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REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Table of Contents
Table of Contents............................................................................................................................................1
Introduction.....................................................................................................................................................2
Locomotives Affected.....................................................................................................................................2
Recommended Tooling...................................................................................................................................2
Documents Referenced ...................................................................................................................................2
Theory of Operation .......................................................................................................................................2
Standard Operating Description .....................................................................................................................4
Fault Codes Addressed ...................................................................................................................................7
Troubleshooting Procedures .........................................................................................................................11
IGBT Monitoring Faults Procedure #1...................................................................................................11
IGBT Power Supply Faults Procedure #2 ..............................................................................................20
Control Power Supply Faults Procedure #3............................................................................................21
Inverter Interface Board Connector Faults Procedure #4 .......................................................................24
Phase Module Temperature Faults Procedure #5 ...................................................................................25
Speed Sensor Faults Procedure #6..........................................................................................................27
Unbalanced AC Current Faults Procedure #7 ........................................................................................32
TCC DC Link Overvoltage Faults Procedure #8....................................................................................35
TCC DC Link Undervoltage Faults Procedure #9..................................................................................36
TCC Inverter Output Overcurrent Faults Procedure #10 .......................................................................42
Traction Motor Lead Miswire Faults Procedure #11 .............................................................................43
Wheel Mismatch Faults Procedure #12 ..................................................................................................45
Speed Sensor Wrong Rotation Faults Procedure #13.............................................................................46
MPU Hardware/Software Faults Procedure #14 ....................................................................................47
Help Desk Troubleshooting..........................................................................................................................49
Appendix A: Programming an EM2000 Data Meter Screen........................................................................50
Appendix B: Phase Module Qualification Procedure...................................................................................51
Appendix C: Connector Check Circuit Diagram..........................................................................................54
Feedback Form .............................................................................................................................................56
NOTE: The troubleshooting procedures contained in this guide are intended as general guidelines.
If any specific step within this guide causes a violation of railroad or local safety rules, do not
perform that specific step and contact your local EMD rep for troubleshooting guidance.
Page 1
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Introduction
This Troubleshooting Guide (TSG) is issued to provide an overview and troubleshooting guidelines for the
IGBT inverter system.
Locomotives Affected
JT56ACe
SD70ACe
Recommended Tooling
The tools and sockets listed below are for use on the interface module CN plugs
Insertion tool: P/N 40118461
Extraction tool: P/N 40118483
Crimper: P/N 40052278
Contact Male: Positronic Industries P/N MC120N
Contact Female: P/N: 40108612
Documents Referenced
SD70ACe IGBT Inverter Safety Manual (EMD p/n: G00027EP)
JT56ACe Locomotive Service Manual (EMD p/n: S00227EP)
SA 05-025 Procedure to Validate Functionality of Radar on the Locomotive
TSG 01-002 EMDEC SRS Faults and Radial Bracket Adjustment
TSG 02-001 SD70ACe and SD70M-2 Fuel System
TSG 07-009 APC Troubleshooting
TSG 07-010 Chopper Troubleshooting
TSG 07-021 Surrette Battery Qualification
Theory of Operation
The purpose of the IGBT inverter system is to convert the DC output of the traction alternator to a 3-phase
alternating current to drive the traction motors. The inverter system for each truck consists of a voltage
source (DC Link), three-phase modules to perform the switching of DC Link for inversion to AC, an MPU
module, an interface module and an IGBT power supply. Figure 1 shows JT56ACe IGBT inverter power
and control block diagram. The SD70ACe block diagram is same as JT56ACe expect for location of the
phase modules. The main components of the inverter system are as follows:
Page 2
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Page 3
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Upper electrical
locker
Lower electrical
Traction Alternator
DC Switchgea
Rectifie
IGB
Inverte
B Contacto
Brakin
Resisto
DC Switchgea
B Contacto
EM200
MPU
200
Tractio
Alternato
Chop &
MPU
VME
I
N
T
E
R
F
A
C
E
B Contacto
Brakin
Resisto
DC Switchgea
IGBT
Inverte
Rectifie
B Contacto
DC Switchgea
Signal
CAV
Description
Companion Alternator Voltage
Normal Operation
235-245 volts in Throttle 8
Page 4
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Signal
ChpDty
DCLnV
EEngRPM
EngineR
EngRPM
MGFA Rf
MGFld A
No IPS<
Op Mode
PCS
RdrStFg
TnDCLV
Description
Chopper duty cycle
Normal Operation
Range 0.1 1
1 = max excitation (100% ON)
0.5 = 50% ON
0.1 = min excitation (10% ON)
~600V with the reverser thrown
and throttle in idle
Page 5
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TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Signal
TnFirst
TnIU
TnIV
TnIW
TnPMI15
TnPMTU
TnPMTV
TnPMTW
TnPPI15
Description
Indicates which IGBT first reported a fault. Can have
values of:
U+
U-
V+
V-
W+
W-
ALL
0 (indicates no fault)
TCC phase U current
TCC phase V current
TCC phase W current
Indication of a fault on the 15V power supply (for
sensors)
Temperature of the phase module U heat sink. Used on
This temperature is read directly by the EM2000 ADA
module
Temperature of the phase module V heat sink. Used on
This temperature is read directly by the EM2000 ADA
module
Temperature of the phase module W heat sink. Used on
This temperature is read directly by the EM2000 ADA
module
Indication of a fault on the 5V power supply
TnPSGDL
TnPSM15
TnPSP15
TnPSP5
TnPSPG
Normal Operation
0
-40C to 80C
-40C to 80C
Page 6
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Fault
Code
765
766
810
811
1009
1010
1011
1012
1013
1014
3591
3592
3593
3594
3595
3596
3597
3598
3599
3600
3601
3602
3603
3604
Description
TCC #1 Torque Reduction Wheel Diameter
Mismatch
TCC #2 Torque Reduction Wheel Diameter
Mismatch
TCC #1 Warning Wheel Mismatch Warning
TCC #2 Warning Wheel Mismatch Warning
Failed Feedback TM1 RPM
Failed Feedback TM2 RPM
Failed Feedback TM3 RPM
Failed Feedback TM4 RPM
Failed Feedback TM5 RPM
Failed Feedback TM6 RPM
TCC #1 Lockout Cut Out Truck #1
IGBT Monitoring Fault
TCC #2 Lockout Cut Out Truck #2
IGBT Monitoring Fault
TCC #1 Reset No Control Power Supply
TCC #2 Reset No Control Power Supply
TCC #1 Reset IGBT Power Supply
Undervoltage
TCC #2 Reset IGBT Power Supply
Undervoltage
TCC #1 Reset - MPU Hardware Watchdog
TCC #2 Reset - MPU Hardware Watchdog
TCC #1 Reset IGBT Monitoring Fault
TCC #2 Reset IGBT Monitoring Fault
TCC #1 Internal Reset Inverter Output
Overcurrent
TCC #2 Internal Reset Inverter Output
Overcurrent
TCC #1 Reset DC Link Overvoltage
TCC #2 Reset DC Link Overvoltage
Troubleshooting
Procedure #
12
12
12
12
6
6
6
6
6
6
1
1
3
3
2
2
14
14
1
1
10
10
8
8
Page 7
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
3605
3606
3617
3618
3619
3620
3621
3622
3629
3630
3631
3632
3633
3634
3718
3719
3720
3721
3722
3723
3724
3725
3726
5
5
6
6
6
6
6
6
5
5
5
5
5
5
8
8
8
8
7
7
5
5
6
Page 8
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
3727
3728
3729
3849
3850
3859
3860
3868
3869
3870
3871
3872
3873
3874
4117
4118
4119
4120
4278
4279
4280
6
9
9
4
4
14
14
13
13
13
13
13
13
13
11
11
11
11
10
10
5
Page 9
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
4281
4282
4283
5
6
6
Page 10
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Troubleshooting Procedures
CAUTION: Before following the procedures below, make sure the locomotive is properly locked out
and flagged per your local procedures. Ensure the proper job briefing, safety
procedures and Personal Protective Equipment required for the task was discussed.
Review the SD70ACe IGBT Traction Inverter safety manual Part Number G00027EP:
SD70ACe IGBT Traction Inverter - Safety Manual and the appropriate section of the
JT56ACe LSM for safety precautions relating to the DC Link.
Page 11
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Attempt to load the locomotive.
Results/Notes
Repair and verify that the IGBT monitoring
faults no longer occur when the reverser is
If the fault occurs on both inverters immediately thrown in any direction with engine running,
after the reverser is thrown (OP MODE is Idle isolation switch in RUN and GEN FLD switch
just before the fault), and the TnFirst has a value up.
If no problems are found, go to step 2.
of ALL, check that the interface module is
connected to the 74V power. Ensure the
Traction Control circuit breaker is closed.
Qualify the circuit between the circuit breaker
and the PS1 connector on the interface module.
Verify that the cables between the interface
Repair any defects noted and verify the IGBT
module and the EM2000 chassis are properly
faults no longer occur.
connected.
Visually inspect the P1&, P3 plugs on the
interface module and the 9A & 10A plugs on the
EM2000 chassis.
Page 12
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
4
Action
Fault occurs on only one TCC when the throttle
handle is pulled out from IDLE (Op Mode is
PROP just before the fault and TnDCLV is
>500V just before the fault), and the TnFirst has
any value of U+, U-, etc, indicating a
problem with a specific phase module.
Check that the appropriate EO and OE fiberoptic connectors are properly and securely
connected to the interface. Refer to the chart
below for EO/OE connections on the interface
module:
IGBT
U+
UV+
VW+
WCrowbar
TCC1
EO1/OE1
EO2/OE2
EO3/OE3
EO4/OE4
EO5/OE5
EO6/OE6
EO7
Results/Notes
Repair/correct the problem. Otherwise go to
step 5.
TCC2
EO8/OE8
EO9/OE9
EO10/OE10
EO11/OE11
EO12/OE12
EO13/OE13
EO14
Page 13
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
5
Action
Inspect the CN hybrid circular plug (Figure 2)
that carries both the optical and electrical
signals on the appropriate phase module. This
circular, quick disconnect connector is keyed
and uses a twist on-twist off ring.
Disconnect the plug and visually inspect
the connectors (both optical and electrical).
Specifically look for any pushed back
electrical connectors or loose optical
connectors.
Inspect the receptacle on the phase module
for any defects or damage.
Reconnect the plug and ensure it is seated
well and is securely connected.
Results/Notes
Repair/correct if any problems are found with
the plug. Otherwise go to step 6.
Figure 2
Page 14
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
6
Action
In this step, you will check the integrity of the
appropriate fiber optic cables.
Make sure that the circuit breakers for the IGBT
Power Supplies and the Traction Control are
closed. This is to ensure that the power supplies
are working and the interface module is
powered up.
NOTE: Observe the Caution Label
(Figure 4) on the Interface Module for
Proper Handling of the Fiber Optic
Connections. No tools are to be used when
disconnecting the optical connectors.
Results/Notes
IF the red light does not appear on the feedback
OE fiber connector, it is most likely due to the
broken or damaged fiber optic cable.
A good cable assembly should give bright red
light feedback indicating good light intensity.
Before you replace the bad cable assembly,
continue with step 7 to firmly establish if the
cable assembly is bad.
Page 15
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
7
Action
Results/Notes
On the interface module, disconnect the P1 plug Go to the next step
if the problem is on TCC #1 or the P3 plug if the
problem is on TCC #2. In this step, you will
gate the appropriate IGBT and check for the
feedback voltage using a voltmeter.
Refer to the table below and jumper the
appropriate pin to the common. For instance, if
the problem is on TCC#1 U+, connect a
jumper wire between pin 15 and the common
pin 1 or 14 of the P1 on the interface
module. See Figure 3 below for reference.
IGBT
U+
UV+
VW+
WCommon
Pin
15
2
16
3
17
4
1 or 14
Figure 3
Page 16
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
8
Action
With jumper wire connected between the pin
and the common, refer to the table below check
for feedback voltage on the appropriate pins
using a voltmeter. For instance, if the problem
is with TCC #1 U+, check the voltage across
pin 19 and the common pin 1 or 14.
IGBT
U+
UV+
VW+
WCommon
10
Pin
19
7
20
8
21
9
1 or 14
Results/Notes
If you see the feedback voltage >3 V, both the
fiber optic cable assembly and the interface
module are good.
If you see the feedback voltage <1 V, it could be
either the bad fiber optic cable assembly or the
bad interface module. To determine which part
is bad, go to the next step.
Page 17
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
11
Action
If both the interface module and the fiber optic
cable assembly prove to be good, it is most
likely that the phase module is bad.
Results/Notes
Replace the bad phase module.
Page 18
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Page 19
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Is the fault currently active?
Results/Notes
If yes, go to step 3
If no, go to the next step
Page 20
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
5
Action
If 24VAC is present at the input to the interface
module, it will be necessary to qualify the
feedback circuit for the undervoltage fault
signal. This feedback is generated by the
interface module and is fed to the MPU module
in the EM2000 chassis.
Create a programmable meter screen with the
TnPSGDL value so it can be monitored during
troubleshooting.
Perform the steps listed to the right
Results/Notes
a) Swap the MPU modules to see if the fault
transfers. If the fault swaps to the other
TCC, replace the MPU module.
b) Disconnect the P2 plug if the fault is on
TCC1 or the P4 plug if the fault is on TCC2.
The fault signal is supplied via pin 9 of these
plugs to the MPU module. If the fault
clears, replace the interface module.
c) Reconnect the P2 or P4 plug and disconnect
the 9B (TCC1) or 10B (TCC2) plug on the
back of the EM2000 chassis. Check for 5
volts between pin 9 and pin 1 of this plug. If
5 volts is not present, replace the EM2000
chassis.
d) If 5 volts was present in the step above,
there is a short in the wiring harness.
Qualify the harness.
Repair/correct the problems as needed.
Page 21
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Control Power Supply faults indicate a problem
with one of the power supplies in the interface
module. Note that both TCCs share these power
supplies, so these faults should simultaneously
occur on both TCCs.
Check the power supply fault data pack to see
which power supply is reporting the fault.
For TnPPI15 or TnPMI15, the problem is likely
a miswired voltage or current sensor that is
shorting out the power supply.
Results/Notes
Page 22
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
3
Action
For TnPSPG, the problem is likely a miswired
speed probe.
Results/Notes
Correct/repair the problem as needed.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
4
Action
TnPSM15, TnPSP15, and TnPSP5 indicate a
problem with a power supply that is used
internally by the interface module only.
Results/Notes
Replace the interface module and make sure the
problem is fixed.
Step
1
Action
Interface Module Connector faults indicate the
jumper keying on CN1-CN6 on the interface
module is not correct. This could indicate that
two connectors are swapped (CN1 and CN2, for
example) or that the jumpers are not installed
correctly. This fault does not prevent loading,
however the locomotive may not load correctly
if connectors are not correctly connected. This
fault is archived only and not displayed as a
crew message.
If only TCC1 is logging this fault, check CN1
and CN3 on the interface module. If only TCC2
is logging this fault, check CN2 and CN4. If
both are logging this fault, check CN5 and CN6,
and make sure that CN1/2 or CN3/4 are not
swapped
Ensure that the P1, P2, P3 and P4 plugs on the
interface module are in the correct sockets
Results/Notes
Correct as needed.
Correct as needed.
Page 24
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
4
Action
Results/Notes
Ensure the 9A, 9B, 10A and 10B plugs on the
Correct as needed.
back of the EM2000 chassis are in the correct
sockets.
Verify continuity through the connector check
Correct any defects noted
circuit shown in Appendix C: Connector Check
Circuit Diagram.
Open the computer control circuit breaker and
There should be 5 volts across the pins.
remove the 9A plug if the fault is on TCC1 or
If there is not 5 volts, swap MPU modules
10A if the fault is on TCC2. Close the computer
to see if the problem transfers. If it does
control circuit breaker.
not transfer, replace the EM2000 chassis.
Measure the voltage between pins 1 and 6 on the
back of the EM2000 chassis at the removed plug
receptacle.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
On the SD70ACe locomotive, the #1 traction motor blower pulls air across the phase module cooling fins.
This blower is mounted on the floor of the generator room.
Table 7: Phase Module Temperature Sensor Fault Troubleshooting Steps
Step
Action
1. Was a single Feedback Out of Range fault
logged?
2. Review the EM2000 phase module temperature
fault. View the six phase module temperature
values in the fault data pack.
Are all 6 phase module temperature values
reading high?
3. Is the ambient temperature reading also
abnormally high at the time of the fault?
Results/Notes
If yes, go to step 5.
If no, go to the next step.
Possible causes:
Poor connection at plug pins or sockets
Shorted wiring harness
PDP panel
ADA module
EM2000 chassis
Page 26
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
6. Qualify the temperature sensor in the phase
module. Reference the appropriate locomotive
schematic for the specific pins to meter. The
sensor resistance at specific temperatures is
shown below.
Temp (F)
50
60
70
77
85
Temp (C)
10
15
20
25
30
Resistance ()
1039 3
1058 3
1078 3
1097 3
1117 3
Results/Notes
If the temperature sensor does not match the
resistance table, the phase module will need to
be replaced. It is not possible to replace the
sensor.
If the sensor does match the resistance table,
the sensor is within specifications and the
problem is elsewhere.
Clean as necessary.
Page 27
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
FC 1009-1014: Failed Feedback TMn RPM. This fault is logged when both channels of an
individual speed probe fail and no feedback whatsoever is received by the MPU module. This fault
may also be accompanied by a locked axle fault.
FC 3617-3622: TCC #n Warning Speed Sensor Fault Axle n. This fault is logged if one feedback
channel of an individual speed probe fails.
FC 3726, 3727 TCC Internal Reset No Speed Detectable. This fault will be logged if all three
probes on a truck have a failure of both feedback channels. This fault will cause the locomotive to
drop load as the computer is unable to determine the motor speeds.
FC 4282, 4283 Reduced Load No Direction Detectable. This fault will be logged if one
feedback channel fails on all speed probes within a truck. In this case, the computer is still able to
determine speed, but is unable to determine direction.
Table 8: Speed Sensor Fault Troubleshooting Steps
Step
Action
1. Was a Connector check (FC 3849 or 3850) fault
logged in the EM2000 fault archive?
2.
Results/Notes
If this fault was logged in the archive, check the
CN3 and CN4 plugs on the interface module and
ensure they are securely connected.
See Connector Faults section for additional
troubleshooting.
See Control Power Supply Faults section for
troubleshooting of these faults.
Page 28
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
4. Were faults logged for all three speed sensors
within the TCC?
Results/Notes
Check the appropriate CN connector on the
interface module for that truck.
Visually inspect for any pushed back pins or
sockets within the plug or on the interface
module. Verify that all pins are tightly crimped
to the wires.
Should it be necessary to extract a pin from the
CN plug, it is imperative to use the proper
tooling. Not using the proper tool will
permanently damage the contacts.
Insertion tool: P/N 40118461
Extraction tool: P/N 40118483
Page 29
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
7. Visually inspect the application of the speed
probe at the traction motor end cover. The
speed probe flange must lay flat against the end
cover.
It is also possible, to bolt the speed probe in
backwards on the end cover. Unbolt the probe
and ensure the guide pin on the probe mounting
face is correctly oriented and mates with the
hole in the end cover.
8. Visually inspect to ensure that the speed probe
cable is not run parallel to the traction motor
power cables under the locomotive.
It is acceptable for the speed probe cable to
intersect the traction motor cables and to be tiewrapped to the power cables with a spacer inbetween
9. Visually inspect to ensure that the speed probe
cable is not bundled with the traction motor
power cables along the outside of the under
frame.
10 Swap the CN3 and CN4 plugs on the interface
module and track test the locomotive. Verify if
the faulty speed signal swaps to the other truck.
While swapping the plugs, visually inspect for
any pushed back pins or sockets within the plug
or on the interface module. Verify that all pins
are tightly crimped to the wires.
Results/Notes
Correct the speed probe application
Page 30
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
11 Swap the MPU modules and track test the
locomotive. Verify if the faulty speed signal
swaps to the other truck.
Results/Notes
If the faulty signal swapped to the other truck,
replace the MPU module.
If the fault signal did not swap, go to the next
step.
Repair any defects.
Visually inspect all plugs for pushed back pins
or sockets within the plug or on the receptacle.
Verify that all pins are tightly crimped to the
wires.
From
P1-10
P1-11
P1-12
P1-22
P1-23
P1-24
P3-10
P3-11
P3-12
P3-22
P3-23
P3-24
To
9A-10
9A-11
9A-12
9A-22
9A-23
9A-24
10A-10
10A-11
10A-12
10A-22
10A-23
10A-24
Color
YBK
BRBK
BKR
BKO
RDO
BLO
YBK
BRBK
BKR
BKO
RDO
BLO
Function
Speed signal B for axle #1
Speed signal B for axle #2
Speed signal B for axle #3
Speed signal A for axle #1
Speed signal A for axle #2
Speed signal A for axle #3
Speed signal B for axle #4
Speed signal B for axle #5
Speed signal B for axle #6
Speed signal A for axle #4
Speed signal A for axle #5
Speed signal A for axle #6
Page 31
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Determine which TCC is logging the fault.
Then program the following signals on the
programmable meter screen:
Results/Notes
After you identify the bad feedback (TnIU,
TnIV or TnIW), go to the next step.
TnIU
TnIV
TnIW
Page 32
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
3
Action
Follow the procedure listed in the SD70ACe
Inverter Safety Manual or JT56ACe LSM and
ensure the DC Link is fully discharged. Open
the traction control circuit breaker. Now gain
access to the suspect phase current sensor. The
sensor is located immediately in front of the
phase module on the AC bus bar.
Disconnect the connecter from the current
sensor and inspect the contacts. Look for
recessed or damaged contacts. Please note that
you must not insert the meter probes in the
connector as it will permanently damage the
contacts.
Note: Before you disconnect or connect any
plugs from the interface module, make sure to
open the Traction Control circuit breaker.
Results/Notes
Repair as needed. Damaged contacts must be
replaced.
If no defects are found, go to the next step.
Pin
F
F
L
L
R
R
Voltage
+15V
-15V
+15V
-15V
+15V
-15V
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
5
Action
It is possible but unlikely that the cable between
the interface module and the current sensor is
bad. In order to troubleshoot the cable, you
must have AMP Tyco connecter P/N 178314-3.
This AMP connector is the same matting
connector that is on the current sensor, and it
must be connected to the sensor cable connecter
before checking the voltage with a meter. The
connecter is needed to prevent damage to the
contacts inside the connecter. If you dont have
the AMP connecter go the next step,
otherwise perform the following:
Results/Notes
If the voltage is not present, most likely the
cable is bad and must be replaced. Otherwise,
go to the next step.
Page 34
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
See TSG 07-005 for DC Link Overvoltage
troubleshooting steps
Results/Notes
Page 35
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
It is first necessary to determine if the
undervoltage was a true undervoltage or if the
fault is due to an erroneous feedback. Were DC
Link Undervoltage faults logged on both TCCs
at the same time?
Often DC Link Undervoltage faults will be
logged due to a drop in engine RPM. This will
cause the DC Link voltage to droop, triggering
the fault on both TCCs.
In order to determine if the faults were logged
due to external circumstances, review the
signals for the indications described below and
illustrated in Table 12A.
CAV Companion alternator volts decline.
ChpDty Chopper duty cycle increases
rapidly and significantly in an attempt to
maintain generator output.
DC Link voltage (DCLnV and TnDCLV)
droop.
Engine RPMs (EngRPM and EEngRPM)
values droop
EngineR Engine fuel ratio increases
rapidly to maximum fuel in an attempt to
maintain engine RPM.
An additional description of these signals is
provided in the Signals to Monitor Table.
Results/Notes
If the conditions described are not evident in the
fault data pack, continue with the next step.
If the conditions described were observed in the
fault data pack, the undervoltage condition was
most likely due to an engine underloading
problem. For some reason the engine is not able
to maintain horsepower. Reference:
TSG 01-002 SD70ACe and SD70M Fuel
Systems
TSG 01-003 EMDEC SRS Faults and
Radial Bracket Adjustment.
Page 36
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
Results/Notes
ChpDty
78.1
95.7
99.2
99.3
99.3
99.2
1.000
1.000
0.800
0.593
0.545
0.667
DCL1V
919
1,035
1,106
1,104
1,106
1,106
DCL2V
907
1,021
1,092
1,090
1,090
1,090
EEngRPM
RPM
287
357
370
371
370
370
Eng RPM
RPM
EngineR
297
342
370
370
370
370
0.994
0.718
0.577
0.577
0.581
0.589
MGFA Rf
308.4
167.3
65.2
61.9
61.4
63.9
MGFld A
70.7
67.6
63.9
63.7
63.4
63.5
WPWR
PWR
PWR
PWR
PWR
PWR
Op Mode
RadarMp
MPH
42.9
43.1
43.1
42.9
42.8
42.9
T1DCLV
890
1,021
1,074
1,073
1,072
1,073
906
1,028
1,085
1,083
1,083
1,083
T1First
T2DCLV
T2First
Page 37
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TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
4
Action
a) Create a programmable meter with DCL1V,
DCL2V, MGFldA, MGFA Rf and ChpDty.
Instructions for creating a programmable
meter can be found in Appendix A:
Programming an EM2000 Data Meter
Screen.
b) Perform a self-load test and monitor the
feedbacks programmed above.
Note: T1DCLV and T2DCLV will not show
any voltage during load test. No DC Link
voltage is applied to the inverters during load
test.
Results/Notes
In Throttle 8 load test, the values should show
roughly the following readings
Signal
DCL1V
DCL2V
MGFldA
MGFA Rf
ChpDty
TH8 LT Value
2500-2600 volts
2500-2600 volts
85-95 amps
~90 amps
<0.2
Page 38
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
5
Action
a) Add the following values to the
programmable meter created in the step
above: T1DCLV and T2DCLV.
b) Perform one of the three tests described
below and monitor the programmable meter
for erratic or varying readings.
Note: The last test option recommends a throttle
3-stall test. This test MUST BE performed
with one truck cut out; otherwise the
locomotive will start to move. In the steps
below, follow the instructions regarding truck
cut out carefully.
Results/Notes
Monitor the programmable meter for erratic or
varying readings.
If DCL1V or DCL2V show abnormal
feedbacks, go to the next step.
If T1DCLV or T2DCLV show abnormal
feedbacks, go to step 7.
Page 39
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TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
6
Action
If DCL1V or DCL2V show abnormal
feedbacks, perform the steps to the right. The
feedback path for these readings is from the
sensor, through the PDP panel, to the ADA
module.
Note:
Steps a, c, f and g require that the Computer
Control breaker be opened while disconnecting
or reconnecting plugs or modules.
Steps b, d and e require that the locomotive be
shut down and the DC Link voltage discharged
before performing. Perform the DC Link
discharge procedure as listed in the SD70ACe
IGBT Inverter Safety Manual.
Step h requires all circuit breakers and the
battery knife switch to be open.
Results/Notes
a) Swap the ADA module with a replacement.
Reference SA 06-076 Rev. A, if needed,
to check the valid replacement for a
given ADA module.
If the replacement ADA module appears
to cure the problem, re-insert the bad
module and ensure the problem returns.
If the problem did not return, the module
is most likely not at fault. Inspect for
corroded or bent pins on the EM2000
chassis and continue with the steps
below.
b) Verify that the 15-volt feed supplied through
the PDP panel is 15v 5% when metering
from positive to common and negative to
common. This voltage will be doubled
when metering from +15v to 15v at the
sensor itself.
c) Reference the appropriate locomotive
schematic and disconnect the feedback plug
at the PDP panel. Insert the Analog Circuit
Splitter (PDP Cable) EMD p/n: 40085567,
into the circuit. Connect your meter to pin 5
of the splitter and verify the feedback signal
is correct. This will require loading of the
locomotive. The feedback signal is a
milliamp signal with a conversion factor of
40 volts per milliamp. Ensure that the
metered reading agrees with the reading
displayed on the screen.
If the reading does agree:
d) Qualify the wiring between sensor and PDP.
e) Replace the voltage sensor
If the reading does not agree:
f) Qualify wiring between PDP and ADA
g) Replace the PDP panel
h) Replace the EM2000 chassis
Page 40
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
7
Action
If T1DCLV or T2DCLV show abnormal
feedbacks, perform the steps to the right.
a)
Note:
Step a requires that the Computer Control
breaker be opened while disconnecting or
reconnecting plugs or modules.
Steps b, c and d require that the locomotive be
shut down and the DC Link voltage discharged
before performing. Perform the DC Link
discharge procedure as listed in the SD70ACe
IGBT Inverter Safety Manual. Open the IGBT
Power Supply and Traction Control circuit
breakers when disconnecting or reconnecting
plugs.
Step e requires the IGBT Power Supply,
Traction Control and Computer Control circuit
breakers to be open.
Step f requires all breakers and the battery knife
switch to be open.
If no sensor or feedback defects are noted,
inspect the affected DC Link circuit for a high
resistance connection that may be dragging
down the voltage.
b)
c)
d)
e)
f)
Results/Notes
Swap the MPU modules and retest per step
6. If the abnormal feedbacks swap between
TCC1 and TCC2, when the module is
swapped, place the MPUs back in their
original slots and ensure the faulty feedback
follows the suspect module. Replace the
suspect MPU module.
Verify the 15-volt feed to the sensor.
Metering from +15v to 15v at the sensor
should show 30volts 5%. The 15-volt feed
is supplied through 2 of the small wires that
connect to the sensor. Reference the
appropriate locomotive schematic for wire
labels.
Qualify the wiring between the feedback
sensor and the CN1 or CN2 plug on the
Interface module. Pay particular attention to
the CN plug.
Replace the voltage sensor
Replace the Interface Module
Replace the EM2000 chassis
Page 41
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
1. There are several causes of the inverter
overcurrent faults, the first of these
being excessive wheel slips. Look at
the TM speeds in the fault data packs
for evidence of excessive wheel slips.
Control system improvements are being
made to lessen or prevent this from
taking place in the future.
2. View the TM speed signals in the fault
archive data pack. If one of the speed
signals is erratic but the remaining
speed feedbacks appear steady, the
most likely root cause of the problem is
the bad speed feedback. The control
systems handles bad speed sensor that
is reading 0 very well but runs into
control issues if the sensor reading
swings out of control.
Results/Notes
Page 42
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
Action
3. Erratic engine RPM due to possible fuel
issues or engine timing sensor issues
can also result in inverter overcurrent
faults. If sagging engine speed is
evident in the fault data packs, see the
following troubleshooting guides to
find root cause of the problem:
Results/Notes
Repair as needed. Otherwise go to the
next step.
Repair as needed.
Page 43
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Inspect cable connections on all three traction
motors on affected truck. Each cable is labeled
to indicate the phase connection along with a
color code. See the table below and Figure 5.
Phase
U
V
W
Results/Notes
Correct the cable connections on the affected
traction motors.
Color
Red
White
Blue
Page 44
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consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
Take wheel measurement readings of all wheels
on the locomotive. If one truck is logging faults
for wheel mismatch, there is a good chance the
other truck may be approaching the allowable
limits.
Results/Notes
Cut the wheels to bring them within the limits
stated below.
Wheels on the
same axle
Wheels on the
same truck
Wheels on the
same
locomotive
Radius
0.8 mm
(1/32)
3.2 mm
(1/8)
16 mm
(5/8)
Tapes
2
6
32
Page 45
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
3
Action
The wheel diameters are recalibrated by the
computer when specific operational conditions
are met.
Results/Notes
The following conditions must be TRUE for 5
seconds for recalibration to occur:
Brakes not applied
o PCS = ON
It is possible that, due to a component or
o No IPS< = ON
feedback failure, one of these conditions may
Radar Speed > 8.1 KPH (5 MPH)
not be met for a significant period of time. This Locomotive not accelerating or decelerating
could prevent the computer from recalibrating
more than 0.16 KPH/sec (~0.1 MPH/sec)
the wheel sizes and cause this fault to be logged. Radar is not failed and is working: RdrStFg
= 0 or 1
The conditions for recalibration are listed at
OpMode = IDLE, WPRP or PROP
right. View these values on a programmable
Throttle in idle with reverser thrown
meter screen. Ensure the conditions can be
achieved and attempt to recalibrate the
Note: Previous experience has show that a
locomotive by moving it around the yard
faulty No IPS< signal has prevented
recalibration. Ensure this signal changes
when the brakes are released.
Step
1
Action
Review the locomotive fault archive to determine
which axle is logging the wrong direction faults.
Was the speed sensor or traction motor recently
replaced at that position
Results/Notes
If yes, continue with the next step
If no, go to step 4
Page 46
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
2
Action
If the speed sensor was recently replaced, open
the Traction Control circuit breaker and
disconnect the CN plug corresponding to that
sensor at the interface module. Reference the
appropriate locomotive schematic and confirm
that the proper wires are connected at the
specified terminals.
Note: early versions of the SD70Ace locomotive
have a junction box mounted on the outside of the
under frame which the speed sensor wiring
connects to. Verify the wiring here on those
locomotives.
If a traction motor was recently replaced, visually
inspect the application of the speed probe at the
traction motor end cover. The speed probe flange
must lay flat against the end cover.
Results/Notes
Correct any defects noted using the tools listed
in the Recommended Tooling section.
Step
1
Action
Is an MPU hardware watchdog fault currently
active in the fault archive?
Results/Notes
If yes, replace the MPU module.
Page 47
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
2
Action
Is an MPU software fault currently active in the
fault archive?
Results/Notes
Cycle the EM2000 circuit breaker and wait 10
minutes to see if the MPU will reprogram.
It is also possible to force the software to the
MPU module typing the following commands at
the Empath 16> prompt (This can only be done
by an EMD Rep)
call mpu1prg (for MPU1)
call mpu2prg (for MPU2)
Page 48
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Step
1
Action
If the locomotive is logging a fault for a locked
axle or failed speed probe, stop the train and
then visually ensure the affected wheel rolls
freely by moving the locomotive a short
distance.
If the locomotive is logging a TCC fault, stop
the train and cut out the affected truck. This can
be done using the Traction Cutout option on
the computer display.
Results/Notes
If the wheel rolls freely without binding or
grinding noises, cut out the affected speed
probe. Do not cut out the entire truck for speed
probe problems
Page 49
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Page 50
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Set your meter at the diode position to check the diode values.
Please allow time (at least one minute) for the readings to stabilize.
Please note that the overload (O.L) condition on the meter indicates an open circuit.
If the bus bars that connect to the phase modules are disconnected, it is important to take the diode
readings at the phase module surface where the bus bar mates the phase module. A diode reading
may be invalid if made at the threads for bolts that connect the bus bars to the phase modules.
Diode Check
Reading (Volts)
O.L.
< 0.7
< 0.7
O.L.
Phase
U1
Phase
V1
Phase
W1
Phase
U2
Phase
V2
Phase
W2
Page 51
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Pin
15
16
17
1 or 14
With the positive gate turned on, take the diode measurements at the appropriate phase module:
Measurement
Points
P to AC
AC to P
N to AC
AC to N
Diode Check
Reading (Volts)
< 0.5
< 0.5
< 0.7
O.L.
Phase
U1
Phase
V1
Phase
W1
Phase
U2
Phase
V2
Phase
W2
Pin
2
3
4
1 or 14
Page 52
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
With the negative gate turned on, take the diode measurements at the appropriate phase module:
Measurement
Points
P to AC
AC to P
N to AC
AC to N
Diode Check
Reading (Volts)
O.L.
< 0.7
< 0.5
< 0.5
Phase
U1
Phase
V1
Phase
W1
Phase
U2
Phase
V2
Phase
W2
Page 53
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Page 54
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
Page 55
Copyright Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-025
REVISION: Release
REVISION DATE:
ISSUE DATE: March 14, 2008
AUTHOR: Asjad Lateef
APPROVED BY: Aaron Vath
Customer Engineering Electro-Motive Diesel, Inc. 9301 W. 55th Street LaGrange, IL 60525
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