Simens Dual Cab TSG (Trouble Shooting) PDF

Troubleshooting Guide Page 1 of 97
Troubleshooting Guide
SIEMENS make
WDG4/WDP4B/WDP4D
4500 HP Locomotives.
Issue Date: 08.02.2012

Document No: ZFI-001-V1.1
Applicable for: WDG4/WDP4B/WDP4D-4500HP
Version: 1.1
TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

Overview of revisions
Version Author Date published Revised Revisions
sections
V1.0 New Version for S3 locomotives
V1.1 F and I Changed as per Dual Cab.
Document has been checked by

Name Department Telephone
Typographical conventions
Font type Significance
Courier New The Courier New font type designates program text, user
entries and text that is displayed on the screen.
File Open Vertical separating lines represent the command sequence in
menu structures. File Open refers to the Open command
in the File menu item.

List of abbreviations
Abbreviation Significance
4QC Four quadrant controller (chopper)
ADU Analog-digital converter
AGT Automatic Guided Train
TCU Traction Control Unit
C1 Cyclic pulse-synchronous time class 1
DG Bogie
EM Event message, Ereignismeldung
FPGA Field Programmable Gate Array
SSC Slip and slide control
AUX INV Auxiliary inverter
HSSC High Speed Serial Connection
HW Hardware
IGBT Insulated Gate Bipolar Transistor
MVB Multifunction Vehicle Bus
PWI Pulse width modulation inverter
SIBAS Siemens Bahn-Automatisierungssystem [Siemens Railway Automation
System]
SITRAC Siemens Traction Control
SR Status register
SW Software
CPU Central Processing Unit TCU
CCU Central Control Unit

INTRODUCTION
General information on this document

The objective of this document is to provide service personnel with practical support
so that they can quickly restore operational readiness and when troubleshooting and
resolving faults.
Introduction includes general information and instructions on how to handle the
SIBAS diagnostics system. A general description on Safety Measure and
information is elaborated in Chapter A.
Chapter B, C,D,E,Fand G contains the tools required and procedure for
downloading the Fault Archive, and how to read the Archive faults,
Chapter H explains the environment of the CPU and Chapter I is the place where
one can find the troubleshooting tips. In this the faults are arranged in the increasing
order and so is a handy tool for the mainitenance personal to troubleshoot.
Area of validity of this document
The contents of this document are based on the general detailed troubleshooting
instructions for the SIBAS software in the CPU with Version 1.24 or higher.This
document has been adapted for the WDG4/WDP4B/WDP4D 4500 HP Locomotives
with Siemens AC-AC traction system. Reference is made to the specific features of
this Locomotive with SIBAS as the sole Loco Controller – e.g. the actual hardware
components. Subjects that are not applicable have been omitted.
This document refers to software version V1.24 or higher, status as on 08.08.2010.
The descriptions on the the SIBAS monitor apply to monitor versions >= V3.2.
Information on how to use this document
There are many cross-references to additional information or more in-depth
information in this document. A jump is automatically made to the corresponding
reference location by clicking on these cross-references.

TABLE OF CONTENT
A. SAFETY MEASURES AND INFORMATION 6
B. TOOLS & INSTRUMENTS REQUIRED TO CONNECT LAPTOP WITH

SIBAS 7
C. PROCEDURE TO READ THE EVENT MEMORY IN CPU AND SIP. 8
D. PROCEDURE WHEN TROUBLESHOOTING 22
E. EVENT RESPONSES AND OPERATIONAL RESTRICTIONS 24
F. COMPREHENSIVE STUDY ON DIAGNOSTIC MESSAGES AND

RESTRICTION CLASS 25
G. CREW MESSAGES 31
H. EXPLANATION OF THE EVENT ENVIRONMENT DATA OF CPU 32
I. DETAILED TROUBLESHOOTING TIPS 52

A. SAFETY MEASURES AND INFORMATION

DANGER
Strictly observe the usual safety rules when carrying-out work on electrical
equipment.
Only use tools and equipment that are permitted when working at and in the
traction inverter cabinet. This also refers to all cables that are either temporarily or
permanently connected to the CPU and SIP. Connecting cables between the
CPU,SIP and PC or measuring/test equipment must fulfill special
requirements/specifications. This is the reason that only equipment released by
Siemens may be used!
Safety rules when carrying-out work on electrical equipment:

1. Bring the system into a no-voltage condition!
2. Lock-out the system so that it cannot be powered-up again!
3. Ensure that the system actually is in a no-voltage condition!
4. Ground the system and short-circuit it!
5. Live parts and components must be covered!
Further, please carefully consider the following:
- Even after a longer period of time powered-down, a traction converter can still be
dangerous due to the residual charge and can severely injure people.
- The same dangers exist when working on components of the traction equipment and
their associated feeder cables associated with the traction converter and all of the
connecting cables.
- It can take longer than one hour until the capacitors have been discharged. Even after a
longer waiting time, carefully ensure that the capacitors have really been discharged and
actually are in a no-voltage condition.
Capacitors that have not been suitably short-circuited, resume a voltage even when
disconnected! This is the reason that when replacing capacitors, their connections must be
suitably short-circuited; it goes without saying that this short-circuit must be removed after
installation and connecting-up.
- Since it is necessary to open the traction converter cabinets to access the service
interfaces of the TCU, the same safety rules apply as when carrying-out work on the traction
converter cabinet. When “temporarily” connecting interfaces to external equipment, extreme
care must be taken when routing cables so that the cables have an adequate protective
clearance to the live parts and components. Connectors must be fixed in place
corresponding to their design (latched-in or screwed into place).
- Carefully observe all of the safety information and instructions provided in this
documentation and at the devices and vehicles.
- Only use original spare parts from the manufacturers or parts and components
recommended by the manufacturer.

B. TOOLS & INSTRUMENTS REQUIRED TO CONNECT LAPTOP WITH SIBAS
1. Laptop (Windows 2000/XP, serial port or a USB interface with a USB-to-

serial interface adapter, Monitor Software version or higher)
2. Programming Bridge (required only during loading of software)
3. ASG door key
4. For connecting the PC and Sibas:

A standard “null modem” cable (9 / 9 pin connector) can be used to connect from the
laptop to Sibas directly. Connect the 9 pin female end to the RS232 port of the laptop
and the other end to the X3 port of G027 (CPU) card of sibas32. The requirement of
the cable layout is shown.
below:
OR
a standard "null modem" cable (RS232 serial communication cable 9 pin connector)
is connected witht the 15 pin connector on the diagnostic panel with the following
configuration:

C. PROCEDURE TO READ THE EVENT MEMORY IN CPU AND SIP.
1. Start the monitor.
2. Create a file for storing diagnostic datas on the laptop by inputting the following
command Set | String
3. A small window pops up, select /Record

4. Enter the folder and file name in the monitor buttom line.
At most 8 letters or numbers are permitted, followed by a dot and three signs expansion i.e. txt.
(E:\S3 Tools\12276PPT.TXT) as shown below.

5. Start recording by inputting the following command in the editor menu of monitor
Set | Record
a small window pops up, select Create

At this moement, all datas from the serial connection are written into the file. The type of file is
ASC (text file).
6. Reading out diagnostic memory CPU

Events | DStatistics <Enter>
Events | DHistory <Enter>
Events | AEL_allEvntL <Enter>


7. Reading out operating data memory CPU

Events | PStatistics <Enter>
Events | PHistory <Enter>

8. Reading out SIP-1 diagnostic memory

Hardw. | DSP
a small window pops up, select 0_PWR0

After press [Enter] the SIP Monitor window pops up.

Events | Statistics
Events | History
Events | AEL_allEvntL
Hardw. | ZR the CPU Monitor pops up.




9. Reading out SIP-2 diagnostic memory

Hardw. | DSP
a small window pops up, select 1_PWR1

After press [Enter] the SIP Monitor window pops up.

Events | Statistics
Events | History
Events | AEL_allEvntL
Hardw. | ZR the CPU Monitor pops up.
Just as was done for SIP1.

10. Close the recorded file

Important! (Otherwise you will lose datas). Now is the possibility to rename the data file.
Only then can a comprehensive analysis be made. When required, experts from Siemens
service can provide support. Data is centrally read-out via the MVB using the service connector
(located to the right of the driver’s control desk) or via a serial service interface of one of the
control units in SIBAS.
The event memory should only be erased once the cause of the fault has been identified!
Erasing the memory itself is also saved as an event. The events available at this instant are re-
entered, however, the original data relating to the environment are overwritten by data that is
presently available at that instant in time.

D. PROCEDURE WHEN TROUBLESHOOTING

The event memory in the CPU
The diagnostics memory
The diagnostics memory is the most important basis when troubleshooting.
In the case of a diagnostic event (also called maintenance message), a diagnostics entry is set-
up in the CPU involved and suitable protective responses are initiated. In addition, an entry is
made when the event disappears – i.e. generally if the event conditions no longer exist. Each
entry includes an event time (appearing time and disappearing), an event code, the event text,
event frequency and the data set number and the data in an extensive event environment.
The event environment data represent a process image at the instant that the fault occurred
(“snap shot”). This data provides important information about the operating state of the system
at the instant that the fault occurred. In the case of group messages, the environment data
provide valuable information about the individual fault causes.
The operating data memory
In addition to the diagnostics memory there is also the operating data memory. Operational
events are saved in this memory - and can then be used to identify the reason for the
operational restrictions. The operating events are operational events that are not based on fault
events. However, they can lead to operational restrictions as a result of the CPU. In conjunction
with diagnostic events, this information can also be of significance for faultfinding.
Additional responses in the vehicle control system
In the CPU
If a diagnostics entry was saved in any CPU, the existence of an entry is displayed by an event
in the CPU.
Displays
A diagnostics event that results in an operational restriction and where the locomotive driver
must be informed, results in a corresponding message on the driver’s cab display SITET. Only
the type of operational restriction is displayed and not the individual fault cause. The message
only remains as long as the operational restriction is present.
Other helpful monitor menus
Hardware | Info
and
User | Versions
Identification of the hardware and software used
Events | Userfunction
Language changeover, German – English.
Component test
The component test routine is performed when starting up – with a different scope - and
automatically after specific diagnostic events. For troubleshooting, it can also be manually
started via a menu in the CPU
Commissioning | Run Comp. Test.
If a fault is found during the component test, then an appropriate diagnostics entry is
Software Traco
Using the Software Traco the characteristics of up to 32 freely selectable software signals can
be recorded in the CPU and SIP memory. (Traco = Transient recorder)
The record can be triggered using any signals from the software. Two trigger signals can be
specified. It is also possible to trigger the record from analog signals - or from the CPU.
The record can be triggered from a diagnostics or operational event to be traced by specifying
the signal DMxyz.IN as trigger source. “xyz” stands in this case for the event code – whereby
for two-digit event code, a leading zero should be added.
A trigger delay of between 0 and 100% can be set.
Any time slice can be specified as sampling time; a sub-sampling factor can also be specified.
The fastest time slice is typically 250us. This means that signal recording times ranging from
several milliseconds up to several hours are possible. The record time is calculated and
displayed after entering the associated parameters.
Observer
The observer is a standard function of the SIBAS monitor and allows up to eight software
signals to be continuously monitored online. When monitoring is stopped – either manually or as
a result of a trigger signal that can be set – the signal characteristics with respect to time are
saved.

E. EVENT RESPONSES AND OPERATIONAL RESTRICTIONS
The possible event responses and the resulting operational restrictions are specified in this
Chapter. The necessary measures to restore operational readiness are also specified in this
chapter.
The event responses are those made from the CPU, supplemented by additional event
responses by the SIP and CCB including messages on the driver’s cab display.
Type Restriction Class Restriction Imposed

A Engine Shoutdown Inverter Pulses are blocked immediately.
Excitation is cutt-off (GFD/GFC drop).
B Hard Stop Excitation Inverter Pulses are blocked immediately.
Excitation is cutt-off (GFD/GFC drop).
C Soft Stop Excitation Blocker after reaching zero torque.Torque value
consider for action is REFERANCE value.
Excitation is cutt off (GFC/GFD drop)
D Discharge TCC Stop the excitation.Inverter pulses block
immediately.DC link discharge through DB
grids
E Hard Stop Inverter A/B Inverter Pulses are blocked immediately.
F Soft Stop Inverter A/B Blocker after reaching zero torque.Torque value
consider for action is REFERANCE value.
G Event Code Alarm Bell Bell for crew attention (5/30/120 sec)
H SIBAS Lock Out Mode SIBAS goes to lock mode ,hence no
information can be passed to Display
I Information Message Stored in fault archive.No operation affected
J Power or Torque Reduction Only power or torque is reduced,but operation

is not effected.
K KNORR CPU Action taken by KNORR CPU.Refer KNORR
manual
L No Battery Charge Battery charging inhibited.

F. Comprehensive Study on Diagnostic Messages and Restriction Class






G. CREW MESSAGES

H. EXPLANATION OF THE EVENT ENVIRONMENT DATA OF CPU
Instance of the CPU Environment
vehicle number ......................... = 012276

tcu number ............................. = 16
software version ....................... = 1.14
last delete time ....................... = 00.00.0000 00:00:00
diagnosis code ......................... = 506
diagnosis freq. ........................ = 1
Dgn.text: Plug loop X11 to X13 is open, torque reduction for Inverter 1
activated
incoming (date, time) .................. = 13.04.2010 07:08:56
outgoing (date, time) .................. = 00.00.0000 00:00:00
event number ........................... = 5
Switch-on time LCU ..................... = 25.03 s
State circuit breakers ................. = 0000 H |0000|0000|0000|0000|
MVB input signals 1 .................... = 0000 H |0000|0000|0000|0000|
MVB output signals 1 ................... = 0800 H |0000|1000|0000|0000|
Input signals CPU board ................ = 0016 H |0000|0000|0001|0110|
Input signals EBIN 1 ................... = 0E01 H |0000|1110|0000|0001|
Input signals IO board ................. = 00BC H |0000|0000|1011|1100|
Status Word Temperatures ............... = 0800 H |0000|1000|0000|0000|
Status Word 1 .......................... = 00FF H |0000|0000|1111|1111|
Status word 2 .......................... = 4F04 H |0100|1111|0000|0100|
Status word 3 .......................... = 0000 H |0000|0000|0000|0000|
Status word 4 .......................... = 0C0B H |0000|1100|0000|1011|
Status word 5 .......................... = 0064 H |0000|0000|0110|0100|
Logic Word 1 Speed Monitoring .......... = 1000 H |0001|0000|0000|0000|
Logic Word Creep Control B/A ........... = 4040 H |0100|0000|0100|0000|
Loco type checked and unchecked ........ = 257
Logic word excitation .................. = 0000 H |0000|0000|0000|0000|
Status word from SIP PWR-A ............. = 0182 H |0000|0001|1000|0010|
Status word from SIP PWR-B ............. = 0182 H |0000|0001|1000|0010|
State time PWR-A ....................... = 25.05 s
State time PWR-B ....................... = 25.05 s
State time excitation .................. = 25.05 s
Load Req. Gov.Req. TH position ........ = F001 H |1111|0000|0000|0001|
Reference for DC-Link voltage .......... = 600.00 V
DC-Link Ground voltage ................. = -1.75 V
DC Link-A voltage ...................... = 0.00 V
DC Link-B voltage ...................... = -0.25 V
Reference for excitation current ....... = 0.00 A
Excitation current ..................... = 0.00 A
DC-Link current plus side .............. = 1.47 A
DC-Link current minus side ............. = 1.47 A
CA voltage ............................. = -0.20 V
DC-Link power Inv.A .................... = 0.00 kW
DC-Link power Inv.B .................... = 0.00 kW

CA frequency ........................... = -0.07 Hz

Engine speed ........................... = 0.00 1/min
Turbo speed ............................ = 0.00 1/min
Current brake grid A ................... = 2.57 A
Current brake blower A ................. = 0.02 A
Current brake grid B ................... = 1.65 A
Current brake blower B ................. = -0.02 A
TE reference for bogie 1 ............... = 0.00 kN
Torque ref.CPU to SIP-A ................ = 0.00 Nm
Torque feedback SIP-A to CPU ........... = 0.00 Nm
Torque ref.CPU to SIP-B ................ = 0.00 Nm
Torque feedback SIP-B to CPU ........... = 0.00 Nm
Rotorspeed TM1 ......................... = 0.00 1/s
Rotorspeed TM2 ......................... = 0.00 1/s
Rotorspeed TM3 ......................... = 0.00 1/s
Rotorspeed TM4 ......................... = 0.00 1/s
Rotorspeed TM5 ......................... = 0.00 1/s
Rotorspeed TM6 ......................... = 0.00 1/s
Track speed ............................ = 0.00 m/s
Radar speed checked .................... = 0.00 km/h
Engine temp probe1 ..................... = 0.00 degC
Temp. Ambient .......................... = -50.00 degC
Temp. electronic SIBAS ................. = 36.65 degC
Temp. IGBT junction inv.A .............. = 2.50 degC
Temp. modul A11 ........................ = 93.55 degC
Temp. modul A12 ........................ = 91.58 degC
Temp. modul A13 ........................ = 86.95 degC
Temp. IGBT junction inv.B .............. = 2.50 degC
Temp. modul A21 ........................ = 84.65 degC
Temp. modul A22 ........................ = 81.18 degC
Temp. modul A23 ........................ = 82.50 degC
Temp.laminated core TM1 ................ = 61.78 degC
Temp.winding TM1 ....................... = 61.23 degC
Signal: $82A4D01 Loco number, set via Monitor Menu

vehicle number ......................... = 012276
Signal: $82A4D01 Loco number, set via Monitor Menu

tcu number ............................. = 16
Signal: by system CPU software version

software version ....................... = 1.14

Signal: by system Fault archive was deleted on this date and time
last delete time ....................... = 00.00.0000 00:00:00
Signal: by system Diagnosis code (between 1 and 1023)

diagnosis code ......................... = 506
Signal: by system How often has this event occurred

diagnosis freq. ........................ = 1
Signal: by system Text for the diagnosis code

Dgn.text: Plug loop X11 to X13 is open
Signal: by system Incoming time stamp

incoming (date, time) .................. = 08.04.2010 16:16:31
Signal: by system Outgoing time stamp

outgoing (date, time) .................. = 00.00.0000 00:00:00
Signal: by system actual number for this event entry. (Equal to "time stamp" below 1s)
event number ........................... = 5
if there are more entrees at the same time, then the lower number shows the preview entree. The
highest number is the last entree.
Signal: $04A1T01 time is starting with power supply on

Switch-on time LCU ..................... = 25.03 s
Signal: $02D2010 feedback signals circuit breakers

State circuit breakers ................. = 0000 H
|0000|0000|0000|0000|
Bit 0 CB for loco control is on
1 CB Filter blower is on
2 CB TCC1 blower is on
3 CB TCC2 Blower is on
4 CB pneumatic control is on
5 CB turbo lube pump is closed
6 CB CB Aux. Gen. field is closed
7 CB event recorder is closed
8 CB fuel pump is on
9 CB local control is on
10 CB Air brake electronic is on
11 0
12 0
13 0
14 0
15 0

Signal: $02D2011 MVB Input Signals part 1

MVB input signals 1 .................... = 0000 H
|0000|0000|0000|0000|
Bit 0 switch VCD (equal to SIFA) is off
1 brake warning relays is on (1= no dynamic brake)
2 compressor synchronisation relays is on (1=syn. for multiple unit)
3 GFD contactor is on
4 Contactor TCC1 Blow is on
5 Contactor TCC2 Blow is on
6 TCC power supply chopper is on
7 wheel slip light is on
8 radiator fan 1 slow speed contactor is on
9 radiator fan 2 slow speed contactor is on
10 radiator fan 1 fast speed contactor is on
11 radiator fan 2 fast speed contactor is on
12 brake contactor B1 is on

|0000|0000|0000|0000|
Bit 0 air dryer control relays is on
1 start contactor is on
2 alerter reset switch is closed (equal to --> reset SIFA)
3 blended brake enabled
4 dynamic brake enabled
5 engine filter switch is on (1=limit TH)
6 filter vacuum switch is on (0=limit TH)
7 low oil switch (shut down engine)
8 ISOLATION switch in isolate position
9 ISOLATION switch in run position
10 Horn is activated
11 engine water level is ok
12 engine fuel switch is in normal position
13 engine start switch in prime position
14 start engine cranking
15 alarm is on (bell is ringing)


|0000|0000|0000|0000|
Bit 0 engine run switch, 1=allow throttling
1 wheel slip light is on (TL 10)
2 compressor run relays is on (1=compressor is on)
3 brake warning relays is on (stop dynamic braking)
4 CB fuel pump switch is on
5 loco is in lead position
6 Manual Sanding switch is pressed
7 REVERSER Handle in Forward
8 REVERSER Handle in Reverse
9 Tractive effort limit signal from trailing loco (TL 14)
10 tractive effort limit relays feed back also to trailing locos (TEL FB)
11 automatic emergency brake is selected
12 tractive effort switch (own loco) is on (TEL SW)
13 turbo lube relays is on (TLPR)
14 head light short hood, switch is closed
15 head light long hood, switch is closed

|0000|0000|0000|0000|
Bit 0 fuel pump relays is on (FPRLY)
1 start fuse is ok
2 governor booster pump is running (while cranking)
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0

Signal: $30D3010 MVB output signals part 1

MVB output signals 1 ................... = 0800 H
|0000|1000|0000|0000|
Bit 0 cmd. Valve A on engine stop = 8H; low idle = 9 H
1 cmd. Valve B on idle and notch 1 = 0 H
notch 2 = 1 H; notch 3 = 4 H; notch 4 = 5 H; notch 5 = E H
2 cmd. Valve C on
notch 6 = F H; notch 7 = 6 H; notch 8 = 7 H
3 cmd. Valve D on
4 0
5 Contactor Brake Gird 1 on
6 Contactor Brake Gird 2 on
7 0
8 Compressor Synchronisation on
9 Dryer Control Relay is on (DCR)
10 Dewatering valve is on
11 MV Compressor Control is OFF
12 MVS F sanding forward
13 MVS R sanding reverse
14 MVS F sanding forward
15 MVS R sanding reverse

|0000|1000|0000|0000|
Bit 0 0
1 cmd. fuel pump relays on
2 cmd. Flasher relays on
3 cmd. GFC on (excitation box input voltage)
4 cmd. GFD on (excitation box output voltage)
5 0
6 cmd. RADAR wipe system on (MVRB energizing)
7 cmd. Relay for RADAR test on (RDRTST active)
8 cmd. Relay for Lube pump on
9 cmd. wheel flange lubrication Nozzle forward
10 cmd. wheel flange lubrication Nozzle reverse
11 cmd. TURBO PUMP RELAIY on
12 Wheel slip test (turn on wheel slip relais)
13 Alerter Light ON
14 Alerter alarm ON
15 Sanding active


|0000|1000|0000|0000|
Bit 0 0
1 0
2 cmd. FAN1 contactor fast on
3 cmd. FAN2 contactor fast on
4 cmd. FAN1 contactor slow on
5 cmd. FAN2 contactor slow on
6 cmd. START RELAY on
7 cmd. TCC1 blower relay on
8 cmd. TCC2 blower relay on
9 0
10 0
11 0
12 0
13 0
14 0
15 0
Signal: $03A2X03 Input signals CPU board

Input signals CPU board ................ = 0016 H
|0000|0000|0001|0110|
Bit 0 hard crowbar is fired
1 GFD Relays via SIP not enabled
2 hardware blocking UWSI-A G011
3 hardware blocking ESH C163
4 LCU electronic blower monitoring
5 Status Bit 0 board "power start-up unit"
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0

Signal: $03A2X04 Input signals EBIN 1

Input signals EBIN 1 ................... = 0E01 H
|0000|1110|0000|0001|
Bit 0 feedback K11 is on
1 feedback Q8 is on
2 feedback Q8 is off
3 feedback Q9 is on
4 feedback Q9 is off
5 reserved for HEP: feedback Q10 is on
6 reserved for HEP: feedback Q10 is off
7 reserved for HEP: feedback Q11 is on
8 reserved for HEP: feedback Q11 is off
9 feedback internal fault excitation box
10 feedback external fault excitation box
11 X21, X22, X23 Plug Loop is open (signals for PWR-B)
12 0
13 0
14 0
15 input d08, signal L_TESTE
Signal: $03A2X02 Input signals IO boards

Input signals IO board ................. = 00BC H
|0000|0000|1011|1100|
Bit 0 hard crowbar PWR-A is on
1 hard crowbar PWR-B is on
2 soft crowbar PWR-A is on
3 soft crowbar PWR-B is on
4 pulse blocking by hardware
5 hardware protection signal "HTOT_A" active
6 plug monitoring LCU boards
7 -
8 DC-Link current plus side hardware limit reached
9 DC-Link current minus side hardware limit reached
10 Brake Grid current A hardware limit reached
11 Brake Grid current B hardware limit reached
12 DC-Link current minus side hardware limit reached
13 IG1, MGeno Diodes monitoring on plus side active
14 IG2, MGeno Diodes monitoring on minus side active
15 -

Signal: $83A4X01 Status word temeperatures from SIP-A

Status Word Temperatures ............... = 0800 H
|0000|1000|0000|0000|
Bit 0 PWA: Module temperature Phase L1 ok
1 PWA: Module temperature Phase L2 ok
2 PWA: Module temperature Phase L3 ok
3 Communication Back Ground 1 P11 SIP-A ok
4 PWB: Module temperature Phase L1 ok
7 Communication Back Ground 1 P12 SIP-B ok
8 measured laminated core temperature TM1 ok
11 A/D Ambient Temperature valid
15 Board temperatures from SIP-A and SIP-B valid
Signal: $84A1X02 Status word 1

Status Word 1 .......................... = 00FF H
|0000|0000|1111|1111|
Bit 0 speed value TM1 not valid
1 speed value TM2 not valid
3 direction request checked (1 = F1; 0 = F2) F1=SH; F2=LH
7 RADAR for wheel slip off
8 enable pulses for PWR A
9 PWR-A in power state
10 PWR-A in electrical braking state
11 any speed value of TM1 or TM2 or TM3 is permanently not valid
12 enable pulses for PWR B
13 PWR-B in power state
14 PWR-B in electrical braking state
15 any speed value of TM4 or TM5 or TM6 is permanently not valid


Status word 2 .......................... = 4F04 H
|0100|1111|0000|0100|
Bit 0 Propulsion command for TCU
1 Braking command for TCU
2 engine is running
3 Request for operation PWR-A
4 Request for operation PWR-B
5 SIP A: request for cut out DC-Link A
6 SIP B: request for cut out DC-Link B
7 Crowbar on (maybe)
8 Torque reduction by electrical creep control in Bogie 1
9 Torque reduction by electrical creep control in Bogie 2
10 PWR-A module Over Temperature
11 PWR-B module Over Temperature
12 Over Temperature TM1 or TM2 or TM3 in Bogie 1
13 Over Temperature TM4 or TM5 or TM6 in Bogie 2
14 hardware blocking by UWSI board
15 1: 4 Traction Motors 0: 6 Traction Motors

Status word 3 .......................... = 0000 H
|0000|0000|0000|0000|
Bit 0 PWR-A warning level junction temperature reached
1 PWR-A junction over temperature
2 PWR-B warning level junction temperature reached
3 PWR-B junction over temperature
4 Contactor for TCC Blower 1 is on
5 Contactor for TCC Blower 2 is on
6 Circuit Breaker for TCC blower 1 is on
7 Circuit Breaker for TCC blower 2 is on
8 Radar speed valid
9 0
10 0
11 0
12 0
13 0
14 0
15 0

Signal: $21A3X01 Status Word 4 based on FP "ZUST"

Status word 4 .......................... = 0C0B H
|0000|1100|0000|1011|
Bit 0 request for soft stop PWR A
1 request for soft stop PWR B
2 request for enable excitation
3 generator power is disconnected
4 generator power is connected
5 cmd. Reset buffered locks
6 PWR A is in operation
7 PWR B is in operation
8 PWR A ready for operation
9 PWR B ready for operation
10 Request for Soft Crowbar A
11 Request for Soft Crowbar B
12 Request for Brake Grid A
13 Request for Brake Grid B
14 Request to SIP-A for enabling pulses
15 Request to SIP-B for enabling pulses
Signal: $21A3X02 Status Word 5 based on FP "ZUST"

Status word 5 .......................... = 0064 H
|0000|0000|0110|0100|
Bit 0 contactor Q8 is closed
1 contactor Q9 is closed
2 contactor K11 is closed
3 Contactor brake grid 1 is on
4 Contactor brake grid 2 is on
5 DC Link is discharged
6 Engine is running
7 Enable excitation from FP "LOCCTRL"
8 FP "GENO" Load Enable
9 Request for blocking PWR-A and PWR-B
10 bogie cut out operation
11 Direction Forward
12 Direction Reverse
13 Propulsion command for TCU
14 Braking command for TCU
15 Setup dynamic brake

Signal: $43A2001 monitoring speed values TM1 to TM3

Logic Word 1 Speed Monitoring .......... = 1000 H
|0001|0000|0000|0000|
Bit 0 Speed value TM1 total defective
1 Speed value TM1 difference to other speed values too big
2 SIP-A has set speed value TM1 to not valid
3 Speed value TM1 permanently not valid
4 Speed value TM1 sign is wrong
5 Speed value TM2 total defective
15 data from SIP-A to CPU not valid
Signal: $43A2002 monitoring speed values TM4 to TM6

|0000|0000|0000|0100|
Bit 0 Speed value TM4 total defective
15 data from SIP-B to CPU not valid

Signal: $43A7011 monitoring locked wheels

|0000|0000|0000|0000|
Bit 0 locked wheel axle 1 for display
1 locked wheel detection for axle 1 is enabled
2 locked wheel axle 2 for display
12 Radar speed valid
13 Engine speed not valid
14 bogie 1 is rolling back
15 bogie 2 is rolling back
Signal: $83A2W03 logic word for electrical creep control

Logic Word Creep Control B/A ........... = 4040 H
|0100|0000|0100|0000|
Bit 0 heavy reduction because of mech. chattering over torque in bogie 1
1 less reduction because of mechanical chattering over torque in bogie 1
2 heavy reduction because of mech. chattering over wheel slip in bogie 1
3 less reduction because of mechanical chattering over wheel slip in bogie 1
4 heavy reduction because of dn/dt control bogie 1
5 less reduction because of dn/dt control bogie 1
6 reduction done by wheel flat protection bogie 1
7 reserved
8 heavy reduction because of mech. chattering over torque in bogie 2
9 less reduction because of mechanical chattering over torque in bogie 2
10 heavy reduction because of mech. chattering over wheel slip in bogie 2
11 less reduction because of mechanical chattering over wheel slip in bogie 2
12 heavy reduction because of dn/dt control bogie 2
13 less reduction because of dn/dt control bogie 2
14 reduction done by wheel flat protection bogie 2
15 reserved

Signal: $93A7W16 Loco type

Loco type checked and unchecked ........ = 257
Bit 0 Loco type from hardware coding
to 0 = S1 MAC Type; 1 = PAC Type; 2 = S2 MAC Type; 3 = S2 PAC Type
7 4 = S3 MAC Type; 5 = S3 PAC Type
8 Loco type checked for using in software
to 1 = S1 MAC Type; 2 = PAC Type; 3 = S2 MAC Type; 4 = S2 PAC Type
15 5 = S3 MAC Type; 6 = S3 PAC Type
Signal: $14A3X01 Excitation in FP "GENO"
Logic word excitation .................. = 0000 H
|0000|0000|0000|0000|
Bit 0 feedback failure GFC and/or GFD
1 Feedback Load Enable
2 GENO has no Load
3 feedback Excitation Device has no faults
4 Command GFD ON
5 Command GFC ON
6 Feedback GFD is ON
7 Feedback GFC is ON
8 Feedback Excitation is Ready
9 Feedback Excitation is ON
10 Excitation Failure message
11 Enable Excitation Device
12 ACK Excitation Test Running
13 ACK Self load-Test Running
14 0
15 0
Signal: $83A2B03 Status word 1 from SIP-A to CPU

Status word from SIP PWR-A ............. = 0182 H
|0000|0001|1000|0010|
Bit 0 reserved
1 SIP-A can not close DC Link conductors
2 reserved
3 reserved
4 reserved
5 reserved
6 reserved
7 SIP-A is not ready for operation
8 SIP-A is not ready for enabling pulses
9 SIP-A inverter 1 permanent lock
10 SIP-A request for cut out DC Link for PWR-A
11 SIP-A common cut out request

12 SIP-A cut out request for testing components

13 SIP-A cut out request for own DC-Link (final)
14 SIP-A cut out request common final
15 SIP-A cut out request indefinite final
Signal: $83A2B07 Status word 1 from SIP-B to CPU

Status word from SIP PWR-B ............. = 0182 H
|0000|0001|1000|0010|
Bit 0 reserved
1 SIP-B can not close DC Link conductors
2 reserved
3 reserved
4 reserved
5 reserved
6 reserved
7 SIP-B is not ready for operation
8 SIP-B is not ready for enabling pulses
9 SIP-B inverter 1 permanent lock
10 SIP-B request for cut out DC Link for PWR-A
11 SIP-B common cut out request
12 SIP-B cut out request for testing components
13 SIP-B cut out request for own DC-Link (final)
14 SIP-B cut out request common final
15 SIP-B cut out request indefinite final
Signal: $TIZ_PA time for actual state PWR-A

State time PWR-A ....................... = 25.05 s
time will start from zero again if the actual state will change. (Idle, Power, dyn. Braking)
Signal: $TIZ_PB time for actual state PWR-B

State time PWR-B ....................... = 25.05 s
time will start from zero again if the actual state will change. (Idle, Power, dyn. Braking)
Signal: $TIZ_EXC time for actual state excitation

State time excitation .................. = 25.05 s
time will start from zero again if the actual state will change. (disable or enable excitation)
Signal: $26A3001 Load request, notch position

Load Req. Gov.Req. TH position ........ = F001 H
|1111|0000|0000|0001|
Bit 0 Notch position based on signal $09M3I00
to Recalculated from engine speed
7

8 Load request based on signal $14E4X04

to Used for calculating TE and Torque curves
15
Signal: $14A2U01
Reference for DC-Link voltage .......... = 600.00 V
actual reference for the DC-Link voltage, calculated in FP "GENO"
Signal: $03A2U01 actual measured ground voltage, sensor U33

DC-Link Ground voltage ................. = -5.75 V
measured Ground voltage, should be in static conditions ½ DC-Link voltage
Signal: $UDISTA actual DC-Link voltage, feedback from SIP-A, sensor U31
DC Link-A voltage ...................... = 0.00 V
measured DC-Link voltage from sensor U31, measured by SIP-A
Signal: $UDISTB actual DC-Link voltage, feedback from SIP-B, sensor U32
DC Link-B voltage ...................... = 0.00 V
measured DC-Link voltage from sensor U32, measured by SIP-B
Signal: $14A2I01 current reference to Excitation Box

Reference for excitation current ....... = 0.00 A
output value from FP "GENO" for controlling DC-Link voltage
Signal: $03A2I10 measured excitation current, feedback from Excitation Box

Excitation current ..................... = 0.00 A
measured excitation current, measured by excitation box
Signal: $03A2I01 absolute value DC-Link input current plus side, sensor U1
DC-Link current plus side .............. = 1.47 A
measured DC-Link current in plus side. You will see always a absolute value which is generated by
hardware on IO board
Signal: $03A2I02 absolute value DC-Link input current minus side, sensor U2
DC-Link current minus side ............. = 1.47 A
measured DC-Link current in minus side. You will see always a absolute value which is generated by
hardware on IO board
Signal: $03A2U14 measured CA voltage, feedback from excitation box

CA voltage ............................. = -0.20 V
measured CA voltage. Measurement is done by excitation box. Feedback will show the CA voltage
only if GFD and GFC is closed.
Signal: $83A2P07 DC Link power from PWR-A, calculated value

DC-Link power Inv.A .................... = 0.00 kW
calculated DC-Link power by SIP-A
Signal: $83A2P08 DC Link power from PWR-B, calculated value

DC-Link power Inv.B .................... = 0.00 kW
calculated DC-Link power by SIP-B
Signal: $03A2F15 measured CA frequency, feedback from Excitation Box

CA frequency ........................... = -0.03 H
measured CA frequency. Measurement is done by excitation box. Feedback will show the CA
frequency only if GFD and GFC is closed.
Signal: $43A2N07 engine speed, can be based on measured value or CA frequency

Engine speed ........................... = 0.00 1/min
measured and checked engine speed. At this time there is no over switching between measured eng.
speed and CA frequency in case of sensor fault, because of switching of GFC in operation. Without
GFC we also have no information about CA frequency.
Signal: $43A2N08 Turbo speed, based on Engine speed and measured Turbo value
Turbo speed ............................ = 0.00 1/min
measured and checked Turbo speed. If engine speed lower then TH6 then Turbo speed is engine speed
multiplied with 16,7
With engine speeds higher then TH6 the measured Turbo speed value is used.
Signal: $03A2I11 measured value

Current brake grid A ................... = 2.57 A
measured value of current in brake grid A, for DC-Link A (PWR-A)

Current brake blower A ................. = 0.00 A
measured value of current in blower for brake grid A for monitoring airflow

Current brake grid B ................... = 2.57 A
measured value of current in brake grid B, for DC-Link B (PWR-B)

Current brake blower B ................. = 0.00 A
measured value of current in blower for brake grid B for monitoring airflow
Signal: $21A4K21 Tractive Effort for Bogie 1 (SWK)

Reference for Tractive Effort Bogie 1, output FP "SWK"
Signal: $MSA Torque reference to SIP-A

Torque ref.CPU to SIP-A ................ = 0.00 Nm
Torque reference for SIP-A
Signal: $MISTA Torque feedback from SIP-A

Torque feedback SIP-A to CPU ........... = 0.00 Nm
Torque feedback from SIP-A
Signal: $21A4K22 Tractive Effort for Bogie 2 (SWK)


Reference for Tractive Effort Bogie 2, output FP "SWK"
Signal: $MSB Torque reference to SIP-B

Torque ref.CPU to SIP-B ................ = 0.00 Nm
Torque reference for SIP-B
Signal: $MISTB Torque feedback from SIP-B

Torque feedback SIP-B to CPU ........... = 0.00 Nm
Torque feedback from SIP-B
Signal: $NIST1 measured speed value TM1 from SIP-A

Rotor speed TM1 ......................... = 0.00 1/s
measured rotor speed traction motor 1, measured by SIP-A

Rotor speed TM2 ......................... = 0.00 1/s

Rotor speed TM3 ......................... = 0.00 1/s
Signal: $NIST4 measured speed value TM4 from SIP-B

Rotor speed TM4 ......................... = 0.00 1/s
measured rotor speed traction motor 4, measured by SIP-B

Rotor speed TM5 ......................... = 0.00 1/s

Rotor speed TM6 ......................... = 0.00 1/s
Signal: $_VISTGS calculated ground speed

Track speed ............................ = 0.00 m/s
calculated ground speed by electrical creep control (FP "GSS")
Signal: $43A2V01 measured and checked radar speed

Radar speed checked .................... = 0.00 km/h
measured and checked RADAR speed. RADAR is working only above 5,5 km/h
Signal: $15A4C01 measured engine water temperature sensor 1

measured engine cooling water temperature, probe 1
Signal: $15A4C02 measured engine water temperature sensor 2

measured engine cooling water temperature, probe 2

Signal: $02E3C30 measured ambient temperature

Temp. Ambient .......................... = -50.00 degC
measured ambient temperature. Feedback signal is corrected by software. It shows ~38°C at a
measured temperature of ~48°C
Signal: $83A4C66 measured electronic temperature, maximum from SIP-A and SIP-B
Temp. electronic SIBAS ................. = 36.25 degC
Maximum of measured temperature from SIP-A and SIP-B. Sensor fault is included.
Signal: $83A4C64 calculated IGBT Junction temperature from SIP-A

Temp. IGBT junction inv.A .............. = 2.50 degC
Calculated IGBT Junction temperature. Maximum for modules A11 to A13
Signal: $83A4C51 measured temperature phase module A11

Temp. modul A11 ........................ = 93.55 degC

Temp. modul A12 ........................ = 93.45 degC

Temp. modul A13 ........................ = 93.47 degC
Signal: $83A4C65 calculated IGBT Junction temperature from SIP-B

Temp. IGBT junction inv.B .............. = 2.50 degC
Calculated IGBT Junction temperature. Maximum for modules A21 to A23

Temp. modul A21 ........................ = 93.55 degC

Temp. modul A22 ........................ = 93.45 degC

Temp. modul A23 ........................ = 93.47 degC
Signal: $83A4C57 measured value, sensor placed in laminated core

Signal: $84A6C01 calculated winding temperature for TM1












I DETAILED TROUBLESHOOTING TIPS

Diag Fault
Fault Text Possible Causes Troubleshooting Tips
Code Class
1 H Software time error 1) Software not 1)If the fault occurs for the first
cycle T 1 uploaded properly. time then reload the software.
2) CPU Card Defective 2) Replace Central Processing

Unit (G067)

Unit (G067)

Unit (G067)

Unit (G067)

Unit (G067)

Unit (G067)

Unit (G067)
10 H Genaral-protection 1) CPU Card Defective 1) Replace central processing
or Ready-control unit(G067)
error occurred 2) TCU Modules 2) Check plugging of TCU-
modules
11 H CPU card (G067) 1) CPU Card Defective 1) Replace Central Processing
Self test failed Unit(G067)
Watchdog test Unit(G067)
failed
Diag Fault
Code Class
Self test failed Unit(G067)

15 H 5V power supply 1) Card Faulty 1) Check if both the LEDs on
faulty (card C145) front of the card C145 are
2) DC/DC Converter glowing
Faulty
2) Input voltage LED is off then
replace power supply card.
3) If output LED is OFF then

exchange the power supply
board.
4) If still the message appears

change one by one card by
switching off 74V, Switch 74V on
again (and so on ...) The last
removed electronic board should
be the reason for the short circuit
of 5V power supply card.
16 H +/-15V power 1) Card Faulty 1) Check if the output LED is
supply faulty (card 2) DC/DC Converter glowing
C121) Faulty in front of the card C121.
2) If not Change the power

supply card.
3) If the -15V still not working

then switch off the 74 V supply
for the ASG and try replacing
other electronic cards one by
one.
Switch 74V on again (and so on
...)
The last removed electronic card
should be the reason for the
short
circuit of -15V power supply
card.
4) At first exchanging the power

supply card. Is the +15 V still not
working then switch off the 74 V
supply for the ASG and remove
one more electronic board.
Switch 74V on again (and so on

Diag Fault
Code Class
...). The last removed electronic

board should be the reason for
the short circuit +15V.
18 H +/-24V power 1) Card Faulty C049 1) Check the output on DC/DC
supply faulty (card Converter A91 with Multimeter.
C049) 2) DC/DC Converter
Faulty A91 2)If the output is below 24 V
replace A91.
3)Check the output LED of C049

card if not glowing replace the
card.
20 H TCC control supply 1) Battery 1)Check battery voltage.

74V faulty undervoltage.
2)Check Front plug X01 loose
2) front plug X-01 contact.
21 H Power-start-up unit 1)Card faulty C163. 1) Check and replace power
C163 clock failure start-up unit board
23 I Undervoltage Battery in the TCU 1) Replace the battery in the
lithium back-up blower panel TCU blower panel
battery (fan unit is empty
N000)
24 I LCU electronic 1) Blower panel 1) Check blower panel. If
cooling fan failed defective. message disappears the blower
(fan unit N000) panel is
2) Central processing defective. Apply 24 V externally
unit defective. to the panel and check which fan
is not running.
3) Broken cable.
2) Change CPU Card
3) Check wiring.
26 I Desigh Error 1)Wrong how type 1) Check X01 configuration
Torque Curves coding for different Locmotive.
CPU 2) Check for 74V power supply
on X01-7
27 E Hardware coding 1) Configuration on 1) Ensure the following

for Loco type X01 not correct. regarding X01 Plug:
undefinded • For MAC Loco all pins X01-6,
2)G159 Card Faulty X01-7, X01-8, X01-9, X01-10
should be opened.
3)74V power Supply • For PAC Loco with 4 motors
Faulty pins X01-6 and X01-7 should be
Diag Fault
Code Class
shorted.
• For PAC Loco with 6 motors
pins X01-7 and X01-8, shpuld be
shorted.
2) Check for wiring continuity
b/w X01-6 to G159-X1 b2,
X01-8 to G159-X1 z4, X01-9
to G159-X1 z6, X01-10 to
G159-X1 z18.
3) Change G159 card.
28 D SIP-A: feedback 1)Parameter file not 1) Reload the latest SIP
parameter type correct for SIP. software
fault
29 E SIP-B: feedback 1)Parameter file not 1G159 card to be checked
parameter type correct for SIP. 2) SW version to be checked
fault 3) SIP Faulty
4) X01 plug to be checked.
30 E MVB : Initalisation 1)Software not loaded 1)Try loading the MVB sofware,
error correctly. please refer the manual on how
to load NSDB file into MVB.
31 A MVB : Wrong 1) Software version 1) Check for latest software
software version on not according to according to version on
a MVB station Hardware version. hardware.
32 A MVB : Line A 1)Software version. 1)Software version for the MVB
frozen 1 not correct.
2)MVB 1 hardware
2)Check the version on MVB 1
and its software.
33 I MVB : Line B 1)Software version. 1)Software version for the MVB
frozen 2 not correct.
2)MVB 2 hardware
2)Check the version on MVB 2
and its software.
34 I MVB : 1) Display SITET not 1)Reboot the display.
Communication in normal mode. 2)Check for MVB connections
error Display (Sink 2) When loading the from Display to Sibas Klip
Time Supervision) Display software. station.
3)Change the Display.
35 I MVB : 1)Any Klip faulty. 1) Check for RED LED on
Communication SKS1.
error SKS 1 Sink 2)MVB1 station faulty.
Time Supervision) 2) Swap MVB1 with a new MVB
with s/w loaded.
3)Change the MVB1 station.

Diag Fault
Code Class
36 A MVB : 1)Any Klip faulty. 1) Check if any RED LED

Communication glowing on Klips of MVB2. If so
error Sibas KLIP 2)MVB2 station faulty. check for its wiring.
Station 2 (Sink
Time Supervision) 2) If the problem persists,
interchange the module with its
own kind or change with the
new one.

37 A MVB : 1)MVB Cable loose 1)Check for the loose
Communication connection connection of the cable.
error Display (Busy
Byte Supervision) 2)Reboot and then check if the
fault is still active.
3)Replace and check the MVB.

38 I MVB : Sibas KLIP 1)MVB1 station faulty. 1) Check if any RED LED
station 1 AS318 glowing MVB1.
failure
39 A MVB : Sibas KLIP 1)MVB2 station faulty. 1) Check if any RED LED
station 2 AS318-2 glowing MVB2.
failure
40 A MVB: collective 1)Bus Module faulty 1)Check for the red LED on I/O
fault Ext.1 & MVB.
2)NSDB s/w not proper
2)reload the NSDB software and
3)MVB faulty check for the fault.
3)Replace the MVB.
4)Check for loose connection

between the bus module
5)If data between CPU & MVB

not exchanged then bus module
faulty.
41 A MVB: collective 1)Bus Module faulty 1)Check for the red LED on
fault Ext.2 MVB. If MVB fault then this LED
2)NSDB s/w not proper glows.
3)MVB faulty 2)reload the NSDB software and

check for the fault.

Diag Fault
Code Class
3)Replace the MVB.
4)Check for Power Supply 24V

from PRG 05 (ports 4,8 & ports
6,10), PD4 (ports 1&3), 2&4 and
so on upto 30, 31 and finally on
each MVB and cards.
42 A SIBAS Klip: Modul 1)All Klips on any one 1)Check if any klip working
Group Alarm station or both stations properly. If any klip working then
faulty. recycle the computer and check
2)Accompanied by fault for the fault again.
codes 60,61,62,63,64,
65,66 and so on upto 2)Check for the klip station due
79. to which fault is coming and
3)Power Supply for replace
24V not available.
46 A Parametrization 1)Card Faulty (L135). 1)Check for the Turbo
fault for speed Speed,Radar speed and Engine
measurement IO speed. If all three not coming
card then card faulty.
2) If any one coming then

recycle TCC and check if the
fault appears again. If so replace
the card with the new one.
47 D SIP-B permanent 1)Truck 2 cut out 1)Check if truck 2 is cut out
not ready for
operation 2) SIP Card faulty 2)Recycle/Navigate the screen
to enable the truck.
3) SIP-B PWR (G027) defective,

change.
48 D SIP-A permanent 1)Software not properly 1)Try reloading the SIP
not ready for loaded. software.
operation
2) SIP Card faulty 2) Recycle/Navigate the screen
to enable the truck.
3)SIP-A PWR (G035) defective,

change.
49 I No communication 1)Circuit Breaker for 1)Check if Circuit Breaker for
between LCU and event Recorder not in event Recorder not in On
Event recorder On position. position.

Diag Fault
Code Class
2)Loco speed occurs 2)Check continuity b/w Plug J4-

only above 2 Kmph A, X05-11 to G103-X3-11 and
and reverser thrown. plug J4 B, X05-12 and G103-4.
3)Loose Connection on
Event recorder.
4)Plug J4 or X 05 on
TCC loose.
50 A Power startup unit 1) C163 faulty 1) Check for 5V power supply
C163 is disabling
both output board 2) Check for 15V power supply
G127 & G135
3)Check for 24V power supply
card
4) If all OK, then replace C163

card.
54 B Communication 1) SIP Card faulty 1) SIP-A PWR (G027) defective
with SIP A faulty
(card G019) 2) CAN Card Faulty 2) ZR board (G075) defective
3) ZR Card Faulty 3) CAN board (G095) defective
4) X-3 Connector 4) Check connector X3 on CAN

card (G095)
55 B Communication 1) SIP Card faulty 1) SIP-B PWR (G035) defective
with SIP B faulty
(card G027) 2) CAN Card Faulty 2) ZR board (G075) defective
3) ZR Card Faulty 3) CAN board (G095) defective
4) X-3 Connector 4) Check connector X3 on CAN

card (G095)
57 B IO-Card G083 1)Card faulty. 1) Check for other signals on
faulty (Clock this card.
failure)
2) Replace the IO-Card G083.
58 I electr.creep control This must not appear in This must not appear in
initialization fault operation. operation.
59 I monitoring This is only a message
electr.creep control which appears when
creep control is active.
60 I Sibas KLIP Station 1) Power Supply PRG 1)Check the 24V Power supply
1 module DI 1 05 out put from PRG

Diag Fault
Code Class
faulty
2) DI-1 Module 2)Swap with DI-2 & check if the
fault code 61 is logged.
3)Change the DI-1 Module

faulty
2) DI-2 Module 2) Swap with DI & check if the
fault code 60 repeats.

faulty
2) DI-3 Module 2) Swap with DI-2 & check if the
fault code 61 repeats.
3) Change the DI-3 Module

faulty
fault code 61 appears.

faulty
fault code 61 appears
3) Change the DI-5 Module

1 module DO 1 05 out put from PRG
faulty
2) DO 1 Module 2) Swap with DO-2 & check if the
3) Change the DO-1 Module

faulty
2) DO 2 Module 2) Swap with DO-1 & check if the

Diag Fault
Code Class
3) Change the DO-2 Module

faulty
2) DO 3 Module 2) Swap with D)-1 & check if the
fault code 65 appears
3)Change the DO-3 Module

faulty
2) DO 4 Module 2) Change the DO-4 Module
faulty
1 module DO 6 05 out put from PRG 05
faulty
1 module AI 3 05 to the card
faulty
2) AI-3 Module 2) Change the AI-3 Module
faulty
2) DI 6 Module 2) Change the DI-6 Module
2 module AI 1 05 out put from PRG 05
faulty
2) AI 1 Module 2)Swap with AI
3)Change the AI-1 Module

2 module AI 2 05 out put from PRG 05
faulty
2) AI 2 Module 2) Change the AI-2 Module
2 module AO 1 05 out put from PRG 05
faulty
2) AO 1 Module 2) Change the AO-1 Module
2 module AO 2 05 out put from PRG 05
Diag Fault
Code Class
faulty
2) AO 2 Module 2) Change the AO-2 Module
80 B IO-Card G083 ADC 1)Card faulty. 1) Check for other signals on
faulty this card(either viz DC link
currents, Brake Grid currents,
CA voltage, SCR O/P voltage,
CA frequency does not appear
on Display)
2) Replace the IO-Card G083.

82 F signal TL-24 1)Control Stand 1)Check for the Braking
voltage out of Throttle esistance reference in the Barake screen
range faulty by putting the Throttle handle in
full brake position that 65V is
2)Wiring problem coming.
3)QPSW sensor faulty 2)Check for the wiring and loose

connection on QPSW sensor.
3)Measure the output of the

sensor with multimeter in max
position that voltage is approx
than 4.8V ad the input is approx
65 V. If input is correct and
output wrong then sensor faulty.
If not coming then check the
control stand side.
83 Circuit breaker for 1)Breaker Not closed 1)Check the Breaker Inter lock
Event Recorder not connections
closed 2) Breaker Defective
2) Check LED status on DI- 5
3) DI-5 card faulty channel No.80
4) Feed Back Faulty of 3)Check the feed back wires of

CB CB
84 B SCR: Internal Fault 1)CB SCR faulty. 1)Check the healtyness of the
CB and continuity upto XB10.
2)Wrong Wiring on
XC10 of SCR. 2) Check for wiring on XC10 and
X03,02 and 04 plugs on TCC.
3)Wrong wiring on
XB10 of SCR. 3)Check the continuity between
XC10 and SIBAS cards.
4)Internal circuit faulty

Diag Fault
Code Class
4)Replace the SCR.

85 B SCR: External fault 1)CB SCR faulty. 1)Check the healtyness of the
CB and continuity upto XB10.
2)Wrong Wiring on
XC10 of SCR. 2) Check for wiring on XC10 and
X03,02 and 04 plugs on TCC.
3)Wrong wiring on
XB10 of SCR. 3)Check the continuity between
XC10 and SIBAS cards.
4)Internal circuit faulty
4)Check for the 4-20 mA on the
XC10-11 and 12 pins of SCR by
switching ON CBs SCR and
Computer Control.
5)Replace the SCR.

86 B M.G. Diode 1)IG1 faulty 1)Check for 15V Power signal on
monitoring TA17 MG Diode current sensor.
right (Sensor IG1) 2)15V Power Supply
faulty. 2)Check for wiring from X03 to
IG1.
3)IO board faulty L135.
3)If the fault is in plus side only
interchange the CT with minus
side one and if the fault repeats
then replace IG1 CT plus side.
4)If the fault is accompanied by

Fault code 087,191,192,190 then
IO card L135.
87 B M.G. Diode 1)IG2 faulty 1)If the fault is in minus side
monitoring TA17 only interchange the CT with
left (Sensor IG2) 2)15V power supply plus side one and if the fault
faulty. repeats then replace IG2 CT
minus side.
3)IO board faulty L135.
2)If the fault is accompanied by
Fault code 087,191,192,190 then
IO card L135.
88 B Feedback failure 1)Loose Connection on 1) Read the output of the
sensor U31 or U32 Voltage transducer Transducer on the Display
(DC-Link voltage) SITET on Diesel Engine Screen
2)24V power supply on for DC link voltages.
U31 faulty
2)Check for the wirings and

Diag Fault
Code Class
3) Voltage Transducers loose connection. Continuity on

faulty X10, X20 and X1 connectors of
4)LO95 card faulty. U31 & U32
3)Swap with U32 and check if

the problem repeats and if yes
Change voltage transducer.
4)Swap LO95 with L111 and

check if problem repeats.
89 B failure feedback 1)Wrong wiring. 1)check wiring b/w U01&LO95
current sensor U1 card and U02&LO95 card.
or U2 Short 2)Outpurt Current
Text 1: PWR-A Transducer faulty(U1 2)Check for +/- 24V on U01 &
blocked or U2). U02 if not coming, then check
the wiring or change the card.
3)LO95 card defective.
3)Swap and Check if the
problem exists and if yes change
the transducer.
4)Swap card with L111 & check

if problem repeats
90 C EPU Probe faulty 1)Wiring Defect 1)check wiring b/w EPU plug and
X03 and L135 card.
2)EPU sensor faulty
2)Check if TPU is also affected,
3)Card L135 faulty then change the card and check
3)Change the EPU sensor and

check
91 CA voltage not 1)Wiring defective 1)check wiring b/w Grau
available Assembly X10 connector and
2)Card L103 defective 3T3 A and X03 and 403 card.
3)Grau assembly 2)Check if CA rpm also not

defective coming, then Grau assembly or
card defective
4)Companion
Alternator defective 3)Check voltage or I/P supply of
Grau assembly, if not coming
then CA defective.
151 C No load: GF CB 1) GF circuit breaker 1)Check the GF Circuit Breakers

Diag Fault
Code Class
Active in both the ON in both the cabs in both the cabs.

cabs 2) Auxiliary contact of
GF CB is shorted.
152 C No Load:BL key 1) BL Key On in both 1) BL key Switch position in
Active in both the the cabs. botht the Cabs.
cabs
190 B DC-Link current > 1)DC side overcurrent 1)Check for DC side wiring for
hardware limit possible short circuit.
2) Power Wiring
Shorted.
191 B Brake Grid A 1)Overcurrent in Grid 1)Check for value of grid

current > hardware A Current A in Brake Screen of
limit SITET.
2) If more check for short

circuiting in the circuit.
192 B Brake Grid B 2)Overcurrent in Grid 1)Check for value of grid Current
current > hardware B B in Brake Screen of SITET.
limit
2) If more check for short
circuiting in the circuit.
199 I Snap shot 1) When trying to take 1)Delete from the Monitor the D-
snapshot from Monitor. static memory with the code 199.
200 G Hot engine throttle 1) Overtemperature of 1)Check for the signals of the
6 limit Short the engine more than FCF and FCS contactors in the
Text 1: throttle 6 100 degree Celsius. SITET I/O Screen.
limit
2)Radiator Fan not 2)Manually check for the
working. operation of the Fans/individual
Fan test.
3)Can do self test for Fans in the

Self test menu of the Display.
4) If the fans not working check

for the opearation of the
contactors.
5)Check for the wirings or burns

or change the contactor if not
working.
201 G Hot engine 1) Overtemperature of 1)Check for the signals of the
Short Text the engine. FCF and FCS contactors in the
1:throttle 6 limit SITET I/O Screen.

Diag Fault
Code Class
extended time 2)Radiator Fan not

working. 2)Manually check for the
operation of the Fans.
3)Can do self test for Fans in the

Self test menu of the Display.
4) If the fans not working check

for the opearation of the
contactors.
5)Check for the wirings or burns

or change the contactor if not
working.
202 I Engine protection 1)LOPS trips open 1) Check for the LOPS switch, if
shutdown open push the switch and try
Short Text 1: low 2)Governor oil low loading the engine.
oil pressure
3)Wiring defect 2)Check for Governor oil, if low
fill the oil.
3)Check wiring b/w TB 83D &

823B, 383D upto DI-2CH15
203 Engine air filters 1)Engine air filters 1) Clean the air filter.
dirty (FVS tripped) dirty.
2)Clean the conduit.
2)Coduit between
differential pressure 3) Check wiring b/w FVS switch
switch and Engine and DI-2, channel 14.
dirty. 4) Replace FVS with a new one
and check if the message
3)FVS switch defective. goes away.
4)Wiring defect
204 J Engine air filters 1)Engine air filters 1) Clean the air filter.
dirty Short Text dirty.
1: changeout 2)Clean the conduit.
required (FVS and 2) Coduit between
EFS tripped) differential 3)Check for wiring between EFS
Short Text 2: TH6 pressure switch and DI-2 channel 13.
limit and Engine dirty.
3) EFS switch 4)Replace EFS with a new one.
defective .
4) Wiring defective

Diag Fault
Code Class
205 I FVS/ EFS switch 1)Engine air filters 1) Clean the air filter.
and / or wiring error dirty.
2)Clean the conduit.
2) Coduit between
differential 3)Check for other channels on
pressure switch DI-2 card if more than one
and Engine dirty. problem, then change the card.
3) EFS/FVS switch
defective 4)Check after replacing both the
4) DI-2 card defective switches.
206 A No start 1)Water temperature 1)Check and replace the
Short Text 1: below 2 deg C. temperature sensor ETP1/ETP2
engine dead with if accompanied by FC 207
too cold water 2)Faulty Sensor ETP.
temperature 2)Wait for water temperature to
rise above 2 deg C.
207 Engine dead with 1)Faulty Sensor ETP. 1)Check and replace the
failed Engine water temperature sensor ETP1/ETP2.
temperature probes 2)Check for wiring 2) Check wiring b/w ETP’s and
fault. plug 384A, Temp converters
ETP1 & ETP2 and AI-2
209 A No start starter 1)Battery 1) Check the battery voltage.
motor overload Undervoltage
Short Text 1: 2)Check for starter motor
starter motor 2)Mechanical Problem plungers and other mechanical
overload couplings.
3)Condition for starting 3)Check if start signal coming,
has a problem. isolate signal coming,FP Relay
feedback coming ,Engine not
running, MU Shutdown not
coming, Engine temperature
values present,LWS On, Fuse
feedback ON, Temperature
above 2 deg and below 100 deg.
210 A Start failed 1)Battery 1) Check the battery voltage.
Short Text 1: Undervoltage
maximum starting 2)Check for starter motor
time delay of 20s 2) Mechanical Problem plungers and other mechanical
reached couplings.
3) Check if start signal coming,

isolate signal coming,FP Relay
feedback coming ,Engine not
running, MU Shutdown not
coming, Engine temperature

Diag Fault
Code Class
values present,LWS On, Fuse

feedback ON, Temperature
above 2 deg and below 100 deg.
212 I Governor speed 1)Governor Speed not 1)Read the Governor Speed
setting not according to notch
accurarte position.( Difference of 2)Check for Rack setting.
50 rpm per notch)
213 A Engine protection 1)Low Water level 1)Check for Low Water level
shutdown Short Switch tripped. Switch. Press the switch and try
Text 1: low water to again crank the engine.
level 2)Bubble formation in
the water 2)Contact Engine maintainance
personal.
3)Wire defective
3)Check for wiring b/w TB83C,
plug 823A,833D,& DI-3
channel1.
214 I Warning 1)Turbo cooldown 1)Check for Turbo CB, keep in
Short Text 1: cycle not completed for ON position after engine
turbo cool-down engine have run for on shutdown.
cycle not finished 4th notch and has not
completed 60 min. 2)Computer CB in ON position
after engine shutdown.
3)Duration b/w 2 start after

engine being run on 4th notch is
less than 60 min.
4)The Driver might ignore the

start or leave fo 60 min to reset.
215 A Fuel pump relay 1)Fuel pump relay 1)Check if fuel pump relay in
failure Short Text failure. ON position during engine
1:timeup FPRLY cranking. Red Flag if ON.
close at prime 2)Wiring problem
2)Check for wiring b/w coil of
FPR and SDR.
3)Check for feedback signal for

relay on I/O Screen of Dispaly
SITET.
4)Replace the relay after

manually checking the relay.
5)Check for output signal or DO-

Diag Fault
Code Class
4 channel 4.
219 A Turbo lube pump 1)TLPR relay failure. 1)Check if TLPR relay in ON
relay failure position during engine cranking.
Short Text 2)Wiring problem Green Flag if ON.
1:timeup TLPRLY
close at prime 2)Check for wiring.

SITET.

223 J Turbo freerun test 1) Turbo not free 1)Check the turbo.
failed running occurs when
Short Text 1: difference of real turbo
only low traction speed and engine
power increase coupled turbo is more
possible than 500 rpm.
Short Text 2:
throttle 6 limit
224 G Very hot Engine 1)Radiator Fan not 1)Check manually if the
Short Text 1: working. Radiator fan working/individual
throttle 2 limit Fan test.
Short Text 2: fans 2)Wiring Problem.
maximum cooling 2)Check for wiring on
3)FCF or FCS Contactors.
Contactor failure.
3)Perform Self test for All
4)FCF/FCS relay Cooling Fans.
failure.
4)Check for contactors and
replace accordingly.
5)Check for relay of FCF/FCS

and replace accordingly.
225 A Fuse starter motor 1)Starting fuse faulty. 1)Check for loose connection of
failed during start Starter motors.
2)Wiring defect.
2)Change the fuse.
226 A Governer booster 1) GBC relay failure. 1)Check if GBC relay in ON
pump relay failure position during engine cranking.
Short Text 1: 2)Wiring Problem. RED Flag if ON.
timeup GBC close
at time 3)Short Ckt on GBC 2)Check for wiring b/w plug 823
Diag Fault
Code Class
pump side. and GBC relay and Governer

booster pump CB.

SITET.
4)Check for short circuiting on

GBC side.

227 A Engine shutdown 1) EFCO switch 1) Check weather EFCO switch
EFCO pressed pressed strucked
2) EFCO Switch 2) Check the EFCO switch

Defective
3) Check DI-3 channel no 5
3) DI Card Faulty
4)Loss of 74V supply on EFCO
switch.
228 J Turbo over speed ! 1) Ovetempeature 1)Check for the speed of turbo
Power limited to 2) Turbo problem. in the Power meter Screen.
TH6
2)Check for the healthyness of
Turbo if working properly.
230 A Engine speed 1) AI Card faulty 1) Check AI-2 card and replace if
faulty. Check faulty
governer plug 2) Engine Temperature
probe 2) Check the engine temperature
probe and replace if faulty
231 A Fuel pump relay 1) FPCB not ON 1) Check for wiring b/w Fuel
failure, FPCB pump relayand FPCB and DI-5.
dropped during 2) FPCB faulty
start/run
3)DI card 6 channel1
300 K NYAB: Self test 1)Air Brake Failure 1)Look for the fault code on Air
failure Brake Computer with RED LED.
2)Inform about the same to Air

Brake personal.
301 K No communication 1)Circuit Breaker 1)Check for CB Micro Air Brake
between NYAB and Micro air Brake failure.
LCU 2)Check for fault code on NYAB
2)Communication computer.

Diag Fault
Code Class
failure between SIBAS

and NYAB 3)Check for communication
connection wires.
302 K Failed feedback 1)MR Pressure 1)Check for wiring b/w MRPT
LCU - MR sensor Transducer failure. connector and plug 384A,plug k
of PDP1 plug K & SKS2-AI2
2)Wiring defect.
2)Replace sensor and check.
303 K Failed feedback 1)Air Brake Failure 1)Look for the fault code on Air
CCB - MR sensor Brake Computer with RED LED.

Brake personal.
304 K Air Brake Penalty - 1)Leakage in Main 1)Look for the fault code on Air
Low MR Pressure Resorvoir. Brake Computer with RED LED.
2)Air Brake failure. 2)Perform Air Brake Self test.

Brake personal.
305 K MR Pressure < 6 1)Leakage in Main 1)Look for the fault code on Air
Bar Resorvoir. Brake Computer with RED LED.
2)MRPT sensor faulty 3)MRPT sensor loose

and failure of signal connection.
from Air Brake
simultaneously. 3)Perform Air Brake Self test.

Brake personal.
306 K Feedback failure - 1)DCR relay feedback 1)Recycle the computer.
Dryer Control failure.
Relay DCR 2)Check for DCR relay wiring &
2)Wiring Defect relay opeation.
307 K Feedback failure - 1) CMPSYN relay 1)Recycle the computer.
Compressor feedback failure.
Synchronisation 2) Wiring Defect 2)Check for CMPSYN relay and
Relay CMPSYN associated wiring.
310 K CB MAB off 1) CB failure. 1)Check for wiring b/w between
Micro Air Brake CB upto DI6
2) Wiring problem card
2)Replace CB.
311 K NYAB: Electronic 1)Air Brake Failure 1) Perform Air Brake Self test.
Air Brake Failure

Diag Fault
Code Class
2)Look for the fault code on Air

Brake Computer with RED LED.

Brake personal.
312 K NYAB: Brake 1)Air Brake Failure 1) Perform Air Brake Self test.
Controller #1
Failure 2)Look for the fault code on Air

Brake personal.
Controller #2

Brake personal.
314 K NYAB: Lead/Trail 1) : Lead/Trail Module 1)Check for the selection on
Module Selection Selection not correct. both the control stands.
Failure
2)Recycle computer breaker and
Air Brake CB.
3) Perform Air Brake Self test.


Brake personal.
315 K NYAB: MREQ 1)Air Brake Failure 1) Perform Air Brake Self test.
Pipe/Flow Module

Brake personal.
316 K NYAB: Brake Pipe 1)Air Brake Failure 1) Perform Air Brake Self test.
Control Failure

Diag Fault
Code Class

Brake personal.
317 K NYAB: 1)Air Brake Failure 1) Perform Air Brake Self test.
Independent/BCEQ
Pipe Control 2)Look for the fault code on Air
Failure Brake Computer with RED LED.

Brake personal.
Cylinder Failure

Brake personal.
319 K NYAB: Auxiliary 1)Air Brake Failure 1) Perform Air Brake Self test.
Input/Output

Brake personal.
327 K Feedback failure - 1)Air Brake Failure 1) Perform Air Brake Self test.
sensor BC
pressure 2)Look for the fault code on Air

Brake personal.
328 K Air Brake: 1)Air Brake Failure 1) Perform Air Brake Self test.
undefined fault

Brake personal.
350 B DC-Link too low 1)DC link voltage A/B 1)Check for short circuit for DC
during pre charging below 600 V during first link.
notch throw.
2)Swap and check the Voltage
2)Voltage sensor sensors.
faulty.
3) Change the Voltage sensors.
351 B DC-Link too high 1)DC link voltage 1)Check for open circuit for DC

Diag Fault
Code Class
during pre charging much above 600 V link.

during first notch throw.
2)Swap and check the Voltage
2)Voltage sensor sensors.
faulty.
3) Change the Voltage sensors.
352 B Excitation current 1)Excitation current 1)Recycle and prechage.
too low during pre crosses the lower value
charging during 2)Perform excitation Test.
precharging(30A)
353 B Excitation current 1)Excitation current 1)Recycle and prechage.
too high during pre crosses the higher
charging value during 2)Perform excitation Test.
precharging
354 B Current main 1)main generator 1)Recycle and prechage.
generator too high Current on plus or
during pre charging minus side more during 2)Perform Self Test.
precharging.
3) Check for wiring faults.
2)Possible Short Circuit
on Main Generator
Side.
360 I Close loop control 1)Recycle the Computer CB
for DC-Link voltage
stuck on maximum
limit
361 I Close loop control 1)Recycle the Computer CB
for DC-Link voltage
stuck on minimum
limit
365 I Excitation current 1)Recycle the Computer CB
permanent lower
then reference
366 I Excitation current 1)Recycle the Computer CB
permanent higher
then reference
369 B GFC contactor 1)GFC Conactor 1)Check for the resistance of
does not open failure. the coil.
2)Wiring Defect 2) Check for the pickup and drop

of the GFC & GFD actually by
putting IS switch in RUN.
3)Check for the feedback in the

I/O screen of the Display for

Diag Fault
Code Class
GFC & GFD.
4)Check for wiring b/w GFD &

GFC and DO-3, channel4.
5)Replace the contactor.

370 B GFD contactor 1)GFD Conactor 1)Check for the resistance of
does not open failure. the coil.
2) Check for the pickup and drop

of the Contactor by appling
external supply.
3)Check for the feedback in the

I/O screen of the Display.
4)Replace the contactor.

371 E SIP-A card faulty 1)SIP A Card faulty 1) Swap and check if the
(G019) problem repeats for other truck
also.
2) Check for the SIP fault also.
3)Replace the card.

372 E PWR-A modul A11 1) IGBT power supply 1)Check for the A91 healthyness
phase L1 faulty at the module faulted. by checking the LED on this
power supply and by manually
2)SIP Card Faulty checking the voltages at the
input and output.
3)Module A11 faulty
2) Swap and check if the
problem repeats for other truck
also.If so replace the SIP card. If
the problem is again in the same
truck then IGBT module faulty.
3)Check for the possible short

circuit close to the inverter output.
input and output.
3)Module A12 faulty

Diag Fault
Code Class


input and output.
3)Module A13 faulty

375 E Supply voltage for 1)C049 card faulty. 1)Check for the input and output
sensors faulty on C049,converts 72V to +/-24V.
(C049) 2)SIP A Faulty. ON LED shows the input
condition OK.and test points
available for output to be
checked from multimeter.
2)Check for other faults of CTs

like fault codes 377,378 etc.
3)Replace the C049 Card.
4)Replace the SIP A card.

376 E IGBT power supply 1) IGBT power supply 1)Check for the A91 healthyness
for inverter A faulty at the module faulted. by checking the LED on this
(A91) power supply and by manually
checking the voltages at the
input and output.
377 E Feedback signal for 1)Current Transducer 1)Swap U11 with U12 and
inverter A current U11 faulty. check for the fault if it gets
Phase L1 faulty repeated in other motor then
(Sensor U11) 2)L095 faulty. replace the CT.

Diag Fault
Code Class
2)Replace L095.
inverter A current U12 faulty. check for the fault if it gets
2)Replace L095.
379 E Feedback signal for 1)Current Transducer 1)Check for 24 Voltage input to
voltage DC-Link-A U31 faulty. the transducer and the output.
faulty (Sensor U31)
2)L095 faulty. 2)Replace the Voltage
Transducer U31
3)Replace L095.
380 E Short circuit in DC- 1)DC link short 1) Check for the wiring for the
Link A detected circuited. possible short circuit.
2)Crowbar Faulty A17. 2)Check for the crowbar

healthyness.
381 E PWR-A over 1)Short circuit in Truck 1) Check for the wiring for the
current 1. possible short circuit.
382 E Soft crowbar DC- 1) Over Voltage on the 1)Perform excitation test.If
Link A fired Power Circuit side. doesn’t pass check the main
because of over generator.
voltage
2)Check for the power side
wiring.
383 E DC-Link-A module 1) Crowbar Faulty 1)Check for the possible short
A17 (hard crowbar) circuit of the DC link.
faulty
2)Replace the Crowbar Module.
384 E DC-Link-A module 1) Crowbar Faulty 1)Check for the possible short
A17 (soft crowbar) circuit of the DC link.
faulty
2)Replace the Crowbar Module.
385 E SIP-B card faulty 1)SIP B Card faulty 1) Swap and check if the
(G027) problem repeats for other truck
also.
2) Check for the SIP fault also.
3)Replace the card.

Diag Fault
Code Class

input and output.
3)Module A11 faulty

input and output.
3)Module A12 faulty

input and output.
3)Module A13 faulty

389 E Supply voltage for 1)C073 card faulty. 1)Check for the input and output
sensors faulty on C073,converts 72V to +/-24V.
(C073) 2)SIP B Faulty. ON LED shows the input
condition OK.and test points
available for output to be
checked from multimeter.

Diag Fault
Code Class
2)Check for other faults of CTs

like fault codes 377,378 etc.
3)Replace the C073 Card.
4)Replace the SIP B card.

390 E IGBT power supply 1) IGBT power supply 1)Check for the A92 healthyness
for inverter B faulty at the module faulted. by checking the LED on this
(A92) power supply and by manually
checking the voltages at the
input and output.
inverter B current U21 faulty. check for the fault if it gets
2)Replace L111.
inverter B current U22 faulty. check for the fault if it gets
2)Replace L111.
393 E Feedback signal for 1)Current Transducer 1)Check for 24 Voltage input to
voltage DC-Link-B U32 faulty. the transducer and the output.
faulty (Sensor U32)
2)L111 faulty. 2)Replace the Voltage
Transducer U32
3)Replace L111.
394 E Short circuit in DC- 1)DC link short 1) Check for the wiring for the
Link B detected circuited. possible short circuit.
2)Crowbar Faulty A27. 2)Check for the crowbar

healthyness.
395 E PWR-B over 1)Short circuit in Truck 1) Check for the wiring for the
current 2. possible short circuit.
396 E Soft crowbar DC- 1)Over voltage 1)If the message appears again
Link B fired and again check for the
because of over Generator side circuitory.
voltage
397 E DC-Link-B module 1)Crowbar faulty. 1) Check for the short circuit of
A27 (hard crowbar) the Crowbar with the DC link

Diag Fault
Code Class
faulty circuit.
2)Replace the Crowbar module.

398 E DC-Link-B module 1)Crowbar faulty. 1) Check for the short circuit of
A27 (soft crowbar) the Crowbar with the DC link
faulty circuit.
2)Replace the Crowbar module.

400 J Bogie 1: Torque 1) Traction Motors 1)Check for the proper air flow
reduction because Winding temperature in in the TM bellows.
of TM over Bogie 1 Over a
temperature specified limit. 2)Check for the load attached.
2) Overloading
401 J Bogie 2: Torque 1) Traction Motors 1)Check for the proper air flow
reduction because Winding temperature in in the TM bellows.
of TM over Bogie 1 Over a
temperature specified limit. 2)Check for the load attached.
2) Overloading
403 Inverter A: Torque INTERNAL ASG This must not appear in
reference ERROR operation.
characteristic curve
faulty
404 Inverter B: Torque INTERNAL ASG This must not appear in
reference ERROR operation.
characteristic curve
faulty
408 C Version monitoring 1) Software version of 1)Check for the latest software.
software SIP - A SIP A not correct.
card (G019) 2)Reload the SIP A software.
3) Follow the proper method to

load the SIP software using 9-9
pin connector from SIP to Laptop
and using jumper cables.
409 G Version monitoring 1) Software version of 1)Check for the latest software.
software SIP - B SIP B not correct.
card (G027) 2)Reload the SIP A software.
3) Follow the proper method to

load the SIP software using 9-9
pin connector from SIP to Laptop
and using jumper cables.
410 I Version monitoring 1) Software version of 1)Check for the latest software.

Diag Fault
Code Class
CPU software CPU not correct.

2)Reload the CPU software.
412 I speed value 1) G011 card Faulty2) 1)Swap the Xplug (X11) with thw
traction motor 1 Speed sensor faulty3) normal working TM & check if
faulty X-11 Connector loose the fault message appears.
connection
2)Check G011 card and replace
if faulty2) Check speed sensor
and replace if faulty3) Check X-
11 connector for loose
connections 4)check
pin(b4,z4,d4 and d2) loose in the
connector
413 I speed value 1) G011 card Faulty 1) Check G011 card and replace
traction motor 2 if faulty
faulty 2) Speed sensor faulty
2) Check speed sensor and
3) X-12 Connector replace if faulty
loose connection
3) Check X-12 connector for
4)Loose connection of loose connections
TM speed connector
4)check pin(z6,z8,d6 and b6)
loose in the connector
loose connection 3) Check X-13 connector for
loose connections
4)Loose connection of
TM speed connector 4)check pin(b10,z10,d8 and b8)
traction motor 4 if faulty.
3) X-21 Connector replace if faulty.
loose connection
3) Check X-4 connector for loose
4)Loose connection of connections
TM speed connector
4)check pin(z4,b4,d4 and d2)

Diag Fault
Code Class
loose in the connector X21
416 I speed value 1) G035card Faulty 1) Check G035 card and replace
loose connection
4)Loose connection of loose connections
TM speed connector
4)check pin(z8,z6,d6 and b6)
loose connection
loose connections
4)check pin(z10,b10,d8 and b8)

418 F locked wheel 1)Axle locked from 1) Check the Speed sensor and
detected on axle 1 Display through screen replace if faulty
navigator
2) Check by swaping the SIP
2) Speed Sensor cards whether the
Faulty TM 1 fault is shifting if problem is
shifted then replace the defective
3) SIP-1 Card Faulty SIP card
4) X-Plugs 3) Check for the tightness of X-

Plug X11
5) Wiring
4) Check the wiring of the X-Plug
of X11
navigator
Diag Fault
Code Class


Plug X12
5) Wiring
of X12
navigator

Plug X13
5) Wiring
of X13
navigator

Plug X21
5) Wiring
of X22
navigator
2) Speed Sensor cards whether the fault is shifting
Faulty TM 1 if problem is shifted then replace
the defective SIP card
3) SIP-1 Card Faulty
3) Check for the tightness of X-

Diag Fault
Code Class
4) X-Plugs Plug X22) Check the wiring of

the X-Plug of X22
5) Wiring
navigator

Plug X23
5) Wiring
of X24
424 E Bogie 1: All speed 1) Loose connection in 1) Check X-11 to X13 connector
feed back values front connector for loose connection
wrong
2) Card G011 faulty 2) Check and replace the faulty
card
3) 15 V Power faulty
3) Check 15V power supply and
cahnge (C121)
425 E Bogie 2: All speed 1) Loose connection in 1) Check X21 to X23 connector
feed back values front connector for loose connection
wrong
2) Card G035 faulty 2) Check and replace the faulty
card
3) 15 V Power faulty
3) Check 15V power supply and
cahnge (C121)
428 I Bogie 1: Wheel 1) Wheel mismatch 1) Wheel dia of bogie-1 has to
diameter difference exeeds limits be checked
exceeded
permitted limit
429 I Bogie 2: Wheel 1) Wheel mismatch 1) Wheel dia of bogie-2 has to
diameter difference exeeds limits be checked
exceeded
permitted limit
430 RADAR speed 1)Radar Faulty 1)check for Raw Radar Speed
value faulty on the Power Meter Screen.

Diag Fault
Code Class
2)Self Test for Radar
3)Replace Radar.
431 RADAR Test not 1) Radar Faulty. 1)Check and replace Radar
passed
2)PRG-04 Faulty 2)Check and replace PRG-04
432 F Bogie 1: traction 1)TM Speed more than 1) Check for the TM Speed
motor over speed Average bogie 1 sensors loose connection.
speed(not within 90%
of bogie speed.) 2)Check for the X plugs X11 to
X13 for loose connection.
3)Check for the sensor in which

2)Sensor faulty. problem is coming and rep;ace
it.
433 F Bogie 2: traction 1)TM Speed more than 1) Check for the TM Speed
motor over speed Average bogie 2 sensors loose connection.
speed(not within 90%
of bogie speed.) 2)Check for the X plugs X21 to
X23 for loose connection.
3)Check for the sensor in which

2)Sensor faulty. problem is coming and rep;ace
it.
434 D Ground Fault 1)Ground Fault 1)When ripple in Ground voltage
Detected (common Generator side. is between 180 to 140V then
signal) generator side fault. In this case
2)Ground Fault megger and high pot the
Traction Motor side. generator side cables.
3)Ground Voltage 2)Ground Voltage or average

detection Sensor faulty. ground voltage not between 10
to 90% of Average DC link
Voltage then Grounding on TM
side. Do the meggering and high
pot for motor side cabling.
3) If the problem is during DB

then the grid has to meggered to
check the fault.
440 I Contactor brake 1)When there is 1)Check for the closing and
grid A does not request to close the opening of the Grid contactor.
close Grid contactor but error
in closing it.(B1 and 2)Recycle the computer CB if the

Diag Fault
Code Class
B2) fault is active.

447 E DC-Link-A voltage 1)DC link voltage more 1) Check for the healthyness of
exist without IGBT than 70 V but IGBT IGBT power supply A91 by
power supply power supply not checking the LED on the power
present. supply and manually measuring
the input and output voltage
2)IGBT power supply values.
A91 faulty.
2)Replace the Power supply.
448 E DC-Link-B voltage 1)DC link voltage more 1) Check for the healthyness of
exist without IGBT than 70 V but IGBT IGBT power supply A91 by
power supply power supply not checking the LED on the power
present. supply and manually measuring
the input and output voltage
2)IGBT power supply values.
A91 faulty.
2)Replace the Power supply.
450 E DC link 1) Voltage Transducer 1)Check thoroughly if there is
undervoltage faulty external undervoltage (may be
due to low engine rpm, voltage
2) Card Faulty transduce)
2)Check TCC1 voltage

transducer U31 power supply +/-
24V (X1 connector between pins
1 & 4 it should be 48V).Swap
U31 & U32, check if the fault
shifts.
3)Check L103 card & front

connector on it.
453 I Contactor brake 1)When there is 1)Check for the closing and
grid B does not request to close the opening of the Grid contactor.
close Grid contactor but error
in closing it.(B3 and 2)Recycle the computer CB if the
B4) fault is active.
458 B Ground fault 1)Ground Fault not 1) Reset the Ground Fault from
detection lock out reseted for three the Display in the Coutouts
cosecutive occurence Screen.
of fault from the
Display in the Coutouts
Screen
484 B switch gear Q8 1)Contactor Q8 faulty 1)Check for the traction cutouts
failed to pick up if possible.
2)Switch Gear Faulty.

Diag Fault
Code Class
2)Check for manual operation of

switch gears during this
operation and for the contactors
position.
3)Replace the contactor and if

contactor picks up but no
movement of switch gear then
replace the switch gear.
485 B switch gear Q8 1)Contactor Q8 faulty 1)Check for the traction cutouts
failed to drop out if possible.
2)Switch Gear Faulty.
2)Check for manual operation of
switch gears during this
operation and for the contactors
position.
3)Replace the contactor and if

contactor picks up but no
movement of switch gear then
replace the switch gear.
486 B switch gear Q9 1) G151 card faulty 1) Check the card and replace
failed tp pick up
2) Feed back wire 2) Check weather the feed back
problem signal is coming or not
3) wiring 3) Check weather contact is

making proper contact and
wiring of the coils.
487 B switch gear Q9 1) DC Link Low 1) Check for the Voltage
failed to drop out Voltage weather it below 40V
2) Power operation not 2) Check the power operations

enabled like reversar handel thrown and
all power operating modes
3) GFD or GFC
feedback 3) Check weather feedbacks of
GFD or GFC is enabled.
490 B Hardware 1) Voltage sensor 1) Check the volage feed back
Protection LCU faulty and related wiring and change if
active voltage sensor is defective
2) DC Link voltage
2) Check the DC link Voltage

Diag Fault
Code Class
3) G083 Card Faulty weather it is exceeding 3200V
3) Check and replace the G083

card
491 B Soft crowbar is 1) If voltage is less 1) Check the voltage whether it
active than 70V (means if the is equvalent or less than 40V
voltage is 40V or
below) 2) Check for any hard ware
faulty
2) Hardware faulty
3) check whether LCU is taking
3) If LCU takes more more time to switch ON.
than 40s to Switch ON
4) Check SIP-A card and replace
4) If SIP-A card faulty
5) Check SIP-B card and replace
5) If SIP-B card faulty
492 B Hard crowabar is 1) If voltage is less 1) Check the voltage whether it
active than 70V (means if the is equvalent or less than 40V
voltage is 40V or
below) 2) Check for any hard ware
faulty
2) Hardware faulty
3) check whether LCU is taking
3) If LCU takes more more time to switch ON.
than 40s to Switch ON
4) Check SIP-A card and replace
4) If SIP-A card faulty
5) Check SIP-B card and replace
5) If SIP-B card faulty
495 B SIP A: request for 1) This message will be 1) Check diagnostic memory
isolate inverter A activated, SIP-A (G027), regarding this
if the individual inverter fault.
section cannot be
operated.
496 B SIP B: request for 1) This message will be 1) Check diagnostic memory
isolate inverter B activated, if the SIP-B (G035), regarding this
individual inverter fault.
section cannot be
operated.
501 B LCU electronic plug 1) Plug Loop open 1) Check for Plug of LCU
loop is open
2) Plug is Loose 2) Wiring of the same if not
resolved after providing the Plug.
502 Hardware coding 1) Check the coding 1) Check the X1E Plug

Diag Fault
Code Class
for loco type wrong. on X01 plug.

Check plug X01 2) Change card G135 if faulty
2) Check card G135
503 Hardware coding 1) Check the coding 1) Check the X1E Plug
for loco type on X01 plug.
changed during 2) Change card G135 if faulty
operation: Check 2) Check card G135
plug X01
504 SIP A (G019) 1) Software version 1)Try reloading the SIP software
Parameter type wrong. latest version.
feedback faulty
2) Card Faulty G019 1) Check the card by swaping
with SIP-A if fault shift to SIP A
(G019) Parameter type feedback
faulty replace the card G027
505 SIP B (G027) 1) Software version 1)Try reloading the SIP software
Parameter type wrong. latest version.
feedback faulty
2) Card Faulty G027 1) Check the card by swaping
with SIP-A if fault shift to SIP A
(G019) Parameter type feedback
faulty replace the card G027
506 I Plug loop X11 to 1) X-Plugs open 1) Check X-11 to X-13 open if
X13 is open open provide the copulers
2) X-Plugs Loose
2) Check the continuity of the
loop witht the multimeter.
507 I Plug loop X21 to 1) X-Plugs open 1) Check X-21 to X-23 open if
X23 is open open provide the copulers
2) X-Plugs Loose
2) Check the continuity of the
loop witht the multimeter.
510 J Bogie 1: Stator 1) The temperature of 1) Check airflow for cooling
winding all TMs in a bogie1 traction motors.
temperature model exceeds 240deg
exceeded trip limit 2) Check Resistance of motor
temp sensor
3) Check and change Card L143
4) Check Harting Plugs X11,

X12, X13
5) Check Connectors X21, X22

Diag Fault
Code Class
& X23 inside TCC cabinet.
511 Bogie 1: Stator 1) If the difference of 1) Check airflow for cooling

laminated core Tempaerature between traction motors.
temperature two traction motors in
exceeded trip limit Bogie-2 is greater than 2) Check Resistance of motor
150 deg C. . temp sensors
2)This will get reset at 3) Check and change Card L143

100 deg C
X12, X13

512 F Bogie 1: Stator 1)The difference 1) Check air-flow for cooling
laminated core temperature of traction motors.
temperature laminated core of all
difference traction motors bogie 1 2) Wait till the differance
exceeded trip limit exceeds (150 °C). temperatures reaches below 100
to get fault reset
513 J Bogie 2: Stator 1) The temperature of 1) Check airflow for cooling
winding all TMs in a bogie2 traction motors.
temperature model exceeds 240deg
exceeded trip limit 2) Check Resistance of motor
temp sensor
3) Check and change Card

L143

514 Bogie 2: Stator 1) If the difference of 1) Check airflow for cooling
laminated core Tempaerature between traction motors.
temperature two traction motors in
difference Bogie-2 is greater than 2) Check Resistance of motor
exceeded trip limit 150 deg C temp sensors
2)This will get reset at 3) Check and change Card L143

100 deg C
X12, X13

Diag Fault
Code Class

515 F Bogie 2: 1)The difference 1) Check air-flow for cooling
temperature temperature of traction motors.
differential stator laminated core of all
winding exceeds traction motors bogie 2 2) Wait till the differance
trip limit exceeds (150 °C). temperatures reaches below 100
to get fault reset
516 I Temperature value 1) Temperature Sensor 1) Check the Front connector
traction motor 1 Faulty wiring
faulty
2) Temperature 2) Check the Temperature
Monitoring card (L111) coupler on TM-1 and pins.
Card Faulty
3) Change the (L111) Card.
4) Change Temperature Sensor.

faulty
Card Faulty

faulty
Card Faulty

faulty
Card Faulty

Diag Fault
Code Class

faulty
Card Faulty

faulty
Card Faulty

525 J Junction 1) This fault occurs if 1) Check TCC blower motors
temperature Junction temperature
Inverter A limit exceeds 125dec 2) Check and Change the L135
exceeded Card
2) Card Faulty
3) Check the connector for any
3) Connector loose connection
connection of L135 card
526 J Junction 1) This fault occurs if 1) Check TCC blower motors
temperature Junction temperature
Inverter B limit exceeds 125dec
exceeded
2) Card Faulty
530 74V for IGBT- 1) Card faulty 1 Check IGBT power supply
power supply A91-DC/DC converter
missing and DC- 2) Loose connection on
Link Inverter A G127 pin number Z4 & 2) Check front connector of
charged B4. Card G127
3) IGBT (DST) card 3) If still fault then replace card

Faulty G127
4) Ensure if any case of IGBT

phase module faults, the IGBT
power supply will be switched off
by SIP.

Diag Fault
Code Class
531 74V for IGBT- 1) Card faulty 1 Check IGBT power supply
power supply A92-DC/DC converter
missing and DC- 2) Loose connection on
Link Inverter B G127 pin number Z8 & 2) Check front connector of
charged B8. Card G127
3) IGBT (DST) card 3) If still fault then replace card

Faulty G127
4) Ensure if any case of IGBT

phase module faults, the IGBT
power supply will be switched off
by SIP.
532 B Board G127 ABIN1 1) Card Defective 1) Shows Power supply to IGBT
faulty module faulty
2) Replace the card.

533 B Board G135 ABIN2 1) Card Defective 1) Shows all temperature values
faulty defective
2) Replace the card.

534 F Inverter 1 lock due 1) Inverter 1 1) Check the wiring
to phase modul temperature exceeded
temperature 2) Check G135 card replace if
2) Card Faulty faulty
3) Check the Temperature

Sensors
535 F Inverter 2 lock due 1) Inverter 2 1) Check the wiring
to phase modul temperature exceeded
temperature 2) Check G135 card replace if

Sensors
536 J Torque reduction 1) Inverter 1 1) Check the wiring
due to inverter 1 temperature exceeded
modul temperature 2) Check G135 card replace if

Sensors
537 J Torque reduction 1) Inverter 2 1) Check the wiring
due to inverter 2 temperature exceeded
modul temperature 2) Check G135 card replace if

Diag Fault
Code Class

Sensors
550 L Aux.Gen. 1) This message 1) Check AI card
overvoltage occurs if battery
voltage reaches to 90V 2) Check voltage sensor and
wiring
2) AI card faulty
3) Check SYKO-2 Logic
3) Voltage sensor connector and wiring
defective
552 L CB Aux.Gen. is not 1) Breaker not closed 1) Check whether breaker is
closed closed
2) Breaker defective
2) Check the breaker
3) No feed back to DI
card 3) Check the feed back of the
breaker in DI-5 channel No.9
4) DI card faulty
4)Check the DI card and replace
if Faulty
600 I Filter Blower Motor 1) Breaker not closed 1) Check whether breaker is
Circuit Breaker is closed
not closed 2) Breaker defective
2) Check the breaker
3) No feed back to DI
4) DI card faulty
if Faulty
601 I No aux power - 1) Breaker not closed 1) Check whether breaker is
LOCAL CONTROL closed
CIRCUIT 2) Breaker defective
BREAKER is not 2) Check the breaker
closed 3) No feed back to DI
4) DI card faulty
if Faulty
602 G&I No aux power - 1) Breaker not closed 1) Check whether breaker is
CONTROL closed
CIRCUIT 2) Breaker defective

Diag Fault
Code Class
BREAKER is not 2) Check the breaker

closed 3) No feed back to DI
4) DI card faulty
if Faulty
603 I TCC #1 BLOWER 1)Breaker not closed 1)Check the Breaker Inter lock
CIRCUIT connections
BREAKER is not 2) Breaker Defective
closed 2) Check LED status on DI-1
3) DI card faulty channel No.3
4) Feed Back Faulty 3)Check the feed back wires
4) If break is tripping g check the

blower motor connections.
604 I TCC #2 BLOWER 1)Breaker Not closed 1) Check the Breaker Inter lock
CIRCUIT connections
BREAKER is not 2) Breaker Defective
closed 2) Check LED status on DI-1
3) DI card faulty channel No.4
4) Feed Back Faulty 3) Check the feed back wires
4) If break is tripping g check the

blower motor connections.
605 I TCC #1 BLOWER 1) DO card Faulty 1) Check the LED status of DI-1
CONTACTOR Channel No.8
FAULT - failed to 2) DI card Faulty
pick up 2) Check DO-6 Card channel
3) Contactor faulty No.5
4) TCC1SR relay 3) Check contactor manualy
4) Check the status of TCC1SR

relay
606 I TCC #1 BLOWER 1) DI card faulty 1) Check whether DO-6 channel
CONTACTOR No.6 is active if it is replace DO
FAULT - failed to 2) DO card faulty
drop out 2) Check whether DI-1 channel
3) Contactor faulty No.8 is active if it is then check
the inter lock of contactor & the
feed back wires of contactor.

Diag Fault
Code Class
3) Check contactor manualy for

any mechanical struck up

relay
607 I TCC #2 BLOWER 1) DO card Faulty 1) Check the LED status of DI-1
CONTACTOR Channel No.9
pick up 2) Check DO-6 Card channel
3) Contactor faulty No.6
4) TCC2SR relay 3)Check contactor manualy
4)Check the status of TCC2SR

relay
608 I TCC #2 BLOWER 1) DO card Faulty 1) Check whether DO-6 channel
CONTACTOR No.6 is active if it is replace DO
drop out 2) Check whether DI-1 channel
4) TCC2SR relay feed back wires of contactor.


relay
610 I Radiator cooling 1) DO card Faulty 1) Check whether DO-6 channel
Fan 1 Slow speed No.2 is active if it is replace DO
contactor FCS1 2) DI card Faulty
failed to drop out 2) Check whether DI-1 channel
4) FCS1R relay feed back wires of contactor.


relay
611 I Radiator cooling 1) FCS1 Contactor 1) Check contactor physically
Fan 1 Slow speed defective
contactor FCS1 2) Check LED status on DI-1
failed to pick up 2) DI Card Faulty channel No. 12 and DO-6

Diag Fault
Code Class
channel No. 2 of the cards

3) DO card Faulty
3) Check the status of the
4) FCS1R relay FCS1R relay
612 I Radiator cooling 1) FCF1A or FCF1B 1) Check Contactor Interlock
Fan 1 Fast speed contactors defective Input at DI 1 channel 14.
contactor FCS1A
or FCF1B failed to 2) FCF1R Relay 2) Check LED status on DI and
pick up defective DO cards
3) DO Card Faulty 3) Check First LED on Digital out

put card No.6.
4) DI Card Faulty
FCF1R Relay
5) Check Manually the operation

of the Contactor
Fan 1 Fast speed no.0 and replace the DO
contactor FCS1A 2) DI card Faulty
or FCF1B failed to 2) Check whether DI-1 channel
drop out 3) Contactor faulty No.14 is active if it is then check


relay
Fan 2 Slow speed No.3 is active if it is replace DO
contactor FCS2 2) DI card Faulty
failed to drop out 2) Check whether DI-1 channel


relay

Diag Fault
Code Class
615 I Radiator cooling 1) FCS2 Contactor 1) Check contactor physically

Fan 2 Slow speed defective
contactor FCS2 2) Check LED status on DI-1
failed to pick up 2) DI Card Faulty channel No.13 and DO-6
channel No. 3 of the cards
3) DO card Faulty
4) FCS2R relay FCS2R relay
Fan 2 Fast speed no.1 and replace the DO
contactor FCF2A or 2) DI card Faulty
FCF2B failed to 2) Check whether DI-1 channel
drop out 3) Contactor faulty No.15 is active if it is then check


relay
617 I Radiator cooling 1) FCF2A or FCF2B 1) Check Contactor Interlock
Fan 2 Fast speed contactors defective Input at DI 1 channel 15.
contactor FCF2A or
FCF2B failed to 2) FCF2R Relay 2) Check LED status on DI and
pick up defective DO cards
3) DO Card Faulty 3) Check channel No. 1 in DO

card 6
4) DI Card Faulty
4) Check the status of the Relay
5) Check Manual operation of

contactor
618 E Reduced dynamic This fault occurs if the 1)Check the DC voltgae
brake average DC link weather it is exceeding more
voltage exceeds 400V than 400V during Dynamic Brake
2) Check Voltage sensor and

related wirings
3) Check the respective card of

SIBAS for any card fault
4) Check respective Grid

Diag Fault
Code Class
619 E Reduced dynamic This fault occurs if the 1)Check the DC voltgae
brake average DC link weather it is exceeding more
voltage exceeds 400V than 400V during Dynamic Brake
2) Check Voltage sensor and

related wirings
3) Check the respective card of

SIBAS for any card fault
4) Check respective Grid

700 I VCD penalty brake Vigilance system in Press Reset after Loco stops or
action 35 seconds whichever is later
701 I VCD bypass switch 1) Indicates Vigilance 1) Keep the By-Pass switch in
on system By-Pass Switch OFF condition if not required
has kept in ON position
2) Check feedback in channel
2) DI card No. 1 of DI-1
Malfunctioning
3) Check the bypass switch and
3) By-Pass Switch replace.
Malfunctioning

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Troubleshooting Guide Page 1 of 97

Issue Date: 08.02.2012

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

Document has been checked by

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

General information on this document

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

A. SAFETY MEASURES AND INFORMATION 6

B. TOOLS & INSTRUMENTS REQUIRED TO CONNECT LAPTOP WITH

C. PROCEDURE TO READ THE EVENT MEMORY IN CPU AND SIP. 8

D. PROCEDURE WHEN TROUBLESHOOTING 22

E. EVENT RESPONSES AND OPERATIONAL RESTRICTIONS 24

F. COMPREHENSIVE STUDY ON DIAGNOSTIC MESSAGES AND

H. EXPLANATION OF THE EVENT ENVIRONMENT DATA OF CPU 32

I. DETAILED TROUBLESHOOTING TIPS 52

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

A. SAFETY MEASURES AND INFORMATION

Safety rules when carrying-out work on electrical equipment:

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

B. TOOLS & INSTRUMENTS REQUIRED TO CONNECT LAPTOP WITH SIBAS

1. Laptop (Windows 2000/XP, serial port or a USB interface with a USB-to-

2. Programming Bridge (required only during loading of software)

3. ASG door key

4. For connecting the PC and Sibas:

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

C. PROCEDURE TO READ THE EVENT MEMORY IN CPU AND SIP.

1. Start the monitor.

3. A small window pops up, select /Record

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

6. Reading out diagnostic memory CPU

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

7. Reading out operating data memory CPU

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

8. Reading out SIP-1 diagnostic memory

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

After press [Enter] the SIP Monitor window pops up.

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

9. Reading out SIP-2 diagnostic memory

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

After press [Enter] the SIP Monitor window pops up.

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

10. Close the recorded file

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

D. PROCEDURE WHEN TROUBLESHOOTING

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

E. EVENT RESPONSES AND OPERATIONAL RESTRICTIONS

Type Restriction Class Restriction Imposed

J Power or Torque Reduction Only power or torque is reduced,but operation

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

F. Comprehensive Study on Diagnostic Messages and Restriction Class

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1

TSG WDG4/WDP4B/WDP4D Doc.No. ZFI-001-V1.1