INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
Page 1
SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR TRACTION CONTROL
AND SERIES PUMP CONTROL
INSTALLATION AND OPERATION MANUAL
(IC3645SR4U404N2 and IC3645SP4U400N3)
Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles
in the application, installation and service of GE solid-state controllers. This manual does not purport to
cover all variations in OEM vehicle types. Nor does it provide for every possible contingency to be met
involving vehicle installation, operation or maintenance. For additional information and/or problem
resolution, please refer the matter to the OEM vehicle manufacturer through his normal field service
channels. Do not contact GE directly for this assistance.
Table of Contents
Copyright by General Electric Company January 2000
Section 1.0
INTRODUCTION ........................................................................................................................................................4
1.1
1.2
1.3
1.4
Motor Characteristics .............................................................................................................. 4
Solid-State Reversing............................................................................................................... 5
Flexible System Application..................................................................................................... 5
More Features with Fewer Components ................................................................................ 5
Section 2.0
FEATURES OF SX FAMILY OF MOTOR CONTROLLERS ....................................................................................6
2.1
2.1.1
2.1.1.a
2.1.1.b
2.1.1.c
2.1.2
Performance.............................................................................................................................. 6
Oscillator Card Features .................................................................................................. 6
Standard Operation .................................................................................................. 6
Creep Speed............................................................................................................... 6
Controlled Acceleration .......................................................................................... 6
Current Limit ...................................................................................................................... 6
Braking............................................................................................................................... 6
Plug Braking .............................................................................................................. 6
Regenerative Braking to Zero Speed...................................................................... 6
Pedal Position Plug Braking .................................................................................... 6
2.1.3
2.1.3.a
2.1.3.b
2.1.3.c
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
Page 3
Table of Contents ( Continued )
4.2.5
4.2.6
4.3
4.4
4.5
RF Interference.......................................................................................................................... 17
Suppression............................................................................................................................... 17
Recommended Lubrication of Pins and Sockets Prior to Installation........................................ 18
General Troubleshooting Instructions ........................................................................................... 19
Traction Controller Status Codes ................................................................................................... 20-40
TMM Status Codes ........................................................................................................................... 41-45
Pump Control Status Codes............................................................................................................. 46-52
4.6
4.7
Section 5.0
TRUCK MANAGEMENT MODULE (TMM)............................................................................................................53
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.5
General Features .............................................................................................................................. 53
Operation ...................................................... .................................................................................... 53
Installation......................................................................................................................................... 53
Connection Diagrams....................................................................................................................... 53
TMM7A Card Connections ...................................................................................................... 53
TMM7A Typical Brush Wear Sensor Connections ............ ................................................. 53
TMM Pump Control Connections ........................................................................................... 54
TMM7A Outline Drawings ............................................................................................................... 54
Section 6.0
SX FAMILY - GE HANDSET INSTRUCTIONS ......................................................................................................55
6.1
6.2
6.3
6.3.1
6.3.2
6.3.3
6.4
6.5
6.6
General Features .............................................................................................................................. 55
Purpose/Setup Functions ............................................................................................................... 55
Setup Function Procedures ............................................................................................................ 56
Setup Mode ............................................ .................................................................................. 56
Status Code Scrolling............................................................................................................... 56
SX Handset Plug Connections & Outline Drawing.... ........................................................... 56
Setup Functions for Traction Controller .. ..................................................................................... 57-62
Summary of Current Limit Adjustments ......................................................................................... 62
Setup Functions for Hydraulic Pump Controller . ......................................................................... 64-66
Section 7.0
DASH DISPLAYS.......................................................................................................................................................67
7.1
7.2
7.3
7.4
7.5
Application ............................................. ............................................................................................. 67
Standard Dash Displays .................................. .................................................................................. 67
Interactive Dash Displays................................................................................................................... 67
Start-up Display Sequence ................................................................................................................ 68
Outline Drawings ........................................ ........................................................................................ 68
Section 8.0
Section 9.0
TURN ANGLE POTENTIOMETER INSTALLATION..............................................................................................69
8.1
8.2
8.3
General................................................................................................................................................. 69
320 Degree Potentiometer Input........................................................................................................ 70
Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings..................................... 71
MEMORY MAPS........................................................................................................................................................72
9.1 Typical Memory Map for Traction Control.................................................................................... 72-74
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 4
current to increase, providing the greater torque needed to
drive the increased mechanical load. If the mechanical
load is decreased, the process reverses. The motor speed
and the back EMF increase, while the armature current and
the torque developed decrease. Thus, whenever the load
changes, the speed changes also, until the motor is again
in electrical balance.
Section 1. INTRODUCTION
Section 1.1 Motor Characteristics
The level of sophistication in the controllability of traction
motors has changed greatly over the past several years.
Vehicle manufacturers and users are continuing to expect
more value and flexibility in electric vehicle motor and
control systems as they are applied today. In order to
respond to these market demands, traction system
designers have been forced to develop new approaches to
reduce cost and improve functions and features of the
overall system. Development is being done in a multi-
generational format that allows the market to take
advantage of today’s technology, while looking forward to
new advances on the horizon. GE has introduced a second
generation system using separately excited DC shunt
wound motors. The separately excited DC motor system
offers many of the features that are generally found on the
advanced AC systems. Historically, most electric vehicles
have relied have on series motor designs because of their
ability to produce very high levels of torque at low speeds.
But, as the demand for high efficiency systems increases,
i.e., systems that are more closely applied to customers’
specific torque requirements, shunt motors are now often
being considered over series motors. In most applications,
by independently controlling the field and armature
currents in the separately excited motor, the best attributes
of both the series and the shunt wound motors can be
combined.
In a shunt motor, the variation of speed from no load to
normal full load on level ground is less than 10%. For this
reason, shunt motors are considered to be constant speed
motors (Figure 2).
SPEED
TORQUE
ARMATURE CURRENT
Figure 2
In the separately excited motor, the motor is operated as a
fixed field shunt motor in the normal running range.
However, when additional torque is required, for example,
to climb non-level terrain, such as ramps and the like, the
field current is increased to provide the higher level of
torque. In most cases, the armature to field ampere turn
ratio can be very similar to that of a comparable size series
motor (Figure 3.)
SPEED
SPEED
TORQUE
ARMATURE CURRENT
Figure 1
As shown in from the typical performance curves of Figure
1, the high torque at low speed characteristic of the series
motor is evident.
TORQUE
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
ARMATURE CURRENT
Figure 3
constant, the torque developed will vary directly with the
armature current. If the mechanical load on the motor
increases, the motor slows down, reducing the back EMF
(which depends on the speed, as well as the constant field
strength). The reduced back EMF allows the armature
Aside from the constant horsepower characteristics
described above, there are many other features that
provide increased performance and lower cost. The
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 5
following description provides a brief introduction to
examples of some of these features.
armature, the motor performance curve can be maximized
through proper control application.
Section 1. 2 Solid-State Reversing
Section 1. 4 More Features with Fewer Components
The direction of armature rotation on a shunt motor is
determined by the direction in which current flows through
the field windings. Because of the of the shunt motor field
only typically requires about 10% of the armature current at
full torque, it is normally cost effective to replace the
double-pole, double-throw reversing contactor with a low
power transistor H-Bridge circuit (Figure 4).
Field weakening with a series wound motor is
accomplished by placing a resistor in parallel with the field
winding of the motor. Bypassing some of the current
flowing in the field into the resistor causes the field current
to be less, or weakened. With the field weakened, the motor
speed will increase, giving the effect of “overdrive”. To
change the “overdrive speed”, it is necessary to change
the resistor value. In a separately excited motor,
independent control of the field current provides for
infinite adjustments of “overdrive” levels, between
motor base speed and maximum weak field. The
desirability of this feature is enhanced by the
LINE POS
FUSE
Q5
Q3
elimination of the contactor and resistor required for
field weakening with a series motor.
A1 +
F1
F2
ARM
A2 -
CAP
Q2
With a separately excited motor, overhauling speed
limit, or downhill speed, will also be more constant. By
its nature, the shunt motor will try to maintain a
constant speed downhill. This characteristic can be
enhanced by increasing the field strength with the
control. Overhauling load control works in just the
opposite way of field weakening, armature rotation
slows with the increase of current in the field.
Q4
Q6
Q1
NEG
Figure 4
Regenerative braking (braking energy returned to the
battery) may be accomplished completely with solid-state
technology. The main advantage of regenerative braking is
increased motor life. Motor current is reduced by 50% or
more during braking while maintaining the same braking
torque as electrical braking with a diode clamp around the
armature. The lower current translates into longer brush
life and reduced motor heating. Solid state regenerative
braking also eliminates a power diode, current sensor and
contactor from the circuit.
By energizing the transistors in pairs, current can be made
to flow in either direction in the field. The armature control
circuit typically operates at 12KHZ to 15KHZ, a frequency
range normally above human hearing. This high frequency
coupled with the elimination of directional contactors,
provides very quiet vehicle operation. The field control
circuits typically operate at 2 KHZ.
The line contactor is normally the only contactor required
for the shunt motor traction circuit. This contactor is used
for both pre-charge of the line capacitors and for
emergency shut down of the motor circuit, in case of
problems that would cause a full motor torque condition.
The line can be energized and de-energized by the various
logic combinations of the vehicle, i.e. activate on key, seat
or start switch closure, and de-energize on time out of idle
vehicle. Again, these options add to the quiet operation of
the vehicle.
For GE, the future is now as we make available a new
generation of electric traction motor systems for electric
vehicles having separately excited DC shunt motors and
controls. Features that were once thought to be only
available on future AC or brushless DC technology vehicles
systems are now achievable and affordable.
Section 1. 3 Flexible System Application
Because the shunt motor controller has the ability to
control both the armature and field circuits independently,
the system can normally be adjusted for maximum system
efficiencies at certain operating parameters. Generally
speaking, with the ability of independent field and
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 6
Section 2. FEATURES OF SX FAMILY OF TRANSISTOR
MOTOR CONTROLLERS
Section 2.1.3 Braking
Section 2.1.3.a Plug Braking
Section 2.1 Performance
Section 2.1.3.b Regenerative Braking to Zero Speed
Section 2.1.1 Oscillator Card Features
Section 2.1.1.a Standard Operation
Slow down is accomplished when
reversing direction by providing a
small amount of retarding torque for
Q2
deceleration. If the vehicle is
moving, and the directional lever is
moved from one direction to the
other, the regen signal is initiated.
Once the regen signal has been
With the accelerator at maximum ohms or volts, the creep
speed can be adjusted by Function 2 of the Handset or a
trimpot. The field control section allows the adjustment of
the field weakening level in order to set the top speed of the
motor. This top speed function (Minimum Field Current) is
enabled when the armature current is less than the value
set by Function 24 and the accelerator input voltage is less
than 1 volt. Top Speed can be adjusted by Function 7 of the
Handset or a trimpot.
The percent on-time has a range of approximately 0 to 100
percent. The SX controllers operate at a constant
frequency and the percent on-time is controlled by the
pulse width of the voltage / current applied to the motor
circuits.
ARM
Q1
initiated, the field current is
increased (armature circuit shown in
Figure 5
Figure 5). Armature current is
regulated to the regen current limit as set by Function 9. As
the vehicle slows down, the field current continues to
increase, and transistor Q2 begins to chop. The field
current will increase until it reaches a preset value set by
Function 10, and transistor Q2 on-time will increase until it
reaches 100% on-time. Once both of the above conditions
have been met, and regen current limit can no longer be
maintained, the braking function is canceled. The fields
will then reverse, and the control reverts back to motoring.
Part of the energy produced by the motor during regen is
returned to the battery, and part is dumped in the motor as
heat.
Section 2.1.1.b Creep Speed
With the accelerator at maximum ohms or volts
(approximately 3.7 to 3.5 VDC), the creep speed can be
adjusted by Function 2 of the Handset. At creep speed, the
ON time can decrease to approximately 5%, with the OFF
time at approximately 95%. At full transistor operation, this
condition will be reversed (short OFF time, long ON time).
This variation of ON and OFF time of the oscillator varies
the voltage applied to the motor, thereby varying the speed
of the motor for a given load.
Section 2.1.3.c Pedal Position Plug Braking
This feature allows control of the plugging distance based
on pedal position when there has been a “directional
switch" change. Pedal position will reduce the regenerative
current to the "value set by this function" as the accelerator
is returned to the creep speed position. Maximum regen
current is obtained with the accelerator in the top speed
position.
Section 2.1.1.c Control Acceleration
This feature allows for adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration. Armature C/A is
adjusted by Function 3 from 0.1 to 22 seconds.
Section 2.1.3.d Auto Braking
This feature is enabled by initiating a "neutral position"
using either the directional switch or the accelerator
switch. Once activated, Auto Braking operates similar to
Pedal Position Plug Braking and is adjusted by using
Function 21 of the Handset.
Section 2.1.2 Current Limit
This circuit monitors motor current by utilizing sensors in
series with the armature and field windings. The
information detected by the sensor is fed back to the card
so that current may be limited to a pre-set value. If heavy
load currents are detected, this circuit overrides the
oscillator and limits the average current to a value set by
Function 4 and Function 8 of the Handset. The C/L setting is
based on the maximum thermal rating of the control.
Because of the flyback current through 3REC, the motor
current is usually greater than battery current, except at
100% ON time.
Section 2.1.4 Auxiliary Speed Control
Section 2.1.4.a Field Weakening
This function allows the adjustment of the field weakening
level in order to set the top speed of the motor. The function
is enabled when the armature current is less than the value
set by Function 24 and the accelerator input voltage is less
than 1 volt. It is important to note that this function is used
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 7
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.
At this point, the inside wheel will stop, as the steer angle is
increased toward the 90° point, the inside wheel will
reverse direction and start to accelerate proportionally in
speed. As the steer angle reaches the 90° point, the inside
wheel speed will be the same as that of the outside wheel.
During this entire turn, except for several degrees when the
motor was stopped to change direction, torque was always
present on the inside wheel, providing a smoother ride
throughout the turning radius of the vehicle.
Section 2.1.4.b Speed Limits
This feature provides a means to control speed by limiting
motor volts utilizing three "adjustable speed limits. This
motor volt limit regulates top speed of the transistor
controller, but actual truck speed will vary at any set point
depending on the loading of the vehicle. Each speed limit
can be adjustable with the Handset using Functions 11, 12,
and 13.
Details for adjustment of the steer angle potentiometer can
be found in Appendix A of this manual.
100%
50%
90O
100%
50%
90O
RIGHT
MOTOR
LEFT
MOTOR
Section 2.1.4.c Proportional Operation for Dual Motor
Vehicles
LEFT
MOTOR
RIGHT
MOTOR
80O 70O 60O 50O 40O 30O 20O 10O 0O 10O 20O 30O 40O 50O 60O 70O 80O
LEFT
TURN
STEERING ANGLE
RIGHT
A key performance advantage of this control is the ability to
achieve actual "proportioning" of motor speed. In a
non-proportioning, or single control, system when the
vehicle starts to turn, the outside drive wheel turns in a
larger circle than the inside wheel. Depending on the
geometry of the vehicle, at some degree of turn angle, the
inside wheel must slow down to prevent scrubbing of the
wheel. This is accomplished on single control system by
disconnecting the inside motor and letting the wheel "free
wheel" or "float" at whatever speed is dictated by the
outside wheel that is still under power. The main
disadvantage of this system is that no torque is available on
that motor when the inside wheel is in the "free-wheel"
mode, and performance in a turn is reduced. When the
steer wheel nears to the 90° turn angle, the inside motor is
re-connected in the opposite direction of the outside. At
this point, torque is returned to the inside wheel and the
speed is the same on both motors.
0O
50%
100%
50%
100%
LEFT
CONTROL
RIGHT
CONTROL
TURN
90O
90O
Section 2.1.5 Ramp Operation
Section 2.1.5a Ramp Start
This feature provides maximum control torque to restart a
vehicle on an incline. The memory for this function is the
directional switch. When stopping on an incline, the
directional switch must be left in its original or neutral
position to allow the control to initiate full power when
restarted. The accelerator potentiometer input will
modulate ramp start current.
Section 2.1.5b Anti-Rollback
This feature provides retarding torque to limit rollback
speed in the non-travel direction when the ACC pedal is
released when stopping on a grade, or when the brake
pedal is released when starting on a grade. This feature
forces the vehicle to roll very slowly down the grade when
accelerator or brake is released. Because the vehicle can
gain significant speed during roll-back, the torque needed
to re-start on the ramp is lower than an unrestricted roll-
back speed.
With two controls, the speed of each motor can be
regulated independently. The driver controls the speed of
the outside wheel with the accelerator input signal. The
inside wheel speed is controlled by the turn angle of the
steer wheel . A potentiometer is attached to the steer wheel
in order to communicate the steer angle to the controllers.
During vehicle manufacture, software selection identifies
each control for its application as a right or left control.
The controls are physically identical, and it is only software
that separates a right from a left control or differentiates a
control for a dual motor application from one intended for a
single motor vehicle. As the steer reaches some
Section 2.1.6 Steer Pump Contactor Time Delay
This feature provides two options for SP time delay. Option
1 provides a 0.5 to 63 second time delayed drop out of the
steer pump contactor when the Forward or Reverse
directional switch is opened. This Option 1 is overridden by
a 1.5 second time delayed drop out whenever the seat
switch is opened. Option 2 provides a 0.5 to 63 second time
delayed drop out of the SP contactor when the seat switch
is opened.
pre-selected turn angle, approximately 20o, the speed of the
inside wheel decrease proportionally to the speed of the
outside wheel. This proportional decline will continue on a
linear path until the steer angle reaches another pre-
determine angle of, approximately 65o.
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 8
reach sufficient speed. As the control cools, the thermal
protector will automatically reset, returning the control to
full power.
Section 2.1.7 On-Board Coil Drivers & Internal Coil
Suppression
Coil drivers for the LINE and SP contactors
are on-board the control card. These contactors must have
coils rated for the vehicle battery volts.
Section 2.2.5 Low Voltage
Batteries under load, particularly if undersized or more
than 80 percent discharged, will produce low voltages at
the control terminals. The SX control is designed for use
down to 50 percent of a nominal battery voltage of 36-84
volts, and 75 percent of a nominal battery voltage of 24
volts. Lower battery voltage may cause the control to
operate improperly, however, the resulting PMT should
open the Line contactor, in the event of a failure.
Section 2.2 System Protective Override
Section 2.2.1 Static Return to Off (SRO)
This inherent feature of the control is designed to require
the driver to return the directional lever to the neutral
position anytime he leaves the vehicle and returns.
Additionally, if the seat switch or key switch is opened, the
control shuts off and cannot be restarted until the
directional lever is returned to neutral. A time delay of
approximately 2 seconds is built into the seat switch input
to allow momentary opening of the seat switch, if a bump is
encountered.
Section 2.3 Diagnostics
Section 2.3.1 Systems Diagnostics
The control detects the system's present operating status
and can be displayed to either the Dash Display or the
Handset. There are currently over 70 status codes that are
available with SX systems using Traction and Pump
controls and Truck Management Module (TMM). Along
with the status code display from the TMM, the SX control
is capable of reducing the current to the motor, alerting the
operator of a critical fault condition.
Section 2.2.2 Accelerator Volts Hold Off
This feature checks the voltage level at the accelerator
input whenever the key switch or seat switch is activated.
If, at start up, the voltage is less than 3.0 volts, the control
will not operate. This feature assures that the control is
calling for low speed operation at start up.
Section 2.3.2 Status Codes
Section 2.2.3 Pulse Monitor Trip (PMT)
Section 2.3.2a Standard Status Codes
The PMT design contains three features which shut down,
or lock out, control operation if a fault conditions occurs
that would cause a disruption of normal vehicle operation:
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.
•= Look ahead
•= Look again
•= Automatic look again and reset
With the status code number, follow the procedures
outlined in DIAGNOSTIC STATUS CODES to determine the
problem and a solution.
The PMT circuit will not allow the control to start under the
following conditions:
Note: The Status Code Instruction Sheets do not claim to
cover all possible causes of a display of a "status code ".
They do provide instructions for checking the most direct
inputs that can cause status codes to appear.
•= The control monitors both armature and field FET's at
start-up and during running.
•= The control will not allow the line contactor to close at
start-up, or will drop it out during running, if either the
armature or field FET's are defective, so as to cause
uncontrolled truck movement.
Section 2.3.2.b Stored Status Codes
This feature records the last 16 "Stored Status Codes" that
have caused a PMT controller shut down and/or disrupted
normal vehicle operation. (PMT type faults are reset by
cycling the key switch). These status codes, along with the
corresponding BDI and hourmeter readings, can be
accessed with the Handset, or by using the RS 232
communications port and dumping the information to a
Personal Computer terminal.
Section 2.2.4 Thermal Protector (TP)
This temperature sensitive device is internal to the power
transistor (Q1) module. If the transistor's temperature
begins to exceed the design limits, the thermal protector
will lower the maximum current limit, and maintain the
transistors within their temperature limits. Even at a
reduced current limit, the vehicle will normally be able to
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
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Section 2.3.3 Hourmeter Readings
Section 2.3.6.a Interactive Dash Display
Modes
This feature will display the recorded hours of use of the
traction and pump control to the Dash Display each time
the key switch is turned off.
The Interactive Custom Dash Display allows the operator to
select the best vehicle performance for changing factory
(task) conditions. There are four (4) "operator interaction
modes" that can be selected by depressing a push button
on the dash display.
Section 2.3.3.a Maintenance Alert & Speed Limit
This feature is used to display Status Code 99 and/or
activate a speed limit when the vehicle operating hours
match the hours set into the maintenance alert register.
This feature is set with the Handset using Functions 19 and
20. The operator is alerted that maintenance on the vehicle
is required.
From the Dash Display, the operator may select any of four
pre-set interactive modes consisting of (4) Controlled
Acceleration levels, (4) Field Weakening levels and (4)
Speed Limits.
These interactive modes are "pre-set" using the Handset
(Functions 48-62) or a personal computer (Functions 97-
112). This feature allows the operator to select the best
vehicle performance for changing factory (task) conditions.
Section 2.3.4 Battery Discharge Indication (BDI)
The latest in microprocessor technology is used to provide
accurate battery state of charge information and to supply
passive and active warning signals to the vehicle operator.
Features and functions:
Section 2.3.7 Circuit Board Coil Driver Modules
Coil drivers are internal to the control card, and are the
power devices that operate the Line and SP contactor
coils. On command from the control card, these drivers
initiate opening and closing the contactor coils. All driver
modules are equipped with reverse battery protection, such
that, if the battery is connected incorrectly, the contactors
can not be closed electrically.
•= Displays 100 to 0 percent charge.
•= Display blinks with 20% charge. Disables pump circuit
with 10% charge. Auto ranging for 36/48 volt operation.
Adjustable for use on 24 to 80 volts.
Section 2.3.4.a Internal Resistance Compensation
Section 2.3.8 Truck Management Module (TMM)
This feature is used when the Battery Discharge Indicator
is present. Adjustment of this function will improve the
accuracy of the BDI.
The Truck Management Module is a multifunction
accessory card, or an integral function of the GE Pump
controls when used with the SX Traction control. The
Module provides the OEM the ability to initiate status codes
or operator warning codes to be displayed on the Dash
Display, whenever a normally open switch or sensor wire
provides a signal to the Module.
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.
The TMM Module can be used to display a separate status
code indicating over-temperature of traction motors,
hydraulic motors, or any other device or system that can
activate a switch that closes.
Features and functions:
•= Monitor existing system status codes for both traction
and pump controls. Monitor intermittent random status
codes.
•= Monitor battery state of charge, if available.
•= Monitor hourmeter reading on traction and pump
controls. Monitor or adjust the control functions.
The TMM Module can also be used as a Brush Wear
Indicator (BWI). The Brush Wear Indicator is designed to
detect a "worn out brush" and display a fault code on the
Dash Display to warn maintenance personnel that the
motor brushes need to be replaced before they wear to the
point of causing destructive damage to the motor
commutator surface.
Section 2.3.6 RS 232 Communication Port
This serial communication port can be used with
Section 2.4 Hydraulic Pump Control
Interactive Custom Dash Displays to allow changes to
vehicle operating parameters by the operator. Or, it can be
used by service personnel to dump control operating
information and settings into a personal computer program.
This hydraulic motor controller consists of the following
features:
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BASIC OPERATION AND FEATURES
SX TRANSISTOR CONTROL
Page 10
•= Three 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 PMT functions. Battery positive is
applied through a main control fuse to the key switch,
energizing the control card power supply input to P1.
When a pump contactor is used, PMT operation is the
same as outlined for the traction controllers.
The three speed (motor volts) reference points P12, P19,
and P20 are selected by connecting these points
independently to battery negative.
The first speed is obtained by closing Speed Limit I (P12) to
control negative. SLl is adjustable by Function 11 using the
Handset to adjust motor voltage from O to 100%. The
specified motor volts will be regulated, however, the
magnitude of motor current will vary depending on the
loading of the vehicle.
The second speed is obtained by closing SL2 (P19) to
control negative. SL2 is adjusted using the Handset and
Function 12 similar to SL1.
The third speed is obtained by closing SL3 (P20) to control
negative. SL3 is adjusted using the Handset and Function
13 similar to SL1.
If more than one Speed Limit is activated, the selected
speed with the highest motor volts will override the low
motor volt speed. The current limit circuit is adjustable and
operates the same as the traction current limit.
The controlled acceleration circuit is adjustable and
operates the same as the traction circuit. Adjustment range
is from 0.1 to 5.5 seconds.
The Battery Discharge Indicator (BDI) interrupt will disable
the hydraulic controller if the connection at P10 loses the
12 volt signal from the traction control. BDI interrupt can be
disabled by Function 17 using the Handset. Select card type
with or without BDI function.
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL
Page 11
Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS
Section 3.1 Ordering Information for Separately Excited Controls
Example:
Part Number:
IC3645
SE
4
D
33
2
C3
Argument Number:
01
02
03
04
05
06
07
Argument 01:
Argument 02:
Basic Electric Vehicle Control Number
Control Type:
SP
SH
SR
=
=
=
Series Control (Pump)
Separately Excited Control ( Plugging )
Separately Excited Control ( Regen to Zero )
Argument 03:
Argument 04:
Argument 05:
Operating Voltage:
1
2
3
7
=
=
=
=
120 volts
24 volts
36 volts
4
5
6
=
=
=
48 volts
36/48 volts
24/36 volts
72/80 volts
Package Size:
D
R
U
W
=
=
=
=
6.86” X 6.67”
6.86” X 8.15”
8.66” X 8.13”
8.66” X 10.83”
Armature Current
( 2 characters )
22
33
40
=
=
=
220 Amps
330 Amps
400 Amps
etc.
Argument 06:
Argument 07:
Field Current
( 1 character )
2
3
4
=
=
=
20 Amps
30 Amps
40 Amps
etc.
Customer / Revision
A1
B1
=
=
Customer A / Revision 1
Customer B / Revision 1
etc.
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL
Page 12
Section 3.2 Outline: SX-3 and SR-3 Package Size
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL
Page 13
Section 3.3 Traction Elementary
U T R A E R A M
D L F I E
.
S E S W E V R E R
. W R A D S R W O F
.
S T W A R S T
U T R A E R A M
D L F I E
.
S W S E A T
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL
Page 14
Section 3.4 Pump Elementary
S P E E D 1
S P E E D 2
S P E E D 3
P L 2
L P L U G N T R C O O
S X -
2
U T R A E A R M
E L F D I
FU2
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
SX TRANSISTOR CONTROL
Page 15
Section 3.5. Traction and Pump Control Input and Output List
CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN)
TRACTION
PUMP
PIN
1
INPUT/OUTPUT DESCRIPTION
BATTERY VOLTS FROM BATTERY
INPUT/OUTPUT DESCRIPTION
BATTERY VOLTS FROM BATTERY
2
3
4
5
6
7
8
9
BATTERY VOLTS FROM KEY
BATTERY VOLTS FROM KEY
STATUS CODE 93 INPUT
STATUS CODE 93 INPUT
STATUS CODE 94 INPUT
STATUS CODE 94 INPUT
POTENTIOMETER INPUT VOLTAGE SIGNAL
STATUS CODE 95 INPUT
STATUS CODE 95 INPUT
PUMP ENABLE SIGNAL 12VDC
STATUS CODE 91 INPUT
SPEED LIMIT #1 INPUT
TMM1 BRUSHWEAR INDICATER OUTPUT
TMM1 OVER TEMPERATURE OUTPUT
STATUS CODE 92 INPUT
STATUS CODE 90 INPUT
LINE CONTACTOR DRIVER
1A CONTACTOR DRIVER
SPEED LIMIT #2 INPUT
SPEED LIMIT #3 INPUT
NOT USED
BATTERY VOLTS FROM START SWITCH
BATTERY VOLTS FROM FORWARD SWITCH
BATTERY VOLTS FROM REVERSE SWITCH
BATTERY VOLTS FROM SEAT SWITCH
ACCELERATOR INPUT VOLTAGE SIGNAL
STEER ANGLE POT NEGATIVE
STEER ANGLE POT +5 VOLTS SUPPLY
10 BDI INTERRUPT
11 PLUG/RGN OUTPUT SIGNAL +12V 1.0V=REGEN
12 STEER ANGLE INPUT VOLTAGE SIGNAL
13 RGN BRAKE POTENTIOMETER INPUT
14 TMM BRUSHWEAR
15 IMOTOR OUT
16 MOTOR CURRENT COMPENSATION
17 LINE CONTACTOR DRIVER AND SUPPRESSION
18 STEER PUMP CTR DRIVER AND SUPPRESSION
19 DASH DISPLAY + 5 VOLT SUPPLY
20 TMM OVERTEMP
21 NOT USED
22 SERIAL RECEIVE / DASH DISPLAY
23 SERIAL TRANSMIT / DASH DISPLAY
MOTOR PROPORTIONING "Y" PLUG
SERIAL RECEIVE
SERIAL TRANSMIT
PUMP "Y" PLUG
PIN
1
2
INPUT/OUTPUT DESCRIPTION
INPUT/OUTPUT DESCRIPTION
CLOCK (OUT)
DATA (OUT)
CLOCK (OUT)
DATA (OUT)
3
ENABLE (OUT)
ENABLE (OUT)
4
NEGATIVE
NEGATIVE
5
+5V SUPPLY
+5V SUPPLY
6
7
8
CONT/STORE (IN) (HANDSET)
EXTERNAL JUMPER TO PY12
VALUE
CONT/STORE (IN) (HANDSET)
EXTERNAL JUMPER TO PY12
VALUE
9
FUNCTION
FUNCTION
10 EXTERNAL JUMPER TO PY11
11 SERIAL RECEIVE / CONNECT TO P22
12 SERIAL TRANSMIT / CONNECT TO P23
EXTERNAL JUMPER TO PY11
SERIAL RECEIVE / CONNECT TO P22
SERIAL TRANSMIT / CONNECT TO P23
1
2
3
4
5
6
6
8
1
7
2
8
3
9
4
5
6
9
10
11
12
13
14
15
10
11
12
16
17
18
19
20
21
22
23
WIRE END VIEW "Y" PLUG
WIRE END VIEW - MAIN PLUG
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 16
Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES
Section 4.1 General Maintenance Instructions
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.
The transistor control, like all electrical apparatus, does
have some thermal losses. The semiconductor junctions
have finite temperature limits, above which these devices
may be damaged. For these reasons, normal maintenance
should guard against any action which will expose the
components to excessive heat and/or those conditions
which will reduce the heat dissipating ability of the control,
such as restricting air flow.
GE does not recommend that any type of welding be
performed on the vehicle after the installation of the
control(s) in the vehicle. GE will not honor control failures
during the warranty period when such failures are
attributed to welding while the control is installed in the
vehicle.
Section 4.2 Cable Routing and Separation
The following Do’s and Don’t’s should be observed:
Electrical noise from cabling of various voltage levels can
interfere with a microprocessor-based control system. To
reduce this interference, GE recommends specific cable
separation and routing practices, consistent with industry
standards.
Any controls that will be applied in ambient temperatures
over 100° F (40° C) should be brought to the attention of the
vehicle manufacturer.
All external components having inductive coils must be
filtered. Refer to vehicle manufacturer for specifications.
Section 4.2.1 Application Responsibility
The wiring should not be directly steam cleaned. In dusty
areas, blow low-pressure air over the control to remove
dust. In oily or greasy areas, a mild solution of detergent or
denatured alcohol can be used to wash the control, and
then low-pressure air should be used to completely dry the
control.
The customer and customer’s representative are
responsible for the mechanical and environmental
locations of cables. They are also responsible for applying
the level rules and cabling practices defined in this section.
To help ensure a lower cost, noise-free installation, GE
recommends early planning of cable routing that complies
with these level separation rules.
For the control to be most effective, it must be mounted
against the frame of the vehicle. The metal vehicle frame,
acting as an additional heat sink, will give improved vehicle
performance by keeping the control package cooler. Apply
a thin layer of heat-transfer grease (such as Dow Corning
340) between the control heat sink and the vehicle frame.
On new installations, sufficient space should be allowed to
efficiently arrange mechanical and electrical equipment.
On vehicle retrofits, level rules should be considered during
the planning stages to help ensure correct application and
a more trouble-free installation.
Section 4.2.2. Signal/PowerLevel Definitions
Control wire plugs and other exposed transistor control
parts should be kept free of dirt and paint that might
change the effective resistance between points.
The signal/power carrying cables are categorized into four
defining levels: low, high, medium power, and high power.
Within those levels, signals can be further divided into
classes.
CAUTION: The vehicle should not be plugged when the
vehicle is jacked up and the drive wheels are in a free
wheeling position. The higher motor speeds can create
excessive voltages that can be harmful to the control.
Sections 4.2.2.a through 4.2.2.d define these levels and
classes, with specific examples of each. Section 4.2.3
contains recommendations for separating the levels.
Do not hipot (or megger) the control. Refer to control
manufacturer before hipotting.
4.2.2.a Low-Level Signals (Level L)
Use a lead-acid battery with the voltage and ampere hour
rating specified for the vehicle. Follow normal battery
maintenance procedures, recharging before 80 percent
discharged with periodic equalizing charges.
Low-level signals are designated as level L. These consist
of:
•= Analog signals 0 through ±15 V
•= Digital signals whose logic levels are less than 15 V DC
•= 4 – 20 mA current loops
•= DC busses less than 15 V and 250 mA
Visual inspection of GE contactors contained in the traction
and pump systems is recommended to occur during every
The following are specific examples of level L signals used
in drive equipment cabling:
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 17
customer must apply the general guidelines (section
•= Control common tie
4.2.3.a), outlined below.
•= DC buses feeding sensitive analog or digital hardware
•= All wiring connected to components associated with
sensitive analog hardware with less than 5V signals (for
example, potentiometers and tachometers)
•= Digital tachometers and resolvers
•= Dash display cabling
4.2.3.a General Cable Spacing
The following general practices should be used for all
levels of cabling:
•= RS-232 cabling
•= All cables and wires of like signal levels and power
levels must be grouped together.
•= In general, different levels must run in separate wire
bundles, as defined in the different classes, identified
above. Intermixing cannot be allowed, unless noted by
exception.
Note: Signal inputs to analog and digital blocks should be
run as shielded twisted-pair (for example, inputs from
tachometers, potentiometers, and dash displays).
4.2.2.b High-Level Signals (Level H)
•= Interconnecting wire runs should carry a level
designation.
High-level signals are designated as level H. These signals
•= If wires are the same level and same type signal, group
those wires from one location to any other location
together in multiconductor cables or bind them
together with twine or zip-ties.
consist of:
•= Analog and digital signals greater than 15 V DC and
less than 250 mA
•= When unlike signals must cross, cross them in 90°
angles at a maximum spacing. Where it is not possible
to maintain spacing, place a grounded steel barrier
between unlike levels at the crossover point.
For example, switch inputs connected to battery volts are
examples of level H signals used in drive equipment
cabling.
4.2.4 Cabling for Vehicle Retrofits
4.2.2.c Medium-Power Signals (Level MP)
Reducing electrical noise on vehicle retrofits requires
careful planning. Lower and higher levels should never
encircle each other or run parallel for long distances.
It is practical to use existing wire runs or trays as long as
the level spacing (see section 4.2.2) can be maintained for
the full length of the run.
Medium power signals are designated as level MP. These
signals consist of:
•= DC switching signals greater than 15 V
•= Signals with currents greater than 250 mA and less than
10A
Existing cables are generally of high voltage potential and
noise producing. Therefore, route levels L and H in a path
separate from existing cables, whenever possible.
The following are specific examples of level MP signals
used in drive equipment cabling:
For level L wiring, use barriers in existing wire runs to
minimize noise potential.
•= DC busses less than 10 A
•= Contactor coils less than 10 A
•= Machine fields less than 10 A
Do not loop level L signal wires around level H, level MP, or
HP wires.
4.2.2.d. High Power Signals (Level HP)
4.2.5 RF Interference
Power wiring is designated as level HP. This consists of DC
buses and motor wiring with currents greater than 10 A.
The following are specific examples of level HP signals
used in drive equipment cabling:
To prevent radio frequency (RF) interference, care should
be taken in routing power cables in the vicinity of radio-
controlled devices.
•= Motor armature loops
•= DC outputs 10 A and above
Section 4.2.6 Suppression
•= Motor field loops 10 A and above
Unless specifically noted otherwise, suppression (for
example, a snubber) is required on all inductive devices
controlled by an output. This suppression minimizes noise
and prevents damage caused by electrical surges.
4.2.3. Cable Spacing Guidelines
Recommended spacing (or clearance) between cables (or
wires) is dependent on the level of the wiring inside them.
For correct level separation when installing cable, the
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 18
2. Locate the plug that contains the socket (female)
Section 4.3 Recommended Lubrication of Pins and
Sockets Prior to Installation
terminals. Maintenance needs only to be performed on
the plug containing the socket (female) type terminals.
Reconnecting the plugs will lubricate the pin (male)
terminals.
Beginning in January of 1999, GE will implement the
addition of a lubricant to all connections using pins and
sockets on EV100/EV200 and Gen II products. Any
connection made by GE to the A, B, X, Y, or Z plugs will
have the lubricant NYE 760G added to prevent fretting of
these connections during vehicle operation.
3. Clean each terminal using Chemtronics contact
cleaner “Pow-R-WasH CZ “ as shown in Figure 1.
Fretting occurs during microscopic movement at
the contact points of the connection. This movement
exposes the base metal of the connector pin which, when
oxygen is present, allows oxidation to occur. Sufficient
build up of the oxidation can cause intermittent contact
and intermittent vehicle operation. This can occur at any
similar type of connection, whether at the control or in any
associated vehicle wiring, and the resultant intermittent
contact can provide the same fault indication as actual
component failure.
s
c
i
n
o
r
t
m
e
h
C
r
e
n
a
e
l
c
t
c
a
t
n
o
c
e
n
a
z
o
r
i
c
The addition of the NYE 760G lubricant will prevent
the oxidation process by eliminating the access of oxygen
to the contact point. GE recommends the addition of this
lubricant to the 12 pin and 23 pin plugs of all new Gen II
controls at the time of their installation into a vehicle
Figure 1
4. Lubricate each terminal using Nye 760G lubricant as
shown in figure 2. Apply enough lubricant to each
terminal opening to completely fill each opening to a
depth of .125” minimum.
When servicing existing vehicles exhibiting
symptoms of intermittent mis-operation or shutdown by the
GE control, GE recommends the addition of this lubricant to
all 12 and 23 pin plugs, after proper cleaning of the
connectors, as a preventative measure to insure fretting is
not an issue before GE control replacement. Also, for long
term reliable control operation, the plug terminals must be
maintained per these instructions with the recommended
contact cleaner and lubricant which provides a high
degree of environmental and fretting protection.
New and re-manufactured control plugs are cleaned and
lubricated prior to shipment from the factory. However, in
applications where severe vibration or high temperature
cycling and excessive humidity ( such as freezers ) are
present, it is recommended that the plug terminals be
cleaned and lubricated every year, per this instructions. In
normal applications, plug maintenance should be
performed every two years, unless intermittent problems
arise with the plugs, requiring more immediate attention.
Warning: Do not use any other cleaners or lubricants
other than the ones specified.
Figure 2
5. Reconnect plugs.
Reference
Cleaner
Chemtronics Pow-R-WasH CZ Contact
Cleaner
WARNING: Before conducting maintenance on the
vehicle, jack up the drive wheels, disconnect the battery
and discharge the capacitors. Consult the Operation and
Service Manual for your particular vehicle for details on
discharging the capacitors; this procedure differs
between SCR and Transistor controls.
Lubricant
Nye Lubricants NYOGEL 760G
GE Plug Lub Kit Contains both above products:
328A1777G1
1. Disconnect plug from controller or mating plug.
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 19
Section 4.4 General Troubleshooting Instructions
Trouble-shooting the SX family of controls should be quick
and easy when following the instructions outlined in the
following status code instruction sheets.
If mis-operation of the vehicle occurs, a status code will be
displayed on the Dash Display (for vehicles equipped with a
Dash Display) or made available by plugging a Handset into
the plug "Y" location, and then reading the status code.
Note: Status code numbers from 00 to 99 are traction
control status codes. Status codes with the prefix 1 (101 to
199) are pump control status codes.
With the status code number, follow the procedures
outlined in the status code instruction sheets to determine
the problem.
Important Note: Due to the interaction of the logic card
with all vehicle functions, almost any status code or
control fault could be caused by the logic card. After all
other status code procedures have been followed and no
problem is found, the controller should then be replaced as
the last option to correct the problem.
The same device designations have been maintained on
different controls but the wire numbers may vary. Refer to
the elementary and wiring diagrams for your specific
control. The wire numbers shown on the elementary
diagram will have identical numbers on the corresponding
wiring diagrams for a specific vehicle, but these numbers
may be different from the numbers referenced in this
publication.
WARNING: Before trouble-shooting, jack up the drive
wheels, disconnect the battery and discharge the
capacitors. Reconnect the battery as needed for specific
checks. Capacitors should be discharged by connecting a
200 ohm 2 watt resistor between the positive and negative
terminals on the control panel.
Check resistance on R x 1000 scale from frame to power
and control terminals. A resistance of less than 20,000
ohms can cause misleading symptoms. Resistance less
than 1000 ohms should be corrected first.
Before proceeding, visually check for loose wiring,
mis-aligned linkage to the accelerator switch, signs of
overheating of components, etc.
Tools and test equipment required are: clip leads, volt-ohm
meter (20,000 ohms per volt) and basic hand tools.
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 20
Section 4.5 Traction Control Codes
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Segments do not illuminate on the
Dash Display and/or the Handset.
No input voltage to the control card or the display unit.
NONE
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Circuits valid
for
Display screen on Dash Display and/or Handset
is blank.
KEY
SWITCH
FU3
Traction
Controller
POSSIBLE CAUSE
Positive or negative control voltage is not
present.
FU5
•= Insure that the key switch is closed and
voltage is present between P1 & battery
negative (Power Terminal “NEG”). Also check
for voltage between P2 and control negative.
+
-
Open circuit between control card AND the Dash
Display or Handset.
P1 P2
NEG
•= Check for an open circuit or loose connection
going from the control and the Dash Display or
Handset.
Defective Dash Display or Handset.
•= Replace Dash Display or Handset.
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-01
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid
for
Traction
Controller
KEY
SWITCH
FU3
POSSIBLE CAUSE
Mis-adjusted or defective seat or deadman
switch.
FU5
•= Check to see that the seat switch closes
properly.
+
Open circuit between battery positive and P6.
•= Check for loose connections or broken wires:
−= Between the seat switch and P6
−= Between the key switch and the battery
positive side of the seat switch.
-
P1 P2 P6
NEG
−= Between the seat switch and P2.
•=On vehicles without a seat/deadman switch,
check for a loose connection or broken wire
from P2 and/or P6.
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 21
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Forward directional switch is closed on This status code will be displayed when P4 is greater
initial power up.
than 60% of battery voltage at initial key switch on.
-02
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
KEY
SWITCH
Control will not operate because of Static Return
to Off (SRO) lock out.
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Forward directional switch is closed on initial
start up (i.e. closure of battery, key switch or
seat switch).
L
•= Return directional switch lever to neutral and
then return lever to forward position.
Forward directional switch is welded closed or
mis-adjusted to be held closed.
•= Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.
Short circuit between P3 and P4.
•= Disconnect the wire from P4 and check for a
short circuit between P3 and the wire that was
connected to P4.
P1 P17
P2
P6
P3
P4
P5
Defective control.
•= Replace the controller unit.
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Reverse directional switch is closed on This status code will be displayed when P5 is greater
initial power up.
than 60% of battery voltage at initial key switch on.
-03
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
KEY
SWITCH
Control will not operate because of Static Return
to Off (SRO) lock out.
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
seat/deadman switch).
L
•= Return directional switch lever to neutral and
then return lever to reverse position.
Reverse directional switch is welded closed or
mis-adjusted to be held closed.
•= Replace or adjust directional switch to insure
that it opens when the directional switch is
returned to neutral.
Short circuit between P3 and P5.
•= Disconnect the wire from P5 and check for a
short circuit between P3 and the wire that was
connected to P5.
P1 P17
P2
P6
P3
P4
P5
Defective control. Replace the controller unit.
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 22
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Start switch fails to close.
This status code will be displayed when P7 is less
than 2.5 volts and P3 is less than 60% of battery volts.
-05
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
KEY
SWITCH
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Defective start switch circuit.
•= Check start switch to insure closure when
accelerator is depressed.
•= Check for open circuit or loose connections in
wiring from brake switch to start switch and
from P3 to start switch.
L
Defective accelerator switch.
NEG
•= Check accelerator switch potentiometer for
proper operation and ohmic value.
P1 P17
P2
P6
P3
P4
P5
P7
KEY SWITCH
ACCPOT
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-06
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
KEY
Control will not operate.
SWITCH
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Accelerator pedal is depressed before closing
forward or reverse directional switch.
•= Status code will disappear when directional
switch is closed or when accelerator pedal is
released.
L
Defective directional switch
•= Check forward or reverse switch to insure
closure when direction is selected.
NEG
Open circuit between directional switch(es) and
battery positive or between directional switch(es)
and P4 or P5.
P1 P17
P2
P6
P3
P4
P5
P7
KEY SWITCH
•= Check all control wires and connections shown
in Trouble Shooting Diagram.
ACCPOT
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 23
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Accelerator input voltage too high on
power up after initial key switch
closure.
This status code will be displayed when the
accelerator input voltage at P7 is higher than 4.2
volts, and a directional contactor is picked up.
-07
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate when accelerator pedal
is depressed or status code -07 is displayed
then disappears when the vehicle starts to
accelerate.
Circuits valid
for
Traction
Controller
P7
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
•= Input voltage at P7 should be less than 3.7
volts. Adjust or replace accelerator unit to
insure that the voltage at P7 will vary from 3.5
volts to less than .5 volts when the pedal is
depressed.
KEY
NEGATIVE
SWITCH
Open circuit between battery negative and P7 in
accelerator input circuit.
•= Check for broken wires or loose connections
or open potentiometer / voltage supply.
ACC POT
Short circuit from battery positive to wiring in
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.
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Accelerator input voltage too low on
power up after initial key switch
closure.
This status code will be displayed when the
accelerator input voltage at P7 is less than 3.0 volts,
and any of the following connections are opened and
closed: battery plug or key switch.
-08
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
P7
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
•= Input voltage at P7 should be more than 3.0
volts. Adjust or replace accelerator unit to
insure that the voltage at P7 is more than 3.0
volts before depressing pedal.
KEY
NEGATIVE
SWITCH
Short circuit between battery negative and P7 in
accelerator input circuit.
•= Disconnect wire from P7. Check for short
circuit from wire to battery negative.
ACC POT
Defective Control
•= Disconnect wire from P7. Measure voltage
from P7 to negative. Voltage should be greater
than 4.5 volts, if not, replace control.
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 24
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Both the forward and reverse
directional switches are closed at the
same time.
This status code will be displayed when P4 and P5
are greater than 60% of battery volts at the same
time.
-09
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
KEY
SWITCH
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Forward or reverse directional switch welded
closed or mis-adjusted to be held closed.
•= Replace or adjust directional switches to
insure that they open when directional switch
is returned to neutral.
L
Short circuit between battery positive and P4
and/or P5.
•= Disconnect wires from P4 and P5 and check
wire for short circuit to positive side of
directional switch.
Defective Control
•= Disconnect wires and measure voltage at P4
and P5. Voltage should be less than 60% of
battery volts.
P1 P17
P2
P6
P3
P4
P5
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Steer angle potentiometer voltage is
too high.
This status code will be displayed when P12 is greater
than 3.9 volts.
-10
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Steer angle potentiometer input mis-adjusted or
defective. Loose or missing connections at P8,
P12 or P9.
•= Input voltage at P12 should be less than 3.9
volts at all times. Insure that the adjustment
of the steer potentiometer is in accordance
with Section 9 of this instruction.
P8
P9 P12
Defective control.
•= Replace control unit.
STEER ANGLE
POT
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 25
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-11
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
KEY
SWITCH
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Start switch input mis-adjusted or defective.
•= Input voltage at P3 should be less than 60% of
battery volts at key switch closing. Adjust or
replace accelerator unit to insure that the
voltage at P3 is less than 60% of battery volts
before closing the start switch.
L
Short circuit between battery positive and P3 in
start switch input circuit.
•= Disconnect wire from P3. Check for short
circuit from this wire to battery positive.
Defective control.
•= Disconnect wire from P3. Measure voltage
from P3 to negative. Voltage should be zero,
if not, replace control.
P1 P17
P2
P6
P3
P4
P5
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Steer angle potentiometer voltage is
too low.
This status code will be displayed when P12 is less
than 0.39 volts.
-12
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid
for
Traction
Controller
POSSIBLE CAUSE
Steer angle potentiometer input mis-adjusted or
defective. Loose or missing connections at P9,
P12 or P8.
•= Input voltage at P12 should be greater than
0.39 volts at all times. Insure that the
adjustment of the steer potentiometer is in
accordance with Section 9 of this instruction.
P9 P12 P8
Defective control.
•= Replace control unit.
STEER ANGLE
POT
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 26
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Battery voltage is too low or control
card is mis-adjusted.
This status code will be displayed when the battery
volts are less than 1.95 volts per cell at initial key
switch on. See table below.
-15
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU5
Control will not operate.
Circuits valid
for
Traction
Controller
MINIMUM
NOMINAL
POSSIBLE CAUSE
Discharged battery
•= Check battery for proper open circuit voltage
as shown in “Trouble Shooting Diagram”,
charge battery, if required.
LIMIT VOLTS
BATTERY
AT 1.95 VDC
VOLTAGE
PER CELL
24
36
48
72
80
23.4
35.1
46.8
70.2
78.0
Defective battery
P1
+
-
•= Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or
repair battery.
Incorrect control card adjustment.
NEG
•= Check Function 15 for proper adjustment for
battery being used. See Handset instruction
sheet for details. Adjust to proper settings.
Check “minimum” battery volts at P1 and NEG.
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Battery voltage is too high or control
card is mis-adjusted.
This status code will be displayed when the battery
volts are greater than 2.4 volts per cell at initial key
switch on. See table below.
-16
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
FU5
Control will not operate.
Circuits valid
for
Traction
Controller
MINIMUM
NOMINAL
POSSIBLE CAUSE
LIMIT VOLTS
BATTERY
Incorrect control card adjustment
Check Function 15 for proper adjustment for
battery being used. See Handset instructions
for details. Adjust to proper setting.
AT 1.95 VDC
VOLTAGE
PER CELL
24
36
48
72
80
23.4
35.1
46.8
70.2
78.0
Battery over charged or incorrect battery used.
•= Check battery for proper open circuit voltage
per table at right. If voltage is excessive, check
battery charger for proper output voltage.
P1
+
-
Check “maximum” battery volts at P1 and NEG.
NEG
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 27
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor field current is high on start up in This status code will be displayed when the current
the reverse direction.
draw in the motor field is too high at start up in the
reverse direction.
-23
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor field current is high on start up in This status code will be displayed when the current
the forward direction.
draw in the motor field is too high at start up in the
forward direction.
-24
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective Control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 28
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Control’s power supply is less than 10
Volts DC.
This status code will be displayed when the control’s
power supply is less than 10 volts.
-27
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
KEY
SWITCH
Line contactor opens and closes, then can only
be closed by opening and closing the key
switch.
FU3
Circuits valid
for
Traction
Controller
FU5
POSSIBLE CAUSE
Discharged Battery
•= Check battery to insure proper state of charge.
Voltage may be dropping below 10 Volts DC
under load.
+
Loose connection at P1.
-
•= Insure that the wire connection at P1 is tight.
P1 P2
NEG
Defective control.
•= Replace controller unit.
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor field current is too high during
the run mode.
This status code will be displayed when the current
draw in the motor field is sustained above a preset
limit for longer than 70 seconds.
-28
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Continued operation of vehicle in high motor
current condition.
•= Operate vehicle at lower motor current
condition for 70 seconds.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
Function 7 is mis-adjusted to allow higher than
normal motor field current.
FU1
LINE
Adjust function per OEM instructions.
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 29
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor field current is too high during
the run mode (Dual motor
proportioning controls only)
This status code will be displayed when the motor
current in control “A” is greater than 98A, while the
motor current in control “B” is less than 26A for a 16
second interval.
-29
MEMORY RECALL
CORRECTIVE ACTIONS
YES
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Continued operation of vehicle in high motor current condition.
•= Verify operation of other control during the run mode.
Circuits valid
for
Traction
Controller
TROUBLE-SHOOTING DIAGRAM
12
BRAKE SW.
KEY SWITCH
P5
P1
SP
FU5
FU7
P2
L
TO ACCESSORIES
24
60
P4
FU6
P3
8
15
6
10
7
12-1
PLUG PY
10
12-1
CONNECTIONS
PY7
PY7
OSCILLATOR CARD
RIGHT CONTROL
P15
PY12
PY10
PY11
P5
P1 P2 P6 P3 P4
P18
P3
P4
P10
P5
PY12
PY10
PY11
P16
P15
P1 P2
P6
P17
P21 P16
P10 P7 P12P13
P18
P7
P9 P12 P8
P11
OSCILLATOR CARD
LEFT CONTROL
PLUG PY
CONNECTIONS
25
29
66 65
50 30
PMT ENABLE OUTPUT
LINE
AUTO REGENERATIVE
BRAKING ENABLE
FU1
3
STEER PUMP
CONTACTOR DRIVER
ACC POT
13A
REGEN OUTPUT
SIGNAL
STEER ANGLE
POT
5
2
BDI INTERRUPT
FU2
+
FU4
A1
43
TMM7
P
A1
88
A1
A2
A1
A2
-
A2
S1
F1
POS
A1
F1
POS
A1
SP
POWER CONNECTIONS
LEFT CONTROL
POWER CONNECTIONS
RIGHT CONTROL
89
TMM7
SP
NEG
A2
F2
A2
NEG
F2
A2
S2
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 30
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
PMT enable signal from auxiliary
control to master at PL21 is missing
during SRO check (Dual motor
proportioning controls only)
This status code will be displayed when the voltage at
PL21 of the master control is less than 5 volts. This
fault is not stored.
-30
MEMORY RECALL
CORRECTIVE ACTIONS
NO
SYMPTOM
Auxiliary control shutdown.
POSSIBLE CAUSE
Circuits valid
for
Traction
Controller
•= Check auxiliary control for status codes.
•= Verify connection between PL21 of the master control and PL10
of the slave/auxiliary control.
TROUBLE-SHOOTING DIAGRAM
12
BRAKE SW.
KEY SWITCH
P5
P1
SP
FU5
FU7
P2
L
TO ACCESSORIES
24
60
P4
FU6
P3
8
15
6
10
7
12-1
PLUG PY
10
12-1
CONNECTIONS
PY7
PY7
OSCILLATOR CARD
RIGHT CONTROL
P15
PY12
PY10
PY11
P5
P1 P2 P6 P3 P4
P18
P3
P4
P10
P5
PY12
PY10
PY11
P16
P15
P1 P2
P6
P17
P21 P16
P10 P7 P12P13
P18
P7
P9 P12 P8
P11
OSCILLATOR CARD
LEFT CONTROL
PLUG PY
CONNECTIONS
25
29
66 65
50 30
PMT ENABLE OUTPUT
LINE
AUTO REGENERATIVE
BRAKING ENABLE
FU1
3
STEER PUMP
CONTACTOR DRIVER
ACC POT
13A
REGEN OUTPUT
SIGNAL
STEER ANGLE
POT
5
2
BDI INTERRUPT
FU2
+
FU4
A1
43
TMM7
P
A1
88
A1
A2
A1
A2
-
A2
S1
F1
POS
A1
F1
POS
A1
SP
POWER CONNECTIONS
LEFT CONTROL
POWER CONNECTIONS
RIGHT CONTROL
89
TMM7
SP
NEG
A2
F2
A2
NEG
F2
A2
S2
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 31
Open thermal protector (TP) or
transistor over temperature.
This status code will be displayed when the voltage at
the thermal protector is too high.
-41
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Circuits valid
for
Reduced or no power to traction motor in control
range.
BRAKE SW.
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
Traction
Controller
POSSIBLE CAUSE
TO
L
Control is in thermal cut-back.
•= Allow control to cool, status code should
disappear.
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
Defective control.
•= Replace controller unit.
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor armature offset voltage is too
high.
This status code will be displayed when the voltage at
the current sensor input is greater than 2.6 volts with
no current flowing in the motor circuit.
-42
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 32
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-43
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Armature transistor did not turn off
properly.
This status code will be displayed when, during
control operation, the armature transistor fails to turn
off. This will result in a PMT condition.
-44
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
BRAKE SW.
Line contactor opens and closes, then can only
be closed by opening and closing the key switch.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 33
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-45
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
BRAKE SW.
Line contactor opens and closes, then can only
be closed by opening and closing the key
switch.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
L
ACCESSORIES
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
“Look Ahead” test for A2 volts less
than 12% of battery volts.
This status code will be displayed when the voltage at
A2 is less than 12% of battery volts.
-46
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Line contactor will not pick up.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
POSSIBLE CAUSE
Check for short circuit from the motor armature
to the frame of the vehicle.
L
ACCESSORIES
P4
FU6
P3
PY7
Defective control.
•= Replace controller unit.
P4
P7 P10 P9 P12 P8
PY12
PY10
PY11
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 34
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor field current is too low during the This status code will be displayed when the current
run mode.
draw in the motor field is too low during the run mode.
-49
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Capacitor volts are low before the line
contactor closes.
This status code will be displayed during “key on”
when the capacitor voltage is less than 85% of battery
volts at initial key switch on.
-51
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Line contactor does not close when capacitor
does not precharge.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
L
ACCESSORIES
POSSIBLE CAUSE
Defective control fuse.
•= Check control fuse for open circuit. Replace
fuse, if necessary.
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
Defective control.
•= Replace controller unit.
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 35
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Controller “motor current sensor”
input too low during running.
This status code will be displayed when the voltage
input from the current sensor is too low during running.
-57
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
Defective control.
•= Replace controller unit.
TO
L
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
The line driver input (P2-17) is less
than 12% of battery volts
This status code will be displayed when the control
detects that the line driver input (P2-17) is less than
12% battery volts when the key switch is turned on.
-64
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
-Open wire connection to Pin 17
- Shorted line Driver transistor
TO
L
ACCESSORIES
P4
FU6
P3
Defective control.
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
•= Replace controller unit.
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 36
TRACTION
STATUS CODE
DESCRIPTION OF
CAUSE OF STATUS INDICATION
STATUS
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 will drop
out and the key switch will have to be recycled to reset the control.
-65
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
TO
L
ACCESSORIES
- Shorted line contactor coil
- Short between wires connected to
line coil (wires #10 and 24)
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
If line coil resistance is correct:
Defective control.
FU1
LINE
•=
Replace controller unit.
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF
STATUS
CAUSE OF STATUS INDICATION
The field current exceeds the
current limit of the field transistor.
This status code will be displayed when the field transistor exceeds
its specific current limit. The line contactor will drop out and the key
switch will have to be recycled to restart the control.
-66
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
•=
Line contactor opens
POSSIBLE CAUSE
TO
L
•= Shorted field F1 to F2
•= F1 or F2 terminals shorted to battery
positive (B+)
•= F1 or F2 terminals shorted to battery
negative (B-)
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 37
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
The armature current exceeds the
armature transistor limit.
This status code will be displayed when the armature
transistor exceeds its specific current limit. The
control is reset by recycling the key switch.
-67
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
TO
L
•= Shorted motor armature A1 to A2
•= Power cables may be shorted to each other
(Measure at control terminals)
•= A1 to A2 terminals may be shorted to battery
positive or negative
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 38
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
The PMT enable signal from the
auxiliary (slave) control to the master
control drops below 5V.
This status code will be displayed when the voltage at
the master PL21 drops below 5V.
-68
MEMORY RECALL
CORRECTIVE ACTIONS
YES
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Auxiliary control shut down.
•= Check auxiliary control for stored faults.
Circuits valid
for
Traction
Controller
Verify connection between the master control P21 and the
auxiliary/slave control P10.
TROUBLE-SHOOTING DIAGRAM
12
BRAKE SW.
KEY SWITCH
P5
P1
SP
FU5
FU7
P2
L
TO ACCESSORIES
24
60
P4
FU6
P3
8
15
6
10
7
12-1
PLUG PY
10
12-1
CONNECTIONS
PY7
PY7
OSCILLATOR CARD
RIGHT CONTROL
P15
PY12
PY10
PY11
P5
P1 P2 P6 P3 P4
P18
P3
P4
P10
P5
PY12
PY10
PY11
P16
P15
P1 P2
P6
P17
P21 P16
P10 P7 P12P13
P18
P7
P9 P12 P8
P11
OSCILLATOR CARD
LEFT CONTROL
PLUG PY
CONNECTIONS
25
29
66 65
50 30
PMT ENABLE OUTPUT
LINE
AUTO REGENERATIVE
BRAKING ENABLE
FU1
3
STEER PUMP
CONTACTOR DRIVER
ACC POT
13A
REGEN OUTPUT
SIGNAL
STEER ANGLE
POT
5
2
BDI INTERRUPT
FU2
+
FU4
A1
43
TMM7
P
A1
88
A1
A2
A1
A2
-
A2
S1
F1
POS
A1
F1
POS
A1
SP
POWER CONNECTIONS
LEFT CONTROL
POWER CONNECTIONS
RIGHT CONTROL
89
TMM7
SP
NEG
A2
F2
A2
NEG
F2
A2
S2
P
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 39
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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 recycling the key switch.
-69
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Control will not operate.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
POSSIBLE CAUSE
TO
L
•=
•=
Shorted power steering control coil
Short between wires connecting to the
power steering coil (wire # 10 and 60)
ACCESSORIES
P4
FU6
P3
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
If the power steering coil resistance is correct
then:
OSCILLATOR CARD
LEFT CONTROL
•=
Defective control. Replace control unit
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Capacitor (1C) voltage too high.
This status code will be displayed when the voltage on the
capacitor goes above limit voltage* during the regenerative
braking cycle.
-76
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
BRAKE SW.
Line contactor opens and closes, then
opens and can only close by opening
and closing the key switch.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
L
ACCESSORIES
P3
P4
FU6
POSSIBLE CAUSE
•=Unplugging the battery connector
during regenerative braking.
•=Line contactor bouncing open during
regen.
PY7
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
•=Main power fuse opening during
regen.
•=Intermittent battery plug connection.
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
* Limit Voltage:
Limit
50V
70V
96V
Batt.
36V
48V
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
72/80V
A2
NEG
F2
SP
P
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 40
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Motor current is detected during
regenerative braking.
This status code will be displayed when motoring current is
detected during the regenerative braking cycle.
-77
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
BRAKE SW.
Line contactor opens and closes, then
opens and can only close by opening and
closing the key switch.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
L
ACCESSORIES
P3
P4
FU6
POSSIBLE CAUSE
Defective control.
PY7
•=Replace controller unit
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
When armature motor current is greater
than 400 amps for more than 3.5 sec the
armature motor current will be turned off.
This status code will be displayed when the armature motor
current exceeds 400 amps for 3.5 sec and the accelerator
pedal is calling for maximum performance.
-82
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
The Control will not operate, and can only
be reset by cycling the key switch.
BRAKE SW.
Circuits valid
for
Traction
Controller
FU5
FU7
KEY SWITCH
P5
P1
SP
P2
TO
L
POSSIBLE CAUSE:
•= Continued operation of vehicle in high
motor current condition
ACCESSORIES
P4
FU6
P3
PY7
•= Operating control at stall motor current
for more than 3.5 seconds.
•= Function 16 is incorrectly adjusted for
control % on time.
PY12
PY10
PY11
P4
P7 P10 P9 P12 P8
P18 P17
P3
P5
P1 P2 P6
OSCILLATOR CARD
LEFT CONTROL
FU1
LINE
STEER
- Adjust function per OEM
instructions
ANGLE
POT
FU2
ACC POT
POS A1
BDI INTERRUPT
+
FU4
AP
A1
POWER
F1
POS
F1
-
POWER
CONNECTIONS
LEFT CONTROL
SP
CONNECTIONS
RIGHT CONTROL
NEG
A2
F2
A2
NEG
F2
SP
P
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 41
Section 4.6 TMM Status Codes
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Traction motor temperature has
This status code will be displayed when the voltage at
exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic
Card is at zero volts.
-90
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
Traction
Motor
Temperature
POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Plug P16 (pump) is shorted to battery negative.
Defective input switch (shorted).
Defective TMM card.
P16
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
NEG
SC90
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Pump motor temperature has
This status code will be displayed when the voltage at
exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic
Card is at zero volts.
-91
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
Traction
Motor
Temperature
POSSIBLE CAUSE
User defined status code is displayed by switch
closure to battery negative.
Plug P11 (pump) is shorted to battery negative.
Defective input switch (shorted).
Defective TMM card.
P11
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
NEG
SC91
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 42
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-93
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Steer
Pump
Motor
Brush Wear
Indicator
Plug P3 (pump) is shorted to positive.
Defective input switch (shorted).
Defective TMM card.
P3
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
POS
SC93
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-93
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Steering
Pump
Motor
Brush Wear
Indicator
Plug P4 (pump) is shorted to positive.
Defective input switch (shorted).
Defective TMM card.
P4
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
POS
SC93A
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 43
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Traction motor brush wear indicator
has detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
-94
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
Traction
Motor
Brush Wear
Indicator
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Plug P5 (pump) is shorted to positive.
Defective input switch (shorted).
Defective TMM card.
P5
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
POS
SC94
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
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.
-94
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
Traction
Motor
Brush Wear
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
.
Plug P6 (pump) is shorted to positive.
P6
WHEN SR Series PUMP
Defective input switch (shorted).
Defective TMM card.
CONTROL IS USED
Defective pump card.
USER SW
POS
SC94A
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 44
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Pump motor brush wear indicator has
detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
-95
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Pump
Motor
Brush Wear
Indicator
Plug P8 (pump) is shorted to positive.
Defective input switch (shorted).
Defective TMM card.
P8
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
POS
SC95
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Pump motor brush wear indicator has
detected worn brush.
This status code will be displayed when the voltage at
the respective terminal of the TMM or Pump Logic
Card is at battery volts.
-95
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code flashes “on and off”.
Circuits valid
for
POSSIBLE CAUSE
User defined status code is displayed by motor
brush sensor closure to battery positive.
Pump
Motor
Brush Wear
Indicator
Plug P9 (pump) is shorted to positive.
Defective input switch (shorted).
Defective TMM card.
P9
WHEN SR Series PUMP
CONTROL IS USED
Defective pump card.
USER SW
POS
SC95A
January 2000
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DIAGNOSTIC STATUS CODES
SX TRANSISTOR CONTROL
Page 45
TRACTION
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Maintenance alert and speed limit.
This status code will be displayed when the “normal”
hour meter exceeds the “maintenance alert hours”
setting for the vehicle.
-99
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Status code is displayed for 4 seconds when the
key switch is first turned on, and/or the vehicle
may run at a reduced speed.
Circuits valid
for
Traction
Controller
NO DIAGRAM
CUSTOMER SELECTED SETTING WITH THE
HANDSET:
User defined status code is displayed when the
normal hour meter reading exceeds the
programmed “maintenance alert hours” setting
selected by the user
•= Maintenance Code Hour Meter, Functions 19
and 20, are programmed with the Handset and
command the display of status code -99.
•= If desired, Maintenance Code Speed Limit,
Function 13, can be programmed with the
Handset.
USER SHOULD PERFORM THE DESIRED
MAINTENANCE FUNCTION
User should perform the desired maintenance
function. Re-set maintenance alert hour meter
after maintenance is performed.
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 46
Section 4.7 Pump Control Codes
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
“Card Type” selection is invalid.
This status code will be displayed when the card type
selection value is set to an invalid number.
-117
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate.
Circuits valid
for
Pump
Controller
NO
GRAPHIC
POSSIBLE CAUSE
Invalid card type selection.
•=Review function 17 in the Handset
Instruction sheets. Adjust and set
card type value as instructed by OEM
service manual.
FOR THIS
STATUS CODE
Verify that the correct logic card
catalog number is installed in the
controller.
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Control logic card power supply is less
than 10 VDC.
This status code is displayed when the logic card
power supply is less than 10 volts.
-127
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
KEY SWITCH
FU3
SYMPTOM
Circuits valid
for
Control will not operate.
FU2
POSSIBLE CAUSE
Pump
Controller
Discharged Battery
•=Check battery to insure proper state of
charge.
LINE FU1
P1 P2
Loose connection at P1.
•=Insure that the wire connection at P1 is
tight.
+
Defective logic card
•=Replace control.
POS A1
-
POWER CONNECTIONS
NEG A2
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 47
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Armature current is too high during the Status code displayed when the current in the
lift mode.
armature circuit is sustained above 300A for 70 sec.
-128
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
KEY SWITCH
FU3
SYMPTOM
Circuits valid
for
Pump
Controller
Control will not operate.
FU2
POSSIBLE CAUSE
Continued operation of vehicle in high
motor current condition.
•=Operate vehicle at lower motor current
LINE FU1
condition for 70 seconds.
P1 P2
+
POS A1
-
POWER CONNECTIONS
NEG A2
PUMP
STATUS CODE
DESCRIPTION OF
STATUS
CAUSE OF STATUS INDICATION
Open thermal protector (TP1) or This status code is displayed when the voltage at the thermal
transistor is over temperature.
protector is greater than 0.8 volts.
-141
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
Reduced or no power to pump motor in
control range.
Circuits valid
for
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Pump
POSSIBLE CAUSE
Controller
Control is in thermal cut-back.
•= Allow control to cool, status code
should disappear.
FU1
LINE
+
-
POS
A1
POWER
CONNECTIONS
TO
TRACTION
CARD
NEG A2
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 48
PUMP
STATUS CODE
DESCRIPTION OF
CAUSE OF STATUS INDICATION
STATUS
Pump Controller “motor current
sensor” input is missing.
This status code is displayed when the voltage at the
current sensor is greater than 0.1 volts with no current
flowing in the motor circuit.
-142
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
No power to pump motor in
control range.
Circuits valid
for
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Pump
Controller
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Pump Controller “motor current
sensor” input is too low.
This status code is displayed when the voltage at the
current sensor is greater than 0.1 volts with no current
flowing in the motor circuit.
-143
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
No power to pump motor in
control range.
Circuits valid
for
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Pump
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
Controller
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 49
PUMP
STATUS CODE
DESCRIPTION OF
CAUSE OF STATUS INDICATION
STATUS
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.
-144
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
With no pump contactor, control
may run continuously.
Circuits valid
for
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Pump
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
Controller
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Power Transistor (Q1) did not turn on
properly.
This status code is displayed when during pump
control operation, the transistor fails to turn on.
-145
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
With no pump contactor, the control
may run continuously.
Circuits valid
for
Pump
Controller
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 50
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
“Look Ahead” test for T2 volts
less than 12% of battery volts.
This status code will be displayed when the voltage at T2 is
less than 12% of battery volts.
-146
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
Pump control will not operate.
Circuits valid
for
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Pump
POSSIBLE CAUSE
Check for short circuit from the
motor armature to the frame of
the vehicle.
Controller
FU1
LINE
Control is defective.
•=Replace controller unit.
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
PUMP
STATUS
CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Capacitor volts are low after the line
contactor closes.
This status code will be displayed when the capacitor voltage
is less than 85%of the battery voltage in the run mode.
-150
MEMORY
RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
YES
SYMPTOM
Pump control will not operate.
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
Circuits
valid for
Pump
PY7
POSSIBLE CAUSE
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
Defective line contactor.
•= Check for open line contactor power
tips.
Controller
Check for loose or open connections in
cables from battery positive to control
positive circuit.
FU1
LINE
Defective power fuse.
•= Check power fuse for open circuit.
+
-
POS
A1
No battery voltage at P1.
•= Check for battery voltage at POS and
P1.
POWER
CONNECTIONS
TO
TRACTION
CARD
NEG A2
•= Check for loose connection at P1.
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 51
PUMP
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
STATUS CODE
Capacitor volts are low before the line
contactor closes. (Internal card
function during precharge)
This status code will be displayed during “key on” when
the capacitor volts is less than 85% of battery volts at
initial key switch on.
-151
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Pump control will not operate.
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
Circuits valid
for
Pump
Controller
PY7
POSSIBLE CAUSE
Defective control fuse.
•=Check control fuse for open
circuit, replace fuse, if
necessary.
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
FU1
LINE
Defective control.
•=Replace controller unit.
+
-
Note: Repeated
POS
A1
“charging/discharging” the
capacitors during troubleshooting
will cause status code 51. Also
“do not” connect any loads to the
load side of the line contactor.
POWER
TO
TRACTION
CARD
CONNECTIONS
NEG A2
PUMP
STATUS CODE
DESCRIPTION OF
STATUS
CAUSE OF STATUS INDICATION
Controller “motor current
sensor” input voltage polarity
check.
This status code will be displayed when the voltage input to
motor current sensor is of the wrong polarity.
-157
MEMORY RECALL
CORRECTIVE ACTIONS
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
SYMPTOM
Pump control will not operate.
Circuits valid
for
Pump
Controller
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
POSSIBLE CAUSE
Control is defective.
•=Replace controller unit.
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
January 2000
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DIAGNOSTIC STATUS CODES
TRANSISTOR PUMP CONTROL
Page 52
PUMP
STATUS CODE
DESCRIPTION OF STATUS
CAUSE OF STATUS INDICATION
Voltage at capacitor (1C) is less than
14 volts.
This status code will be displayed when the voltage at
P1 is less than 14 volts. This occurs typically in the run
mode of operation.
-180
MEMORY RECALL
CORRECTIVE ACTIONS
SYMPTOM
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
Pump control will not operate.
Circuits valid
for
Pump
Controller
POSSIBLE CAUSE
(Line contactor controlled by traction
control).
Line Contactor opened up during run.
•= Check connection from P17 to Line
coil (-) for loose connection.
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
•= Check connection from battery (+) to
Line coil (+) for loose connection.
•= Check power connection from battery
(+) to contactor L.
FU1
LINE
•= Check for blown fuse at pump control.
•= Check for dirty contactor tips.
+
-
POS
A1
POWER
CONNECTIONS
TO
TRACTION
CARD
NEG A2
PUMP
STATUS CODE
DESCRIPTION OF
STATUS
CAUSE OF STATUS INDICATION
Battery voltage is less than 14
volts.
This status code will be displayed when the battery voltage
measured at P1 is less than 14 volts.
-181
MEMORY RECALL
CORRECTIVE ACTIONS
SYMPTOM
TROUBLE-SHOOTING DIAGRAM
NO
FU3
FU6
KEY SWITCH
TO TRACTION
P10 - BDI
Pump control will not operate.
Circuits valid
for
Pump
Controller
POSSIBLE CAUSE
•= Defective control fuse.
Check control fuse for open circuit,
replace fuse, if necessary.
•= Check connection from control fuse to
pump P1 for loose connections.
PY7
P1 P2
P3
PY12
P21 P19 P12 PY10
PY11
FU1
LINE
+
-
POS
A1
POWER
TO
CONNECTIONS
TRACTION
CARD
NEG A2
January 2000
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INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL
Page 53
Section 5. TRUCK MANAGEMENT MODULE (TMM)
Section 5.1 General Features
IMPORTANT NOTE: Status Codes 93, 94 and 95 are only
checked when a neutral signal is present (i.e., open start
switch or open F/R switch). The status code is displayed
and the speed limit enabled when the control is returned
to the run mode. Do not use status code 93 speed limit for
applications requiring immediate speed limit on switch
closure.
The Truck Management Module is a multi-functional
accessory card (IC3645TMM7A), or an integral function of
the SR Pump control when used with the SX Family of
Traction controls. The Module provides the OEM with the
ability to initiate status codes or operator warning codes to
be displayed on the Dash Display whenever a normally
open switch or sensor wire provides a signal to the
Module.
Typical wiring diagrams and outline drawings for the
TMM7A accessory card and SR family of Pump TMM
functions are shown in Sections 5.4 and 5.5.
Section 5.3 Installation
The TMM Module can be used to display a separate status
code indicating an over temperature of traction motors,
hydraulic motors, or any other device or system that can
activate a switch that closes.
WARNING: Before any adjustments, servicing or act
requiring physical contact with working components,
jack drive wheels off the floor, disconnect the battery and
discharge the capacitors in the traction and pump
controls, as explained in Section 4.4.
It can also be used as a Brush Wear Indicator (BWI). The
Brush Wear Indicator is designed to detect a “worn-out
brush” and display a fault code on the Dash Display to
warn maintenance personnel that the motor brushes need
to be replaced before they wear to the point of causing
destructive damage to the motor commutator surface. 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 battery acid. Mounting dimensions are shown in
Section 5.5. Two (0.187 inch, 4.75mm) mounting holes are
provided.
Section 5.4 Connection Diagrams
Note: Motor armature must be in the positive side of the
battery circuit.
Section 5.4.1 TMM7A Card Connections
PLUG Y
8
10
9
Section 5.2 Operation
The Module utilizes 9 OEM input points and 3 output points
that connect to the "Y" plug on the traction logic card. Due
to the low level signal value of this output, shielded wire
should always be used to insure proper operation. The
input to the Module is either a switch or sensor wire
closure to battery negative or positive. The following table
outlines the status code displayed for each input, when
that point is closed to battery negative or positive, as
indicated.
TMM7A CARD CONNECTIONS
2
7
9
14
1
3
4
5
6
8
10
11
12
13
15
1
3
4
8
10
11
12
5
6
BATTERY
NEGATIVE
BATTERY
POSITIVE
TMM7A
Card
Terminal
TB1
TB3
TB4
TB5
TB6
TB8
Pump
Control
Terminal
P16
P11
P15
P3
Status
Code
90 *
91
Connect To
Neg
Neg
Neg
Pos
Section 5.4.2 Typical Brush Wear Sensor Connections
BRUSH WEAR SENSOR CONNECTIONS (TYPICAL)
92
2
7
9
14
93 *
93 *
94
P4
P5
Pos
Pos
1
3
4
5
6
8
10
11
12
13
15
TB10
TB11
TB12
P6
P8
P9
94
95
95
Pos
Pos
Pos
ARM
2
ARM
1
ARM
3
1
2
1
2
1
2
* Status codes 90 and 93 can also be programmed with the
Handset to reduce the speed of the truck from 100 to 0
percent-on-time.
TRACTION
PUMP
PWR STEER
January 2000
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INSTALLATION AND OPERATION MANUAL
SX TRANSISTOR CONTROL
Page 54
Section 5.4.3 TMM Pump Control Connections
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
3
4
BATTERY
NEGATIVE
8
10
11
12
5
6
BATTERY
POSITIVE
TO PY10
TRACTION
Section 5.5 TMM7A Outline Drawings
2
1
7
3
9
4
5
6
14
8
10
11
12
13
15
1.60
(40.6)
.8
x
(20.3)
January 2000
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 55
Section 6. SX FAMILY GE HANDSET
INSTRUCTIONS
START-UP DISPLAY SEQUENCE
Section 6.1 General Features
Key Switch On
The GE Handset is a multi-functional tool to be used with
the LX, ZX, and SX Series GE solid-state controls. The
Handset consists of a Light Emitting Diode (LED) display
and a keyboard for data entry.
Verify Each LED Segment
8 8 8 8
Note: The Handset is the same for all GE controls,
however, the cable will change between some control
types.
If Maintenance Code
If Maintenance Code
Is Active
Is Not Active
Section 6.2 Purpose / Setup Functions
The purpose of the Handset is to allow authorized
personnel to perform the following functions of the SX
family of Controls:
Display Code "-99"
For Four Seconds and
Activate Speed Limit
(if selected)
•=Monitor existing system fault codes
•=Monitor intermittent random fault codes
•=Monitor battery state of charge on systems with BDI
•=Monitor hourmeter reading
•=Monitor or adjust the following control functions:
♦ = Creep speed
♦ = Armature Controlled Acceleration and 1A Time
♦ = Regenerative Braking Current Limit and Disable
♦ = Armature and Field Current Limit
♦ = Plugging Distance (Current)
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
♦ = Pedal Position Plug Range or Disable
♦ = 1A Drop Out Current or Disable
Run Mode
♦ = Speed Limit Points
♦ = Truck Management Fault Speed Limit
♦ = Internal Resistance Compensation for Battery
State of Charge Indication
♦ = Battery Voltage ( 36/48 volts is auto ranging )
♦ = Selection of Card Operation Type.
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
Key Switch
Off
Warning: Before connecting or disconnecting the Handset
tool, turn off the key switch, unplug the battery and jack
up the drive wheels of the vehicle.
Display Traction Hourmeter
For Four Seconds
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:
Display Pump Hourmeter
For Four Seconds
NOTE: The vehicle can be operated with the Handset
connected, however, the adjustment knob must be set
fully clockwise to insure the control operates at top
speed.
Warning: Before making any adjustments to the control,
you must consult the operating and maintenance
instructions supplied by the vehicle manufacturer. Failure
to follow proper set up instructions could result in mis-
operation or damage to the control system.
January 2000
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 56
status codes will be overwritten each time a new status
code occurs. This stored status code register can be
cleared from memory by using the Handset.
Section 6.3 Set-up Function Procedures
With the Handset connected, hold down the CONT key and
turn on the key switch. This will place you in the set-up
mode, ready to monitor or adjust control function settings.
ACCESSING STORED STATUS CODES
WITH GE HANDSET
NOTE: The term “Push” means to depress key for
approximately one second.
Key Switch Off
Section 6.3.1 Setup Mode
Push ESC and CONT
At The Same Time
SET-UP MODE
DISPLAY
SHOWS
Release ESC and CONT
Key
ACTION
REMARKS
Hold Down CONT
And Turn On Key
Segment Check
Displayed
8 8 8 8
Status Code Displayed
Push CONT Key
Selected Function No.
Is Displayed
Push Function Number
U 0 0 5
0 8 5
0 8 5
125
After One Second
Time Delay
Stored Value For The
Function Is Displayed
Displays Battery
State-Of-Charge When
Fault Occurred
Display Value
Will Blink
Push CONT
Push CONT Key
Change Value With
Adjustment Knob
Value Changes
While Blinking
Display Hourmeter Reading
Push CONT Key
When Fault Occurred
New Value Stored And
Blinking Stops
Push STORE
Push ESC
125
Push CONT Key
Segment Check
Displayed
8 8 8 8
Section 6.3.3 SX Family Handset, Plug
Connections and Outline Drawing
At this point, another function can be monitored/changed
by pushing another function number, or the vehicle can be
placed in the run mode by holding the ESC key down for
one second or longer. The display will return to either the
diagnostics mode, the BDI display, or a blank display (if
BDI is not used and there are no fault codes). The vehicle
can now be operated with the Handset connected, or the
Handset can be disconnected before operation.
“Y” Plug
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 vehicle operation (a PMT type fault that is reset by
cycling the key switch) and the battery state of charge
reading at the time the fault occurred. The first of the 16
Handset Cable Part Number - 325B1002G1
January 2000
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 57
accelerator ohm input between 6.0K and 4.0K ohms is
provided.
HANDSET
LX g
EVC
Range
Set
2% to 15% on-time
0 to 255
Resolution
Example
0.05% per set unit
Setting of 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.
STORE
2
CONT
FUNCTION 3
ARMATURE CONTROLLED
ACCELERATION
(Push 3)
1
3
7
4
8
+
+
5
9
6
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration.
10 11 12
Range
Set
0.025 to 6.3 seconds
0 to 255
ESC
13 14 15
Resolution
Example:
0.025 seconds per set unit
Setting of 20 = 0.5 seconds
FUNCTION 4
ARMATURE CURRENT LIMIT
(Push 4)
Section 6.4 Setup Functions for Traction Controller
This function allows for the adjustment of the armature
current limit of the control. The rating of the control will
determine the range of adjustment for this function. Please
refer to the specification sheets and current limit curves for
the control used in your vehicle.
FUNCTION 1
MOTOR VOLTS TO ENABLE AUTO REGEN
(Push 1)
This function allows for the adjustment of motor volts to
enable AutoRegen.
Range
Set
Example:
See control C/L curves
0 to 255
0 = min. current, 255 = max.
current
For a setting value of less than 25 (corresponding to a soft
release of auto regen and normal regen), the motor voltage
to enable regen is calculated by multiplying the value of the
setting by 0.375. For example, a setting of 16 will be
multiplied by 0.375 to enable regen at 6 motor volts.
FUNCTION 5
PLUGGING DISTANCE (CURRENT)
(Push 5)
Vm = VAL(setting) X .375
This function allows for the adjustment of the plugging
distance of the vehicle. The larger the current setting, the
shorter the stopping distance.
For a setting value of greater than 25, the motor voltage to
enable auto regen is calculated by subtracting 25 from the
setting value and multiplying that number by 0.375. For
example, a setting of 33, the motor volts necessary to
enable auto regen is (33 - 25) x 0.375, or 3 volts.
Min
Max Set
455
Resolution
Per Unit Value If Set at 20
0 to 255 1.57 amps
Example
55
86.4 amps
FUNCTION 2
CREEP SPEED
(Push 2)
Warning: Plug settings must be made in accordance with
control operating instructions. Too high of a setting could
cause damage to the control system or traction motor.
This function allows for the adjustment of the creep speed
of the vehicle. Creep speed can be adjusted when an
accelerator input voltage between 3.9 and 3.3 volts or an
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 58
FUNCTION 6
FW RATIO
(Push 6)
FUNCTION 9
REGEN BRAKING C/L
(Push 9)
This function sets the ratio between armature and field
current when operating below the Field Weakening Start
point. The setting represents the quantity of field current
changed for each 1 amp of armature current changed.
This function allows for the adjustment of the Regen
braking current limit. High current correlates to shorter
stopping distance.
Resolution
Per unit value If set at 20
468A 0 to 255 1.63 amps 84.6 amps
Example
Max Fld Ref Set
40 0 to 10
Resolution Per Unit Value
0.029 amps
Min
52A
Max Set
The ratio value (VAL) is the set value divided by 10 and
rounded to the whole number.
REGEN BRAKE IA = (VAL X 1.63) + 52
FUNCTION 10
FIELD CURRENT FOR REGEN
( Push 10 )
Example: Setting of 45 = 45/10 = 4.5 = 4 VAL
IFIELD = VAL (IMOTOR x 0.029)
This function allows for the adjustment of the field current
to be used during the regen braking mode.
FUNCTION 7
MIN FIELD CURRENT
( Push 7 )
Resolution
Per unit value If set at 71
51 to 255 0.185 amps
Example
This function allows the adjustment of the field weakening
level in order to set the top speed of the motor.
Min
0
Max Set
40
3.7 amps
Min Max Set
Resolution Per Unit Value
IF = (VAL-51) X 0.185
0
40 51 to 255 0.185
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.
MIN IF = (VAL-51) X 0.185
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 11
TURN SPEED LIMIT
(Push 11)
FUNCTION 8
MAX FIELD CURRENT
( Push 8 )
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 signal is
calculated from the turn angle potentiometer by the control
card.
This function allows for the adjustment of the maximum
field current in order to obtain the maximum torque of the
motor.
Range
Set
100% to 0% battery volts
51 to 180
Min Max Set
Resolution Per Unit Value
Resolution
Example
0.78% per set unit
Setting of 71 = 84.4% of battery volts
0
40 51 to 255 0.185
MAX IF = (VAL-51) X 0.185
Note: To disable speed limit, and assure no 1A hold off, set
this function to a value of zero.
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 12
MAX ARMATURE PERCENT ON
( Push 12 )
Same as function 11, this function allows for the
adjustment of the motor speed limit (maximum battery volts
to the motor). The dash display mode selection enables the
speed limit as well as setting the level of speed limit.
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 59
FUNCTION 13
SPEED LIMIT 3
( Push 13 )
Battery volts
24 volts
36 volts
48 volts
72 volts
80 volts
36/48 volts
No BDI
Set units
Between 0 and 31
Between 32 and 44
Between 45 and 69
Between 70 and 80
Between 81 and 183
Between 184 and 250
Between 251 and 255
The SL3 set speed limit is activated by the Truck
Management Module 90, 91 and 92. See Section 5 for
Truck Management Module details.
FUNCTION 14
INTERNAL RESISTANCE
COMPENSATION
( Push 14 )
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions, push the CONT key and the number
shown in the following instructions at the same time.
This function is used when the Battery Discharge Indicator
is present. Adjustment of this function will improve the
accuracy of the BDI. In order to determine this setting the
voltage drop of the battery under load must first be
calculated by the following method:
.FUNCTION 16 STALL TRIP POINT WITH % ON-TIME
1. Load the traction motor to 100 amps at 100% on-time of
( Push CONT 1)
the control and record the open circuit voltage (V ) at
O
the control panel positive and negative power terminal.
2. Load the traction motor to 200 amps at 100% on time of
This function allows for the adjustment of control percent
on time for the stall motor trip point
the control and record the voltage (V ) at the control
L
panel positive and negative power terminal.
3. Calculate voltage drop (VDrop) as follows:
Control % On time = 163 -(Set Point Val)*.892
V
Drop = V - V
If 163 or greater, then “0.0” % on time
If 51 or less, then “100.”% on-time
O
L
4. Use the table below to determine the appropriate setting
using the calculated VDrop as a reference.
FUNCTION 17
CARD TYPE SELECTION
( Push CONT 2 )
INTERNAL RESISTANCE COMPENSATION
TABLE
This function allows for the selection of the card type used
for your vehicle's application. The table below shows the
setting to select card application type, depending on which
control card is used. Note that the right (slave) control for
a dual motor proportioning system will be set differently
than the left (master) control.
Setting
V
Setting
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
V
Drop
Drop
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
01.34
01.27
01.20
01.14
01.09
01.04
00.99
00.95
00.91
00.88
00.85
00.82
00.79
00.76
00.74
Note: Non-Auto Plug/Regen Logic cards must be used for
settings below:
FUNCTIONS
Std C/L
Std C/L (Right)
STANDARD
5 to 9
69 to 73
REGEN
45 to 49
109 to 113
Note: Auto Plug/Regen Logic cards must be used for
settings below:
FUNCTIONS
STANDARD REGEN
Std C/L Auto Plug
Std C/L Auto Plug (Right)
15 to 19
79 to 83
55 to 59
119 to 123
FUNCTION 15
BATTERY VOLTS
(Push l5)
Settings for these functions should be made within the
ranges indicated above.
This function allows for the adjustment of voltage range for
controls equipped with the Battery Discharge Indication
function. In order for the BDI to operate properly, the
setting as shown in the table must be entered:
Warning: These settings must be changed by authorized
personnel only, following instructions supplied by the
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 60
Range
Set
Example
0 to 240
0 to 240
9999 Hours
vehicle manufacturer. Card type selection must be made
within the capabilities of the control panel used and the
supporting electro mechanical devices. Failure to comply
with proper application standards could result in mis-
operation or damage to the control and/or motors.
FUNCTION 21
AUTO REGEN BRAKING C/L
(Push CONT 6)
FUNCTION 18
STEER PUMP TIME DELAY
( Push CONT 3 )
This function allows for the adjustment of the Regen
braking current limit. High current value correlates to
shorter stopping distance.
This function allows for the selection of steer pump
contactor pick up input, either seat switch or directional
switch closing, and adjustment of the time delay for the
contactor drop out.
Setting greater than 143 disables this function.
( [
AUTO REGEN REGEN C/L
FNT 21-51
-
=
-
6.50
[(
C/L AMPS
VAL
VAL
•= Pick up steer pump contactor on seat switch closure
and time delay drop out of steer pump contactor on
seat switch opening:
FUNCTION 24
FIELD WEAKENING START
( Push CONT 9)
Range
1.5 to 65 seconds
Setting
Resolution
Between 0 and 128
0.5 seconds per set unit
This function allows for setting the armature current at
which minimum field current will achieved .
Example: Setting of 20 = (20 x 0.5) + 1.5 = 11.5 seconds
Range
Setting
Resolution
I MOTOR FWS = VAL. x 1.625
0 to 414 Amps
0 to 255
1.625 per set unit
•= Pick up steer pump contactor on directional switch
closure and time delay drop out of steer pump
contactor on directional switch opening:
Example: Setting of 20 = 32.5 amps
Range
0.5 to 63 seconds
Setting
Resolution
Between 129 and 255
0.5 seconds per set unit
FUNCTION 25
MONITOR
( Push CONT 10)
Example: Setting of 149 = ((149-129) x 0.5) + 1.5 = 11.5
seconds
This function allows the monitoring of certain control
functions by looking directly at the RAM of the
microprocessor. Because absolute memory locations need
to be known, this function should not be used without
detailed instructions from the GE application engineer.
Note: Contactor drop out will be 1.5 seconds after the seat
switch opens.
FUNCTION 19
MAINTENANCE CODE TENS AND UNITS
HOURS SET
( Push CONT 4 )
This function should only be adjusted by the vehicle OEM.
To ensure optimum operation of the control, this function
must be left with zero stored in this register.
This function allows for the adjustment of the tens and
units hours of the maintenance code activation time.
FUNCTION 26
BASE RATIO
( Push CONT 11)
Range
Set
Example
0 to 99
0 to 99
9999 Hours
This function sets the ratio between armature and field
current when operating below the maximum field current
and above the Field Weakening Start point. The setting
represents the quantity of field current changed for each 1
amp of armature current changed.
FUNCTION 20 MAINTENANCE CODE THOUSANDS
AND HUNDREDS HOURS SET
( Push CONT 5 )
Max Fld Ref Set
40 0 to 10
Resolution Per Unit Value
0.029 amps
This function allows for the adjustment of the thousands
and hundreds hours of the maintenance code activation
time.
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 61
The ratio value (VAL) is the set value divided by 10 and
rounded to the whole number.
FUNCTION 49
MODE 1 FIELD WEAKENING START
( Push CONT 2)
Example: Setting of 45 = 45/10 = 4.5 = 4 VAL
IFIELD = VAL ( IMOTOR x 0.029 )
This function allows for setting the armature current at
which minimum field current will achieved .
Range
Setting
Resolution
0 to 414 Amps
0 to 255
1.625 per set unit
FUNCTION 28
STORED STATUS CODE COUNT POINTER
( Push CONT 13)
This register contains the location of the last stored status
code recorded of the 16 stored status codes. These stored
status codes have caused a PMT controller shutdown
and/or disruption of normal vehicle operation.
Example: Setting of 20 = 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.
To determine which stored status code was the last one
recorded, read the number stored in Function 28. Using the
Memory Map for your logic card, match the "stored status
code pointer number" [the number shown in (bold italics)
in the HS (Handset) number column] on the memory map,
with the number obtained from Function 28. This will be the
last stored status code recorded.
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 current
changed.
Note: When scrolling through the stored status code
register, the register always starts at status code 1 and
scrolls to status code 16. Instructions for scrolling the
register are in section 6.3.2 of this instruction booklet.
Max Fld Ref Set
40 0 to 10
Resolution Per Unit Value
0.029 amps
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions. Push the CONT key and the number
shown in the following instructions at the same time.
THE SEAT SWITCH MUST BE CLOSED.
The ratio value (VAL) is the set value divided by 10 and
rounded to the lowest whole number.
Example : Setting of 45 = 45/10 = 4.5 = 4 VAL.
IFIELD = VAL ( IMOTOR X .029 )
This FW RATIO takes effect when the Mode 1 settings are
called for by the interactive Dash Display.
FUNCTION 48
MODE 1 (TURTLE) - ARMATURE
CONTROLLED ACCELERATION
( Push CONT 1)
FUNCTION 51
MODE 1 MAX ARMATURE % ON
( Push CONT 4)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration.
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 limit
switch input signal is received by the control card. The SL1
limit switch is a normally closed switch connected to
battery negative; the switch opening enables speed limit.
Range
Set
0.025 to 6.3 seconds
0 to 255
Resolution
Example:
0.025 seconds per set unit
Setting of 20 = 0.5 seconds
Range
100% to 0% battery volts
51 to 180
Set
Resolution
Example
0.78 % per set unit
Setting of 71 = 84.4 % battery
volts
This C/A takes effect when the Mode 1 settings are called
for by the interactive Dash Display.
This MAX ARMATURE % ON takes effect when the Mode 1
settings are called for by the interactive Dash Display.
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 62
FUNCTION 52
MODE 2 ARMATURE CONTROLLED
ACCELERATION
( Push CONT 5)
FUNCTION 58
MODE 3 FW RATIO
( Push CONT 11 )
Same as Function 50.
Same as Function 48.
This F/W RATIO takes effect when the Mode 3 settings are
called for by the interactive Dash Display.
This C/A takes effect when the Mode 2 settings are called
for by the interactive Dash Display.
FUNCTION 59
MODE 3 MAX ARMATURE % ON
( Push CONT 12 )
FUNCTION 53
MODE 2 FIELD WEAKENING START
( Push CONT 6)
Same as Function 51.
Same as Function 49.
This MAX ARMATURE % ON takes effect when the Mode 3
settings are called for by the interactive Dash Display.
This FIELD WEAKENING START takes effect when the
Mode 2 settings are called for by the interactive Dash
Display.
FUNCTION 60
MODE 4 ARMATURE
CONTROLLED ACCELERATION
( Push CONT 13)
FUNCTION 54
MODE 1 FW RATIO
( Push CONT 7 )
Same as Function 48.
Same as Function 50.
This C/A takes effect when the Mode 4 settings are called
for by the interactive Dash Display.
This FW RATIO takes effect when the Mode 2 settings are
called for by the interactive Dash Display.
FUNCTION 61
MODE 4 FIELD WEAKENING START
( Push CONT 14)
FUNCTION 55
MODE 2 MAX ARMATURE % ON
( Push CONT 8 )
Same as Function 49.
Same as Function 51.
This FIELD WEAKENING START takes effect when the
Mode 4 settings are called for by the interactive Dash
Display.
This MAX ARMATURE % ON takes effect when the Mode 2
settings are called for by the interactive Dash Display.
FUNCTION 62
MODE 4 FW RATIO
( Push CONT 15 )
FUNCTION 56
MODE 3 ARMATURE
CONTROLLED ACCELERATION
( Push CONT 9)
Same as Function 50.
This F/W RATIO takes effect when the Mode 4 settings are
called for by the interactive Dash Display.
Same as Function 48.
This C/A takes effect when the Mode 3 settings are called
for by the interactive Dash Display.
FUNCTION 63
MODE 4 MAX ARMATURE % ON
( Push CONT ESC )
FUNCTION 57
MODE 3 FIELD WEAKENING START
( Push CONT 10)
Same as Function 51.
This MAX ARMATURE % ON takes effect when the Mode 4
settings are called for by the interactive Dash Display.
Same as Function 49.
This FIELD WEAKENING START takes effect when the
Mode 3 settings are called for by the interactive Dash
Display.
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ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS
Page 63
Section 6.5 Summary of Current Limit Adjustments
Maximum field
current is fixed at
37.5 amps
The " maximum fieldcurrent" setting
is adjusted by Function 8. This
function, along with the"armature
current limit",Function 4
,
sets the
maximum torque of the motor.
MAXIMUM
The " ratio" setting isadjusted by Function 26.
This function sets the ratio between armature
and field current when operating,MOI TOR 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 " error compensation" setting isadjusted by
Function 23. This function is used to reduce the ripple
in field current due to the interaction between motor
field design and the digital field current regulation
circuit. The value for this function will be defined by the
GE application engineer.
The " minimum field
current" setting isadjusted
by Function 7. The function
sets the top speed of the
motor. If used.
The " field weakening start"
setting isadjusted by Function
24. This function sets the
armature current at which
minimum field current will be
achieved .
ZERO
ARMATURE CURRENT
The "full load transition point"
is calculated by the controlT. his
function sets the maximum field
current transition point at
approximately 300A armature
current.
The " ratio-2 " setting isadjusted by Function 6.
This function sets the ratio between armature
and field current when operating,MOI TOR is
below FWS. Setting is the value of field current
changed for each 100 amps of armature current
changed.
The "armature current limit"
setting isadjusted by Function 4.
The function along with the
"maximum field current",
Function 8
,
sets the maximum
torque of the motor.
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ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS
Page 64
adjusted until the total IR compensation voltage has been
added.
Section 6.6 Setup Functions for Hydraulic Pump Control
FUNCTION 1:
NOT APPLICABLE
Range
Setting
0.0015 to 0.383 seconds
0 to 255
This function is not applicable to this type of control and
should not be adjusted.
Resolution
0.0015 seconds per set unit
Example: Setting of 20 = 0.032 seconds
FUNCTION 2:
INTERNAL RESISTANCE
COMPENSATION START
(Push 2)
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
This function allows for the adjustment of the current level
at which the internal resistance compensation feature
(Function 16) will take effect.
FUNCTION 11: SPEED LIMIT 1 (SL1)
(Push 11)
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL1 limit
switch input signal is received by the control card. SL1
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Range
Setting
Resolution
0 to 1325 amps
52 to 255
6.5 amps per set unit
Example: Setting of 72 = (72-52) x 6.5 = 130 amps
Range
Setting
Resolution
0% to 100% battery volts
0 to 255
0.375 volts per set unit
FUNCTION 3:
CONTROLLED ACCELERATION
(Push 3)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration.
Example: Setting of 50=18.75 volts
FUNCTION 12: SPEED LIMIT 2 (SL2)
(Push 12)
Range
0.1 to 5.5 seconds
0 to 255
Setting
Same as Function 11 except using SL2 limit switch for input.
Resolution
0.021 seconds per set unit
FUNCTION 13: SPEED LIMIT 3 (SL3)
(Push 13)
Example: Setting of 20 = 0.52 seconds C/A
FUNCTION 4:
CURRENT LIMIT
(Push 4)
Same as Function 11 except using SL3 limit switch for input.
FUNCTION 14: NOT APPLICABLE
This function allows for the adjustment of the current limit
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the
OEM operating instructions for the control used in your
vehicle.
This function is not applicable to this type of control and
should not be adjusted.
Note: The following functions have function numbers
larger than the numbers on the Handset keyboard. To
access these functions, push the CONT key and the
number shown in the following instructions at the same
time. THE KEY SWITCH MUST BE OPEN.
Range
Setting
See OEM control C/L curves
0 to 255
Example: 0 = min. current, 255 = max. current
FUNCTION 7:
INTERNAL RESISTANCE
COMPENSATION RATE
(Push 7)
FUNCTION 16: SPEED / TORQUE COMPENSATION
(Push CONT 1)
This function is used to stabilize pump speed at heavy
loads. The voltage selected will be added to the motor at
each 100 amp increment starting at the value set in
Function 2. The voltage compensation selected will be
added in increments of 0.375 volts until the entire voltage is
added. For example, a setting of 2 will be added in 30 steps
This function allows for the adjustment of the rate of time it
takes for the control to add the internal resistance
compensation voltage that is applied to the motor. This
function will add 0.375 volts to the motor at the rate of time
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ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS
Page 65
status codes have caused a PMT controller shutdown
of 0.375 volts each whereas, a setting of 4 will be added in
15 steps of 0.375 volts each.
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 (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.
SPEED / TORQUE
COMPENSATION TABLE
VOLTAGE
DROP
11.44
7.60
VOLTAGE
DROP
1.34
SETTING
SETTING
17
2
3
4
18
1.27
1.20
1.14
5.72
19
5
4.57
20
6
7
8
9
10
11
12
13
14
15
16
3.81
3.27
2.86
2.54
2.28
2.08
1.90
1.76
21
22
23
24
25
26
27
28
1.09
1.04
0.99
0.95
0.91
0.88
0.85
0.82
Note: When scrolling the stored status code register, the
register always starts at status code 1 and scrolls to
status code 16. Instructions for scrolling the register are
in Section 6.3.2 of this instruction booklet.
Note: The following functions have function numbers
larger than the numbers on the Handset keyboard. To
access these functions, push the CONT key and the
number shown in the following instructions at the same
time. THE KEY SWITCH MUST BE CLOSED.
1.63
1.52
1.43
29
30
31
0.79
0.76
0.74
FUNCTION 17: CARD TYPE SELECTION
(Push CONT 2)
FUNCTION 48: MODE 1 - CONTROLLED ACCELERATION
(Push CONT 1)
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration.
This function should be set in accordance with the control
type in use in the vehicle:
Without Pump
Range
Setting
0.1 to 22.0 seconds
0 to 255
Function
High C/L
Ctr/PMT
Resolution
0.084 seconds per set unit
BDI Lockout
63 to 71
Example: Setting of 20 = 1.8 seconds C/A
BDI Lockout means that the BDI signal from the traction
control must be present in order for the pump control to
operate. This control will stop operation when the battery
state of charge reaches 10%.
FUNCTION 49: MODE 1 - SPEED LIMIT 2 (SL2)
(Push CONT 2)
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL2 limit
switch input signal is received by the control card. SL2
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
Settings for these functions should be made in between the
values shown.
Warning: These setting must be changed by authorized
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within
the capabilities of the TRANSISTOR control panel used
and the supporting electro-mechanical devices. Failure to
comply with proper application standards could result in
mis-operation or damage to the control and/or motors.
Range
Setting
0% to 100% battery volts
0 to 255
Resolution
0.375 volts per set unit
Example: Setting of 50=18.75 volts
FUNCTION 50: MODE 1 - SPEED LIMIT 3 (SL3)
(Push CONT 3)
FUNCTION 28: FAULT COUNT POINTER
(Push CONT 13)
This function allows for the adjustment of the speed limit
(maximum battery volts to the motor) when the SL3 limit
This register contains the location of the last stored status
code recorded of the 16 stored status codes. These stored
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ADJUSTABLE FEATURES
TRANSISTOR PUMP CONTROLS
Page 66
switch input signal is received by the control card. SL3
limit switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
FUNCTION 61: MODE 4 - SPEED LIMIT 2 (SL2)
(Push CONT 14)
Same as Function 49.
Range
Setting
Resolution
0% to 100% battery volts
0 to 255
0.375 volts per set unit
FUNCTION 62: MODE 4 - SPEED LIMIT 3 (SL3)
(Push CONT 15)
Example: Setting of 50=18.75 volts
Same as Function 50.
FUNCTION 52: MODE 2 - CONTROLLED ACCELERATION
(Push CONT 5)
Same as function 48.
FUNCTION 53: MODE 2 - SPEED LIMIT 2 (SL2)
(Push CONT 6)
Same as Function 49.
FUNCTION 54: MODE 2 - SPEED LIMIT 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 APPLICABLE
This function is not applicable to this type of control and
should not be adjusted.
FUNCTION 60: MODE 4 - CONTROLLED ACCELERATION
(Push CONT 13)
Same as function 48.
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INSTALLATION AND OPERATION MANUAL
IT/IP TRANSISTOR CONTROL
Page 67
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.
Section 7. DASH DISPLAYS
Section 7.1 Application
The SX family Standard and Interactive Dash Displays
allow the operator and maintenance personnel easy
access to truck operation information and real-time system
diagnostics of the controller, motor and various
accessories. Hourmeter readings, battery discharge
information, maintenance information and system status
codes are clearly displayed during startup and running
modes. Shielded cable connections are made to the Dash
Display by means of five (5) 22-gage wires to the “Y” Plug
of the traction and hydraulic pump controls.
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) conditions.
The Custom Dash Display incorporates all the features and
functions of the Standard Dash Display, in addition to the
following customer options:
•=LED graphics to display Battery Discharge Indication
status.
Section 7.2 Standard Dash Displays
•=Various LED indicators for Maintenance Required Status
Codes. These can include options for traction, pump and
power steer motors, hourmeter, over-temperature, seat
belt, brake and other safety sensors.
•=A push-button associated with the four segment LED that
displays Status Codes can be used to scroll the last 16
“Stored Status Codes” that shut down vehicle operation
with a PMT fault.
GE Electric Vehicle
Motors & Controls
g
Connections
Connections are made to the Dash Display with five (5) 22-
gage wires to Plug "Y" of each control. Shielded cable is
required to eliminate signal interference.
-
+
Part Number
IC3645LXTDD
T
3
The GE Standard Dash Display is a four segment Light
Emitting Diode (LED) instrument that displays the GE LX, ZX,
and SX Status Codes, Hourmeter Readings, Battery
Discharge Indication, and Maintenance Required Code.
The four LED's above the symbols indicate the active
readout mode.
T=Traction Only
P=Traction & Pump
3=Round Face with four
display symbols
For Custom Dash Displays,
contact your vehicleOEM.
Section 7.3 Interactive Custom Dash Displays
Reference
+
AMP#102241-3 Dash Display mating plug
AMP#1-87195-8 Dash Display mating pin
44A723596-G09 Dash Display plug kit
AMP#175965-2 "Y" Plug
PUSH
EVT100ZX
-
PUSH
AMP#175180-1 "Y" Plug receptacle
The Interactive Custom Dash Display allows the operator to
select the best vehicle performance for changing factory
(task) conditions. There are four (4) “operator interaction
modes” that can be selected by depressing a push-button
on the dash display.
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INSTALLATION AND OPERATION MANUAL
IT/IP TRANSISTOR CONTROL
Page 68
Section 7.4 Start-Up Display Sequence
Section 7.5 Outline Drawings
START-UP DISPLAY SEQUENCE
GE Electric Vehicle
Motors & Controls
g
Key Switch On
Verify Each LED Segment
8 8 8 8
-
+
0.41
(10.4)
If Maintenance Code
If Maintenance Code
3.20 (81.3)
Is Active
Is Not Active
Display Code "-99"
For Four Seconds and
Activate Speed Limit
(if selected)
CONNECTOR OMITTED
IF NOT REQUIRED
PUMP
0.19
(4.8)
TRACTION
BDI Display or
Blank Display
(no BDI used)
Diagnostics Override
With Fault
PY3
PY4
PY2
PY1
PUMP
Run Mode
1
2
3
4
5
BDI Display or
Blank Display
(no BDI used)
Wiring connections to "Y"
plugs of Traction & Pump
controls.
Diagnostics Override
With Fault
BACK VIEW OF DISPLAY
5
4
3
2
1
Key Switch
Off
TRACTION
PY3
PY4
PY2
PY1
Display TractionHourmeter
For Four Seconds
PY5
Display PumpHourmeter
For Four Seconds
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TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROL
Page 69
Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION
Section 8.1 GENERAL:
The potentiometer used for the turn angle must be a 320 degree rotation device that is attached to the steer wheel in a manner to
cause a 1:1 rotation ratio between the two devices. Any ohm value potentiometer can be used, but it is suggested that it be at
least 2K ohms or above, to keep the wattage of the potentiometer to a minimum. The turn angle potentiometer provides a voltage
divider circuit that allows the left and right motor controller to determine the turn angle of the rear steer wheel of the vehicle.
The potentiometer is connected to the two controls as show in Figure 1. After the potentiometer is installed on the vehicle, it will
need to be adjusted to insure proper operation of the vehicle.
Section of Left Motor
Control (Master)
P9 P12 P8
Section of Right Motor
Control (Slave)
P12
OPERATION:
To insure proper operation, the input voltage at P12 on both the left and right
controls must coincide with the turn angle of the steer wheel. When the steer
wheel is straight ahead ( Zero Degree Turn Angle), the input voltage at each
control should be 2.15 volts. As the vehicle turns left, this input voltage will
decrease, as the vehicle turns right, the input voltage will increase. The graph
in Figure 2 outlines the input voltages, the actions of the controls and the
corresponding turn angles of the steer wheel. A complete listing of input
voltages, steer angles and control actions can be found in Section 8.2 - 320
Degree Potentiometer Input. As an example of control operation as
320 Degree
Potentiometer
compared to the input voltage, the following series of events takes place in a
Figure 1
left turn from the zero to the 90 degree steer wheel position. In the first 16 o of
travel (2.15 to 1.90 volts), there is no change to the inside wheel speed. Between 16o (1.90V) and 66o (1.10V), the inside motor will
reduce its speed proportionally from top speed at 16o to creep speed at 66o. There will also be also available two vehicle speed
limit enable points during the transition from 16o to 66o. Speed limit 1 can be enabled at 41o and speed limit 2 can be enabled at
60o. Between 66o and 71o, the inside wheel will be in a free wheel mode. As the steer reaches the 71o point, the inside wheel can
now be programmed to reverse and accelerate proportionally in the opposite direction. Above 86o is over travel for the turn
angle potentiometer.
SETUP:
Before any adjustments are done, jack up the drive wheels.
Install the potentiometer on the vehicle steer wheel in such a way to allow adjustment of the shaft with the potentiometer and
connected to both the left and right controls. Setup of the turn angle pot can be done in several ways, detailed below.
Volt Meter Method:
Attach a volt meter, positive to P12 and negative to P8. Insure that the steer wheel is pointing straight ahead (Zero Degree
Angle); connect the battery and adjust the potentiometer until the voltage between P12 and P8 is 2.15 volts. Lock down the
potentiometer shaft and turn the vehicle all the way to the left turn stop, the voltage should be .93 volts or less. Turn the wheel to
the right turn stop, the voltage should be 3.32 volts or greater.
Handset Monitor Mode Method:
Plug the Handset into the left motor controller. Insure that the steer wheel is pointing straight ahead (Zero Degree Angle) and
connect the battery. Place the Handset into the monitor routine (Function 25) to view RAM location 95, which is turn angle volts,
using the following steps:
1. Push CONT 10
2. Adjust Handset to 95
3. Push STORE
4. Angle Value Displayed
5. ESC to 8888 ( To verify that you have the correct location )
6. Push CONT 10
7. Display should read 95
8. Push STORE
9. Angle Value Displayed
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TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROL
Page 70
Adjust the potentiometer until the Handset reads 110. Lock down the potentiometer shaft and turn the vehicle all the way to the
left turn stop, the reading should be 37 or less. Turn the wheel to the right turn stop, the reading should be 183 or greater.
After adjusting the potentiometer, be sure to ESC out of the monitor routine and then reset Function 25 to zero using the same
procedure as outlined above.
Section 8.2 320 Degree Potentiometer Input
320 DEGREE POTENTIOMETER FOR STEER ANGLE INPUT
4.30V
Over Travel
3.31V
Reverse Direction
and Re-Accelerate
3.10V
3.04V
Proportionally
Reduces The Speed
of the Right Motor
As Steer Angle
Increases
2.37V
No Speed Change
2.15V
No Speed Change
1.94V
Proportionally
Reduces The Speed
of the Left Motor As
Steer Angle
Increases
1.26V
1.20V
Reverse Direction
and Re-Accelerate
0.99V
Over Travel
0.00V
LEFT TURN
Figure 2
RIGHT TURN
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TURN ANGLE POTENTIOMETER INSTALLATION
SX TRANSISTOR CONTROL
Page 71
Section 8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings
320 Degree Potentiometer
320 Degree Potentiometer
Right
Left
Volts Deg HS Volts Deg HS
2.15 Ctr 110 2.15 Ctr 110
Right
Left
Actions
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
No Change
Top Speed Reduce
Volts
Deg HS Volts
Deg HS
2.77 46 141
2.78 47 142
2.80 48 143
2.81 49 143
2.82 50 144
2.84 51 145
2.85 52 145
2.86 53 146
2.88 54 147
2.89 55 147
2.90 56 148
2.92 57 149
2.93 58 149
2.94 59 150
2.96 60 151
2.97 61 151
2.98 62 152
3.00 63 153
3.01 64 154
3.02 65 154
3.04 66 155
3.05 67 156
3.06 68 156
3.08 69 157
3.09 70 158
3.10 71 158
3.12 72 159
3.13 73 160
3.14 74 160
3.16 75 161
3.17 76 162
3.18 77 162
3.20 78 163
3.21 79 164
3.23 80 164
3.24 81 165
3.25 82 166
3.27 83 167
3.28 84 167
3.29 85 168
3.31 86 169
3.32 87 169
3.33 88 170
3.35 89 171
3.36 90 171
Actions
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Proportional Reduce
Creep Speed
1.53 46 78
1.52 47 77
1.51 48 77
1.49 49 76
1.48 50 75
1.46 51 75
1.45 52 74
1.44 53 73
1.42 54 73
1.41 55 72
1.40 56 71
1.38 57 71
1.37 58 70
1.36 59 69
1.34 60 69
1.33 61 68
1.32 62 67
1.30 63 66
1.29 64 66
1.28 65 65
1.26 66 64
1.25 67 64
1.24 68 63
1.22 69 62
1.21 70 62
1.20 71 61
1.18 72 60
1.17 73 60
1.16 74 59
1.14 75 58
1.13 76 58
1.12 77 57
1.10 78 56
1.09 79 56
1.08 80 55
1.06 81 54
1.05 82 53
1.03 83 53
1.02 84 52
1.01 85 51
0.99 86 51
0.98 87 50
0.97 88 49
0.95 89 49
0.94 90 48
2.14
2.12
2.11
2.10
2.08
2.07
2.06
2.04
2.03
1
2
3
4
5
6
7
8
9
109
108
108
107
106
106
105
104
103
2.16
2.18
2.19
2.20
2.22
2.23
2.24
2.26
2.27
1
2
3
4
5
6
7
8
9
110
111
112
112
113
114
114
115
116
2.02 10 103
2.00 11 102
1.99 12 101
1.98 13 101
1.96 14 100
1.95 15 99
1.94 16 99
1.92 17 98
1.91 18 97
1.89 19 97
1.88 20 96
1.87 21 95
1.85 22 95
1.84 23 94
1.83 24 93
1.81 25 93
1.80 26 92
1.79 27 91
1.77 28 90
1.76 29 90
1.75 30 89
1.73 31 88
1.72 32 88
1.71 33 87
1.69 34 86
1.68 35 86
1.67 36 85
1.65 37 84
1.64 38 84
1.63 39 83
1.61 40 82
1.60 41 82
1.59 42 81
1.57 43 80
1.56 44 79
1.55 45 79
2.28 10 117
2.30 11 117
2.31 12 118
2.32 13 119
2.34 14 119
2.35 15 120
2.37 16 121
2.38 17 121 Proportional Reduce
2.39 18 122 Proportional Reduce
2.41 19 123 Proportional Reduce
2.42 20 123 Proportional Reduce
2.43 21 124 Proportional Reduce
2.45 22 125 Proportional Reduce
2.46 23 125 Proportional Reduce
2.47 24 126 Proportional Reduce
2.49 25 127 Proportional Reduce
2.50 26 127 Proportional Reduce
2.51 27 128 Proportional Reduce
2.53 28 129 Proportional Reduce
2.54 29 130 Proportional Reduce
2.55 30 130 Proportional Reduce
2.57 31 131 Proportional Reduce
2.58 32 132 Proportional Reduce
2.59 33 132 Proportional Reduce
2.61 34 133 Proportional Reduce
2.62 35 134 Proportional Reduce
2.63 36 134 Proportional Reduce
2.65 37 135 Proportional Reduce
2.66 38 136 Proportional Reduce
2.67 39 136 Proportional Reduce
2.69 40 137 Proportional Reduce
2.70 41 138 Proportional Reduce
2.71 42 138 Proportional Reduce
2.73 43 139 Proportional Reduce
2.74 44 140 Proportional Reduce
2.75 45 140 Proportional Reduce
Zero Speed
Zero Speed
Zero Speed
Zero Speed
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Reverse
Over Travel
Over Travel
Over Travel
Over Travel
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RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL
Page 72
Section 9.0 MEMORY MAPS
Section 9.1 Traction Control
2
E
Func No.
HS
No.
1
Traction Control
Function
Motor Volts to Enable Auto Regen
Access By
Restrictions
0
1
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
PC Only
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
1
2
2
Creep
2
3
3
Controlled Acceleration
Armature Current Limit
Plug Current Limit
FW Ratio
3
4
4
4
5
5
5
6
6
6
7
7
Minimum Field Current
Maximum Field Current
Regen Current Limit
Field Current for Regen
Turn Speed Limit
Max Armature % On
Speed Limit 3
7
8
8
8
9
9
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
IR Compensation
Battery Volts Select
Stall Trip Point with % On-Time
Card Type Select
Steer Pump Time Delay
Maintenance Code HM (Tens/Units)
Maintenance Code HM (Thou/Hun)
Auto Regen
Not Used
For DD on power up
None
Not Used
FW Start
None
Monitor
GE Temporary Storage
GE Temporary Storage
GE Temporary Storage
None
Ratio
HM Minutes
Fault Count Pointer
Aux HM (Tens/Ones) Adj
Aux HM (Thou/Hun) Adj
Aux HM (Tens/Ones)
Aux HM (Thou/Hun)
Stored Status Code #1
BDI 1
None
None
None
PC Only
None
PC Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
(18)
(20)
(22)
PC Only
Hours (Tens/Ones) 1
Hours (Thou/Hun) 1
Stored Status Code #2
BDI 2
PC Only
PC Only
PC Only
PC Only
Hours (Tens/Ones) 2
Hours (Thou/Hun) 2
Stored Status Code #3
BDI 3
PC Only
PC Only
PC Only
PC Only
Hours (Tens/Ones) 3
PC Only
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RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL
Page 73
2
E
Func No.
HS
No.
Traction Control
Function
Hours (Thou/Hun) 3
Access By
Restrictions
Reset to Zero Only
43
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
44
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
; 74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
BDI 4
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Hours (Tens/Ones) 4
Hours (Thou/Hun) 4
Stored Status Code #5
BDI 5
(26)
(28)
(30)
(32)
(34)
(36)
(38)
(40)
Hours (Tens/Ones) 5
Hours (Thou/Hun) 5
Stored Status Code #6
BDI 6
Hours(Tens/Ones) 6
Hours(Thou/Hun) 6
Stored Status Code #7
BDI 7
Hours(Tens/Ones) 7
Hours(Thou/Hun) 7
Stored Status Code #8
BDI 8
Hours;(Tens/Ones) 8
Hours(Thou/Hun) 8
Stored Status Code #9
BDI 9
Hours(Tens/Ones) 9
Hours(Thou/Hun) 9
Stored Status Code #10
BDI 10
Hours(Tens/Ones) 10
Hours(Thou/Hun) 10
Stored Status Code #11
BDI 11
Hours(Tens/Ones) 11
Hours(Thou/Hun) 11
Stored Status Code #12
BDI 12
Hours(Tens/Ones) 12
Hours(Thou/Hun) 12
Stored Status Code #13
BDI 13
.
(42)
Hours(Tens/Ones) 13
Hours(Thou/Hun) 13
Stored Status Code # 14
BDI 14
(44)
(46)
Hours(Tens/Ones) 14
Hours(Thou/Hun) 14
Stored Status Code # 15
BDI 15
Hours (Tens/Ones) 15
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RS-232 MEMORY MAP TABLES
SX TRANSISTOR CONTROL
Page 74
2
E
Func No.
HS
No.
Traction Control
Function
Hours (Tens/Ones) 15
Access By
Restrictions
Reset to Zero Only
90
91
PC Only
PC Only
PC Only
PC Only
PC Only
91
92
Hours (Thou/Hun) 15
Stored Status Code #16
Hours (Tens/Ones) 16
Hours (Thou/Hun) 16
Dash Display CA-1
Dash Display FWS-1
Dash Display Ratio2-1
Dash Display Speed Limit 2 - 1
Dash Display CA-2
Dash Display FWS-2
Dash Display Ratio2-2
Dash Display Speed Limit 2 - 2
Dash Display CA-3
Dash Display FWS-3
Dash Display Ratio2-3
Dash Display Speed Limit 2 - 3
Dash Display CA-4
Dash Display FWS-4
Dash Display Ratio2-4
Dash Display Speed Limit 2 - 4
Secure HM (Tens/Ones)
Secure HM (Thou/Hun)
Secure Aux HM (Tens/Ones)
Secure Aux HM (Thou/Hun)
Reserved
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
Reset to Zero Only
92
93
(48)
94
95
95
96
96
67
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
97
98
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
HS or PC
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
PC Only
None
98
99
None
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
None
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
None
None
None
None
None
None
None
None
None
None
None
None
OEM Read Only
OEM Read Only
OEM Read Only
OEM Read Only
GE Future Use
GE Future Use
GE Future Use
GE Future Use
None
Reserved
Reserved
Reserved
OEM Use
OEM Use
None
OEM Use
None
OEM Use
None
OEM Use
None
OEM Use
None
OEM Use
None
OEM Use
None
Numbers in (bold italics) are Stored Status Code pointers.
January 2000
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