TROUBLE SHOOTING GUIDE

FOR
WHEEL SLIDE PROTECTION EQUIPMENT
OF
DISC BRAKED COACHES

SAB WABCO INDIA LIMITED

HARITA,HOSUR,TAMILNADU-635109.
Telephone:+4344-276761 TO 276765 Fax +91(0)4344-76035
Email:su.in@sabwabco.com
 CONTENTS

WHEEL SLIDE PROTECTION EQUIPMENT OF

DISC BRAKED COACHES

SECTION
Health and safety General

Troubleshooting Details A
HEALTH AND SAFETY
Following points must be considered and appropriate precautions taken while
working on the equipment during dismantling, testing. It should be taken as an
exclusive list of hazards.
This works in connection with the compressed air and care to be taken to isolate the
pneumatic lines. The unit should be removed after switching of all the electrical
power pertaining to individual equipment.
When the unit is dismantled proper precautions has to be taken to handle the PCB,
since these PCBS have CMOS integrated circuits which is susceptible to static
electricity which is present in human body, therefore, before touching any of ICS
the briststrap to be put on and that to be connected to a proper earth line.
Whenever, handling the electric power, only right hand to be used and the left hand
to be put in your pocket to prevent touching the power line through the left hand.
Chemical agents may be used for certain components that need a strict compliance
to the manufacturer’s handling procedures.
Trouble shooting guide for Wheel Slide Protection
TSG-001/WSP
WHEEL SLIDE PROTECTION DEVICE:

Objective: To give awareness to the service personnel and

Railway staff to prevent the anticipated faults in the Wheel Slide
Protection equipment
WSP system has the following
1.Electronic unit
2.Dump valve
3.Proximity sensor
4.Phonic wheel
5.Junction boxes
6.Pressure switch
7.Associate connectors
Electronic unit has 8 modules
N1 card (power pack 1)
N2 card (power pack 2)
OP (opto coupler unit)
RE (relay unit

MV (solenoid amplifier)
Status display
Central processing unit
Speed recording
Power pack N1
1.Power pack N1 is a DC-to-DC
converter accepts 16.8 to 150V and
produces output Voltage of 24V±3%.
2.This is used for operating dump
valves and also the supply can be
used for the oscilloscope to monitor

Power pack N2
1.Power pack N2 is a DC-to-DC
converter accepts 16.8 to 150V
2.It produces output voltages of 5
and 15V for logic supplies and as
excitation voltage for proximity
switches.
Optocoupler input(OP):
1.It accepts 8 potential free inputs.
2.from 1-6 not used
3.7 inputs are used for emergency brake
information to the electronic unit.
4. 8 input is used for monitoring pressure
switch.
RE( RELAY OUTPUT):
1.It has 6 potential free outputs used
for 16 to 150 VDC
2.Most of them are not used except
for CDTS
3.Another output is used for Km
counter.
MV (Solenoid amplifier):
It has 4 solenoid amplifiers used for
amplifying the proximity sensor output
to required level and to drive the
solenoid valves. The output of which is
constant 24V irrespective of input
voltage to the electronic unit
ST (status display):
It has battery of LED’S to indicate the
status of opto-coupler inputs, relay
outputs, and dump valve supplies, logic
supplies and excitation voltage
CPU (central processing unit):
It uses RS-232 9 channel SUB-D plug by
which we can monitor acquired data, stored
diagnostic data, error with date, time and
frequency and it can be used to set the
desired parameters to set the operation,
CPU can calculate the total distance
traveled.
This also drives four seven-segment
displays, which is used to indicate the
failure code.
GE module speed recording:
GE supplies excitation voltage and
continuous test parameters. And also
this derives analogue output from the
speed sensor signal.

CPU module has 5 push buttons for

1. Push button 1 to read the diagnostic
fault code.
2.push button 2 for test purposes when
this is pushed for 3s the display will
indicate “89” and CPU will enter into the
test programme to test all dump valves.
 3. Push button 3 to clear the history of
fault code when pressed 3 sec. And also
will display Clear.
4. Push button 4 when pressed for 3s will
check all the door-control.
5.Push button 4 when pressed for 3s will
display total Kilometer run in the form of
8 digits. First press will show first part of 8
digits. Second press will indicate the last
four digits.
Checklist:
1.Check that all the dump valve 3 pin connectors are
fully tightened. While tightening continuously shake the
cable and tighten fully.
2.Inspect that phonic wheel is fitted with the axle with
out off-centered.
3.Check with the filler gauge that the distance between
crust of phonic wheel and the face of proximity sensor
should be 1.5±0.5mm. This can be accessed through the
access panel of Axle end cover.
Fault Diagnosis and Error Management:
Permanent failure
Code in Failure code Failure cause Corrective action
display

72/73 10 Hardware watchdog of Acknowledgement the failure, continue

solenoid valve of axle1 is the operation.
triggered

72/73 11 Short circuit or interruption of Check the wires for short circuit or
speed sensor of Axle1 interruption.

72/73 13 Short circuit of solenoid valve Wires or solenoids of the dump valve
of Axle 1. should be checked for short circuits,
acknowledge the failure.

72/73 14 Interruption of solenoid valve Wires or solenoids of the dump valve

of Axle 1. should be checked for interruption,
acknowledge the failure

72/73 20 Hardware watchdog of Acknowledgement the failure, continue

solenoid valve of axle2 is the operation.
triggered

72/73 21 Short circuit or interruption of Check the wires for short circuit or
speed sensor of Axle2 interruption.
72/7 23 Short circuit of Wires or solenoids of
3 solenoid valve the dump valve
of Axle 2. should be checked
for short circuits,
acknowledge the
72/7 24 Interruption of failure
Wires or solenoids of
3 solenoid valve the dump valve
of Axle 2. should be checked
for interruption,
acknowledge the
failure
 Permanent failure :

Code in Failure code Failure cause Corrective action

display
72/73 30 Hardware watchdog of solenoid Acknowledgement the failure, continue the
valve of axle3 is triggered operation.

72/73 31 Short circuit or interruption of Check the wires for short circuit or
speed sensor of Axle3 interruption.

72/73 33 Short circuit of solenoid valve of Wires or solenoids of the dump valve should
Axle 3. be checked for short circuits, acknowledge the
failure.
72/73 34 Interruption of solenoid valve of Wires or solenoids of the dump valve should
Axle 3. be checked for interruption, acknowledge the
failure
72/73 40 Hardware watchdog of solenoid Acknowledgement the failure, continue the
valve of axle4 is triggered operation.

72/73 41 Short circuit or interruption of Check the wires for short circuit or
speed sensor of Axle4 interruption.

72/73 43 Short circuit of solenoid valve of Wires or solenoids of the dump valve should
Axle 4. be checked for short circuits, acknowledge the
failure.
72/73 44 Interruption of solenoid valve of Wires or solenoids of the dump valve should
Axle 4. be checked for interruption, acknowledge the
failure
Intermittent failure:

Code in Failur Failure cause Corrective action

display e
code

95 20 Hardware watchdog Acknowledgement

of solenoid valve of the failure,continue
axle2 is triggered the operation
Code in Failure Failure Corrective action
display code cause

95 21 Short 1.Check the wires for

circuit or short circuit or
interruptio interruption.
n of 2.Replace speed Sensor,
connection acknowledge the failure.
between 3.Contact for further
speed information SABWABCO
sensor at KP
axle2 and
WSP.
Code in Failure Failure Corrective action
display code cause

95 23 Short 1.Check the wires and valve

circuit of for short circuit
solenoid acknowledge the failure.
valve of 2.Replace solenoid valve,
Axle 2. acknowledge the failure.
3.Contact for further
information SABWABCO KP.
Code in Failure Failure cause Corrective action
display code
95 24 Interruption of 1.Check the wires
solenoid valve and valve for
of Axle 2. interruptions,
acknowledge the
failure.
2.Replace solenoid
valve, acknowledge
the failure.
3.Contact for further
information
SABWABCO KP.
Code Failure Failure Corrective action
in code cause
display
95 30 Hardware Acknowledgement the
watchdog failure,continue the operation.
of
solenoid
valve of
axle3 is
triggered
Code in Failure Failure cause Corrective action
display code

95 31 Short circuit 1.Check the wires for

or short circuit or
interruption interruption.
of 2.Replace speed
connection Sensor, acknowledge
between the failure.
speed sensor 3.Contact for further
at axle3 and information SABWABCO
WSP. KP.
Code in Failure Failure Corrective action
display code cause

95 33 Short 1.Check the wires

circuit and valve for short
of circuit acknowledge
solenoid the failure.
valve of 2.Replace solenoid
Axle 3. valve,acknowledge
the failure.
3.Contact for further
information
SABWABCO KP.
Code in Failure Failure Corrective action
display code cause

95 34 Interruptio 1.Check the wires and

n of valve for
solenoid interruptions,acknowle
valve of dge the failure.
Axle 3. 2.Replace solenoid
valve,acknowledge the
failure.
3.Contact for further
information
SABWABCO KP.
Code in Failure Failure Corrective action
display code cause
Intermitt
ent
failure:

95 40 Hardware Acknowledgement the

watchdog failure,continue the
of operation
solenoid
valve of
axle4 is
triggered
Code in Failure Failure Corrective action
display code cause

95 41 Short 1.Check the wires for

circuit or short circuit or
interruptio interruption.
n of 2.Replace speed Sensor,
connection acknowledge the failure.
between 3.Contact for further
speed information SABWABCO
sensor at KP.
axle4 and
WSP
Code in Failure Failure Corrective action
display code cause

95 43 Short 1.Check the wires and

circuit of valve for short circuit
solenoid acknowledge the
valve of failure.
Axle 4. 2.Replace solenoid
valve, acknowledge the
failure.
3.Contact for further
information SABWABCO
KP.
Code Failur Failure Corrective action
in e cause
display code
95 44 Interrupti 1.Check the wires and
on of valve for
solenoid interruptions,acknowledge
valve of the failure.
Axle 4. 2.Replace solenoid valve,
acknowledge the failure.
3.Contact for further
information SABWABCO
KP.