GE IC3645SR4U404N2, IC3645SP4U400N3 User Manual

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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL Page 1

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

Section 1.0 INTRODUCTIO N ........................................................................................................................................................4

1.1 Motor Characteristics.............................................................................................................. 4

1.2 Solid-State Reversing............................................................................................................... 5

1.3 Flexible System Application..................................................................................................... 5

1.4 More Features with Fewer Components................................................................................ 5

Section 2.0 FEATURES OF SX FAMIL Y OF MOTOR CONTROL L ERS ....................................................................................6

2.1 Performance.............................................................................................................................. 6

2.1.1 Oscillator Card Features.................................................................................................. 6

2.1.1.a Standard Operation..................................................................................................6

2.1.1.b Creep Speed...............................................................................................................6

2.1.1.c Controlled Acceleration .......................................................................................... 6

2.1.2 Current Limit...................................................................................................................... 6

2.1.3 Braking............................................................................................................................... 6

2.1.3.a Plug Braking..............................................................................................................6

2.1.3.b Regenerative Braking to Zero Speed...................................................................... 6

2.1.3.c Pedal Position Plug Braking....................................................................................6

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INSTALLATION AND OPERATION

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Table of Contents ( Continued )

2.1.3.d Auto Braking.............................................................................................................. 6

2.1.4 Auxiliary Speed Control.................................................................................................... 6

2.1.4.a Field Weakening................................................................................................................ 6

2.1.4.b Speed Limits ......................................................................................................................7

2.1.4.c Proportional Operation for Dual Motor Vehicles.......................................................... 7

2.1.5 Ramp Operation................................................................................................................ 7

2.1.5.a Ramp Start................................................................................................................. 7

2.1.5.b Anti-Rollback............................................................................................................. 7

2.1.6 Steer Pump Contactor Time Delay ................................................................................. 7

2.1.7 On-Board Coil Drivers and Internal Coil Suppression ................................................. 8

2.2 System Protective Override..................................................................................................... 8

2.2.1 Static Return to Off (SRO) ...............................................................................................8

2.2.2 Accelerator Volts Hold Off............................................................................................... 8

2.2.3 Pulse Monitor Trip (PMT)................................................................................................. 8

2.2.4 Thermal Protector (TP)..................................................................................................... 8

2.2.5 Low Voltage ...................................................................................................................... 8

2.3 Diagnostics................................................................................................................................ 8

2.3.1 Systems Diagnostics........................................................................................................ 8

2.3.2 Status Codes......................................................................................................................8

2.3.2.a Standard Status Codes............................................................................................. 8

2.3.2.b Stored Status Codes ................................................................................................ 8

2.3.3 Hourmeter Readings ........................................................................................................ 9

2.3.3.a Maintenance Alert and Speed Limit ...................................................................... 9

2.3.4 Battery Discharge Indication (BDI)................................................................................9

2.3.4.a Internal Resistance Compensation ................................................................................ 9

2.3.5 Handset ............................................................................................................................. 9

2.3.6 RS-232 Communication Port ........................................................................................... 9

2.3.6.a Dash Display Interaction Modes .................................................................................. 9

2.3.7 Circuit Board Coil Driver Modules.................................................................................. 9

2.3.8 Truck Management Module (TMM)...............................................................................9

2.4 Hydraulic Pump Control........................................................................................................... 9

Section 3.0 ORDERING INFORMAT ION, ELEMENTARY AND OUTLINE DRAWINGS......................................................11

3.1 Ordering Information for Separately Excited Controls................................................................. 11

3.2 Outline: SX-3 and SR-3 Package Size............................................................................................. 12

3.3 Traction Elementary......................................................................................................................... 13

3.4 Pump Elementary.............................................................................................................................. 14

3.5 Traction and Pump Control Input / Output List............................................................................. 15

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODE S..............................................................................16

4.1 General Maintenance Instructions.................................................................................................16

4.2 Cable Routing and Separation ...............................................................................................16

4.2.1 Application Responsibility...............................................................................................16

4.2.2 Signal/Power Level Definitions...............................................................................................16

4.2.2.a Low Level Signals (Level L).............................................................................................. 16

4.2.2.b High Level Signals (Level H).............................................................................................17

4.2.2.c Medium-Power Signals (Level MP)................................................................................ 17

4.2.2.d High-Power Signals (Level HP).......................................................................................17

4.2.3 Cable Spacing Guidelines........................................................................................................ 17

4.2.3.a General Cable Spacing..................................................................................................... 17

4.2.4 Cabling for Vehicle Retrofits.................................................................................................... 17

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Table of Contents ( Continued )

4.2.5 RF Interference.......................................................................................................................... 17

4.2.6 Suppression...............................................................................................................................17

4.3 Recommended Lubrication of Pins and Sockets Prior to Installation........................................18

4.4 General Troubleshooting Instructions........................................................................................... 19

4.5 Traction Controller Status Codes...................................................................................................20-40

4.6 TMM Status Codes........................................................................................................................... 41-45

4.7 Pump Control Status Codes.............................................................................................................46-52

Section 5.0 TRUCK MANAGEMENT MODULE (TMM)............................................................................................................53

5.1 General Features .............................................................................................................................. 53

5.2 Operation ..........................................................................................................................................53

5.3 Installation......................................................................................................................................... 53

5.4 Connection Diagrams....................................................................................................................... 53

5.4.1 TMM7A Card Connections...................................................................................................... 53

5.4.2 TMM7A Typical Brush Wear Sensor Connections .............................................................53

5.4.3 TMM Pump Control Connections ...........................................................................................54

5.5 TMM7A Outline Drawings............................................................................................................... 54

Section 6.0 SX FAMILY - GE HANDSE T INSTRUCTIONS ......................................................................................................55

6.1 General Features .............................................................................................................................. 55

6.2 Purpose/Setup Functions ...............................................................................................................55

6.3 Setup Function Procedures ............................................................................................................ 56

6.3.1 Setup Mode ..............................................................................................................................56

6.3.2 Status Code Scrolling............................................................................................................... 56

6.3.3 SX Handset Plug Connections & Outline Drawing............................................................... 56

6.4 Setup Functions for Traction Controller .......................................................................................57-62

6.5 Summary of Current Limit Adjustments......................................................................................... 62

6.6 Setup Functions for Hydraulic Pump Controller .......................................................................... 64-66

Section 7.0 DASH DISPLAYS.......................................................................................................................................................67

7.1 Application ..........................................................................................................................................67

7.2 Standard Dash Displays ....................................................................................................................67

7.3 Interactive Dash Displays................................................................................................................... 67

7.4 Start-up Display Sequence ................................................................................................................68

7.5 Outline Drawings ................................................................................................................................ 68

Section 8.0 TURN ANGLE POT ENTIOMETER IN STALLATION..............................................................................................69

8.1 General................................................................................................................................................. 69

8.2 320 Degree Potentiometer Input........................................................................................................ 70

8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings..................................... 71

Section 9.0 MEMORY MAPS........................................................................................................................................................72

9.1 Typical Memory Map for Traction Control.................................................................................... 72-74

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BASIC OPERATION AND FEATURES

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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

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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 +

ARM

A2 -

F2F1

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.

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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

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.

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

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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%

LEFT

TURN

50%

REV - SPEED - FWD

100%

LEFT

MOTOR

0O10O10O20

50O60

RIGHT

TURN

30O40

STEERING ANGLE

100%

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

, 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

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.

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LEFT

RIGHT

MOTOR

RIGHT

LEFT

CONTROL

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SX TRANSISTOR CONTROL Page 8

Section 2.1.7 On-Board Coil Drivers & Internal Coil Suppression

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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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 CONTROL Page 10

•= Three speeds, adjustable from O to 100% motor

volts. Fixed speeds actuated by switch closure to negative.

•= Current limit and controlled acceleration adjustable.

•= Battery Discharge Indicator interrupt compatible.

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.

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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 )

Argument 03: Operating Voltage: 1 = 120 volts 4 = 48 volts

2 = 24 volts 5 = 36/48 volts 3 = 36 volts 6 = 24/36 volts 7 = 72/80 volts

Argument 04: Package Size: D = 6.86” X 6.67”

R = 6.86” X 8.15” U = 8.66” X 8.13” W = 8.66” X 10.83”

Argument 05: Armature Current ( 2 characters )

22 = 220 Amps 33 = 330 Amps 40 = 400 Amps etc.

Argument 06: Field Current ( 1 character ) 2 = 20 Amps 3 = 30 Amps 4 = 40 Amps etc.

Argument 07: Customer / Revision A1 = Customer A / Revision 1

B1 = Customer B / Revision 1 etc.

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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SX TRANSISTOR CONTROL Page 12

Section 3.2 Outline: SX-3 and SR-3 Package Size

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SX TRANSISTOR CONTROL Page 13

Section 3.3 Traction Elementary

PLUG PY

CONNECTIONS

PY7

PY12

PY10

615

PY11

P11

710

12-1

P6P2P1 P3 P4

P18

P13

P7 P12

P10

ELEMENTARY DRAWING FOR

POWER CONNECTIONS

ARMATURE

FIELD

RIGHT CONTROL

NEG A2 F2

SEPARATELY EXCITED DUAL MOTOR

PROPORTIONING CONTROLLERS WITH

SOLID-STATE REGENERATIVE BRAKING

REVERSE SW.

FORWARD SW.

START SW.

OSCILLATOR CARD

P15

P4 P5

RIGHT CONTROL

P15

P16

STEER PUMP

P16 P21

P12 P8 P9

P10

PMT ENABLE OUTPUT

66 65

50 30

BRAKING ENABLE

AUTO REGENERATIVE

SIGNAL

BDI INTERRUPT

REGEN OUTPUT

CONTACTOR DRIVER

POT

STEER ANGLE

ACC POT

13A

POS A1

ARMATURE

SEAT SW.

POWER

CONNECTIONS

FIELD

LEFT CONTROL

NEG A2 F2

TMM7

POS A1

TMM7

TO ACCESSORIES

FU7

P1 P17 P2 P6

P18

OSCILLATOR CARD

LEFT CONTROL

PY7

PY12

PY10

12-1

FU6

PY11

PLUG PY

CONNECTIONS

FU1

LINE

FU2

FU4

BRAKE SW.

KEY SWITCH

FU5

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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SX TRANSISTOR CONTROL Page 14

Section 3.4 Pump Elementary

CONNECTIONS

SPEED 1

SPEED 2

SPEED 3

ARMATURE

13C

FIELD

SUPPLIED BY CUSTOMER

POWER CONNECTION

TO TRACTION

PL2-10

PY11

CONTROL PLUG PL2

1345689

STATUS CODE 93 INPUT

STATUS CODE 94 INPUT

SX-2

STATUS CODE 95 INPUT

STATUS CODE 94 INPUT

STATUS CODE 95 INPUT

STATUS CODE 92 INPUT

STATUS CODE 90 INPUT

BRUSH WEAR OUTPUT

STATUS CODE 91 INPUT

OVER TEMP OUTPUT

PY10

PY12

PY7

PLUG PY

12-1

FU2

FU6

KEY SW.

LINE

CONTACTOR

PUMP CONTROL

POWER CONNECTION

BATT (-)

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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SX TRANSISTOR CONTROL Page 15

Section 3.5. Traction and Pump Control Input and Output List

CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN)

TRACTION PUMP

PIN INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION

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

MOTOR PROPORTIONING "Y" PLUG PUMP "Y" PLUG

PIN INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION

1 CLOCK (OUT) CLOCK (OUT)

2 DATA (OUT) DATA (OUT)

3 ENABLE (OUT) ENABLE (OUT)

4 NEGATIVE NEGATIVE

5 +5V SUPPLY +5V SUPPLY

6 CONT/STORE (IN) (HANDSET) CONT/STORE (IN) (HANDSET)

7 EXTERNAL JUMPER TO PY12 EXTERNAL JUMPER TO PY12

8 VALUE VALUE

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

1 2 3 4 5 6

7 8 9 10 11 12

WIRE END VIEW "Y" PLUG

1 2 3 4 5 6 6 8

9 10 11 12 13 14 15

16 17 18 19 20 21 22 23

WIRE END VIEW - MAIN PLUG

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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:

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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.

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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.

oni

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

NyeNye

RICA

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.

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 20

Section 4.5 Traction Control Codes

TRACTION

STATUS CODE

NONE

MEMORY RECALL

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE 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

FU3

FU5

TRACTION

STATUS CODE

-01

MEMORY RECALL

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE 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

FU3

FU5

•=On vehicles without a seat/deadman switch,

check for a loose connection or broken wire from P2 and/or P6.

SEAT SWITCH

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 21

TRACTION

STATUS CODE

-02

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3P17 P5

START SW.

FORWARD SW.

REVERSE SW.

TRACTION

STATUS CODE

-03

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3P17 P5

START SW.

FORWARD SW.

REVERSE SW.

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 22

TRACTION

STATUS CODE

-05

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3

P17 P5P4P6

KEY SWITCH

START SW.

FORWARD SW.

REVERSE SW.

ACCPOT

NEG

TRACTION

STATUS CODE

-06

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3

P17 P5P4P6

KEY SWITCH

START SW.

FORWARD SW.

REVERSE SW.

NEG

ACCPOT

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 23

TRACTION

STATUS CODE

-07

MEMORY RECALL

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

NEGATIVE

ACC POT

TRACTION

STATUS CODE

-08

MEMORY RECALL

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

NEGATIVE

ACC POT

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 24

TRACTION

STATUS CODE

-09

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3P17 P5

START SW.

FORWARD SW.

REVERSE SW.

TRACTION

STATUS CODE

-10

MEMORY RECALL

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

P9 P12

STEER ANGLE

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 25

TRACTION

STATUS CODE

-11

MEMORY RECALL

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

SEAT SWITCH

P1 P2 P3P17 P5

START SW.

FORWARD SW.

REVERSE SW.

TRACTION

STATUS CODE

-12

MEMORY RECALL

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

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

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

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

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

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

RIGHT CONTROL NEG

START SW.

POS A1 F1

POWER

CONNECTIONS

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective Control.

•= Replace controller unit.

FU2

FU6

LINE

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

RIGHT CONTROL NEG

FOR. SW.

START SW.

P10

P9P3P12 P8

BDI INTERRUPT

POS A1 F1

POWER

CONNECTIONS

SW.

REV.

STEER ANGLE

POT

FIELD

ARMATURE

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

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.

ACCESSORIES P3

FU1

KEY SWITCH

PY7 PY12

P18 PY10 PY11

A1 F1

POS

POWER

CONNECTIONS

LEFT CONTROL

NEG A2

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

CONNECTIONS RIGHT CONTROL NEG

FU2

FU6

LINE

FU5

FU4

START SW.

POWER

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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

FU5

FU7

TO ACCESSORIES

FU6

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

12-1

10 PY7

PY12 PY10 PY11

P18

P17

OSCILLATOR CARD

LEFT CONTROL

P2 P6

BRAKE SW.

SEAT SW.

START SW.

FORWARD SW.

P10 P21

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

12-1

P10

P7 P12

710

P6P2P1 P3 P4

P13

P18

P11

PY7

PY12 PY10 PY11

PLUG PY

CONNECTIONS

FU2

LINE

FU1

FU4

TMM7

POS A1

POWER CONNECTIONS

LEFT CONTROL

NEG A2

FIELD

ACC POT

13A

ARMATURE

STEER ANGLE

POT

POS A1

POWER CONNECTIONS

RIGHT CONTROL

NEG

AUTO REGENERATIVE

BRAKING ENABLE

STEER PUMP

CONTACTOR DRIVER

REGEN OUTPUT

FIELD

SIGNAL

BDI INTERRUPT

ARMATURE

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 30

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-30

MEMORY RECALL

Circuits valid

for

Traction

Controller

FU5

FU7

TO ACCESSORIES

FU6

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

12-1

10 PY7

PY12 PY10 PY11

P18

P17

OSCILLATOR CARD

LEFT CONTROL

P2 P6

BRAKE SW.

SEAT SW.

START SW.

FORWARD SW.

P10 P21

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

12-1

P10

P7 P12

710

P6P2P1 P3 P4

P13

P18

CONNECTIONS

PY7

PY12 PY10

P11

PY11

PLUG PY

FU2

LINE

FU1

FU4

TMM7

POS A1

POWER CONNECTIONS

LEFT CONTROL

NEG A2

FIELD

ACC POT

13A

ARMATURE

STEER ANGLE

POT

POS A1

POWER CONNECTIONS

RIGHT CONTROL

NEG

AUTO REGENERATIVE

BRAKING ENABLE

STEER PUMP

CONTACTOR DRIVER

REGEN OUTPUT

FIELD

SIGNAL

BDI INTERRUPT

ARMATURE

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

BRAKE SW.

SEAT SW.

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

START SW.

ACC POT

POS A1 F1

POWER

CONNECTIONS RIGHT CONTROL NEG

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective control.

•= Replace controller unit.

FU2

LINE

FU6

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

POWER

CONNECTIONS

LEFT CONTROL

NEG A2

P18

P17

OSCILLATOR CARD

LEFT CONTROL

A1 F1

FIELD

BRAKE SW.

SEAT SW.

ARMATURE

FOR. SW.

START SW.

P10

ACC POT

POS A1 F1

POWER

CONNECTIONS

RIGHT CONTROL

NEG

SW.

REV.

P9P3P12 P8

STEER ANGLE

POT

BDI INTERRUPT

FIELD

ARMATURE

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 32

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-43

MEMORY RECALL

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

FU6

FU4

FU5

ACCESSORIES

FU1

KEY SWITCH

POS

CONNECTIONS LEFT CONTROL

NEG A2

PY7 PY12 PY10 PY11

POWER

P18

P17

OSCILLATOR CARD

A1 F1

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

SW.

REV.

STEER ANGLE

POT

FIELD

ARMATURE

-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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

RIGHT CONTROL NEG

START SW.

POS A1 F1

POWER

CONNECTIONS

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

REV.

SW.

STEER ANGLE

POT

FIELD

ARMATURE

-46

MEMORY RECALL

“Look Ahead” test for A2 volts less than 12% of battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

This status code will be displayed when the voltage at A2 is less than 12% of battery volts.

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

BRAKE SW.

SEAT SW.

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

FOR. SW.

START SW.

P10

ACC POT

POS A1 F1

CONNECTIONS RIGHT CONTROL NEG

BDI INTERRUPT

POWER

SW.

REV.

P9P3P12 P8

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

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

REV.

SW.

STEER ANGLE

POT

FIELD

ARMATURE

-51

MEMORY RECALL

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

LEFT CONTROL

BRAKE SW.

SEAT SW.

ACC POT

FIELD

ARMATURE

RIGHT CONTROL

NEG

FOR. SW.

START SW.

P10

POS A1 F1

POWER

CONNECTIONS

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

LEFT CONTROL

BRAKE SW.

SEAT SW.

ACC POT

FIELD

ARMATURE

RIGHT CONTROL

NEG

FOR. SW.

START SW.

P10

POS A1 F1

POWER

CONNECTIONS

SW.

REV.

P9P3P12 P8

STEER ANGLE

POT

BDI INTERRUPT

FIELD

ARMATURE

SW.

REV.

P9P3P12 P8

STEER ANGLE

POT

BDI INTERRUPT

FIELD

ARMATURE

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

FU5

ACCESSORIES P3

FU1

FU4

POS

NEG A2

KEY SWITCH

PY7 PY12

P18 PY10 PY11

A1 F1

POWER CONNECTIONS LEFT CONTROL

BRAKE SW.

SEAT SW.

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

FOR. SW.

START SW.

P10

P9P3P12 P8

ACC POT

POS A1 F1

CONNECTIONS

RIGHT CONTROL

NEG

BDI INTERRUPT

POWER

SW.

REV.

STEER ANGLE

POT

FIELD

ARMATURE

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

FU5

ACCESSORIES P3

FU1

FU4

POS

NEG A2

KEY SWITCH

PY7 PY12

P18 PY10 PY11

A1 F1

POWER CONNECTIONS LEFT CONTROL

BRAKE SW.

SEAT SW.

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

FOR. SW.

START SW.

P10

P9P3P12 P8

ACC POT

POS A1 F1

CONNECTIONS

RIGHT CONTROL

NEG

BDI INTERRUPT

POWER

SW.

REV.

STEER ANGLE

POT

FIELD

ARMATURE

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

BRAKE SW.

SEAT SW.

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

FOR. SW.

START SW.

P10

ACC POT

POS A1 F1

CONNECTIONS RIGHT CONTROL NEG

BDI INTERRUPT

POWER

SW.

REV.

P9P3P12 P8

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

FU5

FU7

TO ACCESSORIES

FU6

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

12-1

10 PY7

PY12 PY10 PY11

P18

P17

OSCILLATOR CARD

LEFT CONTROL

P2 P6

BRAKE SW.

SEAT SW.

START SW.

FORWARD SW.

P10 P21

50 30

REVERSE SW.

P5 P9P3P12 P8

66 65

P15

P16

PMT ENABLE OUTPUT

OSCILLATOR CARD

P16

P15

12-1

RIGHT CONTROL

P10

P7 P12

710

P6P2P1 P3 P4

P13

P18

P11

PLUG PY

CONNECTIONS

PY7 PY12 PY10 PY11

FU2

LINE

FU1

FU4

TMM7

POS A1

POWER CONNECTIONS

LEFT CONTROL

NEG A2

FIELD

ACC POT

13A

ARMATURE

STEER ANGLE

POT

POS A1

POWER CONNECTIONS

RIGHT CONTROL

NEG

AUTO REGENERATIVE

BRAKING ENABLE

STEER PUMP

CONTACTOR DRIVER

REGEN OUTPUT

FIELD

SIGNAL

BDI INTERRUPT

ARMATURE

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

FU6

FU5

FU4

ACCESSORIES P3

FU1

KEY SWITCH

PY7 PY12

P18 PY10 PY11

A1 F1

POS

POWER

CONNECTIONS

LEFT CONTROL

NEG A2

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

BRAKE SW.

SEAT SW.

FOR. SW.

START SW.

P10

ACC POT

POS A1 F1

CONNECTIONS RIGHT CONTROL NEG

BDI INTERRUPT

POWER

SW.

REV.

P9P3P12 P8

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 ACTIONS TROUBLE-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.

•= Line contactor bouncing open during regen.

•= Main power fuse opening during regen.

•= Intermittent battery plug connection.

* Limit Voltage: Limit Batt. 50V 36V 70V 48V 96V 72/80V

FU2

LINE

FU6

FU5

FU4

ACCESSORIES P3

FU1

KEY SWITCH

PY7 PY12

P18 PY10 PY11

A1 F1

POS

POWER

CONNECTIONS

LEFT CONTROL

NEG A2

P17

OSCILLATOR CARD

LEFT CONTROL

FIELD

ARMATURE

BRAKE SW.

SEAT SW.

FOR. SW.

START SW.

P10

ACC POT

POS A1 F1

CONNECTIONS RIGHT CONTROL NEG

BDI INTERRUPT

POWER

SW.

REV.

P9P3P12 P8

STEER ANGLE

FIELD

POT

ARMATURE

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 40

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-77

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

REV.

SW.

STEER ANGLE

POT

FIELD

ARMATURE

-82

MEMORY RECALL

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

FU5

FU4

FU1

KEY SWITCH

ACCESSORIES

PY7 PY12 PY10 PY11

POS

CONNECTIONS

LEFT CONTROL

NEG A2

P18

A1 F1

POWER

P17

OSCILLATOR CARD

BRAKE SW.

LEFT CONTROL

FIELD

ARMATURE

SEAT SW.

ACC POT

POS A1 F1

RIGHT CONTROL NEG

START SW.

POWER

CONNECTIONS

FOR. SW.

P10

P9P3P12 P8

BDI INTERRUPT

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.

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.

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.

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.

Defective input switch (s horted). Defective TMM card. Defective pump card.

WHEN SR Series PUMP

CONTROL IS USED

USER SW

POS

SC94A

January 2000

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 44

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 P8 (pump) is short ed t o positive. Defective input switch (s horted). Defective TMM card. Defective pump card.

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.

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

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

PUMP

STATUS CODE

-127

MEMORY RECALL

YES

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE 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 STATUS CAUSE 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

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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

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

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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

CARD

SPEED LIMIT 3

PY7

PY12 PY10

P12

P19P21

PY11

SPEED LIMIT 2

SPEED LIMIT 1

PUMP

STATUS CODE

-143

MEMORY RECALL

Circuits valid

for

Pump

Controller

ARMATURE

DESCRIPTION OF STATUS CAUSE 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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

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 STATUS CAUSE 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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

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 STATUS CAUSE 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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

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 STATUS CAUSE 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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

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

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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

CARD

ARMATURE

SPEED LIMIT 3

PY7

PY12

P12

P19P21

PY10 PY11

SPEED LIMIT 2

SPEED LIMIT 1

PUMP

STATUS CODE

-157

MEMORY RECALL

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 ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Pump control will not operate.

POSSIBLE CAUSE

Control is defective.

•=Replace controller unit.

LINE

FU3 FU6

FU1

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

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

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE 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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

TRACTION

CARD

ARMATURE

SPEED LIMIT 3

PY7

PY12

P12

P19P21

PY10 PY11

SPEED LIMIT 2

SPEED LIMIT 1

PUMP

STATUS CODE

-181

MEMORY RECALL

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

POS A1

CONNECTIONS

NEG A2

KEY SWITCH

POWER

TO TRACTION

P10 - BDI

P1 P2 P3

FIELD

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.

Section 5.4 Connection Diagrams Section 5.4.1 TMM7A Card Connections

PLUG Y

108

TMM7A CARD CONNECTIONS

279

BATTERY

NEGATIVE

BATTERY POSITIVE

1345

6 8 10 11 12 131415

A1-1

A1-2

A2-1

81110 12

A2-2

A3-1

A3-2

Section 5.4.2 Typical Brush Wear Sensor Connections

BRUSH WEAR SENSOR CONNECTIONS (TYPICAL)

279

1345

6 8 10 11 12 131415

PUMP PWR STEER

ARM

TRACTION

January 2000

INSTALLATION AND OPERATION MANUAL

SX TRANSISTOR CONTROL Page 54

Section 5.4.3 TMM Pump Control Connections

PUMP CONTROL CONNECTIONS

PA3PA6PB6PA1PA2PA4PA5PZ10PZ11PY10PA

A1-1

A1-2

BATTERY

NEGATIVE BATTERY

POSITIVE

A2-1

81110 12

A3-1

A2-2

Section 5.5 TMM7A Outline Drawings

A3-2

TO PY10

TRACTION

3.36

(85.3)

(

)

(20.3)

1.60

(40.6)

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ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 55

Section 6. SX FAMILY GE HANDSET

START-UP DISPLAY SEQUENCE

INSTRUCTIONS

Section 6.1 General Features

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

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

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ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 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

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

Connections and Outline Drawing

“Y” Plug

Handset Cable Part Number - 325B1002G1

January 2000

ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 57

accelerator ohm inp u t b etween 6. 0K a n d 4. 0K ohms is

HANDSET

CONT

CONTCONT

STORE

STORESTORE

EVC

+ +

ESC

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

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

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ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 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

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

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

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

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 CONTROLS Page 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

) 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

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

as a reference.

Drop

INTERNAL RESISTANCE COMPENSATION

TABLE

Setting V

Drop

2 11.44 17 01.34 3 07.60 18 01.27 4 05.72 19 01.20 5 04.57 20 01.14 6 03.81 21 01.09 7 03.27 22 01.04 8 02.86 23 00.99

9 02.54 24 00.95 10 02.28 25 00.91 11 02.08 26 00.88 12 01.90 27 00.85 13 01.76 28 00.82 14 01.63 29 00.79 15 01.52 30 00.76 16 01.43 31 00.74

FUNCTION 15 BATTERY VOLTS (Push l5)

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 CONTROLS Page 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

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

[

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ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 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

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.

January 2000

ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 62

FUNCTION 52 MODE 2 ARMATURE CONTROLLED ACCELERATION ( Push CONT 5)

Same as Function 48. This C/A takes effect when the Mode 2 settings are called

for by the interactive Dash Display.

FUNCTION 53 MODE 2 FIELD WEAKENING START ( Push CONT 6)

Same as Function 49. This FIELD WEAKENING START takes effect when the

Mode 2 settings are called for by the interactive Dash Display.

FUNCTION 54 MODE 1 FW RATIO ( Push CONT 7 )

Same as Function 50. This FW RATIO takes effect when the Mode 2 settings are

called for by the interactive Dash Display.

FUNCTION 55 MODE 2 MAX ARMATURE % ON ( Push CONT 8 )

Same as Function 51. This MAX ARMATURE % ON takes effect when the Mode 2

settings are called for by the interactive Dash Display.

FUNCTION 56 MODE 3 ARMATURE CONTROLLED ACCELERATION ( Push CONT 9)

Same as Function 48. This C/A takes effect when the Mode 3 settings are called

for by the interactive Dash Display.

FUNCTION 57 MODE 3 FIELD WEAKENING START ( Push CONT 10)

Same as Function 49.

FUNCTION 58 MODE 3 FW RATIO ( Push CONT 11 )

Same as Function 50. This F/W RATIO takes effect when the Mode 3 settings are

called for by the interactive Dash Display.

FUNCTION 59 MODE 3 MAX ARMATURE % ON ( Push CONT 12 )

Same as Function 51. This MAX ARMATURE % ON takes effect when the Mode 3

settings are called for by the interactive Dash Display.

FUNCTION 60 MODE 4 ARMATURE CONTROLLED ACCELERATION ( Push CONT 13)

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 CONTROLS Page 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.

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

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.

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.

SPEED / TORQUE

COMPENSATION TABLE

SETTING

VOLTAGE

DROP

SETTING

VOLTAGE

DROP

2 11.44 17 1.34 3 7.60 18 1.27 4 5.72 19 1.20 5 4.57 20 1.14 6 3.81 21 1.09 7 3.27 22 1.04 8 2.86 23 0.99

9 2.54 24 0.95 10 2.28 25 0.91 11 2.08 26 0.88 12 1.90 27 0.85 13 1.76 28 0.82 14 1.63 29 0.79 15 1.52 30 0.76 16 1.43 31 0.74

FUNCTION 17: CARD TYPE SELECTION

(Push CONT 2)

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.

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

Example: Setting of 20 = 1.8 seconds C/A

FUNCTION 49: MODE 1 - SPEED LIMIT 2 (SL2) (Push CONT 2)

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

Example: Setting of 50=18.75 volts

FUNCTION 50: MODE 1 - SPEED LIMIT 3 (SL3) (Push CONT 3)

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)

Same as function 48.

FUNCTION 57: MODE 3 - SPEED LIMIT 2 (SL2) (Push CONT 10)

Same as Function 49.

FUNCTION 58: MODE 3 - SPEED LIMIT 3 (SL3)

FUNCTION 61: MODE 4 - SPEED LIMIT 2 (SL2) (Push CONT 14)

Same as Function 49.

FUNCTION 62: MODE 4 - SPEED LIMIT 3 (SL3)

(Push CONT 15) Same as Function 50.

(Push CONT 11) Same as Function 50.

FUNCTION 59: NOT APPLICABLE

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

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

IC3645LXTDD T 3

T=Traction Only P=Traction & Pump

3=Round Face with four display symbols

For Custom Dash Displays, contact your vehicleOEM.

Reference

AMP#102241-3 Dash Display mating plug AMP#1-87195-8 Dash Display mating pin 44A723596-G09 Dash Display plug kit AMP#175965-2 "Y" Plug AMP#175180-1 "Y" Plug receptacle

January 2001

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

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

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

1 2 3 4 5

Wiring connections to "Y"

BACK VIEW OF DISPLAY

plugs of Traction & Pump controls.

5 4 3 2 1

TRACTION

PY3 PY4 PY2 PY1 PY5

January 2001

TURN ANGLE POTENTIOMETER INSTALLATION

SX TRANSISTOR CONTROL Page 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)

P12P9 P12

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

. 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

to creep speed at 66o. There will also be a l so a va il a b l e two veh icle speed

to 66o. Speed limit 1 can be enabled at 41o and speed limit 2 can be enabled at

(1.90V) and 66o (1.10V), the inside motor will

is over travel for the turn

January 2000

TURN ANGLE POTENTIOMETER INSTALLATION

SX TRANSISTOR CONTROL Page 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

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

66o71

LEFT TURN RIGHT TURN

Figure 2

66o71o85

January 2000

TURN ANGLE POTENTIOMETER INSTALLATION

SX TRANSISTOR CONTROL Page 71

Section 8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings

320 Degree Potentiometer 320 Degree Potentiometer

Left Right Left Right

Volts Deg HS Volts Deg HS Actions Volts Deg HS Volts Deg HS Actions

2.15 Ctr 110 2.15 Ctr 110 No Change 1.53 46 78 2.77 46 141 Proportional Reduce

2.14 1 109 2.16 1 110 No Change 1.52 47 77 2.78 47 142 Proportional Reduce

2.12 2 108 2.18 2 111 No Change 1.51 48 77 2.80 48 143 Proportional Reduce

2.11 3 108 2.19 3 112 No Change 1.49 49 76 2.81 49 143 Proportional Reduce

2.10 4 107 2.20 4 112 No Change 1.48 50 75 2.82 50 144 Proportional Reduce

2.08 5 106 2.22 5 113 No Change 1.46 51 75 2.84 51 145 Proportional Reduce

2.07 6 106 2.23 6 114 No Change 1.45 52 74 2.85 52 145 Proportional Reduce

2.06 7 105 2.24 7 114 No Change 1.44 53 73 2.86 53 146 Proportional Reduce

2.04 8 104 2.26 8 115 No Change 1.42 54 73 2.88 54 147 Proportional Reduce

2.03 9 103 2.27 9 116 No Change 1.41 55 72 2.89 55 147 Proportional Reduce

2.02 10 103 2.28 10 117 No Change 1.40 56 71 2.90 56 148 Proportional Reduce

2.00 11 102 2.30 11 117 No Change 1.38 57 71 2.92 57 149 Proportional Reduce

1.99 12 101 2.31 12 118 No Change 1.37 58 70 2.93 58 149 Proportional Reduce

1.98 13 101 2.32 13 119 No Change 1.36 59 69 2.94 59 150 Proportional Reduce

1.96 14 100 2.34 14 119 No Change 1.34 60 69 2.96 60 151 Proportional Reduce

1.95 15 99 2.35 15 120 No Change 1.33 61 68 2.97 61 151 Proportional Reduce

1.94 16 99 2.37 16 121 Top Speed Reduce 1.32 62 67 2.98 62 152 Proportional Reduce

1.92 17 98 2.38 17 121 Proportional Reduce 1.30 63 66 3.00 63 153 Proportional Reduce

1.91 18 97 2.39 18 122 Proportional Reduce 1.29 64 66 3.01 64 154 Proportional Reduce

1.89 19 97 2.41 19 123 Proportional Reduce 1.28 65 65 3.02 65 154 Proportional Reduce

1.88 20 96 2.42 20 123 Proportional Reduce 1.26 66 64 3.04 66 155 Creep Speed

1.87 21 95 2.43 21 124 Proportional Reduce 1.25 67 64 3.05 67 156 Zero Speed

1.85 22 95 2.45 22 125 Proportional Reduce 1.24 68 63 3.06 68 156 Zero Speed

1.84 23 94 2.46 23 125 Proportional Reduce 1.22 69 62 3.08 69 157 Zero Speed

1.83 24 93 2.47 24 126 Proportional Reduce 1.21 70 62 3.09 70 158 Zero Speed

1.81 25 93 2.49 25 127 Proportional Reduce 1.20 71 61 3.10 71 158 Reverse

1.80 26 92 2.50 26 127 Proportional Reduce 1.18 72 60 3.12 72 159 Reverse

1.79 27 91 2.51 27 128 Proportional Reduce 1.17 73 60 3.13 73 160 Reverse

1.77 28 90 2.53 28 129 Proportional Reduce 1.16 74 59 3.14 74 160 Reverse

1.76 29 90 2.54 29 130 Proportional Reduce 1.14 75 58 3.16 75 161 Reverse

1.75 30 89 2.55 30 130 Proportional Reduce 1.13 76 58 3.17 76 162 Reverse

1.73 31 88 2.57 31 131 Proportional Reduce 1.12 77 57 3.18 77 162 Reverse

1.72 32 88 2.58 32 132 Proportional Reduce 1.10 78 56 3.20 78 163 Reverse

1.71 33 87 2.59 33 132 Proportional Reduce 1.09 79 56 3.21 79 164 Reverse

1.69 34 86 2.61 34 133 Proportional Reduce 1.08 80 55 3.23 80 164 Reverse

1.68 35 86 2.62 35 134 Proportional Reduce 1.06 81 54 3.24 81 165 Reverse

1.67 36 85 2.63 36 134 Proportional Reduce 1.05 82 53 3.25 82 166 Reverse

1.65 37 84 2.65 37 135 Proportional Reduce 1.03 83 53 3.27 83 167 Reverse

1.64 38 84 2.66 38 136 Proportional Reduce 1.02 84 52 3.28 84 167 Reverse

1.63 39 83 2.67 39 136 Proportional Reduce 1.01 85 51 3.29 85 168 Reverse

1.61 40 82 2.69 40 137 Proportional Reduce 0.99 86 51 3.31 86 169 Reverse

1.60 41 82 2.70 41 138 Proportional Reduce 0.98 87 50 3.32 87 169 Over Travel

1.59 42 81 2.71 42 138 Proportional Reduce 0.97 88 49 3.33 88 170 Over Travel

1.57 43 80 2.73 43 139 Proportional Reduce 0.95 89 49 3.35 89 171 Over Travel

1.56 44 79 2.74 44 140 Proportional Reduce 0.94 90 48 3.36 90 171 Over Travel

1.55 45 79 2.75 45 140 Proportional Reduce

January 2000

RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 72

Section 9.0 MEMORY MAPS Section 9.1 Traction Control

Func No. HS

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

GE IC3645SR4U404N2, IC3645SP4U400N3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual