GE IC3645SP4U450N10 Installation And Operation Manual Download Page 47

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DIAGNOSTIC STATUS CODES

TRANSISTOR PUMP CONTROL

Page

PUMP

STATUS CODE

DESCRIPTION OF

STATUS

CAUSE OF STATUS INDICATION

-144

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.

MEMORY RE ALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Pump

Controller

SYMPTOM

With no pump contactor, control
may run continuously.

POSSIBLE CAUSE

Control is defective.

Replace controller unit.

POWER

CONNECTIONS

POS

NEG

ARMATURE

FU1

FU3

KEY SWITCH

P12

LINE

FU6

P19

P21

TRACTION

CARD

SPEED L

IMI

T 1

SPEED L

IMI

T 2

SPEED L

IMI

T 3

TO TRACTION

P10 - BDI

PY7

PY12
PY10
PY11

PUMP

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-145

Power Transistor (Q1) did not turn on
properly.

This status code is displayed when,during pump
control operation, the transistor fails to turn on.

MEMORY RE ALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Pump

Controller

SYMPTOM

With no pump contactor, the control
may run continuously.

POSSIBLE CAUSE

Control is defective.

Replace controller unit.

POWER

CONNECTIONS

POS

NEG

ARMATURE

FU1

FU3

KEY SWITCH

P12

LINE

FU6

P19

P21

TRACTION

CARD

SPEED L

IMI

T 1

SPEED L

IMI

T 2

SPEED L

IMI

T 3

TO TRACTION

P10 - BDI

PY7

PY12
PY10
PY11

October 2002

Summary of Contents for IC3645SP4U450N10

Page 1: ...onal 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 October 2002 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...

Page 2: ... 3 6 RS 232 Communication Port 9 2 3 6 a Dash Display Interaction Modes 9 2 3 7 Circuit Board Coil Driver Modules 9 2 3 8 Truck Management Module TMM 9 2 4 Hydraulic Pump Control 9 Section 3 0 ORDERING 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 Tra...

Page 3: ...stallation 51 5 4 Connection Diagrams 51 5 4 1 TMM7A Card Connections 51 5 4 2 TMM7A Typical Brush Wear Sensor Connections 51 5 4 3 TMM Pump Control Connections 52 5 4 4 Typical Brush Wear Sensor Connections For Pump Control 52 5 5 TMM7A Outline Drawings 52 Section 6 0 SX FAMILY GE HANDSET INSTRUCTIONS 53 6 1 General Features 53 6 2 Purpose Setup Functions 53 6 3 Setup Function Procedures 54 6 3 1...

Page 4: ...nce 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 moto...

Page 5: ...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...

Page 6: ...DC 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 Se...

Page 7: ...eatures which shut down or lock out control operation if a fault conditions occurs that would cause a disruption of normal vehicle operation Section 2 1 5b Anti Rollback Look ahead This feature provides retarding torque to limit rollback speed in the non travel direction when the ACC pedal is Look again Automatic look again and reset released when stopping on a grade or when the brake pedal is rel...

Page 8: ... 2a Standard Status Codes Section 2 3 4 a Internal Resistance Compensation 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 This f...

Page 9: ...hat 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 Three speeds adjustable from O to 100 motor volts Fixed speeds actuated by switch closure to negative Current limit and controlled acceleration adjustable Battery D...

Page 10: ...ol 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 Argum...

Page 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3 2 Outline SX 4 and SR 4 Package Size October 2002 ...

Page 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3 3 Outline SX 3 and SR 3 Package Size October 2002 ...

Page 13: ...F1 NEG A2 F2 FIELD ARMATURE A1 A2 SP FU1 STEER PUMP ARM PUMP CONNECTION BATT NEG LINE FU4 FU3 FU5 PUMP CONNECTION POS L SP REG BRAKING POTENTIOMETER INPUT REGEN OUTPUT SIGNAL I MOTOR VOLTAGE OUT BDI INTERRUPT KEY SWITCH DIRECT SWITCH P18 P17 P2 P6 P4 PY7 P5 P3 PY12 PY10 PY11 P10 P15 P11 P13 P1 P7 P9 SEAT SW 3 15 7 24 60 10 10 10 6 8 13A A2 A1 F1 F2 TMM7 TMM7 88 43 44 89 MOTOR CONNECTIONS CUSTOMER ...

Page 14: ...SH WEAR OUTPUT OVER TEMP OUTPUT DASH DISPLAY 2 1 3 4 5 6 8 9 15 16 11 13 14 PY7 PY12 PY10 PY11 10 12 19 20 21 50 51 53 13C 13C 13C 13C PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P 5A 10 12 1 KEY SW FU6 LINE CONTACTOR BATT TO TRACTION PL2 10 SPEED 3 SPEED 2 SPEED 1 PL2 3 PL2 4 PL2 5 PL2 6 PL2 8 PL2 9 PL2 15 PL2 16 PL2 11 TRACTION CARD TRACTION CARD 5 V SUPPLY P22 P23 TRACTION CONTROL NEG...

Page 15: ...BRUSHWEAR INDICATER OUTPUT 14 TMM BRUSHWEAR TMM1 OVER TEMPERATURE OUTPUT 15 IMOTOR OUT STATUS CODE 92 INPUT 16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CONTACTOR DRIVER 18 1A OR STEER PUMP CTR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER 19 DASH DISPLAY 5 VOLT SUPPLY SPEED LIMIT 2 INPUT 20 TMM OVERTEMP SPEED LIMIT 3 INPUT 21 NOT USED NOT USED 22 S...

Page 16: ...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 1000 hours of vehicle operation Inspection is recommended to verify that the contactors are not binding and that the tips are intact and free of contaminants GE does not recommend that any type of welding be perf...

Page 17: ...eral 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 exce...

Page 18: ...wn 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 h...

Page 19: ...tter 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 ...

Page 20: ...ntation 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 ...

Page 21: ...y 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 ...

Page 22: ...it or loose connection going from the control and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 FU5 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No seat switch or deadman switch input no voltage to P6 This status code will be displayed when P6 is less than 50 battery volts MEMORY R CALL E NO CORREC...

Page 23: ... to P4 Defective control Replace the controller unit KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 03 Reverse directional switch is closed on initial power up This status code will be displayed when P5 is greater than 60 of battery voltage at initial key switch on MEMORY R CALL E NO CORRECTIVE ACT...

Page 24: ... SW P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 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 MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control wil...

Page 25: ...accelerator input circuit Disconnect wire from P7 and measure voltage at wire to negative Should be zero volts for potentiometer type and less than 3 7 volts for solid state type accelerator input P9 P7 ACC POT NEGATIVE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 08 Accelerator input voltage too low on power up after initial key switch closure This status code will be dis...

Page 26: ...than 60 of battery volts KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 11 Start switch closed on power up after initial key switch closure This status code will be displayed when P3 is greater than 60 of battery voltage when the key switch is closed MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SH...

Page 27: ... settings Check minimum battery volts at P1 and NEG NEG FU5 P1 NOMINAL BATTERY VOLTAGE MINIMUM LIMIT VOLTS AT 1 95 VDC PER CELL 24 80 48 72 36 23 4 78 0 46 8 70 2 35 1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 16 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 in...

Page 28: ...eets Adjust and set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is high on start up in the reverse direction This status code will be displayed when the offset voltage is too high at start up in the reverse direction MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOO...

Page 29: ...CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT LINE L REVERSE SW SEAT SW P5 P9 FU5 NEG FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 27 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 MEMORY RE ALL C YES CORRECTIVE ACT...

Page 30: ...STATUS CODE MAY INDICATE AN APPLICATION ISSUE DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL FOR REPAIR OR REPLACEMENT TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Open thermal protector TP or transistor over temperature This status code will be displayed when the voltage at the thermal protector is too high MEMORY RE ALL C YES CORRECTIVE ACTIONS...

Page 31: ...17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 43 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 M...

Page 32: ...P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 45 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 ...

Page 33: ...ONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 49 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 MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Cont...

Page 34: ...to the open side of the line contactor tips Verify that hydraulic pump motor contactor tips are not welded FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 57 Controller motor current sensor input too low during runni...

Page 35: ...P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 65 The line coil 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 wil...

Page 36: ... Missing or damaged horn suppressor Confirm that all inductive loads accessories are suppressed FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 67 The armature current exceeds the armature transistor limit This statu...

Page 37: ...NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 76 Capacitor 1C voltage too high This status code will be displayed when the voltage on the capacitor goes above limit voltage during the regenerative braking cycle MEMORY RE ALL C YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Control...

Page 38: ...ature motor current is greater than 450 amps for longer than 3 5 sec the armature motoring current will be turned off This status code will be displayed when the armature motor current exceeds 450 amps for 3 5 sec and the accelerator pedal is calling for maximum performance MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM The Control wil...

Page 39: ...attery negative Defective input switch shorted Defective TMM module Defective pump control P16 SC90 NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 91 Pump motor temperature has exceeded maximum temperature limit This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at ze...

Page 40: ...orted to positive Defective input switch shorted Defective TMM module Defective pump controller SC93 POS P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 93 Steering pump motor brush wear indicator has detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card i...

Page 41: ...sitive Defective input switch shorted Defective TMM module Defective pump controller SC94 POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 94 Traction motor brush wear indicator had detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at zero volts ...

Page 42: ...Defective input switch shorted Defective TMM module Defective pump controller SC95 POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 95 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 MEMORY R...

Page 43: ...y 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 M...

Page 44: ...truction sheets Adjust and set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 127 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 MEMORY RE ALL C YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid...

Page 45: ...ITCH P1 P2 FU2 POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 LINE October 2002 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 141 Open thermal protector TP1 or transistor is over temperature This status code is displayed when the voltage at the thermal protector is greater than 0 8 volts MEMORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump ...

Page 46: ... P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 143 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 MEMORY R CALL...

Page 47: ... KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 145 Power Transistor Q1 did not turn on properly This status code is displayed when during pump control operation the transistor fails to turn on MEMORY RE ALL C YES CORRECTIVE ACTIONS TROUBLE S...

Page 48: ...PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 150 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 MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller SYMPTOM Pump control will not operate POSSIBL...

Page 49: ...e status code 51 Also do not connect any loads to the load side of the line contactor POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 FU3 KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 157 Controller motor current sensor input voltage pola...

Page 50: ...e at pump control Check for dirty contactor tips POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 FU3 KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 181 Battery voltage is less than 14 volts This status code will be displayed when the batte...

Page 51: ... Display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface The BWI function is compatible with any sensor that short circuits to the motor armature to signal limits of brush wear The TMM7A accessory card should be mounted to a flat surface in any plane in an area protected from water ...

Page 52: ...Y POSITIVE PUMP CONTROL CONNECTIONS PA 3 PA 6 PB 6 PA 1 PA 2 PA 4 PA 5 PZ 10 PZ 11 PY 10 PA 3 1 A1 1 A1 2 A2 1 A3 1 A2 2 A3 2 TO PY10 TRACTION ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP CONTROL TYPICAL PA 1 PA 2 PA 4 PA 5 PZ 10 PZ 11 2 1 TRACTION PUMP PWR STEER ARM 2 2 1 ARM 3 2 1 Section 5 5 TMM7A Outline Drawings 1 3 4 5 6 7 2 8 10 9 11 12 14 13 15 5 8 147 20 6 15 156 20 8 20 3 3 36 85 3 x 1 6...

Page 53: ...48 volts is auto ranging Selection of Card Operation Type 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 START UP DISPLAY SEQUENCE Key Switch On Ver...

Page 54: ...ault codes The vehicle can now be operated with the Handset connected or the Handset can be disconnected before operation NOTE You can return to the segment check mode at any time by holding down the ESC key until 8888 appears in the display Section 6 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that contains the last 16 stored status codes that shut down ve...

Page 55: ...20 3 on time Important Note This function is used to optimize motor and control performance and this setting will be determined by GE and OEM engineers at the time of vehicle development This setting must not be changed by field personnel without the permission of the OEM FUNCTION 3 ARMATURE CONTROLLED ACCELERATION Push 3 This function allows for the adjustment of the rate of time it takes for the...

Page 56: ...etermined by GE and OEM engineers at the time of vehicle development This setting must not be changed by field personnel without the permission of the OEM FUNCTION 9 REGEN BRAKING C L Push 9 This function allows for the adjustment of the Regen braking current limit The higher the current the shorter the stopping distance Resolution Example Volts Min Max Set Per unit value If set at 20 48 183A 597A...

Page 57: ... 0 and 31 36 volts Between 32 and 44 48 volts Between 45 and 69 72 volts Between 70 and 80 80 volts Between 81 and 183 36 48 volts Between 184 and 250 No BDI Between 251 and 255 FUNCTION 16 STALL TRIP POINT WITH ON TIME Push CONT 1 This function allows for the adjustment of control percent on time for the stall motor trip point Control On time 163 Set Point Val 892 If 163 or greater then 0 0 on ti...

Page 58: ...justment of the Regen braking current limit The higher the current the shorter the stopping distance Setting greater than 143 disables this function AUTO REGEN C L AMPS REGEN C L VAL FNT 21 51 VAL 6 50 FUNCTION 24 FIELD WEAKENING START Push CONT 9 This function allows for setting the armature current at which minimum field current will achieved Range 0 to 414 Amps Setting 0 to 255 Resolution 1 625...

Page 59: ...0 32 5 amps I M 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 FW RATIO Push CONT 3 This function sets the ratio between armature and field current when transitioning from minimum field to maximum field current The setting represents the quantity of field current changed for each 1 amp of armature c...

Page 60: ...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 FW RATIO Push CONT 11 Same as Function 50 This FW RATIO takes effect when the Mode 3 settings are called for by the interactive Dash Display FUNCTION 59 MODE 3 MAX ARMATURE ON Push C...

Page 61: ...djusted by Function 26 This function sets the ratio between armature and field current when operating I MOTOR is above FWS and less than 300 amps Setting is the value of field current changed for each 100 amps of armature current changed The full load transition point is calculated by the control This function sets the maximum field current transition point at approximately 300A armature current T...

Page 62: ...ed until the total IR compensation voltage has been added Range 0 0015 to 0 383 seconds Setting 0 to 255 Resolution 0 0015 seconds per set unit Example Setting of 20 0 032 seconds For example if you had selected 2 08 volts from Function 16 to be added to the motor it would take 0 18 seconds to add a total of 2 08 volts 2 08 0 375 0 032 FUNCTION 11 SPEED LIMIT 1 SL1 Push 11 This function allows for...

Page 63: ...h 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 c...

Page 64: ...ODE 2 SPEED LIMIT 3 SL3 Push CONT 7 Same as Function 50 FUNCTION 55 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 56 MODE 3 CONTROLLED ACCELERATION Push CONT 9 Same as function 48 FUNCTION 57 MODE 3 SPEED LIMIT 2 SL2 Push CONT 10 Same as Function 49 FUNCTION 58 MODE 3 SPEED LIMIT 3 SL3 Push CONT 11 Same as Function 50 FUNCTION 59 NOT APP...

Page 65: ...100ZX From the Dash Display the operator may select any of four pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Field Weakening Pick Up levels and 4 Speed Limit levels These interactive modes are pre set using the Handset Functions 48 63 or a personal computer Functions 97 112 This feature allows the operator to select the best vehicle performance for changing factory ta...

Page 66: ...DI used Diagnostics Override With Fault Run Mode BDI Display or Blank Display no BDI used Diagnostics Override With Fault Key Switch Off Display TractionHourmeter For Four Seconds Display PumpHourmeter For Four Seconds Section 7 5 Outline Drawings g GE Electric Vehicle Motors Controls PY3 PY4 PY2 PY1 PY5 1 2 3 4 5 5 4 3 2 1 PY3 PY4 PY2 PY1 PUMP TRACTION BACK VIEW OF DISPLAY Wiring connections to Y...

Page 67: ...ts 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 Mode Reference HS or PC For DD on power up 22 23 23 Field PWM Gain HS or PC None 23 24 24 FW Start HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio HS or PC GE Temporary Storage 26 27 27 HM Minutes HS or PC GE Temporary Storage 27 28 28 Fault Count Pointer HS o...

Page 68: ...tus Code 9 PC Only Reset to Zero Only 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 36 Stored Status Code 10 PC Only Reset to Zero Only 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 38 Stored Statu...

Page 69: ...PC None 105 106 57 Dash Display FWS 3 HS or PC None 106 107 58 Dash Display Ratio2 3 HS or PC None 107 108 59 Dash Display Speed Limit 2 3 HS or PC None 108 109 60 Dash Display CA 4 HS or PC None 109 110 61 Dash Display FWS 4 HS or PC None 110 111 62 Dash Display Ratio2 4 HS or PC None 111 112 63 Dash Display Speed Limit 2 4 HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 S...

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