GE IC3645SP4U500MC2 Installation And Operation Manual Download Page 42

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Page

September 2004

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-85

Motor armature current is too high, and
the control trip time is less than 1
millisecond. The key must be cycled
off and on to reset the control.

This status code will be displayed when the motor
armature current is >1600 amps in 1A mode, or
>1325 amps in control run mode.

MEMORY RECALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM
Control will not operate. The key switch
must be cycled off and on to clear the
status code.

POSSIBLE CAUSE
Defective control.

•

Replace controller unit.

Shorted motor armature.

•

Verify that no shorts are present in the motor
armature.

NO GRAPHIC FOR THIS

STATUS CODE

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-86

Accelerator pot values obtained during
the auto calibration routine were not
valid.

Refer to Section 8 of this manual for possible causes
of this status code.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM
Accelerator potentiometer auto calibration
routine was not successfully completed.

POSSIBLE CAUSE:

Misadjusted or defective accelerator

potentiometer assembly

Verify the accelerator assembly

Open circuit on the accelerator pedal

FU3

KEY SWITCH

P17

P3 P4

ART SW.

ACC POT

REVERSE S

EAT

SW.

FU5

POWER CONNECTIONS

POS

NEG

ARMAT

LINE

FU1

Summary of Contents for IC3645SP4U500MC2

Page 1: ...ver 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 Se...

Page 2: ...2 Communication Port 8 2 3 6 a Interactive Dash Display 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 Traction Elem...

Page 3: ...agrams 57 5 4 1 TMM7A Card Connections 57 5 4 2 TMM7A Typical Brush Wear Sensor Connections 57 5 4 3 TMM Pump Control Connections 58 5 4 4 Typical Brush Wear Sensor Connections For Pump Control 58 5 5 TMM7A Outline Drawings 58 Section 6 0 SX FAMILY GE HANDSET INSTRUCTIONS 59 6 1 General Features 59 6 2 Purpose Setup Functions 59 6 3 Setup Function Procedures 59 6 3 1 Setup Mode 59 6 3 2 Status Cod...

Page 4: ...ce 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...

Page 5: ... 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 ne...

Page 6: ...proximately 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 This feature allows control of the stopping distance based on pedal position when there has been a directional ...

Page 7: ...s Look ahead Look again 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 roll back speed Automatic look again and...

Page 8: ...or vehicles so equipped or be available by plugging the Handset into the y plug of the logic card 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 With the status code n...

Page 9: ...lic motor controller consists of the following features Four speeds adjustable from O to 100 motor volts Fixed speeds actuated by switch closure to negative Current limit and controlled acceleration adjustable Battery Discharge Indicator interrupt compatible Operation of voltage regulator card This card provides the basic functions required for controlling the pump control optional contactors and ...

Page 10: ...l 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 Argume...

Page 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3 2 Outline SX 4 Package Size September 2004 ...

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 September 2004 ...

Page 13: ...R PUMP ARM PUMP CONNECTION BATT NEG LINE FU4 FU3 FU5 PUMP CONNECTION POS L SP BDI INTERRUPT PUMP CONTROLLER PL2 10 KEY SWITCH DIRECT SWITCH P18 P17 P2 P6 P4 P5 P3 P10 P1 SEAT SW A2 A1 F1 F2 TMM7 TMM7 MOTOR CONNECTIONS CUSTOMER SUPPLIED PY8 PY9 A1 A2 P8 P21 P12 SHIELDED CABLE P7 P9 ACCEL SW PY12 PY4 PY5 DASH DISPLAY PY11 BRAKE SWITCH TYPICAL CONNECTION DIAGRAM FOR USE WITH A PUMP CONTROLLER P13 SEA...

Page 14: ...TT NEG LINE FU4 FU3 FU5 PUMP CONNECTION POS L SP BDI INTERRUPT PUMP CONTROLLER PL2 10 KEY SWITCH DIRECT SWITCH P18 P17 P2 P6 P4 P5 P3 P10 P1 SEAT SW A2 A1 TMM7 TMM7 MOTOR CONNECTIONS CUSTOMER SUPPLIED PY8 PY9 A1 A2 P8 P21 P12 SHIELDED CABLE P7 P9 ACCEL SW PY12 PY4 PY5 DASH DISPLAY PY11 BRAKE SWITCH TYPICAL CONNECTION DIAGRAM FOR USE WITH A PUMP CONTROLLER INCLUDING 1A CONTACTOR PUMP LINE 1A 1A 3 1...

Page 15: ...NTACTOR AND TMM CARD P14 P19 HYDRAULIC SWITCHES TMM7A CARD P21 4 1 2 3 3 2 1 PID PATD P 1 3 4 5 6 8 10 11 12 90 91 92 93 93 94 94 95 95 STATUS CODE TMM7A CARD OVERTEMP TRACTION PY 9 BRUSHWEAR TRACTION PY 8 PL2 19 TRACTION CONTROL 15 7 9 13 KEY SWITCH CONTROL POWER CONNECTION POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 LINE FU3 FU5 P1 A2 A1 F1 F2 MOTOR CONNECTIONS CUSTOMER SUPPLIED A1 A2 A1 A2 SP STEER ...

Page 16: ...19 HYDRAULIC SWITCHES TMM7A CARD P21 4 1 2 3 PATD P 1 3 4 5 6 8 10 11 12 90 91 92 93 93 94 94 95 95 STATUS CODE TMM7A CARD OVERTEMP TRACTION PY 9 BRUSHWEAR TRACTION PY 8 PL2 19 TRACTION CONTROL 15 7 9 13 KEY SWITCH CONTROL POWER CONNECTION POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 LINE FU3 FU5 P1 A2 A1 F1 F2 MOTOR CONNECTIONS CUSTOMER SUPPLIED A1 A2 A1 A2 SP STEER PUMP ARM FU4 TMM7 TMM7 A1 A2 P PUMP ...

Page 17: ...DE 92 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT DASH DISPLAY 2 1 3 4 5 6 8 9 15 16 11 13 14 10 12 19 20 21 PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P KEY SW FU3 LINE CONTACTOR BATT BATT TO TRACTION PL2 10 SPEED 4 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 PY 11 PY 12 SHIELDED CABLE SEE NOTE NOTE COVER SHIELDED CABLE WITH HEAT SH...

Page 18: ...5 PL2 6 PL2 8 PL2 9 PL2 15 PL2 16 PL2 11 TRACTION CARD TRACTION CARD PY 11 PY 12 SHIELDED CABLE SEE NOTE NOTE COVER SHIELDED CABLE WITH HEAT SHRINKABLE TUBING NO CONNECTIONS POWER CONNECTION SUPPLIED BY CUSTOMER PL2 14 PL2 13 7 ACCEL POT INPUT 18 1A CONTACTOR DRIVER SPEED 3 PY 5 PY 4 STATUS CODE 93 INPUT STATUS CODE 93 INPUT STATUS CODE 94 INPUT STATUS CODE 95 INPUT STATUS CODE 91 INPUT STATUS COD...

Page 19: ...DE 91 INPUT 12 SPEED LIMIT B SPEED LIMIT 1 INPUT 13 NOT USED TMM1 BRUSHWEAR INDICATER OUTPUT 14 HYDRAULIC SWITCH SENSOR 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 STEER PUMP CTR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER 19 TMM 5 VOLT SUPPLY SPEED LIMIT 2 INPUT ...

Page 20: ...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 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 perfo...

Page 21: ...ral 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 excep...

Page 22: ...own 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 ...

Page 23: ...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 ...

Page 24: ...r 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 RECALL NO CORRECTIVE A...

Page 25: ...neutral 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 RECALL NO CORRECTIVE ACTI...

Page 26: ...c value KEY SWITCH REVERSE SW FORWARD SW SEAT SWITCH L START SW P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 P8 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 calling for greater than 40 speed MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOO...

Page 27: ...n potentiometer voltage supply Short circuit from battery positive to wiring in accelerator input circuit P9 P7 ACC POT P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 08 Accelerator input speed too high on power up after initial key switch closure This status code will be displayed when the accelerator input voltage at P7 is calling for greater than 20 speed and any of th...

Page 28: ...ery volts KEY SWITCH REVERSE SW FORWARD SW SEAT SWITCH L START SW P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 P8 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 RECALL NO CORRECTIVE ACTIONS TROUBLE SHO...

Page 29: ...er 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 ...

Page 30: ...elerator pot to P8 Verify wire connection between P7 to accelerator pot Verify that the accelerator pot is adjusted properly FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is high on start up i...

Page 31: ...t NO GRAPHIC FOR THIS STATUS CODE 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 RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor opens and closes then can only b...

Page 32: ...TROL 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 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Shorted thermal protector TP or armature transistor over temperature This status code will be displayed...

Page 33: ...tion Controller SYMPTOM Control will not operate POSSIBLE CAUSE Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE 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 ...

Page 34: ...it FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 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 Thi...

Page 35: ...POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 1A TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 47 Motor armature is open This status code will be displayed when the on time is 13 and the current in the motor armature is 26 amps and 26 amps for four seconds MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller...

Page 36: ...7 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 51 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 85 of battery volts at initial key switch on MEM...

Page 37: ... POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 64 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 RE...

Page 38: ...17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 66 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 dro...

Page 39: ... SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 69 The power steering coil current is too high during the run mode This status code will be displayed when the current in the power steering driver circuit exceeds current limit during the run mode The control is reset by ...

Page 40: ...ning during regen Intermittent battery plug connection Limit Voltage Limit Batt 50V 36V 70V 48V 96V 72 80V FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 Motor current is detected during regenerative braking This ...

Page 41: ...ROL 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 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 83 A switch position is incorrect during the accelerator potentiometer auto calibration routine This statu...

Page 42: ...controller unit Shorted motor armature Verify that no shorts are present in the motor armature NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 86 Accelerator pot values obtained during the auto calibration routine were not valid Refer to Section 8 of this manual for possible causes of this status code MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE...

Page 43: ...0ms MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM The truck will not run or the pump will not operate POSSIBLE CAUSE Shorted or welded hydraulic switch Verify connections to hydraulic switches Verify mechanical operation of hydraulic switches FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5...

Page 44: ...isplayed by switch closure to battery negative Defective input switch shorted Defective TMM card Defective pump card NO GRAPHIC FOR THIS STATUS CODE 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 z...

Page 45: ...ositive Defective input switch shorted Defective TMM card Defective pump card 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 is at battery volts...

Page 46: ...ted to positive Defective input switch shorted Defective TMM card Defective pump card 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 47: ...positive Defective input switch shorted Defective TMM card Defective pump card 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 ...

Page 48: ...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 49: ...us code is displayed when the logic card power supply is less than 10 volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller 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 ARMATU...

Page 50: ...or transistor is over temperature This status code is displayed when the voltage at the thermal protector is less than 3 8 volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller 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 SX 2 CONTROL PLUG ...

Page 51: ...CONTACTOR DRIVER 18 1A CONTACTOR DRIVER SPEED 3 ARMATURE FIELD FU2 PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P 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 less than 0 6 volts with no current flowing in the motor circuit MEMORY RECALL NO...

Page 52: ...NTACTOR DRIVER 18 1A CONTACTOR DRIVER SPEED 3 ARMATURE FIELD FU2 PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P 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 RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circu...

Page 53: ...A2 A2 A1 N P 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 POSSIBLE ...

Page 54: ... 3 4 5 6 8 9 15 16 11 13 14 10 12 19 20 21 TO TRACTION PL2 10 SPEED 4 SPEED 2 SPEED 1 7 ACCEL POT INPUT 17 LINE CONTACTOR DRIVER 18 1A CONTACTOR DRIVER SPEED 3 ARMATURE FIELD FU2 PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 157 Controller motor current sensor input voltage polarity check This status code will be displayed...

Page 55: ...OVER TEMP OUTPUT 2 1 3 4 5 6 8 9 15 16 11 13 14 10 12 19 20 21 TO TRACTION PL2 10 SPEED 4 SPEED 2 SPEED 1 7 ACCEL POT INPUT 17 LINE CONTACTOR DRIVER 18 1A CONTACTOR DRIVER SPEED 3 ARMATURE FIELD FU2 PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 181 Battery voltage is less than 14 volts This status code will be displayed wh...

Page 56: ...ump control will not operate POSSIBLE CAUSE Hydraulic handle pulled before pump enable signal given Shorted hydraulic switch Defective control SX 2 CONTROL PLUG PL2 STATUS CODE 93 INPUT STATUS CODE 93 INPUT STATUS CODE 94 INPUT STATUS CODE 95 INPUT STATUS CODE 91 INPUT STATUS CODE 90 INPUT STATUS CODE 95 INPUT STATUS CODE 94 INPUT STATUS CODE 92 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT 2 1 3 4 5 6...

Page 57: ...y 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 oil and...

Page 58: ...ONTROL CONNECTIONS PL2 11 PL2 13 PL2 14 PL2 3 PL2 4 PL2 5 PL2 6 PL2 8 PL2 9 PL2 13 PL2 14 1 A1 1 A1 2 A2 1 A3 1 A2 2 A3 2 TO PY8 TRACTION TO PY9 TRACTION ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP CONTROL TYPICAL PL2 3 PL2 4 PL2 5 PL2 6 PL2 8 PL2 9 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 ...

Page 59: ... 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 Verify Each LED Segment 8 8 8 8 If Maintenance Code Is Active If Maintenance C...

Page 60: ...I is not used and there are no fault codes The vehicle can now be operated with the Handset connected or the Handset can be disconnected before operation NOTE You can return to the segment check mode at any time by holding down the ESC key until 8888 appears in the display Section 6 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that contains the last 16 store...

Page 61: ... to 6 3 seconds Set 0 to 255 Resolution 0 025 seconds per set unit Example Setting of 20 0 5 seconds FUNCTION 4 ARMATURE CURRENT LIMIT Push 4 This function should always remain set at 255 maximum current limit for this family of controls FUNCTION 5 COUNTER EMF TRIP POINT FOR AUTO BRAKING Push 5 This function allows for the adjustment of the speed at which the truck will activate auto braking after...

Page 62: ...36 48V 0 64 51 to 255 0 314 53 amps 72 80 0 55 51 to 255 0 269 45 amps 1000A 0 103 51 to 255 0 507 85 amps IF VAL 51 x 0 314 at 36 48 volts IF VAL 51 x 0 269 at 72 80 volts IF VAL 51 x 0 507 at 1000 amps 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 ...

Page 63: ...function allows for the adjustment of the stall motor protection as well as the display and storing of an 82 fault code This function adjusts the percent on time at which the fault occurs when the accelerator is calling for greater than 50 speed and the armature current is above 500 amps at 36 48V or above 370 amps at 72 80V Range 100 to 0 battery volts Set 46 to 180 Resolution 0 75 per set unit E...

Page 64: ...DS 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 9999 Hours FUNCTION 21 AUTO REGEN BRAKING CURRENT LIMIT Push CONT 6 This function allows for the adjustment of the braking torque applied when the start or directional switch is opened and the counter EMF is above the setti...

Page 65: ...ontroller 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 s...

Page 66: ...t to 52 amps This AUTO REGEN CURRENT LIMIT takes effect when the Mode 1 settings are called for by the interactive Dash Display FUNCTION 51 MODE 1 SPEED LIMIT 2 Push CONT 4 This function allows for the adjustment of the motor speed limit maximum battery volts to the motor Range 100 to 0 battery volts Set 46 to 180 Resolution 0 75 per set unit Example Setting of 80 75 of battery volts SPEED LIMIT 1...

Page 67: ... called for by the interactive Dash Display FUNCTION 60 MODE 4 ARMATURE CONTROLLED ACCELERATION Push CONT 13 Same as Function 48 This C A takes effect when the Mode 4 settings are called for by the interactive Dash Display FUNCTION 61 MODE 4 REGEN CURRENT LIMIT Push CONT 14 Same as Function 49 This REGEN CURRENT LIMIT takes effect when the Mode 4 settings are called for by the interactive Dash Dis...

Page 68: ...e motor The field weakening start setting is adjusted by Function 24 This function sets the armature current at which minimum field current will be achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when operating IMOTOR is above FWS and less than the full load transistion point Setting is the value of field current changed for eac...

Page 69: ... 75 volts 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 FUNCTION 12 LIFT 1 SPEED LIMIT 2 SL2 Push 12 Same as Function 11 except using SL2 limit switch for input Range 0 1 to 5 5 seconds Setting 0 to 255 Resolution 0 021 seconds per set unit FUNCTION 13 TILT SPEED LIMIT 3 SL3 ...

Page 70: ...set number column on the memory map with the number obtained from Function 28 This will be the last stored status code recorded SETTING VOLTAGE DROP SETTING VOLTAGE DROP 2 11 44 17 1 34 3 7 60 18 1 27 4 5 72 19 1 20 5 4 57 20 1 14 6 3 81 21 1 09 7 3 27 22 1 04 8 2 86 23 0 99 9 2 54 24 0 95 10 2 28 25 0 91 11 2 08 26 0 88 12 1 90 27 0 85 13 1 76 28 0 82 14 1 63 29 0 79 15 1 52 30 0 76 16 1 43 31 0 ...

Page 71: ...imum 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 52 MODE 2 CONTROLLED ACCELERATION Push CONT 5 Same as functi...

Page 72: ...SH EVT100ZX From the Dash Display the operator may select any of four pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Auto Regen levels and 4 Speed Limit levels These interactive modes are pre set using the Handset Functions 48 63 or a personal computer Functions 97 112 This feature allows the operator to select the best vehicle performance for changing factory task cond...

Page 73: ...iagnostics Override With Fault Run Mode BDI Display or Blank Display no BDI used Diagnostics Override With Fault Key Switch Off Display Steer PumpHourmeter For Four Seconds Display PumpHourmeter For Four Seconds Display TractionHourmeter 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 VIE...

Page 74: ...the handset AAAA When the four A s are displayed close the forward directional switch with the accelerator pedal fully released The dash display should show three A s AAA Return the forward switch to the open position and the dash display should show two A s AA Fully depress the accelerator pedal and close the forward switch Only one A should be displayed A Re open the forward switch The truck wil...

Page 75: ...one 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 Braking Current Limit HS or PC None 21 22 22 Mode Storage HS or PC For DD on power up 22 23 23 Regen Cancel Current 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 Steer P...

Page 76: ...4 Stored Status 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 ...

Page 77: ...Regen C L 3 HS or PC None 106 107 58 Dash Display Auto Regen C L 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 Regen C L 4 HS or PC None 110 111 62 Dash Display Auto Regen C L 4 HS or PC None 111 112 63 Dash Display Speed Limit 2 4 HS or PC None 112 113 Secure HM Tens Ones Steer Pump PC Only OEM Read Only 11...

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Summary of Contents for IC3645SP4U500MC2

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GE IC3645SP4U500MC2, Installation And Operation Manual, Page: 42 / 77

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Summary of Contents for IC3645SP4U500MC2

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