SEPARATELY EXCITED (SX) T RA N SIST ORIZED DUAL MOTO R T RACTION CONTROL
AND SERIES PUMP CONTROL
INSTALLATION AND OPERA T IO N MANUAL
(IC3645SR4U404N2 and IC3645SP4U400N3)
Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles
in the application, installation and service of GE solid-state controllers. This manual does not purport to
cover all variations in OEM vehicle types. Nor does it provide for every possible contingency to be met
involving vehicle installation, operation or maintenance. For additional information and/or problem
resolution, please refer the matter to the OEM vehicle manufacturer through his normal field service
channels. Do not contact GE directly for this assistance.
Table of Contents
Copyright by General Electric Company January 2000
Section 1.0 INTRODUCTIO N ........................................................................................................................................................4
1.1 Motor Characteristics.............................................................................................................. 4
Section 6.0 SX FAMILY - GE HANDSE T INSTRUCTIONS ......................................................................................................55
6.1 General Features .............................................................................................................................. 55
9.1 Typical Memory Map for Traction Control.................................................................................... 72-74
January 2000
BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 4
Section 1. INTRODUCTION
Section 1.1 Motor Characteristics
The level of sophistication in the controllability of traction
motors has changed greatly over the past several years.
Vehicle manufacturers and users are continuing to expect
more value and flexibility in electric vehicle motor and
control systems as they are applied today. In order to
respond to these market demands, traction system
designers have been forced to develop new approaches to
reduce cost and improve functions and features of the
overall system. Development is being done in a multi-
current to increa se, p r oviding the greater tor que needed to
drive the increased mechanical load. If the mechanical
load is decreased, th e p ro c ess r ever ses. T h e motor speed
and the back EMF increase, while the armature current and
the torque developed dec r ea se. T h u s, whenever the load
changes, the speed ch a n g es a l so , u n til th e mo to r is a g a in
in electrical balance.
In a shunt motor, the variation of speed from no load to
normal full load on level ground is less than 10%. For this
reason, shunt motors are considered to be constant speed
motors (Figure 2).
generational format that allows the market to take
advantage of today’s technology, while looking forward to
SPEED
new advances on the horizon. GE has introduced a second
generation system using separately excited DC shunt
wound motors. The separately excited DC motor system
offers many of the features that are generally found on the
advanced AC systems. Historically, most electric vehicles
have relied have on series motor designs because of their
ability to produce very high levels of torque at low speeds.
NO LOAD C URRENT
TORQUE
FULL
LOAD CURRENT
STARTING
CURRENT
But, as the demand for high efficiency systems increases,
i.e., systems that are more closely applied to customers’
specific torque requirements, shunt motors are now often
being considered over series motors. In most applications,
by independently controlling the field and armature
currents in the separately excited motor, the best attributes
of both the series and the shunt wound motors can be
combined.
In the separately excited motor , th e mo to r is o p er a ted a s a
fixed field shunt motor in the normal running range.
However, when additional torque is required, for example,
ARMATURE CURRENT
Figure 2
to climb non-level terrain, such as ramps and the like, the
field current is increased to provide the higher level of
torque. In most cases, th e a rma tu r e to fiel d a mp er e tu r n
SPEED
ratio can be very similar to that of a comparable size series
motor (Figure 3.)
FULL
NO LOAD CURR ENT
TORQUE
STARTING
LOAD CURRENT
CURRENT
SPEED
ARMATURE CURRENT
Figure 1
As shown in from the typical performance curves of Figure
1, the high torque at low speed characteristic of the series
motor is evident.
In a shunt motor, the field is connected directly across the
voltage source and is therefore independent of variations in
load and armature current. If field strength is held
constant, the torque developed will vary directly with the
armature current. If the mechanical load on the motor
increases, the motor slows down, reducing the back EMF
(which depends on the speed, as well as the constant field
strength). The reduced back EMF allows the armature
FULL
LOAD CURRENT
NO LOAD C URRENT
TORQUE
ARMATURE CURRENT
Figure 3
STARTING
CURRENT
Aside from the constant horsepower characteristics
described above, there are many other features that
provide increased performance and lower cost. The
January 2000
BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 5
following description provides a brief introduction to
examples of some of these features.
Section 1. 2 Solid-State Reversing
The direction of armature rotation on a shunt motor is
determined by the direction in which current flows through
the field windings. Because of the of the shunt motor field
only typically requires about 10% of the armature current at
full torque, it is normally cost effective to replace the
double-pole, double-throw reversing contactor with a low
power transistor H-Bridge circuit (Figure 4).
armature, the motor performance curve can be maximized
through proper control application.
Section 1. 4 More Features with Fewer Components
Field weakening with a series wound mo to r is
accomplished by placing a resistor in parallel with the field
winding of the motor. Bypassing some of the current
flowing in the field into the resistor causes the field current
to be less, or weakened. With th e fiel d wea ken ed , th e mo to r
speed will increase, giving the effect of “overdrive”. To
change the “overdrive speed”, it is necessary to change
the resistor value. In a sepa r a tel y exc ited mo to r ,
independent control of the field current provides for
LINE
FUSE
CAP
POS
A1 +
Q2
ARM
A2 -
Q1
Q3
Q4
Q5
F2F1
Q6
infinite adjustments of “overdrive” level s , b etween
motor base speed and maximu m wea k field. The
desirability of this feature is enhanced by the
elimination of the contactor and resistor required for
field weakening with a series motor.
With a separately excited motor, overhauling speed
limit, or downhill speed, will also be more constant. By
its nature, the shunt mo to r will try to maintain a
constant speed downhill. This characteristic can be
enhanced by incr ea sing the field strength with th e
control. Overhauling load control works in just the
NEG
Figure 4
By energizing the transistors in pairs, current can be made
to flow in either directio n in th e field. The armature control
circuit typically operates at 12KHZ to 15KHZ, a frequency
range normally above human hearing. This high frequency
coupled with the elimination of directional contactors,
provides very quiet vehicle operation. The field control
circuits typically operate at 2 KHZ.
The line contactor is normally the only contactor required
for the shunt motor traction circuit. This contactor is used
for both pre-charge of the line capacitors and for
emergency shut down of the motor circuit, in case of
problems that would cause a full motor torque condition.
The line can be energized and de-energized by the various
logic combinations of the vehicle, i.e. activate on key, seat
or start switch closure, and de-energize on time out of idle
vehicle. Again, these options add to the quiet operation of
the vehicle.
Section 1. 3 Flexible System Application
Because the shunt motor controller has the ability to
control both the armature and field circuits independently,
the system can normally be adjusted for maximum system
efficiencies at certain operating parameters. Generally
speaking, with the ability of independent field and
opposite way of field weakening , a r ma tu r e r o tation
slows with the increase of current in the field.
Regenerative braking (braking energy returned to the
battery) may be accomplished completely with solid-state
technology. The main advantage of regenerative braking is
increased motor life. Motor current is reduced by 50% or
more during br a k in g while maintaining th e same braking
torque as electrical braking with a diode clamp around the
armature. The lower current translates into longer brush
life and reduced motor heating. Solid state regenerative
braking also eliminates a power diode, current sensor and
contactor from the circuit.
For GE, the future is now as we ma ke a va ila b le a new
generation of electric traction motor systems for electric
vehicles having separately excited DC shunt motors and
controls. Features that were once thought to be only
available on future AC or brushless DC technology vehicles
systems are now achievable and affordable.
January 2000
BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 6
Section 2. FEATURES OF SX FAMILY OF TRANSISTOR
MOTOR CONTROLLERS
Section 2.1 Performance
Section 2.1.1 Oscillator Card Features
Section 2.1.1.a Standard Operation
With the accelerator at maximum ohms or volts, the creep
speed can be adjusted by Function 2 of the Handset or a
trimpot. The field control section allows the adjustment of
the field weakening level in order to set the top speed of the
motor. This top speed function (Minimum Field Current) is
enabled when the armature current is less than the value
set by Function 24 and the accelerator input voltage is less
than 1 volt. Top Speed can be adjusted by Function 7 of the
Handset or a trimpot.
The percent on-time has a range of approximately 0 to 100
percent. The SX controllers operate at a constant
frequency and the percent on-time is controlled by the
pulse width of the voltage / current applied to the motor
circuits.
Section 2.1.1.b Creep Speed
With the accelerator at maximum ohms or volts
(approximately 3.7 to 3.5 VDC), the creep speed can be
adjusted by Function 2 of the Handset. At creep speed, the
ON time can decrease to approximately 5%, with the OFF
time at approximately 95%. At full transistor operation, this
condition will be reversed (short OFF time, long ON time).
This variation of ON and OFF time of the oscillator varies
the voltage applied to the motor, thereby varying the speed
of the motor for a given load.
Section 2.1.1.c Control Acceleration
This feature allows for adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration. Armature C/A is
adjusted by Function 3 from 0.1 to 22 seconds.
Section 2.1.2 Current Limit
This circuit monitors motor current by utilizing sensors in
series with the armature and field windings. The
information detected by the sensor is fed back to the card
so that current may be limited to a pre-set value. If heavy
load currents are detected, this circuit overrides the
oscillator and limits the average current to a value set by
Function 4 and Function 8 of the Handset. The C/L setting is
based on the maximum thermal rating of the control.
Because of the flyback current through 3REC, the motor
current is usually greater than battery current, except at
100% ON time.
Section 2.1.3 Braking
Section 2.1.3.a Plug Braking
Section 2.1.3.b Regenerative Braking to Zero Speed
Slow down is accomplished when
reversing direction by providing a
small amount of retarding torque for
Q2
deceleration. If the vehicl e is
moving, and the directional lever is
ARM
moved from one direction to the
other, the regen signal is initiated.
Q1
Figure 5
Once the regen signal has been
initiated, the field current is
increased (armature circuit shown in
Figure 5). Armature current is
regulated to the regen current limit as set by Function 9. As
the vehicle slows down, the field current continues to
increase, and transistor Q2 begins to chop. The field
current will increa se u n til it r ea c h es a p r eset va l u e set b y
Function 10, and transistor Q2 on-time will increase until it
reaches 100% on-time. Once both of the above conditions
have been met, and regen current limit can no longer be
maintained, the braking function is canceled. The fields
will then reverse, and the control reverts back to motoring.
Part of the energy produced by the motor during regen is
returned to the battery , a n d p a r t is dumped in the motor as
heat.
Section 2.1.3.c Pedal Position Plug Braking
This feature allows control of the plugging distance based
on pedal position when there has been a “directional
switch" change. Pedal position will reduce the regenerative
current to the "value set by th is fu n c tio n " a s th e a c c el er a to r
is returned to the creep sp eed p o sition. Maximum regen
current is obtained with th e a ccelerator in the top sp eed
position.
Section 2.1.3.d Auto Braking
This feature is enabled by initiating a "neutral position"
using either the directional switch or the accelerator
switch. Once activated, Auto Braking operates similar to
Pedal Position Plug Braking and is adjusted by using
Function 21 of the Handset.
Section 2.1.4 Auxiliary Speed Control
Section 2.1.4.a Field Weakening
This function allows the adjustment of the field weakening
level in order to set the top sp eed o f th e mo to r . T h e fu n c tio n
is enabled when the armature current is less than the value
set by Function 24 and the accelerator input voltage is less
than 1 volt. It is importan t to n o te th a t th is fu n c tio n is u sed
January 2000
BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 7
to optimize motor and control performance, and this setting
will be determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
field personnel, without the permission of the OEM.
Section 2.1.4.b Speed Limits
This feature provides a means to control speed by limiting
motor volts utilizing three "adjustable speed limits. This
motor volt limit regulates top speed of the transistor
controller, but actual truck speed will vary at any set point
depending on the loading of the vehicle. Each speed limit
can be adjustable with the Handset using Functions 11, 12,
and 13.
Section 2.1.4.c Proportional Operation for Dual Motor
Vehicles
A key performance advantage of this control is the ability to
achieve actual "proportioning" of motor speed. In a
non-proportioning, or single control, system when the
At this point, the inside wheel wil l sto p , a s th e steer a n g l e is
increased toward th e 90° p o in t, the inside wheel will
reverse direction and start to accelerate proportionally in
speed. As the steer angle rea c h es th e 90° p o in t, th e in sid e
wheel speed will be the same as th a t o f th e o u tsid e wh eel .
During this entire turn, excep t fo r sever a l d eg r ees wh en th e
motor was stopped to change direction, torque was always
present on the inside wheel, providing a smoother ride
throughout the turning radius of the vehicle.
Details for adjustment of the steer a n g l e p o ten tio meter can
be found in Appendix A of this manual.
100%
RIGHT
MOTOR
50%
O
90
O
70
80
LEFT
TURN
50%
REV - SPEED - FWD
100%
LEFT
MOTOR
0O10O10O20
O
O
O
30
40
50O60
RIGHT
TURN
O
60
30O40
50
20
STEERING ANGLE
O
O
O
O
100%
50%
O
90
O
O
O
70
80
50%
REV - SPEED - FWD
100%
vehicle starts to turn, the outside drive wheel turns in a
larger circle than the inside wheel. Depending on the
geometry of the vehicle, at some degree of turn angle, the
inside wheel must slow down to prevent scrubbing of the
wheel. This is accomplished on single control system by
disconnecting the inside motor and letting the wheel "free
wheel" or "float" at whatever speed is d icta ted b y th e
outside wheel that is still under power. The main
disadvantage of this system is that no torque is available on
that motor when the inside wheel is in the "free-wheel"
mode, and performance in a turn is reduced. When the
steer wheel nears to the 90° turn a n g l e, th e in sid e mo to r is
re-connected in the opposite direction of the outside. At
this point, torque is returned to the inside wheel and the
speed is the same on both motors.
With two controls, the speed of each motor can be
regulated independently. The driver controls the speed of
the outside wheel with the ac c elerator input signa l . The
inside wheel speed is controlled by the turn angle of the
steer wheel . A potentiometer is attac h ed to th e steer wh eel
in order to communicate the steer angle to the controllers.
During vehicle manufacture, software selection identifies
each control for its application as a right or left control.
The controls are physically identical, and it is only software
that separates a right from a left control or differentiates a
control for a dual motor application from one intended for a
single motor vehicle. As the steer reaches some
pre-selected turn angle, approximately 20
o
, the speed of the
inside wheel decrease proportionally to the speed of the
outside wheel. This proportional decline will continue on a
linear path until the steer angle reaches another predetermine angle of, approximately 65
o
.
Section 2.1.5 Ramp Operation
Section 2.1.5a Ramp Start
This feature provides maximum control torque to restart a
vehicle on an incline. The memory for this function is the
directional switch. When stopping on an incline, the
directional switch must be left in its original or neutral
position to allo w th e c o n tr ol to initiate full po wer wh en
restarted. The accelerator potentiometer input will
modulate ramp start current.
Section 2.1.5b Anti-Rollback
This feature provides retarding torque to limit rollback
speed in the non-trav el d irec t io n wh en th e ACC p ed a l is
released when stopping o n a g r a d e, o r wh en th e b r a ke
pedal is released when starting on a grade. This feature
forces the vehicle to roll ver y sl o wl y d o wn th e grade when
accelerator or brake is released. Because the vehicle can
gain significant speed during roll-back, the torque needed
to re-start on the ramp is lower than an unrestricted rollback speed.
Section 2.1.6 Steer Pump Contactor Time Delay
This feature provides two options for SP time delay. Option
1 provides a 0.5 to 63 second time delayed drop out of the
steer pump contactor when the Forward or Reverse
directional switch is opened. This Option 1 is overridden by
a 1.5 second time delayed drop out whenever the seat
switch is opened. Option 2 provides a 0.5 to 63 second time
delayed drop out of the SP contactor when the seat switch
is opened.
Coil drivers for the LINE and SP contactors
are on-board the control card. These contactors must have
coils rated for the vehicle battery volts.
Section 2.2 System Protective Override
Section 2.2.1 Static Return to Off (SRO)
This inherent feature of the control is designed to require
the driver to return the dir ec tio n a l l ever to th e n eu tr a l
position anytime he leaves the vehicle and returns.
Additionally, if the seat switch or key switch is opened, the
control shuts off and cannot be restarted until the
directional lever is returned to neutral. A time delay of
approximately 2 seconds is built into the seat switch input
to allow momentary opening of the seat switch, if a bump is
encountered.
Section 2.2.2 Accelerator Volts Hold Off
This feature checks the voltage level at the accelerator
input whenever the key switch or seat switch is activated.
If, at start up, the voltage is less than 3.0 volts, the control
will not operate. This feature assures that the control is
calling for low speed operation at start up.
Section 2.2.3 Pulse Monitor Trip (PMT)
The PMT design contains three features which shut down,
or lock out, control operation if a fault conditions occurs
that would cause a disruption of normal vehicle operation:
•=Look ahead
•=Look again
•=Automatic look again and reset
The PMT circuit will not allow the control to start under the
following conditions:
•=The control monitors both armature and field FET's at
start-up and during running.
•=The control will not allow the line contactor to close at
start-up, or will drop it out during running, if either the
armature or field FET's are defective, so as to cause
uncontrolled truck movement.
Section 2.2.4 Thermal Protector (TP)
This temperature sensitive device is internal to the power
transistor (Q1) module. If the transistor's temperature
begins to exceed the design limits, the thermal protector
will lower the maximum current limit, and maintain the
transistors within their temperature limits. Even at a
reduced current limit, the vehicle will normally be able to
reach sufficient speed. As the control cools, the thermal
protector will au to ma tic ally reset, returning th e control to
full power.
Section 2.2.5 Low Voltage
Batteries under load, particularly if undersized or more
than 80 percent discharg ed , wil l p r o d u c e l o w vo l ta g es a t
the control terminals. The SX control is designed for use
down to 50 percent of a nominal battery voltage of 36-84
volts, and 75 percent of a nominal battery voltage of 24
volts. Lower battery voltage may cause the control to
operate improperly, however, the resulting PMT should
open the Line contactor, in the event of a failure.
Section 2.3 Diagnostics
Section 2.3.1 Systems Diagnostics
The control detects the system's present operating status
and can be displayed to either the Dash Display or the
Handset. There are currently over 70 status codes that are
available with SX systems using Traction and Pump
controls and Truck Management Module (TMM). Along
with the status code display from the TMM, the SX control
is capable of reducing the current to the motor, alerting the
operator of a critical fault condition.
Section 2.3.2 Status Codes
Section 2.3.2a Standard Status Codes
The SX traction control has over 30 Status Codes that
assist the service technician and operator in trouble
shooting the vehicle. If mis-operation of the vehicle occurs,
a status code will be displayed on the Dash Display for
vehicles so equipped, or be available by plugging the
Handset into the “y” plug of the logic card.
With the status code number, follow the procedures
outlined in DIAGNOSTIC STATUS CODES to determine the
problem and a solution.
Note: The Status Code Instruction Sheets do not claim to
cover all possible causes of a display of a "status code ".
They do provide instructions for checking the most direct
inputs that can cause status codes to appear.
Section 2.3.2.b Stored Status Codes
This feature records the last 16 "Stored Status Codes" that
have caused a PMT controller shut down and/or disrupted
normal vehicle operation. (PMT type faults are reset by
cycling the key switch). These status codes, along with the
corresponding BDI and hourmeter readings, can be
accessed with the Handset, or by using the RS 232
communications port and dumping the information to a
Personal Computer terminal.
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 9
Section 2.3.3 Hourmeter Readings
This feature will display the recorded hours of use of the
traction and pump control to the Dash Display each time
the key switch is turned off.
Section 2.3.3.a Maintenance Alert & Speed Limit
This feature is used to display Status Code 99 and/or
activate a speed limit when the vehicle operating hours
match the hours set into the maintenance alert register.
This feature is set with the Handset using Functions 19 and
20. The operator is alerted that maintenance on the vehicle
is required.
Section 2.3.4 Battery Discharge Indication (BDI)
The latest in microprocessor technology is used to provide
accurate battery state of charge information and to supply
passive and active warning signals to the vehicle operator.
Features and functions:
•=Displays 100 to 0 percent charge.
•=Display blinks with 20% charge. Disables pump circuit
with 10% charge. Auto ranging for 36/48 volt operation.
Adjustable for use on 24 to 80 volts.
Section 2.3.4.a Internal Resistance Compensation
This feature is used when the Battery Discharge Indicator
is present. Adjustment o f th is fu nction will improve th e
accuracy of the BDI.
Section 2.3.5 Handset
This is a multi-functional tool used with the LX, ZX, and SX
Series GE solid state controls. The Handset consists of a
Light Emitting Diode (LED) display and a keyboard for data
entry. Note, for ordering purposes, a separate Handset part
is required for SX controls.
Features and functions:
•=Monitor existing system status codes for both traction
and pump controls. Monitor intermittent random status
codes.
•=Monitor battery state of charge, if available.
•=Monitor hourmeter reading on traction and pump
controls. Monitor or adjust the control functions.
Section 2.3.6 RS 232 Communication Port
This serial communication port can be used with
Interactive Custom Dash Displays to allow changes to
vehicle operating parameters by the operator. Or, it can be
used by service personnel to dump control operating
information and settings into a personal computer program.
Section 2.3.6.a Interactive Dash Display
Modes
The Interactive Custom Dash Display allows the operator to
select the best vehicle performance for changing factory
(task) conditions. There are four (4) "operator interaction
modes" that can be selected by depressing a push button
on the dash display.
From the Dash Display, the operator may select any of four
pre-set interactive modes consisting of (4) Controlled
Acceleration levels, (4) Field Weakening levels and (4)
Speed Limits.
These interactive modes are "pre-set" using the Handset
(Functions 48-62) or a personal computer (Functions 97-
112). This feature allows the operator to select the best
vehicle performance for changing factory (task) conditions.
Section 2.3.7 Circuit Board Coil Driver Modules
Coil drivers are internal to the control card, and are the
power devices that operate the Line and SP contactor
coils. On command from the control card, these drivers
initiate opening and closing the contactor coils. All driver
modules are equipped with reverse battery protection, such
that, if the battery is connected incorrectly, the contactors
can not be closed electrically.
Section 2.3.8 Truck Management Module (TMM)
The Truck Management Module is a multifunction
accessory card, or an integral function of the GE Pump
controls when used with the SX Traction control. The
Module provides the OEM the ability to initiate status codes
or operator warning codes to be displayed on the Dash
Display, whenever a normally open switch or sensor wire
provides a signal to the Module.
The TMM Module can be used to display a separate status
code indicating over-temperature of traction motors,
hydraulic motors, or any other device or system that can
activate a switch that closes.
The TMM Module can also be used as a Brush Wear
Indicator (BWI). The Brush Wear Indicator is designed to
detect a "worn out brush" and display a fault code on the
Dash Display to warn maintenance personnel that the
motor brushes need to be r ep l a c ed b efo r e th ey wea r to th e
point of causing destructive damage to the motor
commutator surface.
Section 2.4 Hydraulic Pump Control
This hydraulic motor controller consists of the following
features:
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROLPage 10
•=Three speeds, adjustable from O to 100% motor
volts. Fixed speeds actuated by switch closure to
negative.
•=Current limit and controlled acceleration adjustable.
Operation of voltage regulator card: This card provides the
basic functions required for controlling the pump control,
optional contactors, and PMT functions. Battery positive is
applied through a main control fuse to the key switch,
energizing the control card power supply input to P1.
When a pump contactor is used, PMT operation is the
same as outlined for the traction controllers.
The three speed (motor volts) reference points P12, P19,
and P20 are selected by connecting these points
independently to battery negative.
The first speed is obtained by closing Speed Limit I (P12) to
control negative. SLl is adjustable by Function 11 using the
Handset to adjust motor voltage from O to 100%. The
specified motor volts will be regulated, however, the
magnitude of motor current will vary depending on the
loading of the vehicle.
The second speed is obtained by closing SL2 (P19) to
control negative. SL2 is adjusted using the Handset and
Function 12 similar to SL1.
The third speed is obtained by closing SL3 (P20) to control
negative. SL3 is adjusted using the Handset and Function
13 similar to SL1.
If more than one Speed Limit is activated, the selected
speed with the highest motor vol ts wil l o ver r ide th e low
motor volt speed. The current limit circuit is adjustable and
operates the same as the traction current limit.
The controlled acceleration circuit is adjustable and
operates the same as the traction circuit. Adjustment range
is from 0.1 to 5.5 seconds.
The Battery Discharge Indicator (BDI) interrupt will disable
the hydraulic controller if the connection at P10 loses the
12 volt signal from the traction control. BDI interrupt can be
disabled by Function 17 using the Handset. Select card type
with or without BDI function.
January 2000
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL Page 11
Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS
Section 3.1 Ordering Information for Separately Excited Controls
Example:
Part Number: IC3645 SE 4 D 33 2 C3
Argument Number: 01 02 03 04 05 06 07
Argument 01: Basic Electric Vehicle Control Number
Argument 02: Control Type:
SP = Series Control (Pump)
SH = Separately Excited Control ( Plugging )
SR = Separately Excited Control ( Regen to Zero )
1 BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM BATTERY
2 BATTERY VOLTS FROM KEY BATTERY VOLTS FROM KEY
3 BATTERY VOLTS FROM START SWITCH STATUS CODE 93 INPUT
4 BATTERY VOLTS FROM FORWARD SWITCH STATUS CODE 93 INPUT
5 BATTERY VOLTS FROM REVERSE SWITCH STATUS CODE 94 INPUT
6 BATTERY VOLTS FROM SEAT SWITCH STATUS CODE 94 INPUT
7 ACCELERATO R IN PUT VOLTAGE SIGNAL POTENTIOMETER INPUT VOLTAGE SIGNAL
8 STEER ANGLE POT NEGATIVE STATUS CODE 95 INPUT
9 STEER ANGLE POT +5 VOLTS SUPPLY STATUS CODE 95 INPUT
10 BDI INTERRUPT PUMP ENABLE SIGNAL 12VDC
11 PLUG/RGN OUTPUT SIGNAL +12V 1.0V=REGEN STATUS CODE 91 INPUT
12 STEER ANGLE INPUT VOLTAGE SIGNAL SPEED LIMIT #1 INPUT
13 RGN BRAKE POTENTIOMETER INPUT TMM1 BRUSHWEAR INDICATER OUTPUT
14 TMM BRUSHWEAR TMM1 OVER TEMPERATURE OUTPUT
15 I
OUT STATUS CODE 92 INPUT
MOTOR
16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT
17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CONTACTOR DRIVER
18 STEER PUMP CTR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER
19 DASH DISPLAY + 5 VOLT SUPPLY SPEED LIMIT #2 INPUT
20 TMM OVERTEMP SPEED LIMIT #3 INPUT
21 NOT USED NOT USED
22 SERIAL RECEIVE / DASH DISPLAY SERIAL RECEIVE
23 SERIAL TRANSMIT / DASH DISPLAY SERIAL TRANSMIT
9 FUNCTION FUNCTION
10 EXTERNAL JUMPER TO PY11 EXTERNAL JUMPER TO PY11
11 SERIAL RECEIVE / CONNECT TO P22 SERIAL RECEIVE / CON NECT TO P22
12 SERIAL TRANSMIT / CONNECT TO P23 SERIAL TRANSMIT / CONNECT TO P23
123456
789101112
WIRE END VIEW "Y" PLUG
12345668
910 11 12 13 14 15
16 17 18 19 20 21 22 23
WIRE END VIEW - MAIN PLUG
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 16
Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES
Section 4.1 General Maintenance Instructions
The transistor control, like all electrical apparatus, does
have some thermal losses. The semiconductor junctions
have finite temperature limits, above which these devices
may be damaged. For these reasons, normal maintenance
should guard against any action which will expose the
components to excessive heat and/or those conditions
which will reduce the heat dissipating ability of the control,
such as restricting air flow.
The following Do’s and Don’t’s should be observed:
Any controls that will be applied in ambient temperatures
over 100° F (40° C) should be brought to the attention of the
vehicle manufacturer.
All external components having inductive coils must be
filtered. Refer to vehicle manufacturer for specifications.
The wiring should not be directly steam cleaned.
areas, blow low-pressure air over the control to remove
dust. In oily or greasy areas, a mild solution of detergent or
denatured alcohol can be used to wash the control, and
then low-pressure air should be used to completely dry the
control.
For the control to be most effective, it must be mounted
against the frame of the vehicle. The metal vehicle frame,
acting as an additional heat sink, will give improved vehicle
performance by keeping the control package cooler. Apply
a thin layer of heat-transfer grease (such as Dow Corning
340) between the control heat sink and the vehicle frame.
Control wire plugs and other exposed transistor control
parts should be kept free of dirt and paint that might
change the effective resistance between points.
CAUTION: The vehicle should not be plugged when the
vehicle is jacked up and the drive wheels are in a free
wheeling position. The higher motor speeds can create
excessive voltages that can be harmful to the control.
Do not hipot (or megger) the control. Refer to control
manufacturer before hipotting.
Use a lead-acid battery with the voltage and ampere hour
rating specified for the vehicle. Follow normal battery
maintenance procedures, recharging before 80 percent
discharged with periodic equalizing charges.
Visual inspection of GE contactors contained in the traction
and pump systems is recommended to occur during every
In dusty
160 hours of vehicle operation. Inspection is recommended
to verify that the contactors are not binding and that the
tips are intact and free of contaminants.
GE does not recommend that any type of welding be
performed on the vehicle after the installation of the
control(s) in the vehicle. GE will not honor control failures
during the warranty p er io d wh en su c h fa il u r es a r e
attributed to welding wh il e th e control is install ed in th e
vehicle.
Section 4.2 Cable Routing and Separation
Electrical noise from cabling of various voltage levels can
interfere with a microprocessor-based control system. To
reduce this interference, GE recommends specific ca b l e
separation and routing practices, consistent with industry
standards.
Section 4.2.1 Application Resp o n s ib ility
The customer and customer’s representative are
responsible for the mechanical and environmental
locations of cables. They are also responsible for applying
the level rules and cabling practices defined in this section.
To help ensure a lower cost, noise-free installation, GE
recommends early planning of cable routing that complies
with these level separation rules.
On new installations, sufficient space should be allowed to
efficiently arrange mechanical and electrical equipment.
On vehicle retrofits, level rules should be considered during
the planning stages to help ensure correct application and
a more trouble-free installation.
Section 4.2.2. Signal/Power Level Definitions
The signal/power carrying cables are categorized into four
defining levels: low, high, medium power, and high power.
Within those levels, signals can be further divided into
classes.
Sections 4.2.2.a through 4.2.2.d define these levels and
classes, with specific examples of each. Section 4.2.3
contains recommenda tio n s fo r sep a r a tin g th e levels.
4.2.2.a Low-Level Signals (Level L)
Low-level signals are designated as level L. These consist
of:
•= Analog signals 0 through ±15 V
•= Digital signals whose logic levels are less than 15 V DC
•= 4 – 20 mA current loops
•= DC busses less than 15 V and 250 mA
The following are specific examples of level L signals used
in drive equipment cabling:
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 17
•= Control common tie
•= DC buses feeding sensitive analog or digital hardware
•= All wiring connected to components associated with
sensitive analog hardware with less than 5V signals (for
example, potentiometers and tachometers)
•= Digital tachometers and resolvers
•= Dash display cabling
•= RS-232 cabling
Note: Signal inputs to analog and digital blocks should be
run as shielded twisted-pair (for example, inputs from
tachometers, potentiometers, and dash displays).
4.2.2.b High-Level Signals (Level H)
High-level signals are designated as level H. These signals
consist of:
•=Analog and digital signals greater than 15 V DC and
less than 250 mA
For example, switch inputs connected to battery volts are
examples of level H signals used in drive equipment
cabling.
4.2.2.c Medium-Power Signals (Level MP)
Medium power signals are designated as level MP. These
signals consist of:
•= DC switching signals greater than 15 V
•= Signals with currents greater than 250 mA and less than
10A
The following are specific examples of level MP signals
used in drive equipment cabling:
•= DC busses less than 10 A
•= Contactor coils less than 10 A
•= Machine fields less than 10 A
4.2.2.d. High Power Signals (Level HP)
Power wiring is designated as level HP. This consists of DC
buses and motor wiring with currents greater than 10 A.
The following are specific examples of level HP signals
used in drive equipment cabling:
•= Motor armature loops
•= DC outputs 10 A and above
•= Motor field loops 10 A and above
4.2.3. Cable Spacing Guidelines
Recommended spacing (or clearance) between cables (or
wires) is dependent on the level of the wiring inside them.
For correct level separation when installing cable, the
customer must apply the general guidelines (section
4.2.3.a), outlined below.
4.2.3.a General Cable Spacing
The following general practices should be used for all
levels of cabling:
•=All cables and wires of like signal levels and power
levels must be grouped together.
•=In general, different levels must run in separate wire
bundles, as defined in the different classes, identified
above. Intermixing cannot be allowed, unless noted by
exception.
•=Interconnecting wire runs should carry a level
designation.
•=If wires are the same level and same type signal, group
those wires from one location to any other location
together in multiconductor cables or bind them
together with twine or zip- ties.
•=When unlike signals must cross, cross them in 90°
angles at a maximum spacing. Where it is not possible
to maintain spacing, place a grounded steel barrier
between unlike levels at the cr o sso ver p o in t.
4.2.4 Cabling for Vehicle Retrofits
Reducing electrical noise on vehicle retrofits requires
careful planning. Lower and higher levels should never
encircle each other or run parallel for long distances.
It is practical to use existing wire runs or trays as long as
the level spacing (see section 4.2.2) can be maintained for
the full length of the run.
Existing cables are generally of high voltage potential and
noise producing. Therefore, route levels L and H in a path
separate from existing cabl es, wh en ever p o ssib l e.
For level L wiring, use barriers in existing wire runs to
minimize noise potential.
Do not loop level L signal wires around level H, level MP, or
HP wires.
4.2.5 RF Interference
To prevent radio frequen c y (RF) in ter fer en c e, c a r e sh o u l d
be taken in routing power cables in the vicinity of radiocontrolled devices.
Section 4.2.6 Suppression
Unless specifically noted otherwise, suppression (for
example, a snubber) is required on all inductive devices
controlled by an output. This suppression minimizes noise
and prevents damage ca u s ed b y el ec tr ic a l su r g es.
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 18
Section 4.3 Recommended Lubrication of Pins and
Sockets Prior to Installation
Beginning in January of 1999, GE will implement the
addition of a lubricant to all connections using pins and
sockets on EV100/EV200 and Gen II products. Any
connection made by GE to the A, B, X, Y, or Z plugs will
have the lubricant NYE 760G added to prevent fretting of
these connections during vehicle operation.
Fretting occurs during microscopic movement at
the contact points of the connection. This movement
exposes the base metal of the connector pin which, when
oxygen is present, allows oxidation to occur. Sufficient
build up of the oxidation can cause intermittent contact
and intermittent vehicle operation. This can occur at any
similar type of connection, whether at the control or in any
associated vehicle wiring, and the resultant intermittent
contact can provide the same fault indication as actual
component failure.
The addition of the NYE 760G lubricant will prevent
the oxidation process by eliminating the access of oxygen
to the contact point. GE recommends the addition of this
lubricant to the 12 pin and 23 pin plugs of all new Gen II
controls at the time of their installation into a vehicle
When servicing existing vehicles exhibiting
symptoms of intermittent mis-operation or shutdown by the
GE control, GE recommends the addition of this lubricant to
all 12 and 23 pin plugs, after proper cleaning of the
connectors, as a preventative measure to insure fretting is
not an issue before GE control replacement. Also, for long
term reliable control operation, the plug terminals must be
maintained per these instr u c tions with the recommended
contact cleaner and lubricant which provides a high
degree of environmental and fretting protection.
New and re-manufactured control plugs are cleaned and
lubricated prior to shipment from the factory. However, in
applications where severe vibration or high temperature
cycling and excessive humidity ( such as freezers ) are
present, it is recommended that the plug terminals be
cleaned and lubricated every year, per this instructions. In
normal applications, plug maintenance should be
performed every two years, unless intermittent problems
arise with the plugs, requiring more immediate attention.
Warning: Do not use any other cleaners or lubricants
other than the ones specified.
WARNING: Before conducting maintenance on the
vehicle, jack up the drive wheels, disconnect the battery
and discharge the capacitors. Consult the Operation and
Service Manual for your particular vehicle for details on
discharging the capacitors; this procedure differs
between SCR and Transistor controls.
1. Disconnect plug from controller or mating plug.
2. Locate the plug that conta in s th e so c ket (fema l e)
terminals. Maintenance needs only to be performed on
the plug containing the socket (female) type terminals.
Reconnecting the plugs will lubricate the pin (male)
terminals.
3. Clean each terminal using Chemtronics contact
cleaner “Pow-R-WasH CZ “ as shown in Figure 1.
s
c
oni
r
t
m
he
C
r
e
n
a
e
l
c
t
c
a
t
n
o
c
Z
C
H
R
-
s
a
w
W
Po
e
n
a
z
o
r
i
c
Figure 1
4. Lubricate each terminal using Nye 760G lubricant as
shown in figure 2. Apply enough lubricant to each
terminal opening to completely fill each opening to a
depth of .125” minimum.
Nye
Nye
NyeNye
LU
B
RICA
N
TS
Figure 2
5. Reconnect plugs.
Reference
Cleaner Chemtronics Po w- R- Wa sH CZ Co n t a c t
Cleaner
Lubricant Nye Lubricants NYOGEL 760G
GE Plug Lub Kit Contains both above products:
328A1777G1
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 19
Section 4.4 General Troubleshooting Instructions
Trouble-shooting the SX family of controls should be quick
and easy when following the instructions outlined in the
following status code instruction sheets.
If mis-operation of the vehicle occurs, a status code will be
displayed on the Dash Display (for vehicles equipped with a
Dash Display) or made available by plugging a Handset into
the plug "Y" location, and then reading the status code.
Note: Status code numbers from 00 to 99 are traction
control status codes. Status codes with the prefix 1 (101 to
199) are pump control status codes.
With the status code number, follow the procedures
outlined in the status code instruction sheets to determine
the problem.
Important Note: Due to th e in ter a c tio n o f th e l o g ic c a r d
with all vehicle functions, almost any status code or
control fault could be caused by the logic card. After all
other status code procedures have been followed and no
problem is found, the controller should then be replaced as
the last option to correct the problem.
The same device designations have been maintained on
different controls but the wire numbers may vary. Refer to
the elementary and wiring diagrams for your specific
control. The wire numbers shown on the elementary
diagram will have identical numbers on the corresponding
wiring diagrams for a specific vehicle, but these numbers
may be different from the number s r efer en c ed in th is
publication.
WARNING: Before trouble-shooting, jack up the drive
wheels, disconnect the battery and discharge the
capacitors. Reconnect the battery as needed for specific
checks. Capacitors should be discharged by connecting a
200 ohm 2 watt resistor between the positive and negative
terminals on the control panel.
Check resistance on R x 1000 scale from frame to power
and control terminals. A resistance of less than 20,000
ohms can cause misleading symptoms. Resistance less
than 1000 ohms should be corrected first.
Before proceeding, visually check for loose wiring,
mis-aligned linkage to the accelerator switch, signs of
overheating of components, etc.
Tools and test equipment required are: clip leads, volt-ohm
meter (20,000 ohms per volt) and basic hand tools.
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 20
Section 4.5 Traction Control Codes
TRACTION
STATUS CODE
NONE
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Segments do not illuminate on the
Dash Display and/or the Handset.
No input voltage to the control card or the display unit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Display screen on Dash Displ a y and/ or Handset
is blank.
POSSIBLE CAUSE
Positive or negative control vol t age is not
present.
•= Insure that the key switch is cl osed and
voltage is present between P1 & batt ery
negative (Power Terminal “NEG”). Als o check
for voltage between P2 and control negative.
Open circuit between control card A ND the Dash
Display or Handset.
•= Check for an open circuit or loose connection
going from the control and t he Dash Display or
Handset.
Defective Dash Display or Hands et.
•= Replace Dash Display or Handset.
KEY
NEG
SWITCH
P1
P2
FU3
FU5
+
-
TRACTION
STATUS CODE
-01
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
No seat switch or deadman switch
input (no voltage to P6).
This status code will be displayed when P6 is less
than 50% battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Mis-adjusted or defective s eat or deadman
switch.
•= Check to see that the seat switch c l oses
properly.
Open circuit between battery posit i ve and P 6.
•= Check for loose connections or broken wires:
−=Between the seat switch and P 6
−=Between the key switch and t he battery
−=Between the seat switch and P 2.
positive side of the seat switch.
KEY
NEG
SWITCH
P1
P6
P2
FU3
FU5
+
-
•=On vehicles without a seat/deadman switch,
check for a loose connection or broken wire
from P2 and/or P6.
SEAT SWITCH
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 21
TRACTION
STATUS CODE
-02
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Forward directional switch is closed on
initial power up.
This status code will be displayed when P4 is greater
than 60% of battery voltage at initial key switch on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate because of Static Ret urn
to Off (SRO) lock out.
POSSIBLE CAUSE
Forward directional switch is closed on i ni tial
start up (i.e. closure of battery, key switch or
seat switch).
•= Return directional switch lever to neutral and
then return lever to forward position.
Forward directional switch is welded closed or
mis-adjusted to be held closed.
•= Replace or adjust directional switch to i nsure
that it opens when the directional switch is
returned to neutral.
Short circuit between P3 and P4.
•= Disconnect the wire from P4 and check for a
short circuit between P3 and the wire that was
connected to P4.
Defective control.
•= Replace the controller unit.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3P17P5
P6
START SW.
FORWARD SW.
P4
REVERSE SW.
TRACTION
STATUS CODE
-03
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Reverse directional switch is closed on
initial power up.
This status code will be displayed when P5 is greater
than 60% of battery voltage at initial key switch on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate because of Static Ret urn
to Off (SRO) lock out.
POSSIBLE CAUSE
Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
seat/deadman switch).
•= Return directional switch lever to neutral and
then return lever to reverse position.
Reverse directional switch is welded closed or
mis-adjusted to be held closed.
•= Replace or adjust directional switch to i nsure
that it opens when the directional switch is
returned to neutral.
Short circuit between P3 and P5.
•= Disconnect the wire from P5 and check for a
short circuit between P3 and the wire that was
connected to P5.
Defective control. Replace the controller unit.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3P17P5
P6
START SW.
FORWARD SW.
P4
REVERSE SW.
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 22
TRACTION
STATUS CODE
-05
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Start switch fails to close. This status code will be displayed when P7 is less
than 2.5 volts and P3 is less than 60% of battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective start switch circuit.
•= Check start switch to insure cl osure when
accelerator is depressed.
•= Check for open circuit or loose connections in
wiring from brake switch to s t art switch and
from P3 to start switch.
Defective accelerator switch.
•= Check accelerator switch potentiometer for
proper operation and ohmic value.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3
P17P5P4P6
KEY SWITCH
START SW.
FORWARD SW.
REVERSE SW.
ACCPOT
NEG
P7
TRACTION
STATUS CODE
-06
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Accelerator depressed with no
direction selected.
This status code will be displayed when P4 and P5
are less than 60% of battery volts, and P7 is less than
2.5 volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Accelerator pedal is depressed before closing
forward or reverse directional switch.
•= Status code will disappear when directional
switch is closed or when accelerat or pedal i s
released.
Defective directional s witch
•= Check forward or reverse switch to insure
closure when direction is selected.
Open circuit between directional s witch(es) and
battery positive or between directional switch(es)
and P4 or P5.
•= Check all control wires and connections shown
in Trouble Shooting Diagram.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3
P17P5P4P6
KEY SWITCH
START SW.
FORWARD SW.
REVERSE SW.
NEG
P7
ACCPOT
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 23
TRACTION
STATUS CODE
-07
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Accelerator input voltage too high on
power up after initial key switch
closure.
This status code will be displayed when the
accelerator input voltage at P7 is higher than 4.2
volts, and a directional contactor is picked up.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate when accelerator pedal
is depressed or status code -07 is displayed
then disappears when the vehicle starts to
accelerate.
POSSIBLE CAUSE
Accelerator input m i s-adjusted or defective.
•= Input voltage at P7 should be less than 3.7
volts. Adjust or replace accelerator unit to
insure that the voltage at P7 will vary from 3.5
volts to less than . 5 vol ts when the pedal is
depressed.
Open circuit between battery negative and P7 i n
accelerator input circ ui t.
•= Check for broken wires or loose connections
or open potentiometer / volt age supply.
Short circuit from battery positive to wiring in
accelerator input circ ui t.
•= Disconnect wire from P7 and measure
voltage at wire to negative. Should be zero
volts for potentiom eter type and less than 3.7
volts for solid st at e type accelerator input.
KEY
SWITCH
P7
NEGATIVE
ACC POT
TRACTION
STATUS CODE
-08
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Accelerator input voltage too low on
power up after initial key switch
closure.
This status code will be displayed when the
accelerator input voltage at P7 is less than 3.0 volts,
and any of the following connections are opened and
closed: battery plug or key switch.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Accelerator input m i s-adjusted or defective.
•= Input voltage at P7 should be more than 3.0
volts. Adjust or replace accelerator unit to
insure that the voltage at P 7 i s more than 3.0
volts before depressing pedal.
Short circuit between battery negat i ve and P 7 in
accelerator input circ ui t.
•= Disconnect wire from P7. Check f or short
circuit from wire to bat tery negative.
Defective Control
•= Disconnect wire from P7. Measure voltage
from P7 to negative. Vol tage should be greater
than 4.5 volts, if not , repl ace control.
KEY
SWITCH
P7
NEGATIVE
ACC POT
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 24
TRACTION
STATUS CODE
-09
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Both the forward and reverse
directional switches are closed at the
same time.
This status code will be displayed when P4 and P5
are greater than 60% of battery volts at the same
time.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Forward or reverse directional switch welded
closed or mis-adjus t ed to be held closed.
•= Replace or adjust directional switches t o
insure that they open when directional s witc h
is returned to neutral.
Short circuit between battery positive and P4
and/or P5.
•= Disconnect wires from P4 and P5 and chec k
wire for short circuit to positive side of
directional switch.
Defective Control
•= Disconnect wires and measure voltage at P4
and P5. Voltage should be less than 60% of
battery volts.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3P17P5
P6
START SW.
FORWARD SW.
P4
REVERSE SW.
TRACTION
STATUS CODE
-10
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Steer angle potentiometer voltage is
too high.
This status code will be displayed when P12 is greater
than 3.9 volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Steer angle potentiomet er i nput mis-adjusted or
defective. Loose or mi ssing connections at P8,
P12 or P9.
•= Input voltage at P12 should be less than 3.9
volts at all tim es. Insure that the adjus tment
of the steer potentiometer is in accordance
with Section 9 of this instruction.
Defective control.
•= Replace control unit.
POT
P8
P9 P12
STEER ANGLE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 25
TRACTION
STATUS CODE
-11
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Start switch closed on power up after
initial key switch closure.
This status code will be displayed when P3 is greater
than 60% of battery voltage when the key switch is
closed.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Start switch input mis-adjusted or defecti ve.
•= Input voltage at P3 should be less than 60% of
battery volts at key switch closing. Adjust or
replace accelerator unit t o i nsure that the
voltage at P3 is less t han 60% of battery volts
before closing the start switch.
Short circuit between battery positive and P3 in
start switch input c i rcuit.
•= Disconnect wire from P3. Check f or short
circuit from t hi s wire to battery positive.
Defective control.
•= Disconnect wire from P3. Measure voltage
from P3 to negative. Vol tage should be zero,
if not, replace control.
KEY
SWITCH
L
SEAT SWITCH
P1P2P3P17P5
P6
START SW.
FORWARD SW.
P4
REVERSE SW.
TRACTION
STATUS CODE
-12
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Steer angle potentiometer voltage is
too low.
This status code will be displayed when P12 is less
than 0.39 volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Steer angle potentiomet er i nput mis-adjusted or
defective. Loose or mi ssing connections at P9,
P12 or P8.
•= Input voltage at P12 should be greater than
0.39 volts at all times. Insure that t he
adjustment of the steer potentiometer is i n
accordance with Section 9 of t hi s instruction.
Defective control.
•= Replace control unit.
P9 P12 P8
STEER ANGLE
POT
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 26
TRACTION
STATUS CODE
-15
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Battery voltage is too low or control
card is mis-adjusted.
This status code will be displayed when the battery
volts are less than 1.95 volts per cell at initial key
switch on. See table below.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Discharged battery
•= Check battery for proper open circuit voltage
as shown in “Trouble Shooting Diagram”,
charge battery, if required.
Defective battery
•= Check each battery cell for proper voltage
(greater than 1.95 volts at cel l ). Replace or
repair battery.
Incorrect control c ard adj ustment.
•= Check Function 15 for proper adjustment f or
battery being used. See Handset i nstruction
sheet for details. A dj ust to proper settings.
Check “minimum” battery volts at P1 and NEG.
+
-
FU5
NOMINAL
BATTERY
VOLTAGE
24
36
48
P1
NEG
72
80
MINIMUM
LIMIT VOLTS
AT 1.95 VDC
PER CELL
23.4
35.1
46.8
70.2
78.0
TRACTION
STATUS CODE
-16
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Battery voltage is too high or control
card is mis-adjusted.
This status code will be displayed when the battery
volts are greater than 2.4 volts per cell at initial key
switch on. See table below.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Incorrect control c ard adj ustment
Check Function 15 for proper adjust ment for
battery being used. See Handset i nstructions
for details. Adjust to proper setting.
Battery over charged or incorrect bat tery used.
•= Check battery for proper open circuit voltage
per table at right. If volt age i s excessive, check
battery charger for proper output voltage.
Check “maximum” bat tery volts at P1 and NEG.
+
-
FU5
NOMINAL
BATTERY
VOLTAGE
24
36
48
P1
NEG
72
80
MINIMUM
LIMIT VOLTS
AT 1.95 VDC
PER CELL
23.4
35.1
46.8
70.2
78.0
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 27
TRACTION
STATUS CODE
-23
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Motor field current is high on start up in
the reverse direction.
This status code will be displayed when the current
draw in the motor field is too high at start up in the
reverse direction.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
RIGHT CONTROL
NEG
START SW.
P7
POS A1F1
POWER
CONNECTIONS
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
TRACTION
STATUS CODE
-24
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Motor field current is high on start up in
the forward direction.
This status code will be displayed when the current
draw in the motor field is too high at start up in the
forward direction.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective Control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
RIGHT CONTROL
NEG
FOR. SW.
START SW.
P4
P5
P10
P7
P9P3P12 P8
BDI INTERRUPT
POS A1F1
POWER
CONNECTIONS
A2
SW.
REV.
STEER
ANGLE
POT
FIELD
ARMATURE
F2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 28
TRACTION
STATUS CODE
-27
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Control’s power supply is less than 10
Volts DC.
This status code will be displayed when the control’s
power supply is less than 10 volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then can only
be closed by opening and closing the key
switch.
POSSIBLE CAUSE
Discharged Battery
•= Check battery to insure proper state of c harge.
Voltage may be dropping below 10 Volts DC
under load.
Loose connection at P1.
•= Insure that the wire connection at P1 is t i ght .
Defective control.
•= Replace controller unit.
FU3
FU5
+
-
NEG
KEY
SWITCH
P1
P2
TRACTION
STATUS CODE
-28
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Motor field current is too high during
the run mode.
This status code will be displayed when the current
draw in the motor field is sustained above a preset
limit for longer than 70 seconds.
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Continued operation of vehicle in high motor
current condition.
•= Operate vehicle at lower mot or current
condition for 70 seconds.
Function 7 is mis-adjusted to allow higher than
normal motor field current.
Adjust function per OEM ins t ructions.
TROUBLE-SHOOTING DIAGRAM
BRAKE SW.
P2
7
ACCESSORIES
P3
FU1
SP
SP
KEY SWITCH
TO
PY7
PY12
P18
PY10
PY11
A1F1
POS
POWER
CONNECTIONS
LEFT CONTROL
NEG A2
P1
SP
P5
L
P4
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
SEAT SW.
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
P7
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
U
START SW.
P4
POWER
FOR. SW.
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 29
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-29
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
12
FU5
P2
FU7
TO ACCESSORIES
FU6
P3
PLUG PY
CONNECTIONS
Motor field current is too high during
the run mode (Dual motor
proportioning controls only)
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
TROUBLE-SHOOTING DIAGRAM
KEY SWITCH
P5
12-1
10
PY7
PY12
PY10
PY11
24
60
P4
P18
P17
OSCILLATOR CARD
LEFT CONTROL
SP
L
P1
P1
P2 P6
BRAKE SW.
SEAT SW.
START SW.
FORWARD SW.
P4
P10P21
P7
29
50 30
This status code will be displayed when the motor
current in control “A” is greater than 98A, while the
motor current in control “B” is less than 26A for a 16
second interval.
POSSIBLE CAUSE
Continued operation of vehicle in high motor current condition.
•= Verify operation of other c ontrol during the run mode.
REVERSE SW.
P5
P9P3P12 P8
P15
P16
66 65
PMT ENABLE OUTPUT
OSCILLATOR CARD
P16
RIGHT CONTROL
P15
8
15
6
12-1
P10
P7 P12
25
710
P6P2P1P3 P4
P13
P18
P11
PY7
P5
PY12
PY10
PY11
PLUG PY
CONNECTIONS
FU2
LINE
FU1
3
5
2
+
FU4
A1
A2
S1
S2
P
43
TMM7
P
88
89
TMM7
SP
A1
POSA1
SP
POWER CONNECTIONS
LEFT CONTROL
NEGA2
A2
F1
F2
A1
FIELD
A2
ACC POT
13A
ARMATURE
STEER ANGLE
POT
POSA1
POWER CONNECTIONS
RIGHT CONTROL
NEG
A2
AUTO REGENERATIVE
BRAKING ENABLE
STEER PUMP
CONTACTOR DRIVER
REGEN OUTPUT
F1
FIELD
F2
SIGNAL
BDI INTERRUPT
A1
ARMATURE
A2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 30
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-30
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
12
FU5
P2
FU7
TO ACCESSORIES
FU6
P3
PLUG PY
CONNECTIONS
PMT enable signal from auxiliary
control to master at PL21 is missing
during SRO check (Dual motor
proportioning controls only)
CORRECTIVE ACTIONS
SYMPTOM
Auxiliary control shutdown.
TROUBLE-SHOOTING DIAGRAM
KEY SWITCH
P5
12-1
10
PY7
PY12
PY10
PY11
24
60
P4
P18
P17
OSCILLATOR CARD
LEFT CONTROL
SP
L
P1
P1
P2 P6
BRAKE SW.
SEAT SW.
START SW.
FORWARD SW.
P4
P10P21
P7
29
50 30
This status code will be displayed when the voltage at
PL21 of the master control is less than 5 volts. This
fault is not stored.
POSSIBLE CAUSE
•= Check auxiliary control for status codes.
•= Verify connection between PL21 of the master control and PL10
of the slave/auxiliary control.
REVERSE SW.
P5
P9P3P12 P8
P15
P16
66 65
PMT ENABLE OUTPUT
OSCILLATOR CARD
P16
RIGHT CONTROL
P15
8
15
6
12-1
P10
P7 P12
25
710
P6P2P1P3 P4
P13
P18
CONNECTIONS
PY7
P5
PY12
PY10
P11
PY11
PLUG PY
FU2
LINE
FU1
3
5
2
+
FU4
A1
A2
S1
S2
P
43
TMM7
P
88
89
TMM7
SP
A1
POSA1
SP
POWER CONNECTIONS
LEFT CONTROL
NEGA2
A2
F1
F2
A1
FIELD
A2
ACC POT
13A
ARMATURE
STEER ANGLE
POT
POSA1
POWER CONNECTIONS
RIGHT CONTROL
NEG
A2
AUTO REGENERATIVE
BRAKING ENABLE
STEER PUMP
CONTACTOR DRIVER
REGEN OUTPUT
F1
FIELD
F2
SIGNAL
BDI INTERRUPT
A1
ARMATURE
A2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 31
-41
Open thermal protector (TP) or
transistor over temperature.
This status code will be displayed when the voltage at
the thermal protector is too high.
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Reduced or no power to traction motor in control
range.
POSSIBLE CAUSE
Control is in thermal cut-back.
•= Allow control to cool, status code should
disappear.
Defective control.
•= Replace controller unit .
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
BRAKE SW.
P1
SP
L
SEAT SW.
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
START SW.
P7
ACC POT
POS A1F1
POWER
CONNECTIONS
RIGHT CONTROL
NEG
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
-42
Motor armature offset voltage is too
high.
This status code will be displayed when the voltage at
the current sensor input is greater than 2.6 volts with
no current flowing in the motor circuit.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
LINE
+
-
A1
P
FU6
P
FU5
7
F
U
FU4
P3
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
PY7
PY12
PY10
PY11
POS
POWER
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P1
SP
P5
P4
P18
P17
P1
OSCILLATOR CARD
LEFT CONTROL
A1F1
F2
L
P2
FIELD
BRAKE SW.
SEAT SW.
P6
ARMATURE
FOR. SW.
START SW.
P4
P10
P7
ACC POT
POS A1F1
POWER
CONNECTIONS
RIGHT CONTROL
A2
NEG
SW.
REV.
P5
P9P3P12 P8
STEER
ANGLE
POT
BDI INTERRUPT
FIELD
ARMATURE
F2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 32
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-43
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
Motor armature offset voltage is too
low.
This status code will be displayed when the voltage at
the current sensor input is less than 2.4 volts with no
current flowing in the motor circuit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
LINE
+
-
P
FU6
A1
F
FU4
P
FU5
7
U
ACCESSORIES
P3
FU1
SP
SP
KEY SWITCH
P2
TO
POS
CONNECTIONS
LEFT CONTROL
NEG A2
PY7
PY12
PY10
PY11
POWER
P5
P4
P18
P17
OSCILLATOR CARD
A1F1
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
SW.
REV.
STEER
ANGLE
POT
FIELD
ARMATURE
F2
-44
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
Armature transistor did not turn off
properly.
This status code will be displayed when, during
control operation, the armature transistor fails to turn
off. This will result in a PMT condition.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then can only
be closed by opening and closing the key switch.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
RIGHT CONTROL
NEG
START SW.
P7
POS A1F1
POWER
CONNECTIONS
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 33
TRACTION
STATUS CODE
-45
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Armature transistor did not turn on
properly.
This status code will be displayed when, during
control operation, the armature transistor fails to turn
on properly. This will result in a PMT condition.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then can only
be closed by opening and closing the key
switch.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
-46
MEMORY RECALL
“Look Ahead” test for A2 volts less
than 12% of battery volts.
CORRECTIVE ACTIONSTROUBLE-SHOOTING DIAGRAM
This status code will be displayed when the voltage at
A2 is less than 12% of battery volts.
NO
Circuits valid
for
Traction
Controller
SYMPTOM
Line contactor will not pick up.
POSSIBLE CAUSE
Check for short circ ui t from the motor armature
to the frame of the vehicle.
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
BRAKE SW.
P1
SP
L
SEAT SW.
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
FOR. SW.
START SW.
P4
P5
P10
P7
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
BDI INTERRUPT
POWER
A2
SW.
REV.
P9P3P12 P8
F2
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 34
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-49
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
Motor field current is too low during the
run mode.
This status code will be displayed when the current
draw in the motor field is too low during the run mode.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
-51
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
Capacitor volts are low before the line
contactor closes.
This status code will be displayed during “key on”
when the capacitor voltage is less than 85% of battery
volts at initial key switch on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor does not cl ose when capacitor
does not precharge.
POSSIBLE CAUSE
Defective control fus e.
•= Check control fuse for open circuit. Replace
fuse, if necessary.
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 35
TRACTION
STATUS CODE
-57
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
TRACTION
STATUS CODE
-64
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Controller “motor current sensor”
input too low during running.
This status code will be displayed when the voltage
input from the current sensor is too low during running.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
LEFT CONTROL
F2
BRAKE SW.
P1
SP
L
SEAT SW.
P1
P6
P2
ACC POT
FIELD
ARMATURE
RIGHT CONTROL
NEG
FOR. SW.
START SW.
P4
P10
P7
POS A1F1
POWER
CONNECTIONS
A2
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
The line driver input (P2-17) is less
than 12% of battery volts
This status code will be displayed when the control
detects that the line driver input (P2-17) is less than
12% battery volts when the key switch is turned on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
-Open wire connection to Pin 17
- Shorted line Driver transist or
Defective control.
•= Replace controller unit.
FU2
+
-
FU6
LINE
A1
P
FU5
F
FU4
P
7
U
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
LEFT CONTROL
F2
BRAKE SW.
P1
SP
L
SEAT SW.
P1
P6
P2
ACC POT
FIELD
ARMATURE
RIGHT CONTROL
NEG
FOR. SW.
START SW.
P4
P10
P7
POS A1F1
POWER
CONNECTIONS
A2
SW.
REV.
P5
P9P3P12 P8
STEER
ANGLE
POT
BDI INTERRUPT
FIELD
ARMATURE
F2
SW.
REV.
P5
P9P3P12 P8
STEER
ANGLE
POT
BDI INTERRUPT
FIELD
ARMATURE
F2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 36
TRACTION
STATUS CODE
-65
DESCRIPTION OF
The line coil current is too high
during the run mode
STATUS
CAUSE OF STATUS INDICATION
This status code will be displayed when the current limit in the line
coil is exceeded during the run mode. The line contactor will drop
out and the key switch will have to be recycled to reset the control.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
- Shorted line contactor c oi l
- Short between wires connected to
line coil (wires #10 and 24)
If line coil resistance is correct:
Defective control.
•=Replace controller unit.
FU2
LINE
+
-
FU6
A1
P
P
FU5
7
F
U
ACCESSORIES
P3
FU1
FU4
SP
P2
TO
POS
SP
NEG A2
KEY SWITCH
P5
P4
PY7
PY12
P18
PY10
PY11
A1F1
POWER
CONNECTIONS
LEFT CONTROL
BRAKE SW.
P1
SP
L
SEAT SW.
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
FOR. SW.
START SW.
P4
P5
P10
P7
P9P3P12 P8
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
BDI INTERRUPT
POWER
A2
SW.
REV.
STEER
ANGLE
POT
FIELD
ARMATURE
F2
TRACTION
STATUS CODE
-66
MEMORY RECALL
DESCRIPTION OF
The field current exceeds the
current limit of the field transistor.
STATUS
This status code will be displayed when the field transistor exceeds
its specific current limit. The line contactor will drop out and the key
CAUSE OF STATUS INDICATION
switch will have to be recycled to restart the control.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate
•=Line contactor opens
POSSIBLE CAUSE
•= Shorted field F1 to F2
•= F1 or F2 terminals shorted to battery
positive (B+)
•= F1 or F2 terminals shorted to battery
negative (B-)
FU2
LINE
+
-
FU6
A1
P
P
FU5
7
F
U
ACCESSORIES
P3
FU1
FU4
SP
P2
TO
POS
SP
NEG A2
KEY SWITCH
P5
P4
PY7
PY12
P18
PY10
PY11
A1F1
POWER
CONNECTIONS
LEFT CONTROL
BRAKE SW.
P1
SP
L
SEAT SW.
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
FOR. SW.
START SW.
P4
P5
P10
P7
P9P3P12 P8
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
BDI INTERRUPT
POWER
A2
SW.
REV.
STEER
ANGLE
POT
FIELD
ARMATURE
F2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 37
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
-67
The armature current exceeds the
armature transistor limit.
This status code will be displayed when the armature
transistor exceeds its specific current limit. The
control is reset by recycling the key switch.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
•= Shorted motor armature A1 to A2
•= Power cables may be shorted to each other
(Measure at control terminal s)
•= A1 to A2 terminals may be shorted to battery
positive or negative
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
BRAKE SW.
P1
SP
L
SEAT SW.
P17
P1
P6
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
FOR. SW.
START SW.
P4
P5
P10
P7
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
BDI INTERRUPT
POWER
A2
SW.
REV.
P9P3P12 P8
F2
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 38
TRACTION
STATUS CODE
-68
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
12
FU5
P2
FU7
TO ACCESSORIES
FU6
P3
PLUG PY
CONNECTIONS
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
The PMT enable signal from the
auxiliary (slave) control to the master
control drops below 5V.
This status code will be displayed when the voltage at
the master PL21 drops below 5V.
CORRECTIVE ACTIONS
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Auxiliary control shut down.
•= Check auxiliary control for stored faults.
Verify connection between the m aster control P21 and the
auxiliary/slave control P10.
TROUBLE-SHOOTING DIAGRAM
KEY SWITCH
P5
12-1
10
PY7
PY12
PY10
PY11
24
60
P4
P18
P17
OSCILLATOR CARD
LEFT CONTROL
SP
L
P1
P1
P2 P6
BRAKE SW.
SEAT SW.
START SW.
FORWARD SW.
P4
P10P21
P7
29
50 30
REVERSE SW.
P5
P9P3P12 P8
66 65
P15
P16
PMT ENABLE OUTPUT
OSCILLATOR CARD
P16
P15
12-1
RIGHT CONTROL
P10
25
P7 P12
710
P6P2P1P3 P4
P13
P18
8
15
6
P5
P11
PLUG PY
CONNECTIONS
PY7
PY12
PY10
PY11
FU2
LINE
FU1
3
5
2
+
FU4
A1
A2
S1
S2
P
43
TMM7
P
88
89
TMM7
SP
A1
POSA1
SP
POWER CONNECTIONS
LEFT CONTROL
NEGA2
A2
F1
F2
A1
FIELD
A2
ACC POT
13A
ARMATURE
STEER ANGLE
POT
POSA1
POWER CONNECTIONS
RIGHT CONTROL
NEG
A2
AUTO REGENERATIVE
BRAKING ENABLE
STEER PUMP
CONTACTOR DRIVER
REGEN OUTPUT
F1
FIELD
F2
SIGNAL
BDI INTERRUPT
A1
ARMATURE
A2
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 39
TRACTION
STATUS CODE
-69
MEMORY RECALL
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
The power steering coil current is too
high during the run mode.
This status code will be displayed when the current in the
power steering driver circuit exceeds current limit during the
run mode. The control is reset by recycling the key switch.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
YES
Circuits valid
for
Traction
Controller
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
•=Shorted power steering control coil
•=Short between wires connecting to the
power steering coil (wire # 10 and 60)
If the power steering coil resi stance is correct
then:
•=Defective control. Replace control uni t
FU2
LINE
+
-
P
FU6
A1
FU5
F
FU4
P
P2
7
U
ACCESSORIES
P3
FU1
SP
SP
KEY SWITCH
TO
PY7
PY12
P18
PY10
PY11
A1F1
POS
POWER
CONNECTIONS
LEFT CONTROL
NEG A2
P1
SP
P5
L
P4
P17
P1
P2
OSCILLATOR CARD
LEFT CONTROL
FIELD
F2
ARMATURE
BRAKE SW.
SEAT SW.
P6
FOR. SW.
START SW.
P4
P5
P10
P7
ACC POT
POS A1F1
CONNECTIONS
RIGHT CONTROL
NEG
BDI INTERRUPT
POWER
A2
SW.
REV.
P9P3P12 P8
F2
STEER
ANGLE
FIELD
POT
ARMATURE
TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the
-76
MEMORY RECALL
CORRECTIVE ACTIONSTROUBLE-SHOOTING DIAGRAM
capacitor goes above limit voltage* during the regenerative
braking cycle.
YES
Circuits valid
for
Traction
Controller
SYMPTOM
Line contactor opens and closes, then
opens and can only close by opening
and closing the key switch.
POSSIBLE CAUSE
•= Unplugging the battery connector
during regenerative braking.
Motor current is detected during
regenerative braking.
This status code will be displayed when motoring current is
detected during the regenerative braking cycle.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor opens and closes, then
opens and can only close by opening and
closing the key switch.
POSSIBLE CAUSE
Defective control.
•= Replace controller unit
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
-82
MEMORY RECALL
NO
Circuits valid
for
Traction
Controller
When armature motor current is greater
than 400 amps for more than 3.5 sec the
armature motor current will be turned off.
This status code will be displayed when the armature motor
current exceeds 400 amps for 3.5 sec and the accelerator
pedal is calling for maximum performance.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
The Control will not operate, and can only
be reset by cycling the key switch.
POSSIBLE CAUSE:
•=Continued operation of vehicle in high
motor current condition
•=Operating control at stall motor current
for more than 3.5 seconds.
•=Function 16 is incorrectly adjusted for
control % on time.
- Adjust function per OEM
instructions
FU2
+
-
FU6
LINE
A1
P
FU5
F
U
FU4
P
7
FU1
SP
KEY SWITCH
P2
TO
ACCESSORIES
P3
PY7
PY12
PY10
PY11
POS
CONNECTIONS
SP
LEFT CONTROL
NEG A2
P18
A1F1
POWER
P5
P4
P17
OSCILLATOR CARD
F2
BRAKE SW.
P1
SP
L
P1
P6
P2
LEFT CONTROL
FIELD
ARMATURE
SEAT SW.
ACC POT
POS A1F1
RIGHT CONTROL
NEG
START SW.
P7
POWER
CONNECTIONS
FOR. SW.
P4
P5
P10
P9P3P12 P8
BDI INTERRUPT
A2
F2
REV.
SW.
STEER
ANGLE
POT
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 41
Section 4.6 TMM Status Codes
TRACTION
STATUS CODE
-90
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Temperature
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Traction motor temperature has
exceeded maximum temperature limit.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at zero vol ts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by switch
closure to battery negative.
Plug P16 (pump) is short ed to battery negative.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P16
WHEN SR Series PUMP
CONTROL IS USED
USER SW
NEG
SC90
TRACTION
STATUS CODE
-91
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Temperature
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Pump motor temperature has
exceeded maximum temperature limit.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at zero vol ts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by switch
closure to battery negative.
Plug P11 (pump) is short ed to battery negative.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P11
WHEN SR Series PUMP
CONTROL IS USED
USER SW
NEG
SC91
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 42
TRACTION
STATUS CODE
-93
MEMORY RECALL
YES
Circuits valid
for
Steer
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Steering pump motor brush wear
indicator has detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
Plug P3 (pump) is short ed t o positive.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P3
WHEN SR Series PUMP
CONTROL IS USED
USER SW
POS
SC93
TRACTION
STATUS CODE
-93
MEMORY RECALL
YES
Circuits valid
for
Steering
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Steering pump motor brush wear
indicator has detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
Plug P4 (pump) is short ed t o positive.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P4
WHEN SR Series PUMP
CONTROL IS USED
USER SW
POS
SC93A
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 43
TRACTION
STATUS CODE
-94
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Traction motor brush wear indicator
has detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
Plug P5 (pump) is short ed t o positive.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P5
WHEN SR Series PUMP
CONTROL IS USED
USER SW
POS
SC94
TRACTION
STATUS CODE
-94
MEMORY RECALL
YES
Circuits valid
for
Traction
Motor
Brush Wear
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Traction motor brush wear indicator
had detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at zero vol ts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
.
Plug P6 (pump) is short ed t o positive.
Pump motor brush wear indicator has
detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
Plug P8 (pump) is short ed t o positive.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P8
WHEN SR Series PUMP
CONTROL IS USED
USER SW
POS
SC95
TRACTION
STATUS CODE
-95
MEMORY RECALL
YES
Circuits valid
for
Pump
Motor
Brush Wear
Indicator
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Pump motor brush wear indicator has
detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code flashes “on and off”.
POSSIBLE CAUSE
User defined status c ode i s displayed by motor
brush sensor closure to bat tery positive.
Plug P9 (pump) is short ed t o positive.
Defective input switch (s horted).
Defective TMM card.
Defective pump card.
P9
WHEN SR Series PUMP
CONTROL IS USED
USER SW
POS
SC95A
January 2000
DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL Page 45
TRACTION
STATUS CODE
-99
MEMORY RECALL
YES
Circuits valid
for
Traction
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Maintenance alert and speed limit.This status code will be displayed when the “normal”
hour meter exceeds the “maintenance alert hours”
setting for the vehicle.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Status code is displayed for 4 seconds when the
key switch is first turned on, and/or the vehicle
may run at a reduced speed.
CUSTOMER SELE C TED SETTING WITH THE
HANDSET:
User defined status c ode i s displayed when the
normal hour meter reading exceeds the
programmed “maintenance alert hours” setting
selected by the user
•= Maintenance Code Hour Meter, Functions 19
and 20, are programmed with the Handset and
command the dis pl ay of status code -99.
•= If desired, Maintenance Code Speed Limit,
Function 13, can be programmed with the
Handset.
User should perform the des i red maintenance
function. Re-set maintenance alert hour meter
after maintenance is performed.
NO DIAGRAM
USER SHOULD PERFORM THE DESIRED
MAINTENANCE FUNCTION
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 46
Section 4.7 Pump Control Codes
PUMP
STATUS CODE
-117
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
“Card Type” selection is invalid. This status code will be displayed when the card type
selection value is set to an invalid number.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Invalid card type selection.
•=Review function 17 in the Handset
Instruction sheets. Adjust and set
card type value as instructed by OEM
service manual.
Verify that the correct logic card
catalog number is installed in the
controller.
GRAPHIC
FOR THIS
STATUS CODE
NO
PUMP
STATUS CODE
-127
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Control logic card power supply is less
than 10 VDC.
This status code is displayed when the logic card
power supply is less than 10 volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Discharged Battery
•= Check battery to insure proper state of
charge.
Loose connection at P1.
•= Insure that the wire connection at P1 is
tight.
Defective logic card
•= Replace control.
LINE
+
-
FU3
FU2
FU1
POWER CONNECTIONS
KEY SWITCH
P1 P2
POS A1
NEG A2
FIELD
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 47
PUMP
STATUS CODE
-128
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Armature current is too high during the
lift mode.
Status code displayed when the current in the
armature circuit is sustained above 300A for 70 sec.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Continued operation of vehicle in high
motor current condition.
•=Operate vehicle at lower motor current
condition for 70 seconds.
LINE
+
-
FU3
FU2
FU1
POWER CONNECTIONS
KEY SWITCH
P1 P2
POS A1
NEG A2
FIELD
ARMATURE
PUMP
STATUS CODE
-141
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
Open thermal protector (TP1) or
transistor is over temperature.
STATUS
DESCRIPTION OF
This status code is displayed when the voltage at the thermal
protector is greater than 0.8 volts.
CAUSE OF STATUS INDICATION
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Reduced or no power to pump motor in
control range.
POSSIBLE CAUSE
Control is in thermal cut-back.
•= Allow control to cool, status code
should disappear.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 48
PUMP
STATUS CODE
-142
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
Pump Controller “motor current
sensor” input is missing.
STATUS
DESCRIPTION OF
This status code is displayed when the voltage at the
current sensor is greater than 0.1 volts with no current
CAUSE OF STATUS INDICATION
flowing in the motor circuit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
No power to pump motor in
control range.
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
PUMP
STATUS CODE
-143
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
ARMATURE
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Pump Controller “motor current
sensor” input is too low.
This status code is displayed when the voltage at the
current sensor is greater than 0.1 volts with no current
flowing in the motor circuit.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
No power to pump motor in
control range.
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 49
PUMP
STATUS CODE
-144
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
Power Transistor (Q1) did not
turn off properly.
STATUS
DESCRIPTION OF
This status code is displayed when, during pump control
operation, the transistor fails to turn off. This will result in a
CAUSE OF STATUS INDICATION
PMT condition.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
With no pump contactor, control
may run continuously.
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
PUMP
STATUS CODE
-145
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
ARMATURE
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Power Transistor (Q1) did not turn on
properly.
This status code is displayed when during pump
control operation, the transistor fails to turn on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
With no pump contactor, the control
may run continuously.
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 50
PUMP
STATUS CODE
-146
MEMORY RECALL
YES
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
“Look Ahead” test for T2 volts
less than 12% of battery volts.
This status code will be displayed when the voltage at T2 is
less than 12% of battery volts.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
Check for short circuit from the
motor armature to the frame of
the vehicle.
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TO
TRACTION
CARD
ARMATURE
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
PUMP
STATUS
CODE
-150
MEMORY
RECALL
YES
Circuits
valid for
Pump
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Capacitor volts are low after the line
contactor closes.
This status code will be displayed when the capacitor voltage
is less than 85%of the battery voltage in the run mode.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
Defective line contactor.
•= Check for open line contactor power
tips.
Check for loose or open connections in
cables from battery positive to control
positive circuit.
Defective power fuse.
•= Check power fuse for open circuit.
No battery voltage at P1.
•= Check for battery voltage at POS and
P1.
•= Check for loose connection at P1.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TO
TRACTION
CARD
ARMATURE
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 51
PUMP
STATUS CODE
-151
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Capacitor volts are low before the line
contactor closes. (Internal card
function during precharge)
This status code will be displayed during “key on” when
the capacitor volts is less than 85% of battery volts at
initial key switch on.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
Defective control fuse.
•=Check control fuse for open
circuit, replace fuse, if
necessary.
Defective control.
•=Replace controller unit.
Note: Repeated
“charging/discharging” the
capacitors during troubleshooting
will cause status code 51. Also
“do not” connect any
load side of the line contactor.
loads to the
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
CARD
ARMATURE
TO
SPEED LIMIT 3
PY7
PY12
P12
P19P21
PY10
PY11
SPEED LIMIT 2
SPEED LIMIT 1
PUMP
STATUS CODE
-157
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
DESCRIPTION OF
Controller “motor current
sensor” input voltage polarity
STATUS
This status code will be displayed when the voltage input to
motor current sensor is of the wrong polarity.
CAUSE OF STATUS INDICATION
check.
CORRECTIVE ACTIONSTROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TRACTION
TO
CARD
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
ARMATURE
January 2000
DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL Page 52
PUMP
STATUS CODE
-180
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
DESCRIPTION OF STATUSCAUSE OF STATUS INDICATION
Voltage at capacitor (1C) is less than
14 volts.
This status code will be displayed when the voltage at
P1 is less than 14 volts. This occurs typically in the run
mode of operation.
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
(Line contactor controll ed by t raction
control).
Line Contactor opened up during run.
•= Check connection from P17 to Line
coil (-) for loose connect i on.
•= Check connection from battery (+) t o
Line coil (+) for loose connect i on.
•= Check power connection from battery
(+) to contactor L.
•= Check for blown fuse at pump control.
•= Check for dirty contactor tips .
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TO
TRACTION
CARD
ARMATURE
SPEED LIMIT 3
PY7
PY12
P12
P19P21
PY10
PY11
SPEED LIMIT 2
SPEED LIMIT 1
PUMP
STATUS CODE
-181
MEMORY RECALL
NO
Circuits valid
for
Pump
Controller
Battery voltage is less than 14
volts.
STATUS
DESCRIPTION OF
This status code will be displayed when the battery voltage
measured at P1 is less than 14 volts.
CAUSE OF STATUS INDICATION
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Pump control will not operate.
POSSIBLE CAUSE
•= Defective control fuse.
Check control fuse f or open circuit,
replace fuse, if necessary.
•= Check connection from control f use to
pump P1 for loose connections.
LINE
+
-
FU3
FU6
FU1
POSA1
CONNECTIONS
NEGA2
KEY SWITCH
POWER
TO TRACTION
P10 - BDI
P1 P2P3
FIELD
TO
TRACTION
CARD
ARMATURE
SPEED LIMIT 3
PY7
PY12
PY10
P12
P19P21
PY11
SPEED LIMIT 2
SPEED LIMIT 1
January 2000
INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL Page 53
Section 5. TRUCK MANAGEME N T MODULE (TMM)
Section 5.1 General Features
The Truck Management Module is a multi-functional
accessory card (IC3645TMM7A), or an integral function of
the SR Pump control when used with the SX Family of
Traction controls. The Module provides the OEM with the
ability to initiate status codes or operator warning codes to
be displayed on the Dash Display whenever a normally
open switch or sensor wire provides a signal to the
Module.
The TMM Module can be used to display a separate status
code indicating an over temperature of traction motors,
hydraulic motors, or any other device or system that can
activate a switch that closes.
It can also be used as a Brush Wear Indicator (BWI). The
Brush Wear Indicator is designed to detect a “worn-out
brush” and display a fault code on the Dash Display to
warn maintenance personnel that the motor brushes need
to be replaced before they wear to the point of causing
destructive damage to the motor commutator surface. The
BWI function is compatible with any sensor that short
circuits to the motor armature to signal limits of brush
wear.
Note: Motor armatur e must be in the positive side of the
battery circuit.
Section 5.2 Operation
The Module utilizes 9 OEM input points and 3 output points
that connect to the "Y" plug on the traction logic card. Due
to the low level signal value of this output, shielded wire
should always be used to insure proper operation. The
input to the Module is either a switch or sensor wire
closure to battery negative or positive. The following table
outlines the status code displayed for each input, when
that point is closed to battery negative or positive, as
indicated.
TMM7A Pump
Card Control Status
Terminal
Terminal Code Connect To
TB1 P16 90 * Neg
TB3 P11 91 Neg
TB4 P15 92 Neg
TB5 P3 93 * Pos
TB6 P4 93 * Pos
TB8 P5 94 Pos
TB10 P6 94 Pos
TB11 P8 95 Pos
TB12 P9 95 Pos
* Status codes 90 and 93 can also be programmed with the
Handset to reduce the speed of the truck from 100 to 0
percent-on-time.
IMPORTANT NOTE:
Status Codes 93, 94 and 95 are only
checked when a neutral signal is present (i.e., open start
switch or open F/R switch). The status code is displayed
and the speed limit enabled when the control is returned
to the run mode. Do not use status code 93 speed limit for
applications requiring immediate speed limit on switch
closure.
Typical wiring diagrams and outline drawings for the
TMM7A accessory card and SR family of Pump TMM
functions are shown in Sections 5.4 and 5.5.
Section 5.3 Installation
WARNING: Before any adjustments, se rvic in g o r a c t
requiring physical contact with working components,
jack drive wheels off the floor, disconnect the battery and
discharge the capacitors in the traction and pump
controls, as explained in Section 4.4.
The TMM7A accessory card should be mounted to a flat
surface (in any plane) in an area protected from water, oil
and battery acid. Mounting dimensions are shown in
Section 5.5. Two (0.187 inch, 4.75mm) mounting holes are
provided.
The GE Handset is a multi-functional tool to be used with
the LX, ZX, and SX Series GE solid-state controls. The
Handset consists of a Light Emitting Diode (LED) display
and a keyboard for data entry.
Note: The Handset is the same for all GE controls,
however, the cable will change between some control
types.
Section 6.2 Purpose / Setup Functions
The purpose of the Handset is to allow authorized
personnel to perform the following functions of the SX
family of Controls:
•=Monitor existing system fault codes
•=Monitor intermittent random fault codes
•=Monitor battery state of charge on systems with BDI
•=Monitor hourmeter reading
•=Monitor or adjust the following control functions:
♦= Creep speed
♦= Armature Controlled Acceleration and 1A Time
♦= Regenerative Braking Current Limit and Disable
♦= Armature and Field Current Limit
♦= Plugging Distance (Current)
♦= Pedal Position Plug Range or Disable
♦= 1A Drop Out Current or Disable
♦= Speed Limit Points
♦= Truck Management Fault Speed Limit
♦= Internal Resistance Compensation for Battery
State of Charge Indication
♦= Battery Voltage ( 36/48 volts is auto ranging )
♦= Selection of Card Operation Type.
Warning: Before connecting or disconnecting the Handset
tool, turn off the key switch, unplug the battery and jack
up the drive wheels of the vehicle.
At the transistor control traction card, unplug the "Y plug" if
the dash display is in use, and plug in the Handset to the
plug location "Y" on the control card. After installing the
Handset tool, plug the battery in and turn the key switch on.
The following is the start-up display sequence that will
occur:
If Maintenance Code
Is
Active
Display Code "-99"
For Four Seconds and
Activate Speed Limit
(if selected)
BDI Display or
Blank Display
(no BDI used)
BDI Display or
Blank Display
(no BDI used)
Display Traction
NOTE: The vehicle can be operated with the Handset
connected, however, the adjustment knob must be set
fully clockwise to insure the control operates at top
speed.
Warning: Before making any adjustments to the control,
you must consult the operating and maintenance
instructions supplied by the vehicle manufacturer. Failure
to follow proper set up in str u c tio n s c o u ld r e sult in misoperation or damage to the control system.
Key Switch On
Verify Each LED Segment
8 8 8 8
If Maintenance Code
Is Not
Diagnostics Override
With Fault
Run Mode
Diagnostics Override
With Fault
Key Switch
Off
Hourmeter
For Four Seconds
Display Pump
Hourmeter
For Four Seconds
Active
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 56
Section 6.3 Set-up Function Procedures
With the Handset connected, hold down the CONT key and
turn on the key switch. This will place you in the set-up
status codes will be overwritten each time a new status
code occurs. This stored status code register can be
cleared from memory by using the Handset.
mode, ready to monitor or adjust control function settings.
NOTE: The term “Push” means to depress key for
ACCESSING STORED STATUS CODES
WITH GE HANDSET
approximately one second.
Key Switch Off
Section 6.3.1 Setup Mode
Push ESC and CONT
SET-UP MODE
At The Same Time
ACTION
Hold Down CONT
And Turn On Key
Push Function Number
After One Second
Time Delay
Push CONT
Change Value With
Adjustment Knob
Push STORE
Push ESC
DISPLAY
SHOWS
8 8 8 8
U 0 0 5
0 8 5
0 8 5
125
125
8 8 8 8
REMARKS
Segment Check
Displayed
Selected Function No.
Is Displayed
Stored Value For The
Function Is Displayed
Display Value
Will Blink
Value Changes
While Blinking
New Value Stored And
Blinking Stops
Segment Check
Displayed
At this point, another function can be monitored/changed
by pushing another function number, or the vehicle can be
placed in the run mode by holding the ESC key down for
one second or longer. The display will return to either the
diagnostics mode, the BDI display, or a blank display (if
BDI is not used and there are no fault codes). The vehicle
can now be operated with the Handset connected, or the
Handset can be disconnected before operation.
NOTE: You can return to the segment check mode at any
time, by holding down the ESC key until 8888 appears in
the display.
Section 6.3.2 Status Code Scrolling
The SX family of controllers furnishes a function register
that contains the last 16 “stored status codes” that shut
down vehicle operation (a PMT type fault that is reset by
cycling the key switch) and the battery state of charge
reading at the time the fault o c c u r red . The first of the 16
Release ESC and CONT
Status Code Displayed
State-Of-Charge When
Display Hourmeter Reading
Section 6.3.3 SX Family Handset, Plug
Key
Push CONT Key
Displays Battery
Fault Occurred
Push CONT Key
When Fault Occurred
Push CONT Key
Push CONT Key
Connections and Outline Drawing
“Y” Plug
Handset Cable Part Number - 325B1002G1
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 57
accelerator ohm inp u t b etween 6. 0K a n d 4. 0K ohms is
HANDSET
LX
CONT
CONT
CONTCONT
1
g
STORE
STORE
STORESTORE
2
EVC
3
4
++
5
6
7
8
9
10
11
12
ESC
ESC
13
14
Section 6.4 Setup Functions for Traction Controller
FUNCTION 1 MOTOR VOLTS TO ENABLE AUTO REGEN
(Push 1)
This function allows for the adjustment of motor volts to
enable AutoRegen.
For a setting value of less than 25 (corresponding to a soft
release of auto regen and normal regen), the motor voltage
to enable regen is calculated by multiplying the value of the
setting by 0.375. For example, a setting of 16 will be
multiplied by 0.375 to enable regen at 6 motor volts.
Vm = VAL(setting) X .375
For a setting value of greater than 25, the motor voltage to
enable auto regen is calculated by subtracting 25 from the
setting value and multiplying that number by 0.375. For
example, a setting of 33, the motor volts necessary to
enable auto regen is (33 - 25) x 0.375, or 3 volts.
FUNCTION 2 CREEP SPEED
(Push 2)
This function allows for the adjustment of the creep speed
of the vehicle. Creep speed can be adjusted when an
accelerator input voltage between 3.9 and 3.3 volts or an
15
ESCESC
provided.
Range 2% to 15% on-time
Set 0 to 255
Resolution 0.05% per set unit
Example Setting of 20 = 3% on-time
Important Note: This function is used to optimize motor
and control performance, and this setting will be
determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
field personnel without the permission of the OEM.
FUNCTION 3 ARMATURE CONTROLLED
ACCELERATION
(Push 3)
This function allo ws fo r th e a d ju stmen t o f the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration.
Range 0.025 to 6.3 seconds
Set 0 to 255
Resolution 0.025 seconds per set unit
Example: Setting of 20 = 0.5 seconds
FUNCTION 4 ARMATURE CURREN T LIMIT
(Push 4)
This function allows for the adjustment of the armature
current limit of the control. The rating of the control will
determine the range of adjustment for this function. Please
refer to the specification sheets and current limit curves for
the control used in your vehicle.
Range See c o n tr o l C/L c u r ves
Set 0 to 255
Example: 0 = min. current, 255 = max.
current
FUNCTION 5 PLUGGING DISTANCE (CURRE NT)
(Push 5)
This function allows for the adjustment of the plugging
distance of the vehicle. The larger the current setting, the
shorter the stopping distance.
Min Max Set Resolution
Per Unit Value
55 455 0 to 255 1.57 amps 86.4 amps
Warning: Plug settings must be made in accordance with
control operating instructions. Too high of a setting could
cause damage to the control system or traction motor.
Example
If Set at 20
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 58
FUNCTION 6 FW RATIO
(Push 6)
This function sets the ratio between armature and field
current when operating below the Field Weakening Start
point. The setting represents the quantity of field current
changed for each 1 amp of armature current changed.
Max Fld Ref Set Resolution Per Unit Value
40 0 to 10 0.029 amps
The ratio value (VAL) is the set value divided by 10 and
rounded to the whole number.
Example: Setting of 45 = 45/10 = 4.5 = 4 VAL
I
FIELD
= VAL (I
MOTOR
x 0.029)
FUNCTION 7 MIN FIELD CURRENT
( Push 7 )
This function allows the adjustment of the field weakening
level in order to set the top sp eed o f th e mo to r .
Min Max Set Resolution Per Unit Value
0 40 51 to 255 0.185
= (VAL-51) X 0.185
MIN I
F
Important Note: This function is used to optimize motor
and control performance, and this setting will be
determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
field personnel without the permission of the OEM.
FUNCTION 8 MAX FIELD CURRENT
( Push 8 )
This function allows for the adjustment of the maximum
field current in order to obtain the maximum torque of the
motor.
Min Max Set Resolution Per Unit Value
0 40 51 to 255 0.185
MAX I
= (VAL-51) X 0.185
F
Important Note: This function is used to optimize motor
and control performance, and this setting will be
determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
field personnel without the permission of the OEM.
FUNCTION 9 REGEN BRAKING C/L
(Push 9)
This function allows for the adjustment of the Regen
braking current limit. High current correlates to shorter
stopping distance.
Resolution Example
Min Max Set Per u n it value If set at 20
52A 468A 0 to 255 1.63 amps 84.6 amps
REGEN BRAKE I
= (VAL X 1.63) + 52
A
FUNCTION 10 FIELD CURRENT FOR REGEN
( Push 10 )
This function allows for the adjustment of the field current
to be used during the regen braking mode.
Resolution Example
Min Max Set Per unit value If set at 71
0 40 51 to 255 0.185 amps 3.7 amps
= (VAL-51) X 0.185
I
F
Important Note: This function is used to optimize motor
and control performance and this setting will be
determined by GE and OEM engineers at the time of
vehicle development. This setting must not be changed by
field personnel without the permission of the OEM.
FUNCTION 11 TURN SPEED LIMIT
(Push 11)
This function allows for the adjustment of the speed limit
(maximum battery volts to the moto r ) wh en th e SL1 sig n a l is
calculated from the turn angle potentiometer by the control
card.
Range 100% to 0% battery volts
Set 51 to 180
Resolution 0.78% per set unit
Example Setting of 71 = 84.4% of battery volts
Note: To disable speed limit, and assure no 1A hold off, set
this function to a value of zero.
FUNCTION 12 MAX ARMATURE PERCENT ON
( Push 12 )
Same as function 11, this fun c tio n a l l o ws fo r th e
adjustment of the motor speed l imit (max imu m b a ttery vo l ts
to the motor). The dash display mode selection enables the
speed limit as well as setting the level of speed limit.
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 59
FUNCTION 13 SPEED LIMIT 3
( Push 13 )
The SL3 set speed limit is activated by the Truck
Management Module 90, 91 and 92. See Section 5 for
Truck Management Module details.
FUNCTION 14 INTERNAL RESIST AN CE
COMPENSATION
Battery volts Set units
24 volts Between 0 and 31
36 volts Between 32 and 44
48 volts Between 45 and 69
72 volts Between 70 and 80
80 volts Between 81 and 183
36/48 volts Between 184 and 250
No BDI Between 251 and 255
( Push 14 )
This function is used when the Battery Discharge Indicator
is present. Adjustment of this function will improve the
accuracy of the BDI. In order to determine this setting the
voltage drop of the battery under load must first be
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions, push the CONT key and the number
shown in the following instructions at the same time.
calculated by the following method:
1. Load the traction motor to 100 amps at 100% on-time of
the control and record the open circuit voltage (V
O
) at
the control panel positive and negative power terminal.
2. Load the traction motor to 200 amps at 100% on time of
the control and record the voltage (V
) at the control
L
panel positive and negative power terminal.
3. Calculate voltage drop (V
V
= VO - VL
Drop
) as follows:
Drop
4. Use the table below to deter min e th e a p p r o p r ia te settin g
using the calculated V
This function allows for the adjustment of voltage range for
controls equipped with the Battery Discharge Indication
function. In order for the BDI to operate properly, the
setting as shown in the table must be entered:
FUNCTION 16 STALL TRIP POINT WITH % ON-TIME
.
( Push CONT 1)
This function allows for the adjustment of control percent
on time for the stall moto r tr ip point
Control % On time = 163 -(Set Point Val)*.892
If 163 or greater, then “0.0” % on time
If 51 or less, then “100.”% on-time
FUNCTION 17 CARD TYPE SELECTION
( Push CONT 2 )
This function allows for the selection of the card type used
for your vehicle's application. The table below shows the
setting to select card application type, depending on which
control card is used. Note that the right (slave) control fo r
a dual motor proportioning system will be set differently
than the left (master) contro l.
Note: Non-Auto Plug/Regen Logic cards must be used for
settings below:
FUNCTIONS STANDARD REGEN
Std C/L 5 to 9 45 to 49
Std C/L (Right) 69 to 73 109 to 113
Note: Auto Plug/Regen Logic cards must be used for
settings below:
FUNCTIONS STANDARD REGEN
Std C/L Auto Plug 15 to 19 55 to 59
Std C/L Auto Plug (Right) 79 to 83 119 to 123
Settings for these functions sh o u l d b e ma d e with in the
ranges indicated above.
Warning: These settings must be changed by authorized
personnel only, following instructions supplied by the
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 60
vehicle manufacturer. Card type selection must be made
within the capabilities of the control panel used and the
supporting electro mechanical devices. Failure to comply
with proper application standards could result in misoperation or damage to the control and/or motors.
FUNCTION 18 STEER PUMP TIME DELAY
( Push CONT 3 )
This function allows for the selection of steer pump
contactor pick up input, either seat switch or directional
switch closing, and adjustment of the time delay for the
contactor drop out.
•=Pick up steer pump contactor on seat switch closure
and time delay drop out of steer pump contactor on
seat switch opening:
Range 1.5 to 65 seconds
Setting Between 0 and 128
Resolution 0.5 seconds per set unit
Example: Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds
•=Pick up steer pump contactor on directional switch
closure and time delay drop out of steer pump
contactor on directional switch opening:
Range 0.5 to 63 seconds
Setting Between 129 and 255
Resolution 0.5 seconds per set unit
Example: Setting of 149 = ((149-129) x 0.5) + 1.5 = 11.5
seconds
Note: Contactor drop out will be 1.5 seconds after the seat
switch opens.
FUNCTION 19 MAINTENANCE CODE TENS AND UNITS
HOURS SET
( Push CONT 4 )
This function allows for the adjustment of the tens and
units hours of the maintenance code activation time.
Range 0 to 99
Set 0 to 99
Example 9999
FUNCTION 20 MAINTENANCE CODE THOUSANDS
AND HUNDREDS HOURS SET
( Push CONT 5 )
This function allows for the adjustment of the thousands
and hundreds hours of the maintenance code activation
time.
Hours
Range 0 to 240
Set 0 to 240
Example 99
FUNCTION 21 AUTO REGEN BRAKING C/L
(Push CONT 6)
This function allows for the adjustment of the Regen
braking current limit. High current value correlates to
shorter stopping distance.
Setting greater than 143 disables this function.
AUTO REGEN
C/L AMPS
FUNCTION 24 FIELD WEAKENING START
( Push CONT 9)
This function allows fo r settin g th e a r ma tu r e c u r ren t a t
which minimum field cur r en t will achieved .
Range 0 to 414 Amps
Setting 0 to 255
Resolution 1.625 per set unit
FWS = VAL. x 1.625
I
MOTOR
Example: Setting of 20 = 32.5 amps
FUNCTION 25 MONITOR
( Push CONT 10)
This function allows the monitoring of certain control
functions by looking directly at the RAM of the
microprocessor. Because absolute memory locations need
to be known, this function should not be used without
detailed instructions from the GE application engineer.
This function should only be adjusted by the vehicle OEM.
To ensure optimum operation of the control, this function
must be left with zero stored in this register.
FUNCTION 26 BASE RATIO
( Push CONT 11)
This function sets the ratio b etween a r ma tu r e a n d fiel d
current when oper a tin g below the maximum field c u r r en t
and above the Field Weakening Start point. The setting
represents the quantity of field current changed for each 1
amp of armature current changed.
Max Fld Ref Set Resolution Per Unit Valu e
40 0 to 10 0.029 amps
REGEN C/L
=
VAL
99 Hours
FNT 21-51
-
[(
VAL
(
-
6.50
[
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 61
The ratio value (VAL) is the set value divided by 10 and
rounded to the whole number.
Example: Setting of 45 = 45/10 = 4.5 = 4 VAL
I
FIELD
= VAL ( I
MOTOR
x 0.029 )
FUNCTION 28 STORED STATUS CODE COUNT POINTER( Push CONT 13)
This register contains the location of the last stored status
code recorded of the 16 stored status codes. These stored
status codes have caused a PMT controller shutdown
and/or disruption of normal vehicle operation.
To determine which stored status code was the last one
recorded, read the number stored in Function 28. Using the
Memory Map for your logic card, match the "stored status
code pointer number" [the number shown in (bold italics)
in the HS (Handset) number column] on the memory map,
with the number obtained from Function 28. This will be the
last stored status code recorded.
Note: When scrolling through the stored status code
register, the register always starts at status code 1 and
scrolls to status code 16. Instructions for scrolling the
register are in section 6.3.2 of this instruction booklet.
FUNCTION 49 MODE 1 FIELD WEAKENING START
( Push CONT 2)
This function allows fo r settin g th e a r ma tu r e c u r ren t a t
which minimum field cur r en t will achieved .
Range 0 to 414 Amps
Setting 0 to 255
Resolution 1.625 per set unit
Example: Setting of 20 = 32.5 amps
FWS = VAL x 1.625
I
M
This FIELD WEAKENING START takes effect when th e
Mode 1 settings are called fo r b y th e in ter a c tive Dash
Display.
FUNCTION 50 MODE 1 FW RATIO
( Push CONT 3 )
This function sets the ratio b etween a r ma tu r e a n d fiel d
current when tran sitioning from minimum field to maximum
field current. The settin g r ep r esen ts th e q u a n tity o f fiel d
current changed for each 1 amp of armature current
changed.
Max Fld Ref Set Resolution Per Unit Valu e
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions. Push the CONT key and the number
shown in the following instructions at the same time.
THE SEAT SWITCH MUST BE CLOSED.
FUNCTION 48 MODE 1 (TURTLE) - ARMATURE
CONTROLLED ACCELERATION
( Push CONT 1)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration.
Range 0.025 to 6.3 seconds
Set 0 to 255
Resolution 0.025 seconds per set unit
Example: Setting of 20 = 0.5 seconds
This C/A takes effect when the Mode 1 settings are called
for by the interactive Dash Display.
40 0 to 10 0.029 amps
The ratio value (VAL) is the set value divided by 10 and
rounded to the lowest who le number.
Example : Setting of 45 = 45/10 = 4.5 = 4 VAL.
I
FIELD
= VAL ( I
MOTOR
X .029 )
This FW RATIO takes effect when the Mode 1 settings are
called for by the interactive Dash Display.
FUNCTION 51 MODE 1 MAX ARMATURE % ON
( Push CONT 4)
This function allows for the adjustment of the speed limit
(maximum battery volts to the moto r ) wh en th e SL1 l imit
switch input signal is received by the control card. The SL1
limit switch is a normally closed switch connected to
battery negative; the switch o p en in g en a b l es sp eed l imit.
Range 100% to 0% battery volts
Set 51 to 180
Resolution 0.78 % per set unit
Example Setting of 71 = 84.4 % battery
volts
This MAX ARMATURE % ON takes effect when the Mode 1
settings are called for by the interactive Dash Display.
Same as Function 48.
This C/A takes effect when the Mode 4 settings are called
for by the interactive Dash Display.
FUNCTION 61 MODE 4 FIELD WEAKENING START
( Push CONT 14)
Same as Function 49.
This FIELD WEAKENING START takes effect when th e
Mode 4 settings are called fo r b y th e in ter a c tive Dash
Display.
FUNCTION 62 MODE 4 FW RATIO
( Push CONT 15 )
Same as Function 50.
This F/W RATIO takes effect when the Mode 4 settings are
called for by the interactive Dash Display.
FUNCTION 63 MODE 4 MAX ARMATURE % ON
( Push CONT ESC )
Same as Function 51.
This MAX ARMATURE % ON takes effect when the Mode 4
settings are called for by the interactive Dash Display.
This FIELD WEAKENING START takes effect when the
Mode 3 settings are called for by the interactive Dash
Display.
January 2000
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLSPage 63
Section 6.5 Summary of Current Limit Adjustments
The
" maximum field current"
is adjusted by Function 8. This
function, along with the
current limit",
maximum torque of the motor.
"armature
Function 4, sets the
setting
Maximum field
current is fixed at
37.5 amps
MAXIMUM
The
" ratio"
This function sets the ratio between armature
and field current when operating, I
above FWS and less than 300 amps. Setting is
the value of field current changed for each 100
amps of armature current changed.
setting is adjusted by Function 26.
is
MOTOR
The
" error compensation "
Function 23. This function is used to reduce the ripple
in field current due to the interaction between motor
field design and the digital field current regulation
circuit. The value for this function will be defined by the
GE application engineer.
setting is adjusted by
FIELD CURRENT
ZERO
ZERO
The
" ratio-2 "
This function sets the ratio between armature
and field current when operating, I
below FWS. Setting is the value of field current
changed for each 100 amps of armature current
changed.
setting is adjusted by Function 6.
is
MOTOR
The
" minimum field
setting is adjusted
current"
by Function 7. The function
sets the top speed of the
motor. If used.
ARMATURE CURRENT
The
" field weakening start"
setting is adjusted by Function
24. This function sets the
armature current at which
minimum field current will be
achieved .
The
"full load transition point"
is calculated by the control. This
function sets the maximum field
current transition point at
approximately 300A armature
current.
The
"armature current limit"
setting is adjusted by Function 4.
The function along with the
"maximum field current",
Function 8, sets the maximum
torque of the motor.
MAXIMUM
January 2000
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 64
Section 6.6 Setup Functions for Hydraulic Pump Control
FUNCTION 1: NOT APPLICABLE
This function is not applicable to this type of control and
should not be adjusted.
FUNCTION 2: INTERNAL RESIST ANCE
COMPENSATION START
(Push 2)
This function allows for the adjustment of the current level
at which the internal resistance compensation feature
(Function 16) will take effect.
Range 0 to 1325 amps
Setting 52 to 255
Resolution 6.5 amps per set unit
Example: Setting of 72 = (72-52) x 6.5 = 130 amps
FUNCTION 3: CONTROLLED ACCELERATION
(Push 3)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration.
Range 0.1 to 5.5 seconds
Setting 0 to 255
Resolution 0.021 seconds per set unit
Example: Setting of 20 = 0.52 seconds C/A
FUNCTION 4: CURRENT LIMIT
(Push 4)
This function allows for the adjustment of the current limit
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the
OEM operating instructions for the control used in your
adjusted until the total IR c o mp en sa tio n vo ltage has been
added.
Range 0.0015 to 0.383 seconds
Setting 0 to 255
Resolution 0.0015 seconds per set unit
Example: Setting of 20 = 0.032 seconds
For example, if you had selected 2.08 volts from Function 16
to be added to the motor, it would take 0.18 seconds to add
a total of 2.08 volts. (2.08/0.375)=0.032
FUNCTION 11: SPEED LIMIT 1 (SL1)
(Push 11)
This function allows for the adjustment of the speed limit
(maximum battery volts to the moto r ) wh en th e SL1 l imit
switch input signal is received by the control card. SL1
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Range 0% to 100% battery volts
Setting 0 to 255
Resolution 0.375 volts per set unit
Example: Setting of 50=18.75 volts
FUNCTION 12: SPEED LIMIT 2 (SL2)
(Push 12)
Same as Function 11 except using SL2 limit switch for input.
FUNCTION 13: SPEED LIMIT 3 (SL3)
(Push 13)
Same as Function 11 except using SL3 limit switch for input.
FUNCTION 14: NOT APPLICABLE
This function is not applicable to this type of control and
should not be adjusted.
vehicle.
Range See OEM control C/L curves
Setting 0 to 255
Example: 0 = min. current, 255 = max. current
Note: The following functions have function numbers
larger than the numbers on the Handset keyboard. To
access these functions, push the CONT key and the
number shown in the following instructions at the same
time. THE KEY SWITCH MUST BE OPEN.
FUNCTION 7: INTERNAL RESIST ANCE
COMPENSATION RATE
(Push 7)
This function allows for the adjustment of the rate of time it
takes for the control to add the internal resistance
compensation voltage that is applied to the motor. This
function will add 0.375 volts to the motor at the rate of time
FUNCTION 16: SPEED / TO RQUE COMPENSATION
(Push CONT 1)
This function is used to stabilize pump speed at heavy
loads. The voltage selected will be added to the motor at
each 100 amp increment starting at the value set in
Function 2. The voltage compensation selected will be
added in increments of 0.375 volts until the entire voltage is
added. For example, a setting of 2 will be added in 30 steps
January 2000
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 65
of 0.375 volts each whereas, a setting of 4 will be added in
15 steps of 0.375 volts each.
This function should be set in accordance with the control
type in use in the vehicle:
Function
High C/L
BDI Lockout
Without Pump
Ctr/PMT
63 to 71
BDI Lockout means that the BDI signal from the traction
control must be present in order for the pump control to
operate. This control will stop operation when the battery
state of charge reaches 10%.
Settings for these functions should be made in between the
values shown.
Warning: These setting must be changed by authorized
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within
the capabilities of the TRANSISTOR control panel used
and the supporting electro-mechanical devices. Failure to
comply with proper application standards could result in
mis-operation or damage to the control and/or motors.
FUNCTION 28: FAULT COUNT POINTER
(Push CONT 13)
This register contains the location of the last stored status
code recorded of the 16 stored status codes. These stored
status codes have caused a PMT controller shutdown
and/or disruption of normal vehicle operation.
To determine which stored status code was the last one
recorded, read the number stored in Function 28. Using the
Memory Map (See Section 8.1) for your logic card, match
the “stored status code pointer number” (the number
shown in (bold italics) in the HS (Handset) number column)
on the memory map, with the number obtained from
Function 28. This will be the last stored status code
recorded.
Note: When scrolling the stored status code register, the
register always starts at status code 1 and scrolls to
status code 16. Instructions for scrolling the register are
in Section 6.3.2 of this instruction booklet.
Note: The following functions have function numbers
larger than the numbers on the Handset keyboard. To
access these functions, push the CONT key and the
number shown in the following instructions at the same
time. THE KEY SWITCH MUST BE CLOSED.
FUNCTION 48: MODE 1 - CONTROLLED ACCELERATION
(Push CONT 1)
This function allows for the adjustment of the rate of time it
takes for the control to ac c el er a te to 96% a p p l ied b a tter y
voltage to the motor on hard acceleration.
Range 0.1 to 22.0 seconds
Setting 0 to 255
Resolution 0.084 seconds per set unit
This function allows for the adjustment of the speed limit
(maximum battery volts to the moto r ) wh en th e SL2 l imit
switch input signal is received by the control card. SL2
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Range 0% to 100% battery volts
Setting 0 to 255
Resolution 0.375 volts per set unit
This function allows for the adjustment of the speed limit
(maximum battery volts to the moto r ) wh en th e SL3 l imit
August 1999
ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS Page 66
switch input signal is received by the control card. SL3
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Range 0% to 100% battery volts
Setting 0 to 255
Resolution 0.375 volts per set unit
Example: Setting of 50=18.75 volts
FUNCTION 52: MODE 2 - CONTROLLED ACCELERATION
(Push CONT 5)
Same as function 48.
FUNCTION 53: MODE 2 - SPEED LIMIT 2 (SL2)
(Push CONT 6)
Same as Function 49.
FUNCTION 54: MODE 2 - SPEED LIMIT 3 (SL3)
(Push CONT 7)
Same as Function 50.
FUNCTION 55: NOT APPLICABLE
This function is not applicable to this type of control and
should not be adjusted.
FUNCTION 56: MODE 3 - CONTROLLED ACCELERATION
(Push CONT 9)
This function is not applicable to this type of control and
should not be adjusted.
FUNCTION 60: MODE 4 - CONTROLLED ACCELERATION
(Push CONT 13)
Same as function 48.
August 1999
INSTALLATION AND OPERATION MANUAL
IT/IP TRANSISTOR CONTROL Page 67
Section 7. DASH DISPLAYS
Section 7.1 Application
The SX family Standard and Interactive Dash Displays
allow the operator and maintenance personnel easy
access to truck operation information and real-time system
diagnostics of the controller, motor and various
accessories. Hourmeter readings, battery discharge
information, maintenance information and system status
codes are clearly displayed during startup and running
modes. Shielded cable connections are made to the Dash
Display by means of five (5) 22-gage wires to the “Y” Plug
of the traction and hydraulic pump controls.
Section 7.2 Standard Dash Displays
GE Electric Vehicle
Motors & Controls
g
-
+
From the Dash Display, the operator may select any of four
pre-set interactive modes consisting of (4) Controlled
Acceleration levels, (4) Field Weakening Pick Up levels and
(4) Speed Limit levels.
These interactive modes are “pre-set” using the Handset
(Functions 48 - 63) or a personal computer (Functions 97 -
112). This feature allows the operator to select the best
vehicle performance for changing factory (task) conditions.
The Custom Dash Display incorporates all the features and
functions of the Standa r d Da sh Disp l a y, in a d d ition to th e
following customer options:
•= LED graphics to display Battery Discharge Indication
status.
•= Various LED indicators for Maintenance Required Status
Codes. These can include options for traction, pump and
power steer motors, hourmeter, over-temperature, seat
belt, brake and other safety sensors.
•= A push-button associated with the four segment LED tha t
displays Status Codes can be used to scroll the last 16
“Stored Status Codes” that shut down vehicle operation
with a PMT fault.
Connections
Connections are made to the Dash Display with five (5) 22gage wires to Plug "Y" of each control. Shielded cable is
required to eliminate signal interference.
Part Number
The GE Standard Dash Display is a four segment Light
Emitting Diode (LED) instrument that displays the GE LX, ZX,
and SX Status Codes, Hourmeter Readings, Battery
Discharge Indication, and Maintenance Required Code.
The four LED's above the symbols indicate the active
readout mode.
Section 7.3 Interactive Custom Dash Displays
+
EVT100ZX
BATTERY
-
The Interactive Custom Dash Display allows the operator to
select the best vehicle performance for changing factory
(task) conditions. There are four (4) “operator interaction
modes” that can be selected by depressing a push-button
on the dash display.
PUSH
PUSH
IC3645LXTDDT3
T=Traction Only
P=Traction & Pump
3=Round Face with four
display symbols
For Custom Dash Displays,
contact your vehicleOEM.
INSTALLATION AND OPERATION MANUAL
IT/IP TRANSISTOR CONTROL Page 68
Section 7.4 Start-Up Display Sequence
START-UP DISPLAY SEQUENCE
Key Switch On
Verify Each LED Segment
8 8 8 8
If Maintenance Code
Is
Active
Display Code "-99"
For Four Seconds and
Activate Speed Limit
(if selected)
BDI Display or
Blank Display
(no BDI used)
If Maintenance Code
Diagnostics Override
Is Not
Active
With Fault
Section 7.5 Outline Drawings
g
0.41
(10.4)
CONNECTOR OMITTED
IF NOT REQUIRED
2.45 (62.2)
0.19
(4.8)
GE Electric Vehicle
Motors & Controls
-
+
3.20 (81.3)
TRACTION
PUMP
2.00 (50.8)
BDI Display or
Blank Display
(no BDI used)
Display Traction
Display Pump
Run Mode
Diagnostics Override
Key Switch
Off
Hourmeter
For Four Seconds
Hourmeter
For Four Seconds
With Fault
PY3
PY4
PY2
PY1
PUMP
12345
Wiring connections to "Y"
BACK VIEW OF DISPLAY
plugs of Traction & Pump
controls.
54321
TRACTION
PY3
PY4
PY2
PY1
PY5
January 2001
TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROLPage 69
Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION
Section 8.1 GENERAL:
The potentiometer used for the turn angle must be a 320 degree rotation device that is attached to the steer wheel in a manner to
cause a 1:1 rotation ratio between the two devices. Any ohm value potentiometer can be used, but it is suggested that it be at
least 2K ohms or above, to keep the wattage of the potentiometer to a minimum. The turn angle potentiometer provides a voltage
divider circuit that allows the left and right motor controller to determine the turn angle of the rear steer wheel of the vehicle.
The potentiometer is connected to the two controls as show in Figure 1. After the potentiometer is installed on the vehicle, it will
need to be adjusted to insure proper operation of the vehicle.
Section of Left Motor
Control (Master)
P8
P12P9P12
4.3V Supply
Supply Neg
Turn Angle Input
Potentiometer
Section of Right Motor
Control (Slave)
Input
Turn Angle
320 Degree
Figure 1
travel (2.15 to 1.90 volts), there is no change to the inside wheel speed. Between 16
reduce its speed proportionally from top speed at 16
limit enable points during the transition from 16
o
. Between 66o and 71o, the inside wheel will be in a fr ee wh eel mo d e. As th e steer reaches the 71o point, the inside wheel can
60
now be programmed to reverse and accelerate proportionally in the opposite direction. Above 86
angle potentiometer.
SETUP:
Before any adjustments are done, jack up the drive wheels.
Install the potentiometer o n th e veh icl e steer wh eel in su c h a wa y to a llow adjustment of the shaft with th e p o ten tio meter a n d
connected to both the left and right controls. Setup of the turn angle pot can be done in several ways, detailed below.
Volt Meter Method:
Attach a volt meter, positive to P12 and negative to P8. Insure that the steer wheel is pointing straight ahead (Zero Degree
Angle); connect the battery and adjust the potentiometer until the voltage between P12 and P8 is 2.15 volts. Lock down the
potentiometer shaft and turn the vehicle all the way to the left turn stop, the voltage should be .93 volts or less. Turn the wheel to
the right turn stop, the voltage should be 3.32 volts or greater.
Handset Monitor Mode Method:
Plug the Handset into the left motor controller. Insure that the steer wheel is pointing straight ahead (Zero Degree Angle) and
connect the battery. Place the Handset into the monitor routine (Function 25) to view RAM location 95, which is turn angle volts,
using the following steps:
1. Push CONT 10
2. Adjust Handset to 95
3. Push STORE
4. Angle Value Displayed
5. ESC to 8888 ( To verify that you have the correct location )
6. Push CONT 10
7. Display should read 95
8. Push STORE
9. Angle Value Displayed
OPERATION:
To insure proper operation, the input voltage at P12 on both the left and right
controls must coincid e with th e tu r n a n g l e o f th e steer wh eel . Wh en th e steer
wheel is straight ahead ( Z er o Deg r ee T u r n An g l e), th e in p u t vo l ta g e a t ea c h
control should be 2.15 volts. As the vehicle turns left, this input voltage will
decrease, as the vehicle turns right, the input voltage will increase. The graph
in Figure 2 outlines the input voltages, the actions of the controls and the
corresponding turn a n g l es o f th e steer wh eel. A complete listing of inpu t
voltages, steer angles and control actions can be found in Section 8.2 - 320 Degree Potentiometer Input. As an example of control operation as
compared to the input vo l ta g e, th e fo llowing series of events takes plac e in a
left turn from the zero to the 90 d eg r ee steer wheel position. In the first 16
o
to creep speed at 66o. There will also be a l so a va il a b l e two veh icle speed
o
to 66o. Speed limit 1 can be enabled at 41o and speed limit 2 can be enabled at
o
(1.90V) and 66o (1.10V), the inside motor will
o
is over travel for the turn
o
of
January 2000
TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROLPage 70
Adjust the potentiometer until the Handset reads 110. Lock down the potentiometer shaft and turn the vehicle all the way to the
left turn stop, the reading should be 37 or less. Turn the wheel to the right turn stop, the reading should be 183 or greater.
After adjusting the potentiometer, be sure to ESC out of the monitor routine and then reset Function 25 to zero using the same
procedure as outlined above.
Section 8.2 320 Degree Potentiometer Input
320 DEGREE POTENTIOMETER FOR STEER ANGLE INPUT
4.30V
Over Travel
Reverse Direction
and Re-Accelerate
Proportionally
Reduces The Speed
of the Right Motor
As Steer Angle
Increases
3.31V
3.10V
3.04V
No Speed Change
No Speed Change
Proportionally
Reduces The Speed
of the Left Motor As
Steer Angle
Increases
Reverse Direction
and Re-Accelerate
Over Travel
2.37V
2.15V
1.94V
1.26V
1.20V
0.99V
0.00V
o
o
86
66o71
o
16
o
o
0
16
LEFT TURNRIGHT TURN
Figure 2
66o71o85
o
January 2000
TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROLPage 71
Section 8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 72
Section 9.0 MEMORY MAPS
Section 9.1 Traction Control
2
Func No. HS
E
No.
Traction Control
Function
Access By Restrictions
0 1 1 Motor Volts to Enable Auto Regen HS or PC None
1 2 2 Creep HS or PC None
2 3 3 Controlled Acceleration HS or PC None
3 4 4 Armature Current Limit HS or PC None
4 5 5 Plug Current Limit HS or PC None
5 6 6 FW Ratio HS or PC None
6 7 7 Minimum Field Current HS or PC None
7 8 8 Maximum Field Current HS or PC None
8 9 9 Regen Current Limit HS or PC None
9 10 10 Field Current for Regen HS or PC None
10 11 11 Turn Speed Limit HS or PC None
11 12 12 Max Armature % On HS or PC None
12 13 13 Speed Limit 3 HS or PC None
13 14 14 IR Compensation HS or PC None
14 15 15 Battery Volts Select HS or PC None
15 16 16 Stall Trip Point with % On-Time HS or PC None
16 17 17 Card Type Select HS or PC None
17 18 18 Steer Pump Time Delay HS or PC None
18 19 19 Maintenance Code HM (Tens/Units) HS or PC None
19 20 20 Maintenance Code HM (Thou/Hun) HS or PC None
20 21 21 Auto Regen HS or PC None
21 22 22 Not Used HS or PC For DD on power up
22 23 23 Not Used HS or PC None
23 24 24 FW Start HS or PC None
24 25 25 Monitor HS or PC GE Temporary Storage
25 26 26 Ratio HS or PC GE Temporary Storage
26 27 27 HM Minutes HS or PC GE Temporary Storage
27 28 28 Fault Count Pointer HS or PC None
28 29 29 Aux HM (Tens/Ones) Adj HS or PC None
29 30 30 Aux HM (Thou/Hun) Adj HS or PC None
30 31 Aux HM (Tens/Ones) PC Only None
31 32 Aux HM (Thou/Hun) PC Only None
32 33
Stored Status Code #1 PC Only Reset to Zero Only
(18)
33 34 BDI 1 PC Only Reset to Zero Only
34 35 Hours (Tens/Ones) 1 PC Only Reset to Zero Only
35 36 Hours (Thou/Hun) 1 PC Only Reset to Zero Onl y
36 37
Stored Status Code #2 PC Only Reset to Zero Only
(20)
37 38 BDI 2 PC Only Reset to Zero Only
38 39 Hours (Tens/Ones) 2 PC Only Reset to Zero Onl y
39 40 Hours (Thou/Hun) 2 PC Only Reset to Zero Onl y
40 41
Stored Status Code #3 PC Only Reset to Zero Only
(22)
41 42 BDI 3 PC Only Reset to Zero Only
42 43 Hours (Tens/Ones) 3 PC Only Reset to Zero Onl y
January 2000
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 73
E2 Func No. HS
No.
Traction Control
Function
Access By Restrictions
43 44 Hours (Thou/Hun) 3 PC Only Reset to Zero Onl y
45 46 BDI 4 PC Only Reset to Zero Only
46 47 Hours (Tens/Ones) 4 PC Only Reset to Zero Only
47 48 Hours (Thou/Hun) 4 PC Only Reset to Zero Onl y
48 49
Stored Status Code #5 PC Only Reset to Zero Only
(26)
49 50 BDI 5 PC Only Reset to Zero Only
50 51 Hours (Tens/Ones) 5 PC Only Reset to Zero Onl y
51 52 Hours (Thou/Hun) 5 PC Only Reset to Zero Onl y
52 53
Stored Status Code #6 PC Only Reset to Zero Only
(28)
53 54 BDI 6 PC Only Reset to Zero Only
54 55 Hours(Tens/Ones) 6 PC Only Reset to Zero Only
55 56 Hours(Thou/Hun) 6 PC Only Reset to Zero Only
56 57
Stored Status Code #7 PC Only Reset to Zero Only
(30)
57 58 BDI 7 PC Only Reset to Zero Only
58 59 Hours(Tens/Ones) 7 PC Only Reset to Zero Only
59 60 Hours(Thou/Hun) 7 PC Only Reset to Zero Only
60 61
Stored Status Code #8 PC Only Reset to Zero Only
(32)
61 62 BDI 8 PC Only Reset to Zero Only
62 63 Hours;(Tens/Ones) 8 PC Only Reset to Zero Only
63 64 Hours(Thou/Hun) 8 PC Only Reset to Zero Only
64 65
Stored Status Code #9 PC Only Reset to Zero Only
(34)
65 66 BDI 9 PC Only Reset to Zero Only
66 67 Hours(Tens/Ones) 9 PC Only Reset to Zero Only
67 68 Hours(Thou/Hun) 9 PC Only Reset to Zero Only
68 69
Stored Status Code #10 PC Only Reset to Zero Only
(36)
69 70 BDI 10 PC Only Reset to Zero Only
70 71 Hours(Tens/Ones) 10 PC Only Reset to Zero Only
71 72 Hours(Thou/Hun) 10 PC Only Reset to Zero Only
72 73
Stored Status Code #11 PC Only Reset to Zero Only
(38)
73 ; 74 BDI 11 PC Only Reset to Zero Only
74 75 Hours(Tens/Ones) 11 PC Only Reset to Zero Only
75 76 Hours(Thou/Hun) 11 PC Only Reset to Zero Only
76 77
Stored Status Code #12 PC Only Reset to Zero Only
(40)
77 78 BDI 12 PC Only Reset to Zero Only
78 79 Hours(Tens/Ones) 12 PC Only Reset to Zero Only
79 80 . Hours(Thou/Hun) 12 PC Only Reset to Zero Only
80 81
Stored Status Code #13 PC Only Reset to Zero Only
(42)
81 82 BDI 13 PC Only Reset to Zero Only
82 83 Hours(Tens/Ones) 13 PC Only Reset to Zero Only
83 84 Hours(Thou/Hun) 13 PC Only Reset to Zero Only
84 85
Stored Status Code # 14 PC Only Reset to Zero Only
(44)
85 86 BDI 14 PC Only Reset to Zero Only
86 87 Hours(Tens/Ones) 14 PC Only Reset to Zero Only
87 88 Hours(Thou/Hun) 14 PC Only Reset to Zero Only
88 89
Stored Status Code # 15 PC Only Reset to Zero Only
(46)
89 90 BDI 15 PC Only Reset to Zero Only
90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only
January 2000
RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL Page 74
E2 Func No. HS
No.
Traction Control
Function
Access By Restrictions
90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only
91 92 Hours (Thou/Hun) 15 PC Only Reset to Zero Only
92 93
Stored Status Code #16 PC Only Reset to Zero Only
(48)
94 95 Hours (Tens/Ones) 16 PC Only Reset to Zero Only
95 96 Hours (Thou/Hun) 16 PC Only Reset to Zero Only
96 67 48 Dash Display CA-1
97 98 49 Dash Display FWS-1 HS or PC None
98 99 50 Dash Display Ratio2-1 HS or PC None
99 100 51 Dash Display Speed Limit 2 - 1 HS or PC None
100 101 52 Dash Display CA-2 HS or PC None
101 102 53 Dash Display FWS-2 HS or PC None
102 103 54 Dash Display Ratio2-2 HS or PC None
103 104 55 Dash Display Speed Limit 2 - 2 HS or PC None
104 105 56 Dash Display CA-3 HS or PC None
105 106 57 Dash Display FWS-3 HS or PC None
106 107 58 Dash Display Ratio2-3 HS or PC None
107 108 59 Dash Display Speed Limit 2 - 3 HS or PC None
108 109 60 Dash Display CA-4 HS or PC None
109 110 61 Dash Display FWS-4 HS or PC None
110 111 62 Dash Display Ratio2-4 HS or PC None
111 112 63 Dash Display Speed Limit 2 - 4 HS or PC None
112 113 Secure HM (Tens/Ones) PC Only OEM Read Only
113 114 Secure HM (Thou/Hun) PC Only OEM Read Only
114 115 Secure Aux HM (Tens/Ones) PC Only OEM Read Only
115 116 Secure Aux HM (Thou/Hun) PC Only OEM Read Only
116 117 Reserved PC Only GE Future Use
117 118 Reserved PC Only GE Future Use
118 119 Reserved PC Only GE Future Use
119 120 Reserved PC Only GE Future Use
120 121 OEM Use PC Only None
121 122 OEM Use PC Only None
122 123 OEM Use PC Only None
123 124 OEM Use PC Only None
124 125 OEM Use PC Only None
125 126 OEM Use PC Only None
126 127 OEM Use PC Only None
127 128 OEM Use PC Only None
Numbers in (bold italics) are Stored Status Code pointers.
January 2000
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