FOR LOCO PILOTS

March 2009

Prepared by E V ELDO, SSE/ELEC/WDP4.

CONTACT NO - 9731666463

Introduction
Diesel Loco Shed Krishnarajapuram is one of the major sheds in Indian
Railway. This is the first shed in Indian Railways to maintain WDP4 with
WDM2 locomotives. This booklet is an effort to help the loco pilots when
they are driving WDP4 locomotives. WDP4 locos have world class
microprocessor technology. Other than handling the loco, the Loco
pilots should have thorough knowledge about the working of loco motive
and trouble shooting skills. The crew messages and fault archive gave
almost all problems in the loco. The self test, computer recycling
procedures, traction cutout and lock wheel detec will help the crew to
solve problem in en-route.
The loco pilots can use this trouble shooting tips to rectify the fault and
work further. If the fault cant be rectified, please contact the Helpline
number available in the locomotive cabin door. Check the crew
messages in the display panel and locate the fault code and inform.

Before opening any of the cabin door, ensure that the isolation switch is
in Isolate position, TH in Idle, RH in neutral and MGV is below 20 volts.
A locomotive can be failed, but avoiding a failure is the service to the
passengers and to the nation.
Serve the nation when there is a chance.
Please do not remove the instruction sheets provided in the driver cabin

CONTENTS
1. GENERAL.
2. MAJOR COMPONENT LOCATIONS.
3. ENGINE SHUT DOWN PROCEDURE.
4. ENGINE STARTING PROCEDURE.
5. WDP4 TIPS.
6. COMMON FAULTS AND REMEDIAL ACTIONS.
7. AIR BRAKE SELF TEST PROCEDURE.
8. PROCEDURE FOR ATTACHING & CHARGING THE FORMATION.
9. PROCEDURE FOR DEAD LOCO MOVEMENT.
10.PROCEDURES FOR CONTROL STAND CHANGING.
11.EM 2000 FAULT CODE AND REMEDIAL ACTIONS.
12.AIRBRAKE FAULT CODE AND REMEDIAL ACTIONS.

13.REMOVAL OF THE BRAKE CONTROLLER CONNECTOR WHEN CONTROLLER

FAILURE.
14.TCC RECYCLING PROCEDURE.
15.FAULT CODES NOT AFFECTING THE LOCO WORKING
16.SOME ONLINE SHORTCUTS.
17.HELPLINE.

1. GENERAL

a. ECC1 - Electrical control cabinet -1 in the Driver Cabin where EM2000 is located
with display. High voltage is available inside the cabinet. EM 2000 is the Main
Computer (Microprocessor) in the loco.
b. ECC2- This Electrical Cabinet is in the under frame between Fuel tank and rear
truck. Radar is mounted on this. All circuits and contactors related to cranking,
battery charging is located inside this. High voltage is available inside ECC2.
c. ECC3 -The cabinet in the side of compressor room where circuit and contactors
related to radiator fan and MRPT sensor is located. This cabinet is also called AC
cabinet (CA voltage). No high voltage available in this cabin.
d. TCC1-(TRACTION CONTROL CABINET) .The electrical cabinet next to ECC1 towards
engine side is TCC1 (below DB grids).
e. TCC2- The electrical cabinet is in between TCC1 and TA.TCC1 and TCC2 convert
rectified traction alternator output in to 3 phase AC, which is given to traction

motors. In new locos fitted with IGBT these two cabinets are made in box.
Accessibility to TCC1 andTCC2 is with a special key only and it is fully closed.
f. CCB - (Computer Controlled Brake system). This cabinet is below the front lookout
glass in driver cabin. This cabinet is accessed from the driver cabin with two wing
nut fitted doors. High voltage is not available inside the cabinet. The air brake
computer system is placed inside the rectangular shaped black colored box, which
have a front door fixed with 8 screws. A glass window is provided in the front
cover to check the airbrake fault codes.
g. TA-Traction Alternator
h. CA- Companion Alternator. Both TA and CA are inside the TA unit along with TA
rectifier.
i. TE METER-Tractive effort meter, in the console showing the power going to
traction motor.
j. EPD-Engine protection device (Low water pressure and low crankcase pressure) is
below the lay shaft in Governor Room.
k. BCV- Brake Control Valve in both console
l. Clean room-The TA room is also called clean room. TM blower, inertial filter
blower, TCC blower, Radar air blow magnet valve and crow bar resister are inside
this room. Air for turbo, compressor, TM and TA cooling and air for ECC cabinets
are taken from this room.

2. MAJOR COMPONENT LOCATIONS

1. Nose compartment outside (short hood)
Sander magnet valve, HLPR, head light, flasher light, marker lamp, pneumatic
valves of airbrake, Terminal board-TB18.
2. Nose compartment inside Driver cabin
Air brake computer system (CCB), transducers of BP,MR and BC, dead engine
cutout coc, airbrake power supply(VCU),passenger/goods valve and switch, CCB
cooling fans, air brake magnet valves.
3. Short hood console (console1)
Master controller, brake controller valve, LT switch, head light switches, push
buttons for sand and horn, toggle switches for cab light, cab fan, gauge light,
flasher light, gauge light dimmer, Attender call bell push button, alerter reset
button, alerter warning lamp, airbrake gauges, speedometer, TE meter, indication
panel, wiper control valves, air brake emergency valve, resistors for dynamic
brake and gauge lights, Couplers-543A, 543B, 543C, 543D, 544A,
4. Long hood console (console2)
Master controller, brake controller valve, LT switch, head light switches, push
buttons for sand and horn, toggle switches for cab light, cab fan, gauge light,
flasher light, gauge light dimmer, attender call bell push button, alerter reset

button, alerter warning lamp, airbrake gauges, speedometer, TE meter, indication

panel, wiper control valves, air brake emergency valve, Dynamic brake Control
switch, engine run switch, GF switch, FP/CONT switch, MU shutdown switch,
Electrical Terminal Boards-44A,43A,43B,43C,43D and 43E, Alarm bell, Resistors for
dynamic brake and gauge lights.
5. Driver cabin
Cab fan, SH horn COC, cab lights, viper motors, additional horns, FP gauge.
6. ECC1
Bottom door
a. Event r recorder, GFC, GFD, DCL contactor and SCR assembly.
Center door
b. B1, B2, B3, B4 DB Contactors, Power chasis consist of PRG, PSM300,
PSM310, PSM320, MODULES -DVR, ASC, TLF, FCD, FCF, EM 2000 Computer
consists of COM305, CPM, ADA, DIO1, DIO2, and DIO3.
Top door
c. EM 2000 Display, Engine control panel, circuit breaker panel.
7. Engine control panel

a. Isolation switch, EFCO, Fuel prime/start switch, classification switch,

battery charging ammeter, alerter alarm, DB cutout switch, Blended brake
cutout switch, External light switch, Maintenance room switch.
8. Inside ECC1 behind ECP panel
a. HLPR
Dim,reagfd,FLR,PD1,PD2,PD3,PD3,CMU1,CMU2,CM3,DIP30,DIP31,DIP32
9. Inside ECC1 behind Display panel
a. Barometer, relays-DBGR, CRL, TEL, FLR, GBM,AR, MCB, FPR, SDR, BWR,
PCR, SPR1, VPC, EFCO, TLPR, SPR2, WL,DIODES
10.Inside ECC1 behind Circuit Breaker panel
a. DBGR, GR, REVDCL, VDCL
11.ECC1 BACK PANEL
a. TCC1SS,TCC2SS, GTO1PS, GTO2PS, Signal distribution board, FC signal
distribution board,3G2A connector, MU connectors, MUTB, TCC and GRID
current transducers.
12.TCC
TCC1, TCC2, TCC blower, Dynacell filter, DB Grids, DB blower motors, X plugs.
13.TA Room (Clean room)

TA.TM BLOWER, inertial filter motor, TCC Compt blower, Radar blower magnet
valve, crow bar resistor, Dynacell filter, Air intake panel filter, Turbo air intake
baggy filter, Battery charging shunt, Aspirator.
14.Turbo room
Turbo, After cooler, AUX GEN, TA BLOWER, TPU, EPU, Starter motor gears, CA
connections.
15.Power pack
Lube oil level dip stick, turbo soak back pump, AUG drive shaft, Starter motors
16.Governor room
Hand brake, Water level indicator, Fuel filter indicator, Water filling cap, lube oil
strainer, Woodward governor, low water pressure detec, crank case vacuum
pressure detec, OST, lay shaft, fuel oil return sight glass, LLOB, cooling water
drain COC, water pump, lube oil pump.
17.Compressor room
Compressor, MVCC, Magnet valve for sander, Magnet valve for horn, Magnet valve
for MR auto drain, ETP1, ETP2, ELWS, FPM, MRPT COC, Fuel oil drain valve, Fuel oil
air release valve, Fuel oil filter, Lube oil filter, Expansion tank, Lube oil cooler ,lube
oil filter indicator.
18.ECC3

Radiator fan contactor full speed(FCF1A,FCF1B,FCF2A,FCF2B) and half

speed(FCS1,FCS2),Radiator fan fuses or radiator fan circuit breaker, MRPT sensor,
DIP80,
CMU4,Couplers-823A,823B,823C,823D,833A,83B,833C,833D,Terminal
boards TB83A,TB83B,TB83C.
19.Radiator room
Radiator fan1, Radiator fan 2, Air compressor air intake filter and cooling coil.
20.LONG HOOD
Head light, Flasher light, Marker light, Platform light, HLPR, Flasher Resistor,
Terminal Board-TB-27.
21.Under frame
a. ECC2- ST, STA, AUX GEN Breaker, Battery charging assembly, L456 inductor,
Filter, Radar, Terminal boards TB61A, TB62A.
b. Truck 1-Traction motor 1and 2, Speed sensor1 and 2, Temperature sensor 1
and 2.vertical and horizontal dampers.
c. Truck2 - Traction motor 3and 4, Speed sensor3 and 4, Temperature sensor 3
and 4. vertical and horizontal dampers.
d. Other items - Battery, Radar, Air drier, MR auto drain valve, BP COC, MREQ
COC, BCEQ COC, BC COC, Fuel tank and Fuel gauge.

3. ENGINE SHUT DOWN PROCEDURE

10

1.
2.
3.
4.
5.
6.

Put the REVERSER handle to centre position and remove REVERSER handle.
Put ENGINE RUN switch and GF switch to OFF position.
Put ISOLATION switch to ISOLATE position.
Apply HAND BRAKE and SKIDS.
Press EMERGENCY FUEL CUT OFF switch till engine gets shut down.
Put OFF all WHITE and BLACK labeled breakers EXCEPT YELLOW labeled TURBO and
COMPUTETR CONTROL breakers.
7. PUT OFF BATTERY KNIFE switch. Apply hand brake.
8. Enter time and date of loco shutdown in engine log book.

4. ENGINE STARTING PROCEDURE

1. Check time and date of loco shut down from the engine logbook. If the loco has been
shut down for more than 48 hours, DO NOT START THE ENGINE and contact loco shed
for advice.
2. Ensure that in breaker panel all the breakers (white, black and yellow) are in OFF
position and ISOLATION switch is in ISOLATE position. If not then, do so.
3. Put ON BATTERY KNIFE switch.
4. Put LEAD TRIAL switch in one control stand is in LEAD position and other in TRAIL
position.
5. Put ON all BLACK labeled breakers and WHITE labeled GOVERNOR booster pump
breaker
6. Put FUEL PUMP control switch and MU STOP switch to ON position.
7. Put ON TURBO breaker.

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8. Check if all the other circuit breakers have been put in ON position. If so, now put
Computer circuit breaker in ON position.
9. Keep the ENGINE START switch to PRIME POSITION (left) and check fuel return sight
glass is full and no air bubbles.
10. Then immediately turn the ENGINE START switch to START position (right) and hold in
the same position till engine start and holds.
11. DO NOT shift the ISOLATION switch to RUN position immediately after
cranking to avoid Automatic shut down due to low water or low lube oil
pressure.
12. In EM2000 screen display, PRESS CREW for any active CREW message.
13. RECOVER AIR BRAKE PENALTY by putting AUTO BRAKE (A9) in full service (FS) for 10
seconds.
14. Switch on engine run switch in LH console.
15. Now loco is ready for service.
16.Apply loco brake fully, RH thrown to working direction, move throttle to first
notch. Check any crew message active in the display and TE meter shows
30KN, before moving the locomotive.
Since these locos are fitted with low capacity (150Amp Hr) battery, a
maximum of 4 repeated cranking is only possible.

5. WDP4 TIPS

12

Whenever any air brake faults is logged in EM2000 display, open airbrake cabin and,
check the fault code (FC) displayed in the computer through the glass window over
the cover and try to trouble shoot as per the guidelines.
1. BP RECOVERY AFTER AIR BRAKE TEST
After successful airbrake test if the EM2000 crew message shows to keep the A9
(auto handle) handle in FS for 10sec, it may not recreate BP .To create BP, change the
controller and keep A9 handle in FS position for 10 sec in that brake controller.
2. BP INDICATION
There may be a slight difference in BP indicating in the display and the gauges in the
control console. Check for air flow indicator is showing, air brake fault in the display
or brake binding, loco pilots can take EM2000 display value as standard and work
further. This may be an error in the gauge.
3. SPEED INDICATION
There may be a slight difference in loco speed indicating in display and the
speedometers in the control console. Drivers can work by keeping EM2000 value as
standard by calculating the error in the meter. A speed of 3 Kmph excess in
speedometer is permissible.
4. AUTO FLASHER INDICATION
All KJM based locomotives are modified to give flasher indication glowing in indication
panel when auto flasher is functioning.
5. BAIL OFF SWITCH

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Do not keep bail off switch in lifted condition for more than 3 minutes as it will cause
air brake controller failure.
6. TEA /WATER GLASSES
Do not keep Tea/Water glasses on the top of control console. Spillage can cause
damage to the electronic components inside the console.
7. EPD/LLOB TRIP
Whenever loco shut down automatically with LLOB tripped message, check for low
water, crank case and OST is in tripped condition. If so reset before cranking.
8. STARTER MOTOR OVERLOAD
If the Prime/Start switch kept in start position more than 20 sec and engine is not
firing, fault will log as starter motor overload and prevent next cranking for 5 minutes
to cool down starter motor. To overcome this delay, recycle the computer control
breaker and again start the engine. It is better to press the lay shaft slightly inside
during cranking.
9. LOW WATER SWITCH
If low water message is continuously coming in display, then check water level and
take appropriate action. If shut down with low water indication, loco cant be cranked.
If water is full and low water indication is coming, short the two wires connected to
LWS switch fitted in the expansion tank above FPM. (Cut both wires and joint).if fault
continues interchange DIO1 with DIO3.
10.EPU SENSOR

14

EPU sensor failure or EPU RPM inconsistent message can be ignored as it has no
effect in loco normal working.
11.AIR BRAKE SELF TEST
Before conducting air brake self test, ensure that BP train line coc is closed in loco
and hand brake is applied.
12.WATER LEAK
Whenever water leaking is noticed in the loco, keep open the pressure relief cap near
water filling pipe in expansion tank. This will reduce the pressure in the water system
and also reduce water leakages.
13.LOW HAULING POWER
Whenever low hauling, TE meter fluctuating or RPM hunting is experienced, check the
fuel sight glass for discoloration or air bubbles. Open the valve above the fuel filter
tank to release any air locked in the fuel system.
14.VERTICAL DAMPER
If vertical damper mounting bolts are broken, remove the damper and keep it in the
cabin and work further or tie the damper with truck to avoid falling down with a wire
rope.
15.INERTIAL FILTER BLOWER BREAKER
If inertial filter blower breaker is tripped loco can work normally without switching on
the breaker.
16.TCC BLOWER MOTOR BREAKER

15

If TCC1 and TCC2 blower breaker is tripping continuously, do not reset, but open the
circuit breaker panel door and short the two small (yellow color) wires connected to
the circuit breaker with pin type shoe. Loco can work more than 4 hrs without
problem. Inform shed.
17.CIRCUIT BREAKER FEED BACK
The following circuit breakers if not switched ON or tripped message will log in
display. Check the breaker is OFF or tripped. If tripped, contact shed for guidance. But
if the breaker is ON and message is logging then the feedback switch inside the
breaker is defective. Open the circuit breaker door and remove the small two wires
connected with pin type shoe and short them. Control breaker, AC Control breaker,
TCC1 and TCC2 computer breaker, AUX GEN FLD breaker, and TCC1 and TCC2 blower
motor circuit breaker.
18.INDICATION PANEL BULB
If any of the indication panel bulbs are glowing, check for active crew messages in
display. If no message the test switch may be defective. Ignore this indication.
19.DIGITAL MUX FAILURE
Before cranking the engine wait for EM2000 to start properly with all systems and
display indicating the crew messages. If cranked immediately after computer control
breaker switch on, fault may logged as Digital MUX failure. Recycling of computer
control breaker will inactive this fault.
20.PARALLEL CRANKING

16

When battery discharged fully, loco can be cranked with parallel connection from
other loco motive. The other loco motive should be WDM2, WDG3 or WDG4.Before
crank, charge the battery for half hour. During cranking keep the charging loco in 8 th
notch. Do not connect or disconnect the cable if battery knife switch is closed.
21.REVERSOR HANDLE
Whenever dead loco is moved to the shed, keep the Reverser handle in the event
recorder room.
22.TCC PROBLEMS
For all TCC related problem, an equivalent fault will be logged in EM2000 also.
The options for TCC faults are,
a. Recycle TCC, EM 2000 and GTO/IGBT POWER SUPPLY breaker. Follow the
procedure given in this booklet.
b. Disable defective TCC/truck. Loco can work more than 3 hours with single truck. If
possible work in 7th notch there by engine will run at 8th notch which cool the
traction motors. Once disabled the truck, switch OFF TCC and GTO power supply
breaker for that truck. Once truck disabled for GR -power, do not enable the truck
as it can damage the components.
c. Disable defective speed sensors- Up to 3 TM speed sensors can be disabled
.Before disable, ensure that the wheel is rotating freely. If fault continuing, switch
off relevant TCC breaker in GTO locos.if possible remove the speed sensor coupler
from traction motor.
2. DIO CARDS

17

Problem related to relays and contactors can be solved by interchanging DIO

cards.All the DIO cards are interchangeable. In most case, replace DIO3 with DIO1
or DIO2.Always switch off computer control breaker and wear antistatic hand band
before touching the modules. Ensure tightness of the fixing screw.
3. FP REALY FAILED TO DROP PUT
In KJM based locos, this fault will be logged during cranking. No problem in
cranking or loco working. This is not a fault but a message that FP Relay is in
picked up condition.
4. IGBT LOCOS
In all IGBT locos after cranking and BP come to 5 kg, wait for 20 seconds to throw
reverser handle. This will true for computer control breaker recycling also .This will
avoid DC LINK Crowbar firing.
5. MR PRESSURE LOW
Always check MR pressure displayed in EM2000 display. This shows the actual
pressure (MR1) from compressor. The pressure shown in the console gauge is
(MR2) for airbrake operation.
27. ACTIVE MESSAGES
When the loco is ready for service, apply loco brake fully, throw reverser handle to
working direction, open throttle to 1st notch. Check tractive effort meter is
showing 30KN.Open power data in data meters in main menu and check both

18

trucks giving torque of 1.8 KN. Open crew messages and check any fault is
logged.
28. TRACTION CUTOUT
Once truck is disabled, the power limited to 2400 HP, which is WDM2 power. It
may affect hauling power .Also after some time the traction motor in working
truck may overheat and torque reduction will start. In practical the torque
reduction may start after 3 1/2 hours depending on load and working condition.
29. HEAD LIGHT FAILURE
If one bulb fails, loco can work with other bulb. Both bulbs have independent HLPR
and no connection for failing one bulb affect other bulb. Open the wing nut and
bulb can be changed easily.
30. CONSOLE DESK
It is noticed that Tea/Water glasses were kept on top of the Console Desk. Spillage
can cause serious damage to electronic component in side the brake controller.
31. GTO/IGBT LOCOS
There are two type of TCC. Older versions are provided with GTOs and new locos
fitted with IGBT. This can be identified by checking the circuit breaker panel. For
GTO locos there are two TCC circuit breaker (TCC1, TCC2) but for IGBT locos only
one circuit breaker (TCC1).

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6. COMMON FAULTS AND REMEDIAL ACTIONS

1. GROUND RELAY
Check GROUND RELAY tripped in DB OR POWER
a) Dynamic brake
Avoid dynamic brake and work further. Switch OFF blended brake cut out switch.
Check any foreign body struck up with the Grid.
b) POWER
Check GR operates in standstill or loco moving. Check GR tripping frequently or
occasionally.
Stop loco and disable truck 1 and work further. If GR trip again enable truck 1 and disable
truck 2.Inform PRC/Shed as loco can work around 3 hours with single truck.
Check any cable rubbing in TA room, behind ECC1, water in ECC2, water falling to IPR
resistance in TA room, water entry to ECC1.
If GR trip in both truck stop loco and conduct excitation test from self test menu. If GR
trip in excitation test, problem may be in TA circuit. Conduct self load test and GR trip is
noticed arrange for relief loco.
2. COMMUNICATION FAILURE TCC1, TCC2, MAB
a. Recycle TCC, COMPUTER CONTROL AND MICRO AIR BREAKER.
b. Switch OFF computer control breaker and check COM304 card slack.
c. Check any RED LED glowing in EM2000 cards.
d. Remove COM304 card and refit properly.

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e. Check CRJ10 connector in CCB.

f. Remove back cover of ECC1 and check cables connected are intact in signal
distribution board above GTO power supply.
3. NO COMPANION ALTERNATOR OUTPUT/AUX GEN OUTPUT
a. Check AUX GEN coupling intact near turbo supercharger.
b. Check AUX GEN circuit breaker is tripped in ECC3 near radar.
c. Check AGFB/AGFB feedback breaker tripped.
d. Check DVR connector slack.
e. Check any burning indication in Traction alternator near turbo.
f. Check any breaker tripped.
g. Check battery charging ammeter shows charging side.
h. Check ENG RPM is showing in data meters.
i. Recycle the computer control breaker.
4. CONTINUOUS HORN WORKING.
a. Check horn button is struck up condition.
b. Press and release the switch. Remove the outer cap of the actuator.
c. For short hood horn remove the door outside the driver cabin in short hood below
the FP gauge. Press the manual button in the magnet valve. Tap the magnet valve
with hammer or stone.
d. If valve energized continuously remove wire no HRB18 from 43D terminal board
L11 location inside LH console.
e. For LH do same to the magnet valve in the compressor room wall. Remove wire
no- HRC from 83A terminal board in ECC3 cabinet in L10 location.

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5. CONTINUOUS SANDING
a. Check the sand button is in struck up condition .if so release.
b. Check in the program meter for SAND1 and SAND2. It should be OFF. If it shows
ON remove wire no 13 H5 from 43B- L10 terminal board in long hood console
inside.
c. If OFF and sand falling, the sand valve struck up. Tap the valve.
6. ENGINE RPM RISING BUT POWER NOT PRODUCING
a. Check
GFB
breaker
is
in
ON,GFS
switch
is
on
in
LH
console,TCC1,TCC2,ACGTO1,ACGTO2 circuit breakers are in ON. Recycle computer
control breaker and TCC breaker.
b. Check in other control stand
c. Select Main Menu in Display
d. Select Data meter in main menu
e. Select digital input/output in meter menu
f. Select DIO 1 input channel 14-24
g. Check the status of the data Ldunit. When RH is throwing to any direction the
status should show ON.
h. If OFF, Interchange DIO1 and DIO3.
i. If still OFF, with a loop wire short TB43A-1 wire no 13T and TB 43B-R5 wire no 13
R5.
7. TRACTIVE EFFORT METER NOT SHOWING IN ONE DIRECTION BUT SHOWING IN
OTHER DRIRECTION

22

a.
b.
c.
d.
e.

This is due to master controller defect.

Open cover of long hood console near foot step.
Inside the console terminal boards can be seen.
Locate 43A terminal board.
Take a loop wire and connect one end to wire no.13Tin 43Aterminal board in 1 or 2
locations from top.
f. For Short hood working- Connect the other end of the loop wire to wire no 8T5 in
43A-L5 terminal.
g. For long hood working- Connect the other end of the loop wire to wire no 9T5 in
43A-L6 terminal.
h. Once this loop wire connected loco can work only to that side.
i. For reverse working the loop wire to be removed.
8. DEFECTIVE AIR DRIER
In case Air Dryer continuous blowing, switch off the air dryer circuit breaker or
disconnect Air Dryer Electrical coupler. (Provided in Air Dryer) Still if it is blowing.
a. Remove Spare 1 dummy plug provided in MR EQ. Swan neck ( Provided Near
BP/FP angle cocks)
b. Shut down loco & drain MR.
c. Provide 1 dummy plug to Air dryer purge valve (where exhaust blowing).
d. Crank the loco and do not re-connect Air dryer electrical coupler.
9. TCC FAULTS-NO HAULING / LOW HAULING POWER
Whenever the loco pilot is noticed that, Loco having Low hauling power, check the crew
message in the display panel for TCC Communication failure, TCC Braking mode denied,

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TCC failed to acknowledge direction request etc. Check Power data in Main menu for
both TCC shows equal torque. Recycle the TCC breaker with computer control breaker.
Whenever TCC - LOCKOUT message logged ,recycle the TCC breaker .After recycling the
breaker still this message is coming then DISABLE THE RELEVENT TRUCK and work
further.
Locomotive will produce only 2400HP.
10. WATER LEVEL REDUCING
Normally the water level will not reduce in WDP4 locos. If external leakage is noticed add
water and work further. If not external water leakage or lube oil level is increasing,
contact shed for advice. Whenever water reducing is noticed in the loco, keep open the
pressure relief cap near water filling pipe in expansion tank. This will reduce the pressure
in the water system and also reduce water leakages.
11. LOW MR PRESSURE
Whenever MR pressure is dropped below 7 Kg, PCS will knock out. Check air exhausting
continuously in air drier. Do as explained in defective air drier. Check any external
leakages. Continuous air leakages in sand, horn, radar blow valve, MR moisture drain
valve etc to be checked. Tap the relevant magnet valves. Close the MRPT sensor COC
(red color) in compressor room behind the ECC2 cabinet. Close the EPG coc PROVIDED IN
THE COMPRESSOR ROOM WALL.
12. HOT ENGINE

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Whenever hot engine message logged with throttle limit to 6 th notch check both radiator
fans running in full speed. If fan not running check open ECC3 cabinet and check the
contactors (FCF1A, FCF1B, FCF2A, FCF2B) is picked up. If the circuit breakers are
provided, check for tripped condition. If so, switch off the breaker and switch on. If any
fuse is burnt condition by pass the fuse with thick wire.
13. TM SPEED SENSOR FAULTY/LOCKED AXLE DETECTION
After ensuring wheel free movement, stop loco motive, disable traction motor speed
sensor through display panel-main menu. Ensure that loco motive is stopped and
reverser in neutral. After disabling the sensor, if fault logged related to TCC, remove the
speed sensor cable coupler from the motor and work further. Still fault continues, disable
the truck, switch OFF the TCC computer breaker and work in single truck.
14. BP DROPPING/PCS knock out
Whenever BP drops automatically, check for airflow indicator showing value. If the gauge
is indicating it shows BP leakages externally. Check formation and air pipe coupling. If air
flow indicator not showing, check MR pressure in the display (not the gauge in the
console). It should be above 7.5 kg .if not check MR leakages in the loco.
When ever PCS knock out, check MR pressure in the display (not the gauge in the
console).if it below 7.2 PCS will knock out. If MR is above 7.2 check air brake fault in air
brake computer and act accordingly.

7. AIR BRAKE SELF TEST PROCEDURE

25

1. Stop the Locomotive (loco speed is zero)

2. Apply hand brake and take all precautions as per laid down procedures to secure
locomotive & formation against rolling.
3. Ensure MR pressure minimum 110 PSI (7.8 kg/cm2.
4. Close the BP, FP angle cocks MR and BC equalizing cocks at coupling ends of the
loco.
5. On working control stand keep:
1. Throttle handle in idle position.
2. Reverser in center position
3. Lead/Trail switch in LEAD position.
4. Auto Brake position in RUN position.
5. Direct (Independent) brake handle in full application position.
6. On Non-working control stand keep:
1. Throttle handle in idle position.
2. Lead/Trail switch in Trail position.
3. Auto brake handle in full service position.
4. Direct (Independent) brake handle in release position.
NOTE: Also the above 5th & 6th points should be followed while changing the control
stand.
Running Air Brake SELF-TEST from EM 2000
Press Main Menu key.
Select SELF TEST.
Press F2 key to select NEXT (Page 2:2).

26

Select AIR BRAKE SELF TEST.

Press F1 key to Select Continue.
Wait until SUCCESSFUL, TEST COMPLETED, NO DEFECTS FOUND.RECOVER BP.
Press F4 key THREE times to exit from Self Test and keep cursor on DATA meters.
Press crew key, see crew message, if any active message available, act
accordingly.
Open the BP/FP angle cocks, MR & BC equalizing cocks at the coupling end of
loco for normal operation.
NOTE: If SELF TEST fails & PCS is ON, repeat SELF TEST in other control stand
To change the position of Lead/Trail switch, stop the locomotive (Locomotive
speed is zero).
If PCS is open, keep the reverser in Forward/Reverse, bring the throttle to DB
zone and again bring back to idle. PCS will get reset.
If BC Pressure is not building in working control stand bring Auto/Direct brake
valve to release position& again apply.
PRESS AND TURN THE LEAD /TRAIL SWITCH. DO NOT OPERATE THE SWITCH
WHEN LOCO IN MOVING.

8. PROCEDURE FOR ATTACHING & CHARGING THE FORMATION

Step 1: Couple the B.P & F.P angle cock hose pipes to that of the Formation.

27

Step 2: Open the Corresponding F.P angle cock to get F.P pressure charged to
5.0 to 6.0kg/cm2.
Step 3: Keep lead/Trail switch in TEST position in the working control stand and
open corresponding B.P angle cock & wait for 3 to 5 seconds.
Step 4: Switch over the Lead/Trail switch to LEAD position.
Step 5: Allow B.P to charge to 5.2 kg/cm2.
NOTE: In case B.P. & F.P angle cocks have been opened simultaneously, keep
working control stand BVC (A-9) in emergency position for 60 seconds & then
release.
Again repeat the Steps 1 to 5.
In case Air Dryer is malfunctioning switch OFF the circuit breaker of Air dryer in
control panel located in driver cab.

9. PROCEDURE FOR DEAD LOCO MOVEMENT

Apply hand brake.

Shut down the loco.
Switch OFF all breakers.
Drain MR I & MR II reservoirs.
Open DEAD ENGINE COC (Location- Remove CCB panel cover next to SH C/S.)
Open the COC to close line parallel position- 90 to pipe line.
Keep BC equalizing COC located above L1, L6 wheel in open position.
Couple BP hose and open angle cock to charge BP for 15 minutes.

28

Apply A-9 in lead loco, brake should apply in dead loco.

Release A-9, brake should release in dead loco. If brake is not released, adjust BP
pressure to 5.2 kg/cm2 in lead loco. Release the hand brake.
Keep the reverser handle in the loco.

10. PROCEDURE FOR CONTROL STAND CHANGING

Working control stand keep:
Throttle handle in idle position.
Reverser in center position
Lead/Trail switch in LEAD position.
Auto Brake position in RUN position.
Direct (Independent) brake handle in full application position.
Non-working control stand keep:
Throttle handle in idle position.
Lead/Trail switch in Trail position.
Auto brake handle in full service position.
Direct (Independent) brake handle in release position.
Press and turn the lead /trail switch .Do not operate the switch when loco in
moving

11. EM 2000 FAULT CODE AND REMEDIAL ACTIONS

29

These are some of the EM 2000 faults logged in KJM locomotives for the last 2 years. Check the
crew messages in the display panel and locate the fault code. Capital letters are fault message in
display and small letters are the remedy.
If the trouble shooting is not given for the displayed fault, please contact the helpline numbers
available in locomotive.
Before opening any ECC cabin ensure that isolation switch in isolate, TH in idle, RH in neutral and
MGV is below 20 volts (open power data in data meters and check).
The fault code for GTO based locos and IGBT based locos are same but may require different
trouble shooting. Contact helpline numbers for this.
FC
1
14

15

16

17
61

Fault message and remedial action

FP RLY FAILED TO DROP OUT No problem, this message will log in all KJM based locos during cranking. Can be
ignored.
ENGINE AIR FILTERS ARE DIRTY - CHANGEOUT REQUIRED, POWER MAY BE LIMITED TO THR 6
-This may be due to defective DIO card. Replace DIO-2 with DIO-3 and check. Switch off EM2000 breaker before
card removal.
#1 LOCKED WHEEL OR SPEED SENSOR FAULT STOP TRAIN AND VERIFY THAT AXLE ROTATES
-Disable the speed sensor ensuring there is no physical locked axle. Recycle the EM 2000 breaker after disable.
Remove the sensor coupler from the motor.
#2 LOCKED WHEEL OR SPEED SENSOR FAULT STOP TRAIN AND VERIFY THAT AXLE ROTATES
-Disable the speed sensor ensuring there is no physical locked axle. Recycle the EM 2000 breaker after disable.
Remove the sensor coupler from the motor.
LOSS OF TRAIN LINE PRESSURE, EMERGENCY - PLACE HANDLE IN EMERGENCY FOR 60 SEC
- Crew message to recreate BP. Keep A9 handle for 60 sec and release. Check BP creating.
GROUND RELAY - DYNAMIC BRAKE, LOAD TEST Avoid dynamic brake. Check any foreign body struck to the

30

149
151
152
157
158
228

321
322
324
331
359

361

grids
TRAIN LINE ALARM-Check any fault is active in crew message. If no message and loco working normal . Recycle
computer control breaker.
#1 MOTOR SPEED SENSOR DISABLED FOR LOCKED WHEEL DETECTION-Indicative message that speed sensor
already disabled. No problem in loco working
#2 MOTOR SPEED SENSOR DISABLED FOR LOCKED WHEEL DETECTION-Indicative message that speed sensor is
already disabled. No problem in loco working
#1 MOTOR SPEED SENSOR ENABLED FOR LOCKED WHEEL DETECTION- indicative message .No problem
#2 MOTOR SPEED SENSOR ENABLED FOR LOCKED WHEEL DETECTION- indicative message .No problem
NO LOAD - SIMULTANEOUS FORWARD/REVERSE REQUEST
This fault will log normally in MU operation with both loco having RH handles. If happen in single loco check
master controller in non working stand is thrown to any direction or struck up. If loco working in SH direction
open LH console cover near foot step and locate 43A terminal board. In this, in L6 location wire no 9T5 remove
and work further. If working LH side, remove wire no 8T5 from TB 43A-L5 location.
ARCHIVE RESET - The fault memory in EM2000 is reset by shed, no problem
NO LOAD - DC LINK OVERCURRENT-Mostly come when some other TCC faults logged, reset automatically.
DC LINK OVERVOLTAGE-Mostly logged when some other TCC faults logged or speed sensor or temp sensor fault
etc, reset automatically.
ENGINE AIR FILTERS DIRTY-This may be due to defective DIO card. Replace DIO-2 with DIO-3 and check. Switch
off EM2000 breaker before card removal.
GROUND RELAY POWER This will automatically reset when voltage came below 20. If continues 3 times GR will lock out. Disable truck 1
and check. If coming disable truck 2...still coming, conduct Excitation test and load test from self test menu.
Check water leakages inside TA room in IPR resistance or TA cables rubbing with body or chocked in water.
ENGINE PROTECTION SHUTDOWN - LOW OIL PRESSURE Check LLOB tripped in governor. If so reset and crank.
Check EPD/OST is also in tripped condition. Check both radiator fans are working.

31

367
368
370
371
376
383
388
392
393
396
401
408
410
428
436
444
467
473

TCC #1 FAILED TO ACKNOWLEDGE - DYNAMIC BRAKE REQUEST Recycle TCC, EM2000 circuit breakers; check
COM card is seated properly in EM2000.
TCC #1 FAILED TO ACKNOWLEDGE - DIRECTION REQUEST Recycle TCC,EM2000 circuit breakers ,check COM
card is seated properly in EM2000
TCC #1 FAILED TO ACKNOWLEDGE - POWER MODE REQUEST Recycle TCC,EM2000 circuit breakers, check COM
card is seated properly in EM2000
TCC #1 INTERNAL RESET - A TO D CONVERSION TIME EXCEEDED-Recycle TCC ,still continue, disable truck
TCC #1 INTERNAL RESET - UNBALANCED AC CURRENT SYSTEM-Reset automatically. If Fault log again disable
the TCC 1
TCC #1 INTERNAL RESET - PULSE FREQUENCY IS TOO HIGH (SHORT TIME)-Reset automatically.
TCC #1 INTERNAL RESET - DC LINK UNDERVOLTAGE-Fault will reset automatically. check engine RPM hunting
TCC #1 RESET - PROTECTION TRIGGERED: REASON UNDEFINED-Recycle the TCC.
TCC #1 RESET - GTO MONITORING-If the Fault log frequently, disable the relevant TCC
TCC #1 RESET - TCC PROTECTION TRIGGERED: REASON UNDEFINED-This fault will be come along with some
other TCC fault or if loco shut down in power mode. Try to locate other faults.
TCC #1 RESET - GTO POWER SUPPLY UNDERVOLTAGE-Check fault logged in cranking time, if so ignore. This
fault common in IGBT locos and can be ignored.
TCC #1 LOCKOUT - CUT OUT TRUCK #1 GTO MONITORING -Disable TCC1
TCC #1 LOCKOUT - CUT OUT TRUCK #1 WRONG HARDWARE CODING OR HARDWARE LIMIT
-Recycle the TCC breaker. If message is still active, isolate TCC 2 and switch of the TCC breaker.
TCC #1 LOCKOUT - CUT OUT TRUCK #1 SUBPROCESSOR HEAVY FAULT-Recycle the TCC. Fault still log, disable
the relevant TCC and switch off relevant breakers.
TCC #1 TORQUE REDUCTION - BRAKING MODE DENIEDThis fault will reset automatically. If not recycle TCC.
TCC #1 TEMPORARY TORQUE REDUCTION - TCC TEMPERATURE LIMIT EXCEEDED-check for TCC2 is disabled.
TCC #1 WARNING - SPEED SENSOR FAULTDisable the defective speed sensor and recycle the EM2000 breaker
TCC #2 FAILED TO ACKNOWLEDGE - DYNAMIC BRAKE REQUEST Recycle TCC,EM2000 circuit breakers, check

32

474
476
477
482
489
494
499
502
507
514
516
534
541
542
573
587
620

COM card is seated properly in EM2000

TCC #2 FAILED TO ACKNOWLEDGE - DIRECTION REQUEST Recycle TCC,EM2000 circuit breakers, check COM
card is seated properly in EM2000
TCC #2 FAILED TO ACKNOWLEDGE - POWER MODE REQUEST Recycle TCC,EM2000 circuit breakers, check COM
card is seated properly in EM2000
TCC #2 INTERNAL RESET - A TO D CONVERSION TIME EXCEEDED-Recycle TCC ,still continue disable truck
TCC #2 INTERNAL RESET - UNBALANCED AC CURRENT SYSTEM-Reset automatically. If Fault log again disable
the TCC 2
TCC #2 INTERNAL RESET - PULSE FREQUENCY IS TOO HIGH (SHORT TIME)-Reset automatically
TCC #2 INTERNAL RESET - DC LINK UNDERVOLTAGE-Fault will reset automatically. Check for engine rpm
hunting.
TCC #2 RESET - GTO MONITORINGIf the Fault log frequently, cutout the relevant TCC
TCC #2 RESET - PROTECTION TRIGGERED: REASON UNDEFINED- Recycle the TCC.
TCC #2 RESET - GTO POWER SUPPLY UNDERVOLTAGE-If fault logged during cranking ignore.
TCC #2 LOCKOUT - CUT OUT TRUCK #2 GTO MONITORING-Disable TCC2
TCC2 - Lockout, Wrong hardware coding/Hardware limit.- Recycle the TCC breaker. If message is still active,
disable TCC 2 and switch of the TCC breaker.
TCC #2 LOCKOUT - CUT OUT TRUCK #2 SUBPROCESSOR HEAVY FAULT-Recycle the TCC. If Fault still logged,
disable TCC2 and switch off relevant breakers.
TCC #2 TORQUE REDUCTION - UNDEFINED FAULT CODE-Mostly related to IGBT locos. But check any hauling
power, low engine HP like problems.
TCC #2 TORQUE REDUCTION - BRAKING MODE DENIED-This fault will reset automatically. If not recycle TCC.
TCC #2 WARNING - SPEED SENSOR FAULT-Disable the sensor and recycle EM2000 breaker.
MU ENGINE STOP REQUEST Release the MU STOP switch if pressed; remove wireno-13X6 from SDR relay
interlock.
NO LOAD - TCC #1 COMMUNICATION FAILURE Recycle TCC, EM2000 circuit breakers. check COM card seated

33

626
637

638
668
672
700
726

727
732
733
742
743
753
757
758

properly
NO LOAD - TCC #2 COMMUNICATION FAILURE Recycle TCC, EM2000 circuit breakers. check COM card seated
properly
NO LOAD - NO COMPANION ALTERNATOR OUTPUT CHECK AUX GEN FIELD CIRCUIT BREAKER.
- If this fault log during cranking ignore. Check EPU RPM, if this is below 150 this fault will log. If not check AUX
GEN coupling, AUX GEN breaker in ECC2, AGFB breaker tripped any loose connection in DVR connector, loose
connection in 3G2A connector in ECC1 back panel.
NO LOAD - ALL ONLINE TCC COMPUTERS HAVE CEASED OPERATION OF INVERTERS-Auto recovery fault. If not
Recycle the TCC.
REDUCED LOAD - TCC #1 COMPUTER HAS CEASED OPERATION OF INVERTER- Auto recovery fault. If not Recycle
the TCC
REDUCED LOAD - TCC #2 COMPUTER HAS CEASED OPERATION OF INVERTER- Auto recovery fault. If not Recycle
the TCC
TCC COMMUNICATIONS FAILED - TRUCK#2 MOTOR SPEED SENSORS DISABLED Recycle TCC,EM2000 circuit
breakers
ENGINE SPEED FAILURE- check AUX GEN coupling failure, Aux GEN circuit breaker tripped in ECC2 cabin, check
AGFB breaker tripped, all connections to DVR, FCF are intact. Check 3G2A connector intact in the ECC1 back
panel.
REDUCED POWER - ENGINE SPEED FAILURE- same as FC 726
TCC #1 INTERNAL RESET - NO SPEED DETECTABLE no problem
TCC #2 INTERNAL RESET - NO SPEED DETECTABLE - no problem
TCC #1 WARNING - PHASE MODULE TEMPERATURE SENSOR FAULT-No problem in loco working.
TCC #2 WARNING - PHASE MODULE TEMPERATURE SENSOR FAULT-No problem in loco working.
TCC #1 RESET - OPEN CIRCUIT BETWEEN ASG AND GATE DRIVER T OR CROWBAR- Recycle the TCC
TCC #1 RESET - ASG HARDWARE WATCHDOG-Recycle the TCC 1.
TCC #2 RESET - ASG HARDWARE WATCHDOG-Recycle the TCC 2.

34

766
767
768
771
781
783
784
801
802
811
819
820

872
873
874
878
879
880

TCC #2 TORQUE REDUCTION - WHEEL DIAMETER MISMATCH-Rare case of fault. If logged, recycle TCC, EM2000
Circuit breakers
TCC #1 TORQUE REDUCTION - SUBPROCESSOR FAULT- Recycle TCC, isolate truck
TCC #2 TORQUE REDUCTION - SUBPROCESSOR FAULT-Recycle TCC, isolate truck
TCC #1 WARNING - SNUBBER RESISTOR TEMPERATURE SENSOR FAILURE-No effect in loco working.
NO LOAD - TCC #1 CROWBAR FIRED
Mostly this fault log in both TCC and reset
GFD DELAY TIMER INITIATED
automatically. If not recycle TCC, EM2000
NO LOAD - TCC #1 RESISTIVE CROWBAR FIRED
circuit breakers. check engine rpm hunting
NO LOAD - TCC #2 RESISTIVE CROWBAR FIRED
TCC #1 RESET - DC LINK OVERVOLTAGE
TCC #2 RESET - DC LINK OVERVOLTAGE
TCC #2 WARNING - WHEEL MISMATCH WARNING-Rare case of fault. If logged, recycle TCC, EM2000 Circuit
breakers.
NO DYNAMIC BRAKE, LOAD TEST - GROUND RELAY LOCKOUT - Keeps in idle, RH in neutral, isolation switch in
isolate, check GR reset, work further without Dynamic Brake.
NO POWER - GROUND RELAY LOCKOUT-Reset by pressing the F button in display below the reset, when
voltage came below 20. Disable truck 1 and check. If GR trip again disable truck 2.Still coming, conduct
Excitation test and load test from self test menu. Check water leakages inside TA room in IPR resistance or TA
cables rubbing with body or chocked in water.
NO LOAD - DC LINK SHORT CIRCUIT
Mostly came with other faults and reset automatically. If
NO LOAD - DC LINK SHORT CIRCUIT LOCKOUT
not recycle TCC, EM2000 circuit breakers.
DC LINK UNANNOUNCED CROWBAR LOCKOUT-This fault mostly related in IGBT locos. Can ignore .automatically
reset. If not Recycle the TCC
TCC #1 LOCKOUT - CUT OUT TRUCK #1 DC LINK OVERVOLTAGE Disable truck and work further
TCC #2 LOCKOUT - CUT OUT TRUCK #2 DC LINK OVERVOLTAGE Disable truck and work further
TCC #1 RESET - GTO POWER SUPPLY OVERVOLTAGE-If the Fault is active, cutout the TCC 1

35

881
918
919
974

975

100
7
100
8
108
0
108
1
112
6
115
3
116
4
117
0
118

TCC #2 RESET - GTO POWER SUPPLY OVERVOLTAGE-If the Fault is active, cutout the TCC 2
NO BLENDED BRAKE - LOCKOUT, FAILED TO CHARGE AIR- no effect in working of loco
NO BLENDED BRAKE - LOCKOUT, FAILED TO RELEASE AIR- no effect in working of loco
REDUCED POWER - TCC #2 OVERTEMPERATURE TEMPORARY CONDITION-Happen due to truck 1disabled, work in
7th notch so engine rpm goes to 8 th notch and cool the motors. Check any TCC temp sensor fault also logging.
Recycle the TCC.
REDUCED POWER - TCC #1 OVERTEMPERATURE TEMPORARY CONDITION-Happen due to truck 2 disabled, work
in 7th notch so engine rpm goes to 8 th notch and cool the motors. Check any TCC temp sensor fault also logging.
Recycle the TCC.
TCC #1 INTERNAL RESET - RIPPLE ON FLUX FEEDBACK PRESENT- Reset automatically ,no action required
TCC #2 INTERNAL RESET - RIPPLE ON FLUX FEEDBACK PRESENT- Reset automatically ,no action required
NO START - START FUSE IS OPEN OR MISSING- Check the start fuse if missing or fused short with thick copper
conductor and crank or battery knife switch burnt, battery terminal burnt. interchange DIO1 and DIO3
NO ENGINE START - TURBO PUMP NOT RUNNING RUN PUMP FOR 15 MINUTES TO COOL TURBO. -This due to
TLPR breaker switched off before cooling cycle. Wait till cooling cycle completed.
NO LOAD - GENERATOR FIELD OVEREXCITATION-- This mostly came with some other fault. Check for other faults.
Conduct self test- Excitation,
DC LINK UNANNOUNCED CROWBAR-This mostly came in IGBT locos. Automatically reset.
FAILED FEEDBACK - DCL V FEEDBACK IS OUT OF RANGE-Mostly related to ADA card in EM2000 problem. Check
up card seated properly
FAILED FEEDBACK - TCC2 A FEEDBACK IS OUT OF RANGE-Mostly related to ADA card in EM2000 problem. Check
up card seated properly
FAILED FEEDBACK - CA VOLTAGE FEEDBACK IS OUT OF RANGE-Mostly related to ADA card in EM2000 problem.

36

2
118
3
118
9
119
0
119
1
119
2
120
1
130
5
130
6
130
8
130
9
131
0
131

Check up card seated properly

FAILED FEEDBACK - MR PRES FEEDBACK IS OUT OF RANGE-Mostly related to ADA card in EM2000 problem.
Check up card seated properly. Check MRPT sensor connector intact.
FAILED FEEDBACK - TM #1 TEMPERATURE FEEDBACK IS OUT OF RANGE-No problem
FAILED FEEDBACK - TM #2 TEMPERATURE FEEDBACK IS OUT OF RANGE-No problem
FAILED FEEDBACK - TM #3 TEMPERATURE FEEDBACK IS OUT OF RANGE-No problem
FAILED FEEDBACK - TM #4 TEMPERATURE FEEDBACK IS OUT OF RANGE-No problem
TRUCK #1 DISABLED - MULTIPLE FAILED TRACTION MOTOR TEMPERATURE SENSORS-Disable truck 1
TCC #1 TEMPORARY TORQUE REDUCTION - HOT TRACTION MOTORS-If truck 2 is disabled this condition will
come after a long time of working. Try to keep notch in 7 th notch there by engine rpm goes to 8 th notch. Or cool
the traction motors. By fast pumping.
TCC #1 WARNING - MOTOR TEMPERATURE SENSOR FAULT-No problem.
TCC #2 TEMPORARY TORQUE REDUCTION - HOT TRACTION MOTORS-If truck 1 is disabled this condition will
come after a long time of working. Try to keep notch in 7 th notch there by engine rpm goes to 8 th notch. Or cool
the traction motors. By fast pumping.
TCC #2 WARNING - MOTOR TEMPERATURE SENSOR FAULT-No problem.
ENGINE DEAD WITH COLD WATER TEMPERATURE-No problem in cranking or working.
NO LOAD - ENGINE TEMPERATURE FEEDBACK FAILURE-Check both ETP1 and ETP2 sensor cable coupler intact.

37

4
131
5
168
8
168
9
169
2
169
4
169
6
169
8
170
2
170
3
170
4
171
0
171
7
171

Check ADA in EM2000 is seated properly.

HOT ENGINE - THROTTLE 6 LIMIT EXTENDED TIME-Check radiator fans working. Check radiator fan fuse blown or
breaker tripped.
FAILED FEEDBACK - ETP1 FEEDBACK IS OUT OF RANGE-Check ETP1 sensor coupler intact. Loco work normally if
ETP2 working normal. Sensor available below water tank
FAILED FEEDBACK - ETP2 FEEDBACK IS OUT OF RANGE-Check ETP1 sensor coupler intact. Loco work normally if
ETP2 working normal. Sensor available below water tank
FAILED FEEDBACK - GBLW1 A FEEDBACK IS OUT OF RANGE-Avoid Dynamic brake and work further.
FAILED FEEDBACK - GBLW2 A FEEDBACK IS OUT OF RANGE-Avoid Dynamic brake and work further.
FAILED FEEDBACK - GRID1 A FEEDBACK IS OUT OF RANGE-Avoid Dynamic brake and work further.
FAILED FEEDBACK - GRID2 A FEEDBACK IS OUT OF RANGE-Avoid Dynamic brake and work further.
FAILED FEEDBACK - LR FEEDBACK IS OUT OF RANGE-Check WW governor Amphenol plug intact. Check ASC front
connectors intact, check ADFA seated properly. Conduct Load regulator self test.
FAILED FEEDBACK - LR FEEDBACK HAS AN OFFSET-Check WW governor Amphenol plug intact. Check ASC front
connectors intact, check ADFA seated properly. Conduct Load regulator self test.
FAILED FEEDBACK - MG CTA FEEDBACK IS OUT OF RANGE-Check ASC front connection intact
FAILED FEEDBACK - MGFLD A FEEDBACK IS OUT OF RANGE-Check ADA seated properly
FAILED FEEDBACK - TL 24T FEEDBACK IS OUT OF RANGE- Avoid Dynamic Brake and work further.
FAILED FEEDBACK - TM AIR FEEDBACK IS OUT OF RANGE-No problem

38

8
176
4
177
6
177
7
177
8
177
9
178
0
178
1
178
2
178
3
178
5
178
8
178
9
180

FAILED FEEDBACK - TPU RPM-No problem, loco work normally

FAILED FEEDBACK - PHASE MODULE 1 TEMP FEEDBACK IS OUT OF RANGENo problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - PHASE MODULE 2 TEMP FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - PHASE MODULE 3 TEMP FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - PHASE MODULE 4 TEMP FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - PHASE MODULE 5 TEMP FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - PHASE MODULE 6 TEMP FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - SIBAS TEMPERATURE 1 FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - SIBAS TEMPERATURE 2 FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - SNUBBER TEMPERATURE 2 FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - TCC TEMPERATURE 1 FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - TCC TEMPERATURE 2 FEEDBACK IS OUT OF RANGE
-No problem in working. No effect in loco working. If require recycle TCC
FAILED FEEDBACK - TRUCK #1 TM TEMPERATURES ARE INCONSISTENT-Mostly no problem

39

4
180
5
186
1
187
4
187
5
187
8
187
9
188
5
189
3
191
7
191
9
192
0

FAILED FEEDBACK - TRUCK #2 TM TEMPERATURES ARE INCONSISTENT-Mostly no problem in loco working

REDUCED POWER, DYNAMIC BRAKE - TCC BLOWER LOCKOUT-Disable the truck
TCC #1 BLOWER CONTACTOR FAULT - SLOW SPEED FAILED TO DROP OUT-no problem, ignore the
fault
TCC #1 BLOWER CONTACTOR FAULT - SLOW SPEED FAILED TO PICK UP-Disable truck
TCC #2 BLOWER CONTACTOR FAULT - SLOW SPEED FAILED TO DROP OUT--no problem, ignore the
fault
TCC #2 BLOWER CONTACTOR FAULT - SLOW SPEED FAILED TO PICK UP-Disable truck
LOW ENGINE WATER LEVEL DETECTED -Check the water level in the glow rod, if it is low inform Diesel shed for
further action.
-If water is full and message logging ignore the fault.
FAILED FEEDBACK - EPU RPM FEEDBACK IS INCONSISTENT WITH ENGINE RPM- no problem in loco working
FAILED FEEDBACK RADAR- Remove radar coupler and work further
NO LOAD - TCC #1 BLOWER CIRCUIT BREAKER IS NOT CLOSED- Switch on the breaker if OFF condition. open
breaker panel cover and short the small 2 wires connected to the TCC blower circuit breaker (pin type shoe) and
work further
NO LOAD - TCC #2 BLOWER CIRCUIT BREAKER IS NOT CLOSED- Switch on the breaker if OFF condition. open
breaker panel cover and short the small 2 wires connected to the TCC blower circuit breaker (pin type shoe wire
connected to interlocks) and work further

40

196
0

196
1
196
2
196
3
196
4
196
5
196
7
196
8
196
9
200
2
200
3
200

GFD FAILED TO PICK UP-Check the contactor picked up physically. Swap DIO1 with DIO3.check any digital MUX
failure also logged. Move isolation switch to isolate and run and check the contactor drops and pick up .remove
the archutes assembly and see any obstructions. Short with a wire the PA27 in the coil to the coil wire no GFBC
in GFC contactor.
GFD FAILED TO DROP OUT-No problem, Interchange DIO1 and DIO3
GFC FAILED TO PICK UP-Check isolation switch in run, GF switch in ON. Check GFD pick up condition, interchange
DIO1 and DIO3, Short with a wire the PA27 in the GFD coil to the coil wire no GFBC in GFC contactor. Change
control stand and check.
GFC FAILED TO DROP OUT - Interchange DIO1 and DIO3
FP RLY FAILED TO PICK UP-Interchange DIO2 and DIO3.if not working, SWITCH OFF FUEL PUMP CIRCUIT BREAKER
and remove the following wire from FPR relay and short them all. PA 63, PA 62, SRX8, SRA6, SRX6, SRY6.
FP RLY FAILED TO DROP OUT-No problem. Ignore the fault
WH SLP FAILED TO DROP OUT-Check real wheel slip in the loco. Remove wire no WAL6, 13T61 and MUD4 from
WR RELAY.
TLPR FAILED TO PICK UP-Check battery knife switch, computer control breaker, TLPR circuit breaker is in ON.
Interchange DIO1 and DIO3. SHORT the following wires TLD8, TLD6, TLX6 and TLA6 in TLPR relay.
TLPR FAILED TO DROP OUT-If this message coming when loco is in dead condition then Switch off TPLM circuit
breaker.
FCS1 FAILED TO PICK UP-Recycle computer control breaker. Interchange DIO2 and DIO3.check FCF1A contactor
dropped. Short wire no PA82, PA83 and CFK in FCF1A CONTACOTR or Short CFX and CFL WIRE in FCF1A.
FCS1 FAILED TO DROP OUT-CONTACT SHED
FCS2 FAILED TO PICK UP-CONTACT SHED

41

4
200
5
200
8
200
9
201
0
201
1
206
4
206
5
206
6
206
7
206
9
208
1
208
3
216

FCS2 FAILED TO DROP OUT-CONTACT SHED

FCF1A or FCF1B FAILED TO PICK UP-CONTACT SHED
FCF1A or FCF1B FAILED TO DROP OUT-CONTACT SHED
FCF2A or FCF2B FAILED TO PICK UP-CONTACT SHED
FCF2A or FCF2B FAILED TO DROP OUT-CONTACT SHED
B1 FAILED TO PICK UP-CONTACT SHED. Interchange DIO2 and
DIO3
B1 FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and
DIO3
B2 FAILED TO PICK UP-CONTACT SHED. Interchange DIO2 and
DIO3
B2 FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and
DIO3
BWR FAILED TO DROP OUT-CONTACT SHED. Interchange DIO1 and DIO3

Avoid DB

DCCl FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and DIO3

DCOP FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and DIO3
CMPSYN FAILED TO PICK UP

If MR pressure reducing close the coc of MRPT sensor o in

42

0
216
1
218
2
218
3
218
6
218
7
218
8
218
9
219
1
221
0
224
0
225
0
225
1
225

the back side of ECC3 cabin or remove the cable to MRPT

sensor .close MVCC COC

CMPSYN FAILED TO DROP OUT

TCC1SC FAILED TO PICK UP-CONTACT SHED. Interchange DIO2 and DIO3

TCC1SC FAILED TO DROP OUT-CONTACT SHED. -no problem, ignore the fault
TCC2SC FAILED TO PICK UP-CONTACT SHED. Interchange DIO2 and DIO3
TCC2SC FAILED TO DROP OUT-CONTACT SHED. -no problem, ignore the fault
TI1CO FAILED TO PICK UP-CONTACT SHED. Interchange DIO2 and DIO3
TI1CO FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and DIO3
TI2CO FAILED TO DROP OUT-CONTACT SHED. Interchange DIO2 and DIO3
VPC FAILED TO PICK UP- Check battery voltage low if fault logged before crank. Interchange DIO1 and DIO3.
ST FAILED TO DROP OUT-contact shed. Interchange DIO1 and DIO3
B4 FAILED TO DROP OUT-CONTACT SHED. Interchange DIO1 and DIO3 ,avoid dynamic brake,
B3 FAILED TO PICK UP-CONTACT SHED. Interchange DIO1/DIO2 and DIO3
B3 FAILED TO DROP OUT- Avoid dynamic brake CONTACT SHED. Interchange DIO1/DIO2 and DIO3

43

6
225
7
233
2
234
5
234
8
242
2
242
3
243
8
261
2
261
3
261
4
261
5
265
5
265

B4 FAILED TO PICK UP-avoid dynamic brake CONTACT SHED. Interchange DIO1 and DIO3
#1 MOTOR SPEED SENSOR DISABLED FOR LOCKED WHEEL DETECTION-no problem
COMMUNICATIONS LINK FAILURE MAB. -Recycle EM2000 and Air brake computer breaker. Check the fault code
in air brake and act accordingly
NO BLENDED BRAKE - LOCKOUT, AIR BRAKE COMMUNICATION LINK FAILURE- no problem in loco working
NO BLENDED BRAKE - LOCKOUT, INVALID CALL PRESSURE- no problem in loco working
NO BLENDED BRAKE - LOCKOUT, INVALID BRAKE CYLINDER PRESSURE- no problem in loco working
TCC COMMUNICATIONS FAILED - TRUCK#1 MOTOR SPEED SENSORS DISABLED - Recycle TCC,EM2000 circuit
breakers
GTOPS2 FAILED TO PICK UP-Check GTO power supply breaker is closed. CONTACT SHED
GTOPS2 FAILED TO DROP OUT-CONTACT SHED. If IGBT loco ignore.
GTOPS1 FAILED TO PICK UP- Check GTO power supply breaker is closed. CONTACT SHED
GTOPS1 FAILED TO DROP OUT-CONTACT SHED. If IGBT loco ignore
REDUCED DYNAMIC BRAKE, NO LOAD TEST - NO GRID BLOWER #2 CURRENT-Avoid dynamic brake and work
further
REDUCED DYNAMIC BRAKE, NO LOAD TEST - HIGH GRID BLOWER #1 CURRENT-Avoid dynamic brake and work

44

6
265
7
292
4
292
6
295
5

296
7
296
8
296
9
297
0
297
1
297
2
297
3
298

further
REDUCED DYNAMIC BRAKE, NO LOAD TEST - HIGH GRID BLOWER #2 CURRENT-Avoid dynamic brake and work
further.
COMMUNICATIONS LINK FAILURE - EVENT RECORDER Recycle event recorder breaker and EM2000 breaker.
EVENT RECORDER CIRCUIT BREAKER IS NOT CLOSED- check breaker is not closed, if so switch on. Check event
recorder LEDs are glowing. If so ignore this message.
DIGITAL INPUT SYSTEM FAILURE (CHECK MUX CIRCUIT)--Check other faults logged, switch off EM2000 breaker
and check DIO cards seated properly, CMU1,2,3,4 connectors above DVR ,DIP30,31,32,80 panel connectors in
ECC1 and ECC3 .SWITCH ON EM2000 breaker and still fault logging fail the loco. if this fault log during cranking
recycle computer control breaker and wait for 20 second before doing priming.
AIR BRAKE FAULT - BRAKE CONTROLLER NUMBER 1 FAILURE- check relevant air brake fault and act accordingly
AIR BRAKE FAULT - BRAKE CONTROLLER NUMBER 2 FAILURE- check relevant air brake fault and act accordingly
AIR BRAKE FAULT - LEAD/TRAIL MODE SELECTION FAILURE- check relevant air brake fault and act accordingly
AIR BRAKE FAULT - MREQ-PIPE/FLOW MODULE FAILURE- check relevant air brake fault and act accordingly. Check
MR pressure is above 7 kg in both console gauges and EM2000 display. If it is less check MR leakage and attend.
AIR BRAKE FAULT - BRAKE PIPE CONTROL FAILURE- check relevant air brake fault and act accordingly
AIR BRAKE FAULT - INDEPENDENT/BCEQ-PIPE CONTROL FAILURE- check relevant air brake fault and act
accordingly
AIR BRAKE FAULT - BRAKE CYLINDER CONTROL FAILURE- check relevant air brake fault and act accordingly
LOSS OF TRAIN LINE PRESSURE, EMERGENCY - PLACE HANDLE IN EMERGENCY FOR 60 SEC- Crew message to

45

4
326
1
326
2
326
3
326
4
328
8
328
9
332
6
347
3
351
1
351
2
351
3
351

recreate BP. Keep A9 handle for 60 sec and release. Check BP creating.
TCC #1 LOCKOUT - CUT OUT TRUCK #1 INVERTER OUTPUT OVERCURRENT --If Fault log frequently, Cutout the
TCC 1 and switch off TCC breaker.
TCC #2 LOCKOUT - CUT OUT TRUCK #1 INVERTER OUTPUT OVERCURRENT --If Fault log frequently, Cutout the
TCC 2 and switch off TCC breaker.
TCC #1 RESET - INVERTER OUTPUT OVERCURRENT --If Fault log frequently, Cutout the TCC 1 and switch off TCC
breaker.
TCC #2 RESET - INVERTER OUTPUT OVERCURRENT --If Fault log frequently, Cutout the TCC 2 and switch off TCC
breaker.
AIR BRAKE SELF TEST - SUCCESSFUL COMPLETION --No action.
COMPUTER TURNED OFF OR RESET WHILE REVERSER NOT CENTERED --This will come normally when recycling
EM2000 breaker without RH in neutral position.
NO BLENDED BRAKE - BACKUP BRAKE SYSTEM ACTIVE - PERFORM AIR BRAKE SYSTEM TEST -- No effect in
working of loco
EVENT RECORDER HARDWARE FAULT No problem work further
#5 LOCKED WHEEL OR SPEED SENSOR FAULT STOP TRAIN AND VERIFY THAT AXLE ROTATES-Disables the speed
sensor ensuring there is no physical locked axle. Recycle the EM 2000 breaker after disable. Remove the sensor
coupler from the motor.
#6 LOCKED WHEEL OR SPEED SENSOR FAULT STOP TRAIN AND VERIFY THAT AXLE ROTATES-Disables the speed
sensor ensuring there is no physical locked axle. Recycle the EM 2000 breaker after disable. Remove the sensor
coupler from the motor.
#5 MOTOR SPEED SENSOR DISABLED FOR LOCKED WHEEL DETECTION --Indicative message that speed sensor
already disabled. No problem in loco working
#6 MOTOR SPEED SENSOR DISABLED FOR LOCKED WHEEL DETECTION --Indicative message that speed sensor

46

4
351
5
351
6
354
8

already disabled. No problem in loco working

#5 MOTOR SPEED SENSOR ENABLED FOR LOCKED WHEEL DETECTION -- Indicative message .No problem
#6 MOTOR SPEED SENSOR ENABLED FOR LOCKED WHEEL DETECTION-- Indicative message .No problem
FAILED FEEDBACK - JACKET WATER TEMPERATURE PROBE --Check the ETP1 and ETP2 connectors
water tank are intact. Check ADA card seated properly.

below cooling

12. AIRBRAKE FAULT CODE AND REMEDIAL ACTIONS.

For air brake faults, try to recover BP by
keepingA9 handle in emergency for 60
seconds.
Conduct airbrake self test by keeping both
controller handle in mid position.Before
doing self test, check the air brake
computer front connectors inside the
computer box and CRJ connectors in the
bottom of the computer are intact. Check all
the connectors to magnetic valve and transducers available below the CRU are intact.
Always check tightness of the connectors (couplers) not slackness.

47

Whenever any air brake fault logged in the EM2000, open airbrake cabin and check the
fault code (FC) displayed in the computer through the glass window and try to trouble
shoot as per the guidelines given below.
Software/CPZ/Communication faults
FC
02
04
05
06
07
08
09
10
11

Description
Messaging Crash
Message Checksum Error
Buss Access Error
Message Overrun Error
Message Loop back Error
Message Framing Error
Communication Break Received
Air Brake Self-Test
Air Brake Watchdog Time-out

No problem, no effect in
No problem, no effect in
CPZ failure , loco failure
No problem, no effect in
CPZ failure , loco failure
No problem, no effect in
No problem, no effect in

working of loco
working of loco
working of loco
working of loco
working of loco

No chance to log, till date not logged in the locos

Brake Controller faults-do not conduct self test for this fault.
20
21
22
23
24
25
26
27
28
29

C1
C1
C1
C1
C1
C1
C1
C1
C1
C1

Controller Missing
Automatic Handle Frequency Low
Automatic Handle Frequency High
Automatic Release Switch Stuck Open
Automatic Release Switch Stuck Closed
Automatic Emergency Switch Stuck Open
Automatic Emergency Switch Stuck Closed
Independent Handle Frequency Low
Independent Handle Frequency High
Independent Release Switch Stuck Open

If the fault is coming intermittently ignore this faults.

If permanent, apply A9 handle to emergency and
recover BP. If BP not recreating change to other
control stand by changing LT switch position. Check
for BP creating. If not remove the BVJ1 (a big round
connector inside the console which is connected to
the controller from the bottom back. It can be
accessed by opening the console cover near the foot
step) connector from the defective controller, put A9

48

2A
2B
2C
2D
30
31
32
33
34
35
36
37
38
39
3A
3B
3C
3D

C1 Independent Release Switch Stuck Closed

C1 Independent Max Switch Stuck Open
C1 Independent Max Switch Stuck Closed
C1 Bail-Off Switch Stuck Closed
C2 Controller Missing
C2 Automatic Handle Frequency Low
C2 Automatic Handle Frequency High
C2 Automatic Release Switch Stuck Open
C2 Automatic Release Switch Stuck Closed
C2 Automatic Emergency Switch Stuck Open
C2 Automatic Emergency Switch Stuck Closed
C2 Independent Handle Frequency Low
C2 Independent Handle Frequency High
C2 Independent Release Switch Stuck Open
C2 Independent Release Switch Stuck Closed
C2 Independent Max Switch Stuck Open
C2 Independent Max Switch Stuck Closed
C2 Bail Off Switch Stuck Closed

40

Both Controllers Selected

41
42

C1 Operating Mode Switch Change at Speed

C2 Operating Mode Switch Change at Speed

4A

Service Mode Switch Stuck Open

handle to emergency and recreate BP and work from

other console. If BP not creating Recycle the air
brake computer breaker. Even after recycling BP not
creating, fail the loco.
When these faults logged, air brake self test not pass
.If self test conducted the test will fail and air brake
failure message will log.
Whenever controller fault came along with system
If fault is permanent, remove the BVJ1 connector
from the non working controller.
This fault will come when LT switch changed when
loco is moving. BP will drop and loco came to stop.
then fault will also go automatically
No system effect.

49

4B
4C

Service Mode Switch Stuck Closed

Service Mode Switch Change at Speed

Fault will also go automatically when loco speed

comes to zero.

System faults - To clear these fault, conduct self test.

50

Defective MR Transducer

60
61
62
64
65

Defective ER Transducer
No ER Supply Control
No ER Exhaust Control
Brake Pipe Cut-Off Valve Stuck Open
Brake Pipe Cut-Off Valve Stuck Closed

66

Brake Pipe Cut-Off Magnet Valve Stuck Off

69
6A

Defective BP Transducer
Brake Pipe Control Self-Test Failure

6B
6C
6D
6E

Brake Pipe Leakage Self-Test Failure

PVBP Stuck Open
PVBP Stuck Closed
Emergency Magnet Valve Self-Test Failure

70
71

Defective 20 Transducer
No 20 Supply Control

Check MRPT sensor connector. If BP not creating

Recycle the air brake computer breaker. If not fail the
loco.
Do self test and recover BP .If not recover, fail the
loco.
No system effect.
Do self test and recover BP .if not recover, fail the
loco.
No system effect. Recover BP by putting A9 in
emergency. Loco work only in lead.
Check BPT sensor connector. Fail the loco
Do self test .Put A9 in emergency and recover. If not
fail the loco. Ensure BP COC to be closed while self
test.
Put A9 in emergency and recover.
No system effect.
Self test failure. Recover BP by keeping A9 in
emergency. Still not recover, fail loco.
Mostly fault occur in MU operation. Do self test, if

50

72
74

No 20 Exhaust Control
20 Control Magnet Valve Stuck Off Self-test Failure

75

20 Control Magnet Valve Stuck On Self-test Failure

80
81
82
83

Defective 16 Transducer
No 16 Supply Control
No 16 Exhaust Control
No Electronic BC Control Self-Test Failure

89
8E

Defective BC Transducer
KE Distributor Valve Application Self-Test Failure

90

Defective ADZ Board

fails, fail the loco.

Self test fault. Try to recover by keeping a9 in
emergency position. If not recover, fail the loco.
Loco work in lead only. No system affected in lead
operation. Put A9 in emergency and recover. Problem
due to BCEQ pipe leak.
No problem in loco, put A9 to emergency and
recover BP. But BC will be 3.8 only
Self test will fail. Recover BP, check BC COC closed.
No problem in loco working
No problem, no action
No effect on loco working, but self test fail, recover
BP.
Fail the loco

13. REMOVAL OF THE BRAKE CONTROLLER CONNECTOR WHEN

CONTROLLER FAILURE.

51

Defective brake controller

console

Open cover below the controller

Opened

. The arrow indicate the coupler

Switch off air brake circuit breaker. Remove this connector from the defective controller
(1). Keep the LT switch in trail position. Change to other controller (2).put LT switch in
lead position. Put the controller no2 A9 handle to emergency. After 60 sec, release the
handle to run position. Check BP is recovering. Work further in the controller.

14. TCC RECYCLING PROCEDURE

52

Any message logged regarding TCC, please do recycling of TCC.

Stop the loco motive. Apply SA9 Full.

Keep
TH
to
idle, RH
to
neutral

53

Keep isolation switch in isolate.

Switch OFF Circuit breakers
TCC1 COMPUTER, TCC2 COMPUTER, COMPUTER CONTROL, AC GTO-1 PWR
SUPPLY, AC GTO-2PWR SUPPLY.Do not switch off Air brake circuit breaker for TCC
related problems. Wait for 20 sec. Close all the above 5 breakers with Computer control
breaker last. Recover BP by keeping A9 handle in FS position for 10 sec.
For IGBT locos switch OFF the following breakers
TCC1 COMPUTER, COMPUTER CONTROL, IGBT PS#1, IGBT PS#2
AFTER CREATING BP keep RH in neutral for 20 sec.
IGBT based locomotives
The following locomotives of KJM is fitted with IGBT based TCC.
20040, 20044 and all loco No above. In these loco motives only one circuit breaker is
available for TCC. Also GTO power supply circuit breakers are replaced with IGBT power
supply. Refer recycling procedure for these locos in point 13.

54

FEED BACK WIRES IN CIRCUIT

BREAKER

15. SOME FAULTS

Fault codes not affecting the loco working
1.
1965
FP RELAY FAILED TO DROP OUT.
2.
2984
LOSS OF TRAIN LINE PRESSURE

55

3.
2924
COMMUNICATION LINK FAILURE EVENT RECORDER
4.
733
NO TCC2 INTERNAL RESET SPEED DETECTABLE
5.
919
NO BLENDED BRAKE
6.
918
NO BLENDED BRAKE
7.
3473
EVENT RECORDER HARDWARE FAULT
8.
1917
RADAR FAILED FEEDBACK
9.
1874,1878
TCC SS blower contactor fault fails to drop out.
FAULT LOGGED DUE TO MALOPERATION
2669
AIR BRAKE FAULT,LEAD/TRAIL MODE SELECTION
2967/ 2968
AIR BRAKE FAULT,BRAKE CONTROLLER (1/2)FAILURE
3289
COMPUTER TURED OFF OR RESET WHILE REV NOT CENTERED
SOME CRITICAL FAULTS
1. 361-ENGINE SHUT DOWN LOW OIL-check EPD before cranking
2. 368-TCC1 FAILED TO ACKNOWLEDGE DIRECTION REQUEST. Do TCC recycling
3. 2612/2614 GTO (1/2 ) FAILED TO PICK UP. Check engine RPM above 180 and AG failure
4. 626/620 NO LOAD TCC ( 2/1) COMMUNICATION FAILURE. Do TCC recycling
5. 872 DCLINK SHORT CIRCUIT
6. 1960 GFD FAILED TO PICK UP
7. 396- TCC 1 RESET- TCC PROTECTION TRIGGED REASON UNIDEFINED
8. 2002 / 2010 - FCS1/FCF2A OR FCF2B FAILED TO PICK UP
9. 801- TCC 1 RESET DC LINK OVER VOLTAGE
10. 1183- FAILED FEEDBACK-MR PRES FEEDBACK IS OUT OF RANGE
11. 2160- CMPSYN FAILED TO PICK UP
12. 2955- DIGITAL INPUT SYSTEM FAILURE(CHECK MUX CIRCUIT)

56

13.
14.
15.
16.
17.
18.
19.

1962- GFC FAILED TO PICK UP

401- TCC 1 RESET-GTO POWER SUPPLY UNDER VOLATAGE
2973- AIR BRAKE FAULT- BRAKE CYLINDER CONTROL FAILURE.
1308- TCC 2 TEMPORARY TORQUE REDUCTION-HOT TRACTION MOTORS.
974- REDUCED POWER TCC2 OVERTEMPERATURE.
820- NO POWER GROUND RELAY LOCKOUT
359- GROUND RELAY POWER

16. Some Online Shortcuts.

1. In LH CONSOLE.
Use a small piece of wire .open the LH console door. The terminal boards (TB) can
be seen. Locate the TB.TB number starts from top as A. Each TB has 2 sets of
terminal. Left side is coded as L and right side as R. After shorting some crew
message may come. If power is coming ignore the messages.
a. PCS knock out
Short TB - 43A 2nd terminal (13T) to 43B-L9 (13 wire) in LH control stand.
b. GF switch defective
Short TB - 43A 2nd terminal (13T) to 43A-L3 (6T wire)
c. TE meter not respond when RH thrown to one direction but
respond to other direction.
TB - 43A 2nd terminal (13T) to 43A-L5 (wire no 9T) or

57

d.
e.
f.

g.
h.
i.
j.
k.

TB - 43A 2nd terminal (13T) to 43A-L6 (wire no 8T).

Engine RPM rising but TE meter not responding
TB - 43A 2nd terminal (13T) to 43B- R5 (wire no 13R5)
Sander continuously working
Remove wire no 13H5 from TB 43B-L10
Continuous alarm ringing
Recycle computer control breaker. Still ringing remove wire no2T1 from
43B- R4.
Engine Run switch down message logging
Short TB - 43A 2nd terminal (13T) to 43A- R4
Flasher light continuously glowing even though PCS not knock out
Check flasher switch closed. If not remove wire no FLP5 from TB-43C-L6.
Short hood head light not burning (switch defective).
Remove HP5 wire from 43D-L7 and short with HB18 wire in 43D-L2.
Long hood head light not burning (switch defective).
Remove HP5 wire from 43D-L7 and short with HB18 wire in 43D-L6
MU stop request message coming even MU switch green button
pressed inside.
Remove wire no 13X5 from TB -43B-L7.

58

2. OTHER LOCATIONS
a. Fuel pump motor not working.( for message-FPR Relay fails to
pick up also).
Remove SFPX wire from EFCO relay and touch with SFP8/SFP wire in EFCO
relay.
Switch off FPB. Remove the following wires from FPR relay and short all 4
wires --SRX8, SRA6 (Both blue wires), SRX6, SRY6 (both small brown wires).
b. GFC fails to pick up
Check GFC picking up by throwing RH. If picking up, short wire MUC 3 and
MUCC6 in GFC. Interchange DIO-1 with DIO -3
c. TCC2SS blower contactor fails to pick up
Remove wire no MUED6 and connect it to MUE4 IN THE CONTACTOR.
Contactor will pick up.
Press manually in the center black button. The contactor picks up
d. TCC1SS blower contactor fails to pick up
Remove wire no MUJD6 and connect it to MUJ4 IN THE CONTACTOR.
Contactor will pick up.
Press manually in the center black button. The contactor picks up
e. LLOB TRIP message logging even after reset the LLOB button

59

REMOVE wire no MUPD from TB-83B-R7 and short to MUP4 IN 83B-R6 in

ECC3 cabinet.
f. FCF1 fail to pick up
Remove CFL wire from FCF1B CONTACTOR. Short wires no CFA and CFA1 in
FCS1 contactor interlock to PA80/PA81.Short wire no MUP1 and MUPZ in
FCF1B.Short wire no. MUPZ and MUPA in FCF1A.Fan will rotate in full speed
always.FCS1 fails to pick up and FCF1A, FCF1B fails to drop out message
will log in display. ENSURE FUSE ARE INTACT
g. FCF2 fail to pick up
Remove CFP wire from FCF2B CONTACTOR. Short wire no CFD and CFD1 in
FCS2 contactor interlock to PA82/PA81.Short wire no MUP2 and MUPY in
FCF2B.Short wire no. MUPY and MUPB in FCF2A.Fan will rotate in full speed
always.FCS2 fails to pick up and FCF2A, FCF2B fails to drop out message
will log in display. ENSURE FUSE ARE INTACT
h. ALARM ringing continuously
Recycle computer control breaker. If working in MU check rear loco for
faults .Remove wire no-ARA6 from AR relay coil. Remove wire no-2T1 from
TB 43B-R4.
i. STA not picking

60

Remove wire no STM from FP/ES (FUEL PROME /ENGINE STSRT SWITCH)
and touch with wire no PA94/PA95 in FP/ES Switch. Replace DIO1 with
DIO3.

17. Helpline
For any help please contact or send SMS to these numbers.
ELDO.E.V- SE/WDP4/ELEC
THIMESH PRABHU- SSE/ELEC
S
A
RAHMAN

9731666463
9731666459
9731666469

61

SE/MECH/AIRBRAKE
S
RAMESH
KUMAR
SE/WDP4/MECH/UT
Dy.CME/DSL/KJM
CONTROL ROOM

9731666462
9731666450
9731666486,

080-25610727

All these are Railway CUG numbers. Whenever any fault noticed in the loco, please
contact directly on this numbers. We can help the loco pilots and reduce on line
detention time.
Any correction, suggestions about this booklet is welcomed.
This booklet is prepared only for internal training purpose of loco pilots and
not for sale.
For soft copies, contact the E-mail ID-eldoev@gmail.com
This booklet cant be used for any official purpose as a reference.
Prepared by,
E. V.ELDO, SSE/ELEC/WDP4.
DIESEL
LOCO
SHED,
KRISHNARAJAPURAM,
SOUTH
WSTRN
RAILWAY,
BANGALORE.

62

25

years of
Glorious
service

to the Nation (1983-2008)

Diesel Loco Shed, Krishnarajapuram, Bangalore.
Version-1, Issue-2, 01/03/2009

63