9.2 Fault Finding Sprinter

- unlock and reset the telescopic rails

- apply park brake

- minimum 750 K PA in Main res

- brake pipe pressure zero

- push uncouple button 3 secs-light extinguishes

- check indication marks on top of the coupler

Won’t uncouple

- Push uncouple button from another cab-push button in both cabs at once *if possible

- Move the sprinter to straight track

- Pull the ripcord

- Push the uncouple push buttons outside

- isolate air supply in door control panel

- Isolate power supply in door control panel

- Manually close doors

- ensure they’re locked

- when one or more passenger doors need to be isolated inform conductor

- 50% of the doors on each side of each sprinter can be isolated and the train remain in service until it returned to Southern Cross

- One of the sliding doors on either side at each driving cab end of each sprinter must be able to be operated normally for the sprinter train to remain in service

- Airbags

- Airbag isolates

- Leveling rods

- Main res pressure

- Max speed 80k/h

Park brake will not release in cab with cab button

- Check brake pipe pressure is 500 K PA-will release at 380kpa

- Open pressure switch cabinet (external) and operate shuttle valve

- Release park brake manually using manual release tool

- Notify Central

Park brake will not apply with Cab button

- to reapply the park brake restore BP and battery power press ON OFF ON buttons in cab

- Open pressure switch cabinet (external) and operate shuttle valve

- If still not applying dump brake pipe by making an emergency brake application

- Notify Central

Electrically

- min 750kPa in main res or won’t go into gear

- go to neutral & forward -wait 15 secs

- go to neutral & reverse -wait 15 secs

- roll forward a short distance

- Change ends and check REVERSER or attempt to change direction from there

Pneumatically

- Ensure park brake is ON

Open transmission control panel

- Select TFV & FV @ No1 end

- Select TFV & RV @ No2 end

Mechanically

- STOP both engines

- Go to engine control panel and isolate both engines

- switch off No1 & No2 Engine control circuit breakers

- Use a ring spanner to manually select direction via the shift selector nut A or B

*listed on back wall of sprinter cabs

- TCA fault light is Train lined 2 x TCAs per sprinter

- 1 x functional TCA required per sprinted to run

- TCA fault light will illuminate along with the fault light in the affected sprinter

- Obtain permission to isolate the defective TCA by breaking the seal and turning to isolate

If All TCAs have failed

- Advise central

- Proceed under absolute block conditions

- run at reduced speed (eg 15 k/h) over level crossings, frequent use of whistle

- If level crossings not activated move up to 3 m before crossing can activate

- Air cons receive power directly from the static inverters - no 1 air-con = failed static inverter. Also toilets, primary lights and headlights will stop operating.

- depending on which inverter was being used to power the auxiliary transformer there may no longer be power to:

- Headlights

- transmission cooling fans

- Fridge

- Drivers heater

- Battery charger

As well as a safety aspect of no headlight, with no battery charging, eventually the sprinter becomes totally disabled with flat batteries.

- The aux gen is no longer charging the batteries

- Check the 415 V battery change over C/B breaker

- Check the 24 V 1 and 2 inverter C/B

- Check the static inverter 1 light is green not red or extinguished

- Open the cab door and check if emergency lighting has come on

- Change the auxiliary supply changeover switch from 1 to 2

- Check the static inverter 2 light is green not red or extinguished

If this does not rectify the problem stop the train.

-Contact Train control and request permission to fault find- cab unattended

- Check battery charger 35-55 amps 24-28 V

- Go to battery charger and flick alternator C/B ON OFF

We lose four things with an Aux fault - static inverter fault

D-door control

E-EP brake to air

E-engines eventually shutdown

P-penalty brake

- Try from another Cab

- Use engine control panel

- Operate actuating Rod

Axle speed sensor

- Move throttle to lower notch and until light extinguishes then resume powering

- Stop vehicle, then restart increasing power gradually

- Stop vehicle, inspect axle speed sensor cabling for damage

Wheel slip/slide protection system fault

- Stop vehicle, shut down engines, turn battery isolation switch to isolate

- Restart engine and try again

- If it persists leave reversers set for forward direction

- Break the seal on the wheel slip/slide circuit breaker number 1 Cab

- Trip to OFF position

Note: 4 things

- Transmission CAN’T be reversed

- Keep brake cylinder pressure below 140 KPA

- Allow for longer stopping distances

- Speedometer will not operate

When it is required to haul or push a sprinter using a vehicle fitted with a standard coupler it is necessary to attach a transition coupler to the multifunction coupler.

Fitting the transition coupler

- Close the brake pipe and main res isolating Cocks

- Electrical cut out lever to non-electrical position

- Remove transition coupler from storage bracket

- Place transition coupler onto multifunction coupler. It is held in position by two locating hooks on top of the coupler head

- Grasp the transition coupler at the bottom of the frame and push down hard

- Ensure the transition coupler is securely attached to the multifunction coupler by observing the indicating mark on the coupler head

- Couple the other vehicle to the sprinter

- couple the brake pipe and Main res flexible hose couplings and open the isolating cocks

Removing the transition coupler

- Close brake pipe and Main res isolating cocks

- Disconnect the brake pipe and Main res flexible hose couplings

- Uncouple the vehicles using the lifting pin on the standard couple of the other vehicle

- Pull the ripcord wire located on the side of the couple ahead - this will release the transition coupler

- Lift the transition coupler from the multifunction coupler and lock it in the storage bracket

- Return the electrical cut out lever to the NORMAL position

- Open brake pipe and Main res isolating cocks

- The multifunction coupler is now ready for normal use

Lead sprinter

- Brake selection switch = airbrake

- Set to non-electrical on sharfenberg coupler

- Ensure reverser is in neutral

- ensure brakes are in release

- Ensure main res and brake pipe cocks are open

- run at BC pressure MAX 140kpa

Dead sprinter

- Isolate the VC electrically in cab

- Isolate the VC pneumatically on the end frame - break the seal

- No1 end - plug the dump valve

- Isolate both engines via the engine control panel

- Release a park brakes via the shuttle valve solenoid

- Ensure reversers in neutral

- Ensure brakes are in release

- ensure MR and BP cocks are Open

- Place ETM at end of Train

*if leaving dead sprinter CHOCK the wheels*

- Once engine shutdown, switch engine run/isolation switch to ISOLATE on engine control panel (external)

- Inform CENTROL

- If engine is isolated, no fault lights will illuminate on engine panel

The emergency dump valves are located beneath the drivers cab floor at each end and will function to vent break pipe air to atmosphere in the event of:

- Conductors emergency brake handle operated at THAT end of the sprinter

- VC penalty break application dumps at No1 end cab only

If there is a malfunction of the emergency dump valve, with permission the driver can insert the plug in the valve. This will enable the vehicle to return to Southern Cross for repairs.

The plug is supplied in the tool kit with a labelled red and white instruction tag. The tag must be attached to the brake controller to ensure the repairs are not overlooked.

* The use of this plug at No1 end cab will prevent the VC control from being able to dump brake pipe pressure and apply the brakes in case of an emergency. Under these circumstances the sprinter must not continue in operation unless a second person qualified to operate the airbrake accompanies the driver.

The conductors emergency valve at that end of the sprinter is also inoperative and the conductor should be informed.

If the fuel system runs dry, air must be vented from the fuel system using the hand pump on the engine.

- Slacken the bleed screw located on the top of the pre-filter by two or three turns

- Give the knurled knob of the hand priming pump a few turns counterclockwise to release it from the locked position

- Operate the pump until the fuel free from air bubbles emerges at the released pre-filter bleed screw

- Re-tighten prefilter bleed screw

- Continue to operate the hand pump for approximately two minutes

- Firmly screw the knob of the hand pump back to the locked position

Sprinter shutdown for this procedure:

- With the battery isolation switch on, test the spare fuse

- Battery isolation switch turned off

- Remove spare fuse and battery positive fuse

- Place positive fuse in tester and turn battery isolation switch on to test fuse

- If defective/blown turn off battery isolation switch and replace with spare fuse

- If working repeat process with battery negative fuse

Engine low oil pressure

- Engine oil pressure falls below 0.5 bar = engine shuts down

Transmission

- Transmission fluid temperature reaches 130°C the traction control system will return the engine to IDLE and disengage the transmission

- When the transmission fluid cools down the fault will reset automatically and the engine control will be returned to the throttle

Overspeed

- Engine speed reaches 2550 rpm = engine shutdown

Over temperature

- cylinder head temperature reaches 220°C = engine shutdown

- Engine oil temperature reaches 130°C = engine shutdown

Low oil shutdown

- check the engine oil level

Coupler centring pushbutton

When pressed, disconnects the coupler self centring mechanism and allows free movement of the coupler shaft.

This allows a coupler to be aligned by hand by a person on the ground if coupling on a curve.

Coupling centring feature

The coupler is secured in the central position by means of a self centring mechanism.

This feature is provided to protect both the coupler and the vehicle from damage due to unintentional lateral swings of the coupler.

When two sprinters are coupled together, the self centring mechanism is disconnected and the coupler shaft can pivot normally.

When coupling on a curve, press the coupler centring isolate pushbutton on the drivers overhead console to enable the coupler to be manually positioned.