के वल कायाालयीन उपयोग हेतु

(For Official Use Only)

भारत सरकारGOVERNMENT OF INDIA

रे ल मंत्रालयMINISTRY OF RAILWAYS

VANDE BHARAT EXPRESS

TRAINSET (T-18)
MAINTENANCE MANUAL

VOLUME - 2
System Documentation
IRCAMTECH/GWL/2020-21/T-18/MM/1.0
August, 2020
Vande Bharat Express(T-18) Maintenance Manual (Version1.0) System Documentation

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) System Documentation
Volume 2

System Documentation

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,

RDSO and OEMs

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) System Documentation

Amendments and Revisions

The correction slips to be issued in future for this report will be numbered as follows:

IRCAMTECH/GWL/2020-21/T-18/MM/1.0# XX date .......

Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).

Version Date Corrections Remarks

1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) System Documentation
Content

1 Technical Description
2 Cleaning
3 Maintenance Schedules
4 Tools and Accessories
5 Maintenance
6 Drawing Index
7 General Information
8 Troubleshooting

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description

1. TECHNICAL DESCRIPTION

Version : 1.00

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,

RDSO and OEMs

Page
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
List of Amendments
Version Date Corrections Remarks
1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
Table of Content

1.1. TECHNICAL DESCRIPTION - DRIVING TRAILER COACH (DTC) ................................. 11

1.2. TECHNICAL DESCRIPTION -TRAILER COACH (TC) ................................................... 14
1.3. TECHNICAL DESCRIPTION - NON DRIVING TRAILER COACH (NDTC)...................... 18
1.4. TECHNICAL DESCRIPTION - MOTOR COACH (MC) ................................................. 22
1.5. LAYOUTS................................................................................................................. 26
Layout of Air Conditioned DTC ............................................................................................. 27
Layout of Air Conditioned TC ................................................................................................ 28
Layout of Air Conditioned NDTC ........................................................................................... 29
Layout of Executive Air Conditioned NDTC .......................................................................... 30
Layout of Air Conditioned MC .............................................................................................. 31
Layout of Executive Air Conditioned MC .............................................................................. 32

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
CONTENTS - DRIVING TRAILER COACH (DTC)

1.1. TECHNICAL DESCRIPTION - DRIVING TRAILER COACH (DTC) ................................. 11

1.1.1. GENERAL ................................................................................................................ 11
1.1.2. COACH DESCRIPTION ............................................................................................. 11
1.1.3. TECHNICAL DATA ................................................................................................... 11
1.1.4. CARBODY PART ...................................................................................................... 11
1.1.4.1. CARBODY SHELL ..................................................................................................... 11
1.1.4.2. DRAW AND BUFFER GEAR ..................................................................................... 11
1.1.4.3. SEMI PERMANENT COUPLER ................................................................................. 11
1.1.4.4. PLUG DOORS (ENTRY DOORS) ............................................................................... 12
1.1.4.5. SLIDING DOORS (TRANSIT DOORS) ........................................................................ 12
1.1.4.6. GANGWAYS ............................................................................................................ 12
1.1.5. WINDOWS .............................................................................................................. 12
1.1.6. INTERIOR EQUIPMENT ........................................................................................... 12
1.1.6.1. INTERIOR FITTING .................................................................................................. 12
1.1.6.2. INTERIOR PANELLING ............................................................................................. 12
1.1.7. LIGHTING ................................................................................................................ 12
1.1.8. TOILET SYSTEMS ..................................................................................................... 12
1.1.9. BRAKE ..................................................................................................................... 12
1.1.10. ELECTRICAL EQUIPMENT ....................................................................................... 13
1.1.10.1. EQUIPMENT IN DRIVING TRAILER COACH ............................................................. 13
1.1.10.2. PASSENGER INFORMATION SYSTEM & CCTV ........................................................ 13
1.1.11. AIR CONDITIONING SYSTEM .................................................................................. 13
1.1.11.1. AIR CONDITIONING UNITS ..................................................................................... 13
1.1.12. BOGIES ................................................................................................................... 13

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.1. TECHNICAL DESCRIPTION - DRIVING TRAILER COACH (DTC)

1.1.1. GENERAL
New air conditioned light weight coach for service up to 160 km / h on special high speed
lines of Indian Railways.

1.1.2. COACH DESCRIPTION

DTC is a non-powered vehicle with a driver cab at one end. The driver cab is furnished with a
pre-fabricated driver desk. All driving operations are possible from this driver desk. Feedback
from the system in all the coaches/basic units is available for viewing by motor man on the
driver desk. In this regard, CCU aggregates the information from all the coaches and a 10.4 ‫ײ‬
TFT driver display screen provides information to motor man. Further an illuminated
indication panel is provided for important driving related information for quick viewing by
motor man. Various gauges are also provided for viewing MR, BP, BC pressure. Motor man
can also control the passenger information system from the driver desk DTC. Apart from the
driver cab is called as passenger saloon area. Passenger saloon area is similar to trailer
coach, except the space occupied by driver cab.

DTC also consists of battery box, battery charger, compressor, water tank, main reservoir, air
supply unit, end pneumatic panel which are mounted under-slung. Rest of the DTC apart
from the driver cab is passenger saloon area which consists of pantry, RMPU control unit,
mono block pump controller, CRW, GCRW panel and various end wall panels. It is a air-
conditioned coach. All passenger comfort related load is controlled by driver from driver cab.

1.1.3. TECHNICAL DATA

Designation Value
Track gauge 1,676 mm
Speed Max. 160 km/h
Length of car-body (Over Coupler) 24000 mm
Width of car-body 3240 mm
Car height above top of rail 4140 mm
Wheels 952 mm dia.
Distance between center pivots 14900 mm
Number of Toilets 1
Number of Seats- (Chair Car) 44

1.1.4. CARBODY PART

1.1.4.1. CARBODY SHELL

Economical light weight steel construction.

1.1.4.2. DRAW AND BUFFER GEAR

Tight lock center buffer coupler type AAR - H. Provided on driver cabin side of coach.

1.1.4.3. SEMI PERMANENT COUPLER

The Front Driving Coaches (DTCs) has CBC couplers and the in between coaches have
permanently coupled with Semi-permanent couplers.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.1.4.4. PLUG DOORS (ENTRY DOORS)
Automatic plug door includes locking and opening mechanism is a sophisticated system in
which the coach doors shall remain closed whenever the train starts from Railway station.
Similarly, these doors remain closed till the train stops at the next station and eliminate
chances of passengers detraining from the moving train.

1.1.4.5. SLIDING DOORS (TRANSIT DOORS)

Interior sliding doors serve to separate the boarding area of the carriage from the seating area with
advantages of the solution: reliability and comfort of operation. The interior door can be controlled
either by a radar signal when the person approaches or by pressing a button on the door.In case of
power failure, the doors are freely movable manually or in case of emergency, the door is
disconnected from the power supply when emergency button is pressed and is freely movable
manually.

1.1.4.6. GANGWAYS
The gangway is the flexible part of the train, allowing the relative movements between the
Coaches and offering passengers a secure and comfortable passageway.

1.1.5. WINDOWS
Double-pane insulating glass especially designed for air conditioned coaches with reflective
laminated glass on the outside and tempered safety glass on the inside.

1.1.6. INTERIOR EQUIPMENT

1.1.6.1. INTERIOR FITTING

Saloon passenger area in the coach center, 2 plus 3 arrangement for the chair car separated
via sliding doors from the entrance area. Seats designed in light weight construction
especially for the new coach type. Continuous luggage rack above the seats with halogen
reading lamps for each seat. Pantry compartment for storing, preparing and serving of
precooked meals with equipment like freezer, heating furnace, soup warmer, water boiler
and serving trolley.

1.1.6.2. INTERIOR PANELLING

Side walls and ceilings in the passenger area made of modular glass-fiber reinforced poly-
ester parts. The floor is made of sound absorbing multiplex plates on special noise damping
rubber profiles. PVC floor covering provided with carpet in the executive class (passenger
area).

1.1.7. LIGHTING
Lighting by means of a centrally arranged LED luminous band. Illumination of entrance area
and toilets with LED lamps. LED reading lamps above each seat. Diffused lighting system.

1.1.8. TOILET SYSTEMS

FRP modular toilet module at the coach end. Train-18 contains vacuum assisted bio-toilet
system. Water tank (1100 liters) under-slung.

1.1.9. BRAKE
Pneumatic disc brake type, anti-skid device, electro-pneumatic control system and
regenerative braking.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.1.10. ELECTRICAL EQUIPMENT

1.1.10.1. EQUIPMENT IN DRIVING TRAILER COACH

Battery Charging System (Battery Charger), Battery and Battery box, Inter-Vehicular (IV)
couplers, Isolation (pantry) transformer- 20 kVA, Master Controller, Driver console (left-
driver, right-Guard), Cabin control, driving control, door control switches, DDU (TFT driver
display screen), Gauges, Speed Recorder, Indication lamps, Man Machine Interface(MMI),
Brake controller, Signal bell, Horn switch, VCD reset switch, Emergency brake handle,
Buzzers, Connector and TB panel.CRW (cab rear wall) panel, it consists CCU'S, LRMS, TPWS,
ECN Switches, MCB's, Relays & contactors, GCRW (Guard cab rear wall) panel, it consists
PCU'S, EBCU's, CCTV NVRs, CCTV Ethernet Switches MCB's, Relays &contactors, EWP (End
wall panel)- TBs, MCBs, MPCB, Reading lights, mono block pump controller, Passenger
information system (HCD,ICD, SDB, speaker, ANM, PECU,MMI), CCTV, Saloon & Gangway
Lights, Roof Mounted AC Package Unit (RMPU), RMPU control unit, LED Marker Lights, LED
Flasher Lights and control unit, Wiper, Driver’s Cab Air Conditioning Unit, Earth return
ground contact (ERCU), Mini Pantry Items, Power supply socket junction box for external 415
V AC, Speedometer, Frequency Generator Unit, Pump controller, Mono block pump.

1.1.10.2. PASSENGER INFORMATION SYSTEM & CCTV

Train-18 is fitted with GPS based passenger information system. This train has CCTV system
for monitoring and security purpose.

1.1.11. AIR CONDITIONING SYSTEM

1.1.11.1. AIR CONDITIONING UNITS

Two microprocessor-controlled roof-mounted package units. Supply of conditioned air via
perforated ceiling in the passenger room. Separate Cab air conditioning unit for driver cabin.

1.1.12. BOGIES
Bolster less bogie for semi high speed operation.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
CONTENTS - TRAILER COACH (TC)

1.2. TECHNICAL DESCRIPTION -TRAILER COACH (TC) ................................................... 15

1.2.1. GENERAL ................................................................................................................ 15
1.2.2. COACH DESCRIPTION ............................................................................................. 15
1.2.3. TECHNICAL DATA ................................................................................................... 15
1.2.4. CARBODY PART ...................................................................................................... 15
1.2.4.1. CARBODY SHELL ..................................................................................................... 15
1.2.4.2. SEMI PERMANENT COUPLER ................................................................................. 15
1.2.4.3. PLUG DOORS (ENTRY DOORS) ............................................................................... 15
1.2.4.4. SLIDING DOORS (TRANSIT DOORS) ........................................................................ 15
1.2.4.5. GANGWAYS ............................................................................................................ 16
1.2.5. WINDOWS .............................................................................................................. 16
1.2.6. INTERIOR EQUIPMENT ........................................................................................... 16
1.2.6.1. INTERIOR FITTING .................................................................................................. 16
1.2.6.2. INTERIOR PANELLING ............................................................................................. 16
1.2.7. LIGHTING ................................................................................................................ 16
1.2.8. TOILET SYSTEMS ..................................................................................................... 16
1.2.9. BRAKE ..................................................................................................................... 16
1.2.10. ELECTRICAL EQUIPMENT ....................................................................................... 16
1.2.10.1. EQUIPMENT IN TRAILER COACH ............................................................................ 16
1.2.11. AIR CONDITIONING SYSTEM .................................................................................. 17
1.2.11.1. AIR CONDITIONING UNITS ..................................................................................... 17
1.2.12. BOGIES ................................................................................................................... 17

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.2. TECHNICAL DESCRIPTION -TRAILER COACH(TC)

1.2.1. GENERAL
New air conditioned light weight coach for service up to 160 km / h on special high speed
lines of Indian Railways.

1.2.2. COACH DESCRIPTION

TC is a non-powered vehicle with only a passenger saloon area. The passenger saloon area
includes lights, fans, emergency lights, air handling unit (for ventilation), and passenger
information system consisting of LED displays and speakers (for announcements). TC consists
of a pantograph, vacuum circuit breaker and HV isolator on roof. It also consists of auxiliary
converter unit and power transformer mounted under-slung. Power to LTC units of both
motor coaches is distributed from same power transformer.

1.2.3. TECHNICAL DATA

Designation Value
Track gauge 1,676 mm
Speed Max. 160 km/h
Length of car-body (Over Coupler) 24000 mm
Width of car-body 3240 mm
Car height above top of rail 4140 mm
Wheels 952 mm dia.
Distance between center pivots 14900 mm
Number of Toilets 2
Number of Seats- (Chair Car) 78

1.2.4. CARBODY PART

1.2.4.1. CARBODY SHELL

Economical light weight steel construction.

1.2.4.2. SEMI PERMANENT COUPLER

Provides rigid connection on both sides and minimizes both draft and buff forces (600kN
draft / 1000kN buff).

1.2.4.3. PLUG DOORS (ENTRY DOORS)

Automatic plug door includes locking and opening mechanism is a sophisticated system in
which the coach doors shall remain closed whenever the train starts from Railway station.
Similarly, these doors remain closed till the train stops at the next station and eliminate
chances of passengers detraining from the moving train.

1.2.4.4. SLIDING DOORS (TRANSIT DOORS)

Interior sliding doors serve to separate the boarding area of the carriage from the seating area with
advantages of the solution: reliability and comfort of operation. The interior door can be controlled
either by a radar signal when the person approaches or by pressing a button on the door.In case of
power failure, the doors are freely movable manually or in case of emergency, the door is

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
disconnected from the power supply when emergency button is pressed and is freely movable
manually.

1.2.4.5. GANGWAYS
The gangway is the flexible part of the train, allowing the relative movements between the
Coaches and offering passengers a secure and comfortable passageway.

1.2.5. WINDOWS
Double-pane insulating glass especially designed for air conditioned coaches with reflective
laminated glass on the outside and tempered safety glass on the inside.

1.2.6. INTERIOR EQUIPMENT

1.2.6.1. INTERIOR FITTING

Saloon passenger area in the coach center, 2 plus 3 arrangement for the chair car separated
via sliding doors from the entrance area. Seats designed in light weight construction
especially for the new coach type. Continuous luggage rack above the seats with halogen
reading lamps for each seat. Pantry compartment for storing, preparing and serving of
precooked meals with equipment like freezer, heating furnace, soup warmer, water boiler
and serving trolley.

1.2.6.2. INTERIOR PANELLING

Side walls and ceilings in the passenger area made of modular glass-fiber reinforced poly-
ester parts. The floor is made of sound absorbing multiplex plates on special noise damping
rubber profiles. PVC floor covering provided with carpet in the executive class (passenger
area).

1.2.7. LIGHTING
Lighting by means of a centrally arranged LED luminous band. Illumination of entrance area
and toilets with LED lamps. LED reading lamps above each seat. Diffused lighting system.

1.2.8. TOILET SYSTEMS

FRP modular toilet module of European and Indian (squatting) style at the coach end. Train-
18 contains vacuum assisted bio-toilet system. Fresh water tank (1100 liters) under-slung.

1.2.9. BRAKE
Pneumatic disc brake type, anti-skid device, electro-pneumatic control system and
regenerative braking.

1.2.10. ELECTRICAL EQUIPMENT

1.2.10.1. EQUIPMENT IN TRAILER COACH

Auxiliary Converter Unit (ACU), Pantograph with insulator, Vacuum Circuit Breaker (VCB),
Earthing switch for VCB (Roof), AC Surge Arrester / Lightning arrester, Main transformer
(Traction), Jumper Couplers (Power Couplers), Power Coupler Junction Box, Inter-Vehicular
(IV) couplers, Isolation (pantry) transformer- 20 kVA, ECC (Electrical cubical)-It consists
EPCU'S, EBCU'S, MCB's, Relays & contactors, EWP (End wall panel) - Terminal Blocks & MCBs,
TBs, MCBs, MPCB, Reading lights mono block pump controller, Passenger information
system (ICD, SDB, speaker, ANM, PECU), CCTV, Saloon & Gangway Lights, Roof Mounted AC
Package Unit (RMPU), RMPU control unit, Return Current Transformer, Primary Current
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
Transformer, Voltage Transformer, Earth return ground contact (ERCU), Mini Pantry Items,
Power supply socket junction box for external 415 V AC, HT cable, Pump controller, Mono
block pump.

1.2.11. AIR CONDITIONING SYSTEM

1.2.11.1. AIR CONDITIONING UNITS

Two microprocessor-controlled roof-mounted package units. Supply of conditioned air via
perforated ceiling in the passenger room. Separate Cab air conditioning unit for driver cabin.

1.2.12. BOGIES
Bolster less bogie for semi high speed operation.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
CONTENTS - NON DRIVING TRAILER COACH (NDTC)

1.3. TECHNICAL DESCRIPTION - NON DRIVING TRAILER COACH (NDTC)...................... 18

1.3.1. GENERAL ................................................................................................................ 19
1.3.2. COACH DESCRIPTION ............................................................................................. 19
1.3.3. TECHNICAL DATA ................................................................................................... 19
1.3.4. CARBODY PART ...................................................................................................... 19
1.3.4.1. CARBODY SHELL ..................................................................................................... 19
1.3.4.2. SEMI PERMANENT COUPLER ................................................................................. 19
1.3.4.3. PLUG DOORS (ENTRY DOORS) ............................................................................... 19
1.3.4.4. SLIDING DOORS (TRANSIT DOORS) ........................................................................ 19
1.3.4.5. GANGWAYS ............................................................................................................ 20
1.3.5. WINDOWS .............................................................................................................. 20
1.3.6. INTERIOR EQUIPMENT ........................................................................................... 20
1.3.6.1. INTERIOR FITTING .................................................................................................. 20
1.3.6.2. INTERIOR PANELLING ............................................................................................. 20
1.3.7. LIGHTING ................................................................................................................ 20
1.3.8. TOILET SYSTEMS ..................................................................................................... 20
1.3.9. BRAKE ..................................................................................................................... 20
1.3.10. ELECTRICAL EQUIPMENT ....................................................................................... 20
1.3.10.1. EQUIPMENT IN NDTC ............................................................................................. 20
1.3.11. AIR CONDITIONING SYSTEM .................................................................................. 20
1.3.11.1. AIR CONDITIONING UNITS ..................................................................................... 21
1.3.12. BOGIES ................................................................................................................... 21

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.3. TECHNICAL DESCRIPTION - NON DRIVING TRAILER COACH (NDTC)

1.3.1. GENERAL
New air conditioned light weight coach for service up to 160 km / h on special high speed
lines of Indian Railways.

1.3.2. COACH DESCRIPTION

NDTC consists of passenger saloon area, pantry, RMPU, mono block pump controller,
electrical cabinet and various End wall panels. It is an air-conditioned coach. Non Driving
Trailer Coach (NDTC) is similar to DTC except driver related interface. It also consists of
battery box, battery charger and compressor mounted under-slung. It also consists of
passenger saloon area which consists of pantry, RMPU control unit, mono block pump
controller, and various end wall panels.

1.3.3. TECHNICAL DATA

Designation Value
Track gauge 1,676 mm
Speed Max. 160 km/h
Length of car-body (Over Coupler) 24000 mm
Width of car-body 3240 mm
Car height above top of rail 4140 mm
Wheels 952 mm dia.
Distance between center pivots 14900 mm
Number of Toilets 2
Number of Seats- (Chair Car) 78
Number of Seats- (Executive Class) 52

1.3.4. CARBODY PART

1.3.4.1. CARBODY SHELL

Economical light weight steel construction.

1.3.4.2. SEMI PERMANENT COUPLER

Provides rigid connection on both sides and minimizes both draft and buff forces (600kN
draft / 1000kN buff).

1.3.4.3. PLUG DOORS (ENTRY DOORS)

Automatic plug door include locking and opening mechanism is a sophisticated system in
which the coach doors shall remain closed whenever the train starts from Railway station.
Similarly, these doors remain closed till the train stops at the next station and eliminate
chances of passengers detraining from the moving train.

1.3.4.4. SLIDING DOORS (TRANSIT DOORS)

Interior sliding doors serve to separate the boarding area of the carriage from the seating area with
advantages of the solution: reliability and comfort of operation. The interior door can be controlled
either by a radar signal when the person approaches or by pressing a button on the door. In case of
power failure, the doors are freely movable manually or in case of emergency, the door is
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
disconnected from the power supply when emergency button is pressed and is freely movable
manually.

1.3.4.5. GANGWAYS
The gangway is the flexible part of the train, allowing the relative movements between the
Coaches and offering passengers a secure and comfortable passageway.

1.3.5. WINDOWS
Double-pane insulating glass especially designed for air conditioned coaches with reflective
laminated glass on the outside and tempered safety glass on the inside.

1.3.6. INTERIOR EQUIPMENT

1.3.6.1. INTERIOR FITTING

Saloon passenger area in the coach center, 2 plus 2 arrangement for the executive class and
2 plus 3 arrangement for the chair car separated via sliding doors from the entrance area.
Seats designed in light weight construction especially for the new coach type. Continuous
luggage rack above the seats with halogen reading lamps for each seat. Pantry compartment
for storing, preparing and serving of precooked meals with equipment like freezer, heating
furnace, soup warmer, water boiler and serving trolley.

1.3.6.2. INTERIOR PANELLING

Side walls and ceilings in the passenger area made of modular glass-fiber reinforced poly-
ester parts. The floor is made of sound absorbing multiplex plates on special noise damping
rubber profiles. PVC floor covering provided with carpet in the executive class (passenger
area).

1.3.7. LIGHTING
Lighting by means of a centrally arranged LED luminous band. Illumination of entrance area
and toilets with LED lamps. LED reading lamps above each seat. Diffused lighting system.

1.3.8. TOILET SYSTEMS

FRP modular toilet module of European and Indian(squatting) style at the coach end. Train-
18 contains vacuum assisted bio-toilet system. Fresh water tank (1100 liters) under-slung.

1.3.9. BRAKE
Pneumatic disc brake type, anti-skid device, electro-pneumatic control system and
regenerative braking.

1.3.10. ELECTRICAL EQUIPMENT

1.3.10.1. EQUIPMENT IN NDTC

Battery Charging System (Battery Charger),Battery and Battery box, Inter-Vehicular (IV)
couplers, Isolation (pantry) transformer- 20 kVA, Passenger information system
(ICD,SDB,speaker,ANM,PECU), CCTV, Saloon & Gangway Lights, Roof Mounted AC Package
Unit (RMPU),RMPU control unit, Earth return ground contact (ERCU),Mini Pantry Items,
Power supply socket junction box for external 415 V AC, Shunting Panel, Pump controller,
Mono block pump.

1.3.11. AIR CONDITIONING SYSTEM

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.3.11.1. AIR CONDITIONING UNITS
Two microprocessor-controlled roof-mounted package units. Supply of conditioned air via
perforated ceiling in the passenger room. Separate Cab air conditioning unit for driver cabin.

1.3.12. BOGIES
Bolster less bogie for semi high speed operation.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
CONTENTS - MOTOR COACH (MC)

1.4. TECHNICAL DESCRIPTION - MOTOR COACH (MC) ................................................. 22

1.4.1. GENERAL ................................................................................................................ 23
1.4.2. COACH DESCRIPTION ............................................................................................. 23
1.4.3. TECHNICAL DATA ................................................................................................... 23
1.4.4. CARBODY PART ...................................................................................................... 23
1.4.4.1. CARBODY SHELL ..................................................................................................... 23
1.4.4.2. SEMI PERMANENT COUPLER ................................................................................. 23
1.4.4.3. PLUG DOORS (ENTRY DOORS) ............................................................................... 23
1.4.4.4. SLIDING DOORS (TRANSIT DOORS) ........................................................................ 23
1.4.4.5. GANGWAYS ............................................................................................................ 24
1.4.5. CARBODY PART ...................................................................................................... 24
1.4.5.1. CARBODY SHELL ..................................................................................................... 24
1.4.5.2. SEMI PERMANENT COUPLER ................................................................................. 24
1.4.5.3. PLUG DOORS (ENTRY DOORS) ............................................................................... 24
1.4.5.4. SLIDING DOORS (TRANSIT DOORS) ........................................................................ 24
1.4.5.5. GANGWAYS ............................................................................................................ 24
1.4.6. WINDOWS .............................................................................................................. 24
1.4.7. INTERIOR EQUIPMENT ........................................................................................... 24
1.4.7.1. INTERIOR FITTING .................................................................................................. 24
1.4.7.2. INTERIOR PANELLING ............................................................................................. 25
1.4.8. LIGHTING ................................................................................................................ 25
1.4.9. TOILET SYSTEMS ..................................................................................................... 25
1.4.10. BRAKE ..................................................................................................................... 25
1.4.11. ELECTRICAL EQUIPMENT ....................................................................................... 25
1.4.11.1. EQUIPMENTS IN MOTOR COACH ........................................................................... 25
1.4.12. AIR CONDITIONING SYSTEM .................................................................................. 25
1.4.12.1. AIR CONDITIONING UNITS ..................................................................................... 25
1.4.13. BOGIES ................................................................................................................... 25

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
1.4. TECHNICAL DESCRIPTION - MOTOR COACH (MC)

1.4.1. GENERAL
New air conditioned light weight coach for service up to 160 km / h on special high speed
lines of Indian Railways.

1.4.2. COACH DESCRIPTION

MC is a powered vehicle with one traction motor driving each axle. The motor coach consists
Line and Traction Converter Unit (LTC) for each Bogie mounted under-slung. Also Brake
chopper resister is mounted under-slung. Transformer secondary cable for both LTC unit
from power transformer come from Trailer Coach through under-slung mounted IV Coupler.
It also consists of passenger saloon area, pantry, RMPU, mono block pump controller,
electrical cabinet and various end wall panels. It is air-conditioned coach. The passenger
saloon area is similar to trailer coach.

MC with electrical changeover switch is known as MC2 and 180 degree rotated is MC3.

1.4.3. TECHNICAL DATA

Designation Value
Track gauge 1,676 mm
Speed Max. 160 km/h
Length of car-body (Over Coupler) 24000 mm
Width of car-body 3240 mm
Car height above top of rail 4140 mm
Wheels 952 mm dia.
Distance between center pivots 14900 mm
Number of Toilets 2
Number of Seats- (Chair Car) 78
Number of Seats- (Executive Class) 52

1.4.4. CARBODY PART

1.4.4.1. CARBODYSHELL
Economical light weight steel construction.

1.4.4.2. SEMI PERMANENT COUPLER

Provides rigid connection on both sides and minimizes both draft and buff forces (600kN
draft / 1000kN buff).

1.4.4.3. PLUG DOORS (ENTRY DOORS)

Automatic plug door include locking and opening mechanism is a sophisticated system in
which the coach doors shall remain closed whenever the train starts from Railway station.
Similarly, these doors remain closed till the train stops at the next station and eliminate
chances of passengers detraining from the moving train.

1.4.4.4. SLIDING DOORS (TRANSIT DOORS)

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 1. Technical Description
Interior sliding doors serve to separate the boarding area of the carriage from the seating area with
advantages of the solution: reliability and comfort of operation. The interior door can be controlled
either by a radar signal when the person approaches or by pressing a button on the door. In case of
power failure, the doors are freely movable manually or in case of emergency, the door is
disconnected from the power supply when emergency button is pressed and is freely movable
manually.

1.4.4.5. GANGWAYS
The gangway is the flexible part of the train, allowing the relative movements between the
Coaches and offering passengers a secure and comfortable passageway.

1.4.5. CARBODY PART

1.4.5.1. CARBODY SHELL

Economical light weight steel construction.

1.4.5.2. SEMI PERMANENT COUPLER

Provides rigid connection on both sides and minimizes both draft and buff forces (600kN
draft / 1000kN buff).

1.4.5.3. PLUG DOORS (ENTRY DOORS)

Automatic plug door include locking and opening mechanism is a sophisticated system in
which the coach doors shall remain closed whenever the train starts from Railway station.
Similarly, these doors remain closed till the train stops at the next station and eliminate
chances of passengers detraining from the moving train.

1.4.5.4. SLIDING DOORS (TRANSIT DOORS)

Interior sliding doors serve to separate the boarding area of the carriage from the seating area with
advantages of the solution: reliability and comfort of operation. The interior door can be controlled
either by a radar signal when the person approaches or by pressing a button on the door.In case of
power failure, the doors are freely movable manually or in case of emergency, the door is
disconnected from the power supply when emergency button is pressed and is freely movable
manually.

1.4.5.5. GANGWAYS
The gangway is the flexible part of the train, allowing the relative movements between the
Coaches and offering passengers a secure and comfortable passageway.

1.4.6. WINDOWS
Double-pane insulating glass especially designed for air conditioned coaches with reflective
laminated glass on the outside and tempered safety glass on the inside.

1.4.7. INTERIOR EQUIPMENT

1.4.7.1. INTERIOR FITTING

Saloon passenger area in the coach center, 2 plus 2 arrangement for the executive class and
2 plus 3 arrangement for the chair car separated via sliding doors from the entrance area.
Seats designed in light weight construction especially for the new coach type. Continuous
luggage rack above the seats with halogen reading lamps for each seat. Pantry compartment
for storing, preparing and serving of precooked meals with equipment like freezer, heating
furnace, soup warmer, water boiler and serving trolley.
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1.4.7.2. INTERIOR PANELLING
Side walls and ceilings in the passenger area made of modular glass-fiber reinforced poly-
ester parts. The floor is made of sound absorbing multiplex plates on special noise damping
rubber profiles. PVC floor covering provided with carpet in the executive class (passenger
area).

1.4.8. LIGHTING
Lighting by means of a centrally arranged LED luminous band. Illumination of entrance area
and toilets with LED lamps. LED reading lamps above each seat. Diffused lighting system.

1.4.9. TOILET SYSTEMS

FRP modular toilet module of European and Indian(squatting) style at the coach end. Train-
18 contains vacuum assisted bio-toilet system. Fresh water tank (1100 liters) under-slung.

1.4.10. BRAKE
Pneumatic disc brake type, anti skid device, electro-pneumatic control system and
regenerative braking.

1.4.11. ELECTRICAL EQUIPMENT

1.4.11.1. EQUIPMENTS IN MOTOR COACH

Line and Traction Converter (LTC), Brake Chopper Resistor, DC Link Earthing Switch, TM
Cable Junction Box, Jumper Couplers (Power Couplers), Power Coupler Junction Box, Inter-
Vehicular (IV) couplers, Isolation (pantry) transformer, ECC (Electrical cubical)-It consists
MCUS, EBCUS, MCB, Relays & contactor, EWP (End wall panel)- Terminal Blocks & MCBs,
TBs, MCBs, MPCB, Reading lights mono block pump controller, Passenger information
system (ICD,SDB,speaker,ANM,PECU), CCTV, Saloon & Gangway Lights, Roof Mounted AC
Package Unit (RMPU),RMPU control unit, Earth return ground contact (ERCU),Mini Pantry
Items, Power supply socket junction box for external 415 V AC, Pump controller, Mono block
pump.

1.4.12. AIR CONDITIONING SYSTEM

1.4.12.1. AIR CONDITIONING UNITS

Two microprocessor-controlled roof-mounted package units. Supply of conditioned air via
perforated ceiling in the passenger room. Separate Cab air conditioning unit for driver cabin.

1.4.13. BOGIES
Fully suspended traction motor and bolster less bogie for semi high speed operation.
Traction motor and drive gear unit in motor coaches only.

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1.5. LAYOUTS

1.5.1. LAYOUT OF AIR CONDITIONED DTC

1.5.2. LAYOUT OF AIR CONDITIONED TC

1.5.3. LAYOUT OF AIR CONDITIONED NDTC

1.5.4. LAYOUT OF EXECUTIVE AIR CONDITIONED NDTC

1.5.5. LAYOUT OF AIR CONDITIONED MC

1.5.6. LAYOUT OF EXECUTIVE AIR CONDITIONED MC

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Layout of Air Conditioned DTC

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Layout of Air Conditioned TC

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Layout of Air Conditioned NDTC

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Layout of Executive Air Conditioned NDTC

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Layout of Air Conditioned MC

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Layout of Executive Air Conditioned MC

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning

2. CLEANING

Version : 1.00

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,

RDSO and OEMs

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
Amendment and Revisions
Version Date Corrections Remarks
1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
Content

2. CLEANING ............................................................................................................................ 1
2.1. INTERNAL CLEANING................................................................................................ 4
2.1.1. GENERAL .................................................................................................................. 4
2.1.2. DEFINATION ............................................................................................................. 4
2.1.3. INTERIOR CLEANING (NORMAL) .............................................................................. 4
2.1.4. INTERIOR CLEANING (INTENSIVE) ............................................................................ 4
2.1.4.1. FRP PANELS .............................................................................................................. 5
2.1.4.2. GLASSES.................................................................................................................... 5
2.1.4.3. PASSENGER SEATS.................................................................................................... 6
2.2. EXTERNAL CLEANING ............................................................................................... 8

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
2.1. INTERNAL CLEANING

2.1.1. GENERAL
It is to be noted that the cleaning instruction to be followed during the internal and external
cleaning of Train-18.

2.1.2. DEFINATION
Clean: Re-create clean external and internal conditions
Damp wipe: For “damp wipe”, all work must be undertaken with a damp cloth without the
addition of any cleaning agent.
Wash: All following work designated "wash" must be undertaken with a cloth dampened
with a non- aggressive cleaning solution.
Wash over and wipe clean: Cleaning glass surfaces with the aid of water, cleaning agent and
cleaning implements.
Take up loose dirt from the floor: Use dustpan and brush, broom or similar equipment to
sweep up general loose dirt from the floor, collecting larger items manually.
Unusual contaminants: All troublesome soiling, requiring use of special cleaning agents or
methods for removal
Emptying: All rubbish, including any wedged-in.
Clean up: Waste-bins, ash-trays and similar equipment, returning them to their places.

2.1.3. INTERIOR CLEANING (NORMAL)

Complete Vehicle
Collect all rubbish, if possible dividing according to type, using plastic sacks in the same
operation, rubbish bins and similar containers.

Sweep up dirt on the floor with dustpan and brush, causing as little dust to fly as possible.

Replace seats, rubbish bins and similar containers in their appointed places
Warning:
1. When cleaning areas which cannot be reached from the floor, steps must be used.
2. Never stand on the seats
3. Guideline to be followed as per Railway Board’s letter, reference no:
2016/EnHM/06/09 Dated 23/08/2018

2.1.4. INTERIOR CLEANING (INTENSIVE)

Complete Vehicle
Damp wipe luggage racks, handrails and covers with light wiping-cloth.

Marks to be removed from ceilings, walls, doors, visible surfaces of containers, trim-panels,
covers, light-fittings.

Dirty marks on mirrors and windows to be sprayed with glass cleaner and wiped with a clean
recommended cloth.

Clean the floor. Remove troublesome, loose dirt (e.g. crumbs, sand) from upholstery with
either an recommended brush or a vacuum cleaner.

Damp-wipe handrails, door-handles, door-pushes and emergency handles.

Note: List of chemical used in cleaning of coaches as per Railway Board’s letter, reference
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
letter : 2016/EnHM/06/09 Dated 23/08/2018.

Warning:
1. The cleaning staff should take necessary precautions. Personal protective equipment
must be used.
2. The toilet used in this train is vacuum assisted bio-toilet. Only approved cleaning
agent as per Compendium on bio-toilet issued by IRCAMTECH to be used.
3. CARE MUST BE TAKEN that no water is allowed to get into the ventilation slits,
partitions, at the seats and hand-holds, floor-plates, articulation joints and
surrounding areas or in the corridor connection.

2.1.4.1. FRP PANELS

Cleaning of FRP Surface from (Soil, Oil and Contaminate):
 Clean soiled, oil and contaminate FRP surfaces with pressure water.
 To remove surface contaminants such as grease, soil and oils use a 5-10% diluted
household liquid dishwasher cleaning agent. Wipe contamination with a sponge,
soft brush, or cotton pad as necessary or use pressure washers.
 Thoroughly clean contaminated surface with water. Be sure all detergent residues is
rinsed from the surface.
 Wipe with cotton cloth to remove water from FRP surface and allow for drying.
 Apply a single wipe of carnauba wax with cotton cloth or buffing machine. Allow for
drying 2-3hours at room temperature.
 If required apply Ethanol or Iso-propanol based sanitizer for interior and allow for
drying.
 FRP is ready for use.

Removal minor burns or scratches from FRP surface:

 Clean soiled, oil and contaminate FRP surfaces with pressure water.
 To remove surface contaminants such as grease, soil and oils use a 5-10% diluted
household liquid dishwasher detergent. Gently scrub with a sponge, soft brush, or
cotton pad as necessary or alternatively use pressure washers.
 Thoroughly clean contaminated surface with water. Be sure all detergent residues is
rinsed from the surface. Wipe with cotton cloth to remove water from FRP surface
and allow for drying.
 Minor burns or scratches can be removed by careful, localized wet sanding to
remove the stain and scratches renewing the gel coat finish with polishing.
 Start wet sanding with #240 grit and progressing with finer grits: #320; #600; #800;
#1200and then polish with a polishing compound-1000, 2000 by buffing machine.
 Apply a single wipe of carnauba wax with cotton cloth and rub with dry cotton.
Allow for drying 2-3hours at room temperature. Apply Ethanol or Iso-propanol
based sanitizer for interior and allow for drying.
 FRP is ready for use.

2.1.4.2. GLASSES
Cleaning of Glass Surface from (Soil, Oil and Contaminate):
 Clean soiled, oil and contaminate FRP surfaces with pressure water.
 Use pressure washers with low pressure to wet glass surface. To remove surface
contaminants such as grease, soil and oils from glass gently wipe with a sponge, soft
brush, or cotton pad as necessary and rings with pressure washer.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
 Again clean with glass cleaning agent to remove deep grease and contamination.
Allow for drying and it is ready for use.

Note: Details should be taken into account from the below mentioned documents.–
1. Railway Board’s letter, reference no: 2016/EnHM/06/09 Dated 23/08/2018
2. Details from OEMs manual for equipment/component such as Vacuum bio-toilet,
automatic sliding and plug doors, chairs etc.

2.1.4.3. PASSENGER SEATS

Cleaning Upholstery leather
 In the event of a stain, the most important thing is to clean immediately
 The stain must be removed with circular movements from outside towards the
center of the stain without rubbing strongly
 Once the operation is done, it is advisable to dry the area on which we have worked
with a clean cloth.
 In the case of not disappearing a spot replace the cover

Cleaning Upholstery Moquette

To clean moquette type fabric, simply shake the surface to remove the dust, so that it is
pushed to the external surface, where it can be easily removed with a vacuum cleaner or
soft brush

I. Brushing the seat covers

 Remove all dust off the upholstery with a vacuum cleaner.
 If no vacuum cleaner is available, press on the seats so that the dust is pushed
upwards to the surface, where it can be easily cleaned off with a brush, brushing it in
the direction of the fabric at all times

II. Full cleaning of the upholstery

 Remove the assemblies with upholstery that must be cleaned (seats and seat backs).
 Replace the seat covers of these assemblies with clean seat covers.
 Take the seat covers that have been removed to a place where they can be cleaned
with dry cleaning or industrial procedures.

III. Cleaning stains on the moquette

 Method-1: Apply non-flammable solvent (certified stain remover) with the use of a
clean and absorbent cloth, starting on small surfaces and moving outwards, towards
the inside of the stain. Dry often with a dry cloth to prevent the formation of rings
around the stain.
 Method-2: Remove the stain with a sponge impregnated in a detergent solution and
lukewarm water. DO NOT DAMPEN TOO MUCH: Rub the surface with a damp cloth
and rinse the cloth after each application.

Warning:
1. Do not use ammonia, caustic soda, decolouring agents or other products that could
contain these elements.
2. Ventilate or open doors and windows, to make sure that all vapours are driven out of
the area.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
Alcoholic beverages Clean with water, following the
instructions described in method 2.
Other beverage stains Use method 1. Try to remove the stain
with methyl alcohol if it cannot be
removed with this method.
Burns Scrape off the burnt area with a scraper
and treat by following method 2. Larger
burns must be treated by a specialist.
Cosmetic products Use method 1 first and then apply
method 2.
Ballpoint pen ink Treat with methyl alcohol, pressing on
the stain often with a dry cloth to make
sure that the ink is not spread over the
surface. Complete the treatment with
method 2.
Marking ink (felt-tip pens) Remove with methyl ketone and apply
method 2.
Stains: Oil, Grease, Paint Remove the excess material with a
scraper or spoon. Next, treat with
method 2.
Urine Use method 2.
Vomit Use method 2.
Lipstick, Glitter, Oil and Shoe Polish Apply a small quantity of commercial
stain remover with a cloth and
immediately press on the stain with
blotting paper. Repeat this process,
making sure that only the clean surface of
the blotting paper is used, until there is
no dirt or signs of the stain on its surface.
Candy, Ice cream, Fruit, Liquor, Wine Use clean lukewarm water and a clean
and soft drinks cloth to soften the stain. Scrape the stain
with a blunt scraper. If the stain remains,
rub with a cloth or sponge dampened in
lukewarm cleaning foam. Remove the
foam with a damp cloth. When the stain
is dry, use a sponge dampened with
cleaning solvent to clean the stain and
dry with a dry and clean cloth.
Blood Rub the stain with a clean cloth,
dampened with cold water. If the stain
cannot be removed, repeat the process
using homemade ammonia and rub with
a dry clean cloth. Do not use hot water or
soap on the bloodstain, since this would
make the stain further penetrate into the
fabric.
Ink Different types of ink have different
compositions, so that it is impossible to
find a stain remover that works on all
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 2. Cleaning
types of ink stains. Different methods
should be tried in most cases. Rub the
stain with alcohol and acetone. Next, rub
glycerine with alcohol on the stain and
rinse with solvent. If the stain cannot be
removed, let it dry and dampen with
water, rubbing a synthetic detergent on
the stain to helps often it. Use lukewarm
soap with 4 large spoonful of ammonia
per litre of water and leave to dry.

Cleaning the paint coated metallic parts

This section is applicable to the cleaning of the chassis, frames, arm supports, fixing
elements and legs.
 Use a cloth dampened with Isopropyl alcohol to clean these parts.
 Next, rinse these parts with a cloth dampened with water and dry with a dry cloth.

Cleaning of covers
In covers, when stains of grease or dirt are observed, in general they can be cleaned with
Isopropyl Alcohol.

Repair of lateral covers

 Locate the damaged area.
 - Lightly sand the damaged point.
 - Remove the dust, and clean with a vacuum cleaner.
 - Apply the filling with a spatula.
 - Allow the filling to dry following the commercial instructions of the product.
 - Once the padded surface is dry, sand the excess so that it is smooth.
 - Repeat the filling operation if there are still empty areas on the surface.
 - Repaint the area covered with a paint gun.
 - Allow the paint to dry at a temperature of 94ºF - 97ºF for 8 hours.
 - To repair larger cracks or scratches, a filler that is more difficult to manipulate must
be used, soan expert should do it.
2.2. EXTERNAL CLEANING
Exterior cleaning to be done as per below mentioned documents
1. Railway Board’s letter, reference no: 2016/EnHM/06/09 Dated 23/08/2018

Caution: The exterior of the coach is painted with anti-graffiti paint. Necessary precautions
to be observed.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

3. MAINTENANCE SCHEDULE

Version : 1.00

All rights reserved. This book or any portion thereof may not be
reproduced or used in any manner whatsoever without authorization
from Indian Railways.
The schedule activities have been prepared with input from ICF, RDSO,
NR and OEMs. Activities may be updated as per experienced gained by
field units and other related agencies.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Amendment and Revisions

Version Date Corrections Remarks
1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Table of Content

3. MAINTENANCE SCHEDULE .................................................................................................. 1

3.1. ASSUMPTION FOR TRAIN-18 ...................................................................................................... 4
3.2. MAINTENANCE INTERVAL........................................................................................................... 4
3.3. FREQUENCIES – PERIODIC WORK ............................................................................................... 4
3.3.1. SCHEDULE ACTIVITIES FOR MECHANICAL EQUIPMENT ............................................................. 4
3.3.2. SCHEDULE ACTIVITIES FOR ELECTRICAL EQUIPMENT .............................................................. 46
DAILY SCHEDULE MAINTENANCE ACTIVITIES ........................................................................................ 46
OTHER MAINTENANCE SCHEDULE ACTIVITIES ...................................................................................... 49
ANNEXURE - A
SUMMARY OF MAINTENANCE ACTIVITIES FOR WHEELS AND AXLES ................................................... 98
ANNEXURE - B
AIR PRESSURE BUILT -UP TEST .............................................................................................................. 99
ANNEXURE - C
MR PRESSURE DROP TEST ................................................................................................................... 100
BP Pressure Drop Test ......................................................................................................................... 100
ANNEXURE - D
BC PRESSURE TEST............................................................................................................................... 101
ANNEXURE - E
SUMMARY OF MAINTENANCE ACTIVITIES FOR TRACTION GEAR BOX MAINTENANCE (TSA) ............ 102
ANNEXURE - F
SUMMARY OF MAINTENANCE ACTIVITIES FOR TRACTION GEAR BOX MAINTENANCE (IRCAMTECH) 103
ANNEXURE-G
FUNCTIONAL TEST UNDER TRIP SCHEDULE ........................................................................................ 104
ANNEXURE-H
FUNCTIONAL TEST UNDER MONTHLY SCHEDULE ............................................................................... 109
ANNEXURE-I
FUNCTIONAL TEST UNDER QUARTERLY SCHEDULE ............................................................................ 116
ANNEXURE-J
FUNCTIONAL TEST UNDER NINE MONTHLY SCHEDULE ...................................................................... 123

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

3.1. ASSUMPTION FOR TRAIN-18

Kilometres per day: 1500 km

3.2. MAINTENANCE INTERVAL

Schedule Periodicity
Daily Every Day
Trip Every 3 Days or 5000 kms (Whichever is earlier)
Monthly 30 Days ± 2 Days
Quarterly 90 Days ± 3 Days
Nine Monthly 270 Days ± 3 Days
Shop Schedule-1 (SS-1) 18 Months ± 5 Days
Shop Schedule-2 (SS-2) 36 Months ± 5 Days
Shop Schedule-3 (SS-3) 72 Months ± 5 Days

The interval to be observed is always the first reached by the vehicle.

Tolerance must not be allowed to exceed.

Annexure G to J to be referred for the Functional Tests under different maintenance

schedules.

3.3. FREQUENCIES – PERIODIC WORK

3.3.1. SCHEDULE ACTIVITIES FOR MECHANICAL EQUIPMENT

9 Monthly
Quarterly
Monthly
Daily

Equipment
Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

1 Bogie
1.1 Bogie Frame(DTC,NDTC,MC,TC)
Visually inspect the bogie
frame and their
components for crack,
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
loose, missing and leakage
etc. and check whether all
1 equipment is secure.
Perform careful visual
check on longitudinal
beams, cross beams for ✓ ✓ ✓ ✓ ✓ ✓ ✓
cracks, damages and
2 corrosion.
Perform careful visual
check on brake supports,
damper supports, traction
center supports and ✓ ✓ ✓ ✓ ✓ ✓ ✓
stabilizer assembly
supports for cracks,
3 damages and corrosion.
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SS2
SS3
S.No Activities
/ Sub-Assy.

Carefully check bogie

brackets visually for
✓ ✓ ✓ ✓ ✓ ✓ ✓
cracks, damages and
4 corrosion.
Carefully check safety
cables visually for
✓ ✓ ✓ ✓ ✓ ✓ ✓
damages, cracks and
5 corrosion.
Clean the bogie frame
thoroughly with high
Pressure Air Jet in washing
line. Remove dust, mud & ✓ ✓ ✓
oil deposit in all parts, on
the bogie frame by wet
6 wiping.
Thoroughly check bogie
parts for loose, missing ✓ ✓ ✓ ✓ ✓ ✓
7 and leakage of oil.
Visually inspect the all
bogie frame components
(longitudinal beams, cross
beams etc.) for crack, ✓ ✓ ✓ ✓ ✓
corrosion / damages/dent,
especially at critical
8 locations.
Clean the bogie frame
thoroughly with high
Pressure Air/water Jet
✓ ✓ ✓
&Remove dust, mud & oil
deposit in all parts, on the
9 bogie frame.
Thoroughly check all weld
✓ ✓ ✓
10 joint of bogie frame.
Clearance of center pivot
bottom from traction
✓ ✓ ✓
center base plate to be
11 ensured.
Condition of stabilizer
bearing to be checked. A
thin layer of oil should be
✓ ✓ ✓
applied to prevent
corrosion (self-lubricated
12 bearing).
1.2 Axle Box CTRB(DTC,NDTC,MC,TC)
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SS2
SS3
S.No Activities
/ Sub-Assy.

Visual Inspection for

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Check the bearing for any
sign of over heating or ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 detection of hot bearing.
Check bearings for grease
leakage or any abnormal ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 sound
Rotate the bearing
assembly to detect any
abnormal condition. Check
the bearing mounted end
play. If end play is beyond
✓ ✓ ✓
permissible limit or if any
roughness is detected while
rotating the bearing,
dismount the bearing and
4 send for reconditioning.
Replacement of CTRB as per
mileage earned by train set
✓ ✓ ✓
and as recommended by
5 OEM
Mounting of axle speed
sensor, condition of phonic
wheel and gap between
✓ ✓ ✓
sensor and Gap between
sensor and phonic wheel to
6 be ensured.
NOTE:
1. Bearing reconditioning is
to be carried out whenever
bearing is removed from
axle due to wheel-shelling /
bearing failure or other
reasons.
2. If the wheel sets are sent
for re-profiling without ✓ ✓ ✓
dismounting bearings,
lubricate the lathe centers
with heavy grease and
cover the bearings during
re-profiling.
3. For reconditioning of
bearings, please refer to
7 OEM’s instructions.
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/ Sub-Assy.

1.3 Primary Springs(DTC,NDTC,MC,TC)

Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Visually check springs for
cracks, damages, corrosion ✓ ✓ ✓ ✓
2 or foreign objects presence.
Check primary spring pads
for cracks, damages and ✓ ✓ ✓ ✓
3 ageing.
The split pin installed in pin
for primary suspension
may be checked for any ✓ ✓ ✓ ✓
visible damage and may be
4 replaced if required..
Clean the primary springs
thoroughly with suitable
✓ ✓ ✓
detergent water jet in
5 disassembled condition.
Inspect for cracks/damages
and in case found any, the
✓ ✓ ✓
primary spring may be
6 replaced.
Clean the contact line on
the end coils of primary
springs and repaint the
✓ ✓ ✓
paint damaged areas duly
following the proper paint
7 procedure.
Any damage to coating
(paint) in locations other
than the contact line may
also be repaired. In case the ✓ ✓ ✓
paint damage is extensive,
the spring may be taken for
8 complete overhauling.
Check spring pad plates and
pins of the primary
suspension for corrosion,
✓ ✓ ✓
crack and damage. Remove
signs of corrosion and
9 repaint wherever required
Replace spring pad and
other rubber parts of ✓ ✓ ✓
10 primary suspension.
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SS2
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/ Sub-Assy.

Install the springs properly

duly ensuring proper spring
orientation as per relevant ✓ ✓ ✓
spring orientation
11 instruction.

1.4 Air Spring Systems(DTC,NDTC,MC,TC)

Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Visually check the air
spring rubber bellow in
inflated condition for any
external damage, cracks, ✓ ✓ ✓ ✓ ✓ ✓ ✓
air leakage ,bulging and
infringement of any
2 fittings
Deflate the suspension, if
any signs of damage are
visible and if required
✓ ✓ ✓ ✓ ✓ ✓
carefully probe the
damage/crack with a blunt
3 edged instrument.
Visually inspect the outer
layer; if only the outer
layer is marked and the
✓ ✓ ✓
textile reinforcement is
not visible then the airbag
4 is serviceable.
Visually inspect the textile
reinforcement , if the
textile reinforcement is ✓ ✓ ✓ ✓ ✓ ✓
seen or felt, replace the
5 air spring.
Check the air spring for oil
or organic solvent adhered
on the surface of rubber. If ✓ ✓ ✓
found, wipe it off with
6 clean cloth immediately.
Checking of installation
lever with inflated air ✓ ✓ ✓
7 spring for normal function.
Thorough checking of
square platform provided
✓
on bogie frame for any
8 crack and deformation.
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SS2
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/ Sub-Assy.

Tightening of air spring

bottom plate bolts and ✓
9 nuts.
Measure and ensure the
bump stops clearances in
✓
primary & secondary
10 stage.
Air suspension pipe
leakage check by using ✓ ✓ ✓
11 soap water.
Thorough visual check of
air spring after ✓ ✓ ✓
12 dismantling from bogie.
Clean the Exhaust port of
✓ ✓ ✓
13 air spring systems.
Leakage test of air springs
should be done by
pressure drop test : the
✓ ✓ ✓
drop should not be more
than 1% of test pressure
14 (6 kgf/cm2) in 15 minutes.
Inspect air spring seating
area and spigot ID on body
bolster. Remove corrosion
if any and apply a thin
layer of grease (lOC- ✓ ✓ ✓
Servogem.RR3 or BPC
Make RR grade-3 or BL-
BALMERAO multi grease
15 LL3)
Remove all valves and
carry out external
✓ ✓ ✓
cleaning, overhauling and
16 function test.
Cleaning of air filter
provided in pneumatic
✓ ✓ ✓
pipe line for air spring
17 assembly system.
Checking securing
arrangement of ✓ ✓ ✓
18 pneumatic pipeline.
Tightening of installation
✓ ✓ ✓
19 lever nuts.
20 Installation lever ✓ ✓ ✓
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/ Sub-Assy.

adjustment.
Measurement of bogie
clearances related to air ✓ ✓ ✓
21 spring. (after assembly)
Checking of spring height
& maintained as per ✓ ✓ ✓
22 requirement.

1.5 Wheels and Axles(DTC,NDTC,MC,TC)

Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Perform a visual check on
wheels for cracks, ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 damages and defects.
Check by wheel profile
gauge, the wheel flange ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 thickness and profile.
Visually inspect the axle
for cracks and signs of ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 corrosion, if any.
Check treads diameter
and wear of wheel profile.
✓ ✓ ✓ ✓ ✓ ✓
If necessary, perform re-
5 profiling.
Perform wheel profiling
and wheel balancing (for
Speed >= 130 Kmph).
✓ ✓ ✓
Refer to RCF Specification
no. MDTS – 168 for
6 balancing procedure.
Perform a general
overhaul of the axle,
remove signs of corrosion,
✓ ✓ ✓
renew corrosion
protection and re-paint
7 the axle.
Check wear of wheels, if
✓ ✓ ✓
8 necessary, replace them.
Perform an ultrasonic test
on the axle to verify
✓ ✓ ✓
absence of internal cracks
9 and damages.
Wheel profiles of all
✓ ✓ ✓
10 wheels to be recorded.
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SS2
SS3
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/ Sub-Assy.

Wheel condition to be
checked for spalling,
✓ ✓ ✓
thermal cracks, rolling
11 contact fatigue etc.
Ensure that no debris is
lodged between traction ✓ ✓ ✓
12 motor and powered axle.
Marking on wheel set to
be checked for any sign of
movement between
wheel and axle, for ✓ ✓ ✓
evidence of wheel
overheating or derailment
13 damage.
Maintenance of wheel and
Axle to be done as per ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
14 Annexure-A.
Primary vertical /Secondary vertical and
1.6 Lateral /Yaw dampers(DTC,NDTC,MC,TC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Perform a visual check on
dampers for damage, ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 cracks and oil leakage.
Perform a visual check on
all fixings for loosening
✓ ✓ ✓ ✓ ✓ ✓ ✓
and/or missing
3 components
Perform a visual check on
rubber elements for cracks ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 and ageing.
Damper should be tested
during SS-I (or early in
case of oil leakages) as per
parameters given in ✓ ✓ ✓
respective drawings/
specification of particular
5 type of damper.
Examine the bogie frame
for corrosion at damper
✓ ✓ ✓
bracket and surrounding
6 area.

Check dampers for correct ✓ ✓ ✓

7 functionality, absence of
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/ Sub-Assy.

deformations and oil

leakages.

During installation, ensure

proper orientation of ✓ ✓ ✓
8 dampers.
Replace fixings/fasteners, if
✓ ✓ ✓
9 necessary.
Note:
1. Damper fitting
misalignment & pre
angular twist in end
fasteners due to level
difference should not be
✓ ✓ ✓
there and proper torque to
be ensured during the
fitment of dampers.
2. Dampers to be cleaned
properly before testing
10 and fitment.
1.7 Stabilizer assembly(DTC,NDTC,MC,TC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Perform a visual check on
torsion bar, stabilizer links
✓ ✓ ✓ ✓ ✓ ✓ ✓
and brackets for cracks,
2 damages and corrosion
Perform a visual check on
rubber joints for cracks, ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 damage and ageing
Visually inspect for grease
oozing out of stabilizer
assembly bearings, which ✓ ✓ ✓ ✓ ✓ ✓ ✓
may result in bearing
4 failure.
Perform visual check on all
fixings for loose/missing ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 fittings
Stabilizer Bearing to be ✓ ✓ ✓ ✓ ✓ ✓
6 checked
Length to be checked and ✓ ✓ ✓ ✓ ✓ ✓
7 adjusted as per drawing.

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SS2
SS3
S.No Activities
/ Sub-Assy.

Check the sub assembly

clamp which is mounted
at both ends and
tightened at specified ✓ ✓ ✓ ✓ ✓
amount of torque. If found
loose should be tightened
8 correctly.
Visually inspect the
stabilizer assembly for
rusting on metallic parts.
✓ ✓ ✓ ✓
Clean foreign articles/dust
and apply suitable rust
9 preventive oil.
Check the rubber surfaces
for any damage, foreign
article hitting or contact
during service or
application. If yes, please
ensure no external ✓ ✓ ✓ ✓
object/article getting
contact to rubber surface,
in case major damages
observed on rubber may
10 need to replace.
Check the ball joint of
stabilizer assembly
(rubber to metal bonded)
✓ ✓ ✓ ✓
which is assembled at
both ends. If any damage
11 in Ball joint to be replaced.
The stabilizer link is
assembled at 600mm, if
required it can be
adjusted from 590 to
640mm by opening both
ends. To adjust the length,
loosen the clamp
assembly, one side of end ✓ ✓ ✓ ✓
is having LH thread and
another side is bearing RH
thread. After adjustment
to desired length clamp
assembly shall
betightened to specified
12 torque with positioning
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/ Sub-Assy.

mark.

13 Clean the grease nipples. ✓ ✓ ✓

Remove the end covers,
clean the bearings and re-
grease (BECHEM high -LUB
SW2 of M/s Carl BECHEM
Lubricants or SYNTHOX
✓ ✓ ✓
(HS-NS) Non staining high
speed synthetic grease of
M/s STANVAC chemicals
(India) Ltd. (Same grease
14 of FIAT bogies)
Traction rod and traction Centre
1.8 (DTC,NDTC,MC,TC)

Visual Inspection for ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

1 general condition
Perform a visual check on
the traction center
housing and bars for ✓ ✓ ✓ ✓ ✓ ✓ ✓
cracks, damages and
2 corrosion.
The assembly should be
free to move, and not
✓ ✓ ✓ ✓ ✓ ✓ ✓
blocked by any foreign
3 objects.
Perform a visual check on
all fixings for loosening ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 and the ball joints.
Perform a visual check on
rubber joints for ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 cracks/damages.
Visually inspect the lateral
damper as per ✓ ✓ ✓ ✓ ✓ ✓ ✓
6 specification
Visually inspect the lateral
bump stop for loosening, ✓ ✓ ✓ ✓ ✓ ✓ ✓
7 missing and damages etc.
Check the rust on metallic
parts and clean foreign
articles/dust and apply ✓ ✓ ✓ ✓
suitable rust preventive
8 oil.
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SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

Check any damage on

rubber surfaces foreign
article hitting or contact
during service or
application. If yes, please
ensure no external ✓ ✓ ✓ ✓
object/article getting
contact to rubber surface,
in case major damages
observed on rubber may
9 need to replace.
Check the lateral bump
stop bolt and should be ✓ ✓ ✓ ✓
10 tightened correctly.
Control Arm and other components on
1.9 primary suspension(DTC,NDTC,MC,TC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Visually check control arm
parts for damages, cracks ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 or corrosion marks.
Perform a visual check on
all fixings for loosening
✓ ✓ ✓ ✓ ✓ ✓ ✓
and / or missing
3 components
Inspect the rubber joint
for cracks, damages and ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 ageing
All Rubber metal bonded parts on bogie.
1.10 (DTC,NDTC,MC,TC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Perform a visual check for
cracks, damages, peeling, ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 bulging, looseness etc.
Elastomer components to
be checked after
✓ ✓ ✓ ✓ ✓
installation (Thereafter 6
3 months at least)
4 Clean and wipe dry. ✓ ✓ ✓
1.11 Center Pivot Bearing (DTC,NDTC,MC,TC)
Clean foreign particle /
dust and apply preventive ✓ ✓ ✓
1 oil. In case of any damage
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observed on rubber, the

same should be replaced
immediately
2 Brakes and Air Supply
2.1 Main Air Compressor(DTC/NDTC)
Visual check for
loose/damage/missing ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 parts or abnormal sound
Check Main air
Compressor running on ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 TCMS.
Vacuum indicator
inspection – Check the
functionality of indicator
plunger (red). The
indicator plunger appears
entirely and latches once
the maximum acceptable
negative pressure (OEM
recommendation) is ✓ ✓ ✓ ✓ ✓ ✓ ✓
reached. The plunger
remains fully in view even
when the compressors
shut down. Replace the
filter element of dry type
air filter if the indicator
plunger appears entirely
3 and latches
Check the functioning of
compressor for loading/ ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 unloading.
Check for damage; Clean
Air inlet filter and electric ✓ ✓ ✓ ✓ ✓ ✓
5 motor.
6 Check mounting tightness. ✓ ✓ ✓ ✓ ✓ ✓
Check the Earthing Cable
✓ ✓ ✓ ✓ ✓ ✓
7 tightness
Compressor cut-in & cut-
✓ ✓ ✓ ✓ ✓
8 out test.
Compressor Set Annual
Inspection & Servicing and ✓ ✓ ✓ ✓
9 Function Test:

Vacuum indicator ✓ ✓ ✓ ✓
10 inspection – check for red
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indicator, if the plunger is

out, exchange the filter.

Switch off the compressor

set motor, wait until the
compressor comes to a
standstill. Slight-check the
resilient mounting.
Exchange the spring wire
✓ ✓ ✓ ✓
shock absorbers in case
any of the wire strands are
fractured. Exchange
rubber shock absorbers in
case of cracking or
11 embrittlement.
Pneumatic and Air
Distribution
System(Leakage Test- The
test run is needed after
the unit has been
assembled or installed on ✓ ✓ ✓ ✓
board to the vehicle. The
unit and its downstream
components must be
tested for leakage and
12 functionality.
Air pressure build up test
may be done for individual
✓ ✓ ✓
compressors (format
13 enclosed at Annexure-B)
MR & BP pressurized
2.2 system(DTC,NDTC,MC,TC)
Visual Inspection for
general condition & sound ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 of leakage
MR and BP leakage test to
be done(format enclosed ✓ ✓ ✓
2 at Annexure-C)
2.3 Auxiliary Compressor(TC)
Visual check for
loose/damage/missing ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 parts or abnormal sound

2 Check the oil level ✓ ✓ ✓ ✓ ✓ ✓ ✓

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3 Check for any damage ✓ ✓ ✓ ✓ ✓ ✓ ✓

Clean air inlet filter and
✓ ✓ ✓ ✓ ✓ ✓ ✓
4 electric motor
Check oil inlet filter for
✓ ✓ ✓ ✓ ✓ ✓ ✓
5 any damage
Check for any abnormal
✓ ✓ ✓ ✓ ✓ ✓ ✓
6 sound
Check earthing cable
✓ ✓ ✓ ✓ ✓ ✓ ✓
7 tightness.
Clean the cooling fins
using compressed air and ✓ ✓ ✓ ✓ ✓ ✓
8 cotton cloth.
Functional check:-when
Aux Compressor is running
✓ ✓ ✓ ✓ ✓
pantograph must raise
9 and touch to OHE.
Filter element to be
changed. After
replacement test the pipe
connections for leakage at ✓ ✓ ✓ ✓
the maximum acceptable
working pressure. Air
10 bubbling is unacceptable.
2.4 Brake System(DTC,NDTC,MC,TC)
Inspect MR Pressure (8 to
10 bar), BP pressure (5
bar) and BC/AR pressure
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
(8 to 10 bar)from dual
pressure gauges in the
1 Cab.
Check the Brake page on
TCMS monitor by visual
for Brake cylinder
pressure on applying and
releasing brake :
1. Service brake through
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Master controller
2. Emergency brake
through master controller.
3. Emergency brake
through Driver’s brake
2 valve.
Parking brake to be tested
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 by pressing apply and
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release command from

CRW panel.
Brake pipe continuity test
applying brake through
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DBV for BP drop in last
4 coach.
Self-test of BECU from
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 TCMS ( brake + WSP ).
Emergency brake by
Assistant. Emergency ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
6 brake handle.
Check error free state for
all coaches either by self-
test or by IST software
7 provided by M/s KBIL
2.5 Brake Control System(DTC,NDTC,MC,TC)
Visual Inspection for
general condition, any ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 sound of leakage
Automatic Load Braking
Function Test (Including ✓ ✓ ✓ ✓
2 Suspension Equipment)
Simulated T pressure as
empty (train is in tare
✓ ✓ ✓ ✓
weight) condition in all
3 car.
Move master controller to
full service braking
position. Check that the
BC pressure increases as
✓ ✓ ✓ ✓
per KBIL (OEM)
recommendation and the
BP pressure gauge is
4 about 5.0 bars.
Move master controller to
“COAST” position. Ensure
✓ ✓ ✓ ✓
that the BC pressure
5 decreases.
Move master controller to
emergency brake “EB”
position. Check that the
✓ ✓ ✓ ✓
BC pressure increases as
per KBIL recommendation
6 and the BP pressure gauge
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is about 5.0 bar.

Move master controller to

“COAST” position. Ensure
✓ ✓ ✓ ✓
that the BC pressure
7 decreases.
Note :
1. Parking brake
application or suitable
protection against rolling
down to be ensured before
any testing. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2. Status update of
isolating cocks and wire
connectors may be
checked in case of no
8 status update.
BC pressure in various
brake position like FSB,
Holding brake, EB may be ✓ ✓ ✓
recorded (format at
9 Annexure D)
2.6 Air Horn-Tyfon (DTC,NDTC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
2 Check functioning of horn ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Under Frame Brake
2.7 components(DTC,NDTC,MC,TC)
Visual Inspection for
general condition, any ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 sound of leakage.
Check operation of
automatic drain (correct
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
drainage) of main
2 reservoir.
Check for noticeable air
leakages incompressed air ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 system.
Inter-unit air house
couplings visual check for ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 open/damage.
Hose pipe of caliper visual
check open/ damage/ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 missing.
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/ Sub-Assy.

Brake Caliper, disc & pad

visual check for ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
6 loose/damage/missing .
Brake equipment box
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
7 cover in position.
Renew the worn-out
brake pad (thickness < 8
mm) if necessary.
Particular attention be
✓ ✓ ✓ ✓ ✓ ✓ ✓
paid to deferential rate to
wear between motor
coaches & other type
8 Coaches.
Speed sensor visual checks
✓ ✓ ✓ ✓ ✓ ✓ ✓
9 for any loose/ damage.
Brake Disc and Caliper
2.8 assembly(DTC,NDTC,MC,TC)
Visual Inspection for
general condition, any
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
damage/loose or missing
1 part.
Clean the brake discs and
pads with compressed air.
Push the breather hole
✓ ✓ ✓ ✓ ✓ ✓
plug provided in caliper
assembly to remove the
2 internal air.
Check and verify the
clearance between each
pad and disc surface shall ✓ ✓ ✓ ✓ ✓ ✓
be within permissible
3 limits.(2-4 mm)
Check the wear of brake
pads and brake discs. If
groove depth is reached, it ✓ ✓ ✓ ✓ ✓ ✓
is necessary to replace the
4 brake discs or pads.
Functional Check :
Application/release and
✓ ✓ ✓ ✓ ✓
slack adjuster functional
5 check.
2.9 Air Dryer Unit (DTC,NDTC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition, any
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/ Sub-Assy.

damage/loose or missing
part.
Functional Check: The
valve magnet must shuttle
audibly every two
minutes. A blast of air ✓ ✓ ✓ ✓ ✓ ✓
must briefly be discharged
from exhaust port at every
2 changeover.
Pressure Dew Point
Measurement using dew
point meter. The dew
point reading must be
✓ ✓ ✓ ✓
below the boundary curve
of 35% relative humidity
at the prevailing ambient
3 temperature.
Do a check of the drainage
port on the silencer for ✓ ✓ ✓ ✓
4 obstructions.
Check whether the socket
and the screw holding the
pressure switch are firm.
The machine screw used
to assemble the socket
✓ ✓ ✓ ✓
should not be over
tightened, as the cabling
and insulation inside the
socket might otherwise be
5 damaged.
Test pressure switch for
correct operation with a
continuity tester. The
tower must be placed ✓ ✓ ✓ ✓
under pressure. The
pressure switch must
6 operate at 2.7±0.5 bar.
2.10 Micromesh Filter(DTC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Micromesh Filter Venting
and Draining through
✓ ✓ ✓ ✓ ✓ ✓
drain plug must be done.
2 Remove the oil precipitate
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/ Sub-Assy.

from the unit.

Filter element to be
changed. After
replacement test the pipe
connections for leakage at ✓ ✓ ✓ ✓
the maximum acceptable
working pressure. Air
3 bubbling is unacceptable.
2.11 Air Reservoirs(DTC,NDTC,MC,TC)
Visual Inspection for
general condition, any ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 1 sound of leakage
Visual check and Drain
condensate water through ✓ ✓ ✓ ✓ ✓ ✓
2 drain valve/cock, if any.
2.12 B01Panel(DTC,NDTC,MC,TC)
Fault checking only if
appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
1 log.
Functional test:
1. For BO1 panel, check
application/release of
parking brake through
push button.
2. Speed sensor check
✓ ✓ ✓ ✓ ✓
through TCMS if the
failure is set because
of the speed sensor
3. Fault checking only if
appears in TCMS event
2 log.
Filter element to be
changed. After
replacement test the pipe
connections for leakage at ✓ ✓ ✓ ✓
the maximum acceptable
working pressure. Air
3 bubbling is unacceptable.
Ballcock with or without switch module or
2.13 exhaust (DTC,NDTC,MC,TC)
Visual Inspection for
general condition, any ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 sound of leakage
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/ Sub-Assy.

Fault checking only if

appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
2 log.
Function test:
1. Turn the ball cock
handle to closed/open
position. Make sure
that the cock handle is
easy to turn without
jerking and the venting
noise can be heard
(Ballcock with
exhaust).
✓ ✓ ✓ ✓ ✓
2. Magnet valve Coil
movement sound on
energising and de-
energising(Ballcock
with switch module).
3. Fault checking based
only on TCMS data
during train operation
(Ballcock with switch
3 module).
2.14 Magnet Valve(DTC,NDTC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages (sound).
Fault checking only if
appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
2 log.
Function test:
1. Turn the cock handle
to closed/open
position. Make sure
that the cock handle is
easy to turn without
jerking and the venting
noise can be heard ✓ ✓ ✓ ✓ ✓
2. Magnet valve Coil
movement sound on
energising and de-
energising.
3. Fault checking based
only on TCMS data
3 during train operation.
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2.15 Axle Speed Sensor(DTC,NDTC,MC,TC)

Visual check for looseness
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 or any damage.
Fault checking only if
appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
2 log.
Speed sensor check
through TCMS if the
✓ ✓ ✓ ✓ ✓
failure is set because of
3 the speed sensor.
Mounting of axle speed
sensor, condition of
phonic wheel and gap
between sensor and Gap ✓ ✓ ✓
between sensor and
phonic wheel to be
4 ensured
2.16 Pressure Sensor(DTC,NDTC,MC,TC)
Fault checking only if
appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
1 log.
2.17 Pressure Governors(DTC,NDTC,TC)
Fault checking only if
appears in TCMS event ✓ ✓ ✓ ✓ ✓ ✓
1 log.
Check for pressure
governor connections for ✓ ✓ ✓ ✓
2 any leakages
2.18 Check and Drain valve-All(DTC,NDTC,MC,TC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages (sound).
2.19 Brake Control Unit (DTC,MC,TC)
Self-test of BECU from
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 TCMS (brake + WSP ).
Function check (Fault
checking based only on
✓ ✓ ✓ ✓ ✓ ✓
TCMS data during train
2 operation).
2.20 Safety Valves(DTC,TC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages(sound).

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Function test:
Safety valves to operate as
per their desired setting
(opening/Closing pressure,
leakage, freedom of
✓ ✓ ✓ ✓
movement etc.) by
overriding the compressor
or cutting out CMS. Any
dirt deposits lodged in the
2 valve seat.
Drain Valves, Hose Couplings, Duplex Check
Valve, MeanPress. Valve, Hose Pipes, Hose
2.21 Connections (DTC,NDTC,MC,TC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages(sound).
2.22 Driver Desk Control, Driver Brake Valve(DTC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages(sound).
Function test:
Driver desk control (DBV)
✓ ✓ ✓ ✓
check by application and
2 release of brake.
Dual Gauges (MR/BP), Dual gauge (BC/BR), BP
2.23 Gauge(DTC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 leakages(sound).
Function test:
Air pressure Gauges: Test
the compressed air
connection to unions for
leakage by applying a
liquid leakage testing
substance. Air bubbling is
unacceptable. Check ✓ ✓ ✓ ✓
Gauges for correct
reading. If the pressure
gauge is thought to be
working incorrectly, it
must be removed and
tested on a separate test
2 bench.
2.24 B02 Panel,BCU-Bogie1&2(DTC,NDTC,MC,TC)

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Check B02 /BCU panel by

application of direct and
✓ ✓ ✓ ✓
indirect brake. Also visual
1 check for any abnormality
2.25 Traction Cut-Out Panel
Traction cut out panel
check by indirect braking
✓ ✓ ✓ ✓
(DBV) to emergency
1 application.
2.26 LB Panels(DTC,NDTC,MC,TC)
LB panel check for
pressure governor
✓ ✓ ✓ ✓
connections and isolation
1 cock.
Anti-Skid Valve (Dump
2.27 valve)(DTC,NDTC,MC,TC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓
1 leakages(sound).
Anti-skid valve by brake
✓ ✓ ✓ ✓
2 self-test through TCMS.
Functioning of axle speed
sensor on both channels
and anti-skid valves to be
✓ ✓ ✓
checked using pole wheel
apparatus and
3 available/OEM software.
2.28 Levelling Valve(DTC,NDTC,MC,TC)
Observe for noticeable air
✓ ✓ ✓ ✓ ✓
1 leakages(sound).
Check air suspension
✓ ✓ ✓ ✓
2 pressures on TCMS.
3 Shell and Under-Frame
3.1 Underframe/Car-body(DTC,NDTC,MC,TC)
Visual inspection of coach
underframe and its ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 components.
Check visually the
following for any
damages/defects/deficien
✓ ✓ ✓ ✓ ✓ ✓ ✓
cies: Condition of head
stock, sole bar and other
2 under frame members.

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Examine trough floor and

other under frame
members from
underneath for any sign
of damage/ cracks/
corrosion. If corrosion has
just started and not ✓ ✓ ✓ ✓
significant, clean the
surface to bare metal and
inspect it, if found in
order, immediately apply
anticorrosive paint at the
3 affected area.
Under slung equipment
fixing brackets and
fasteners – Check for ✓ ✓ ✓
corrosion/breakage and
4 replace if necessary.
Interior cleaning of
lavatories, cleaning of
coach floor, cleaning of ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
passenger amenities,
5 windows etc.
Exterior coach cleaning
with recommended
cleaning solution as per
latest RDSO specification
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
no. M&C/PCN/101/2007
for Liquid Cleaning
Composition for Exterior
6 of Railway Coaches.
Checking of hand rails,
sliding doors, body side,
lavatories and vestibule ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
doors for proper
7 functioning.
Amenities fittings should
be checked for proper ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
8 functioning.

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/ Sub-Assy.

All missing passenger

amenity fittings must be
replaced and the rake
must be turned out as
‘Zero-Missing-Fitting’
rake. Check visually the
following for any
damages/defects/deficien
cies:
1. Destination board and ✓ ✓ ✓ ✓ ✓ ✓ ✓
brackets.
2. Body side walls
3. End walls
4. Windows, Body side
doors, Lavatory doors,
inter communication
doors (vestibule doors)
etc. for their functioning.
9 5. Fire Extinguishers.
Exterior panels & End
panels” should be
replaced with Exterior ✓ ✓ ✓ ✓ ✓ ✓ ✓
Body side walls and End
10 walls.
External Cleaning
Exterior coach cleaning
with recommended
cleaning solution as per
latest RDSO specification
no. M&C/PCN/101/2007
For the coaches with vinyl ✓ ✓ ✓ ✓ ✓ ✓ ✓
wrap instructions of ICF/
RDSO should be follow.
Coach cleaning/washing
should be done by
Automatic Coach Washing
11 Plant (ACWP).
However, where these
plants are not available,
external cleaning/washing
of coaches can be done in
✓ ✓ ✓ ✓ ✓ ✓ ✓
following manner:
1. Place the rake/coaches
on the washing pit
12 provided with equipment
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required for washing and

cleaning. It should be
ensured that the
rake/coach is protected
with proper board/signal
for safety of the staff
working on washing/
cleaning job to prevent
movement/ disturbance
in the activity. Scotch
blocks with locking
arrangement should
protect lines and
keys should be kept with
Engineer(C&W) till the
time rake is under
maintenance. In
electrified section, C&W
supervisor shall in
addition, obtain power
block from OHE before
commencing work.
2All VCBs may be
grounded before
commencing washing and
isolation keys may be
kept securely
3. The cleaning solution
should be spread/ rubbed
with nylon brush or
sponge brushes and then
rubbed thoroughly to
clean the panels. Extra
attention should be given
to oily and badly stained
surfaces.
4. Clean the external
surface by high pressure
jet where facilities are
available.
All exterior panels
including end panels
should be hosed with ✓ ✓ ✓ ✓ ✓ ✓ ✓
water and brushed with
13 diluted soft soap
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(detergent solution) the

strength of the solution
may be increased or
decreased according to
RDSO specification.
Internal Cleaning
1. Collect the newspaper
from magazine bag and
waste from dust bin.
Sweep the whole coach
with broom in sleeper
coaches. Clean the floor
of AC coaches with
vacuum cleaner.
2. Remove dust from
floor, berths/seat,
magazine nylon wire
mesh bag fitted on panels
and fan guards with
duster. Use of vacuum
cleaner is excellent in
such areas.
3. Also remove dust/dirt
from under the berths,
window sill, sliding door,
✓ ✓ ✓ ✓ ✓ ✓ ✓
railing corner and all
corner & crevices of
coach interior with
vacuum cleaner if
provided.
4. Aluminum frames,
strips, and other metal
fittings, etc. should be
cleaned with
recommended cleaning
agent.
5. The coach flooring
should be rubbed with
hard coir brush and PVC
flooring should be rubbed
with nylon
bristles/sponge brush and
cleaned with
recommended cleaning
14 agent.
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6. The amenity fittings

and toilet fittings such as
coat hanger, stools, arm
rest, foot rest, towel
hanger, etc. should be
cleaned with duster.
Stains on these items
should be removed with
recommended detergent
solution.
7. Spray recommended
air freshener in the coach.
No employee should be
✓ ✓ ✓ ✓ ✓ ✓ ✓
allowed to enter the
coach for any
purpose/work after
complete cleaning.
8. Precaution should be
taken to prevent nuisance
of cockroaches and
rodents in AC coaches and
pantry car.
9. No repair works should
generally be left to be
carried out after washing
15 and cleaning of the coach.
Pest and rodent control
should be done as per
extant instructions issued ✓ ✓ ✓ ✓ ✓ ✓ ✓
by the Railway Board
16 from time to time.

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1. The compartment
carpet should be cleaned
with vacuum cleaner.
Every month, the carpet
should be cleaned
thoroughly by taking it
out from compartment
and if necessary they
should be dry cleaned in
every three to four
months. Before relaying
the carpet, the
✓
compartment floor should
be thoroughly cleaned.
2. Ceiling panels, wall
panels, cushion berths,
fittings, table top, etc.
should be cleaned with
duster and stain marks on
these should be removed
by use of recommended
soft detergent.
3. Intensive cleaning and
17 disinfection of the coach.
The carpet should be dry
cleaned in every three to
four months. Before
✓ ✓ ✓ ✓ ✓
relaying the carpet, the
compartment floor should
18 be thoroughly cleaned.
Perform intensive
cleaning and disinfection ✓ ✓ ✓
19 of coaches.
Examine condition of
exterior paint of coaches,
if found scratches or
minor damages at
scattered locations, the ✓ ✓ ✓
paint touch up should be
done as per
recommendation as it has
20 anti-graffiti paint.
3.2 Roof(DTC,NDTC,MC,TC)

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Warning : Necessary
precaution to be taken for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
OHE lines while working
1 on roof
Roof of Train 18 Coaches
should be checked for
corrosion. Special
attention should be paid
at location where gutter ✓ ✓ ✓
moldings are welded.
Corroded roof should be
repaired according to the
2 instructions
Cleaning of rain gutter,
drain holes and pipes
must be ensured.
Condition of pipe ✓ ✓ ✓
traveling from roof till
exhaust near bogie to be
3 checked.
Care to be taken that HT
cables or jumpers should
✓ ✓ ✓
not be damaged on the
4 roof.
4 Interior and Furnishing
4.1 Gangway(DTC,NDTC,MC,TC)
Visual inspection for Tears
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 or Holes in bellows fabric.
Visual inspection of
Loosening of connection
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
between Bellows and
2 folding Wall.
Intactness of all inter
coach gangways to be ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 ensured.
Visual inspection of
tears/holes in bellows
.Fabric torn out of bellows
frames, broken aluminum
profiles, sealing of screw ✓ ✓ ✓ ✓ ✓ ✓
on frames worn/
damaged, no gap-free fit
of screw-on frames at
4 coach-interfaces, loose
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connection between
bellows and folding wall&
visual inspection/cleaning
of dirt/garbage on
bellows floor.
Visual and functional
inspection of sliding ✓ ✓ ✓ ✓ ✓ ✓
5 ledges worn/damage.
Visual inspection of
✓ ✓ ✓ ✓ ✓ ✓
6 Linking ceiling damage.
Visual/functional
inspection of Firm fit & ✓ ✓ ✓ ✓ ✓ ✓
7 tears in gap covering.
Visual /functional
inspection of dirt and
rubbish on the bellows
floor area (visual ✓ ✓ ✓ ✓
inspection through
flipping-up the floor flaps
8 of the bridge plates).
Visual inspection for
Tears/Holes in bellows
fabric, Fabric torn out of
bellows frames, broken
aluminum profiles, sealing
of screw-on frames
worn/damaged, no gap-
free fit of screw on
frames at coach-
interfaces, loose
connection between
bellows and folding wall &
visual/functional ✓ ✓ ✓
inspection of dirt and
rubbish on the bellows
floor area (visual
inspection through
flipping-up the floor flaps
of the bridge plates).
Combination bridge:
Visual and functional
inspection of sliding
ledges (bridge plates).
Check for the flexibility of
9 scissors arrangement. If
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found defective, should

be repaired/replaced.
Linking ceiling: Visual
inspection of Linking
ceiling damage, if found
defective, should be
repaired/replaced.
Side wall:
Visual/functional
inspection of Firm fit &
tears in gap covering, if
not proper, maintain it.
4.2 Seat Assembly(DTC,NDTC,MC,TC)
Visual inspection for
Tears/Holes in Upholstery ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 & Foam sets.
Cleaning of Sets, Grab Rail
(Exec. Class) & Armrest ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 for dust.
Inspect Seats and check
✓ ✓ ✓ ✓ ✓ ✓ ✓
3 for completeness.
Visual inspection for loose
screws/ nuts, tearing of
covers, height loss of seat
& back cushions and ✓ ✓ ✓ ✓ ✓ ✓
stains & dirt in general.
Necessary remedial action
4 to be taken.
Note : Take remedial
action as per Doc. No.
ICF/IndianRailways-771 ✓ ✓ ✓ ✓ ✓ ✓
(Rev.-00) Oct- 2018 of
5 M/s FAINSA.
Cleaning of Upholstery
leather and greasing to be
done.( Refer Doc. No.
✓ ✓ ✓ ✓ ✓
ICF/Indian Railways-771
(Rev.-00) Oct- 2018 of
6 M/s FAINSA Manual .)
First degree general
revision.(Refer Doc. No.
ICF/INDIANRAILWAYS-771 ✓ ✓ ✓ ✓
(Rev.-00) Oct-2018of M/s
7 FAINSA.)
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Upholstery- Check for

worn out/ Peeling off/
shabby look/ torn/ stitch ✓ ✓ ✓
break (repair/ clean/
8 replace as necessary).
Cushion - Check for
Permanent set(replace as ✓ ✓ ✓
9 necessary).
All internal panels are FRP
panels and not painted.
Repair procedures as per ✓ ✓ ✓
standard practice to be
10 adopted.
Seat assembly should be
maintained as per
ICF/INDIAN RAILWAYS- ✓ ✓ ✓
771 (Rev.-00) Oct-2018 of
11 M/s FAINSA.
4.3 Table (Executive Class) (DTC,NDTC,MC,TC)
1 Cleaning of Tables. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Checking for loosened
hinges and tightening (if ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 any).
Tightening of screws/nuts
and cleaning should be ✓ ✓ ✓ ✓ ✓ ✓
3 done.
4.4 FloorMat/Cover(DTC,NDTC,MC,TC)
1 Cleaning of Floor Mat. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Checking for peel off and
repair, if any (using
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
suitable
2 adhesives/fasteners).
Check for worn
out/shabby look/ torn/
opened joints (repair/ ✓ ✓ ✓
clean/ replace as
3 necessary).
4.5 Window(DTC,NDTC,MC,TC)
1 Cleaning to be done. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Intactness of windows to
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 be ensured.
Checking for cracks and
breakage (replace ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 immediately, if any
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found).

Checking for cracks and

breakage, moist, opaque,
rubber profiles (replace ✓ ✓ ✓
immediately, if any
4 found).
The windows glasses to
be checked for air ✓ ✓ ✓
5 tightness.
Broken, cracked, defaced
or scratched glass should
be replaced and the
window frame repaired as
necessary. The rubber or ✓ ✓ ✓
felt lining between the
glass and the FRP panel
should be changed every
6 time the glass is removed.
Check the adhesive used
for bonding with the car
body. If any crack or ✓ ✓ ✓
broken found, change the
7 window
4.6 Roller Blind(DTC,NDTC,MC,TC)
1 Cleaning of Roller Blind ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Checking for any tear of
Blind Roll and Pull String.
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Repairing or replacing the
2 same.
4.7 Luggage Rack(DTC,NDTC,MC,TC)
1 Cleaning of Luggage Rack. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Checking of Fasteners for
looseness and tightening ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 (if any looseness found).
4.8 Side & Roof Panels(DTC,NDTC,MC,TC)
Visual inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Checking side panels for
crack, damage, condition
of paint & shabby look.
✓ ✓ ✓
Apply putty/re-
paint/replace the panels
2 (if necessary).
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All internal panels are FRP

panels and not painted.
Repair procedures as per ✓ ✓ ✓
standard practice to be
3 adopted.
4.9 Fire Extinguisher(DTC,NDTC,MC,TC)
Confirm Fire Extinguisher
is visible, unobstructed
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
and at designated
1 location
Verify Locking Pin is intact
and pressure gauge is ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 indicator.
Check for expiry date in
label ( Should not be ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 overdue
Fire Extinguisher to be
✓ ✓ ✓ ✓
4 refilled
Check for proper
functioning of Fire
Extinguishers. Condition
✓ ✓ ✓
of hose and nozzle.
(repair/replace if
5 necessary).
5 Couplers
5.1 CBC(DTC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Check visually for any
crack/wear and missing of
✓ ✓ ✓ ✓ ✓ ✓
parts like knuckle, lock &
2 external damage etc.
Check tell tale of tight
✓ ✓ ✓ ✓
3 lock CBC coupler.
Attend the Tight lock CBC
as given in RDSO’s CMI
✓ ✓ ✓ ✓
no. RDSO/2006/CG/CMI -
4 01
5.2 Semi-Permanent Coupler(DTC,NDTC,MC,TC)
Visual Inspection for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 general condition
Check visually for any
missing/loose parts like ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 nut, bolt, screw etc.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

Check visually for any

✓ ✓ ✓ ✓ ✓ ✓ ✓
3 damage/ crack/ wear etc.
Visual check of torque
marks on sleeve and
✓ ✓ ✓ ✓ ✓ ✓ ✓
wedges bolts. Torqueing
4 to be done if necessary.
Visual inspection of
complete coupler as per
✓ ✓ ✓ ✓ ✓
DELLNER Document
5 No:130175
Lubrication as per para
DELLNER Document No: ✓ ✓
6 130175
Condition of draft gear
✓ ✓ ✓ ✓
7 pad for any crack/wear.
Cleaning as per DELLNER
document No. 130175 of
✓
preventive maintenance
8 manual.
Inspection of Elastomer
✓ ✓ ✓
9 spring package.
Check for sign of
deformation, rust or ✓ ✓ ✓
10 damage.
After uncoupling inspect
the guide cone and the
guide cone interface with
✓ ✓ ✓
regards to wear, damages
on structure and / or
11 paint.
After uncoupling,
inspecting socket joint,
specially the insides and
the socket joint interface
✓ ✓ ✓
on center section with
regards to wear, damages
on structure and / or
12 paint.
Cleaning
1. Clean coupler
thoroughly with water.
✓ ✓ ✓
2. Dry coupler with clean
lint free cloths.
13 3. Use a low aromatic
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

white spirit or equivalent

to remove excessive
grease from the coupler.
Lubrication.
1. Perform external
greasing with
LAGERMEISTER 3000+.
✓ ✓ ✓
Use a brush or similar to
apply the grease to visual
mounting interfaces on all
14 socket joints.
6 Doors
6.1 Internal Sliding Door(DTC,NDTC,MC,TC)
Check the Entrance door
glass for cracked, fixing ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 with frame
Check door leaf for any
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 damage, crack.
Check step for any
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 damage crack.
Checking the fluent
opening & Closing of the
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
door, noise, jerking
4 motion and knocking.
Check functioning of
emergency isolation ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 handle.
6 Cleaning of all doors ✓ ✓ ✓ ✓ ✓ ✓
Checking fixation of bolts
their looseness
✓ ✓ ✓ ✓ ✓ ✓
mechanical damage &
7 corrosion
Checking completeness of
the mechanism, screwing
up, binding cables, loose ✓ ✓ ✓ ✓ ✓ ✓
connections etc. Visually
8 of internal sliding door
Checking the door
protection function-
contact bar in the door ✓ ✓ ✓ ✓
leaf and over current
9 protection.
Lubricate Travel bearings-
✓ ✓ ✓ ✓
10 ball bushing with ISOFLEX
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

18 SPECIAL A

Checking the drive screw

system &replacing the ✓ ✓ ✓
11 plastic nut.
Check the end position
sensors of the door
✓ ✓ ✓
&functionality, properly
12 set switching.
Checking the bottom
guides replacing the ✓ ✓ ✓
13 plastic slider, if necessary.
Checking the rubber
sealing replacing, if ✓ ✓ ✓
14 necessary.
Lubricate the Motion
Screw with dry lubricant
spray with PTFE particles ✓ ✓ ✓
BERUCOAT AF 438
15 (BECHEM)
Note :
1. The motion screw is
forbidden to lubricate any
other than the BERUCOAT
AF 438 dry lubricant.
✓ ✓ ✓
2.The motion screw
bearings have a
permanent lubricating
filling and do not require
16 lubrication.
6.2 Plug Doors(DTC,NDTC,MC,TC)
Check the Entrance door
glass for cracked, fixing ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 with frame
Check door leaf for any
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 damage, crack.
Check step for any
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 damage crack.
Check the functioning of
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
4 indication lamps.
Check the functioning of
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
5 emergency button
Safety-Check-Safety-
Checklist as per OEM ✓ ✓ ✓ ✓ ✓ ✓
6 Document-
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

DDSTE11071E36

Check function of locking

✓ ✓ ✓ ✓ ✓
7 device of step.
Check painting in
accordance OEM
✓ ✓ ✓ ✓
document
8 DDSTE11071E01.
Visually check for flats at
rollers of roller swing arm,
roller on the door leaf
carrier, and roller from
✓ ✓ ✓ ✓
roller bracket on the
bottom door leaf area.
Exchange defective
9 component if required.
Clean door seals and re-
grease in accordance with
✓ ✓ ✓ ✓
Lubrication instruction
10 DDSTE11071E05.
Visual check brush for
✓ ✓ ✓ ✓
11 wear out.
Check visually the anti-slip
✓ ✓ ✓ ✓
12 coating.
Check the bearings and
the torsion spring at
✓ ✓ ✓ ✓
locking unit and locking
13 bracket.
Check visually the seals at
maintenance cover at
✓ ✓ ✓ ✓
step, exchange if
14 necessary.
Check tension of toothed
✓ ✓ ✓ ✓
15 belt.
Check corrosion
protection for mechanical
✓ ✓ ✓ ✓
damage. Correct locally if
16 required.
Visual inspection for
cracks in the radius area
on the right and left ✓ ✓ ✓ ✓
trolley on drive unit and
17 replace if necessary.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

Clean all surroundings of

door seals and foot step
seals. All surroundings
door seals, the finger
protection rubber, the
✓ ✓ ✓
portal rubber and seals of
the foot step front cover
must be lubricated with –
KLUEBER BARRIERTA L 25
18 DL – free of silicone.
After the finger
protection rubber and the
portal rubber have been
✓ ✓ ✓
greased, the need to be
dried with a clean piece of
19 cloth.
7 Vacuum Bio-Toilet(DTC,NDTC,MC,TC)
Check the Operation of
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1 flush push button.
Check for foul smell and
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2 clogging of toilet.
Check the LCD screen for
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3 any fault code.
Perform a visual check on
WC seat and cover, toilet
✓ ✓ ✓ ✓ ✓ ✓ ✓
Bowl for damages and
4 corrosion.
Check the bolts of
fixation, toilet seat hinge
✓ ✓ ✓ ✓ ✓ ✓ ✓
for their looseness and
5 condition.
6 Cleaning vacuum toilet. ✓ ✓ ✓ ✓ ✓ ✓
7 Cleaning spray nozzle. ✓ ✓ ✓ ✓ ✓ ✓
Cleaning liquid level
✓ ✓ ✓ ✓ ✓ ✓
8 guard.
9 Check for leakage ✓ ✓ ✓ ✓ ✓
Changing of Bio-culture if
required (Based on test ✓ ✓ ✓ ✓ ✓
10 required.)
Cleaning filter pressure
✓ ✓ ✓ ✓
11 regulator
12 Disinfection vacuum toilet ✓ ✓ ✓ ✓
Decalcification vacuum
✓ ✓ ✓ ✓
13 toilet
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

9 Monthly
Quarterly
Monthly
Daily
Equipment

Trip

SS1
SS2
SS3
S.No Activities
/ Sub-Assy.

Visual inspection of bio

✓ ✓ ✓ ✓
14 toilet system
Proper & leak free
connections in the
complete system including
✓ ✓ ✓
air, water pipelines and
interface piping up to
15 retention tank.
Proper stench trap and no
odor passing through to
✓ ✓ ✓
the toilet room from the
16 bio digester tank.
Functional check of the
✓ ✓ ✓
17 flush cycle.
Proper functioning of the
complete system
including clean-ability ✓ ✓ ✓
&maintenance of
18 hygiene.
8 Traction Gearbox(MC)
Perform maintenance as
per OEM and items
✓ ✓ ✓ ✓ ✓ ✓ ✓
mentioned in Annexure- E
1 and Annexure - F.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
3.3.2. SCHEDULE ACTIVITIES FOR ELECTRICAL EQUIPMENT

DAILY SCHEDULE MAINTENANCE ACTIVITIES

S.No. Equipment Maintenance Activity

1. General Carry out detailed checks in regard to any unusual occurrence
reported by Crew in the logbook.
Check all fasteners for under-slung equipment for tightness, check
for any loose hanging parts.
2. Cab Facilities Read Driver Display Unit for any active fault and note down.
Check general appearance of all buttons, indicators, switches,
toggles.
Check the functioning of all buttons by pressing lamp test button.
Check console Light, Cab Light, Fire Extinguisher, Function of Horn
etc.
Check the condition of LP/ALP seat.
Check the condition of DDU, MMI & CCTV screen.
Check the functioning of BAL, ISO, Single unit operation, EOL
bypass, EBL bypass, UVISO, ADCR bypass selector switches in
normal position and EMY off switch in release position.
3. Wiper Check wiper blades for damages, torn or missing.
Fill wash tank with washer fluid.
Clean windscreen with methylated spirits (denatured alcohol).
Do function test of wiper washer system in all positions.
4. TCMS Do all the self-tests.
5. Speedometer Check operation of indicating light of speedometer.
6. IV Couplers, Check for coupler mounting properly and presence of corrosion.
Jumper cables Check Jumper cables are not hanging with one end free, secure
and them if necessary.
receptacles Check power couplers for the intactness.
7. Isolation Ensure that isolation transformer is bolted tightly to the vehicle.
Transformer Check for any external damages.
Check electrical connections and ground connections for
corrosions to resolve and ensure all the connections are tight.
Check components and cables for any damage.
Do visual inspection for excessive temperature and arcing (voltage
flash over) and resolve it.
8. Driver Desk Check operation & function of all switches & push buttons with
their indications on Driver Desk and their stencilling.
Check master controller in each driving cab.
Check the operations from both the driver’s cab and working of
cab occupation functionality.
9. Pantograph Visually inspect the upper and lower arm and their components for
any abnormality.
Visually inspect carbon strips for break and wear.
Check physically for any damage & loose fasteners.
Check the Pantograph raising and lowering function.
10. ERCU/ Ground Visually inspect the ground contact for any damages after flow of a
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
S.No. Equipment Maintenance Activity
Contact shirt circuit current.
Check earth cable for proper connection, lug for any looseness and
condition of the insulating tape on lug.
11. HV Potential Check insulator surface for any sign of damage, crack or
Transformer chipping/grazing.
Check the earth cable for damage and loose connection.
12. Lightning Visually inspect the Insulator surface for any sign of damage,
Arrester crack/punctures or chipping/grazing.
Make sure that the line and ground terminals remain tight.
Visually inspect and check the earth cable for any damage and
ensure it is connected properly.
13. Transformer Check following visually for any abnormality/ damage:
 Silica gel breather and silica gel condition.
 H.T. cable (main bushing) and connection.
 Transformer for any oil leakage from any point, coupling,
joints etc.
 Transformer oil level.
14. Traction Visual inspection of TM coupling and gear case etc.
Motor and TM Check mounting bolts for their looseness.
Cable Junction Ensure that TM Cable Junction Box is bolted tightly to the vehicle
Box and check for any damage.
Visual inspection of TM JB for all the manufacturing hardware for
the doors for any slackness by seeing changes in torque marking.
Check electrical connections and ground connections for corrosion
to resolve and ensure all the connections are tight.
Check components and cable for damage.
Do visual inspection for excessive temperature and arcing (voltage
flash over) and resolve it.
15. VCB Check insulators for crack & flash marks.
Check for any air leakage in VCB.
Check the sealing of connectors, flexible pipe, regulator, air tank
etc.
Check contact spring visually.
16. Head light Head light by operating.
17. Flasher light Flasher light by operating.
18. Marker Light Tail lights working by moving mode selector (MS) and TCMS
display.
19. Cab light and Working of cab light by operating cab light switch.
Driver console Working of driver console light by operating driving console light
light switch.
20. Saloon & Working of compartment/saloon and reading lights.
Reading light
21. CCTV Check operation of all inside and outside cameras on display unit at
driver desk.
Clean outdoor camera dome cover (glass) with microfiber cloth
with gentle pressure.
22. HVAC Check function of HVAC system.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
S.No. Equipment Maintenance Activity
System(RMPU Check function of emergency blower by opening VCB after RMPU
) on command.
23. CAB Air Check function of cab air conditioner.
conditioner
24. PECU Check function of PECU system from minimum two coaches.
25. Passenger Clean & check function head code unit.
information Clean & check in coach display unit.
system (PIS) Clean & check side destination code unit.
26. Pantry Do cavity cleaning of Hot case and check the complete unit for any
Equipment damage or wire cut.
Do cavity cleaning of refrigerating unit and check the complete unit
for any damage, wire cut or abnormal sound.
Do cavity cleaning of water boiler and check the complete unit for
any damage or wire cut.
27. On-board Functional Test
27.1 For DTC
Cab Occupation in Key ON Mode-Cab Selector Switch in Normal
Mode.
Cab Occupation in RDM Mode-Cab Selector Switch in Normal
Mode.
Cab Occupation in Key ON Mode-Cab Selector Switch in High
Priority Mode.
Cab Occupation in RDM Mode-Cab Selector Switch in High Priority
Mode.
Check the Panto Rising & Lowering Observe the symbols on TCMS
DDU.
Check the VCB On & OFF Observe the symbols on TCMS DDU.
Check Emergency Off Functionality by pressing Emergency Off
button on Driver Desk.
Check the Emergency Off Bypass switch functionality during
Emergency Off button is in pressed condition.
Check the TCMS Network Screen for any abnormalities.
Check the High Voltage Screen for any abnormalities.
Check the ACU Screen for any abnormalities or any Earth Faults.
Check the Signal Bell Functionality from both driver and guard
panels.
Check the Emergency Bell Functionality by pressing SB2 button in
driver and guard panel.
Check Emergency bell by pressing EMY Stop button in passenger
saloon area and observe the indication on TCMS DDU and also on
SB2 Switch.
Check the Train BN Battery voltage.
27.2 For all cars
Check the 100 % Saloon Lights. Observe the symbols on TCMS DDU.
Check the 50 % Saloon Lights Observe the symbols on TCMS DDU.
Check the Lights functionality by operating DLL Control SW & IDDL
Control SW in Auto, OFF & ON modes and observe the symbols on
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
S.No. Equipment Maintenance Activity
DDU.
Close all the doors and observe the symbol TCMS DDU.
Give AC on command and observe the symbol TCMS DDU.

OTHER MAINTENANCE SCHEDULE ACTIVITIES

In addition to following perform all activities of daily schedule also.

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
1. Line & Traction Converter (MEDHA)–MC1,2,3
1. Check that the converter unit is bolted
      
tightly to the vehicle.
2. Check the converter unit for any
      
damage.
3. Check that the air inlet and outlet
      
openings are UN- obstructed.
4. Check the healthiness of all the blowers,
there should not be any abnormal       
sound.
5. Inspect all the manufacturing hardware
of the doors for any slackness by seeing
      
changes in torque marking. Add any
missed hardware.
6. While doing maintenance if any
abnormality/ damage found, it should be       
addressed.
7. Remove inlet and outlet doors and clean
     
the inlet and outlet chambers.
8. Clean information and warning labels on
     
doors.
9. Check the healthiness (colour) of silica
gel, they should be blue, replace silica      
gel if found pink.
10. Clean heat sink fins.      
11. Open and clean all converter unit doors.
    
Remount properly with all bolts.
12. Check all door gaskets for total
availability and in good condition.
    
Replace/add any damaged/ missed
gasket with new.
13. Inspect all the mounting hardware for
    
the mechanical and electrical
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
components for any slackness by seeing
changes in torque markings.
14. Check electrical connections and ground
connections for corrosion. Ensure that     
connections are tight.
15. Check components and cables for
    
damage. If found rectify them.
16. Inspect for evidence of excessive
temperature and arcing (Voltage flash     
over’s) and resolve it.
17. Check that all the cable ties are tight and
    
intact.
18. Clean the ventilated sections with dry
  
compressed air.
19. Replace any jammed hardware by new
hardware with anti-seize compound   
applied by using screw extractor.
20. Remove all unventilated section doors
and clean the equipment sections and
  
components with vacuum cleaner, brush
and lint free cloth.
1.1 HS Module
21. Remove all DCL bus-bar, all power and
control cables and detach connectors   
gently.
22. Remove the module by sliding on
  
module sliding bracket.
23. Clean the Heat sink fins with ISO-propyl
alcohol by using lint free cloth and   
brush.
24. Suck the air through fins by vacuum
  
blower for removing the dirt from fins.
1.2 Blower
25. Remove all power, control connections&
  
mounting screws.
26. Remove the blower from duct.   
27. Clean the Blower with ISO-propyl alcohol
  
by using lint free cloth and brush.
28. Suck the air through fins by vacuum
  
blower for removing the dirt from fins.
29. Clean all dust and dirt deposits with
  
vacuum cleaner and brush.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
30. Check the healthiness of all the blowers,
there should not be any abnormal   
sound.
2. Auxiliary Converter Unit (MEDHA)–TC
1. Check that the converter unit is bolted
      
tightly to the vehicle.
2. Check the converter unit for any
      
damage.
3. Check that inlet and outlet air openings
      
are un-obstructed
4. Air blowing for inlet air filter to be done.       
5. Change the filter if torn out or damage.
      
After checking secure the filter properly.
6. Check the healthiness of all the blowers,
      
there should not be any abnormal sound.
7. While doing maintenance if any
abnormality/ damage found, it should be      
rectified.
8. Remove inlet air filters and clean the
filters with compressed air/vacuum
     
cleaner by separating the fins and wire
mesh filter.
9. Change the filter if torn out or damage.
     
After checking secure the filter properly.
10. Check the inlet air velocity at multiple
locations on the air inlet doors & ensure
     
the air flow average values should be ≥ 4
m/s.
11. Check the exit air velocity at multiple
locations on the air outlet doors &
     
ensure the air flow average values
should be ≥ 2.8 m/s.
12. Check healthiness (color) of Silica gel,
they should be Blue, Replace silica gel if      
found Pink.
13. Check all door sealing gaskets for any cut
mark and physical damage, If found      
replace with new one.
14. Clean all doors and information and
    
warning labels.
15. Inspect all the mounting hardware
    
(mechanical and electrical components)
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
for any slackness by seeing changes in
torque markings.
16. Check electrical connections and ground
connections for corrosion to resolve.     
Check that connections are tight.
17. Check components and cables for
    
damage. If found address them.
18. Inspect for evidence of excessive
temperature and arcing (Voltage     
flashovers) and resolve it.
19. Check that all the cable ties are tight and
    
intact.
20. Open and clean all converter unit doors.
    
Remount properly with all bolts.
21. Clean the inlet filter with pressurized
water, till the filter is free from dirt, dust     
& other debris.
22. Apply pressurized air on to filter to
    
remove entrapped water particles.
23. Clean the sticky dust accumulated on
    
blower impeller blades with cloth.
24. Check the gland seals, grommets and
other cable sealing accessory for any
    
damages. Replace them for any damage
found.
25. Check for dust traces present in
electronics zone. If found, seal it properly     
by applying Silicon sealant.
26. Clean all magnetics surface (i.e outer
surface, terminals and other accessible
  
dust deposited surfaces) with
compressed air and soft brush only.
27. Suck the dust with vacuum cleaner &
  
blow the magnetics with blower.
2.1 LC & Inverter Modules
28. Check electrical, earth connections and
all components for any abnormality/
  
damage and rectify or replace on need
basis.
29. Check mounting of the modules for
  
proper fitment.
2.2 DC-DC Modules
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
30. Check electrical, earth connections and
all components for any abnormality/
  
damage and rectify or replace on need
basis.
31. Check mounting of the module for proper
  
fitment.
2.3 Heat Sink
32. No preventive maintenance is required.   
33. If there is any Heat Sink thermal
performance degradation is identified
through temperature derations or
shutdowns in the converter even if the
  
blower motor is running in the right
direction, then remove the Heat Sink
module and clean it as per the procedure
given below.
34. Remove the modules from the unit.   
35. Clean the Heat sink fins with ISO-propyl
alcohol by using lint free cloth and brush.
  
Suck the air through fins by vacuum
blower for removing the dirt from fins.
3. Battery Charger (MEDHA)-DTC, NDTC
1. Check the Battery Charger mounting
bolts for the tightness, there should not
      
be any slackness in all the mounting
fasteners, Cotter pin should be intact.
2. Check the Battery Charger unit for any
      
damage.
3. Ensure that the heat sink heat sink fins
top and bottom areas are unobstructed       
to air flow through the fins.
4. Inspect visually all the manufacturing
hardware of the doors for any slackness
      
by seeing changes in torque marking.
Add any missed hardware.
5. Check the healthiness (colour) of silica
gel (inside the door), they should be      
blue, replace silica gel if found pink
6. Check door sealing gaskets for any cut
     
mark and physical damage.
7. Clean information and warning labels on
    
doors.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
8. Inspect all the mounting hardware
(mechanical and electrical components)
    
for any slackness by seeing changes in
torque markings
9. Check electrical connections and ground
connections for corrosion to resolve.     
Check connections tightness.
10. Check the inductor whether potting is
detached from enclosure at terminal     
face.
11. Check cracks on potting surface of the
    
inductor.
12. Check components and cables for
    
damage. If found, rectify them.
13. Do visual inspections for evidence of
excessive temperature and arcing    
(Voltage flash over’s) and resolve it.
14. Clean heat sink fins. On need basis if
there is any heat sink thermal
performance degradation is identified
   
through temperature durations and
shutdowns, then remove the modules
and clean the heat sink fins).
15. Clean all magnetics surface (i.e outer
surface, terminals and other accessible
   
dust deposited surfaces) with soft brush
only.
16. Check the gland seals, grommets and
other rubber components for any
   
damages. Replace them for any damage
found.
17. Check all the cable ties are tight and
   
intact.
18. Open and clean all BCS doors. Remount
   
properly with all bolts.
19. While doing maintenance if any
abnormality/ damage found, it should    
rectified.
4. Battery (AMARA RAJA)-DTC, NDTC
1. Check battery boxes mounting bolts for
the tightness, there should not be any       
slackness in all the mounting fasteners,
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
Cotter pin should be intact.
2. Check visually battery boxes and
suspension for any damage or       
irregularity.
3. Check for by-passing of the failed cells. If
the cells are found by-passed, replace
   
these failed cells immediately with the
healthy ones.
4. Clean dust accumulation with dry cotton
cloth and apply Vaseline on cell terminal    
after cleaning.
5. Check cell cover / container for any
crack, leakage or burst, if noted, replace    
the cell with a healthy cell immediately.
6. In case of battery terminal/ cable over
heating sign, check for loose connection
   
at the cell terminal post / cable end. If
required, replace the cable immediately.
7. Check, protective lid on safety valve if
   
missing, provide new one immediately.
8. Charge the cell, preferably for 6-8 hrs.,
after arrival of train by 111V for 48 cell of
   
battery bank i.e. 2.3 Volt per cell, as cells
maybe partially discharged.
9. Do not boost charge the cells for more
   
than 12 hrs.
10. Confirm the 10 ± 1 Nm, tightening
torque of terminals bolt. Do not over   
tight.
11. Terminal post corrosion – if observed
remove the cable and clean the terminal
post and cable lug with brass brush or  
fine emery paper and apply petroleum
jelly.
12. Check the open circuit voltage.  
13. If the open circuit voltage of total battery
bank (48 Cell), is above 98.5 Volt:  
The following steps shall be followed:-
14. Discharge the battery bank with full
coach load for 15 minutes (based on  
coach arrival battery state of charge).
15. Note down the individual cell readings  
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
after 15 minutes while the coach is still
connected during the discharge.
16. If all the cell voltages are 1.98 Volts and
above then the cells are in healthy
condition –Charge the cells with system  
voltage of 111V, i.e. 2.3V per cell and put
back into service.
17. If some of the cell voltages are less than
1.98 Volts then give boost charging with
2.30V per Cell for 12 hrs. By charging  
them separately with current limited to
20% of battery rated capacity.
18. The weak cells, which are charged
separately, must be checked through a
discharge at C-10 rate for 30 minutes,
the end of discharge voltage should be  
above 2.0 V. If such re-charged cell fails
to qualify the above test, it should not be
put back in the service.
19. After performing the discharge test on
the revived cells, the cells need to be
 
charged at least for 4 hours, prior to
fitment in the service.
20. If the open circuit voltage of total battery
 
bank (48 cell) is less than 98.5V.
21. Charge the cells for 12 hrs. with 2.30 V
 
per cell and follow the following steps:
22. Discharge the battery bank with full
coach load for 15 minutes (based on  
coach arrival battery State of charge).
23. Note down the individual cell readings
after 15 minutes while the coach is still  
connected during the discharge.
24. If all the cell voltages are 1.98 Volts and
above then the cells are in healthy
condition – Charge the cells with system  
voltage of 111V, i.e. 2.3V per cell and put
back into service
4.1 Major Schedule
25. Remove all the cell terminal connections
  
and stacking bolts.
26. Remove the modules with batteries from   
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
battery box.
27. Clean all the cell terminal posts and inter
cell connectors / cable lugs with a brass   
wire brush.
28. Examine batteries for damaged areas,
Vent plugs, cell cover for electrolyte   
leakage etc.
29. Check connectors and terminals of cells
  
for hot spots.
30. Record lug date to determine the life of
  
the battery.
4.1.2 Charging
31. Refit the inter cell connectors’/cables
and tighten the bolts along with the flat
  
and spring washers to specified torque.
Replace old spring washers 100%.
32. Discharge the battery banks @ 10% of
capacity and by-pass each cell
  
whenever it reaches end cell voltage of
1.75V.
33. Charge the cells at 5% constant current
  
for 24 hours (5% of 300Ah i.e.15 Amps).
34. Again give rest to the cells for 6-8
  
hours.
35. Discharge the cells at C10 capacity i.e.
30Amps and gradually by passing each
cell whenever any cell reaches to 1.75
V. Duration of discharge shall be
  
recorded. If the discharge duration of
the cells is found to be more than 8.5
hrs. these cells can be put back in
service after charging.
36. If the cells do not give more than 8.5
hrs. of discharge duration before
reaching end cell voltage of 1.75 V,
  
repeat this charging and discharging
cycle once more. Cells should not be
discharged below 1.75 Volts.
37. Even then, if the cells do not give more
than 8.5 hrs. then the cells shall not be   
put in service.
4.1.3 Battery Boxes
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
38. Clean and repair battery boxes and
repaint with anti-corrosive epoxy based   
paint.
39. Clean and repaint the modules / cell
trays. These may be numbered with
the help of stencilling to identify the
modules consisting of a battery set for
a coach (Say Module No/ Set
No.E.g.08/01 means 8th module of Set.
  
No.1). The other details like cell
number, date of manufacture as
indicated on the cell lid and date of
fitment shall also be recorded to
monitor age-wise performance of the
cells.
4.1.4 Loading on to the Coach
40. After recharge, remove all the inter
module connectors/ cables etc., to avoid
shorting of the cell/modules during   
loading on to the battery box/ cradle
with care to avoid the physical damages.
41. Apply petroleum jelly over the module
  
connectors, wherever necessary.
42. Put back the batteries into the battery
box/ cradle as per the connection
  
diagram and fix the stacking bolts
between the battery boxes to cradle.
5. Brake Chopper Resistor (MEDHA)- MC1,2,3
1. Check the Brake Chopper resistor for
damages and welded joints. If any
     
damages/ cracks found, take corrective
action.
2. Check the insulators .If any cracks are
     
observed, then replace the same.
3. Make sure that the VCB is opened and
manual DC link discharge switch is      
operated in the basic unit.
4. The resistor cannot be energized it is
necessary to wait for 30 minutes after
     
power cut off to allow the resistor active
parts and the frame to cool.
5. Blow compressed air on active parts of      
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
the resistor and their own insulation
washers.
6. Remove the covers (mesh) and do air
blowing. Clean internal insulators using a
     
duster and brush for removing greasy or
sticky contamination.
7. Check for any foreign bodies trapped on
     
covers and elements. Remove if any.
8. Do visual inspection for evidence of
excessive temperature and arcing      
(voltage flash over).
9. Measure the cold resistance value,
corresponds to 20°C ambient
     
temperature shall be in between 3.42 to
3.85Ω.
10. Check tightness of all bolts and electrical
connections as per torque values    
mentioned in OEM’s Manual.
6. DC Link Earthing Switch (MEDHA)-MC1,2,3
1. Check that the unit is bolted tightly to the
      
vehicle.
2. Check the unit visually for any damage.       
3. Clean information and warning labels on
     
doors.
4. Inspect visually all the manufacturing
hardware of the doors for any slackness
      
by seeing changes in torque marking.
Add any missed hardware.
5. Check electrical connections and ground
connections for corrosion to resolve.       
Check connections tightness.
6. Check components and cables for
      
damage. If found, rectify them.
7. Do visual inspections for evidence of
excessive temperature and arcing     
(Voltage flash over’s) and resolve it.
8. Check all the cable ties are tight and
    
intact.
9. Check the healthiness (color) of silica gel
(inside the door), they should be blue,     
replace silica gel if found pink.
10. While doing maintenance if any     
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
abnormality / damage found, it should
rectified.
11. Check door mountings for total
presence/ availability and in good      
condition.
12. Clean dust and dirt deposits with vacuum
     
cleaner.
13. Check tightness of electrical connection
as per torque values mentioned in OEM’s     
Manual.
7. Pantograph (SCHUNK)-TC
1. Clean insulators with soft, clean & dry
      
cloth.
2. Check insulators for cracks and flash
      
marks.
3. Check tightness of fasteners.       
4. Inspect carbon strips for damages on
surface and wear. Replace carbon strips       
if thickness is < 5-6 mm.
5. Check contact force according technical
data. As per practical experience the
      
contact force should be between 75N &
80N i.e. 75N (+5-0N)
6. Check raising and lowering time of
pantograph.
      
Raising time: 6 to 10 Sec.
Lowering time: 6 to 10 Sec.
7. Check for lateral play of panto-pan
   
minimum 2degree.
8. Inspect parallel guide bar for free
      
movement of the pan head.
9. Inspect Teflon insulating hose for any
      
damage. Exchange if necessary.
10. Inspect air hose for any damages on
      
surface. Exchange if necessary.
11. Check functioning of ADD & ORD device      
12. Inspect cam & cable with thread fittings
     
of raising mechanism for any damages.
13. Clean & apply Moly Graf CC2 Grease on
     
cable and cam groove.
14. Exchange cable, if more than ten single
     
wires or one single braid
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
broken/damaged.

15. Inspect shunt strains for damages/

cutting. Change shunts in case more      
than 5% of wire strains are broken.
16. Whenever shunts are required to
replace, clean contact area and apply
     
copper content contact grease
MolygrafTC-55
17. Inspect the pneumatic connectors for
    
tightness and any air leakages.
18. Check function of Pressure Regulator as
    
described in OEM’s manual.
19. Check function of Safety Valves as
    
described in OEM’s manual.
20. Inspect pan head leaf springs and
support spring of base frame for any
    
bend, coating peel-off. Exchange, if
necessary.
21. Remove diaphragm of ADD Valve and
clean. After refitting, carry out functional     
inspection of ADD valve.
22. Inspect hydraulic dampers for any
    
leakage of fluid.
23. Functional inspection of hydraulic
    
dampers.
24. Fix damper at one end and hang 2 kg
weight at other end and damper should
open to max. extension in 1 min. ±     
10sec. Exchange, if necessary for any
damage.
25. Inspect of Air bellows drive for any
leakages/ damages/ rubbing marks.     
Exchange, if necessary for any damage.
26. Functional check of Air Filter.     
27. Replace the Element, O-Rings when one
of followings occurs.
    
 Pressure drop reaches0.1Mpa.
 Element operates for 1.5years.
28. Check for friction of ball bearings of base
frame, upper frame and coupling rod.     
Replace ball bearings, if necessary.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
29. Ensure Pressure Switch setting (P-max
   
and P-min)
7.1 General Information
30. Each pantograph has been calibrated by
   
the manufacturer.
31. Adjustment works are to be carried out
   
in the following order:
32. Adjust coupling rod and resting position.    
33. Adjust the air bellow drive.    
34. Adjust pneumatic control.    
35. Adjust curve of contact pressure.    
36. Adjust parallelism of carbon mounted
   
panto-pans.
37. Adjust mobility of pantograph head.    
8. Vacuum Circuit Breaker (AAL)-TC
1. Clean insulators with soft, clean & dry
     
cloth.
2. Check insulators for cracks and flash
     
marks.
3. Check for damage to connection of the
     
earthing isolator.
4. Cleaning & greasing earthing isolate if
     
necessary.
5. Drain the pressure regulator. (To be
     
done before each winter period strictly.)
6. Drain the air tank. (To be done before
     
each winter period strictly.)
7. Check contact spring.      
8. Check the tightening torque 70Nm of
    
H.V. connection.
9. Check the torque of VCB fixing screws,
    
tightening torque 70 Nm.
10. Check the earthing connection,
    
tightening torque 70 Nm.
11. Check for any air leakage in VCB.     
12. Check the sealing of connectors, flexible
    
pipe, regulator, air tank etc.
13. Check for any damages, cut & tightness
of the connectors, connections, pins etc.
    
Including pressure switch, EP valve
solenoid coil and connector.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
14. Check the tightness of pneumatic
    
connection of pressure switch.
15. Weigh the air dryer. If increase in weight
is more than 0.8 kg from new weight,
  
regenerate molecular sieves by heating
and replace, if required.
16. Check and set valve of the pressure
   
regulator.
17. Change the filter cartridge of pressure
   
regulator with O-Ring.
18. Check screw of auxiliary switch for
 
breakage or other damage.
19. Check the moving contacts of auxiliary
 
switch for its continuity.
20. Check the cables and lugs of auxiliary
 
switch for broken cables, lugs looseness
21. Check securing of auxiliary switches and
 
support plate (Tightening torque- 10Nm)
22. Check the working order of each
 
auxiliary contact.
23. Check proper fixing/ sticking of shock
 
absorber plate.
24. Check for any air leakage from piston
   
assembly.
25. Change the kit of O-ring of side cover
   
(First time after 3 years then every year).
26. Check the healthiness of EP valve coil
   
resistance1510 Ω ± 8 % at 35°C.
27. Check the setting of pressure switch.    
28. Lubricate contact spring.    
29. Lubricate driving plate assembly as per
   
OEM guidelines.
30. Lubricate shafting head bearing guides,
vertical springs, flexible braids, piston    
seal, piston rod& EP valve.
31. RC network – Measure individual
resistance and capacitance value 4.7Ω ±
   
10 % and 25 µF ± 10 %. Replace
abnormal components.
32. Check Torque Tightening:
Rear flange- 19.3Nm    
Shafting head – 67Nm    
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
Vertical insulator -67Nm    
Bolts of cover for holding cylinder -39.4
   
Nm.
33. Air tank mounting nuts – 15Nm.    
34. Check for damage to connection of the
  
earthing isolator.
8.2 Vacuum Switch Tube
1. Check the healthiness of VST (Di-electric
  
test 40 kV for 10sec.)
2. Check closing & opening speed (First
after 3 years on new breaker & then   
every year).
3. Inspections of main contacts wear in
vacuum switch tube. (First after 3 years   
on new breaker & then every year)
8.3 Additional Items for SS-2, SS-3
4. Check compression springs.  
5. Change the auxiliary switch  
6. Change the shock absorber plate.  
7. Replace pressure switch with union
 
bend.
8. Replace molecular sieves of air dryer.  
9. Check torque tightening of Nuts of base
 
plate-15Nm
10. Change pressure regulator. 
11. Replace piston seal of piston assembly. 
9. Earthing Switch for VCB (PATRA & CHANDRA)-TC
1. Check for smooth operation and
      
intactness.
2. Clean earthing switch Isolator blade&
     
fixed contacts and apply grease lightly.
3. Ensure tightness of all connections.     
4. Seal/ rubber gasket to be replaced with
new one whenever entire switch is  
removed from the roof.
5. Replace Scrapper (Seals)for Main Shaft
with new one and clean the inside of 
the cover and apply grease.
6. Replace contact spring with new one. 
7. Replace key-A (Blue) and Key-B (Yellow)

with new keys.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
10. AC Surge Arrester (Siemens)-TC
1. Clean the dust and dirt from the
      
Insulator surface with cotton cloth.
2. Inspect the insulator thoroughly, in case
there is tearing of the silicone housing
      
(black), the arrester must be replaced
immediately.
3. Check the TELLTALE gap, if installed.      
4. Make sure that the line and ground
     
terminals remain tight.
5. Check the earth cable for any damage
     
and ensure it is connected properly.
6. Check the M16 bolt for high tension line
connection for looseness. If found loose,   
apply the torque value of 105Nm.
11. Main Transformer (JST)-TC
1. Check color change of the desiccant
(silica gel) through air dryer window. If
color has switched from orange to green   
or if oil is present in the air dryer, replace
the desiccant.
11.1 Cooling System
2. Clean the cooler surface by soft brush
and remove deposits with industrial      
vacuum cleaner.
3. Clean the cooler surface by soft brush
and remove deposits with industrial     
vacuum cleaner.
4. Apply a small quantity of soft detergent
on the clogged surface and make it act     
for 30-45 minutes.
5. Wash aluminum radiator (by a pressure
equipment, pressure must not exceed     
50bar.
6. Dry the cooler by passing pressurized air
(it must not exceed 6bar).Refer OEM     
manual for details.
11.2 Transformer – General check
7. Check for any apparent damage, oil
leakage or rust on the transformer and all     
the equipment.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
8. Check the transformer’s oil level. Get the
temperature of oil from Thermometer.     
Compare oil level with oil temperature.
9. If the temperature differs by more than
10 °C, look for leaks visually at
    
transformer appearance (weld
accessories, connections).
10. Check if all screws are well tightened.     
11.3 Tommy Gun
11. Check the level of oil in the oil sight glass
placed on the container.
    
Note: This procedure has to be done
every time an alarm has been triggered.
12. If there is oil, drain the container by
unscrewing the drain plug. Mount back
    
the drain plug by 75 Nm torque once the
container is empty.
11.4 PT100 Sensors
13. Check the resistance of PT100 sensor
   
while it’s mounted.
14. With a laser thermometer, check the
temperature of the tank just close to the    
PT100.
15. Take a matching table between
resistance value and temperature.
Compare this temperature with
   
temperature measured on tank. If there
is a difference more than 5 degrees
Celsius, please refer OEM’s manual.
11.5 Air Dryers - Dehydrating Agent
16. Remove air dryers from conservator and
   
LV bushing.
17. Empty silica gel from the air dryer body.    
18. Clean inside the air dryers body by
   
blowing compressed air.
19. Slowly put a charge of Silica gel with new
   
or regenerated through top opening.
20. Screw back air dryer for conservator with
   
60 N.m. torque.
21. Install back air dryer LV bushing on the
   
pipe and screw it with a 40Nm torque.
11.6 Damper
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
22. Inspect visually the rubber of the damper
and check that there is no cracks, no
   
missing material, no shock and no
marking etc.
23. Inspect visually the damper and check
that there is no shock, no missing bolt.    

11.7 Oil Sampling

24. Collect oil sample of transformer oil as
per procedure and send to the lab for
testing as per OEM’s manual and RDSO
guidelines.    
Breakdown voltage>40kV
Water content < 30 ppm
Acidity < 0.3 mgKOH/ gm. Oil
25. Filtration to be done if required.    
11.8 Pressure Relief Device
26. Clean thoroughly the outside of the
   
pressure relief device.
27. Ensure the healthiness of pressure relief
   
valve
11.9 Cooling System Vibration Checking
28. Check level of vibration of cooling system
  
motors while powered.
29. Analyze the vibration of oil pump while
  
it‘s powered.
11.10 Oil Level Indicator
30. Check for any sign of leakage or crack. If
oil leakage is detected, replace the oil   
level indicator.
31. Check tightening of oil level indicator-
  
10N.m
32. Clean the surface of the oil level
  
indicator.
11.11 Windings
33. Check IR of primary and secondary
  
windings.
11.12 Oil pump – Bearings replacement
34. Close both ends valves of oil pump pipe

lines and drain oil of the pipe.
35. Remove the oil pump and replace the ball

bearings of the pump as per pump
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
manufacturer guidelines.
36. Install back the oil pump and other

accessories.
37. Refill transformer with recycled oil, run

the pump during 5 minutes and purge it.
11.13 Main Bushing
38. Clean the main bushing thoroughly.      
39. Check for any damage or defect.      
40. Check tightness of all connections
including earthing and roof bushing      
connections.
12. Traction Motor (TSA) – MC 1, 2, 3
1. Clean air inlet filters with vacuum
cleaner from outside without
dismounting of air filters from traction
      
motors. If required clean filters after
dismantling. Replace the air filters in
case of damage.
2. Check mounting bolts for their
      
looseness.
3. Check visually for external damage of
traction motor, power supply cable &       
traction motor suspension.
4. Clean the traction motor & its
     
accessories thoroughly.
5. Repair or damage or change mounting
     
parts, if necessary.
6. If necessary, replace the corrosion
     
protection on the damaged spots.
7. Inspect of mechanical connection
     
elements.
8. Check attachment points of traction
motor to bogie for cracks on the motor      
nose and lower mounting points.
9. Check for signs of overheating, presence
     
of bad odor.
10. Check external bolts/screws for
     
tightness.
11. Check for bolt tightness for the traction
motor power supply cable connections.     
Required torque -35Nm.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
12. Check earthing cable connection, speed
sensor cable & temperature sensor
cable with connector for any external/      
mechanical damage like stone hitting
etc.
13. Check the tightness of connector
connection of speed sensor and      
temperature sensor.
14. Check for bolt tightness for traction
motor mounting on bogie. Refer
     
drawing no. Train/MC/AC-0-0-003 for
tightening torque values.
15. Dissemble the air filters and clean with
dry cloth, brush or vacuum cleaner for      
removing dirt.
16. Clean the air filter thoroughly on both
sides with dry compressed air or water      
with cleaning agent.
17. Dry the filters before re-assembling.      
18. If the air filters are heavy polluted and
     
cannot be cleaned, replace with a new.
19. Fit the air filters and brackets to the
stator housing and tighten with a torque      
30Nm.
20. Visual Inspect the guard grids for any
     
damages. Remove any debris.
21. Clean the guard grids with a brush and a
vacuum cleaner externally without      
dismounting.
22. If cleaning from outside is not proper,
then dissemble the guard grids & clean
them thoroughly on both sides with dry      
compressed air or vacuum cleaner and
brush.
23. If the grids are heavy polluted for
cleaning or damaged, replace with a      
new.
24. Fit the guard grids to the stator housing
and tighten with a torque 10Nm if      
dissembled.
25. Check that all outlet portions of bearing
   
box and end bracket are not clogged
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
with foreign material.
26. Remove accumulated dust in rotor vent
holes by using dust blowing equipment    
and compressed air.
27. Check bearings for signs of grease
   
leakage.
28. Re-grease the cylindrical roller bearing
in the end shield NDE with 9 g and the
deep groove ball bearing in the end
   
shield DE with 21 g roller bearing grease
SHELL GADUS S3 V220C 2 as per OEM
guidelines.
29. Replace the Motor bearings , Whole
motor reconditioning/ Periodic
overhauling (POH)** as per OEM’s 
“Operating Manual” (every 30,00,000
km)
13. TM Cable Junction Box-MC 1, 2, 3
1. Check that the TM cables junction box
      
bolted tightly to the vehicle.
2. Check the junction box for any damage.       
3. Inspect all the manufacturing hardware
of the doors for any slackness by seeing       
changes in torque marking.
4. Check electrical connections and ground
connections for corrosion to resolve.       
Ensure the connections are tight.
5. Check components and cables for
      
damage. If found address them.
6. Inspect visually for evidence of excessive
temperature and arcing (voltage flash       
overs) and resolve it.
7. Clean information and warning labels on
      
doors.
8. Open and clean junction box doors.
     
Remount properly with all bolts.
9. Check that the door sealing gaskets are
free from cut marks and physical      
damages.
10. Inspect all the mounting hardware
(mechanical and electrical components)      
for any slackness by seeing
Page
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
torque markings.
14. Jumper Couplers (Power Couplers)-MC, TC
1. Clean & check the power coupler
junction box, HARTING connector plate,
and cable holding plate for damages and       
welded joints. If any damages/ cracks are
found, rectify them.
2. Check the insulators. If any cracks are
      
observed, they are to be replaced.
3. Check for corrosion in the electrical
      
contacts.
4. Check the tightening torque of all bolts,
cable glands, HARTING connectors and
      
electrical connections as per OEM’s
instructions.
5. Tighten cable glands with proper tool.       
6. Inspect the unit visually for any cracks.      
7. Inspect hardware and unit mounting
     
frame for cracks.
15. Power Coupler Junction Box-MC, TC
1. Check that the Power Coupler JB & Plates
      
are bolted tightly to the vehicle.
2. Check the Power Coupler JB & Plates for
      
any damage.
3. Open and clean all Power Coupler JB
     
doors. Remount properly with all bolts.
4. Clean information and warning labels on
     
doors.
5. Inspect all the manufacturing hardware
of the doors for any slackness by seeing      
changes in torque marking.
6. Check door sealing gaskets for any cut
     
mark and physical damage.
7. Inspect all the mounting hardware
(mechanical and electrical components)
     
for any slackness by seeing changes in
torque markings.
8. Check electrical connections and ground
connections for corrosion to resolve.      
Ensure that connections are tight.
9. Check components and cables for
     
damage. If found address them.
Page
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
10. Inspect for evidence of excessive
temperature and arcing (Voltage flash      
overs) and resolve it.
16. Inter Vehicular (IV) Coupler-All Coaches
1. Inspect and clean MU receptacles and
jumper cables.
      
Jumper cables should not be allowed to
hang with one end free.
2. Visual inspection of the cable in rest
position, should not be deformed or     
crossed.
3. Visual inspection:
 Mechanical damage
    
 Tightness of the fixing bolts
(controlling the safety marks)
4. Visual inspection of the cable jacket /
sheath and grommets:
 Cracks and scratches.
 Damage caused by a hitting rocks.
    
 Damage on the cable jacket.
 Grommets shouldn’t be pulled from
the cable glands.
 Safety marks of cable glands.
5. The cables located in the inner and
outer positions have to be controlled
with more intensity, since they have is a    
higher risk to be damaged and to be hit
by a rock.
6. Intensive visual inspection for
   
mechanical damage.
7. Visual check that all screws are tight.
   
(controlling the safety marks)
8. Check for tightness of the fixing
   
screws.(controlling the safety marks)
9. Tightness testing by opening the plugs
and check for corrosion in the electrical    
contacts.
10. Clean & check the IV coupler for
damages and welded joints. If any
   
damages/ cracks are found, rectify
them.
Page
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
11. Check that all the coupler sockets and
jumpers are bolted and fitted correctly   
to the vehicle.
12. Inspect hardware and unit mounting
  
frame for cracks.
13. Visually inspect all the mounting
  
hardware for corrosion.
14. Inspect the unit visually for any cracks.   
15. Do visual inspection for evidence of
excessive temperature and arcing   
(voltage flash overs) and resolve it.
17. Isolation Transformer (MEDHA)-All Coaches
1. Ensure that the isolation transformer is
      
bolted tightly to the vehicle.
2. Check the Isolation Transformer visually
      
for damages.
3. Check that heat sink guard is not
clogged (any foreign material should be       
removed by hand).
4. Check electrical connections and ground
      
connections for corrosion to resolve.
5. Check components and cables for any
      
damage. If found address them.
6. Do visual inspection for evidence of
excessive temperature and arcing       
(voltage flash over’s) and resolve it.
7. Blow compressed air over the
Transformer (especially on heat sink      
guard) to remove the dust on mesh).
8. Check the visual aspect and the
tightening torque of 75 N-m on
     
transformer mounting frame at 4
locations.
18. Master Controller (SCHALTBAU)-DTC
1. Check that master controller handle is
      
not loose and there is no excessive play.
2. Visually check master controller handle
and mode selector handle for signs of
    
damage such as cracking, excessive
wearing etc.
3. Confirm that the master controller and     
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
mode selector handle can be operated
smoothly and without excessive force.
4. Check the interlocking between MSH
    
and MCH.
5. Check multiple pin connectors for
    
damage or loosening.
6. Check all screws and nuts for loosening.     
7. Clean all parts with dry compressed air    
8. Visually check all electrical/ mechanical
connections and springs with regard to    
visible damages.
9. Check notch roll, if necessary replace.
Grease by using high performance    
grease.
10. Check snap-action switches of the
   
complete Master Controller
11. Lubricate bearings with the special
   
lubricating oil as per OEM guidelines.
12. Grease toothed wheels and notch disks
with high- performance lubricating    
grease as per OEM guidelines.
19. Driver Console (MEDHA)-DTC
1. Clean driver console externally with soft
brush and lint free cloth soaked with tap       
water.
2. Check DDU for any active fault.       
3. Check general appearance& function of
all switches & push button with their
      
indications on Driver Desk and their
stenciling.
4. Check console light, cab light, fire
      
extinguisher, function of horn etc.
5. Check function of all pressure gauges.       
6. Check the condition of DDU, MMI
      
(HMI) & CCTV screen for any damage.
7. Ensure the intactness of USB port, Ether
Net Connector & power supply       
connector.
8. Check the healthiness of touch function
      
and its response time.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
9. Ensure the healthy and working status
of all equipment at train level (entire       
rake).
10. Ensure the healthy and working status
      
of all equipment at unit level.
11. Check for any active failure on events
      
screen.
12. Ensure healthy status of
equipment/functions on train level and
      
unit level of various screens of Main
System.
13. Check the healthiness of all Door Proving
      
Loop on DDU.
14. Check the healthiness of all EBL on DDU.       
15. Check working of Flasher light in both
      
normal and standby mode.
16. Focus setting of Main head light.       
17. Check working of Dim/Full function of
      
Main head light.
18. Working of Marker light Red and white.       
19. Check working of Frequency Generator
      
Unit.
20. Cab Light (Driver/ Asst Driver side) –
      
Inspection
21. Spot Light (Driver/ Asst Driver side) –
      
Inspection
22. Check Compartment/saloon light by
      
operating.
23. Check function of Signal Bell.       
24. Clean the entire internal housing and the
     
equipment with the vacuum cleaner.
25. Visually inspect the entire box, enclosure
walls, covers, and welds for any damage      
or cracks.
26. Visually inspect all internal and external
cable connections of the Driver console      
for damage.
27. Ensure that all glands and connectors
     
are in good condition.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
28. Ensure that all terminal blocks,
HARTING connectors are in good      
condition.
29. Visually inspect the screws securing the
Driver console to the supporting beams.
     
Ensure that all screws are present and
tightened.
30. Check the condition of hinges/brackets
for the hinged assembly, if any defect      
found, rectify the same.
31. Check The Network screen for
communication healthiness of all the      
nodes.
32. Check The Communication screen for
communication healthiness of TCMS      
various interfaces.
33. Check the version number screen for
     
various modules s/w details.
34. Ensure healthy status of all Auxiliary
     
Convertor on DDU.
35. Ensure healthy status of Cab
occupation on DDU in Regular & High      
Priority mode.
36. Check the Door screen for status of
     
each door.
37. Check the RMPU screen for status of
     
each RMPU.
38. Calibrate all pressure gauges.   
19.1 General
39. Replace all cable ties (straps), removed
during the maintenance work by new       
ones of the same type and size.
20. CRW, GCRW, ECC, and EWP – All coaches
20.1 MCBs, Contactor, TBs& relays
1. Open the doors of the unit by unlocking
      
with a square key.
2. Check MCBs, contactors for any loose
mounting and also visually inspect for       
any abnormality.
3. Visually inspect for any abnormality.       
4. Check the connection intactness for
      
main and auxiliary contact.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
5. Check for any loose contact block or
      
burn mark at cable connections.
6. Check the operation of all MCBs.       
7. If there is any faulty component, they
are to be replaced by taking proper       
precautions
8. Ensure all the doors of the unit are
tightly closed and locked during       
cleaning/ water wash of coach.
9. Check intactness of all Ethernet & IP
      
connectors.
10. Check & ensure intactness of earthing
      
shunts at all earthing points.
11. Clean the entire internal housing and the
     
equipment with the vacuum cleaner.
12. Visually inspect the entire box, enclosure
walls, covers, and welds for any damage      
or cracks.
13. Visually inspect all internal and external
     
cable connections for damage.
14. Check all glands and connectors are in
     
good condition.
15. Clean & check all other electronics
equipment & their accessories/      
connectors for their healthiness.
16. Inspect the bolts, used for mounting the
unit to bottom and top mounting
     
frames. Ensure that all bolts are available
and tightened.
17. Check door gasket is in good condition
without holes and cracks. If the gasket is      
damaged, replace it with a new gasket.
18. Check the condition of hinges.      
19. Clean & check availability of labels on all
     
cabinets and their equipment.
20. Close the doors of the unit after
     
compressing the gasket properly.
21. Lock the doors with the square key.      
21. Passenger information System (PIS)-All coaches
1. Ensure all PIS sub systems health status
      
in driver display unit.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
2. Do the display test from MMI unit. Verify
the LED displays (In coach display, Head
      
code displays, Side Destination board
display) functionality.
3. Enable PA communication by pressing
PA button in the MMI keypad and verify       
the audio.
4. Do the audio test listen jingle sound
      
from each speaker.
5. Enable IC communication by pressing IC
button in the MMI keypad and verify the       
audio.
6. Check function of PECU system from
      
minimum two coaches.
7. Clean the speaker units and check for
      
any damages.
8. Clean & check the ambient noise
measurement modules for any       
damages.
21.1 Head Code Unit- DTC only
9. Clean the dust particle settled on the
      
screen glass with a cloth from outside.
10. Check the status of LED’s in the HCD at
      
the outside of the cab.
11. Check the damage of HCD. If found any
damage such as Cracking, distortion,       
deformation replace the HCD.
12. Clean the dust particle if settled on the
    
screen with a cloth.
13. Check the power Connections, Ensure
    
they are tightly connected.
14. Check the fasteners for tightness. If
loosened, tighten the fasteners to the     
torque of 4.4Nm.
21.2 In Coach Display Unit – All Coaches
15. Check the status of LED’s in the ICD.       
16. Open the ICD mounting panel.     
17. Check the power Connections, Ensure
    
they are tightly connected.
18. Clean the dust particle settled on the
    
screen with a cloth.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
19. Check the damage of ICD. If found any
damage such as Cracking, distortion,     
deformation replace the HCD.
20. Check the fasteners for tightness. If
loosened, tighten the fasteners to the     
torque of 4.4Nm.
21. Close the ICD panel after inspection of
    
ICD.
21.3 Side Destination Board Unit – All Coaches
22. Check the status of LED’s in the SDB at
      
the outside of the Cab.
23. Check and clean the glass covering of
      
SDB. Replace, if found broken.
24. Open the Luggage rack cover for SDB on
    
upper Side panel of the cab
25. Check the power Connections, Ensure
    
they are tightly connected
26. Clean the dust particle settled on the
    
Screen with a cloth
27. Check the damage of SDB, If found any
damage such as Cracking, distortion,     
deformation replace the SDB.
28. Check the fasteners for tightness. If
loosened, tighten the fasteners to the     
torque of 4.4Nm.
29. Close the side cover for SDB on upper
    
Side panel of the cab.
21.4 Man Machine Interface-DTC only
30. Visually inspect the damage of Keypad
      
and LCD of MMI
31. Remove MMI from installed location.     
32. Visually inspect the damage on the
    
connector and cable.
33. Remove the foreign substance and dirt.     
34. Install MMI.     
35. Check the fasteners for tightness. If
loosened, tighten the fasteners to the     
torque of 4.4Nm.
36. Clean the relevant components, after
    
careful inspection.
37. If found any damage such as Cracking,
    
distortion, deformation replace the
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
MMI.

21.7 Passenger Emergency Communication Unit – All Coaches

38. Clean & inspect the LED, micro phone
      
switch and name plate of PECU.
39. Check the power connections for
     
tightness.
40. Check PECU for any distortion,
     
deformation etc., replace if required.
41. Check the fitment and tighten the
     
fasteners to the torque of 2.5Nm.
22. CCTV System – All Coaches
1. Blow off the loose dirt and dust from the
      
camera with compressed air carefully.
2. Clean camera dome cover (glass) with
      
microfiber cloth with gentle pressure.
3. Check the connections and fitment for
     
any abnormality.
23. Saloon, Reading & Gangway Lights-All Coaches
1. Clean all saloon, reading& gangway
      
lights.
2. Check saloon, reading& gangway lights
and their diffusers for any crack or       
mechanical damage.
3. Check mounting hardware position and
      
intactness.
4. Check the working of all lights and
      
replace the defective part.
24. Head Lights (LED)-DTC
1. Clean head light thoroughly with soft
      
cloth and powder.
2. Ensure proper working of head light.       
25. LED Marker Lights (Altos)-DTC
1. Clean and check marker light glass for
      
any damages.
2. Check the proper functioning of marker
      
lights.
3. Check the electrical connections and
     
fitment for healthiness.
26. LED Flasher Lights (Altos)-DTC
26.1Control Box

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
1. Clean and check the flasher light control
      
box, toggle switches, fuses etc.
2. Check the availability of spare fuses.       
3. Check the mounting fitment and
     
electrical connection for intactness.
26.2 Flasher Light
4. Check the flasher light and its protection
      
net and hood for any damages.
5. Ensure the tightness of mounting
      
hardware.
6. Check the function of LED flasher light in
      
both normal and standby mode.
7. Remove the protection net and clean
the glass with soft cloth and soft      
cleaner.
27. LP & ALP Seats (FISA) – DTC
1. Check the condition of LP seat, ALP seat
      
and their proper functioning.
2. Remove dust with industrial vacuum
cleaner from LP and ALP seat. Remove       
Stains if any.
3. Check both pilot seats for all
adjustments and perfect working of      
suspension mechanism.
4. Clean the both pilot seats and lubricate
the mechanism with MOLYCOTE DX high     
pressure grease.
28. Wiper (Hepworth Rail)-DTC
1. Check wiper blades for damage, torn
  
and replace if worn or perished.
2. Remove oil, transports or similar
deposits from the windscreen with       
methylated spirits (denatured alcohol).
3. Ensure wash tank is filled with washer
fluid to prevent wipers being used on a       
dry screen.
4. Perform function test of wiper washer
system. Do not carry out function test       
on a dry screen.
5. Inspect tubing for damage or loose
connection on nozzle. Check operation       
of spray nozzle on windscreen
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
6.Check fixing nut tightness of wiper arm
to wiper spindle with torque wrench as     
per OEMs .
7. Check complete system for wear,
    
Replace/ overhaul parts if necessary.
8. Check all torque settings for complete
    
wiper system as per OEM.
9. Carryout visual check for wear in rod
    
end as per OEM.
10. Ensure all electrical connections in good
   
condition.
11. Replace the wiper blades with new one.    
29. Roof Mounted AC Package Unit (SIDWAL) – All Coaches
1. Check the log sheet maintained in each
AC coach and attained the defects       
recorded by escorting staff during run.
2. Clean all dust by vacuum cleaner or by
compressed air from the switch board
      
cabinet and tighten the cable terminals, if
found loose.
3. Replace/ reconnect defective/ bypassed
      
components.
4. Verify that filters are not worn/
   
damaged.
5. Remove fresh and return air filters by
opening the access doors of the unit.
Clean these filters with compressed air
after taking out the filters and place them
gently in their places or replace with pre-
cleaned/ new filter/ filter media and
   
close the doors properly.
Note: After this activity, the service doors
shall be latched properly in case of
return air and fresh air filter.
Similarly, the fresh air grill shall be
positioned and locked properly.
6. Inspect microprocessor’s input/ output
      
connections for loose wires.
7. Verify that the microprocessor controller
      
is firmly mounted.
8. Operate rotary switches (AIR CO/
      
PRESSURE) on switch panel.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
9. If insufficient cooling is noticed, check
the system for a possible refrigerant leak
(soap solution, electronic leak detector).
If a leak is found, it must be attended       
before the system is re-charged. If the
refrigerant charge is removed, replace
the filter drier.
10. Verify toggle latches of mixed air
compartment covers are in good       
condition.
11. Check the condenser fan impellers for
     
visible damages/ cracks.
12. Clean the condenser coil after opening
the cover of condenser area.
     
To clean the condenser coils, flush out
dust and dirt with clean soft water.
13. Run the plant with microprocessor
controller and check for any abnormality      
(sound, vibration, smell)
14. Check the heater overheat protection as *
  
follows: 
• Switch off 100 VDC supply to control
unit
• Install jumper wire to energize heater
output of control unit with+110 DC.
• Trip MCBs of blowers, compressors,
condenser fans
• Switch on 110 V supply to control unit
• Verify LED at OHP input of control unit
lights up
• On Display Unit, select temperature &
humidity screen
• Monitor rising supply air temperature
• Verify OHP input LED goes off at 50
°C... 80 °C.
• Switch off 110 V DC supply and remove
jumper wire.
*Note: Check once a year before the
start of the winter season.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
Warning: This test bypasses the control unit
and its protective devices (except ESTI fuse).
Never leave the unit unattended during this
test.
15. Check the continuity of the ESTI switch,
by disconnecting power supply and
verify that three-phase resistances
*
across the heater MCB output are the 

same.
*Note: Check once a year before the
start of the winter season.
16. Run the plant for half an hour and then
check the three phase operating current
   
with the help of clamp tester (tongue
tester).
The normal operating currents are:
• Package unit in cooling mode – 23 -28
Amps
• Compressor currents - 8 – 12 Amps.
• Condenser fan motor - 1.5 – 2.1    
Amps.
• Blower motor - 1.5-2.5 Amps
• Package unit in heating mode – 13-15
Amps.
17. Check and tighten mountings of blower,
compressor and blower motors and    
ensure that they are in good condition.
18. Verify that screws of supply fan
   
compartment cover is tightened
19. Verify braided earth wires are installed
 
to connect the RMPU to the coach body
20. Check the condition of canvas ducts
(‘bellows’) provided at return & supply 
interfaces. Replace the same, if torn.
21. Visually inspect anti-vibration mounts
(between RMPU frame and coach roof)  
for damages.
22. Replace fresh and return air filters.   
23. Replace canvas ducts (‘bellows’)
  
provided at return & supply interfaces.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
24. Disconnect microcontroller and measure
the insulation resistance of all the
motors &compressors with 1 kV
  
insulation resistance tester (‘MEGGER’).
Attend the motors, if insulation
resistance of a motor falls below 2 MΩ.
25. Check electric cables for any visible
damages (cuts, chafing, makeshift   
joints).Replace as required
26. Inspect RMPU housing enclosure for
  
damages and cracks
27. Take ESTI apart and check condition.  
28. Replace braided earth wires connected
 
RMPU to the coach body.
29. Replace anti-vibration mounts (between
 
RMPU frame and coach roof).
29.1 Pipe work
30. Check all threaded joints of pipe work for
leaks (by soap solution, electronic leak
detector) of-.    
• LP, HP, PC switches
• Service access valves
31. Verify all refrigerant pipe work is
  
properly supported and held in place.
32. Check pipe work any sign of chafing. A
gap must remain between neighboring
  
pipe work items and between pipe work
and sheet metal parts.
33. Check the feeler capillary of the heater
  
overheats protector for damages.
29.2 Refrigerant Compressors
34. Check holding clamps for looseness.    
35. Check compressor mounting screws for
   
looseness.
36. Check accumulator mounting screws for
   
looseness.
37. Verify condenser covers are fastened
and do not touch the top of the    
compressors.
38. Verify compressor cables are terminated
   
with lugs and terminal box is closed.
29.3 Condenser and Supply Fans
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
39. Verify all fasteners are properly
   
tightened.
40. Verify terminal boxes are closed and in
   
good condition.
41. Verify that all motors have two earth
 
leads.
42. Verify that impellers are
 not damaged    
 do not touch any other part
43. Verify cables & conduits are in good
   
condition and securely fastened.
44. Ensure that impellers are properly
   
tightened.
45. Electrical terminal box is properly
tightened & cables are terminated with    
lugs.
46. Replace all earth leads of all motors.  
47. Overhauling of Blower and condenser
fan motors include the following:
 The incoming motors shall be
checked for abnormal noise and
vibration.
 Check the condition of bearing and
replace with specified make.
 The IR value of motor stator shall be
measured between motor terminal
and frame before and after
overhauling. The value of IR shall not
 
be less than 2 MΩ, when measured
with 1000 volt MEGGER.
 Winding resistance of motors shall be
measured between RY, YB & BR
phases. The winding resistance shall
be ±10% of resistance declared by
OEM in cold condition.
 Check closely terminal block and
connecting lead for any physical
damage or any flash mark over it.
Replace the same, if not satisfactory.
29.4 Pressure Switches and Transducer, OHP
48. Verify wires attached to the pressure
   
switches are in good condition.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
49. Verify OHP cover is in good condition.    
50. Remove dust from OHP sensor bulb.
*
*Note: Check once a year before the   

start of the winter season.
29.5 Heaters
51. Check heating elements for looseness.    
52. Check heater terminals for looseness and
   
signs of deterioration.
29.6 RAT / FAT/ SAT Sensors
53. Check for looseness.    
54. Verify wires are properly clamped.    
55. Remove dust from temperature probes.    
29.7 Thermal Expansion Valves
56. Ensure that the bulb is attached to the
   
suction line and thermally insulated.
57. Check TX valve, capillary, bulb and
   
equalizing line for visible damages.
29.8 Cooling Coil (Evaporator)
58. Check fins for visible damages. Apply fin
  
comb to straighten bent fins.
59. Verify that no air bypasses the filter and
  
coil.
60.  Clean coil.
• Use spray bottle to apply a
cleaning fluid approved for use on
aluminum-finned heat exchangers.
  
• Let fluid soak in before washing
the coils with clean soft water.
Verify that wash water leaves through
the condensate drain holes.
61. Verify coil is properly fastened to the
  
frame
29.9 Filter Driers & Sight Glass
62. Verify that the drier is installed with the
refrigerant low in the direction of the    
arrow on the filter label.
63.  Never try to clean / reuse a filter
drier.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
64.  To minimize the moisture ingress in
the system, install filter drier &
compressor before the system is leak
tested, evacuated and charged
29.10 Service Covers
65. Verify sealing profiles of mixed air &
blower compartment covers are in good    
condition.
29.11 Condensate Trays
66. Verify that
 Condensate trays are clean.
 Condensate drains freely.    
 No condensate leaks into the mixed
or supply fan sections.
29.12 Condenser compartments
67. Check fins for visible damages. Apply fin
   
comb to straighten bent fins.
68. Verify coil is properly fastened to the
  
frame.
29.13 Microprocessor Controller
69. Check control logic of microprocessor
  
controller on simulating kit.
30. Driver’s Cab Air Conditioning Unit (SUBROS)-DTC
30.1 Cabin side inspection
1. Check the MCB operation (three pole).       
2. Operate AC and check cooling effect
      
(feeling wise).
3. Check AC Cut-off/Cut-in operation.       
4. Check display in control box.       
5. Check blower operation in all speeds.       
6. Clean and check rotary switch panel
      
switches and indications for healthiness.
7. Remove (unfasten) the return air grill
and clean the filter using water or air   
below and re-assemble.
8. Check the MCB and electrical
connections for tightness and proper     
fitment.
9. Check main supply connector tightness.     

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
10. Check & ensure proper Locking of
Amphenol connector to avoid loose     
contact.
11. Clean fresh air filter and replace if

required.
12. Replace the fresh air filer with new one.   
13. Replace the return air filer with new one.   
30.2 Roof side Inspection
14. Clean wall perforations of RMPU
(condenser intake air side) using water       
spray/wire brush/ compressed air.
15. Check for condensate water drain
     
blockage and clean.
16. Check all pipe joints for any oil traces.    
17. Check and clean Evaporator core for
   
clogging.
18. Check Compressor mounting bolts and
   
tighten them.
19. Check Condenser fan bracket mounting
   
bolts and tighten them.
20. Clean Condenser fins using water
   
spray/compressed air.
21. Clean and check for condensate water
  
drain blockage.
22. Clean and check blower for proper
  
fitment.
23. Check and clean heater element with
  
compressed air.
31. Earth Return JB and Return CT JB (STE) - TC
1. Check that the CT Box is bolted tight to
      
the vehicle.
2. Check the CT Box for any damage.       
3. Clean information and warning labels on
      
doors.
4. Visual inspection of all manufacturing
hardware for the doors for any
      
slackness by seeing changes in the
torque markings.
5. Check electrical connections and ground
connections for corrosion to resolve.       
Ensure that connections are tight.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
6. Check components and cables for
      
damage. If found address them.
7. Do visual inspection for evidence of
excessive temperature and arcing       
(Voltage flash overs) and resolve it.
8. Clean thoroughly the external surface of
the current transformer and its      
accessories.
9. Check the external aspect of the current
     
transformer for any damage.
10. Check the tightness of the screws or the
    
tie rods of the fixing structure
11. Check tightness of the screw of the
    
fixing screws of the two parts.
12. Check the tightness of terminals and
    
connections.
13. Open and clean all CT box doors.
    
Remount properly with all bolts.
14. Check that the door sealing gaskets are
free from cut marks and physical     
damages.
15. Visual inspection of all the mounting
and electrical connection hardware for
the mechanical and electrical for any     
slackness by seeing changes in torque
markings.
32. Primary CT - TC
1. Check covers for any damage.       
2. Clean the external surface of CT.       
3. Check the external aspects of CT for any
      
damage.
4. Check the fitting of CT.       
5. Check for terminal tightness.       
6. Check for tightness of glands.       
7. Check the electrical connection on CT.       
8. Check cracks to mounting brackets.       
9. Check the Earthing Cables.       
33. Potential Transformer (STE)-TC
1. Check visually the external surface for
      
any mechanical damage.
2. Check the surface of the PT for eventual
      
damages (flaws in the silicon, peeling off
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
the silicon) on composite insulator.
Replace without delay if deep flaws in
the silicon to the glass fibre reinforced
tube or damages of the tube (de-
lamination) observed.
3. Check the earth cable for damage and
loose connection. If found any damage,       
replace it with new.
4. Clean insulator surface with cotton cloth
soaked in neutral detergent solution
      
with water and wipe clean with wet
cloth and thereafter with dry cloth.
5. Check the high tension connection by
hand for looseness. If found loose,       
tighten the bolt.
6. Visually check for any insulation damage
      
on HV Cable.
7. Check the low tension connections/
secondary terminals which can be
accessed from inside of the TC by hand     
for looseness. If found loose, tighten the
bolts.
8. Check the insulation resistance between
HV/LV terminals to the Ground using
1000 Volt Insulation Resistance Tester.     
Confirm that the measured value is
minimum 10 MΩ.
9. Check the tightness of mounting bolts, If
required; tighten to a torque of 50 Nm.
Caution: The transformer has to be
    
earthed by the screw connection of the
PT to the TC roof. Ensure correct
potential bonding.
34. ERCU-Ground Contact (FROST) - All Coach
1. Check ground contact for any damage
after flow through a short circuit
current.       
In case of damages found, replace the
ground contact parts.
2. Visually inspect insulating ring for any
cracks. If found, parts have to be       
replaced.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
3. Carry out a visual inspection of the
ground contact. Basically damaged parts
    
of the carbon brush have to be replaced
with new ones.
4. Remove the cover and the sealing from
the brush holder, spring support and the
    
carbon brushes out of the shafts of the
brush holder.
5. Clean the spring support with a lint-free
    
cloth.
6. Measure the height of the carbon
    
brushes with a slide gauge.
7. Replace the carbon brush if the
remaining height to the wearing mark is     
equal or smaller than 3mm.
8. In case of damages of the carbon brush,
    
it has also to be replaced.
9. Replace the wear parts with new ones
as per procedure mentioned in OEM’s   
manual.
10. Replace insulation ring with new one as
per procedure mentioned in OEM’s  
manual.
35. Mini Pantry Items-All Coaches
1. Check all the items and complete unit
      
visually for any damage or any wire cut.
2. Clean all the pantry equipment
      
thoroughly as per OEM’s instructions.
3. Check the working of indication lamps.       
4. Check earthling of each equipment.       
5. Replenish the item if found deficient.       
6. Check and test working of all mini-pantry
      
equipment.
7. Check the insulation resistance of live
   
terminals to body.
35.1 Hot Case
8. Inspect door gasket for any damage,
     
proper fitment.
9. Inspect door window gasket of Hot case
     
for any damage, proper fitment.
10. Clean out cooling fan intake and exhaust
     
vents of Hot Case.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
11. Inspect cavity door vent slides for proper
     
operation
12. Open control area and inspect/tighten all
   
wiring.
13. Inspect all electrical components.    
14. Test elements for electrical short to
   
ground. Replace/repair as needed.
15. Visually inspect the cavity for structural
   
integrity.
16. Inspect door gasket. Replace if needed.    
17. Visually inspect any door handles and
   
hinges. Replace/repair as needed.
18. Remove any loose handle and hinge
screws. Loctite and then properly secure    
the screws.
19. Inspect and test control and control
   
functions.
20. Inspect temperature or thermostat
   
control knobs. Replace if needed.
21. Inspect power cord. Tighten cord
connection inside the appliance control    
area.
22. Test/Replace independent indicator lights
   
(where applicable).
23. Inspect Heating element.    
24. Confirm proper current draw of heating
   
elements.
35.2 Refrigerating Unit
25. Inspect door gasket for any damage
     
and proper fitment.
26. Inspect Electrical Component& Wiring.      
27. Clean drainage Pipe.      
28. Open control area and inspect/tighten all
   
wiring.
29. Inspect all electrical components.    
30. Test elements for electrical short to
   
ground. Replace/repair as needed.
31. Visually inspect the cavity for structural
   
integrity.
32. Inspect door gasket. Replace if needed.    
33. Visually inspect any door handles and
   
hinges. Replace/repair as needed.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
34. Remove any loose handle and hinge
screws. Loctite and then properly secure    
the screws.
35. Inspect temperature or thermostat
   
control knobs. Replace if needed.
36. Inspect power cord. Tighten cord
connection inside the appliance control    
area.
37. Test/Replace independent indicator lights
   
(where applicable).
35.3 Water Boiler
38. Clean the water tank and tap as per
     
OEM guidelines.
39. Inspect and test control and control
     
functions.
40. Confirm proper current draw of heating
     
elements.
41. Inspect Wiring connection, tight if any
     
loose connection.
42. Open control area and inspect/tighten all
   
wiring.
43. Inspect all electrical components, replace
   
/ repair if required.
44. Inspect Wiring connection, tight if any
loose connection.
45. Inspect Heating element.    
46. Inspect and test control and control
   
functions.
47. Confirm proper current draw of heating
   
elements.
36. Power supply socket junction box for external 415 V AC-
All Coaches
1. Check that the Power Supply Socket
Junction Box is bolted tightly to the      
vehicle.
2. Check the Power Supply Socket Junction
      
Box for any damage.
3. Open and clean all Power Supply Socket
Junction Box doors. Remount properly      
with all doors.
4. Clean information and warning labels on
     
doors.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
5. Visual inspection of all the manufacturing
hardware of the doors for any slackness      
by seeing changes in torque marking.
6. Ensure that the door sealing gaskets are
free from cut marks and physical      
damages.
7. Visual inspection of all the mounting
hardware for the mechanical and
     
electrical components for any slackness
by seeing changes in torque markings.
8. Check electrical connections and ground
connections for corrosion to resolve.      
Ensure the connections are tight.
9. Check components and cables for
     
damage. If found address them.
10. Do visual inspection for evidence of
excessive temperature and arcing      
(Voltage flash overs) and resolve it.
37. Speedometer-DTC
1. Visually inspect for any abnormality.       
2. Check the intactness of all connector.       
3. Check for any loose contact block or burn
      
mark at cable connections.
4. Ensure that the indicating light for
      
speedometer is in operation.
5. Clean & check the function of
      
speedometer.
6. Ensure the closing of all plate and door
      
lock
7. Check mechanical speedometer flexible
    
drive and lubricate if necessary.
8. Overhaul speedometer, gear unit and
   
flexible drive.
9. Calibration and testing of
speedometer/speed recorder and techo-    
generator to be done.
38. Frequency Generator Unit-DTC
1. Check the FGU for signs of damage.      
2. Check the mounting of FGU.      
3. Check the multiple pin connectors for
     
proper tightness.
4. Check earthing of FGU.      
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Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
5. Check all screws and nuts for loosening.      
6. Calibration and testing of frequency
  
generator to be done.
39. HT cable-TC
1. Cleanthe housings to prevent excessive
build-up of pollution deposits that can
eventually lead to increased risk of
electrical flash-over.
Water with mild detergent can be used
     
warm (up to 45°C) may be used cleaning.
Recommended Citrus based cleaning
products,: TE EPPA-004 cable cleaning
tissue, 3M NOVEC Contact Cleaner & IPA
(for removal of localized sticky residues).
2. Soft, lint free, cleaning cloth should be
used and any residual cleaning deposits
washed off the EVA using clean water.
     
Abrasive cloths or cleaning materials
must not be used. The EVA must not be
coated in grease or paint for any reason.
3. Visual inspection to check that the earth
     
lead connection is intact.
T-connector
4. boot should be replaced if
found to have tears or cuts to the      
rubber.
Replace
5. EPDM rubber T-connector boots if
exposed to oil contamination from a      
leaking transformer bushing.
40. Water supply system – All Coaches
1. Check functioning of water pumping
arrangement in test mode/pump       
controller.
2. Visual check the mounting arrangement
      
for proper fitment.
3. Check the mono-block pump set for any
      
damage.
4. Replace old Mono-block pump with new
 
one.
41. Lavatory equipment – All Coaches
1. Check and ensure working of lavatory
      
exhaust fans and saving razor socket.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule

Maintenance
Periodicity
Equipment
S.No. / Sub- # Activities

9 Monthly
Quarterly
Monthly
Assy.

Trip

SS1
SS2
SS3
2. Ensure cleaning and availability of sealing
     
of covers/grills.
3. Cleaning the impellers of the exhaust
  
items
4. Replace old saving razor socket.  
General Applicable to all
1. Check condition of attachment points of
all under-slung equipment with car       
body.
2. Check for tightness of all mounting
hardware, terminal hardware of each      
equipment.
3. IR values of power and control cables
  
shall be checked.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE - A
(For details refer: BONATRANS - Maintenance Manual for Wheels, Motors and Trailer Axles.
Ver-1)
SUMMARY OF MAINTENANCE ACTIVITIES FOR WHEELS AND AXLES
Maintenance level
Inspection Reference

3M
2W

2O
2D

1Y
Part To be checked
method

Condition of surface and its visual      6.1.1.1

protection
Condition of wheel tread and visual     6.1.1.2
rim face surfaces
Electrical resistance (≤ 0.01 Ω) measurement 
Back-to-back dimension “a11”, 
measurement 6.1.3.1
“a12”, “a13” @ 120°, a1=
(a11+a12+a13) / 3 (AR)
Diameter difference between After   
wheels on the same axle |d1 - measurement re- 6.1.3.2
Wheel d2| profiling
set Dimensions of wheelset’s measurement    6.1.3.3
wheel treads (wheel treads)
“e“, “h“, “qR“, “L“
Front-to-front dimension a2= calculation  6.1.3.4
(e1+a1+ e2), (SR)
Axial and radial run-out of measurement  6.1.3.5
both wheelset’s wheels
Defectoscopy test of axle for measurement   6.1.6.1
presence of cracks
Defectoscopy test of wheel 
rims for presence of cracks measurement 6.1.6.2

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE - B
AIR PRESSURE BUILT -UP TEST
Pressure
BU1/DT BU2/ BU3/ BU4/
S. N. Activity Built up Time Remarks
C NDTC NDTC DTC
(minutes)
Cut off all compressor
A Cut Out Cut Out Cut Out Cut Out
from DDU
1 Drain MR in whole train-set to zero bar
Cut in BU1
Compressor and all Remains Remains Remains
2 other Compressor Cut In Cut Out Cut Out Cut Out
shall remain cut out
Note Down Pressure Build up time from 0 bar to 10 bar MR in
3
whole train-set
Cut off all compressor
B from DDU Cut Out Cut Out Cut Out Cut Out
1 Drain MR in whole train-set to zero bar
Cut in BU2
Compressor and all Remains Cut In Remains Remains
2
other Compressor Cut Out Cut Out Cut Out
shall remain cut out
Note Down Pressure Build up time from 0 bar to 10 bar MR in
3
whole train-set
Cut off all compressor
C Cut Out Cut Out Cut Out Cut Out
from DDU
1 Drain MR in whole train-set to zero bar
Cut in BU3
Compressor and all Remains Remains Remains
2 Cut In
other Compressor Cut Out Cut Out Cut Out
shall remain cut out
Note Down Pressure Build up time from 0 bar to 10 bar MR in
3
whole train-set
Cut off all compressor
D from DDU Cut Out Cut Out Cut Out Cut Out
1 Drain MR in whole train-set to zero bar
Cut in BU4
Compressor and all Remains Remains Remains Cut In
2
other Compressor Cut Out Cut Out Cut Out
shall remain cut out
Note Down Pressure Build up time from 0 bar to 10 bar MR in
3
whole train-set

Note: If pressure build up time is more, then leakage areas to be found out for their
rectification. After completing test cut-in all compressors.

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ANNEXURE - C
MR PRESSURE DROP TEST

Train-set:

Pressure Reading Time Total Drop per

S.No Remark
Initial (Bar) Final (Bar) Initial Final Hour

Note:

1. Charge MR Pressure to 10 Bar and BP pressure to 5Bar.

2. Cut Out all compressors from DDU.
3. Leave the train in this condition for one hour. Don't do any other activity on train.
4. Note down initial pressure and final pressure reading within one hour.

BP Pressure Drop Test

Train-set:

Pressure Reading Time Total Drop per

S.No Remark
Initial (Bar) Final (Bar) Initial Final Hour

Note:

1. Charge MR Pressure to 10 Bar and BP pressure to 5Bar.

2. Put the Auto Brake Handle in BP Charging Position
3. Cut Out all compressors from DDU.
4. Leave the train in this condition for one hour. Don't do any other activity on train.
5. Note down initial pressure and final pressure reading within one hour.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE - D
BC PRESSURE TEST
Holding EB by Push
Brake Type FSB EB EB by ABH
Brake Button
Press
Auto Brake Emergency
MCH at MCH at
Handle Position MCH at EB Handle at Brake Switch
FSB Coast
EB on Control
Desk
B1
DTC
B2
B1
MC1
B2
BU1
B1
TC
B2
B1
MC2
B2
B1
NDTC
B2
B1
MC1
B2
BU2
B1
TC
B2
B1
MC2
B2
B1
NDTC
B2
B1
MC1
B2
BU3
B1
TC
B2
B1
MC2
B2
B1
MC3
B2
B1
TC
B2
BU4
B1
MC1
B2
B1
DTC
B2

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE - E
For details refer: TSA Traction Gearbox(1-52-372A) - Operating Manual (TSA017120)

SUMMARY OF MAINTENANCE ACTIVITIES FOR TRACTION GEAR BOX

MAINTENANCE (TSA)

* Whatever comes first.

** Maintenance work on the installed traction drive.
*** Maintenance work on the de-installed traction drive.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE - F
For details refer: IRCAMTECH - BOOKLET ON TRACTION MOTOR & GEAR BOX OF TRAIN SET

SUMMARY OF MAINTENANCE ACTIVITIES FOR TRACTION GEAR BOX

MAINTENANCE (IRCAMTECH)

Every Every Every

Every Every
After the 300,000 1,200,000 1,600,000
25,000 3,000,000 km
S. No Maintenance Task first km or km or km or
km or 45 or after
5,000km once a after 4 after 6
Days* 10years*
year* years* years*

1. First oil change to


remove debris**
2. Check for damages oil

glass window**
3. Ensure intactness of
Motor & gear box

mounting bolts with
Bogie**
4. Gear box oil level

check &top-up**
5. Gear box oil change** 
6. Gear box alignment
verification / 
adjustment**
7. Changing elastomer of

reaction rod ***
8. Grease change in the

coupling ***
9. Inspection of Gear &

Pinion for damage***
10. General overhaul ***
includingReplace
Pinion bearings, Main
gear bearings,
suspension bearing 
from reaction rod, All
O-rings (Periodic
overhauling (POH)

* Whatever comes first.

** Maintenance work on the installed traction drive.
*** Maintenance work on the de-installed traction drive.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE-G
FUNCTIONAL TEST UNDER TRIP SCHEDULE

Task 1: Function Test I (with only DC power)

Work Preparation
1. Turn on the Switch for DC power.
2. Examine that all the switches are in normal position in the cab.

S.No. System/ Functional Test Remark

Equipment
1. Pantograph Check the lifting and lowering times of the
pantograph
• Lifting time-should be within 6 to 10 Sec
• Lowering time-should be within 6 to 10 Sec.

Task 2: Function Test II (with AC & DC power)

Work Preparation
1. Safety Inspection and energizing the overhead supply line.
2. Make sure that all switches are in normal position.
3. Raise the Panto and Close the VCB.

S.No. System/ Functional Test Remark

Equipment
2. Brake System • Inspect MR pressure (8 to 10 bar) by the MR
gauge and the TCMS in DT-cars.
• Apply and release the service brake several
times by MCH and check the brake cylinder
pressure (BC pressure) is increased and
decreased according to the position of MCH by
the MR gauge and TCMS.
• Check the application and release of service
brake.
• Check that brake equipment is working
without any abnormal noise.
• Check that pressure gauge in the cab working
properly.
• TCMS brake system on board test during train
testing.
• Difference between TCMS and pressure gauge
reading to be checked and recorded in any
difference found there.
3. Emergency • Inspect MR pressure (8 to 10 bar) by the MR
Brake Test gauge and the TCMS in DT-cars.
• Apply and release the emergency brake
several time by MCH, Drivers brake valve and
Emergency Brake Push Buttons. Verify EB from
BC gauge as well as TCMS.
4. Parking Brake • Release Holding brake from DDU. Apply
parking brake by “Parking Brake ON” push
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S.No. System/ Functional Test Remark
Equipment
button and check parking brake ON by
“Parking Brake ON” lamp and moving each
brake caliper unit.
• Check the parking brake application through
TCMS and visually (static condition) during
testing.
• Release Parking brake by Parking brake release
push button. Verify the status of parking brake
in DDU.
• Enable Holding from DDU.
5. Driver Display • Ensure the intactness of USB port, Ether Net
Unit Connector & power supply connector.
• Check the healthiness of touch function and its
response time.
• Train Overview: Ensure the healthy and
working status of all equipment.
• Unit Level: Ensure the healthy and working
status of all Equipment.
• Events Screen: Check for any active failure on
events screen.
• Ensure healthy status of equipment /functions
on train level and unit level of various screens
of Main System.
• Check the healthiness of all Door Proving Loop
on DDU.
• Check the healthiness of all EBL on DDU.
• Check The Network screen for communication
healthiness of all the nodes.
• Check The Communication screen for
communication healthiness of TCMS various
interfaces.
• Check the version number screen for various
modules s/w details.
• Ensure healthy status of all Auxiliary Convertor
on DDU.
• Ensure healthy status of Cab occupation on
DDU in Regular & High Priority mode.
• Check the Door screen for status of each door.
• Check the RMPU screen for status of each
RMPU.
6. Cab light • Check Cab driver/guard light by operating
respective Switch
7. Cab Spot light • Check Cab driver/guard Spot light by operating
respective Switch
8. Cab • Check Cab Emergency light by operating Cab
Emergency Emergency Light Switch
Light
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S.No. System/ Functional Test Remark
Equipment
9. Cab Fans • Check Cab Fans by operating Cab Fan Switch
10. Head light • Check head light by operating Head Light
Switch.
Marker light • Check marker lights by operating marker light
switch.
Flasher light • Check Flasher lights by operating Flasher Light
Switch.
11. Horn Check the operation in all the 3 Functionalities.
 Electro Pneumatic Horn
 Driver Foot Operated Horn
 Guard Horn
12. CCTV • Check and ensure all cameras live views are
showing in CCTV display unit.
13. Cab AC • Turn on the Cab AC system and check the
cooling states.
• Correct working of 'Fan speed selector switch'
in all positions.
14. Wiper • Check the wiper function in low/ high & wash
mode from wiper switch
15. Saloon Light • Check all saloon lights (50%, 100%) Emergency
lights, Gangway lights are glowing by giving
command from driving cab.
16. Lights • Check the Lights functionality by operating DLL
Control Switch& IDLL Control Switch in Auto,
OFF & ON modes and observe the symbols on
DDU.
17. RMPU • Turn on the RMPU system and check the
cooling states.
• Check the RMPU unit from inside & outside of
the train.
• Examine that refrigerant is full with green
color. If the sight glass is not full and bubbles
appear, the refrigeration system may have a
less refrigerant.
• Check for proper function of inverter by
running the RMPU in emergency mode
through TCMS and air duct in the saloon.
• Check for proper function RMPU through
TCMS.
18. Passenger • Open/close the Passenger Saloon doors in
Saloon Door standby mode by pressing two push buttons
from both Cabs.
• Check the results while opening and closing
door, check that doors open and close without
obstruction on TCMS Display.
• After opening of door, check all outside and
inside lamp should glow.
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S.No. System/ Functional Test Remark
Equipment
• After closing of door check the DPL Left, DPL
Right in both cab and LDSLR, LDSRR of all
coach status on TCMS. It should be energizes.
• After closing all doors, check ADCR status on
TCMS, it should be in energize.
19. PA & PIS Ensure all the units working condition by
Switching ON Power supply:
• MMI should boot up and display the default
screen as “Cab Not Active” up-to Cab
Occupied Key enable.
• ICDs, HCDs & SDBDs should display default
message “Indian Railways”.
• Coach Control should “announce Jingle”
through Speakers at Power ON.
• Indication LED of all the PECU units should
blink continuously. After Completion of all
above units power ON to be verified all units
health status for Selecting the “PIS Health”
from TCMS DDU screen.
Ensure all the units working condition by Train
Route Selection:
• Select the Train Route from MMI unit.
• Check End to End when route is selected, MMI
unit on other side shall become Slave.
• Check the HCD display for displaying the
Destination of the selected route in both DTC's
HCD Displays
• Check the SDBD display for displaying the
Source & Destination with Via station name of
the selected route in All coaches SDBD
Displays.
• Check the selected train route is displayed
properly in ICDs of each coach.
• Check the selected train route is announced
properly in Coach Control through speakers of
each coach.
20. Main Air Ensure that the Compressor and Air dryer are
Compressor working during the pressure is building.
21. Leakage Test Ensure that MR pressure is 7 bar
1. Check that pressure in MR (through gauge in
Motor car) does not fall below 0.1bar in 5min
value.
2. Check the pressure on TCMS. If the pressure
are different, it should be recorded.
22. Log book • Check the Crew remarks.
23. Data • Download Data Through MAE675U Application
download Software.
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S.No. System/ Functional Test Remark
Equipment
24. Reading Note • Note Down the Energy Consumption.
Down
• Note Down the Regeneration Energy.
• Note Down the Kilometer Reading.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
ANNEXURE-H
FUNCTIONAL TEST UNDER MONTHLY SCHEDULE

Task 1: Function Test I (with only DC power)

Work Preparation
1. Turn ON the Switch for DC power.
2. Examine that all the switches are in normal position in the cab.

S.No. System/ Equipment Functional Test Remark

1. DC/LT Test • Check the TCMS DDU for any
abnormality indications.
• Check the TCMS Network Screen for any
abnormalities.
• Check the High Voltage Screen for any
abnormalities.
• Check the ACU Screen for any
abnormalities or any Earth Faults.
• Cab Occupation in Key ON Mode-Cab
Selector Switch in Normal Mode.
• Cab Occupation in RDM Mode-Cab
Selector Switch in Normal Mode.
• Cab Occupation in Key ON Mode-Cab
Selector Switch in High Priority Mode.
• Cab Occupation in RDM Mode-Cab
Selector Switch in High Priority Mode.
• Check the Signal Bell Functionality from
both driver and guard panels.
• Check the Emergency Bell Functionality
by pressing SB2 button from both driver
and guard panel.
• Check Emergency bell by pressing
emergency stop button in passenger
saloon area and observe the indication
on TCMS DDU and also on SB2 Switch.
• Check the Train BN Battery voltage.
2. Auxiliary Air • Check the Auxiliary Air Compressor is
Compressor working without any abnormal sound.
• Check the Auxiliary Air Compressor is
working based on the pressure
switch(5.3Kg-6.3Kg).
3. Pantograph • Check the lifting and lowering times of
the pantograph
⁻ Lifting time-should be within 6 to 10
Sec
⁻ Lowering time-should be within6 to
10 Sec

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
Task 2: Function Test II (with AC &DC power)
Work Preparation

1. Safety Inspection and Energizing the overhead supply line.

2. Make sure that all switches are in normal position.
3. Raise the Panto and Switch On the VCB.

S.No. System/ Equipment Functional Test Remark

4.
Cab light • Check Cab driver/guard light by
operating respective Switch.
5.
Cab Spot light • Check Cab driver/guard Spot light by
operating respective Switch.
6.
Cab Emergency • Check Cab Emergency light by operating
Light Cab Emergency Light Switch.
7.
Cab Fans • Check Cab Fans by operating Cab Fan
Switch.
8.
Head light • Check head light by operating Head
Light Switch.
9.
Marker light • Check marker lights by operating marker
light switch.
10.
Flasher light • Check Flasher lights by operating Flasher
Light Switch.
11.
Horn • Check the operation in all the 3
Functionalities.
⁻ Electro Pneumatic Horn
⁻ Driver Foot Operated Horn
⁻ Guard Horn
12.
CCTV • Check and ensure all cameras live views
are showing in CCTV display unit.
13.
Cab AC • Turn on the Cab AC system and check
the cooling states.
• Correct working of 'Fan speed selector
switch' in all positions.
14.
Wiper • Check the wiper function in low / high &
wash mode from wiper switch
15.
Saloon Light • Check all saloon lights (50%, 100%)
Emergency lights, Gangway lights are
glowing by giving command from driving
cab.
• Check the lights by operating DLL/IDLL
control Switch in Auto, ON and OFF
modes.
16.
RMPU • Turn on the RMPU system and check the
cooling states.
• Check the RMPU unit from inside &
outside of the train.
• Examine that refrigerant is full with
green color. If the sight glass is not full
and bubbles appear, the refrigeration
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S.No. System/ Equipment Functional Test Remark
system may have a less refrigerant.
• Check for proper function of inverter by
running the RMPU in emergency mode
through TCMS and air duct in the saloon.
• Check for proper function RMPU
through TCMS.
17.
Passenger Saloon • Open/close the Passenger Saloon doors
Door in standby mode by pressing two push
buttons from both Cabs.
• Check the results while opening and
closing door, Check that doors open and
close without obstruction on TCMS
Display.
• After opening of door check all outside
and inside lamp should glow.
• After closing of door check the DPL Left,
DPL Right in both cab and LDSLR, LDSRR
of all coach status on TCMS. It should be
energizes.
• After closing all the doors and check the
status of ADCR relay, it should energize.
18.
PA & PIS Ensure all the units working condition by
Switching ON Power supply:
• MMI should boot up and display the
default screen as “Cab Not Active” up-to
Cab Occupied Key enable.
• ICDs, HCDs & SDBDs should display
default message “Indian Railways”.
• Coach Control should “announce Jingle”
through Speakers at Power ON.
• Indication LED of all the PECU units
should blink continuously. After
Completion of all above units power ON
to be verified all units health status for
Selecting the “PIS Health” from TCMS
DDU screen.
Ensure all the units working condition by
Train Route Selection:
• Select the Train Route from MMI unit.
• Check End to End when route is
selected, MMI unit on other side shall
become Slave
• Check the HCD display for displaying the
Destination of the selected route in both
DTC's HCD Displays
• Check the SDBD display for displaying
the Source & Destination with Via
station name of the selected route in All
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S.No. System/ Equipment Functional Test Remark
coaches SDBD Displays
• Check the selected train route is
displayed properly in ICDs of each coach
• Check the selected train route is
announced properly in Coach Control
through speakers of each coach
Ensure HCD units working condition by
Manual Route Selection(In case of
Emergency condition)
• Select the train route in TCMS DDU
• Check the HCD display for displaying the
Destination of the selected route
Display Test: The purpose of this test is to
ensure all the display units status.
• Select the “Display Test” from
'Diagnostics' option in MMI then all the
ICD, SDBD and HCD displays should
displays the Test Pattern screen
Speaker Test: The purpose of this test is to
ensure all the display units status.
• Select the “Loud Speaker Test” from
'Diagnostics' option in MMI then all
Coach Control units should “announce
Jingle” through Speakers in all coaches
Inter-Com(IC) Test:
• Press 'IC' Button on the MMI – Non
Active Cab.
• MMI should display the “Inter
Communication Enabled” message on
both sides of MMI display.
• IC Indication LEDs shall be blink on both
MMI’s & Jingle Sound shall be played
from both Cab Loudspeakers
• Press IC button on the MMI Keypad of
Active cab then both MMI IC Indication
LEDs should be ON continuously.
• Speak through Microphone then voice
should be heard from other cab speaker
and Vise-Versa.
• After that again Press 'IC' Button on the
MMI – Non Active Cab
• MMI should display the “IC” Disabled”
message on both sides of MMI display.
• IC indication LED should OFF at both
sides of MMI.
Repeat the above case from other side
MMI.
Passenger Announcement (PA) Test:
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• Press 'PA' Button on the MMI – Non
Active Cab
• MMI should display the “PA Enabled”
message on both sides of MMI display.
• PA indication LED should ON at both
sides of MMI.
• Speak through Microphone and Listen
the voice from all the speakers in coach
area.
• After that again Press 'PA' Button on the
MMI –Non Active Cab
• MMI should display the “PA Disabled”
message on both sides of MMI display
and PA indication LED should OFF mode.
• PA indication LED should OFF mode at
both sides of MMI.
• Speak through Microphone then
observe, No voice shall be heard from
any of the speaker.
Repeat the above case from other side
MMI.
Passenger Emergency
Communication Unit (PECU) Test:
• Power On Health check PECU indication
LED should blink in Red color
continuously.
• Then Press the PECU Push Button of any
of the PECU from any of the
coach.(Example: PECU1 from CC1)
• PECU indication LED should stop blinking
and glow in Red color constantly.
• MMI should get and display the PECU
information.
• PAS buzzer in driver cab should be ON
continuously until PAS
acknowledgement button is pressed.
• Select “CC1” to enable the PECU
communication establishment. MMI
should display the PECU request menu
to Accept/Reject.
• Press “Accept” button to enable the
PECU.
• MMI should display the PECU
communication establishment screen.
• PECU Indication LED should glow
constantly in Green color and Push
button LED should continuously ON.
• Speak through Cab Microphone Voice
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S.No. System/ Equipment Functional Test Remark
should be heard from PECU speaker.
• Speak through PECU microphone Voice
should be heard from Cab loud speaker.
• Press “Call End” button on MMI then
changed to normal operation mode
automatically and PECU call should be
disconnected, in PECU indication LED
shall start blinking and Push button LED
should be in OFF mode.
Note: During One PECU call other call will be
maintained in queue
Same procedure can be applicable for other
PECU units testing.
19.
Main Air  Ensure that the Compressor and Air dyer
Compressor are working during the pressure is
building.
20.
Brake System  Inspect MR pressure (8 to 10 bar) by the
MR gauge and the TCMS in DT-cars.
 Apply and release the service brake
several times by MCH and check the
brake cylinder pressure (BC pressure) is
increased and decreased according to
the position of MCH by the MR gauge
and TCMS.
 Check the application and release of
service brake.
 Check that brake equipment is working
without any abnormal noise.
 Check that pressure gauge in the cab
working properly.
 TCMS brake system on board test during
train testing.
 Difference between TCMS and pressure
gauge reading to be checked and
recorded in any difference found there.
21.
Parking Brake  Release Holding brake from DDU. Apply
parking brake by “Parking Brake ON”
push button and check parking brake ON
by
 “Parking Brake ON” lamp and moving
each brake caliper unit.
 Check the parking brake application
through TCMS and visually (static
condition) during testing.
 Release Parking brake by Parking brake
release push button. Verify the status of
parking brake in DDU.
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S.No. System/ Equipment Functional Test Remark
 Enable Holding from DDU
22.
Emergency Brake  Inspect MR pressure (8 to 10 bar) by the
Test MR gauge and the TCMS in DT-cars.
 Apply and release the emergency brake
several time by MCH, Drivers brake valve
and Emergency Brake Push Buttons.
Verify EB from BC gauge as well as
TCMS.
23.
Leakage Test Ensure that MR pressure is 10bar
1. Check that pressure in MR(through
gauge in M car) does not fall below
0.1bar in 5minvalue.
2. Check the pressure on TCMS. If the
pressure are different, it should be
recorded
24.
Log book  Check the Crew remarks
25.
Data download  Download Data ThroughMAE675U
Application Software
26.
Reading Note Down  Note Down the Energy Consumption
 Note Down the Regeneration Energy
 Note Down the Kilometer Reading

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ANNEXURE-I
FUNCTIONAL TEST UNDER QUARTERLY SCHEDULE

Task 1 : Function Test I (with only DC power)

Work Preparation
1. Turn on the Switch for DC power
2. Examine that all the switches are in normal position in the cab.

S.No. System/ Equipment Functional Test Remark

1. DC/LT Test • Check the TCMS DDU for any
abnormality indications.
• Check the TCMS Network Screen for any
abnormalities
• Check the High Voltage Screen for any
abnormalities
• Check the ACU Screen for any
abnormalities or any Earth Faults
• Cab Occupation in Key ON Mode-Cab
Selector Switch in Normal Mode.
• Cab Occupation in RDM Mode-Cab
Selector Switch in Normal Mode.
• Cab Occupation in Key ON Mode-Cab
Selector Switch in High Priority Mode.
• Cab Occupation in RDM Mode-Cab
Selector Switch in High Priority Mode.
• Check the Signal Bell Functionality from
both driver and guard panels.
• Check the Emergency Bell Functionality
by pressing SB2 button from both driver
and guard panel.
• Check Emergency bell by pressing
Emergency stop button in passenger
saloon area and observe the indication
on TCMS DDU and also on SB2 Switch.
• Check the Train BN Battery voltage
2. Auxiliary Air • Check the Auxiliary Air Compressor is
Compressor working without any abnormal sound
• Check the Auxiliary Air Compressor is
working based on the pressure
switch(5.3Kg-6.3Kg)
3. Pantograph • Check the lifting and lowering times of
the pantograph
⁻ Lifting time-should be within 6 to 10
Sec
⁻ Lowering time-should be within6 to
10 Sec

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Task 2 : Function Test II (with AC &DC power)
Work Preparation
1. Safety Inspection and Energizing the overhead supply line
2. Make sure that all switches are in normal position
3. Raise the Panto and Switch On the VCB

S.No. System/ Equipment Functional Test Remark

1. Cab light • Check Cab driver/guard light by
operating respective Switch
2. Cab Spot light • Check Cab driver/guard Spot light by
operating respective Switch
3. Cab Emergency Light • Check Cab Emergency light by
operating Cab Emergency Light Switch
4. Cab Fans • Check Cab Fans by operating Cab Fan
Switch
5. Head light • Check head light by operating Head
Light Switch.
6. Marker light • Check marker lights by operating
marker light switch.
7. Flasher light • Check Flasher lights by operating
Flasher Light Switch.
8. Horn • Check the operation in all the 3
Functionalities.
⁻ Electro Pneumatic Horn
⁻ Driver Foot Operated Horn
⁻ Guard Horn
9. CCTV • Check and ensure all cameras live
views are showing in CCTV display unit.
10. Cab AC • Turn on the Cab AC system and check
the cooling states.
• Correct working of 'Fan speed selector
switch' in all positions.
11. Wiper • Check the wiper function in low / high
& wash mode from wiper switch
12. Saloon Light • Check all saloon lights (50%, 100%)
Emergency lights, Gangway lights are
glowing by giving command from
driving cab.
• Check the lights by operating DLL/IDLL
control Switch in Auto, ON and OFF
modes
13. RMPU • Turn on the RMPU system and check
the cooling states.
• Check the RMPU unit from inside &
outside of the train
• Examine that refrigerant is full with
green color. If the sight glass is not full
and bubbles appear, the refrigeration
system may have a less refrigerant.
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S.No. System/ Equipment Functional Test Remark
• Check for proper function of inverter
by running the RMPU in emergency
mode through TCMS and air duct in the
saloon.
• Check for proper function RMPU
through TCMS.
14. Passenger Saloon • Open/close the Passenger Saloon
Door doors in standby mode by pressing two
push buttons from both Cabs.
• Check the results while opening and
closing door, Check that doors open
and close without obstruction on TCMS
Display.
• After opening of door check all outside
and inside lamp should glow.
• After closing of door check the DPL
Left, DPL Right in both cab and LDSLR,
LDSRR of all coaches’ status on TCMS.
It should be energizes.
15. PA & PIS Ensure all the units working condition by
Switching ON Power supply:
• MMI should boot up and display the
default screen as “Cab Not Active” up-
to Cab Occupied Key enable.
• ICDs, HCDs & SDBDs should display
default message “Indian Railways”
• Coach Control should “announce
Jingle” through Speakers at Power ON
• Indication LED of all the PECU units
should blink continuously. After
Completion of all above units power
ON to be verified all units health status
for Selecting the “PIS Health” from
TCMS DDU screen.
Ensure all the units working condition by
Train Route Selection:
• Select the Train Route from MMI unit
• Check End to End when route is
selected, MMI unit on other side shall
become Slave
• Check the HCD display for displaying
the Destination of the selected route in
both DTC's HCD Displays
• Check the SDBD display for displaying
the Source & Destination with Via
station name of the selected route in
All coaches SDBD Displays
• Check the selected train route is
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S.No. System/ Equipment Functional Test Remark
displayed properly in ICDs of each
coach
• Check the selected train route is
announced properly in Coach control
through speakers of each coach
Ensure HCD units working condition by
Manual Route Selection(In case of
Emergency condition)
• Select the train route in TCMS DDU
• Check the HCD display for displaying
the Destination of the selected route
Display Test: The purpose of this test is to
ensure all the display units status.
• Select the “Display Test” from
'Diagnostics' option in MMI then all the
ICD, SDBD and HCD displays should
displays the Test Pattern screen
Speaker Test: The purpose of this test is to
ensure all the display units status.
• Select the “Loud Speaker Test” from
'Diagnostics' option in MMI then all
Coach Control units should “announce
Jingle” through Speakers in all coaches
Inter-Com (IC) Test:
• Press 'IC' Button on the MMI – Non
Active Cab.
• MMI should display the “Inter
Communication Enabled” message on
both sides of MMI display.
• IC Indication LEDs shall be blink on
both MMI’s & Jingle Sound shall be
played from both Cab Loudspeakers
• Press IC button on the MMI Keypad of
Active cab then both MMI IC Indication
LEDs should be ON continuously.
• Speak through Microphone then voice
should be heard from other cab
speaker and vise-versa.
• After that again Press 'IC' Button on the
MMI – Non Active Cab
• MMI should display the “IC” Disabled”
message on both sides of MMI display.
• IC indication LED should OFF at both
sides of MMI.
Repeat the above case from other side
MMI.
Passenger Announcement (PA) Test:
• Press 'PA' Button on the MMI – Non
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S.No. System/ Equipment Functional Test Remark
Active Cab
• MMI should display the “PA Enabled”
message on both sides of MMI display.
• PA indication LED should ON at both
sides of MMI.
• Speak through Microphone and Listen
the voice from all the speakers in coach
area.
• After that again Press 'PA' Button on
the MMI –Non Active Cab
• MMI should display the “PA Disabled”
message on both sides of MMI display
and PA indication LED should OFF
mode.
• PA indication LED should OFF mode at
both sides of MMI.
• Speak through Microphone then
observe No voice shall be heard from
any of the speaker.
Repeat the above case from other side
MMI.
Passenger Emergency
Communication Unit (PECU) Test:
• Power on Health check PECU indication
LED should blink in Red color
continuously.
• Then Press the PECU Push Button of
any of the PECU from any of the
coach.(Example: PECU1 from CC1)
• PECU indication LED should stop
blinking and glow in Red color
constantly.
• MMI should get and display the PECU
information.
• PAS buzzer in driver cab should be ON
continuously until PAS
acknowledgement button is pressed.
• Select “CC1” to enable the PECU
communication establishment. MMI
should display the PECU request menu
to Accept/Reject.
• Press “Accept” button to enable the
PECU.
• MMI should display the PECU
communication establishment screen.
• PECU Indication LED should glow
constantly in Green color and Push
button LED should continuously ON.
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S.No. System/ Equipment Functional Test Remark
• Speak through Cab Microphone Voice
should be heard from PECU speaker.
• Speak through PECU microphone Voice
should be heard from Cab loud
speaker.
• Press “Call End” button on MMI then
changed to normal operation mode
automatically and PECU call should be
disconnected, in PECU indication LED
shall start blinking and Push button LED
should be in OFF mode.
Note: During One PECU call other call will
be maintained in queue.
Same procedure can be applicable for
other PECU units testing.
16. Main Air • Ensure that the Compressor and Air
Compressor dyer are working during the pressure is
building.
17. Brake System • Inspect MR pressure (8 to 10 bar) by
the MR gauge and the TCMS in DT-cars.
• Apply and release the service brake
several times by MCH and check the
brake cylinder pressure (BC pressure) is
increased and decreased according to
the position of MCH by the MR gauge
and TCMS.
• Check the application and release of
service brake.
• Check that brake equipment is working
without any abnormal noise.
• Check that pressure gauge in the cab
working properly.
• TCMS brake system on board test
during train testing.
• Difference between TCMS and
pressure gauge reading to be checked
and recorded in any difference found
there.
18. Parking Brake • Release Holding brake from DDU.
Apply parking brake by “Parking Brake
ON” push button and check parking
brake ON by
• “Parking Brake ON” lamp and moving
each brake caliper unit.
• Check the parking brake application
through TCMS and visually (static
condition) during testing.
• Release Parking brake by Parking brake
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S.No. System/ Equipment Functional Test Remark
release push button. Verify the status
of parking brake in DDU.
• Enable Holding from DDU
19. Emergency Brake • Inspect MR pressure (8 to 10 bar) by
Test the MR gauge and the TCMS in DT-cars.
• Apply and release the emergency brake
several time by MCH, Drivers brake
valve and Emergency Brake Push
Buttons. Verify EB from BC gauge as
well as TCMS.
20. Leakage Test • Ensure that MR pressure is 10 bar
1. Check that pressure in MR(through
gauge in M car) does not fall below
0.1bar in 5minvalue.
2. Check the pressure on TCMS. If the
pressure are different, it should be
recorded
21. Log book • Check the Crew remarks
22. Data download • Download Data Through MAE675U
Application Software
23. Reading Note Down • Note Down the Energy Consumption
• Note Down the Regeneration Energy
• Note Down the Kilometer Reading.

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ANNEXURE-J
FUNCTIONAL TEST UNDER NINE MONTHLY SCHEDULE

Task 1 : Function Test I (with only DC power)

Work Preparation

1. Turn on the Switch for DC power.

2. Examine that all the switches are in normal position in the cab.

S.No. System/ Equipment Functional Test Remark

1. DC/LT Test • Ensure the intactness of USB port,
Ether Net Connector &power supply
connector.
• Check the healthiness of touch
function and its response time.
• Train Overview: Ensure the healthy and
working status of all equipment.
• Unit Level: Ensure the healthy and
working status of all Equipment.
• Events Screen: Check for any active
failure on events screen.
• Ensure healthy status of equipment
/functions on train level and unit level
of various screens of Main System.
• Check the healthiness of all Door
Proving Loop on DDU.
• Check the healthiness of all EBL on
DDU.
• Check The Network screen for
communication healthiness of all the
nodes.
• Check The Communication screen for
communication healthiness of TCMS
various interfaces.
• Check the version number screen for
various modules s/w details
• Ensure healthy status of all Auxiliary
Convertor on DDU.
• Ensure healthy status of Cab
occupation on DDU in Regular & High
Priority mode.
• Check the Door screen for status of
each door.
• Check the RMPU screen for status of
each RMPU.
2. Auxiliary Air • Check the Auxiliary Air Compressor is
Compressor working without any abnormal sound
• Check the Auxiliary Air Compressor is
working based on the pressure
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• switch(5.3Kg-6.3Kg)
3. Pantograph • Check the lifting and lowering times of
the pantograph
⁻ Lifting time should be within 6 to
10 Sec
⁻ Lowering time should be within 6
to 10 Sec
• Check pantograph raise/ lower
smoothly.

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Task 2: Function Test II (with AC & DC power)
Work Preparation

1. Safety Inspection and Energizing the overhead supply line

2. Make sure that all S/W are in normal position
3. Raise the Panto and Switch On the VCB

S.No. System/ Equipment Functional Test Remark

1. Cab light • Check Cab driver/guard light by
operating respective Switch
2. Cab Spot light • Check Cab driver/guard Spot light by
operating respective Switch
3. Cab Emergency Light • Check Cab Emergency light by
operating Cab Emergency Light Switch
4. Cab Fans • Check Cab Fans by operating Cab Fan
Switch
5. Head light • Check head light by operating Head
Light Switch.
• Check Aux head lights by operating
Head Light Switch.
6. Marker light • Check tail/ marker lights by operating
tail/ marker light switch.
7. Flasher light • Check Flasher lights by operating
Flasher Light Switch.
8. Horn • Check the operation in all the 3
Functionalities.
⁻ Electro Pneumatic Horn
⁻ Driver Foot Operated Horn
⁻ Guard Horn
9. CCTV Check and ensure all cameras live views
are showing in CCTV display unit.
10. Cab AC • Turn on the Cab HVAC system and
check the cooling states.
• Correct working of 'Selector switch' in
all positions.
• Check the operation of CAB HVAC in
'Back Up' Mode.
11. Wiper • Check the wiper function in low / high
& wash mode from wiper switch
12. Saloon Light • Check all saloon lights (50%, 100%)
Emergency lights, Gangway lights are
glowing by giving command from
driving cab.
• Check the lights by operating DLL/IDLL
control Switch in Auto, ON and OFF
modes
13. Saloon RMPU • Turn on the RMPU system and check
the functioning.
• Check the RMPU unit from inside
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&outside of the train
• Examine that refrigerant is full with
green color. If the sight glass is not full
and bubbles appear, the refrigeration
system may have a less refrigerant.
• Check for proper function of inverter
through TCMS by ‘ON BOARD’ test.
14. Saloon RMPU • Check for proper function of inverter
functional check by running the RMPU in emergency
mode through TCMS and feel air by
hand in duct in the saloon.
• Function check using Laptop or other
device(DDU).
• Check for proper function through
TCMS by on board test during testing.
15. Passenger Saloon • Open/close the Passenger Saloon
Door doors in standby mode by pressing two
push buttons from both Cabs.
• Check the results while opening and
closing door, Check that doors open
and close without obstruction on TCMS
Display.
• After opening of door check all outside
and inside lamp should glow.
• After closing of door check the DPL
Left, DPL Right in both cab and LDSLR,
LDSRR of all coaches status on TCMS. It
should be energizes.
• After closing all the doors and check
the status of ADCR relay, it should
energize.
16. PA & PIS Ensure all the units working condition by
Switching ON Power supply:
• MMI should boot up and display the
default screen as “Cab Not Active” up-
to Cab Occupied Key enable.
• ICDs, HCDs & SDBDs should display
default message ”Indian Railways”
• CC should “announce Jingle” through
Speakers at Power ON
• Indication LED of all the PECU units
should blink continuously. After
Completion of all above units power
ON to be verified all units health status
for Selecting the “PIS Health” from
TCMS DDU screen.
Ensure all the units working condition by
Train Route Selection:
• Select the Train Route from MMI unit
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• Check End to End when route is
selected, MMI unit on other side shall
become Slave
• Check the HCD display for displaying
the Destination of the selected route in
both DTC's HCD Displays
• Check the SDBD display for displaying
the Source & Destination with Via
station name of the selected route in
All coaches SDBD Displays
• Check the selected train route is
displayed properly in ICDs of each
coach
• Check the selected train route is
announced properly in CC through
speakers of each coach
Ensure HCD units working condition by
Manual Route Selection (In case of
Emergency condition)
• Select the train route in TCMS DDU
• Check the HCD display for displaying
the Destination of the selected route
Display Test: The purpose of this test is to
ensure all the display units status.
• Select the “Display Test” from
'Diagnostics' option in MMI then all the
ICD, SDBD and HCD displays should
displays the Test Pattern screen
Speaker Test: The purpose of this test is to
ensure all the display units status.
• Select the “Loud Speaker Test” from
'Diagnostics' option in MMI then all CC
units should “announce Jingle” through
Speakers in all coaches
Inter-Com (IC) Test:
• Press 'IC' Button on the MMI – Non
Active Cab.
• MMI should display the “Inter
Communication Enabled” message on
both sides of MMI display.
• IC Indication LEDs shall be blink on
both MMI’s & Jingle Sound shall be
played from both Cab Loudspeakers
• Press IC button on the MMI Keypad of
Active cab then both MMI IC Indication
LEDs should be ON continuously.
• Speak through Microphone then voice
should be heard from other cab
speaker and vise-versa.
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• After that again Press 'IC' Button on the
MMI – Non Active Cab
• MMI should display the “IC” Disabled”
message on both sides of MMI display.
• IC indication LED should OFF at both
sides of MMI.
Repeat the above case from other side
MMI.
Passenger Announcement (PA) Test:
• Press 'PA' Button on the MMI – Non
Active Cab
• MMI should display the “PA Enabled”
message on both sides of MMI display.
• PA indication LED should ON at both
sides of MMI.
• Speak through Microphone and Listen
the voice from all the speakers in coach
area.
• After that again Press 'PA' Button on
the MMI –Non Active Cab
• MMI should display the “PA Disabled”
message on both sides of MMI display
and PA indication LED should OFF
mode.
• PA indication LED should OFF mode at
both sides of MMI.
• Speak through Microphone then
observe No voice shall be heard from
any of the speaker.
Repeat the above case from other side
MMI.
Passenger Emergency
Communication Unit (PECU) Test:
• Power on Health check PECU indication
LED should blink in Red color
continuously.
• Then Press the PECU Push Button of
any of the PECU from any of the
coach.(Example: PECU1 from CC1)
• PECU indication LED should stop
blinking and glow in Red color
constantly.
• MMI should get and display the PECU
information.
• PAS buzzer in driver cab should be ON
continuously until PAS
acknowledgement button is pressed.

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• Select “CC1” to enable the PECU
communication establishment. MMI
should display the PECU request menu
to Accept/Reject.
• Press “Accept” button to enable the
PECU.
• MMI should display the PECU
communication establishment screen.
• PECU Indication LED should glow
constantly in Green color and Push
button LED should continuously ON.
• Speak through Cab Microphone Voice
should be heard from PECU speaker.
• Speak through PECU microphone Voice
should be heard from Cab loud
speaker.
• Press “Call End” button on MMI then
changed to normal operation mode
automatically and PECU call should be
disconnected, in PECU indication LED
shall start blinking and Push button LED
should be in OFF mode.
Note: During One PECU call other call will
be maintained in queue.
Same procedure can be applicable for
other PECU units testing.
17. Main Air • Check the all compressor for abnormal
Compressor sound in working condition during
testing
18. Brake System • Inspect MR pressure (8 to 10 bar) by
the MR gauge and the TCMS in DT-cars.
• Apply and release the service brake
several times by MCH and check the
brake cylinder pressure (BC pressure) is
increased and decreased according to
the position of MCH by the MR gauge
and TCMS.
• Check the application and release of
service brake.
• Check that brake equipment is working
without any abnormal noise.
• Check that pressure gauge in the cab
working properly.
• TCMS brake system on board test
during train testing.
• Difference between TCMS and
pressure gauge reading to be checked
and recorded in any difference found
there.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 3. Schedule
19. Emergency Brake • Inspect MR pressure (8 to 10 bar) by
Test the MR gauge and the TCMS in DT-cars.
• Apply and release the emergency brake
several time by MCH, Drivers brake
valve and Emergency Brake Push
Buttons. Verify EB from BC gauge as
well as TCMS.
19. Parking Brake • Release Holding brake from DDU.
Apply parking brake by “Parking Brake
ON” push button and check parking
brake ON by “Parking Brake ON” lamp
and moving each brake caliper unit.
• Check the parking brake application
through TCMS and visually (static
condition) during testing.
• Release Parking brake by Parking brake
release push button. Verify the status
of parking brake in DDU.
• Enable Holding from DDU
20. Leakage Test • Do not perform any task after isolating
overhead line which will cause air
consumption for 5 minutes.
• Check that MR gauge reading should
not decrease below 0.2bar (from
setting pressure value.) in 5 minutes.
duration
21. Log book • Check the Crew remarks
22. Data download • Download Data Through MAE675U
Application Software
23. Reading Note Down • Note Down the Energy Consumption
• Note Down the Regeneration Energy
• Note Down the Kilometer Reading

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories

4. TOOLS AND ACCESSORIES

Version : 1.00

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,

RDSO and OEMs

Page
IRCAMTECH/GWL/2020-21/T-18/MM/1.0 Page 1 of 15
Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
Amendment and Revisions
Version Date Corrections Remarks
1.00 31/08/2020 First Release

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
Content

4. TOOLS AND ACCESSORIES ................................................................................................... 1

4.1. WHEELS AND AXLES ................................................................................................. 4
4.2. BEARING ................................................................................................................... 4
4.3. DRIVE GEAR UNIT ..................................................................................................... 5
4.4. AIR SPRING ............................................................................................................... 6
4.5. CBC ........................................................................................................................... 6
4.6. SEMI PERMANENT COUPLER ................................................................................... 7
4.7. SLIDING DOOR.......................................................................................................... 7
4.8. PLUG DOOR .............................................................................................................. 7
4.9. GANGWAY ................................................................................................................ 7
4.10. VACUUM BIOTOILET ................................................................................................ 8
4.11. SEATS ........................................................................................................................ 8
4.12. ELECTRO PNEUMATIC BRAKES AND AIR SUPPLY ..................................................... 8
4.13. BRAKE CHOPPER RESISTOR .................................................................................... 10
4.14. VACUUM CIRCUIT BREAKER ................................................................................... 10
4.15. MAIN TRANSFORMER ............................................................................................ 11
4.16. TRACTION MOTOR ................................................................................................. 11
4.17. JUMPER COUPLER .................................................................................................. 12
4.18. DRIVER CABIN ........................................................................................................ 12
4.19. ECC AND CRW UNIT ............................................................................................... 13
4.20. PASSENGER INFORMATION SYSTEM ..................................................................... 13
4.21. SALOON AND GANGWAY LIGHT ............................................................................ 13
4.22. GROUND CONTACT ................................................................................................ 14
4.23. WIPER MOTOR ....................................................................................................... 14

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
4.1. WHEELS AND AXLES

S.No Instrument Purpose Specification

As per
BONATRANS
Measurement
manual for
NEXTSENSE CALIPRI CW40 of basic
wheels and
1 measuring instrument with operating
axles –
add-on measurement modules. characteristics
Document no –
of wheelsets
22 – 388 Date
:2018-11-23
NEXTSENSE CW40 measuring Measurement
2 system with a D-1050 diameter of wheel same
measuring gauge diameter
NEXT SENSE CW40 measuring Measurement
3 same
system of wheel tread
Measurement
Measuring system NEXT sense
4 of back-to-back same
CW40 with a gauge
dimension
Measuring system NEXTSENSE Measuring axial
5 CW40 with a trigger wedge K1 and radial run- same
and a stand out
Measurement
6 Special shape gauge of Wheel tread same
shape gauge
Measurement
Wheel Diameter Checking
7 of Wheel same
Gauge
diameter
Measurement
8 Wheel Distance gauge of Back to back same
dimension
Measuring
alignment of
9 Axial and radial run-out device same
press-fitted
wheels
4.2. BEARING

S.No Instrument Purpose Specification

1 Portable jacks consisting of an Bearing As per : TIMKEN

1 assembly sleeve, withdrawal installation and Maintenance
plate, puller rods, and a pulling removal Manual
ring adapter MAINTENANCE
MANUAL (A-
73980) Section
A1 Date :
07/09/2018
2 Micrometer Measure the Not Specific
bearing seat
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
diameters of
axles

4.3. DRIVE GEAR UNIT

S.No Instrument Purpose Specification

1 Ejector screws M8, M12, various
lengths
2 Collecting volume > 8 l, low
receptacle/collecting cup height
3 Axial fastening For demounting
coupling
4 Wooden blocks For supporting
the wheelset
shaft and the
gear box
5 Torque wrench 6 to 592 Nm
6 Spring balance 500 N
7 Threaded rod M8, L= length of
hydraulic
cylinder + 70 mm;
including M8 hex
nuts
8 Lifting devices with a for loads of 70 to
sufficient bearing capacity 1650 kg
and fine control
9 Hydraulic cylinder
10 Hydraulic press-off device Glycerine 2000
bar Max – G1/4”
Connection
11 Hollow hydraulic cylinder
single-action (spring return)
12 Induction heater with
demagnetization and
temperature probe
13 Freezer for temperatures
of -30 up to -70
°C
14 Long hole bars L = 170 189 mm
with hexagonal
bolts
15 Long hole bars L = 240 mm with
hexagonal bolts,
thickness of the
long hole bar
16 Dial gauge Gage: 1/100 mm
or better
17 Dial gauge with lever gage Gage: 1/100 mm
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
or better
18 Stand with magnetic base For the dial
gauges
19 3D lifting ring M12
20 Vacuum cleaner
21 Flashlight
22 Assembly device main gear AAV002150R0001
( Figure 62) of
TSA manual -
TSA017120 / 0 /
EN
23 Adapter for measuring same
bearing clearance
24 Adapter for measuring flank same
clearance
25 Height control device same
26 Press out device for same
spherical bearing
27 Pressing device for spherical same
bearing
4.4. AIR SPRING

S.No Instrument Purpose Specification

1 Torque key 0 Nm up to 120
Nm
2 Hexagon socket screw key Not specific
3 Hammer 1000 g
4 Assembling aid Hard wood
5 Press As per GMT
manual -
WH_17305201_Air
Spring System
_en_01
6 Mounting level same
4.5. CBC

S.No Instrument Purpose Specification

1 Contour maintenance As per FAIVELEY
gauge (Profile gauge) maintenance
manual for CBC
document -
FT0050978-100-
E57MUM
2 Aligning wing limit gauge same
3 Vertical height aligning wing same
pocket and guard arm
gauge (Go‐Gauge)
4 Vertical height condemning same
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
limit aligning wing pocket
and guard arm gauge
(No‐Go‐Gauge)
5 Contour condemning limit same
gauge
6 Knuckle nose wear and same
stretch limit gauge
7 Central pin – puller same
8 Balanced Draft Gear same
scragging fixture
9 Supporting device assy. same
fixture
10 Coupler head assembly same
fixture
11 Spherolastic bearing same
assembly fixture
4.6. SEMI PERMANENT COUPLER

S.No Instrument Purpose Specification

1 Suitable Lifting Device Not Specific
2 Standard Toolkit same
3 Clamp, (169895) As per DELLNER
maintenance
manual document
- 130174_0_en
4.7. SLIDING DOOR

S.No Instrument Purpose Specification

1 No Special tools required As per PRAG
manual document-
Maintenance-ISD-
001 (Rev0.0)
4.8. PLUG DOOR

S.No Instrument Purpose Specification

1 No Special tools required As per IFE
maintenance
manual document
- DDSTE11071E09
(Rev.00)
4.9. GANGWAY

S.No Instrument Purpose Specification

1 Overhead crane with a As per HUBNER
capacity of at least 600 kg technical
description
document –
049395349 (Rev-)
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
2 Fork lift same
3 Ropes For mounting same
purposes
4 Standard-Work shop same
equipment and tools
5 Hollow square spanner (9 same
mm)
4.10. VACUUM BIOTOILET

S.No Instrument Purpose Specification

1 10531 Service terminal HT- As per EVAC
793-English HT793E or maintenance
69833 Service terminal PC description
version document – 01
– 2018-08
2 23474 Tool for pan head same
screw
3 79017 Cleaning tool for same
EVAC flush nozzles
4.11. SEATS

S.No Instrument Purpose Specification

1 Allen wrench 4 mm As per FAINSA
maintenance
description
document – 771
Rev.00
2 Allen wrench 5 mm same
3 Allen wrench 6 mm same
4 Allen wrench 2.5 mm same
5 Screwdriver Phillips PH2 same
6 Screwdriver head 81150 M4 same
7 Screwdriver head 81150 M6 same
8 Screwdriver head Torx same
9 Fixed wrench8 mm same
10 Fixed wrench10 mm same
11 Fixed wrench13 mm same
12 Tubular wrench 13 mm same
13 Fixed wrench17 mm same
14 Thread sealant same
4.12. ELECTRO PNEUMATIC BRAKES AND AIR SUPPLY

S.No Instrument Purpose Specification

1 Special hook (B64617). For As per KBIL
check valve with damping. overhaul
See figure 1 for details instruction
document – U-
OF11-21 Rev-05-
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
03.06.2009 en
2 Same tool as above for Document – U-
Impulse valve WIMHV5-NT GD80-24 Rev-00-
13.11.2009
3 Same tool as above for Document – U-
Double Check Valve DRV7-T GF20-27 Rev-02-
14.10.2010
4 Same tool as above for Document – U-
Pressure reducing Valve GE50-25 Rev-02-
DMV15/T 01.06.2009
5 Same tool as above for Document – U-
Piston valve WKV1-T GD70-23 Rev-03-
14.01.2015
6 Same tool as above for Document – U-
Mean Pressure valve MDV1 KF20-22 Rev-04-
10.07.2012
7 Same tool as above for Document – U-
Magnet valve WMV1-ZEST GG21-41 Rev-03-
17.05.2011
8 Same tool as above for Document – U-
Driver Brake Valve FB11, FB22-21 Rev-02-
FB11-1 11.2006
9 Same tool as above for Document – U-
Magnet Valve WMV- 20/2Z OG21-41 Rev-02-
29.09.2009
10 Same tool as above for Document – U-
Overflow valve without TD20-28 Rev-01-
reflux DR07-T 21.07.2014
11 Assembly drift (dependent Document – U-
on the nominal bore) for GJ20-23 Rev-02-
Ballcock with an exhaust 27.07.2016
and switch module(SK-T-
DN..E-SM, SK-T-DN..E-SM-K)
12 Test gauge (dependent on same
the nominal bore) for
Ballcock with an exhaust
and switch module(SK-T-
DN..E-SM, SK-T-DN..E-SM-K)
13 Press for Ballcock with an same
exhaust and switch
module(SK-T-DN..E-SM, SK-
T-DN..E-SM-K)
14 Assembly drift (dependent Document – U-
on the nominal bore) for GJ10-22 Rev-01-
Ballcock with an exhaust 22.08.2016
(SK-T-DN..E, SK-T-DN..E-K)
15 Test gauge (dependent on same
the nominal bore) for
Ballcock with an exhaust
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
(SK-T-DN..E, SK-T-DN..E-K)
16 Press for Ballcock with an same
exhaust and switch
module(SK-T-DN..E, SK-T-
DN..E-K)
17 Special hook (B64617). And Document – U-
Diaphragm extractor EC90-22 Rev-00-
(A54802) for Distributor 29.02.2012
valve STV200. See Figure -1
and 2 for details
18 Precision torque wrench, For assembling Document – U-
and a sleeve ( As per figure - the piston rod TD10-25 Rev-00
3) for Levelling Valve assembly. The
SV1205 latter must be
made by the
customer
19 Regular strap wrench for Document – U-
Motor Compressor set V10- LG10-22 Rev-05-
T 25.01.2016
4.13. BRAKE CHOPPER RESISTOR

S.No Instrument Purpose Specification

1 Double end open Spanner For tightening 24x27mm
or holding bolt
2 Ring spanners For tightening 24x27mm
or holding bolt
3 Torque wrench For Torque 70 - 350 N-m
tightening bolt.
4 Fork lift Shifting the 0.5 Ton
Brake Chopper
Resistor from
installation
premises to
maintenance
location by
using Fork lift.
5 Hydraulic lifter Lift and adjust 0.5 Ton
the Brake
Chopper
Resistor in
between
mounting
brackets by
using Hydraulic
lifter.
4.14. VACUUM CIRCUIT BREAKER
As per details available in OEM’s manual

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
4.15. MAIN TRANSFORMER

S.No Instrument Purpose Specification

1 Air gun Not Specific
2 Brush Not Specific
3 Elevating table Not Specific
4 Hexagon key 6mm
5 High pressure washer Not Specific
6 Hydrant wrench Not Specific
7 Jerry can Not Specific
8 Laser thermometer Not Specific
9 Manual pump Not Specific
10 Mohr clamp Not Specific
11 Screwdriver Not Specific
12 Spirit Level Not Specific
13 Syringe Not Specific
14 Tissue Not Specific
15 Vacuum cleaner Not Specific
16 Wrench size :
10mm,13mm,17mm,19mm,
22mm, 24mm, 36mm,
41mm, 46mm, 8mm
17 mallet Not Specific
18 pliers Not Specific
19 tool LV bushing Not Specific
20 Oil Filling/Draining tool kit As per JST Transformers
(oil pump, vacuum pump, maintenance manual Part
filter,flexible pipes) no - 1066463G000
4.16. TRACTION MOTOR

S.No Instrument Purpose Specification

1 Grease gun As per TSA manual
document no -
TSA018528 / 0 / EN
2 Torque wrench 5 230 Nm
3 Depth gauge As per TSA manual
4 Shaft extension same
5 Extension tube same
6 Lifting eye bolts M12, M16, M20
7 Ejector Screws M8, M10, M12, M16
8 Wooden beams For supporting As per TSA manual
the rotor
9 Hydraulic puller For labyrinth same
ring Drive End
10 Hydraulic pressure device same
11 Hoisting devices Motor: 997 kg ±5%
Gearbox: 620 kg ±10%
12 Two arm puller As per TSA manual
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
13 Hydraulic press same
14 Induction bearing heater same
with demagnetization and
temperature test probe
15 Balancing machine same
16 Vacuum cleaner same
17 Electric torch same
18 Ohmmeter As per OEM
recommendation
NORMA
Insulation*Tester /
UNILAP ISO 5 kV
19 Furnace As per TSA manual
20 Freezer same
21 Mandrels M12, M16
22 Shaft extension NDE As per TSA manual
23 Sleeve For pulling same
rotor
24 Dial Gauge same
25 Compressed Air Dry and de-oiled
4.17. JUMPER COUPLER

S.No Instrument Purpose Specification

1 Measuring tape For measuring Not specific
the Centre
distances on
Mounting base
and Mounting
base to Side
wall
2 Double end open Spanner For tightening 18x19mm
or holding bolt
3 Ring spanners For tightening 18x19mm
or holding bolt
4 Double end open Spanner For tightening 12x13mm
or holding bolt
5 Ring spanners For tightening 12x13mm
or holding bolt
6 Torque wrench For tightening Up to 70 Nm
or holding bolt
4.18. DRIVER CABIN

S.No Instrument Purpose Specification

1 Allen key Harting M4
connectors
2 Allen key TFT Display M5
units
3 Allen key FGU, Flasher M6
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
light unit
4 Allen key wiper motor M8
5 Allen key D0 panels M10
assembly
6 Star screw driver For switch Not specific
panels
7 Soft brush Dust Cleaning Not specific
8 Vacuum cleaner Dust Cleaning ESD protected
type
4.19. ECC AND CRW UNIT

S.No Instrument Purpose Specification

1 Measuring tape For measuring the Not specific
Centre distances on
Mounting base and
Mounting base to
Side wall
2 Double end open Spanner For tightening or 18x19mm
holding bolt
3 Ring spanners For tightening or 18x19mm
holding bolt
4 Double end open Spanner For tightening or 12x13mm
holding bolt
5 Ring spanners For tightening or 12x13mm
holding bolt
6 Torque wrench For tightening or 70 to 350 Nm
holding bolt
7 Soft brush Dust Cleaning Not specific
8 Vacuum cleaner Dust Cleaning Not specific
9 Wago Inserting tool For wago assembly / Not specific
dissembly
10 Cable cutter For cutting cabel ties Not specific
11 star philips screw driver For screwing / M3, M4, M5
unscrewingelectronic
components
12 Gland spanner For tightening glands PG 21, PG 36, PG
48
4.20. PASSENGER INFORMATION SYSTEM

S.No Instrument Purpose Specification

1 Rachet box and handle For Covers Not specific
4.21. SALOON AND GANGWAY LIGHT

S.No Instrument Purpose Specification

1 Measuring tape For measuring Not specific
the Centre
distances on
Mounting base
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
and Mounting
base to Side
wall
2 Ring spanners For tightening 10x11mm
or holding bolt
3 Ring spanners For tightening 12x13mm
or holding bolt
4 Torque wrench For tightening 70 to 350 Nm
or holding bolt
5 Hand grindingmachine For removing Not specific
weld spatters,
foreign particle
etc. on
mounting
bracket
6 Fork lift For shifting the 3 Tons
Nose Cone
Equipment from
stores to
installation
premises
7 Pallet For coach inside Not specific
movement of
the panel
4.22. GROUND CONTACT

S.No Instrument Purpose Specification

1 Drive socket set metric 10mm,
17mm + 19 mm
2 Plug-in with Allen metric 5mm
3 Torque wrenches ½” drive, ratchet
head
4 Manual hot air blower min. 2000W

4.23. WIPER MOTOR

S.No Instrument Purpose Specification

1 Arm Extractor Tool As per HEPWORTH
manual Part no -
60680600

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 Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 4. Tools and Accessories
Figure – 1 : Special hook

Figure – 2 : Diaphragm extractor

Figure – 3: Assembly Sleeve

Figure – 4: Arm Extractor tool.

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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

5. MAINTENANCE

Version : 1.00

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,

RDSO and OEMs

Page
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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

Amendment and Revisions

Version Date Corrections Remarks

1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

Contents - Bogie

5.1 BOGIE ........................................................................................................................... 4

5.1.1 SAFETY INSTRUCTIONS ................................................................................................ 5
5.1.2 DRAWING ..................................................................................................................... 5
5.1.3 TOOLS AND ACCESSORIES............................................................................................ 5
5.1.4 MAINTENANCE AND INSPECTION................................................................................ 5
5.1.5 LIFTING THE VEHICLE ................................................................................................... 5
5.1.6 DISCONNECTING THE BOGIES...................................................................................... 6
5.1.6.1 ELECTRICAL DISCONNECTION ...................................................................................... 6
5.1.6.2 DISCONNECTING AIR-PIPE ........................................................................................... 7
5.1.6.3 MECHANICAL DISCONNECTING ................................................................................... 8
5.1.7 REMOVING BOGIES FROM THE VEHICLE ..................................................................... 9
5.1.8 ATTACHING BOGIES TO THE VEHICLE ........................................................................ 11
5.1.9 TORQUE TABLES......................................................................................................... 14
5.1.10 FINAL INSPECTIONS ................................................................................................... 14

List of Figures
Figure 1 ................................................................................................................................................... 4
Figure 2 ................................................................................................................................................... 4
Figure 3: .................................................................................................................................................. 7
Figure 4 ................................................................................................................................................... 7
Figure 5 ................................................................................................................................................... 7
Figure 6 ................................................................................................................................................... 8
Figure 7 ................................................................................................................................................... 8
Figure 8 ................................................................................................................................................... 9
Figure 9 : ............................................................................................................................................... 10
Figure 10 ............................................................................................................................................... 12
Figure 11 ............................................................................................................................................... 13
List of Tables
Table 1:.................................................................................................................................................... 5
Table 2 : ................................................................................................................................................. 11
Table 3................................................................................................................................................... 14

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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

5.1 BOGIE
a. Trailer Bogie ( SeeFigure 1)

Figure 1

b. Motor Bogie( See Figure 2)

Figure 2

Features:
1. Bolster-less bogie design i.e. Carboy rests on air spring.
2. Fully Suspended Traction Motor so lesser un-sprung mass.
3. Wheel mounted Disc Brakes.
4. Secondary suspension with Air springs.

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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

5.1.1 SAFETY INSTRUCTIONS

Basically, the regulations and safety precautions as set out in the previous chapter apply.
Descriptions of the work following assumes they are being observed.
Warning!

When working on the bogies, the vehicle MUST be secured against rolling
away. Any system components, on which it will be necessary to work, and
any individual pressure pipes or hoses MUST, before work is started, be
depressurised at both sides of the component.

The usual safety rules for electrical equipment must be observed:

 Switch off,
 Secure against re-energising,
 Check that no current is flowing.

When identical components are mounted more than once on a bogie, e.g. guides, dampers,
springs etc., the appropriate instructions for removal or assembly always applies to each
part.

Before assembling a bogie, all mechanical assembly surfaces must be cleaned!

5.1.2 DRAWING
Designation Drawing number
Bogie General Arrgt. for Train18 DTC & NDTC Train18/DTC/AC/0-0-002
Bogie General Arrgt. for Train18 Motor Coaches Train18/DTC/AC/0-0-001
Table 1: Drawings for dismantling and assembly of bogies

5.1.3 TOOLS AND ACCESSORIES

Tools and accessories for dismantling and assembly
 Torque-wrench in the range 29 N-m to 800Nm
 4-point lifting apparatus for complete vehicle (50t)
 Lifting apparatus for bogie (5t)
 Tool for disconnecting and reconnecting of cable-connectors

5.1.4 MAINTENANCE AND INSPECTION

Maintenance and inspection must be carried out in accordance with the intervals prescribed
in the Maintenance Schedule of VANDE BHARAT EXPRESS (for further maintenance and
inspection instructions, see manufacturer’s documentation).
5.1.5 LIFTING THE VEHICLE

Warning!
Follow safety instructions relating to the lifting equipment!
Ensure that the marked lifting-points are used!

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Vande Bharat Express(T-18) Maintenance Manual(Version1.0) 5. Maintenance

Information
For disconnecting the bogies, a maintenance pit is essential.
To
separate the bogies from the vehicle, disconnection of electrical connections, air-pipesand
mechanical separation is first necessary.

All connections between body and the bogies must be split. The individual procedures willbe
described in the next section.

After disconnecting the bogies, the complete vehicle must be lifted by means of a four-point
lifting apparatus at the jacking-points. The jacking-points are marked and are located behind
or in front of the bogies.

The same basic procedure is also adopted when only one bogie is to be removed.

When lifting the vehicle, care must be taken to ensure no connections remain attached; if
there are, they must be separated.

Assembly of the bogies takes place in the reverse order.

5.1.6 DISCONNECTING THE BOGIES

Disconnecting the bogies is accomplished in the following order:
 Electrical disconnection
 Disconnecting air-pipes
 Mechanical disconnection

5.1.6.1 ELECTRICAL DISCONNECTION

Warning!
Cables hanging loose must be secured both against being damaged and becoming dirty

Removal of Cables: Disconnect all cables to traction (Figure 4) motors and axle end
equipment i.e ERCU, speed sensor, phonic wheel sensor, earthing connection (body to
bogie) etc. See Figure 3.

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Figure 3: Axle End Equipments

Cable to Traction Motor

Figure 4

5.1.6.2 DISCONNECTING AIR-PIPE

Disconnect all pneumatic hose connections to brake caliper units & parking brake units.
(Figure 5) Pull manual release & ensure release of all PB units.

Hose to caliper unit Figure 5 Hose to Parking brake unit

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5.1.6.3 MECHANICAL DISCONNECTING

Under-frame and Bogie are connected with each other through following mechanical links and
joints:
a. Centre pivot pin bottom cover – 1 no. 5
b. Safety wire rope – 2 nos. 1
c. Air Spring- 2 nos. 4
d. Secondary vertical damper –2 nos. 3
e. Yaw Damper – 2 nos. 3
f. Stabiliser Link – 2 nos. 3
6 Under-frame

Air Spring

Y-Shape Bracket

Secondary Vertical Damper

Yaw Damper

Figure 6
4

6
Stabiliser Link Stabiliser Lever

Figure 7

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Safety wire rope

Under-frame
1

Figure 8 2

Remove all connections given in numeric code above from 1 to 6. To remove connection
between air-spring and under-frame, four fitment screws are to be opened. Two numbers of
Yaw damper and vertical dampers are connected with under-frame. Similarly two numbers
of safety wire rope and stabiliser link are connected with under-frame.

5.1.7 REMOVING BOGIES FROM THE VEHICLE

 Ensure all components / cables / hoses / screws as detailed above are removed on both
the bogies.
 Suitably rotate stabiliser lever away from stabiliser link and secure with suitable rope /
wire (with bogie) to avoid hitting on ground.
 Suitably push wire rope away from bracket & ensure it not entangles / damages any
bogie bracket / component.
 Suitably & slowly (preferably inching up control to be used) lift the car body using
synchronized jacks on all four lifting positions.
 While lifting, suitably ensure air spring’s spigot is relieved from car body. If necessary,
use suitable lever / wedge in between air spring top plate & car body to push down air
spring.
 Run out both the bogies and suitably place in pit line. Provide suitable packing on all 4
wheels to arrest bogie movement.

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Figure 9 : Coach Body and Bogie after complete disconnection

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5.1.8 ATTACHING BOGIES TO THE VEHICLE

Warning!
As a general rule, all safety devices such as lock-nuts, split-pins, cotters etc., must be replaced with new parts.

Attaching the bogies is accomplished in the reverse order to removing them. The following Working instructions are to be observed, and the
torque limits must not be exceeded. When re-attaching the bogie to the vehicle body, various measurements must be checked. See table of
measurements at Table 2 and Figure 10 & 11.

Shim Air spring height (with air) +

Brake caliper Air spring CBC height from
thickness shim thickness
Wheel tread dia. & range mounting seating from Coupler height RL in mm
below air (Machined area of bogie frame
of dia. surface from RL from RL in mm (for driving end
spring in mm to machined area of body
RL'A' in mm 'C' in mm of DTC only)
bolster)

At 952
(Ne wheel) 701 ±3 688 ±3 NIL 300 +5/-0 940 +0/-5 1105 +0/-10
(above 932 to 952)

601 ±3 678 ±3 10 (300 air spring height + 10 shim) 940 +0/-5 1105 +0/-10
At932 (above912upto 932)
310 +5/-0
591 ±3 668 ±3 20 (300 air spring height + 20 shim) 940 +0/-5 1105 +0/-10
At 912(above 892 upto 912)
320 +5/-0
591 ±3 668 ±3 30 (300 air spring height + 30 shim) 940 +0/-5 1105 +0/-10
At 892 (above 877upto 892)
330 +5/-0
Table 2 : Various Clearance and height adjustment

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Safety Wire Rope

Figure 10

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Figure 11

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5.1.9 TORQUE TABLES

Designation Figure Torque
Tightening Bogie / vehicle Figure 7, Item 5,6 174Nm, 242Nm
body Figure 6, Item 4 192Nm
Tightening dampers Figure 6, Item 2,3 192Nm, 80Nm
Table 3

5.1.10 FINAL INSPECTIONS

All components must be tested for perfect functioning. All bolted items must be checked for
tightness.
A brake test must be carried out, in accordance with the brake manufacturer’s instructions.

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Content - Coupler

5.2. COUPLERS - TIGHT LOCK COUPLER HEAD TYPE ‘H’ .............................................. 16

5.2.1 CONSTRUCTION ........................................................................................................ 16
5.2.2 COUPLER MOUNTING ............................................................................................... 17
5.2.3 COUPLER DISMOUNTING .......................................................................................... 19
5.2.4 COUPLING AND UNCOUPLING PROCEDURE ............................................................. 20

5.3. COUPLERS – SEMI PERMANENT COUPLER .......................................................... 22

5.3.1 CONSTRUCTION ........................................................................................................ 22
5.3.2 COUPLING ................................................................................................................. 22
5.3.3 UNCOUPLING ............................................................................................................ 23
5.3.4 REPLACEMENT........................................................................................................... 23

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5.2. COUPLERS - TIGHT LOCK COUPLER HEAD TYPE ‘H’

5.2.1 CONSTRUCTION
The coupler consists of the following main parts:

I. Tight lock Coupler head Type “H”

II. Balanced Draft gear

III. Supporting device :

IV. Manual uncoupling device :

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V. Mounting plates

5.2.2 COUPLER MOUNTING

I. Preparation of the vehicle

 The dimension of draft gear pocket on coach has to conform to that shown as per
OEM document.
 Apply adequate grease on all bearing surfaces of Balanced draft gear (except in Pads
fitment area) and in the draft gear pocket in the car-body, before mounting the
Balanced draft gear.
 The coupler parts delivered are ready for mounting to the vehicle under frame.
 Mounting procedure/sequence to be followed for installation of coupler on the
vehicle as described below.
 For lifting the coupler parts, a standard hydraulic lifting table is to be used.

II. Mounting of the Balanced draft gear

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 The elastomer pads of the Balanced draft gear is pre-compressed to the defined
distance. Wedges and Mounting Bolt‐M27 and washer‐M27 are required for
Balanced Draft Gear.

Note: Before mounting the Balanced Draft Gear into the pocket, measure and confirm
the dimension of the pocket length and height in the car-body.

 The Balanced draft gear is to be lifted from underneath the car into the draft pocket
by means of a standard hydraulic lifting fixture.

Note : Balanced Draft Gear should be 6mm (min) inside from the car body pocket
bottom surface, where Base plate and Support plates will be fitted.

 Fix the bottom wedges and bolt them with the Torque of 400‐500 Nm. Tie the bolts
with the locking wire. This torque is to be checked during periodic inspection.
 Fix the Base plate and Support plate with M16x55 Hex. head Bolts, Grade 10.9 and
are to be tightened to the torque of 180‐200 Nm. This torque is also to be checked
during periodic inspection. Use of loctite as a thread locking agent is recommended.

III. Mounting of the Coupler head

 First mount the Supporting device and fix with four no's of Hex head bolt M20x50mm
– grade 10.9.
 The coupler head has to be placed on hydraulic lifting fixture or on the forklift and
insert into the Balanced Draft Gear from front end of coach to connect the coupler
head linkage to the Balanced draft gear by means of the central pin.
 Fix the base plate sub assembly at the bottom side of under frame of the coach.
 The position of central pin has to be secured by the locking plate in between the base
of central pin and base plate. Locking plate is secured by two M16 bolt/nut and
locked with spring dowel/split pin and torque up to 180‐200 Nm.

IV. Mounting of the supporting device

 Hold the coupler head in lifted position (above horizontal), the supporting device
position is to be adjusted to make the coupler head in horizontal position.

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 Ensure the torque of 450 +50 Nm in the mounting bolts M20x50mm – grade 10.9.
This torque is also to be checked during periodic inspection. Use of loctite agent 243
is recommended.
 Apply grease on the wear plate of supporting device.

V. Mounting of the manual uncoupling device

 Mounting brackets (LH & RH) are to be fastened on the vehicle structure.
 Manual uncoupling device, bearing brackets (LH and RH) are to be fastened to these
mounting brackets.
 Use of loctite and tightening with adequate torque (for M16 Bolt, 180‐200 Nm and
for M12)
 Bolt, 60‐80 Nm) is recommended and this torque is also to be checked during
periodic inspection.
 Fix the Sliding rod to the coupler head rotor assembly, before fastening the device to
mounting bracket.
 Fix the Operating rod with Sliding rod ‘H’ piece and then fix the both ends of the
operating rod in the bearing brackets.
 Uncoupling will be done by lifting and turning operating rod handle in clockwise
direction

VI. Final check of coupler installation

After completion of coupler installation the following functional checks are to be executed:

 Proper fastening and securing of all bolt connections to recommended torque.

 Free movement of the coupler head in horizontal and vertical direction.
 Free movement of the lever system of the manual uncoupling device.
 Functional check of the uncoupling device on coupler head by operating manual
uncoupling device.
 Coupling and uncoupling test.

5.2.3 COUPLER DISMOUNTING

I. Dismounting coupler head

 Remove sliding rod from the rotor assembly of coupler head by removing operating
rod from the mounting brackets fitted on coach.
 Coupler head is dismounted first by pulling out central pin with central pin puller. To
access the central pin, remove the Locking plate fitted in base plate. If not feasible
remove the Base plate assembly and take out the Central pin.
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Note : Support coupler head on a hydraulic lifting fixture while removing the central
pin.
II. Dismounting of Balanced draft gear from the coach
 Remove the Base plate and put a hydraulic trolley below the Balanced Draft Gear and
hold it.
 Now remove the Support plate.
 Using ratchet and socket to suit M27 Bolt, loosen the bolts fitted in Wedges.
 Now takeout the Bottom side wedges.
 Slowly lower the hydraulic table ensuring that the Balanced draft gear also slides
down the pocket.
 Take out the top side wedges.
Note : In any case, if the wedges are struck / jammed in the assembly and couldn’t
able to remove, follow the below steps to take corrective action :
 Remove M27 Bolt from the wedges.
 Take 1 ¼” – 7UNC threaded Bolt / Screw and fix at the Bottom wedges.
 Shake and Drag / pull the Bolt down to loosen the wedges.
 Once the wedges got loosened, Balanced Draft Gear can be removed easily.

5.2.4 COUPLING AND UNCOUPLING PROCEDURE

I. General Information
To facilitate the safe operation of building up trains and coupling of coaches by the tight lock
couplers it is absolutely necessary to follow the instructions given below.

The specified coupler head is a tight lock coupler head according to the AAR standard type
“H”. This coupler head for the IR ‐ Coaches has the following gathering range as specified in
technical specification RDSO‐2011‐CG‐03 issued by RDSO:

 Horizontal: ± 110 mm
 Vertical: ± 90 mm
Proper coupling procedure is recommended to achieve an easy and safe coupling/uncoupling
of vehicles in practical service. During coupling and uncoupling, care should be taken that no
person stands between the vehicles. Coupling is automatic. For uncoupling ‐ unlock, lift and
rotate manually the handle of manual uncoupling device in a clockwise direction.

II. Coupling procedure

 Bring the vehicles near to each other at a slow speed (approx. 2‐3 km/h) and stop the
vehicles at approximately 1‐2 meter distance of each other.
 Check alignment and position of coupler centres. Couplers must stand within the
gathering range as given above.
 If required pull the couplers manually towards each other and make sure that they
are in the gathering range of the coupler geometry.
 For coupling, move the Locomotive with a speed of 3 ‐ 5 kmph.
 Check the position of tell-tale area to ensure proper coupling. It should be free. Also
ensure that, the Double Rotary Lock lifter rib should be vertical.
 Make sure, that the handle of manual uncoupling device is locked after coupling.
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Tell-tale position in coupler

Note :Coupling cannot be done when both the knuckles are closed. Coupling can be
done when
 Two Knuckles are in open condition or
 One knuckle in open condition and other one in closed condition or vice versa
 After coupling, reverse the power to pull (snatch) the vehicles apart. This is a
typical pull test to reconfirm a positive coupling.

Vice versa position of couplers

III. Uncoupling procedure
 For uncoupling, use the uncoupling lever of the Operating rod which is accessible
from the trackside.
 Unlock the handle by rotating the locking screw with a special key.
 Lift and turn the handle in clockwise direction to a horizontal position (minimum 90°)
and pull the coaches apart.
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Note : Before uncoupling make sure that the couplers are not subjected to any tensile
load and the uncoupling lever is fairly free to turn. A common practice for this
uncoupling operation is also to push the vehicles together (with one vehicle applied
with parking brake) to avoid excessive binding in the system.

For further details, please refer OEMs manual.

5.3. COUPLERS – SEMI PERMANENT COUPLER

5.3.1 CONSTRUCTION

No Component
1 Socket joint
2 Tube
3 Socket joint
4 Draft gear
5 Locking wedge
6 Clamping device

5.3.2 COUPLING
I. Make sure that the semi coupler half (5) is equipped with the guide cone (9).
Note If a socket joint is being reused the screws (6), washers (3) and nuts (2) shall be
replaced with new ones.

II. Grease the contact surfaces of the flanges and both socket joint halves (4 and 8) with
Lagermeister 3000+.
III. Slowly bring cars together. Note Make sure to align the two coupler halves
accurately, both vertically and horizontally, before bringing the vehicles together.
IV. Gently knock the socket joint halves (4 and 8) into place over the flange joint. Make
sure that the guide pins on the socket joint halves are correctly positioned in
corresponding recess in the guide cone (9).
V. Check that both socket halves are parallel within 2 mm, equal distance. If they are
not parallel remove one of the socket joint halves and start the procedure again.
VI. Apply Molykote 1000, to the screw threads and fit screws (6), lock washers (7) to the
socket joint half (8).
VII. Fit the washers (3) and nuts (2) to the socket joint (4) and tighten nuts (2) by hand,
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without tools.
VIII. Again check that both socket joint halves are parallel within 2 mm, equal distance
and apply 60 Nm torque to the nuts in a crosswise pattern.
IX. Verify that both sockets halves are still parallel and apply 120 Nm torque to the nuts
continuing with the crosswise pattern.
X. Verify that both sockets halves are still parallel and apply the total 185 Nm torque to
the nuts in a crosswise pattern. Repeat the sequence of torque nuts to 170Nm in a
crosswise pattern until there is no further rotation of the nuts.

Coupling/Uncoupling

No Component
1 Mating coupler
2 Lock nut
3 Washer
4 Socket joint half
5 Semi-Permanent Coupler
6 Screw
7 Lock washer
8 Socket joint half
9 Guide cone

5.3.3 UNCOUPLING
I. Remove the socket joint halves (4 and 8) by removing the nuts (2), washers (3) and screws
(6).
II. Separate the cars.

5.3.4 REPLACEMENT
REMOVAL

I. Loosen the locking wedge (4) by removing screws (5), washers (10) and nuts (11).
II. Fit M16 screws to the holes (5) in the locking wedge (6).
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III. Remove the locking wedge (6) from the vehicle by tightening the M16 screws.
IV. Remove the screws (2), washers (12) and nuts (13) and carefully remove the draft gear(1)
from the vehicle.
V. Remove the clamping device (6) by removing screws (7), washers (8) and nuts (9).

Replacement of Semi-Permanent Coupler

No Component
1 Draft gear
2 Screw
3 M16 hole
4 Locking wedge
5 Screw
6 Clamping device
7 Screw
8 Washer
9 Nut
10 Washer
11 Nut
12 Washer
13 Nut

Replacement

Replace all fasteners and rubber parts if applicable.

I. Carefully fit the draft gear (1) to the vehicle using a suitable lifting device.
II. Mount screws (2), washers (12) and nuts (13).
NOTE: Do not fully tighten the screws, only tighten the screws so that the draft gear is
loosely fitted.

III. Fit the clamping device (6) to the vehicle and mount screws (7), washers (8) and nuts
(9).

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NOTE: Do not fully tighten the screws, only tighten the screws so that the clamping
device is loosely fitted.

IV. Make sure that the distance between the clamping device and draft gear is smaller
than the space needed by the locking wedge. This action provides a tight interface
between the locking wedge and draft gear, and locking wedge and clamping device.
V. Fit the locking wedge (4) to the vehicle, push it upwards to fit it in between the draft
gear (1) and clamping device (6). Mount screws (5), washers (10) and nuts (11).
Tighten screws (5) to 170 Nm and mark screws with torque seal.
VI. Fasten the draft gear: tighten the screws (2), washers (12) and nuts (13).
VII. Fasten the clamping device: tighten the screws (7), washers (8) and nuts (9).

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Content - Gangway

5.3. GANGWAY......................................................................................................... 27
5.3.1 CONSTRUCTION ........................................................................................................ 27
5.3.2 MOUNTING COMPONENTS/ASSEMBLY GROUPS ..................................................... 27

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5.3. GANGWAY
5.3.1 CONSTRUCTION
The gangway consists of the following main parts:

No Component
1 Corrugated bellows, assy., mounted
2 Linking ceiling, assy.
3 Side wall, assy. inner covering
4 Covering brush, assy.
5 Combination bridge, assy:
6 Screw-on frame
7 Folding wall, assy.

5.3.2 MOUNTING COMPONENTS/ASSEMBLY GROUPS

Mounting the loose parts – Overview

Both wagon-interfaces have to have the hole pattern to receive:

 the screw-on frames of the “corrugated bellows, assy. final mounted”

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 the folding wall
 the combination bridge,
 the covering brushes,
 the guiding bodies and
 the shackles.
Mount the following components to each wagon-interfaces

 4 pc. Covering brush, assy.

 - 4 pc. Shackle, assy.

Mounting parts – Wagon-interface No. 1 and No. 2 (No. 2 = opposite side)

No Component
1 Wagon-interface
2 Shackle
3 Covering brush

The covering brushes to the wagon-interfaces

 Bolt the covering brushes to the wagon-interfaces (each 10x M6).

The shackles to the wagon-interfaces

 Bolt two shackles (receiving later-on the linking ceiling) to each wagon-interface.
Each 2x M10

The folding wall, assy. to the corrugated bellows

I. Lift the folding walls by means of a crane and bring it into approximate mounting
position.

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II. Bolt with screws, washers and nuts the connecting plates of the folding wall with the
connecting plates of the corrugated bellows.
III. Perform the same procedure for the other folding wall.

Mounting folding wall, assy. on corrugated bellows

No Component
1 Folding wall, assy.
2 Screw and washer
3 Nut and washer
4 Corrugated bellows, assy., final mounted
5 Connecting plate (bellows)
6 Connecting plate (folding wall)

The corrugated bellows, final mounted to wagon interfaces

I. Couple the wagon coupling of the cars.

II. Lift the corrugated bellows by means of a crane and bring it into approximate
mounting position between the wagons.
III. Align the hole pattern of the wagon-interface and the screw-on frame. Screw the
screw-on frame of the corrugated bellows to the wagon- interface.
IV. Repeat the previous step at the other wagon-interface.
V. Bolt on the screw-on frames of the folding walls to the wagon interfaces.

After mounting the “Corrugated bellows, assy. final mounted” mount the following
components tothe wagon-interfaces
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 1 pc. Combination bridge, assy.
 1 pc. Linking ceiling, assy.
 2 pc. Guiding body, assy. screw-on frame side
 2 pc. Guiding body, assy. locking side
 2 pc. Side wall, assy.

Mounting corrugated bellows on vehicle interfaces

No Component
1 Wagon-interface
2 Bolt Bellows to hole pattern of wagon-
interface all around contour
3 Corrugated bellows, assy., final mounted

The combination bridge, assy.

I. Before installing the combination bridge, assy. between the wagon interfaces.
Unscrew the six screw of the tread plate and remove the tread plate.
II. Insert the combination bridge into the corrugated bellows.
III. Flip up the wagon sided bridge plates of the combination bridge.
IV. Screw the combination bridge to the vehicle interface near the scissors by using
appropriated screws.
V. Bolt the combination bridge to the vehicle interface on the other side near the
scissors using screws.
VI. Flip down the bridge plates.
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VII. Put in the tread plate and bolt it on with the six screws.

Mounting combination bridge, assy.

No Component
1 Tread plate, assy.
2 Bridge plate, assy.
3 Wagon interface
4 Holes for screws

The linking ceiling

Mounting of the linking ceiling requires two persons.

I. Compress the unmounted linking ceiling by pushing the outer ceiling plates onto the
middle (simple) ceiling plate.
II. Bring the linking ceiling into mounting position into the gangway area.
III. Bolt the hinges (per hinge 2x M8) of the linking ceiling to the already mounted
shackles of the screw-on frame side No. 1 by sliding the hinges of the linking ceiling
in-between the plate of the shackle and the shackle body
Note: The attachment drillings of the rod hinges are slots in order to be able to align the
height of the linking ceiling with the interior lining in the respective area. Place (hang) the
hinges onto the screws before used to bolt the shackles to the wagon-interfaces.

IV. Tighten the attachment screws of the linking ceiling (per hinge 2x) by reaching into
the gap between wagon-interface and linking ceiling using a flat open-end spanner
(Size 13).
V. Repeat on 2nd wagon-interface.

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Mounting the linking ceiling to the shackles already mounted to the wagon interfaces

No Component
1 Wagon-interface.
2 Linking ceiling.

Mounting the linking ceiling to the shackles already mounted to the wagoninterfaces

(schematic)

No Component
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1 Wagon-interface
2 Shackle
3 Plate
4 Screw

Handling – Height adjustment of linking ceiling

I. The attachment screws of the linking ceiling can be loosened through the horizontal
gaps between wagon-interface and linking ceiling element using a flat open end
spanner size 13.
II. Adjust the height of the linking ceiling successively on each side is up to ±5 mm
possible to meet the interior lining. After height adjustment retighten the
attachment screws at the required height.

Mounting the guiding bodies to the wagon-interfaces

I. Bring the guiding body into mounting position into the gangway area.
II. To each wagon-interface one “screw-on side” and one “locking side” guiding body is
mounted.
III. Align the hole pattern and bolt the cast holders to the wagon-interface (4x M10).
IV. Repeat for other guiding bodies.

Mounting the guiding bodies to the wagon-interfaces

No Component
1 Wagon-interface
2 Guiding body, locking side
3 Guiding body, screw-on side
4 Holder side wall

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Mounting the side walls

Mounting of the side wall requires two persons.

Pre-condition:

 The bellows is mounted

 The combination bridge is mounted
 The linking ceiling is mounted
 The guiding bodies are mounted to the wagon-interfaces.
I. At the guiding body screw-on side (right hand side; looking orthogonal to the
longitudinal axis of the wagons) pull the guiding body downwards.
II. Place a spacer (Size: approx. 100 mm x 50 mm x 20 mm) in the upper opening at the
guiding body – (The spacer will pre-tension the spring. It is suggested to secure the
spacer with a tape to prevent it from falling into the inside of the gangway).
III. Insert the pin of the side wall into the hole of the guiding body screw-on side.
IV. Bolt (2x M8x30) the screw-on side of the side wall to the guiding body (screw-on
side) which is already mounted to the wagon-interface
V. Repeat for opposite side wall.
VI. Remove the spacer out of the opening (guiding body).
VII. Lock the walls

Guiding body without (left) and with spacer (right) as mounting aid

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Mounting the side wall to the guiding bodies, screw-on side

No Component
1 Wagon-interface
2 Side wall
3 Guiding body – screw-on side
4 Guiding body, locking side
5 Attachment points of side wall at guiding body,
screw-on side
6 Screw-on side of side wall

Locking the side wall(s)

Pre-condition:

The vehicles must be in normal position on straight track.

Procedure:

I. Prior to locking the side wall ensure that the curve shaft and the locking bar of the
guiding body are in locked position (Illustration 18b)). For this the curve shaft is
turned clockwise to the right until the stop is reached. The locking bar should now be
in the lower position This position of the locking rod is required to make the locking
of the side wall possible.
II. To lock the side walls they have to be turned and guided between brush ledge and
guiding body until locked with the locking bar of the guiding body.
III. Repeat procedure for second side wall.

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Locking the Side wall(s) (schematic)

No Component
1 Guiding body
2 Locking rod
3 Curve shaft
4 Square end of curve shaft
5 Place hollow square spanner onto curve shaft
6 Direction of turning curve shaft for locking
7 Stop (Guiding body)

Hollow square spanner – Aid

No Component
1 Hollow square spanner

Unlocking the side wall(s)

The side walls have to be unlocked and opened prior to proceeding with unmounting
maintenance tasks.
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I. Unlocking of the side walls occurs at the lower left hand side of the side wall behind
the folds of the gap covering by means of a 9 mm square spanner.

II. Correct unlocking of the side wall through turning the curve shaft is achieved if the
locking rod at the upper end of the guiding body is pushed out by approx. 30 mm

Unlocking the Side wall(s)

No Component
1 Lower left hand side of side wall

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Unlocking the Side wall(s) (schematic)

No Component
1 Guiding body
2 Locking rod
3 Curve shaft
4 Square end of curve shaft
5 Place hollow square spanner onto curve shaft
6 Direction of turning curve shaft for unlocking
7 Stop (Guiding body)

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Contents – Passenger Amenities

5.4. PASSENGER AMENITIES

5.4.1. PASSENGER INFORMATION SYSTEM .....................................................................................40
5.4.1.1. TECHNICAL DESCRIPTION.......................................................................................................40
5.4.1.2. DISMOUNTING PIS EQUIPMENT ............................................................................................40
5.4.1.3. MOUNTING PIS EQUIPMENT .................................................................................................42
5.4.2. CCTV .......................................................................................................................................42
5.4.2.1. TECHNICAL DESCRIPTION.......................................................................................................42
5.4.2.2. REMOVAL OF CCTV ................................................................................................................43
5.4.2.3. MOUNTING CCTV ...................................................................................................................44
5.4.3. AIR CONDITIONING SYSTEM ..................................................................................................44
5.4.3.1. TECHNICAL DESCRIPTION.......................................................................................................44
5.4.3.2. DISMOUNTING AIR CONDITIONING UNIT..............................................................................45
5.4.4. LIGHTING ................................................................................................................................46
5.4.4.1. TECHNICAL DESCRIPTION.......................................................................................................46
5.4.5. SEATS......................................................................................................................................48
5.4.5.1. TECHNICAL DESCRIPTION NDTC/EC SEATS ............................................................................49
5.4.5.2. DISMOUNTING & MOUNTING (NDTC/EC) SEATS ..................................................................50
5.4.6. DOORS....................................................................................................................................51
5.4.6.1. INTERNAL SLIDING DOOR ......................................................................................................51
5.4.6.2. SINGLE LEAF PLUG DOOR .....................................................................................................................54
5.4.7. VACUUM BIO-TOILET ...........................................................................................................................55
5.4.7.1. Technical Description ...........................................................................................................................55
5.4.7.2. DISMOUNTING VACUUM TOILET .........................................................................................................57
5.4.7.3. INSTALLING VACUUM TOILET ..............................................................................................................57

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5.4. PASSENGER AMENITIES
The train -18 has better passenger amenities such as on board Wi-Fi infotainment, GPS
based passenger information system, plush interiors, Vacuum bio-toilet, diffused LED
Lighting, charging points beneath every seat, individual touch based reading lights,
intelligent air conditioning system that will adjust the cooling according to the climate
/conditions/occupancy ,concealed roller blinds facility Passenger with disability (PWD) to
enter the driving trailer coach using their wheel chairs, PWD friendly toilets, auto sensor
taps in the toilets modern pantry and food service facilities, rotating seats to match with the
direction of the train in executive class automatic sliding doors inside the coach
compartments modular luggage rack with glass bottom and many more.

5.4.1. PASSENGER INFORMATION SYSTEM

5.4.1.1. TECHNICAL DESCRIPTION
It is an electronic information system which will provide reliable and relevant information to
the passengers regarding the Destination, Present station, Next station using GPS
technology.

Warning : When working on the PIS, the vehicle MUST be secured against rolling away. Any
system components, on which it will be necessary to work. The usual safety rules for
electrical equipment must be observed:
 Switch off,
 Secure against re-energising,
 Check that no current is flowing.

Drawing & Part lists

The PIS equipment comprises the Head Code Unit, In Coach Display, Slave Destination Board
Unit, Speaker Unit and Ambient Noise Measurement Module. For dismantling and
assembling the PIS equipment, the following drawings and parts lists are to be noted

Designation Drawing number/Part code

Medha equipment's in DTC – Train 18 B-A675U-62946
Medha equipment's in TC – Train 18 B-A675U-63402
Medha equipment's in MC – Train 18 B-A675U-63399
HEAD CODE UNIT for in DTC – Train 18 B-A675U-63425
In coach Display Unit on DTC, MC,TC 90006401401
SPEAKER UNIT 90106416701

5.4.1.2. DISMOUNTING PIS EQUIPMENT

When dismounting the PIS equipment electrical and mechanical disconnection will be
necessary.
Dismounting Head Code Unit from car
 Power of the all Circuit Breakers
 Open the cover for HCD access
 Disconnect the Power, Communication and Earthing Cables from the Unit
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 Loosen and remove four M6X40LG (4no's) Screws of HCD.
 Remove the HCD from the Cab.

HEAD CODE UNIT

Mounting location of Head Code on DTC shell

Dismounting ICD Unit from car

 Power of the all Circuit Breakers
 Open the ICD Panel
 Disconnect the Power, Comm. and Earthing Cables from the Unit
 Loosen and remove four M6 - HEX NUT M6 (4no's) Nuts of ICD
 Remove the ICD from the Coach

Mounting location of IN COACH DISPLAY on DTC, MC&TC shell

Dismounting SBD from car
 Power of the all Circuit Breakers
 Remove the panel in front of SDB open the luggage rack cover
 Disconnect the Power, Comm. and Earthing Cables from the Unit
 Loosen and remove four M6X15LG (4no's) Screws of SDB
 Remove the SDB from the Cab

Dismounting Speaker Unit from car

 Power of the all Circuit Breakers
 Remove the speaker front plate for accessing the mtg. screws
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 Loosen and remove four M5X20LG (4no's) Screws
 Disconnect the Wago and Earthing Cables from the Unit
 Remove the Speaker from the Coach

Mounting location of Speaker unit

Dismounting ANM module from car

 Power of the all Circuit Breakers
 Remove the ANM front plate
 Loosen and remove four M5X20LG (4no's) Screws of ANM
 Disconnect the Wago and Earthing Cables from the Unit
 Remove the ANM from the Coach Power of the all Circuit Breakers

5.4.1.3. MOUNTING PIS EQUIPMENT

Mounting proceeds basically in the reverse order to dismounting. Manufacturer’s tips and
working instructions for mounting must be observed.

Final Inspection
All components must be tested for perfect functioning. All bolted items must be checked for
tightness.

5.4.2. CCTV
5.4.2.1. TECHNICAL DESCRIPTION
Closed Circuit Television (CCTV) Surveillance system is used to capture and record the live
view from cameras which are located in Ladies Compartment for post analysis purpose.

Warning: When working on the CCTVs. The usual safety rules for electrical equipment must
be observed:
 Switch off
 Secure against re-energising,
 Check that no current is flowing.

Drawing & Part lists

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The CCTVs equipment comprises the Dome Cameras, External Cameras, and Display Unit
CCTV. For dismantling and assembling the CCTVs, the following drawings and parts lists are
to be noted.

Designation Drawing number/Part Code

Medha equipment's in DTC – Train 18 B-A675U-62946
Medha equipment's in TC – Train 18 B-A675U-63402
Medha equipment's in MC – Train 18 B-A675U-63399
IP DOME CAMERA,1.3MP,2.8MM LENS 30701300003
IP WATERPROOF CAMERA,2MP,6MM LENS 30701300012
Display Unit CCTV 90108021501

5.4.2.2. REMOVAL OF CCTV

When dismounting the CCTVs electrical and mechanical disconnection will be necessary.
 Remove the Rear viewing camera DTC as shown in below fig.2.1
 Remove the Track viewing camera DTC as shown in below fig.2.1
 Remove the CCTV Display Unit in DTC as shown in below fig.2.2
 Remove the Camera dome as shown in belowFig.2.3
 Remove the Camera from Roof as shown in belowFig.2.4
 After removing the camera attach the dome to camera

Fig-2.1

Fig-2.2

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Fig-2.3

Fig2.4

5.4.2.3. MOUNTING CCTV

Mounting proceeds basically in the reverse order to dismounting. Manufacturer’s tips and
working instructions for mounting must be observed.

Final Inspection
All components must be checked for perfect functioning. All bolted items must be checked
for tightness and security of fixings must be checked before release into service.

5.4.3. AIR CONDITIONING SYSTEM

5.4.3.1. TECHNICAL DESCRIPTION
The RMPU (Roof Mounted Package Unit) is a modular type completely assembled and
factory gas charged with hermetically sealed refrigerant. Being a sealed system with short
connecting piping, incidence of leakage is almost eliminated. Due to its being mounted on
the roof, damage due to flash flooding, cattle runs, flying ballast and condenser clogging is
eliminated.

Two microprocessor-controlled roof-mounted compact units Supply conditioned air leaves

the air conditioner through a front opening. It is discharged into the supply air duct running
above the false ceiling of the passenger saloon. Return air enters the air conditioner through
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two opening in the front. The openings interface with the return duct and grilles installed in
the passenger saloon. Ambient air enters the air conditioner through two openings in the
bottom. Ambient air enters the condensers on both sides of the air conditioner. After
passing through the heat exchangers, the condenser fans push the hot air vertically up into
the atmosphere.

The electrical couplers are situated on the left side of the unit. There are three couplers for
the three phase power supply, DC power supply and control system connections·
Attachment points for the protective earth connections are provided on both sides of the
unit.

Eight mounting brackets are provided to fasten the air conditioner to the car roof. The side
holes interface with the lifting beam when the unit is picked and handled with hoist or crane.

Condensate and rain water drains through openings in the bottom.

Warning: When working on the Air Conditioning, the vehicle must be secured against rolling
away. The usual safety rules for electrical equipment must be observed:
 Switch off,
 Secure against re-energising,
 Check that no current is flowing.

5.4.3.2. DISMOUNTING AIR CONDITIONING UNIT

When dismounting the roof-mounted air-conditioner, electrical and mechanical
disconnection will be necessary.

Electrical disconnection
When disconnecting the air-conditioning unit, it is essential that the manufacturer’s handling
instructions are observed.
Warning: Cables hanging loose must be secured both against being damaged and becoming
dirty.
 Disconnect the power-supply to the air-conditioning unit
 Disconnect the earthling cable.

Mechanical Disconnection
When dismounting or re-installing the air-conditioning equipment, it is essential that the
manufacturer’s instructions are observed.

Pick up the air conditioner with a eight-legged lifting beam. Do not use slings. Do not lift up
the air conditioner with a fork lift. The air conditioner is fastened in the roof trough with
eight M16 screws.

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Fig: Roof Mounted Air ConditionerRCAC-2400EF

Final Inspection
Correct function of the air-conditioning equipment and the security of its fastening must be
checked before release to traffic.
Note: For further details, please refer to OEM’s manual.

5.4.4. LIGHTING
5.4.4.1. Technical Description
Saloon light 110CVDC (TVP2200x): Saloon Light consists of Direct & In-Direct Lighting; it
will be mounted on AC grills of all the coaches.

Gangway spot light 110VDC (TVP22003):Gang Way lights will be mounted on Vestibule
zone of all the coaches

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Lights Quantity in different coaches:

S. no. Description DTC MC & NDTC TC

1 SALOON LIGHT 110VDC 1948MM 16 32 28
2 DIFFUSER FOR SALOON LIGHT 1948MM 16 32 28
3 SALOON LIGHT 110VDC 1830MM 0 0 4
4 DIFFUSER FOR SALOON LIGHT 1830MM 0 0 4
5 SALOON LIGHT 110VDC 1101MM 4 0 0
6 SALOON LIGHT 110VDC 1652MM 4 0 0
7 DUMMY DIFFUSER 400MM 0 4 0
8 DUMMY DIFFUSER 200MM 0 0 4
9 DIFFUSER SAWING 1213MM 4 0 0
10 DIFFUSER SAWING1710MM 4 0 0
11 GANGWAY LIGHT 110VDC 13 13 13

Safety Instruction
 Helmets, Hand gloves, Safety Shoes, Goggles should be used for Personal protection.
 Person should not have loose long hair and loose clothes.
 Pay attention while loading equipment to avoid accidents; don't keep hands or
fingers in between mounting bracket and equipment while loading

Drawings & Part list

S. no. Drawing. no. Part name
1 DRW-1000-2676 REV PR0 SALOON LIGHT 110VDC 1948MM
2 DRW-1000-2674 REV PR0 DIFFUSER FOR SALOON LIGHT 1948MM
3 DRW-1000-2677 REV PR0 SALOON LIGHT 110VDC 1830MM
4 DRW-1000-2673 REV PR0 DIFFUSER FOR SALOON LIGHT 1830MM
5 DRW-1000-3377 REV PRO SALOON LIGHT 110VDC 1101MM
6 DRW-1000-3383 REV PRO SALOON LIGHT 110VDC 1652MM
7 DRW-1000-2668 REV PR0 DUMMY DIFFUSER 400MM
8 DRW-1000-2669 REV PR0 DUMMY DIFFUSER 200MM
9 DRW-1000-3384 REV PRO DIFFUSER SAWING 1213MM
10 DRW-1000-3385 REV PRO DIFFUSER SAWING1710MM
11 DRW-1000-2675 REV PR0 GANGWAY LIGHT 110VDC
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5.4.5. SEATS
The seats in train-18 providing a high degree of comfort and safety to the passenger. The
seats are distributed on both sides of a central aisle. They are composed, by modules, two
seats on both sides in the case of executive class and three seats on one side and two seats
on the other in the case of chair car. Seats that perfectly match the robustness and rigidity
with their comfort, especially suitable for easy maintenance, both in the change of
upholstery and in the replacement of components, being able to disassemble these partially,
thus lightening the time spent in its conservation.
Out of 16 coaches, 12 coaches are normal chair car type with 78 seats, two coaches are
executive type with 52 seats and two driving coaches are normal chair car type.

Seating in normal AC Chair Car

Seating in Executive AC Chair Car

The total seating capacity of the train 18 is 1128.

Coach Class No of seats No of coaches

DTC II AC 44 2
TC II AC 78 4
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MC II AC 78 7
NDTC II AC 78 1
NDTC Executive AC 52 1
MC Executive AC 52 1

5.4.5.1. TECHNICAL DESCRIPTION NDTC/EC SEATS

The seats are designed to offer the best ergonomic application, providing them with a
controlled recline by sliding the seat forward and the inclination of the backrest, the upper
part of the backrest does not slide forward (only the lower one), causing the position of the
backrest to be reclined in the relax position or vice versa thanks to the action of the
mechanical mechanism that we regulate by pressing the recline buttons, that we find
located in the lateral housing of each square. We also have a second system that we operate
using the lever that is located under the seat and that advances the seat to 50mm extras
regardless of the backrest. One of the particularities of the design is a folding table that is
placed in the back structure of the chair (this will always serve for the seat that is behind the
chair). All seats have their own power outlet. All elements subject to periodic maintenance
or restoration are designed for rapid disassembly within the design's particularities. The
seats pivot on a center of rotation, which allows them to turn 180 degrees on always in the
direction of the window. To effect the blocking and unblocking of this rotation must
bemounted lateral support that contains the mechanism that acts on the seat lock.

Technical Data -NDTC/EC seats

Total width 1209 mm
Maximum total height 1273 mm
Total depth 655 mm
Maximum seat height 459 mm
Space between arms 504 mm
Side armrest 53 mm
Center armrest (2pl) 80 mm
Depth of seats 468 mm
Armrest length 352 mm

General description-NDTC/EC seats

Upholstered and foam sets: They are formed by metallic or plastic reinforcement
structures, these serve as a support for adhesion to the cushions, the cushion's is made of
cold molded polyurethane foam. There are three independent flutes, the soft backrest, seat,
armrest. All three are upholstered with removable fabric covers.

Lateral and central armrests: They are formed by folding metal reinforcement structures
that serve as support for the fixings of the fluffs, the fluff is made of cold molded
polyurethane foam with a contribution of graphite.

The central armrest will only be found in two-seater seats.

The soft ones of the armrest will be upholstered with some fabric covers.

Power suppliers: Each square, has a 220 V socket with alveoli with child protection, the
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One individual shot in the middle central part of the 2-seater and another on theside.

Folding table: The table is folding, each seat has its own, the table is on the back of the chair,
this has a security mechanism so that it cannot be opened accidentally.

Aisle grab handle: Some seats are equipped with an aluminum handle on the aisle side, to
facilitate the grip of passengers standing or circulating in the corridor.

Reclining control: The recline is made thanks to the action on a special locking
mechanism, it acts on the advance, and the inclination of the seat and backrest
respectively, the advance of the seat causes the backrest to tilt creating an ergonomic
position that we call relax. All this mechanical management is communicated thanks to a
special clutch cable. The control over the recline, the user will get through the use of the
corresponding buttons, the consoles found in the side cases of the chair.

We also have the possibility of advancing the seat by an extra 50mm by activating the
lever located in the lower part of the seat.

Estructure covers: The side fairings are made of magnesium, and are fixed to a rear
fairing made of pressed sheet metal, which, when joined by means of special bolts, form
the structure of the seat. In this same structure we will fix the following elements:
backrest guides, little table, magazine rack, table top, armrests, side cases.

Estructure profiles:the bench is formed by two profiles of aluminium extrusion especially

created to house a special fastener that holds the fairing structure on one side, and
cantilever on the other. These special aluminium profiles have been designed with the
appropriate shapes to obtain, together with the rest of the structural elements, a solid
and light armchair.

Turn up system :The seats are attached to the floor of the car by a central structure fixed to
the floor by four points; this structure contains the rotation system that is operated with the
foot by pressing the actuator located in the lower part of the wall.

Warning :All the assembly and disassembly actions of the seat must be done with the
armchair disconnected from the electrical network.

Drawings (NDTC/EC) seats

For dismantling and assembling the seat, the following drawings are to be noted

Designation Drawing number

NDTC/EC) seats TraiN18/MC/EC/AC 6-1-001

5.4.5.2. Dismounting & Mounting (NDTC/EC) seats

As per OEM’s manual.

Technical data Seat 2 places 2CC (Chair car) with accessories

Total width of the module 1010 mm
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Useful width 452 mm
Seat height on the floor 455 mm
Plumb 614 mm
Seat deep 454 mm
Total height 1227mm

Technical data Seat 3 places 2CC (Chair car) with accessories

Total width of the module 1496 mm
Useful width 452 mm
Seat height on the floor 455 mm
Plumb 614 mm
Seat deep 454 mm
Total height 1227mm

5.4.6. DOORS
5.4.6.1. INTERNAL SLIDING DOOR
Technical Description
Interior sliding doors consist of a door leaf, drive and carrier mechanism, door leaf bottom
guide, bearing counterpart of the doors, electric block, and a pair of emergency
disconnecting switches. The left and the right door versions are mirror-opposed.

Technical data:
 Internal passing (width)810 ±5 mm
 Internal passing (height) -1960 ±5mm
 Distance between door posts-900 ±2.5 mm
 Opening time of the door leaf 3-5 s
 Weight of the door leaf-30 kg
 Weight of the carrier mechanism-18 kg
 Nominal voltage-110 V DC ±30 %
 Nominal current-0.5 A, max. 2 A

Interior sliding doors Left

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Name of the component:

1. Circular cam
2. Washer
3. Carrier
4. Padding
5. IR energy sensor
6. Emergency release switch
7. Wire
8. Rare wire
9. Equipped leaf L
10. Complete drive L
11. Terminal block X8 + RJ
12. Main cable harness

Interior sliding doors Right

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Name of the component:

1. Lower rails
2. Ringlet
3. Cover L
4. Carrier
5. Terminal block console
6. Glass ECE 43R
7. Padding
8. Contact bar
9. Switch
10. Silent-block
11. Wago clamp
12. Leaf frame L

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Warning: Before any work on the door system, the power supply of the door has to be
Switched off to prevent injury.
• When using noted lubricants, safety instructions of lubricants manufacturer have to be
observed to avoid health risks and environmental damage.
• Instructions of manufacturers regarding the processing of lubricants have to be considered
to ensure compatibility with other materials

Drawing & Part lists

For dismantling and assembling the internal sliding door, the following drawings and parts
lists are
Designation Drawing number to be
internal sliding door left 1.0269.36.01.0 noted
internal sliding door right 1.0269.36.02.0

Dismounting Internal sliding

Electrical and mechanical separation is necessary when dismounting the internal sliding
Door.

Electrical Separation
When separating the door, the manufacturer’s instructions MUST be observed.

Mechanical Separation
When dismounting Manufacturer’s instructions MUST be observed.

Mounting Internal Sliding Door

Mounting is accomplished basically in the reverse order to dismounting. Manufacturer’s
working instructions must be observed.

Final Inspection Internal Sliding Door

The door must be checked as to correct function and secure fixing before release to traffic.

5.4.6.2. SINGLE LEAF PLUG DOOR

Technical Description
Each car is equipped with 4 electrical single leaf sliding plug doors whereas every door is
controlled by the IFE door control unit MDC2-110-I-RS4.The door control unit MDC2-110-I-
RS4 controls the door and step motors in open and close position, in accordance with local
door control commands (e.g. push button) , train control signals (e.g. v > 5kph, central close).

Technical Data
 Voltage supply: 110VDC +25/-30%
 Pressure supply: 6 – 9bar (IFE pressure regulator is pre-set at 6bar)
 Door opening time 4 ± 1 seconds
 Door closing time 4 ± 1 seconds
 Step opening time 2 ± 1 seconds
 Step closing time 2 ± 1 seconds
 Average power consumption of the door 140 W (opening and closing sequence)
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 Maximum power consumption of the door 500 W (for a time of 500 ms)(locking,
unlocking, reopening)
 Free opening width door 800 +5/-0 mm
 Free opening width step 150 +5/-0 mm Maximum motor current: 10A

Warning: Before any work on the door system, the power supply of the door has to be
Switched off to prevent injury.
• When using noted lubricants, safety instructions of lubricants manufacturer have to be
observed to avoid health risks and environmental damage.
• Instructions of manufacturers regarding the processing of lubricants have to be considered
to ensure compatibility with other materials

Drawing & Part lists

For dismantling and assembling the Single leaf Plug Sliding Door Assembly drawing, the
following drawings and parts lists are to be noted
Designation Drawing number
Single leaf Plug Sliding Door 66408U1AR11
Assembly drawing

5.4.7. VACUUM BIO-TOILET

5.4.7.1. Technical Description
Vacuum toilet assembly is designed to transport human waste from the toilet bowl to a
waste tank or sewage pipe. Vacuum Bio-toilets are based on vacuum pumps and comprise
three main elements: appliances such as toilets, piping, and the collection units. The
generation units generate the vacuum in the piping using a vacuum pump. When a toilet is
flushed, the lower pressure atmospheric air flows into the higher pressure piping through
the toilet. The air travels at high velocity because of the pressure difference, carrying the
waste water with it.

Components Description – (Squatting system India):

Vacuum toilet (squatting or western type) equipped with a pinch valve
• Base unit equipped with an sliding gate valve
• Water system
• Pneumatic panel
• Connection set
• Cable set

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1 Bowl Unit 2 Pressure Guard

3 Pinch Valve 4 Water Inlet Valve
5 Liquid Level Guard 6 Flush Nozzle (5x)

Technical Data – Squatting Toilet:

 Materials Bowl-Stainless steel
 Weight approx. -12.5 kg
 Supplies Compressed air-6.2 (4 bar to 10 bar), Filter 5 μm max. grain size
 Water Pressure: 0.2 bar to 1.5 bar Filter: 250 µm max. grain size Minimum flow rate:
2 l/min
 Electrical-24 V DC

External connections
 Mechanical-Mounting holes Ø 6.5 mm (8x)
 Compressed air Ø 6 mm
 Water Ø 12 mm
 Outlet Ø 48 mm
 Electrical connections Mini Mate-N-Lok, 4 pol

Warning: When working on the vacuum toilet,

 Wear protective clothing, do not eat, drink or smoke!
 Immediately change and disinfect contaminated clothing!
 Thoroughly clean yourself with soap and water after working in a sewage handling
area or coming in contact with
 sewage handling equipment. This precaution is an absolute requirement before
eating, drinking, smoking or performing any hand-to-mouth functions!
 Skin abrasions, punctures or any other wounds require immediate and appropriate
medical attention!
 After coming in contact with sewage, do not handle potable water hoses or work on
potable water systems until thoroughly washed!
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 Sewage spills are to be cleaned up immediately, before they dry. Rinse the
contaminated area with water and non-scented disinfectant!

The usual safety rules for electrical equipment must be observed:

 Switch off,
 Secure against re-energizing,
 Check that no current is flowing.

5.4.7.2. DISMOUNTING VACUUM TOILET

When dismounting the vacuum toilet, electrical and mechanical, air, water disconnection
will be necessary.

Electrical disconnection
When disconnecting the vacuum toilet, it is essential that the manufacturer’s instructions
are observed.

Mechanical Disconnection
When dismounting or re-installing the vacuum toilet, it is essential that the manufacturer’s
instructions are observed.

5.4.7.3. INSTALLINGVACUUM TOILET

Installation proceeds basically in the reverse order to removal. Manufacturer’s tips and
working instructions for assembly must be observed.

Final Inspection
All items are to be checked for correct functioning, and security of fixings must be checked
before release into service.

Note: For further details, please refer to OEM’s manual.

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CONTENTS – Traction and Control

5.5 TRACTION AND CONTROL ..................................................................................................... 65

5.5.1 Traction Converter .................................................................................................... 65
5.5.1.1 Important Parameters of LTC .................................................................. 65
5.5.1.2 Line and Traction Converter.................................................................... 66
5.5.1.3 Line Converter Protections ..................................................................... 67
5.5.1.4 Traction Inverter ..................................................................................... 67
5.5.1.5 Line & Traction Control Unit (LTCU) ........................................................ 68
5.5.1.6 DC Link Capacitor .................................................................................... 68
5.5.2 Auxiliary Converter ................................................................................................... 69
5.5.2.1 Auxiliary Power Supply............................................................................ 69
5.5.2.2 Functional Description ............................................................................ 70
5.5.2.3 Important Parameters of Auxiliary Converter ........................................ 70
5.5.2.4 ACU consists below modules/ sections:.................................................. 71
5.5.2.5 Auxiliary Loads ........................................................................................ 74
5.5.2.6 Cooling .................................................................................................... 75
5.5.3 Battery Charger ......................................................................................................... 76
5.5.3.1 Sections of Battery Charger .................................................................... 77
5.5.3.2 Technical Data ......................................................................................... 78
5.5.4 Brake Chopper Resistor............................................................................................. 79
5.5.4.1 Brake Chopper Description ..................................................................... 80
5.5.5 D.C. Link Earthing Switch Unit ................................................................................... 81
5.5.5.1 DC Link Capacitor .................................................................................... 82
5.5.6 Pantograph ................................................................................................................ 82
5.5.6.1 Technical Details ..................................................................................... 82
5.5.6.2 Description of Pantograph Components................................................. 84
5.5.6.3 Pneumatic Control (Valve plate) ............................................................. 86
5.5.6.4 Pneumatic Control .................................................................................. 86
5.5.6.5 Panto Control .......................................................................................... 87
5.5.6.6 Pantograph status Indication Lamps ....................................................... 88
5.5.6.7 Auto Drop Down (ADD) feature .............................................................. 88
5.5.6.8 Over Reach Detection (ORD) feature ...................................................... 88
5.5.6.9 Panto mode ............................................................................................. 89
5.5.7 Vacuum Circuit Breaker (VCB)................................................................................... 89
5.5.7.1 Technical Details ..................................................................................... 90
5.5.7.2 Constructional Features .......................................................................... 91
5.5.7.3 Operation of VCB .................................................................................... 93
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5.5.7.4 Opening of VCB ....................................................................................... 95

5.5.7.5 Vacuum Switch Tube Construction ......................................................... 96
5.5.7.6 VCB Control ............................................................................................. 97
5.5.8 Earthing Switch for VCB ............................................................................................ 98
5.5.8.1 Technical details ...................................................................................... 99
5.5.8.2 Constructional Features .......................................................................... 99
5.5.9 Lightning/ Surge Arrestor ........................................................................................ 100
5.5.9.1 Constructional Features ........................................................................ 101
5.5.10 Traction Transformer .............................................................................................. 102
5.5.10.1 Technical Specifications ........................................................................ 102
5.5.10.2 Constructional Description.................................................................... 103
5.5.10.3 TRANSFORMER MONITORING .............................................................. 108
5.5.11 Traction Motor & Gear Drive Unit .......................................................................... 110
5.5.11.1 Technical Data of Traction Motor ......................................................... 111
5.5.11.2 Constructional Details of Traction Motor ............................................. 112
5.5.11.3 Gear Drive ............................................................................................. 117
5.5.11.4 Technical Data for Gear Drive ............................................................... 117
5.5.11.5 Constructional Details of Gear Drive..................................................... 118
5.5.12 Jumper Couplers ..................................................................................................... 122
5.5.13 Pantry/ Isolation Transformer................................................................................. 123
5.5.14 Master Controller .................................................................................................... 124
5.5.14.1 Technical Data ....................................................................................... 125
5.5.15 Driver Desk .............................................................................................................. 126
5.5.15.1 Section A is divided in 10 panels ........................................................... 126
5.5.15.2 Driver Display Unit (DDU)...................................................................... 135
5.5.16 ECC and CRW Unit ................................................................................................... 136
5.5.16.1 DTC CRW ............................................................................................... 136
5.5.16.2 DTC GCRW ............................................................................................. 138
5.5.16.3 MC ECC, TC ECC & NDTC ECC ................................................................ 140
5.5.17 Light (Headlight & Marker Flasher) ......................................................................... 143
5.5.17.1 Head Light ............................................................................................. 143
5.5.17.2 Flasher Light .......................................................................................... 144
5.5.17.3 Marker Light/Tail Lamp ......................................................................... 144
5.5.18 Electrical Driven Wiper............................................................................................ 145
5.5.18.1 Wiper Linkage Assembly ....................................................................... 145
5.5.18.2 Wiper Arm Assembly............................................................................. 146
5.5.18.3 Wiper Blade ........................................................................................... 147
5.5.18.4 Wash Tank/Pump Assembly.................................................................. 147

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5.5.19 PT & CT .................................................................................................................... 148

5.5.19.1 Technical Details of PT .......................................................................... 150
5.5.20 Earth Return Current Unit (ERCU) ........................................................................... 150
5.5.20.1 Technical data ....................................................................................... 152
5.5.21 Battery (VRLA Battery) ............................................................................................ 152
5.5.21.1 Major Advantages of VRLA Batteries .................................................... 152
5.5.21.2 Charging of Batteries............................................................................. 153
5.5.21.3 Charge Method ..................................................................................... 153
5.5.22 Mini Pantry Equipment ........................................................................................... 154
5.5.22.1 Technical Specification: ........................................................................ 154
5.5.22.2 Equipment Constructional Detail .......................................................... 155

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LIST OF FIGURES

Figure 1: Schematic Diagram of Line and Traction Converter ........................................... 66

Figure 2: Block Diagram of Line Converter ........................................................................ 67
Figure 3: Auxiliary Converter Schematic Diagram ............................................................. 71
Figure 4: Bloc Diagram of Battery Charging System .......................................................... 77
Figure 5: Battery Charger ................................................................................................... 78
Figure 6: BC Heat Sink Assembly ........................................................................................ 78
Figure 7: Brake Chopper Resistor....................................................................................... 80
Figure 8: Block Diagram of Brake Chopper Resistor .......................................................... 80
Figure 9: Brake Chopper Unit without Covers ................................................................... 81
Figure 10: DC Link Earthing Switch ...................................................................................... 81
Figure 11: Pantograph at the Roof of Trailer Coach ............................................................ 82
Figure 12: Vacuum Circuit Breaker ...................................................................................... 89
Figure 13: Earthing Switch for VCB ...................................................................................... 99
Figure 14: Lightning/ Surge Arrester .................................................................................. 100
Figure 15 Traction Transformer ........................................................................................ 102
Figure 16: Block Diagram of Traction Transformer Windings............................................ 103
Figure 17: Train Set Bogie with Traction Motor and Gear Box Assembly ......................... 111
Figure 18: Main Assembly of Traction Drive Complete ..................................................... 112
Figure 19: Stator ................................................................................................................. 113
Figure 20: Rotor ................................................................................................................. 113
Figure 21: Motor Connection ............................................................................................. 114
Figure 22: Air Outlet/ Inlet of Traction Motor ................................................................... 115
Figure 23: Speed Sensor Location in Stator ....................................................................... 115
Figure 24: Temperature Sensor Location in Sensor ........................................................... 116
Figure 25: Flood Water Drain Plug (53) ............................................................................. 116
Figure 26: Drive Complete ................................................................................................. 117
Figure 27: Gear Drive Assembly ......................................................................................... 118
Figure 28: Gear Drive Sub-Assemblies ............................................................................... 119
Figure 29: Main Component of Gear Box .......................................................................... 119
Figure 30: Motor Coupling ................................................................................................. 120
Figure 31: Gear Box Housing .............................................................................................. 121
Figure 32: Overview of the Location of Jumper coupler in Loco ....................................... 122

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Figure 33: Mounting location of power coupler assembly on under-frame-motor coach 123
Figure 34: Mounting location of power coupler assembly ................................................ 123
Figure 35: Isometric View of Isolation Transformer .......................................................... 124
Figure 36: Master Controller .............................................................................................. 124
Figure 37: Dimensions of Master Controller...................................................................... 124
Figure 38 : Driver Desk (Section-A) ..................................................................................... 126
Figure 39: Cabin Control Switches ..................................................................................... 127
Figure 40: MR-BP Duplex Gauge and BC Gauge ................................................................ 127
Figure 41: Main Display Panel ............................................................................................ 128
Figure 42: Driving Control Switches ................................................................................... 128
Figure 43: Speed Recorder ................................................................................................. 129
Figure 44: Indications for Train Functional Parameters .................................................... 129
Figure 45: Cabin Control Switches for Assistant Driver and Gauges ................................. 130
Figure 46: MMI unit of PIS (Operation by Assistant Driver) .............................................. 130
Figure 47: Doors control switches ..................................................................................... 131
Figure 48: Brake Controller ............................................................................................... 132
Figure 49: Master Controller, Horn, Signal bell and VCD Reset Switch ............................. 132
Figure 50: Mic, Horn , Signal Bell and VCD Reset Switch ................................................... 133
Figure 51: Emergency Brake Handle .................................................................................. 133
Figure 52: Front Bottom side components of Driver Desk (Section-C1) ........................... 134
Figure 53: Front Bottom Internal side components of Driver Desk (Section-C2) .............. 134
Figure 54: Bottom Left side components of Drivers desk (Section-C3) ............................. 134
Figure 55: DTC CRW and GCRW Location .......................................................................... 136
Figure 56: CRW Front and Rear View ................................................................................. 137
Figure 57: GCRW Front and Rear View .............................................................................. 139
Figure 58: Location of ECC in MC, TC, NDTC ...................................................................... 141
Figure 59: ECC Front and Rear View .................................................................................. 142
Figure 60: Head Light ......................................................................................................... 144
Figure 61: Flasher Light ...................................................................................................... 144
Figure 62: Marker Light ...................................................................................................... 145
Figure 63: Wipers ............................................................................................................... 145
Figure 64: Wiper Motor ..................................................................................................... 146
Figure 65: Wiper Arm Assembly ........................................................................................ 146
Figure 66: Wash Tank/Pump Assembly ............................................................................. 147

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Figure 67: Filler Spout ........................................................................................................ 148

Figure 68: CT on Roof of TC ................................................................................................ 149
Figure 69: Potential Transformer ....................................................................................... 150
Figure 70: ERCU on Boogie................................................................................................. 151
Figure 71: Earth Return Current Unit (ERCU)..................................................................... 151
Figure 72: Battery............................................................................................................... 152
Figure 73: Hot Case ............................................................................................................ 156
Figure 74: Refrigerating Unit .............................................................................................. 157
Figure 75: Water Boiler ...................................................................................................... 157

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LIST OF TABLES

Table 1: Parameters of LTC .................................................................................................... 65

Table 2: Parameters of Auxiliary Converter .......................................................................... 70
Table 3: Auxiliary Loads - 415V AC, 3 phase .......................................................................... 74
Table 4: Auxiliary Loads - 110 VDC ....................................................................................... 75
Table 5: Technical Data of Battery Charger ........................................................................... 78
Table 6: Parameters of Brake Chopper Resistor ................................................................... 79
Table 7: Technical Details of Pantograph .............................................................................. 82
Table 8: Technical Details of Vacuum Circuit Breaker ........................................................... 90
Table 9: Technical Details of Earthing Switch for VCB........................................................... 99
Table 10: Traction Transformer Winding Specifications ....................................................... 102
Table 11: Traction Transformer Voltage Rating .................................................................... 102
Table 12: Traction Transformer - Dimensions and weights .................................................. 103
Table 13: Technical Data of Traction Motor.......................................................................... 111
Table 14: Technical Data for Gear Drive................................................................................ 117
Table 15: Bearings Details of Gear Box ................................................................................. 121
Table 16: Technical data of Master Controller ...................................................................... 125
Table 17: Technical Details of Potential Transformer .......................................................... 150
Table 18: Technical Details of Earth Return Current Unit (ERCU) ......................................... 152
Table 19: Battery Charge Time According to Module Volts .................................................. 153
Table 21: Technical Specification of Hot Case ...................................................................... 154
Table 22: Technical Specification of Refrigerating Unit ....................................................... 155
Table 23: Technical Specification of Water Boiler ................................................................ 155

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5.5 TRACTION AND CONTROL

5.5.1 Traction Converter

Each basic unit has 2 motor coaches and each motor coach has 4 traction motors.
Each motor coach has 2 nos. of line and traction converter (LTC) mounted under
slung and each control two traction motors of a bogie.

Input power to line converter comes from transformer kept in adjacent trailer coach.
Line and traction converters are forced air-cooled.

5.5.1.1 Important Parameters of LTC

Table 1: Parameters of LTC

Description Rating
Input voltage 950 V AC at 25 kV AC
Input current 639 A
Weight <800+/-50 Kg
Dimension 2250*1220*700 mm
Line and traction converter rating 554 KVA

Each traction converter cubicle consists of one-line converter, DC link, one traction
inverter and line & traction control unit.

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5.5.1.2 Line and Traction Converter

Figure 1: Schematic Diagram of Line and Traction Converter

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Line Converter

The line converter interfaces with transformer secondary traction winding AC

voltage on one side and DC link on the other side.

Main function of line converter is to maintain stable DC link voltage at 1800 V

irrespective of line and load variations at unity power factor.

Figure 2: Block Diagram of Line Converter

The line converter consists of single-phase full bridge rectifier with IGBTs as active
switching devices.

Line converter consists of input pre-charging circuit and line contactor. It consists
of output DC link capacitor.

The DC link consists of earth leakage detection circuit, DC link capacitor bank and
brake chopper circuit (for over voltage protection).

5.5.1.3 Line Converter Protections

 Transformer primary over voltage and under voltage protection.

 Traction transformer secondary over current protection.
 IGBT heat sink over temperature protection.
 Failure of pre-charging contactor / resistor protection.
 Failure of main contactor protection.

5.5.1.4 Traction Inverter

The traction inverter consists of a 3-phase full bridge inverter with IGBTs as active
switching devices. Main function of TIC:
 Converts the DC input voltage to 3-phase Variable Voltage Variable Frequency
(VVVF) output.
 Controls the traction motor torque in both motoring mode and braking mode.
 Each inverter controls two traction motors in parallel.
 Controls wheel slip/slide.
 Performs various fault diagnostics.

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Traction Inverter protections:

 Output over current protection.

 Output short circuit protection.
 IGBT heat sink over temperature protection.
 Traction motor over temperature protection.
 Traction motor over speed protection.
 Phase imbalance protection.

5.5.1.5 Line & Traction Control Unit (LTCU)

Line & Traction Control Unit (LTCU) controls both the line converter and traction
inverter and communicate switch the Main Control Unit (MCU) through CAN
interface. All the LTC's are similar in construction.

5.5.1.6 DC Link Capacitor

DC link capacitor has following functions:

• DC link capacitor is used to buffer the energy differences between line-side

and motor-side of the converter.
• DC link capacitor absorbs the harmonic currents produced by line side and
motor-side of the converter, thus reducing the ripple voltage.
• DC link capacitor is used to limit the switching over voltages of IGBTs. These
over voltages occur due to loop inductance.
• Two DC link capacitors of 2mF value are connected in parallel and forms the
DC Link and are directly connected to the IGBT Phase modules.

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5.5.2 Auxiliary Converter

Auxiliary Converter is used to supply power for 3-phase 415 V loads, 110 V DC and
Battery charger. Auxiliary Converter Unit is provided under slung in each TC coach of
a Basic unit (to supply all power supply requirements in that Basic Unit).

Auxiliary converter generate 415 V AC and 110 V DC to provide supply to various

loads. A 20 kVA isolation transformer is provided in each coach to convert 415 V AC
supply to 230V AC and 110 V AC. 230 V AC supply is used for pantry related loads and
toilet related loads like shaver and hand drier. 110 V AC supply is used for laptop and
mobile charging for passengers.

5.5.2.1 Auxiliary Power Supply

 All auxiliaries and controls of coaches are required to work on two voltages
415VAC, 3phase, 50Hz and 110VDC.
 Auxiliary converter unit is required to generate these types of voltages to serve
these loads.
 It gets power directly from 2 nos. of secondary windings of transformer.
 Transformer and auxiliary converter are mounted in trailer coach (TC).
 It is mounted under-slung and forced air cooled system type.
 Auxiliary converter is a PWM based IGBT converter, which converts 285VAC –
450V AC into two outputs:

i. Output-1: 415 V ac (line to line), 3 phase, 50Hz

ii. Output-2: DC output is isolated from input by using DC -DC isolation

transformer. DC output is connected to BN Bus.

415VAC, 3phase, 50Hz loads

 RMPU
 CAB AC

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 Main compressor
 Traction converter cooling blowers
 Transformer radiator fan
 Transformer oil pump
 Water pump for toilet tank
 Aux converter cooling blower.

110VDC Loads

 Battery charging

 Coach, vestibules and driver cabin normal lights

 Coach and driver cabin emergency lights
 Twin beam/ auxiliary head light, marker light, tail light, flasher light, cluster
light, spot lights, passenger alarm
 Indication light, electronic signal bell
 Control electronics loads: PIS, CCTV, Relays, Contactors,
 Driver desk, brake systems and all other control units
 Auxiliary compressor for pantograph
 Emergency ventilation blowers
 110Vdc toilet loads, seat lights & doors.

5.5.2.2 Functional Description

Auxiliary power supply consists of two physical cubicles in each basic unit.

(i) Auxiliary Converter Unit (ACU) - Each ACU consists of below modules

 AC1 module (415VAC 3-phase inverter module)

 AC2 module (415VAC 3-phase inverter module)
 110 VDC converter module
(ii) Battery Charging System (BCS)

5.5.2.3 Important Parameters of Auxiliary Converter

Table 2: Parameters of Auxiliary Converter

Requirement Parameters
AC input 285 V to 450 V, 1 phase, AC input from auxiliary secondary
voltage winding of main transformer
Control supply 77V to 137.5 V DC from battery (110Vdc nominal)
AC-1 output 275 kVA, 415V±5% (L-L), 50 Hz±3%, 3 Phase, Sine wave (at
capacity >19kVac OHE) at <19kVac OHE, output voltage shall drop by
maintaining V/F ratio constant.
AC-2 output 235kVA, 415V±5% (L-L), 50Hz±3%, 3 Phase, Sine wave (at
capacity >19kVac OHE) at <19kVac OHE, output voltage shall drop by
maintaining V/F ratio constant.
DC converter 115 V to 130 V DC (It is varying as per DC load sharing current
output requirement) DC Power: 30kW at 110V DC (BN, BD & battery
capacity charger loading on this).
Efficiency 92%
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Schematic description of ACU

Figure 3: Auxiliary Converter Schematic Diagram

5.5.2.4 ACU consists below modules/ sections:

 Input section
 AC-1 module (line converter & inverter section including master control)
 AC-2 module (line converter & inverter section including master control)
 415VAC output section
 DC converter module
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 DC output section
 DC link voltage indicators
 Control &communication connectors
 Blower section
 Isolation switch.

Input section

• The input of the auxiliary converter is taken from the independent secondary
windings of main transformer.
• Input section consists of input fuse, input main & pre- charging contactors &
input ac current sensor.
• The purpose of input fuse is to protect DC link from over current.
• The purpose of input ac current sensor is to control the line converter for
regulating DC link voltage & to maintain unity power factor at input.
• The purpose of pre- charging contactor & resistor is to limit the DC link
capacitor charging current at source sudden ON. It will be switched off when
DC link voltage reaches to defined value.
• The purpose of input main contactor is to isolate the unit from source if any
abnormalities in ACU.

AC-1 & AC-2 Modules

AC-1 & AC-2 modules consists of below sections:

i. Line converter section
ii. Inverter section
iii. Master & module control section (both control &communication)

Line Converter Section

• The line converter section takes the input (variable single phase AC input)
from secondary winding of main transformer and converts to fixed DC-link by
controlling pulses of the IGBT's by using DSP controller.
• Line converter maintains unity power factor at AC input. Full bridge
architecture is used for the line converter.
• Transformer primary, secondary, DC link voltages and input AC current
sensors are used for feedback control, display the parameters and protect the
line converter.
• Line converter output is connected to common DC link.

Inverter Section

• The inverter takes the input from common DC link. The IGBT based inverter
section is provided after DC link capacitor. A three phase full bridge
architecture is used for the inverter.
• An IGBT based inverter is controlled by using DSP. Input voltage and output
current sensors are used for feedback control, display the parameters and
protect the inverter.
• Temperature sensors are provided for sensing the heat sink temperatures of
the IGBT modules and for protecting it.
• DSP controller is used for PWM control of line converter &inverter.
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Master Control Section

• There is a controller which controls the line converter &inverter. It is also

responsible for monitoring and protecting the complete auxiliary converter
unit and records the faults in the memory.
• It also interfaces to TCMS to get commands and to send status to display at
driver cabin through ethernet communication.
• It is also responsible for driving the contactors & to monitor it's healthiness by
taking their feed backs.
• It is also responsible for handling & processing the hardwired signals which
are coming from LCC.

ACU 415VAC Output Section

• It consists of sine filter inductor, capacitor, current transformers, ELD sensor &
output contactor.
• 3Ph 415V AC, which is passing through Sine filter capacitors for filtering PWM
Sine waveform to pure Sine waveform. After filtering, the output is
connecting to output terminal through output contactor.
• ELD sensor is used to measure the earth leak current if any AC output live
terminal touches to the body & to isolate the faulty section by tripping the
contactor.
• Current transformer is used to feedback control, display the output AC current
and protects the inverter.
• The purpose of output contactor is to isolate the AC module from load when
AC module fails.

ACU DC Converter Module

• DC converter takes supply form common DC-link of AC2 and converts DC link
voltage to isolated and regulated 110Vdc output by controlling pulses of IGBTs
by using DSP controller.
• DC converter consists of H-bridge converter, isolation transformer, rectifier
and filter.
• DC converter shall also regulate output voltage to maintain current share at
output.
• An IGBT based DC-DC Converter is controlled by using DSP. Output voltage
and output current sensors are used for feedback control, display the
parameters and protect the DC Converter.
• Temperature sensors are provided for sensing the heat sink temperatures of
the IGBT modules and for protecting it.
• It communicates with AC-2 module through CAN Communication.

ACU DC Converter Output Section

• DC converter output section consists of DC output contactor, DC output

reverse polarity sense & BN-bus voltage indication (for both forward &
reverse direction).
• The output of DC converter is fed to BN (Battery Normal) loads, BD (Battery
Direct) loads as well as battery charger.

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• DC converter output is connected to BN bus terminals through DC output

contactor. It is used to isolate the DC converter module from load when DC
module fails and if any reverse connection at BN bus.
• Contactor driving, monitoring, DC output reverse polarity check is done by AC-
2 master controller.
• Voltage indication card is used for visual indication of BN bus voltage
availability & if any reverse connections on BN bus.

ACU DC Link Voltage Indicators

• Voltage indicators are used to indicate voltage availability at DC link of AC-1,

AC-2 &input of DC converter module by visual to avoid touching the power
modules while servicing.

ACU Cooling System

• Self-contained blower is used for air cooling of the auxiliary converter.

• This blower takes 3phase 415V ac supply from AC-2 inverter output.
• Blower will take supply from AC-1 inverter output if AC-2 inverter fails.
• This action will be done by using change over contactors based on health
feedback of other AC.

5.5.2.5 Auxiliary Loads

Auxiliary systems in all coaches work on two different voltages- 415VAC 3-phase,
50Hz and 110VDC. Major equipment working with these power sources are as
below-

Table 3: Auxiliary Loads - 415V AC, 3 phase

S.no Load Name Description
1. RMPU Air conditioning unit for coaches.
Cooling rating - 8TR
2. CAB AC Air Conditioning unit for driver cabin.
Cooling rating - 2TR
3. Main compressor Main compressor for brake system.
FAD – 920 lpm
4. Traction converter cooling Blower for cooling of traction converter unit
blower
5. Transformer radiator fan Radiator fan for cooling of main
transformer
6. Transformer oil pump Oil pump for cooling of main transformer
7. Water pump for toilet tank For water pumping for toilet tank
8. 230V supply for coach Wi-Fi TV screen (4nos.)
and TV Wi-Fi control unit (1no.)
Wi-Fi router (2nos.)
9. Pantry appliances load at Microwave Oven (1no.)
230V Hot case (1no.)
Soup Warmer (1no.)
Mini Refrigerator (1no.)
Water Boiler (1no.)

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10. Toilet Loads at 230Vac Per Toilet loads are as below-

Hand drier (1no.)
Shaver socket (1no.)
Exhaust fan (1no.)
11. 110Vac sockets for Mobile 110Vac single phase sockets in coaches for
& Laptop charging Mobile and Laptop charging.

Table 4: Auxiliary Loads - 110 VDC

S.no Load Name Description
1 Battery Charger Battery charger is provided in Converter unit
to charge the battery with C/10 rate.
2 Coach, Vestibules and Coach, Vestibules and Driver Cabin lights
Driver Cabin normal lights
3 Coach and Driver Cabin Coach and Driver Cabin Emergency lights
Emergency lights
4 Twin Beam/Auxiliary Head Twin Beam/Auxiliary Head light, Marker
light, Marker Light, Tail Light, Tail Light, Flasher light, Cluster Light,
Light, Flasher light, Cluster Spot Lights, Passenger Alarm Indication Light,
Light, Spot Lights, Electronic signal bell
Passenger Alarm
Indication Light, Electronic
signal bell
5 Control Electronics Loads PIS, CCTV, Relays, Contactors, Driver desk,
Brake systems and all other control units.
6 Doors Doors
7 Auxiliary compressor Auxiliary compressor for Pantograph.
8 Emergency Ventilation Emergency Ventilation Blower for coaches
Blowers when RMPU is not working.
9 Toilet Loads at 110Vdc Vacuum toilet Loads
10 Seat Lights Seat Lights for reading

5.5.2.6 Cooling

The ACU is forced-air cooled. Blower air is used for POWER MODULES and
magnetics cooling. Auxiliary converter cooling is achieved by means of forced
convection. Air will be drawn from outside through air inlet filter panel. Inside the
Auxiliary converter one blower is used for cooling of modules and magnetics, it
draws air from the inlet air filter on front and Right side of unit and forces it over
module heat sinks, the air then flows over the magnetics and finally leaves outside
through two louvered doors.

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5.5.3 Battery Charger

Battery Charging System (BCS) is a PWM based IGBT converter, which is getting
supply from BN bus and charge the battery with constant voltage & constant current
limit topology.

Battery charger is used to charge 110 V batteries. One battery charger unit is
provided in each DTC and NDTC coach of a basic unit. Battery charger unit is made
natural cooled design.

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Figure 4: Bloc Diagram of Battery Charging System

5.5.3.1 Sections of Battery Charger

BCS consists of below sections:

BN Contactor:

• BCS is having one contactor called BN contactor. It is used to isolate the BN bus
from battery. BN contactor can be turned ON/OFF from driver cabin.

Battery Charger:

• Used to provide the 110Vdc supply for battery charging by taking supply from
BN bus (115Vdc-130Vdc).

Reverse Flow Diode:

• It is used to provide the conductive path at the time of battery backup.

Controller Section:
• There is a controller used which is responsible for monitoring and protecting
the complete battery charger and records the faults in the memory and also it
interfaces to TCMS to get commands and to send status to display at driver
cabin.

Fuses Section:
 Consists of battery fuse, BD fuse, battery charger input & out put fuse. These
are used to isolate the BCS from loads or source if any short circuit happens.

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Figure 5: Battery Charger

5.5.3.2 Technical Data

Table 5: Technical Data of Battery Charger

Item Parameters
Input Voltage 115 V to 125 V DC (From BN Bus i.e. from DC output of BC)
Control Supply 77 V to 137.5 V DC from battery (110 Vdc nominal)
Output 77 V to 115 V DC (It is varying as per battery charging current
capacity requirement)
Current: Charging current limit is provided at 30 A. Whereas,
BCS is
designed with 10% margin i.e. 33 A.
Short time Short time rating Current limit topology is used so there will
rating not be any short
time rating.
Efficiency > 95%
Noise Level < 70dB(A)
Converter Size 1310X576X450 (LXBXH)
Cabinet SS-409M
Mass 130 kg (approx)
Degree of IP65
protection

Component Layout in the Cabinet

The following diagram shows the position of the major components in the BC.

Figure 6: BC Heat Sink Assembly

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5.5.4 Brake Chopper Resistor

Brake chopper Resistor is used to limit the DC Link voltage during dynamic
conditions leading to over voltages, partial braking load is dissipated during blended
braking and full braking load is dissipated during braking operation between stations.
Each Motor Coach has two independent Brake Chopper Resistors. But both these
resistors are placed in a single cubicle. Each Resistor is connected across DC link of
Line and Traction Converter unit. The Brake chopper resistor unit is under-slung
mounted.

Brake chopper circuit comprises of BCH IGBT module and BCH resistor. The Brake
chopper circuit is used to limit the over-voltages in DC link capacitors during
abnormal conditions or during transients.

Over voltages in the DC link capacitors may occur due to:

 Non receptive OHE during regeneration
 Transient load conditions.

Table 6: Parameters of Brake Chopper Resistor

Sr.No. Description Value
1. Resistance (nominal) 3.6 Ω
2. Resistance (minimum) 3.42 Ω
3. Resistance (Maximum) 3.85 Ω
4. Power Rating 719 kW for 2.5 sec
5. Energy Rating 1.8 MW-sec

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Figure 7: Brake Chopper Resistor

Figure 8: Block Diagram of Brake Chopper Resistor

5.5.4.1 Brake Chopper Description

There are two sets of resistor branches connected in series (their equivalent
resistances are R1 and R2) between DC link terminals. R1 and R2 are different
resistances each of values 66 kΩ and 20.4 kΩ respectively.

● Brake Chopper unit is mounted directly to under frame.

● Unit outline dimensions are 884 mm(L) x 648 mm (W) x 475 mm (H).
● Unit Max.weight is 100 Kgs.

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Figure 9: Brake Chopper Unit without Covers

Measurement of Cold Resistance Value

The cold resistance value, measured corresponds to 20°C ambient temperature shall
be in between 3.42Ω to 3.85Ω. The resistance can be measured by an LCR meter or
with a digital multimeter. Usually if the resistor is failed and open then reading will
show infinite resistance (OL on the display) and in case if the resistor is short, then it
shows almost zero or very low value.

If the resistance is measured by digital multimeter, then the measurement cable

resistance shall be subtracted from the measured value.

5.5.5 D.C. Link Earthing Switch Unit

Each motor coach has two LTC units and has one common DC link earthing switch to
protect the operating personnel from high voltage during maintenance activity.

Figure 10: DC Link Earthing Switch

One Earthing switch has four poles. Two LTC units DC link +ve and –ve are
connected to a common earthing switch.

The operation is through a key interlocking system similar to the EMU. When the
earthing switch is in open condition, all four poles are completely independent.

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5.5.5.1 DC Link Capacitor

DC link capacitor has following functions:

DC link capacitor is used to buffer the energy differences between line-side and
motor-side of the converter.
• DC link capacitor absorbs the harmonic currents produced by line side and
motor-side of the converter, thus reducing the ripple voltage.
• DC link capacitor is used to limit the switching over voltages of IGBTs. These
over voltages occur due to loop inductance.
• Two DC link capacitors of 2mF value are connected in parallel and forms the DC
Link and are directly connected to the IGBT Phase modules.

5.5.6 Pantograph

In electric traction vehicles, pantograph acts as mobile current carrying equipment

which is mounted on the roof. It collects power from the overhead equipment under
both static and dynamic conditions and transfers it to traction transformer.

In train-18, the Single Arm Pantograph model WBL 22.03 is mounted on the roof of
Trailer Coach (TC). The main purpose of pantograph is to collect the supply from
overhead OHE for train propulsion system and to send back energy to the OHE during
regeneration braking.

Figure 11: Pantograph at the Roof of Trailer Coach

One auxiliary compressor is mounted under frame in TC coach to build pressure in

panto reservoir for pantograph electro pneumatic control initially. During normal
run, main compressor is used to maintain the pressure for panto operation.

5.5.6.1 Technical Details

Table 7: Technical Details of Pantograph

Description Parameter
Standard IEC 60494-1
Minimum height with insulators 585 ± 10 mm
Insulating distance 250mm
Minimum working height over resting 100mm
position
Maximum working height over resting Min2290mm
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position
Maximum Extension Min2400mm
Width of pan head 1800 ± 10mm
Height of pan head 310 ± 10mm
Total length in resting position 2335 ± 10 mm
Total weight without Insulators approx. 150 kg
Current collector strips - Length 1030 mm
Current collector strips - spacing 390 ± 10 mm
Current collector strip – material Metalized Carbon
Frame Insulators (4) 25 kV
Frame Insulators Height 320 mm
Nominal voltage 25 kV
Nominal current 60A at 25kV
Lateral deflection at max. working height Max.30mm
& lateral force of 300N according to IEC
60494-1
Static upward force of pantograph 75 N +5-0 N
(modified for train-18)
Pan head Individual suspension of carbon
strip, parallel mounted
Spring rate of pan suspension 8750 N/m ± 10%
Maximum speed under good overhead Max.160 km/h
wire conditions
Speed according specification Max.120 km/h
Ambient temperature -10 to +50°C
Air pressure supply from vehicle for raising min.5.5 bar
of pantograph
Air pressure for continuous operation (dry min 6 bar
and oil-free air because of isolating
characteristics)
Raising time to maximum working height 6 to 10 s
Lowering time from maximum working 6 to 10 s
height
Air-pressure connection-High voltage 1000mm
insulating hose

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5.5.6.2 Description of Pantograph Components

i. Base Frame
The base is a welded structure of closed rectangular hollow steel profiles. The
following component parts are located on the base frame:
 Basic bearings for the lower frame
 Resting buffer for upper and lower frame
Mounting fixtures for:
 Air bellow
 Coupling rod
 Hydraulic damper
 Insulators
 High voltage hook-up
 Valve unit ADD
 Support spring
 Shunts

ii. Lower Frame

The lower frame is a welded structure. Its seating is located on the base frame.
The following component parts are mounted to the lower frame:
 Cam disks with suspension fixture for the bellow-drive cables
 Parallel guide bar
 Hydraulic oscillation damper
 Shunts

iii. Upper Frame

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The upper frame is a welded structure made of seamless tubes. Necessary

lateral stability is achieved through a cross wire-rope construction. Following
component parts attached to the upper frame are the:
 Pan head
 Coupling rod
 Lower frame
 Bearing blocks for the knuckle joint bearings
 Shunts

iv. Air Bellow

The pneumatic bellow drive allows the pantograph to rise. It is mounted
between the base frame and the lower frame. A pneumatic line connects the
bellow drive with the pneumatic control, and then continues via the solenoid
valve on to the compressor. The contact pressure is adjusted through the
pneumatic control system.

v. Coupling Rod
The coupling rod consists of two individually welded round-tubes. Both tubes
are then connected through a control element. Through this control element
the geometry of the pantograph will be adjusted and fine tuned.

vi. Parallel Guide Bar

The parallel guide bar prevents the pan head from distorting, while the
pantograph is raised or lowered.

vii. Pan Head

The pan head is located at the crest of the upper frame and uses leaf springs
for the suspension of the carbon strips. They are affixed in the rocker box, and
carry at each end bearing supported mounts to which the carbon strips
arethen attached. Parallel guiding links assure that the carbon strips operate
parallel to the catenary.

viii. Damper

The pantograph damping is attained through the oscillating damper between

base frame and lower frame. This guarantees a good contact between the
carbon strips and the overhead wire.

ix. Shunts

All bearing locations are by-passed by shunt connectors. These prevent the
current from flowing through the bearings. The shunts are consisting of
flexible copper cables with clamped end pieces. The current connectors are
greased with copper grease to achieve good conducting properties between
the shunts and the frame parts.

x. Base- and Upper frame bearing

The bearings of the pantograph are maintenance free and greased for life. At
each bearing, in a certain distance on an axle arranged, two ball bearings are
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used. To avoid condensation the gap between the ball bearings is filled with
grease. The outside of the bearings is protected with cover plates against
mechanical damage.

xi. ADD Valve unit (Auto Drop Device)

The pantograph is equipped with a pneumatic carbon monitoring system to

minimize damages of catenary and pantograph through worn or damaged
carbon strips (e.g. broken carbon pieces).
For this purpose, the pantograph is fitted with special suitable carbon strips, a
valve unit is fixed on to the base frame consisting of the rapid exhaust valve,
cut off cock and an air hose leading from the base frame, lower frame and
upper frame to the carbon strips.

xii. Over Reach Detector (ORD)

The pantograph is equipped with a ORD system to avoid damages to

pantograph when pantograph reaches un wired section. The overreach
detection provides a pneumatic signal (pressure) to the vehicle in the case
that the pantograph reaches a certain height (preferred by Customer) The
overreach detection mainly consists of a 3/2 way valve mounted on the base
frame, a clamp with a cam clamped to the lower frame and an insulating
tube.

5.5.6.3 Pneumatic Control (Valve plate)

The pneumatic control (Valve plate) consists mainly of a filter, 5/2-Way valve and
Phoenix connector. The main part of the valve unit is the 5/2-Way valve, it is
responsible for raising and lowering control of pantograph. Phoenix connector is
responsible to transfer electrical signal from the system to 5/2 way valve.

5.5.6.4 Pneumatic Control

The pneumatic control consists mainly of a filter, two throttle valves, two safety
valves, a 3/2-Way valve, pressure regulator, two pressure switches and Harting
connector.

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The main part of the valve unit is the pressure regulator, it is responsible for a
constant pressure for the air bellow during all service conditions. The pressure
regulator has a high sensitivity and is adjustable in a range of 1 to 8 bar.
Pressure switches mounted inside the pneumatic control box to monitor ADD and
ORD
For the connection to the pneumatic system three connections available:
 One for the pressure supply of the air bellow
 One for the pressure supply to the Pressure switch from the ADD Valve
 One for the pressure supply to the Pressure switch from the ORD Valve

5.5.6.5 Panto Control

i. Panto control at Train level

In case of normal mode, CCC shall derive panto up/ down commands and
send to all the basic units and MCC units for final action.

In case of panto momentary switch is operated toward ‘up’ in the occupied

cab, CCC drives panto up command by checking the ‘Panto up’ digital input
signal pulse status and sends to all MCC units through ETB communication for
final action. Likewise, CCU detects all momentary inputs based on a pulse
read for a specific time.

Similarly in case, panto momentary switch is operated toward ‘down’ in the

occupied cab, CCC drives panto down command by checking the ‘down’
digital input signal pulse status and sends to all MCC units through ETB
communication for final action.

At the same time, corresponding train lines are generated from occupied cab.
MCC also determines up, down commands through train lines. MCC ignores
these commands in case of normal mode. Train line commands are accepted
only during RDM mode.
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ii. Panto control at Basic unit level

Based on panto related commands received from ETB (in case of normal
mode) or panto related commands derived from train lines (in case of RDM
mode), EPCC drivespanto up digital output by considering following
conditions.
 Panto selector switch mode
 No EOL loop condition triggered
 No Panto low pressure switch is detected
 Panto up command detected
 No basic unit isolation is selected and
 No VCB contactor stuck at high-level condition occurred.

EPCC drives the panto down digital output based on panto down command
detected or if any above conditions are not satisfied.

In case VCB trip condition occurs in the basic unit, EPCC downs the
pantograph when VCB contactor stuck at high condition is detected (unable
to open VCB condition).

5.5.6.6 Pantograph status Indication Lamps

In driver desk, one lamp is available related to pantograph status name it as ‘min 1
panto up’. This lamp is driven through state of panto hard-wired train line.
This state of panto hardwired train line is driven by any of EPCC unit in MC coach
based on panto up status and OHE voltage available information.

In DDU rake screen and individual basic units screens, panto symbol is available.
DDU gets each basic unit Panto status from EPCC, based on panto status will be
displayed on DDU.

5.5.6.7 Auto Drop Down (ADD) feature

ADD feature, available in pantograph design is used to lower the pantograph

automatically in case of any break or damages of the collector strip. This feature
helps to avoid further damage of pantograph as well as catenary.
 ADD feature status can be detected by EPCU through ADD pressure switch.
 In case of pantograph healthy condition, which means no ADD detected,
pressure switch status becomes ON (pressure is greater than 3.0 bar).
 In case pantograph lowers by ADD feature, the pressure switch status becomes
OFF (pressure is less than 2.7 bar).
 With the detection of pressure switch status as OFF by EPCU, EPCU opens VCB
immediately and generate fault message and send the same information to
CCU.
 EPCU disables pantograph UP control operation G.

5.5.6.8 Over Reach Detection (ORD) feature

 ORD feature, available in pantograph design is used to lower the pantograph

automatically in case pantograph raises beyond the set height limit.
 This ORD feature status can be detected by EPCU through ORD pressure switch.
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 In case pantograph healthy operation, which means no ORD detected, pressure

switch status becomes ON (pressure is about 0 bar).
 In case, pantograph lowers by ORD feature, the pressure switch status become
OFF (pressure is greater than 1 bar).
 On detection of pressure switch status OFF by EPCU, EPCU opens VCB
immediately and generate fault message and sends the same information to
CCU.
 EPCU disables pantograph UP control operation until fault can be reset by
maintenance person.

5.5.6.9 Panto mode

 On driver desk Panto mode selector switch is provided with 2 selection

positions to select Panto 1-4 mode or Panto 2-3 mode.
 In corresponding position one train line will be generated, which can be used
during RDM mode.
 Based on the selection, corresponding Pantos will made UP.
 In case of one panto failure of corresponding mode, corresponding panto UP
lamp indication (Either Panto 1-4 UP or Panto 2-3 UP lamp) will start blinking.
 Based on this driver need to move the switch to other position to select the
other 2 pantos.

5.5.7 Vacuum Circuit Breaker (VCB)

VCB is used as a line circuit breaker to close and open the power circuit and also to
break the circuit under overload and short circuit conditions or any other abnormal
working conditions defined and implemented for the application. It provides
connection between catenary and propulsion equipment.

Figure 12: Vacuum Circuit Breaker

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In Train set it is mounted in roof of Trailer Coach (TC).It is an electro pneumatic

control. EPCC drives one digital output to energize VCB on relay, only if pantograph
has already raised, providing supply to electro pneumatic valve for VCB close
operation.

The Vacuum Circuit Breaker (VCB) type VCBA25.10Tr, make Autometers Alliance Ltd.
is provided on Train-18. It is a single phase 25kVAC circuit breaker used to protect
power circuit.

5.5.7.1 Technical Details

Table 8: Technical Details of Vacuum Circuit Breaker

Description Details
Make Autometers Alliance Ltd.
Type VCBA25.10 Tr
Maximum rated voltage kV 30
Nominal rated voltage kV AC single 25
phase
Power frequency withstand voltage kV 75
(dry & wet)
Lightning impulse withstand kV 175
voltage
Rated current A 1000
System frequency Hz 50
Short circuit rupturing capacity kA 16 (440 MVA)
Making current kA 40
Short time current capacity kA (3 sec.) 16
Opening time * ms ≤ 60
Closing time ms < 100
Control voltage VDC 110
Auxiliary contacts (type & no.) NO/NC (Fish bone 4NO + 4N
type) Configurable contacts
for external circuit and
1 NO for internal use.
2
Input air supply pressure Kg/cm 4.5 to 10
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Rated operating sequence -- O-3min-CO-3 min-CO

Weight Kg App. 150
Power consumption (max.) W 23

5.5.7.2 Constructional Features

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The vacuum circuit breaker comprises three main parts which are:
1. The upper part, which is the high voltage circuit (HT)
2. The intermediate part, which assures isolation from earth
3. The lower part with the electro-pneumatic and the auxiliary circuit (LT)

Upper Part

It is outside the vehicle, on the roof, and comprises:

 A vacuum switch tube (VST), which houses the main switching contacts
 A horizontal ceramic insulator (HI) which is fixed
 To a shafting head (TR), which converts the vertical movement of the drive
system into horizontal movement. One of the electrical connections (HT) is
mounted on this conductive part.
 A rear flange (B) which closes and seals the horizontal insulator and carries the
second electrical connection (HT).
 A vacuum switch tube moving contact is fitted with pushed screw, flexible shunts
to carry the current from moving contact to shafting head. Spring box houses the
contact springs and operating cam to transfer the vertical motion into Horizontal
direction.

Intermediate Part

Serves to isolate the upper part (HT) from the lower part (LT) i.e. it isolates the
vehicle roof, which is earthed with the high tension part of the circuit breaker.

It comprises:

 A vertical insulator (VI) supporting the upper part and fixed to base plate (E)
which is mounted on the vehicle roof by means of 6nos. M12 hex screws. The
lifting hooks 4nos.are fitted in this base plate permanently.
 To ensure waterproof sealing between traction vehicle roof and the base plate of
circuit breaker, an o-ring is provided.
 An insulating drive rod (T) is connected between operating mechanism of vacuum
switch tube and drive mechanism.

Lower Part

This is inside the vehicle in a protection cover (PC) which includes the control and the
drive mechanism which consists of:

(a) The Pneumatic Circuit

It comprises:
 Air inlet connector (C)
 An air pressure regulator with filter (FR)
 An air reservoir (AR)
 A pressure switch (PS) for monitoring minimum pressure
 An electro-pneumatic valve (EP)
 A regulator (R) whose flow is proportional to the movement of the drive
system
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(b) The Drive Mechanism

It comprises:
 Pneumatic cylinder (PN)
 Piston (K) which is guided inside the cylinder to transfer the movement to
 insulating drive rod
 Spring system (RS/CS) provided to keep the circuit breaker in open
position.
 Non-return valve (N) is fitted with air cylinder for exhaust throttling.

(c) The Auxiliary Circuit (LT)

It comprises:
 Polarized circular connector (LT) for fail safe connection to the electrical
circuit of the vehicle.
 Auxiliary switch (AS) which changes its status depending on the circuit
breaker position. Auxiliary switch is configurable and is of proven fish
bone type.
 Auxiliary switch drive (AD) mechanism which is linked with the drive rod
(T).
 An electro-pneumatic valve assuring closing and opening function.

5.5.7.3 Operation of VCB

The method of operation of the circuit breaker is described in the following

different sequences:

Closing of VCB

(a) VCB Open

 Status of VCB in open condition.

(b) Order (Pulse) to Close the VCB

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 Energizing of the electro-pneumatic valve solenoid coil.

 Operating of the electro-pneumatic valve (EP).
 Air flows from air tank (AR) to the piston drive.

(c) Mechanism Movement

 Movement of the closing piston (K), the insulating rod (T) and the moving
contact(MC) along horizontal distance (X).
 Closing of the main contacts inside the vacuum bottle.
 Exerting extra pressure on the contact pressure spring (CPS) for desired
contact pressure.

(d) Holding of VCB in Close Position

 Holding of VCB in close position is achieved by the compressed air.
 VCB switched ON.

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5.5.7.4 Opening of VCB

(a) VCB Closed (Figure-1.5)

 Status of VCB in close condition.

(b) Interruption of Current Supply of EP Valve Solenoid Coil

 De-energisation of EP valve solenoid coil results into changes in the status

of the valve.
 Air supply from air tank is blocked and exhausts port open of the EP valve.
 Exhaust of compressed air available in pneumatic cylinder (PN).
 The compressed springs release their store energy which acts as returning
force to the piston.
 Start of return of piston stroke through above mentioned action ensures
safe opening of the contacts.

(c) Rapid Movement of Piston

 The piston is accelerated by the release of the air pressure and release of
contact pressure springs stored energy.
 The air displaced by the piston escapes fast via exhaust port of electro-
pneumatic valve (EP).
 The arc caused by the opening of the contacts is extinguished by the
vacuum inside the vacuum switch tube.
 Just before the end of piston travel, the piston travel is cushioned by the
function of non-return valve (N).

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(d) End of Piston Stroke

 VCB switched OFF (open position).

5.5.7.5 Vacuum Switch Tube Construction

 The vacuum switch tube comprises two copper alloy contacts, one fixed and
the other moving.
 The fixed contact is mounted on a metal flange which carries the ceramic
outer cover of the chamber.
 The ceramic cover is generally in two parts with a metal screen fixed between
them. This screen protects the ceramic parts against deposition of metallic
vapour produced by the arc when the contacts open.
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 The moving contact travels in a guide who assures its axial positioning and
correct angle.
 Sealing of the moving contact is assured by a metal bellows which is welded
both to it and to the end flange which is integral with the external cover. A
metal screen is also provided around the bellows.

5.5.7.6 VCB Control

Train level VCB control

 In case of normal mode, CCC derives VCB close or open commands and send to
all basic unit EPCC units for final action.
 In case VCB momentary switch is operated toward ‘ON’ position in the
occupied cab, CCC derives VCB close command by checking the ‘ON’ digital
input signal pulse status and sends to all EPCC units through ETB
communication for final action.
 Similarly In case VCB momentary switch is operated toward ‘OFF’ position in
the occupied cab, CCC derives VCB open command by check the ‘OFF’ digital
input signal pulse status and sends to all EPCC units through ETB
communication for final action.
 At the same time corresponding train lines are generated from occupied cab.
EPCC also determines VCB close, open commands through train lines. But EPCC
ignores these commands in case of normal mode, but considers only in RDM
mode.

Basic unit level VCB control

Based on VCB related commands received from ETB (in case of normal mode) or
panto related commands derived from train lines (in case of RDM mode), EPCC
drives VCBON digital output by considering following conditions.
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 No EOL loop condition triggered

 No Panto low pressure switch is detected
 Panto up command detected
 No basic unit isolation is selected and
 No VCB contactor stuck at high-level condition occurred.

EPCC opens VCB based on the VCB open command detected or any of the above
condition are satisfied.

In case VCB trip condition occurs in the basic unit, EPCC opens VCB.

VCB status indication lamps

 In driver desk one lamp is available related to VCB on status name it as ‘min 1
VCB close’. This lamp is driven through state of VCB hard-wired train line.
 This state of VCB hardwired train line is driven by any of EPCC unit in MC
coach based on VCB on feedback status.
 In DDU rake screen, individual basic units screens, VCB symbol is available.
DDU gets each basic unit VCB status from EPCC, based on this VCB status will
be displayed on DDU.
 EPCC will know the status of VCB by read redundant feedback auxiliary NO,
NC contacts.

5.5.8 Earthing Switch for VCB

Earthing switch for VCB is provided on the roof of Trailer coach (TC) adjacent to VCB
to protect the operating personal during maintenance schedule from OHE Voltage.

This two poles earthing switch is used to earth the circuits on both sides of the air
operated vacuum circuit breaker (VCB) of electric traction vehicle, to ensure the
safety of the loco pilots and maintenance personnel safety during checking and fault
finding operations.

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Figure 13: Earthing Switch for VCB

 The upper casing of the earthing switch is mounted on the roof of the traction
vehicle, this houses the main shaft on which the two break blades are fitted.
 To make the earth connection, theses blades establish the contact between the
frame and electric circuits on both sides of the air operated main circuit breaker.

The lower casing which houses the operating and inter-locking mechanism of the
earth isolating switch is installed inside of vehicle.

5.5.8.1 Technical details

Table 9: Technical Details of Earthing Switch for VCB

Make Patra& Chandra
Type PCE.VES.25.4
Rated voltage 25 kV ac
Rated current 400 A
Poles 2
Weight 26Kg. (Approx.)
Place of mounting Roof

5.5.8.2 Constructional Features

 The operating lever of the earthing switch is connected through the

arrangement of uni-ball joint to the main shaft. Two isolator blades are fitted
on the both sides the shaft.
 The operating lever mechanism is kept in the lower casing of the switch.The
main shaft along-with the blades are kept in the upper casing. Both upper and
lower casing are fitted with the bolts.
 At the earthing position these blades establish the contact between the frame
and electric circuits on both sides of the vacuum circuit breaker.

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 Operator/Driver can operate the switch by operating the interlocking

arrangement from the machine room through operating lever.

5.5.9 Lightning/ Surge Arrestor

Two nos. Surge Arresters Type 3EL2are provided on the roof of the Trailer Coach
(TC) of Train set. These surge arrester serve to protect the insulation of the power
system (or of one of its components) from undue stresses resulting from over-
voltages.

Figure 14: Lightning/ Surge Arrester

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5.5.9.1 Constructional Features

 The active components of the arrester are metal oxide resistors. They are
arranged in a stack and hermetically protected against environmental influences
by means of directly mounted silicon enclosure.
 The mechanical strength is attained by glass-fibre-reinforced polymer rods
which tightly enclose and compress the resistor stack.
 Due to its hydrophobic properties, the silicon enclosure minimises electrical
discharges on the enclosure surface and thus ensures particularly good
operating characteristics, even under conditions of heavy pollution.
 The flanges are made of a lightweight metal alloy suitable for use outdoors and
directly connected with the silicon enclosure.

1- Polymeric composite housing

2- Non-linear Metal Oxide Resistor
3- Insulating Rods
4- Flange

The metal-oxide (MO) resistors are tightly enclosed by the fibre-reinforced plastic
(FRP) rods (as if in a cage). In the event of resistor overload, an extremely unlikely
case, but which cannot entirely be ruled out, the resultant arc produces no
overpressure, since the resistors are not enclosed by a sealed, mechanically rigid
casing.

The arc escapes immediately through the silicon enclosure, without any abrupt
rupturing of the mechanical load bearing enclosing structure. At the same time the
Metal Oxide resistors are held largely in place by a considerable number of FRP
rods. The risk of parts flying off is therefore minimised.

In the case of over-voltages due to lightning or to switching operations, the resistors

become conductive (ohm range) thereby allowing a discharge current to flow to
ground and the overvoltage to be reduced to the value of the voltage drop at the
arrester (“discharge voltage”).

Here the discharge currents may range up to 2 kA in the case of switching surges
and 1 - 10 -20 kA in the case of lightning surges.

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5.5.10 Traction Transformer

In train set, Trailer Coach (TC) consists of traction transformer mounted under-slung
with auxiliary converter unit. Power to Line and Traction Converter (LTC) units of
both motor coaches is distributed from same traction (power) transformer.

Figure 15 Traction Transformer

The transformer is an electro technical element of the whole traction system

which is in charge to propel the train. The transformer main function is to
transform energy coming from the catenary to the traction and auxiliary
converters.

5.5.10.1 Technical Specifications

Table 10: Traction Transformer Winding Specifications

Description HT Traction Auxiliary
Quantity 1 4 2
Capacity (kVA) 2880 603 234
Voltage (V) 22500 855 343
Current (A) 128 705 682
Insulation Class A A A

Table 11: Traction Transformer Voltage Rating

Primary Traction x 4 Auxiliary x 2
U line Power Current Power Voltage Current Power Voltage Current
(kV) (kVA) (A) (kVA) (V) (A) (kVA) (V) (A)
Exceptional 16 2109 132 429 608 705 197 240 820
19 2505 132 509 722 705 234 285 820
22.5 2880 128 603 855 705 234 343 682
Continuous
25 2880 115 603 950 635 234 376 623
27.5 2880 105 603 1045 577 234 413 566
Exceptional 30 2880 96 603 1140 529 234 451 519
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Table 12: Traction Transformer - Dimensions and weights

Length 3200 mm
Width 2600 mm
Height 730 mm
Total weight with oil 4900 kg +/-3% kgs
Weight of oil 550 kg 550 kg
Others
Frequency range 47 – 53 Hz

5.5.10.2 Constructional Description

Transformer
Traction transformer is used to supply 4 traction (Line) converters and 2 auxiliary
converters.

Line Converter

Line Converter

Line Converter
High Voltage

Line Converter

Aux. Converter

Aux Converter

Figure
Figure : Block
16: Block diagram
Diagram of Transformer
of Traction Traction Transformer
Windings

The overhaul transformer is composed by three main elements:

i. Transformer itself: a steel tank containing the active part immersed in

mineral oil.
ii. Cooling system: Oil Directed Air Forced (ODAF):
• one aluminium coolers with stone protection grids + two fans
supported by steel frame
• an hydraulic network and one axial pump for oil circulation

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• an oil expansion tank allows oil expansion linked to warming with an

air dryer.
iii. Monitoring: several sensors (temperature, flow, oil level, etc…) linked by
wires to connectors.

The interfaces are:

• Electrical interfaces: 13 low voltage bushings, 1 high voltage bushing and 1 earth
terminals
• Mechanical interfaces: 6 fixing points for fixing to train coach body.
• 3 phase equipment (motor-fan) : 1 connector.
• Monitoring interfaces: 1 connector.

The main transformer is fixed to the frame using 16 dampers in order to filter
vibrations generated by active part.

The cooling system is fixed to the frame using 4 dampers in order to filter vibrations
generated by motors.

 The active part of the transformer is placed in a tank, immersed in Mineral

Inhibited high grade oil IEC 60296 which ensures insulation and cooling.
 The tank has a welded cover. The oil expansion tank (1)that is part of the
transformer's bell communicates directly with the tank.
 The top of the oil expansion tank is connected to the atmosphere through an air
dryer (2). A second air dryer (5)is connected to the LV connector box.
 An oil level indicator (3)graduated in °C, with max and min labels, is placed on the
side of the oil expansion tank for reading oil level.
 The transformer is protected from overpressure through a pressure relief device
(4).This valve has an operating indicator and a contact signalling that it is opened.
 The frame has earthing terminals for electrically bonding the unit.

Air dryer

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When the oil inside the transformer is cooled or heated, the volume of oil inside the
transformer changes. Through the air dryers, air could enter or leave the
transformer’s oil expansion tank and avoid over or under pressure. This air is
dehumidified by a desiccant.

The first air dryer is connected to the oil expansion tank by the air dryer pipe. The
second air dryer is connected to the LV connector box in order to avoid rust on the
connectors.

Bushings

There are two types of bushings located on the transformer:

• 1 no. high voltage plug-in bushing for 36kV, 630A input (1) .

• 13 nos. identical ceramic bushings (2) : 12 low voltage outputs, 1 neutral input.

Tommy gun
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A container is set on the air link between air dryer and conservator tank to avoid air
dryer pollution with oil. An oil sight glass is placed on the container to check the
presence of oil.

Cooling system

• The transformer assembly is cooled by means of one cooler, fed with oil by oil
pump. The cooler is equipped with 2 motor fan sucking air through the radiator
and blowing it on the bottom side of the train.
• The refrigeration assembly can be isolated by means of four isolating valves
DN80. This makes it possible to change motor pump set, cooler and oil flow
switch by limiting the draining of oil to the volume of these parts.

Motor pump set

The immersion type pump which ensures the flow of the oil starts as soon as the
railcar is powered up. The oil pump is supplied with 415 V three-phase 50Hz, directly
connected to the train inside the terminal box by harting connector.

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Coolers and motor fan sets

The cooler is operating as follows:

• Fresh air get from external side of the car body

• Then this air get through coolers made of aluminium and bars, and cools the oil
inside
• Finally the air now heated is sucked by the motor fan and blow on bottom side.

 The cooling unit is removable from below with transformer on the train.
 The motor fan sets are supplied with 415 V three phases 50Hz, connected to the
train inside the terminal box by harting connector.

Valves

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 Two DN25 valves are arranged at the bottom (5) and at the opposite part of the
tank (6), allowing the oil to be filtered through a treatment device.
 The valve (5) located at the tank bottom is also used to drain the transformer.
 Four isolating valves DN80 (1) ,(2) ,(3) , (4) isolate the refrigeration assembly.

5.5.10.3 TRANSFORMER MONITORING

Different information are available on the transformer, with three main

functions:

Oil cooling monitoring

• 2 PT100 sensors
• oil flow switch

Oil level monitoring

• Visual Oil level indicator

• 2 oil level switches

The auxiliary connections (oil flow switch, Pressure relief device, PT100 sensors,
oil level switches) are grouped in a terminal box.

Oil level indicator

A graduate glass on the oil expansion tank indicates oil level in °C: because of oil
expansion, level of the oil expansion tank is directly related to oil temperature.

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Oil level switches

 Two oil level switches are mounted on the oil box between the oil tank and the
expansion tank in order to monitor the oil level.
 The two oil level switches are mounted on two different levels. The top one
indicates a low level of oil, the bottom one indicates critical level of oil.

PT100 sensors
Two PT100 sensors are mounted on the tank. The signals are sent to the supervision
which regulate the oil temperature with the fan motor speed.

Oil flow switch

Oil flow switch is a paddle type. It detects the minimal oil flow. This equipment
monitors oil circulation and proper functioning of the oil pump.

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Pressure relief device (or Overpressure valve)

Pressure relief device, rated at one dry contact 0.7 bar, protects the transformer
from accidental overpressure. A valve opening indicator (red pushbutton) is directly
mounted on the pressure relief device cover.

5.5.11 Traction Motor & Gear Drive Unit

Train set coaches are equipped with modern bolster-less design bogies with fully
suspended traction motors. Motor coach is a powered vehicle with four axles each
equipped with a 3 phase asynchronous Traction Motor (TM).

Traction motors are fully suspended i.e. traction motor weight is not loaded on to
the wheel directly. This reduces the un-sprung mass, resulting in better ride
comfort.

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Figure 17: Train Set Bogie with Traction Motor and Gear Box Assembly

5.5.11.1 Technical Data of Traction Motor

Table 13: Technical Data of Traction Motor

S. No. Description Details
1. Designation 3 phase AC Asynchronous
Traction Motor
2. Designed by TSA
3. Make Medha
4. Type designation TME 49-35-4
5. Weight of traction motor drive with 1000 kg ±3%
half coupling
6. Power 265.26 kW (electrical)
7. Shaft output 252 kW (mechanical)
8. rpm 3338 rpm
9. Voltage 1375 V
Continuous rating
10. Current 123 A
11. Frequency 112.3 Hz
12. Slip at full load 0.89%
13. Power factor 0.9
14. Power 291.88 kW (electrical)
15. Voltage 1375 V
1 hour rating
16. Current 136 A
17. Frequency 112.4 Hz
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18. Slip 0.99%

19. Shaft output 277 kW (mechanical)
20. Power factor 0.9
21. rpm 3337 rpm
22. Motor efficiency at rated power 95.00%
23. Maximum working speed of TM 4992 rpm
24. Maximum frequency 167.5 Hz
25. Maximum temperature index of 237°C
winding insulation
26. Type of suspension Fully suspended motor with partly
suspended gear drive
27. Speed at 160kmph with full worn 4992 rpm
wheels (877mm dia)
28. Type of cooling Self ventilated, air cooled
29. Air entrance temperature ≤ 50°C
30. Protection system IP 20 (machine protected solid
objects greater than 12 mm)
31. Class of insulation material Class 220
32. Terminal box protection degree IP 65 (machine protected against
ingress of dust)
33. Overall dimensions 1431 (L)x1157 (W) x 701 (H)
Constructional details viz. Rotor bar Rotor bar and end ring joints
and rotor end ring arrangement, protected by use of high strength
overhang to terminal box alloy shrink ring. All overhangs
connection etc. suitably supported.

5.5.11.2 Constructional Details of Traction Motor

Figure 18: Main Assembly of Traction Drive Complete

A. Traction Motor
B. Gear Box
C. Gear coupling

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Traction motor provided in train set motor coach is a 3-phase asynchronous self-
ventilated machine.

Stator

The stator consists of lamination stack, which are fitted in a cast metal housing. The
stator windings are shaped copper coils, which are wound from insulated
rectangular profile - banded with additional coiling insulation and into which slots
equipped with a slot lining are inserted.

Figure 19: Stator

The connections (“circuitry") of the stator coils take place on the non drive side
(NDE). The stator winding is insulated in accordance with TSA standard and
conforms to insulation class 220 in accordance with IEC60349-2.

Rotor

The rotor lamination stack made of layered dynamo sheets is mounted on a solid
motor shaft and clamped on both sides by rotor moulding press rings. On the non-
drive side (NDE), the lamination stack is secured further with a ring shrunk onto the
shaft.

Figure 20: Rotor

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Short circuit bars and short circuit rings are welded on both sides. Shrink collars
made up of high-strength, non-magnetic material absorb the loading from the
centrifugal force load on the short circuit rings.

Motor connections

Terminal box is located on top of the motor and provided with cable glands.

Figure 21: Motor Connection

Traction Motor bearings

The motor shaft is mounted with ceramic rolling element bearings at both DE
(Driving End) & NDE (Non Driving End) in the stator housing. The details are as
under.

 DE (Driving End) : Deep groove ball bearing - 6217 M/HC5C4HS0

 NDE (Non Driving End) : Cylinder roller bearing - NU1012 MR/HC5C4

Advantages of Ceramic bearing (Hybrid bearing)

 Bearings balls are made from Ceramic material
 Bearing insulated at rollers
 No deformation at higher speed
 No deformation at higher temperature
 No wear & tear of the rollers

Traction motor bearing lubrication re-greasing details

Fill the grease -
DE Bearing : 21 gms
NDE Bearing : 9 gms
Grease type : Shell Gadus S3 V2220C 2

Traction Motor Cooling

The motor is air cooled by a fan mounted at the non-drive end (NDE) of the rotor
shaft, air flow is mainly routed through heat exchange channels at the external

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periphery of the magnetic stack, one part is ducted inside the rotor, cooling air is
filtered at the inlet (grid type).

Figure 22: Air Outlet/ Inlet of Traction Motor

Speed sensor
For monitoring the speed, a speed sensor is mounted in the stator housing.

Figure 23: Speed Sensor Location in Stator

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Pt100 Temperature Sensors

For monitoring the stator temperature, Ptl00 temperature sensor is positioned in the
stator housing.

Figure 24: Temperature Sensor Location in Sensor

Traction Motor Water Flood Level

 Traction motor : Water flood level : 400 mm from Rail level

 Water draining from stator housing in rainy season by opening the drain plug
(53)

Figure 25: Flood Water Drain Plug (53)

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5.5.11.3 Gear Drive

Partly suspended drive with bogie frame fixed motor and axle-mounted gear.
Motor shaft and gearbox input shaft are connected by a coupling that transfers
torque and compensates for displacements between motor and gearbox.

The main gear is mounted directly onto the wheel set shaft and transfers torque
directly to the wheel set shaft.

The gearbox is a helical gear with oil sump splash lubrication.

Figure 26: Drive Complete

5.5.11.4 Technical Data for Gear Drive

Table 14: Technical Data for Gear Drive

S. No. Description Details
1. Designation Partly suspended gear box assembly
2. Type designation GKD 1-52-372A
3. Dimensional drawing TSA016533
4. Weight of gearbox unit with half 490kg
coupling and without oil m Gearbox
5. No. of teeth of Main Gear 98
6. No. of teeth of Pinion 19
7. Gear ratio 5.157
8. Gear system Single stage spur gear
9. Center distance between Pinion 372 mm
and Main gear
10. Gear Box : Oil lubrication Type / Servo SynGear 75W-90LL / Indian Oil
Make Make

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5.5.11.5 Constructional Details of Gear Drive

Figure 27: Gear Drive Assembly

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Figure 28: Gear Drive Sub-Assemblies

1. Axle 5. Taper roller bearing – 2 nos.
2. Main Gear 6. Cylindrical roller bearing – 2 nos.
3. Pinion 7. Four Point contact bearing
4. Flexible coupling

Gear Box Description

The gearbox is a helical gear with oil sump splash lubrication.

Figure 29: Main Component of Gear Box

D : Gear box assembled 21 : Reaction Rod complete

2 : Pinion 610 : Main Gear
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14 : Coupling Half gear box side W : Wheel set Shaft

Motor & Gear half Coupling

A curved teeth coupling connects motor with gearbox. The coupling is torsional
rigid, the halves are self-centering by the teething. The coupling consists of two
halves whose flanges are bolted together.

Figure 30: Motor Coupling

The coupling is lubricated by oil and is hermetic sealed to the outside by two steel
bellows, so leakage can be suspended. For the regular oil change both coupling
halves are equipped with drain plugs, this can be performed on the installed coupling
without disassembling from the shafts.

The coupling halves are mounted onto the shafts by tapered press fits, including oil
injections for mounting and dismounting.

The coupling transfers torque and compensates radial, axial and angular mis-
alignments between motor and gearbox.

At the general overhaul the coupling has to be checked visually for checking the
ability for further use in operation.

A slipping bush is installed at the gearbox side to protect the gearbox of too high
shock torques that can be generated in the motor in case of a converter short circuit.

The coupling is insulated, this ensures that the gearbox bearings are not affected by
discharging currents of the rotor.

Connection Gearbox to Wheel Set

The main gear is directly mounted onto the wheel set shaft by a cylindrical shrink fit
(the main gear is heated up for the joining operation), including oil injections for
dismounting.

Gear box Housing

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The gearbox housing is casted. The gearbox housing is designed to high stiffness and
low noise radiation and protects oil level indicators from direct hits by rocks from the
track.

Figure 31: Gear Box Housing

Gear box Support

The gearbox is supported by a reaction rod on the bogie frame. The reaction rod
incorporates two spherolastic bushings. During operation, the elastomers will wear
and must be checked regularly and exchanged when the end of the life time is
reached.

Bearings

The input shaft is supported in the gearbox housing by two cylindrical roller bearings
and one four- point contact bearing for the axial forces. These bearings have single
piece solid brass cages.

The output shaft is supported by two tapered roller bearings. For the tapered roller
bearings pressed steel cages are used. All bearings are oil lubricated.
Table 15: Bearings Details of Gear Box
Bearing Data SKF Type FAG Type Replaceme
nt interval
in km
Input motor Cylindrical roller NU 2217 NU 2217 30,00,000
shaft side bearing ECML/C4 E-MPA/R120-140
wheel Cylindrical roller NU 2217 NU 2217 30,00,000
side bearing ECML/C4 E-MPA/R120-140
wheel Four point ball QJ 217 QJ 217-N2-MPA- 30,00,000
side bearing N2MA/C4H C4
Output motor Tapered roller BT1- F-801207.01 30,00,000
shaft side bearing 0054/VE679
wheel Tapered roller BT1- F-801207.01 30,00,000
side bearing 0054/VE679

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Lubrication and cooling

 The gears are lubricated by oil splash lubrication. The gearbox is cooled by
convection.

 The design of the bearing area (oil stow provisions) ensures that a minimum
amount of oil remains in the bearing. A smooth start-up of the gearbox is
allowed, especially at low speeds and low environmental temperatures.
 The gearbox includes an oil filling hole, an overfill protection, an oil sight glass
(changeable from outside) and a magnetic drain plug, which collects metallic
wear floating in the oil.
 The oil level can be checked quickly and reliably through an oil sight glass,
marked with minimum and maximum. The oil lubricant for gear drive is Indian
Oil Servo Syn Gear 75W-90 LL

Sealing
 Contact-free labyrinths are used to seal the shafts. The gearbox housing and
covers are sealed with liquid sealing substances. O-rings are used for sealing the
bearing cartridges, bearing covers and labyrinth covers.
 During cleaning of the vehicles pay attention, that high-pressure water is not
directed into the labyrinth gaps, or protects them with covers.

5.5.12 Jumper Couplers

Jumper coupler (Power coupler) is used for transmission of power supply from one
coach to the other coach. The Unit is mounted directly to under-frame of MC and
TC coaches. Power coupler assembly consists of three sub assemblies:
 Junction box
 Harting connector plate
 Cable holding plate

Overview of the Location of Jumper coupler in Loco

Figure 32: Overview of the Location of Jumper coupler in Loco

Mounting location of power coupler assembly on under-frame-motor coach and

Trailer coach is shown in below figure

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Figure 33: Mounting location of power coupler assembly on under-frame-motor coach

Figure 34: Mounting location of power coupler assembly

on under-frame in Trailer coach

5.5.13 Pantry/ Isolation Transformer

20 kVA, 415V/230V/110V AC, 3 phase, dry type and air cooled power distribution
transformer for the Pantry Car, Toilets, Infotainment, Charging Sockets load. It has
15.0 kVA-230VAC (3 x single phase winding)+ 4.1kVA-110V AC (3 x single phase
winding).

Overview & Location

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Figure 35: Isometric View of Isolation Transformer

5.5.14 Master Controller

The Master Controller model S334 H32 makes SCHALTBAU is mounted to the table
plate of the Driver’s console and protected from contamination and free from
distortion. Dimensions and shape is given below.

Figure 36: Master Controller

Figure 37: Dimensions of Master Controller

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The layout of the Master Controller is symmetrical and visually in figure. The
operating elements were arranged in such a way that an ergonomic flow of operation
is guaranteed. The key switch, the reverser handle and the main handle are
integrated into a mechanical locking system. The switching elements are wired which
means that the operator still needs to connect the device as a vehicle component
after assembly.

5.5.14.1 Technical Data

Table 16: Technical data of Master Controller

Operating Voltage 110 V/ 24 V
Insulation Test Voltage According to VDE 0115
Control Switch – housing 1.0kV AC
Temperature range : -30 degree C to +70 degree C
Protection class IP 00

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Weight Approx. 15 kgs. Including plug and conductors

Switching elements 12 pcs. Snap-action switches S847b

5.5.15 Driver Desk

Driver Desk is provided in driver cab for user interface. All equipment such as
switches, lamps, master controller, DDU, PIS interface which are required for driver
interface are mounted on driver desk. Layout of equipment are given in below
sections. Driver's cab is for motor man and guard. The left-hand side of the driver's
cab is the workstation for the motor man. The operation switches, lamps, gauges
displays which are used motor man during driving are provided in front of motor
man. The right-hand side is designed for the guard. The easy understanding the
driver desk is further divided into sections A,B & C. further C is divided into 3 sub
sections C1, C2 & C3.

Figure 38 : Driver Desk (Section-A)

5.5.15.1 Section A is divided in 10 panels

1. Cabin Control Switches

2. MR-BP Duplex Gauge and BC Gauge
3. Main Display Panel
4. Driving Control Switches
5. Speed Recorder
6. Indications for Train Functional Parameters

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7. TPWS Display Unit (Dummy Panel)

8. Cabin Control Switches for Assistant Driver and Gauges
9. MMI unit of PIS (Operation by Assistant Driver)
10. Doors Control Switches

Cabin Control Switches

Figure 39: Cabin Control Switches

MR-BP Duplex Gauge and BC Gauge

Figure 40: MR-BP Duplex Gauge and BC Gauge

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Main Display Panel

Figure 41: Main Display Panel

Driving Control Switches

Figure 42: Driving Control Switches

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Speed Recorder

Figure 43: Speed Recorder

Indications for Train Functional Parameters

Figure 44: Indications for Train Functional Parameters

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Cabin Control Switches for Assistant Driver and Gauges

Figure 45: Cabin Control Switches for Assistant Driver and Gauges

MMI unit of PIS (Operation by Assistant Driver)

Figure 46: MMI unit of PIS (Operation by Assistant Driver)

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Doors control switches

Figure 47: Doors control switches

Driver Desk (Section-B)

Driver Desk (Section-B)

Brake Controller

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Figure 48: Brake Controller

Master Controller, Horn, Signal bell and VCD Reset Switch

Figure 49: Master Controller, Horn, Signal bell and VCD Reset Switch

Mic, Horn , Signal Bell and VCD Reset Switch

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Figure 50: Mic, Horn , Signal Bell and VCD Reset Switch

Emergency Brake Handle

Figure 51: Emergency Brake Handle

Under Driver Desk Front View (Section-C)

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Figure 52: Front Bottom side components of Driver Desk (Section-C1)

Figure 53: Front Bottom Internal side components of Driver Desk (Section-C2)

Figure 54: Bottom Left side components of Drivers desk (Section-C3)

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5.5.15.2 Driver Display Unit (DDU)

TCMS DDU provides information for the TCMS system to support Loco pilot in
operating rake while normal operation, as well as in case of malfunction of a
subsystem. DDU supports the maintenance staff in setting basic system
parameters and fault finding. In case of failure of TCMS DDU, train can still be
operated. There is one DDU installed in each DTC cab. DDU communicates with
TCMS and performs the following basic functions:

 Provide an interface to control train functions

 Display operational status of train functions
 Display diagnostic events
Screen layout consists of 7 sections which are described below:

Section 1 - Head line area

Head Line area gives the information about train number configured, screen heading,
date and time fields

Section 2 – Soft key buttons area

The soft key button area contains 10 touch sensitive buttons for different menu
entries.

Section 3 – Main Screen area

The main screen area shows the actual content of the selected screen. If required,
further touch sensitive buttons are shown in the main screen area.

Section 4 - High Priority Message field

Active diagnostic events which require acknowledgement by motor man are present
in high priority message field area. For each event, the source of the event (basic unit
number) and its event text are displayed along with an acknowledge button. If no
such event is present, the text field and acknowledge button are not displayed. The
events are presented in the order of their time of occurrence, across all event
sources. When the acknowledge button is pressed, the respective event is

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acknowledged and disappears from this area. Clicking on the event is available at
events list.

Section 5 - Scrolling Events area

All pending active events are presented in scrolling events area in a scrolling pattern.
For each event, the source of the event (basic unit, module details) and its event
texts are displayed. If no such event is present, the text field is not displayed. Motor
man can manually scroll up and down the list with the provided scroll buttons.

Section 6 - Pop up Messages area

Pop up messages area is used to show informative (Popup) messages to motor man
depending on the operational status of the train. If no popup message is pending, the
area shall be blank.

Section 7 – V max area

V max area indicates the maximum available/allowed speed of the train. If traction
interlock condition is detected by CCC, then ‘Zero Force’ appears in this area.

5.5.16 ECC and CRW Unit

Each Driving Trailer coach consists one CRW & GCRW. CRW is located behind the loco
pilot, who operates circuit breakers and switches of CRW panel. The weight of CRW
panel is 490 Kgs approximately. MC, TC, and NDTC contain one ECC panel in each
coach.

Figure 55: DTC CRW and GCRW Location

5.5.16.1 DTC CRW

One electrical cubicle is provided at rear side of driver cab. It houses all electrical
and electronics components required for rake level control. It houses CCU'S,
LRMS, TPWS, ECN Switches, MCB's, Relays & contactors for various application.

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Figure 56: CRW Front and Rear View

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5.5.16.2 DTC GCRW

One Electrical Cubicle is provided at guard rear side of DTC cab. It houses all
electrical & electronics components required for rake level control. It houses
PCU'S, EBCU's, CCTV NVRs, CCTV Ethernet Switches MCB's, Relays & contactors
for various application. Equipment layouts are shown in below section.

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Figure 57: GCRW Front and Rear View

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5.5.16.3 MC ECC, TC ECC & NDTC ECC

One Electrical Cubical is provided at driving end of MC, TC, NDTC cab. It houses all
electrical & electronics components required for rake level control. It houses

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MCUS, EBCUS, MCB, Relays & contactor for various application. Equipment layouts
are shown in below section. The location for ECC is same in MC, TC, NDTC.

Figure 58: Location of ECC in MC, TC, NDTC

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Figure 59: ECC Front and Rear View

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5.5.17 Light (Headlight & Marker Flasher)

5.5.17.1 Head Light

Twin LED type headlights are provided at both the DTC. Head light illuminates
front track ahead at night time or even at daytime when train passes through
dark places e.g. tunnels etc.. It facilitates for train pilot to have good visibility to
look for any obstruction or any abnormality on track. Accordingly driver can take
necessary action for ensuring safe and efficient operation of the train.

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Figure 60: Head Light

5.5.17.2 Flasher Light

LED type Flasher lights are provided at both the DTC. The control box of flasher light is
provided in driver’s cab. The provision of flasher light has great significance from
both the safety and operating point of view. It attracts the attention of driver of
approaching train on the adjacent track and indicates him to be cautious and
stop train in the event of any unsafe track conditions.

Figure 61: Flasher Light

5.5.17.3 Marker Light/Tail Lamp

LED type Marker/tail lights are provided at both the DTC.

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Figure 62: Marker Light

5.5.18 Electrical Driven Wiper

Wiper assemblies are provided on front look out glass (wind screen) of Driver Trailer
Coach (DTC) in train set to clean the glass during rainy season and also wet clean
the dust with washer system.

Figure 63: Wipers

5.5.18.1 Wiper Linkage Assembly

The wiper motor is mounted on a fabricated steel bracket which is polyester

powder coated black to prevent corrosion. The motor is connected electrically by
means of a multi-pin connector.

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Figure 64: Wiper Motor

The drive crank is secured to the wiper motor shaft and connected through a
double bearing or a tie-bar/bearing assembly, to the main spindle lever assy.
These components transfer the motor shaft rotation to the wiper arm assy.
The drive mechanism transfers the rotary output from the motor to a
reciprocating motion of the spindles. This mechanism is zinc plated and is sized
to give the correct angle of arc for the windscreen wiper arm being driven.
A main spindle and idler spindle are used on pantograph units. These pass
through the bulkhead, connecting the drive mechanism to the wiper arm. These
are manufactured from stainless steel, to prevent corrosion.

5.5.18.2 Wiper Arm Assembly

The wiper arm is manufactured from stainless steel with brass castings and is
polyester powder coated to prevent corrosion and to be of good appearance.
One wiper arm assembly is used on each unit. The wiper arm assembly mounts
directly onto the spindles protruding through the cab structure. The wiper arm is
secured to the spindles with a series of nuts and washers.

Figure 65: Wiper Arm Assembly

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5.5.18.3 Wiper Blade

The blade is secured to the arm assembly using the blade clip arrangement on
the arm with a blade retaining screw and Nylock nut.

5.5.18.4 Wash Tank/Pump Assembly

The 9.6L water tank is fabricated from stainless steel. Mounting is achieved by
bolting via four slotted brackets on the side of the tank. The wash pump is
mounted on the inside of the wash tank, it is powered by a 24v DC supply, and
when energised, the pump supplies washer fluid to the wash jet mounted on the
wiper arm, through suitable tubing.

Figure 66: Wash Tank/Pump Assembly

Filler spout with wash hose

The external filler spout is fabricated form stainless steel, and polyester powder
coated black mounting brackets. Mounting is achieved by bolting via 4 holes on the
two welded brackets.

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Figure 67: Filler Spout

Off/Intermittent/Slow/Fast & Push Wash Switch

4 position, 90º switching angle, – Off; Intermittent; Slow; Fast & Push to Wash

Control Unit

The control box is fabricated from stainless steel, and polyester powder coated
black to be of good appearance. Mounting is achieved by bolting via flanges welded
to the sides of the box. Electrically connected by means of a multi-pin connector via
a harness to the two motors, switch, pump and train interface.

5.5.19 PT & CT

Current Transformer (CT)

Split core ring type current transformer is provided on roof of TC at HT side. Primary
is composed by two semi cores:
 Fixed Part: the part without secondary terminal
 Mobile Part: the part with secondary terminal box

Primary cable is positioned and centralized in the semi circumference of fixed part.
It senses the primary current.

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Figure 68: CT on Roof of TC

Potential Transformer

Potential Transformer is a transducer provided at the roof of TC and it senses the

OHE Voltage.

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Figure 69: Potential Transformer

5.5.19.1 Technical Details of PT

Table 17: Technical Details of Potential Transformer

Installation outdoor
Insulation silicone resin
Insulation level 36/70/170 kV
Frequency 16 2/3, 50 and 60 Hz
Primary voltage 25 kVac
Voltage Factor 1.5 Un / 30 s
Total weight 60 kg approx.

5.5.20 Earth Return Current Unit (ERCU)

The ERCU ”AB 436 P” is an axial operating sliding contact for the return of operating
currents and for earthing of the vehicle. Electrically insulated for the protection of
the roller ends the ERCU closes the electrical circuit to the rotating wheel set shaft.
The grounding cable carries the reverse current from the coach body pivoted bogie
via a sliding contact to the wheel set shaft, from where it can flow into the rail via
the wheel. The critical point in the reverse current flow is the roller bearing or the
wheel set roller bearing is bypassed in a controlled manner.

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Figure 70: ERCU on Boogie

The ERCU is attached on the wheel set. The brush holder is insulated to the wheel
set end cover. A contact disc which is used as contact surface is mounted on the
pressure cap of the wheel set. The ERCU has a connection point on the brush holder
for the grounding line.

Figure 71: Earth Return Current Unit (ERCU)

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5.5.20.1 Technical data

Table 18: Technical Details of Earth Return Current Unit (ERCU)

Dimension Details
Type AB 436 P
Drawing no 436.7240-0
Product no 7802455
Dimension 400x195 mm
Installation height 58,5 mm
Weight 5.9 ± 5% kg
Technical Data
Effective current 600 A
Maximum current 900 A at 5 min
Number of carbon brushes 3 pc
Total contact surface 24 cm2
Contact resistance < 20 mW at I=50 A
Protection class IP 65 (DIN EN 60529)

5.5.21 Battery (VRLA Battery)

VRLA batteries (110V/300AH) conforming to RDSO specification No.:

RDSO/PE/SPEC/AC/0009-2014 (REV-2) is being used in Train-18 for standby power
supply systems. Total 48 nos

Figure 72: Battery

5.5.21.1 Major Advantages of VRLA Batteries

 Supplied in factory filled, charged and ready to use condition.

 No topping up is required. (No Acid handling)
 Spill proof and leak proof.
 No corrosive fumes are emitted, hence user friendly.
 Safe and Explosion proof.
 Easy to install & Environment friendly.

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5.5.21.2 Charging of Batteries

Never keep the batteries in discharged condition. All the batteries should be
recharged within 24 hrs. followed by a discharge. In this application, the battery
set may be given a terminal charge/boost charge at 2.35 VPC based on the
battery conditions as explained below

The terminal charging should be given using constant voltage current limited
charged having the following minimum features:

Voltage Regulation Less than 2%

Voltage ripple Less than 3% rms
Current ripple Less than 10% rms
Max.20% of Ah rating current limit to be set
Charging current between
10 to 20% based on the time for recharge.
Over voltage protection Charger trip at 2.35 V/ cell
Under voltage protection Battery disconnection at designed End cell voltage.
Otherwise to control manually.
Boost charging is not recommended more than 12 hrs.

5.5.21.3 Charge Method

Constant voltage charging is the method for giving a terminal / equalizing charge.
Determine the maximum voltage that can be set in the charger. This voltage,
divided by the number of cells connected in series, will establish the maximum
volts per cell that may be used to perform the terminal charge in the shortest
period of time. Refer the below Table-1 for voltage and recommended time
periods. Current can be setted to 20% of the battery capacity.

Table 19: Battery Charge Time According to Module Volts

Module Volts Charge time

2.25 30Hrs.
2.30 12HRs
2.35 8Hrs

NOTE: Time period listed in Table-1 are for ambient temperatures from 15°C to
40°C for Temperatures less than 15°C double the number of hours.

Test Discharge

The batteries are shipped at 90% of the rated capacity; the same will be delivered
100% capacity after 5-6 charge / discharge cycles @ C10 capacity or 6 months in
float service. However, the boost charge is mandatory for minimum of 24 hours
prior to conduct capacity test.

Pilot Cell

A pilot cell is selected in the series string to reflect the general condition of all cells
in the battery. The cell selected should be the lowest cell voltage in the series string

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following the initial charge. Refer section- 8.1 for FRESHENING CHARGE. Reading
and recording pilot cell voltage monthly serves as an indicator of battery condition
between the previous reading and the present reading.

Tap Connections

Tap connections should not be used on battery. This can cause over charging of the
unused cells and under charging of those cells supplying the load, thus reducing
battery life.

If these instructions are not adhered to and any damage is caused to the cells as
result of tap connections, the guarantee issued at the time of supply of the battery
will be treated as null and void.

5.5.22 Mini Pantry Equipment

Each coach of Train 18 have a mini-pantry with heating chambers for food and
refrigerating units for beverages. The Pantry equipment for heating and chilling
food and beverages are better quality, making for uniformly warmer and colder
beverages for passengers. Pantry equipment like hot case, refrigerating unit, water
boiler, washing module sink etc. Pantry equipment are manufactured with stainless
steel for a long life. Safety devices are available in equipment like Refrigerating unit,
Hot Case & Water Boiler.

5.5.22.1 Technical Specification:

Hot Case Unit

2 nos. Hot Cases are provided in each DTC coach and 3 nos. in each coach of
Executive chair car & Chair car Coaches.

Table 20: Technical Specification of Hot Case

Heating capacity .95 KW each., 2 no.

Electrical Power Unit 230 V AC 1~50Hz
Pan capacity
Volume 47.5 Ltr.
Maximum Full Size 6 Pan size 530 x325x65 mm
Half Size Pan 11 Pan Size 457 x 330 x 25 mm
Dimensions:
Height 809 mm
Width 483 mm
Depth 675 mm
Weight 50 kg. each
No. of Trays: 6 Trays (530x325x65 mm)
11 Trays (457X330X25MM)
Safety Device Specification
Thermostat Solid state Electronic control with temperature
setting 16 °C to 93 °C with LED display and with 6

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setting Timer

Refrigerating Unit

Table 21: Technical Specification of Refrigerating Unit

Operating voltage 230 V AC 1~50Hz
Wattage 600 Watt
Refrigerant R134a
Dimensions
Height 1000 mm
Width 1250 mm
Depth 585 mm with door
Weight 150 kg
Thermostat 2 °C -12 °C for bottle cooler area
-8 °C to -18 °C for Deep Freezer area

Water Boiler:

Table 22: Technical Specification of Water Boiler

Operating Voltage 230V ± 10%, 50Hz ±3%
Heating element 2Nos (1500 W+1300watt)
Dimensions
Height 640mm
Diameter 318 mm
Weight 5.5 Kg
Thermostat (OHP) 30°C to 100°C

5.5.22.2 Equipment Constructional Detail

Hot Case
 Stainless Steel construction.
 Corrosion Resist Stainless Steel Interior / Exterior body.
 Solid doors, hinged on right
 Compact Design to Save Space.
 Chrome Plated Side Racks.
 Simple On / Off Control System.
 Digital Temperature Controller.
 Good Heating Application Maintain Ideal serving Temperature throughout
the Cabinet.
 Adjustable thermostat
 Quick Heat Recovery Time.
 Quick Temperature Drop Time.
 Easy to Read LED Display.
 Temperature Range 16°� to 93°�.
 Heat Indicator Light, Temperature Display
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 Button.
 Chrome Plated Handle.
 Side Racks Have 35mm Eleven Pan Space.
 Chrome Plate Wire Shelves 2 Nos.
 For easy mobility Heavy duty caster wheel 2 rigid and 2 swivel with brake
 Door with magnetic latch
 Deluxe control option.
 Deluxe control is available with six multiple timers for each
compartment to facilitate first in first out concept.

Figure 73: Hot Case

Refrigerating Unit:

 Stainless Steel Cabinet

 Automatic Defrost System.
 Night Mode Set back option
 Temperature Range 2°C to 12°C for Bottle Cooler
 Temperature Range -8°C to -18 °C for Deep Freezer
 No. of Shelves 4 Nos.
 Refrigerant Gas R134a.
 Power – 600 W / 230V
 Dimension – W 1250X D 585 X h 1000 MM
 Weight: - 150 KGS.

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Vande Bharat Express(T-18) Maintenance Manual(1.0) 5. Maintenance

Figure 74: Refrigerating Unit

Water Boiler:

 Tank and lid is made of stainless steel.

 Filling level indicator.
 Double wall anti bum.
 Capacity 30 Liters.
 Adjustable thermostat 30° to 100°�.
 Anti-drip system.
 Safety thermostat with reset button.

Figure 75: Water Boiler

Washing Module Sink:

Washing module with sink is fabricated from 1.0 mm thick stainless steel sheet. It
will be fitted right bottom corner of the modular pantry compartment .A
stainless steel work surface with a surrounding raised edge and a drawn type
sink is provided. The sink will be positioned in the centre suitably covered by a
sink panel.

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Drawing Index
CHAPTER - 6

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Contents

6. Drawing Index: .................................................................................................................... 3

6.1 Bogie .................................................................................................................................... 4
6.2 Wheel & Axle ..................................................................................................................... 32
6.3 Braking System .................................................................................................................. 43
6.4 Gangway ............................................................................................................................ 53
6.5 SPC ..................................................................................................................................... 65
6.6 Electrical Schematic ........................................................................................................... 74
6.7 Water System .................................................................................................................. 100

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6. Drawing Index:

---Drawing related to Bogie

---Drawing related to Wheel & Axle
---Drawing related to Braking System
---Drawing related to Gangway
---Drawing related to Semi Permanent Coupler (CPC)
---Drawing related to Electrical Schematic
---Drawing related to Water System

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6.1 Bogie
Designation Drawing
Key diagram for axle end equipment ICF/SK3-0-2-024
Bogie general arrangement Train18/DTC/AC-0-0-001
Bogie general arrangement Train18/DTC/AC-0-0-002
Bogie general arrangement Train18/MC/AC-0-0-001
Reaction Rod fixing arrangement Train18/MC/AC-0-0-002
Traction Motor fixing arrangement Train18/MC/AC-0-0-003
Primary Suspension arrangement Train18/MC/AC-0-0-003
Wheel & Axle Set Train18/MC/AC-0-2-001
Roller Bearing arrangement 72702002
(Outer wheel-set)
Roller Bearing arrangement 72702003
(Inner wheel-set)
Bogie Frame complete (sheet-1) 72703001
Bogie Frame complete (sheet-2) 72703001
Secondary Suspension(sheet-1) 72705001
Secondary Suspension(sheet-2) 72705001
Stabiliser assembly 72705003
Secondary Suspension(sheet-1) 72705004
Secondary Suspension arrgt. with adjustment Train18/MC/AC-0-5-009
Disc brake fixing arrangement Train18/MC/AC-3-2-001
Suspension diagrammatic arrgt. (sheet-1) Train18/MC/AC-9-0-006
Suspension diagrammatic arrgt. (sheet-2) Train18/MC/AC-9-0-006
Bogie general arrgt. Train18/TC/AC-0-0-001
Wheel & Axle Set Train18/TC/AC-0-2-001
Roller Bearing arrgt.(wheel-set with Tacho for DTC) 72802003
Roller Bearing arrgt.(Inner wheel-set) 72802004
Roller Bearing arrgt.(Outer wheel-set) 72802005

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6.2 Wheel & Axle

Designation Drawing
Motor Axle 455.0.000.227.28
Trailer Axle 455.0.000.227.35
Solid Wheel 455.0.164.000.30
Wheel Assembly 455.8.164.000.30
Motor Wheel-Set 455.9.164.227.00-30.28
Trailer Wheel-Set 455.9.164.227.00-30.35
Solid Wheel Marking D11-4-01686
Axle Marking D11-4-01687

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6.3 Braking System

Designation Drawing
Piping Schematic DTC TA46991/11A
Piping Schematic MC TA46991/11B
Piping Schematic TC TA46991/11D
Piping Schematic NDTC TA46991/11E

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6.4 Gangway

Designation Drawing
Gangway Assy. Mounting (SH-1) 041448517
Gangway Assy. Mounting (SH-2) 041448517
Corrugated Bellows assy. final Mounting 041448515
Folding wall assy. 041448420
Combination bridge assy. 041445191
Linking ceiling assy. 041448481
Side wall assy. inner covering 041445174
Guiding body assy. locking side 041448060
Guiding body assy. screw on side 041448066
Covering brush assy. 041448476

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6.5 SPC

Designation Drawing
Semi Permanent coupler 1053693
Socket Joint Kit 1048969
Guide Cone 1048970
Locking Wedge 1020187
Draft Gear 1011453
Tube 1055509
Socket Joint Kit 1049392

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6.6 Electrical Schematic

Designation Drawing
Schematic Diagram for Roof Wiring-DTC Train18/DTC/AC-7-0-001
Schematic Diagram for Roof Wiring Train18/DTC/AC-7-0-002
Brake Schematic and Wiring Train18/DTC/AC-7-0-015
Layout of Air Conditioning Driving Trailer Car Train18/DTC/AC-9-0-001
Schematic Diagram for Roof Wiring- MC Train18/MC/AC-7-0-001
Wiring Diagram for Roof MC/AC Train18/MC/AC-7-0-002
Train Line formation and Pin Assignment Couplers Train18/MC/AC-7-0-007
Power Schematic Diagram Train18/MC/AC-7-0-008
Auxiliary Schematic for DTC, MC,TC & NDTC Train18/MC/AC-7-0-011
Door Schematic Train18/MC/AC-7-0-012
Brake Schematic & Wiring Train18/MC/AC-7-0-013
Schematic & Wiring for PIS Train18/MC/AC-7-0-015
ETB, ECN, PCU, EPCU & MCU Wiring Train18/MC/AC-7-0-018
Battery Control Scheme Train18/MC/AC-7-0-019
Layout of Air Conditioned Motor Car Train18/MC/AC-9-0-001
Schematic Diagram for Roof Wiring (MC3/AC) Train18/MC3/AC-7-0-001
Wiring Diagram for Roof (MC3/AC) Train18/MC3/AC-7-0-002
Layout of Air Conditioned Motor Car (MC3/AC) Train18/MC3/AC-9-0-001
Schematic Diagram For roof wiring (NDTC/AC) Train18/NDTC/AC-7-0-001
Wiring Diagram for Roof NDTC/AC Train18/NDTC/AC-7-0-002
Layout of Non-Driving Air Conditioned Trailer Car Train18/NDTC/AC-9-0-001
Schematic Diagram for Roof Wiring (TC/AC) Train18/TC/AC-7-0-001
Wiring Diagram for Roof (TC/AC) Train18/TC/AC-7-0-002
Layout of Air Conditioned Trailer Car Train18/TC/AC-9-0-001

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6.7 Water System

Designation Drawing
Laboratory & Piping Layout Train18/DTC/AC-6-3-001
Layout of pipe for under-slung water tank(SH-1) 72663002
Layout of pipe for under-slung water tank(SH-2) 72663002
Layout of pipe for under-slung water tank(SH-3) 72663002
UNDER-Slung water tank suspension arrangement 72663003
CAB AC Drain outlet arrangement 72663004
RMPU Drain outlet arrangement 72663005
Floor & Washbasin Drain arrangement 72663006
CAB AC & Drain Pipe arrangement 72663007
FRP Modular Toilet with commode for disabled 72663008
passenger(SH-1)
FRP Modular Toilet with commode for disabled 72663008
passenger(SH-2)
FRP Modular Toilet with commode for disabled 72663008
passenger(SH-3)
Laboratory & Piping Layout Train18/MC/AC-6-3-001
Under-Slung water Tank(SS) 72763002
Rib Assembly 72763003
Front Plate Assembly 72763004
DRDE Bio- Retention Tank Mounting Arrgt. 72763005
DRDE Bio- Retention Tank Assembly 72763006
Bio- Retention Tank 72763007
Fixing Piece Assembly 72763008
FRP Modular Toilet for Train-18 Train18/MC/AC-6-3-010
Auxiliary Water Tank 72763011
DRDE Bio- Retention Tank Mounting Arrgt.(RH) 72763012
Layout of pipe for under-slung water tank(SH-1) 72763013
Layout of pipe for under-slung water tank(SH-2) 72763013
Layout of pipe for under-slung water tank(SH-3) 72763013
UNDER-Slung water tank suspension arrangement 72763014
RMPU Drain outlet arrangement 72763015
Floor & Washbasin Drain arrangement (SH-1) 72763016
Floor & Washbasin Drain arrangement (SH-2) 72763016
FRP Modular Toilet for Train-18 (SH-1) 72763018
FRP Modular Toilet for Train-18 (SH-2) 72763018
FRP Modular Toilet for Train-18 (SH-3) 72763018
FRP Modular Toilet for Train-18 (SH-4) 72763018
FRP Modular Toilet for Train-18 (SH-5) 72763018
Laboratory & Piping Layout Train18/TC/AC-6-3-001
UNDER-Slung water tank suspension arrangement 72863002
Layout of pipe for under-slung water tank(SH-1) 72863003
Layout of pipe for under-slung water tank(SH-2) 72863003
Layout of pipe for under-slung water tank(SH-3) 72863003

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Laboratory & Piping Layout Train18/NDTC/AC-6-3-001

Layout of pipe for under-slung water tank(SH-1) 74463002
Layout of pipe for under-slung water tank(SH-2) 74463002
Layout of pipe for under-slung water tank(SH-3) 74463002
UNDER-Slung water tank suspension arrangement 74463003
General Installation of Executive AC Motor Car Train18/MC/EC//AC-9-0-
002
General Installation of Executive AC Trailer Car Train18/NDTC/EC//AC-9-0-
002
General Installation of Executive AC Motor Car Train18/MC2/EC//AC-9-0-
002
General Installation of Executive AC Motor Car Train18/MC3/EC//AC-9-0-
002

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information

7. GENERAL INFORMATION

Version : 1.00

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,

RDSO and OEMs

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
Amendment and Revisions
Version Date Corrections Remarks
1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
Table of Content

7. GENERAL INFORMATION
7.1. QUALITY OF COMPRESSED AIR ....................................................................................... 4
7.2. QUALITY OF WATER .......................................................................................................... 4
7.3. LOCAL MAIN SUPPLY ........................................................................................................ 5
7.4. TRANSPORTATION CODE ................................................................................................. 5
7.5. LIST OF ABBREVIATIONS .................................................................................................. 5
7.6. PRECAUTIONS WHILE WORKING ON TRAIN-18 ............................................................ 7
7.6.1. GENERAL PRECAUTIONS .................................................................................................. 7
7.6.2. SAFETY PRECAUTIONS WHILE ACCESSING THE ROOF ................................................. 8
7.6.3. PROCEDURE TO OPERATE DCLINK EARTHING SWITCH ............................................... 9
7.6.4. BEFORE STARTING MAINTENANCE OF LINE AND TRACTION CONVERTER UNIT ... 10
7.6.5. BEFORE STARTING MAINTENANCE AUXILLIARY CONVERTER UNIT, BATTERY
CHARGER ......................................................................................................................... 10
7.6.6. BRAKE CHOPPER RESISTOR ........................................................................................... 10
7.6.7. MAIN TRANSFORMER..................................................................................................... 10
7.6.8. TRACTION MOTOR AND GEAR BOX.............................................................................. 11
7.6.9. ECC, CRW AND GCRW UNIT........................................................................................... 11
7.6.10. WIPER ............................................................................................................................... 11
7.6.11. ROOF MOUNTED PACKAGE (AIR CONDITIONER) UNIT ............................................. 11
7.6.12. HIGH TENSION (AC AND DC) TESTING ......................................................................... 12

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
7.1. QUALITY OF COMPRESSED AIR

Quality of compressed air: ISO 8573-1

Definition for solids: 5 μm Maximum particle size

5 mg/m3 Maximum concentration
Definition for water: 3°C Maximum pressure dew point
Definition for oil: 1 mg/m3 Maximum content
~0,8 ppm Maximum concentration

Illegal impurity: PAO-/Ester-oil, antifreeze, alcohol

Other impurity test on compatibility.

Contaminants in compressed air

Compressed air quality according to IS0 8573-1

Definition for solids Definition Definition for oil

for water

IS0Class Maximum Maximum Maximum Maximum Maximum

particle concentration[mg/m3] pressure Content Concentration
size [μm] dew point [mg/m3] [ppm]
[°C]
1 0,1 0,1 -70 0,01 ~0,01

2 1 1 -40 0,1 ~0,1

3 5 5 -20 1 ~0,8

4 15 8 3 5 ~4

5 40 10 7 25 ~20

6 -- -- 10 -- --

The values are defined at pressure = 0 bar, 20 °C, 60 % rel. humidity.

7.2. QUALITY OF WATER

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 Low degree of hardness
 Part of bacteria as minimum as possible

7.3. LOCAL MAIN SUPPLY

 Demands of local mains supply Voltage: AC 415V (Power supply socket junction box for
external power supply)

7.4. TRANSPORTATION CODE

Unique
S.No Coach Name Lay-Out Drawing Number
Transportation Code
Driving Trailor Coach
1 TS-18/DTC/AC Train 18 /DTC/AC-9-0-001
(DTC)
2 Motor Coach (MC) TS-18/MC/AC Train 18 /MC/AC-9-0-001
3 Trailor Coach (TC) TS-18/TC/AC Train 18 /TC/AC-9-0-001
Non Driving Trailor
4 TS-18/NDTC/AC Train 18 /NDTC/AC-9-0-001
Coach (NDTC)
Motor Coach - Executive
5 TS-18/MC/EC/AC Train 18 /MC/EC/AC-9-0-001
Class (MC2/EC)
Non Driving Trailor
6 Coach - Executive Class TS-18/NDTC/EC/AC Train 18 /NDTC/EC/AC-9-0-001
(NDTC/EC)
7 Motor Coach (MC2) TS-18/MC2/AC Train 18 /MC2/AC-9-0-001
7.5. LIST OF ABBREVIATIONS
Acronym Description
AC Alternating Current
ACU Auxiliary converter Unit
ADC Analog to Digital Converter
AIP Analog Input
AWS Auxiliary warning system
BC Brake Cylinder
BCP Brake Cylinder Pressure
BE Braking effort
BP Brake Pipe
CAN Controlled Area Network
CBC Center Buffer Coupler
CCTV Closed-Circuit Television
CCU Coach Control Unit.
CRW Cab Rear Wall (Panel)
DC Direct Current
DCS Key Driver control Switch Key
DDU Driver Display Unit
DE Driving End
DIP Digital Input
DOP Digital Output
DPRAM Dual Port Random Access Memory
DSP Digital Signal Processor
DTC Driving trailer coach

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
EBCU Electronic Brake Control Unit
EBL Emergency Brake Loop
ECC Electrical Control Cabinet
ECN Ethernet Consist Network
ED Electro Dynamic
Electrically Erasable and Programmable
EEPROM
Read Only Memory
EMU Electrical Multiple Unit
EOL Emergency Off Loop
EP Electro Pneumatic
EPCC Enhanced Passenger comfort computer
EPCU Enhanced Passenger comfort unit
ERCU Earth Return Current Unit
EWP End Wall Panels.
FDP Fault Data Pack
FRP Fibre-Reinforced Plastic
GCRW Guard Cab Rear Wall (Panel)
GPS Global Positioning System
HS High Speed
HSCB High Speed Circuit Breaker
HVAC Heating, Ventilation and Air Conditioning
HWTL Hard Wired Train Line
ICF Integral Coach Factory, Chennai
IV Inter-Vehicular
LED Light Emitting Diode
LRMS Locomotive Remote Monitoring System
LS Low Speed
LTC Line and Traction Converter
LTCU Line and Traction Converter Computer
Locomotive and Train Management
LTMS
System
MC Motor Coach
MCB Miniature Circuit Breaker
MCU Main Control Unit
MMI Man-Machine Interface
MPCB Motor Protection Circuit Breaker
MR Main Reservoir
MS Motor Side
MVB Multifunction Vehicle Bus
NDE Non Driving End
NDTC Non Driving Trailer Coach
NVR Network Video Recorders
PIS Passenger Announcement and
PA
Passenger Information System
PCC Passenger comfort computer
RDM Rescue Drive Mode
PVC Ply Vinyl Chloride
RDSO Research Development and Standards
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
Organization
PCB Printed Circuit Board
PCU Pneumatic Control Unit
PS Power Supply
PWM Pulse Width Modulation
RMPU Roof Mounted Packaged Unit
TB Terminal Board
TC Trailer Coach
TCMS Train Control and Management System
TCN Train communication network
TE Tractive Effort
TFT Thin Film Transistor
TIC Traction Inverter Computer
TM Traction Motor
TPWS Train Protection and Warning System
TSA Traction System Austria
USB Universal Serial Bus
VOC Volatile Organic Compounds
VCB Vacuum Circuit Breaker
VCD Vigilance Control Device
WS Wheel Side
WTB Wire train bus

7.6. PRECAUTIONS WHILE WORKING ON TRAIN-18

7.6.1. GENERAL PRECAUTIONS
 Death, severe injury and considerable damage to property and environmental
damage may result if the safety instructions are not followed.
 Provide “Man at Work” board at both side of the train set.
 Set the display card “Work in progress” on the vehicle.
 Put the proper wheel skids on both end wheels of train set.
 Before commencing work on the vehicle, ensure that all voltages are disconnected.
 Be careful and vigilant.
 Always wear helmets, boots and personal protective equipment as per
requirement of work.
 Insulated tools, insulating protective clothing, protective devices, safety belts,
equipment and other auxiliary material must be preserved in good order and
condition.
 Before every use, the user must inspect the insulating protective clothing for
apparent damage.
 Damage to the insulating protective clothing must be rectified by technically qualified
workshops only.
 However, gloves should not be repaired and should be replaced.
 At specific time intervals, the insulating gloves and shoes must also be inspected
electrically for their protectiveness.
 The personnel should not have loose long hair, loose clothes or jewellery, including
rings. There is risk of injury e.g. by getting caught or drawn in.

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 Always, discharge the meggered circuit to ground with the help of flexible insulated
wire after meggering.
 Working on electrical equipment must only be carried out by a qualified
electrician/technician or by instructed persons under the leadership and supervision
of a qualified electrician/technician.
 Use appropriate Personal Protective Equipment (PPE) when working with hot
components and dusty environment.
 Always wear a dust mask when working in dusty environment.
 Ensure the adequate cooling time has been allowed, if train has recently been
running.
 No one shall be allowed underneath the equipment while being transported by a
crane or other means.
 Individual components and bigger components should be carefully fastened and
secured to the hoisting devices during replacement.
 Only use suitable and technically perfect hoisting devices as well as load carrying
equipment with adequate load carrying capacity.
 Only experienced people should be entrusted with fastening of loads and instructing
the crane operators. The concerned staff must remain within the range of vision of
the operator or they must be able to speak to each other.
 Do not stand or work under suspended loads.
 Take care when dealing with hot consumables and auxiliary materials (burn or
scalding hazard).
 During cleaning work with compressed air, pay attention to suitable extraction and
personal safety measures (safety gloves, safety goggles, respiration filter etc.).
 The chemical products used for cleaning must be kept in clearly visible and
recognizable designated areas or cabinets, and always away from areas provided for
food preparation.
 Aggressive cleaning agents should not be touched with hand.
 Wash off immediately with a large volume of water if touched with hand.
 Do not drink or inhale the vapors.
 A doctor's assistance should be sought immediately if the cleaning agent has been
drunk inadvertently.
 Use heat resistant gloves when heating up parts.
 Before commencing any work on the vehicle the personnel shall always, set the
vehicle to the correct operating position for the task to be performed.
 Study the necessary safety precautions within the documentation and on the Vehicle.
 Count all the tools after completion of work and keep them in a proper tool bag.
 Do not drop oil/ grease on pits as staff may slip and get injured.
 Do not leave released hardware on shop floor and inside the pits.
 Do not leave any tool, cotton waste or any other foreign material after completion of
work.

7.6.2. SAFETY PRECAUTIONS WHILE ACCESSING THE ROOF

 Switch off OHE supply by opening the controlling isolator and provide pad lock in OHE
isolated condition in supervision of maintenance gang in-charge.
 Earth OHE by providing earth discharge rods on both ends.
 The sequence of fixing discharge rod should be- first connect clamp to earth and then
connect to OHE.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
 Staff will further provide individual pad lock in controlling isolator in OHE isolated
condition and retain key with him till such time the work is completed.
 Ground the Train set by operating roof earthing switch before accessing to the roof.
 Always use ladder for accessing to the roof.
 Clean the hands and sole of the shoes to avoid slipping before climbing on the ladder.
 Use a suspended bag to hand tools or parts to workers.
 After completion of every repair or maintenance, ensure that no tools or other are
left on top of the vehicle roof.
 After completion of the work, the concerned supervisor, after satisfying himself that
all staff, tools, ladder etc. and the discharge-rods provided on OHE have been
removed, may re-energize the OHE.

7.6.3. PROCEDURE TO OPERATE DCLINK EARTHING SWITCH

 During maintenance of Line and Traction Converter (LTC) unit or DC link earthing
switch, entire rake OHE power is switched OFF and power circuit in the Basic Unit
(BU) is safely connected to earth from the pantograph to traction transformer and
then to LTC unit. To properly ensure all these things, a safety interlock system with
lock and key is provided in the system.
 For any maintenance activities related to LTC unit and DC link earthing switch user
need to be ensured and also secured that the DC link voltage shall be at zero volts. To
avoid charging of DC link capacitor from stray charging, it is recommended to short
the DC link positive and negative terminals of LTC unit. This can be done by operating
the DC link earthing switch.
 Each motor coach consists one DC link earthing switch box, which has one 4-pole DC
link earthing switch. Both the LTC unit positive and negative terminals in the same
MC are connected to 4-poles of DC link earthing switch.

To operate DC link earthing switch, follow the following procedure:

 Down the pantograph of Basic Unit and release the pantograph blue color key. After
removing the blue color key, pneumatic pressure does not build up, even if command
comes from the system, due to any reason and pantograph will not raise.
 Insert blue key in 25 kV roof earthing switch and operate its handle to earth position.
 Two Yellow color keys gets released and blue key will be locked in the panel. Remove
any one of the yellow color key and insert it into the DC link earthing switch box in
the under-frame and operate it. With this, all the positive and negative terminals of
two LTC units in the same Motor coach shall be shorted and are connected to earth
and provides safe condition for maintenance activities.
 Yellow color key will be locked in the DC link earthing switch panel. Release green
color key from the DC link earthing switch panel.
 To know the status of the DC link earthing switch, NO/ NC feedback signals are
connected to MCC unit. But the MCC reads the signal feedback when its control
supply is in ON state only.

To restore to actual conditions, follow the same steps from last to first:
 Insert green color key into the DC link earthing switch and rotate the handle to
normal working mode. Then green color key will gets locked and yellow key is
released from the DC link earthing switch.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
 Insert yellow key in 25 kV AC roof earthing switch and move the earthing switch
handle to working conditions. Then two yellow keys get locked and blue color key will
be released from the 25 kV AC roof earthing switch.
 Insert blue key into pantograph and rotate the key into its normal slot. With this,
pantograph does not raise automatically. If command comes from the system,
pantograph raises.

7.6.4. BEFORE STARTING MAINTENANCE OF LINE AND TRACTION CONVERTER

UNIT
Before doing any maintenance activity related to Line and Traction Converter unit or any
activity in the under frame, the following sequence of steps to be followed for human safety
against dangerous high voltages:
 Make sure that the all the pantographs are in down conditions in the rake. If not
down the pantographs and open all the VCBs in the system. Wait for 10 minutes from
the instant the VCBs are open.
 Take out the blue key from all the pantographs in the rake. This gives guarantee that
the pantographs will not be raised in the rake during maintenance periods.
 Follow the procedure as mentioned earlier to remove Green colour key from the DC
link Earthing switch. By using the Green key LTC converter unit door can be opened.
 After completion of maintenance work follow the opposite sequence to restore the
normal conditions. Otherwise the system will not get the OHE power supply.

7.6.5. BEFORE STARTING MAINTENANCE AUXILLIARY CONVERTER UNIT,

BATTERY CHARGER
 Put the train in duty position.
 Verify that there is no voltage remaining between DC+ and DC- by measuring with a
voltmeter.
 The propulsion equipment is secured by the key interlock system. It ensures that the
high voltage supply is always earthed before it is possible to get in contact with the
equipment.
I. Open the isolation switch guard cover by unscrewing the knob.
II. Place the key-A in to the isolation switch and rotate clockwise for accessing
key-B. Rotate the key-B anti-clockwise and remove it. With Key-B Main door
lock to be opened.

7.6.6. BRAKE CHOPPER RESISTOR

 Before starting any maintenance operations, make sure that VCB is opened and
Manual DC Link discharge switch is operated in that basic unit and the resistor cannot
be energized.
 It is necessary to wait for 30 minutes after power cut off to allow the resistor active
parts and the frame to cool.

7.6.7. MAIN TRANSFORMER

Deadly voltages are present inside the transformer and all electrical connection points,
creating a risk of electric shock. Before working on the electrical connections, it is mandatory
to:
 Before working in an electrical box, carry out an analysis of potential risks and take
adequate and appropriate measures.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
 Before working on the device, turn off the train supply and secure the electrical
installations by earthing and short circuit as well as equi-potential bonding.
 Before any maintenance operation, operating personnel must leave the time to the
equipment to cool down to avoid injury.
 Verify that there is no voltage left in any bushing (LV and HV) by measuring with a
voltmeter.
 OIL System may be under pressure, and may cause skin irritations and damage to
eyes from escaping fluids.
 Switch off the cooling unit and relieve pressure from the system before disconnecting
the hoses for cleaning and maintenance.

7.6.8. TRACTION MOTOR AND GEAR BOX

 Carry out maintenance and repair work only when the traction motor is switched off
and secured against inadvertent restarting.
 In the case of any intervention, the power supply to the traction motor should be
disconnected.
 Before welding, burning and grinding, the traction motor and its surroundings should
be cleaned of dust and combustible materials and must make sure there is enough
ventilation (explosion hazard).
 Never operate the traction motor without safety devices and an open junction box.
 For measurements of Insulation resistance with megger, the motor should be
isolated from all cable connections.
 For all work on the gearbox in which the drive is installed in the bogie or is connected
to another power supply, it must be ensured that the drive and all connections are
switched off and secured against being switched ON again.

7.6.9. ECC, CRW AND GCRW UNIT

 CRW, GCRW and ECC contain electrical equipment, which uses/ carries high voltage.
This can be highly dangerous.
 Any maintenance/ installation work is to be carried out by trained staff with
appropriate precaution only.
 Before commencing work, ensure all voltages are disconnected.
 Lock the switches, isolators, fuses, etc. where possible.

7.6.10. WIPER
 Always disconnect the power, when servicing the Windscreen Wiper System, or on
any ancillary components. Serious damage to the Equipment and/or Personal Injury
may occur if the power is not disconnected.

7.6.11. ROOF MOUNTED PACKAGE (AIR CONDITIONER) UNIT

Air conditioners are charged with the refrigerant R-407C. R-407C is colorless with a faint
ether-like odor.
 Pressurized, liquid refrigerant escaping from the system may cause cold burn and
blindness. If there is a risk of contact with liquid R-407C, suitable protective
equipment must be worn (goggles or face-shield, insulation gloves, clothes and
footwear).
 R-407C is not flammable but toxic and/or corrosive gases may be produced when R-
407C is involved in a fire. Never use direct flame (e.g. a brazing torch) in the presence
of R-407C.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 7. General Information
 R-407C vapor is heavier than air and may accumulate in confined spaces, particularly
at or below ground level.
 High concentrations, R-407Cmay cause asphyxiation. Symptoms may include loss of
mobility/consciousness. Victims may not be aware of asphyxiation.
 In low concentrations may cause narcotic effects. Symptoms may include dizziness,
headache, nausea and loss of co-ordination. Keep workplace well ventilated.
 The refrigerant circulates through the air conditioner under high pressure. Make sure
that the refrigerant charge is removed with suitable equipment before carrying out
any repairs of the refrigeration system. An explosion may occur when excessive heat
(e.g. a gas flame) is applied to the charged system.

7.6.12. HIGH TENSION (AC AND DC) TESTING

 After isolating OHE as described earlier, check the roof of the train set for any foreign
material.
 Ensure that no one is working on the train set.
 Make sure that all switches are in normal position.
 After safety Inspection and energizing the overhead supply line.
 Before taking traction, check the brake power and ensure that the brakes are
effective.
 Follow all safety norms and speed restrictions during testing and shunting in the
depot.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting

8. TROUBLE SHOOTING

Version : 1.00

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,

RDSO and OEMs.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
Amendment and Revisions
Version Date Corrections Remarks
1.00 31/08/2020 First Release --

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
Content

8. TROUBLE SHOOTING ........................................................................................................... 1

8.1. FAULT DISPLAY ON DRIVER DISPLAY UNIT (DDU) .................................................... 4
8.2. TROUBLESHOOTING OF CENTER BUFFER COUPLER ................................................ 4
8.3. TROUBLESHOOTING OF SEMI PERMANENT COUPLER ............................................ 4
8.4. TROUBLESHOOTING OF PLUG DOOR ....................................................................... 4
8.5. TROUBLE SHOOTING VACUUM BIO TOILET ............................................................. 5
8.6. TROUBLESHOOTING BRAKE YSYTEM AND AIR SUPPLY ........................................... 6
8.7. TROUBLESHOOTING PANTOGRAPH ......................................................................... 8
8.8. TROUBLESHOOTING MAIN TRANSFORMER............................................................. 9
8.9. TROUBLESHOOTING TRACTION MOTOR ............................................................... 12
8.10. TROUBLESHOOTING GEAR DRIVE .......................................................................... 13
8.11. TROUBLESHOOTING CCTV SYSTEM ....................................................................... 14
8.12. TROUBLESHOOTING RMPU.................................................................................... 14
8.13. TROUBLESHOOTING CABIN AIR CONDITIONER UNIT ............................................ 14

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
8.1. FAULT DISPLAY ON DRIVER DISPLAY UNIT (DDU)
DDU provides information for the Train Computer Management System (TCMS) system to
support motor man in operating rake while normal operation, as well as in case of
malfunction of a subsystem.

DDU supports the maintenance staff in setting basic system parameters an fault finding. In
case of failure of TCMS DDU, train can still be operated. There is one DDU installed in each
DTC cab.

It provides an interface to control train functions

 Display operational status of train functions
 Display diagnostic events

For details, kindly refer - Troubleshooting Manual for 25 KV AC Three Phase Propulsion&
Other Equipment for Train 18 by MEDHA Document No- IM-292 rev 0

8.2. TROUBLESHOOTING OF CENTER BUFFER COUPLER

The following are the typical trouble shooting points occurring in couplers

 Tell-tale recess obstructed

 Coupling height disturbed from rail level.
 Manual Uncoupling Device Lever not in position

For details, kindly refer -Descriptive and Maintenance Manual for High Tensile Centre Buffer
Couplers with AAR ‘H’ Type Head and Balanced Draft Gear. Document no CBC-001. Rv.005

8.3. TROUBLESHOOTING OF SEMI PERMANENT COUPLER

Fault Possible Cause Operator Intervention

Foreign material obstructing Manually remove foreign

coupling/uncoupling. material.
Will not couple/uncouple Coupling details worn/rusty. Check socket joint kit.
Replace as required
Flanges will not catch, Lift coupler half a bit more
excessive height difference
Rear nut loose Check rear nut. Replace as
Slack when coupled required.
Rubber springs broken or Check rubber springs.
exhausted Replace as required.
Cannot absorb the draft Exhausted or broken Rubber Draft gear requires repair
and buff loads. springs

For details, kindly refer – Operating Instruction Semi-Permanent Coupler by DELLNER –

Rev.00 31/01/2018

8.4. TROUBLESHOOTING OF PLUG DOOR

For details, kindly refer –Door Diagnostic Description Document - DDSTE11071E13 Rev.00
27/07/2018

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
8.5. TROUBLE SHOOTING VACUUM BIO TOILET
Flush button is pushed but toilet does not flush
Cause Action
No power Supply power
No fresh water Check water supply
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 bowl

Cause Action
Water Inlet valve clogged Remove blockage
Pinch valve defective Replace pinch valve
Quick exhaust valve blocked due to Defrost quick exhaust valve
frost
Quick exhaust valve blocked due to Clean quick exhaust valve
pollution
Water filter clogged Clean filter
Liquid level guard in flush water tank Contact EVAC service Remove flush water
defective tank

Toilet bowl is not flushed sufficiently

Cause Action
Flush nozzles polluted Clean flush nozzles
Flush nozzles calcified Decalcify flush nozzles
Flush nozzles swivelled out of optimal Adjust flush nozzles
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

For details, kindly refer – Operation Manual Vacuum Toilet System by EVAC Train Rev.: 01 –
2018-08

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
8.6. TROUBLESHOOTING BRAKE YSYTEM AND AIR SUPPLY

Micromesh oil filter(OEF 1-5)

kindly refer – Descriptive Manual Micromesh oil filter Doc. no.: B-LE70.21(Rev.15-en).

Check valves with damping (G1; G1 1 / 2 ; G3/ 4)

kindly refer – Descriptive Manual Check valves with damping Doc. no.: B-OF11.21 (Rev.06-
en).

Safety valves(SV1809, SV1810, SV1811, SV1812)

kindly refer – Descriptive Manual Safety valves Doc. no.: B-OS10.29 (Rev.00-en).

Drain valve(EW6)
kindly refer – Descriptive Manual Drain valve Doc. no.: B-MB20.21 (Rev.01-en).

Silencers(NW6, NW12)
kindly refer – Descriptive Manual Silencers Doc. no.: B-TB10.21 (Rev.02-en).

Test fitting(T2-TS)
kindly refer – Descriptive Manual Test fitting Doc. no.: B-VC40.29 (Rev.03-en).

Test fitting(K1-ES)
kindly refer – Descriptive Manual Test fitting Doc. no.: B-VC10.22 (Rev.01-en).

Pressure Governor(MCS4, MCS11, MCSN11)

kindly refer – Descriptive Manual Pressure Governor Doc. no.: B-EN20.22 (Rev.05-en).

Ball cocks with a switch module and with or without an exhaust (SK-DN-SM)
kindly refer – Descriptive Manual Ball cocks with a switch module and with or without an
exhaust Doc. no.: B-OJ41.21 (Rev.09-en).

Pressure sensors with a current output(DG10, DG10-B, DG10-S)

kindly refer – Descriptive Manual Pressure sensors with a current output Doc. no.: B-IS30.24
(Rev.07-en).

General Servicing Instructions

kindly refer – Descriptive Manual General Servicing Instructions Doc. no.: B-IE21.175
(Rev.12-en).

Check valve(RV19-T)
kindly refer – Descriptive Manual Check valve Doc. no.: B-GF10.21 (Rev.05-en).

Check valve(RV7-T)
kindly refer – Descriptive Manual Check valve Doc. no.: B-GF10.29 (Rev.05-en).

Ball cock with an exhaust and a switch module (SK-T-DN.E-SM, SK-T-DN.E-SM-K)

kindly refer – Descriptive Manual Ball cock with an exhaust and a switch module Doc. no.: B-
GJ20.23 (Rev.02-en).

Impulse valve (WIMHV5-NT)

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
kindly refer – Descriptive Manual Impulse valve Doc. no.: B-GD80.24 (Rev.00-en).

Double check valve(DRV7-T)

kindly refer – Descriptive Manual Double check valve Doc. no.: B-GF20.27 (Rev.06-en).

Filter (FIL100)
kindly refer – Descriptive Manual Filter Doc. no.: B-GQ10.22 (Rev.04-en).

Ball cock with an exhaust (SK-T-DN.E, SK-T-DN.E-K)

kindly refer – Descriptive Manual Ball cock with an exhaust Doc. no.: B-GJ10.22 (Rev.01-en).

Pressure reducing valve (DMV15/T)

kindly refer – Descriptive Manual Pressure reducing valve Doc. no.: B-GE50.25 (Rev.04-en).

Distributor valve (STV200)

kindly refer – Descriptive Manual Distributor valve Doc. no.: B-EC90.22 (Rev.00-en).

Mean pressure valve (MDV1, MDV1-T)

kindly refer – Descriptive Manual Mean pressure valve Doc. no.: B-KF20.22 (Rev.05-en).

Brake calliper units (RZTS, RZTM)

kindly refer – Descriptive Manual Brake calliper units Doc. no.: B-CT60.26 (Rev.02-en).

Wheel-mounted brake disc with keyed plug centring

kindly refer – Descriptive Manual Wheel-mounted brake disc with keyed plug centring Doc.
no.: B-CM00.22 (Rev.10-en).

Magnet valves (WMV-01/1NZG)

kindly refer – Descriptive Manual Magnet valves Doc. no.: B-OG20.31 (Rev.00-en).

Magnet valves (WMV1-ZES, WMV1-ZEST)

kindly refer – Descriptive Manual Magnet valves Doc. no.: B-GG21.41 (Rev.06-en).

Magnet valves (WMV-20/2ZG, WMV-20/2ZE, WMV-20/2ZES)

kindly refer – Descriptive Manual Magnet valves Doc. no.: B-OG21.24(Rev.03-en).

Anti-skid valve (GV12-3, GV12-3S)

kindly refer – Descriptive Manual Anti-skid valve Doc. no.: B-HE10.40 (Rev.03-en).

Air Filter (LF7-T; LF7-TF; LF7-TFF)

kindly refer – Descriptive Manual Air Filter Doc. no.: B-GQ10.21 (Rev.03-en).

Overflow valve without reflux (DR07-T)

kindly refer – Descriptive Manual Overflow valve without reflux Doc. no.: B-TD20.28 (Rev.02-
en).

Double check valve (DRV7-T)

kindly refer – Descriptive Manual Double check valve Doc. no.: B-GF20.27 (Rev.06-en).

Piston valve (WKV1-T)

kindly refer – Descriptive Manual Piston valve Doc. no.: B-GD71.23 (Rev.04-en).

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
Tyfon (MKT)
kindly refer – Descriptive Manual Tyfon Doc. no.: B-VE20.23(Rev.06-en).

Drain valve (EE1104)

kindly refer – Descriptive Manual Drain valve Doc. no.: B-MB20.25 (Rev.00-en).
8.7. TROUBLESHOOTING PANTOGRAPH
Defect Reason(s) Correction
Check air bellow, exchange
broken air bellow. (also see
Air bellow damaged.
defect: Bellow drive
defective).
Replace cable. (also see
Cable torn
defect: Cable torn)
Pneumatic control unit Exchange pneumatic
defective. control.
Pneumatic tube defect. Replace pneumatic tube.
Pantograph does not Raise Shock absorber between
or Lower. base frame and lower frame Replace shock absorber.
defect.
Check pantograph for
Inner friction of panto is too damages, and eliminate
high. damages.
Replace defective bearings
Check auto drop device,
Auto drop device activated especially carbon strips for
adjusted. air leakage or damage.
Change defective parts
Contact pressure is poorly Check contact pressure and
adjusted. adjust.
Frequent interruption of
Check pantograph for
current transmittal (strong
Inner friction of panto is too damages, and eliminate
arcing).
high. damages.
Replace defect bearings.
Carbon strips show strong
Replace carbon strips.
breakage.
Pan head springs are slow Clean bearings, replace
motion.. defect bearings.
Frequent interruption of
Carbon strip parallelism is Adjust carbon strip to
current transmittal
not correct adjusted. parallel to catenary.
(strong arcing).
Parallel guide bar is poorly
adjusted (pan head doesn‘t Adjust turning capacity of
turn freely from horizontal pan head.
position).
Uneven wear of carbon Parallel guide bar is poorly Adjust turning capacity of
strips. adjusted pan head.
Insulators between base
Current flashover from Clean insulators between
frame and vehicle roof are
pantograph to vehicle roof base frame and vehicle.
dirty
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
Replace cable and grease in
Cables are not greased area of cam disk with non-
water soluble grease.
Cable torn.
Bellow drive is improper Replace cable, adjust bellow
adjusted; bellow does not to achieve straight
expand straight-lined. expanding line.
Screws are loose. Tighten screws.
Exchange leaking hose with
Hose line leaking.
new hose line.
Bellow drive defective.
Exchange bellow cylinder;
Bellow cylinder leaking. find reason for leakage and
check bellow joints.
Pressure-regulator defective
(normal air leakage of Exchange pressure
Excessive air leakage.
pressure regulator = 0,5 l / regulator.
min.).
Increase of contact
pressure without previous Exchange pressure
Pressure regulator defective.
adjustment of pressure regulator.
regulator.

For details, kindly refer – Description Maintenance and Operating Manual FOR Single Arm
Pantograph by SCHUNK Metal & Carbon (India) Pvt. Ltd. Document No 4 -14062-22.03
(Rev.2)
8.8. TROUBLESHOOTING MAIN TRANSFORMER

Event / Fault Immediate action Diagnostic / Action

 Stop transformer / Do not

 Check if air dryer is not
reenergize transformer.
blocked (disassemble it)
 Visual checking of pressure relief
 Electrical measurements
device, bushings, and tank.
(ratio, winding resistances,
 Check circuit breaker tripping.
insulation resistances).
 Check oil level.
Pressure relief device  Visual checking of pressure
 Perform electrical
tripping relief device, bushings, and
measurements.
tank.
 Perform dissolved gas analysis.
 Perform dissolved gas
 Do not reenergize without full
analysis.
diagnostic.
 Analyse train parameters
 Contact main transformer
records.
manufacturer.
 Check pressure relief device  Electrical measurements
tripping, visual checking of (ratio, winding resistances,
pressure relief device, bushings, insulation resistances).
Circuit breaker and tank.  Visual checking of pressure
tripping  Check oil level. relief device, bushings, and
 Do not reenergize transformer if tank.
some anomaly is detected during  Perform dissolved gas
above checks. analysis.
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
 Perform electrical measurements  Analyse train parameters
 Perform dissolved gas analysis records.
 Contact main transformer
manufacturer.
 Check pressure relief device
tripping, visual checking of
 Electrical measurements
pressure relief device, bushings,
(ratio, winding resistances,
and tank.
insulation resistances)
 Check oil level.
 Visual checking of pressure
 Do not reenergize transformer if
Current Transformer relief device, bushings, and
some anomaly is detected during
over current tank
above checks.
 Perform dissolved gas
 Perform electrical
analysis
measurements.
 Analyse train parameters
 Perform dissolved gas analysis.
records
 Contact main transformer
manufacturer.
 Reduce power, if not sufficient
stop
 transformer.
 Check pressure relief device  Check load and other train
tripping, visual checking of parameters records.
Over temperature pressure relief device, bushings,  Check cooling system : oil
tripping (temp. and tank. flow, air flow, and radiator
sensor or  Check oil level. cleaning.
thermostat)  Do not reenergize transformer if  Check temperature sensors.
some  Check for any oil presence in
 anomaly is detected during air dryer.
above checks.
 Contact main transformer
manufacturer.
Different reading
from temp. sensors
or Check temperature sensor /
Tripping of one thermostat and change device if --
thermostat without necessary.
tripping of lower
range thermostat
 Look for any leakage
including tank, pipe, gasket
assembly, air plug, cracks
Visual oil level too  Check for any leakage.  Clean suspected area, and
low  Add dry and filtered oil. check if oil appear 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, gasket
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
assembly, air plug, cracks
 Clean suspected area, and
check oil appear again
(preferably with hot oil).
 When located repair leakage
 Check recorded load and oil
temperature(train
parameters).
 Perform dissolved gas
 Stop transformer.
analysis.
 Check visual oil level.
 Look for any leakage
Very low oil level  Check for any leakage.
including tank, pipe, gasket
sensor tripping  Check for consistency of sensors :
assembly, air plug, cracks
low oil sensor tripping before
 Clean suspected area, and
very low level.
check if oil appear again
(preferably with hot oil).
 When located repair
leakage.
 Look for any leakage
including tank, pipe, gasket
assembly, air plug, cracks
 If gaskets are mounted with
 Check Oil level. Vaseline lubrification and
 If very low oil level stop transformer being heated, it
Oil leakage transformer. could be sometime
 Look also for other train misinterpreted as leakage.
equipment in the vicinity.  Clean suspected area, and
check if oil appear again
(preferably with hot oil).
 When located repair
leakage.
If pump is running and valves
are ok, check oil flow switch
 Stop transformer.
contactor, if necessary
 Check oil level.
Oil flow stop tripping change oil flow switch. if not,
 Check if pump is running.
check pump supply and
 Check for every valves position.
windings, if necessary change
pump.
Air dryer change of
 Check oil water content, if below
colour start on Check for any crack on air
limit oil needs to be dried.
opposite site of air dryer.
 Change gasket or air dryer.
entrance
 Look for any loosening of
Check possible overheating
connection, and correct it
Bushing colour from loosening connection or
 Look for any crack, if any stop
change possible damage creating
transformer and advise
electrical ageing
manufacturer
Bushing crack Check for any leakage. Advise --
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
manufacturer.
 Check there isn't any
loosed equipment and
correct immediately if
necessary
 Pump: check rotation and if
necessary correct phases
supply.
Try to locate area involved:  Check bearings and replace
 pump if necessary.
 hydraulic noise  Hydraulic: try to evacuate
Abnormal noise  fans air by air drain plugs
 main tank  Fans : looks for some
 some loosing equipment friction or any external part
 other train component blocking fan rotation.
 Check rotation and if
necessary correct phases
supply.
 Check bearings and replace
if necessary.
 Main tank : advise
manufacturer
Paint damage or According to maintenance
Paint repair
corrosion manual
 on bushings: replace
 on accessories: replace
 on main tank: advice
Shocks Check for any leakage
manufacturer
 on flexible pipe: replace
 on auxiliary connectors : replace
Physical properties
of oil (water content, Refer to maintenance manual Check air dryer
breakdown voltage)
Expert diagnostic and
DGA indicating fault Consult expert to decide
sampling interval

For details, kindly refer –Maintenance Manual Main Transformer by JST Transformers
8.9. TROUBLESHOOTING TRACTION MOTOR

Distinctive feature Possible reason Corrective measure

 Do visual check of motor
suspension.
Motor suspension defect  Renew motor suspension if
Motor vibrates necessary.
 Do check of screws check if correct
tightening torque is applied.
Loose screws
 Replace broken or damaged screws.

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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
 Disassemble rotor and check
balance.
Unbalanced rotor  If necessary do new balancing of
rotor.

Bearing damage Replace bearings.

 Replace rotor and check stator for
Rotor and rotor parts
damage.
Unusual motor rubbing on stator  Renew damaged stator.
noise
Bearing damage Replace bearings.
Ventilation grid is dirty
Temperature of the (paper, plastic bag) Clear ventilation grid.
motor is too high
Ventilation holes are dirty
Clean ventilation holes

Bearing damage Replace bearings

 Check winding visually and check
Smoke emission
insulation of winding.
Damage of winding
 If necessary replace stator.

For details, kindly refer – Operating Manual for Traction Motor TME 49-35-4 by TSA
Document - TSA018528 / 0 / EN
8.10. TROUBLESHOOTING GEAR DRIVE

Malfunction Possible cause Checks/corrective actions

Check oil volume on the oil
level indicator and adjust if
Oil level in gearbox too high
necessary
Water has penetrated into
Oil leaking off the
the gearbox (e.g., while
labyrinth Seals of the
cleaning the wheel set Perform oil change
shafts
gearbox)
Disassemble, clean and
Gearbox was tilted too much
assemble labyrinth seal
(with oil filling)
parts.
Bolt not tightened according Tighten bolt with specified
Oil escaping on a locking to specifications torque
bolt
Seals worn or defective Replace affected seal
Check oil volume on the oil
Wheelset gearbox gets too Oil level in gearbox too high
level indicator and adjust if
hot or too low
necessary
Damage to toothing or Check the toothing and the
Loud noises bearings bearings
Retaining bolts of the Check whether retaining
Vibration or knocking
gearbox mounting are loose bolts are seated firmly on the
when load changes
or spherolastic bearing is gear box mounting and
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Vande Bharat Express(T-18) Maintenance Manual (Version1.0) 8. Trouble Shooting
defective retighten if necessary.
Inspect spherolastic bearing
visually; replace if necessary.
Check and replace the gear
coupling according to
Gear coupling defective
operating manuals of the
coupling KWN31426 of KWD

For details, kindly refer – Operating Manual for Traction Gearbox GKD 1-52-372A by TSA
Document - TSA017120 / 0 / EN

8.11. TROUBLESHOOTING CCTV SYSTEM

For details, kindly refer – Maintenance manual for 25 KV AC Three Phase Propulsion & Other
Equipment for Train 18 by MEDHA. Document No: IM-291 rev 0

8.12. TROUBLESHOOTING RMPU

For details, kindly refer – Maintenance manual for Roof Mounted Air Conditioner RCAC-
2400EF by SIDWAL. Document No: SID-T18- 5 Rev. 0

8.13. TROUBLESHOOTING CABIN AIR CONDITIONER UNIT

Trouble Cause Remedy/Check
 Check main supply
connector tightness
MCB Switched on but AC
No input voltage  Check voltage at MCB input
unit does not start
 Check phase sequence
(RYB)
A) Check voltage at input
A) No voltage applied to
Condenser/Blower fan terminal of condenser motor
motor
does not start B) Check winding continuity,
B) Motor defective
if broken, change motor
A) No voltage applied to A) Check voltage at input
motor terminal of condenser motor
Compressor does not start
B) Compressor Motor B) Check winding continuity,
defective if broken, change motor
 Refrigerant shortage
 Clogged filter
 Blower rotation in reverse
Compressor starts but A) Suction pressure too low direction
stops before set temp is B) Discharge pressure too  Check liquid line,
achieved high evaporator and TXV.
 Condenser contaminated/
clogged
 Defective condenser coil

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