Revision of Chapter 08-LHB Power Car of LHB Manual (Electrical)
Revision of Chapter 08-LHB Power Car of LHB Manual (Electrical)
Revision of Chapter 08-LHB Power Car of LHB Manual (Electrical)
CHAPTER 8
POWER CAR INTRODUCTION
Power supply generation based on the End-On-Generation system requires two power
cars, one on the front end and other on the rear end. Each power car is equipped with
two Diesel Alternator sets to supply hotel load to the coaches through two sets of
feeders running along the rake and coupled in between with the help of inter-vehicle
couplers (ZS couplers). These couplers also carry the earth wires and 2 wires for the
control circuit.
FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II
GENERATOR GENERATOR
CAR CAR
Generated power supply through Diesel Alternator sets is distributed through switch
board cabinet in power Car. Accordingly Electrical supply system in power car consists
of following items:-
1. Diesel Alternator sets
2. Switch Board Cabinet
Power Car is similar to a LHB AC coach. Following Electrical equipment are also
provided in power car:
Above items are similar to AC Coach. Detail item wise description of all above
equipment already given in Chapter-6 i.e. LHB AC Coach.
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Alternator
The alternator provided has a capacity of 500kVA, 0.8 pf 3phase, 4 wire 750
volts 50 HZ +\- 3 %. The alternator used is self ventilated brushless design
with voltage regulation of dual type i.e both electric and electronic. The
electrical control is through compound transformer or magnetic amplifier and
electronic regulation through solid state automatic voltage control and sensing
from all the three phases. The combined regulation is 2.5 % approximately.
Standby facility is provided to ensure voltage regulation within 5 % even in the
event of failure of automatic voltage regulator and this standby facility is
automatically cut in with the help of OVR/UVR which indicates through two
LED’s of the failure of AVR and that the system is in manual mode
Automatic voltage regulator is suitably mounted in the power panel. The
alternator has a stator, rotor insulation of H class and exciter insulation class
F. The alternator is capable of handling 30% unbalance load in any of the
phases with current in any of the phases not exceeding the rated current with
regulation maintained at 5% or less or 2.5% or better in manual and AVR mode
of operation respectively.
Alternator is designed such that the total harmonic distortion is below 5% of
the rated capacity. Alternatively a neutral reactor 125 volts, 50 amps, 150 Hz
is to provided in LHB coaches.
8.1.4.1 Layout
The Diesel alternator sets are placed back to back at the centre of the coach.
Layouts for the LHB type coaches is as per drawing no. LP90100.
Fuel System
Two under-slung fuel tanks are provided in the underframe with an individual
capacity of 1540 liter. The engines are fed through respective tanks and the
tanks are connected through an equalizing pipe with a cut off valve in-between.
8.1.5.1 Fuel Transfer Pumps
The engine installed by Greaves Cotton has a fuel pump provided to suck the
fuel from the diesel tanks provided at the bottom
Engine Room Ventilation
Two centrifugal type blowers per DG set are provided at the cant rail level of
capacity 25000 CMH at 30mm WG each are provided such that the air is drawn
from the engine room through the opening on the false ceiling and blown out
laterally through rectangular louvered openings provided on either side on the
sloping roof sheet. To minimize the air dust ingress in the engine room four
hatch door louvered openings with dry type re-usable, fire retardant, non-
woven synthetic media with a filtering capacity of upto20microns are provided.
The blowers are driven by 415volts, 3-phase, ac motors of 5 KW.
Engine Room Filters
To minimize the dust into the engine room through the four hatch doors
louvered openings, dry type, re-usable fire retardant, non-woven synthetic
media panel filters, with a filtering capacity of upto 20 microns size dust
particles have been used for both LHB and Garib Rath power cars. Each filters
module comprises of 9 detachable panels
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Battery
For starting the engine 290 Ah Lead acid battery is provided to feed the power
to the engine starter motor for cranking one engine at a time by means of
changeover switch for the two DG sets.
8.2 PROTECTIONS
The diesel alternator set for the power cars are provided with various
protections and safeties for the safe working of the rakes
For Diesel Engine
High water temperature:- The high water temperature switch is mounted
on the engine and senses the temperature of water in the cooling jacket of
the engine. The device is set at 97 Deg.C for putting off the engine. Once
the ICHT closes, water temperature indication comes on and the common
fault relay is energized
Over speed of the engine :- over speed switch
ICOS mounted on the engine senses the over
speed when the engine governor fails. When the
engine RPM exceeds the set value its NO contact
closes the over speed relay OSR. One of the NO
contacts of the OSR maintains the supply to OSR
and another contact closes and completes the CFR
circuit. The over speed is set at 1800 4.5 % RPM
Lube Oil Pressure :- The lube oil pressure switch
is mounted on the engine senses the lube oil
pressure. The NC contact of the lube oil pressure
switch remains open when the lube oil pressure is sufficient. When the
pressure is below the set value, the switch closes the LOP relay. One of the
NO contacts of the LOP maintains the supply to LOP relay and another NO
contact energizes the CFR circuit.
At the time of starting one of the NC contact of the start push button opens
the LOP circuit. It is a positive interlock that ensures that the engine does
not stop for the want of lube oil pressure build up at the moment of starting.
A delay contact of the Time delay relay for the starter solenoid (FSRD) relay
keeps the LOP circuit closed. Once engine starts, the lube oil pressure
develops, opens the oil pressure switch ICLOP ( Internal Combustion
Engine Low Oil Pressure) which keeps the LOP de-energised as long as
there is sufficient pressure of the lube oil. The permissible limits for
Cummins engine is 3.16-6.33 kg/sqcm.
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LOW WATER LEVEL SWITCH:- A low water level switch has been provided
on the top of the radiator for sensing the presence of water in the radiator. If
ever the water level goes down below a certain level, it gives a indication on
the panel and the same can be integrated in the panel control circuit for
switching off the load or the engine
Alternator Protection
Alternator Overload: - This protection is in-built
in the ACB. The ACB has an integrated solid state
relay of thermal overload type which incorporates
the following precautions:-
1. Short circuit
2. IDMT and Overload
3. Earth Fault
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Its NO contact energizes the earth leakage relay ELR. One of the NO
contacts of ELR energizes the Earth fault indication lamp and AFR circuit.
Another NO contact of ELR maintains the supply to ELR itself, even after
ACB has been switched OFF. This protection is mainly for the alternator /
interconnecting cables between the ACB and the alternators.
The technical details are as under:-
a. Size of cable – 150 sqmm
b. Auxiliary supply voltage – 440 volts ac
c. Contact arrangement 1 N/O + 1 N/C independent
d. Contact rating 230volts 50 Hz, 5 amps, ac resistive
e. Suitable for 750volts, 3 phase, 50 Hz, 4-wire system
Short Circuit: - This feature is incorporated in the ACB .This results in the
instantaneous tripping of the ACB, when set value of the current is sensed.
Feeder Protection
The two individual feeders are protected by individual contactors, with the
following trips
Earth Leakage :- The protection scheme for the conventional (3 wire
system) and LHB type (4 wire system) relay is different
LHB Type Power Cars:- These Power cars are equipped with residual
current type relays of BENDER make.
Feeder Overload :-
LHB POWER CARS: - The relay
provided for the protection was
originally of ZAHRA make which was
finally changed to MICOM make due to
malfunctioning. The MICOM make
relay is Universal programmable relay
which can be programmed to suit to the
usage. The relay is used an over
current relay to protect the feeder.
8.3 OPERATIONAL SAFETY AND PROTECTION IN POWER CARS
Plant selection
A plant selection switch has been provided on the Switchboard cabinet to give
following modes of operation.
A Position – I 12’O clock OFF
B Position – II 3’O clock Plant ‘A’ Only
C Position – III 6’O clock Plant ‘A’ & ‘B’
D Position – IV 9’O clock Plant ‘B’ Only
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The engines are of two types –Cummins KTA19G5I and Greaves Cotton
TBD41V12P engine. The Greaves Cotton Engine incorporates Electronic
Instrumentation panel for starting the engine
8.4 STARTING THE DG SET WITH CUMMINS ENGINE
The starting sequence of the engine is as follows
Precautions
i) Before starting the engine, ensure that necessary quantity of lubricating oil
, fuel oil, and cooling water have all been filled and the witches are in good
condition
ii) Switch on the dc control switch which will light the DC On indication lamp
iii) Switch on the starter motor Isolation switch connects the DC supply from
the starter battery to the starter motor circuit
iv) Press the test push button 1,2 & 3 to check the status of the fault indication
lamps
Press the engine start push button of any one engine selected for running
First NC contact of the start push button opens the LOP circuit. It is
positive interlock to ensure that the engine does not stop for the want of
lube oil pressure build up at the moment of starting. Second NC contact
opens the engine starting circuit of the other plant. This is an interlock to
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Same procedure can be adopted for the other feeder and plant
Safety Loop
The safety loop is the most important protective safety circuit. It guarantees
the standard operation of generators and power supply. The generators must
not work other than in ”stand alone” operation. A parallel operation is not
possible because the generators are not designed for synchronous operation
and the compensating currents can grow up to a dangerous size. Normally
generator 1 supplies the bus bar 1 and the generator 2 supplies the bus bar-2
To achieve maximum flexibility it is possible to supply bus bar 2 via a coupling
contactor from generator 1, or bus bar 1 from generator 2 , or both bus bars
from one generator, respectively. The coupling can only be switched if one
generator operates while the other is disconnected. Because the coupling is
only allowed if the IV-coupler is voltage less, a protective circuit is required
which before separating the couplers switches off the bus bar. For this purpose
a safety loop is created by 2 control current contacts. A limit switch mounted
on the receptacle terminal box is part of the safety loop. During coupling, after
opening the mechanical locking, the limit switch is actuated causing an
interruption of the control current circuit. Afterwards a power contactor is
switched off and the main contacts become voltage less. To close the safety
loop, the free plug of the last feeding line car has to be mated with the dummy
receptacle where two bridged spring pressure contacts close the circuit.
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Interlock Preventing Accidental Paralleling Of Alternators In Rear Car With Alternator In Front
Car
Each of the two alternators of the power car on rear-1 supplies one
feeder. The alternators of the rear power car- 2 are switched off.
REAR-1 REAR-2
ACB-A K-1 K-3 ACB-B
FEEDER A
ENGINE ENGINE
A B
K-2
K-2 COACHES
FEEDER B
ENGINE ENGINE
B A
ACB-B K-3 K-1 ACB-A
Each of the two alternators of the power car on rear 2 supplies one
feeder. The alternators of the rear power car- 1 are switched off.
REAR-1 REAR-2
ACB-A K-1 K-3 ACB-B
FEEDER A
ENGINE ENGINE B
A
K-2
K-2 COACHES
FEEDER B
ENGINE B ENGINE
A
ACB-B K-3 K-1 ACB-A
One of the two alternators of the power car on rear 1 and 2 supplies one
feeder. Alternator-A on rear 1 supplies feeder A and alternator-A on rear
2 supplies feeder B.
REAR-1 REAR-2
ACB-A K-1 K-3 ACB-B
FEEDER A
ENGINE A ENGINE B
FEEDER B
ENGINE B ENGINE A
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Keys on the switch cabinet door and the voltmeter permit to measure the voltage
between positive and negative potential of DC mains and earth. In such a way
the mains insulation condition can be checked.
For monitoring the AC mains insulation protective devices are used, their
function is described later.
Accordingly in the Generator-cum-brake van earthing points are provided:
- To be earthed in the underframe:
Battery Box
Battery fuse boxes (positive and negative)
Transformer container
Tank for fresh water
Brake PCB
Diesel tank
Uprated engine supplied by M/s Cummins India Ltd., Kothrud, Pune complies
with the emission norms as laid down by the Automotive Research
Association of India.
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8.1.3 High Neutral Current (In BHEL/KEL & Kirloskar Alternator only)
LHB coaches are provided with power transformer of star
-star connection. The generator neutral is connected to
star point of the generator. Due to star -star connection
3rd Harmonics are generated and triple frequency
which is normally three times the normal current
flowing through the neutral conductor. To overcome
the problem one reactor is provided in between the
generator neutral and the local neutral, which restricts
the 3rd harmonic component to go back to the
generator.
As per latest RDSO specification, harmonics should not
be more than 5%.
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car.Two nos. of rotary switches are to be mounted to select one set of the
existing CT and additional set of CT
8. The modification works involves introduction of 750 V 3 Ph contactors,
between each IV coupler input and ACB output, designated as HOG A and
HOG B respectively. Interlocking circuit between the HOG NB and ACB AIB
will ensure that either of HOG or ACB is operated at time
place of
S.N Item Drawing No
installation
1 12 A04 Over Current relay Feeder RITX S2A4
1 STR 515 CT 210/Wpm
5A;Auxilliary voltage Poland!GEN-
DC24 V 10 with CT30
2 12 A05 Earth leakage device RCM470LY- S2A5
feeder -1 21ELR-3C
3 12 A09 Over Current relay Feeder RITX S2A9
1 STR 515 CT 210/Wpm
5A;Auxilliary voltage Poland!GEN-
DC24 V 10 with CT30
4 12 A10 Earth leakage device RCM470LY- S2A10
feeder -2 21ELR-3C
5 12 ACB1 Air circuit breaker CN-CS CNCS800C S2A3
800C 3x750V;800A;6NO /E21,1800/RIV
+ 6NC CT for 240.. S-9D
300Amps DN1E Voltage
release MV Earth Fault
Release 30,40,50%
6 12 ACB2 Air circuit breaker CN-CS CNCS800C S2A6
800C 3x750V;800A;6NO /E21,1800/RIV
+ 6NC CT for 240.. S-9D
300Amps DN1E Voltage
release MV Earth Fault
Release 30,40,50%
7 12 F08 Fuse 5x30 mm fuse 12-K7 S2F08
T6.3 A , 440 V
8 12 F09 Fuse 5x30 mm S2F09
fuse bus coupler ACB1
16.3 A , 440 V
9 12 F10 Fuse 5 x 30 mm fuse for S2F10
12 K4 T-2A, 440 volts
10 12 F11 Fuse 5 x 30 mm fuse for S2F11
12 K5 T-2A, 440 volts
11 12 F19 Fuse 5x30 mm fuse for S2F17
bus coupler ACB2 T6.3
amps ,440 volts
12 12 F20 Fuse 5x3Omm fuse S2F18
feeder 2 16.3 A, 440 V
13 12 F21 Fuse 5x3Omm fuse 12-K6 S2F21
T6.3 A, 440 V
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place of
S.N Item Drawing No
installation
14 12 F22 Fuse 5x3Omm fuse S2F22
feeder 2 T6.3 A. 440 V
15 12 F32 Low Voltage Fuse (with 3NA:.830 & S1F79
Holder ) Transformer-1 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
16 12 F33 Low Voltage Fuse (with 3NA:.830 & S1F80
Holder ) Transformer-1 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
17 12 F34 Low Voltage Fuse (with 3NA:.830 & S1F81
Holder ) Transformer-1 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
18 12 F38 Low Voltage Fuse (with 3NA:.830 & S1F82
Holder ) Transformer-2 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
19 12 F39 Low Voltage Fuse (with 3NA:.830 & S1F83
Holder ) Transformer-2 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
20 12 F40 Low Voltage Fuse (with 3NA:.830 & S1F84
Holder ) Transformer-2 3NH3030 of
Secondary GrOO. M/s Siemens
500V/100A, GL/GG 03919,03760
of ms Wohner
21 12K01 Contactor Feeder1 3Pole LC1- S2K01
voltage 1KV control F630
voltage AC440 V +101-
20% 50 Hz current 630
amps 4 no + 4 nc
22 12K02 Contactor Bus Coupler LC1- S2K02
3Pole voltage 1KV control F630
voltage AC440 V +101-
20% 50 Hz current 630
amps 4 no + 4 nc
23 12K03 Contactor Feeder2 3Pole LC1- S2K03
voltage 1KV control F630
voltage AC440 V +101-
20% 50 Hz current 630
amps 4 no + 4 nc
24 12K04 supply generator 1 EK110- S2K04
contactor LS55K4.11; AC 40-11
440V+10/-20%;50Hz mit
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place of
S.N Item Drawing No
installation
Hilfsschalter 1S+10z.B.
HS 8K11
place of
S.N Item Drawing No
installation
or HV networks AC or DC
Aux. Supply
Measurement & Display
11,V,I,In
P,Q,S,PF,F,Ea,Er & Es
THD for V&l with lead bar
graph in 96x96
Sq.mm.Flush mounted
case with six direct
access keys & backlit
LCD,Accuracy Class 1.0
39 12 P12 Ammeter NP72 class 1.5 ; S2P12
CT 400/5 A; scale
0..400/800 A
40 12 S01 rotary switch with marking 3LB3 230- S2S01
" L1-L2-L3-0 " L1-L2-L3 6RQ01
41 12 S05 Press button power car 3593 001- S2S05
from net gaff rd, dia 22.5 0AA213SB3
mm with "0" 400 -OD35131
901-4AZ/KlY"0"
42 12 S06 Light push button S2S06
power car from feeder 2
on green , dia 22.5 mm
with "V' LED type 24 VOC
43 12 T04 Current transformer 4NC13 25- S2T04
4NC13 25-2CE20-Z 2CE20-Z
A13+A15 Al3+A15,
400A15A;5VA;voltage
800V;class 3;
44 12 T05 Current transformer 4NC13 25- S2T05
4NC13 25-2CE20-Z 2CE20-Z
A13+A15 A13+A15,
400A15A;5VA;voltage
800V;class 3;
45 12T06 Current transformer 4NC13 25- S2T06
4NC13 25-2CE20-Z 2CE20-Z
A134A15 A13+A15,
400A/5A;5VA;voltage
800V;class 3;
46 12 T07 Current transformer 4NC13 25- S2T07
4NC13 25-2CE20-Z Al 2,E20-Z Al 34-
3+A15 A15,
400A/5A;5VA;voltage
800V;class 3;
47 12 T08 Current transformer 4NC13 25- S2T08
4NC13 25-2CE20-Z Al 2CE20-Z S2T09
3+A15 Al3+A15,
400A15A;5VA;vottage 4NC13 25-
800V;class 3; Current 2CE20-Z
transformer 4NC13 25- A13+A15,
48 12 T09 2CE20-Z
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place of
S.N Item Drawing No
installation
A13+A15400A/5A;5VA;vo
ltage 800V;class 3;
49 12 T10 Measuring Current 911 728 CT- S2T10
Transformer; Rated 1/110
burden
180ohm;10A,50mVA W4-
P dia 100mm
50 S2T14 Currenttransformer4NC 4NC13 25- S2T14
13 25-2CE20-Z A13+Al 5 2CE20-Z Al S2T15
400A15A;5VA;voltage 3+A15,
800V;dass 3; 4NC13 25-
Currenttransformer4NC1 2CE20-Z
3 25-2CE20-ZA13+A15 A13+A15,
51 12 T15 400A15A;5VA;voltage
800V;class 3;
52 12 T16 Current transformer 4NC13 25- S2T16
4NC13 25-2CE20-Z 2CE20-Z
A13+A15 Al3+A15,
400A/5A;5VA;voltage
800V;class 3;
53 12 T17 Current transformer 4NC13 25- S2T17
4NC13 25-2CE20-Z 2CE20-Z Al
A13+A15 3+Al 5,
400A/5A;5VA;voltage
800V;class 3;
54 12 T18 Current transformer 4NC13 25- S2T18
4NC13 25-2CE20-Z 2CE20-Z
A13+A15 A13+A15,
400A/5A;5VA;voltage
800V;class 3;
55 12 T19 Current transformer 4NC13 25- S2T19
4NC13 25-2CE20-Z A13- 2CE20-Z
FA15 A13+A15,
400A/5A;5VA;voltage
800V;class 3;
56 12 T20 Measuring Current 911 728 CT- S2T20
Transfomer; Rated 1/110
burden
180ohm;10A,50mVA W4-
P dia 100mm
57 13S02 rotary switch with marking 3LB3 230- S2S02
" L1-L2-L3-0 " L1-L2-L3 6RQ01
58 14S03 press button 3S83 001- S2S03
power car from feeder 1 0AA21 3SB3
off rd, dia 22.5 mm 40) -OD
59 15 S04 Light push button S2S04
power car from feeder 1
on
green , dia 22_5 mm LED
type 24 VDC
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place of
S.N Item Drawing No
installation
60 16H16 Indication S2S04H1
lamp(LED)power supply
from feeder 1 Integrated
in 12 SO4
61 21S03 press-button trafa 2 off 3SB3 001- S2S09
rd,dia22.5mm, 0AA21 3SB3
400-OD
62 21 F07 Fuse 5x20mm ( fuse 19 201 282- S2F19
clamp at X1.2) safety 122(damp)
loop-2 T1A
63 21 F08 fuse5x20mm( fuse clamp 19 201 282- S2F20
at X1.2) safety loop-1TlA 122(camp),
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PERIODICITY
D1 = TRIP INSPECTION
D2 = 03 MONTHS
D3 = 06 MONTHS
8.6.1 Alternator
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vi) Check leakage of fuel, lubricating oil and coolant. Attend, if required
vii) Check all hoses, pipes for any leakage. Arrest all leakages immediately
to make Generator Car free from oil & water tracing
viii) Check and ensure proper condition of safety nut bolts of fuel tank.
ix) Check and clean engine & its oil tray to make it free from any oil traces
& dust
x) Drain water from fuel water separator through drain valve
xi) Check and ensure proper condition of mounting bolts and various
vibration dampers/ anti vibration pads etc.
xii) Check and ensure proper cleaning of floor, wall etc in engine room
8.7.2 B Check/ 3 Monthly Schedule (D2)
Carry out B- Check after 300 running hrs/ 03 months for M/s Cummins make
Diesel Engine which shall include all works mentioned above in A check
schedule that must be carried out in addition to carrying out following additional
works during B- check of diesel engine:
a) Air system
i) Check condition of element for chocking/ torn sealing and attend
same,
ii) Check and ensure proper condition of Pre-Cleaner,
iii) Check and change Air cleaner element if required,
iv) Check and ensure proper condition of air hose,
v) Check and clean breather and
vi) Inspect exhaust line and rectify leakage, if any.
b) Fuel system
i) Change fuel filter,
ii) Check hose condition: fuel supply & drain line,
iii) Check & clean the tank and Non Return Valve and attend the same,
if required
iv) Inspect fuel system and attend same, if required.
c) Lubricating system:
i) Change lube oil filters,
ii) Change lube oil,
iii) Change super by pass filters,
iv) Check Lube Oil Pressure (LOP) Gauge,
v) Check Lube Oil Temperature (LOT) Gauge,
vi) Check the filter for any metal particles due to wear and tear of any
part inside engine,
vii) Change Governor oil
d) Cooling System:
i) Check and ensure proper coolant Ph value,
ii) Check and ensure proper coolant concentration,
iii) Check and ensure proper Cleaning of Breather,
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ix) The above is as per OEM recommendation and may be suitably changed
if the OEM issues any change. The recommendation of the OEM shall be
final.
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ANNEXURES
POWER SUPPLY DIAGRAM FOR HOG POWER CAR SWITCH BOARD CABINET
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60 kVA Transformer
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Alternator B Supply
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