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WAG9 Locomotive
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Maintenance and Repair
Manual

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Page 4 of 4 Bombardier Transportation Ltd ABB No. 3EHQ600382

Indian Railways WAG-9 Preface
Maintenance and Repair Manual

Preface

Introduction
@.1050

These Maintenance & Repair Manuals of technical documentation for the Indian Railways
wAG-9 locomotives are divided into Chapters; each of which contains information pertinent
to a specific area of the locomotive. The Chapter numbers correspond to the Breakdown
Structure of the Locomotive (GAPL), shown on the inside front cover of this binder. The same
delineation of Chapters is used throughout the technical documentation for theWAG-9 loco-
motives.
Information in each Chapter is divided into various Sections which describe the locomotive
equipment and procedures required for maintenance. See Section Description, as follows.

The Maintenance & Repair Manuals span more than one binder. For ease of identification,
each Volume is labelled on its spine and front cover, indicating the Volume and binder number,
and the Chapters contained within.

WAG-9
ILOCOMOTIVES.

I 1 LOCOBOOY l r 2BOGIES&
RUNNING GEAR
r 3POWERSUPPLY
1 1
·~ON
I I SAUXIUARY
SYstEM 1
r 8AIRSUPPLV&
PNEU, BRAKES
1 r l I
71Nl£RIOR
I
SCOHTROl
SYstEM

H 1.1 STRUCTURE I -{ 2..1 BOGIE FRAME I -13.1 ROOFUNE

l1 4.1 TRACTION
1CONVERTER
I 1~E~ Ii 8.1MAIN
COMPRESSOR
1
I 1'·'000RS l ,1.1 CAB I
CONTROL

H ,'-2 EXTERK>A
FINISH
I -{ 2.2 WHEELSET I -13.2 PANTOGRAPH
I 114.2 TR. CONVERTER
OllCOOUNG
I 1~ I 18.2
COMIEATER
AIR DRYER
I i 7.2SEATS
I ~~hEAOOM I
~ 1.3000RS
&STEPS
IH 2.3 PRIMARY
SUSPENSK)N
I ~ 3.3 MAIN QRCUIT
BREAKER
I 1~CONVERTER I I
-{ 5.3 BATrERV &
CHARGER
-{ 8.3 RESERVOIRS
IH I1
7.3UGHTING
I
1.3 CXlNTRlt.
ELEC'TRONICS

H 1.4 DRAFTGEAR &

COUPI..ERS
IH 2..4SECONOARV
SUSPENSION
I H_ 3.o4SURGE
ARRESTER
I H. . . TRACTION
MOTOR
I H ,..otIH IH
5.4 HOTEL LOAD
apphc:abl•
8.4 AUXIUARY
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UNK
13.5 TRANSFORMER Iy 4.5 CABLING
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FRAME
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H I.e HORNS&
UGHTS
IH 2.8 TRANSMISSION H T~ORMER l
3.8
OK.COOUNG H~N;~ I H~ l H~ l
H 1.7WASHERS&
WIPERS
lH 2.7SANOING
EQUIPMENT
lK 3. 7 TRANSOUCEAS I H I4 14'·'~
5.7 TRACTION MOTOR
BlOWERS
47 BRAKE
ACTUATORS
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5.9 POWER SUPPLY
4151110V

Bombardier Transportation Ltd. !dent. No. Chapter Preface Page 1 I 18

3EHW 411479 Revision Date: 12.2001

. -----·--·--·- ~------··· ····-----·----- --··- - - · - · --

A
Preface Indian Raihvays WAG-9
Maintenance and Repair Manual

Section Description

Section Group Summary describes the equipment covered by the Chapter. Figures. show
the various components and a .legend beneath identifies the items.

Section Functional Description explains the function that the equipment performs on the
locomotive.

Section Technical Data contains technical information and specifications on the equipment
covered in the chapter. The information varies according to the type of equipment. In some
instances, specifications for equipment may be located in the appropriate chapter of
Volume F, Suppliers Documentation.

Section Tolerances and Wear Limits List contains information regarding the allowable in
service wear or tolerance specifications for the equipment covered in the chapter. In some
instances the service tolerances for equipment may be located in the appropriate chapter of -
Volume F, Suppliers Documentation.

Section Tools & Special Tools provides information of any non-standard tools and appar-
atus that are required to undertake the procedures described in the chapter. Throughout this
documentation it is assumed that conventional railways workshop tools and equipment are
available. As such, these items are not listed.

Section Miscellaneous Materials lists the materials required for the operations described
in this chapter. Materials needed for the procedures in the chapter, such as sealants, thread
locking agents, oil binding agents, solvents, cleaners and alike are listed in this section. It is
assumed that normal workshop consumables and materials are available. As such, these
items are not listed.

Section Before Removal Operations provides a list of procedures necessary prior to the re-
moval of the equipment described in the chapter.

Many before removals operations require procedures described in other chapters or docu-
ments. The necessary references are given, see References.

Some before removals operations require isolation of other equipment. Details are provided
as necessary, along with appropriate references. Isolation of equipment must always be car-
ried out in accordance with the prevailing workshop safety regulations. Any equipment that
is isolated as part of the before removals operations must be reconnected after the work is
completed and the associated equipment tested to ensure it functions correctly.

Section Removal describes the procedures for removal of the entire equipment assemblies
from the locomotive. Some equipment can be serviced in situ:-it may not be necessary tore-
move the entire assembly from the locomotive. See Scope of Work.

Chapter Preface Page 2 I 18 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Preface Indian Railways W AG-9
Maintenance and Repair Manual

Section Description

Section Group Summary describes the equipment covered by the Chapter. Figures show
the various components and a legend beneath identifies the items.

Section Functional Description explains the function that the equipment performs on the
locomotive.

Section Technical Data contains technical information and specifications on the equipment
covered in the chapter. The information varies according to the type of equipment. In some
instances, specifications for equipment may be located in the appropriate chapter of
Volume F, Suppliers Documentation.

Section Tolerances and Wear Limits List contains information regarding the allowable in
service wear or tolerance specifications for the equipment covered in the chapter. In some
instances the service tolerances for equipment may be located in the appropriate chapter of
Volume F, Suppliers Documentation.

Section Tools & Special Tools provides information of any non-standard tools and appar-
atus that are required to undertake the procedures described in the chapter. Throughout this
documentation it is assumed that conventional railways workshop toots and equipment are
available. As such, these items are not listed.

Section Miscellaneous Materials lists the materials required for the operations described
in this chapter. Materials needed for the procedures in the chapter, such as sealants, thread
locking agents, oil binding agents, solvents, cleaners and alike are listed in this section. It is
assumed that normal workshop consumables and materials are available. As such, these
items are not listed.

Section Before Removal Operations provides a list of procedures necessary prior to the re-
moval of the equipment described in the chapter.

Many before removals operations require procedures described in other chapters or docu-
ments. The necessary references are given, see References.

Some before removals operations require isolation of other equipment. Details are provided
as necessary, along with appropriate references. Isolation of equipment must always be car-
ried out in accordance with the prevailing workshop safety regulations. Any equipment that
is isolated as part of the before removals operations must be reconnected after the work is
completed and the associated equipment tested to ensure it functions correctly.

Section Removal describes the procedures for removal of the entire equipment assemblies
from the locomotive. Some equipment can be serviced in situ:-it may not be necessary tore-
move the entire assembly from the locomotive. See Scope of Work.

Chapter Preface Page 2 I 18 Idcnt. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways W AG-9 Preface
Maintenance and Repair Manual

Section Disassembly describes procedures for the disassembly of equipment; generally

once it is removed from the locomotive. However, some equipment can be serviced in situ.
See Scope of Work.

Section Inspection and Repair describes how to inspect equipment for wear, defects or
damage. Where appropriate, repairs may also be described in this section. In some in-
stances, details of inspection and/or repair are given in Volume F, Suppliers Documentation.
In such cases, the appropriate Volume and Chapter of Volume F is given in this Section, see
References. Some equipment cannot be repaired. These items are replaced as an assembly,
if unserviceable.

Section Waste Disposal provides information regarding special disposal requirements for
particular items due to their composition or contents.

Section Assembly describes procedures for reassembly of equipment.

Section Installation describes the procedures for the reinstallation of entire equipment as-
semblies to the locomotive.

Section After Installation Operations provides a list of procedures necessary after reinstal-
ling equipment to the locomotive.

Any equipment that is isolated or disconnected as part of the before removals operations
must be reconnected and tested.

Section Adjustments describes any adjustments that are required for the equipment cov-
ered in the chapter.

Associated Volumes

Volume A: Driver's Manual

Volume B: Scheduled Maintenance Manual

Volume C: Fault Finding

Volume E: Spare Parts Catalogue

Volume F: Suppliers Documentation

Volume G: Cable Schematics

Repair Competencies

The procedures in this manual expect the user to have the appropriate competencies and
skills. The scope of work associated with the procedures described should only be carried out
by suitably qualified and properly trained railway engineers. Personnel must have an ap-

Bombardier Transportation Ltd. ldent. No. Chapter Preface Page 3 I 18 ~

3EHW 411479 Revision Date: 12.2001
 Preface Indian Railways W AG-9
Maintenance and Repair Manual

propriate level of technical and engineering understanding before undertaking any oper-
ations on the locomotive. This manual describes the technical procedures required to service
and maintain the specifics of theW AG-9 series locomotives, not general locomotive engin-
eering practices. Workshop procedures and practices are not covered within these instruc-
tions.

Scope of Work

Due to the complex nature of locomotive engineering, every instance in which equipment can
be removed or installed cannot be taken into consideration in these Volumes.

Some equipment can be serviced in situ:-it may not be necessary to remove the entire as-
sembly from the locomotive. For example, the valve sets can be removed from the traction
- converter without removing the traction converter from the locomotive. Before undertaking
any work on the locomotive, the entire chapter must be read, and the user acquainted with
all aspects of the procedures. The scope of work is then to be established.

General Information

Throughout this preface, the term 'equipment' refers to the components and systems that
comprise the locomotive.

All figures in these volumes are graphical representations intended as general illustrations
to represent the situation. They may not be dimensionally or otherwise accurate. Figures
should not be used for scaling. Only the items numbered in an illustration are referenced in
the associated text passages. No additional information should be inferred from the figure.

Figures, photographs and drawings may appear pictorially different from the physical situ-
ation being represented. Extraneous components may not be shown in the illustration for clar-
ity. Others may be shown redundantly to provide a frame of reference for the situation.

References

Maintenance, removal or installation of some equipment on the locomotive can require inter-
action with other components described in different chapters, or volumes. In these cases, a
reference is given directing the user to the appropriate documentation. For example, "refer
to Chapter 3, Primary Suspension" directs the user to another chapter in VolumeD where the
necessary procedures are described. References, such as, "refer to Chapter 5, Oil Blowers
of Volume F1 0, Suppliers Documentation." direct the user to the appropriate volume and
chapter of the Suppliers Documentation, Volume F. Or "refer to Section Actual value Detec-
tion, Sheet 12A, Catenary & Battery Voltage of Volume G1, Cabling Documentation" directs
the user to the appropriate sheet in the locomotive schematics, Volume G.

Chapter Preface Page 4 I 18 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
Indian Railways W AG-9 Preface
Maintenance and Repair Manual

Safety Information
@.1060

Workshop Safety
All employees must take care to avoid the risk of injury to themselves and others. Precautions
and care should be taken in accordance with the prevailing workshop regulations.
Caution signs, stating personal working on locomotive, are to be located at both ends of the
locomotive whenever any maintenance procedures are undertaken.
Before carrying out maintenance or repairs on the locomotive, make sure that the locomotive
is safely parked with the parked brakes released. Chock wheels to prevent locomotive
movement.
Many systems on the locomotives interact with other systems, eg. powering-up the auxiliary
converters causes the blowers to start. Therefore, if the operation of any ancillary equipm~t
could endanger the safety of any person, then the appropriate systems must be isolated.

Electrical Precautions
Where the scope of work requires the isolation of the overhead catenary, the overhead must
be isolated in accordance with the prevailing workshop regulations, before any person works
on high voltage equipment. Refer Electrical Isolation of the Locomotive.
Whenever working on the roof area, the locomotive must be shunted to a section track that
contains no overhead catenary, and the traction converter must earthed. Refer Electrical
Isolation of the locomotive.
Do not attempt to make repairs or adjustments in the control cubicles or drivers desk when
power is on. Ensure that the battery supply is isolated.
11 OV binary signal train lines are a potential electrical hazard. Before working on the systems
connected to these sockets, ensure that the locomotive is electrically uncoupled at both ends,
the locomotive is isolated and earthed at the main circuit breaker, and that the batteries c.
isolated.
Do not operate the controls of functional apparatus (eg. move contactors, actuators, relay or
EP valves by hand, connect or disconnect wires, remove temporary packing or interface with
pneumatic equipment) of a locomotive undergoing maintenance/testing, without first ensuring
that there are no persons engaged in any work on, within or beneath that locomotive, who
may be injured in any way by the operation.

Bombardier Transportation Ltd. Ident. No. Chapter Preface Page 5 1 1f

3EHW 411479 Revision Date: 12.2001
 q
Preface Indian Railways W AG-9
Maintenance and Repair Manual

Care should also be taken to ensure that capacitor systems on the locomotive have dis-
charged prior to undertaking operations. The traction converters and the BUR cabinets con-
tain capacitors. Voltage indicators on these cabinets warn of any residual voltage in the cabi-
net. Always ensure that indicator LEOs are flashing slower than once every 15 seconds. See
Electrical Isolation of the Locomotive, Chapters 4.1, Traction Converter and 5.1, Auxiliary
Three-Phase Power for more information on voltage indicators. The filter cubicle also con-
tains capacitors, but these are automatically discharged whenever the main circuit breaker
is opened.

The gases generated by a battery are highly flammable. Where a battery is found to be or
suspected to be overheated, extreme caution should be taken to prevent ignition until the
gases have been allowed to disperse. Keep flames, lighted cigarettes and welding operations
away from batteries. ·

Electronics Precautions

Do not use a buzzer, bell, megger, or flash test equipment until all circuits which include semi-
conductor devices have been isolated. Ensure the manufacturers directions are followed
whenever testing electrical and electronic devices. Special tools and testing procedures may
be required.
Whenever working with electrical equipment, it is good practice to become familiar with the
related schematics. Volume G, Cabling Documentation contains the electrical schematics for
the locomotive. Always ensure that any removed wiring is reconnected correctly, as incorrect
wiring can cause irreparable damage to equipment and incomprehensible error messages
from the control electronics.

When electrical and electronic equipment is to be removed, all wiring should first be tagged
before it is disconnected. This will aid in the correct reinstallation and reconnection of the
equipment.

In many chapters, references are given to the appropriate Sheet in Volume G, Cabling
Documentation. Otherwise, wiring should be reconnected as tagged during removal. The
wiring and terminal numbers located on equipment are referenced in the electrical
schematics in Volume G.

Cabinets and Equipment Cubicles

WARNING:
Extreme care must be taken when approaching equipment which has been
live, and could remain live for a short period of time because of the delayed
discharge time of capacitors.

Chapter Preface Page 6 I 18 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways WAG-9 Preface
Maintenance and Repair Manual

The following systems have covering panels to prevent accidental contact with electrical sys-
tems.

• Control Cubicles (SB1, SB2)

• Auxiliary Cubicles (HB1. HB2)
• Filter Cubicle (FB)
• Traction Converters (SR1, SR2)
• Auxiliary Converters (BUR1, BUR2, BUR3)
• Driver's Desk, including Cubicle F and Panels A, 8, C and D
These systems contain high-power AC systems connected to the main transformer and/or
DC systems connected to the battery. Electrical systems must be isolated and earthed, and
the capacitor systems discharged prior to removing any panels from these areas or working __
on any of these systems. See Electrical Precautions. Covers on the HB, FB, SR (traction con-
verters) and BUR cabinets require keys from the key interlocking system for access. See
Electrical Isolation of the Locomotive.

Handling Precautions

Most locomotive equipment is heavy. Generally, the weight of equipment is listed in Section
Technical Data. Care must be taken to avoid personal injury or damage to adjacent equip-
ment. Heavy items must be lifted in accordance with the prevailing workshop safety regula-
tions using suitable lifting equipment. Such lifting equipment must be rated to carry the weight
involved. Always ensure that the weight of the item to be lifted is known before commencing
the procedure. For example, some equipment contains oil or other fluids, which may not be
included in the listed weight for the equipment. Operate the lifting equipment in accordance
with the manufacturers recommendations. Always ensure that the item to be lifted is trans-
ported in accordance with its manufacturers directions.

Fluids Precautions

When handling lubricants, sealants, paints, adhesives, cleaning fluids or similar, the local
workshop regulations or the manufacturer's instructions must be strictly observed.

Ensure that appropriate cleaning materials and preparations are used whenever cleaning any
equipment. Ensure the manufacturers documentation for the equipment is consulted prior to
cleaning any equipment, as some cleaning agents and solvents may cause damage to some
equipment.

Always observe the cleaning solvent manufacturer's instructions. Some solvents may be
toxic or flammable.

Bombardier Transportation Ltd. ldcnt. No. Chapter Preface Page 7 I 18

3EH\V 411479 Revision Date: 12.2001
 I(

Preface Indian Railways WAG-9

Maintenance and Repair Manual

Lubrication Precautions

Clean lubricating points before applying the recommended lubricant, and remove any excess
after applying new lubricant.

Pneumatic Precautions

Before performing any operations on systems incorporating pneumatic components, ensure

the locomotive pneumatic system is isolated and vented, as described in Chapter 6.3, Main
Reservoirs.

Before operating any pneumatic cocks, check the direction in which any air may be vented
and ensure that the blast of compressed air cannot cause injury or damage.

Before attempting to dismantle or remove any equipment that is connected to a compressed

air system, isolate it from the air supply and exhaust all air from it and the associated system.

When blowing out pipes with compressed air, wear goggles and take care to avoid any open-
ings from which the air may blow out, as blown particles can be harmful.

During brake testing involving application and release of the brakes, ensure that no other per-
sonnel are in positions where they could be endangered by the movement of the brake blocks,
rigging etc. Warning signs must be located at both ends of the locomotive during brake testing
or brake maintenance. If the brake system is isolated, warning indicators must also be in posi-
tion at each end of the locomotive and on both driver's desks.

Welding Precautions

When welding operations are being carried out on a vehicle, the welding return lead shall be
secured as near as possible to the point of welding. All electronic devices shall be individually
grounded. The locomotive structure is a critically stressed unit, and welding should only be
carried out to an Approved Welding Procedure by suitably qualified technicians.

Technical Information
@.1130

Electrical Isolation of the Locomotive

Chapter Preface Page 8 I 18 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways WAG-9 Preface
Maintenance and Repair Manual

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1 Pantograph air supply isolating cock 10 Earthing switch on traction converter 2

2 Earthing switch of main circuit breaker 11 Key multiplier 2
3 Key multiplier 1 12 Door lock, traction converter 1
4 Door lock auxiliary circuits, Block 1 13 Door lock, traction converter 1
5 Door lock auxiliary circuits, Block 2 14 Door lock, traction converter 1
6 Door lock auxiliary converter 1 15 Door lock, traction converter 2
7 Door lock auxiliary converter 2 16 Door lock, traction converter 2
8 Earthing switch on traction converter 1 17 Door lock, traction converter 2
9 Door lock on filter block

Bombardier Transportation Ltd.

Ident. No.
Chapter Preface Page 9 I 18
Revision Date: 12.2001
3EHW 411479
 13

Preface Indian U.ailways WAG-9

Maintenance and Repair Manual

When carrying out repairs or testing of electrical equipment (unless specifically authorised
otherwise), the locomotive high voltage equipment must be isolated by using the Key Inter-
locking System. The key interlocking system isolates and earths various parts of the locomo-
tive electrical system. The key interlocking system comprises five different key types; A, B,
C, 0 and E. Each key type is coloured distinctly;

Key Colour Qty. Location

A Light Blue 1 Pantograph air supply isolating cock
B Yellow 2 Main circuit breaker earthing switch
c Green 7 Key Multiplier No. 1
D Black 2 1 on each traction converter earthing switch
E White 6 Key multiplier No. 2
The following steps describe how to earth and isolate the locomotive using the key interlock-
ing system.

• Shut down the locomotive as describ~d in Chapter 4, Vehicle Operation of Volume A,

Driver's Manual.
• Turn off the air supply to the pantographs by switching Key A on the air supply isolating
cock, located on the brake frame (pneumatic panel). The air in the system will be ex-
hausted, locking the pantograph in the lowered position.
• To release Keys B, insert and turn key A in the main circuit breaker Earthing Switch. A
bolt will be released, unlocking the arm of the main circuit breaker. Move the arm to the
EARTH position then turn and remove the Keys B.
• One Key B should be held by the maintenance supervisor. The other is used in the key
multiplier No. 1 to release Keys C. The seven Keys C are used for:
Unlocking the earthing switch on traction converter 1

Unlocking the earthing switch on traction converter 2

Opening the auxiliary circuit block 1

Opening the auxiliary circuit block 2

Opening the auxiliary converter 1

Opening the auxiliary converter 2

Opening the filter block

• Move the battery isolating switch to the Off position, as required.

• The Keys Care used to unlock the earthing switches on each traction converter. Before
operating the traction converter earthing switches, ensure the master switch on the
driver's desk is in the "0" position and that the "Control Circuits Locomotive" (112.1) cir-

Chapter Preface Page 10 I 18 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways W AG-9 Preface
Maintenance and Repair Manual

cuit breaker is in the "OFF" position. Circuit breaker 112.1 is situated in 882. Ensure
that there is no fault message, "Fault DC_Link Discharge", on display terminal in the
cabin, and the voltage indicator LED is OFF for at least 15 seconds. From the time the
locomotive is powered down. it can take approximately 5 minutes to completely dis-
charge the DC-Link capacitors. Always ensure that indicator LED is flashing slower
than once every 15 seconds before earthing the traction converter.
• To release Keys D from the traction converter, insert and turn a Key C in the traction
converter earthing switch. A bolt will be released, unlocking the traction converter earth-
ing switch arm. Move the arm to the EARTH position then turn and remove the Key D
from the traction converter. Repeat the procedure on the other traction converter.
• Once both of the Keys D have been removed from the traction converters, they are
used to release Keys E from key multiplier No.2, located in the machine room behind
the cab. The six keys E are used unlock:
Traction converter 1, door locks 1 - 3

Traction converter 2, door locks 1 - 3

Steam Cleaning

Steam cleaning equipment uses high pressure, high temperature steam and cleaning prep-
arations to blast dirt, debris and other built up deposits from surfaces. Care must be taken
to ensure that the nozzle of the steam cleaning equipment does not spray onto persons or
sensitive equipment, as severe damage may occur. Always operate steam cleaning equip-
ment in accordance with the manufacturers recommendations.

Some equipment contains air vents for cooling and venting, such as the vents in the axle
boxes and traction motors. Steam cleaning of such equipment must be performed in a careful
and controlled manner to ensure that the cleaning jet is not directed into such vents. Refer
to Chapter 2.6, Transmission.

Non-Destructive Testing & Inspection

Non-Destructive Testing (NOT) is required in many areas of locomotive maintenance andre-

pair. There are many forms of NOT that can be used as an aid to \dentify cracks, holes, flaws
or other discontinuities in components. This section outlines the basic principals of five forms
of NOT: visual inspection, penetrant, ultrasonic, magnetic and radiographic.

Information given in this section is intended as a guide only and is in no way an exhaustive
list of NOT procedures, operation or techniques. All non-destructive testing must be per-
formed by a qualified operator and the resulting data must be interpreted by qualified person-
nel.

Bombardier Transportation Ltd. ldent. No. Chapter Preface Page 11 I 18

3EHW 411479 Revision Date: 12.2001
 75

Preface Indian Railways WAG-9

Maintenance and Repair Manual

Visual Inspection

Visual inspection is usually the first form of testing or evaluation performed. Many defects,
cracks and points of corrosion may be quickly discovered through a visual inspection.

Impact or stress damage, flaking, scratches and other conditions may also be apparent dur-
ing a visual inspection. This type of damage is usually specific for each component. The In-
spection and Repair Sections in these Maintenance and Repair volumes give more specific
details of the visual inspections necessary to identify likely damage or faults which may occur
some of components and systems covered in these volumes.

The following information discusses some forms of damage that may be apparent during a
visual inspection.

Corrosion

Corrosion is common on metallic surfaces and can be readily identified through discolour-
ation, scaling and flaking. While certainly indicators of corrosion, these symptoms may be
caused by a means other than corrosion and must not be used solely as confirmation of cor-
rosion. Overheating may appear to be similar to corrosion, both giving a brown colour and
a similar texture.

Overheating

Overheating can appear similar in colour and texture to corrosion. Discolouration from heat
usually appears to fade at the edges, whereas corrosion generally has defined edges of a
more constant colour. Overheating may also result in a bluish colouring, quite distinct from
corrosion that fades towards the edges.

Cracking

Cracks may appear in many surfaces. A crack may appear to run along the surface or to be
coming out from inside the component. In either case, the source of the crack and the extent
of the crack must be evaluated, possibly by use of another NOT technique, to establish the
best course of action regarding the repair or rejection of the cracked component.

Chapter Preface Page 12 I 18 Idcnt. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways WAG-9 Preface
Maintenance and Repair Manual

Penetrant Testing

Cracks that penetrate the surface of a material may not always be visible to the naked eye.
Dye penetrants can aid in identifying discontinuities in components.

Penetrants must always be used only by qualified personnel, in accordance with equipment
manufacturers recommendations and within the prevailing workshop regulations.

When a penetrant is applied to a clean surface containing a crack, hole or other flaw, the pene-
trant is drawn into the discontinuity through capillary action. When the excess penetrant is
cleaned from the surface, the penetrant within the discontinuity remains visible. If the pene-
trant and the cleaned surface provide sufficient visual contrast, the penetrant can be easily
observed, revealing the discontinuity. Some penetrants may be fluorescent to provide a stark
contrast, others require a specialised ultraviolet or laser light source to highlight the penetrant
against the material.

Ultrasonic Testing

Ultrasonic testing uses high frequency sound waves to locate discontinuities in a component.

Ultrasonic testing must always be performed by personnel fully qualified in the particular type
of equipment. Testing must be performed in accordance with the equipment manufacturers
recommendations and within the prevailing workshop regulations.

A typical ultrasonic testing machine displays a graph representing discontinuities in a compo-

nent on a Cathode Ray Oscilloscope (CRO). Peaks or spikes in the graph indicate the severity
of the discontinuity; the bigger the spike, the greater the discontinuity.

When using ultrasonics to test for discontinuities, it is good engineering practice to maintain
accurate records to develop a history of test results. The graph should be approximately the
same for all items of a particular component type. This information can be used to develop
a standard for a particular component type. For comparison purposes, reference can then be
made to the standard to evaluate the condition of an individual component against a known
standard. For example, axles should always produce a similar graph when tested. Each end
of the axle, along with edges and shoulders machined into the axle will appear as spikes on
the CRO. Variations may be an indication of a difference in a particular axle to the standard
axle. Additional spikes, where no shoulder, edge or end exists on the axle, are indicators of
discontinuities in the axle, such as cracks. Such a variation may indicate that a further, or a
more in depth, test is required to fully evaluate the axles condition.

Bombardier Transportation Ltd. Ident. No. Chapter Preface Page 13 I 18

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 f7-

Preface Indian I~ailways WAG-9

Maintenance and Repair Manual

Magnetic Testing

When a discontinuity is present in a material, the magnetic flux within the material changes
greatly as it approaches the discontinuity. This noticeable change in magnetic flux can be use-
ful for finding and evaluating flaws and cracks in a material.

Magnetic testing equipment must always be operated by fully qualified personnel in accord-
ance with equipment manufacturers recommendations and within the prevailing workshop
regulations.

Some materials are ferromagnetic (eg. iron, steel, cobalt, nickel) and can be magnetised to
provide a suitable magnetic flux for testing. Other materials, such as aluminium, copper and
some stainless steels are not ferromagnetic and do not possess a magnetic flux suitable for
testing. However, by inducing a current in such materials, a magnetic flux is also induced. This
induced magnetic flux can be suitable for testing for discontinuities in the material.

Any item that has been magnetically tested must be demagnetised after the testing pro-
cedure, before re-use in service.

Radiographic Testing

Radiographic, or x-ray, testing involves exposing a component to a radiographic source

(such as x-rays or gamma rays) and measuring the change in the source after it has passed
through the material. Voids, porosity and cracks are shown as a change in radiographic dis-
tribution within the material. The distribution through a discontinuity is noticeably different
than for the surrounding, continuous material.

Radiographic testing equipment must always be operated by fully qualified personnel in ac-
cordance with equipment manufacturers recommendations and strictly within the prevailing
workshop regulations.

Sealant Preparation

Surfaces to be sealed and joined with Sikaflex 221, Sikalastomer 710 or Sikaflex 15LM must
first be prepared in accordance with the sealant manufacturers directions. If the proper prep-
arations are not performed, the integrity of the sealant can not be guaranteed.

Some sections of this volume require that sealed joins be cut in order that some components
may be removed from the loco. When reinstalling such components, a new seal must also
be achieved. Any traces of the previous seal must be completely removed and the surfaces
prepared accordingly so that a new seal may be achieved.

Chapter Preface Page 14 I 18 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways \VAG-9 Preface
Maintenance and Repair Manual

The following table shows the preparations required for particular surface types and finishes
prior to the application of Sikaflex 221.

Painted Surfaces Painted surfaces must be cleaned with Sikacleaner 205.

Bare Metallic Surfaces All unfinished metallic surfaces require three stages of preparation; sur-
face scuffing, cleaning with Sikacleaner 205 and priming with Sikaprimer
210T.
Powder-coated Surfaces Powder-coated surfaces must be cleaned with Sikacleaner 205 and
then primed with Sikaprimer 21 OT.
Fibreglass Surfaces Fibreglass (GAP or GFRP) must be cleaned with Sikacleaner 205 and
then primed with Sikaprimer 21 OT. New fib reg lass components must be
ground down approximately 0.5 mm on the area to be sealed prior to
cleaning. Gel-coats, waxes and other release agents present on the
surface must be removed, as the sealant will not bond to these coatings.

Surface Preparations

The following table shows the preparation required prior to the application of Sikaflex 221.

Surface Scuffing Using a suitable steel wool pad or equivalent, gently scour the surface area to be
sealed. Gentle scuffing of the surface enables the sealant to adhere more fully
with the surface.
Cleaning Surfaces to be cleaned with Sikacleaner 205 must first be dry and clean of any
loose paint flakes, oxides, grease, lubricants, release agents and other conta-
minants. Cleaning with Sil<acleaner 205 should be done in two stages. First,
apply Sikacleaner 205 with a clean cloth to the area to be sealed, wiping thor-
oughly. Allow this to dry, then clean area again with a clean cloth, wiping in one
direction only. This is to prevent recontaminating the area just wiped by wiping
over it again. Allow the cleaner to dry for the recommended time before applying
sealant. If thirty minutes is exceeded before the sealant has been applied, lightly
reapply Sikacleaner 205 as previously described.
Priming Sikaprimer 21 OTis to be applied over an area already cleaned using Sikacleaner ..._
205, as described previously. Once cleaned, allow to dry for 10 minutes then
apply a thin, even coat of Sikaprimer 21 OT using a suitable brush. Allow to dry
before applying sealant. If 5 hours is exceeded before sealant has been applied,
lightly sand the surface, remove any dust and prime again.
Sealing All areas to be seated must first be cleaned and/or primed. Once the sealant has
been applied to the surface to be joined, joining must take place as quickly as
possible to avoid the sealant curing. As a general guide, Sikaflex 221 has a tack-
free time of approximately 50 minutes at 20 oc and 50% relative humidity. This
time is likely to be shorter in increased temperature and/or humidity. Once the
sealant has been applied and the two surfaces joined, clamping must be applied
if no other fixing method is used on the sealed components. Refer to the manu-
facturers documentation for details regarding tack-free times and curing rates.

Bombardier Transportation ltd. !dent. No. Chapter Preface Page 15 I 18 -

3EHW 411479 Revision Date: 12.2001
 Preface Indian Railways WAG-9
Maintenance and Repair Manual

Water Test

In various chapters throughout these Maintenance and Repair Volumes, a water test is re-
quired after work has been performed. The test is to be performed to ensure the locomotive
is water tight. Any water leaks on the locomotive pose an operational hazard, as the ingress
of water to the locomotive can cause damage to electrical components and corrosion of me-
tallic parts.

The locomotive must be in full operational condition for the water test. All equipment is to be
installed and all sealant curing times observed. All blowers are to be running during the water
test.

Do not spray water directly into breather ports on axle boxes or traction motors, or into roof
vents on the cab or the mushrooms on the machine room roof hatches.

The locomotive should be positioned below a spray gantry, consisting of horizontal top rows
of nozzles, each with two vertical rows of nozzles, one on each side of the locomotive. Each
row of nozzles should be capable of uniformly delivering 500 litres of water per minute at 200
kPa with 90° solid cone nozzle spray patterns. With all blowers running (traction motor, oil
cooler and machine room blowers, complete with scavenge blowers), the locomotive should
be tested under the gantry for a period of 15 minutes. During this period, personnel within the
locomotive cabs and machine room should be inspecting the locomotive for leaks. Typical
areas to inspect would be seals, through bolt holes, areas where equipment passes from the
outside to the inside of the locomotive, and opening with covers/doors and windows.

Tightening Torques

The tightening torques in the following tables only apply to the grade and size of bolt listed,
unless otherwise specified in the procedure described in these volumes, or Volume F,
Suppliers Documentation.

As a general rule, a locking compound, such as Loctite, should be used when assembling
fasteners, except on the bogies. A thread sealing compound should be used on all threads
opening into any compartment of the locomotive structure, and on all pipe fittings. Some com-
pounds and coatings may alter the required tightening torque. Use the compound manufac-
turer's recommendations for modification of the tightening torques to avoid mechanical fail-
ure.

Chapter Preface Page 16 I 18 Idcnt. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 Indian Railways W AG-9 Preface
Maintenance and Repair Manual

Steel Hexagon Head Bolts and Screws

Tightening Torque (Nm)

Size Thread Pitch Grade Grade Grade Grade Grade
(mm) 4.6 5.8 8.8 10.9 12.9
M 1.6 Coarse 0.35 0.1 0.1 0.2 0.2 -
M2 Coarse 0.4 0.1 0.2 0.3 0.5 -
M 2.5 Coarse 0.45 0.3 0.4 0.6 0.9 -
M3 Coarse 0.5 0.4 0.7 1.1 1.6 1.9
M4 Coarse 0.7 1 1.7 2.7 3.8 4.4
M5 Coarse 0.8 2.1 3.5 5 8 8.9
M6 Coarse 1 3.5 5.9 9 13 15
M8 Fine 1 - - 24 34 40
M8 Coarse 1.25 8.5 14 22 32 37
M 10 Fine 1.25 - - 46 66 77 ....
M 10 Coarse 1.5 17 29 44 63 73
M 12 Fine 1.25 - - 83 119 139
M 12 Coarse 1.75 30 49 77 109 128
M 14 Fine 1.5 - - 132 189 220
M 14 Coarse 2 47 79 122 174 203
M 16 Fine 1.5 - - 202 189 336
M 16 Coarse 2 73 124 190 270 316
M 18 Fine 1.5 - - 304 418 493
M 18 Coarse 2.5 101 171 269 371 436
M 20 Fine 1.5 - - 424 588 688
M 20 Coarse 2.5 143 242 372 528 620
M 22 Fine 1.5 - - 572 788 924
M22 Coarse 2.5 195 329 519 722 840
M24 Fine 2 - - 720 994 1162
M24 Coarse 3 248 418 640 914 1066
M27 Fine 2 - - 1048 1447 1690
M27 Coarse 3 361 610 967 1339 1561
M30 Fine 2 - - 1452 2010 2346
M30 Coarse 3.5 491 828 1314 1817 2124
M33 Fine 2 - - 1960 2713 3168
M33 Coarse 3.5 667 1135 1782 2449 2884
M36 Fine 3 - - 2426 3362 3924
M36 Coarse 4 864 1454 2297 3173 3708
M42 Coarse 4.5 1378 2327 3671 - -
M48 Coarse 5 2064 3485 5500 - -
M56 Coarse 5.5 3338 5611 8870 - -
M64 Coarse 6 5030 8473 13376 - -

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 2/

Preface Indian Railways WAG-9

Maintenance and Repair Manual

Steel Socket Head Cap Screws

Size Tightening Torque (Nm)
®
M1.4 0.2
M 1.6 0.3
M2 0.7
M 2.5 1.3
M3 2.4
M4 5.7
M5 11.4
M6 19
M8 46
M 10 88
M 12 162
M 14 257
M 16 397
M 18 552
M20 772
M 24 1324
M 30 2685
M 36 4707
M 42 7539
Stainless Steel (304 & 316) Bolts and Screws
Tightening Torque (Nm)
Size Pitch Grade Grade Grade
(mm) PC 50 PC70 PC 80
M 1.6 0.4 0.1 0.2 0.4
M2 0.4 0.3 0.3 0.4
M 2.5 0.5 0.5 0.6 0.7
M3 0.5 1.0 1.1 1.6
M4 0.7 1.3 2.6 3.5
M5 0.8 2.4 5.1 6.9
M6 1.0 4.1 8.8 11.8
M8 1.3 10.1 21.4 29.0
M 10 1.5 20.3 44.0 58.0
M 12 1.8 34.8 74.0 100.0
M 14 2 56 119 159
M 16 2 86 183 245
M 18 2.5 133 260 346
M 20 2.5 173 370 494
M 22 2.5 234 - -
M 24 3 298 - -
M27 3 421 - -
M 30 3.5 571 - -
M 33 3.5 779 - -
M36 4 998 - -

Chapter Preface Page 18 I 18 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411479
 2'L

~
6.00 Air Supply & Pneu, Brakes 1
BOMBARDIER ....,IIA.DIER
TRANSPORTATION~

IRWAG9 6.01 Main Compressor 2

Volume 03

Air Supply &

Pneu, Brakes 6.02 Air Dryer 3

6.03 Reservoirs 4

6.04 Auxiliary Compressor 5

6.05 Brake Frame 6

6.06 Brake Controller 7

6.07 Brake Actuators 8

10

11

12
 ~
6.00 Air Supply & Pneu, Brakes 1
BOMBARDIER ...........
TRANSPORTATIOfJ ~

IRWAG9 6.01 Main Compressor 2

Volume 03

Air Supply &

Pneu, Brakes 6.02 Air Dryer 3

6.03 Reservoirs 4

6.04 Auxiliary Compressor 5

6.05 Brake Frame 6

6.06 Brake Controller 7

6.07 Brake Actuators 8

10

11

12
 Indian Railways W AG-9 Air Supply & Pneu, Brakes
Maintenance and Repair Manual 2- "?,

' ..r I
~2)
6 Air Supply & Pneu, Brakes'
For complementary information see following Chapters in Volume 02:

Main Compressor 6.1

Air Dryer 6.2
Reservoirs 6.3
Auxiliary Compressor 6.4
Brake Frame 6.5
Brake Controller 6.6
Brake Activators 6.7

Bombardier Transportation Ltd. Ident. No. Chapter. 6.00 - Page 1 1 2

3EHW 411444 Revision Date: 12.2001
Air Supply & Pneu, Brakes Indian Railways W AG-9
I\1aintenance and Repair Manual

empty page

Chapter 6.00 - Page 2 1 2 ldent. No. Bombardier Transportation Ltd.

Revision Date: ~ 2.2001 3EHW 411444
 Indian Railways WAG-9 Main Compressor
Maintenance and Repair Manual
z5

6.1 Main Compressor

Group Summary
@.1120

This chapter contains information regarding the main compressors for the locomotive pneu-
matic system.

0601004a
1 Resilient mount
2 Electrical terminals
3 Main compressor motor
4 Main compressor assembly

Bombardier Transportation Ltd. Ident. No. Chapter 6.01 - Page 1 1 10

3EH\V 411445 Revision Date: 12.2001
 Indian KauwaJ~ ,, L~~ _

Main Compressor
Maintenance and Repair Manual

Functional Description
@.1140

TheW AG-9loco is fitted with two electrically driven, three cylinder, Davies and Metcalfe Type
2A320D reciprocating air compressors. The main compressors provide the pneumatic supply
on the locomotive.

Air from the atmosphere is drawn into the compressor through the air intake filter by the two
low pressure cylinders. Output from the low pressure cylinders is fed past a safety valve, to
the intercooler, then to the high pressure cylinder. Output from the high pressure cylinder, at
a pressure of 10 bar, is fed past a second safety valve to the aftercooler, which is combined
with the intercooler in a single unit. Final cooled air output is taken from a delivery port located
at the top of the aftercooler. Condensate produced during the process is discharged to the
atmosphere through an automatic drain valve fitted to the underside of the aftercooler.

The electric drive motor is connected to the compressor crankshaft by a Fenner HAC coupling
with taper lock bush fixation. The coupling assembly also carries an impeller to provide cool-
ing air for both the motor and compressor and two flywheels to smooth the rotation of the pis-
ton compressor. Air is drawn across the outside of the motor by the impeller, blown into the
outlet duct, and through the intercooler/aftercooler housing. Leaving the cooler housing, the
air then passes through the cylinder fins and out to the atmosphere.

A sight glass is fitted adjacent to the oil filler cap to enable a regular check to be made on the
oil level. An oil pump, coupled directly to the drive shaft, ensures satisfactory circulation of
the lubricating oil. A primary oil filter prevents any debris entering the crankcase when the unit
is being topped up with new oil. A secondary filter in the oil circulation path, and a magnetic
drain plug in the crankcase, maintain the oil in a clean condition.

The compressors are mounted to the locomotive underframe in three point frames with resil-
ient mounts to reduce vibration.

Fault finding for the compressor is described in Chapter 8, Metcalfe Compressor of Volume
F13, Suppliers Documentation.

Fault finding for the compressor motor is described in Chapter 9, Metcalfe Compressor Motor
of Volume F13, Suppliers Documentation.

Chapter 6.01 - Page 2 I 10 Ident. No. Bombardier Transportation Ltd.

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Indian Railways V{AG-9 Main Compressor
Maintenance and Repair Manual
2?-

Technical Data
@.1160

Air Compressor

- Manufacturer Davies & Metcalfe

- Model 2A3200, Type 32
- Type Piston
- Free air delivery 1, 745 lifres per minute (nominal)
- Displacement 2,330 litres per minute (nominal)
- Operating speed 750 rpm
- Operating pressure 10bar
- Weight 528 kg
- Outlet size 1 1/ inch. SSP.
4

Motor

- Motor 15 kW
- Operating speed 730 RPM
- Voltage 415Volt AC, 3 phase

Lubrication

- Lubrication oil approved Shell Coren a P1 00 (1 year change period)

Indian Oil Co. SS68 (3 month change period)
- Oil capacity 11 litres
- Oil pressure 2.8- 3.4 bar

Bombardier Transportation Ltd. !dent. No. Chapter 6.01 - Page 3 1 10

3EHW 411445 Revision Date: 12.2001
 Indian Railways n .cn.r _..
Main Compressor
Maintenance and Repair Manual

Tolerances and Wear Limits

@.1170

Lubrication

- Oil pressure 2.8- 3.4 bar

/

Tolerances and wear limits applicable to the compressor are described in Chapter 8, Metcalfe
Compressor of Volume F13, Suppliers Documentation.

For further information regarding the compressor motor, refer to Chapter 9, Metcalfe Com-
pressor Motor of Volume F13, Suppliers Documentation.

Tools and Special Tools

@.1180

Conventional railways workshop tools and equipment are required for the maintenance pro-
cedures described in this chapter.

Overhaul of the compressor requires the special Davies and Metcalfe tools described in
Chapter 8, Metcalfe Compressor of Volume F13, Suppliers Documentation.

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Plastic plugs for sealing pneumatic lines .

• Tags for tagging locations of pneumatic and electrical connections .
• Loctite 222 is also required for some fasteners .
• Oil to specification described in Section Technical Data is required for the main
compressor.

Before- Removal Operations

@.1220

Isolate the electrical power to the main compressor at the circuit breaker 47.1. Circuit breaker
47.1/1 for the No. 1 End is situated in Auxiliary Circuits Cubicle 1 (HB1) and circuit breaker
47.1/2 for the No.2 is located in Auxiliary Circuits Cubicle 2 (HB2). For more information on
circuit breakers, refer Chapter 5.2, Auxiliary Converter Control.

Vent the locomotive pneumatics as described in Chapter 6.3, Main Reservoirs.

Chapter 6.01 - Page 4 I 10 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9
Main Compressoe
Maintenance and Repair Manual
1'-7

Removal
Crack loose the union (2) between the flex-
ible pipe (1) and compressor outlet (3).
Allow any residual pressure to vent, then
disconnect the flexible pipe (1) from the
compressor.

Seal the pipe and compressor union with

suitable plastic plugs to prevent the ingress
of foreign material.

Remove the bolt (1) and the earthing cable

(2).

Loosen the clamp (3).

Remove the cover (4} from the compressor

motor electrical terminals. Tag and discon-
nect the harness from the motor.

NOTE:
Do not use the motor cowl or casting to
support the weight. These areas are
not designed to support a load.

Support the compressors weight with suit-

able lifting equipment. Ensure the lifting
equipment will not damage the compressor
or its fittings.

Raise the lifting equipment slightly to sup-

port the weight of the compressor.

Bombardier Transportation ltd.

!dent. No. Chapter 6.01 - Page 5 1 10
Revision Date: 12.2001
3EHW 411445
 Indian Railways vv A\.r7
Main Compressor
Maintenance and Repair Manual

II Remove the nuts (5) and washers (6) secur-

ing the resilient mounts (3) to the mounting
brackets (4), then withdraw the bolts (1) and
~-~--c:c---~-3

--+---i+---4
washers (2).
G"---="'=~-5.6
Raise the compressor until the resilient
mounts (3) are clear of the mounting
brackets (4). Ensure the compressor does
not collide with the surrounding structure.

Check to ensure nothing is entangled be-

tween the compressor and underframe,
then withdraw the compressor from below
the locomotive.

Disassembly
@.1240

Disassembly of the compressor is described in Chapter 8, Metcalfe Compressor of Volume

F13, Suppliers Documentation.

Inspection and Repair

@.1250

Inspection and repair of the compressor is described in Chapter 8, Metcalfe Compressor of

Volume F13, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts and materials according to the prevailing environmental standards or
workplace practices.

Assembly
@.1270

Assembly of the compressor is described in Chapter 8, Metcalfe Compressor of Volume F13,

Suppliers Documentation.

Chapter 6.01 - Page 6 I 10 Id en.t N o. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Main Compressor
Maintenance and Repair Manual
f~ 1

Installation
@.1280

NOTE:
Do not use the motor cowl or casting to support the weight. These areas are not de-
signed to support a load.

Support the compressors weight with suitable lifting equipment. Ensure the lifting equipment
will not damage the compressor or its fittings.

Move the compressor into position on the locomotive underframe. Ensure the resilient
mounts are above the mounting bracket feet.

Align the holes in the resilient mounts {3)

and mounting foot, then install the bolts {1)
with washers (2) through the mount and
foot.

Apply Loctite 222 to the threads. Install the

nuts (5) and washers (6) on the bolts (1) and
torque to 80 Nm.

Bombardier Transportation Ltd.

Ident. No. Chapter 6.01 - Page 7 1 10
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3EHW 411445
 Main Compressor Indian Railways W AG-9
Maintenance and Repair Manual

Remove the protective plugs and attach the

flexible pipe {1) to the union (2) on the com-
pressor outlet (3).

Connect the electrical harness to the ter-

minals at the compressor motor as tagged
during removal. Refer to Chapter 21, Aux.
Circuits 3- Phase of Volume G 1, Cabling
Documentation. Replace the cover (4) and
secure the screws.

Tighten the clamp (3) around the cable con-

duit.

Install the earthing wire (2) between the

compressor and mounting frame. Tighten
the bolt {1).

Chapter 6.01 - Page 8 I 10 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Main Compressor
Maintenance and Repair Manual
5'3

After-Installations Operations
@.1290

Close the pneumatic system exhaust cocks.

Close circuit breaker, 47.1/1 or 47.1/2 as appropriate, to the compressor.

Check the operation of the locomotive pneumatics and the main compressor as described
in Chapter 13, Static Test of Volume F14, Suppliers Documentation.

Check, and if necessary, adjust the compressor oil pressure, refer to Section Adjustments.

Adjustments
@.1310

Adjustment of the compressor oil pressure is described in Chapter 8, Metcalfe Compressor

of Volume F13, Suppliers Documentation.

Bombardier Transportation Ltd. Chapter 6.01 - Page 9 1 10

!dent. No.
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 Main Compressor Indian Railways W AG-9
Maintenance and Repair Manual
\

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Chapter 6.01 - Page 10 I 10 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Air Dryer
Maintenance and Repair Manual
?,"5
-------·--------------------------==-------

6.2 Air Dryer ®

Group Summary
@_1120

This Chapter contains information regarding the Salem twin tower air dryer which consists
of: air dryer, connecting flange, final filter.

The locomotive is equipped with one air dryer located adjacent to the No. 2 End main com-
pressor.

1 Air dryer inlet

2 Air dryer
3 Connecting flange
4 Final filter
5 Final filter outlet

Bombardier Transportation Ltd. Chapter 6.02 - Page 1 1 10

!dent. No.
Revision Date: 12.2001
3EHW 411446
 Air Dryer
Indian Railways W AG-9
Maintenance and Repair Manual

Functional Description
@ 1140

WAG-9 Co Co locomotives are fitted with a Metcalfe Salem FF4092 twin tower air dryer to
remove contaminates and moisture from the pneumatic system. The air dryer is situated
behind right hand side of the cowcatcher at the Cab No.1 end.

Air from the main compressor is filtered and dried before being stored in the main reservoirs.
The twin tower air dryer uses a pre-coalescer to remove impurities, and desiccants (molecu-
lar sieves) which absorb moisture from the compressed air supply. A final filter fitted after
the outlet manifold removes any remaining impurities in the air stream.

The air dryer comprises two air finned dryer towers connected by manifolds. While one
tower is cleaning and dehydrating the air supply from the compressor, the other tower is
regenerating. During regeneration, impurities are exhausted through drain vales on the
bottom of the tower and the desiccants beads are dried. The cycle between dehydrating and
regeneration is controlled by an electronic timer.

Operation of the air dryer system is described in Chapter 10, Metcalfe/Salem Twin Tower
Air Dryer and Final Filter of Volume Fl2, Suppliers Documentation.

Fault finding for the air dryer and final filter is described in Chapter 10, Metcalfe/Salem
Twin Tower Air Dryer and Final Filter of Volume Fl2, Suppliers Documentation.

Chapter 6.02 - Page 2 I 10 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Air Dryer
Maintenance and Repair Manual
07-

Technical Data
@.1160

Filter

- Type Salem twin tower

- Model FF4092
- Weight 48 kg
- Operating pressure 6.9 bar (1 00 psi)
- Working pressure 6.9 ± 0.34 bar
- Electrical requirement 67-130 Volt DC
- Coil Type Class F (continuous duty)
- Outlet fitting 1 1/ 4 inch BSP
- Inlet fitting 1 1/ 4 inch BSP

Heater Thermostats

- Operating voltage 110Volt DC

- Thermostat elements 3 x 35 Watts
- Opening temperature 0.7- 3.7 oc
- Closing temperature· 5.0- 110 oc

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 Air Dryer Indian Railways W AG-9
Maintenance and Repair Manual

Tolerances and Wear Limits

@.1170

Tolerances and wear limits applicable to the air dryer are described in Chapter 10, Metcalfe/
Salem Twin Tower Air Dryer and Final Filter of Volume Fl 2, Suppliers Documentation.

Tools and Special Tools

@1180

Conventional railways workshop tools and equipment are required for the maintenance pro-
cedures described in this chapter.

Miscellaneous Materials
@1200

Miscellaneous materials required for maintenance procedures described in this chapter in-
clude
• Plastic plugs for sealing pneumatic lines
• Tags for identification of pipes.

Before-Removal Operations
.. 1220

Allow the air dryer to cool to ambient temperature.

Isolate the electrical power to the air dryer by setting the "Pneumatic Panel" circuit breaker
(127.7) to the Off position. The circuit breaker is situated in Control Cubicle-2 (SB2). For
more information on circuit breakers, refer Chapter 8.2, MR Control.

Close the isolating cock between the main compressor and air dryer. Close the two isolation
cocks from the air dryer to the main reservoirs. The isolation cocks are situated adjacent to
the air dryer.

Chapter 6.02 - Page 4 I 10 Id en.

t N o. Bombardier Transportation Ltd.
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Indian Railways W AG-9 Air Dryer
Maintenance and Repair Manual
'l, q

Removal
@.1230

Remove the clamp securing the cable conduit to the union. Unscrew the ring, then remove
the electrical harness from the air dryer junction box socket.
Crack loose the pipe' unions (1 ,4) at the air
dryer (2) and final filter {3).

Allow any residual pressure to vent, then

disconnect the pipes from the air dryer and
final filter.

Seal the pipe, air dryer and final filter unions

with suitable plastic plugs to prevent the in-
gress of foreign material.

Remove the bolts (1) securing the male and

female flanges between the air dryer and
final filter (4), then remove the flanges.

Remove the bolts (2) securing the final filter

(4) to the bracket (3), then remove the final
filter (4).

Support the air dryer using suitable lifting

equipment. Raise slightly to support the
weight.

Bombardier Transportation Ltd. !dent. No. Chapter 6.02 - Page 5 1 10

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 Air Dryer Indian Railways W AG-9
Maintenance and Repair Manual

Ensure the air dryer is properly supported

with suitable lifting equipment.

Remove the bolts (1) and washers securing

the air dryer (3) to the underframe bracket
(2). Have an assistant hold the air dryer to
stabilize it during the removal.

Lower the lifting equipment slightly and

check to ensure nothing is entangled be-
tween the air dryer and underframe.

Withdraw the air dryer from below the loco-

motive.

Chapter 6.02 - Page 6 l 10 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Air Dryer
Maintenance and Repair Manual
41

Disassembly
@.1240

Disassembly of the air dryer is described in Chapter 10, Metcalfe/Salem Twin Tower Air Dryer
and Final Filter of Volume F12, Suppliers Documentation.

Inspection and Repair

@.1250

Inspection and repair of the air dryer is described in Chapter 10, Metcalfe/Salem Twin Tower
Air Dryer and Final Filter of Volume F12, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts and materials according to the prevailing environmental standards or
workplace practices.

Assembly
@.1270

Assembly of the air dryer is described in Chapter 10, Metcalfe/Salem Twin Tower Air Dryer
and Final Filter of Volume F1·2, Suppliers Documentation.

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 Indian Railways W AG-9
Air Dryer
Maintenance and Repair Manual
1\~
---------------------------------------------------------------------

Installation
@.1280

Position the air dryer on suitable lifting equipment, then move the air dryer into position on
the locomotive underframe. Have an assistant stablize the air dryer during positioning and
installation of the bolts.
Align the holes in the underframe bracket (2)
and air dryer (3), then install the bolts (1)
with washers through the bracket (2) into the
air dryer (3). Tighten the bolts finger tight.

Position the final filter (4) on the underframe

bracket. Ensure the outlet union is facin·g to-
wards the main reservoir feed pipe.

Align the holes in the underframe bracket (3)

and final filter (4), then install the bolts (2)
with washers through the bracket (3) into the
filter (4}. Tighten the bolts finger tight.

Position the male and female flanges be-

tween the air dryer and final filter (4). Install
the bolts (1) and washers, then tighten the
bolts.

Tighten the bolts securing the air dryer and

final filter to the underframe brackets.

Chapter 6.02 - Page 8 I 10 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Air Dryer
Maintenance and Repair Manual
-13

Remove the protective plugs and attach the

pipes (1 ,4) to the final filter (3) outlet union
and the air dryer (2) inle.t union.

Insert the air dryer harness plug into the

socket on the ai :Jryer. Secure the con-
nector by tightening the ring.

Secure the cable conduit to the bracket

using the clamp.

If necessary, refer to Chapter 60, Control

Pneumatic Devices of Volume G 1, Cabling
Documentation for air dryer electrical sche-
matic details.

After-Installations Operations
@.1290

If necessary, close the drain cocks on the main reservoir tanks.

Open the main reservoir and air dryer isolation cocks at the No. 2 End of the locomotive.

Close th~ "Pneumatic Panel" circuit breaker {127.7) in Contr91 Cubicle-2 {SB2). For more
information on circuit breakers, refer Chapter 8.2, MR Control.

Run the compressor and allow the system to reach normal operating pressure. Ensure that
no loose material is below the final filter drain cock. Then open the cock to exhaust the impu-
rities from the final filter.

Test the operation of the loco pneumatic system and the air dyer unit as described in
Chapter 13, Static Test of Volume F14, Suppliers Documentation.

Adjustments
@.1310

For more information on the air dryer, see Chapter 10, Metcalfe/Salem Twin Tower Air Dryer
and Final Filter of Volume F12, Suppliers Documentation.

Bombardier Transportation Ltd. Ident. No. CAlapter 6.02 - Page 9 1 10

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 Indian Railways W AG-9
Air Dryer
Maintenance and Repair Manual

empty page

I
l

Chapter 6.02 - Page 10 I 10 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual

6.3 Reservoirs

General Notes on Hazards in the Work Area

@.1040

WARNING:
HIGH PRESSURE PNEUMATIC SYSTEMS. Ensure the pneumatic system
is depressurised before commencing maintenance work.

The reservoirs are heavy. To avoid personal injury use suitable lifting equipment
to handle the reservoirs.

Overview
@.1120

C603006

The air reservoirs for the braking system are situated at each end of the machine room. A
main reservoir (1) and an auxiliary reservoir (2} are situated near the Cab 2, while only a single
main reservoir (1) is located near the Cab 1.

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Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

r-- -if ----Jl I

II l
·-~.
--
-~-l

L +O:J: Q J I" -']

'J I
l
1=-
,..

B~[
18 m
B-B A-A
____ ... -

C603001
1 Mounting angle 4 Tank bracket, rear
2 Air reservoir 450L 5 Air reservoir 240L
3 Tank bracket, front

Chapter 6.03 - Page 2 I 14 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual

Functional Description
@.1140

[Not applicable]

Technical Data
@.1160

- Main air reservoir capacity: 450 litres

- Auxiliary air reservoir capacity: 240 litres

Tolerances and Limits List

@.1170

[Not applicable]

Tools and Special Tools

@.1180

Standard Workshop Equipment is required for maintenance work.

Miscellaneous Materials
@.1200

Plastic plugs, or alike to seal the pneumatic pipes and reservoirs against the ingress of dirt,
moisture and foreign material.

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 Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual
A~
-------------------------------------------------------------------

Before Removal Operations

@.1220

WARNING:
HIGH PRESSURE PNEUMATIC SYSTEMS. Air held at ten times atmos-
pheric pressure.

Isolate the electrical power to the compressor.

Close the isolation cock between the compressor and the air dryer. Close the isolation cocks
from the air dryer to the main reservoirs. The isolation cocks are situated adjacent to the air
dryer.

WARNING:
Air in the reservoirs is under high pressure. Ensure the area below drain
cocks is clear of all debris to prevent personal injury.

Open the drain cocks on all the main reservoir tanks and allow the pressure to vent.

Reservoirs must be lifted from the machine room through the roof aperture. Remove the pan-
tograph roof hatches as described in Chapter Structure, Section Removal.

Chapter 6.03- Page 4 I 14 !dent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual

Removal
@.1230

Main Reservoirs

Purge the reservoirs of air as described in

Section Before Removal Operations.

Remove the tread plates (2) from the ma-

chine room floor around the base of the res-
ervoir (1 ).

C603002

Remove the bolt (2) securing the pipe

saddle (3) to the tank bracket (4). Separate
the pipe (1) and insulator from the bracket
(4).

Crack loose the pneumatic connections at

the top and bottom of the reservoir and allow
2
any residual pressure to vent.

Tag and disconnect the pipes and other

pneumatic equipment from the reservoir
3
unions. Seal the pipes and apertures with
suitable plastic plugs to prevent the ingress
C603003 of foreign material.

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Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

NOTE:
Ensure that none of the pneumatic equipment is entangled in the lifting equip-
ment.

Attach suitable overhead lifting equipment to the reservoir and raise slightly to sup-
port the weight.

Remove the bolts (1 ), nuts (3) and washers

(2) securing the mounting angle (4) to the
tank and machine room wall (5). Remove
the mounting angle (4) from the machine
room.

Remove the four bolts (1) and washers (2)

securing the reservoir legs (3) to the ma-
chine room floor.

Chapter 6.03- Page 6 I 14 Ident. No. Bombardier Transp01tation Ltd.

Revision Date: 12.2001 3EHW 411447
Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual 5'1

NOTE:
When removing the reservoir it may be necessary to manoeuvre the pipes clear.
Take care not to excessively bend the pipes. If necessary, remove the pipes to
prevent damage.

Raise the reservoir slightly and ensure nothing is entangled. When all attachments are dis-
connected, lift the reservoir from the machine room through the pantograph hatch opening.

For inspection see supplier's documentation volumes F11 - F14.

Auxiliary Reservoir

Purge the reservoirs of air as described in Section Before Removal Operations.

Remove the tread plates from the machine room floor around the base of the reservoir.

Crack loose the pneumatic connections at the top and bottom of the reservoir and allow any
residual pressure to vent.

Tag and disconnect the pipes and other pneumatic equipment from the reservoir unions. Seal
the pipes and apertures with suitable plastic plugs to prevent the ingress of foreign material.

NOTE:
Ensure that none of the pneumatic equipment is entangled with the lifting equip-
ment.

Attach suitable overhead lifting equipment to the reservoir and raise slightly to sup-
port the weight.

Remove the bolts (1 ), nuts (3) and washers

(2) securing the mounting angle (4) to the
tank and machine room wall (5). Remove
the mounting angle (4).

C603 04

Bombardier Transportation Ltd. !dent. No. Chapter 6.03- Page 7 I 14

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Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

Remove the four bolts (3) and washers (2)

securing the reservoir legs (1) to the ma-
chine room floor.

NOTE:
When removing the reservoir it may be necessary to manoeuvre the pipes clear.
Take care not to excessively bend the pipes. If necessary, remove the pipes to
prevent damage.

Raise the reservoir slightly and ensure nothing is entangled. When all attachments are dis-
connected, lift the reservoir from the machine room through the pantograph hatch opening.

For inspection see supplier's documentation volumes F11 - F14.

Chapter 6.03- Page 8 I 14 ldent. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual r:;-3

Disassembly
@.1240

[Not applicable]

Inspection and Repair

@.1250

Disassembly, maintenance and inspection of the reservoirs are described in the Davies and
Metcalfe manual.

Sanitation Parts/Operating Material

@.1260

[Not applicable]

Assembly
0.1270
[Not applicable]

Installation
@.1280

Main Reservoirs

NOTE:
When installing the reservoir it may be necessary to manoeuvre it around the
pneumatics pipes clear. Take care not to excessively bend the pipes. If necessary,
remove the pipes to prevent damage.

Ensure that none of the pneumatic equipment is entangled with the lifting equipment.

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Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

Attach suitable overhead lifting equipment to the reservoir and raise the reservoir into the ma-
chine room through the pantograph hatch opening.

Align the bolt holes in the reservoir legs with

those in the machine room floor. Install the
four bolts (1) and washers (2) through the
reservoir legs (3) into the machine room
floor. Tighten the bolts finger tight.

Install the mounting angle (4) between the

machine room wall and reservoir. Align the
holes, then install the bolts (1 ), nuts (3) and
washers (2) the mounting angle (4) to the
tank and machine room wall (5). Tighten the
nuts (3) to specification.

C603 04

Tighten the bolts in the reservoir legs to specification.

Remove the protective plugs and reconnect the pneumatic pipes and equipment to the reser-
voir as tagged during disassembly.

Chapter 6.03- Page 10 I 14 ldent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual :;15

Secure the pipes (1) to the tank bracket (4)

with the saddle (3). Ensure that the insula-
tion is seated between the pipe and saddle.
Install the bolt (2) through the pipe saddle (3)
to the nut. Tighten the bolts to specification.

C603003

Install the tread plates {2) into the machine

room floor around the base of the reservoir
(1 ).

C603002

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Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

Auxiliary Reservoir

NOTE:
When installing the reservoir it may be necessary to manoeuvre it around the
pneumatics pipes clear. Take care not to excessively bend the pipes. If necessary,
remove the pipes to prevent damage.

Ensure that none of the pneumatic equipment is entangled with the lifting equipment.

Attach suitable overhead lifting equipment to the reservoir and raise the reservoir into the ma-
chine room through the pantograph hatch opening.

Align the bolt holes in the reservoir legs with

those in the machine room floor. Install the
four bolts (1) and washers (2) through the
reservoir legs (3) into the machine room
floor. Tighten the bolts finger tight.

Install the mounting angle (4) between the

machine room wall (5) and reservoir. Align
the holes, then install the bolts (1 ), nuts (3)
and washers (2). Install the mounting angle
(4) to the tank and machine room wall (5).
Tighten the nuts (3) to specification.

Chapter 6.03- Page 12 I 14 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Reservoirs
Maintenance and Repair Manual t; 1-

Tighten the bolts in the reservoir legs to specification.

Remove the protective plugs and reconnect the pneumatic pipes and equipment to the reser-
voir as tagged during disassembly.
Install the tread plates {2) into the machine
room floor around the base of the reservoir
(1 ).

C603002

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3EHW 411447 Revision Date: 12.2001
 Reservoirs Indian Railways WAG-9
Maintenance and Repair Manual

After Installation Operations

@.1290

[Not applicable]]

Adjustments
@.1310

Close the circuit breaker to the compressor.

Test the operation of the compressor and check the unions for leaks. Rectify any faults found.

'~J,,., ----------------------------------

Chapter 6.03- Page 14 I 14 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Auxiliary Compressor
Maintenance and Repair Manual
s-cr

6.4 Auxiliary Compressor

Group Summary

This chapter contains information regarding the auxiliary compressor, which consists of an
auxiliary compressor and compressor hose to the brake frame.

1 Brake frame
2 Pneumatic pipe auxiliary compressor -
brake frame
3 Auxiliary compressor

Bombardier Transportation Ltd. !dent. No. Chapter 6.04 - Page i I 6

3EHW 411448 Revision Date: 12.200i
 Auxiliary Compressor Indian Railways W AG-9
Maintenance and Repair Manual
~~--------~~ --------------

Functional Description
@~1140

The auxiliary air compressor is of the single-stage single-acting air-cooled type and is di-
rectly coupled and flange mounted to the electric motor, in the form of a self-contained unit.

The auxiliary compressor is used to raise the pantograph when the locomotive is not con-
nected to catenary power and is powered by the batteries. The auxiliary compressor is
mounted on studs on the machine room floor directly adjacent to the brake frame.

Technical Data
@~1160

Compressor

- Working pressure 7 bar (1 00 psi)

- Displacement 0.14 m3/min
- Speed 1450 RPM
- Cylinder bore 2x50.8 mm
- Stroke 25.4 mm
- Oil capacity 150 ml
- Oil specification SAE 20 for use < 5 oc
- Oil specification SAE 30 for use > 5 oc
- Weight 50 kg (nominal)

Motor

- Output power 0.74 kW

- Voltage 110 Volt DC
- Drive direct coupled

Chapter 6.04 - Page 2 I 6 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9
Auxiliary Compressor
Maintenance and Repair Manual

Tolerances and Wear Limits

@.1170

Tolerances and wear limits applicable to the auxiliary compressor and drive motor are de-
scribed in Chapter 5, Auxiliary Air Compressor of Volume F12, Suppliers Documentation.

Tools and Special Tools

@.1180

Conventional workshop tools are required for the procedures described in this chapter.

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Plastic plugs for sealing pneumatic lines

• Cable ties to secure electrical wiring
• Tags for identification of pneumatic and electrical connections
• Oil to specification described in Section Technical Data is required for the auxiliary com-
pressor.

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 Auxiliary Compressor Indian Railways W AG-9
Maintenance and Repair Manual

Before- Removal Operations

(Q).1220

Set the "Auxiliary Compressor" circuit breaker (48.1) to the Off position. The circuit breaker
is situated in Control Cubicle 2 (882). For more information on circuit breakers, refer to
Chapter 8.2, MR Control.

Removal

Remove the cover from the junction box,

then tag and disconnect electrical harness.

Crack loose the pipe from the compressor

outlet (1) and allow any residual pressure to
vent.

Disconnect the pipe from the compressor

outlet union (1). Seal the pipes and com-
pressor union with suitable plastic plugs to
prevent the ingress of foreign material.

Remove the nuts (2) and washers securing

the auxiliary compressor to the studs on the
machine room floor.

Separate the compressor from the machine

room floor bracket.

--~~-~~-----~~~--~~~---

Chapter 6.04 - Page 4 I 6 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Auxiliary Compressor
Maintenance and Repair Manual

Disassembly
@.1240

Fdr further information regarding the auxiliary compressor and drive motor, refer to
Chapter 5, Auxiliary Air Compressor of Volume F12, Suppliers Documentation.

Inspection and Repair

@.1250

Inspection and Repair of the auxiliary compressor and drive motor is described in Chapter
5, Auxiliary Air Compressor of Volume F12, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts and materials according to the prevailing environmental standards or
workplace practices.

Assembly
@.1270

For further information regarding the auxiliary compressor and drive motor, refer to
Chapter 5, Auxiliary Air Compressor of Volume F12, Suppliers Documentation.

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3EHW 411448 Revision Date: 12.2001
 Auxiliary Compressor Indian Railways W AG-9
(/\ Maintenance and Repair Manual

Installation
@1280

Install the auxiliary compressor over the studs on the machine room floor bracket.

Install the nuts (2) and washers onto the

studs, then tighten the nuts.

Remove the plastic plugs and reconnect the

pneumatic supply line (1) between the aux-
iliary compressor and brake frame.

Reconnect the electrical cables to the auxili-

ary compressor as tagged during disassem-
. bly. Refer to Chapter 6D, Control Pneumatic
Devices of Volume G1, Cabling Documenta-
tion.

Install and secure the junction box cover.

After-Installations Operations
@.1290

Close the auxiliary compressor circuit breaker, 48.1 located in ControJ Cubicle 2 (SB2).

Test the operation of the loco pneumatics and the auxiliary compressor as described in
Chapter 13, Static Test of Volume F14, Suppliers Documentation. Check the union for leaks.
Rectify any faults found.

Adjustments
@.1310

For more information on the auxiliary compressor and drive motor, see Chapter 5, Auxiliary
Air Compressor of Volume F12, Suppliers Documentation.

Chapter 6.04 - Page 6 I 6 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Brake Frame
Maintenance and Repair Manual

6.5 Brake Frame

Group Summary
@.1120

Information in this chapter covers the Davies and Metcalfe brake equipment module (brake
frame).

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3EHW 411449 Revision Date: 12.2001
 Brake Frame Indian Railways WAG-9
Maintenance and Repair Manual

0605004
Control electronics pneumatic 14 Pneumatic equipment
manifold 15 Relay valve, automatic brake
2 Vigilance control equipment 16 Relay valve, direct brake
3 Instructions regarding isolating cock 17 Pneumatic equipment sanding
position
18 Distributor, automatic brake
4 Pressure switch pantograph 1
19 Blending unit EBC5
5 Pressure switch pantograph 2
20 Pneumatic equipment, wheel flange
6 Pressure switch emergency brake lubrication, traction converter, filter
7 Pressure switch auxiliary compressor cubicle
8 Pressure switch parking brake 21 Pressure switch, flow indication
9 Isolating cock brake pipe control 22 Pressure switch, vigilance control
system 23 Pressure switch, brake feed pipe
10 Isolating cock on emergency brake/ 24 Rotary switch, pantograph selection
vigilance control
25 Brake equipment frame to locomotive
11 Pressure switch direct brake
26 Pantograph interface manifold
12 Pneumatic equipment, pantograph
27 Flange lubricate interface manifold
and VCB
13 Brake pipe control unit

Chapter 6.05 - Page 2 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Brake Frame
Maintenance and Repair Manual

Functional Description
@.1140

The Davies and Metcalfe brake equipment module incorporates the brake and air system
control equipment for the locomotive. The brake frame is located on the left hand side of the
machine room, towards the No. 2 End of the locomotive.

The interface to the locomotive pneumatic system is through a floor mounted manifold and
two secondary manifolds for the pantograph and auxiliary equipment. The electrical interface
to the vehicle wiring is through three multi-pin plugs and sockets.

The braking system is described in more detail in Chapter 1, Metcalfe Brake System of Vol-
ume F11, Suppliers Documentation. The brake frame, and the equipment attached to it, are
described in Chapter 3, Brake Equipment Module of Volume F11, Suppliers Documentation.

Technical Data
@.1160

- Weight (assembled) 445 kg

- Height 1,640 mm
- Width 894mm
- Depth 767mm

Technical data for the brake frame, and the equipment attached to it, are described· in
Chapter 3, Brake Equipment Module of Volume F11, Suppliers Documentation.

Tolerances and Wear Limits

@.1170

Tolerances and wear limits applicable to the brake frame, and the equipment attached to it,
are described in Chapter 3, Brake Equipment Module of Volume F11, Suppliers Documenta-
tion.

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3EHW 411449 Revision Date: 12.2001
 Brake Frame Indian Railways WAG-9
Maintenance and Repair Manual

Tools and Special Tools

@.1180

In addition to conventional railways workshop tools and equipment, the following are also
required for the procedures described in this chapter:

• Davies and Metcalfe lifting brackets, MM3821 /1 and MM3821 /2, and 4 x M 16 attach-
ment bolts are required for lifting the brake frame.
• Once the brake frame is removed from the locomotive it should be fixed to Davies and
Metcalfe transit frame MM3785.

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Plastic plugs for sealing pneumatic fines

• Tags for identification of pneumatic and electrical connections
• Plastic sheeting and tape to cover the brake frame and electrical connectors is required
whenever the brake frame is removed from the locomotive.

Before-Removal Operations
@.1220

Isolate the electrical power to the compressor, as described in Chapter 6.1, Main Com-
pressor.

CAUTION:
Air in the reservoirs is held under high pressure. To prevent personal injury,
ensure that the area below the drain cocks is clear of all debris.

Open the drain cocks on the main reservoirs and allow the pressure to vent.

Ensure the Brake Cylinder Pressure gauge, Brake Feed Pipe/Main Reservoir Pressure
gauges, Air Flow Meter and Brake Pipe Pressure gauge on Panel B all read zero pressure.
For more information, refer to Chapter 3, System Description of Volume A, Driver's Manual.

Close the cocks once all the air is released.

Remove the No. 2 End pantograph roof hatch as described in Chapter 1.1 , Structure .

.. ~--~··---

Chapter 6.05 - Page 4 I 14 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411449
 Indian Railways WAG-9 Brake Frame
Maintenance and Repair Manual

Removal

Tag and disconnect the wiring harness from

the multi-pin socket on the vigilance unit.

Tag and disconnect the earthing lead (3)

from the stud adjacent to the connectors on
the electronics enclosure (2).

Tag and disconnect the two wiring har-

nesses (1) from the multi-pin sockets on the
electronics enclosure (2).

Attach lifting brackets, MM3821/1 and

MM3821/2 (2) to the brake frame (1) using
suitable M16 (2.0 mm pitch) bolts (3) at the
attachment points (4).

Attach suitable overhead lifting equipment

to the lifting brackets and raise slightly to
take the weight.

0605005

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Brake Frame Indian Railways WAG-9
Maintenance and Repair Manual
---------- ·----------------- ·------- -~

Crack loose the flexible hose (2) between

the brake frame (1) centrifugal strainer and
auxiliary compressor. Allow the residual
pressure to vent, then tag and disconnect
the hose.

------

Chapter 6.05 - Page 6 I 14 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411449
 71
Indian Railways WAG-9
Maintenance and Repair Manual Brake Frame

Before removing the mounting bolts, ensure

the weight of the brake frame is properly
supported by the lifting equipment.

Remove the two bolts securing the brake

frame upper mounting bracket to the ma-
chine room wall.

Remove the five socket head bolts (4) and

washers (3) securing the auxiliary equip-
ment pipe bracket (2) to the auxiliary equip-
ment manifold (1 ).

Remove the two screws (7) and washers (8)

securing the pantograph pipe bracket (5) to
the pantograph interface manifold (6).

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Brake Frame Indian Railways W AG-9
Maintenance and Repair Manual

Loosen the five bolts (1) securing the brake

frame (2} to the pipe bracket (3). The bolts
cannot be removed with components on the
brake frame in place. Ensure the bolts are
fully loosened to aUow removal of the brake
frame.

Raise the lifting equipment and ensure noth-

ing is entangled between the brake frame
and locomotive, then carefully lift the brake
frame from the machine room.

Remove and discard the a-rings from the

0605003a pipe, pantograph and auxiliary equipment
brackets.

Seal all pneumatic orifices on the brake

frame and the three pipe brackets in the ma-
chine room with suitable plastic plugs to pre-
vent the ingress of foreign material.

Cover the electrical connector plugs and

sockets with plastic tape to prevent damage
and the ingress of moisture.

Lower the brake frame into Davies and Met-

calfe transit frame MM3785. Secure the
brake frame to the transit frame using five
M 12 at the pipe bracket interface and two
M16 through the upper mounting bracket.

Cover the brake frame with plastic sheeting

to prevent contamination and the ingress of
water if the brake frame is not to be rein-
stalled immediately.

Chapter 6.05 - Page 8 I 14 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411449
 7-3
Indian Railways WAG-9
Brake Frame
Maintenance and Repair Manual

Disassembly
@.1240

Disassembly of the brake frame is described in Chapter 3, Brake Equipment Module of Vol-
ume F11, Suppliers Documentation.

Inspection and Repair

@.1250

Inspection and repair of the brake frame, and the equipment attached to it, is described in
Chapter 3, Brake Equipment Module of Volume F11, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

Assembly of the brake frame, and the equipment attached to it, is described in Chapter 3,
Brake Equipment Module of Volume F11, Suppliers Documentation. ·

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 Indian Railways WAG-9
Brake Frame
Maintenance and Repair Manual

Installation

Remove any protective covering from the

brake frame.

If necessary, attach lifting brackets,

MM3821/1 and MM3821/2 (2) to the attach-
ment points (4) of the brake frame (1).
Fasten the lifting brackets with M16 {2.0 mm
pitch) bolts {3).

Attach suitable overhead lifting equipment

to the lifting brackets and raise slightly to
take the weight.

CAUTION:
Before removing the mount-
ing bolts, ensure the weight
of the brake frame is properly
supported by the lifting
0605005 equipment.

Loosen the M 12 at the pipe bracket interface

securing the brake frame to the transit
frame. The bolts cannot be removed with
components on the brake frame in place.
Ensure the bolts are fully loosened.

Remove the M16 bolts securing the upper

mounting bracket to the transit frame.

Remove any covering from harness con-

nector plugs and sockets and sockets on the
brake frame.

Remove any plastic plugs from the orifices

on the brake frame and the three pipe
brackets in the machine room.

Position new o-rings into the pipe, panto-

graph and auxiliary equipment brackets.

Chapter 6.05 - Page 10 I 14 Ident. No. Bombardier Transportation ltd.

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Indian Railways W AG-9
Brake Frame
Maintenance and Repair Manual

Carefully raise the lifting equipment and en-

sure nothing is entangled between the brake
frame and transit frame, then carefully lower
the brake frame into the machine room.
Take care not to damage the brake frame or
any equipment in the machine room during
installation. Ensure the dowels of the pipe
bracket engage correctly in the base of the
brake frame.

Tighten the five bolts (1) securing the brake

frame (2) to the pipe bracket (3).
2
0605003a

Install and tighten the two bolts securing the

brake frame upper mounting bracket to the
machine room wall.

Remove the lifting brackets.

Install and tighten the five socket head bolts

(4) and washer (3) securing the auxiliary
equipment pipe bracket (2) to the auxiliary
equipment manifold (1).

Install and tighten the two screws (7) and

washer (8) securing the pantograph pipe
bracket (5) to the pantograph interface
manifold (6).

Bombardier Transportation ltd.

!dent. No. Chapter 6.05 - Page 11 I 14
Revision Date: 12.2001
3EHW 411449
Brake Frame Indian Railways WAG-9
Maintenance and Repair Manual

Remove any protection and connect the

flexible hose (2) between the brake frame
(1) centrifugal strainer and auxiliary com-
pressor.

Connect the wiring harness from the mufti-

pin socket on the vigilance unit, as tagged
during removal.

Chapter 6.05 - Page 12 1 14 ldent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9
Maintenance and Repair Manual Brake Frame

Connect the earthing lead (3) to the stud ad-

jacent to the connectors on the electronics
enclosure (2), as tagged during removal.

Connect the two wiring harnesses {1) to the

multi-pin sockets on the electronics enclos-
ure (2), as tagged during removal.

Install the bolts (1) and washers through the

brake frame into the machine room floor.
Tighten the bolts to specification.

Remove the temporary fixing holding the

brake frame.

1
0605003

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 Brake Frame Indian Railways W AG-9
Maintenance and Repair Manual

Remove the protective plugs and connect

the electrical harness (1) to the electronic
control module (2).

Remove the plugs covering the pneumatic

pipes and brake frame pneumatic unions.
Connect the pneumatic pipes to the brake
frame as tagged during removal.

After-Installations Operations
@.1290

If necessary, close the drain cocks on the main reservoir tanks.

Open the main reservoir and air drier isolation cocks at the No. 2 End of the locomotive.

Close the compressor circuit breaker.

Check the pipe unions for leaks. Rectify any faults found.

Install the No. 2 End pantograph roof hatch as described in Chapter 1.1, Structure.

If necessary, close the drain cocks on the main reservoir tanks.

Open the main reservoir and air drier isolation cocks at the No. 2 End of the locomotive.

Close the circuit breaker to the main compressors, refer to Chapter 6.1, Main Compressor.

Test the operation of the brake frame and the locomotive and pneumatic systems as de-
scribed in Chapter 13, Static Test of Volume F14, Suppliers Documentation. Rectify any faults
found.

Adjustments
@.1310

For more information on the auxiliary compressor, see Chapter 3, Brake Equipment Module
of Volume F11, Suppliers Documentation.

-~---------------------------

Chapter 6.05 - Page 14 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Brake Controller
Maintenance and Repair Manual

'
\\ 1
/
6.6 Brake Controller

Group Summary
@.1120

This group contains information on the direct air brake valve and automatic train brake con-
troller.

0606100n
Direct air brake valve
2 . Automatic train brake controller

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 Brake Controller Indian Railways W AG-9
Maintenance and Repair Manual
---------~~--~-------~-- --------------~----

Direct Air Brake Valve

Direct aW: brake valve

2 Handle
3 Legend plate

Automatic Train Brake Controller

1 Automatic train brake controller

2 Removable handle
3 Legend plate

Functional Description
@.1140

The locomotive braking system is controlled by the direct air brake valve, automatic train
brake controller and master controller (TE/BE throttle). The controls are situated on the
driver's side of the cab console. The master controller governs the regenerative braking of
the locomotive. The direct air brake valve and automatic train brake controller govern the
pneumatic braking ofthe locomotive. For further information on the loco braking system, refer
to Chapter 3, System Description of Volume A, Driver's Manual.

Chapter 6.06 - Page 2 I 12 Idem. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Brake Controller
Maintenance and Repair Manual

Direct Air Brake Valve

The direct air brake valve is designed to provide accurately controlled, variable air pressure
which is fed directly to the locomotive brake cylinders. The valve allows direct control of the
locomotive brakes during slow speed manoeuvring, shunting operations or hill starts.

Rotation of the handle in an anticlockwise direction results in the application of direct braking
effort to the locomotive only. In multiple operation, the slave locomotive direct braking system
is also activated by the driver's direct air brake controller in the master locomotive. Full rota-
tion of the controller handle in the clockwise direction results in the brakes being fully re-
leased. By varying the position of the controller handle, accurate control of the pneumatic
braking system is possible.

Automatic Train Brake Controller

The automatic train brake controller is an electric switching device located on the driver's con-
sole.

Rotating the handle generates a variable voltage code in accordance with the position ofthe
controller. A pneumatic valve is incorporated into the controller to provide a pneumatic emerg-
ency brake function. lri normal operation, the voltage code is sent to the E70 unit within the
machine room. The E70 unit then calculates the optimal braking requirements and applies
the brakes accordingly. More information on the E70 system may be found in Chapter 4, E70
Brake Pipe Control System of Volume F13, Suppliers Documentation.

The driver's brake controller has six positions of operation, each position indicating a different
demand of the braking system by the driver; Release, Running, Initial, Full Service, Emerg-
ency and Neutral.

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 Brake Controller Indian Railways W AG-9
Maintenance and Repair Manual

Technical Data
@1160

Direct Air Brake Valve

- Weight 3.3 kg
- Operating pressure 10 bar

Automatic Train Brake ControUer

- Weight 8 kg
Maximum working pressure 5 bar

Tolerances and Wear Limits List

@.1170

Tolerances and wear limits for the direct air brake valve are described in Chapter 5, Driver's
Direct Air Brake Valve Type FD1 Overhaul of Volume F11, Suppliers Documentation.

Tolerances and wear limits for the automatic train brake controller are described in Chapter 2,
Driver's Brake Controller Overhaul of Volume F13, Suppliers Documentation.

Tools & Special Tools

@.1180

Conventional railway workshop tools are required for the maintenance procedures described
in this chapter.

A Davies & Metcalfe Electrical test Box MM3778 is required to check the automatic train brake
controller when repairing the unit. The requirements are described in Chapter 2, Driver's
Brake Controller Overhaul of Volume F13, Suppliers Documentation.

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Plastic plugs for sealing pneumatic pipes and apertures

• PTFE tape or a suitable pneumatic pipe thread sealant.

Chapter 6.06 - Page 4 I 12 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411450
 Indian Railways W AG-9
Brake Controller
Maintenance and Repair Manual

Before- Removal Operations

@.1220

Remove the panels from the cab console below the brake controllers. Refer to Chapter 7.5,
Cab.

Direct Air Brake Valve

Isolate the locomotive pneumatic system. Isolate the main compressors from the pneumatic
system and vent the main reservoirs.

Automatic Train Brake Controller

Isolate the locomotive pneumatic system. Isolate the main compressors from the pneumatic
system and vent the main reservoirs.

Move the automatic train brake controller handle to the emergency position to ensure the
brake feed pipe is fully vented.

Set the "Driver's Cab" circuit breaker (127.3) to the Off position. Circuit breaker 127.3/1 for
the No.1 End is situated in Control Cubicle-1 (881) and circuit breaker 127.3/2 for the No.2
End is situated in Control Cubicle-2 (882). For more information on circuit breakers, refer
Chapter to 8.2, MR Control.

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Brake Controller Indian Railways W AG-9
Maintenance and Repair Manual

Removal
@.1230

Direct Air Brake Valve

Loosen the bolt securing the handle to the

spindle, then remove the handle from the
valve.

From below the console, tag the pneumatic

pipes (3), then crack loose the unions (2)
and allow any residual pressure to vent. Dis-
connect the piping (3) from the direct air
brake valve (1).

Seal piping and unions with suitable plastic

plugs to prevent the ingress of moisture and
foreign material.

Remove the screws (3) securing the brake

valve (2) to the console panel. Hold the nuts
and washers, on the underside of the con-
sole panel, using a suitable spanner.

Withdraw the air brake valve (2) from below

the console.

Replace the handle and secure the bolt

finger tight.

If necessary, remove the screws (1) secur-

ing the legend plate to the console. Remove
the plate.

Chapter 6.06 - Page 6 I 12 !dent. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Brake Controller
Maintenance and Repair Manual

Automatic Train Brake Controller

Rotate the handle to the Neutral position,

then remove the handle from the controller.

From below the console, tag the pneumatic

pipes (1, 2}, then crack loose the unions and
allow any residual pressure to vent. Discon-
nect the piping (1, 2) from the brake con-
troller.

Seal piping and unions with suitable plastic

plugs to prevent the ingress of moisture and
foreign material.

Unscrew the retaining ring, then separate

the electrical plug from the socket.

Remove the four screws (1) securing the

brake. controller (2} to the console panel.
Hold the nuts and washers on the underside
of the console panel.

Withdraw the brake controller (2) from below

the console.

Replace the handle.

Bombardier Transportation Ltd. Chapter 6. 06 - Page 7 I 12

!dent. No.
Revision Date: 12.2001
3EHW 411450
 Brake Controller Indian Railways W AG-9
Maintenance and Repair Manual

Disassembly
@.1240

Disassembly of the direct air brake controller is described in Chapter 5, Driver's Direct Air
Brake Valve Type FD1 Overhaul in Volume F11, Suppliers Documentation.

Disassembly of the automatic train brake controller is described in Chapter 2, Driver's Brake
Controller Overhaul in Volume F13, Suppliers Documentation.

Inspection and Repair

@.1250

Inspection and repair of the direct air brake controller is described in Chapter 5, Driver's Direct
Air Brake Valve Type FD1 Overhaul in Volume F11, Suppliers Documentation.

Inspection and repair of the automatic train brake controller is described in Chapter 2, Driver's
Brake Controller Overhaul in Volume F13, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

Assembly of the direct air brake controller is described in Chapter 5, Driver's Direct Air Brake
Valve Type FD1 Overhaul in Volume F11, Suppliers Documentation.

Assembly of the automatic train brake controller is described in Chapter 2, Driver's Brake
Controller Overhaul in Volume F13, Suppliers Documentation.

Chapter 6.06 - Page 8 I 12 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411450
 7>7-
Indian Railways WAG-9
Brake Controller
Maintenance and Repair Manual

Installation
@.1280

Direct Air Brake Valve

If necessary, install the legend plate to the

console and secure using the four screws
(1).

Loosen the bolt securing the handle to the

spindle, then remove the handle from the
valve.

Position the air brake valve (2) from below

the console. Align the screw holes in the air
brake valve (2) with the ho\es in the conso\e.

Install the two screws (3) through the valve

body, then install the nuts and washers on
the underside of the console panel.

Tighten the screws (3).

From below the console, connect the air

lines (3) to the unions (2) on the_ air brake
valve (1} as tagged during removal.

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3EHW 411450 Revision Date: 12.2001
Brake Controller Indian Railways WAG-9
Maintenance and Repair Manual

The valve ports are numbered 1 to 3. The

diagram shows the locations of the pipe ar-
rangement.

2 3 1

0606103n

Chapter 6.06 - Page 10 I 12 Ident. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Brake Controller
Maintenance and Repair Manual

Automatic Train Brake Controller

If necessary, remove the handle from the

brake controller (2) before installing the
brake controller.

Position the brake controller (2) in the con-

sole. Align the screw holes in the brake con-
troller (2) with the holes in the console.

Install the four screws (1) and the nuts and

washers on the underside of the console
panel.

Tighten the four screws (1).

From below the console, connect the air

lines (1, 2) to the unions on the brake con-
troller as tagged during removal.

Reinstall the brake controller handle.

Bombardier Transportation Ltd. Ident. No. Chapter 6.06 - Page 11 I 12

3EHW 411450 Revision Date: 12.2001
 Brake Controller Indian Railways W AG-9
Maintenance and Repair Manual

After-Installations Operations
@.1290

Test the operation of the direct air brake valve as described in Chapter 5, Driver's Direct Air
Brake Valve Type FD1 of Volume F11, Suppliers Documentation.

Test the operation of the driver's direct air brake controller as described in Chapter 5, Driver's
Direct Air Brake Valve Type FD1 Overhaul in Volume F11, Suppliers Documentation.

Test the operation of the brakes and brake controller units as described in Chapter 13, Static
Test Specification For WAP5 Locomotive of Volume F14, Suppliers Documentation. Rectify
any faults found.

Install the panels to the cab console below the brake controllers. Refer to Chapter 7.5, Cab.

Adjustments
@.1310

Adjustment ofthe driver's brake controller is described in Chapter 2, Driver's Brake Controller
Overhaul in Volume F13, Suppliers Documentation.

Adjustment of the driver's direct air brake controller is described in Chapter 5, Driver's Direct
Air Brake Valve Type FD1 Overhaul in Volume F11, Suppliers Documentation.

Chapter 6.06 - Page 12 I 12 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411450
 ~I I

Indian Railways WAG-9 Brake Actuators

Maintenance and Repair Manual

6.7 Brake Actuators

General Notes on Hazards in the Work Area

0.1040

WARNING:
High pressure pneumatic systems. Ensure the bogie pneumatic system is
depressurised before commencing maintenance work.

The brake actuators are heavy; service brake actuators weigh over 55 kg and
parking brake actuators weigh over 64 kg. Use lifting equipment to handle the
brake actuators during maintenance to avoid personal injury.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Overview
@.1120

C607025
Pivot bolt, hex. head 10 Brake rod
2 Actuator brake lever 11 Locking pin
3 Brake actuator 12 Adjusting equipment (Shoe support
4 Adjusting equipment (Slack adjuster) arm)
5 Spacer tube 13 Slave brake shoe
6 Actuator brake shoe 14 Slave brake lever
7 Brake block key 15 Pivot bolt, hex. head
8 Brake blocks 16 Track rod
9 Pivot bolt, hex. head

-..

Chapter 6.07 - Page 2 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Functional Description
@.1140

Each wheel on the bogie is fitted with a tread brake operated by a pneumatic brake actuator
and brake rigging. Application of the brakes is by either the driver's brake controller via the
Davies & Metcalfe E70 brake frame, or directly through the driver's air brake valve.

Service brake actuators are fitted on left hand axles 1, 2 and 3 and the 2 right hand axle. Com-
bination service and spring parking brake actuators are fitted to right hand axles 1 and 3. Axle
1 is located at the cab end of the bogie. Air pressure from the locomotive pneumatic system
is required to release the parking brakes. In the event the locomotive pneumatic system fails,
the loss of pressure causes the spring parking brakes to apply. Service brake actuators only
apply the brakes when pressure is supplied from the brake pipe.

The brake rigging consists of levers and rods that distribute the force of the brake blocks on
each half of the wheel tread. Slave and actuator brake levers are hung from pivot points on
the bogie frame. Slave levers are located at the cab end of the wheel. The brake actuator is
fixed with in the actuator levers at the opposite side of the wheel. The slave and actuator levers
are connected by a pair of brake rods, one on the inside and another on the outside of the
wheel.

Each wheel has two brake shoes, one at the slave lever and the other at the actuator lever.
The actuator shoe is integral to, and moved directly by, the brake actuator cylinder. The slave
shoe is operated by the brake rods. Two brake blocks are situated within each shoe and clamp
against the wheel tread by the action of the brake actuators and rigging.

Brake block wear is compensated for by slack adjusting equipment. All the brake actuators
are equipped with internal automatic slack adjusters. A slack adjusting arm is fitted to the
actuator lever to maintain the clearance between the brake block and wheel tread. A shoe
support arm adjusts the operating angle of the slave shoe. Track rods situated between the
slave levers on each side of the bogie maintain the alignment of the brake blocks with the
wheel tread.

All pivot points on the brake rigging are fitted with bushes and hardened steel bolts to minimise
friction and wear.

The actuator shoe moves away from the actuator when air pressure is applied to the actuator
cylinder. The cylinder continues to expand moving the actuator blocks into contact with the
wheel tread; the actuator levers move in the opposite direction, away from the wheel. The
brake rods pull the slave lever, shoe and blocks, towards the wheel tread. The two levers re-
main in a parallelogram during brake application. The stroke of the actuator cylinder deter-
mines the friction between the brake blocks and wheel tread. The brakes return to their static
position when the air pressure is released from the cylinder.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Technical Data
@.1160

Braking Data

- Shoe force (maximum) 40,000 N

- Shoe force (emergency brake max) 50,000 N

Brake Actuators

- Service brake actuator weight 55 kg

Par~ngbrnkeactu~orwe~hl 64 kg
- Piston area 248.8 cm 2
Operating pressure (min) 0.3 bar
- Operating pressure (max) 6.0 bar
- Service brake stroke (max) 18.0 mm
- Maximum automatic adjustment stroke 12.0 mm
- Maximum adjustment per stroke 6.0mm

Chapter 6.07 -Page 4 I 46 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411451
 ct5
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Actuator Operating Force

Shoe force (N)

50,000

=+ v v ~-~v
i

45,000
40,000
35,000
30,000
i / I
i I
25,000 -
20,000
15,000 -
10,000 / I
5,000
0 /:

2 3 4
.~--

5 6
Brake pneumatic pressure bar
c 607041

Brake Blocks

Material Grey Cast Iron

- Weight 9kg
Thickness (new) 60mm
Width (nominal) 80mm
Brake block surface area (new) 202.4 mm 2
Brake block per wheel 4
Wheel to brake block clearance (nominal) Smm

Brake Block Composition

C (carbon) 2.80-3.30%
Mn (magnesium) 0.40-0.60%
- S (sulphur) 0.15 % (maximum)
- Si (silicon) 1.30-2.00%
P (phosphorous) 0.90-1.20%

Bombardier Transportation Ltd. !dent. No. Chapter 6.07- Page 5 I 46

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Slack Adjuster Arm

- Adjustment capacity (max) 125.0 mm

Compression spring

Free height [X] 101.2 mm

Installed length 70mm
Number of active coils 5.0
Wire diameter 10.0 mm
Outside diameter 60mm
Spring rate 157.0 Nm (linear)

Return spring

Free height [X] 71.0 mm

Installed length 48mm
Number of active coils 3.5
Wire diameter 4.0mm
Spring rating 10.2 Nm (linear)

Shoe Support Arm Compression Spring

Free height [X] 48-52 mm

Installed height 40mm
Number of active coils 3.5
Wire diameter 7.5mm

Chapter 6.07 - Page 6 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Tolerances and Wear Limits

@.1170

Brake Block

- Minimum thickness 10 mm
- Locking pin diameter (nominal) 14mm
- Allowable brake block wear SOmm
- Allowable wheel wear (diameter) 76mm

Bombardier Transportation Ltd. Ident. No. Chapter 6.07 - Page 7 I 46

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Brake Rigging

- Maximum bush to bolt clearance (all types) 1.5mm

Chapter 6.07 - Page () I 46 Iclcnt. No. Bombardier Transportation Ltd.

Revision Date: 12.200 l 3EHW4tl451
 Cl1
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Bushes

///' _/ 1
~ // / //~

- '------ r-- X >-

C607023

Symbol y X z
Outside diameter mm Inside diameter Length
Bush location (ISO tolerance spec.) (min - max) mm mm
e Bush 60 (x8) 50.00 - 50.75 30.0
• Bush 40 (z8) 30.00 - 30.75 20.0
.A Bush 40 (z8) 30.00 - 30.75 30.0
+ Bush 40 (z8) 30.00 - 30.75 16.0
0 Bush 40 (z8) 30.00 - 30.75 12.0

Bombardier Transportation Ltd. !dent. No. Chapter 6.07 - Page 9 I 46

3EHW411451 Revision Date: 12.2001
(;

Brake Actuators Indian Railways WAG-9

Maintenance and Repair Manual

Pivot Bolts

C607022

Symbol X y
Shank diameter
Bolt location (min - max) mm Length mm
o Bolt 29.25 - 29.90 295
L\ Bolt 29.25 - 29.90 177
0 Bolt 29.25 - 29.90 112

Track Rod

- Bush journal diameter 49.210-49.370 mm

Chapter 6.07- Page 10 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Tools and Special Tools

@ 1180

Normal workshop tools are required for brake maintenance procedures.

Miscellaneous Materials
@.1200

Plastic plugs, or alike, to seal the brake cylinders and pneumatic piping against the ingress
of foreign material.

Before-Removal Operations
@.1220

Steam clean the bogies. Remove all dirt and foreign material.

If necessary, remove the bogie from the locomotive. All brake maintenance can be performed
while the bogie is attached to the locomotive. However, for ease of access it may be appropri-
ate to remove the bogie from the locomotive.

Isolate the bogie air supply and drain all pressure from the bogie pneumatic system. Chock
the wheels to prevent the bogie rolling, then cage the parking brake.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Removal
@.1230

Pneumatic Connections

Loose the pneumatic connections (1) to the

brake actuators (2).

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 lD 3
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Blocks

Chock the wheels and, if necessary, cage

the parking brakes.

Approximately 12 mm of clearance is re-

quired between the brake blocks (1) and the
wheel tread (2) for removal of the blocks.

At the actuator, loosen the actuator slack ad-

juster locking nut {3) until the maximum
clearance is obtained between the brake
block (1) and wheel tread (2).

Loosen the nut (3) securing the slack ad-

juster arm to the brake lever. The arm must
be free to slide against the brake lever with-
out interference.

Remove the split pin {2), then loosen the

lock nut (4) at the shoe support arm (3).

Loosen the shoe support arm lock and re-

taining nuts (4) until the brake shoe (1) is
free to move without interference.

Move the actuator lever away from the

wheel until the maximum clearance is ob-
tained between the wheel tread and brake
block.

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 Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Remove A-clip (1) from the locking pin (2),

then withdraw the locking pin (2) from the
brake shoe (3).

C607010

Pull the key (2) from the brake shoe (1 ).

Withdraw the brake blocks (3) from the shoe
(1 ).

Move the brake lever to the opposite end of

its travel, then remove the brake blocks at
3 the other side of the wheel in the same
manner.

Inspect the brake block, key and R-clip as

described in Section Inspection and Repair.

C607028

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Rigging

Actuator Lever

Disconnect the slack adjuster as described in Adjusting Equipment.

Remove the brake blocks as described in Brake Blocks.

Remove the brake actuator as described in Section Disassembly, Brake Actuator.

Disconnect the brake rods as described in Brake Rod

WARNING:
The brake actuators are heavy; service brake actuators weigh over 55 kg
and parking brake actuators weigh over 64 kg. Use lifting equipment to
handle the brake actuators during maintenance to avoid personal injury.

Support the lever (3) then undo the nut (5)

and remove the washer (4) and pivot bolt
(2}.

Remove the lever (3) and actuator assembly

from the bogie frame (1 ).

If necessary, separate the actuator from the

levers as described in Section Disassembly,
Brake Actuators.

Inspect the levers as described in Section

Inspection and Repair.

C607002

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Slave Lever

Support both ends of the track rod using suitable stands.

Remove the blocks as described in Brake Blocks.

Remove the shoe support arm as described in Adjusting Equipment.

Loosen the M36 nut securing the track rod and brake shoe to the slave brake lever.

Note the position of the brake rods to the brake lever adjusting holes.

Undo the nut {5), then remove the washer

(4) and withdraw the pivot bolt (2) securing
slave brake lever (3) to the bogie frame (1 ).
5 --~--1{@! @
Move the lever so that the top is clear of the
4
bogie frame mounting lugs, then slide the
lever and shoe from the track rod. Support
the shoe during removal.

Separate the brake shoe from the lever.

Inspect the lever as described in Section In-

spection and Repair.

C607003

Chapter 6.07- Page 16 I 46 ldent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Rod

Note the position of the brake rods at the

brake lever adjusting holes.

Undo and remove the nuts (1) and washers

(2).

Support the brake rods (5), then withdraw

the pivot bolt (3).

Remove the spacer tube (4) between the

actuator levers.

Lower the ends of the rods then repeat the

procedure at the slave lever.
C607004 Inspect the brake rods as described in Sec-
tion Inspection and Repair.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Track Rod

NOTE:
The track rod is heavy, over 37 kg. Use lifting equipment to handle the rod during
maintenance procedures.
Support both ends of the track rod using suitable lifting equipment. Raise the
equipment slightly to support the weight.

Loosen the M36 nuts (1) at each end of the

track rod (3).

Remove the slave brake lever from one side

of the bogie, as previously described.

Remove the M36 nut (1) and washer (2) se-

curing the opposite end of the track rod (3)
to the slave brake lever and shoe.

Slide the track rod (3) from the brake lever

at the opposite end.

Lift the track rod from the bogie using the lift-
C607005 ing equipment.

Inspect the track rod as described in Section

Inspection and Repair.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Adjusting Equipment

Slack Adjuster

Remove the nut (1) and washer (2) from the

end of the slack adjuster arm (4).

Loosen the nut (5) securing the slack ad-

juster arm (4) to the brake lever (11 ). The
arm (4) will move as the nut (5) is loosened.

Remove the nut (5), compression spring (7),

spring supports (6, 8), arm (4) and washer
{10) from the brake lever {11).

11 Withdraw the arm (4) from the bogie frame

lug. Hold the spring (3) to prevent it falling.

C607006 If necessary, remove the threaded rod (9)

from the lever (11 ), using a pair of nuts
locked against one another.

Inspect the slack adjuster components as

described in Section Inspection and Repair.

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Maintenance and Repair Manual

Shoe Support Arm

Remove the split pin (4) from the bolt (9),

then loosen the lock nut (5) and slowly re-
move the two nuts (5, 6) from the bolt (9).

Separate the washer (3), compression

spring (2) and spring seat (1) from the lever
(8).

Remove the shoe support arm spigot (7)

from the brake shoe.
/ '
4
,/ Inspect the condition of the shoe support
r'
5 arm components as described in Section In-
spection and Repair.
C607007

Chapter 6.07 - Page 20 I 46 Jdent. No. Bombardier Transportation Ltd.

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 ftf
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Disassembly
@.1240

Brake Actuator

NOTE:
The brake actuators can be removed while the brake levers are attached to the
bogie. Loosen the pivot bolts at the bogie frame and brake rods to allow clearance
for removal.

Remove the brake lever and actuator assembly from the bogie as described in Section Re-
moval, Brake Rigging.

WARNING:
High pressure pneumatic systems. Ensure the bogie pneumatic system is
depressurised before commencing maintenance work.

Isolate the pneumatic supply to the bogie.

Crack loose the pneumatic connections at the actuator. Allow any residual pressure to vent,
then separate the air lines from the unions.

Seal the air pipes and actuator unions with suitable plastic plugs to prevent the ingress of
moisture and foreign matter.

Disconnect the brake rods as described in Section Removal, Brake Rod.

Remove the slack adjuster arm as described in Section Removal, Adjusting Equipment.

Remove the brake blocks as described in Section Removal, Brake Blocks.

WARNING:
The brake actuators are heavy; service brake actuators weigh over 55 kg
and parking brake actuators weigh over 64 kg. Use lifting equipment to
handle the brake actuators during maintenance to avoid personal injury.

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/

Brake Actuators Indian Railways WAG-9

Maintenance and Repair Manual

If necessary, remove the brake lever (2}

from the bogie frame as described in Sec-
tion Removal, Brake Levers.

Remove the bolts (1} and nuts (3) securing

the actuator (4) to the levers (2).

Inspect the levers and actuator as described

in Section Inspection and Repair.

Chapter 6.07 - Page 22 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Rigging

Bushings

Bushings must be pressed out using a suitable hydraulic press and tooling. Do not drive out
bushes using a drift and hammer.

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Maintenance and Repair Manual

Inspection and Repair

@.1250

Brake Blocks

Inspect the brake blocks for wear cracks or damage. Replace the block if the minimum thick-
ness is less than the dimension specified in Section Tolerances and Wear Limits List, or as
appropriate.

The brake shoe and block keyways must be free of burrs and other obstructions. Check the
brake blocks and shoes before installation to ensure clear passage for the key.

Inspect the brake block key for wear or

damage.

C607013

Inspect the locking pin (1) and R-clip (2).

Replace if worn, damaged or bent.

C607040

Chapter 6.07 - Page 24 I 46 ldent. No. Bombardier Transportation Ltd.

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 I l!)

Indian Railways WAG-9 Brake Actuators

Maintenance and Repair Manual

Brake Rigging

Bushings

NOTE:
Replace both the bush and pivot bolt if either part is worn. Never use a new bush
with an old bolt, or vice versa.

Check all the bushes for wear or damage. Replace the bushes and pivot bolts as
necessary. Dimensions of the bushes are given in Section Tolerances and Wear Li-
mits List.

Bushes must be pressed in or out of the assembly using a suitable hydraulic press
and tooling. Do not drive the bushes from any components with a hammer and drift.

Pivot Bolts and Nuts

NOTE:
Replace both the pivot bolt and bush if either part is worn. Never use a n~w bolt
with an old bush, or vice versa. Always use a new lock nut on a new bolt.

Check all the pivot bolts for wear or damage. Replace the bolts and bushes as
necessary. The outside diameter of pivot bolt shaft is given in Section Tolerances and
Wear Limits List.

Check the condition of the threads. If necessary, repair the thread using an appropri-
ate thread chaser, or replace the pivot bolt.

Do not reuse worn or damaged locking nuts. Discard locking nuts after 5 uses.

Brake Levers

Check the levers for cracks, damage or wear. Loose or worn brake rigging can cause wear
on adjacent parts. Replace the levers if worn or damaged.

Check the condition of the bushes and measure the inside diameter as described in Bushes.
Replace any bush where the inside diameter is larger than the dimension specified in Section
Tolerances and wear Limits List.

Check all pivot holes for wear or damage. Wear must not exceed specification. Rectify any
faults found. (allowable wear= 0.75 mm)

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Check the welded joint between the slave lever and mounting bosses. Discard the lever if the
weld is damaged or cracked.

Brake Rods

Check the brake rods for cracks, wear or damage. A loose connection between the brake rods
and levers may cause wear on adjacent parts. Replace the rods if worn or damaged.

Check the condition of the bushes and measure the inside diameter as described in Bushes.
Replace any bush where the inside diameter is larger than the dimension specified in Section
Tolerances and wear Limits List.

Track Rod

Check the track rod for cracks, bend, wear or damage. Replace the rods if worn, bent or dam-
aged.

Carefully inspect the welded joints at each end of the rod. Discard the rod if the weld is dam-
aged or cracked.

Check the condition of the threads at each end of the track rod. If necessary, repair the thread
using an appropriate thread chaser, or replace the track rod.

Measure the diameter of the bush journal at each end of the track rod. Recondition the track
rod if the diameter is less than the dimension specified in Section Tolerances and Wear Limits.

Do not reuse worn or damaged lock nuts. Discard lock nuts after 5 uses.

Adjusting Equipment

Slack Adjuster

Check the condition of the thread at end of the slack adjuster arm. If necessary, repair the
thread using an appropriate thread chaser, or replace the arm.

Do not reuse worn or damaged locking nuts. Discard locking nuts after 5 uses.

Check the bogie frame lug for wear, cracks or damage. Rectify any faults found.

Check the condition of the slack adjuster arm.

Inspect the spring support for excessive wear. Replace if worn or damaged.

Chapter 6.07 -Page 26 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Check the condition of the washer used between the arm and brake lever. Replace if worn
or damaged.

Check the condition of the stop washer. Replace if worn or damaged.

Inspect the compression spring for cracks.

Measure the free height [X] of the compres-
~
sion spring. Replace if less than the specifi-
----- -----'~----~
l
cation in Section Technical Data.

0203004

Inspect the return spring for cracks.

Measure the free height [X] of the return
spring. Replace if less than the specification
in Section Technical Data.

Check the threaded rod is secure in the

brake lever. If necessary, remove the rod
check the condition of the thread. Repair
using a thread chaser or replace, if necess-
ary. Apply Loctite 271 to the first 6 mm of
thread on the rod, then install and tighten the
rod into the brake lever boss using a pair of
locked nut.
0203004

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 Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Shoe Support Arm

Check the condition of the shoe support arm and parts for wear, bend or damage. Replace
any damaged or worn parts.
Inspect the shoe support compression
spring for cracks. Measure the free height
1 [X] of the spring. Replace if less than the
I specification in Section Technical Data.

Check the condition of the spring seat. Re-

place if worn or damaged.
I
X
Check the condition of the bolt. Replace if
I the thread is damaged or the shaft is bent.
I Check the condition of the washer and nuts.
I
! Replace if worn or damaged.

C607020 Discard the split pin. Install a new split pin

during assembly.

Brake Actuators

Inspection of the brake actuators is described in the Davies and Metcalfe manual.

Chapter 6.07 -Page 28 I 46 fdcnt. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Sanitation Parts/Operating Material

@.1260

[Not applicable]

Assembly
@.1270

Brake Actuators

Parking brake actuators (3) are fitted at

0
=l=u
•
=r==o
axles A 1 and A3 on the right hand side of the
bogie. Service brake actuators (1 ,2) are
fitted to all left hand side axles and axle A2
I
~ A2 on the right hand side. Two types of service
=l=o =l=o brake actuators are fitted to Co-Co bogies
and are handed for specific side installation.
D D D Right hand side service brakes (2) have the
identification RC 61668/2 cast into the pivot
webbing, while left hand side service brakes
3
J (1) have the identification RC 61668/1. All
(~)
brake actuators, service and parking, are in-
stalled with the pneumatic inlet unions to the
inside of the bogie frame.

C607018

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

WARNING:
The brake actuators are heavy; service brake actuators weigh over 55 kg
and parking brake actuators weigh over 64 kg. Use lifting equipment to
handle the brake actuators during maintenance to avoid personal injury.

NOTE:
The brake actuators can be assembled to the levers while the levers are attached
to the bogie. Loosen the lever bolts at the bogie frame and brake rod to allow
clearance for installation. Torque the bogie frame and brake rod bolts to 220 Nm
after installation.

Position the brake actuator between the two

actuator levers. Ensure that the brake levers
are orientated as previously described.

Install the bolts (4) through the levers (2) into

the brake actuators (5).

Install the bolt (1) through the levers (2) into

the actuator (5), then install the lock nut (3).

Torque the bolts (1) and nuts (3) to MA =

535 Nm.

Install the brake lever and actuator assem-

C607008 bly onto the bogie as described in Installa-
tion, Brake Rigging.

Install the brake rods as described in Sec-

tion Installation, Brake Rod.

Install the brake blocks as described in Sec-

tion Installation, Brake Blocks.

Install the slack adjuster as described in

Section Installation, Adjusting Equipment.

Open the air supply to the bogie and test the

operation of the brakes. Rectify any faults
found.

Chapter 6.07 -Page 30 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Rigging

Whenever assembling brake rigging, apply a light film of a suitable lubricant to the inside of
bushes and the bolt shafts.

Apply a light film of a suitable lubricant between any sliding surfaces.

Bushings

NOTE:
Replace both the bush and pivot bolt if either part is worn. Never use a new bush
with an old bolt, or vice versa.

Bushes must be pressed in using a suitable hydraulic press and tooling. Do not drive
the bushes in using a hammer.

Check the interference fit between the hole and bush before assembly.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Installation
@.1280

General Information

Always use new lock nuts on new bolts.

Do not reuse worn or damaged lock nuts. Discard lock nuts after 5 uses.

Coat any exposed metal surfaces using a suitable rust preventative after installation.

Never reuse split pins. Discard spit pins after removal and install new parts during installation.

Brake Blocks

Chock the wheels to prevent the bogie moving.

The brake shoe and block casting keyways must be free of burrs and other obstructions.
Check the brake blocks and shoes before installation to ensure clear passage for the key.

Move the slave lever away from the wheel until the maximum clearance is obtained between
the wheel tread and brake shoe to install the brake block.

Install the brake blocks (3), with the radiused

edge towards the wheel flange, into the
brake shoe (1 ).

Insert the brake key (2) through the shoe (1)

and blocks (3). Ensure the key (2) is cor-
rectly installed.

Move the actuator lever to the opposite end

of its travel, then install the brake blocks (3)
at the other shoe in the same manner.

Install the key (2) as before.

C607009

Chapter 6.07 - Page 32 I 46 Ident. No. Bombardier Transportation Ltd.

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 t '2 ~

Indian Railways WAG-9 Brake Actuators

Maintenance and Repair Manual

Check the brake blocks (2) are correctly

aligned with the wheel tread (3). The block
must not rub against the flange (1) or over-
lap the tread (3). Rectify any misalignment
as necessary.

C607026

Ensure the brake blocks (2) and key (3) are

correctly installed. Check the security of the
blocks {2), then insert the locking pin (5)
through the brake shoe (1) and key (3). Se-
cure the A-clip (4).

Install and adjust the slack adjuster as de-

scribed in Adjusting Equipment.

Install and adjust the shoe support arm on

the slave lever as described in Adjusting
Equipment.
3'
Open the air supply to the bogie and test the
C607030 operation of the brakes. Rectify any faults
found.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Brake Rigging

The bogie has three different types of brake actuators. The locations for installation are de-
scribed in Section Assembly, Brake Actuators. Ensure the brake actuators are installed in the
correct positions.

Actuator Lever

WARNING:
The brake actuators are heavy; service brake actuators weigh over 55 kg
and parking brake actuators weigh over 64 kg. Use lifting equipment to
handle the brake actuators during maintenance to avoid personal injury.
If necessary, install the brake actuator to the brake levers as described in
Section Assembly, Brake Actuators.

Position the lever (3) and brake actuator as-

sembly on the bogie frame (1 ). Support the
lever {3} using suitable stands. The loca-
tions of the three different actuators are de-
scribed in Section Assembly, Brake Actua-
tors.

Align the holes in the levers (3) and bogie

frame hangers (1 ).

Install the pivot bolt (2) through the levers (3)

and hangers (1 ).

Install the washer (4) and nut (5}, then

C607002 torque the nut to MA =220 Nm.

Connect the brake rods as previously de-

scribed.

Install the brake blocks as described in

Brake Blocks.

Install the slack adjuster as described in Ad-

justing Equipment.

Open the air supply to the bogie and test the

operation of the brakes. Rectify any faults
found.

Chapter 6.07 --- Page 34 I 46 Ident. No. Bombardier Transportation Ltd_

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Slave Lever

Install one brake lever (3) in the bogie frame

hangers (1 ). Align the holes in the lever (3)
and hanger (1 ).
s __ J'@ @
Install the pivot bolt (2) through the lever (3)
4
and hanger (1 ). Install the washer (4) and
-~
nut (5), then torque the nut (5) to MA =
I 220 Nm.
2

C607003

Install the track rod (4) as described in Track

Rod. Support the rod (4) at each end using
suitable stands.

Position the brake shoe (5) on the lever (3).

Insert one end of the track rod (4) through

the brake shoe (5) and lever (3).

Install the washer (2) and nut (1) on the track

(@!
~ (f,/ rod (4). Tighten the nut (1) finger tight.

C607015

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Slide the lever (4) and brake shoe (2) as an

assembly onto the track rod (3).

Install the washer (5) and nut {6) on the track

rod (3). Tighten the nut (6) finger tight.

Manipulate the lever (4) between the bogie

frame mounting lugs (1 ).

\~~
·.·~'
·. ~ , I
I
I 6
5

C607016

Install the pivot bolt (2) through the levers (4)

and hanger (1 ). Install the washer (5) and
nut (6), then torque the nut (6) to MA =
220 Nm.

Torque the track rod nuts (3) to MA =

770 Nm.

Install the blocks as previously described.

Install the brake rods as described in Brake

Rod.

Install the slack adjuster and shoe support

C607017 arms as described in Adjusting Equipment.

Chapter 6.07 -Page 36 I 46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Brake Rod

Position the brake rods (5) between the

slave and actuator levers. Support the rod
(5) using suitable stands.

Align the holes in the brake rod (5) levers

and spacer tube (4) as noted during disas-
sembly. Positioning the brake rods (5) is de-
scribed in Section Adjustments.

Apply a thin film of a suitable lubricant to the

bolt shafts (3). Install the pivot bolt (3),
washers (2) and nuts (1 ). Torque the nuts (1)
to MA = 220 Nm.
C607004 Adjust the slack adjuster and shoe support
arms as described in Adjusting Equipment.

If necessary, install the brake blocks as

previously described.

Open the air supply to the bogie and test the

operation of the brakes. Rectify any faults
found.

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Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Track Rod

NOTE:
The track rod is heavy, over 37 kg. Use lifting equipment to handle the rod during
maintenance procedures.

One of the slave brake levers must be re-

moved to install the track rod.

Position the track rod in the bogie frame be-

tween the slave levers.

Support both ends of the track rod using

suitable stands.

Install one end of the track rod (4) through

~~
I
the slave brake lever (3) and brake shoe (5).
I
1 Install the washer (1) and nut (2}. Tighten the
nut (2) finger tight.

C607015

Install the brake lever (4) and shoe (2) at the

other end of the track rod (3}. Install the
washer (5) and nut (6). Tighten the nut (6)
finger tight.

~- ~~~
- ~) I
I 6
5

C607016

Chapter 6.07- Page 38/46 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Install the lever (4) to the bogie frame

hangers (1) as previously described.

6 __ 5@ {fi Torque the M36 track rod nuts (3) to MA =

770 Nm.
5
If necessary, install the brake blocks as
previously described.

If necessary, install the slack adjuster as de-

scribed in Adjusting Equipment.

If necessary, install the shoe support arm as

described in Adjusting Equipment.
C607017 Open the air supply to the bogie and test the
operation of the brakes. Rectify any faults
found.

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Maintenance and Repair Manual

Adjusting Equipment

Slack Adjuster

Ensure the actuator cylinder slack adjuster

nut is completely backed-off.

If necessary, install the threaded rod (9) into

the lever (11 ). Apply Loctite 271 to the end
of the threaded rod (9) before installation.
Install and tighten the rod (9) using a pair of
nuts locked against one another.

Install the return spring (3) into the cup at the

end of the slack adjuster arm (4).

Install the threaded end of the slack adjuster

arm (4) through the bogie frame bracket.
C607006
Install the spring support (2) and lock nut {1 ).
Tighten the lock nut (1 ).

At the brake lever, install the washer {1 0),

slack adjuster arm (4), spring supports
(8, 6), spring (7), and lock nut (5).

Position 5 mm thick shims between the

brake blocks and wheel tread. Ensure the
brakes are centralised over the wheel.

Adjust the position of the slack adjusting arm

(2) on the lever (1) to the specified clearance
between the slack adjuster cup (4) and the
bogie frame lug (3). ([X]= 7.5 mm)

C607011

Chapter 6.07 - Page 40 I 46 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.200 I 3EHW 411451
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

Screw the slack adjuster lock nut (2) at the

brake lever (3) until the spring (1) is com-
1 2 pressed to the specified length. ([X] =
~

70 mm)

- -- ·-.
3
- :IDP
L-x__J
C60 l70 4

Bombardier Transportation Ltd. Ident. No. Chapter 6.07- Page 41 I 46

3EHW 411451 Revision Date: 12.2001
v
Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Shoe Support Arm

Install the shoe support arm spigot (7) into

the brake shoe hole. Align the elongated slot
in the arm with the boss on the lever.

Install the bolt (9) through the lever (8) and

arm (7).

Place the spring seat (1 ), compression

spring (2), and washer (3) on the bolt (9).

C607007

Centralise the shoe on the wheel tread. The

clearance between the brake block and
wheel tread should be the same for the top
and bottom extremities of the shoe.

Install the nut (3) and lock nut (2). Screw the
nut (3) until the spring height is compressed
to the correct height. ([X] = 40 mm)

Tighten the lock nut (2) against the adjusting

nut (3).

Install a new split pin (1 ).

Chapter 6.07- Page 42/46 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411451
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

After-Installations Operations
@.1290

Adjustments
@.1310

Brake Rod Adjustment

The brakes are equipped with two types of compensation for brake block and wheel wear:

a. Brake block wear is compensated for by internal adjustment within the brake
actuators and the slack adjusting arm on the actuator lever. The actuator cylinder
expands pressing the brake blocks at the actuator shoe against wheel tread. The
actuator cylinder continues to expand pushing the actuator lever away from the
wheel tread. This action pulls the brake rods, which in turn pulls the slave lever to-
wards the wheel until the brake blocks at the slave lever contact the tread. The out-
ward movement of the actuator arm causes the slack adjusting arm cup to contact
the bogie frame bracket. Continued expansion of the cylinder overcomes the com-
pression spring allowing the lever to move in the adjusting arm slot. The lever
moves towards the bogie frame bracket decreasing the distance the slave lever
will move away from the wheel when the brake is released. Once the pressure is
released from the actuator cylinder the spring tension on both the slack adjusting
and shoe support arms will hold the position of the lever. This arrangement en-
sures that the brake blocks maintain the correct clearance between the wheel
tread.

Similarly at the slave shoe, the force of the shoe equalising over its pivot point over-
comes the shoe support arm spring pressure and aligns the brake shoe with the
wheel tread.

b. Initial clearance between the brake block and wheel tread is set by the relationship
of the brake rod and brake levers.

Three holes arranged at each end of the brake rods allow for adjustment according
to wheel diameter. The position of the brake rods requires adjustment only after
wheel profiling has been performed or where the wheel has worn to the dimension
shown in the table.

Bombardier Transportation Ltd. ldent. No. Chapter 6.07 - Page 43 I 46

3EHW 411451 Revision Date: 12.200 l
\

Brake Actuators Indian Railways WAG·9

Maintenance and Repair Manual

IMPORTANT:
Worn wheels should be re-profiled to the next appropriate size.

The arrangement of each set of three holes is such that moving the position
of the brake fevers as indicated in the table changes the distance between
the brake shoes.

Never use combinations other than those described in the table.

Adjustment Procedure

The slack adjuster (4) allows for in service

wear of brake block as previously described.
Adjustment of brake rods (5) is only per-
formed whenever the wheels are re-profiled
or worn to the dimensions in the table.

At the actuator, loosen the actuator slack ad-

juster locking bolt about 1/ 2 turn. Back-off
the actuator slack adjuster nut until the
maximum clearance is obtained between
the brake blocks (2} and wheel tread (1 ).

loosen the nut securing the slack adjuster

arm (4) to the brake lever (3). The arm must
C607027
be free to slide against the brake lever with-
out interference.

Remove the split pin, then loosen the lock

nut at the shoe support arm.

Loosen the shoe support arm lock and re-

taining nuts until the brake shoe is free to
move without interference.

Remove the bolts securing one end of the

brake rod to the brake lever.

Align the appropriate hole in the rod and

lever (refer to the table) for the wheel diam-
eter.

Chapter 6.07 - Page 44 I 46 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411451
Indian Railways WAG-9 Brake Actuators
Maintenance and Repair Manual

NOTE:
Wheels with a diameter of less than 1,032 mm should not be used.

Wheel Brake Rod Brake Rod

Diameter Leading End Trailing End
Bolt Position Bolt Position
1,092 mm 1 1
1,072 mm 2 2
1,052 mm 3 3
1,032 mm 4 4
IMPORTANT: DO NOT USE OTHER COMBINATIONS

Apply a thin film of suitable lubricant to the

shaft of the bolt and the inside of the bushes,
then re-install the bolt through the lever and
rods.

Install the washer and nut, then torque the

·~JL. X nut. MA = 220 Nm.

Repeat the procedure at the other brake

lever.
C607011
Adjust the position of the slack adjusting arm
(2) on the lever ( 1) to the specified clearance
between the slack adjuster cup (4) and the
bogie frame lug (3). ([X]= 7.5 mm)

Ensure the shoes are centralised over the

wheel tread, then position 5 mm thick shims
between each brake block and the wheel
treads.

Bombardier Transportation Ltd. Ident. No. Chapter 6.07 - Page 45 I 46

3EHW 411451 Revision Date: 12.2001
Brake Actuators Indian Railways WAG-9
Maintenance and Repair Manual

Screw the slack adjuster lock nut (2) at the

brake lever (3) until the spring (1} is com-
pressed to the specified length. ([X] =
70 mm)

C6070 4

Check the shoe support arm spigot is cor-

rectly positioned in the brake shoe hole.

The brake shoes must be centralised over

the wheel tread. Screw the nut (3) until the
spring height is compressed to the correct
height. ([X]= 40 mm)

Tighten the lock nut (2) against the adjusting

nut (3}.
Install a new split pin (1 ).

Remove the shims and test the operation of

the brakes.

Apply and release the brakes several times

to allow the slack adjuster to move into the
correct position.

With the brakes released, check the clear-

ance between the brake blocks and wheel
tread. Rectify any faults found.

Chapter 6.07 - Page 46 I 46 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411451
 7.00 Interior
~
BOMBARDIER "''''..."""
TRANSPORTAT/01./ ~
1

7.01 Doors
IR WAG9 2
Volume 03

Interior 7.02 Seats

3

7.03 Lighting
4

7.04 Blinds
5

7.05 Cab
6

7.06 Key Interlocking

7

7.07 Cabling
8

10

11

12
 f:)D

Indian Railways WAG-9 I

Interior
Maintenance and Repair Manual ' "!\. 1''
·' '.
. ~ '
t

7 Interior
For complementary information see following Chapters in Volume 03:

Doors 7.1
Seats 7.2
Lighting 7.3
Blinds 7.4
Cab 7.5
Key Interlocking 7.6

Cabling 7.7

Bombardier Transportation ltd. Ident. No. Chapter 7.00 -Page 1 J 2

3EHW 411452 Revision Date: 12.2001
 Indian Railways WAG-9
Interior
Maintenance and Repair Manual

empty page

Chapter 7.00 - Page 2 I 2 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411452
 Indian Railways WAG-9
Doors
Maintenance and Repair Manual

7.1 Doors

Group Summary
@.1120

This chapter contains information on the machine room door and the locker door which con-
sist of the door assembly, hinges and latch.

Machine Room Door

0701004a

Door 5 Hinge
2 Door catch 6 Lock
3 Door catch clamp 7 Latch
4 Screw

Bombardier Transportation Ltd. !dent. No. Chapter 7 .0'1 - Page '1 J '12
3EHW 411453 Revision Date: 12.2001
Uoors Indian Railways WAG-9
Maintenance and Repair Manual

Locker Door

1 Piano hinge
/
/ 2 Rivet
. ------ 3 Door assembly
4 Lock

/~

1------- l
~j
•J

l
.J
j

l
'1

0701003

Chapter 7.01 - Page 2 I 12 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411453
 Indian Railways WAG-9
l>oors
Maintenance and Repair Manual
-----------------~---- ------

Functional Description
@.1140

Machine Room Doors

The machine room doors provide access from the cab to the machine room. Insulation in the
doors and double glazed windows aid in reducing noise from the machine room being trans-
mitted to the cab. Seals around the door surface provide an air tight seal between the door
and the door frame to prevent the pressure differential between the cab and the machine
room causing air flow past the door.

Locker Doors

Lockers are located in the cab to provide storage.

Technical Data
@.1160

Machine room doors

- Door assembly weight 41 kg

- Door to frame clearance 5 mm (nominal)
- Compressed seal height 14 ± 1 mm

Locker doors

- Door assembly weight 13 kg

Tolerances and Wear Limits List

@.1170

There are no tolerances or wear limits applicable to the machine room and locker doors.

Bombardier Transportation Ltd. Ident. No. Chapter 7.01 - Page 3 1 12

Revision Date: 12.2001
3EHW 411453
 Doors Indian Railways W AG-9
Maintenance and Repair Manual

Tools and Special Tools

@.1180

Normal workshop equipment is required for the procedures described in this chapter.

Miscellaneous Materials
@.1200

Suitable wooden wedges are required for removal and installation of the machine room doors.

Before-Removal Operations
@.1220

Machine Room Doors

Ensure the machine room, oil and traction motor blowers are not operating. Turn the key
switch, BL on cab console panel A, to the '0' position to switch off the locomotive electrical
systems.

locker Doors

There are no before removal operations applicable to the machine.room doors.

Chapter 7.01 -Page 4 I 12 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411453
 Indian Railways WAG-9
Maintenance and Repair Manual Doors

Removal
@.1230

Machine Room Door

NOTE:
The machine room door assembly is heavy. Have an assistant help when instal-
ling and removing the door

Unlatch the door (2).

Chock the door (2) in position using suitable

wedges (1).

Loosen the screws (3) in all three hinges {2)

at the door pillar.

Remove the screws (3) starting at the bot-

tom hinge.

With the aid of an assistant lift the door from

the door opening, then remove the door
from the cab.

r'
0701001

Bombardier Transportation Ltd. !dent. No. Chapter 7.01 - Page 5 1 12

3EHW 411453 Revision Date: 12.2001
 Doors Indian Railways W AG-9
Maintenance and Repair Manual

Locker Door

Unlatch and open the locker door (3).

Have an assistant hold the door in position.

Using a suitable drill, drill out the pop rivets

2--~

c/ (2) starting at the bottom of the hinge (1).

With the aid of an assistant, lift the door from

1·--
the opening.

0701003

Disassembly
@.1240

Machine Room Doors

Disassembly of the machine room doors is described in the Chapter 1.3, Doors and Steps
of Volume F1, Suppliers Documentation.

Chapter 7.01 - Page 6 I 12 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411453
 Indian Railways W AG-9
Maintenance and Repair Manual Doors

Locker Doors

If necessary, drill out the rivets securing the hinge to the door to remove the hinge from the
door.

The lock assembly may be removed from

the locker door with the door installed on the
locker.

With the locker door open or removed, re-

move the screws (3) securing the front half
of the lock assembly (2) to the locker door
(1 ).

Withdraw the lock bar (10).

Remove the screws (5) securing the rear

half of the lock assembly (4) to the locker
door (1).
0701100n
If necessary, remove the screws {7), spring
washers (8) and washers (9) securing the
keep plate (6) to the locker frame.

Inspection and Repair

@.1250

Machine Room Doors

Inspect the condition of the door seals, hinges and handles. Replace if worn or otherwise
damaged, refer to Chapter 3, Doors and Steps of Volume F1, Suppliers Documentation.

Locker Doors

Inspect the condition of the locker door sealing strips, hinge and handle. Replace if worn or
damaged.

·-~---··---- ~---~----

Bombardier Transportation Ltd. !dent. No. Chapter 7.01 - Page 7 1 12

3EHW 411453 Revision Date: 12.2001
 Doors Indian Railways W AG-9
Maintenance and Repair Manual

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@1270

Machine Room Doors

Assembly of the machine room doors is described in the Chapter 3, Doors and Steps of Vol-
ume F1, Suppliers Documentation.

Locker Doors

Install the screws (5) through the rear half of

5
the lock assembly (4) and into the locker
4 J l door (1) and tighten.

/~Jt
Insert the lock bar (1 0) through the locker
door (1) and into the lock assembly (4).
/ 7 8
/ Position the outer half of the lock assembly
/ {2) over the lock bar (1 0) and screw to the
locker door (1) using the screws (3).

If necessary, secure the keep plate (6) to the

locker frame with the screws {7), spring
washers (8} and washers (9).
0701100n

Chapter 7.01 -Page 8 I 12 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411453
 Indian Railways W AG-9
Maintenance and Repair Manual Doors

----------------- ---------------------------------

Installation
@.1280

Machine Room Door

NOTE:
The machine room door assembly is heavy Have an assistant help when instal-
ling and removing the door.

Stand the door upright with the window towards the top and the door hinges facing inside the
machine room.
Lift the door (2) into the door opening. Posi-
tion suitable wedges (1) at the top bottom
and sides of the door (2} to centralise it
within the frame.

Install two screws (3) in the top and bottom

~ hinge (4) then tighten the screws (3) to hold
the door (2) in position.

Align the door (2) so that the gap between

the door and opening is even around the en-
tire perimeter. The gap dimension is given in
Section Technical Data.

Tighten the screws in the hinges (4).

Install and tighten the remaining screws.

Remove all wedges.

Check the operation of the door. Ensure it

latches securely.

1
/
0701001

Bombardier Transportation Ltd.

ldent. No. Chapter 7.01 - Page 9 1 12
Revision Date: 12.2001
3EHW 411453
i\
Doors Indian Railways W AG-9
Maintenance and Repair Manual

Locker Door

Stand the door (3) upright with the door

/

//
./
handle (4) facing inside the cab.
3 //
\ //. Position the door (3) on the locker.
\ __;://
2---;;oo With an assistant holding the door (3) in the
///
open position and the hinge (1) towards the
pillar, install a small number of pop rivets {2)
in the middle, top and bottom of the hinge
(1).

Check the operation of the door. Ensure it

latches securely. Rectify any faults found.

Once satisfied that the door is latching cor-

rectly, install pop rivets (2) in the remaining
holes in the hinge (1).

0701003

Chapter 7.01 -Page 10 I 12 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411453
 Indian Railways WAG-9
Doors
Maintenance and Repair Manual

After-Installations Operations
@.1290

Machine Room Door

Check the operation of the door. Ensure it latches securely.

Check the distance between the door handle and cubicle face when the door is in the open
position. A clearance of 25 mm should exist between the handle and the cubicle.

Adjust the door if necessary as described in Section Adjustments.

Locker Doors

Check the operation of the locker door. Ensure it latches securely without excessive slop. Ad-
just the position of the keep plate if necessary as described in Section Adjustments.

Adjustments
@.1310

Machine Room Doors

Adjustments to the machine room door are obtained by placing shims behind the hinges on
the door or by changing the thickness of the striker plate.

Changing the thickness ofthe striker plate may be required ifthe door is not latching securely
or the compressed height of the door seal is not within the specification given in Section
Technical Data.

Shimming of the machine room door hinges may be required if the compressed height of the
door seal is not within the specification given in Section Technical Data.

Locker Doors

The position of the keep plate may be adjusted by loosening the screws securing the keep
plate sufficiently to allow the keep plate to be moved in or out. Once the keep plate is in a suit-
able position, the keep plate screws may be tightened to secure the keep plate.

-·~---~----------------~

Bombardier Transportation Ltd. Ident. No. Chapter 7.01 - Page 11 1 12

Revision Date: 12.2001
3EHW 411453
\

Doors Indian Railways W AG-9

Maintenance and Repair Manual

empty page

----------

Chapter 7.01 -Page 12 I 12 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001
3EHW 411453
 Indian Railways W AG-9
Maintenance and Repair Manual Seats

7.2 Seats
I ~~

Group Summary
@ 1120

' '
~":.-':::--=---=--=--:.--=~~-= -=--= ':."l:: -=--=--=. -::::.-::. =r;=-r_-=-_-=-~-.;-=--::."'~\

--~
lj
·- ..
If • '

0702003
1 Seat assembly
2 Seat pedestal
3 Pedal

Bombardier Transportation Ltd. Chapter 7.02 - Page 1 I 6

!dent. No.
Revision Date: 12.2001
3EHW 411454
 Seats Indian Railways WAG-9
Maintenance and Repair Manual

Functional Description
@.1140

The same type of seat is used for the driver's and assistant's positions. The seats are
equipped with various adjustments for the occupant's comfort and ease of operation. The
seats are mounted on a height adjustable pedestal, that provides approximately 115 mm of
vertical movement.

The horizontal position of the seat can be adjusted fore and aft to suit the requirements of the
occupant by slides between the seat and pedestal. A total of 115 mm of fore aft adjustment
is provided. The seat position can be locked in incremental positions by the lever.

The seat backrest can be inclined 35° from vertical according to the occupant's requirements.
Backrest adjustment is controlled by a lever on the left hand side of the seat.

A foot operated lever on the seat pedestal allows swivel action of the seat and provides auto-
matic positive lock in the driving position.

Technical Data
@.1160

Technical data for the driver's and crew seats is described in Chapter 2, Seats of Volume F15,
Suppliers Documentation.

Tolerances and Wear Limits List

@.1170

Seat coverings should be repaired or replaced if worn or damaged. The mechanism should
be repaired or replaced if loose, damaged or functioning incorrectly. Refer to Chapter 2, Seats
of Volume F15, Suppliers Documentation.

Tools and Special Tools

@.1180

Conventional railways workshop tools and equipment are required for procedures in this
group.

Chapter 7.02 - Page 2 I 6 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411454
 Indian Railways WAG-9
Seats
Maintenance and Repair Manual

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Vinyl upholstery cleaner

• Clean water
• Light grease

Before-Removal Operations
@.1220

Clean any debris from around the pedestal base to provide access to the bolts.

Removal
@.1230

Seat

Removal of the driver's and assistant

driver's seats are identical.

Lower the seat height adjustment to mini-

mum.

Remove the six bolts (2) and spring washers

securing the seat assembly (1) to the cab
floor.

Remove the seat assembly (1) from the

locomotive cab.

Bombardier Transportation Ltd. !dent. No. Chapter 7.02 - Page 3 I 6

3EHW 411454 Revision Date: 12.2001
 Seats Indian Railways W AG-9
Maintenance and Repair Manual
·-------------------

Disassembly
@.1240

Seat

Disassembly of the driver's and assistant

driver's seats are identical.

Remove the nuts (2) securing each seat

runner to the seat pedestal (3).

Remove the seat assembly (1) from the seat

pedestal (3).

If necessary, the seat pedestal (3) may be

removed from the mounting pedestal (4) by
removing the bolts, nuts and spring washers
(5,6 and 7) securing the seat pedestal (3) to
the mounting pedestal (4).

Inspect the seat (1) as described in Chapter

2, Seats of Volume F15, Suppliers Docu-
mentation.

Inspection and Repair

@.1250

Replace or repair the seat covers as necessary.

Check the operation of the seat and pedestal mechanisms. Rectify any faults found.

Refer to Chapter 2, Seats of Volume F15, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts and materials according to the prevailing environmental standards or
workplace practices.

Chapter 7.02 - Page 4 I 6 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411454
 Indian Railways WAG-9
Maintenance and Repair Manual Seats

Assembly
@.1270

Seat

Assembly of the driver's and assistant

driver's seats are identical.

Position the seat on the seat pedestal. Align

the studs from the seat runners with the
holes in the pedestal (3).

Install and tighten the nuts (2).

If necessary, position the seat pedestal (3)

on the mounting pedestal (4) with the holes
aligned. Install bolts, spring washers and
nuts (5, 7 and 6) then tighten.

Bombardier Transportation Ltd. Ident. No. Chapter 7.02 -Page 5 I 6

3EHW 411454 Revision Date: 12.2001
 Seats Indian Railways W AG-9
Maintenance and Repair Manual
------------------------

Installation
@.1280

Seat assembly

Align the holes in the seat assembly (1) with

the holes in the cab floor. Ensure the seat as-
sembly (1) is correctly oriented with the
pedal facing towards the windscreen.

Install the bolts (2) and washers and tighten

the bolts (2).

After-Installations Operations
@.1290

Check the operation of the seat and pedestal. Ensure the mechanisms move freely with mini-
mal restriction. Lubricate the mechanism if necessary. Rectify any faults found.

Adjustments
@.1310

There are no adjustments applicable to maintenance procedures regarding the driver's or as-
sistant driver's seats.

Chapter 7.02 - Page 6 I 6 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411454
 Indian Railways W AG-9 Lighting
Maintenance and Repair Manual

7.3 Lighting

Group Summary
@.1120

This chapter contains information on the internal lighting, including the cab lighting, machine
room lighting, and the hand lamp sockets located in the cab and machine room.

11
5 6

------
2
3 3
2

10 10 10 8 ·6 5

0703001n
1 Lamp, driver's desk illumination 7 Lamp, assistant driver's desk
2 Switch, cab lighting illumination
3 Switch, driver's desk illumination 8 Fluorescent lamp, cab lighting
4 Switch, assistant driver's 9 Latching push button, machine room
desk illumination lighting
5 Socket, hand lamp 10 Fluorescent lamp, machine room il-
lumination
6 Switch, hand lamp socket
11 Terminal bar, 110 V DC

Bombardier Transportation Ltd. Ident. No. Chapter 7.03 - Page 1 1 14

3EHW 411455 Revision Date: 12.2001
 Indian Railways WAG-9
Lighting
Maintenance and Repair Manual

Functional Description
@.1140

The driver's and assistant driver's desk illumination lamps are provided to illuminate the
driver's and assistant driver's consoles when required. The incandescent lamps are switched
on and off by a switch. The switches for the driver's and assistant driver's desk illumination
lamps are ZLDD on Panel C and ZLDA on Panel D respectively.

A fluorescent light in each cab is provided for general cab illumination, and is controlled by
switch ZLC on Panel C.

Socket PCLH on Panel D is provided for connection to a hand lamp. Switch ZLH on Panel D
controls socket PCLH.

Five fluorescent lights in the roof of the machine room are provided for illumination of the ma-
chine room. A push button switch is located on the roof line, at each end of the machine room.
The fluorescent lights in the machine room can be turned on or off at either end, regardless
of the state of the switch at the opposite end.

A terminal bar, located near the machine room light switches, is provided at either end of the
machine room for connection of a hand lamp.

For more information regarding Panel C and Panel D, refer to chapter 7.5, Cab.

Technical Data
@.1160

- Desk illumination lamps 24 V, 15 W

- Desk illumination lamp socket B15d (DIN 49721)
- Cab illumination lights 110 v, 20 w
- Machine room lights 110V, 20 W
- Hand lamp sockets 110 v
- Terminal bars 110 v

·--·-···--····---------------------

Chapter 7.03 - Page 2 I 14 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411455
 \ b C'
Indian Railways W AG-9
Maintenance and Repair Manual Lighting

Tolerances and Wear Limits List

@.1170

There are no tolerances and wear limits applicable to the lighting.

Tools and Special Tools

@.11BO

Conventional railway workshop tools are required for the procedures described in this
chapter.

Miscellaneous Materials
@.1200

No miscellaneous materials are necessary for the procedures described in this chapter.

Bombardier Transportation Ltd. Ident. No. Chapter 7.03 - Page 3 1 14

3EHW 411455 Revision Date: 12.2001
 Indian Railways WAG-9
Lighting
Maintenance and Repair Manual

Before- Removal Operations

@.1220

Cab Lighting

CAB ILLUMINATION

Set the "Lighting Machine Room" circuit breaker (31 0.4) to the Off position. Circuit breaker
310.4 is situated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer
Chapter 8.2, MR Control.

DRIVER'S AND ASSISTANT DRIVER'S DESK ILLUMINATION

Set the "24V/48V Power Supply" circuit breaker {127.91) to the Off position. Circuit breaker
127.91/1 for the No. 1 End is situated in Control Cubicle-1 (SB 1) and circuit breaker 127.91/2
for the No. 2 End is situated in Control Cubicle-2 (SB2). For more information on circuit
breakers, refer Chapter 8.2, MR Control.

Hand Lamp Sockets and Terminal Bars

Set the "Lighting Machine Room" circuit breaker (31 0.4) to the Off position. Circuit breaker
310.4 is situated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer
Chapter 8.2, MR Control.

Machine Room Lighting

Set the "Lighting Machine Room" circuit breaker {31 0.4) to the Off position. Circuit breaker
310.4 is situated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer
Chapter 8.2, MR Control.

Chapter 7.03 - Page 4 I 14 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411455
 tb 'L-

Indian Railways W AG-9

Maintenance and Repair Manual Lighting

Removal
@.1230

The globes can be replaced without removing the light assemblies. Refer to Section Di sas-
sembly

Desk Illumination Lamps

Undo the clasp (4) securing the light assem-

bly (2) to the cab ceiling {3). The light assem-
bly (2) can then be swung downwards.

Tag and disconnect the wiring to the light as-

sembly (2).

Loosen and remove the screws, washers

and nuts {5) securing the light assembly
hinge (6) to the cab ceiling (3), then vvith-
drawthe light assembly (2) from the cab ceil-
ing (3).

0703002n

Cab Lights

Remove the cover (1) from the cab light as-

sembly (3).

Loosen and remove the screws (4) fixing the

5
cab light assembly (3) to the mounting bars
~~­ (5) in the cab ceiling, then lower the assem-
jiG\ ~ bly (3) slightly.
4 4
Tag and disconnect the wiring from the light
assembly (3), then remove the assembly (3)
from the cab ceiling.

0703003n

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 Indian Railways W A G-9
Lighting
Maintenance and Repair Manual

Machine Room Lights

Tag and disconnect the wiring from the light assembly.

Remove the light assembly from the machine room roof.

Hand Lamp Sockets

Removal of Panel Dis described in Chapter 7.5, Cab.

Terminal Bars

Tag and disconnect the wiring from the terminal bar, then remove the terminal bar from the
machine room roof.

Chapter 7.03 - Page 6 I 14 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Lighting
Maintenance and Repair Manual

Disassembly
@.1240

Desk Illumination Lamps

Undo the clasp (4) securing the light assem-

bly (2) to the cab ceiling (3), then swing light
assembly (3) downwards, as required.

Remove the bulb (1) from the light assembly

(2).

Replace the bulb (1), as necessary, as de-

scribed in Section Assembly.

0703002n

Cab Lights

Remove the cover (1) from the cab light as-

sembly (3), as required.

Remove the fluorescent tube (2) from the

5 5
light assembly (3).
L~ o $1Y
Replace the fluorescent tube (3), as necess-
4 4 ary, as described in Section Assembly.

0703003n

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 Indian Railways W AG-9
Lighting
Maintenance and Repair Manual

Machine Room Lights

Remove the cover from the machine room light assembly, as required.

Remove the fluorescent tube from the light assembly.

Replace the fluorescent tube, as necessary, as described in Section Assembly.

Hand Lamp Sockets

For more information regarding Panel D, refer to Chapter 7.5, Cab.

Terminal Bars

There is no disassembly applicable to the terminal bars.

Chapter 7.03 - Page 8 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Lighting
Maintenance and Repair Manual

Inspection and Repair

@.1250

Desk Illumination Lamps

Inspect the condition and operation of the desk illumination lamp assembly. Replace if
necessary.

Inspect the condition of the desk illumination bulb. Replace if faulty or damaged.

Cab Lights

Inspect the condition and operation of the cab illumination light assembly. Replace if necess-
ary.

Inspect the condition of the cab light cover. Replace if broken, cracked or damaged.
Inspect the condition of the cab illumination fluorescent tube. Replace if faulty or damaged.

Machine Room Lights

Inspect the condition and operation of the machine room illumination light assembly. Replace
if necessary.

Inspect the condition of the machine room light cover. Replace if broken, cracked or dam-
aged.

Inspect the condition of the machine room light fluorescent tube. Replace if faulty or dam-
aged.

Hand Lamp Sockets

For more information regarding Panel D, refer to Chapter 7.5, Cab.

Terminal Bars

Inspect the condition of the terminal bars. Replace if faulty or damaged.

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 Indian Railways WAG-9
Lighting
Maintenance and Repair Manual

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

Desk Illumination Lamps

Install the bulb (1) to the light assembly (2).

Swing the light assembly {2) into position in

the cab ceiling (3), as required, then secure
with the fastener (4).

0703002n

Cab Lights

Install the fluorescent tube (2) to the light as-

sembly (3).

Install the cover (1) to the cab light assembly

5
(3), as required.
I~
jn \ ~
4 4

0703003n

Chapter 7.03 - Page 10 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Lighting
Maintenance and Repair Manual

Machine Room Lights

Install the fluorescent tube to the light assembly.

Install the cover to the machine room light assembly, as required.

Hand Lamp Sockets

For more information regarding Panel D, refer to Chapter 7.5, Cab.

Terminal Bars

There is no assembly applicable to the terminal bars.

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 Lighting Indian Railways W AG-9
Maintenance and Repair Manual

Installation
@ 1280

Desk Illumination Lamps

Position the light assembly (2) into the cab

ceiling (3), then secure the light assembly
hinge (6) to the cab ceiling (3) with screws,
nuts and washers (5).

Reconnect the wiring to the light assembly

(2) as tagged during removal.

Refer to Chapter 7A, Driver's Cab Lighting

Control of Volume G, Cabling Documenta-
tion.

Swing the light assembly (2) into position in

the cab ceiling (3), then secure with the fas-
0703002n tener (4).

Cab Lights

Reconnect the wiring to the light assembly

(3) as tagged during removal, then install the
assembly into the cab ceiling.
5
Refer to Chapter 7A, Driver's Cab Lighting
~-~ Control of Volume G, Cabling Documenta-
tion.
4 4
Install screws (4) to fix the light assembly (3)
to the mounting bars (5) in the cab ceiling.

Install the cover (1) to the cab light assembly

(3).

0703003n

Chapter 7.03 - Page 12 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Lighting
Maintenance and Repair Manual

Machine Room Lights

Reconnect the wiring to the light assembly, as tagged during removal.

Install the light assembly to the machine room roof.

Hand Lamp Sockets

Installation of Panel Dis described in Chapter 7.5, Cab.

Terminal Bars

Install the terminal bars to the machine room roof, then reconnect the wiring as tagged during
removal.

After-Installations Operations
@.1290

Close the circuit breakers, then test the operation of the locomotive internal lighting
systems. Rectify any faults found.

Adjustments
@.1310

There are no adjustments applicable to the lighting.

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1'\
\.
Lighting Indian Railways W A G-9
Maintenance and Repair Manual

empty page

Chapter 7.03 - Page 14 I 14 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Blinds
Maintenance and Repair Manual

7.4 Blinds
Group Summary
@.1120

This chapter contains information regarding the windscreen and side window blinds fitted
over the interior of each window in the cab.

Windscreen Blinds

0704006a

Roller 6 Spring
2 Fabric 7 Guide rails
3 Guide block 8 Cable assembly
4 Tube 9 Pop rivet
5 Adjusting nipple assembly

Bombardier Transportation Ltd. Ident. No. Chapter 7.04 - Page 1 1 18

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 Blinds Indian Railways W AG-9
Maintenance and Repair Manual

Side Window Blinds

'
\/1 /""4/A,
y--

j (\"
! 3

i
K-5 6

\ 8

9
0704007a

Roller 7 Guide rails

2 Fabric 8 Pop rivet
3 Guide block 9 Cable assembly
4 Tube 10 Spring washer
5 Adjusting nipple assembly 11 Screw
6 Spring

Chapter 7.04 - Page 2 I 18 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411456
 '1-4
Indian Railways W AG-9
Blinds
Maintenance and Repair Manual

Functional Description
@.1140

Both cab side windows and the windscreens are fitted with vertically sliding binds that can be
drawn over the windows to reduce glare. The blinds operates on a "Holland Blind" principle;
pull the blind down to close, or lift using an upward action to open. The front blind rolls toward
the windscreen, while the side window blinds away from the side window.

Guide rails maintain the alignment of the blind in relation to the windows. Guides for the wind-
screen are riveted to the cab pillars. The forward guide of the side window blind is riveted to
brackets at the top and bottom of the window. The rear guide of the side window blind guide
is fixed to the door pillar using screws.

Cables are used to counter-balance the spring tension of the blind roller. The cables are se-
cured into the bottom of the guide rails, then through the guide block and tube, crossing to
the opposite side. Atthetop of the guide, the cable is secured by a spring and adjusting nipple.
The blind's restrictive effort can be altered by the adjusting nipple.

Technical Data
@.1160

- Material Dura-cover 11 OOD TEX

Tolerances and Wear Limits List

@.1170

No specific tolerances or wear limits are applicable to the blinds. Items should be inspected
as described in Section Inspection and Repair, and replaced or repaired as necessary.

Tools and Special Tools

@.11BO

Conventional railways workshop tools and equipment are required for the procedures de-
scribed in this Chapter.

A 4.8 mm diameter drill bit is required to remove the pop rivets securing the guide rails.

Bombardier Transportation Ltd. Ident. No. Chapter 7.04 - Page 3 1 18

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 Blinds Indian Railways W AG-9
Maintenance and Repair Manual

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• A small nail, or a short piece of 2.5 mm diameter wire is required during the bind roller
installation
• Vinyl upholstery cleaner
• Plastic tape or 3 mm diameter heat shrinkable plastic for the end of the blind cables .

Before- Removal Operations

@.1220

There are no before removals operations applicable to the blinds.

----·-------- - ----------- ---

Chapter 7.04 - Page 4 I 18 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Blinds
Maintenance and Repair Manual
------------------------·------------

Removal

Windscreen Blinds

Removal of the left and right hand side wind-

screen blinds is the same.

Remove the screws (1) securing the cover

panel above the windscreen blind.

Remove the panel (2) from above the wind-

screen blind (3).

Remove the plastic tip from the top of the

cable.

Slacken the screws (2) on the nipple (1) at

the top end of the cable, located at the end
of the cable.

Remove the nipple (1) and coil springs (3).

Withdraw the cable from the top of the guide
rail.

0704002

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Blinds Indian Railways W A G-9
Maintenance and Repair Manual

Disconnect the nipple (2) from the bottom of

the guide rail (1) on both sides.

Lift the blind (2) up from the guide rails (3)

(the blind spring will rapidly uncoil).

Raise the guide block (1) and lift from the top
of the guide rails (3).

With<;! raw the cable from the guide block (1)

and the tube, if necessary.

Chapter 7.04 - Page 6 I 18 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9
Blinds
Maintenance and Repair Manual

Side Window Blinds

Removal of the left and right side window blind is the same.

Remove the plastic from the top end of the cables.

Slacken the screws (2) on the nipple (1) at
the top end of the cable, located at the end
of the cable.

Remove the nipple (1) and coil springs (3).

Withdraw the cable from the top of the guide
rail.

0704002

Disconnect the nipple (2) from the bottom of

the guide rail (1) on both sides.

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 Blinds Indian Railways WAG-9
Maintenance and Repair Manual

Lift the blind (2) up from the guide rails (3)

(the blind spring will rapidly uncoil).

Raise the guide block ( 1) and lift from the top

of the guide rails (3).

Withdraw the cable from the guide block (1)

and the tube, if necessary.

--~~~-~~-~--~-- -------------------

Chapter 7.04 - Page 8 I 18 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Blinds
Maintenance and Repair Manual

Disassembly
@.1240

Blinds

Withdraw the cables from the tube, if necessary.

Separate the guide blocks from the tube, if necessary.

Withdraw the tube from the blind, if necessary.

The blind roller should not be disassembled, but replaced if faulty or damaged.

Guide Rails

The forward guide of the side window blind is riveted to brackets at the top and bottom of the
window. The rear guide of the side window blind guide is fixed to the door pillar using screws.

Remove the pop rivets securing the guide rails using a 4.8 mm diameter drill, where necess-
ary. Remove the screws securing the guide rail, where necessary.

Remove the guide rail.

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 Blinds Indian Railways WAG-9
Maintenance and Repair Manual

Inspection and Repair

@.1250

Blinds

Check the blind fabric for rips, tears, damage or fraying. Repair or replace the blind as necess-
ary. Clean the blinds with a suitable vinyl cleaning solution.

Blind Roller

Check the blind roller for bend, distortion or damage. Replace the roller if necessary.

Wind the roller spring four turns, then release. The spring should uncoil rapidly. Do not wind
the spring more than four turns.

Blind Tube

Check the condition of the tube for bend or wear. Movement of the cables through the tube
may cause wear grooves. Replace the tube if bent, worn or damaged.

Guide Blocks

Inspect the condition of the guide blocks. Check for wear caused by movement of the cables
in the blocks and for wear on the guide rail contact surfaces. Replace the guide blocks if worn
or damaged.

Cable

Check the condition of the cable over its full length for wear, damage or fraying.

Check the cable for kinks or bends.

Inspect the fixed nipple at the end of the cable for wear or the nipple or fraying of the cable.

Worn, damaged or fraying cables may restrict the movement of the blinds. Replace the cable
if necessary.

Chapter 7.04 - Page 10 I 18 ldent. No. Bombardier Transportation ltd.

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 Indian Railways W AG-9
Blinds
Maintenance and Repair Manual

Guide Rails

Inspect the condition of the guide rails for wear, bend, twist or damage.

Check the fixed nipple seat in the lower end of the guide rail for wear. Ensure the nipple fits
securely in the seat.

Replace the guide rail if necessary.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

Blinds

Insert the tube into the pocket of the blind.

Insert the guide blocks into each end of the tube.

Install the cables through the guide blocks and tube. Each cable should be inserted from op-
posite sides.

Guide Rails

Position the guide rail in the cab ensuring the seat for the fixed nipple is facing downward.

The forward guide of the side window blind is riveted to brackets at the top and bottom of the
window. The rear guide of the side window blind guide is fixed to the door pillar using screws.

Secure the guide rail to the brackets using pop rivets or screws, as appropriate. Ensure the
guide rails are parallel.

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 Blinds Indian Railways W A G-9
Maintenance and Repair Manual

Installation
@.1280

Windscreen Blinds

Installation of the left and right windscreen

blind is the same.

Orientate the blinds so that the windscreen

blind (1) unrolls towards the windscreen.

Pretension the blind springs by winding the

spring end of blind 15 turns counter clock-
wise.

Align the Jock hole in the inner (spring) tube

with the hole in the outer tube and install a
suitable locking device eg. nail or similar.

0704005

Insert the guide blocks (1) into the guide rails

(3).

Position the blind (2) into the recesses in the

top of the guide rails {3). Ensure the tang en-
gages correctly in the grove.

Chapter 7.04 -Page 12 I 18 Ident. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Blinds
Maintenance and Repair Manual

Install the fixed nipple (2) of the cable into

the bottom of the guide rail (1).

Bring the opposite end of the cable up the

------------ guide rail (1) and through the top ofthe guide
/
I
"I
I I
rail (1).
I I
I I
I I

r~
I

fft1f:--1
~~l
~~
v I
'- -------------
I~ 1\3

0704003

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3EHW 411456 Revision Date: 12.2001
 Blinds Indian Railways WAG-9
Maintenance and Repair Manual

Install the spring (3) and top nipple (1), then

~~-2
tighten the screw (2) on the nipple (1} to hold

,_, the cable.

Repeat the procedure for the other cable.

Remove the locking pin from the blind roller.

Pull the cables taught and push the nipples

(1) against the spring (3), to compress the
spring (3) slightly, then tighten the screws
(1) to clamp the cables.

Check the operation of the blinds to ensure

0704002 that the blinds hold the selected position.
Adjust the blinds as necessary as described
in Section Adjustments.

Position the panel (2) above the blind (3).

Align the holes in the panel with the holes in

the cab panel.

Install and tighten the screws (1).

Chapter 7.04 - Page 14 I 18 Ident. No. Bombardier Transportation ltd.

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 Indian Railways W AG-9 Blinds
Maintenance and Repair Manual

Side Window Blinds

Installation of the left and right side window

blind is the same.

Orientate the blinds so that the side window

blind (1) unroll away from the side window.

Pretension the blind springs by winding the

spring end of blind 15 turns clockwise.

Align the lock hole in the inner (spring) tube

with the hole in the outer tube and install a
suitable locking device eg. nail or similar.

Insert the guide blocks (1) into the guide rails

(3).

Position the blind (2) into the recesses in the

top of the guide rails {3). Ensure the tang en-
gages correctly in the grove.

Bombardier Transportation Ltd. !dent. No. Chapter 7.04 - Page 15 1 1 8

3EHW 411456 Revision Date: i 2.2001
Blinds Indian Railways WAG-9
Maintenance and Repair Manual

Install the fixed nipple (2) ot the cable into

the bottom of the guide rail (1).

Bring opposite end of the cable up the guide

------------ rail (1) and through the top of the guide rail
r
"I
I

I I
(1).
I I
I I
I I
I I

l~:
;/;~
<:j)~
v I
' ------------
/~~

0704003

Chapter 7.04 - Page 16 I 18 ldent. No. Bombardier Transportation Ltd.

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Indian Railways W A G-9 Blinds
Maintenance and Repair Manual

Install the spring (3) and top nipple (1), then

~1 tighten the screw (2) on the nipple (1) to hold

the cable.
' ~-2

1--3 Repeat the procedure for the other cable.

Remove the locking pin from the blind roller.

Pull the cables taught and push the nipples

(1) against the spring (3), to compress the
spring (3) slightly, then tighten the screws
(1) to clamp the cables.

Check the operation of the blinds to ensure

0704002 that the blinds hold the selected position.
Adjust the blinds as necessary as described
in Section Adjustments.

Bombardier Transportation Ltd. !dent. No. Chapter 7.04 - Page 17 1 18

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 Blinds Indian Railways WAG-9
Maintenance and Repair Manual

After-Installations Operations
@.1290

There are no after installation operations applicable to the blinds.

Adjustments
@.1310

Test the operation of the blind. The blind should be free to move up and down with minimum
restriction, and hold in position when released.lfnecessary, adjust the blind to achieve proper
operation.

Loosen the screw on the top nipple of one cable. Adjust the position of the nipple to provide
greater or less tension on the spring as required, then tighten the screw.

Repeat the process for the opposite cable, then re-check the operation of the blind. Re-ad-
just the top nipples if necessary.

Cover the ends of the cable with heat shrinkable plastic, or plastic tape.

Chapter 7.04 - Page 18 1 18 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Maintenance and Repair Manual Cab

7.5 Cab

Group Summary
@1120

This chapter contains information on the locomotive cab and equipment, which consists of:
cab console, panels "A", "8", "C" and "0", cab heater, cab heater control switch, crew fans,
fire extinguisher, horn control, wiper/washer control, TE/BE master controller, Memotet re-
corder/Speedometer, parking brake pressure gauge, cubicle "F" and foot pedals.

Cab Overview

0705001a
1 Driver's air brake valve 10 Panel "0"
2 Automatic train brake controller 11 Heater control
3 Foot switch 12 Wiper/washer control
4 Panel "8" 13 Emergency-isolating cock
5 Panel "A" 14 Cubicle "F"
6 Horn control 15 Plate-foot pedal
7 Master controller 16 Parking brake pressure gauge
8 Panel "C" 17 Cab heater exhaust vents
9 Speedometer recorder

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 Cab Indian Railways W AG-9
Maintenance and Repair Manual

Cab Heater

0705017
1 Clamp 3 Heater bend
2 Flexible duct 4 Heater unit

Chapter 7.05 - Page 2 I 52 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Maintenance and Repair Manual Cab

Crew Fan

0705018
r-an housing assembly 8 Adjustment knob, vertical
2 Adjustment bolt, horizontal 9 Fibre washer
3 Mounting bracket 10 Conduit
4 Adjustment bolt, vertical 11 Fitting
5 Insulation pad 12 Access cover
6 Frame bracket 13 Switch
7 Adjustment knob, horizontal

Bombardier Transportation Ltd. !dent. No. Chapter 7.05 - Page 3 J 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Fire Extinguisher

0705015
Fire extinguisher in crew cab 2 Fire extinguisher in machine room

Chapter 7.05 - Page 4 I 52 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9
Maintenance and Repair Manual Cab
----~------~-----~-----------------

Functional Description
@~1140

Panels A, B, C, D

Panels contain various switches, sockets, gauges and lights required for locomotive oper-
ation. Refer to Volume A, Driver's Manual for further information regarding the panels.

Cab Heater

The cab heater provides normal and heated air flow, which is vented upwards from the cab
desk onto the windscreens. This provides heating for the cab and demisting for the wind-
screens.

Cab Heater Control Switch

The cab heater control switch operates the cab heater.

Crew Fans

Crew fans are provided near the driver's and assistant driver's desks. These fans circulate
the air in the cab when activated.

Fire Extinguisher

A fire extinguisher is provided in each cab.

Horn Control

The horn control levers are used to activate the two-tone horn system, which is described
in Chapter 1 .6, Horns and Lights.

Wiper/Washer Control

The wiper/washer control lever activates the windscreen wiper and washer system, which is
described in Chapter 1.7, Wipers and Washers.

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 Cab Indian Railways WAG-9
Maintenance and Repair Manual

TE/BE Master Controller

The master controller regulates the tractive and braking effort of the traction control system.
Refer to Volume A, Driver's Manual for further information regarding the master controller.

Speedometer Recorder (MEMOTEL)

The MEMOTEL is an autonomous, microprocessor-controlled indicating and recording unit.

This multi-functional device is used for measuring and displaying the speed, and for record-
ing the speed together with other operating data either in the internal memory or on a memory
card.
For further information regarding the Memotel unit, refer to Volume A, Driver's Manual and
Chapter 1, Secheron Memotel of Volume F16, Suppliers Documentation.

Parking Brake Pressure Gauge

The parking brake pressure gauge displays the pressure in the parking brake system.

Cubicle F

Cubicle F contains connectors for integrating the cab electronics to the locomotive elec-
tronics. Cubicle F also contains a resistor for the headlight dimming function and a trans-
former for the voltage display on Panel A.

Foot Pedals

Foot pedals are located within the driver's foot well. For further information regarding the func-
tion of the foot pedals, refer to Volume A, r>river's Manual.

Chapter 7.05 - Page 6 I 52 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9
Maintenance and Repair Manual Cab

Technical Data
@.1160

Panel A

GAUGE WORKING RANGES

- Battery voltmeter 0- 150 v

- Catenary voltmeter 0-30 kV
- Bogie tractive effort BE 100 - 0 - 100 % TE

PanelS

GAUGE WORKING RANGES

- Brake cylinder pressure 0- 7 kg/cm2

- Brake pipe pressure 0-7 kg/cm2
- Brake pipe flow meter dimensionless ratio, LP to HP
- Main reservoir pressure 0- 11 kg/cm2
- Brake feed pipe pressure 0- 11 kg/cm2

PaneiC

- Diagnostic display terminal ICT-30.XX

- Display LCD with LED backlight
- Power consumption 6W

Cab Heater

- Heater 110 V AC
- Blower 110 V single phase, asynchronous

Crew Fans

- Fan motor 11 0 V, 1 A, single phase

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 7 J 52

3EHW 411457 Revision Date: 12.2001
 0..~ Indian Railways WAG-9
\ Cab
Maintenance and Repair Manual

Fire Extinguisher

- Model FCO 2.0

- Capacity 2 kg
- Type Carbon Dioxide (C02)

TE/BE Master Controller

- Direction selector Rotary switch, type SG 460039 P1

- Drive/Brake handle contact elements, type AM 400660 R1
- Direct current 24 V/16 A
48 V/4 A
110 V/1 A
- Drive/Brake handle angle converter, type 7W1
Input 24 V/30 rnA
Output 20-2-20 rnA

Memotel Recorder/Speedometer

- Pointer deflection 240°

- Illumination 11 LED's on dial
- Brightness control Manual, stepless from 0 to 100%
- Digits 8 digit, 6 mm high
- Accuracy ±1%
- Power consumption 20W
- Memory type Flash Memory
- Memory capacity, internal 256k8
- Memory capacity, memory card 384 kB or 1 .5 MB

Brake Pipe Pressure Gauge

- Working range 0- 7 kg/cm2

Chapter 7.05 - Page 8 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Maintenance and Repair Manual Cab

Tolerances and Wear Limits List

@1170

No specific tolerances or wear limits are applicable to the equipment described in this chapter.
Items should be inspected as described in Section Inspection and Repair, and replaced or
repaired as necessary.

Tools and Special Tools

@.1180

Conventional railway workshop tools are required for the procedures described in this chap-
ter.

Miscellaneous Materials
@.1200

Plastic plugs or alike to seal pneumatic pipes and valve unions against the ingress of dirt and
foreign material.

Before- Removal Operations

@.1220

General

Some parts of the cab console may need to be removed prior to removing/disassembling
some components in the cab. If necessary, remove the appropriate cab console panels as
described in Section Removal.

Set the "Driver's Cab" circuit breaker {127 .3) to the Off position. Circuit breaker 127.3/1 for
the No. 1 End is situated in SB1 and circuit breaker 127.3/2 for the No.2 End is situated in
SB2. For more information on circuit breakers, refer to Chapter 8.2, MR Control.

Set the "Power Supply 24V/48V" circuit breaker (127 .91) to the Off position. Circuit breaker
127.91/1 for the No. 1 End is situated in SB1 and circuit breaker 127.91/2 for the No.2 End
is situated in SB2. For more information on circuit breakers, refer to Chapter 8.2, MR Control.

Set the "Control Circuits Locomotive" circuit breaker (112.1) to the Off position. Circuit breaker
112.1 is situated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer
to Chapter 8.2, MR Control.

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 9 1 52

3EHW 411457 Revision Date: 12~2001
 Cab Indian Railways W AG-9
Maintenance and Repair Manual

Cab Console

Some cab console panels cover electrical and pneumatic systems, and isolation of these sys-
tems is required prior to the removal of these panels. For example, the removal of the panel
covering cubicle F requires the same before-removal operations as cubicle F.

PanelS

Isolate and vent the pneumatic systems monitored by the gauges on Panel B. This includes
the brake cylinders, the brake feed pipe, the main reservoirs and the locomotive pneumatic
system.

Horn Control

Open the cover marked "Wiper & Horn Isolation" on the driver's side of the cab console. Turn
the horn isolation cock to the Off position.

Heater

Set the "Cab Heater" circuit breaker (69.62) to the Off position. Circuit breaker 69.62 is situ-
ated in Auxiliary Circuits, Cubicle-1 (HB1). For more information on circuit breakers, refer to
Chapter 8.2, MR Control.

Set the "Cab Ventilation" circuit breaker (69.61) to the Off position. Circuit breaker 69.61 is
situated in Auxiliary Circuits, Cubicle-1 (HB 1). For more information on circuit breakers, refer
to Chapter 8.2, MR Control.

Heater Control

Set the "Cab Heater" circuit breaker (69.62) to the Off position. Circuit breaker 69.62 is situ-
ated in Auxiliary Circuits, Cubicle-1 (HB1 ). For more information on circuit breakers, refer to
Chapter 8.2, MR Control.

Set the "Cab Ventilation" circuit breaker (69.61) to the Off position. Circuit breaker 69.61 is
situated in Auxiliary Circuits, Cubicle-1 (HB 1). For more information on circuit breakers, refer
to Chapter 8.2, MR Control.

Chapter 7.05 - Page 10 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Cab
Maintenance and Repair Manual

Crew Fan

Set the "Crew Fan" circuit breaker (69. 71) to the Off position. Circuit breaker 69.71 is situated
in Auxiliary Circuits, Cubicle-1 (HB 1). For more information on circuit breakers, refer to
Chapter 8.2, MR Control.

Wiper/Washer Control

Open the cover marked "Wiper & Horn Isolation" on the driver's side of the cab console. Turn
the wiper isolation cock to the Off position.

TE/BE Master Controller

Isolate the locomotive pneumatic system. Isolate the main compressors from the pneumatic
system and vent the main reservoirs.

Emergency Isolation Cock

Isolate the locomotive pneumatic system. Isolate the main compressors from the pneumatic
system and vent the main reservoirs.

Move the emergency isolation cock to the emergency position to ensure the brake feed pipe
is fully vented.

Memotei/Speedometer

Set the "MEMOTEL speedometer'' circuit breaker (127.92) to the Off position. Circuit breaker
127.92 is situated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer
to Chapter 8.2, MR Control.

Cubicle F

Set the "Lighting Front" circuit breaker (310.0) to the Off position. Circuit breaker 310.0 is situ-
ated in Control Cubicle-2 {SB2). For more information on circuit breakers, refer to Chapter
8.2, MR Control.

Set the "Marker Lights" circuit breaker (31 0. 7) to the Off position. Circuit breaker 310.7 is situ-
ated in Control Cubicle-2 (SB2). For more information on circuit breakers, refer to Chapter
8.2, MR Control.

Bombardier Transportation Ltd. ldent. No. Chapter 7. 05 - Page 11 I 52

3EHW 411457 Revision Date: 12.2001
 Cab Indian Railways W AG-9
Maintenance and Repair Manual

Removal
@.1230

Cab Console

1
I \ 2
5

0705101n

The panel (1) containing the door for wiper and horn isolation can be removed if required.
However, most operations requiring access behind this panel can be achieved by opening
the wiper and horn isolation door, or by removing the panel (2) adjacent to the driver's seat.

The panel (4) containing the emergency isolation cock (7) can be removed if required. The
isolation cock handle (7) must first be removed before the panel (4) can be removed.

Panels (1 ,2,3,4,5,6) can be removed simply by removing the screws securing the panels in
place.

Chapter 7.05 - Page 12 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Maintenance and Repair Manual Cab

Fire Extinguisher Bracket

Open the retaining clamp, then remove the

tire exfmgu·Jsher tram the bracket.

Remove the fire extinguisher (1} from the

bracket (2).

Remove the bolts (4) and spring washers

(3}.

Remove the bracket (2) from the cab wall.

4'- I

~
3-~1
I
,..----;-
1---

I
I
I
I
/I
2 I
I

0705019

Bombardier Transportation Ltd. ldent. No. Chapter 7.05 - Page 13 1 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Horn Control

The procedure is the same for the horn control on either the driver's or assistant driver's side.

Remove the access panel from the foot well.

Unscrew the knob (1) from the lever arm (2).

Remove the six screws (3) and washers (4)

securing the retaining ring (5) to the console.

Remove the rubber boot (6).

Tag and disconnect the three air lines (6)

votb'f'::_
0 . 1
from the valve unions (5). Seal the air lines
(6) and valve unions (5) with suitable plastic
plugs to prevent the ingress of foreign ma-
terial.

Remove the two screws (1) securing the

0
d, 0

valve (2) to the console. Hold the valve (2),

nuts (4) and washers (3) on the underside of
the console panel.

Withdraw the valve from below the console.

Chapter 7.05 -Page 14 I 52 Idcnt. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
Indian Railways W AG-9 Cab
Maintenance and Repair Manual

Wiper/Washer Control

Remove the access panel from the assistant's foot well.

Tag and disconnect the air lines from the uni-
ons (3) on the control valve (2). Seal the air
lines and valve unions with suitable plastic
plugs to prevent the ingress of foreign ma-
terial.

--- 2
Remove the four screws (1) securing the
control valve (2) to the console. Hold the
nuts (5) and washers (4) on the underside of
the console panel.

Remove the control valve (2) from the con-

sole.
0705004

Bombardier Transportation ltd. Jdent. No. Chapter 7.05 - Page 15 I 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Panel A

Individual switches, indicator lights and gauges are held in the panel "A" with screws and nuts
either on the front or the rear of the panel. The panel assembly must be removed from the
console to remove any one switch, indicator light or gauge.
Remove the screws (1) securing the panel
(2) to the console.

Tilt the top of the panel (2) forwards until it is

clear of the console brow. Lift the panel (2)
from the console.

Tag and disconnect the plugs (1, 2, 3) from

the panel.

Withdraw the panel from the console.

Chapter 7.05 - Page 16 I 52 !dent. No. Bombardier Transportation ltd.

Revision Date: i 2.200i 3EHW 411457
Indian Railways W AG-9
Maintenance and Repair Manual Cab

PanelS

The instrument cluster is on panel "B" of the driver's console. Individual gauges are held in
the panel with screws and nuts on the rear of the panel. The panel assembly must be removed
from the console to remove any one gauge.
Remove the screws (1) and washers (2)
from each corner of the panel (3).

Tilt the top of the panel (1) forwards until it is

clear of the console brow. Lift the panel (1)
from the console.

NOTE:
The air lines are still connected
and the panel (1) can only be
moved a short distance from the
console.
Crack loose the pneumatic connections (2)
at the instruments. Allow any residual pres-
sure to vent.
Tag and disconnect the air lines from the uni-
0705006
ons (2) on the gauges. Seal the air lines and
valve unions with suitable plastic plugs to
prevent the ingress of foreign material.
Withdraw the panel (1) from the console.

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 17 I 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways W AG-9
Maintenance and Repair Manual

PaneiC

Individual switches, indicator lights and gauges are held in the panel "C" with screws and nuts
either on the front or the rear of the panel. The panel assembly must be removed from the
console to remove any one switch, indicator light or gauge.
Remove the screws (1) securing the panel
(2) to the console.

Tilt the top of the panel (2) forwards until it is

clear of the console brow. Lift the panel (2}
from the console.

Tag and disconnect the plugs (1, 2, 3) from

the panel.

Withdraw the panel from the console.

Chapter 7.05 - Page 18 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
Indian Railways WAG-9
Maintenance and Repair Manual Cab

PaneiD

Individual switches and indicator lights are held in the panel "D" with screws and nuts either
on the front or the rear of the panel. The panel assembly must be removed from the console
to remove any one switch or indicator light.
Remove the screws (1) securing the panel
(2) to the console.

Tilt the top of the panel (2) forwards until it is

clear of the console brow. Lift the panel (2)
from the console.

Tag and disconnect the plugs from the

panel.

Withdraw the panel from the console.

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 19 1 52

3EHW 411457 Revision Date: 12.2001
 C\
c Indian Railways W AG-9
n,1 Cab
Maintenance and Repair Manual

Cab Heater

HEATER DUCT

Remove the access cover from the assistant's foot well.

Loosen the clamps (1) at the demister inlet
and at the heater bend (3).

Disconnect and remove the flexible duct (2).

Chapter 7.05 - Page 20 I 52 !dent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9
Maintenance and Repair Manual Cab

Remove the bolts (4) and washers {3) secur-

0
ing the heater bend (5) to the heater unit (1).
8 Remove the gasket (2) and inspect. Re-
place if damaged.

0705008

HEATER CONTROL

Remove the access panel from the assistant's foot well.

From below the console, tag and disconnect

the wires from the terminals on the heater
control switch {1). Cover any exposed wires
with suitable insulation.

Remove the four screws (2) securing the

control switch (1) to the console panel. Hold
the nuts (4} and washers {3} on the under-
side of the console panel.

Withdraw the control switch (1) from the

console.

0705010

Bombardier Transportation ltd. !dent. No. Chapter 7.05 - Page 21 1 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways W AG-9
Maintenance and Repair Manual

Crew Fan

Remove the four screws (1), spring washers

(2) and plain washers (3).

Withdraw the cover (4).

Tag and disconnect the wires from the ter-

minal block. Cover any exposed wire with
suitable insulation.

Undo and remove the nut (1) holding the

conduit fitting (3) to the fan housing (2).

Chapter 7.05 - Page 22 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Cab
Maintenance and Repair Manual

Remove the four bolts (5) with the spring

washers (4) and the washers (3).

Remove the crew fan assembly (6} and the

insulating mounting pad (1} from the pillar.

,~

I
1

6
0705007

Bombardier Transportation Ltd. ldent. No. Chapter 7.05 -Page 23 1 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

TB/BE Master Controller

Remove the access panel on the underside of the console.

From below the console, tag the air lines and the electrical wires on the master controller. Re-
move the electrical connections to the master controller. Crack loose the pneumatic connec-
tions and allow any residual pressure to vent, then disconnect the pneumatic connections.
Remove the four screws (1) securing the
master controller {2) to the console panel.
Hold the nuts and washers on the underside
of the console panel.

Withdraw the master controller (2) from the

console.

39021

Speedometer Recorder (MEMOTEL)

Remove the screws (1) securing the speed-

ometer recorder (2) to the console.

Tilt the top of the panel (2) forwards until it is

clear of the console brow.

Tag and disconnect the wires from the

speedometer recorder.

Withdraw the speedometer recorder from

the console.

Chapter 7.05 - Page 24 1 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
Indian Railways WAG~9
Cab
Maintenance and Repair Manual

Parking Brake Pressure Gauge

Loosen and remove the screws (2) securing

the gauge (1) to the gauge housing (3).

Withdraw the gauge (1) from the housing {3)

slightly to gain access to the connections on
the rear of the gauge {1).

Tag and disconnect the connections from

the rear of the gauge (1), then remove the
gauge (1).

0705102n

Bombardier Transportation ltd. Ident. No. Chapter 7.05 - Page 25 J 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Cubicle F

Remove the screws (1).

Remove the access panel (2).

Tag and disconnect the wires from the cu-

bicle "F".

Withdraw the cubicle "F" from the console.

--------·-- ---------------·

Chapter 7.05 - Page 26 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Cab
Maintenance and Repair Manual

Plate-Foot Pedal

Remove the twelve screws securing the

plate (5).

Remove the panel (5).

Tag and disconnect the wires at the back of

the plate-foot pedal.

With9raw the plate-foot pedal from the foot

well.

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Cab Indian Railways WAG-9
Maintenance and Repair Manual
----------

Disassembly
@.1240

Horn Control

For further information regarding the horn control, refer to Chapter 3, Metcalfe Duplex Air
Valve of Volume F12, Suppliers Documentation.

Wiper/Washer Control

For further information regarding the wiper/washer control, refer to Chapter 7, Washers/
Wipers of Volume F1, Suppliers Documentation.

Crew Fan

Unscrew the knob (5). Remove the knob (5)

and the washer (4).

Withdraw the bolt (1) and separate the fan

housing (6) from the bracket (3). Fibre
washers (2) are situated between the
bracket (3) and housing (6).

Inspect the fan as described in Section In-

spection and Repair.

Chapter 7.05 - Page 28 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
Indian Railways WAG-9
Cab
Maintenance and Repair Manual

Unscrew the knob {6).

Withdraw the bolt (1) and separate the

bracket {4} from the frame bracket (2). Fibre
washers (3) are situated between the frame
bracket (2) and bracket (4).

0705014

Remove the four screws (1 ), spring washers

(2) and plain washers (3) securing the ac-
cess cover (4). Withdraw the access cover
(4).

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 29 1 52

3EHW 411457 Revision Date: 12.2001
 Cab
Indian Railways WAG-9
Maintenance and Repair Manual

,---------------------,
Tag and disconnect the wires from the
switch (1 ). Cover any exposed wire with suit-
able insulation.

Remove the nut (3).

Withdraw the switch (1) from the access

cover (2).

0705016

Speedometer Recorder (MEMOTEL)

Refer to Chapter 1, Secheron Memotel of Volume F16, Suppliers Documentation.

Plate-Foot Pedal

FOOT SWITCH
Remove the four screws (1) securing the
foot switches (2,3,4) to the plate.-foot pedal
(5).

Remove the foot switch (2,3 or 4) as requi-

red.

Chapter 7.05 - Page 30 I 52 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 ') '2 ('

Indian Railways WAG-9

Cab
Maintenance and Repair Manual

Inspection and Repair

@ 1250

Horn Control

For further information regarding the horn control, refer to Chapter 3, Metcalfe Duplex Air
Valve of Volume Fi 2, Suppliers Documentation.

Wiper/Washer Control

For further information regarding the wiper/washer control, refer to Chapter 7, Washers/
Wipers of Volume F1, Suppliers Documentation.

Crew Fan

Heater Duct

Inspect the flexible duct for cracks, tears or damage. Replace if required.

Speedometer Recorder (MEMOTEL)

Refer to Chapter 1, Secheron Memotel of Volume F16, Suppliers Documentation.

Waste Disposal
@1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

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3EHW 411457 Revision Date: i 2.2001
Cab Indian Railways W AG-9
Maintenance and Repair Manual

Assembly
@.1270

Horn Control

For further information regarding the horn control, refer to Chapter 3, Metcalfe Duplex Air
Valve of Volume F12, Suppliers Documentation.

Wiper/Washer Control

For further information regarding the wiper/washer control, refer to Chapter 7, Washers/
Wipers of Volume F1, Suppliers Documentation.

Crew Fan

NOTE:
The lugs to capture the horizontal
adjustment bolt head must face
upwards.
Place fibre washers (3) on each side of the
bracket (4) over the pivot hole.
Position the bracket (4) between the frame
bracket plates.
II NOTE:
j )

s---4
v Ensure the stop Jugs are facing
upwards and the fibre washers (3)
remain aligned over the pivot hole.
~ Insert the bolt (1) through the frame bracket
6--t:::iJ:jJ (2) and the bracket (4).

0705014 NOTE:
Ensure the fibre washers (3) are
correctly aligned and positioned.

Place the washer (5) and knob (6) on the bolt

(1). Tighten the knob (6).

·---···-----·····--···---··· --------------

Chapter 7.05 - Page 32 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457

··-··---- ---·---
Indian Railways W AG-9
Cab
Maintenance and Repair Manual

Position the fibre washers (2) over the pivot

holes on the fan housing (6).

Slide the fan housing (6) into the bracket {3)

and align the pivot holes.

NOTE:
Ensure the fibre washers (2) are
correctly positioned and aligned
with the pivot holes.

Insert the bolt (1) through the bracket (3) and

fan hous~ng (6).

Place the washer (4} and knob {5) on the bolt

(1). Tighten the knob (5).

Install the switch (1) into the access cover

(2) and secure the nut (3).

0705016

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3EHW 411457 Revision Date: 12.2001
 Cab Indian Railways WAG-9
Maintenance and Repair Manual

Remove any temporary insulation, then

connect the wires to the switch as tagged
during removal.

Position the access cover (4) on the fan

housing (5).

Install the screws (1) with spring washers (2)

and plain washers (3). Tighten the screws
(1).

Speedometer Recorder (MEMOTEL)

Refer to Chapter 1, Secheron Memotel of Volume F16, Suppliers Documentation.

Chapter 7.05 - Page 34 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9 Cab
Maintenance and Repair Manual

Plate-Foot Pedal

FOOT SWITCH
Position the foot switches (2,3,4) into the
plate-foot pedal (5) as tagged during disas-
sembly.

Install and tighten the four screws (1 ).

Install the plate-foot pedal {5) as described

in Section Installation.

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3EHW 411457 Revision Date: 12.2001
 Cab Indian Railways W AG-9
Maintenance and Repair Manual

Installation
@.1280

\ 2
5

3
/
5
0705101n

Installation of panels (1, 2, 3, 4, 5, 6) only to be done after all other components have been
installed/assembled.

Place the appropriate panel in place, then secure with screws.

The panel (4) containing the emergency isolation cock (7) can be removed if required. The
isolation cock handle (7) must first be removed before the panel (4) can be removed.

Chapter 7.05 - Page 36 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Cab
Maintenance and Repair Manual

Fire Extinguisher Bracket

Position the bracket (2) on the cab wall.

Install the bolts (4) with spring washers (3).

Tighten the bolts (4).

Position the fire extinguisher (1) into the

bracket {3).

Secure the fire extinguisher {1).

4, I

~
3J~.dI
!----
,.._ - - +.:

I
I
I
I
I
2 I

I
I

~
I

0705019

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3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Horn Control

The procedure is the same for the horn control on either the driver's or assistant driver's side.
1 \ / / "/~ Position the valve (2) from below the con-
\ \ \ //--//// sole. Ensure the unions (5) are facing in the
\ \/-~/ / / appropriate direction to meet the pneumatic
\ / pipes.
) //
Install the two screws (1) through the con-
sole panel and valve (2).

From below the console, install the washers

(3) and nuts (4) on the screws (1). Tighten
the screws (1).

Remove the plastic plugs from the air lines

(6) and valve unions (5).

Connect the air lines (6) to the valve unions

(5) as tagged during removal.

Install the rubber boot (6) over the lever arm

(2). Position the retaining ring (5) over the
0
boot (6).

Align the holes in the console panel, boot (6)

@?I[!] and retaining ring (5).

U £J0GIE Install the six screws (3) with spring washers

(4). Do not over tighten the screws (3).

Screw the knob (1) onto the lever arm (2).

Chapter 7.05 - Page 38 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457

' ---~----·····---
 Indian Railways WAG-9 Cab
Maintenance and Repair Manual

Wiper/Washer Control

Position the control valve {2) in the console.

Install the four screws {1) through the control

valve (2) and console panel.

From below the console, install the spring

washers {4} and nuts (5) on the screws {1).
Tighten the screws (1 ).

Remove the plastic plugs from the air lines

and valve unions (3).

Connect the air lines to the valve unions as

tagged during removal.
0705004 Test the operation of the wipers and
washers as described in Chapter 1 .7,
Washers and Wipers. Rectify any faults
found.

Reinstall the access panel in the foot well.

Bombardier Transportation Ltd. ldent. No. Chapter 7.05 - Page 39 I 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual
---------------------------

Panel A

Position the panel at the console. Tilt the

panel to allow access to the unions (1,2,3)
on the back of the panel.

Connect the plugs (1,2,3) as tagged during

removal.

Manipulate the panel (2) into position in the

console.

Install the screws (1) through the panel (2)

into the console. lighten the screws (1).

Connect electrical power to the instrument

gauges, indicator lights and switches.

Chapter 7.05 - Page 40 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 .~()
2-
Indian Railways W AG-9 Cab
Maintenance and Repair Manual

PanelS

Position the panel (1) at the console. Ti It the

panel (1} to allow access to the unions (2) on
the back of the gauges.

Remove the plastic plugs from the air lines

and valve unions (2) of the gauges.

Connect the air lines to the valve unions (2)

as tagged during removal.

0705006

6 5 4 3 2 1

0705100n
1 to gauge #122, Brake Pipe Pressure 4 to gauge #131, Brake Cylinder Pres-
Gauge, BP sure Gauge, Bogie 1, BC1
2 to gauge #132, Brake Pipe Flow 5 to gauges #121 , Main Reservoir Pres-
Meter, FM sure Gauge, MR and to gauge #132,
3 to gauge #131 , Brake Cylinder Pres- Brake Pipe Flow Meter
sure Gauge, Bogie 2, BC2 6 to gauge #121, Feed Pipe Pressure
Gauge, FP
For further information regarding the cab piping, refer to the Pneumatic Schematic located
in Chapter 1, Metcalfe Brake System of Volume F11, Suppliers Documentation.

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 41 1 52

3EHW 411457 Revision Date: 12.2001
Cab Indian Railways WAG-9
Maintenance and Repair Manual

Manipulate the panel (3) into position in the

console.

Install the screws (1) with spring washers (2)

through the panel (3) into the console.
Tighten the screws (1).

PaneiC
Position the panel at the console. Tilt the
panel to allow access to the unions (1 ,2,3)
on the back of the panel.

Connect the plugs (1 ,2,3) as tagged during

removal.

Manipulate the panel (2) into position in the

console.

Install the screws (1) through the panel (2)

into the console. Tighten the screws (1).

Connect electrical power to the instrument

gauges, indicator lights and switches.

Chapter 7.05 - Page 42 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Cab
Maintenance and Repair Manual

PaneiD

Position the panel at the console. Tilt the panel to allow access to the unions on the back of
the panel.

Connect the plugs as tagged during removal.

Manipulate the panel (2} into position in the
console.

Install the screws (1) through the panel (2)

into the console. Tighten the screws (1).

Connect electrical power to the indicator

lights and switches.

Cab Heater

Heater Duct
Place the gasket (2) on the heater bend (5).
0
a Position the heater bend (5) with the gasket
(2) on the heater unit (1).

Install the bolts (4) with spring washers {3)

through the heater unit (1) and gasket (4)
into the heater bend (5).

Tighten the bolts (4).

0705008

Bombardier Transportation Ltd. Ident. No. Chapter 7.05 - Page 43 I 52

3EHW 411457 Revision Date: 12.2001
 ~'?
'V Cab Indian Railways W AG-9
Maintenance and Repair Manual

Place a cramp (1) on each end of the flexible

duct (2).

Install one end of the flexible duct (2) onto

the heater bend (3). Tighten the clamp (1 ).

Install the other end of the flexible duct (2)

onto the demister inlet.

Tighten the clamp (1).

----------·· ~----~~--------

Chapter 7.05 - Page 44 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9
Maintenance and Repair Manual Cab

Heater Control

Position the heater control switch {1) in the

console. Align the screw holes in the panel
and control switch.

Install the four screws (2} through the control

switch (1) and console panel.

From below the console, install the spring

washers {3) and nuts (4) on the screws (2).
Tighten the screws (2).

0705010

Crew Fan

Position the crew fan assembly (6) and the

insulation mounting pad (1) on the pillar.

Align the holes in the frame bracket (2) with

the holes in the pillar.

Insert the four bolts (5) with the spring

washers (4) and the washers (3} through the
frame bracket (2) into the pillar.

6
0705007

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 Indian Railways WAG-9
Cab
Maintenance and Repair Manual

Feed the wires through the hole in the back

of the fan housing (2).

Insert the conduit fitting (3) into the hole. In-

stall the nut (1) from inside the fan housing
(2).

Remove any temporary insulation and con-

nect the wires to the terminal block as
tagged during removal.

Install the access cover {4) onto the fan

housing (5). Install the screws {1) with spring
washers (2) and plain washers (3). Tighten
the screws (1).

Chapter 7.05 - Page 46 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001
3EHW 411457
 Indian Railways W AG-9
Maintenance and Repair Manual Cab

TB/BE Master Controller

Position the master controller (2) in the con-

sole. Align the screw holes in the master
controller {2) with the holes in the console.

Install the four screws (1) and the nuts and

washers on the underside of the console
panel.

Tighten the four screws (1).

From below the console, connect the air

lines and the electrical wires to the master
1
controller as tagged during removal.

39021 Reinstall the access panel.

Speedometer Recorder (MEMOTEL)

Connect the wires to the speedometer re-

corder as tagged during removal.

Position the speedometer recorder (2} in the

console. Align the screw holes in the speed-
ometer recorder (2) with the holes in the
console.

Install and tighten the four screws (1 ).

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3EHW 411457 Revision Date: 12.2001
 Indian RaiJways WAG-9
Cab Maintenance and Repair Manual

Parking Brake Pressure Gauge

Connect the connections to the rear of the

gauge (1) as tagged during removal.

Install the gauge (1) into the housing (3) and

secure using screws (2).

0705102n

Chapter 7.05 - Page 48 I 52 Ident. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Cab
Maintenance and Repair Manual

Cubicle F

Position the cubicle "F" into the console.

Connect the wires to the cubicle "F" as

tagged during removal.

Position the access panel (2). Align the

holes in the access panel (2) with the holes
in the console.

Install and tighten the screws (1 ).

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3EHW 411457 Revision Date: "12.2001
Cab Indian Railways W AG-9
Maintenance and Repair Manual

Plate-Foot Pedal

Connect the wires to the plate-foot pedal as

tagged during removal.

Position the plate-foot pedal (5) on the foot-

well. Align the holes in the plate-foot pedal
(5) with the holes in the foo twell.

Install and tighten the twelve screws.

Chapter 7.05 - Page 50 I 52 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways WAG-9
Cab
Maintenance and Repair Manual

After-Installations Operations
@ 1290

Panef A

Test the operation of the instrument gauges, indicator lights and switches. Rectify any faults
found.

PaneiB

Open the air supply to the instruments.

Close the instrument circuit breaker.

Test the operation of the instruments. Rectify any faults found.

PaneiC

Test the operation of the instrument gauges, indicator lights and switches. Rectify any faults
found.

PaneiD

Test the operation of the indicator lights and switches. Rectify any faults found.

Cab Heater

Close the circuit breaker and test the operation of the heater. Rectify any faults found.

Reinstall the access cover into the assistant's foot wei\.

Crew Fans

Close the crew fan circuit breaker and test the operation of the fan. Rectify any faults found.

Horn Control

Test the operation of the horns, as described in Chapter 1.6, Horns(Lights. Rectify any faults
found.

Reinstall the access panel in the foot well.

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 Cab Indian Railways WAG~9
Maintenance and Repair Manual

Wiper/Washer Control

Test the operation of the wipers and washers as described in Chapter 1 .7, Washers/Wipers.
Rectify any faults found.

Reinstall the access panel in the foot well.

Cab Heater Control Switch

Close the heater circuit breaker and test the operation of the heater. Rectify any faults found.
Connect the wires to the terminals as tagged during disassembly.

Reinstall the access panel in the foot well.

TE/BE Master Controller

Open the air supply to the master controller.

Close the electrical power circuit to the master controller.

Test the operation of the master controller. Rectify any faults found.

Memotel Recorder/Speedometer

Close the electrical power circuit to the speedometer recorder.

Test the operation of the speedometer recorder. Rectify any faults found.

Brake Pipe Pressure Gauge

Foot Pedals

Close the electrical power circuit to the plate-foot pedal.

Test the operation of the foot switches. Rectify any faults found.

Chapter 7.05 - Page 52 I 52 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411457
 Indian Railways W AG-9 Key lnterlocki ng
Maintenance and Repair Manual

7.6 Key Interlocking

Functional Description

Access to high voltage power equipment such as the filter cubicle, auxiliary converters, trac-
tion converters, auxiliary cubicles and control cubicles, is strictly forbidden unless the equip-
ment is de-energised and grounded by means of the appropriate earth switches. Mainten-
ance staff are required to operate a key interlock system which ensures access to power
equipment is only permitted once the equipment is safe.

The key interlock system comprises 5 different types of colour coded keys, each identified
by a letter stamped on the key head. The keys of colour type are interchangeable with keys
of the same colour but not with keys of a different colour. When used in the correct sequence,
the different keys isolate specific systems on the locomotive, allowing safe operation and
maintenance on the locomotive and its sub-systems.

Key Location

The normal locations for the various keys are given below:

Type Colour No. Of Location

A light blue 1 Pantograph air supply isolating cock
B yellow 2 Earthing Switch of main circuit breaker
c green 7 Key Multiplier No. 1
D black 2 1 Key on the Earthing Switch of each Traction Converter
E white 6 Key multiplier No. 2

Bombardier Transportation Ltd. ldent. No. Chapter 7.06 - Page 1 I 4

3EHW 411458 Revision Date: 12.2001
 Indian Railways WAG-9
Key Interlocking
Maintenance and Repair Manual

Operation of the Key Interlocking System

For information regarding the operation of the key interlocking system, refer to Chapter 4, Ve-
hicle Operation of Volume A, Driver's Manual.

Interlocking concept

dm 223
.
1004.1 Pantograph air supply 15.82/1 8 Earthing switch on
isolating cock traction converter 1
4 2 Earthing switch of main 1004.4 9 Door lock on filter block
circuit breaker 15.82/2 10 Earthing switch on traction
1004.2 3 Key multiplier 1 converter2
1004.4 4 Door lock auxiliary circuits, 1004.5 11 Key multiplier 2
Block 1 ~004.6 12 Door lock, traction converter 1
1004.4 5 Door lock auxiliary circuits, 1004.6 13 Door lock, traction converter 1
Block 5
1004.6 14 Door lock, traction converter 1
1004.4 6 Door lock auxiliary
1004.6 15 Door lock, traction converter 2
converter 1
1004.6 16 Door lock, traction converter 2
1004.4 7 Door lock auxiliary
converter 2 1004.6 17 Door lock, traction converter 2

Chapter 7.06 - Page 2 I 4 Ident. No. Bombardier Transportation Ltd.

Revision Date: i 2.200i 3EHW 411458
Indian Railways WAG-9
Key Interlocking
Maintenance and Repair Manual

Location Key Interlocking

-------·-----

2 3 4 5 6 7

CAB 2

ff 204
Pantograph air supply isolating cock, 6 Door lock, cubicle auxiliary circuits 1
pneumatic panel 7 Key multipliers
2 Earthing switch main circuit breaker, 8 Door lock on filter block
middle roof hatch
9 Three door locks, traction converter 2
3 Three door locks, traction converter 1
10 Earthing switch, traction converter 2
4 Earthing switch, traction converter 1
11 Door lock, auxiliary converter 2
5 Door lock, auxiliary converter 1
12 Door lock, cubicle auxiliary circuits 2

Bombardier Transportation Ltd. Ident. No. Chapter 7.06 - Page 3 I 4

3EHW 411458 Revision Date: 12.2001
 Indian Railways WAG-9
Key Interlocking
Maintenance and Repair Manual

empty page

----~ ~~- -~~--~~~-

Chapter 7.06 - Page 4 I 4 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411458
Indian Railways W AG-9 Cabling
Maintenance and Repair Manual

7.7 Cabling
For complementary information see Suppliers Documentation Volume G:

ABB Three Phase Electric Drive Locomotive W AG-9

Cabling Schematics

Bombardier Transportation Ltd. Ident. No. Chapter 7.07 - Page 1 1 2

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 Indian Railways W AG-9
Cabling Maintenance and Repair Manual

empty page

Chapter 7.07 - Page 2 I 2 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411473
 8.00 Control System
1

8.01 Cab Control

IR WAG9 2
Volume 03

Control System 8.02 Machine Room Control

3

8.03 Control Electronics

4

8.04 Loco-Loco Bus

5

10

11

12
Indian Railways W AG-9 Control System
Maintenance and Repair Manual

8 Control System
For complementary information see following Chapters in Volume 02:

Cab Control 8.1

Machine Room Control 8.2

Control Electronics 8.3

Loco- Loco Bus 8.4

Bombardier Transportation Ltd. ldent. No. Chapter 8.00 - Page 1 1 2

3EHW 411459 Revision Date: 12.2001
 Indian Railways W AG-9
Control System
Maintenance and Repair Manual

empty page

Chapter 8.00 - Page 2 I 2 ldent. No. Bombardier Transportation Ltd.

Revision Date: i 2.200i 3EHW 411459
Indian Railways W AG-9 Cab Conirol
Maintenance and Repair Manual

8.1 Cab Control

Group Summary
@.1120

This chapter contains information regarding the components located in panels A, B, C and
D in the driver's cab.

···- -----------~----------- ------------------

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 1 1 30
Revision Date: 12.2001
3EHW 411460
 Indian Railways WA\J--~
Cab Control
Maintenance and Repair Manual

Panel A

3 4 5 6 7 8 9 10
\
\ I

0
\ \
I I 0
I
[@] ~~. lUSA
··~
- -
\

~~
0
lSHO
LSP LSAF

u BOGIE1 BOGIE2
ZBAN LSWI

0 0

11 12 13 14 15 16 17 18 19 20 21

dm 402
Voltmeter, battery "UBA" (116) 12 Key switch, cab activating "BL'' (125)
2 Voltmeter, catenary "U" (74) 13 Spring loaded switch, pantograph
3 Meter, tractive/braking effort bogie 1 "ZPT" (129)
(79.1) 14 Spring loaded switch, VCB "BLDJK
4 Meter, tractive/braking effort bogie 2 (134)
(79.2) 15 Spring loaded switch, main com-
5 Switch, banking operation pressor "BLCP" (172)
"ZBAN"(153) 16 Spring loaded switch, hotel load sup-
6 Indication lamp, VCB "LSDJ" (137.3) ply "BLHO" (169.1)
7 Indication lamp, hotel load supply 17 Switch, maximum tractive effort limita-
"LSHO" (169.3) tion "ZTEL" (151.1)
8 Indication lamp, wheel slipping "LSP" 18 Illuminated push button, constant
(92) speed control "BPCS" (151.4)
9 Indication lamp, train parting "LSAP' 19 Illuminated push button, parking brake
(81.5) "BPPB" (268)
10 Indication lamp, vigilance warning 20 Push button, vigilance control reset
"LSVW" (242. 1) "BPVR" (237 .5)
11 Indication lamp, control electronic tem- 21 Push button, emergency stop (244)
perature "LSCE" (166)

Chapter 8.01 - Page 2 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 Indian Railways W AG-9
Cab Control
Maintenance and Repair Manual

PanelS

1 2

0 0

0 0

3 4
dm 403
1 Gauge, bogie 1 & 2 brake cylinder 3 Meter, air flow
pressure 4 Gauge, brake pipe pressure
2 Gauge, brake feed pipe I main reser-
voir pressure

Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 3 I 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual

PaneiC
----·-- --------------·

2 3 4 5 6
'
\ I
0 0

4Gf
0 0

ZLC ZLI ZLDD

0 0 \~ ~
0 0
OJ @] 0 BZ-V-0-F o
~AR)~~ Gt.l
[[) CD

0 0

7 8 9 10 11 12

dm 405
Terminal, fault indication and diagnos- 7 Illuminated push button, fault indica-
tics (435) tion/acknowledge "BPFA" (163. 1)
2 Lamp, fault status "LSFI" (163) 8 Switch, headlights "BLPR" (316)
3 Switch, driver's cab lighting "ZLC" 9 Switch, headlights Intensity "ZPRO"
(324) (317)
4 Switch, instrument lighting "ZLI" 10 Switch, marker lights white "ZLFW'
(324.1) (316.11)
5 Switch, driver's desk illumination 11 Switch, marker lights red "ZLFR"
"ZLDD" (324.21) (316.12)
6 Buzzer, overspeed/fire alarm/Vigilance 12 Illuminated switch, emergency flash
warning (238) lights "BPFL" (316.2)

Chapter 8.01 - Page 4 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.200·1 3EHW 411460
 Indian Railways W AG-9 Cab Control
Maintenance and Repair Manual
--------

PaneiD

1 Switch, assistant's desk illumination

"ZLDA" (324.22)
2 Push button, vigilance control "BPVG"
0 0 (236)
3 Socket, handlamp "PCLH" (334. 1)
4 Switch, handlamp "ZLH" (337)

ZLDA

0
0PC H
110 v c
\
0

2 3 4
dm 406

Numbers in brackets ( ) denote the electrical equipment apparatus item number used in the
locomotive schematics, refer to Volume G, Cabling Documentation.

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 5 1 30

3EHW 411460 Revision Date: i 2.2001
 Cab Control Indian Railways WAG-9
Maintenance and Repair Manual

Functional Description
@1140

Panels contain various switches, sockets, gauges and lights required for locomotive oper-
ation. Refer to Volume A, Driver's Manual for further information regarding the instruments
located in the panels.

Technical Data
@.1160

Gauge Working Ranges

- Battery voltmeter 0- 150 v

- Catenary voltmeter 0-30 kV
- Bogie tractive effort BE 100 - 0 - 100 % TE
- Brake cylinder pressure 0- 7 kg/cm2
- Brake pipe pressure 0- 7 kg/cm 2
- Brake pipe flow meter dimension-less ratio, LP to HP
- Main reservoir pressure 0- 11 kg/cm2
- Brake feed pipe pressure 0- 11 kg/cm2

Tolerances and Wear Limits List

@.1170

No specific tolerances or wear limits are applicable to the equipment described in this chapter.
Items should be inspected as described in Section Inspection and Repair, and replaced or
repaired as necessary.

Tools and Special Tools

@.1180

Conventional railway workshop tools are required for the procedures described in this chap-
ter.

Miscellaneous Materials
@.1200

Plastic cable clamps for re-fixing the cable connections after replacement of components.

Chapter 8.01 - Page 6 I 30 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
Indian Railways W AG-9
Cab Control
Maintenance and Repair Manual

Before-Removal Operations
@.1220

Lower the pantograph and isolate the locomotive from the overhead catenary. Earth the loco-
motive at the vacuum circuit breaker. Refer to the Preface of this Volume.

Set the "Battery Charger Input" circuit breaker (1 00) to the Off position. Circuit breaker 100
is situated in auxiliary converter cubicle-2 (BUR_Box_2). For more information on circuit
breakers, refer to Chapter 5.1, Auxiliary Three Phase Power.

Ensure the voltage indicators on the BUR cubicles are not flashing. A flashing voltage indica-
tor shows a voltage present in the cabinet. No work should be performed until the capacitor
banks have discharged, indicated by no flashing on the voltage indicator. Ensure the voltage
indicator does not flash for a period of at least 15 seconds.

Set the "Battery Charger Output" circuit breaker (11 0) to the Off position. Circuit breaker 110
is situated in control cubicle-2 (882). For more information on circuit breakers, refer to
Chapter 8.2, Machine Room Control.

Isolate the batteries at the battery box isolation switch, as described in Chapter 5.3, Battery 1
Charger.

Isolate the electrical power to the main compressor at circuit breaker 47.1. Circuit breaker
47.1/1 for the No. 1 End is situated in Auxiliary Circuits Cubicle 1 (HB1) and circuit breaker
47.1/2 for the No.2 is located in Auxiliary Circuits Cubicle 2 (HB2). For more information on
circuit breakers, refer Chapter 5.2, Auxiliary Converter Control.

Vent the locomotive pneumatics as described in Chapter 6.3, Main Reservoirs.

Remove the appropriate panels from the driver's cab before removing components from the
panels. Refer to Chapter 7.5, Cab for details on removing Panels A, 8, C and D.

------------ -----------------
Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 7 I 30
3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways WAG-9
Maintenance and Repair Manual

Removal
@ 1230

Indication Lamps

The procedure described here is applicable to the items shown in the following table.

Description Indication Location Equipment Item

Lamp Number
Vacuum Circuit Breaker LSDJ Panel A 137.3

Hotel Load Supply LSHO Panel A 169.3

Wheel Slipping LSP Panel A 92

Train Parting LSAF Panel A 81.5

Vigilance Warning LSVW Panel A 242.1

Control Electronic Temperature LSCE Panel A 166

Fault Status Lamp LSFI PaneiC 163

Tag and disconnect the cables from the

electrical terminals.

From behind the panel, loosen the screws

(4) in the lamp body (1).

Rotate the lamp head (2) 90° counterclock-

wise to release the locking mechanism.

From behind the panel, pull the lamp body

(1) from the lamp head (2).

Depress the two tangs on either side of the

lamp head (2) and withdraw the head from
0801007a the panel.

The LED (3) is a bayonet mounting in the

same way as a light bulb. If necessary, push
the LED (3) inwards slightly and rotate
counterclockwise to release, then withdraw
the LED (3) from the lamp body (1).

Chapter 8.01 - Page 8 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 Indian Railways W AG-9
Cab Control
Maintenance and Repair Manual

Illuminated Push Buttons

The procedure described here is applicable to the items shown in the following table.

Description Indication Location Equipment Item

Lamp Number
Fault Indication/Acknowledge BPFA PaneiC 163.1

Constant Speed Control BPCS Panel A 151.4

Parking Brake BPPB Panel A 268

Vigilance Reset Control BPVR Panel A 237.5

Vigilance Control BPVG Panel D 236

Loosen the two screws (4) in the button's

body (1).

Rotate the button's head (2) counterclock-

wise to loosen it.

Remove the head {2) and the body (1 ).

If it is necessary to change the LED (3),

slightly push downwards. Turn counter-
clockwise and remove.

0801013a

----------------- -~----- ----------- ---------- -- ---- - - - - - - - - - - - - -

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 9 1 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways WAG-9
Maintenance and Repair Manual

Rocker Switches

The procedure described here is applicable to the items shown in the following table.

Description Switch Location Equipment Item

Number
Banking Operation ZBAN Panel A 153

Pantograph Operation ZPT Panel A 129

Vacuum Circuit Breaker BLDJ Panel A 134

Main Compressor BLCP Panel A 172

Hotel Load Supply BLHO Panel A 169.1

Maximum Tractive Effort Limitation * ZTEL Panel A 151.1

Driver's Cab Lighting ZLC PaneiC 324

Instrument Lighting ZLI Panel C 324.1

Driver's Desk Illumination ZLDD Panel C 324.21

White Marker Lights ZLFW PanelC 316.11

Red Marker Lights ZLFR Panel C 316.12

Driver's Assistant's Desk Illumination ZLDA PaneiD 324.22

Socket Hand Lamp ZLH Panel D 337

*This switch is inactive on the WAP-5 locomotive

Tag and take off the cables on the switch's

2 rear side.

Loosen the two front screws (1) above and

below the switch (2).

Remove the screws (1) and the switch (2).

_0_8_01_008~--------------~----~

------------------------------

Chapter 8.01 - Page 10 I 30 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
Indian Railways W AG-9
Cab Control
Maintenance and Repair Manual

Panel A

Meters

The procedure described here is applicable to the items shown in the following table.

Description Meter Equipment Item

Number
Catenary Voltmeter u 74

Tractive/Braking Effort Meter, Bogie 1 Bogie 1 79.1

Tractive/Braking Effort Meter, Bogie 2 Bogie 2 79.2

Tag and disconnect the cables from the

terminals.

Remove the nuts (1) and clamps (2).

Remove the meter {3) from the front.

0801006

---- ----···-··--··~-- ------~·---~------~~-~ ---~-~----~------ ----

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 11 1 30
3EHW 411460 Revision Date: i 2.200"1
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual

Voltmeter Battery "UBA" {116)

Tag and disconnect the cables from the

terminals.

Remove the screws (1) and clamps (2).

Remove the meter (3) from the front of the

panel.

0 1005

Cab Activating Key Switch "BL" (125)

Tag and disconnect the cable connections

on the rear of the switch.

Loosen the two front screws (1) fastening

the key switch to the panel.

Remove the screws (1) and the key switch

(2).

0801009

Chapter 8.01 - Page 12 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
Indian Railways W AG-9 Cab Control
Maintenance and Repair Manual

Push Button Emergency Stop (244)

.--------------------------~

Tag and disconnect the cables from the ter-

minal blocks (6).

Remove the outer terminal blocks first, then

the remaining block in the middle. Release
the snap-on clips (5) to remove the terminal
block (6).

Loosen the screws (3} that fasten the flange

(4} to the panel (2}.
5
NOTE:
Ensure the screws (3) are rotated
counterclockwise, otherwise the
0801010 front plate (2) will be damaged.

Rotate the loosened flange (4) 90° counter-

clockwise and remove.

Push the button head (1) from behind out of

the panel recess (2).

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 13 1 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual
-- -~---------------------------------- -------------

PanelS
Gauges

The procedure described here is applicable to the items shown in the following table.

Description Meter Equipment Item

Number
Pressure Brake Cylinder Gauge Bogie 1,2 131

Pressure Brake Main Reservoir I Feed Pipe Gauge MR- FP 121

Pressure Brake Pipe BP 122

Loosen the four nuts (3). Remove the nuts

(3) and lock washers (2). Remove the
0 screws (1).

Slightly tilt the gauge (4) and lift it out of the

panel recess.

Disconnect the pneumatic line from the

gauge.

0801015

Gauge BP Flow Indicator (Pneumatic Item Number 132)

Loosen the _two nuts (1). Remove the nuts

(1) and the holder (2).

Take the gauge (3) off the panel recess from

the front.

Disconnect the pneumatic line from the

gauge.

0801016

-----------------·--------------

Chapter 8.01 - Page 14 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 '2-e:,S
Indian Railways WAG-9 Cab Control
Maintenance and Repair Manual
--------~------- ---~-----

Panel B Lighting
-----------------------,
Tag and disconnect the cables from the ter-
3 minal block.
'·

Release the clamps (2) and remove the

lamp block (3).

NOTE:
It is not necessary to remove the
block (4).

Turn the lamp (1) counterclockwise to re-

lease the spring contact, then remove the
lamp (1).
0801017

PaneiC

Terminal Fault Indication And Diagnostics (435)

Tag and disconnect.the cables to the diagnostic terminal.

Loosen the screw connections that fasten the terminal to the panel.

Remove the screws and the terminal.

-------------------------
Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 15 1 30
3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways WAG-9
Maintenance and Repair Manual

Buzzer Overspeed I Fire Alarm I Vigilance Warning (238)

Loosen the two screws (1) and remove the

cover (2).

Tag and disconnect the cables from the

terminals.

Loosen the four front screws (3). Remove

the nuts, lock washers. Remove the screws
(3).

Remove the buzzer (4) from the panel re-

cess (5).

0801011

Illuminated Switch Emergency Flash Light "BPFL" {316.2)

Tag and disconnect the cables from the

terminals.

Loosen the two screws (4) in the lamp's

body (1).

Rotate the switch's head (2) counterclock-

2 wise to loosen it.

4 3
Remove the head (2) and the body (1).

If it is necessary to change the lamp (3),

push the lamp slightly to release the spring
contact. Turn counterclockwise and re-
0801018 move.

Chapter 8.01 - Page 16 I 30 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 Indian Railways WAG-9
Cab Control
Maintenance and Repair Manual

Illuminated Switches

The procedure described here is applicable to the items shown in the following table.

Description Meter Equipment Item

Number
Switch Headlights BLPR 316

Switch Headlights Intensity ZPRD 317

Tag and disconnect the cables from the rear

of the switch.

Loosen the two front screws (1) above and

below the switch (2).

Remove the screws (1) and the switch (2).

0801014

PaneiD

Socket Handlamp "PCLH" (334.1)

Tag and disconnect the cables from the

socket (2) terminals.
0
Loosen the four nuts (5) on the screws (1).
Remove the nuts (5), lock washers (4) and
washers (3) from behind the panel. Remove
the screws (1) from the front.

Remove the socket (2).

5
4

I /
2
0801012~ _________________~
Bombardier Transportation Ltd. ldent. No. Chapter 8.01 - Page 17 1 30
3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual

Disassembly
@.1240

There is no disassembly applicable to the components located in the cab panels.

Inspection and Repair

@ 1250

Check rubber cover on push buttons for cracks and replace rubber if necessary. Check
translucent plastic heads on indication lamps, push buttons and switches for cracks. Replace
head if necessary.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

There is no assembly applicable to the components located in the cab panels.

------~------------~------------- ---------------------

Chapter 8.01 - Page 18 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: i 2.200i 3EHW 411460
Indian Railways WAG-9 Cab Control
Maintenance and Repair Manual
--------

Installation
@.1278

Indication Lamp

The procedure described here is applicable to the items shown in the following table. Details
of the electrical connections are given in the locomotive schematics, Volumes G, Cabling
Documentation. The table gives the schematic sheet number where the electrical connec-
tions are shown.

Description Indication Location Equipment Schematic

Lamp Item Reference
Number
Vacuum Circuit Breaker LSDJ Panel A 137.3 osc
Hotel Load Supply LSHO Panel A 169.3 050

Wheel Slipping LSP Panel A 92 08E

Train Parting LSAF Panel A 81.5 06F

Vigilance Warning LSVW Panel A 242.1 11A

Control Electronic Temperature LSCE Panel A 166 088

Fault Status Lamp LSFI PaneiC 163 17A

Insert the LED (3) into the lamp's body (1 ).

Slightly push and turn to the right at the
same time.
Insert the lamp's head (2) through the front
panel recess.
Insert the lamp body (1) from behind the
panel. Rotate the head {2) clockwise until
3 locked.

NOTE:
Do not over-tighten. Excessive
force when tightening may result
0801007a in damage to the panel.

Slightly tighten the two screws (4) in the

body (1) until they just touch the panel.
Tighten screws (4) evenly.

Reconnect the electrical cables as tagged

during disassembly.

--------------------
Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 19 1 30
3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual

Illuminated Push Buttons

The procedure described here is applicable to the items shown in the following table. Details
of the electrical connections are given in the locomotive schematics, Volumes G, Cabling
Documentation. The table gives the schematic sheet number where the electrical connec-
tions are shown.

Description Indication Location Equipment Schematic

Lamp Item Reference
Number
Fault Indication/Acknowledge BPFA PaneiC 163.1 17A

Constant Speed Control BPCS Panel A 151.4 08E

Parking Brake BPPB Panel A 268 068

Vigilance Reset Control BPVR Panel A 237.5 11A

Vigilance Control BPVG Panel D 236 11A

Insert the LED (3) into the button's body (1).

Push slightly and turn clockwise.

Insert the button's head (2) through the front

panel recess.

Insert the body (1) from behind the panel.

Rotate the head (2) clockwise until it is lock-
ed.

NOTE:
Do not over- tighten. Excessive
force when tightening may result
in damage to the panel.
0801013a
Slightly tighten the two screws (4} in the
body (1) until they just touch the panel.
Tighten screws (4) evenly.

Reconnect the electrical cables as tagged

during disassembly.

Chapter 8.01 - Page 20 I 30 !dent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 '21'
Indian Railways W AG-9 Cab Control
Maintenance and Repair Manual
--------------------

Rocker Switches

The procedure described here is applicable to the items shown in the following table. Details
of the electrical connections are given in the locomotive schematics, Volumes G, Cabling
Documentation. The table gives the schematic sheet number where the electrical connec-
tions are shown.

Description Indication Loca- Equipment Schematic

Lamp tion Item Reference
Number
Banking Operation ZBAN Panel A 153 06F
Pantograph Operation ZPT Panel A 129 268
Vacuum Circuit Breaker BLDJ Panel A 134 268
Main Compressor BLCP Panel A 172 268
Hotel Load Supply BLHO Panel A 169.1 268
Maximum Tractive Effort Limitation * ZTEL Panel A 151.1 08E
Driver's Cab Lighting ZLC PaneiC 324 07A
Instrument Lighting ZLI PaneiC 324.1 07E
Driver's Desk Illumination ZLDD PaneiC 324.21 07A
White Marker Lights ZLFW PaneiC 316.11 07C
Red Marker Lights ZLFR PaneiC 316.12 07C
Driver's Assistant's Desk Illumination ZLDA Panel 0 324.22 07A
Socket Hand Lamp ZLH PaneiD 337 07A

*This switch is inactive on the WAP-5 locomotive

Insert the switch (2) from behind the panel

2 and install the screws {1).

Tighten the screws (1).

Reconnect the electrical cables as tagged

during disassembly.

I o§o1oos

Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 21 1 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways WAG-9
Maintenance and Repair Manual
----------------------- - - - - -

Panel A

Meters

The procedure described here is applicable to the items shown in the following table. Details
of the electrical connections are given in the locomotive schematics, Volumes G, Cabling
Documentation. The table gives the schematic sheet number where the electrical connec-
tions are shown.

Description Meter Equipment Item Schematic

Number Reference
Catenary Voltmeter u 74 07E

Tractive/Braking Effort Meter, Bogie 1 Bogie 1 79.1 07E

Tractive/Braking Effort Meter, Bogie 2 Bogie 2 79.2 07E

Insert the voltmeter (3) through the panel re-

cess from the front.

Install the clamps (2) and screws, then

tighten the screws (1).

3
Reconnect the electrical cables as tagged
during disassembly.

0801006

Chapter 8.01 - Page 22 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 Indian Railways WAG~9 Cab Control
Maintenance and Repair Manual

Voltmeter Battery "UBA" (116)

Insert the voltmeter (3) through the panel re-

cess from the front.

Install the clamps (2) and screws, then

tighten the screws (1).

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Actual value Detection,

Sheet 12A, Catenary & Battery Voltage of
Volume G 1, Cabling Documentation for
electrical connections.

0801005

Cab Activating Key Switch "BL" (125)

Insert the key switch (2) from behind the

panel and install the screws ( 1).

Tighten the screws (1).

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Pin Assignments, Electrical

Components, Sheet 268, Switches of Vol-
ume G2, Cabling Documentation for electri-
cal connections.

0801009

Bombardier Transportation ltd. !dent. No. Chapter 8.01 - Page 23 1 30

3EHW 411460 Revision Date: 12.2001
Cab Control Indian Railways W AG-9
Maintenance and Repair Manual

Push Button Emergency Stop (244)

Fit the button head (1) into the panel recess.

Slightly push in the button head until the
retention lugs touch the panel's surface.

Insert the flange (4) onto the head (1) and ro-
tate 90° clockwise.

NOTE:
Do not over-tighten. Excessive
force when tightening may result
5 in damage to the panel.

Slightly tighten the two screws (3) until they

0801010 just touch the panel (2). Tighten screws (3)
evenly.

Snap in the central terminal block (6) onto

the flange (4), then fit the adjacent terminal
blocks.

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Pin Assignments, Electrical

Components, Sheet 268, Switches of Vol-
ume G2, Cabling Documentation for electri-
cal connections.

---- ---~---~-~~-------- ·~------~------ -- ·~-----~--

Chapter 8.01 - Page 24 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
Indian Railways WAG-9 Cab Colltro I
Maintenance and Repair Manual

PanelS

Gauges

The procedure described here is applicable to the items shown in the following table.

Description Meter Equipment Item

Number
Pressure Brake Cylinder Gauge Bogie 1,2 131

Pressure Brake Main Reservoir I Feed Pipe Gauge MR- FP 121

Pressure Brake Pipe BP 122

Insert the gauge (4) from the front of the pan-

el.

Install the screws(1).

Install the lock washers (2) and nuts (3) from

behind the panel. Tighten the nuts (3).

Reconnect the pneumatic lines as tagged

during disassembly.

0801015

Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 25 1 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual
---------------- - - - - -------

Gauge BP Flow Indicator (Pneumatic Item Number 132)

------rc/- Insert the gauge (3) from the front.

Install the holder (2) and tighten the two nuts

(1).

Reconnect the pneumatic lines as tagged

during disassembly.
~- -/ I

0
Y.
- /

0801016

Panel B Lighting

Install the lamp (1) onto the lamp block (3)

3 and turn clockwise.
2
Snap the lamp block (3) onto the rail.

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Lighting Control, Sheet

07E, Instrument Lighting Test Lamp of Vol-
ume G1, Cabling Documentation for electri-
cal connections.

0801017

Chapter 8.01 - Page 26 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: i 2.2001 3EHW 411460
 Indian Railways WAG-9 Cab Control
Maintenance and Repair Manual

PaneiC

Terminal Fault Indication And Diagnostics (435)

Insert the terminal into the panel recess.

Install all of the screws. Then tighten screws in a cross pattern.

Reconnect the electrical cables as tagged during disassembly.

Refer to Section Pin Assignments, Third Party, Sheet 268, Fire Detection, Display Memotel
of Volume G2, Cabling Documentation for electrical connections.

Buzzer Overspeed 1 Fire Alarm I Vigilance Warning {238)

Insert the buzzer (4) into the panel recess

(5) from the front.

Install the screws(3).

Install the two screws (1) through the cover

(2).

Install the lock washers and nuts. Tighten

the nuts.

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Main Power Circuit, Sheet

0801011 11 8, Vigilance, Fire Detection of Volume G 1,
Cabling Documentation earthing coil electri-
cal connections.

-----"" - - - - - - - - - - - - - - - - - - ------------------------------- --- -----

Bombardier Transportation Ltd. Ident. No. Chapter 8.01 - Page 27 f 30
3EHW 411460 Revision Date: 12.2001
Cab Control Indian Railways W AG-9
Maintenance and Repair Manual
- - --~---~--------------------~--------

Illuminated Switch Emergency Flash Light "BPFL" (316.2)

----- -------------~
Insert the lamp (3) into the lamp's body (1).
Slightly push and turn clockwise.

Insert the lamp's head (2) through the front

panel recess·.

Insert the lamp's body (1) from behind the

2 panel. Rotate the head (2) clockwise until it

4 3
()_ is locked.

NOTE:
1~/ Do not over-tighten. Excessive
force when tightening may result
in damage to the panel.
0801018
Slightly tighten the two screws (4) in the
lamp's body (1) until they just touch the
panel. Tighten screws (4) evenly.

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Lighting Control, Sheet

070, Emergency Flashing Lights of Volume
G1, Cabling Documentation earthing coil
electrical connections.

Chapter 8.01 - Page 28 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 ·LC('
2- r

Indian Railways W AG-9 Cab Control

Maintenance and Repair Manual

Illuminated Switches

The procedure described here is applicable to the items shown in the following table. Details
of the electrical connections are given in the locomotive schematics, Volumes G, Cabling
Documentation. The table gives the schematic sheet number where the electrical connec-
tions are shown.

Description Switch Equipment Item Schematic

Number Reference
Switch Headlights BLPR 316 07C

Switch Headlights Intensity ZPRD 317 O?C

Insert the switch (2) from behind the panel.

Install and tighten the screws (1).

Reconnect the electrical cables as tagged

during disassembly.

0801014

Bombardier Transportation Ltd. !dent. No. Chapter 8.01 - Page 29 1 30

3EHW 411460 Revision Date: 12.2001
 Cab Control Indian Railways W AG-9
Maintenance and Repair Manual
-------------------·

PaneiD

Socket Hand lamp "PCLH" (334.1)

Insert the socket (2).

Install the screws (1) through the socket.

0
Install the washers (3), lock washers (4) and
nuts (5). Tighten the nuts (5) in a cross pat-
tern.

Reconnect the electrical cables as tagged

during disassembly.

Refer to Section Lighting Control, Sheet

07A, Driver's Cab Lighting of Volume G1,
2 Cabling Documentation for socket electrical
0801012 connections.

After-Installation Operations
@1290

Install the panels to the driver's console as described in Chapter 7.5, Cab.

0• r'\ '
\
\, # ' - - - - - - - - ----- - - - - - - ------- - ------

:' Chapter 8.01 - Page 30 I 30 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411460
 1n<11an Kmlways W AG-9 Machine Room Control
Maintenance and Repair Manual

8.2 Machine Room Control

Bombardier Transportation Ltd. Ident. No. Chapter 8.02 - Page 1 f 44

3EHW 411461 Revision Date: 12.2001
 Machine Room Control Indian Railways W A G-9
Maintenance and Repair Manual

Group Summary

Control Cubicle SB1

@.1120

This chapter contains information regarding the machine room control systems, which in-
cludes all the devices in the SB cubicles.

1 2 3 4 5 6 7 8

10
11
12

13
14
15
16
35
34
33
32

31
30 21
29
22
28-
27 23
43 24
25
44
26

dm 410 1a

Chapter 8.02 - Page 2/ 44 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411461
 Indian Railways W AG-9
Machine Room Control
Maintenance and Repair Manual

1 152 Rotary switch Failure mode operation

2 154 Rotary switch Bogie cut-out
3 160 Rotary switch Configuration
4 237.1 Rotary switch Vigilance device cut-off
5 179 Key switch Simulation
6 161 Illuminated push-button Configuration
7 381.71 Wire resistor Earthing screen Train bus
8 78.1 Resistor Maximum current relay
9 211.1/1 Thermostat Control electronics
10 78 Relay Maximum current
11 86 Relay Minimum voltage
12 90.7 Resistor Earth fault detection, Control circuit
13 381.7 Connecting box Train bus
14 126.5A Relay Control electronics "OFP'
15 136.4A Snubber circuit to item 136.4
16 126.7A Snubber circuit to item 126.7
17 136.3A Snubber circuit to item 136.3
18 136.3 Relay Time delay VCB
19 136.4 Contactor Auxiliary contactor VCB
20 126.7/1 Contactor Power supply cab
21 126.5 Relay Control Electronics OFF
22 218 Contactor Control electronics
23 126 Contactor Control circuits "ON"
24 118.5/1 DC/DC converter
25 118.4/1 DC/DC converter
26 411 Rack Central electronics (CEL 1)
27 123.1/1 Blocking diode Illumination test
28 123n Blocking diodes
29 123/5 Blocking diodes
30 123/3 Blocking diodes
31 123/1 Blocking diodes
32 89.7 Relay Earth fault Control circuit
33 127.9/2 Circuit breaker Central electronics
34 127.9/1 Circuit breaker Central electronics
35 127.22/1 Circuit breaker Electronics, auxiliary converter
36 127.2/1 Circuit breaker Monitoring
37 127.11/1 Circuit breaker Power supply Gate Units
38 127.1/1 Circuit breaker Electronics traction converter
39 310.1/1 Circuit breaker Lighting front
40 127.91/1 Circuit breaker Power supply 24V/48V
41 127.12 Circuit breaker PantographNCB Control
42 127.3/1 Circuit breaker Driver's cab
43 123/9 Blocking diode Head light
44 338/1 Contactor Head light

~----~------·------- -----
Bombardier Transportation Ltd. Ident. No. Chapter 8.02 - Page 3 1 44
3EHW 411461 Revision Date: 12.2001
Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Control Cubicle SB2

---'.A- ~- 24
40 ---+--l ~:z::§:~~~tt-r-- 25

39 ---..-;~ ~~~=~~~~

26
27
28
29
30
34 31
33-- 32
42

dm 410 2

Chapter 8.02 - Page 4/ 44 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411461
 ')._'6 /

Indian Railways W AG-9 Machine Room Control

Maintenance and Repair Manual

1 110 Circuit breaker Output battery charger

2 112.1 Circuit breaker Control circuit locomotive
3 127.81 Circuit breaker Commissioning 1
4 127.15 Circuit breaker Vigilance control
5 127.7 Circuit breaker Pneumatic panel
6 127.82 Circuit breaker Commissioning 2
7 48.1 Circuit breaker Auxiliary compressor
8 127.3/2 Circuit breaker Driver's cab
9 127.91/2 Circuit breaker Power supply 24V/48 V
10 310.7/1 Circuit breaker Marker lights
11 310.1/2 Circuit breaker Lighting front
12 310.4 Circuit breaker Lighting machine room
13 127.1/2 Circuit breaker Electronics traction converter
14 127.11/2 Circuit breaker Power supply Gate Units
15 127.2/2 Circuit breaker Monitoring
16 211.1/2 Thermostat Control electronics
17 127.22/2 Circuit breaker Electronics auxiliary converter
18 127.22/3 Circuit breaker Electronics auxiliary converter
19 127.9/3 Circuit breaker Central electronics
20 127.9/4 Circuit breaker Central electronics
21 127.92 Circuit breaker MEMOTEL speedometer
22 212 Fire detection equipment
23 130.1A Snubber circuit to item 130.1
24 211.A Snubber circuit to item 211
25 126.7N2 Snubber circuit to item 126.7
26 126.7/2 Contactor Power supply driver's cab
27 126.6 Safety relay Control electronics "ON"
28 211 Relay Temperature control,
electronics
29 130.1 Auxiliary contactor Pantograph
30 118.5/2 DC/DC converter
31 118.4/2 DC/DC converter
32 412 Rack Central electronics (CEL2)
33 300.3/2 Auxiliary contactor Wheel flange lubrication
34 300.3/1 Auxiliary contactor Wheel flange lubrication
35 48.2 Contactor Auxiliary compressor
36 123/6 Blocking diodes
37 12314 Blocking diodes
38 123/2 Blocking diodes
39 123/8 Blocking diodes
40· 123.1/2 Blocking diodes Illumination test
41 127.24 Circuit breaker Electronics auxiliary converter
42 338/2 Auxiliary Contactor Head Light

Bombardier Transportation Ltd. ldent. No. Chapter 8.02 - Page 5 1 44

3EHW 411461 Revision Date: 12.2001
 Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Functional Description
@.1140

The SB cubicles are located within the machine room. SB1 is situated near the No. 1 End wall
and SB2 is located near the No. 2 End wall. The two machine room control cubicles, SB 1 and
SB2, are fitted with different components.

Refer to Volume F17, Supplier's Documentation for information on the components within the
SB cubicles.

Cubicle SB1

Rotary Switches (152, 154, 160, 237.1)

Rotary switch 152 is for failure mode operation.

Rotary switch 154 is for bogie cut-out.

Rotary switch 160 is for control electronics configuration.

Rotary switch 237.1 is a cut-off switch for the vigilance device.

Key Switch (179)

Key switch 179 is used to activate simulation of circuits during commissioning.

Illuminated Push Button (161)

Illuminated push button 161 is a control electronics configuration button.

Wire Resistor (381.71)

Resistor 381.71 is for the earthing screen of the train bus.

Resistor (78.1)

Resistor 78; 1 is used to increase the current setting of maximum current relay 78 during VCB
closing. Resistor 78.1 is connected in parallel to relay 78 through the action of timing relay
136.3.

Chapter 8.02 - Page 6/ 44 !dent. No. Bombardier Transportation ltd.

Revision Date: 12.2001 3EHW 411461
Indian Railways W AG-9 Machine Room Control
Maintenance and Repair Manual

Thermostat (211.1/1)

Thermostat 211.1/1 monitors the control electronics temperature and opens at 70 oc and de-
energises relay 211.

Circuit Breakers

Circuit breakers are safety devices that protect electrical circuits from the effects of excessive
currents. A circuit breaker will be tripped whenever the circuit in which it is connected is made
to carry a current larger than that for which the circuit breaker will allow.

A clear protective panel covers the circuit breakers in the SB cubicles. An aperture in the panel
allows access to the switch on the circuit breaker mechanism.

Circuit Breaker Driver's Cab (127.3/1)

Circuit breaker 127.3/1 is the circuit breaker to the electrical equipment in the No. 1 end cab.

Minimum Voltage Relay (86)

Minimum voltage relay 86 is closed when catenary voltage is greater than 17.5 kV and opens
if catenary voltage falls below 17.5 kV.

Maximum Current Relay (78)

Maximum current relay 78 picks up when the output from the primary current transformer 6. 1
increases beyond a preset value.

Earth-fault Relay (89.7)

Earth fault relay 89.7 is provided to detect earth faults in the control circuit to the battery
charger.

Resistor {90.7)

Resistor 90.7 is connected across the 110 V DC output of the auxiliary converter and feeds
the earth fault relay 89. 7.

Bombardier Transportation ltd. Ident. No. Chapter 8.02 - Page 7 1 44

3EHW 411461 Revision Date: 12.2001
 Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Connecting Box {381.7)

Connecting box 381.7 is a connection junction for the train bus.

Stocking Diodes (123 /1, 123/3, 123/5, 123/7, 123.1)

Blocking diodes are used to prevent return current flows in other circuits powered from a com-
mon source, when a circuit is activated.

Snubber Circuits {126.5A, 136.4A, 126.7A, 136.3A)

Snubber circuits are used to reduce the overvoltage peaks that occur during the energising
or de-energising of certain electrical equipment, such as relays.

Relays And Contactors (126.5, 136.4A, 126.7/1, 136.3)

Relay 126.5 is a normally de-energised relay. In the open state, contactor 126 remains pow-
ered by the control electronics until the coil of relay 126.5 is energised, which opens contactor
126.

Auxiliary relay 136.4A is used to close timing relay 136.3 when the locomotive is in cooling
mode.
Contactor 126.7/1 provides power to the No. 1 end cab.

Timing relay 136.3 is used to provide the closing coil of the main circuit breaker with power
for a period of one second. Timing relay 136.3 is closed by auxiliary relay 136.4 when the loco-
motive is in cooling mode and by the control electronics when the locomotive is in driving
mode.

Contactors (126, 218)

Contactor 126 supplies power to the pantograph, vacuum circuit breaker and other control
circuits.

Contactor 218 connects supply to central and auxiliary converter electronics, which switches
the auxiliary converters (three-phase supply) outputs.

Chapter 8.02 - Page 8 I 44 Ident. No. Bombardier Transportation Ltd.

Revision Date: i 2.2001 3EHW 411461
 Indian Railways W AG-9 Machine Room Control
Maintenance and Repair Manual

DC- DC Converters (118.4/1, 118.5/1)

DC to DC converters 118.4 and 118.5 convert 110 V DC from the battery to 48 V DC and 24 V
respectively. The 48 V DC supply is used to run cooling fans in the cubicles and the 24 V DC
supply is used for driver's desk illumination and indication lamps.

Cubicle SB2

Thermostat Control Electronics (211.1 /2)

Thermostat 211.1/2 monitors the control electronics temperature and opens at 70 oc and de-
energises relay 211.

Circuit Breakers

Circuit breakers are safety devices that protect electrical circuits from the effects of excessive
currents. A circuit breaker will be tripped whenever the circuit in which it is connected is made
to carry a current larger than that for which the circuit breaker will allow.

A clear protective panel covers the circuit breakers in the SB cubicles. An aperture in the panel
allows access to the switch on the circuit breaker mechanism.

Circuit Breaker Output Battery Charger (110)

Circuit breaker 110 is fitted to the output of the battery charger to prevent excessive charging
of the batteries.

Circuit Breaker Control Circuit Locomotive (112.1)

Circuit breaker 112.1 is the circuit breaker to the locomotive control circuits.

Fire Detection Equipment (212)

Fire detection equipment 212 monitors the air in the machine room. Appropriate messages
are displayed in the active cab if a fire or smoke is detected. Refer to Chapter 3, System De-
scription of Volume A, Driver's Manual.

Bombardier Transportation Ltd. Ident. No. Chapter 8.02 - Page 9 1 44

3EHW 411461 Revision Date: 12.2001
 Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Blocking Diodes

Blocking diodes are used to prevent return current flows in other circuits powered from a com-
mon source, when a circuit is activated.

Snubber Circuits

Snubber circuits are used to reduce the overvoltage peaks that occur during the energising
or de-energising of certain electrical equipment, such as relays.

Auxiliary Contactor Pantograph (130.1)

Contactor 130.1 is opened by the control electronics to lower the pantograph if the air pres-
sure in the pantograph falls below a specified value. Contactor 130.1 is closed by the control
electronics for raising the pantograph.

Relays And Contactors (211, 126.6, 126.7/2)

Relay 211 is opened whenever thermostat 211.1/1 or 211.1/2 reaches 70 oc. This signals
high control electronics temperature to the control electronics and also illuminates lamp 166
on the driver's desk to inform the driver of high control electronics temperature.

Control electronics safety relay 126.6 closes only when the cab switch 125 is in the d~iving
(D) position.

Contactor 126.7/2 provides power to the No.2 end cab.

Contactor (48.2)

Contactor 48.2 provides power to the auxiliary compressor.

Auxiliary Contactors Wheel Flange Lubrication {300.3)

Contactors 300.3 are auxiliary contactors for the wheel flange lubrication system.

DC-DC Converters (118.4/2, 118.5/2)

DC to DC converter 1i 8.4 and 1'18.5 convert 11 0 V DC from the battery to 48 V DC and

24 V DC respectively. The 48 V DC supply is used to run cooling fans in the cubicles and the
24 V DC supply is used for drivers desk illumination and indication lamps.

Chapter 8.02 - Page 10/ 44 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Machine Room Control
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Technical Data
@.1160

Key Switch, Simulation

Nominal current IN 2Amp

Nominal voltage UN 250VoltAC

Earth-Fault Relay

Internal resistance at nominal current Rl 43 Q

Nominal current IN 150mA

Blocking Diodes DIBL0-5

Nominal current IN 1.5 Amp

Nominal voltage UN 1.6kV

Blocking Diodes DIBL0-8

Nominal current IN 0.3 Amp

Nominal voltage UN 1.6kV

Tolerances and Wear Limits List

@.1170

Refer to Chapter 2, Machine Room Control of Volume F16, Suppliers Documentation for more
information on tolerances and wear limits applicable to the components in the SB cubicles.

Bombardier Transportation Ltd. Chapter 8.02 - Page 11 1 44

!dent. No. Revision Date: 12.2001
3EHW 411461
 Machine Room Control Indian Railways W A G-9
Maintenance and Repair Manual
--·--------------------

Tools and Special Tools

@.1180

In addition to conventional railway workshop tools, the following are required for the pro-
cedures described in this chapter.

• Detector extraction tool DZ11 01. Refer to Chapter 2, Machine Room Control, Section
Cerberus OptoRex Wide Spectrum Smoke Detectors of Volume F16, Suppliers Docu-
mentation.

Miscellaneous Materials
@.1200

Molycote White is required for a procedure described in this chapter

Cable ties

Before-Removal Operations
@.1220

Lower the pantograph and isolate the locomotive from the overhead catenary. Earth the loco-
motive at the vacuum circuit breaker. Refer to the Preface of this Volume.

Isolate the batteries at the battery box isolation switch, as described in Chapter 5.3, Battery 1
Charger.
Remove the pantograph roof hatches from the locomotive body as described in Chapter 1 .1 ,
Structure.

Chapter 8.02 - Page 12/ 44 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Machine Room Control
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Removal
@ 1230

The procedure in this Chapter describes removal of the SB cubicle from the machine room
with the MICAS vehicle control unit cubicle (411 or 412) attached. Removal of the MICAS ve-
hicle control unit cubicle from the SB cubicle is described in Chapter 8.3, Control Electronics.
Hold the MICAS vehicle control unit cubicle
cover (2) to prevent it falling, then remove
the screws (1) securing the cover (2) to the
control unit rack (3).

Press the upper edge of cover (2) slightly

backwards. Pull the lower edge slightly for-
ward. Slide the cover {2) upward and re-
move it from the vehicle control unit rack (3).

Remove the cover plates from the cable

I
3
flanges, then tag and disconnect the wires
and fibre optic connections from the mod-
0403101n ules in the MlCAS vehicle control rack (3).

Cut the ties securing the cables to the loom-

ing bars and cable ducts. Manipulate the
cables clear of the cubicles.

1 Disconnect the harness from the sockets ( 1)

at the top of the SB cubicles. Turn the rings
[c::J. . 0· 1 counterclockwise to release the bayonet
.-
m~~~~o :- connector.

~~~~~j
~~~ ~ r----.
Cut the ties securing the cables to the SB cu-
bicle and cable duct.
\,.I

if!t~mmi·IIII@J?JEfflfmllllllllli
0802003 00000 . 00000000
~~
0

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 C\..P---
1"); Machine Room Control Indian Railways W AG-9
Maintenance and Repair Manual

For cubicle SB2; open the SB cubicle doors,

then disconnect the harness (1) from the
sockets below the fire detection unit. Turn
the rings counterclockwise to release the
bayonet connector.

Cut the ties securing the cables and manipu-

late the harness from the cubicle. Secure
the cables clear of the cubicle.

Disconnect the hose from the socket (2) of

the fire detection equipment (1) at the back
of cubicle SB2.

Remove the bolt (2) and washers securing

the earthing cable (1).

Chapter 8.02 - Page 14/ 44 Ident. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Machine Room Contro
Maintenance and Repair Manual

Remove the bolt (1 0)~ plain and sprin~

washers (8~ 9) and nut (7) securing the angl~
2
bracket (5) to the SB cubicle on the righ
hand side.

Remove the bolt (3) plain and spring

I

washers (1 2) securing the angle bracke1

I

(4) to the machine room waif. The angle

brackets (41 5) remain together.

8 7
0802105n

Remove the bolt (1 0), plain and spring

washers {8, 9} securing the angle bracket
8 9 10
(5) to the SB cubicle on the left hand side.

Remove the bolt (3), plain and spring

washers (1, 2) securing the angle bracket
0
4 7
(4) to the bracket on the machine room wall
with nut- (6) and washer (7). The angle
A---------------------r--t---:J-,---/--j brackets (4, 5) remain bolted together with
5 11 :

l 0 2
connection plate {11).

6
0802104n

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 {A_~
·'11 Machine Room Control Indian Railways W AG-9
Maintenance and Repair Manual

.---------
Remove the bolts (1) spring and plain
washers (2, 3} securing the front corners of
the MICAS vehicle control unit cubicle to the
machine room floor member (4).
1,
-~

:~
r
4~L_ !-------------------------
=
0502006

Attach suitable lifting equipment to the eye-

bolts (1) on the SB cubicle (2). Raise the lift-
ing equipment slightly to take the weight of
the cubicle (2).

Ensure that all the harnesses are discon-

nected and clear of the cubicle, then lift the
SB cubicle slightly. Ensure that nothing is
entangled between the locomotive and the
SB cubicle, then lift from the locomotive ma-
chine room.

Chapter 8.02 - Page 16/ 44 Ident. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Machine Room Control
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Disassembly
@.1240

The two machine room control cubicles SB1 and SB2 are fitted with different components.
Refer to Section Group Summary.

Cubicle Doors

The removal of the doors of both control cubicles SB1 and SB2 is the same.
Open the locks (1) using a square key, then
open the doors (2).

Support the door (2) to prevent it falling.

Remove pin (1) between the two halves of

the upper hinge using a hammer and suit-
able drift.

Remove pin (3) between the two halves of

the lower hinge using a hammer and suit-
able drift.

Remove the door (2) from the cubicle.

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Protective Covers

Support the protective cover (2) to prevent

it falling once the fasteners are removed.

Remove the screws (1) securing the protec-

tive cover (2) to the cubicle frame.

Remove the protective cover (2) from the

cubicle.

The battery charger output and control cir-

cuits locomotive circuit breakers also have
protective covers.

Remove the protective covers on the battery

charger output and control circuits locomo-
tive circuit breakers (electrical equipment
Nos. 110 & 112.1) in cubicle 882.

Support the protective cover (1) to prevent

it falling once the fasteners are removed.

Remove the screws securing the protective

cover (1) to the cubicle frame.

Remove the protective cover (1) from the

cubicle.

Remove the protective covers on the wheel

flange lubrication auxiliary contactors and
auxiliary compressor contactor (electrical
equipment Nos. 300.3/1, 300.3/2 & 48.2) in
cubicle 882.

Support the protective cover (2) to prevent

it falling once the fasteners are removed.

Remove the screws securing the protective

cover (2) to the cubicle frame.

Remove the protective cover (2) from the

cubide.

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Indian Railways WAG-9 Machine Room Control
Maintenance and Repair Manual
---~----

Blocking Diodes (123/1, 123/3,123/5, 123/7, 123.1; 123(2, 123/4,123/6, 123/8, 123.1/2)

Removal of the blocking diodes from the panel is the same for all diodes. The diode shown
is for illustrative purposes only.
Pull the diode carefully so that the connec-
tions do not bend. Pull out diode (1) horizon-
tally towards the front of the cabinet.

Circuit Breakers (127.1/1, 127.2/1,127.3/1, 127.9/1, 127.9/2, 127.11/1, 127.12,

127.22/1,127.91/1, 310.1/1; 48.1, 127.1/2, 127.2/2, 127.3/2, 127.7, 127.9/3, 127.9/4,
127.11/2, 127.15,127.22/2,127.22/3,127.81,127.82,127.91/2, 127.92, 310.7, 310.1/2,
310.4)

The removal procedure is the same for all these circuit breakers. The circuit breaker shown
is for illustrative purposes only.
Loosen.the screws at the terminals, then tag
and disconnect the cables from the circuit
breaker terminals. It is not necessary to dis-
connect the cable from the rail.

Using a screwdriver, press the spring clip (at

the bottom) downwards, and simulta-
neously tilt the circuit breaker to remove it
from the rail.

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 Machine Room Control Indian Railways WAG-9
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Circuit Breakers {110, 112.1)

Remove the protective cover as described

in Protective Covers in this Section.

Tag and disconnect the cables from the ter-

minals. Remove the screws (2) and discon-
nect the cables from the terminals.

Support the circuit breaker (4); note that it is

heavy. loosen the screws (3).

Remove the circuit breaker (4).

Connecting Box (381.7)

Tag and disconnect the plugs (2) from the

connection box (3).

Remove the screws (1), washers and lock

washers.

Remove connection box (3).

Chapter 8.02 - Page 20/ 44 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Machine Room C()ntr<>l
Maintenance and Repair Manual

Contactors (126.5, 136.4A, 126.7, 136.3; 130.1, 211, 126.6, 126.7/2)

Tag and disconnect the cables from the con-

tactor terminals. Loosen the screws secur-
ing the cables (1) to the contactors (2), but
do not remove the screws.

Remove the screws (1), washers, Jock

washers securing the cqntactor (2).

Remove the contact or (2).

The contactor shown is for illustrative pur-

poses only.

Contactors (48.2, 300.3; 126, 218)

Tag and disconnect the cables from the ter-

minals (4). Remove the nuts (2}, washers
and spring washers securing the cables to
the terminals (4). Disconnect the cables.

Remove the screws (1), washers securing

the contactor (3).

Remove the contactor (3).

Contactor shown is for illustrative purposes

only.

Bombardier Transportation Ltd.

!dent. No. Chapter 8.02 - Page 21 1 44
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 Machine Room Control Indian Railways W AG-9
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DC- DC Converters {118.4/2, 118.5/2; 118.4/1, 118.5/1)

The DC- DC converters with item numbers 118.4 and 118.5 are fitted on the back of the control
cubicle.
Tag and disconnect the cables (2) from the
terminals.

Remove the screws (3) and washers secur-

ing the converter.

Remove the converters (4, 5} from the panel

assembly.

Earth-Fault Relay (89.7)

Remove the protective cover as described

in Protective Covers in this Section.

Tag and disconnect the cables from the four

connections (3). Remove the screws (1),
washers and lock washers securing the·
cables.

Remove the relay (2).

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 Indian Railways WAG-9 Machine Room Control
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Fire Detection Equipment (212)

Tag and disconnect the plug (5) from the

socket. Remove the screw ( 1) and take off
cable (2).

From the front of the panel, remove the

screws (3), washers and lock washers.

Carefully pull the box (4) towards the rear of

the panel.

If necessary, smoke detectors can be re-

moved using detector extractor tool
DZ1101. Tag and disconnect the cables
from the detector, then remove the detector
from the machine room.

Illuminated Push Button (161)

Tag and disconnect the cables from the switch.

Loosen, but do not remove, the two screws on the back of the flange of the push- button body.
Rotate the push-button head counterclockwise and remove the head.

Remove the push-button body from the back of the plate.

Key Switch (179)

Ensure the key has been removed from the key switch.

At the rear of the switch, tag and disconnect the cables from the switch.
Remove the fasteners securing the key switch to the panel.

Remove the switch from the panel.

Relay Minimum Voltage (86)

Loosen the screws securing the cables to the relay, then tag and disconnect the cables. To
prevent the screws from falling out, screw them back in again slightly. It is not necessary to
disconnect the cable from the rail.

Remove the clip on the lower side of the relay. Tilt the relay forward, lift slightly and remove
from the rail.

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Relay (78)

Remove the screws securing the relay to the panel, then pull the relay from the panel.

Resistor (78.1)

Remove the protective cover as described

in Protective Covers in this Section.

Tag and disconnect the cables from the re-

sistor terminals.

Remove the bolts securing the resistor

brackets to the panel, then remove the resis-
tor.

Resistor (90.7)

Tag and disconnect the cables from the resistor terminals.

Remove the bolts securing the resistor to the panel, then remove the resistor.

Resistor (381.71)

Remove the protective cover as described

in Protective Covers in this Section.

Remove the nuts (1) and spring washers

from the resistor terminals. Then tag and
disconnect the cables from the terminals.

Remove the screws (3) and lock washers

securing the resistor assembly to the panel.

Remove resistor (2) from the panel.

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Indian Railways W A G-9 Machine Room Control
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Rotary Switches (152, 154, 160, 237.1)

Loosen, but do not remove, the screw in the

centre of the knob. Remove the knob from
the rotary switch.

Remove the nut from the centre of the

switch, then remove the covering plate from
the switch.

Remove the bolts securing the switch to the

panel.

Tag and disconnect the cables from the

switch, then remove the switch from the
panel.

Snubber Circuits (126.5A, 136.4A, 126.7A, 136.3A; 130.1A, 211.A & 126.7A/2)

The snubber circuits are fitted immediately

above the corresponding relay or contactor.
The snubber circuit shown is for illustrative
purposes only.

Tag and disconnect the cables from the ter-

minals (3).

Remove the screws (1), washers and Jock

washers.

Remove the snubber circuit (2).

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 Machine Room Control
Indian Railways WAG-9
Maintenance and Repair Manual

Thermostat (211.1/1, 211.1/2)

Thermostat (2) is fitted on the right of the

control cubicle.

Cut the cable ties securing the capillary tube

to the cubicle frame.

Disconnect the temperature probe.

Remove the screws (1) securing the ther-

mostat (2) to the cubicle frame.

Remove the thermostat (2) from the cubicle.

Inspection and Repair

@.1250

Inspect the condition and operation of electrical components as required. Replace any faulty
or damaged components. Electrical items are to be replaced as assemblies.

Inspect the condition of the SB cubicles. Inspect the surface finish for wear, cracks or chips.
Re-coat the cubicles if necessary, as described in Chapter 1.2, Exterior Finish.

Inspect the glass panels in the SB cubicle doors. Replace the glass if cracked, damaged or
broken.

Replace the protective covers inside the SB cubicles if cracked, damaged or broken.

Relay (78)

Inspection and repair of maximum current relay (78) is described in Chapter 2, Machine Room
Control, Section Maintenance of 01 Relay of Volume F16, Suppliers Documentation.

Waste Disposal
@.12GO

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

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 Indian Railways WAG-9
Machine Room Control
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Assembly
@.1270

CAUTION:
The cables are labelled to facilitate assembly. Always check the connections
before assembly. If in doubt, refer to Volume G, Cabling Documentation.
Wrongly connected cables can irreparably damage components or cause
incomprehensible error messages on the diagnosis monitor.

The two machine room control cubicles SB1 and SB2 are fitted with different components.
Refer to Section Group Summary.

Cubicle Doors

Assembly of the doors onto the control cubicles is the same for both SB cubicles.
Lift the door (2) and insert the pin (1) into the
upper hinge.

Align door (2) and insert the pin (3) into the
lower hinge.

Close the doors (2) and check the align-

ment.

If necessary, adjust the position of the

hinges until the door alignment is correct

Lock the locks (1) with a square key.

Bombardier Transportation Ltd. Chapter 8.02 - Page 271 44

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 Machine Room Control Indian Railways WAG-9
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Protective Covers

The protective covers are fitted in the same way in both control cubicles SB1 and control cu-
bicle SB2.
Align the protective cover (2).

Install, but do not tighten, the screws (1) in

the corners of the cover.

Once all six screws have been installed,

align the cover, then tighten the screws ( 1).
Do not over tighten the screws (1).

Assemble the remaining protective covers

in the same manner.

~-~------------~------ ----------------------------
Chapter 8.02 - Page 28/ 44 !dent. No. Bombardier Transportation ltd.
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 Indian Railways W AG-9
Machine Room Control
Maintenance and Repair Manual

Blocking Diodes (123/1, 123/3,123/5,123/7, 123.1;/1123/2, 123/4,123/6,123/8,

123.1/2)

NOTE:
Fit the diode carefully. The long
connections are easily bent.

Installation of the blocking diodes is the

same for all diodes. The diode shown is for
illustrative purposes only.

Mount the diode on the connection plate ( 1).

Refer to Section Pin Assignment Electrical

Components, Sheet 26C, Diode Blocks of
Volume G2, Cabling Documentation for
electrical connections.

Circuit Breakers (127.1/1, 127.2/1, 127.3/1, 127.9/1, 127.9/2, 127.11/1, 127.12,

127.22/1,127.91/1, 310.1/1; 48.1, 127.1/2, 127.2/2, 127.3/2, 127.7, 127.9/3, 127.9/4,
127.11/2, 127.15, 127.22/2, 127.22/3, 127.81, 127.82, 127.91/2, 127.92, 310.7, 310.1/2,
310.4)

The installation procedure is the same for all these circuit breakers. The circuit breaker shown
is for illustrative purposes only.
Attach the circuit breaker to the upper edge
of the rail. The spring on the back of the con-
tactor snaps into place with slight pressure.

Connect the cables to the terminals as

tagged during disassembly. Install and
tighten the screws on the terminals.

Refer to Section Control Circuits, Sheets

04B, 04C, 04D and 04E of Volume G1, Cab-
ling Documentation for electrical connec-
tions.

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~~-----------

Circuit Breakers {110, 112.1)

Position and support the circuit breaker;

note that it is heavy.

Attach the circuit breaker to the upper edge

of the rail. The spring on the back of the con-
tactor snaps into place with slight pressure.

Connect the cables to the terminals as

tagged during disassembly. Instal( and
tighten the screws on the terminals.

Install the protective cover as described in

Protective Covers in this Section.

Refer to Section Pin Assignment Electrical

Components, Sheet 25A, Circuit Breakers
of Volume G2, Cabling Documentation for
electrical connections.

Connecting Box (381.7)

Mount the connection box (3) and align the

holes.

Secure connection box (3) with screws (1 ),

washers and lock washers.

Connect the cables to the terminals (2) as

tagged during disassembly.

Refer to Section Train bus, UIC-line, Sheet

13A, Train bus of Volume G2, Cabling Docu-
mentation for electrical connections.

Chapter 8.02 - Page 30/ 44 Ident. No. Bombardier Transportation Ltd.

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 ) l '

Indian Railways WAG-9 Machine Room Control

Maintenance and Repair Manual

Contactors (126.5, 136.4A, 126.7, 136.3; 130.1, 211, 126.6, 126.7/2)

Mount the contactor (2) and align the hoi es.

Secure the contactor (2) with two diagonally

positioned screws (1), washers and lock
washers.

Connect the cables (1) to the contactor (2)

terminals as tagged during disassembly.
Loosen, but do not remove, the screws. In-
stall the cables (1) to the terminals, then
tighten the screws.

The contactor shown is for illustrative pur-

poses only.

Refer to Section Pin Assignment Electrical

Components, Sheet 25C, Low Voltage Con-
tactors and Relays of VolumE:l G2, Cabling
Documentation for electrical connections.

Bombardier Transportation Ltd.

Ident. No. Chapter 8.02 - Page 31 1 44
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 Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Contactors (48.2, 300.3; 126, 218)

Mount the contactor (3) and align the holes

in the panel.

Secure contactor (3) with two screws (1} and

washers.

Connect the cables to the contactor ter-

minals (4) as tagged during disassembly.

The assembly procedure is the same for all

contactors (3). Contact or shown is for illus-
trative purposes only.

Refer to Section Pin Assignment Electrical

Components, Sheets 258 and 25C, Low
Voltage Contactors and Relays of Volume
G2, Cabling Documentation for electrical
connections.

DC-DC Converters (118.4/2, 118.5/2; 118.4/1, 118.5/1)

Position the DC-DC converters on the back

of the control cubicle.

Mount the converter (4) onto assembly plate

(1 ).

Align the converter (4) with the holes.

Secure the converter (4) with two screws (3)

onto assembly plate (1).

Connect the cables (2) to the terminals as

tagged during disassembly.

Refer to Section Control Circuits, Sheet 04F,

DC-DC Converters 24V/48Vof Volume G1,
Cabling Documentation for electrical con-
nections.

Chapter 8.02 - Page 32/ 44 Ident. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411461
 ') \ ?

Indian Railways W AG-9 Machine Room Control

Maintenance and Repair Manual

Earth-Fault Relay (89.7)

Position the relay (2) on the panel, and align

with the holes in the plate.

Secure the relay (2) with the screws (1 ),

plain and lock washers.

Connect the cables to the terminals (3) as

tagged during disassembly.

Install the protective cover as described in

Protective Covers in this Section.

Refer to Section Pin Assignment Electrical

Components, Sheet 26A, Earth Fault-, Min/
Max-Relays; Fuses of Volume G2, Cabling
Documentation for electrical connections.

Fire Detection Equipment (212)

NOTE:
Handle the fire detection module
(4) with care. The module (4) elec-
tronics can be damaged by jolts.

Install the module (4} from the rear of the cu-

bicle.
Align module (4) with the holes in the mount-
ing plate.

Secure the module (4) with the screws (3),

plain and lock washers.

Secure the earth cable (2) with the screw

(1).

Plug in plug (5).

Reconnect the cables to the detector as

tagged during disassembly.

Refer to Section Vigilance, Fire Detection,

Sheet 11 8, Fire Detection of Volume G 1,
Cabling Documentation for electrical con-
nections.

Bombardier Transportation Ltd. Chapter 8.02 - Page 33/ 44

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\.~
)
Machine Room Control Indian Railways W AG-9
Maintenance and Repair Manual

Illuminated Push Button (161)

Install the push-button from the back of the plate.

Fit the push-button head by turning in clockwise.

Tighten the two screws on the back of the push-button.

Connect the cables to the switch as tagged during disassembly.

Refer to Section Special Modes, Sheet 178, Configuration, Bogie Cut-Out of Volume G2,
Cabling Documentation for electrical connections.

Key Switch {179)

Install the switch from the rear of the panel.

Install the bolts to secure the switch to the panel.

Install the shimming plates removed during disassembly. Ensure the switch cover will sit flush
over the switch and panel, then install the covering plate to the switch. Add or remove shim-
ming plates as necessary to ensure the covering plate sits flush.

Reconnect the cables to the switch as tagged during disassembly.

Refer to Section Special Modes, Sheet 17A, Fault Acknowledge, Simulation, Failure Mode
of Volume G2, Cabling Documentation for electrical connections.

Relay Minimum Voltage (86)

Attach the relay to the upper edge of the rail. The spring on the back of the relay snaps into
place with slight pressure.

Connect the cables to the relay as tagged during disassembly.

Refer to Section Pin Assignment Electrical Components, Sheet 26A, Earth Fault-, Min/Max-
Relays; Fuses of Volume G2, Cabling Documentation for electrical connections.

Relay (78)

Relay 78 is of the plug-in type. To install the relay, plug the relay into the socket on the panel,
then insert and tighten the retaining screws to secure the relay into the panel.

Refer to Section Pin Assignment Electrical Components, Sheet 26A, Earth Fault-, Min/Max-
Relays; Fuses of Volume G2, Cabling Documentation for electrical connections.

Chapter 8.02 - Page 34/ 44 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways W AG·9 Machine Room Control
Maintenance and Repair Manual

Resistor {78.1)
Mount the resistor on the panel.
-~ ,7 KtW ~ •
l
•:- .'*>'.......
.~. ·~ ,o
I
J:•>
.• • .• Install and tighten the bolts to secure the re-
sistor to the panel.

Connect the cables to the resistor terminals

as tagged during disassembly.

Install the protective cover as described in

Protective Covers in this Section.

Refer to Section Actual Value Detection,

Sheet 12A, Catenary, Battery Voltage of Vol-
ume G1, Cabling Documentation for electri-
cal connections.
Resistor (90.7)

Position the resistor and align with the holes in the panel.

Install and tighten the bolts to secure the resistor to the panel.

Connect the wires to the connectors on the resistor.

Connect the cables to the resistor terminals as tagged during disassembly.

Refer to Section Control Circuits, Sheet 04C, Control Circuits 1 of Volume G 1, Cabling Docu-
mentation for electrical connections.

Resistor (381.71)
Mount the resistor {2) on the panel and align
with the holes.

Secure resistor (2) with two screws (3) and

lock washers.

Connect the cables to the resistor terminals

as tagged during disassembly. Install the
spring washers and nuts (1), then tighten the
nuts (1).

Install the protective cover as described in

Protective Covers in this Section.

Refer to Section Trainbus, UIC Line, Sheet

i 3A, Train bus of Volume G2, Cabling Docu-
mentation for electrical connections.

Bombardier Transportation Ltd.

ldent. No. Chapter 8.02 - Page 35 I 44
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 Machine Room Control Indian Railways W AG-9
Maintenance and Repair Manual

Rotary Switches (152, 154, 160, 237.1)

Connect the cables to the switch as tagged

during disassembly.

Install the switch into the panel.

Install the bolts to secure the switch to the

panel.

Install the covering plate on the switch. In-

stall the nut to the switch to secure the cover-
ing plate.

Install the knob on to the rotary switch, then

tighten the screw in the centre to secure the
knob. Tighten the screw sufficiently to se-
cure the knob. Do not over tighten the screw.
Refer to Section Special Modes, Sheets 17A and 178 of Volume G2, Cabling Documentation
for electrical connections.

Refer to Section Pin Assignments, Electrical Components, Sheet 268, Switches of Volume
G2, Cabling Documentation for electrical connections.

Snubber Circuits {126.5A, 136.4A, 126.7A/1, 136.3A; 130.1A, 211.A & 126.7A/2)

Mount the snubber circuit (2) on the panel.

Secure the snubber circuit (2} to the panel

with the screws (1), plain and lock washers.

Connect the cables to the terminals as

tagged during disassembly.

The snubber circuits are fitted immediately

above the corresponding relay or contactor.
The snubber circuit shown is for illustrative
purposes only.

Refer to Section Control Main Apparatus,

Sheets 05A and 058 of Volume G1, Cabling
Documentation for electrical connections.

Refer to Section Traction Control, Sheets

08A and 08B of Volume G1, Cabling Docu-
mentation for electrical connections.

Chapter 8.02 - Page 36/ 44 Ident. No. Bombardier Transportation ltd.

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 ')\ I

Indian Railways WAG-9 Machine Room Control

Maintenance and Repair Manual

Thermostat (211.1/1, 211.1 /2)

Position the thermostat (2) on the right of the

control cubicle.

Align the thermostat (2) with the mounting

holes.

Install the screws (1) securing the thermo-

stat (2) to the cubicle frame. Tighten the
screws {1).

Reconnect the temperature probe.

Secure the capillary tube to the cubicle

frame using cable ties.

Refer to Section Traction Control, Sheet

088, Temperature Control Electronics of
Volume G 1 , Cabling Documentation for
electrical connections.

Bombardier Transportation Ltd. Ident. No. Chapter 8.02 - Page 37 ( 44

3EHW 411461 Revision Date: 12.2001
Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual

Installation
@.1280

The procedure in this Chapter describes installation of the SB cubicle with the MICAS vehicle
control unit cubicle (411 or 412) attached. Assembly of the MICAS vehicle control unit cubicle
to the SB cubicle is described in Chapter 8.3, Control Electronics.
Seal the edges of the air supply (2) with seal-
ing tape (1}.

Attach suitable lifting equipment to the eye-

bolts (1) on the SB cubicle (2).

Slowly lower the SB cubicle (2) over the as-

sembly studs (1). Ensure the control cubicle
locating holes are correctly aligned with the
locating studs (1) before fully lowering the
cubicle (2).

Chapter 8.02 - Page 38/ 44 ldent. No. Bombardier Transportation Ltd.

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Indian Railways WAG-9 Machine Room Contra
Maintenance and Repair Manual

~-~---~

Place the plain (3) and spring washers (2) 01

the bolts (1).

Apply a coat of Molycote White to thE

threads of the bolts (1 ).
t'-

2~~ Install the bolts (1) to secure the SB cubicle

3~~ and MICAS vehicle control unit cubicle to the

4~
l -------~
machine room floor member (4).

0502006 '= Tighten the bolts (1 ).

The angle brackets ( 1) are adjustable to suit

the space between the SB cubicle and the
machine room wall. Loosen the nut (2) on
the bolt securing the two angle brackets ( 1).
Do not remove the nut (2).

0802005

Position the angle bracket assembly (4, 5)

between the SB cubicle and machine room
wall on the right hand side.

Install the bolt (3), spring and plain washers

(2, 1) to secure the angle bracket to the ma-
chine room wall. Do not tighten the bolt (3).

Install the bolt (10), spring and plain

washers (9, 8) between the angle bracket to
the cubicle. Install the washer (6) and nut
(7).

8 7 Tighten the bolts (3, 10).

0802105n

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Machine Room Control Indian Railways W AG-9
Maintenance and Repair Manual

Tighten the nuts (2) to secure the two halves

of the angle bracket (1).

0802005

Position the angle brackets (4,5) between

the SB cubicle and the machine room wall
8 9 10
on the left hand side.

Install the bolt (3), washer (2) and spring

washer (1) through the bracket (4) and into
0
4 7
the bracket in the machine room wall. Posi-
tion the angle brackets (4,5) correctly, then
A-------- - - -------t--t-~-1--------l install washer (7) and nut (6) and tighten.
5 11 :
i 0 It may be necessary to loosen the bolts se-
!"'---=----::_:.:;----=----.:..:T·-::::.___-;:._;_r-\1
2 curing the connection plate {11) to the angle
brackets {4,5) to position the bracket (5) cor-
6
0802104n rectly on the SB cubicle.

Once the bracket (5) is in the correct posi-

tion, install the bolt (1 0), spring washer (9)
and plain washer (8) and tighten.

Tighten the bolts securing the connection

plate (11) to the brackets (4,5) as necessary.

Chapter 8.02 - Page 40/ 44 ldent. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Machine Room Control
Maintenance and Repair Manual

Install the earthing cable (1 }. Tighten the

screw (2).

CAUTION:
The cables and sockets are
labelled to facilitate assem-
bly. Always check the con-
nections before assembly. If
in doubt, refer to Volume G,
Cabling Documentation.
Wrongly connected cables
can irreparably damage com-
ponents or cause incompre-
hensible error messages on
the diagnostic display.
i~lfl~1111.11!1~/l!l11111i
oso2oCi3~DDDDDD · DDDDDDOO Connect the harnesses to the sockets (1} at
.the top of the SB cubicles. Turn the rings
clockwise to secure the bayonet connector.

Secure the cables to the SB cubicle and

cable duct using cable ties.

Connect the hose to the socket (2) of the fire

detection equipment (1) at the back of cu-
bicle SB2.

Bombardier Transportation Ltd. Chapter 8.02 - Page 41 1 44

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Machine Room Control Indian Railways WAG-9
Maintenance and Repair Manual
--------~-~----~----~------------------

For cubicle SB2; open the SB cubicle doors,

then manipulate the harness into the cu-
bicle. Connect the harness (1) to the sockets
below the fire detection unit. Turn the rings
clockwise to secure the bayonet connector.

Secure the cables to the looming bars and

cable duct using cable ties.

Manipulate the cables into the MICAS ve-

hicle control cubicle.

Connect the harnesses and fibre optic con-

nections at the sockets on the MICAS ve-
hicle control rack.

Secure the cables to the looming bars and

cable ducts.

Install the cover plates over the cable

flanges.

Place the metal cover above the two angle

brackets ( 1). Guide the metal cover carefully
over the lower angle brackets.

Hold the cover (2) so that it does not fall.

Secure cover (2) in place on the control unit

with screws (1).

Chapter 8.02 - Page 42/ 44 !dent. No. Bombardier Transportation Ltd.

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 '':, "13

Indian Railways W AG-9 Machine Room Control

Maintenance and Repair Manual

After-Installation Operations
@.1290

Test the operation of the control circuits. Rectify any faults found.

Adjustments
@.1310

There are no adjustments applicable to the control circuits cubicles and equipment.

Bombardier Transportation Ltd. Chapter 8.02 - Page 431 44

!dent. No.
Revision Date: 12.2001
3EHW 411461
 Indian Railways WAG-9
Machine Room Control
Maintenance and Repair Manual

empty page

Chapter 8.02 - Page 44/ 44 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways W AG-9 Control Electronics
Maintenance and Repair Manual

8.3 Control Electronics

Group Summary
@.1120

This chapter contains information regarding the Central Electronics (GEL 1/2), MICAS vehicle
control units located below the SB cubicles. Electrical Equipment Apparatus Item Numbers
for CEL 1 and CEL2 are 411 and 412, respectively.

2--+--

0303101n
1 SB cubicle
2 Control electronics vehicle control unit

Bombardier Transportation ltd. Chapter8.03 - Page 1 1 8

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 Control Electronics
Indian Railways WAG-9
Maintenance and Repair Manual

Functional Description
@.1140

ZLT 1 ZLT 2
MVB

! !
DA I I DA

[C_}~nl
Ii
IDLts]j
I

I
I

~ L

II
SR BURl BUR 3 BUR 2 SR
0803102n

The vehicle control (ZLT) units are connected to the multi-functional vehicle bus (MVB) and
form a part of the MICAS S2 vehicle control system. Other components in the MICAS S2 sys-
tem include the traction converter {SR) control units, the auxiliary converter (BUR) control
units, and the diagnostic display (DA).

The SR, BUR and DA systems receive control instructions from the ZLT control units.
Changes in driver inputs, along with automated control functions, are interpreted within the
ZLT units. These inputs are computed and suitable control instructions, along with diagnostic
information is generated. Diagnostic information generated is fed to the DA units, located in
the cabs. Control instructions are fed to the BUR and SR control units, which interpret these
instructions and control the BUR and SR units accordingly.

Information regarding the current condition of the SR and BUR systems is fed to the ZLT con-
trol units. The ZLT control units interpret this data and changes to BUR and SR operation are
made if required.

In order to keep the control unit cool, air is ducted up from the machine room floor and blown
through the unit. The air is then vented into the machine room.

For further information regarding the function of the converter control unit, refer to Volume
F17, Suppliers Documentation.

Chapter 8.03 - Page 2 I 8 ldent. No. Bombardier Transportation Ltd.

Revision Date: 12.2001 3EHW 411462
 '_) 21-
Indian Railways W AG-9
Control Electronics
Maintenance and Repair Manual

Trouble shooting for the MICAS vehicle control unit is described in Chapter 11, Repairing In-
struction Bus Station of Volume F17, Suppliers Documentation.

The SB cubicles are described in Chapter 8.2, Machine Room Control.

Technical Data
@.1160

Weight

- Empty rack 21 kg
- Rack complete with components 32 kg

Power Consumption

- Maximum power consumption 126W

- Typical power consumption 107W

Permissible Conditions

- Minimum temperature -25 oc

- Maximum temperature 65 oc
- Recommended temperature 30 to 40 oc
- Mean relative humidity <75%

Tolerances and Wear Limits List

@.1170

For further information regarding the MICAS vehicle control unit, refer to Volume F17,
Suppliers Documentation.

Bombardier Transportation Ltd. Chapter8.03 - Page 3 I 8

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 Indian Railways WAG-9
Control Electronics
Maintenance and Repair Manual

Tools and Special Tools

@.1180

Conventional railway workshop tools are required for the procedures described in this
chapter.

Fault finding and servicing of the MICAS vehicle control unit requires additional tools and in-
struments. These are given in Volume F17, Suppliers Documentation.

Miscellaneous Materials
@.1200

No miscellaneous materials are required for the procedures described in this chapter.

Before- Removal Operations

@ 1220

Remove the SB cubicle from the locomotive machine room as described in Chapter 8.2,
Machine Room Control.

--------------------------

Chapter 8.03 - Page 4 I 8 Bombardier Transportation Ltd.

Ident. No.
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3EHW 411462
 '2, 2- 'l
Indian Railways WAG-9
Control Electronics
Maintenance and Repair Manual

Removal
@.1230

Removal of the assembled SB cubicle and MICAS vehicle control unit cubicle is described
in Chapter 8.2, Machine Room Control.
Attach suitable lifting equipment to the eye
bolts (1) on the SB cubicle (2). Raise the lift-
ing equipment slightly to take the weight of
the cubicle (2).

Remove the bolts (1) spring and plain

washers (2, 3) securing the front corners of
the MICAS vehicle control unit cubicle to the
machine room floor (4).

Ensure nothing is entangled and that the cu-

bicle willnot foul on anything during re-
moval, then lift the cubicle out of the locomo-
tive machine room.

Follow manufacturers instructions regard-

ing the transport and storage of the MICAS
vehicle control unit, as described in Chapter
7, Transport, Storage, Installation/Removal
of Volume F17, Control Electronics Vehicle
Control Unit.

Bombardier Transportation Ltd. Ident. No. Chapter8.03 - Page 5 1 8

Revision Date: 12.2001
3EHW 411462
 Indian Railways W AG-9
Control Electronics
Maintenance and Repair Manual

Disassembly
@.1240

For further information regarding the MICAS vehicle control unit, refer to Chapters 1 to 17,
Control Electronics Vehicle Control Unit of Volume F17, Suppliers Documentation.

Inspection and Repair

@.1250

For further information regarding the vehicle control unit, refer to Chapters 1 to 17, Control
Electronics Vehicle Control Unit of Volume F17, Suppliers Documentation.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

For further information regarding the MICAS vehicle control unit, refer to Chapters 1 to 17,
Control Electronics Vehicle Control Unit of Volume F17, Suppliers Documentation.

Chapter 8.03 - Page 6 I 8 Ident. No. Bombardier Transportation Ltd.

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 '3 3 l
Indian Railways W AG-9 Control Electronics
Maintenance and Repair Manual

Installation
@.1280

Installation of the assembled SB cubicle and MICAS vehicle control unit cubicle is described
in Chapter 8.2, Machine Room Control.
Attach suitable lifting equipment to the eye
bolts (1) on the SB cubicle (2). Raise the SB
cubicle into position above the MICAS ve-
hicle control unit cubicle.

Slowly lower the SB cubicle onto the MICAS

vehicle control unit cubicle, aligning the
holes in the SB cubicle flange with those in
the control unit cubicle.

Install the bolts (1) spring and plain washers

(2, 3) through the corners of the SB cubicle
flange into the MICAS vehicle control unit
cubicle.

Bombardier Transportation Ltd.

Ident. No. Chapter8.03 - Page 7 I 8
Revision Date: 12.2001
3EHW 411462
 •V
Indian Railways WAG-9
0~ Control Electronics
Maintenance and Repair Manual

After-Installations Operations
@.1290

Test the operation of the MICAS vehicle control electronics. Rectify any faults found.

Adjustments
@.1310

There are no adjustments applicable to the MICAS vehicle control units.

'
r
i

Chapter 8.03 - Page 8 I 8 Ident. No. Bombardier Transportation Ltd.

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Indian Railways W AG-9 Loco-Loco Bus
Maintenance and Repair Manual

8.4 Loco-Loco Bus

Group Summary
@1120

This chapter contains information regarding the loco-loco bus socket. The loco-loco bus UIC
socket is Electrical Equipment Apparatus Item Number 353.3.

IQ] [] IQ]
IQ] @

0804100n
Loco-loco bus socket

Bombardier Transportation Ltd. !dent. No. Chapter 8.04 - Page 1 1 8

Revision Date: 12.2001
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 Indian Railways W AG-9
Loco-Loco Bus
Maintenance and Repair Manual

Functional Description
@.1140

The loco-loco bus is used to connect two locomotives together during multiple unit operation.
In multiple unit operation, a master locomotive and a slave locomotive are connected together
to provide more motive power than is available from a single locomotive. The master locomo-
tive and slave locomotive are connected together electronically via the loco-loco bus. The
loco-loco bus allows the master locomotive to control certain functions of the slave locomo-
tive. In addition to this, operating conditions and fault messages from the slave locomotive
are transmitted to the master locomotive. Fault messages are displayed in the driver's cab
of the master locomotive.

For further information regarding multiple unit operation, refer to Chapter 4, Vehicle Operation
of Volume A, Driver's Manual.

Technical Data
@.1160

Loco-Loco Bus

- Data transmission method FSK (Frequency Shift Keying) modulation

Tolerances and Wear Limits List

@.1170

No specific tolerances or wear limits are applicable to the equipment described in this chapter.
Items should be inspected as described in Section Inspection and Repair, and replaced or
repaired as necessary.

Chapter 8.04 - Page 2 I 8 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways W A G-9
Loco-Loco Bus
Maintenance and Repair Manual

Tools and Special Tools

@.1180

The following tools and special tools are required for the procedures described in this
Chapter.

• Crimping tool WZ 25-2.3 UIC

• Extractor tool 1440 0303 77 4

Miscellaneous Materials
@.1200

Miscellaneous materials required for the procedures described in this chapter include:

• Loctite 222
• Sikalastomer 710

Before- Removal Operations

@.1220

Lower the pantograph and isolate the overhead catenary. Earth the locomotive at the vacuum
circuit breaker. Refer to the Preface of this Volume.

Earth the traction converter as described in Chapter 4.1, Traction Converter. Operation of the
key interlocking system is described in Chapter 3.11, Protection Concept of Volume A,
Driver's Manual.

Removal of some cab panels is required to access the loco-loco bus socket wiring from within
the cab. Refer to Chapter 7.5, Cab for information regarding cab panels.

Bombardier Transportation Ltd. !dent. No. Chapter 8.04 - Page 3 1 8

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 Loco-Loco Bus Indian Railways WAG-9
Maintenance and Repair Manual
-----------------------------------

Removal
@.1230

Socket and Cover

From inside the locomotive, remove strain

relief device to allow the cable to be pulled
slightly through the front of the locomotive.

From outside the cab, loosen and remove

the screws (1), flat washers (3) and spring
washers (2) securing the socket cover (4) to
the front of the locomotive {9), then withdraw
the socket cover (4).

Loosen and remove the screws (5) securing

the socket (6) to the locomotive, then with-
draw the socket (6) and cable from the loco-
0804101n motive slightly. To completely remove the
socket, the pins (7) with wires must be
pressed from the socket (6) using the ex-
tractor tool.

Once the socket (6) has been removed, the

rubber seal (8) may be removed.

Disassembly
@.1240

For further information regarding the loco-loco bus socket, refer to Chapter 4, Loco- Loco Bus
of Volume F16, Suppliers Documentation.

Chapter 8.04 - Page 4 I 8 !dent. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Loco-Loco Bus
Maintenance and Repair Manual

Inspection and Repair

@.1250

Socket Cover

Inspect the loco-loco bus socket assembly for wear, cracks or any other signs of damage.
Ensure the handle and cover plate function correctly. Replace any damaged or defective com-
ponents.

For further information regarding the loco-loco bus socket, refer to Chapter 4, Loco- Loco Bus
of Volume F16, Suppliers Documentation.

Socket and Pins

Inspect the socket for wear, cracks or any other signs of damage. Replace any damaged or
defective components. Remove the pins as necessary using extractor tool 1440 0303 774
described in Section Tools and Special Tools. Replace the socket if worn, cracked or other-
wise damaged.

Inspect the condition of the pins. Replace the pins if worn, bent, oxidised, or otherwise dam-
aged. New pins can be crimped on to wire using crimping tool WZ 25-2.3 UIC described in
Section Tools and Special Tools.

Waste Disposal
@.1260

Dispose of waste parts, materials and fluids according to the prevailing environmental stan-
dards or workplace practices.

Assembly
@.1270

For further information regarding the loco-loco bus socket, refer to Chapter 4, Loco- Loco Bus
of Volume F16, Suppliers Documentation.

Bombardier Transportation Ltd. !dent. No. Chapter 8.04 - Page 5 I 8

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Loco-Loco Bus Indian Railways W AG-9
Maintenance and Repair Manual

Installation
@.1280

Socket and Cover

Position the rubber seal (8) over the socket

mounting hole.

If necessary, press the pins (7) with wires

into the socket (6).

Position the socket (6) in the mounting hole

in the locomotive, then insert and tighten the
screws (5) securing the socket (6) to the
front of the locomotive (9).

Install the strain relief device and tension the

device to relieve any strain in the socket
from the wires.
0804101n
Apply a continuous 7 mm diameter bead of
Sikalastomer 710 to the perimeter of the
mounting face on the socket cover (4) then
position the socket cover (4) on to the front
of the locomotive (9}.

Apply Loctite 222 to the threads of the

screws (1), then install and tighten the
screws {1), flat washers {3} and spring
washers {2) to secure the socket cover {4) to
the front of the locomotive (9).

Chapter 8.04 - Page 6 I 8 Ident. No. Bombardier Transportation Ltd.

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 Indian Railways WAG-9 Loco-Loco Bus
Maintenance and Repair Manual

After-Installations Operations
@.1290

Water test the area around the loco-loco bus sockets. Refer to Water Test in the Preface of
this Volume. Ensure no water leaks through the front of the locomotive, or into the socket.

Adjustments
@.1310

There are no adjustments applicable to the loco-loco bus or its socket.

Bombardier Transportation Ltd. !dent. No. Chapter 8.04 - Page 7 1 8

3EHW 411463 Revision Date: i 2.2001
Loco-Loco Bus Indian Railways W AG~9
Maintenance and Repair Manual

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Chapter 8.04 - Page 8 I 8 Ident. No. Bombardier Transportation Ltd.

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