WAG12 LOCOMOTIVE

LOCOPILOT HANDBOOK

This document is the property of Alstom Transport and the recipient

hereof is not authorised to divulge,distribute or reproduce this
documentor any part thereof without prior written authorisation from
Alstom Transport.
 CONTENTS
0. Reference Documents ............................................................. 3
1. Instructions for Loco Pilot ........................................................ 3
1.1. Do’s ............................................................................. 3
1.2. Don’ts.......................................................................... 5
2. Technical Data of WAG12 Locomotive ..................................... 6
3. General Description ................................................................. 8
4. Driver Cab ............................................................................. 10
4.1. Left Panel .................................................................. 10
4.2. Master Controller ....................................................... 11
4.3. Brake Gauges Panel ................................................... 12
4.4. Central Panel ............................................................. 13
4.5. TCMS, DDU (Train Control & Monitoring System, Driver
Display Unit) ............................................................................. 15
4.6. Indication Panel ......................................................... 16
4.7. Line Indicator............................................................. 17
4.8. Right Shelf................................................................. 18
4.9. Pedal Switches .......................................................... 19
4.10. Assistant Panel .......................................................... 20
4.11. Cab Cabinet Right ...................................................... 21
5. Electrical System Description ................................................. 22
5.1. Pantograph................................................................ 22
5.2. HV Cubicle ................................................................. 24
5.3. Main Transformer ...................................................... 24
5.4. E-Block (Traction Convertor) ...................................... 24
5.5. Traction Control Unit (TCU) ........................................ 24
5.5.1. Tractive/Braking Effort Limitation .............................. 25
5.5.2. Traction Isolation ....................................................... 25
5.6. H-OM (Earthing Switch) ............................................ 25

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 5.7. Auxiliary Loads .......................................................... 25
5.8. Battery Unit & Charging System................................. 26
6. Pneumatic System ................................................................ 27
6.1. MASU (Main Air Supply Unit) .................................... 27
6.2. Main Compressor Regulation ..................................... 28
6.3. Auxiliary Compressor Regulation ................................ 28
7. Brake System ....................................................................... 28
7.1. Types of Brakes ......................................................... 28
7.1.1. Regenerative Brake ................................................... 28
7.1.2. Types of Pneumatic Brakes ........................................ 29
7.2. Brake Control Module (BCM)..................................... 30
7.3. Brake Pressure (Nominal) ......................................... 33
7.4. Different Types of Brake Blending Logics ................... 34
7.5. Parking Brake Manual Release Plunger ..................... 34
8. Locomotive Operating Modes ................................................ 35
9. General Procedures ............................................................... 36
9.1. Locomotive Energisation Procedure ........................... 36
9.2. Loco Shutdown Procedure ......................................... 36
9.3. Cab Change Procedure .............................................. 37
9.4. Loco Grounding Procedure......................................... 37
9.5. Dead Engine Brake Configuration .............................. 38
9.6. EB Reset Procedure ................................................... 39
9.7. Penalty brake Reset Procedure in case of EBV Failure 39
9.8. Vigilance Management .............................................. 40
9.9. Back-Up Brake (PTDC) .............................................. 41
9.10. Coupling Two Locomotives ........................................ 41
9.11. BP leak test procedure ............................................... 42
9.12. Single Pipe Loco Configuration (with load) ................. 43
9.13. Charging BP on first power Up (i.e. Loco Charging).... 43
9.14. Helper Mode ............................................................. 44
10. Troubleshooting .................................................................... 45

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0. REFERENCE DOCUMENTS
Reference No. Document Title
NRD0000572523_0 WAG12B Driver Training Manual
NRD0000572572_0 Dead Locomotive Operation
NRD0000258515_8 Operational Context Document

1. INSTRUCTIONS FOR LOCO PILOT

1.1. Do’s
1 In the event of unintended traction after application of
Emergency Brake, immediately lower the pantograph by
moving the pantograph switch to EMERGENCY position.
2 In the event of loss of control on Traction or Braking
command, Loco Pilot should blow horn and trigger an
Emergency Brake.
3 Loco Pilot should ensure proper release of the brakes during
operation to avoid inefficient Tractive Effort or sometimes fire
hazard.
4 Loco Pilot should apply the Parking Brake before proceeding
for brake pipe leak test.
5 Parking Brake should be applied while the cabin is active and
loco is in standstill condition. Also, after application of PB,
Loco Pilot should confirm the application from DDU & Gauge
before leaving the cabin.
6 In train configuration, ensure the brakes on wagons are
manually released before starting the train.
7 Loco Pilot in the event of axle blocking, should stop and
inspect the locomotive before restarting.
8 In case of false alarm due to smoke detectors, remove the
smoke detector by rotating in anti-clockwise direction.

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 a. If smoke detector is covered with dust, try cleaning with
air and re-install, else
b. Continue operation with smoke detector removed
Inform OCC
9 Ensure all the CBs are always closed in both sections, unless
explicitly recommended by TCMS on DDU.
10 Ensure the isolation cocks (Z01/1, Z01/2, B40.09, N55.05),
bypass switches (Vigilance Isolation Switch, Fire Detection
Bypass Switch, Zero Speed Bypass Switch) are in normalised
position unless explicitly recommended by TCMS on DDU.
11 Before leaving the locomotive after making the loco dead, loco
pilot must ensure closure of rear-view mirror.
12 Loco pilot shall enter proper details in DDU regarding Hauling
Load and No. of Wagons attached while taking charge.
13 While leaving locomotive in dead condition, ensure parking
brakes are applied and wedge blocks are placed.
14 Use wiper control knob carefully.
15 Ensure parking brakes are in “Released condition” prior to
hauling the loco in “Dead Mode”.
16 Prior to giving VCB close command, ensure Master Controller
(Throttle) is at neutral Position.
17 Check for any active IOS in DDU page before movement of
locomotive. Inform OCC in case of any failure IOS.
18 In case of continuous glowing of LSAF indicator, physically
check for no leakage in BP line of wagons and Loco.
19 For EBV fault code 153, always check that all TCU’s are
healthy, and compressor(s) is/are in running condition.
20 For EBV fault code 118, reset active BCM CB (62Q06) from
LV cubicle. F1 button from DDU to be pressed only in case of
failure of Speed Freeze button.

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 21 Before start of operation ensure from DDU that TCU’s are not
in isolated condition. Try to normalise in case isolated.
22 Always keep white marker light of active cab in ON condition.
23 Acknowledge all IOS appeared during the operation and
follow the instructions displayed.
1.2. Don’ts
1 Do not operate the locomotive at speeds greater than 100
km/h when operating locomotive without wagons.
2 Do not leave the locomotive without placing the wheel
wedges when the locomotive is parked for maintenance or for
longer duration.
3 After power-up of the locomotive and activating the cab, the
Loco Pilot should NOT release the parking brake of the
locomotive until the main pipe pressure reaches 6 bar.
4 Sanding operation is not recommended when locomotive is
operating without wagons.
5 Bail-OFF mode is prohibited when locomotive is operating
without wagons.
6 Avoid the presence of staff in gangway during locomotive in
motion. Be cautious while passing through the gangway while
locomotive in motion.
7 HVAC shall not be manually switched OFF in non-active cab.
8 Should not Lower the Pantograph without opening the VCB.
9 Do not Operate locomotive with Cab Windows, Machine
room/Gangway door in open condition.
10 Do not Use Direct Brake (SA9) + Regenerative braking
simultaneously when loco attached with load and running
above >10kmph.
11 Do not Operate “Direction Selector Switch (Reverser)” while
locomotive is in running condition.

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 12 Do not Shutdown the locomotive directly from battery box
when electronics are in “On” condition.
13 Do not Leave locomotive unattended with electronic in “ON’
condition.
14 Do not operate “Fire Extinguisher Switch” unless there is an
actual fire/smoke found inside machine room as complete
CO2 gas cylinder will get exhausted. Inform OCC if operated.
15 Do not operate any isolation/ cut-out cocks partially. Ensure
its complete operation.
16 Do not operate wiper without water

2. TECHNICAL DATA OF WAG12 LOCOMOTIVE

Description Specification
Type of vehicle Freight locomotive
Horsepower 12000 Hp
2 (Section-1, Section-2)
No. of Sections
(Section-A, Section-B)
Axial arrangement BoBo
Number of axles 8
Rail gauge 1,676 mm
180 t for 22.5 Tonne/axle
Mass of locomotive
200 t for 25 Tonne/axle
Length 38,400 mm
Width 3,058 mm
Height 4,150 mm
1,250 mm (New Wheel)
Diameter of Wheel 1,207 mm (Half Worn)
1,164 mm (Fully Worn)
Maximum speed 100 km/h (upgradable to 120 km/h)

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 Description Specification
Gearbox ratio 110/23
Nominal: 22.5 kV, 50 Hz, single phase
AC
OHE Voltage
Maximum:31kV
Minimum: 17kV
Traction power in continuous
9,000 kW
rating mode
Maximum starting tractive
705 kN
effort at 22.5 t/axle load
Maximum starting tractive
785 kN
effort at 25 t/axle load
Tractive effort at maximum
270 kN
operating speed 120 km/h
Maximum tractive effort 115.149 kN/motor
Maximum braking effort 79.315 kN/motor
Low voltage supply 110 V DC
Auxiliaries voltage supply 415 V, 3–phase AC
DC Link voltage: 1800 V DC± 3%
Convertor Permanent O/P current DC: 1535A
Permanent I/P current AC: 2000 A rms
DC Link voltage: 1800 VDC± 3%
Inverter Permanent O/P current AC: 850 A rms
Permanent I/P current DC: 1200 A
Multiple unit operation 2 Locomotives
Suitability for remote multiple
2 Locomotives
unit operation
Cattle Guard 196 mm above rail level
Stone Deflector 40 mm above rail level
Side Buffer 968 mm above rail level

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

Figure 1: WAG12 Single Section

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 Figure 2: Main Components of WAG12 Locomotive

Note:
Signalling Cabinet and Toilet Module are future provision, not available in current locomotive.

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4. DRIVER CAB
The WAG 12 locomotive cabin consists of Loco Pilot desk, Loco Pilot seat, Assistant Loco Pilot seat, Cab Cabinet Right & Toolbox
Cubicle.

4.1. Left Panel

Figure 3: Left Panel

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 4.2. Master Controller

Figure 4: Master Controller

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 4.3. Brake Gauges Panel

Figure 5: Brake Gauge

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 4.4. Central Panel

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 Figure 6: Central Panel

S. No Description
1 Emergency Stop Push Button (BPEMS#)
2 Speed Indicator
3 Speed Freeze Push Button
4 Voice Recorder Microphone
5 Fire Alarm Reset Push Button (BPFR)
Flasher Light Latched Push Button
6 13
(Illuminated) (BPFL)
7 Vigilance Ack/Reset Push Button (BPVR)
S. No Description
8 Constant Speed Control Push Button (Illuminated) (BPCS)
9 Main Compressors Forcing Switch (BLCP)
10 Pantograph Toggle Switch (ZPT)
11 VCB Open/Close Toggle Switch (BLDJ)
12 Headlight Toggle Switch (BLPR)
Headlight Control Toggle Switch (ZPRD)
14 Parking Brake Toggle Switch

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 4.5. TCMS, DDU (Train Control & Monitoring System, Driver Display Unit)

Figure 7 TCMS DDU

TCMS DDU displays the status of locomotive and its sub-systems, it provides soft key commands.

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 4.6. Indication Panel

Figure 8 Indication Panel

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

Figure 9 Line Indicator

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 4.8. Right Shelf

Figure 10 Right Shelf

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 4.9. Pedal Switches

Figure 11 Pedal Switches

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 4.10. Assistant Panel
Assistant panel consists of following control equipment:

Figure 12 ALP Desk

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

Figure 13 CAB Cabinet Right

S. No Description S. No Description
1 Fire detection bypass switch(sealed) 6 Zero speed bypass switch (sealed)
2 CCR Lighting Push Button 7 Vigilance isolation switch (sealed)
3 CCR machine room/gangway lighting switch 8 Traction/Brake controller bypass switch(sealed)
4 Panto selector switch 9 Fire Extinguishing Override Switch
5 Battery connect switch (S.BAC) 10 220V switch/socket

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5. ELECTRICAL SYSTEM DESCRIPTION
5.1. Pantograph

The pantograph can be used for normal contact wire and high reach contact
wires with heights ranging from 4.58 to 7.52 m from top of the rail.

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 Figure 14: Electrical Schematic
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 5.2. HV Cubicle
between the pantograph and primary winding of main transformer.
a) Potential Transformer
b) Current Transformer
c) Vacuum Circuit Breaker (VCB)
d) H-HT (High Voltage Disconnector)
e) Surge Arrestor

5.3. Main Transformer

The AC catenary voltage is connected to the primary winding of the main
transformer of the same section via the single-phase main circuit breaker ‘VCB’
and to the main transformer of the other section via a 25kV line between the
sections and the 2 automatic switches.

Figure 15: Traction Power Electrical Schematic

5.4. E-Block (Traction Convertor)

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

5.5. Traction Control Unit (TCU)

In each E-Block there is one Traction Control Unit (TCU) for the driving of
traction and auxiliary converters. Each TCU is an electronic control rack.

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 Tractive Effort
No. of Healthy Bogies
22.5 T Axle Load 25 T Axle Load
4 706 kN 785 kN
3 529 kN 588 kN
5.5.1. Tractive/Braking Effort Limitation
DDU has a provision to limit tractive/braking efforts in two ranges as given
below,
When limit is not selected, locomotive applies default traction curve, as per axle
load configuration.
Traction Effort Limits: Limit can be activated through DDU home page.
a 300 kN
b 529 kN
5.5.2. Traction Isolation
In order to ensure the Service continuation in case of traction isolation (one
bogie isolated) with the maximal haulage load as declared, in any gradient up
to 1/150, the approaching speed of the locomotive shall be
maintained above 15 kmph.
If, in such a situation, the Locomotive comes to very low speed, the train may
not be able to re-start, a Banking Engine would be needed to continue the
Service.
5.6. H-OM (Earthing Switch)
H-OM is used to earth the high voltage system while performing any
maintenance or emergency scenarios such as panto entanglement, VCB Failure
etc.

5.7. Auxiliary Loads

S. No Description
1 E-Block Blower
2 E-Block water pumps
3 Traction Motor Blower
4 Machine Room Blower
5 Punction Blower
6 MASU
7 HVAC
Quantity Per Section Load
2(1 in each E-Block) 14.8 kw
2(1 in each E-Block) 3.05 kw
2 14.05 kw
2 4.93 kw
2 1.35 kw
1 34 kw
1 4.13 kw

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 8 230v Socket 1 5A
9 Battery Charger 1 14 kw
10 MTr Oil Pump 2 3.5 kw
11 Crew Fans 2 -

5.8. Battery Unit & Charging System

The battery charger is fed from a 3 phase 415 V AC output from an auxiliary
transformer.
The function of charger is to feed the entire DC load of the locomotive and to
maintain the charging of the battery unit. The battery system supplies the
load during the unavailability of catenary.

Figure 16: Battery Charger Schematic

Description Specification
Battery in each section
Battery Type Ni-Cd
Number of Cells 80 (40 Cells in each Battery box)
Battery Capacity 100Ah
Nominal Voltage 110V DC

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 Description Specification
Battery Charger
Input Voltage 415 V AC, 3 phase, 50 Hz
Output Voltage 110V DC
Maximum Power Rating 14 kW
Maximum Output
100 A
Current
Battery charging current 20 A
Battery Level Monitoring
• At 89v, Alarm on DDU.
Note:
When Battery voltage is detected as <= 85 Volts, Loco enters shutdown mode
to protect excess draining of batteries.

6. PNEUMATIC SYSTEM
Each section of the WAG 12 locomotives is equipped with a Main Air Supply
Unit (MASU) of 2430 ± 6% LPM capacity (before dryer). Location of MASU is in
the machine room. Oil level can be checked through Spy Glass on Main
compressor.
Synthetic oil Anderol 3057M is used for lubrication. Oil capacity at Max. Level
is 7Ltr and at Min. Level is 6Ltr.

6.1. MASU (Main Air Supply Unit)

i. Air filtration and inlet arrangement
ii. Main compressor with filtration system
iii. Air Dryer
iv. Main Reservoir
v. Auxiliary compressor

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 6.2. Main Compressor Regulation
Compressor Management done by TCMS
Pressure Effect
MR-10 Kg/cm2 Both compressor Off
MR-8 Kg/cm2 One compressor Starts
MR-6.5 Kg/cm2 Both compressors start
MR-5.5 Kg/cm2 Penalty applied, Traction Cut Off
Safety Valves
Pressure Effect
MR-10.7 Kg/cm2 MR safety valve blows
CP-12.2 Kg/cm2 Compressor Safety Valve Blows
- For machine room temperature less than 50°c, the MASU shall operate
on ODD / EVEN day basis
- For machine room temperature between 50°c and 55° the MASU shall
operate on HOURLY basis.
6.3. Auxiliary Compressor Regulation
Pressure Effect Pressure Effect
6 Kg/cm2 Compressor Start 7 Kg/cm2 Compressor Stop

7. BRAKE SYSTEM
7.1. Types of Brakes
7.1.1. Regenerative Brake
Regenerative braking starts above 10Kmph and cuts off at 5Kmph.
Maximum Regenerative effort is available between 10Kmph and 60Kmph.

Regenerative Braking Effort

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

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

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 7.2. Brake Control Module (BCM)

Figure 17 : BCM

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 Figure 18: Auxiliary Panel

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 Figure 19: EPCU

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

ii. Direct Brake

DBP pressure BC pressure
Position
(kg/cm2) (kg/cm2)
Release 0 0
Full 3.8 ± 0.15 3.8 ± 0.15

iii. Emergency Brake

BP pressure BC pressure
Condition
Kg/cm2 Kg/cm2
Applied 0 3.8 ± 0.15

iv. Parking Brake

BC pressure PB pressure
Position
(kg/cm2) (kg/cm2)
Release 0 5.67 ± 0.2
Apply 0 0

Note:
Parking Brake Gauge indicates pressure value of service brakes, if
service brakes are applied during PB applied condition.

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

7.5. Parking Brake Manual Release Plunger

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

Figure 20: Parking Brake Manual release plunger

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8. LOCOMOTIVE OPERATING MODES
Mode Description
Both batteries are isolated from low voltage
distribution circuits through isolation device in each
Dead Mode battery boxes.
Low voltage (110V DC) is not available in the
locomotive
Low Voltage (LV) (110V DC) is available for
Locomotive to energize.
Shutdown In this mode LV is available for:
Mode a) Machine room and Cab Lighting with time out (15
min).
b) Horn
Stand-by mode is activated by closing battery
Contactor through the Battery Connect Switch. The
locomotive is operational with all sub-systems ready
Standby Mode but no cabin is active in the train.
If locomotive remains in this mode for more than 3
minutes, then Locomotive will change over to
Shutdown mode.
This mode can be activated from Standby mode by
activating any one of the Cabins.
Cab Active VCB, panto and driver desk commands are then
Mode available.
Do not leave the cabin active for long durations with
VCB in open condition, as battery gets discharged.

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

9.2. Loco Shutdown Procedure

i. Place the EBV handle in FS position and lock with pin.
ii. Move the VCB open/close switch to Open position.
iii. Move Pantograph toggle switch to lower position.
iv. Ensure pantograph is lowered.
v. Apply the parking brakes on Locomotive.
vi. Turn, Key Switch (BL Key) to OFF Position in Master Controller.
vii. Move battery connect switch to “Stop” position.
viii. Ensure all loads are shutdown.
ix. If the locomotive needs to stay dead mode for longer period, then
Operate Battery Isolation CB to OFF position in both sections.

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

9.4. Loco Grounding Procedure

i. Open the VCB by using the VCB open/close toggle switch.
ii. Lowered the Pantograph by using the Pantograph toggle switch.
(Physically verify that pantograph is lowered)
iii. Isolate Pantograph Cut-out Cock available on PCU in machine
room. This process Releases the pressure available in pantograph
pipe (In Both Sec.)
iv. Ensure Workshop/Shore supply CB in off position (In both Section)

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 v. Operate the Z-SEC key to “HV disconnection” position. Release the
Z-SEC key by rotating Clockwise. Z-SEC key is attached by a welded
ring with the H(O-M) input key (Blue Key-KABA) and with
workshop plug box key (used for the workshop plug function).
vi. Insert the Blue KABA key inside the input barrel, rotate the key and
turn the input barrel.
vii. Rotate the H(O-M) in grounding position through the switch gear
handle.
viii. When the switch gear handle of H(O-M) is in grounding position,
turn the output barrel clockwise direction and the output key
(green) handle linked with the H(O-M).

9.5. Dead Engine Brake Configuration

i. Put EBV mode switch in ‘TRL’ position in both sections.
ii. Put Auto handle in both the section should be kept in FS position &
secure using lock pin and put Direct brake Handle on REL position.
iii. Locomotive shutdown is in Dead Mode (batteries isolated),
iv. Close (horizontal position) SIFA Cock (N55.05), on Auxiliary Panel
of Brake System in both sections
v. Connect BP Hose to another loco or train and Open BP angle cock
so that BP can be charged on dead loco.
vi. DER (Dead Engine Regulator) cock at ERCP in Brake Panel shall be
operated in ‘IN’ position (rotate anti-clockwise position) in both
sections (Rotate anti clockwise to “IN” position written on ERCP)
and allow to charge BP & 150 Litre Reservoir through brake pipe
air up to 5 kg/cm2.
vii. Close (vertical handle position) FP cock (B50.01), on Auxiliary
Panel of Brake System in both sections.
viii. Charge BP to normal level, verify brake are released and BC
pressure is zero. If BC is not reducing to zero, then give brief pulls
to quick release lever at bottom of distributor valve (KE Valve)
Ensure BC reduces to zero.
ix. If loco Brake remains applied, press 20TP (Test point) of 20CP on
Pneumatic Panel to Release BC to Zero.
x. Open one end of DBP & MREP angle cock at one end of dead Loco.
Loco Pilot Handbook - WAG12 [38] NRD0000572585
 xi. Release Parking Brakes by Pressing Plunger (red colour on apply/
release solenoid") on BCM panel of both the sections and ensure
pressure on the parking brake gauge is more than 4.8 kg/cm2.
xii. Release Parking Brakes by Pulling Manual Release Pins on Parking
Brake Unit of each axles in both the sections. Ensure Parking brakes
are released by looking into the gap between brake shoes and
wheel.

9.6. EB Reset Procedure

i. Move the auto brake handle to EMER position once intimation on
EBV comes.
ii. Clear the reason for EB application if any. For example:
a) Normalise EB push button in the section from where EB was
applied.
b) Reset the Assistance Driver Emergency Cock in the section from
where EB was applied
c) Put the auto brake handle in FS, if EB applied from non-active
cab.
iii. Give a VCB close triggered pulse. (no need the give trigger if EB
applied by Auto brake handle)
iv. Move the Auto Brake handle to FS position once intimation of
"Safety Penalty Keep in FS" comes on EBV.
v. Wait for 10 seconds and move the Auto brake handle to RUN to
charge BP once intimation of "Okay to Run" comes on EBV

9.7. Penalty brake Reset Procedure in case of EBV

Failure
Note: - In case Loco cannot run from the section due to failure of EBV
(Electronic Brake Valve)
i. Move Auto Brake Handle (A9) of failed EBV to FS position and lock.
ii. Put selector switch on LEAD of the healthy EBV.
iii. Move the auto brake handle to EMER position once intimation on
EBV comes.

Loco Pilot Handbook - WAG12 [39] NRD0000572585

 iv. Move the Auto Brake handle to FS position once intimation of
"Safety Penalty Keep in FS" comes on EBV
v. Wait for 10 seconds and move the Auto brake handle to RUN to
charge BP once intimation of "Okay to Run" comes on EBV.

9.8. Vigilance Management

Vigilance control is operative in all driving modes except inching mode, it is
also operative for locomotive speeds beyond 5 km/h.
The logic of vigilance is different for driving modes and logic is explained
below:
Loco pilot must perform any of the following actions every 60 seconds
(acknowledgement):
i. Movement of master controller handle (displacement of more
than 5 degree
ii. Movement of auto brake handle
iii. Tap vigilance pedal switch
iv. Press the VCD Ack/Reset push button
If none of the above actions are performed for 60 seconds, an alarm is
triggered and vigilance warning indication lamp is lit on indication panel
along with buzzer.
To reset, Loco Pilot must press and release the vigilance foot pedal.
If alarm is not reset within 16 seconds, then penalty brake is initiated.
To reset vigilance function, Loco Pilot must:
i. Bring traction brake controller handle to “Neutral”
ii. Wait for 32 seconds
iii. Press “VCD Ack/Reset” push button on central panel.
iv. Give VCB close command
v. The reset is recorded in event recorder.
To reset the penalty brake, move auto brake handle to Full Service (FS)
position for 10 seconds and then to RUN position.
Indication is provided when vigilance alarm is active.
a. Visual alarm on Indication Panel
b. Audio alarm through Buzzer Alarm

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

Moving handle completely to Position V leads to emergency brake

application.

Follow Indian Railways speed restrictions while operating locomotive with

Backup-Brake

9.10. Coupling Two Locomotives

i. Bring the two locomotives near to each other at slow speed
(approximately 2 - 3 km/h) and stop them approximately at a
distance of 1 - 2 meters
ii. Check the alignment and position of coupler centres. Couplers
must stand within the gathering range as given above.

Loco Pilot Handbook - WAG12 [41] NRD0000572585

 iii. Ensure that both coupler head knuckles are in open condition or
one open and the other in closed condition.
iv. If required adjust the coupler head position manually towards
each other and make sure that they are in the gathering range of
the coupler geometry.
v. Now bring one locomotive slowly (approximately 3-5 km/h)
towards the stationary locomotive for coupling.
vi. Connect end pipes; feed pipe (white), brake pipe (green), MREP
(red) and DBP (yellow) by operating the respective cocks.
vii. Before starting to move the loco, ensure that the parking brakes
are released. If not, use the manual release lever in the parking
brake cylinder.
Note:

Pull the locomotives and ensure proper coupling.

9.11. BP leak test procedure

i. Ensure all EBV in TRAIL position and EB is not applied before
attempting to set up in TEST.
ii. Set Auto brake handle is lock in FS position in non-active cab.
iii. Put selector switch on LEAD in active cab.
iv. Set Auto brake handle in RUN and Direct brake handle in Full
position in active cab (charge BP)
v. Set EBV Automatic Handle - MIN
a) ER reduces to approximately 4.6 ± 0.10
b). BP reduces to approximately 4.6 ± 0.10
vi. Set EBV Mode switch in TEST, BC develops to approx. 3.8 ± 0.15
vii. Set EBV (SECTION-I) Automatic Handle - FS
a) ER reduces to approximately 3.3 ± 0.10
b) BP remains approximate 4.6 ± 0.10
viii. Wait one (1) minute. Then Monitor brake pipe pressure for two
(2) minutes. Leakage should not exceed 0.07
ix. Set EBV Automatic Handle - RUN
a) ER increases to approx. 5.0 ± 0.1. Wait one (1) minute

Loco Pilot Handbook - WAG12 [42] NRD0000572585

 b) BP must not increase.
x. Set EBV Mode Selector Switch - LEAD
a) BP increases to ER +/-0.1
b) BC reduces to < 0.2

9.12. Single Pipe Loco Configuration (with load)

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

9.13. Charging BP on first power Up (i.e. Loco Charging)

i. Keep Auto/A9 handle in FS, wait until “Okay to Run” message
displayed on EBV.
ii. Place Direct Brake Handle (SA9) at REL position
iii. Move Auto Brake Handle (A9) to RUN position and verify that BP
is charged to 5 kg/cm2, BC drops to 0 kg/cm2.
iv. To overcharge the BP to 5.5 kg/cm2, Hold Auto Brake Handle (A9)
at REL position for minimum 3 seconds.
v. Once BP starts increasing, place Auto Brake Handle (A9) at RUN
position.
vi. BP will charge to 5.5kg/cm2 and then drops back to 5 kg/cm2. (this
process takes approximately 270 +/- 10 seconds)
Note: The overcharge cycle should not be interrupted by any means i.e. EB,
penalty, Cab change etc. If interrupted, initiate the overcharge cycle again and
allow it to complete.

Loco Pilot Handbook - WAG12 [43] NRD0000572585

 vii. Quick release of Auto Brake in Loco either can be by lifting Bail-Off
ring provided on Direct Brake Handle (SA9) or by pressing Bail-Off
foot pedal switch.

9.14. Helper Mode

i. Connect Brake pipe of helper unit to the leading units to
apply brakes in helper loco based on BP drop from lead
locomotive. Other pipe connections can be done based on
configuration to which helper loco is to be connected.
Note: Banker loco is generally placed at the end.
ii. Ensure that the mode selector switch on the EBV in the
inactive section is set to ’TRAIL’, and the auto brake handle
is in ’FS’. The auto brake handle in the inactive cab should
be locked by inserting the provided lock pin into position.
iii. In the active section, place Auto handle in ’FS’ (Full Service)
and Independent (Direct) handle in ’FULL’ application.
iv. Place Reverser Handle in ‘Neutral’.
v. Turn Mode selector switch on EBV to HLPR.
vi. The EBV screen displays the following message: “MODE
CHANGE; MODE = HLPR".
vii. Auto brakes are not available except ‘Emergency’
application and Independent (Direct) handle operation is
still available.

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

Loco Pilot Handbook - WAG12 [45] NRD0000572585

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

Loco Pilot Handbook - WAG12 [46] NRD0000572585

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

Loco Pilot Handbook - WAG12 [47] NRD0000572585

 S. No Fault Help

1. Break the seal of VCD isolation switch located in CCR panel

12 VCD isolation
2. Turn the VCD isolation switch to 'isolated' position.

Cab not getting 1. Turn OFF the master controller key and remove the key.
13
deactivated 2. Trip the CB 74Q01 located in the LVC.

1. Verify that the Flasher Control is in ON position and Mode selector toggle switch in
Main or Standby.
2. Press Flasher Light push button located in Driver Desk and check Flasher Light is
working or not. If it is not working proceed to the next step.
3. Switch the mode to (STANDBY/MAIN) .Still It is not working proceed to the next
Flasher Light not
14 step.
working
4. Try to activate the flasher light using DDU .If it is not working perform the next step.
5. Put the fuse in MAIN/STANDBY by taking from SPARE fuse and check the operation
by following above steps .
6. Flasher light still does not work Complete failure of the flasher control unit. No
controls will work.

Loco Pilot Handbook - WAG12 [48] NRD0000572585

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

Loco Pilot Handbook - WAG12 [49] NRD0000572585

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

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

26 Speed display failure Operate the loco by using DDU

Loco Pilot Handbook - WAG12 [51] NRD0000572585

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

Loco Pilot Handbook - WAG12 [52] NRD0000572585

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

Loco Pilot Handbook - WAG12 [53] NRD0000572585

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

Loco Pilot Handbook - WAG12 [54] NRD0000572585

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

Loco Pilot Handbook - WAG12 [55] NRD0000572585

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

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