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INSTALLATION AND OPERATION MANUAL

SX TRANSISTOR CONTROL

Page

September2004

Section 7.4 Start-Up Display Sequence

START-UP DISPLAY SEQUENCE

Key Switch On

Verify Each LED Segment

8 8 8 8

If Maintenance Code

Is Active

If Maintenance Code

Is Not Active

Display Code "-99"

For Four Seconds and

Activate Speed Limit

(if selected)

BDI Display or

Blank Display
(no BDI used)

Diagnostics Override

With Fault

Run Mode

BDI Display or

Blank Display
(no BDI used)

Diagnostics Override

With Fault

Key Switch

Off

Display Steer Pump Hourmeter

For Four Seconds

Display Pump Hourmeter

For Four Seconds

Display Traction Hourmeter

For Four Seconds

Section 7.5 Outline Drawings

GE Electric Vehicle
Motors & Controls

PY3
PY4
PY2
PY1
PY5

PY3
PY4
PY2
PY1

PUMP

TRACTION

BACK VIEW OF DISPLAY

Wiring connections to "Y"
plugs of Traction & Pump
controls.

2.45 (62.2)

3.20 (81.3)

0.19
(4.8)

2.00 (50.8)

PUMP

TRACTION

CONNECTOR OMITTED

IF NOT REQUIRED

0.41

(10.4)

Содержание IC3645SR4W606MC2

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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