(dsoy dk;kZy; iz;ksx gsrq)

(For official use only)

(Hkkjr ljdkj /Govt. of India)

(jsy ea=ky; /Ministry of Railways)

yksdks ik;yVksa ds fy,

WDM3A/ WDG3A yksdkseksfVo

ekbksizkslslj

MEP-660 (Ver-2.0)

ij yxs
ls lEcfU/kr

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Trouble Shooting Guide

for Loco pilots on
Microprocessor MEP-660 (Ver-2.0) WDM3A & WDG3A
Locomotives

dseVsd@2011@Z,e @Z,e ih lh ,l- Vh,lth@1.0

CAMTECH/2011/M/MPCS-TSG/1.0
April 2011

egkjktiqj, Xokfy;j & 474005

yksdks ik;yVksa ds fy,

WDM3A/ WDG3A yksdkseksfVo ij yxs
ekbksizkslslj MEP-660 (Ver-2.0) ls lEcfU/kr

Vcy kwfVax xkbM

Trouble Shooting Guide
for Loco pilots on
Microprocessor MEP-660 (Ver-2.0)
WDM3A & WDG3A
Locomotives

FOREWORD
Microprocessor Based Control System have been introduced
recently on Diesel Electric Locomotives.

Microprocessor

technology is new to our Loco pilots, therefore, it is necessary

that proper knowledge about troubles which a loco pilot faces
during run should be disseminated properly. Keeping this in
view, this Trouble Shooting directory has been prepared by
CAMTECH to disseminate knowledge about troubles related to
Microprocessor Based Control System.
I hope that this handbook will definitely enhance the knowledge
of concerned staff to do faster restoration of troubles being faced
on line.

Date: 30.04.2011
CAMTECH, Gwalior

S. C. Singhal
Executive Director

Back to contents

ii

PREFACE
Micro Processor Control System is the vital part of a diesel
electric locomotive. This System is recently introduced on Indian
Railways for ensuring higher reliability and better availability of
locomotives. Proper knowledge of system and trouble shooting
is necessary to ensure reliability and availability of locomotives
in sheds as well as on line.
This book contains trouble shooting on Micro Processor based
control system MEP 660 (Ver-2.0) fitted locomotives for diesel
drivers during problems enroute. Loco pilots should understand
the steps sequentially to save time during trouble shooting.
The purpose of this book is to enhance knowledge and
competence of loco pilots in dealing with the problems of Diesel
locomotive on run. This trouble shooting guide also contains the
description of MEP660 (Ver-2.0) Micro processor system so that
loco pilot can easily understand the microprocessor system.
This book will be useful to the maintenance staff and loco
inspectors also for counselling running staff about MEP660
(Ver-2.0) Micro processor system.
It is clarified that this handbook does not supersede any existing
procedures and practices laid down in the maintenance
instructions issued by manufacturers or by RDSO/LKO.
Technological Upgradation and learning is a continuous process.
Hence feel free to write to us for any addition / modification in
this handbook or in case you have any suggestion to improve the
handbook. Your contribution in this direction shall be highly
appreciated.
30th April 2011
CAMTECH, GWALIOR

(K.P.Yadav)
Director/Mech
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iii

CORRECTION SLIPS
The correction slips to be issued in future for this
handbook will be numbered as follows:
CAMTECH/2011/M/MPCS-TSG/1.0/C.S. # XX date --------------Where XX is the serial number of the concerned
correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No.
of C. Slip

Date of
issue

Page No. and Item no.

modified

Remarks

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iv

Contents
SNo.

Description

Page No.

Forward

ii

Preface

ii

iii

Correction Slip

iii

Contents

iv

1.0

Introduction of Excitation Control System

2.0

4.0

Introduction of Microprocessor based Control

System
Salient Features of Microprocessor based
Control System
Additional Features

5.0

Items removed from previous Control System

6.0

Description of some important Assemblies

7.0

Display Unit and Navigation through menus

10

8.0

14

9.0

Classification and Reset Procedure of Faults

Messages
Dos and Donts

10.0

Trouble Shootings

Code
1001

Engine Shuts down. Hot Engine LED glowing

on LED panel and alarm bell ringing.

18

1002

Engine Shuts down with over speeding

20

3.0

1004 & LLOB Reset plunger tripped, Engine Shuts

1005
down
1006
Power cutting off with Hot Engine Alarm
Indication & Engine Speed raised to 8th notch
RPM.

3
5

15
18 to 47

21
23

v
24

1007

Engine Speed comes to idle due to Power

Ground

1008

Control Circuit Starting Ground Fault coming

& Engine not cranking.
Loco over Speeding & not moving in motoring

26

1018

Loco not responding to throttle, GF contactor

not picking

28

1019

CCM Failure indication coming

31

1061

Battery is not charging, Battery voltage is low

33

1074

Loco is moving with Field shunting and

Motoring prohibited in parallel combination.

35

1075

Motoring with field Shunting but motoring in

parallel is prohibited

37

1140

Engine is not Cranking due to Cranking

contactor stuck up.

40

1029

Motoring prohibited, Dynamic prohibited due

to cranking contactor closed.

43

2000

No Battery charging, AG failed or AGFB or

MB1 tripped

45

2029

Engine not cranking, when operator attempts

cranking while Cranking contactor stuck
closed

46

1153

VCD Applied Penalty Brake. Move Master

Controller Handle to IDLE and press Reset to
release Brake.

47

1015

27

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Trouble shooting guide for Loco. Pilots

1.0 INTRODUCTION
SYSTEM:

OF

EXCITATION

CONTROL

Excitation control system regulates the exciter field current

through a Transistor switch operated by the pulse width
modulator basically a magnetic amplifier. The average
current is decided by the ON to OFF ratio of the PWM which
is controlled by the mixer reference network basically a
resistor network with 02 saturable reactors & rectifiers. The
mixer reference network receives proportionate feedback
signals from TA voltage, TA current & engine speed. Based
on the input signal levels it sends a controlling signal to the
PWM, which controls the exciter field current and its output.
The exciter output is directly connected to alternator field
through GF Contactor, which is again controlled by
propulsion control system. Thus traction alternator power is
controlled to the required constant HP at each notch.

Governor
Diesel
Engine

Traction
Alternator

Aux.Gen

Exciter

Rectifier
Panel

Power
Contactor

Excitation
Control

Propulsion
Control

AG
Control

Engine
Control

Traction
Motors

Control
Desk

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2.0 INTRODUCTION OF MICROPROCESSOR BASED

CONTROL SYSTEM
The MEP-660 is a complete locomotive control system
consisting engine cranking, loco propulsion control,
excitation control, Auxiliary generator control and
continuous monitoring of safety devices on the locomotive.
Some of the improved features are Self Load Test of
locomotive and inbuilt event recorder designed and
developed as per RDSO specifications.
MEP-660 loco control system is designed to replace the
existing propulsion and E-type Excitation system.
MEP660 control system

Eliminates mech. interlocking (Sequential /Timing)

Uses microprocessor to control the locomotive

through software logic.
Governor
Diesel
Engine

Traction
Alternator

Aux.Gen

Exciter

Rectifier
Panel

Traction
Motors

Power
Contactor

MICRO PROCESSOR
Propulsion
Excitation
CONTROL
SYSTEM
Control

Control

AG
Control

Engine
Control

Control
Desk

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Trouble shooting guide for Loco. Pilots

3.0 SALIENT FEATURES OF

BASED CONTROL SYSTEM

3
MICROPROCESSOR

A). Fault diagnostics: Microprocessor-based system has

Fault Diagnostic capabilities. The system
continuously
monitors
various
operational
parameters and checks for abnormalities in the
functioning of various traction equipments. The fault
is displayed on the Display Unit along with
restrictions imposed because of the fault, for
information of the driver. The fault code along with
Real Time and date stamp is logged in the Error Log
Memory.
B). Self Diagnostics: This system keeps on monitoring
its own modules and sensors, continually for their
healthiness.
C) Fault tolerance: Fault tolerance capabilities are also
in this system for certain faults. In such cases the
operation of the locomotive continues in the normal
way and the fault is logged in the error log with data
packs for later analysis
D) Automatic fault recovery: For most of the faults,
the recovery conditions are identified and whenever
the fault ceases to exist, the fault recovery is
recognized and displayed to the driver on the display
unit, and the event is registered in the error log.
E) Short term rating of Traction Motors: The
equipment automatically takes care of, short-term
traction motor current ratings and does not depend
upon the driver, for protection of the equipment,
F) Self-test to digital inputs and Outputs: MEP660
has self-test facility for all digital inputs, outputs and
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Trouble shooting guide for Loco. Pilots

out put devices, which enable the maintenance staff

in identification of wiring faults quickly.
G) Self-Load Box Test:. A simple load test can be
carried out to know the performance of the engine and
entire control system.
H) Event Recorders: The system records the data on a
compact nonvolatile Flash Memory Unit that does not
need any electrical power to retain the data in the
memory.
In the short-term memory, the various datas are
recorded in one-second interval. Latest 45 hours data
is available at any time to download.
In the long-term memory, only speed and distance
along with date and time are recorded in 20 seconds
interval. Latest 225 days of data is available at any
time to download.
I) Multi Reset Vigilance Control Device / Alerter: This
Control System (MEP 660) is equipped
with
vigilance control to enhance the safety of the
locomotive operation.
The multi reset vigilance control device provided in
MEP 660 recognizes the following
loco operations performed by the driver and assumes
he is vigilant.
1.
2.
3.
4.
5.
6.
7.
8.

Change of notch position

Application / release of Dynamic brake
Application / release of brakes through A9
Operation of sand buttons
Operation of Elec. Horn buttons
Change of locomotive direction through RH
Operation of GF switches
Sufficient increase / decrease of Dy. Brake level
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Trouble shooting guide for Loco. Pilots

9.

(20%) through master handle

Operation of VCD reset switch.

If the driver performs none of the above operations

within 60 seconds, the MEP660 system initially alerts
the driver with visual indication (blinking LED
provided on each control stand) for a period of 17
seconds.
J) Auto Flasher: The MEP 660 Control System
switches ON the train's Flasher light automatically
during Train Parting or driver applies driver
emergency brake.In addition, driver can also switch
ON Flasher lights whenever needed.
K) Auto Emergency Brake system:
This feature is provided in locomotive to apply
penalty brakes while working in the ghat sections.
4.0 ADDITIONAL FEATURES:
Engine shut down with Failure of Crank case breaker.
Limitation of Power to 4th notch with Failure of RBB
or Diode HOT:
Power De-ration from T3 setting to T4 setting (90 to
95 C): The engine power is de-rated by 20% of the
notch power for every degree raised from 90 onwards.
8th notch RPM at hottest Temperature: When the
Engine temperature reached to T4 setting (95C),
Engine RPMs are raised to 8th notch automatically by
cutting of power for faster cooling of engine.
Low Idle feature: When the locomotive is in IDLE for
more than 10 minutes, the engine RPM is reduced to
350 for reducing the fuel oil consumption.
5.0 ITEM REMOVED FROM PREVIOUS CONTROL
SYSTEM

Control Panels:
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Trouble shooting guide for Loco. Pilots

Excitation Control Panel(EXCP)

Engine Control Panel(ECP)
Voltage Regulator Panel(VRP)
Transition Regulator Panel(TRP)

Resistor Panels:
Wheel slip resistor panel (WSRR1& 2)
Wheel slip control resistors WR8, WR9 & WR10
Oscillator Voltage Dividing panel (OVDR)
Generator Voltage Dividing panel (GVDR/VDP)
Tacho generator load resistor panel (TGLR)
Braking limiting resistor panel (BKER1 & 2)

Relays:
12 Relays have been removed and remaining 11
relays retained.

Rotating machines:
Axle Alternator
Tacho Generator
6 TM Speed sensors
ESS
Miscellaneous items:
Transition Excitation Transformer (TET)
Armature Current control reactor (ACCR)
Stabilizing panel (Stab. Panel)
Voltage regulator current limiting shunt
Load ammeter shunt (LAS)
Engine Temperature Switches

6.0 DESCRIPTION
OF
SOME
IMPORTANT
ASSEMBLIES:
The Microprocessor based Locomotive Control System MEP
660 consists of the following sub assemblies.
6.1 CONTROL UNIT TYPE MEP 660
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Trouble shooting guide for Loco. Pilots

This is main control equipment of the Microprocessor

system. The control unit consists 18+1(spare) plug in module
type cards in dust proof enclosures. These modules are
provided with proper identification number both on the
module and as well on the control unit of each slot.
6.1.1 Control Card MEP-CC
The MEP_CC card is the main control card having a micro
controller along with its programmed software, various
circuits and interface circuits. All the digital, analog and
frequency inputs are connected to this card
6.1.2 Control Card MAU-CC
The MAU-CC card is the second control card having a micro
controller along with its programmed software, various
interface circuits. This card controls the Auxiliary Generator
field current to regulate the terminal voltage at 721V (set
limit).
6.1.3. Control card MWS-CC
The MWS-CC card is the third control having a micro
controller along with its programmed software. This card
detects the wheel slip and communicates to the MEP_CC
card to control the power during wheel slip.
6.1.4. Digital Input Cards (MDIP16 / MIDIP16)
These digital input cards consist the hardware required for
converting the high voltage signals of nominal 72V DC from
the locomotive circuits to isolated low voltage signals of 5V
DC required for the microprocessor of the system. The Green
color LEDs provided on this card indicates presence of 72
VDC voltage on that particular channel. The Yellow LEDs
indicate the signal being sent to Micro controller after
isolation and signal conditioning.
6.1.5 Digital Output cards (MLSD16 & MHSD16/
MIHSD16)

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The digital output card converts 5V digital signals generated

by the microcontroller system (MEP-CC card) to 72VCD
power signals required for driving relays, contactors,
solenoids, indication lamps etc. in the locomotive circuits.
These cards provide electrical isolation, between locomotive
circuits and micro controller circuits. Each card can process
16 output signals. There are two types of Digital Output
cards.
6.1.5.1 High Side drive CArdMHSD16/ MIHSD16)
6.1.5.2 Low Side Drive Card MLSD16
6.1.6. Analog Input Cards
The MEP-660 system continuously monitors various
parameters like voltages, currents, pressures, and
temperatures of various equipments in the locomotive
through different sensors.
6.1.6.1. Analog Input card MAIP8 -AU
This card MAIP8_AU card is connected between MAUCC
card and ADB1 Parameters pertaining to Auxiliary generator
and Battery charging is mainly connected to this card.
6.1.6.2. Analog Input Card MAIP8_WS
This card MAIP8_WS card is connected between MWS_CC
card and ADB2 Individual traction motor current signals are
mainly connected to this card.
6.1.6.3. Analog Input card MAIP8_EP
This card MAIP8_EP card is connected between MEP_CC
card and ADB3 All the excitation related parameters are
mainly connected to this card.
6.1.6..4. Improved Analog Input card MAIP16 / MIAI

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Trouble shooting guide for Loco. Pilots

This Card MAIP16 / MIAI (Modified analog input card)

process the signals received from BPP, BCP, FOP, BAP, and
LOP sensors.
6.1.7 Frequency Input Card (MFIP16)
This card consists of the hardware required for converting the
signals generated by speed sensors of Traction motors and
diesel engine
6.1.8. Pulse Width Modulator Card (MPWM2)
The PWM card converts the low voltage pulse width
modulated signals generated by the micro controller system
to a high power 72V output for controlling the exciter field
current and auxiliary generator field current.
6.1. 9 Excitation and Propulsion - Power Supply Card
(MEPPS)
This module supplies various regulated power supplies of
9V, 12V and 15V required for the operation of all the
cards in the control unit.
6.2 Display Unit - MDS 733
This sub assembly consists of a 40 character X 4 line
alphanumeric vacuum fluorescent display (VFD). It also
consists of a keyboard for data entry by the operator, and an
acknowledge switch to silence the built in Buzzer (Hooter)
and Alarm Gong (ALG) during fault massage display.
6.3. Analog Distribution Box (ADB) - MDB 701
The Analog Distribution Box provides regulated DC power
to various sensors that are connected to the ADB. It also
collects output signals from these sensors and transmits them
to the main control unit. There are 4 ADBs per loco.
6.4. RPM Distribution Box (RDB) - MDB 702
The RPM Distribution Box (RDB) supplies power to all the
speed sensors connected to the RDB. It also collects speed
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Trouble shooting guide for Loco. Pilots

10

signals from these sensors and transmits these signals to the

main control unit.
6.5. Motor Cut Out Switch Box - MSP 707
This module is a traction motor isolation box used to isolate
any defective traction motor in service. Six toggle switches
are provided on the box with an ear marking of MCOS1 to
MCOS6.

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Trouble shooting guide for Loco. Pilots

11

6.6. VCD Magnet Valve Type: 3332-10-4G

VCD magnet valve is direct operated electro Pneumatic valve
used to apply penalty brakes whenever any safety devices
like VCD / AEB / Fire Alert are operated in the locomotive.
6.7 BREAKERS AND SWITCHES
The nomenclature of all the breakers and switches
almost same as conventional WDG3A locomotive.
EXISTING BREAKERS.
MB1
Main Breaker 1
MB2
Main Breaker 2
AGFB
- Auxiliary Generator Field Breaker
MFPB1&2
- Master Fuel Pump Breakers
MCB1&2
- Master Control Breakers
FPB
Fuel Pump Breaker
CEB
Crankcase Exhauster Breaker
DEB (Eng)
- Dust Exhauster Breaker (Eng. Side)
DEB (Carb)
- Dust Exhauster Breaker (Carb. Side)
RBB
- Rectifier Blower Breaker
RFCB
- Radiator Fan Clutch Breaker (ERF)
LPB1,2, HLPB, DLCB-Lighting Circuit breakers
EXTRA BREAKERS ( NEW)
MPCB - Microprocessor circuit breaker
PLPB - Pre lubrication Pump Breaker
7.0 DISPLAY UNIT & NAVIGATION THROUGH MENUS
The display unit is the main interface between the user and
the equipment. Normally a group of parameters are displayed
in real time, on the display unit. Different groups of such
parameters are available for selection. The parameters are
grouped functionally e.g. excitation related parameters,
auxiliary generator related parameters, wheel RPMs and
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Trouble shooting guide for Loco. Pilots

12

traction motor currents etc. User can select anyone of the

groups for display and record the required locomotive
parameters while testing the locomotive. By default the
display unit is in 'Driver Display' mode. In addition to loco
parameters, warning messages are also displayed during fault
occurrence with or without audio based on the severity of the
fault.
The main menu, submenus and display mode are illustrated
below for quick reference. To select a. Menu / Sub-Menu,
operator has to simply press either Menu Option Number or
down arrow key till the required option is high lighted
1).

Main menu
1) Sub Menu 1
1). Sub Menu 2
1). Sub Menu 3
Display
parameters

7.1. Faults
i) View Active faults Registered faults if any will be
displayed User can navigate
through the faults using down
arrow key until 'No more
faults logged' message is
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13

Trouble shooting guide for Loco. Pilots

displayed.
Press 'MENU' key to select
'Exit' option.
ii) Clear Active faults "Use '0' to clear faults" Message
will be displayed. After few
seconds Logged faults are
displayed one by one. After
noting down the faults, to clear
fault Press '0' key and down
arrow key to see next fault..
Continue the above till all
faults are cleared. Press
'MENU' key to select exit
option.
7.2. Display Mode

1) Excitation

2) Auxiliary

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Trouble shooting guide for Loco. Pilots

3) Wheel Slip

4) Mixed

14

5) Driver Display
The driver/ default display has got three screens. a) IDLE
screen, b.) Motoring screen, c.) Braking screen.
Respective screens are changed automatically based on the
control stand signals while the locomotive operation is being
set by the driver. In each screen relative parameters are
displayed as shown below.
IDLE Screen
Notch
Idle
LOT
xxx.x
BAAmps +xxx
LOP
xx.x

Engine RPM xxx.x

Kmph
xxx.x
VCD Contr. xxxx
Gross HP xxx x
BA Volts
xx.x
Eng Temp xx.x
LOCO STATUS
EXCITATION

Motoring Screen

Notch
x Engine RPM xxxx
T A Amps xxxx TA Volts
xxxxx

Kmph
xxx.x
Gross HP xxx x
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Trouble shooting guide for Loco. Pilots

15

BA Amps +xxx AG Volts

xxx.x
Eng Temp xx.x
TM Amps xx.x LOCO STATUS EXCITATION STATUS
Braking Screen

6) MCBG Status

8.0 CLASSIFICATION AND RESET PROCEDURE OF

FAULT MESSAGES
The faults are classified into three levels such as high,
medium and low priority, based on the severity of the effect
of the fault on locomotive operation.
These faults (irrespective of their priority level) are
permitted to be cleared by the driver. By pressing the
MENU key.
Driver can reset the fault by operating the keys available on
the display unit in the following sequence.
A) Press Menu key,
The following Main Menu appears
1) Faults
2) Display Mode
3) Test Mode
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16

Trouble shooting guide for Loco. Pilots

4) Exit
B) Press key 1 to select Faults
The following submenu appears
1) View active Faults
2) Clear Active Faults
C) Press key 2 to select Clear Active Faults
Use 0 key to clear faults message appears first on the
screen. After some time the registered faults are shown one
by one based on the priority of the faults. Press key 0 once
and then Enter key to clear the fault displayed on the
screen. The fault is cleared and next fault is displayed.
9.0 DOS AND DONTS
DOS
1. Keep always TE Limit
switch in Normal
position unless and
until required.
2. Keep MCOS switches
always in ON position
for normal operation.
3. Make a habit to check
position of these TE
Limit
and
MCOS
switches while taking
overcharge.
4. Switch OFF Circuit
breakers MCB1 and
MCB2 on control desks
while cranking.

DONTS
1. Do not keep TE Limit
switch in Limit position
unnecessarily when not
required.
2. Do not keep MCOS in
OFF position while all
motors are working.
3. Do not start the loco with
out ensuring these switch
position.

4.

5. Press start button till 5.

Do not crank the engine

with MCB1 & MCB2 in
ON position. Otherwise
penalty
brakes
are
applied if BCP is not
build up within 94
seconds.
Do not release the start
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17

Trouble shooting guide for Loco. Pilots

cranking
contactors
picks up. (more than 60
sec. if pre lube feature
is available.)
6. Switch ON circuit 6.
breaker CEB within 30
minutes while checking
lube oil level.
7. Switch OFF circuit 7.
breakers MCB1 &
MCB2 in case of Rear
Locomotive to avoid
VCD function.
8. Keep
EPG
cutout
Switch in OFF position
in trail / dead locos.

9. Apply loco brakes

through
SA9
and
ensure BCP is more
than
2Kg./Sq.Cm.
while loco is stabled
10. During
continuous
wheel slip and total
power reduction, act as
in the case of wheel slip
with
conventional
Locos.
11. Apply brakes and do
fast pumping on 8th
notch if loco stalled

button
in
between.
Otherwise the time starts
again.

Do not switch OFF

Circuit breaker CEB and
then do complete loco
checking.
Do not keep MCB1 &
MCB2 in ON position in
rear
locomotive.
Otherwise load meter
does not respond in rear
loco.
8. Do not keep the EPG
cutout switch in ON
position in rear / dead
locos. Otherwise MR
pressure reduces.
9. Do not release loco
brakes while loco is
stabled. Otherwise VCD
apply penalty brakes.

10. Do not reduce notch for

momentary wheel slip
and loco is moving.

11. Do not reduce notch for

the
message
TM#
Excess Current while the
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Trouble shooting guide for Loco. Pilots

with message TM #
Excess current.
12. Apply loco brakes
when total power is
reduced at 95 deg.
Centigrade to avoid roll
back.
13. Press VCD Reset when
the VCD Lamp blinks

14. Reset penalty brakes

only when
1.Loco speed is zero and
2.Throttle is in IDLE
and
3. VCD lamp stops
blinking.

18
loco is moving unless and
until
warranted
by
railroad signals.
12. Do not release brakes till
the locomotive is ready to
move. (@ 90 deg.
Centigrade of engine
temperature.)
13. Do not isolate VCD
magnet valve cutout cock
unless and until the valve
is leaking.
14. Do not try to reset
penalty brakes if
1. Loco is moving, or
2. Throttle is in notch / Dy.
brake
3. VCD lamp is blinking.

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19

Trouble shooting guide for Loco. Pilots

10.0 Trouble Shooting:

1. Engine Shuts down. Hot Engine LED glowing on
LED panel and alarm bell ringing.

Fault Code

1001

Fault Message Low Water Level.

Engine Shuts down. Hot Engine LED will
Restrictions
Glow on LED panel
Continuous ON for 30 seconds
Alarm Bell
Low, Medium
Reset level
Clear the fault in clear active mode. After
manual reset if the fault still present, the fault
will be generated again.
1. LWS operated due to low water level.
Probable
2. Faulty micro switch, bellow, float. etc. in the
Cause
LWS unit.
3. Wire No. TO1 is open circuit in LWS wiring
from LWS to MEP660.
1. Check Water level. If water is less add
Action by
water. Reset the fault.
Loco Pilot
2. If water is full, Check operation of the LWS
by operating the LWS cock.
The number 4 green and yellow LEDs on
MDIP-16 card in slot 11
indicate the status of LWS feed back signal.
Both LEDs glow with LWS normal position
(full water) and both
LEDs are OFF with LWS operated (low
water).
3. If electronics LWS is provided and water
level is sufficient, bypass it with the help of
toggle switch of electronic water level
indicator
4. Put remark in the loco log book and advise
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Trouble shooting guide for Loco. Pilots

For
Maintenance
Staff

20

Power controller
A. If both LEDS are not ON with LWS normal
position (full water),
i) Check Voltage at wire No. TO1 on
backside TB. Observe for any disconnected
wires. If so reconnect.
ii) If voltage at wire No. TO1 is zero
a) Check voltage at wire No. 51 at
backside TB. Observe for any
disconnected wires at the terminal. If
so reconnect.
b) If voltage is >65V.
i. Either LWS wiring or LWS faulty
Check wiring continuity of wire 51
from backside TB to LWS.
Check wiring continuity of wire
No. TO1 from LWS to backside
TB.
Check for any disconnected wires
at LWS.
If wire continuity is good, LWS
micro switch is defective. Replace
and check.
ii) If the Voltage at back side TB on wire
No. TO1 is > 65V
a) Check the wiring continuity of wire No.
TO1 from backside TB to MEP-660 by
removing the coupler (DI32- DI47) - (Pin.
E). If no continuity replace the cable.
b. If only Green LED is glowing, and yellow
LED is not glowing, it indicates that the LWS
feed back input is available upto digital input
card and the DI card in slot 11 is defective.
Replace the card.
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Trouble shooting guide for Loco. Pilots

21

2. Engine Shuts down with over speeding.

Fault Code
1002
Fault Message
Restriction
Alarm Bell
Probable
Causes

Action by
Loco Pilot

For
Maintenance
Staff

Engine Over Speed.

Engine Shuts down
30 seconds
1. OSTA tripped
2. Faulty wiring from Tacho generator to
MEP-660/MCBG Gov. if provided
3. Faulty tacho generator, if provided
4. Defect in ESS connectors on Cam gear
cover. Improper continuity from sensor unit
to back penal.
5. Faulty governor / sticky racks. Fuel rake
stucking or fuel injection pump defective
1. If OSTA is tripped, reset it. Crank the
engine.
2. Ensure that there are no sticky racks or fuel
injection pumps.
3. Check the notch wise engine RPM.
Check the notch wise engine RPM.
A. If the RPM is not correct
a) Check up with the governor and set the
notch wise engine RPMs with in limits.
B. If the displayed RPM is correct
a) Check up with tacho generator wiring from
tacho generator terminal board to backside
TB to MEP-660 for any open circuit or
loose connections.
b) Check up tacho generator frequency
(engine RPM) with
conventional
RPM meter as used in conventional
WDM3A locomotives.
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Trouble shooting guide for Loco. Pilots

22

c) If notch wise readings are not stable and

heavy fluctuation is noticed, check for tacho
generator and replace.

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23

Trouble shooting guide for Loco. Pilots

3. LLOB Reset plunger tripped, Engine Shuts down.

Fault Code

1004 & 1005

Fault Message
Restrictions
Alarm Bell
Fault
Recovery
Probable
causes

LLOB trip, Reset plunger at engine off.

Engine Cranking Prohibited
Continuous ON
Reset WW Gov. plunger. Fault will disappear
after 20 seconds
1. Low Lube Oil Button might have tripped in
the Woodward governor.
OR
2. The feedback input wire OPSFB is getting
wrong supply.
3. Less lube oil level in the Sump
1. Check the Low Lube Oil Button position on
the Woodward governor.
2. If tripped (projecting outside).
A. Press the button inside to reset.
B. Reset the Fault manually and crank the
engine.
3. If LLOB is not in tripped position
A. Pull the knob outside and reset once
again.
B. Check the OPS (LLOB) feed back signal
level with Number 5 Green and Yellow
LEDs on Digital Input card MDIP-16 in
11th slot.
With LLOB in normal position, both LEDs
are OFF.
With LLOB in tripped position, both LEDs
are ON.
C. If both LEDs are ON with LLOB in normal
position

Action by
Loco Pilot

For
Maintenance

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Trouble shooting guide for Loco. Pilots

Staff

For
Maintenance
Staff

24

a) Check voltage at wire No. 1B at the back

side TB.
b) If voltage is > 65V
c) Disconnect the wires 1B and identify
which wire is getting supply.
d) If the wire is from governor amphonal
plug, then the micro switch in the
Governor is shorted. Replace the micro
switch.
e) If the wire is from loco side, there may
be a wrong feed back from indication
panel side. Check up and isolate the
supply.
Note: Most probably this fault is accompanied
with a Fault message LLOB Trip. Reset
Plunger (Fault code 1005). Driver might have
reset the fault on the display with out resetting
the LLOB on the Governor

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Trouble shooting guide for Loco. Pilots

25

4. Power cutting off with Hot Engine Alarm Indication

& Engine Speed raised to 8th notch RPM.

Fault Code

1006

Fault Message Hot Engine. Cant Power Up.

Restrictions

Power cutting off & engine RPM raised to 8th

notch. Motoring and Dynamic Brake are
prohibited.

Alarm bell

Continuous for 30 seconds

Fault
Recovery

Automatic when the engine temperature is less

than 90C.

Probable
causes

1. Engine water temperature is increased more

than 95C.

Action by
Loco Pilot

1. Check water level in display/ gauge

2. Before this message, message comes as
Engine temperature is high, reduce
power
3. Put GF in Off observing Load & Road
& allow the engine to cool till
temperature is reduced below 90C.

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26

Trouble shooting guide for Loco. Pilots

5. Engine Speed comes to idle due to Power Ground

Fault Code

1007

Fault Message Power Circuit Ground Fault.

Motoring and Dynamic Brake Prohibited.
Restrictions
Engine speed comes to Idle.
Continuous ON
Alarm bell
Automatic when the traction alternator neutral
Fault
to ground leakage current value is reduced
Recovery
below the set limit and Master Handle is
brought to IDLE.
1. The fault may be transient or permanent.
Probable
2. The Fault is automatically recovered after
causes
15 seconds once the throttle is brought to
Idle.(Driver can work further without any
trouble.)
3. If the fault is recording for more than 3
times in one hour, it indicates fault is persisting
and needs attention.
5. The fault is logged due to
A. Moisture in Traction Motors.
B. Flash over in Traction Motors
C. Cracked insulators on traction Alternators /
Traction Motors / Power Rectifier / Dynamic
brake grids / BKT / REV / power contactors.
D. Any external metal parts touching to power
terminals.
E. Any power circuit cables are rubbing to
body and insulation is damaged.
If the fault is recurring:
Action by
Put throttle handle on idle, GF switch off put
Loco Pilot
TM isolation toggle switch in off & isolate
Traction motors one by one for rectification. If
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Trouble shooting guide for Loco. Pilots

Action by
Loco Pilot

27

no success 1. Apply Loco brakes and ensure locomotive

brakes are physically applied.
2. Set the display mode to Mixed through
Display Menu setup.
3. Set the locomotive operation to motoring
mode and notch to 1.
4. Observe the traction alternator leakage
current sensor (TANGI) on the display.

For
Maintenance
Staff

5. If the leakage current is more than set (0.4

Amps) value, then there is a real ground.
A. Inspect traction alternator power circuit
cables for any rubbing to loco body. If so
isolate the cables.
B. Inspect traction motor cables for any
rubbing to loco body. If so isolate the cables.
C. Check for any cracked insulators in the
equipments as mentioned above.
D. Check for any flash over / burnt marks in
the power rectifier and connected cables.

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28

Trouble shooting guide for Loco. Pilots

6. Control Circuit Starting Ground Fault coming &

Engine not cranking.

Fault Code 1008

Fault
Message
Restrictions
Alarm bell
Fault
Recovery

Probable
causes

Action by
Loco Pilot

Control Circuit Ground Fault.

Cranking prohibited.
Continuous ON & buzzer for 30 seconds
Automatic when the control circuit negative to
ground leakage current value is reduced below
the set limit and 15 seconds lapsed with Master
Handle in Idle. Automatic Fault reset is
permitted for 3 times in an hour and after that
manually reset is required.
1. Any control circuit wiring is grounded.
2. Any equipments like dust blower motors,
sander coils, lighting circuit etc. connected in
control circuits are having low / zero insulation
resistance value.
3. CGR is open circuited.
1. If CGR is open circuited, open seal of
GRCO2 and put it off, now start cranking of
engine. After successful start of engine, provide
GRCO2 in place.

1. Identify the control circuit having low/zero

For
Maintenance Insulation Resistance (IR) value.
2. Isolate the low insulation either replacing the
Staff
equipment or by insulating the grounded wires.
Note: This fault is logged during cranking
only.

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29

Trouble shooting guide for Loco. Pilots

7. Loco over Speeding & not moving in motoring

Fault Code

1015

Fault Message

Loco over speed. Move Master Controller

Handle to IDLE.

Restrictions

Motoring prohibited.

Alarm Bell

30 Seconds.

Reset Level

Low, Manual
After manual reset if the fault still present, the
fault will be generated again.

Fault Recovery Automatic when loco speed is below the set

limit and Master Handle is brought to IDLE.
Probable
causes

1. Locomotive speed is high.

Action by
Loco Pilot

1. Put throttle handle on Idle.

2. Let the speed of loco come within set
limit
3. Do braking by A-9 if required,
4. Maintain the locomotive set speed.

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Trouble shooting guide for Loco. Pilots

30

8. Loco not responding to throttle, GF contactor not

picking.

Fault code.

1018

Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes

GF stuck open, . Run Auto / Manual tests Can't

Power UP: Electrical Control Problem
Cant power up
30 Seconds
Automatic when GF contactor found closed.

Action by
Loco Pilot

1. Defective GF contactor.
2. GF coil burnt.
3. Defective GFCO
4. Wiring fault from MEP-660 to GF contactor
coil.
5. Positive supply to GF contactor operating
coil is missing.
1. Check wire terminal from MEPP-660 to GF
contactor coil.
2. Check operation of GF contactor
3. Check GF contactor coil
4. Check operation of GFCOs
5. Set the Display to Manual Tests for
Outputs mode through Test Mode Menu and
satisfy the initial conditions required to run
manual test as prompted on the display unit.
6. Press 13 + Enter Key+1 to energize GF
contactor.
7. If GF contactor energizes, then
A. Check up for proper closing of main contact
tips and Auxiliary contacts.
B. The status of GF Aux. Contact 1 can be
checked through 0 number Green and Yellow
LEDs on digital input card MDIP-16 in slot 11.
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Trouble shooting guide for Loco. Pilots

Action by
Loco Pilot

For
Maintenance
Staff

31

C. The status of GF Aux. Contact 2 can be

checked through 1 numbered Green and
Yellow LEDs on Digital Input card MDIP-16
in slot No. 12.
D. All the 4 LEDs should glow.
8. Press 0 key to deenegize the GF contactor.
A. All the 4 LEDs in both the digital input
cards should be OFF.

B. If LEDs are not as per the sequence and

remains always OFF, then
a) Check voltage on wire No. 51 at the GF
contactor auxiliary contacts 1 and 2 with
respect to wire No. 4
b) If the voltage is zero, then
1) Wiring loop of wire No. 51 is open
circuited. Identify the open circuit and ensure
supply at the terminal 51 on Aux. Contact of
GF contactor is available.
c) If Voltage is greater than 65V, then
1) Check voltage at the wire terminals FCD
and FCE on Auxiliary contacts of GF
contactor.
2) If Voltage is zero, then the Aux. Contacts of
GF contactors are bad. Check, clean and adjust
the auxiliary contacts. If necessary replace
them.
3) If voltage is greater than 65V, then wiring
between GF contactor and MEP-660 is open
circuited. Identify and replace the cable.
C. If the GF contactor is not energizing as per
the test sequence, then
a) Connect Voltmeter across the operating coil
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Trouble shooting guide for Loco. Pilots

For
Maintenance
Staff

32

of the GF contactor and switch ON GF

contactor by pressing 1 key.
b) If the Voltage is more than 65V, then
1) The GF contactor-operating coil is open
circuited internally or there may be a physical
obstruction in the contactor operation. Check
and replace the GF contactor if necessary.
c) If the voltage is zero, then
d) Check the voltage on coil terminal wire No.
13 and 4.
1) If Voltage is zero, then wire loop 13
connected to GF operating coil is open
circuited. Identify and replace.
2) If the voltage is more than 65V, then
negative feed is not coming to GF contactor
operating coil.
3) This may be due to cable fault or digital
output card defective.
4) Check the cable continuity from MEP-660
to GF contactor coil. If necessary replace the
cable.
5) If continuity is available, replace the digital
output card. And check the operations of GF
contactor.

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Trouble shooting guide for Loco. Pilots

33

9. CCM Failure indication coming

Fault code.

1019

Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes

CEB Breaker OFF.

Action by
Loco Pilot

No restrictions, only indication.

Continuous ON
Automatic when CEB breaker is switched
ON.
1. Crank Case Exhauster Motor is not getting
supply due to CEB tripped or switched OFF.
2. Crank case Exhauster Breaker Feed Back
(CEB FB) status is low as sensed by MEP660.
1. Check working of Crank Case Motor
personally.
2. Check wire terminal & tap motor slightly.
3. If Breaker is in tripped/OFF position, reset
/ switch ON the breaker.
4. The high level status of the Crankcase
Exhauster Breaker Feed Back is indicated
by 7 Numbered Green and Yellow LEDs
on digital input card MDIP-16 in slot No.
13.
5. With CEB in ON position, CCEM fail
indication LEDs on both control desks
should be OFF. Both 7 numbered Green
and Yellow LEDs on the Digital Input
card in slot 13 should be ON.
A. If the indications LEDs on both the
control desks are ON, then the breaker is
defective and the CCEM is not working.
Replace the breaker.
B. If 7 numbered Green LED is OFF on
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Trouble shooting guide for Loco. Pilots

Action by
Loco Pilot

34

digital input card in slot 13, then wiring

from CEB breaker to MEP-660 open
circuited. Check and replace wiring.
C. If 7-numberED Green LED is ON and
7-numbered Yellow LED is OFF, the
digital input card in slot 13 is defective.
Replace and check.

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35

Trouble shooting guide for Loco. Pilots

10. Battery is not charging, Battery voltage is low.

Fault code

1061

Fault
message

Battery Voltage LOW

Warning: Loco may stall

Restrictions

Loco may stall

Alarm bell

Buzzer sound for 30 seconds for every 10

minutes
Low, Manual
After manual reset if the fault still present, the
fault will be generated again.

Reset level

Fault
recovery
Probable
causes

Action by
Loco Pilot

For
Maintenance
Staff

Automatic when the battery voltage is more

than 62 V for 5 seconds.
1. Auxiliary generator failed to develop
voltage and Batteries are not charging.
2. This is a warning message indicating
Batteries are getting discharged.
Normally this message is followed by
Fault message Aux. Gen. output open
circuited. Fault code 1145 or
Fault message Aux. Gen Field circuit
open / shorted Fault code 1146
1. Check for tripped AGFB and MB1 circuit
breakers on front panel.
2. Check the tightness of ESS connector at
ESS.
1. If none of the above faults are logged, prior
to this fault message:
A. Change the display mode to Auxiliary
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Trouble shooting guide for Loco. Pilots

For
Maintenance
Staff

36

B. Measure Voltage with a voltmeter at the

BATV battery voltage sensor (wire No. 51
and 4) and voltage at AGAV Voltage
sensor (wire No. 49 and 44D).
C. If the measured voltages are tallying with
the displayed parameters and really
battery voltage is low and battery charging
current is zero, Then RCD is open
circuited. Replace RCD.
D. If the measured battery voltage is higher
than displayed voltage the voltage sensor
or its wiring is defect. Check and identify.
2. If the Aux. Gen. output open circuited.
Fault message is also logged trouble shoot
to find open circuit in the Aux. Gen.
output circuit. Refer Fault code 1145.
3. If Aux. Gen. Field Circuit open / Shorted
message is also logged trouble shoot to
find open circuit in the Auxiliary
Generator field circuit. Refer fault log No.
1146. Aux. Gen. Field Circuit Open or
Short.

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Trouble shooting guide for Loco. Pilots

37

11. Loco is moving with Field shunting and Motoring

prohibited in parallel combination.

Fault code.

1074

Fault
message
Restrictions

Field Shunting Relay FSR or FS Contactor

FS2X Stuck Closed.
Motoring always with field shunting.
Motoring in parallel prohibited.
30 seconds
Automatic
when
the
stuck
closed
relay/contactor is detected as open.
1. Welded FS contactors.
2. Defective FSR Relay
3. Defective wiring.
4. Defective output card.
1. Check weld of FS contactor and remove it.
2. Check the status of Green LED 10 and
yellow LED 10 on the digital input card in
slot 12.
3. If both the LEDs are glowing, check the
status of FSR relay.
4. If FSR is energized,
a) Check the condition of FSR relay for
any dislocated springs. If necessary, got
changed the relay.

Alarm bell
Fault
recovery
Probable
causes

Action by
Loco Pilot

For
Maintenance
staff

a) Check the condition of FSR relay for

any dislocated springs. If necessary,
change the relay.
b) The digital output card in slot 15 might
be defective. Replace the card.
5. If FSR is in de-energized position, check
FS contactors for any welded contact tips. If
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Trouble shooting guide for Loco. Pilots

For
Maintenance
staff

38

found welded contactors, separate the tips and

clean them. The LEDs should be OFF.
6. If still LEDs are glowing, FSFB wire is
getting wrongly supply due to
wrong wiring / shorted wiring. Identify and
rectify.
7. If both the LEDs are not glowing but the
fault is logged, check operation of FS
contactors for proper operation. Delayed
dropout of any FS contactor can log this fault
and later on it is recovered.

Note: This Error message will be generated only if either

Series Field Shunting or Parallel Field Shunting
ENABLED flags are set ().

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Trouble shooting guide for Loco. Pilots

39

12. Motoring with field Shunting but motoring in

parallel is prohibited

Fault code.

1075

Fault message
Restrictions

Field Shunting Relay FSR circuit open.

Motoring with field shunting and Motoring in
parallel prohibited.
Ringing Continuously for 30 seconds
Automatic when the Master handle is brought
to IDLE. Automatic reset is permitted for 3
times after which manual reset is required.
1. Defective FSR relay.
2. Defective digital output card
3. Defective wiring of FS contactor feed back.
4. Defective digital input card.
Put master handle in Idle position.
1. Set the display mode to Manual Test for
outputs under Test Mode menu.
2. Enter 24 and press Enter key to test the
FSR operation.
3. Press 1 key to switch on FSR relay.
4. FSR relay should pickup and along with that
FS contactors also should pick up..
5. If FSR relay not picking up check Voltage
across FSR relay coil with a voltmeter.
A. If voltage is more than 65V, then the
Relay is defective. Replace the relay.
6. If voltage is zero, check voltage at FSR coil
terminal (Wire No. 13) with respect to
locomotive 4 wire with a voltmeter.
A. If voltage is zero, check the continuity of
13-wire loop connected to FSR relay.
Check and replaced the open circuited
wires.

Alarm bell
Fault
recovery
Probable
causes

Action by
Loco Pilot

For
Maintenance
staff

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Trouble shooting guide for Loco. Pilots

For
Maintenance
staff

40

7. If Voltage is more than 65V, check the

voltage between Locomotive 13 wire and
wire FSRCL at FSR relay coil terminal.
A. If the voltage is zero:
a) Check slackness of connector of cable
ID: AZ at MEP660 control unit. If slack
tighten the connector.
b) Check continuity of FSRCL wire from
FSR coil terminal to MEP- 660 (Cable
ID: AZ, Pin-J). If necessary replace the
cable.
c) If continuity is available, the digital
output card 2 in slot No. 15 is defective.
Replace the card and recheck.
8. If FSR relay is picking up and FS contactors
are not picking up:
A. Bad interlock of FSR relay. Replace the
FSR relay.
B. There is no 13-wire supply at FSR relay
interlocks. Check up continuity of 13-wire
loop. Replace any open circuited wires.
9. If FS contactors are picking up:
10. Check the status of Green LED 10 on the
Digital input card in slot No. 12. The LED
should glow.
11. If the Green LED 10 is not glowing, check
voltage at incoming wire 51 at FS contactor
auxiliary contacts with respective to
locomotive 4 wire.
A. If the voltage is zero, check continuity of
51-wire loop. Replace any open circuited
wires/ wrong connections.
12. If voltage is more than 65V, Check the
voltage at FS contactor auxiliary contact
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Trouble shooting guide for Loco. Pilots

41

(wire No. FSFB) with respective

locomotive 4 wire.
A. If the Voltage is more than 65V, check
continuity of wire FSFB from FS 26
contactor Auxiliary contact to MEP-660.
(Cable ID: AW, Pin-L). If necessary replace
For
the cable.
Maintenance
13. If the Green LED is glowing and
staff
corresponding yellow LED is not glowing,
the digital input card in slot 12 is defective.
14. Replace the card and check once again

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Trouble shooting guide for Loco. Pilots

42

13. Engine is not Cranking due to Cranking contactor

stuck up.

Fault code.

1140

Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes

Cranking Contactor Stuck Open. Engine may

not Cranking.
Engine cranking prohibited
For 5 Seconds.
Automatic when CK1/CK2/CK3 auxiliary
contacts open.
1. Defective CKC contactor.
2. Defective output card MLSD-16 card in slot
14.
3. Connector of cable ID: AY is slack at MEP660.
4. Defective wiring.
5. Defective cranking contactor.
6. Defective digital input card MDIP 16 in slot
10.
This message will be logged during cranking
only.
1. Open the battery knife switch.
2. Manually operate and check free operation of
CKC contactor and all the three cranking
contactors. Ensure there is no mechanical
obstruction to operate.
3. Ensure that both Green and Yellow LEDs 0,
1 and 2 on the digital input card MDIP-16 in
slot 10 are glowing.
4. If all the three LEDs are glowing:
A. Manually open the Auxiliary contacts of
CK1, CK2 and CK3.
B. Corresponding Green and Yellow LED
should go off.
5. Close Battery knife switch and prepare loco

Action by
Loco Pilot

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Trouble shooting guide for Loco. Pilots

Action by
Loco Pilot
For
Maintenance
staff

43

for cranking.
6. Press start button
7. CKC contactor should pick up
C. If corresponding LED is not going OFF,
a) Check the supply voltage on the
corresponding
feedback
wire
(CK1FB/CK2FB/CK3FB) with respective to
locomotive 4 wire.
b) If the supply is zero while the auxiliary
contact is opened manually and still the
Green/Yellow LED is glowing, then the digital
input card MDIP 16 card in slot 10 is defective.
Replace the card.
c) If the supply voltage is more than 65V, then
wiring mistake. Identify from where the supply
is feeding and rectify.
5. Close the battery knife switch and prepare
the loco for cranking.
6. Pack the CK1, CK2, and CK3 contacts with
an insulating sheet so that auxiliary contacts
open when they operate and no battery supply is
going to Aux. Machines.
7. Press start button.
8. CKC should pick up.
9. If CKC is not picking up.
A. Check the voltage at the operating coil of
CKC.
B. If the voltage is more than 65 Volts and still
CKC is not picking up, then CKC is
defective. Replace the CKC.
C. If the voltage is zero, then check the voltage
at wire No. 71 with respect loco wire No. 4.
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Trouble shooting guide for Loco. Pilots

For
Maintenance
staff

44

D. If the voltage is zero check the wire

continuity of wire 71 connected to CKC
coil.
E. If the Voltage is more than 65 volts at wire
71, then check the voltage between loco
wire 13 and wire CKCCL at CKC coil.

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45

Trouble shooting guide for Loco. Pilots

15. Motoring prohibited, Dynamic prohibited due to

cranking contactor closed.

Fault code

1029

Fault
message

Cranking Contactor CK Stuck Closed.

Restrictions

Motoring Prohibited. Dynamic Brake

Prohibited.
Continuous

Alarm bell
Fault
recovery
Probable
causes

Action by
Loco Pilot

Automatic on releasing of stuck condition as

sensed through
Auxiliary contacts of CK1/CK2/CK3.
1. CK1/CK2/CK3 contactor main tips are
welded.
2. Defective wiring. (Wiring from these
auxiliary interlocks disconnected)
3. Defective MDIP16 card.
1. Shut down the engine.
2. Open battery knife switch
3. Check the status of CK1/CK2/CK3
feedback LEDs on the MDIP-16 card in
slot 10 and green LEDs numbered 0,1,2.
4. Whichever the LED is not glowing,
corresponding cranking contactor is
welded or interlock is bad.
5. LED 0 for CK1, LED 1 for CK2 and LED
2 for CK3. on MDIP16 card in slot 10.
6. Check for any weld condition of the
contactors. Release the main tips with a
wooden stick & clean it.
7. After the tips are separated, alarm bell
stops & the reset message is displayed
CAMTECH/GWL

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Trouble shooting guide for Loco. Pilots

Action by
Loco Pilot
For
maintenance
staff

46

Cranking contactor stuck closed FAULT

RECOVERED
8. Now close Battery knife switch
9. If there is no welding of contactors, check
and clean the concerned N/C interlocks of
that particular contactor.
10. If interlock is good, check the voltage
between CK#FB and locomotive 4 wire.
11. If the Voltage is more than 65V,
A. Check the slackness of the connector of
cable ID: AU at control unit. If slack press
the connector towards the control unit and
tighten the connector.
B. If connector is tight and still the green
LED is not glowing
a) MDIP16 card might be defective.

CAMTECH/GWL

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Trouble shooting guide for Loco. Pilots

47

16. No Battery charging, AG failed or AGFB or MB1

tripped

Fault code

2000

Fault message
Message code

No Battery charging due to major Faults.

1062, 1063, 1141, 1142, 1143, 1144, 1145,
1146
Battery not charging
This message is displayed for 30 seconds (5
seconds ON and 5 seconds OFF) when
Batteries are not charging and battery voltage
is less than 60V for every 10 minutes to alert
the driver.
Buzzer for 30 seconds for every 10 minutes

Restriction
Description of
Fault

Display buzzer
ON duration
Alarm Gong
ON duration
Probable
Causes

Action by
Loco pilot

None
1. Auxiliary Generator failed to develop
voltage and batteries are not charging
1. Check AGFB circuit breaker and MB1 for
tripping.
2. Insure proper tightness of ESS Connector
on ESS.
The following faults will also be displayed
as warning since loco running on batteries.
1062--- Battery Voltage is high
1063 -- AG field drive short
1141 AG output high fault
1142 Battery charging current high .
1143 AG Output over current fault
1144 AG field over Current
1145 AG output open circuit fault.
1146 AG field circuit open or short
CAMTECH/GWL

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48

Trouble shooting guide for Loco. Pilots

17. Engine not cranking, when operator attempts

cranking while Cranking contactor stuck closed

Fault code

2029

Fault
message
Restrictions:
Description
of Fault

Cranking Contactor Stuck Closed.

Displayed
message
duration
Display
buzzer ON
duration
Alarm Gong
ON duration
Fault
Recovery

Probable
causes

Action by
Loco Pilot

Cranking Prohibited.
This message is shown when operator
attempts cranking while Cranking contactor
stuck closed
Fault is already logged in the system.
5 Seconds

5 Seconds

None
Automatically recovers when feedbacks of
CK1, CK2 & CK3 main or auxiliary contacts
are comes to normal condition as sensed by
the system through their respective inputs.
Main tips of cranking contactor CK1, CK2,
CK3 might have welded.
1. Shut down the engine.
2. Open battery knife switch
3. Check for any weld condition of the
contactors. Release the main tips with a
wooden stick & clean it.
4. After the tips are separated, alarm bell
stops & the reset message is displayed
Cranking contactor stuck closed FAULT
CAMTECH/GWL

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49

Trouble shooting guide for Loco. Pilots

17. Engine not cranking, when operator attempts

cranking while Cranking contactor stuck closed
RECOVERED
5. Now close Battery knife switch

CAMTECH/GWL

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Trouble shooting guide for Loco. Pilots

50

18. VCD Applied Penalty Brake. Move Master

Controller Handle to IDLE and press Reset to
release Brake.

Fault code.

1153

Fault
message

VCD Applied Penalty Brake. Move Master

Controller Handle to IDLE and press Reset to
release Brake.
Motoring not permitted till the master handle is
brought to IDLE and loco speed is dropped to
zero and blinking LED should stop.
05 seconds
Automatic when the loco speed is zero, master
handle is brought to IDLE, blinking LED
stopped and Pressed VCD reset button.
1. VCD operated due to improper
operation of loco.
2. Failed to press VCD reset switch
3. Defective VCD unit
(Driver should perform any loco operation or
press alerter reset switch once in 94 sec. to
avoid penalty brakes).
1. Bring the master handle to IDLE, wait
till loco speed is dropped to zero,
2. Wait till VCD LED blinking is stopped.
3. Press VCD reset push button to release
penalty brakes.

Restrictions

Alarm bell
Fault
recovery
Probable
causes

Action by
Loco Pilot

CAMTECH/GWL

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OUR OBJECTIVE
To Upgrade Maintenance Technologies and
Methodologies and achieve Improvement in
Productivity and Performance of all Railway
Assets and Manpower which Interalia would
cover Reliability, Availability, Utilisation and
Efficiency.

If you have any suggestions and any specific

comments, please write to us :
Contact Person :

Director (Mech)

Postal Address :

Indian Railways ,
Centre for Advanced
Maintenance Technology,
Maharajpur,Gwalior.

Pin Code

474005

Phone

0751-2470803, 2470890

Fax

0751-2470841

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