Trainset Troubleshooting Manual Vol 2 Draft

केवल कार्ाालर्ीन उपर्ोग हे तु
(For Official Use Only)
भारत सरकार GOVERNMENT OF INDIA

रे ल मंत्रालर् MINISTRY OF RAILWAYS
Troubleshooting Manual
For
Vande Bharat Trains
(VOLUME – 2)
IRCAMTECH/GWL/2023-24/Trainset/TSM/1.0
Troubleshooting Manual for Vande Bharat Trains
TROUBLE SHOOTING MANUAL ( VOLUME -2)
Version : 1.0
All rights reserved. This book or any portion thereof may not be
reproduced or used in any manner whatsoever without authorization
from Indian Railways.
Content in this document is compiled with the inputs provided by ICF

and OEMs.
IRCAMTECH/GWL/2023-24/Trainset/TSM/1.0 Page 2 of 31
Amendment and Revisions
The correction slips to be issued in future for this report will be numbered as follows:
IRCAMTECH/GWL/2023-24/Trainset/TSM/1.0# XX date .......
Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).
Version Date Corrections Remarks

For chair car trainset with Medha
1.0 August 2023 First Issue
Propulsion System.
Structure of Documentation
This Troubleshooting Manual provides instruction for troubleshooting different
systems and equipment in the trainset. This manual may be used as a base
document to frame troubleshooting guidelines for the trainset.
For ease of understanding and usability the complex trouble shooting - related
information in the documentation has been divided into two volumes:
Volume - 1: Troubleshooting of 25 kV AC Three Phase Propulsion & Other

related equipment for trainset.
This volume contains troubleshooting instructions for the en-route maintenance staff
provided by Medha Servo Drives Pvt. Ltd. In this document troubleshooting
instructions according to the fault code a displayed on the Driver Display Unit are
mentioned. Schematic reference for different coaches, functional groups and their
sub functional groups are provided along with location and check points for
troubleshooting.
Volume - 2: Troubleshooting for various equipment / sub assembly of trainset.
This volume provides troubleshooting information for equipment / sub-assemblies of

trainset coaches provided by various OEMs. The details have been taken from
Vande Bharat Express Trainset (V2.0) Maintenance Manual (Volume-2, Chapter 8 –
Troubleshooting) issued by CAMTECH on September 2022.
Content
1. TROUBLESHOOTING OF SEMI PERMANENT COUPLER (DELLNER) ...6
2. TROUBLESHOOTING OF DAMPER (KONI) ..............................................6
3. TROUBLESHOOTING OF PASSENGER SEAT (STER) ............................9
4. TROUBLESHOOTING OF AUTOMATIC INTERNAL SLIDING DOOR

(PRAG) ......................................................................................................13

(NORGREN)..............................................................................................13
6. TROUBLESHOOTING OF AUTOMATIC SINGLE LEAF PLUG DOORS

(iFE) ..........................................................................................................15
7. TROUBLESHOOTING VACUUM BIO TOILET (EVAC) ............................16
8. TROUBLESHOOTING PANTOGRAPH (SCHUNK) ..................................17
9. TROUBLESHOOTING MAIN TRANSFORMER ........................................19
10. TROUBLESHOOTING TRACTION MOTOR (TSA) ..................................22
11. TROUBLESHOOTING GEAR DRIVE (TSA) .............................................23
12. TROUBLESHOOTING RMPU (AMIT ENGINEERS) .................................24
13. TROUBLESHOOTING SALOON LIGHT (ENSAVE) .................................25
14. TROUBLESHOOTING PAIL LIGHT (ENSAVE) ........................................26
15. TROUBLESHOOTING DRIVER CAB/ GANGWAY LIGHT (ENSAVE) .....27
16. TROUBLESHOOTING MONOBLOCK PUMP (CEC) ................................27
17. TROUBLESHOOTING ERCU (SCHUNK).................................................29
18. TROUBLESHOOTING WIPER SYSTEM (HEPWORTH RAIL).................29
1. TROUBLESHOOTING OF SEMI-PERMANENT COUPLER (DELLNER)
ERROR / FAULT POSSIBLE CAUSE CORRECTIVE ACTION
Foreign material
Manually remove foreign
obstructing
material.
coupling/uncoupling.
Will not couple/uncouple Coupling details Check socket joint kit.
worn/rusty. Replace as required
Flanges will not catch,
Lift coupler half a bit more
excessive height
difference
Rear nut loose Check rear nut. Replace
Slack when coupled as required.
Rubber springs broken or Check rubber springs.
exhausted Replace as required.
Cannot absorb the draft Exhausted or broken Draft gear requires repair
and buff loads. Rubber springs
2. TROUBLESHOOTING OF DAMPER (KONI)

ERROR / CORRECTIVE
POSSIBLE CAUSE
FAULT ACTION
Normal contamination caused by the operating

environment of the dampers is harmless.
If a damper has a damp film over the whole

body (including the dust cover), it is very
probable that this is the result of an outside
source of oil or dirt.
In this case the damper can remain in service.
Dirt No action to be
Accumulation taken.
For a long service life, it is necessary for the
rod oil seal to remain lubricated. The
continuous inward and outward movement of
the piston rod may cause oil “sweat” from the
rod oil seal.
This loss of oil can be recognized by the

outside of the damper being slightly moist and
dirty. However, there should not be any
droplets of oil clinging to the damper.
A slight oil sweating will not affect the damping

force and this damper may remain in service.
No action to be
Sweating
taken
A true oil leakage becomes apparent by a

damp surface, which usually covers a large part
of the reservoir tube.
Isolated oil drop formation is possible.
When wiping the damper with a paper cloth,

clear oil stains are visible.
Replacement/
Oil drops
Overhaul
For surface cracks
No action required
When depth of crack is 8 mm and above.

Cracks in
rubber of
silent block
Replace the
attachment
De-bonding
When De-bonding of metal and rubber is Max Replace the
of metal and
10% of the total rubber attachment
rubber
Pulverized rubber is max. 10% of the total

rubber
Rubber Replace the

deterioration attachment
Creeping of
Loose collar - Only a cosmetic issue No action required
rubber
3. TROUBLESHOOTING OF PASSENGER SEAT (STER)
ERROR / POSSIBLE CAUSE /
CORRECTIVE ACTION
FAULT OBSERVATIONS
Damaged upholstery should be replaced

as soon as possible.
Exchange of seat cushion

1. Unscrew the four screws M6x16.
2. Remove cushion.
3. Place the new cushion back.
4. Put thread locker on the tip of the
screws (Loctite 278)
5. Place the four washers DIN 125
A6.4 Inox and tighten the four screw
M6x16 Inox – DIN 912 to a torque of
10N.m
Upholstery
damaged
due to wear Train can continue operation
of fabric, or without correction
due to
vandalism
Exchange of the seat backrest

1. Remove the cushion as explained
above.
2. Remove the gas spring.
• Remove the bolt M6x20 8.8 DIN
912 and gas spring fixation bush
310008
• Remove the gas spring lever.
3. Untighten the bolt No 218 085 and

disassemble the fasteners.
4. Remove backrest and replace it with
the new one.
5. Place the backrest according to
illustration using spare parts set: 218
085, 310 031, 410 162, 311 012, 410
160
6. Add thread locker (Loctite 278) on the
tip of the screw and tighten to torque
45N
Parts are Train can continue operation

scratched without correction. If after cleaning, the considered area still
, burned,
shows structural damage (and/ or
deformed, If structural damage is aesthetically unacceptable traces), then
broken suspected, the parts shall not replace the part.
due to be used or operated by
vandalism anyone
Chair Car
snack
Train can continue operation Adjust the level by following proper
table is
without correction. procedure.
not
levelled.
Train can continue operation

without correction.
Follow the below mentioned

OEM Instructions:
1. Lift the armrest
2. For second class,
armrests on the gangway
side are fixed and can’t be
Armrest lifted. If the armreststill can't be operated,
doesn't lift exchange the armrest following proper
or lower procedure.

without correction.

OEM Instructions:
1. Push the pedal down.
Executive
class seat
Exchange the corresponding part
doesn't
rotate
2. Start rotating the seat

(around 15 degrees). By
pushing or pulling the
handle.
CAUTION: The rotation is
possible only in one
direction. If the seat
blocks when rotating, then
try the other direction.
3. Release the pedal.

4. Rotate the seat to 180
degrees until the
mechanism locks itself

without correction.

OEM Instructions:
1. Open the armrest.
2. Pull the table and rotate
until blocked in longitudinal
direction.
Executive
class seat
central
console Exchange the corresponding part
table can't
be
opened
3. Rotate the table in lateral
direction.
4. Close the armrest
(PRAG)
ERROR / FAULT CORRECTIVE ACTION
• Push lit button provided on door leaf - Door
When door in not opening will open and close automatically after
automatically on Automatic pressing the push button.
mode (Radar / Spot Scan
• Check the MCB2 it should be ON state in
sensing mode)
case radar is working in auto mode.
• Press the red colour mushroom type

emergency push button located on side panel
of door. The door mechanism will switch over
on manual mode after pressing the
emergency push button.
When radar sensing mode and
green lit push button mode both • Pull the door leaf manually with the help of
are not working. sunk in handle provided on door lead frame
on the direction of opening the door.
• Pull the door leaf manually with the help of

sunk in handle provided on door lead frame
on the direction of closing the door.

(NORGREN)
The 7-segment display (H401) on the controller shows the following status and error
displays.
CODE - 1 Motor torque-free. New

If necessary replace
RAM-, EEPROM-or CPU start after threefold correct
controller
error (system error) additional test
CODE - 3
Motor torque-free: New If necessary replace
Error in second switch-off
start after 5 seconds controller
stroke
Hold-open time extended
CODE - 4 Motor needs longer rest
by minimum 2s to
Motor undefined phases
maximum 4s
Check wiring, if nec-
essary replace controller
Motor undefined start after 30 seconds
or motor
CODE - 6
Check if an obstacle is in
Motor blocked in closing Door stops and reverses
the door
direction
Check wiring, if
CODE - 7 Motor torque-free: New
necessary replace con-
Error pulse generator start after 5 seconds
troller or motor
CODE - 8
Minimal editor is started Door must be taken into
(service button Open and Motor is torque free operation by reapplying
Closed activated at the operating power
same time)
Check wiring, if nec-
essary replace controller
Motor over current start after 30 seconds
or motor
CODE - A Door must be taken into
Minimal editor (power ad- Motor is torque free operation by reapplying
justment) active operating power
CODE - c Check if an obstacle is in
Door stops and reverses
Blockage at opening the door
CODE - C Door must be taken into
Minimal editor (profile ad- Motor is torque free operation by reapplying
justment) active operating power
CODE - d
Door does not move Check if an obstacle is in
Door has stopped
during initializing run (no the door
OPEN or CLOSED signal)
CODE - E Check input voltage from
Motor over current-Motor New start after 30 seconds vehicle, if necessary
torque-free. replace controller
CODE - F Check input voltage from
Door system is slower
Motor low voltage vehicle
The door travels
CODE - H
automatically in both Wait for end of training
Parameter verification
directions until the training run
(training run)
run has been finished.
CODE - L
Motor torque-free: New If necessary replace
Current measurement er-
start after 5 seconds controller
ror
CODE - o The door is outside the
None
Function OK. “Closed” position
Check the door at first
CODE - P
Motor is stopped. No new activation (service). If
Parameter error (error in
automatic start necessary replace
the training run)
controller
CODE - u The door is in the
None
Door is closed “CLOSED” position
Immediate new start. Can Check the door at first
CODE - U only be quit via a training activation (service). If
Max. door mass exceeded run with standard necessary replace
parameter set controller
CODE – (-)
Door does not move
Perform training run for
during the initializing run no
parameter verification
and has no valid
parameters
6. TROUBLESHOOTING OF AUTOMATIC SINGLE LEAF PLUG DOORS
(iFE)
Signal input of the door position

sensor at the DCU, door drive
Motor current monitoring
mechanism, door movement,
at opening sequence
adjustment of the door,
CODE - 7 was activated on a fixed
adjustment and wiring of the
number of successive
limit switch “door closed/locked”
opening attempts
and input circuit of the DCU to
be checked
The activation of the security
relay according to the block
CODE - 8 Internal security relay of diagram of the DCU and
the DCU fails according to the wiring diagram
has to be checked, otherwise
the DCU has to be replaced
Component connected to output
CODE - 13 Short circuit at the output A1, wiring and output of the
A1 of the DCU DCU to be checked
Change the NOVRAM mounted
CODE - 22 Battery backup of the in the DCU
diagnostic memory fails
Door open push button, input
CODE - 34 Door open push button circuit of the DCU and wiring to
inside fails. be checked
Door data bus cable, connectors
CODE - 42 Data bus communication and bus interface to be checked
fails
Mechanical adjustment of the
emergency release device,
adjustment of the limit switch of
Door leaves the the emergency release device,
CODE - 44 closed/locked position door locking mechanism, door
without permission drive mechanism, adjustment
and wiring of the limit switch
“door closed/locked” and input
circuit of the DCU
Door open push button(s), input
CODE - 48 Door open push button circuit of the DCU and wiring to
outside fails be checked
Adjustment and wiring of the
CODE - 71 Limit switch “door 98% limit switch “door 98% closed”
closed” fails and input circuit of the DCU to
be checked
Pressure switch, input circuit of
CODE - 124 the DCU and wiring to be
Pressure supply missing
checked
Signals from the VCU, wiring,
CODE - 134 Signals from the VCU connectors and input circuit of
are faulty DCU to be checked
Coding of the DCU has to be
CODE - 138 checked
Door coding faulty
Speed signals from the VCU,

CODE - 225 Speed signals from the wiring, connectors and input
VCU are faulty circuit of DCU to be checked
Door out of service mechanism,
CODE - 226 Door out of service input circuit of the DCU and
device fails wiring to be checked
Service push button of the DCU
CODE - 246 Service push button on to be checked
the DCU fails
Signals from the vehicle control
CODE - 252 Signal from the vehicle unit, wiring, connectors and
control unit is different input circuit of DCU to be
checked
7. TROUBLESHOOTING VACUUM BIO TOILET (EVAC)
Flush button is pushed No power Supply power

but toilet does not No fresh water Check water supply
flush Bio-digester full Empty Bio-digester
No compressed air Provide compressed air
Flush button defective Check cable, check flush
button, replace if necessary
Water flows into toilet Water Inlet valve clogged Remove blockage
bowl Pinch valve defective Replace pinch valve
Quick exhaust valve Defrost quick exhaust valve
blocked due to
frost
Quick exhaust valve Clean quick exhaust valve
blocked due to
pollution
Water filter clogged Clean filter
Liquid level guard in flush Contact EVAC service
water tank Remove flush water tank
defective
Toilet bowl is not Flush nozzles polluted Clean flush nozzles
flushed sufficiently Flush nozzles calcified Decalcify flush nozzles
Flush nozzles swivelled out Adjust flush nozzles
of optimal
position
Error Routine
Code Cause
Code 01 WWT (Bio-digester) full
Code 02 Pressure rise
Code 03 Pressure Vacuum
Code 04 Pressure detected
Code 05 Bowl full
Code 06 No water
Code 09 Inlet can`t close
Code 10 Inlet can`t open
Code 20 Flush Button Error
8. TROUBLESHOOTING PANTOGRAPH (SCHUNK)
CHECKUP:
Static contact force is poorly Static contact force
adjusted. ADJUSTMENT:
Static contact force
CHECKUP:
Pantograph does not Air bellow drive for damage
Air bellow drive defective.
raise or lower. REPLACEMENT:
Air bellow drive
REPLACEMENT:
Cable with terminals torn.
Cable with terminals
REPLACEMENT:
Air line defective.
Air line
Damper between base frame REPLACMENT:

and lower frame defective. Shock absorber
CHECKUP:
Static contact force
Inner friction of pantograph CHECKUP:
too high. Pantograph for damaged
components.
REPLACEMENT:
Damaged components
CHECKUP:
Leaking test
Valve unit ADD responds.
Functional test
As per OEMs instruction
CHECKUP:
Static contact force is poorly Static contact force
adjusted. ADJUSTMENT: Static contact
force
Frequent interruption of CHECKUP:

current transmittal Static contact force
(strong arcing). CHECKUP:
Inner friction of pantograph
Pantograph for damaged,
too high.
especially bearings.
REPLACEMENT:
Damaged components
REPLACEMENT:
Sliding strips damaged.
Sliding strips (as pairs)
REPLACEMENT:
Stiff pan head suspension.
Rocker boxes
ADJUSTMENT:
Parallel guide poorly adjusted.
Turning capacity of pan head
Uneven wear of sliding ADJUSTMENT:
Parallel guide poorly adjusted.
strips. Turning capacity of pan head
REPLACEMENT:
Cable with terminals Cable w. terminals
ungreased GREASING:
Cable w. terminals
Cable torn
REPLACEMENT:
Air bellow drive poorly Cable w. terminals
adjusted. ADJUSTMENT:
Air bellow drive
Air bellow drive FASTEN:
Loosened screw connections.
defective. Loosened screw connections
CHECKUP:
Leaking test
Leaking air line.
REPLACEMENT:
Air line
REPLACEMENT:
Bellow cylinder leaking.
Air bellow drive
9. TROUBLESHOOTING MAIN TRANSFORMER

ERROR / FAULT IMMEDIATE ACTION DIAGNOSTIC / ACTION
TO BE PERFORMED
Pressure relief • Stop Transformer / Do not • Check if Air dryer is
device tripping reenergize Transformer. not blocked
• Visual checking of Pressure (disassemble it)
relief device, bushings and tank. • Electrical
• Check circuit breaker tripping. measurements (ratio,
• Check oil level. winding resistances,
• Perform electrical insulation
measurements. resistances).
• Perform dissolved gas analysis. • Visual checking of
• Do not reenergize without full Pressure relief device,
diagnostic. bushings and tank.
• Perform dissolved gas
analysis.
• Analyse train
parameters records.
Circuit breaker • Check Pressure relief device • Electrical
tripping tripping, visual checking of measurements (ratio,
Pressure relief device, bushings, winding resistances,
and tank. insulation
• Check oil level. resistances).
• Do not reenergize Transformer if • Visual checking of
some anomaly is detected during Pressure relief device,
above checks. Perform electrical bushings, and tank.
measurements • Perform dissolved gas
• Perform dissolved gas analysis analysis.
• Analyse train
parameters records.
Current Transformer • Check Pressure relief device • Electrical
overcurrent tripping, visual checking of measurements (ratio,
Pressure relief device, bushings, winding resistances,
and tank. insulation resistances)
• Check oil level. Visual checking of
• Do not reenergize Transformer if Pressure relief device,
some anomaly is detected during bushings, and tank
above checks. Perform electrical • Perform dissolved gas
measurements. analysis Analyse train
• Perform dissolved gas analysis. parameters records
Overtemperature • Reduce power, if not sufficient • Check load and other
tripping stop Transformer. train parameters
(temp. sensor or • Check Pressure relief device records.
Thermostat) tripping, visual checking of • Check cooling system:
Pressure relief device, bushings, oil flow, air flow, and
and tank. radiator cleaning.
• Check oil level. • Check temperature
• Do not reenergize Transformer if sensors.
some anomaly is detected during • Check for any oil
above checks. presence in Air dryer.
Different reading • Check temperature sensor /
from temp. sensors Thermostat and change device if
or necessary.
Tripping of one
Thermostat without
tripping of lower
range Thermostat
Visual oil level too • Check for any leakage. • Look for any leakage
low • Add dry and filtered oil. including tank, pipe,
gasket assembly, air
plug, cracks.
• Clean suspected area,
and check if oil
appears again
(preferably with hot
oil).
• When located repair
leakage.
Low oil level sensor • Check for any leakage. • Look for any leakage
tripping • Add dry and filtered oil. including tank, pipe,
plug, cracks
and check oil appear
again (preferably with
hot oil).
leakage.
Very low oil level • Stop Transformer. • Check recorded load
sensor tripping • Check visual oil level. Check for and oil temperature
any leakage. (train parameters).
• Check for consistency of sensors • Perform dissolved gas
: low oil sensor tripping before analysis.
very low level. • Look for any leakage
including tank, pipe,
plug, cracks. Clean
suspected area, and
check if oil appear
hot oil).
leakage.
Oil leakage • Check Oil level. • Look for any leakage
• If very low oil level stop including tank, pipe,
Transformer. Look also for other gasket assembly, air
train equipment in the vicinity. plug, cracks.
• If gaskets are
mounted with
Vaseline lubrification
and Transformer
being heated, it could
be sometime
misinterpreted as
leakage.
and check if oil appear
hot oil).
leakage.
Oil flow stop tripping Stop Transformer. If pump is running and
Check Oil level. valves are ok,
Check if Pump is running. Check Oil flow indicator
Check for every Valves position. contactor, if necessary
change Oil flow indicator.
if not, Check Pump supply
and windings, if
necessary change the
Pump.
Air dryer change of Check oil water content, if below limit Check for any crack on Air
color start on oil needs to be dried. dryer.
opposite site of air Change gasket or Air dryer.
entrance
Bushing color Look for any loosening of Check possible
change connection, and overheating from
correct it. loosening
Look for any crack, if any stop connection or possible
Transformer.. damage creating electrical
ageing
Bushing crack Check for any leakage.
Advise manufacturer.
Abnormal noise Try to locate area involved: • Check there isn't any
• Pump loosed equipment and
• Hydraulic noise correct immediately if
• Fans necessary
• Main tank • Pump : check rotation
• Some loosing equipment and if necessary
correct phases supply.
• Other train component
Check bearings and
replace them if
necessary.
• Hydraulic : try to
evacuate air by air
drain plugs
• Fans : looks for some
friction or any external
part blocking fan
rotation.
• Check rotation and if
necessary correct
phases supply. Check
bearings and replace
if necessary.
• Main tank: advise
manufacturer.
Paint damage or • Paint repair • According to
corrosion maintenance manual.
Shocks • On bushings : replace. • Check for any
• On accessories : replace. leakage.
• On main tank : advice
manufacturer.
• On flexible pipe : replace.
• On auxiliary connectors :
replace.
Physical properties • Refer to maintenance manual. • Check Air dryer.
of oil (water content,
breakdown voltage)
DGA indicating fault • Consult expert to decide. • Expert diagnostic and
sampling interval.
10. TROUBLESHOOTING TRACTION MOTOR (TSA)
Engine vibrates, Engine suspension Carry out a visual inspection of

unusual engine (rubber elements) the motor suspension. If
noises defective necessary, replace the rubber
elements.
Loose screws A screw check is necessary. It
must be checked if the screws
have been tightened with the
correct torque.
Replace broken or broken screws.
Imbalance of Rotor The rotor must be dismantled and
the balancing must be checked.
If necessary, the rotor must be
rebalanced.
Damage of bearing Replace bearing
Damage of coupling Replace coupling
Ventilator damaged or Check ventilator
blocked
Temperature in the Cooling airline (supply or Check cooling airline (supply or
stator is too high. discharge) damaged or discharge).
(warning limit has blocked
been reached)
Ventilator damaged or Check ventilator
blocked
Protective grid on the air Clean the protective grid on the
outlet dirty or clogged air outlet
Cooling air inlet Observe the allowed inlet
temperature too high temperature.
Motor overload Observe technical data
Smoke Bearing damage, Check the engine according to the
development damaged winding, general inspection.
temperature in stator is
too high
Reduced drive Defective supply cable Visual inspection of the supply
power cables. If necessary, replace
them.
Defective connection of Visual inspection of the terminal
the supply cable box.
Defect in the power Check the functions of the
supply of the inverter inverter.
Defective coupling Visual inspection of the coupling.
11. TROUBLESHOOTING GEAR DRIVE (TSA)
Abnormal noise Bearing failure or damage Replace bearings.
Toothing failure or damage Replace damaged gear wheels
Smoke emission Bearing damage Replace bearings
Vibration or knocking Retaining screws of the Check whether retaining

when load changes gearbox mounting are screws are seated firmly on the
loose or spherolastic gearbox mounting and retighten
bearing is defective if necessary. Inspect
spherolastic bearing visually;
replace if necessary.
Gear coupling defective Check and replace the gear
coupling according to operating
manuals of the coupling
Oil escaping on the Oil level in Traction Check oil volume on the oil
labyrinth seals of the Gearbox too high level indicator and adjust if
shafts necessary.
Water has penetrated the Perform oil change.

Traction Gearbox (e.g.,
while cleaning the wheelset
Traction Gearbox)
Gearbox was tilted too Disassemble, clean and

much (with oil filling) assemble labyrinth seal parts.
Oil escaping on a Bolt not tightened Tighten bolt with specified

locking screw according to specifications torque.
Seals worn or defective Replace affected seal.
Wheelset, Traction Oil level in Traction Check oil volume on the oil
Gearbox gets too hot Gearbox too high or too low level indicator or on the dipstick
and adjust if necessary.
12. TROUBLESHOOTING RMPU (AMIT ENGINEERS)

SYMPTOMS TROUBLE SHOOTING
110V DC main MCB • Check availability of 110V DC at MCB
of RMPU Control • Check AIR.CO. Switch ‘ON’ status on DDU
supply ‘ON’, but, (Driver Desk Unit).
HVAC Unit does not
• Check availability of 415V AC at MCB
work.
Controller ‘ON’, But AC not working.
No cooling • Check AIR.CO. Switch ‘ON’ status on DDU
(Driver Desk Unit).
• Check HP fault status on DDU (Driver Desk Unit).
Compressors 1. Check for causes of HP tripping.
not working • Check LP fault status on DDU (Driver Desk Unit).
2. Refer clause no. 4.1.3 for causes of LP tripping.

• Check supply air fan 1 or 2 thermal
protection fortripping.
• All measuring sensors failed.
• Check working of Blower motor.
• Check 415V AC, 3 Ph. Available at
Compressors terminals.
No Heating • Check AIR.CO. Switch ‘ON’ status on DDU
(Driver Desk Unit).
• Check OHP cut for tripping. In healthy condition
LED indications in controller DIP-06 & DIP-28
should glow.
• Refer clause no.6.2 for causes of OHP tripping.
• Check supply air fan 1 or 2 thermal protection
for tripping.
• Check EST1 cartridge fusible link is not broken.
• Check working of Blower motor.
• Check 415VAC, 3 Phase available at Heater
terminals.
In cooling mode • Check thermal protection inside motor for tripping.
Condenser motor In healthy condition LED indications in controller
does not work. DIP-03, DIP-04, DIP-25, DIP-26 should glow.
• Check supply air fans thermal protection for tripping.
• All measuring sensors failed.
• Check 415V AC, 3 Ph. available at Condenser motor
terminals.
Supply air fan • Check AIR.CO. Switch ‘ON’ status on DDU
motorsnot working. (Driver Desk Unit).
• Check supply air fans thermal protection for tripping.
• Check 415V AC, 3 Ph. available at Blower motor
terminals.
13. TROUBLESHOOTING SALOON LIGHT (ENSAVE)
LED array does Improper LED array fitment and Ensure correct terminal
not glow or strike. soldering of it to the input point soldering and the fitment
with LED array.
LED array unit is defective. Replace defective unit with
working one.
Loose wiring at led terminal and Replace loosened contacts
at driver unit output terminal at LED array and driver
output terminal
Driver unit is malfunctioning Replace defective driver
unit with working driver
Driver unit is Loosed wire contacts at driver Ensure positive wire
not working output and the input terminal. contacts at driver and also
input terminal.
Driver unit defective. Replace defective unit with
good and working one.
Improper LED array insertion Ensure LED array insertion
into MCPCB board to no load and positive tightness of
condition. the screw.
Low Lux Level LED array is at the end of its Ensure aged LEDs over
life. 50,000 burning hours need
to be replaced.
Dust accumulation on front Periodic frequency to clean
diffuser. the diffuser surface
externally.
Dust / insect / Removal of end caps provided Ensure end caps are
water ingress at the end sides of the luminaire repositioned after
into the housing. breakdown maintenance at
luminaire the end sides of the
housing. luminaire housing.
14. TROUBLESHOOTING PAIL LIGHT (ENSAVE)
LED array does not Improper LED array fitment Ensure correct terminal
glow or strike. and soldering of it to the input soldering and the fitment
point with LED array.
working one.
Loose wiring at led terminal Replace loosened contacts
and at driver unit output at LED array and driver
terminal. output terminal
Driver unit is malfunctioning. Replace defective driver
unit with working driver.
Driver unit is not Loosed wire contacts at driver Ensure positive wire
working output and the input terminal. contacts at driver and also
input terminal.
into MCPCB board to no load and positive tightness of the
condition. screw.
to be replaced.
externally.
Dust / insect / water Loosed fasteners at the main Ensure adequate tightening
ingress into the diffuser frame assembly. of the diffuser frame
luminaire housing.
assembly fasteners
15. TROUBLESHOOTING DRIVER CAB/ GANGWAY LIGHT (ENSAVE)
LED array does Improper LED array fitment and Ensure correct terminal
not glow or strike. soldering of it to the input point soldering and the fitment
with LED array.
working one.
Loose wiring at led terminal and Replace loosened contacts
at driver unit output terminal. at LED array and driver
output terminal
Driver unit is malfunctioning. Replace defective driver
unit with working driver.
Driver unit is Loosed wire contacts at driver Ensure positive wire
not working output and the input terminal. contacts at driver and also
input terminal.
into MCPCB board to no load and positive tightness of
condition. the screw.
to be replaced.
externally.
Dust / insect / Removal of end caps provided Ensure adequate tightening
water ingress at the end sides of the luminaire of the diffuser frame
into the housing. assembly fasteners
luminaire
housing.
16. TROUBLESHOOTING MONOBLOCK PUMP (CEC)
Motor does not No power supply Ensure power supply
rotate Over heating Remove fan cover & Check for
free rotation of motor shaft
along with fan and allow the
motor to cool & switch on.
Impeller struck up Check the impeller
Pump does not lift Priming not sufficient Fill water till it flows continuously
water without air lock.
Air leak in suction pipe Use proper sealing to arrest
leak or use Teflon tape at joints.
Blocked suction pipe Clean the suction pipe.
Too many bends in

Reduce the bends
suction pipe
Leaking seal Replace the seal

Suction lift too high Install the pump closer to water,
and maintain the suction head
range within 8 m.
Tighten the air cock, renew if
Air cock side leaking required.
Position of casing altered Correct the position of the
delivery casing at 90° vertical.
Monobloc pump running By changing any one phase of

in opposite direction. the electrical connection the
direction can be changed.
Capacity decrease Stainer clogged; suction • Clean the stainer and install
lift too high; inlet mouth of the pump closer to water level.
suction pipe insufficiently • The inlet of suction should
submerged. be atleast 2 inches below
water level.
Total height higher than Reduce the total head.
specified head.
Leaking mechanical Running face is damaged Lap the running face or replace
seal it.
Monobloc get Kept idle running for a Remove fan cover and rotate
jammed longer time. (More than 8 the shaft by hand, to ensure free
hours) rotation. The pump should be
run for a few minutes at least
once in two days.
17. TROUBLESHOOTING ERCU (SCHUNK)

The resistance The corresponding Take appropriate action to
between the contact surfaces on the restore the contact surfaces to
grounding contact axle and the bearing a metallically bright state.
and axle or housing / gear casing
grounding contact are not metallically
and bearing housing bright.
is too high.
The mounting The mounting thread on Take appropriate action to
screws cannot be the axle and on the restore the mounting thread to
screwed in. bearing housing / gear a perfect condition.
casing is not in perfect
condition.
The mounting The usable depth of The usable depth of thread
screws cannot be thread is not sufficient must match the mounting
fully screwed in. or the screws are too screws.
long.
The brush guide is The parallelism Take appropriate action to
incorrectly aligned to between the front-end restore the parallelism between
the axle. mounting surface on the the mounting surfaces.
axle to the front-end
mounting surfaces of
the bearing housing /
gear casing must be
greater than 0.1 mm.
18. TROUBLESHOOTING WIPER SYSTEM (HEPWORTH RAIL)

ERROR / POSSIBLE TESTS AND CHECKS CORRECTIVE
FAULT CAUSE ACTION
Wiper motor On/off switch Check position of switch Turn switch to on
fails to start position
Voltage Level Check supply voltage to • Replace switch.
switch. • Correct loose wiring
connections.
• Replace broken
wires
System Jammed Check wiper linkage • Release linkage.
• Release wiper arm
Defective wiper Replace motor
motor
Defective control Replace control Box
Box
Motor shaft Defective or loose Check linkage for a loose • Secure or replace
turns but drive crank drive crank drive crank.
linkage & • Clean motor output
arm remain shaft with wire brush
static before replacing.
System Wiper arm Check for loose wiper arm Secure or replace
operates but connection onto drive wiper arm after
wiper arm spindle cleaning spindle spline
remains with wire brush.
static
Erratic Voltage level Check supply voltage to Correct voltage supply
Motor wiper system problem
Switch Replace faulty switch
Wiring Check for loose or broken • Repair or replace

wires wiring up to motor.
• Replace motor if
this wiring is
damaged
Slow Motor Voltage Level Check supply voltage to Correct voltage supply
Operation wiper system problem
On/off switch Replace faulty switch
Motor
Bracket Check for broken bracket Replace defective

bracket
Linkage Check to see if Linkage is Free linkage replace
free moving worn or damaged
components
Defective Wiper Replace Wiper Motor
Motor
Arm and Voltage level Check supply voltage to Correct voltage supply
blade not wiper system problem
operating Linkage Check for worn or broken Replace linkage
correctly or linkage
over sweep
Spindle Check for excessive wear Replace spindle
operation in spindle
Arm Check that arm is not loose Re-tighten spindle
on spindle
Check for excessive wear Replace wiper arm
on arm after cleaning spindle
spline with wire brush.
Blade Check fixing for wear Replace blade
Check blade for wear
Check for excessive
smearing on screen
Excessive Spring pressure. Use spring balance on Replace spring/arm.

wear on centre of blade clip till
blade. blade begins to lift off
glass. 1.75-2.25 kg
Washer No washer fluid Check washer fluid level in Fill tank

system not from jets tank
working
Check for damage to tank Replace tank
correctly
Check Pump is operational Replace pump if faulty

Trainset Troubleshooting Manual Vol 2 Draft

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Trainset Troubleshooting Manual Vol 2 Draft

Uploaded by

Copyright:

Available Formats

केवल कार्ाालर्ीन उपर्ोग हे तु

(For Official Use Only)

भारत सरकार GOVERNMENT OF INDIA

Content in this document is compiled with the inputs provided by ICF

Amendment and Revisions

Version Date Corrections Remarks

Volume - 1: Troubleshooting of 25 kV AC Three Phase Propulsion & Other

Volume - 2: Troubleshooting for various equipment / sub assembly of trainset.

This volume provides troubleshooting information for equipment / sub-assemblies of

1. TROUBLESHOOTING OF SEMI PERMANENT COUPLER (DELLNER) ...6

2. TROUBLESHOOTING OF DAMPER (KONI) ..............................................6

3. TROUBLESHOOTING OF PASSENGER SEAT (STER) ............................9

4. TROUBLESHOOTING OF AUTOMATIC INTERNAL SLIDING DOOR

5. TROUBLESHOOTING OF AUTOMATIC INTERNAL SLIDING DOOR

6. TROUBLESHOOTING OF AUTOMATIC SINGLE LEAF PLUG DOORS

7. TROUBLESHOOTING VACUUM BIO TOILET (EVAC) ............................16

8. TROUBLESHOOTING PANTOGRAPH (SCHUNK) ..................................17

9. TROUBLESHOOTING MAIN TRANSFORMER ........................................19

10. TROUBLESHOOTING TRACTION MOTOR (TSA) ..................................22

11. TROUBLESHOOTING GEAR DRIVE (TSA) .............................................23

12. TROUBLESHOOTING RMPU (AMIT ENGINEERS) .................................24

13. TROUBLESHOOTING SALOON LIGHT (ENSAVE) .................................25

14. TROUBLESHOOTING PAIL LIGHT (ENSAVE) ........................................26

15. TROUBLESHOOTING DRIVER CAB/ GANGWAY LIGHT (ENSAVE) .....27

16. TROUBLESHOOTING MONOBLOCK PUMP (CEC) ................................27

17. TROUBLESHOOTING ERCU (SCHUNK).................................................29

18. TROUBLESHOOTING WIPER SYSTEM (HEPWORTH RAIL).................29

2. TROUBLESHOOTING OF DAMPER (KONI)

Normal contamination caused by the operating

If a damper has a damp film over the whole

In this case the damper can remain in service.

This loss of oil can be recognized by the

A slight oil sweating will not affect the damping

A true oil leakage becomes apparent by a

Isolated oil drop formation is possible.

When wiping the damper with a paper cloth,

When depth of crack is 8 mm and above.

Pulverized rubber is max. 10% of the total

Rubber Replace the

Damaged upholstery should be replaced

Exchange of seat cushion

Exchange of the seat backrest

3. Untighten the bolt No 218 085 and

Parts are Train can continue operation

Train can continue operation

Follow the below mentioned

Train can continue operation

Follow the below mentioned

2. Start rotating the seat

3. Release the pedal.

Train can continue operation

Follow the below mentioned

• Press the red colour mushroom type

• Pull the door leaf manually with the help of

5. TROUBLESHOOTING OF AUTOMATIC INTERNAL SLIDING DOOR

ERROR / FAULT POSSIBLE CAUSE CORRECTIVE ACTION

CODE - 1 Motor torque-free. New

ERROR / FAULT POSSIBLE CAUSE CORRECTIVE ACTION

Signal input of the door position

Speed signals from the VCU,

7. TROUBLESHOOTING VACUUM BIO TOILET (EVAC)

ERROR / FAULT POSSIBLE CAUSE CORRECTIVE ACTION

Flush button is pushed No power Supply power