator.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

7. HYDRAULIC TANK AND HYDRAULIC CIRCUIT

A single common hydraulic tank is provided for both engine’s Cooling system, it is located inside the coach.

This tank is equipped with filling cap, sight glass, manifold blocks, oil cooler, return filter ect., on it.

The system has radiator fans driven at variable speeds depending upon the radiator water temperature. It is a

Hydrostatic system in which two fans are driven by independent hydraulic motors from variable flow

delivered by a respective engine driven hydraulic pump. Independent Thermatic valves are mounted on the

water manifold block at the each engine water outlet, where the hot water exits for onward routing to the

radiator.

The Thermatic valve senses the temperature and regulates pressure on the pump's flow control port. This

action affects the hydraulic pump's output flow rate according to the water temperature. It increases with

increase in water temperature. The variable flow connected to motor regulates the variable speed of motor

according to the water temperature. Thus, the entire hydrostatic fan drive system forms a closed loop control

system.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

7.1 Hydraulic pump

A variable displacement pump is mounted on the engine and it is directly driven by engine gear drive

from gear case cover. This hydraulic pump has swash-plate design.

Flow of hydraulic oil is proportional to drive speed required. Fluid Displacement is infinitely

variable by adjustment of swash-plate angle. By adjusting the position of swash-plate, it is possible

to smoothly vary the flow. It has a pilot control valve, which controls the position of swash-plate,

which in turn regulates delivery of fluid flow of the pump after receiving feedback from remote

position. Thermatic valve forms the remote sensing & feedback element for the control.

7.1.1 Working of Variable displacement pump:

1. Hydraulic pump has multiple cylinders whose movements are obtained from rotation of drive shaft.

2. Cylinders suck & deliver liquid by their reciprocating motion proportional to stroke length

(displacement) of the cylinders.

3. These strokes are directly controlled by inclination of the swash plate whose position is governed by

Pilot control valve

4. Pilot control valve receives feed back from remote control (Thermatic valve).

5. Remote control valve is also called as Thermal Relief / Thermatic control valve (as its feedback is

translated on the basis of rise in engine coolant temperature).

6. Hydraulic pump has a leakage return line back to hydraulic tank.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

7.2 Hydraulic motor

The Hydraulic motor is used in this system is of bent axis design with fixed displacement of

cylinders. The pressurized oil, which is pumped from hydraulic pump, routed as inlet to the motor &

develops the torque and speed of motor. Hydraulic motor rotational speed is directly proportional to

flow of the pump; and pressure of the liquid is directly proportional to the torque developed by the

shaft. Hydraulic motor also has a return line flowing freely back to tank. Supply & return lines to the

motor are routed through a manifold block.

7.3 Pressure relief valve

Pressure relief valve is always connected in main delivery line of hydraulic pump (pressure line) to

limit the system pressure to set value.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

7.3.1 Operation of Pressure Relief Valve:

1. System pressure acts on the main spool.

2. At the same time pressure acts via a pilot line fitted with jets, on pilot poppet.

3. If the system pressure exceeds the value set with the spring, the pilot poppet opens and pilot oil is

allowed to flow back to the tank.

4. The jet combination causes sufficient pressure drop across the main spool.

5. The main spool is lifted from its seat and opens the pressure line connection to tank while operating

pressure is maintained, as desired.

6. The spring tension on poppet valve can be adjusted by setting knob to any desired pressure, from 0-

250 bar (set pressure around 160 to 180 bar).

7. The pilot control port should be connected to receive flow for pilot poppet valve.

7.4 Thermal Relief / Thermatic Valve:

Thermatic valve is a direct operated relief valve of poppet-seat design, where the nominal pressure is

proportional to the temperature sensing with in set limits. It is mounted on engine's water outlet

connection. It senses the temperature of engine water outlet and functions.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

Main elements of Thermatic valve are:

1. Thermal Element

2. Control Spring

3. Reset Spring

4. Valve Housing

5. Valve Seat

6. Poppet

P. Pressure port

T. Tank return port

7.4.1 Operation of Thermatic Valve:

1. When Engine outlet water temperature is below 82°C, hydraulic oil from hydraulic pump pilot valve

freely passes through the pressure port 'P' of valve assembly to tank through Tank return port 'T'.

2. When temperature rises above 82°C, thermal element 'a' expands and starts moving its plunger

against control spring 'b'.

3. This moves poppet ' f ' towards valve seat 'e' and creates restriction to incoming flow and generates

backpressure.

4. This backpressure is treated as feedback by pilot control valve, which now starts controlling

inclination of swash plate for more delivery coming out of hydraulic pump.

5. When the temperature drops below 82°C at the thermal element 'a', control spring 'b' is released and

reset spring 'c' allows pressurized hydraulic oil to drain to tank.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

7.5 Manifold block

Manifold block is used primarily for two purposes

1. Simplify hydraulic circuit.

2. Reduce number of components in the system.

Manifold block is a solid block of steel which houses a several non-return valves (check valves),

Pressure relief valves connected to achieve function by internal passages of the block. It facilitates

hose connections to various points in the system.

All of them contain cartridge type check valves. Care to be taken for cleanliness of oil because a

small dirt or foreign material entrapped in their seating area renders these valves non-functioning.

7.6 Suction Strainer

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

1. Separate Strainers are fitted inside the hydraulic tank one each in the suction line and vent line of

pump.

2. Precautions be taken to avoid ingress of dirt particles in the hydraulic tank during initial filling or

scheduled maintenance of the hydraulic system.

3. Suction strainer can remove particles up to 150 microns.

4. The strainer protects pump from the entry of harmful solid particles.

7.7 Return line filter

1. Return Line filter is mounted directly on hydraulic tank.

2. It cleans hydraulic oil that may get contaminated due to poor handling or undesirable entry of dust in

the system or wear and tear of system components.

3. Return Line filter can filter particles up to 10 microns.

4. There is a container around the filter for the purpose of trapping dirt. When element is removed, this

container is drawn out with it, so that any residual dirt is not allowed to flow back into the tank.

5. These filters are fitted with restriction indicator on the top of its head which pops up showing red

signal whenever pressure drop across filter element is above 2.5 bar.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

8.0

FUEL LINE PIPING ARRANGEMENT

A common under slung fuel tank is provided to cater both the power pack of main traction. Each power pack

draws fuel from the fuel tank through an independent piping system. Each line consists of a shut off valve to

isolate the supply whenever required for any maintenance. Suspended particles in the fuel settles at the

bottom of the tank due to gravity. From shut off valve further piping is done via a strainer, water separator,

fuel filter and finally to fuel actuator on the engine. These connections are equipped with flexible hoses. Fuel

filter will filter any foreign particles, waste etc. & thus obtained clean fuel is routed by a hose to Fuel pump

mounted on the engine.

Excess fuel expelled by the engine is returned back to the fuel tank connected by a hose and metal pipes

direct to the common under slung fuel tank. (Fuel return point is positioned at bottom of engine).

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

WATER RISING APPARATUS

Engine block, radiator unit and connecting piping system needs to be filled with coolant prior to starting the

power pack and also may require periodical topping up. The Radiator unit is mounted over the coach roof.

Climbing over the roof for periodical topping up of the radiator with coolant is a laborious, time consuming

and also poses high voltage power line hazard. A pneumatically operated water rising apparatus (WRA) is

mounted under slung to ease out the filling / topping up of coolant. A stainless steel tank comprising a

coolant capacity of 100 liters provided.

A pneumatic line with a limiting valve set at 0.5 to 0.8 kg/cm², a non return valve & insolating valve is

provided before connecting to tank. When the radiator cooling system required to topping up, the existing

pneumatic system’s pressured air is allowed inside the tank and in turn this will pressurizes the water to get

out of the tank, feeding the cold water line of the radiator through an independent isolating cock and thus

tops up the radiator. There are two independent isolating valves are provided in the water lines, these are

required to select or open depends on the required engine cooling system to be topped up. The check valve

provided in the pneumatic line prevents the reverse entry of coolant water into the pneumatic line. During

each top up the shut off valve provided in pneumatic line to be opened first & further isolating valve

provided in water like to be opened depends on the required engine to be topped up. After completing the

process both isolating valves to be closed compulsorily.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

10. PANEL RESISTOR BOX MOUNTING ARRANGEMENT

One number of panel resister box houses 6 resistors in a box. This box mounted under slung, supports are

taken from the under frame structure as shown in the figure.

The box housed excitation resistor panels for both the alternators. One set of panel consists of 3 resistors

each of 36 Ohms, 300 W. Theses 3 resistors are connected in parallel making the equivalent resistance of the

circuit 12 ohms.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

12. MAINTENANCE SCHEDULE FOR DETC POWERPACK

Diesel

Sl.

Engine

Parts

Period

Maintenance Step

Remarks

No.

running /

stopped

General

Daily

Stopped

• Check visually all equipment for

Correct if

any

Examination

visible defects, loose bolt & nuts,

defects

leakages, missing parts etc.

Waste jute should

• Check lube oils, fuel, cooling

never be used.

water and air system for leakage

and rectify if necessary.

• Clean all equipment with lintel

cloth.

• Clean the vehicle thoroughly with

a jet of water and scrub down all

dirt and wash again.

Diesel

Daily

Stopped

Refer Diesel engine part.

Engine

Cardan Shaft

Daily

Stopped

Check Cardan Shaft for any visual

damage.

Alternators

Daily

Running

Check for any abnormal noise or over

heating.

Diesel

Daily

Running

Refer Diesel engine part.

Engine

Gauges

Daily

Running

Check the Gauge & instrument

instrument

operations

Aux.

Daily

Running

Check if alternator is charging the

Alternator

battery.

MAINTENANCE MANUAL FOR DETC-US

POWER PACK ARRANGEMENT

NOTES

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MAINTENANCE MANUAL FOR DETC-US

CIRCUIT DESCRIPTION

CHAPTER III

CIRCUIT DESCRIPTION

1. POWER CIRCUITRY

1.1 SYSTEM DESCRIPTION

A self propelled Diesel Electric Tower Car (DETC) is used for periodical inspection, patrolling and

maintenance of traction overhead equipment. It is also used for attending sites of breakdown, restoration of

damaged OHE equipment. This can also be used to erect small lengths of catenary and contact wire by way

of repairs of damaged OHE.

The power equipment of Diesel Electric Tower Car comprises of two power packs, two separate alternators

two power rectifiers & four traction motors to meet all operating conditions of Diesel Electric Tower Car.

The power pack consists of a Diesel Engine of Cummins India make type NTA-855R developing a power of

340 HP @ 1800 RPM continuously and a Brushless CGL make traction alternator type C1009A1, matching

rectifier, exciter and rotating diode set capable of developing around 310 HP input to traction (by each power

pack).

The Traction Alternator is a single bearing type and compatible for coupling with Cummins Diesel Engine

mentioned above. The exciter field current is limited to 6 amps during entire working range of DETC.

The main rectifiers are suitable for over board mounting and are used for rectifying the output of traction

alternators. The power rectifier assembly is suitable for operation under one bridge failure condition. It has

built-in blower arrangement with fan failure protection.

The traction motors (Type TM2141C) are suitable for mounting on DEMU bogie of Indian Railways. The

Traction Motor is self-cooled type and complies with requirements of IEC - 60349-1. The traction motor has

moulded inter-pole & main-pole coils bonded with poles. The four traction motors in 4P combination will

operate in full field only, utilising full capability of traction alternator. Avoidance of going into a weak field

is beneficial from operation point of view, especially utilisation of available adhesion. In addition, such a

combination provides following advantages:

MAINTENANCE MANUAL FOR DETC-US

CIRCUIT DESCRIPTION

Reduction in control equipment

Reduction in maintenance cost

Avoiding transition jerks and loss of power normally encountered in transition

An electronic diesel engine speed governing, alternator exciter excitation and load control module, type

LCC107B of GAC make, control the diesel engine speed & excitation of the Traction Alternator. The

experience shows that adoption of such a system enables utilisation of maximum diesel engine power on rail,

thus optimally utilising the installed power.

The diesel engine speed will be regulated through the 8 pre-selected steps (notches). Driver can operate the

DETC at any notch depending upon speed restrictions / desired.

2. AUXILIARY CIRCUITRY

Two 8 kW Auxiliary Brushless Alternator rectifier and regulator system, supply 122±5% Volts DC for

Auxiliaries. The alternator is self-cooled and is directly driven from Diesel Engine shaft extension through

cardon shaft and flexible coupling. The output of the rectifier regulator is 125V ± 5%. The regulated

voltage is available from no load to full load and idle engine RPM to maximum engine RPM.

A 110V DC lead acid battery (Not in CGL Scope of Supply) will float against the auxiliary power and will

thus remain in charged condition during normal operation. This battery can supply to fans, lighting and

control loads.

PERFORMANCE OF THE SYSTEM

Performance obtainable using two 340 HP diesel engines at 8th notch & 914 mm half worn wheels and 20/91

gear ratio, two traction motors fed from a power pack in Permanent Parallel combination (operating in full

field only) is shown on curve No. 50702001.

A maximum speed of 110 Km/h is obtainable with the power equipment proposed by us and meets the

following performance requirements as specified in ICF specification no ICF/M/D/SPEC - 300. In addition,

use of our equipment gives following performance capability.

DETC can carry 12 tons of payload without any additional equipment.

MAINTENANCE MANUAL FOR DETC-US

CIRCUIT DESCRIPTION

Period of continuous running for 4 hours at 100 kph on general tangent track followed by frequent to

& fro movement at walking speed for 1.5 hours.

Period of continuous running at 40 kph on up or down gradient of 1 in 60 for 4 hours to be followed

by frequent to and fro movement at 5 kph for 1.5 hours on the same gradient.

When running as a light vehicle, the DETC shall be capable of running at a speed of

110 kph on level track.

26 kph on a 1 in 33 up gradient

The DETC will be able to start and haul a trailing load of 60 tons on up gradient of 1 in 60.

When the DETC hauling a trailing load of 60 tons on 1 in 60 up gradient, the vehicle can reach a

maximum speed of 40 kph.

3. CONTROL CIRCUITRY

3.1 110 V DC SUPPLY

110 VDC supply is available in the coach from 110 VDC, 120 A-H battery. This supply is available to

control circuit in all positions of Battery Isolating Switch (BIS-110V). During OFF position, we can charge

the battery from external source through Battery charging socket. Two Nos. 8 kW Auxiliary Alternators

supply 120 ± 5% VDC to the system for control system operation, supply to electromagnetic equipment,

electropneumatic equipment, train lighting, Headlight, battery charging, Rectifier Blower Motors, Excitation

Control, Governor Supply etc. RCD1, RCD2 and RCD3 are not allowed battery to discharge and allow to

charge the battery when both the Auxiliary Alternators / either of the Auxiliary Alternators are in working

condition. Supply to both the Rectifier Blowers will be available from Auxiliary Alternators when both of

them are in working condition or even when one of the Auxiliary Alternators is working. During normal

working condition the 110 VDC Battery isolating switch shall be in “AA-1 & 2 IN CKT” position.

3.2 24 V DC SUPPLY

24 VDC Supply is available in the coach from 24 VDC battery. 20 A Diesel Engine mounted Battery

Charging Alternator (BCA) is used for charging the battery, supply to control circuit, electromagnetic

equipment, auxiliary equipment etc. This battery is isolated from the circuit when the battery is in OFF

position. When Diesel Engines are running, supply shall be available from BCA and corresponding charging

MAINTENANCE MANUAL FOR DETC-US

8 WHEELER DIESEL ELECRIC TOWER CAR WITH UNDERSLUNG TRANSMISSION. OPERATING & MAINTENANCE MANUAL (2019) - page 1