Troubeshootings 8 Wheeler DHTC Detc-1
Troubeshootings 8 Wheeler DHTC Detc-1
Troubeshootings 8 Wheeler DHTC Detc-1
ELECTRICAL
TRD
DESIGNED BY:-
SSE/TRD/RRD/KGP
ELECTRICAL TRD
Troubeshootings:-
ITEM DEFECT What to do
Put on 24v/110v circuit breakers on control
panel. Ensure 24v knife switch is on
Check for glowing of engine off/ON indication
lamp Ensure indication lamp “ON” local remote panel
Electrical side
Check Local remote switch It should be at “LOCAL POSITION”.
Electrical side Check supply on fue solenoid ( Shut down valve) Tightened the screw and make it direct
Relay/electro pneumatic valve does not operate If not , Refer to Elect Case-1
2.Engine Cranking Relay chatering If not , Refer to Elect Case-1
but Not Firing Check the Actuator Reset it
Mechanical side Fuel Injection not proper Check fuel filters and pipes, clean if required
Poor quality of fuel / grade fuel Ensure good quality during filling of fuel, for dust and other
sediments filters may be used.
3. Engine Cranking, Air leaks in suction lines Proper tightening of joints and remove defective gasket.
Firing but Not Holding Restricted fuel lines Fuel pipes and jammed filters to be cleaned
Plugged injector spray holes Clean the same / replaced if necessary
Cracked injector body or cup Replace
Mechanical
Damaged injector O-ring Replace
side
Water in fuel water/or waxing leakage to be arrested and deffective fuel should be replaced.
Injector flow incorrect clean the same / Adjust if necessary
Long idle periods Check and normal maint of fuel and air ckt to be done
Gasket blow -by or leakage Replace
Broken or worn piston rings Replace
Injectors valve and injection timing Timing adjustment to be done.
Check Supply of Voltage at PT pump If not available then tightened the screw from AUTO to MANUAL
Check the BCH handle in released position Ensure if not then do it in release position.
MR pressure to be more than 5.0 kg/cm2 Check
8. BP Pressure Mechanical Emergency brake valve handles in closed condition
side in both cabs Check and close if not
Not Building Up Ensure proper closing of angle cut out cocks of
BP pipe on either ends of the formation. Check and close if not
Cheeck for any Air leakage at joints If so then tighten same properly.
10. Removing Air Check for Closing of the COC on pipeline connected
Mechanical from fuel tank to primary filter. Then open auxiliary
Lock in Fuel Oil side cocs (two numbers) and disconnect the pipe line
connection on to actuator. Then operate the
System priming pump plunger till such time the oil flows
Do accordingly
out through the disconnected pipeline. Reconnect
the pipe at actuator and close two auxiliary cut out
cocks and open the main COC and crank the engine.
ELECTRICAL TROUBLESHOOTINGS
Defect 1: When starter motor is operated its shaft fails to rotate or rotates slowly and the starter motor does not crank the engine through pinion has engaged with
ring gear.
Defect 5: Pinion engage but starter motor does not crank the engine (whining noise is heard)
Cause Action - Remedy
a) In sufficiently charged battery/corroded terminals. Recharge the battery/clean terminal and smear petroleum jelly.
b) In sufficient pressure on carbon brushes or worn out brushes. Change the brush springs/brushes.
c) Shorted/earthing armature Change armature
d) Slipping clutch assembly Change clutch assembly.
e) Partially earthing field coil. Change starter motor
b) Large voltage drop Check the loose connections. Clean the contact tips of main and auxiliary contacts.
b) Inter turns short circuit caused by mechanical damage in coil. Replace coil
c) Dirt or rust on pole faces increasing the air gap. Clean pole faces with very fine emery paper or dry cloth.
Defect 14: EVEN THOUGH LUB OIL PRESSURE IS MORE, ENGINE DOES NOT SUSTAIN (STOPS AFTER RELEASING THE START PUSH BUTTON)
Cause Action - Remedy
a) Faulty low water level switch Check and replace if necessary.
b) Faulty low water level relay Check and replace if necessary
c) Faulty over speed switch Check and replace if necessary.
d) Faulty lub oil pressure relay Check and replace if necessary
e) Faulty low hydraulic oil level Check and replace if necessary.
Defect 15: ENGINE THROTTLES IN HIGH RANGE BUT CAR DOES NOT MOVE (TRANSMISSION DO NOT ENGAGE)
Probable Cause Remedy
a) Defective timer relay TCE1 Check and replace.
b) Defective clutch cut off valve Check and replace
Defect 16: BRAKE APPLIED INDICATION DOES NOT EXTINGUISH EVEN AFTER ALL THE BRAKES ARE RELEASED.
Probable Cause Remedy
a) Defective service brake pressure switch Check and replace
b) Defective parking brake pressure switch Check and replace
c) Disturbed pressure settings in pressure switch Check and verify for proper settings.
Defect 17: EMERGENCY RAISE OF ENGINE DOES NOT TAKE PLACE I.E. ENGINE REMAINS IDLE WHEN EMERGENCY RAISE PUSH BUTTON IS RAISED.
Probable Cause Remedy
a) Defective push button switch Check and replace
b) Defective ERR relay Check and replace
Defect 18: ENGINE THROTTLE DOES NOT TAKE PLACE EVEN AFTER THE THROTTLE HANDLE IS MOVED TO DIFFERENT NOTCH POSITIONS
Probable Cause Remedy
a) Defective ET1 (ET2) relay Check and replace
b) Defective timer relay TCE2 Check and replace
c) Defective MUTC solenoid Check and replace
d) Defective speed relays (NRA-NRD) Check and replace
Defect 19: CAR DOES NOT MOVE WHEN SELECTED "LO" IN THE "RANGE SELECTOR" EVEN AFTER DIRECTION ENGAGED INDICATION IS CONFIRMED
Probable Cause Remedy
a) Defective LRR relay Check and replace
b) Defective TCE1 timer relay Check and replace
c) Defective GEAR1 solenoid Check and replace
d) Defective clutch cut off valves Check and replace
Defect 20: FORWARD/REVERSE SOLENOID FAILS TO GET ENERGISED EVEN AFTER DIRECTION IS SELECTED.
Probable Cause Remedy
a) Defective ADD ON block CT1 (CT2) power contactor. Check and replace
b) Check 02R relay for its operation. Power to this relay comes from signal converter. Check and replace
c) Defective SIGNAL CONVERTER Check and replace
d) Defective FORWARD/REVERSE solenoid Check and replace
Emergency Lifting (a) Open the shut-off valve fitted between the cylinder outlet and hand-
pump.
(b) Close release valve on the hand pump.
(c) Operate the hand-pump. Ram moves up very slowly to raise the
platform in
loaded condition as well
Emergency Swivelling In case there is any fault in the system when platform is raised and
swivelled
out, proceed as follows :
(a) Lower the platform (as explained above) such that the pinion fitted
on the gear
box comes within the reach of the person standing on the roof.
(b) Unscrew hex bolt and grub screw fitted with pinion assembly.
Remove the pinion
from gear box shaft.
(c) Now the platform is free to rotate in any direction. Manually rotate the
working
platform to normal position.
(d) Lower it completely to bring to its normal retracted position.
INSTRUCTIONS
DAILY CHECK BY DRIVER BEFORE STARTING THE ENGINE
(DAILY CHECKS OF TOWER CAR REDUCES FAILURES)
Insert the master controller switch key and operate reverser handle in ‘FORWARD’ & ‘REVERSE’ and keep it in the ‘OFF’ position.
Switch on 24V DC Battery.
.
STARTING OF ENGINE
Keep Engine Control Switch (ECS) in ‘IDLE’ position.
Press ‘Engine-ON’ switch.
Engine ‘ON’ indication will come as soon as Engine is started.
Once Engine started, auxiliary alternator rectifier set will generate supply and auxiliary alternator failure indication will go ‘OFF’.
CHARGING OF RESERVOIRS
Keep the test sequence switch in ‘ON’ condition and ECS continue to be in ‘IDLE’ position.
Allow the engine to run in ‘IDLE’ position till feed pipe pressure reaches 6.0 kg/cm2.
For fast build up of the pressure engine can be notched up and accordingly press the dead-man’s handle.
CHANGING OF DIRECTION
Keep the master controller handle in ‘OFF’position.
Selection of direction shall be done only in stationary condition.
Select the required direction by operating reverser handle in ‘FORWARD’ or ‘REVERSE’ direction.
2
Ensure the feed pipe pressure is built up to 6 kg/cm .
Ensure that brake pipe pressure is 5 kg/cm
2
Ensure that parking brake is released by pressing the parking brake release switch.
Remove wooden wedges/ skids from wheels.
Put test sequence switch in ‘OFF’ position and ECS switch in ‘RUN’ position.
Switch ‘ON’ Excitation switch in BL box. Alternator Excitation ‘ON’ indication will come.
Move the master controller key in clockwise direction by 90° & set the reverser handle of master controller to the ‘FORWARD’ position from ‘OFF’
position.
Press dead-man’s handle and move it in the ‘Notch-1’ position.
Move the master controller handle to higher notches, notch by notch.
Observe the Load Ammeter Current. The car will move as soon as current starts building up.