GE IC3645SR4W606MC2 Installation And Operation Manual Download

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Page

September 2004

Section 5.4 TMM Codes

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-90

Traction motor temperature has
exceeded maximum temperature limit.

This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at zero volts.

MEMORY RECALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Motor

Temperature

SYMPTOM
Status code flashes “on and off”.

POSSIBLE CAUSE
User defined status code is displayed 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 zero volts.

MEMORY RECALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Motor

Temperature

NO GRAPHIC FOR THIS

STATUS CODE

Summary of Contents for IC3645SR4W606MC2

Page 1: ...er 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 re...

Page 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 INFORMATI...

Page 3: ...grams 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...

Page 4: ...e 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...

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...

Page 6: ...roximately 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 t...

Page 7: ...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 accelerato...

Page 8: ...r 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...

Page 9: ...ic 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 ad...

Page 10: ...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...

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: ...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 M...

Page 14: ...T 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...

Page 15: ...TACTOR 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...

Page 16: ...9 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...

Page 17: ...E 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...

Page 18: ...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 B...

Page 19: ...E 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...

Page 20: ...echarging 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...

Page 21: ...al 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...

Page 22: ...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...

Page 23: ...he 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 eleme...

Page 24: ...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...

Page 25: ...eutral 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...

Page 26: ...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...

Page 27: ...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 Accel...

Page 28: ...ry 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 p...

Page 29: ...r 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 DESCRIPTIO...

Page 30: ...lerator 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 S...

Page 31: ...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 co...

Page 32: ...ROL 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...

Page 33: ...ion 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 INDI...

Page 34: ...t 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 S...

Page 35: ...OWER 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 wh...

Page 36: ...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 INDICAT...

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...

Page 38: ...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 INDICA...

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 c...

Page 40: ...ing 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 FU...

Page 41: ...OL 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...

Page 42: ...ontroller 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 A...

Page 43: ...ms 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 hydr...

Page 44: ...splayed 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...

Page 45: ...sitive 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 INDICATI...

Page 46: ...ed 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...

Page 47: ...ositive 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 INDICAT...

Page 48: ...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...

Page 49: ...s 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 ope...

Page 50: ...r 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 v...

Page 51: ...ONTACTOR 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 Con...

Page 52: ...TACTOR 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 Tran...

Page 53: ...2 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...

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 CON...

Page 55: ...VER 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 PU...

Page 56: ...mp 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...

Page 57: ...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 wit...

Page 58: ...NTROL 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 CO...

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...

Page 60: ...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 a...

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 curre...

Page 62: ...6 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 am...

Page 63: ...unction 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 acce...

Page 64: ...S 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 A...

Page 65: ...ntroller 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 logi...

Page 66: ...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...

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 int...

Page 68: ...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...

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 SP...

Page 70: ...et 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...

Page 71: ...mum 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 enable...

Page 72: ...H 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 interac...

Page 73: ...agnostics 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 Fo...

Page 74: ...he 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 t...

Page 75: ...ne 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...

Page 76: ...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 St...

Page 77: ...egen 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...

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