GE SX Series Installation And Operation Manual

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Page 1

INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL Page 1

SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL

AND SERIES PUMP MOTOR CONTROL

INSTALLATION AND OPERATION MANUAL

(GE Models IC3645SR5W606F1 [software rev. BL3C and higher] and IC3645SP5U600F1)

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

General Electric Company May 2003

Section 1.0 INTRODUCTION .........................................................................................................................................................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 FAMILY OF MOTOR CONTROLLERS .....................................................................................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 Regenerative Braking to Zero Speed.......................................................................6

2.1.3.b Pedal Position Plug Braking..................................................................................... 6

2.1.3.c Auto Braking .............................................................................................................. 6

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

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Table of Contents ( Continued )

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

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

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

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

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

2.1.6 On-Board Coil Drivers and Internal Coil Suppression .................................................7

2.2 System Protective Override......................................................................................................7

2.2.1 Static Return to Off (SRO) ................................................................................................7

2.2.2 Accelerator Volts Hold Off ...............................................................................................7

2.2.3 Pulse Monitor Trip (PMT)................................................................................................. 7

2.2.4 Thermal Protector (TP)................................... ..................................................................7

2.2.5 Low Voltage .......................................................................................................................7

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 .........................................................................................................8

2.3.3.a Maintenance Alert and Speed Limit ....................................................................... 8

2.3.4 Battery Discharge Indication (BDI)................................................................................. 8

2.3.4.a Internal Resistance Compensation ..................... ...........................................................8

2.3.5 Handset ..............................................................................................................................8

2.3.6 RS-232 Communication Port ............................... ............................................................8

2.3.6.a Interactive Dash Display Modes ................... ................................................................8

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 INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS ......................................................10

3.1 Ordering Information for Separately Excited Controls .................................................................10

3.2 Outline: SX-4 and SR-4 Package Size............................................................................................. 11

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

3.4 Traction Elementary.......................................................................................................................... 13

3.5 Pump Elementary...............................................................................................................................14

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

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES ..............................................................................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

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

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

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Table of Contents ( Continued )

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

4.4 Controller Mounting Guidelines.......................................................................................................19

4.4.1 Necessary Tools........................................................................................................................ 19

4.4.2 The GE Control Mounting Surface ..........................................................................................19

4.4.3 Vehicle Mounting Surface........................................................................................................19

4.4.4 Application of Thermal Compound..........................................................................................19

4.4.5 Mounting the GE Control..........................................................................................................20

4.4.6 Maintenance.............................................................................................................................. 20

4.5 General Troubleshooting Instructions............................................................................................ 20

4.6 Traction Controller Status Codes.................................................................................................... 22-39

4.7 TMM Module Status Codes .............................................................................................................39-41

4.8 Pump Control Status Codes .............................................................................................................42-52

Section 5.0 SX FAMILY - GE HANDSET INSTRUCTIONS.......................................................................................................53

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

5.2 Purpose/Setup Functions ...............................................................................................................53

5.3 Setup Function Procedures .............................................................................................................54

5.3.1 Setup Mode ............................................................................................................................... 54

5.3.2 Status Code Scrolling.................................. .............................................................................54

5.3.3 SX Handset Plug Connections & Outline Drawing................................................................54

5.4 Setup Functions for Traction Controller ........................................................................................55-60

5.5 Summary of Current Limit Adjustments..........................................................................................61

5.6 Setup Functions for Hydraulic Pump Controller............................................................................62-64

Section 6.0 AUTO CALIBRATION OF ACCELERATOR POTENTIOMETERS................................................. ........................65

Section 7.0 TRACTION MEMORY MAP......................................................................................................................................66-68

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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 increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses. The motor speed and the back EMF increase, while the armature current and the torque developed decrease. Thus, whenever the load changes, the speed changes also, until the motor is again 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 CURRENT

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, the motor is operated as 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, the armature to field ampere turn

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 CURRENT

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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SX TRANSISTOR CONTROL Page 5

following description provides a brief introduction to examples of some of these features.

Section 1. 2 Solid-State Reversing

The direction of armature rotation on a shunt motor is determined by the direction in which current flows through the field windings. Because of the of the shunt motor field only typically requires about 10% of the armature current at full torque, it is normally cost effective to replace the double-pole, double-throw reversing contactor with a low power transistor H-Bridge circuit (Figure 4).

armature, the motor performance curve can be maximized through proper control application.

Section 1. 4 More Features with Fewer Components

Field weakening with a series wound motor 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 the field weakened, the motor speed will increase, giving the effect of “overdrive”. To change the “overdrive speed”, it is necessary to change

the resistor value. In a separately excited motor, independent control of the field current provides for

LINE

FUSE

CAP

POS

A1 +

ARM

A2 -

F2F1

infinite adjustments of “overdrive” levels, between motor base speed and maximum weak 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 motor will try to maintain a constant speed downhill. This characteristic can be enhanced by increasing the field strength with the 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 direction in the 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, armature rotation 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 braking while maintaining the 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 make available 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 Regenerative Braking to Zero Speed

Slow down is accomplished when reversing direction by providing a small amount of retarding torque for

deceleration. If the vehicle 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 increase until it reaches a preset value set by 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, and part is dumped in the motor as heat.

Section 2.1.3.b Pedal Position Regenerative 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 this function" as the accelerator is returned to the creep speed position. Maximum regen current is obtained with the accelerator in the top speed position.

Section 2.1.3.c 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 speed of the motor. The function is enabled when the armature current is less than the value set by Function 24 and the accelerator input voltage is set for max speed. It is important to note that this function is used to optimize motor and control performance, and this setting will be determined by GE and OEM engineers at the

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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 2.1.5 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 allow the control to initiate full power when 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-travel direction when the ACC pedal is released when stopping on a grade, or when the brake pedal is released when starting on a grade. This feature forces the vehicle to roll very slowly down the 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 On-Board Coil Drivers & Internal Coil Suppression

Coil drivers for the LINE contactor and fan motor are onboard the control card. This contactor must have a coil rated for the vehicle battery volts, and the fan should also be rated for 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 directional lever to the neutral 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 1.8 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 automatically reset, returning the control to full power.

Section 2.2.5 Low Voltage

Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at 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.

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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.

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 48 volts.

Section 2.3.4.a Internal Resistance Compensation

This feature is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the 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) Min Field levels, (4) Field Weakening levels, (4) Ratio levels, and (4) Regen Current Limit levels. These interactive modes are "pre-set" using the Handset (Functions 48-63) or a personal computer (Functions 97-

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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

The Coil drivers are internal to the control card, and are the power devices that operate the Line contactor coil. 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 replaced before they wear to the 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:

· Four speeds, adjustable from O to 100% on.

· Fixed speeds actuated by switch closure to negative.

· Current limit and controlled acceleration adjustable.

· Battery Discharge Indicator interrupt compatible.

· 0 – 100% on, controlled by accelerator voltage (P7).

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 four speed reference points P12, P19, P20 and P21 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 percent on 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.

The fourth speed is obtained by closing SL4 (P21) to control negative. SL4 is adjusted using the Handset and Function 14 similar to SL1.

If more than one Speed Limit is activated, the selected speed with the highest motor volts will override the 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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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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Section 3.2 Outline: SX-4 and SR-4 Package Size

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Section 3.3 Outline: SX-3 and SR-3 Package Size

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Section 3.4 Traction Elementary

P21

P4 P5

P17 P2

P18

NEG

P14

P23P22

MOTOR

TACH SIGNAL

SENSOR INPUT

+12V TACH

P20

P10

P13

TRACTION CONTROL PLUG PL-2

TEMPERATURE

FROM TRACTION

OPEN INPUT OR

SIGNAL DISABLED

VOLTAGE > 3V = BDI

TEMPERATURE INPUT

FROM PUMP CONTROL;

CUSTOMER SUPPLIED

MOTOR CONNECTIONS

CONTROLLER

BDI INTERRUPT TO JOY STICK

ACCEL SWITCH

ARMATURE

2.2K

REV

FWD

BRAKE SWITCH

DIRECT

SEAT SWITCH

SWITCH

PARK BRAKE

SWITCH

FAN

24V

KEY SWITCH

FAN ENABLE

FU1

FIELD

CONNECTION

CONTROL POWER

POS A1 F1

NEG A2 F2

FU3

LINE

FU5

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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SX TRANSISTOR CONTROL Page 14

Section 3.5 Pump Elementary

SPEED 1

SPEED 2

PUMP CONTROL TEMP

ACCEL POT INPUT

P18

FU4

P12

P17

STATUS CODE 93 INPUT

P5P6P8

STATUS CODE 93 INPUT

STATUS CODE 94 INPUT

P19

STATUS CODE 94 INPUT

STATUS CODE 95 INPUT

P15

STATUS CODE 92 INPUT

P21

P20

STATUS CODE 90 INPUT

PUMP CONTROL PLUG PL-2

P13

P16

P14

P11

OVER TEMP OUTPUT

BRUSH WEAR OUTPUT

STATUS CODE 91 INPUT

SPEED 3

SPEED 4

FU2

SUPPLIED BY CUSTOMER

POWER CONNECTION

ARMATURE

PUMP CONTROL

POWER CONNECTION

FIELD

A2N

LINE

CONTACTOR

KEY SW.

BATT (+)

BATT (-)

Revised May 2003

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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

SX TRANSISTOR CONTROL Page 15

Section 3.6 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 -OPTIONAL STATUS CODE 93 INPUT 4 BATTERY VOLTS FROM FORWARD SWITCH -OPTIONAL STATUS CODE 93 INPUT 5 BATTERY VOLTS FROM REVERSE SWITCH -OPTIONAL STATUS CODE 94 INPUT 6 BATTERY VOLTS FROM SEAT SWITCH STATUS CODE 94 INPUT 7 ACCELERATOR INPUT VOLTAGE SIGNAL POTENTIOMETER INPUT VOLTAGE SIGNAL 8 ACCELERATOR NEGATIVE STATUS CODE 95 INPUT

9 ACCELERATOR POT +5 VOLTS SUPPLY STATUS CODE 95 INPUT 10 BDI INTERRUPT PUMP ENABLE SIGNAL 12VDC 11 PLUG/RGN OUTPUT SIGNAL +12V 1=PLUG STATUS CODE 91 INPUT 12 NOT USED SPEED LIMIT #1 INPUT 13 AUX ACCELERATOR INPUT TMM1 BRUSHWEAR INDICATER OUTPUT 14 LINEAR TRACTION MOTOR TEMPERATURE TMM1 OVER TEMPERATURE OUTPUT 15 NOT USED STATUS CODE 92 INPUT 16 NOT USED STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CONTACTOR DRIVER 18 FAN PUMP CONTROL TEMPERATURE 0 = COLD 19 NOT USED SPEED LIMIT #2 INPUT 20 TEMPERATURE FROM PUMP CONTROL SPEED LIMIT #3 INPUT 21 PARK BRAKE (NEG=SL1) SPEED LIMIT #4 INPUT 22 TACH +12V SERIAL RECEIVE 23 TACH INPUT 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 NOT USED NOT USED

8 BWI INPUT/VALUE VALUE

9 OVER TEMP INPUT/FUNCTION FUNCTION 10 NOT USED NOT USED 11 SERIAL RECEIVE / CONNECT TO P22 SERIAL RECEIVE / CONNECT 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

* Pins 3, 4 and 5 These input functions are provided by the accelerator pot input value.

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DIAGNOSTIC STATUS CODES

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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 160 hours of vehicle operation. Inspection is recommended

In dusty

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 period when such failures are attributed to welding while the control is installed in the 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 cable separation and routing practices, consistent with industry standards.

Section 4.2.1 Application Responsibility

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 recommendations for separating the 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:

Revised May 2003

Page 17

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 crossover point.

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 cables, whenever possible.

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 frequency (RF) interference, care should 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 caused by electrical surges.

Revised May 2003

Page 18

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 instructions 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 contains the socket (female)

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

â contact

cleaner “Pow-R-WasH CZ “ as shown in Figure 1.

Figure 1

4. Lubricate each terminal using Nye

â 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

RICA

Figure 2

5. Reconnect plugs.

Reference

Cleaner Chemtronics

â Pow-R-WasH CZ Contact

Cleaner

Lubricant Nye

â Lubricants NYOGELâ 760G

GE Plug Lub Kit Contains both above products: 328A1777G1

Revised May 2003

Page 19

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 19

Section 4.4 Controller Mounting Guidelines

In the design of the GE family of motor controls, performance assumptions were made based on heat transfer between the control and the ambient environment. The vehicle mounting surface acts as a heat sink, which increases the effective surface area for heat dissipation. If this assumed heat transfer is not achieved during control installation and operation, GE controllers will fall short of their anticipated performance. It should be noted that the condition of the mounting surface, and the quality of the resulting interface between the control and the vehicle, can significantly hinder heat transfer from the control. The presence of contaminants, or of air voids created by surface inconsistencies in either the vehicle or the control, degrade the control’s capacity for heat transfer. The control’s performance is de-rated proportionally as its own thermal sensors reduce its operation to protect it from damage due to excessive heating.

Contained within the software of the GE controls are several diagnostic status codes related to controller thermal performance. Failure to follow these mounting recommendations increases the likelihood of encountering these status codes, through no fault of the control itself, thus voiding controller warranty for units returned solely due to the presence of these status codes.

Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs, must be completed during the installation of GE controls. There are many techniques for applying thermal compound, and we have outlined one approach below that has shown to apply a consistent thickness of material.

Section 4.4.1 Necessary Tools

GE recommends the use of the following components, or equivalent substitutions, during the control installation process:

a) Thermal compound, (Dow Corning #340),

maintained per the manufacturer’s recommendations and free of contaminants

b) 3/32” notched trowel, such as a Krusin

adhesive spreader, model 00031

c) Calibrated torque wrench (0 – 15 ft-lbs)

Section 4.4.2 The GE Control Mounting Surface During the manufacture of the GE control, the surface flatness is maintained at 0.005” per linear inch (not to exceed 0.025” per 10.0 inches). The surface finish of the GE control has an R

(average roughness) of 64 (microinches),

or better. This finish is consistent with cold rolled or extruded aluminum.

Care should always be taken in the handling and storage of controllers. The base of the control should be free from nicks, bumps, protrusions or any other foreign object that

would prevent the control from sitting flush with the vehicle mounting surface. Examine the base of the control to verify that it is in good condition and free from damage or contamination.

Section 4.4.3 Vehicle Mounting Surface The quality of the vehicle mounting surface is critical for the optimum heat transfer between the control and the ambient environment. Conduction through the base of the control is the control’s only means of heat rejection. While GE controls are highly efficient, a few percent of the electrical energy will be converted into heat. As previously mentioned, if this energy is not dissipated through the base of the control, a thermal protector will reduce the performance of the control until the temperature stabilizes.

For optimal heat transfer from control to vehicle, the flatness of the vehicle mounting surface should be equivalent to the flatness of the control surface (0.005” per linear inch). Use a straight edge or dial indicator to verify the mounting surface.

The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the vehicle mounting surface. If any of these items are noted, prepare the surface per the following guidelines:

a) Clean the mounting surface with a rotary wire

brush until the metal surface is exposed.

b) Using 80-100 grit emery paper, sand the

surface until the metal shines.

c) Flush the surface clean with an appropriate

liquid de-greaser or parts cleaner.

Section 4.4.4 Application of Thermal Compound

Due to the minute differences in the control mounting surface and the vehicle mounting surface, small pockets of air will be created. These air pockets will add to the overall thermal resistance of the interface.

To avoid these air pockets and improve thermal conductivity, thermal compound must be applied between the GE control base plate and the vehicle mounting surface. The function of this compound is to conform to surface discrepancies, filling gaps and optimizing the metal-tometal contact of the control and the vehicle.

a) Prepare the two mounting surfaces (control

and vehicle) as indicated above.

b) Using a triangular notched trowel of 3/32”

(.09” +/- .01), apply the grease to the vehicle mounting surface.

c) Use straight, non-crossing strokes of the

trowel to apply the compound.

d) Make multiple vertical passes until a uniform

consistency is achieved.

Revised May 2003

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 20

1 4

1 3

Krusin adhesive spreader model 00031

Vehicle surface after proper grease application

Section 4.4.5 Mounting the GE Control a) Place the control unit with desired orientation on

mounting plate with mounting holes aligned.

b) Move the control slightly in all directions to eliminate

voids and enhance the distribution of the thermal compound.

c) Insert the all of the mounting hardware (4, 6 or 8 bolts,

M6 or M8, necessary for the mounting of the respective family of controls).

d) Tighten these bolts (as per sequence shown in

diagrams below) to half of the nominal torque value

(7.5lb-ft).

e) Lastly, tighten the bolts to the nominal torque value (15

lb-ft), following the same sequence.

Calibrated torque wrench for hardware installation

3 2

Proper sequence for use in tightening hardware during

control mounting

Section 4.4.6 Maintenance

If it is necessary to remove the control for service, careful consideration must be given to removing the old thermal compound from the control and mounting surface, prior to replacement of the unit. Never re-use thermal compound. Use a putty knife or similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface. Flush the surfaces with a liquid de-greaser or parts cleaner and allow them to dry, before re-applying the thermal compound and mounting the control. Take care not to contaminate the surfaces with hydraulic fluid or battery acid.

Section 4.5 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.

Revised May 2003

Page 21

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 21

With the status code number, follow the procedures outlined in the status code instruction sheets to determine the problem.

Important Note: Due to the interaction of the logic card 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 numbers referenced in this 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.

Revised May 2003

Page 22

DIAGNOSTIC STATUS CODES

PARK BRAKE SWITCH

SX TRANSISTOR CONTROL Page 22

Section 4.6 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 Display and/or Handset is blank.

POSSIBLE CAUSE

Positive or negative control voltage is not present.

· Insure that the key switch is closed and voltage is present between P1 & battery negative (Power Terminal “NEG”). Also check for voltage between P2 and control negative.

Open circuit between control card AND the Dash Display or Handset.

· Check for an open circuit or loose connection going from the control and the Dash Display or Handset.

Defective Dash Display or Handset.

· Replace Dash Display or Handset.

FU3

FU5

NEG

KEY

SWITCH

TRACTION

STATUS CODE

-01

MEMORY RECALL

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

No brake 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 brake or deadman switch.

· Check to see that the brake switch closes properly.

Open circuit between battery positive and P6.

· Check for loose connections or broken wires:

- Between the brake switch and P6

- Between the key switch and the

battery positive side of the brake switch.

- Between the brake switch and P2.

· On vehicles without a brake/deadman

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

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

DIRECT SWITCH

P4 P5

MOTOR

2.2K 2W

REV

NEG

P21

P14

P23P22

Revised May 2003

Page 23

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 23

TRACTION

STATUS CODE

-02

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Standard truck configuration where the direction is set by accelerator volts –

This status code will be displayed when voltage at P7 is less than 1.9V.

forward direction selected on power up.

MEMORY RECALL

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

SYMPTOM

Control will not operate because of Static Return to Off (SRO) lock out.

POSSIBLE CAUSE

Accelerator calibration is incorrect and it must be recalibrated for a new accelerator pot installation.

24V FAN

ENABLE

KEY SWITCH

FAN

BRAKE SWITCH

SEAT SWITCH

· Repeat the accelerator pot calibration routine outlined in this operating manual

The voltage at P9 is less than 4.2V.

· Measure the accelerator pot to verify that it

reads above 3K ohms. If not, replace the accelerator pot.

Defective control.

· Replace the controller unit.

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

FWD

REV

DIRECT

SWITCH

P4 P5

MOTOR

2.2K 2W

NEG

P21

P14

P23P22

PARK BRAKE SWITCH

-02

MEMORY RECALL

Circuits valid

for

Traction

Controller

Optional truck configuration with directional switch input - 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 Return to Off (SRO) lock out.

POSSIBLE CAUSE

Forward directional switch is closed on initial start up (i.e. closure of battery, key switch or brake 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 insure that it opens when the directional switch is returned to neutral.

Short circuit between B+ and P4.

· Disconnect the wire from P4 and check for positive voltage. Correct source of voltage.

Defective control. Replace the controller unit.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

REV

DIRECT

SWITCH

P4 P5

MOTOR

2.2K 2W

P23P22

P21

P14

NEG

PARK BRAKE SWITCH

Revised May 2003

Page 24

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 24

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-03

MEMORY RECALL

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

Standard truck configuration where direction is set by accelerator volts –

This status code will be displayed when the voltage at P7 is greater than 2.4V.

reverse direction selected on power up.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate because of Static Return to Off (SRO) lock out.

POSSIBLE CAUSE

Accelerator calibration is incorrect and it must be recalibrated for a new accelerator pot installation.

· Repeat the accelerator pot calibration routine outlined in this operating manual

Defective control. Replace the controller unit.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

2.2K 2W

P23P22

P21

P14

NEG

PARK BRAKE SWITCH

-03

MEMORY RECALL

Circuits valid

for

Traction

Controller

Optional truck configuration with directional switch input - reverse

This status code will be displayed when P5 is greater

than 60% of battery voltage at initial key switch on. directional switch is closed on initial power up.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate because of Static Return to Off (SRO) lock out.

POSSIBLE CAUSE

Reverse directional switch is closed on initial start up (i.e. closure of battery, key switch or brake/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 insure

that it opens when the directional switch is returned to neutral.

Short circuit between B+ and P5.

· Disconnect the wire from P5 and check for a

voltage in the wire that was connected to P5. If voltage is measured, locate and correct its source.

Defective control. Replace the controller unit.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

Revised May 2003

Page 25

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 25

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-06

MEMORY RECALL

Circuits valid

for

Traction

Controller

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 accelerator pedal is released.

Defective directional switch

· Check forward or reverse switch to insure closure when direction is selected.

Open circuit between directional switch(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

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

TRACTION

STATUS CODE

-07

MEMORY RECALL

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Accelerator voltage is too high. This status code will be displayed when the

accelerator voltage 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

· Status code is possible if Function 11 is set to a value in excess of 200 while SL1 is activated.

ACC POT

Revised May 2003

Page 26

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 26

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-09

MEMORY RECALL

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

Optional truck configuration - 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-adjusted to be held closed.

· Replace or adjust directional switches to insure that they open when directional switch is returned to neutral.

Short circuit between battery positive and P4 and/or P5.

· Disconnect wires from P4 and P5 and check 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

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

2.2K 2W

P23P22

P21

P14

NEG

PARK BRAKE SWITCH

-11

MEMORY RECALL

Circuits valid

for

Traction

Controller

Accelerator volts too low on power up. This status code will be displayed when accelerator

volts are less than 1.7V at P7.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective accelerator pot.

· Measure the voltage from P9 to NEG. Voltage should be between 4 to 4.8 volts. If not, disconnect the wire from P9. Measure the voltage from P9 to NEG. This voltage should be greater than 4 volts; if not, replace the control.

· Disconnect wire from P7. Measure

voltage from the wire removed from P7 to NEG. Voltage should be greater than 1.9V, if not, replace accelerator pot.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

P23P22

Revised May 2003

P21

P14

2.2K 2W

NEG

PARK BRAKE SWITCH

Page 27

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 27

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-12

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

One or both accelerator pots are defective when the control is configured for dual pot input.

This status code will be displayed when the sum of the voltages of the two pots is greater than 5V or less than 4V.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective accelerator pot.

· Measure the voltage from P9 to P8.

Voltage should be between 4 to 4.8 volts. Voltage from P7 to NEG should be approximately 2.14 V. Connect the voltmeter from P7 to P13. The voltage measured should equal 0 to +/- 0.25V. Connect the voltmeter to the wire removed from P7. Connect the voltmeter negative to the wire removed from P13. The voltmeter should read greater than 4V, but less than 5V. If not, the potentiometer.

replace

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT

SWITCH

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

2.2K 2W

P23P22

P21

P14

NEG

PARK BRAKE SWITCH

-15

MEMORY RECALL

Circuits valid

for

Traction

Controller

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 cell). Replace or repair battery.

Incorrect control card adjustment.

· Check Function 15 for proper adjustment for battery being used. See Handset instruction sheet for details. Adjust to proper settings.

Check “minimum” battery volts at P1 and NEG.

FU5

NOMINAL BATTERY

VOLTAGE

NEG

MINIMUM

LIMIT VOLTS

AT 1.95 VDC

PER CELL

23.4

35.1

46.8

70.2

78.0

Revised May 2003

Page 28

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 28

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 card adjustment Check Function 15 for proper adjustment for battery being used. See Handset instructions for details. Adjust to proper setting.

Battery over charged or incorrect battery used.

· Check battery for proper open circuit voltage per table at right. If voltage is excessive, check battery charger for proper output voltage.

Check “maximum” battery volts at P1 and NEG.

FU5

NOMINAL BATTERY VOLTAGE

NEG

MAXIMUM LIMIT VOLTS AT 1.95 VDC

PER CELL

23.4

35.1

46.8

70.2

78.0

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 (greater than 1.1V) at start up in the reverse direction.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective control.

· Replace controller unit.

NO GRAPHIC FOR THIS

STATUS CODE

Revised May 2003

Page 29

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 29

TRACTION

STATUS CODE

-24

MEMORY RECALL

Circuits valid

for

Traction

Controller

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 (greater than 1.1V) at start up in the forward direction.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective control.

· Replace controller unit.

NO GRAPHIC FOR THIS

STATUS CODE

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 charge. Voltage may be dropping below 10 Volts DC under load.

Loose connection at P1.

· Insure that the wire connection at P1 is tight.

Defective control.

· Replace controller unit.

FU3

FU5

NEG

KEY

SWITCH

Revised May 2003

Page 30

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 30

TRACTION

STATUS CODE

-28

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

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 in the motor field is sustained above a preset limit for longer than 70 seconds.

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.

Function 7 is mis-adjusted to allow higher than normal motor field current.

· Adjust function per OEM

instructions.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A

CONTROL ISSUE. IF FUNCTION 7 IS NOT

MIS-ADJUSTED, THE STATUS CODE INDICATES AN APPLICATION ISSUE

WHERE A MOTOR IS BEING STALLED,

ETC. DISPLAY OF THIS STATUS CODE

SHOULD NOT TRIGGER THE RETURN OF

A CONTROL FOR REPAIR OR

REPLACEMENT.

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-41

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

Open thermal protector (TP) or transistor over temperature.

This status code will be displayed when the voltage at the thermal protector is too high.

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.

THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A

CONTROL ISSUE. THE STATUS CODE

MAY INDICATE AN APPLICATION ISSUE

WHERE A MOTOR IS BEING STALLED,

ETC. DISPLAY OF THIS STATUS CODE

SHOULD NOT TRIGGER THE RETURN OF

A CONTROL FOR REPAIR OR

REPLACEMENT.

Revised May 2003

Page 31

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 31

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-42

MEMORY RECALL

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

Motor armature offset voltage is too high.

This status code will be displayed when the voltage at the current sensor input is greater than 2.7 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.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

FWD

SEAT SWITCH

P4 P5

MOTOR

REV

DIRECT SWITCH

P23P22

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

P21

P14

2.2K 2W

NEG

PARK BRAKE SWITCH

-43

MEMORY RECALL

Circuits valid

for

Traction

Controller

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.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

REV

DIRECT SWITCH

P4 P5

MOTOR

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

Revised May 2003

Page 32

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 32

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-44

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

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.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

REV

DIRECT SWITCH

P4 P5

MOTOR

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

-45

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

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.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

REV

DIRECT SWITCH

P4 P5

MOTOR

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

Revised May 2003

Page 33

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 33

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-46

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

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

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

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Line contactor will not pick up.

POSSIBLE CAUSE

Check for short circuit from the motor armature to the frame of the vehicle.

Defective control.

· Replace controller unit.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

FWD

SEAT SWITCH

P4 P5

MOTOR

REV

DIRECT SWITCH

P23P22

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

P21

P14

2.2K 2W

NEG

PARK BRAKE SWITCH

-49

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

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.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

FWD

REV

DIRECT SWITCH

P4 P5

MOTOR

2.2K 2W

PARK BRAKE SWITCH

NEG

P21

P14

P23P22

Revised May 2003

Page 34

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 34

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-51

MEMORY RECALL

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

Capacitor volts are low before the line contactor closes.

This status code will be displayed during “key on” when the capacitor volts is less than 50% of battery volts at initial key switch on.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Line contactor does not close when capacitor does not precharge.

POSSIBLE CAUSE

Defective control fuse.

· Check control fuse for open circuit. Replace fuse, if necessary.

Defective control.

· Replace controller unit.

FU3

24V

LINE

FAN ENABLE

FU1

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

FU5

KEY SWITC H

FAN

ACCEL

SWITCH

P18

FIELD

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

P17 P2

P13

ARMATURE

-57

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

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.

NO GRAPHIC FOR THIS

STATUS CODE

Revised May 2003

Page 35

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 35

TRACTION

STATUS CODE

-64

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.

MEMORY RECALL

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

-Open wire connection to Pin 17

- Shorted line Driver transistor

Defective control.

· Replace controller unit.

FU3

24V

LINE

FAN ENABLE

FU1

FU5

KEY SWITC H

FAN

ACCEL

SWITCH

P18

P17 P2

P13

TRACTION

STATUS CODE

-65

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

FIELD

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

The line coil or fan current is too high during the run mode.

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.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

- Shorted line contactor coil

- Short between wires connected to

line coil

If line coil resistance is correct: Defective control.

· Replace controller unit.

FU3

24V

LINE

FAN ENABLE

FU1

FU5

KEY SWITCH

FAN

ACCEL

SWITCH

P18

ARMATURE

P17 P2

P13

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

FIELD

ARMATURE

Revised May 2003

Page 36

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 36

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-66

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

The field current exceeds the current limit of the field transistor.

This status code will be displayed when the field transistor exceeds its specific current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

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-)

FU3

24V

LINE

FAN ENABLE

FU1

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

FU5

KEY SWI TCH

FAN

ACCEL

SWITCH

P18

FIELD

ARMATURE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

P17 P2

P13

-67

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

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.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

· Shorted motor armature A1 to A2

· Power cables may be shorted to

each other (Measure at control terminals)

· A1 to A2 terminals may be shorted to battery positive or negative

FU3

24V

LINE

FAN ENABLE

FU1

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

FU5

KEY SWITCH

FAN

ACCEL

SWITCH

P18

FIELD

P17 P2

P13

ARMATURE

Revised May 2003

Page 37

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 37

TRACTION

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

The fan driver current is too high. This status code will be displayed when the current in

-69

the fan driver circuit 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

TRACTION

STATUS CODE

-71

MEMORY RECALL

SYMPTOM

Control will not operate.

FU3

POSSIBLE CAUSE

· Shorted fan driver coil

· Short between wires connecting to

the fan driver coil.

FU5

LINE

24V

FAN ENABLE

If the fan driver coil resistance is correct, then:

· Defective control. Replace

controller unit.

FU1

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Accelerator potentiometer out of range (for single accelerator potentiometer operation).

This status code will be displayed when the voltage at P7 is greater than 4.13V or less than 0.196V.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

KEY SWITCH

FAN

ACCEL

SWITCH

P17 P2

P13

ARMATURE

P18

FIELD

YES

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

· Defective accelerator pot.

· Measure the voltage from P9 to

NEG. It should be between 4.0 to

4.8V. If it is, replace the accelerator pot.

· If the voltage from P9 to NEG is not

between 4.0 to 4.8V, remove the wire from P9 and measure the voltage at P9. It should be between 4.0 to

4.8V. If it is not, replace the control.

FU3

FU5

FAN ENABLE

LINE

POS A1 F1

NEG A2 F2

KEY SWITC H

FAN

24V

FU1

CONTROL POWER

CONNECTION

ACCEL

SWITCH

P18

P17 P2

P13

FIELD

ARMATURE

Revised May 2003

Page 38

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 38

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

-76

MEMORY RECALL

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

the capacitor goes above limit voltage* during the regenerative braking cycle.

YES

Circuits valid

for

Traction

Controller

TRACTION

STATUS CODE

SYMPTOM

Line contactor opens and closes, then

FU3

opens and can only close by opening and closing the key switch.

POSSIBLE CAUSE

· Unplugging the battery connector

FU5

LINE

24V

FAN ENABLE

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

FU1

POS A1 F1

CONTROL POWER

CONNECTION

NEG A2 F2

70V 48V 96V 72/80V

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

KEY SWITCH

FAN

ACCEL

SWITCH

P17 P2

P13

ARMATURE

P18

FIELD

-77

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

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

FU3

24V

LINE

FAN ENABLE

FU1

POS A1 F 1

CONTROL POWER

CONNECTION

NEG A2 F2

FU5

KEY SWITCH

FAN

ACCEL

SWITCH

P18

FIELD

P17 P2

P13

ARMATURE

Revised May 2003

Page 39

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 39

TRACTION

STATUS CODE

-81

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Tachometer signal is lost. This status code will be displayed when the input at

P23 is lost.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Truck regens and will not plug, and status code 81 is displayed on dash.

POSSIBLE CAUSE

Lost input at P23.

· Verify wiring at P23 from

tachometer.

Defective tachometer.

· Replace tachometer unit.

Defective control.

· Replace controller unit.

KEY SWITCH

24V

FAN

ENABLE

ACCEL

SWITCH

BDI INTERRUPT TO JOY

STICK CONTROLLER

P18

TRACTION CONTROL PLUG PL-2

P13

BRAKE SWITCH

P17 P2

P10

P20

+12V TACH

TACH SIGNAL

TEMPERATURE SENSOR

INPUT FROM TRACTION

TEMPERATURE INPUT FROM

PUMP CONTROL; OPEN INPUT

OR VOLTAGE > 3V = BDI

SIGNAL DISABLED

SEAT SWITCH

P4 P5

MOTOR

FWD

REV

DIRECT SWITCH

2.2K 2W

P21

P14

P23P22

NEG

PARK BRAKE SWITCH

TRACTION

STATUS CODE

-82

MEMORY RECALL

YES

Circuits valid

for

Traction

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Traction motor is stalled. This status code will be displayed when the MPH is

less than the value of setting of Function 16 and the I is greater than 370A for 3.5 seconds.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

The control will not operate and can only be reset by cycling the accelerator.

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

o Adjust function per OEM

instructions

THE PRESENCE OF THIS STATUS CODE SI NOT NECESSARILY INDICATIVE OF A

CONTROL ISSUE. IF FUNCTION 16 IS

NOT MIS-ADJUSTED, THE STATUS CODE

INDICATES AN APPLICATION ISSUE

WHERE A MOTOR IS BEING STALLED,

ETC. DISPLAY OF THIS STATUS CODE

SHOULD NOT TRIGGER THE RETURN OF

A CONTROL FOR REPAIR OR

REPLACEMENT.

Revised May 2003

Page 40

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 40

Section 4.7 TMM Codes

TRACTION

STATUS CODE

-92

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 greater than 2.5V.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Status code flashes “on and off”.

POSSIBLE CAUSE

User defined status code is displayed by switch closure to battery negative.

Plug P11 (pump) is shorted to battery negative.

Defective input switch (shorted).

Defective TMM card.

Defective pump card.

P11

WHEN SR Series PUMP

CONTROL IS USED

USER SW

NEG

SC91

TRACTION

STATUS CODE

-93

MEMORY RECALL

YES

Circuits valid

for

Steer 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 code is displayed by motor brush sensor closure to battery positive.

Plug P3 (pump) is shorted to positive.

Defective input switch (shorted).

Defective TMM card.

Defective pump card.

WHEN SR Series PUMP

CONTROL IS USED

USER SW

POS

SC93

Revised May 2003

Page 41

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 41

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 code is displayed by motor brush sensor closure to battery positive.

Plug P5 (pump) is shorted to positive.

Defective input switch (open).

Defective TMM card.

Defective pump card.

WHEN SR Series PUMP

CONTROL IS USED

USER SW

4.7K 2W

NEG

POS

SC94

TRACTION

STATUS CODE

-98

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 P14 is greater than 1.15 V.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Status code flashes “on” and ‘off”.

POSSIBLE CAUSE

Defective motor thermistor. Resistance is greater than 1400 ohms

Measure the voltage from P14 to NEG. This voltage should be greater than 1.15V. If not, the thermistor is defective.

Cold = 25 Hot = 155

C = 750 ohms

C = 1400 ohms

P14

WHEN SX Sep Ex

TRACTION

CONTROL IS USED

TRACTION

MOTOR

THERMISTOR

NEG

SC90

Revised May 2003

Page 42

DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL Page 42

TRACTION

STATUS CODE

-99

MEMORY RECALL

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

YES

Circuits valid

for

Traction

Controller

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 SELECTED SETTING WITH THE HANDSET:

User defined status code is 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 display of status code -

99.

· If desired, Maintenance Code Speed Limit, Function 13, can be programmed with the Handset.

User should perform the desired maintenance function. Re-set maintenance alert hour meter after maintenance is performed.

NO DIAGRAM

USER SHOULD PERFORM THE DESIRED

MAINTENANCE FUNCTION

Revised May 2003

Page 43

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 43

Section 4.8 Pump Control Codes

PUMP

STATUS CODE

-101

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

“SPEED 1” switch closed with the key turned off.

This status code will be displayed when the “SPEED 1” switch closes while the key switch is turned off.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

“SPEED 1” switch is closed or shorted to battery negative.

· Verify connections at P12 and

Battery negative. Replace switch, if necessary

SX-2

BATT

NEG

7 12 19

20 21

PLUG PL2

CONTROL

SPEED 4

SPEED 2

SPEED 3

SPEED 1

SWITCH

ACCELERATOR

PUMP

STATUS CODE

-102

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

“SPEED 2” switch closed with the key turned off.

This status code will be displayed when the “SPEED 2” switch closes while the key switch is turned off.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

“SPEED 2” switch is closed or shorted to battery negative.

· Verify connections at P19 and

Battery negative. Replace switch, if necessary

SX-2

BATT

NEG

7 12 19

20 21

PLUG PL2

CONTROL

SPEED 4

SPEED 2

SPEED 3

SPEED 1

SWITCH

ACCELERATOR

Revised May 2003

Page 44

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 44

PUMP

STATUS CODE

-103

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

“SPEED 3” switch closed with the key turned off.

This status code will be displayed when the “SPEED 3” switch closes while the key switch is turned off.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

“SPEED 3” switch is closed or shorted to battery negative.

· Verify connections at P20 and

Battery negative. Replace switch, if necessary.

SX-2

BATT

NEG

7 12 19

20 21

PLUG PL2

CONTROL

SPEED 4

SPEED 2

SPEED 3

SPEED 1

SWITCH

ACCELERATOR

PUMP

STATUS CODE

-104

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

“SPEED 4” switch closed with the key turned off.

This status code will be displayed when the “SPEED 4” switch closes while the key switch is turned off.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

“SPEED 4” switch is closed or shorted to battery negative.

· Verify connections at P21 and

Battery negative. Replace switch, if necessary

SX-2

BATT

NEG

7 12 19

20 21

PLUG PL2

CONTROL

SPEED 4

SPEED 2

SPEED 3

SPEED 1

SWITCH

ACCELERATOR

Revised May 2003

Page 45

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 45

PUMP

STATUS CODE

-117

MEMORY RECALL

Circuits valid

for

Pump

Controller

PUMP

STATUS CODE

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.

GRAPHIC

· Review function 17 in the Handset Instruction sheets. Adjust and set card type value as instructed by OEM service manual.

STATUS CODE

FOR THIS

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-123

MEMORY RECALL

Circuits valid

for

Pump

Controller

Pump line contactor coil current is low. This status code will be displayed when the current

draw in the pump line contactor coil circuit is less than 100 milliamps and A2 is less than 88% of battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Pump contactor will not pick up. Status code may vary between code 123 and code 124.

POSSIBLE CAUSE

Defective pump contactor coil circuit.

· Check for open circuit or loose connection between P17 and positive side of P line contactor coil.

· Check ohmic value from P17 to positive side of P line coil. Value should be between 10 and 14 ohms.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

FIELD

SPEED 2

SPEED 3

SPEED 4

Revised May 2003

SPEED 1

Page 46

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 46

PUMP

STATUS CODE

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-124

MEMORY RECALL

Circuits valid

for

Pump

Controller

A2 voltage is low (less than 88% of battery volts).

This status code will be displayed when the A2 voltage is less than 88% of battery volts and the pump line driver is energized.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Control does not operate. Status code may vary between code 123 and code 124. Complete checks for code 124 and, if the problem is not found, perform checks for code 123.

POSSIBLE CAUSE

Defective pump line contactor. Contactor power tips are failing to close due to:

· Binding contactor tip assembly.

· Defective pump contactor coil (see status

code 123).

Open motor circuit

· Check for open circuit or loose

connection in the pump motor circuit from the A1 connection to the A2 connection on the control.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

FIELD

SPEED 3

SPEED 4

SPEED 2

SPEED 1

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

P18

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

FIELD

SPEED 3

SPEED 4

PUMP CONTROL TEMP

SPEED 2

SPEED 1

Revised May 2003

Page 47

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 400A 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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

P18

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

FIELD

SPEED 3

SPEED 4

PUMP CONTROL TEMP

SPEED 2

SPEED 1

PUMP

STATUS CODE

-141

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Open thermal protector (TP1) or transistor is over temperature.

This status code is displayed when the voltage at the thermal protector is greater than 2.3 volts.

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

Revised May 2003

SPEED 2

SPEED 1

Page 48

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 48

PUMP

STATUS CODE

-142

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Pump Controller “motor current sensor” input is missing.

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

PUMP

STATUS CODE

-143

MEMORY RECALL

Circuits valid

for

Pump

Controller

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

Revised May 2003

Page 49

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 49

PUMP

STATUS CODE

-144

MEMORY RECALL

YES

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Power Transistor (Q1) did not turn off properly.

This status code is displayed when, during pump control operation, the transistor fails to turn off. This will result in a PMT condition.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

With no pump contactor, control may run continuously.

POSSIBLE CAUSE

Control is defective.

· Replace controller unit.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

PUMP

STATUS CODE

-145

MEMORY RECALL

YES

Circuits valid

for

Pump

Controller

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

Revised May 2003

Page 50

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 A2 volts less than 12% of battery volts.

This status code will be displayed when the voltage at A2 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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

PUMP

STATUS CODE

-148

MEMORY RECALL

YES

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

“Look Ahead” test for A2 volts greater than 88% of battery volts.

This status code will be displayed when the voltage at A2 is greater than 88% of battery volts.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Pump line contactor will not pick up.

POSSIBLE CAUSE

Defective pump contactor.

· Check for welded pump contactor power

tips.

· Check for sluggish operation of pump contactor.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

Revised May 2003

Page 51

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 51

PUMP STATUS

CODE

-150

MEMORY RECALL

YES

Circuits valid

for

Pump

Controller

PUMP STATUS

CODE

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.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 2

SPEED 3

SPEED 4

SPEED 1

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

-151

MEMORY RECALL

Circuits valid

for

Pump

Controller

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 voltage 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 loads to the load side of the line contactor.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

Revised May 2003

Page 52

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 52

PUMP

STATUS CODE

-157

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Controller “motor current sensor” input voltage polarity check.

This status code will be displayed when the voltage input to motor current sensor is of the wrong polarity.

CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM

SYMPTOM

Pump control will not operate.

POSSIBLE CAUSE

Control is defective.

· Replace controller unit.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

SPEED 2

SPEED 1

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 controlled by traction control). Line Contactor opened up during run.

· Check connection from P17 to Line coil () for loose connection.

· Check connection from battery (+) to Line coil (+) for loose connection.

· Check power connection from battery (+) to contactor L.

· Check for blown fuse at pump control.

· Check for dirty contactor tips.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 3

SPEED 4

Revised May 2003

SPEED 2

SPEED 1

Page 53

DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL Page 53

PUMP

STATUS CODE

-181

MEMORY RECALL

Circuits valid

for

Pump

Controller

DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Battery voltage is less than 14 volts. This status code will be displayed when the battery

voltage measured at P1 is less than 14 volts.

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.

· Check connection from control fuse to pump P1 for loose connections.

KEY SW.

BATT (+)

LINE

CONTACTOR

BATT (-)

FU4

FU2

PUMP CONTROL

POWER CONNECTION

POWER CO NNECTION

SUPPLIED BY CUSTOMER

P17

ARMATURE

FIELD

P18

PUMP CONTROL TEMP

ACCEL POT INPUT

P12

P19

P20

PLUG PL-2

P21

PUMP CONTROL

SPEED 2

SPEED 3

SPEED 4

SPEED 1

Revised May 2003

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ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS Page 54

Section 5. SX FAMILY GE HANDSET

START-UP DISPLAY SEQUENCE

INSTRUCTIONS

Section 5.1 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 5.2 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

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 instructions could result 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

Traction Hourmeter

For Two Seconds, Display

Seat Hourmeter

Seconds

Display

Pump Hourmeter

For Four Seconds

for Two

Active

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Section 5.3 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 mode, ready to monitor or adjust control function settings.

NOTE: The term “Push” means to depress key for approximately one second.

reading at the time the fault occurred. The first of the 16 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.

ACCESSING STORED STATUS CODES

WITH GE HANDSET

Section 5.3.1 Setup Mode

Key Switch Off

SET-UP MODE

ACTION

Hold Down CONT

And Turn On Key

Push Function Number

After One Second

Time Delay

Push CONT

DISPLAY

SHOWS

8 8 8 8

U 0 0 5

0 8 5

REMARKS

Segment Check

Displayed

Selected Function No.

Is Displayed

Stored Value For The Function Is Displayed

Display Value

Will Blink

Push ESC and CONT

At The Same Time

Release ESC and CONT

Key

Status Code Displayed

Push CONT Key

Displays Battery

State-Of-Charge When

Fault Occurred

Push ESC to

Erase Stored

Data

Push ESC to

Erase Stored

Data

Hold Both the

ESC and CONT

Keys Down to

Erase All 16

Stored Codes

Change Value With

Adjustment Knob

Push STORE

Push ESC

125

8 8 8 8

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 5.3.2 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

Push CONT Key

Display Hourmeter Reading

When Fault Occurred

Push CONT Key

Push ESC to

Erase Stored

Data

Section 5.3.3 SX Family Handset, Plug Connections and Outline Drawing

“Y” Plug

Handset Cable Part Number - 325B1002G1

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Important Note: This function is used to optimize motor

HANDSET

CONT

STORE

EVC

+ +

Section 5.4 Setup Functions for Traction Controller

FUNCTION 1 MILE PER HOUR SCALING

This function is used in conjunction with a tachometer to determine the speed of the vehicle. The following equation should be used to determine the appropriate setting for this function:

Set = 10 x 3600 x 2 x Pi x RR 5280 x 12 x PPR x 0.010

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 accelerator ohm input between 6K and 4.0K ohms is provided.

Range 2% to 15% on time Set 0 to 255 Resolution 0.05% per set unit Example: Setting of 20 = 3% on time

ESC

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 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

FUNCTION 4 SPEED REGULATION/DECREASING

FIELD

(Push 4)

This function allows for the adjustment of over speed regulation. It allows the user to set the rate at which the field current is decreased when the vehicle speed is less than the over speed limit.

Range 0.0015 to 0.383 seconds Set 0 to 255 Resolution 0.0015 seconds/unit Example: (20 x 0.0015) + 0.0015 = 0.032 sec

FUNCTION 5 POTENTIOMETER/DIRECTIONAL

SWITCH CALIBRATION

( Push 5 )

This function allows the user to alternate between the standard configuration of the truck (with control via the accelerator potentiometer) or the optional configuration of the truck (with control via the directional switches).

Set Mode Control Via

16 to 32 Standard Accelerator potentiometer

144 to 160 Optional Directional switches

FUNCTION 6 MPH BL3C SPEED LIMIT

( Push 6 )

This function is adjusts the value of the over speed limit of the control.

Resolution 1 set unit = 0.1 MPH Example Setting of 100 = 10 MPH

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ADJUSTABLE FEATURES

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FUNCTION 7 MIN FIELD CURRENT ( Push 7 )

This function allows the adjustment of the field weakening level in order to set the top speed of the motor.

Resolution Volts Min Max Set Per unit value 36/48 0 60 51 to 255 .314

MIN I

= (VAL-51) X .314 (36/48 VOLT)

Important Note: This function is used to optimize motor and control performance, and this setting will be determined by GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of the OEM.

FUNCTION 8 OVER SPEED RESPONSE TIME ( Push 8 )

This function allows for the adjustment of the rate at which field current increases in an over speed condition.

Resolution 1 set unit = 0.001 seconds Example Setting of 100 = 0.1 second

FUNCTION 9 REGEN BRAKING C/L (Push 9)

This function allows for the adjustment of the regen braking current limit; the higher the current, the shorter the stopping distance.

Resolution Example Volts Min Max Set Per unit value If set at 20 36/48 183A 597A 0 to 255 (1.625 x

215 amp

setting) + 183

REGEN BRAKE I

= (VAL X 1.625) + 183 at 36/48 VOLTS

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.

Range 0 to 64 amps Set 51 to 255 Resolution (VAL – 51) x 0.314 Example: Setting of 200 = 47 amps

FUNCTION 11 MAINTENANCE AND LOST TACH SPEED

LIMIT or PARK BRAKE SWITCH CLOSED

(Push 11)

This function allows for the adjustment of the motor speed limit (maximum battery volts to the motor) when the tach signal is lost, or a status code –81 appears on the dash display.

Range 100% to 0% battery volts Set 51 to 163 Resolution 0.89% per set unit Example Setting of 71 = (163 – 71) x .89 = 82%

FUNCTION 12 MAX PERCENT ON ( Push 12 )

This function is always active and allows for the adjustment of maximum armature volts, as a percentage of the battery voltage.

Range 100% to 0% battery volts Set 51 to 163 Resolution 0.89% per set unit Example Setting of 71 = (163 – 71) x .89 = 82%

FUNCTION 13 SPEED LIMIT 3 ( Push 13 )

The SL3 set speed limit is activated by status code 98, indicating an overheated traction motor.

Range 100% to 0% battery volts Set 51 to 163 Resolution 0.89% per set unit Example Setting of 71 = (163 – 71) x .89 = 82%

FUNCTION 14 INTERNAL RESISTANCE COMPENSATION ( 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 calculated by the following method. This function can be changed by the dash display mode selection button.

1. On a fully charged battery, record the open circuit

voltage (Vo) by measuring the voltage at the control positive and negative power terminals.

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ADJUSTABLE FEATURES

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2. Load the traction motor to 100 amps in 1A and record the voltage (V

) at the control positive and negative power

terminal.

3. Calculate voltage drop (V V

= VO - VL

Drop

) as follows:

Drop

4. Use the table below to determine the appropriate setting 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:

Battery volts Set units

36 volts Between 32 and 44 48 volts Between 45 and 69 No BDI Between 251 and 255

FUNCTION 16 STALL MPH ( Push CONT 2 )

This function allows for the adjustment of the traction motor stall point.

VAL x 0.1 = MPH

Example: Setting of 10 = 10 x 0.1 = 1.0 MPH

FUNCTION 17 CARD TYPE SELECTION ( Push CONT 2 )

This function allows for the selection of the card type used for your vehicle's application. This function should be set at a value of 54.

Setting Scale

50 - 54 MPH 55 - 59 KPH

Warning: These settings must be changed by authorized personnel only, following instructions supplied by the 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 LINE CONTACTOR DROP OUT DELAY

( Push CONT 3 )

This function allows for the adjustment of the time delay for the line contactor drop out.

(VAL x 0.5) + 1.5 = seconds before contactor drop out

Example: Setting of 10 = (10 x 0.5) + 1.5 = 6.5 seconds

FUNCTION 19 MAINTENANCE CODE TENS AND UNITS

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 OPEN.

( 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

HOURS SET

Hours

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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.

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 when the accelerator is released.

AUTO REGEN

C/L AMPS

FUNCTION 23 PLUG/REGEN TRANSITION POINT ( Push CONT 8)

This function allows for the adjustment of the vehicle speed at which the vehicle transitions from regen braking to plug braking.

Example: Setting of 30 = 30 x 0.1 = 3.0 MPH

FUNCTION 24 FIELD WEAKENING START ( Push CONT 9)

This function allows for setting the armature current at which minimum field current will be achieved.

Range 0 to 414 Amps Setting 0 to 255 Resolution 1.625 per set unit I

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

REGEN C/L

VAL

VAL x 0.1 = MPH

FWS = VAL. x 1.625

MOTOR

99 Hours

FNT 21-51

[(

VAL

(

6.50

[

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 RATIO ( Push CONT 11)

This function sets the ratio between armature and field current when operating below the maximum field current and above the Field Weakening Start point. The setting represents the quantity of field current changed for each 1 amp of armature current changed.

Volts Max Change Set Resolution

36/48 .48 0 to 40 .024

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.

DASH DISPLAY INTERACTIVE MODES

The following functions (functions 48 through 62) are mode settings that are activated from the Interactive Dash Display. Each function must be set using the logic table shown below. If you try to set this function outside these guidelines, an error code will be displayed to prompt you to enter the correct setting: If “80” is displayed, the setting is too low. If “81” is displayed, the setting is too high.

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ADJUSTABLE FEATURES

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This RATIO takes effect when the Mode 1 settings are

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 MIN FIELD ( Push CONT 1)

This function allows the adjustment of the field weakening level in order to set the top speed of the motor.

Resolution Volts Min Max Set Per unit value 36/48 0 60 51 to 255 .314

MIN I

= (VAL-51) X .314 (36/48 VOLT)

This MIN FIELD takes effect when the Mode 1 settings are called for by the interactive Dash Display .

FUNCTION 49 MODE 1 FIELD WEAKENING START ( Push CONT 2)

This function allows for setting the armature current at which minimum field current will be 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 the Mode 1 settings are called for by the interactive Dash Display.

FUNCTION 50 MODE 1 RATIO ( Push CONT 3 )

Volts Max Change Set Resolution 36/48 .48 0 to 40 .024

called for by the interactive Dash Display.

FUNCTION 51 MODE 1 MPH LIMIT ( Push CONT 4)

This function allows for the adjustment of the traction MPH limit, to limit the achievable top speed of the truck.

VAL x 0.1 = MPH.

This MPH LIMIT takes effect when the Mode 1 settings are called for by the interactive Dash Display.

FUNCTION 52 MODE 2 MIN FIELD ( Push CONT 5)

Same as Function 48.

This MIN FIELD 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 2 RATIO ( Push CONT 7 )

Same as Function 50.

This RATIO takes effect when the Mode 2 settings are called for by the interactive Dash Display.

FUNCTION 55 MODE 2 MPH LIMIT ( Push CONT 8 )

Same as Function 51.

This MPH LIMIT takes effect when the Mode 2 settings are called for by the interactive Dash Display.

FUNCTION 56 MODE 3 MIN FIELD ( Push CONT 9)

Same as Function 48.

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This MIN FIELD 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.

This FIELD WEAKENING START takes effect when the Mode 3 settings are called for by the interactive Dash Display.

FUNCTION 58 MODE 3 RATIO ( Push CONT 11 )

Same as Function 50.

This RATIO takes effect when the Mode 3 settings are called for by the interactive Dash Display.

FUNCTION 59 MODE 3 MPH LIMIT ( Push CONT 12 )

Same as Function 51.

This MPH LIMIT takes effect when the Mode 3 settings are called for by the interactive Dash Display.

FUNCTION 60 MODE 4 MIN FIELD ( Push CONT 13)

Same as Function 48.

This MIN FIELD 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 the Mode 4 settings are called for by the interactive Dash Display.

FUNCTION 62 MODE 4 RATIO ( Push CONT 15 )

Same as Function 50.

This RATIO takes effect when the Mode 4 settings are called for by the interactive Dash Display.

FUNCTION 63 MODE 4 MPH LIMIT ( Push CONT ESC )

Same as Function 51.

This MPH LIMIT takes effect when the Mode 4 settings are called for by the interactive Dash Display.

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Section 5.5 Summary of Current Limit Adjustments

The

maximum field current

amps (nominal). The

the control is set at 600 amps, at 50% on-time

(nominal). Together, these values determine the

of the control is set at 63

maximum armature current

maximum torque of the motor.

MAXIMUM

The

" ratio"

setting is adjusted by Function

26. This function sets the ratio between

armature and field current when transitioning

from minimum field to maximum field current.

Setting is the value of field current changed for

each 100 amps of armature current changed.

ZERO

FIELD CURRENT

setting is adjusted by Function 24.

ZERO

The

" minimum field

current"

adjusted by Function 7. The function sets the top speed of the motor.

The

" field weakening start "

This function sets the armature

current at which minimum field

setting is

current will achieved .

The maximum field current of the control is set at

current of the control is set at 600 amps, at 50%

ARMATURE CURRENT

The

"full load transition point"

of this control is set at 500A..

63 amps (nominal). The maximum armature

on-time (nominal). Together, these values

determine the maximum torque of the motor.

MAXIMUM

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Section 5.6 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: PERCENT ON-TIME ADJUSTMENT (Push 2)

This function allows for the adjustment of the percent ontime of the control.

Range 2 – 15% on-time Setting 0 - 255 Resolution 0.05% per set unit Example: Setting of 20 = (20 x 0.05) + 2 = 3%

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 11: SPEED LIMIT 1 (SL1) (Push 11)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit 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: SPEED LIMIT 4 (SL4) (Push 14)

Same as Function 11 except using SL4 limit switch for input.

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

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.

range of adjustment for this function. Please refer to the OEM operating instructions for the control used in your vehicle.

Range See OEM control C/L curves Setting 0 to 255

Example: 0 = min. current, 255 = max. current

FUNCTION 7: NOT APPLICABLE

This function is not applicable to this type of control and should not be adjusted.

FUNCTION 16: NOT APPLICABLE

This function is not applicable to this type of control and should not be adjusted.

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 Without Pump Ctr/PMT

High C/L

BDI Lockout

63 - 71

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ADJUSTABLE FEATURES

TRANSISTOR PUMP CONTROLS Page 64

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)

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 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 motor) when the SL2 limit 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 4 (SL4) (Push CONT 3)

This function allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL4 limit switch input signal is received by the control card. SL4 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 51 NOT APPLICABLE

This function is not applicable to this type of control and should not be adjusted.

FUNCTION 52: MODE 2 - CONTROLLED ACCELERATION

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 accelerate to 96% applied battery 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

(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 4 (SL4)

(Push CONT 7)

Same as Function 50.

September 2001

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ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 65

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 4 (SL4)

(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.

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

Same as Function 49.

FUNCTION 62: MODE 4 - SPEED LIMIT 4 (SL4)

(Push CONT 15)

Same as Function 50.

September 2001

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RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 66

SECTION 6.0 AUTOCALIBRATION OF ACCELERATOR

POTENTIOMETERS

When calibrating the right and left throttle potentiometers (for standard truck configuration), program Function 5 with a handset to a value of 24, and then exit programming mode. Cycle the key switch on and off to store the function setting, and leave the handset plugged in.

When returning the key switch to the “ON” position, make sure that the seat switch is open, and both the left and right accelerator pedals are fully released. Once all of the above conditions have been met, four “A” ’s will appear on the handset.

AAAA

When the four “A” ’s are displayed, close the seat switch, with the accelerator pedals fully released to calibrate the potentiometers to this position. The dash display should show three “A” ’s:

AAA

Re-open the seat switch to begin the calibration of the fully depressed right accelerator pedal position. Depress the right accelerator pedal fully, and close the seat switch to calibrate the fully depressed right accelerator pedal. When this is completed, the dash display should show two “A” ’s:

Re-open the seat switch to begin the calibration of the fully depressed left accelerator pedal position. Depress the left accelerator pedal fully, and close the seat switch to calibrate the fully depressed left accelerator pedal. When this is completed, the dash display will return to normal operation. Confirm this by opening the seat switch, and the dash display will show “-01

The autocalibration routine is now completed.

If truck operation with the forward and reverse switches is desired (optional configuration), set Function 5 to a value of

152. With the key switch in the “OFF” position, the seat switch open, and both the forward and reverse switches in the neutral position, turn the key switch to “ON” and the dash display will show four “A”’s:

----

AAAA

To calibrate the right fully released accelerator pedal position, leave the pedal fully released and close the seat

switch. When this calibration is completed, the display will show three “A”’s:

AAA

Re-open the seat switch and fully depress the right accelerator pedal. Close the seat switch to complete the calibration of the fully depressed pedal. The dash display will then return to normal operation. Confirm this by opening the seat switch, and the dash display will show “01”.

The autocalibration routine is now completed.

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RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 67

Section 7.0 TRACTION CONTROL MEMORY MAP

Func No. HS

No.

Traction Control

Function

Access By Restrictions

0 1 1 MPH Scaling HS or PC None 1 2 2 Creep HS or PC None 2 3 3 Controlled Acceleration HS or PC None 3 4 4 Speed Regulation/Dec. Field HS or PC None 4 5 5 Pot/Directional Calibration HS or PC None 5 6 6 MPH BL3C Speed Limit HS or PC None 6 7 7 Overspeed Response HS or PC None 7 8 8 Maximum Field Current HS or PC None 8 9 9 Regen BrakingCurrent Limit HS or PC None 9 10 10 Field Current for Regen HS or PC None

10 11 11 Maintenance and Lost Tach Speed Limit or

HS or PC None

Park Brake Switch Closed

11 12 12 Max Percent 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 MPH HS or PC None 16 17 17 Card Type Select HS or PC None 17 18 18 Line Driver 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 applicable HS or PC For DD on power up 22 23 23 Plug/Regen Transition HS or PC None 23 24 24 Field Weakening 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 Not applicable HS or PC GE Temporary Storage 27 28 28 Stored Status Code Count Pointer HS or PC None 28 29 29 Not applicable HS or PC None 29 30 30 Not applicable 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 Only 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 Only 39 40 Hours (Thou/Hun) 2 PC Only Reset to Zero Only 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 Only

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RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 68

E2 Func No. HS

No.

Traction Control

Function

Access By Restrictions

43 44 Hours (Thou/Hun) 3 PC Only Reset to Zero Only 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 Only 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 Only 51 52 Hours (Thou/Hun) 5 PC Only Reset to Zero Only 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

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RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 69

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 Min Field -1 97 98 49 Dash Display Field Weakening Start -1 HS or PC None 98 99 50 Dash Display Ratio2 -1 HS or PC None

99 100 51 Dash Display Regen Current Limit - 1 HS or PC None 100 101 52 Dash Display Min Field -2 HS or PC None 101 102 53 Dash Display Field Weakening Start - 2 HS or PC None 102 103 54 Dash Display Ratio2 -2 HS or PC None 103 104 55 Dash Display Regen Current Limit - 2 HS or PC None 104 105 56 Dash Display Min Field -3 HS or PC None 105 106 57 Dash Display Field Weakening Start - 3 HS or PC None 106 107 58 Dash Display Ratio2 -3 HS or PC None 107 108 59 Dash Display Regen Current Limit - 3 HS or PC None 108 109 60 Dash Display Min Field -4 HS or PC None 109 110 61 Dash Display Field Weakening Start - 4 HS or PC None 110 111 62 Dash Display Ratio2 -4 HS or PC None 111 112 63 Dash Display Regen Current Limit - 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 Accelerator Learn – Offset A PC Only None 121 122 Accelerator Learn – Offset B PC Only None 122 123 Accelerator Learn – YINTA PC Only None 123 124 Accelerator Learn – YINTB PC Only None 124 125 Accelerator Learn – Slope A PC Only None 125 126 Accelerator Learn – Slope B 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.

Revised May 2003